SM D375a-5 VHMS

SEBM036101
VHMS Specification
Machine model Serial number
D375A-5 (VHMS Specification) 18052 and up
This shop manual may contain attachments and optional equipment that are not available in
your area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
D375A-5 mounts the SA6D170E-3 engine.

For details of the engine, see the 170-3 Series Engine Shop Manual.
2004
All Rights Reserved 00-1
Printed in Japan 12-04 (03) (1)
00
CONTENTS
No. of page
01 GENERAL ......................................................................................... 01-1
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ...... 10-1
20 TESTING AND ADJUSTING ............................................................. 20-1
30 DISASSEMBLY AND ASSEMBLY ................................................... 30-1
90 OTHERS ............................................................................................ 90-1
00-2 D375A-5
List of revised pages
The affected pages are indicated by the use of the

following marks. It is requested that necessary Mark Indication Action required
actions be taken to these pages according to the
table below. Q Page to be newly added Add
q Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made additions.
Time of Time of Time of Time of Time of

Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
q 00-1 (1) 10-16 10-47 10-76

00-2 10-18 10-48 10-77
Q 00-2-1 (1) 01-1 10-19 10-49 10-78
Q 00-2-2 (1) 01-2 10-20 10-50 10-79
Q 00-2-3 (1) 01-4 10-21 10-51 10-80
Q 00-2-4 (1) 01-5 10-22 10-52 10-81
Q 00-2-5 (1) 01-6 10-23 10-53 10-82
Q 00-2-6 (1) 01-7 10-24 10-55 10-83
q 00-3 01-8 10-25 10-56 10-84
q 00-4 01-10 10-26 10-57 10-85
q 00-5 01-11 10-27 10-58 10-86
q 00-6 01-12 10-28 10-59 10-87
q 00-7 10-29 10-60 10-88
q 00-8 10-30 10-61 10-90
q 00-9 10-1 10-31 10-62 10-91
q 00-10 10-2 10-32 10-63 10-92
q 00-11 10-3 10-34 10-64 10-93
q 00-12 10-4 10-35 10-65 10-94
q 00-13 10-5 10-36 10-66 10-95
q 00-14 10-6 10-37 10-67 10-96
q 00-15 10-8 10-38 10-68 10-97
q 00-16 10-9 10-39 10-69 10-98
q 00-17 10-10 10-40 10-70 10-99
q 00-18 10-11 10-41 10-71 10-100
q 00-19 10-12 10-42 10-72 10-101
q 00-20 10-13 10-44 10-73 10-102
q 00-21 10-14 10-45 10-74 10-103
q 00-22 10-15 10-46 10-75 10-104
D375A-5 00-2-1
(1)

10-106 10-150 10-195 20-114 20-156
10-107 10-151 10-196 20-115 20-157
10-108 10-152 10-197 20-116 20-158
10-109 10-153 10-198 20-117 20-159
10-110 10-154 10-199 20-118 20-160
10-112 10-155 10-200 20-119 20-161
10-113 10-156 10-201 20-120 20-162
10-114 10-157 10-202 20-121 20-163
10-115 10-158 10-203 20-122 20-164
10-116 10-159 10-204 20-123 20-165
10-117 10-160 10-205 20-124 20-166
10-118 10-161 10-206 20-125 20-167
10-119 10-162 10-207 20-126 20-168
10-120 10-163 10-208 20-127 20-169
10-121 10-164 10-209 20-128 20-170
10-122 10-165 10-210 20-129 20-171
10-123 10-166 10-211 20-130 20-172
10-124 10-168 20-131 20-173
10-125 10-169 20-132 20-174
10-126 10-170 20-1 20-133 20-175
10-127 10-171 20-2 20-134 20-176
10-128 10-172 20-3 20-135 20-177
10-129 10-174 20-4 20-136 20-178
10-130 10-175 20-5 20-137 20-179
10-131 10-176 20-6 20-138 20-180
10-132 10-177 20-7 20-139 20-181
10-133 10-178 20-8 20-140 20-182
10-134 10-179 20-9 20-141 20-183
10-135 10-180 20-10 20-142 20-184
10-136 10-181 20-101 20-143 20-185
10-137 10-182 20-102 20-144 20-186
10-138 10-184 q 20-103 (1) 20-145 q 20-187 (1)
10-140 10-185 20-104 20-146 20-188
10-141 10-186 20-105 20-147 20-189
10-142 10-187 20-106 20-148 q 20-190 (1)
10-143 10-188 20-107 20-149 20-191
10-144 10-189 20-108 20-150 20-192
10-145 10-190 20-109 20-151 q 20-193 (1)
10-146 10-191 20-110 20-152 20-194
10-147 10-192 20-111 20-153 q 20-195 (1)
10-148 10-193 20-112 20-154 q 20-196 (1)
10-149 10-194 20-113 20-155 q 20-197 (1)
00-2-2 D375A-5
(1)

20-198 20-240 20-327 20-417 20-459
(20-199) 20-241 20-328 20-418 20-460
20-200 20-242 20-329 20-419 20-461
q 20-201 (1) 20-243 20-330 20-420 20-462
20-202 20-244 20-331 20-421 20-463
20-203 20-245 20-332 20-422 20-464
20-204 20-246 20-333 20-423 20-465
q 20-205 (1) 20-247 20-334 20-424 20-466
q 20-206 (1) 20-248 20-335 20-425 20-467
20-207 20-249 20-336 20-426 20-468
20-208 20-250 q 20-337 (1) 20-427 20-469
20-209 20-251 20-338 20-428 20-470
20-210 20-252 20-339 20-429 20-471
20-211 20-253 20-340 20-430 20-472
q 20-212 (1) 20-254 20-341 20-431 20-473
20-213 20-255 20-342 20-432 20-474
20-214 20-256 20-343 20-433 20-475
20-215 20-301 20-344 20-434 20-476
20-216 20-302 q 20-345 (1) q 20-435 (1) 20-477
20-217 20-303 20-346 20-436 20-478
20-218 20-304 20-347 20-437 20-479
20-219 20-305 20-348 q 20-438 (1) 20-480
20-220 20-306 20-349 20-439 20-481
20-221 20-307 q 20-350 (1) q 20-440 (1) 20-482
20-222 20-308 q 20-351 (1) 20-441 20-483
20-223 20-309 Q 20-352 (1) q 20-442 (1) 20-484
q 20-224 (1) 20-310 20-401 20-443 20-485
20-225 20-311 20-402 20-444 20-486
20-226 20-312 20-403 20-445 20-487
20-227 20-313 20-404 20-446 20-488
20-228 20-314 20-405 20-447 20-489
20-229 20-315 20-406 20-448 20-490
20-230 20-317 20-407 20-449 20-491
20-231 20-318 20-408 20-450 20-492
q 20-232 (1) 20-319 20-409 20-451 20-493
20-233 20-320 20-410 20-452 20-494
q 20-234 (1) 20-321 20-411 20-453 20-496
20-235 20-322 20-412 20-454 20-497
20-236 20-323 20-413 20-455 20-498
20-237 20-324 20-414 20-456 20-499
20-238 20-325 20-415 20-457 20-500
20-239 20-326 20-416 20-458 20-501
D375A-5 00-2-3
(1)

20-502 20-545 20-592 20-715 20-904
20-503 20-546 20-594 20-716 20-905
20-504 20-547 20-595 20-717 20-906
20-505 20-548 20-596 20-718 20-907
20-506 20-550 20-597 20-719 20-909
20-508 20-551 20-598 20-720 20-910
20-509 20-552 20-599 20-721 20-911
20-510 20-553 20-600 20-722 20-912
20-511 20-554 20-601 20-723 20-913
20-512 20-555 20-602 20-724 20-914
20-513 20-556 20-603 20-725 20-915
20-514 20-557 20-604 20-726 20-916
20-515 20-558 20-605 20-727 20-917
20-516 20-559 20-606 20-728 20-918
20-517 20-560 20-607 20-729 20-919
20-518 20-561 20-608 20-730 20-920
20-519 20-562 20-609 20-731 20-921
20-520 20-564 20-610 20-732 20-922
20-521 20-565 20-611 20-733 20-923
20-522 20-566 20-612 20-734 20-924
20-523 20-567 20-613 20-735 20-925
20-524 20-568 20-614 20-736 20-926
20-525 20-569 20-615 20-801 20-927
20-526 20-570 20-616 20-802 20-928
20-527 20-572 20-617 20-803 20-929
20-528 20-573 20-618 20-804 20-930
20-529 20-574 20-619 20-805 20-931
20-530 20-575 20-620 20-806 20-932
20-531 20-576 20-701 20-807
20-532 20-577 20-702 20-808
20-533 20-578 20-703 20-809 q 30-1 (1)
20-534 20-580 20-704 20-810 30-2
20-535 20-581 20-705 20-811 30-3
20-536 20-582 20-706 20-812 30-5
20-537 20-583 20-707 20-813 30-6
20-538 20-584 20-708 20-814 30-7
20-539 20-586 20-709 20-815 30-8
20-540 20-587 20-710 20-816 30-9
20-541 20-588 20-711 20-817 30-10
20-542 20-589 20-712 20-901 30-11
20-543 20-590 20-713 20-902 30-12
20-544 20-591 20-714 20-903 30-13
00-2-4 D375A-5
(1)

q 30-14 (1) 30-51 30-93 30-135 30-177
30-15 30-52 30-94 30-136 30-179
30-16 30-53 30-95 30-137 30-180
q 30-17 (1) 30-54 30-96 30-138 30-181
q 30-18 (1) 30-55 30-97 30-139 30-182
Q 30-18-1 (1) 30-56 30-98 30-140 30-183
Q 30-18-2 (1) 30-57 30-99 30-141 30-184
Q 30-18-3 (1) 30-58 30-100 30-142 30-185
Q 30-18-4 (1) 30-59 30-101 30-143 30-186
Q 30-18-5 (1) 30-60 30-102 30-144 30-187
30-19 30-61 30-103 30-145 30-188
q 30-20 (1) 30-62 30-104 30-146 30-189
q 30-21 (1) 30-63 30-105 30-147 30-190
30-22 30-64 30-106 30-148 30-191
q 30-23 (1) 30-65 30-107 30-149 30-192
30-24 30-66 30-108 30-150 30-193
30-25 30-67 30-109 30-151 30-194
30-26 30-68 30-110 30-152 30-195
30-27 30-69 30-111 30-153 30-196
30-28 30-70 30-112 30-154 30-197
30-29 30-71 30-113 30-155 30-198
30-30 30-72 30-114 30-156 30-199
30-31 30-73 30-115 30-157 q 30-200 (1)
30-32 30-74 30-116 30-158 30-201
30-33 30-75 30-117 30-159 30-202
30-34 30-76 30-118 30-160 30-203
q 30-35 (1) 30-77 30-119 30-161 30-204
q 30-36 (1) 30-78 30-120 30-162 30-205
30-37 30-79 30-121 30-163 30-206
30-38 30-80 30-122 30-164 30-207
q 30-39 (1) 30-81 30-123 30-165 30-208
q 30-40 (1) 30-82 30-124 30-166 30-209
30-41 30-83 30-125 30-167 30-210
30-42 30-84 30-126 30-168 30-211
30-43 30-85 30-127 30-169 30-212
30-44 30-86 30-128 30-170 30-213
30-45 30-87 30-129 30-171 30-214
30-46 30-88 30-130 30-172 30-215
30-47 30-89 30-131 30-173 30-216
30-48 30-90 30-132 30-174 30-217
30-49 30-91 30-133 30-175 30-218
30-50 30-92 30-134 30-176 30-219
D375A-5 00-2-5
(1)

30-220 q 30-262 (1)
30-221 30-263
30-222 30-264
30-223 q 30-265 (1)
30-224 30-266
30-225 30-267
30-226
30-227
30-228 90-1
30-229 90-2
30-230 90-3
30-231 90-4
30-232 90-5
30-233 90-6
30-234 90-7
30-235 90-9
30-236 90-11
30-237 90-13
30-238 90-15
30-239 90-17
30-240 90-19
30-241 90-21
30-242 90-23
30-243 90-24
30-244
30-245
30-246
30-247
30-248
30-249
30-250
30-251
30-252
30-253
30-254
30-255
30-256
q 30-257 (1)
30-258
30-259
30-260
30-261
00-2-6 D375A-5
(1)
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

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

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

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

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: volume to cover all
models
PAGES next to the CONTENTS page.
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
k
Special safety precautions
Safety are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3
4
tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
5
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
Places where oil or water
6
item.
Drain must be drained, and
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may cause

k Heavy parts (25 kg or more) must be lifted the rope to slip off the hook during hoisting, and
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol 4
If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing 3) Do not sling a heavy load with one rope alone,
interference with the part to be removed. but sling with two or more ropes symmetrically
wound onto the load.
k Slinging with one rope may cause turning
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to of the load during hoisting, untwisting of
the table below: the rope, or slipping of the rope from its
original winding position on the load, which
Wire ropes can result in a dangerous accident.
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
Rope diameter Allowable load
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
mm kN tons with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6
vertically, at various hanging angles.
14 21.6 2.2
16 27.5 2.8
When two ropes sling a load vertically, up to
18 35.3 3.6 19.6 kN {2000 kg} of total weight can be sus-
20 43.1 4.4 pended. This weight becomes 9.8 kN {1000 kg}
22.4 54.9 5.6 when two ropes make a 120 hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150.
The allowable load value is estimated to be one-

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

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
The adapter can be pushed in about 3.5
mm.
Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
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. (See Fig. 5)
When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
Hold the mouthpiece of the tightening portion Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, features
Used to prevent rubber gaskets, rub-

LT-1A 790-129-9030 150 g Tube ber cushions, and cock plug from
coming out.
Used in places requiring an immedi-
ately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethyl-
LT-1B 790-129-9050 (2 pcs.) container ene, polyprophylene, tetrafluoroeth-
lene and vinyl chloride), rubber,
metal and non-metal.
Features: Resistance to heat and
Polyethylene chemicals
LT-2 09940-00030 50 g container Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: Used as adhesive or sealant for met-
790-129-9060 al, glass and plastic.
1 kg
(Set of adhesive
LT-3 Hardening Can
and hardening agent:
agent) 500 g
Adhesives
Polyethylene Used as sealant for machined holes.
LT-4 790-129-9040 250 g container
Holtz Used as heat-resisting sealant for re-

790-126-9120 75 g Tube pairing engine.
MH 705
Quick hardening type adhesive
Three bond Polyethylene Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container Used mainly for adhesion of metals,
rubbers, plastics and woods.
Quick hardening type adhesive
Quick cure type (max. strength after
Aron-alpha Polyethylene
790-129-9130 2g 30 minutes)
201 container Used mainly for adhesion of rubbers,
plastics and metals.
Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc Used at joint portions subject to high
648-50 container temperatures.
Used as adhesive or sealant for gas-
LG-1 790-129-9010 200 g Tube kets and packing of power train case,
etc.
Used as sealant for various threads,
pipe joints, flanges.
LG-5 790-129-9080 1 kg Can Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
Features: Silicon based, resistance
to heat, cold
Used as sealant for flange surface,
LG-6 790-129-9020 200 g Tube tread.
Used as sealant for oil pan, final
Gasket drive case, etc.
sealant
Features: Silicon based, quick hard-
ening type
LG-7 790-129-9070 1 kg Tube Used as sealant for flywheel hous-
ing, intake manifold, oil pan, thermo-
stat housing, etc.
Three bond Used as heat-resisting sealant for re-
790-129-9090 100 g Tube pairing engine.
1211
Features: Silicone type, heat resist-
ant, vibration resistant, and impact
Three bond 419-15-18131 100 g Tube resistant sealing material
1207B Used as sealing material for transfer
case
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, features
Used as lubricant for sliding portion

LM-G 09940-00051 60 g Can (to prevent from squeaking).
Molybdenum Used to prevent seizure or scuffling
disulphide of the thread when press fitting or
lubricant LM-P 09940-00040 200 g Tube shrink fitting.
Used as lubricant for linkage, bear-
ings, etc.
SYG2-400LI General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA Used for normal temperature, light

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

SYG2-400M 400 g 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g 20 Bellows type
grease SYGA-16CNM 16 kg Can
LM-G (G2-M)
Seizure resistance and heat resist-
Hyper White
Grease G2-T SYG2-400T-A ance higher than molybdenum di-
SYG2-16CNT 400 g Bellows type sulfide grease
G0-T (*) SYG0-400T-A (*) 16 kg Can Since this grease is white, it does
*: For use in cold SYG0-16CNT (*) not stand out against machine
district body.
Biogrease G2B Since this grease is decomposed
SYG2-400B by bacteria in short period, it has
G2-BT (*) SYGA-16CNB 400 g Bellows type less effects on microorganisms,
*: For high SYG2-400BT (*) 16 kg Can animals, and plants.
temperature SYGA-16CNBT (*)
and large load
SUNSTAR Used as primer for cab side

Glass (Using limit: 4 months)
PAINT PRIMER 20 ml container
580 SUPER
Primer
SUNSTAR Used as primer for glass side
Glass (Using limit: 4 months)
GLASS PRIMER 20 ml container
580 SUPER 417-926-3910
Adhesive for cab glass
"S" is used for high-tempera-

SUNSTAR ture season (April - October)
PENGUINE Polyethylene and "W" for low-temperature
SEAL 580 320 ml container season (November - April) as
SUPER "S" or
Adhesive adhesive for glass.
"W" (Using limit: 4 months)
Sika Japan, Polyethylene Used as adhesive for glass.
20Y-54-39850 310 ml (Using limit: 6 months)
Sikaflex 256HV container
SUNSTAR Used to seal joints of glass

Polyethylene parts.
PENGUINE 417-926-3920 320 ml container (Using limit: 4 months)
SEAL No. 2505
Caulking
material Used to seal front window.
SEKISUI Polyethylene (Using limit: 6 months)
SILICONE 20Y-54-55130 333 ml container
SEALANT
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Tightening torque
Thread diameter Width across
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 7.5
12 19 98 123 10 12.5
14 22 153 190 15.5 19.5
16 24 235 285 23.5 29.5

18 27 320 400 33 41
20 30 455 565 46.5 58
22 32 610 765 62.5 78
24 36 785 980 80 100
27 41 1150 1440 118 147

30 46 1520 1910 155 195
33 50 1960 2450 200 250
36 55 2450 3040 250 310
39 60 2890 3630 295 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 9.8 0.6 1.0

8 13 13.7 23.5 1.4 2.4
10 14 34.3 46.1 3.5 4.7
12 27 74.5 90.2 7.6 9.2
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below. SAD00483
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5 4.9 2.5 0.5

18 24 49 19.6 52
22 27 78.5 19.6 82
24 32 137.3 29.4 14 3
30 36 176.5 29.4 18 3
33 41 196.1 49 20 5
36 46 245.2 49 25 5
42 55 294.2 49 30 5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 59 74 6 7.5
12 17 98 123 10 12.5
16 22 235 285 23.5 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

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

Norminal No.
mm mm Range Target
02 14 35 63 {3.5 6.5} 44 {4.5}

03, 04 20 Varies depending 84 132 {8.5 13.5} 103 {10.5}
05, 06 24 on type of 128 186 {13.0 19.0} 157 {16.0}
10, 12 33 connector. 363 480 {37.0 49.0} 422 {43.0}
14 42 746 1010 {76.0 103} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

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

Norminal No.
mm mm Range Target
08 08 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} 124.4 {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}
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 0 2 1.02 0 0.20
8 24 0 4 2.45 0 0.41
10 43 0 6 4.38 0 0.61
12 77 0 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.41
1/2 24 0 4 2.45 0 0.41
3/4 36 0 5 3.67 0 0.51
1 60 0 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
type
Nominal size Width across
of hose flats Nominal thread
Thread size size Root diameter
Range Target - Threads per
(mm) inch, Thread series (mm) (Reference)
9
34 54 {3.5 5.5} 44 {4.5} 18UN 14.3
02 19 16
34 63 {3.5 6.5} 44 {4.5} 14
11
22 54 93 {5.5 9.5} 74 {7.5} 16UN 17.5
03 16
24 59 98 {6.0 10.0} 78 {8.0} 18
13
04 27 84 132 {8.5 13.5} 103 {10.5} 22 16UN 20.6
16
05 32 128 186 {13.0 19.0} 157 {16.0} 24 1 14UNS 25.4
3
06 36 177 245 {18.0 25.0} 216 {22.0} 30 1 12UN 30.2
16
(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
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR BW RW YR GW LW
2
Color White & Red White & Black Red & White Rellow & Red Green & White Blue & White
Code WB BY RB YB GR LR
3
Color White & Black Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL BR RY YG GY LY
4 Auxi-
liary Yellow & Green &
Color White & Blue Black & Red Red & Yellow Blue & Yellow
Green Yellow
Code WG RG YL GB LB
5
Color White & Green Red & Green Yellow & Blue Green & Black Blue & Black
Code RL YW GL n
6
Color Red & Blue Yellow & White Green & Blue n
00-15
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, then draw a horizontal line
from A.
(2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line down
from B.
(3) Take the point where the two lines cross as C. This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

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

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

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

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
Liter to U.K. Gallon

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 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

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

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

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

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

25.0 13 8.6 5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
24.4 12 10.4 5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
23.9 11 12.2 4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
23.3 10 14.0 3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
22.8 9 15.8 3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

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

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

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

13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 10-04
GENERAL
01 GENERAL
SPECIFICATION DRAWING ..................................................................................................................... 01- 2

SPECIFICATIONS ..................................................................................................................................... 01- 4
WEIGHT TABLE ........................................................................................................................................ 01-10
TABLE OF FUEL, COOLANT AND LUBRICANT ...................................................................................... 01-12
D375A-5 01-1
GENERAL SPECIFICATION DRAWING
SPECIFICATION DRAWING
Semi U-tilt dozer U-tilt dozer Semi U-tilt dozer U-tilt dozer
Item Unit
+ Giant ripper + Giant ripper + Multi-shank ripper + Multi-shank ripper
Overall
A mm 10,330 10,695 10,040 10,405
length
Overall
4,035 4,035 4,035 4,035
B height mm
(4,230) (4,230) (4,230) (4,230)
(with ROPS)
Overall
C mm 4,695 5,140 4,695 5,140
width
01-2 D375A-5
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model D375A-5
Serial number 18052 and up
Machine weight
Bare tractor with semi u-dozer 49,800
Weight
Ditto with variable multi-shank ripper kg 60,340

Ditto with ROPS cab + Air conditioner + 67,060
Seat belt + Perforated side cover + SSC 68,500
Minimum turning radius m 4.2

Gradeability deg. 30
Stability (front, rear, left, right) deg. 35
1st speed 0 3.8

Forward
2nd speed km/h 0 6.8

speed ranges
Transmission
3rd speed 0 11.8

Performance
1st speed 0 5.1

Reverse
2nd speed km/h 0 9.2

3rd speed 0 15.8
Bare tractor 103.16 {1.06}

Ground pressure
With semi U-dozer 125.53 {1.28}

With semi U-dozer + Variable multi- 140.37 {1.43}
shank ripper kPa {kg/cm2}
Ditto with ROPS cab + air conditioner 143.38 {1.46}
+ Seat belt + Perforated side cover +
SSC
Bare tractor 5,770

Overall length
With semi U-dozer 7,635

With semi U-dozer + Variable multi- 10,040
mm
shank ripper
With U dozer + Variable multi-shank 10,405
Dimensions
ripper
Bare tractor 3,220

Overall
width
With semi U-dozer mm 4,695

With U-dozer 5,140
To top of exhaust pipe 4,035

Overall
height
mm
To top of air intake duct 3,429
01-4 D375A-5

Dimensions
Track gauge 2,500

Length of track on ground 3,840
mm
Track shoe width 610
Minimum ground clearance 610
Name SA6D170E-3
Type of engine 4-cycle, water-cooled, in-line vertical type, direct injec-

tion type with turbocharger and aftercooler
Number of cylinders Bore Stroke mm 6 170 170

Piston displacement {cc} 23.15 {23,150}
Flywheel horsepower kw {HP}/rpm 391 {525}/1,800

Max. torque Nm {kgm}/rpm 2,648 {270}/1,300
Performance
Engine
Max. speed at no load rpm 1,900

Min. speed at no load rpm 720
Min. fuel consumption ratio g/kw.h 209 {156}

{g/HP.h}
Starting motor 24 V, 7.5 kW 2

Alternator 24 V, 60 A
Battery 12 V, 170 Ah 2
Radiator core type Type D
Torque converter 3-element, 1-stage, 1-phase (with lockup clutch)
Planetary gear type, multiple disc clutch type, hydraulic

Transmission actuation type, lubricating oil pump force-feeding type,
forward 3-speed, reverse 3-speed
Bevel gear shaft Spiral bevel gear type, lubricating oil splashing type
Power train
Wet type, multiple disc clutch type, spring-boosted

Steering clutch type, hydraulic actuation type (manual type),
brake linkage type
Wet type, multiple disc clutch type, spring-boosted

Steering brake type, hydraulic actuation type (foot operation, manual
type), clutch linkage type
Spur gear 1-stage, planetary gear 1-stage deceleration

Final drive
type, lubricating oil splashing type
D375A-5 01-5
Suspension Rigid, balancing beam type

Undercarriage
Carrier roller 2 each side

Track roller 7 each side
Track shoe Assembly type, single grouser, 40 each side,

pitch: 280.0 mm, width: 610 mm
Power train + lubricating oil pump (tandem) Gear type (BAL 180 + 112)
Scavenging pump (tandem) Gear type (BAR 63 + 277)
PPC charge pump

Gear type (SAR(1) 022)
(work equipment pump and tandem)
Maximum pressure MPa {kg/cm2} 20.6 {210}

Hydraulic pump
Type Gear type, double type (SAR(4) 140 + (3) 071)
Delivery /min 405

(at engine speed of 1,800 rpm)
Type
Work equip-
Work equipment hydraulic system
ment valve
For blade lift Single pilot spool type, with demand spool
For blade tilt, ripper LO Triple pilot spool type
For ripper HI Double pilot spool type
Type Double acting piston type
Cylinder bore 150

blade lift cylinder
Dimensions of
Piston rod outside diameter 90

Hydraulic cylinder
Piston stroke mm 1,505

Max. distance between pins 2,650
Min. distance between pins 1,145
Cylinder bore 225

blade tilt cylinder
Dimensions of

Piston stroke mm 240
01-6 D375A-5
Cylinder bore Left cylinder: 225, Right cylinder: 250

Dimensions of blade
(both right and left)

dual tilt cylinder
Piston stroke 185

(both right and left) mm
Work equipment hydraulic system

Hydraulic cylinder

Dimensions of ripper Dimensions of ripper
Cylinder bore 225

lift cylinder

Cylinder bore 200

tilt cylinder

Control valve assembly type

Hydraulic tank
(external installation type)
Hydraulic semi U-tilt dozer,

Type
Hydraulic U-tilt dozer
Blade support method Brace type
Max. lifting height mm 1,660

Work equipment
(from ground level)

Performance
Max. lowering depth mm 715

(from ground level)
Semi U-dozer
Max. tilt mm 1,065

Blade cutting angle variation deg. 5
3
Blade capacity m 24.0 <SAE18.5>
Dimensions
Blade width mm 4,695

Blade height mm 2,265
Blade cutting angle deg. 55
D375A-5 01-7

(from ground level)
Performance
Max. lowering depth mm 715

(from ground level)
Max. tilt mm 1,165
U-dozer
Blade cutting angle variation deg. 5

Blade capacity m3 26.3 <SAE22.0>
Dimensions Performance Dimensions
Blade width mm 5,140

Blade height mm 2,265
Semi U-dozer
Max. tilt mm 1,150

+ Pitch
Max. pitch angle deg. 5

Work equipment
Max. tilt mm 1,260

U-dozer
+ pitch
Max. pitch angle deg. 5

Max. digging depth mm 1,075

Performance

Multi-shank ripper
Point digging angle deg. 45 (Stepless adjustment is possible

between 32.5 and 55.5 deg.)
Dimensions
Max. beam width mm 2,854

Shank position Number of 2
holes
Max. digging depth mm 1,435

Performance

Point digging angle deg. 45 (Stepless adjustment is possible
Giant ripper
between 32.5 and 55.5 deg.)

Dimensions
Max. beam width mm 1,367

Shank position Number of 3
holes
01-8 D375A-5
GENERAL WEIGHT TABLE
WEIGHT TABLE
k This weight table is for reference in handling or transporting components.
Unit: kg
Engine and damper assemblies 3,080

Engine assembly 2,850
Damper assembly 160
Engine mounting parts 70
Radiator assembly 390

Oil cooler assembly 100
Fuel tank assembly (when full) 478 (1,368)
Power train unit

Torque converter, PTO assembly 795
Transmission assembly 1,000
Transmission valve assembly 13
Steering clutch and brake assembly 1,712
Steering valve assembly 13
Final drive assembly 2,200 2

Main frame assembly 5,541
Track group assembly (each side) 7,259

Track frame 2,038
Idler assembly 478
Track roller assembly (single flange 1) 150 4
Track roller assembly (double flange 1) 160 3
Carrier roller assembly (each) 71 2
First bogie and track roller assembly 258
Second fourth bogies and track roller assembly 717 3
Track shoe assembly 4,200 2

Pivot shaft 210 2
Equalizer assembly 490
Hydraulic tank assembly 370

Work equipment valve (blade lift) 57
Work equipment valve (blade tilt, ripper LO) 36
01-10 D375A-5
GENERAL WEIGHT TABLE
Unit: kg
Semi U-dozer assembly 10,540

Blade 4,870
Straight frame (left) 1,130
Straight frame (right) 1,130
Tilt cylinder assembly 295
Variable multi-shank ripper assembly 6,720

Shank assembly 470 3
Ripper lift cylinder assembly 345 2
Ripper tilt cylinder assembly 265 2
Variable giant ripper assembly 5,470

Shank assembly 650 1
Ripper lift cylinder assembly 345 2
Ripper tilt cylinder assembly 265 2
Radiator guard assembly (including cylinder yoke) 2,100

Radiator guard 1,332
Blade lift cylinder assembly 268 2
Mask 50
Engine underguard 285
Power train underguard (front) 275
Power train underguard (rear) 250
Hood 145
Fender (left) 315
Fender (right) 355
ROPS assembly 766
Floor frame assembly 591
Cab assembly 415
Operator seat assembly 64
D375A-5 01-11
GENERAL TABLE OF FUEL, COOLANT AND LUBRICANT
TABLE OF FUEL, COOLANT AND LUBRICANT
Ambient temperature Specified Refilled

Refilling position Kind of oil oil amount oil amount
30 20 10 0 10 20 30 40C () ()
SAE 30CD
SAE 10WCD
Engine oil pan 68 55.5
SAE 10W-30CD
SAE 15W-40CD
Power train oil pan

SAE 30CD
including torque convert- 275 150
er, transmission and bev- Engine oil SAE 10WCD
el gear case
Damper case 2.1 2.1
Final drive case (each side) SAE 30CD 61 61
Pivot shaft case (each side) 18 18
SAE 10WCD
Hydraulic oil SAE 10W-30CD 280 120
SAE 15W-40CD
Idler (each) 0.95 1.05 0.95 1.05
Track roller (each) 1.40 1.50 1.40 1.50

Gear oil GO 140
Carrier roller (each) 0.70 0.80 0.70 0.80
0.095 0.095
Bogie cartridge pin (each) 0.115 0.115
ASTM D975 No. 2

Fuel tank Diesel fuel 1,050
ASTM D975
No. 1
Cooling system Coolant Komatsu genuine super coolant (AF-NAC added) 165
01-12 D375A-5
STRUCTURE, FUNCTION AND
10 STRUCTURE, FUNCTION AND

POWER TRAIN .......................................... 10- 2 PPC CONTROL PIPING DIAGRAM ........... 10-101
OVERALL DRAWING OF POWER TRAIN WORK EQUIPMENT CONTROL ................ 10-102
UNIT ...................................................... 10- 4 HYDRAULIC TANK ..................................... 10-104
POWER TRAIN HYDRAULIC PIPING PPC CHARGE VALVE ................................ 10-106
DRAWING ............................................. 10- 6 ACCUMULATOR ........................................ 10-109
DAMPER, UNIVERSAL JOINT ................... 10- 8 PPC LOCK VALVE ..................................... 10- 110
TORQUE CONVERTER, PTO .................... 10- 10 PPC VALVE ................................................ 10- 112
TORQUE CONVERTER VALVE ................ 10- 18 WORK EQUIPMENT CYLINDER ............... 10-122
SCAVENGING PUMP ................................ 10- 29 PISTON VALVE .......................................... 10-125
TRANSMISSION CONTROL ...................... 10- 30 QUICK DROP VALVE ................................. 10-126
TRANSMISSION ........................................ 10- 32 PIN PULLER SWITCH ................................ 10-128
TRANSMISSION ECMV ............................. 10- 44 PIN PULLER SOLENOID VALVE ............... 10-129
TRANSMISSION LUBRICATION RELIEF BLADE CONTROL KNOB .......................... 10-131
VALVE ................................................... 10- 50 PITCH, DUAL TILT SOLENOID VALVE ..... 10-132
POWER TRAIN PUMP + LUBRICATION WORK EQUIPMENT + PPC CHARGE
PUMP .................................................... 10- 51 PUMP ..................................................... 10-134
STEERING, BRAKE CONTROL ................. 10- 52 MAIN CONTROL VALVE ............................ 10-136
TRANSFER, BEVEL GEAR SHAFT, CYLINDER STAY ........................................ 10-166
STEERING ............................................ 10- 55 BLADE ........................................................ 10-168
STEERING ECMV ...................................... 10- 62 RIPPER EQUIPMENT ................................ 10-174
STEERING CLUTCH, STEERING BRAKE CAB MOUNT .............................................. 10-176
ECMV .................................................... 10- 66 CAB ............................................................. 10-177
PARKING BRAKE VALVE .......................... 10- 73 AIR CONDITIONER .................................... 10-179
SUDDEN STOPS PREVENTION VALVE .. 10- 74 ENGINE CONTROL .................................... 10-180
FINAL DRIVE ............................................. 10- 75 ENGINE CONTROL SYSTEM .................... 10-181
TRACK FRAME .......................................... 10- 80 DECELERATOR POTENTIOMETER ......... 10-182
RECOIL SPRING ....................................... 10- 82 HPI ENGINE CONTROL SYSTEM ............. 10-184
IDLER ......................................................... 10- 84 MONITOR SYSTEM ................................... 10-186
TRACK ROLLER ........................................ 10- 86 MONITOR PANEL ...................................... 10-188
CARRIER ROLLER .................................... 10- 87 MODE SELECTION SYSTEM .................... 10-195
TRACK ROLLER BOGIE ............................ 10- 88 ELECTRICAL DEVICE ............................... 10-200
TRACK SHOE ............................................ 10- 90 STEERING ELECTRONIC CONTROL ....... 10-202
MAIN FRAME ............................................. 10- 92 VHMS CONTROLLER ................................ 10-204
SUSPENSION ............................................ 10- 94 COMMUNICATION (ORB: ORBCOMM)
WORK EQUIPMENT HYDRAULIC PIPING CONTROLLER/ANTENNA .................... 10- 211
DIAGRAM .............................................. 10- 97
D375A-5 10-1
MAINTENANCE STANDARD POWER TRAIN
POWER TRAIN
Outline
The power generated by engine (1) has its tor- el pinion and bevel gear of the bevel gear shaft,
sional vibration dampened by damper (2), and and it is then divided at right angles to the left
then passes through universal joint (3), and it and right and transmitted to the respective steer-
transmitted to torque converter (7). ing clutches (9).
The power from the engine is transmitted The power transmitted from the bevel gear shaft
through oil by torque converter (7) to the input to the final drive is used to steer the machine by
shaft (turbine shaft) of transmission (8) in accor- engaging on disengaging steering clutch (9).
dance with the change in the load. The steering lever is operated to disengage the
There is a lock-up clutch assembled to the steering clutch on the side to which the machine
torque converter, and when the rotating speed is to be steered in order to change the direction
beyond the torque converter becomes higher, of travel. The size of the turning radius is con-
the lock-up clutch is engaged. When this hap- trolled by steering brake (10) installed to the out-
pens, the drive case and turbine form one unit, side of the steering clutch.
so the power from the engine is transmitted di- Steering brake (10) uses the same disc system
rectly to the transmission input shaft. that is used for the steering clutch.
Transmission (8) uses a combination of a plane- The power output from the steering clutch enters
tary gear system and hydraulic equipment to re- final drive (11), where it is reduced, and rotates
duce the speed and shift the gears (forward: 3 sprocket (12).
gears, reverse: 3 gears). It connects two sets of Final drive (15) is a double reduction type con-
clutches selected with the gear shift lever ac- sisting of a single stage spur gear and single
cording to the change in the load, and transmits stage planetary gear system.
the power from the transmission to transfer (14) It rotates the sprocket to drive track shoe (13)
from the output shaft. and move the machine.
The power entering transfer (14) has its speed
reduced. Its speed is further reduced by the bev-
10-2 D375A-5
MAINTENANCE STANDARD POWER TRAIN
1. Engine (SA6D170E-3) 6. Hydraulic pump 11. Final drive

2. Damper (SAR(4)140 + (3)071 + (1)022) 12. Sprocket
3. Universal joint 7. Torque converter 13. Track shoe
4. Power train pump 8. Transmission 14. Transfer
(BAL 180 + 112) 9. Steering clutch 15. Scavenging pump
5. PTO 10. Steering brake (BAR 63 + 277)
D375A-5 10-3
MAINTENANCE STANDARD OVERALL DRAWING OF POWER TRAIN UNIT
OVERALL DRAWING OF POWER TRAIN UNIT
10-4 D375A-5
MAINTENANCE STANDARD OVERALL DRAWING OF POWER TRAIN UNIT
1. PTO Function
2. Torque converter
The power train unit can be broadly divided into
3. Torque converter valve
the torque converter and transmission unit and
4. Transmission control valve
the steering unit.
5. Transmission
Therefore, after the power train is removed as a
6. Steering clutch, brake
unit, it can be divided into the torque converter
7. Steering control valve
and transmission unit and the steering unit.
8. Power train pump (BAL 180 + 112)
The steering unit consists of the transfer, bevel
9. Transmission lubrication oil filter
gear shaft, steering clutches, and steering
10. Power train oil filter
brakes.
11. Power train oil strainer
12. Scavenging pump (BAR 63 + 277)
13. Power train oil tank
D375A-5 10-5
MAINTENANCE STANDARD POWER TRAIN HYDRAULIC PIPING DRAWING
POWER TRAIN HYDRAULIC PIPING DRAWING
1. Oil cooler A. Torque converter lock-up pressure pick-up port

2. Power train oil filter B. Torque converter stator clutch pressure pick-up port
3. Transmission lubrication oil filter C. Left-steering clutch operating pressure pick-up port
4. Centralized pressure detection port D. Left-steering brake operation pressure pick-up port
5. Torque converter valve E. Transmission 2nd clutch operating pressure pick-up
6. Transmission control valve (ECMV) port
7. Steering control valve (ECMV) F. Transmission R clutch operating pressure pick-up port
8. Power train oil tank G. Transmission 3rd clutch operating pressure pick-up
9. Power train oil strainer port
10. Power train pump (BAL 180 + 112) H. Transmission F clutch operating pressure pick-up port
11. Scavenging pump (BAR 63 + 277) J. Right-steering brake operating pressure pick-up port
K. Right-steering clutch operating pressure pick-up port
L. Transmission 1st clutch operating pressure pick-up
port
M. Transmission main relief pressure pick-up port
N. Torque converter regulator pressure pick-up port
P. Torque converter relief pressure pick-up port
10-6 D375A-5
MAINTENANCE STANDARD DAMPER, UNIVERSAL JOINT
DAMPER, UNIVERSAL JOINT
10-8 D375A-5
MAINTENANCE STANDARD DAMPER, UNIVERSAL JOINT
1. Outer body Outline

2. Engine flywheel
The damper protects the power train (such as
3. Output shaft
the torque converter and transmission) by buffer-
4. Coupling
ing torsional vibrations resulting from fluctua-
5. Universal joint
tions in engine torque or impact torque resulting
6. Flange
from sudden acceleration or heavy-duty opera-
7. Rubber coupling
tion.
8. Cover
The rubber coupling on the damper efficiently
9. Breather
absorbs vibrations by rubber materials internal
10. Oil level gauge tube
damping effects and deformation as well as fric-
tional damping effects of the rubber material.
This arrangement also helps reducing number of
components used.
Operation
Motive power of engine is transmitted to the fly-
wheel (2) and outer body (1) through the rubber
coupling (8). After absorption of torsional vibra-
tions of the engine by the rubber coupling, power
is then transmitted to the coupling (4) via the out-
put shaft (3).
Then, power is further transmitted from the cou-
pling to the universal joint (5) up to the torque
converter input shaft.
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance

Clearance between the flywheel size Shaft Hole clearance limit
11
housing and cover
+0.024 +0.080 0.024
647.7 0.2
+0.105 0 0.185
Clearance between the flywheel 0.022 +0.110 0.022

12 546.0 0.25
and damper 0.092 0 0.202
Standard size Repair limit Replace

Outside diameter of the couplings
13 0
oil seal contact surface 109.9
110 0.035
Outside diameter of the output 0

14 109.9
shafts oil seal contact surface 110 0.035
Dimension between the bearing

15 48 0.1 47.7
and holder
D375A-5 10-9
MAINTENANCE STANDARD TORQUE CONVERTER, PTO
TORQUE CONVERTER, PTO
1. Coupling 14. Bearing cage 28. Scavenging pump gear

2. Seal cage 15. Retainer (63 teeth)
3. Input shaft 16. Shaft 29. Seal seat
[PTO drive gear (61 teeth)] 17. Transmission input shaft 30. Spacer
4. Front housing 18. Stator shaft boss 31. Cover
5. Idler gear (77 teeth) 19. Stator clutch housing 32. Hydraulic pump gear (57 teeth)
6. Idler gear shaft 20. Return spring 33. Power train pump gear
7. Clutch housing 21. Stator clutch plate (57 teeth)
8. Drive case 22. Stator clutch disc 34. Cover
9. Turbine 23. Stator clutch piston 35. Cover
10. Rear housing 24. Turbine boss A. Hydraulic pump mount
11. Stator 25. Lock-up clutch disc B. Power train pump mount
12. Pump 26. Lock-up clutch plate C. Scavenging pump mount
13. Stator shaft 27. Lock-up clutch piston
10-10 D375A-5
D375A-5 10-11
10-12 D375A-5
Unit: mm
Standard size Tolerance Repair limit

Outside diameter of coupling oil
1 0
seal contact surface 125 124.8
0.063 Repair hard
Inside diameter of retainer seal +0.046 chrome plating or
2 190 190.5 replace
ring contact surface 0
Inside diameter of sleeve seal ring +0.035

3 110 110.2
contact surface 0
Backlash between PTO drive gear Standard clearance Clearance limit

4
and scavenging pump drive gear 0.250 0.420
Backlash between PTO drive gear

5 0.204 0.516
and driven gear
Standard size Repair limit

6 Wear of stator shaft seal ring Width: 5.95 Width: 5.35
Height: 6.50 Height: 5.85
Lock-up clutch
Thickness of disk 5.4 5.0
Thickness of plate 5.0 4.5

7
Thickness of Replace
15.8 14.5
overall assembly
Thickness of disk 5.4 5.1

Stator clutch
Thickness of plate 5.0 4.5

8
Thickness of
15.8 14.7
overall assembly
Installed Installed Installed

Free length Free length
9 Stator clutch spring length load load
125.5 N 106.9 N
54.1 37.0 52.5
{12.8 kg} {10.9 kg}
D375A-5 10-13
Outline Structure
The torque converter design employs 3-element, The pump (12) is united with the coupling (1),
1-stage and 3-phase arrangement. It is, structur- shaft (3), clutch housing (7) and drive case (8). It
ally, united with the transmission. is rotated by motive power from the engine.
In order to reduce consumption of fuel and en- The turbine (9) is united with the turbine boss
gine horsepower as well as increase operating (24) and transmission input shaft (turbine shaft)
performance, the torque converter incorporates (17). It is rotated by oil from the pump.
the wet type/double plate clutch type torque con- The stator (l1) is united with the stator shaft (13)
verter lock-up device plus the stator clutch de- and stator boss (18). It is fixed to the rear hous-
vice. ing (10) via the stator clutch device.
In continuous light load dozing operations or lev- The lock-up clutch device is consisted of the
eling operation, motive power of the engine can clutch plate (26) engaged with the drive case (8),
be more effectively utilized when it is transmitted the clutch disk (25) engaged with the turbine
directly to the transmissions input shaft. It is why boss (24), and the clutch piston (27) that slides
the hydraulically operated lock-up clutch is incor- in the housing (7) united with the drive case.
porated into the converter. When the torque con- The stator clutch device is consisted of the clutch
verter is locked up (when the pump and turbine disk (22) engaged with the boss (18) (the boss is
are united), oil supply from the converter relief connected to the stator shaft (13) via the spline),
valve is not stopped. Thus, the oil conducted out the clutch plate (21) being secured to the clutch
of the pump - turbine used to be provided with housing (19) and rear housing (10) with the pin,
unnecessary directivity by the stator, resulting in and the clutch piston (23) that slides in the rear
resisting against the pump and turbine rotation housing.
(stirring of oil). In order to return the oil dis- PTO device is consisted of the input shaft (3),
charged from the pump - turbine to the pump idler gear (5), scavenging pump drive gear (28),
with smaller resistance, the stator clutch has work equipment pump drive gear (32) and power
been installed to enable drag turning of the stator train pump drive gear (33).
accompanying the rotation of the pump and tur-
bine as the torque converter is locked up.
Following describes the lock-up mode of the
torque converter and the conditions to be met by
the torque converter mode.
Lock-up range
Torque converter output shaft rotation speed:
1,260 rpm minimum
Torque converter range
Torque converter output shaft rotation speed:
1,230 rpm maximum
The torque converter mode is maintained as
long as gear speed change from the trans-
mission is taking place.
10-14 D375A-5
Path of transmission of motive force
1. Lock-up clutch OFF, stator clutch ON

When the lock-up clutch is OFF, the connec-
tion between drive case (8) and turbine (9) is
cut; and when the stator clutch is ON, rear
housing (10) and stator shaft (13) are con-
nected, so stator (11) is locked and the
torque converter provides the normal func-
tions of a torque converter.
The power generated by the engine passes
through the damper and universal joint, and
is transmitted to coupling (1). Input shaft (3),
clutch housing (7), drive case (8), and pump
(12) rotate as one unit.
The motive force from the pump uses oil to
rotate turbine (9), and is transmitted to trans-
mission input shaft (17), which forms one unit
with the turbine.
2. Lock-up clutch ON, stator clutch OFF

When the lock-up clutch is ON, drive case (8)
and turbine (9) are connected to form one
unit; and when the stator clutch is OFF, the
connection between rear housing (10) and
stator shaft (13) is cut, so stator (11) follows
the rotation of pump (12) and turbine (9).
The power generated by the engine passes
through the damper and universal joint, and
is transmitted to coupling (1). Input shaft (3),
clutch housing (7), drive case (8), and pump
(12) rotate as one unit. In addition, the drive
case and turbine (9) are connected by the
clutch, so the oil is not used.
The motive force is transmitted directly to the
turbine and transmission input shaft (17).
D375A-5 10-15
Flow of oil
Oil set to within 0.90 MPa {9 kg/cm2} by

the torque converter relief valve flows
from port A, passes through the oil hole
inside rear housing (10), and enters
pump (12).
The pump is always being rotated by the
power from the engine, so the oil enter-
ing the pump is given centrifugal force,
and enters turbine (9). The turbine is ro-
tated by the centrifugal force of the oil.
The turbine forms one unit with trans-
mission input shaft (17), so the motive
force received by the turbine is transmit-
ted to the transmission.
The oil leaving the turbine is sent to sta-
tor (11) and enters the pump again, but
some of the oil passes from the stator
through port B and is sent to the oil cool-
er.
10-16 D375A-5
MAINTENANCE STANDARD TORQUE CONVERTER VALVE
TORQUE CONVERTER VALVE
1. Valve body 14. Lock application clutch 28. Lock-up selector valve P. Status clutch pres-
2. Torque converter relief modulating valve 29. Piston sure pick-up port
valve 15. Cover 30. Cover P1. Torque converter re-
3. Valve spring 16. Piston Lock-up solenoid valve lief pressure pick-up
4. Valve spring 17. Piston ring (small) assembly port
5. Main relieve valve 18. Piston 31. Cap P3. Lock-up clutch pres-
6. Cover 19. Valve spring (outside) 32. Coil sure pick-up port
7. Piston 20. Valve spring (inside) 33. Valve P8. Main relief pressure
8. Piston ring 21. Stopper 34. Ball pick-up port
9. Piston 22. Load piston 35. Valve P10. Torque converter reg-
10. Stator clutch modulat- 23. Cover 36. Base ulator pressure pick-
ing valve 24. Valve spring (outside) 37. Shaft up port
11. Piston 25. Cover 38. Case
12. Piston ring (small) 26. Valve spring 39. Plunger
13. Piston 27. Valve body
10-18 D375A-5
Outline
The torque converter valves are provided at the 4. Torque converter lock-up solenoid valve
top of the torque converter housing. They are As the electric signal from the controller is re-
consisted of the following six types of the valves. ceived, the solenoid valve switches the pilot
pressure to the lock-up selector valve (28) in or-
1. Main relief valve der to turn on or off the two clutches via the se-
The main relief valve (5) regulates pressure on lector valve (28).
the hydraulic circuits of the transmission, steer-
ing clutch, lock-up clutch of the brake and torque 5. Stator clutch modulating valve
converter, and stator clutch to 2.55 to 2.75 MPa The modulating valve (10) regulates the clutch
{26.0 28.0 kg/cm2}. pressure to 2.65 MPa {27.0 kg/cm2} in order to
protect the stator clutch from abnormally high
2. Torque converter relief valve temperature. It is also used to increase pressure
The torque converter relief valve (2) regulates of the oil from the lock-up selector valve (28) to
the pressure at the entrance of the torque con- the specified level.
verter to 0.88 MPa {9.0 kg/cm2} in order to pro-
tect it from abnormally high pressure. 6. Lock-up clutch modulating valve
Function of the modulating valve (14) is similar to
3. Converter lock-up valve that of the stator clutch modulating valve (10).
The lock-up selector valve (24) are used to turn This valve is used to regulate the clutch pressure
on or off the lock-up clutch and the stator clutch. to 1.3 MPa {13 kg/cm2}.
D375A-5 10-19
10-20 D375A-5
Unit: mm

Clearance between main relief size Shaft Hole clearance limit
1
valve and valve body
0.035 +0.016
40 0.035 0.061 0.08
0.045 0
Clearance between torque 0.035 +0.016

2 40 0.035 0.061 0.08
converter relief valve and valve 0.045 0
Clearance between stator clutch

0.035 +0.013
3 modulating valve and valve 25 0.035 0.058 0.08
0.045 0
body
Clearance between lock-up

0.035 +0.013
4 clutch modulating valve and 25 0.035 0.058 0.08
0.045 0
valve body
Clearance between lock-up 0.020 +0.013

5 25 0.020 0.043 0.06
valve and valve body 0.030 0

6 Main relief valve spring length load load
1,339.4 N 1,272.4 N
120.3 103 116.7
{136.7 kg} {129.9 kg}
Torque converter relief valve 550.4 N 523.2 N

7 116.92 90.8 113.41
spring {56.16 kg} {53.35 kg}
Stator clutch modulating valve 151.9 N 144.4 N

8 103.5 95.2 100.4
spring {15.5 kg} {14.7 kg}
Lock-up clutch modulating valve 158.6 N 150.7 N

9 141.4 88.7 137.16
spring (Outside) {16.18 kg} {15.37 kg}
Lock-up clutch modulating valve

10 80.5 80.5 78.09
spring (Inside)
55.9 N 53.1 N
11 Lock-up valve spring 66 54.0 64.0
{5.7 kg} {5.42 kg}
D375A-5 10-21
Operation of main relief valve

The oil from the power train pump passes
through the oil filter, and enters port A of the
main relief valve. It then passes through orifice a
and enters port B.
When the oil from the pump fills the circuit, the
pressure starts to rise.
When the pressure in the circuit rises, the oil en-
tering port B pushes piston (9). The reaction
force compresses spring (4), moves main relief
valve (5) to the left in the direction of the arrow,
and opens ports A and C.
When this happens, the oil from the pump is re-
lieved from port A to port C, and flows port C to
the torque converter.
The pressure in the circuit at this point is 2.55
2.75 MPa {26.0 28.0 kg/cm2}.
Operation of torque converter relief valve

The oil relieved from the main relief valve flows
into the torque converter from port C, and at the
same time passes through orifice b and enters
port D.
When the oil fills the torque converter, the pres-
sure starts to rise.
If the pressure in the torque converter rises, the
oil entering port D pushes piston (9). The reac-
tion force compresses spring (3), moves relief
valve (2) to the right in the direction of the arrow,
and opens ports C and E.
When this happens, the oil at port C is relieved
to port E, and is drained to the oil tank.
The pressure in the circuit at this point is
0.88 MPa {9 kg/cm2}.
10-22 D375A-5
Torque Converter Lock-up Control System

System diagram
Operation
The torque converter lock-up control system au- The machine body controller receives the trans-
tomatically locks up the torque converter de- mission controller gear speed information, and
pending on the load of a machine by one sensor the transmission output shaft rotation sensor sig-
signal and controller. When the torque converter nal which is sent from the SSC controlle to con-
is locked up, the indicator lamp on the monitor nect or disconnect the lock-up solenoid and
panel lights up. indicator lamp, performing the ON/OFF of the
The transmission output shaft rotation sensor lock-up.
signal is input to the transmission controller.
Set the lock-up mode on the mode selection
panel.
D375A-5 10-23
The lock-up ON/OFF operation is carried out

when the sensor signal conforms to the condi-
tions below. (It is not turned ON during gear shift-
ing.)
1. Conditions for ON (AND circuit)
1) Not during gear shifting (The status that Gear speed
the clutch is completely engaged): F2, F3,
F1
The transmission controller recognizes rpm R1, R2, R3
the status.
Low speed side

2) When the right-sided conditions for the 1,230 rpm 1,260 rpm
rpm of transmission output shaft

ON
ON rpm are conformed to: or less or more
When the both above conditions 1) and
2) are conformed to. 1,200 rpm 1,230 rpm
OFF
2. Conditions for OFF (OR circuit) or less or more
1) During gear shifting (The status that the
clutch is not completely engaged.) High speed side ON
2,140 rpm
2) When the right-sided conditions for the or less
OFF rpm are conformed to.
2,200 rpm
The status quo is maintained when the conditions of OFF
or more
either 1 or 2 are not conformed to.
10-24 D375A-5
1. When the machine is in torque converter travel mode
When the machine enters torque converter travel Then, the oil from the pump goes through the port Q
mode, the solenoid valve is demagnetized to bring to the port S to function as the back pressure of the
back the plunger (34) upward by oil pressure, open- piston of the stator clutch. It turns ON the stator
ing the seats of valve (27) and ball (28), and the ports clutch after the oil pressure of the circuit goes up.
P and N. At the same time, the oil which has been functioning
Since the drain circuit of the port N is open, the oil at as the back pressure of the piston of the lock-up
the port M is drained as well. clutch is drained through the port L to the port R,
The lock-up selector valve (24) is pushed rightward turning OFF the lock-up clutch.
by the spring (22), closing the ports Q, L, S, and T The oil from the pump also enters the port P. Since
and opening the ports Q, S, L, and R. the solenoid valve is demagnetized, however, it is
drained through the orifice A.
The oil pressure at the port Q is kept by the orifice A
and regulated by the modulating valve (10).
D375A-5 10-25
2. When the machine is in direct travel mode
When the machine enters direct travel mode, the so- The oil from the pump goes through the port Q to the
lenoid valve is magnetized to push the plunger (34) port L to function as the back pressure of the piston
downward, closing the seats of ball (28) and valve of the lock-up clutch. It turns ON the lock-up clutch
(27) to open the ports P and M and close the drain after the oil pressure of the circuit goes up. At the
circuit of the port N. same time, the oil which has been functioning as the
Then, the oil from M moves the piston (25) and lock- back pressure of the piston of the lock-up clutch is
up selector valve (24) leftward to close the ports Q, drained through the port S to the port T, turning
S, L, and R, and open the ports Q, L, S, and T. OFF the stator clutch.
The oil pressure at the port L is regulated by the
lock-up clutch modulating valve (11).
10-26 D375A-5
Operation of the stator clutch and lock-up clutch

modulating valves
The modulating valve is mounted at the circuit
between the lock-up selector valve and the inlet
of two pairs of clutches. To smoothly turn on the
clutch, it gradually increases the oil pressure ap-
plied to the piston up to the specified level. This
operation reduces a shock to the torque convert-
er or transmission.
In the following operation explanation, the mod-
ulating valve for the stator clutch is taken as an
example, and that for the lock-up clutch is alike.
The oil flow to the clutch is reverse, however, de-
pending on the direct travel mode or torque con-
verter travel mode.
1. When the machine is in direct travel mode

When the machine enters direct travel mode, the
solenoid valve is magnetized to cause the oil at
the port M of lock-up selector valve (24) to push
the piston (25) and valve (24) leftward.
Then, the lock-up selector valve (24) is pushed
leftward by an oil pressure larger than the ten-
sion of the spring (22) to close the ports Q and S
and open the ports S and T, draining the oil at the
port S through the port T.
When the oil pressure at the port S vanishes, the
modulating valve (10) is pushed back by the ten-
sion of spring (16) rightward to open the part B
of the port S completely. At that time, the operat-
ing pressure of the stator clutch is drained
through the port S to the port T to turn OFF the
clutch.
The oil from the pump flows through the port Q
to the port L to turn ON the lock-up clutch.
D375A-5 10-27
2. When the machine is in torque converter

travel mode
When the machine enters torque converter trav-
el mode, the solenoid valve is demagnetized
to drain the oil from the pump and at the port M.
The valve (24) moves the valve rightward by the
tension of the spring (22) to close the ports Q, L,
S, and T, and open the ports Q and S. By this op-
eration, the circuit from the port Q, the modulat-
ing valve (10), and up to the stator clutch is
created.
The oil from the pump flows to the stator clutch
through the port Q to start increasing the oil pres-
sure of the circuit.
When the oil pressure at the circuit is increased,
the oil which flowed through the orifice d of the
modulating valve (10) pushes the piston (13),
and its reaction force moves the modulating
valve leftward to throttle back the part B of the
port S.
The port S, which is connected to the port U
which applies a back pressure to the load piston
(19), moves the load piston rightward to shrink
the spring (16) to open the part B of the port S by
the tension of the spring.
The above operation is intermittently repeated to
increase the load of the spring (16), gradually in-
creasing the oil pressure until the oil pressure in-
crease stops at a position where the part B of the
port S closes.
The oil pressure of the stator clutch at that time
is 2.65 0.1 MPa {27.0 1 kg/cm2}.
The oil pressure of the lock-up clutch is
1.3 +0.1 +1
0 MPa {13 0 kg/cm }.
2
10-28 D375A-5
MAINTENANCE STANDARD SCAVENGING PUMP
SCAVENGING PUMP
BAR 63 + 277
A. Discharge port
B. Small pump suction port
C. Large pump suction port
Unit: mm
1 Spline shaft rotation torque
Rotating Discharge Standard Permissible

discharge discharge
Delivery Type speed pressure amount amount
(rpm) MPa {kg/cm2} (l/min) (l/min)

Oil: E010-CD
Oil temperature: 45 55C BAR 63 0.15 63.3
1,743
BAR 277 {1.5} 276.8
D375A-5 10-29
MAINTENANCE STANDARD TRANSMISSION CONTROL
TRANSMISSION CONTROL
Regarding the steering-related description of the
Palm Command Control System lever (PCCS le-
ver), refer to the Steering/Brake Control.
PCCS: Palm Command Control System
1. Brake pedal Lever position Outline

2. Safety lever
(1): Neutral Control the transmission by the PCCS le-
3. PCCS lever
(2): Forward ver (3).
(Forward-reverse, gear shift)
(3): Reverse The PCCS lever operates forward/reverse
3A, UP switch
(4): OFF shifting and gear shift operation.
(Shift up by every one pressing)
(5): Shift UP The adopted safety mechanism does not
3B, DOWN switch
(6): Shift DOWN cause the transmission neutral safety
(Shift down by every one pressing)
(7): Free switch (4) to function except when the
4. Transmission neutral safety switch
(8): Lock safety lever (2) is at the Lock position,
5. Cable
not allowing the engine to start.
6. Transmission control valve
10-30 D375A-5
MAINTENANCE STANDARD TRANSMISSION CONTROL
Gear shift of the machine

Since gear shift during travel is possible, there is no
need to stop the machine to shift gears.
Gear shift operation

Operate the gear shift lever by pressing the switches
(1) and (2) when the steering, forward/reverse, and
gear shift lever is at the forward or reverse position.
(1) One pressing the up shifts the gear speed one
up.
(2) One pressing the down shifts the gear speed
one down.
If you carry out the gear shift, the gear speed in
use is indicated on the display of the panel.
<Ex.> Neutral: Indicates N on the display.
Forward 2nd speed gear:
Indicates F2 on the display.
Reverse 3rd speed gear:
Indicates R3 on the display.
P is indicated when the safety lever is
placed at the Lock position.
D375A-5 10-31
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
1. Input shaft A. 2nd clutch operating pressure pick-up port

2. Transmission valve B. R clutch operating pressure pick-up port
3. Front case C. 3rd clutch operating pressure pick-up port
4. Rear case D. F clutch operating pressure pick-up port
E. 1st clutch operating pressure pick-up port
10-32 D375A-5
10-34 D375A-5
5. Front cover
6. Sun gear for reverse (34 teeth)
7. Ring gear for reverse (91 teeth)
8. Pinion shaft
9. Planetary pinion for reverse (25 teeth)
10. Ring gear for reverse (84 teeth)
11. Sun gear for forward (41 teeth)
12. Planetary pinion for forward (25 teeth)
13. Ring gear for forward (91 teeth)
14. Pinion shaft
15. Ring gear for 3rd speed gear (91 teeth)
16. Planetary pinion for 3rd speed gear (25 teeth)
17. Sun gear for 3rd speed gear (41 teeth)
18. Ring gear for 2nd speed gear (93 teeth)
19. Planetary pinion for 2nd speed gear (23 teeth)
20. Pinion shaft
21. Sun gear for 2nd speed gear (47 teeth)
22. 1st clutch inner drum
23. 1st clutch piston
24. 1st clutch piston housing
25. Output shaft
26. Collar
27. Block
28. 1st clutch spring
29. Seal ring
30. Carrier for 2nd speed gear
31. Plate
32. Carrier for forward, 3rd speed gear
33. Piston housing for forward, 3rd speed gear
34. Carrier for reverse
35. Piston housing for reverse
36. Clutch piston for reverse
37. Clutch spring
38. Clutch plate
39. Clutch disc
40. Tie bolt
41. Carrier gear for reverse (91 teeth)
D375A-5 10-35
10-36 D375A-5
Unit: mm

No. 1 clutch spring Free length Free length
1 length load load
( 12)
125.5 N 107.9 N
66.0 57.0 64.0
{12.8 kg} {11.0 kg}
No. 2 clutch spring 218.7 N 196.1 N
2 70.0 60.3 68.0
( 12) {22.3 kg} {20.0 kg}
No. 3, 4 clutch spring 149.1 N 127.5 N
3 97.0 82.4 95.0
( 12) {15.2 kg} {13.0 kg}
No. 5 clutch spring 3,422.5 N 3,079.3 N
4 7.75 6.75
( 3) {349 kg} {314 kg}
Overall assembled thickness of Standard size Tolerance Repair limit
5
No. 1 clutch 54.6 0.33 49.0
Overall assembled thickness of
6 50.3 0.33 45.0
No. 2 clutch
7 36.4 0.26 32.0
No. 3 clutch
8 27.3 0.22 24.0
No. 4 clutch
9 50.0 0.33 45.2
No. 5 clutch
Thickness of clutch disc
10 4.8 0.1 4.0
(No. 1 4 clutch)
Thickness of clutch disc
11 5.0 0.1 4.2 Replace
(No. 5 clutch)
Thickness of clutch plate
12 4.3 0.1 4.0
(No. 1 4 clutch)
Thickness of clutch plate
13 4.0 0.1 3.8
(No. 5 clutch)
0.01
Wear of seal ring on transmission Width: 3.0 Width: Width: 2.6
14 0.03
input shaft Thickness: 3.5 Thickness: 3.3
Thickness: 0.15
0.01
Wear of seal ring on transmission Width: 4.5 Width: Width: 4.1
15 0.03
output shaft Thickness: 5.8 Thickness: 5.6
Thickness: 0.1
0.01
Width: 5.0 Width: Width: 4.6
16 Wear of seal ring on No. 5 clutch 0.03
Thickness: 6.0 Thickness: 5.8
Thickness: 0.15
Backlash between No. 1, 2 sun Standard clearance Clearance limit
17
gear and planet pinion 0.13 0.40
Backlash between No. 1 planet
18 0.13 0.40
pinion and ring gear inner teeth
Backlash between No. 2, 3, 4
19 planet pinion and ring gear inner 0.14 0.40
teeth
Backlash between No. 3, 4 sun
20 0.13 0.37
gear and planet pinion
Clearance between bearing and
21 0.16 1.59
thrust washer
D375A-5 10-37
Outline
The transmission is a forward 3 gear, reverse 3
gear transmission that consists of a combination
of a planetary gear system and disc clutches.
The transmission actuates the control valve to
use hydraulic pressure to fix two of the clutches
in the five sets pf planetary gears and disc
clutches to select one rotating direction and one
gear speed.
The clutches are locked as follows: No. 1 clutch
for REVERSE, No. 2 clutch for FORWARD, No.
3 clutch for 3rd, No. 4 clutch for 2nd and No. 5
clutch for 1st.
No. of plates and discs used
Clutch No. No. of plates No. of discs
No. 1 clutch 6 6
No. 2 clutch 5 6
No. 3 clutch 4 4
No. 4 clutch 3 3
No. 5 clutch 5 6
Gear speed, clutch combination.
Clutch combination
Gear speed
(engaged)
FORWARD 1st No. 2 . No. 5
FORWARD 2nd No. 2 . No. 4
FORWARD 3rd No. 2 . No. 3
NEUTRAL 1 . No. 5
REVERSE 1st No. 1 . No. 5
REVERSE 2nd No. 1 . No. 4
REVERSE 3rd No. 1 . No. 3
1: Only low pressure oil fills the 1st clutch.
10-38 D375A-5
Operation of disc clutch

To lock ring gear (7), a disc clutch is used. The
clutch consists of piston (36), plates (38), discs
(39), pins (42) and piston return springs (37).
The internal teeth of the disc engage with the ex-
ternal teeth of the ring gear.
The teeth on the outside diameter of the plate
engage with pins (42) secured by housing (35).
Clutch engaged (Locked)

Oil from the control valve flows under pressure
through the port in housing (35) to the back of
piston (36). The piston presses plates (38) and
discs (39) together, and the resulting frictional
force stops the rotation of discs (39), so ring gear
(7) meshing with the internal teeth of the disc is
locked.
Clutch disengaged (free)

When the supply of pressure oil from the control
valve is shut off, piston (36) is returned to its orig-
inal position by the force of piston return spring
(37). This relieves the frictional force between
plates (38) and discs (39), making the ring gear
(7) free.
Washer spring (43) installed between the plates
at the pin acts to speed up the return of the pis-
ton when the clutch is disengaged, and also to
separate the plate and disc cleanly to prevent
continued rotation.
D375A-5 10-39
1st clutch oil circuit

The 1st clutch is farthest from the control valve, and
the piping to the cylinder is longer, so it takes a long-
er time for the oil to fill the piping.
For this reason, even when the gear shift lever is in
neutral, oil still flows to the 1st clutch.
Therefore, when moving the gear shift lever from
neutral to F1, it is only necessary for the oil from the
pump to fill the FORWARD clutch.
When the gear shift lever is moved from F1 to F2, the
FORWARD clutch is already filled with oil, so the oil
from the pump only needs to fill the 2nd clutch. By
using the oil in this way, the time lag when shifting
gear is reduced.
10-40 D375A-5
OPERATION OF TRANSMISSION
FIRST FORWARD SPEED
For FORWARD 1st, No. 2 clutch and No. 5 Ring gear (13) is locked in position by No. 2
clutch are engaged. The motive force transmit- clutch, so planet gear (12) rotates carrier (32),
ted from the torque converter to input shaft (1) is which is on the inside of ring gear (13).
transmitted to output shaft (25). No. 5 clutch is also engaged, so the No. 5 gear
No. 2 clutch is actuated by the hydraulic pres- (22), sun gears (17) and (21), planet pinions, ring
sure applied by the clutch piston and locks ring gear (15) and (18), and No. 4 carrier (30) form
gear (13) in position. No. 5 clutch is actuated by one unit. In addition, carrier (32) rotates as one
hydraulic pressure applied by the clutch piston unit with the gears of No. 3, 4 and 5 clutches to
and engaged No. 5 gear (22) and No. 4 ring gear rotate output shaft (25).
(18). Output shaft (25) rotates at the same speed as
The motive force from the torque converter is carrier (32).
transmitted to input shaft (1). The rotation of the
input shaft is transmitted through sun gear (11)
to planet pinion (12).
D375A-5 10-41
FIRST REVERSE SPEED
For REVERSE 1st, No. 1 clutch and No. 5 clutch Carrier (34) is locked in position by No. 1 clutch,
are engaged. The motive force transmitted from so the rotation of planet pinion (9) rotates ring
the torque converter to input shaft (1) is transmit- gear (10).
ted to output shaft (25). Ring gear (10) rotates in the opposite direction
No. 1 clutch is actuated by the hydraulic pres- from the input shaft, and it rotates carrier (32).
sure applied by the clutch piston and locks carri- No. 5 clutch is also engaged, so the No. 5 gear
er (34) in position. No. 5 clutch is actuated by (22), sun gears (17) and (21), planet pinions, ring
hydraulic pressure applied by the clutch piston gear (15) and (18), and No. 4 carrier (30) form
and engaged No. 5 gear (22) and No. 4 ring gear one unit.
(18). In addition, carrier (32) rotates as one unit with
The motive force from the torque converter is the gears of No. 3, 4 and 5 clutches to rotate out-
transmitted to input shaft (1). The rotation of the put shaft (25).
input shaft is transmitted through sun gear (6) to
planet pinion (9).
10-42 D375A-5
MAINTENANCE STANDARD TRANSMISSION ECMV
TRANSMISSION ECMV
(Electronic Control Modulation Valve)
10-44 D375A-5
1. Proportional solenoid valve for 3rd clutch ECMV

2. Proportional solenoid valve for 1st clutch ECMV
3. Proportional solenoid valve for R clutch ECMV
4. Proportional solenoid valve for 2nd clutch ECMV
5. Proportional solenoid valve for F clutch ECMV
6. Fill switch for 3rd clutch
7. Fill switch for 2nd clutch
8. Fill switch for 1st clutch
9. Fill switch for R clutch
10. Fill switch for F clutch
11. Connector for 1st proportional solenoid valve
12. Connector for 3rd proportional solenoid valve
13. Connector for R proportional solenoid valve
14. Connector for 2nd proportional solenoid valve
15. Connector for F proportional solenoid valve
16. Connector for 3rd fill switch
17. Connector for 2nd fill switch
18. Connector for 1st fill switch
19. Connector for R fill switch
20. Connector for F fill switch
21. Filter
22. Pressure control valve
23. Oil pressure detection valve
24. Pressure control valve spring
A. 1st operating pressure pick-up port
B. 3rd operating pressure pick-up port
C. R operating pressure pick-up port
D. 2nd operating pressure pick-up port
E. F operating pressure pick-up port
F. To clutch
P. From pump
T. Drain
D375A-5 10-45
10-46 D375A-5
Outline of ECMV
The ECMV (Electronic Control Modulation
Valve) consists of the following two units, a pres-
sure control valve and fill switch.
Pressure control valve
Converts a current sent from the transmission
controller to the proportional solenoid valve, to
an oil pressure.
Fill switch
Detects that the clutch is filled with oil. It has the
functions below.
1) It outputs a signal (fill signal) to the controller
as soon as the clutch is filled with oil to report
the completion of filling.
2) It outputs a signal (fill signal) to the controller
while an oil pressure is applied to the clutch
to report the presence/absence of oil pres-
sure.
A region: Before gear shift (When draining)
B region: Filling starts (During trigger)
C region: Filling finishes
D region: Voltage regulation
E region: During filling
ECMV and proportional solenoid

One proportional solenoid is attached to one EC-
MV. After receiving the command current from
the controller, it produces thrust in the figure be-
low.
By making the proportional solenoid-produced
thrust act on the pressure control valve spool, it
produces an oil pressure shown in the figure be-
low. By controlling the amount of command cur-
rent, the thrust is changed to operate the
pressure control valve, controlling the oil flow
and oil pressure.
ECMV and fill switch

One fill switch is attached to one ECMV. When
the clutch completes filling, the pressure of the
clutch turns ON the fill switch. By this signal,
the oil pressure starts build-up.
D375A-5 10-47
(5)
Operation of ECMV
The ECMV is controlled by the command current
sent from the controller to the proportional sole-
noid and the fill switch output signal.
The relation among the proportional solenoid
command current of the ECMV, the clutch input
pressure, and fill switch output signal is as
shown in the figure to the right.
A region: Before gear shift (When draining)
B region: Filling starts (During trigger)
C region: Filling finishes
D region: Voltage regulation
E region: During filling
The clutch is crimped by the piston when shifting
the gear with the gear shift switch. If a high oil
pressure is applied suddenly, however, the pis-
ton connects to the clutch suddenly, causing the
machine to make a sudden start and give an ex-
cessive shock to the machine.
To prevent them, it is designed so that if you con-
nect the ECMV to shift gears with the gear shift
switch, the oil pressure to the clutch may be
gradually increased up to the specified level. By
this design, the clutch is turned ON smoothly to
eliminate the shock at the start, improve the du-
rability of the power transfer system, and also
provide operator comfort.
1. Before gear shift (Region A in the diagram)

When a current is not carried to the proportional
solenoid (1), the pressure control valve (2) is
draining the oil at the clutch port A through the
drain port dr.
Since, at that time, no oil pressure acts on the oil
pressure detection valve (3), the fill switch (4) is
OFF.
10-48 D375A-5
2. When filling (When inputting the trigger com-

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

If you flow a current to the proportional solenoid
(1), the solenoid produces thrust proportional to
the current. Pressure is regulated by striking a
balance among the thrust of the solenoid, the
thrust of the oil pressure of the clutch port, and
reaction force of the pressure control spring (5).
D375A-5 10-49
MAINTENANCE STANDARD TRANSMISSION LUBRICATION RELIEF VALVE
TRANSMISSION LUBRICATION RELIEF VALVE
1. Lubrication oil pressure measurement plug Function

2. Lubrication relief spool The lubrication relief valve is installed to the right
3. Valve body side face of the transmission, and acts to prevent
any abnormal pressure in the transmission lubri-
cating oil.
Cracking pressure: 0.26 MPa {2.7 kg/cm2}
10-50 D375A-5
MAINTENANCE STANDARD POWER TRAIN PUMP + LUBRICATION PUMP
POWER TRAIN PUMP + LUBRICATION PUMP

BAL 180 + 112
Unit: mm
Standard
Type Clearance limit
clearance
1 Side clearance
BAL 180 0.07 0.12 0.15
BAL 112 0.04 0.10 0.13
Clearance between plain bear- BAL 180
2 ing inside diameter and gear 0.060 0.145 0.20
shaft outside diameter BAL 112
Type Standard size Tolerance Repair limit

3 Driving depth of pin BAL 180 0
14 Replace
BAL 112 0.5
4 Spline shaft rotation torque 5.9 Nm {0.6 kgm} or less

discharge discharge
Delivery Type speed pressure amount amount
Oil: E010-CD
2.5 2.7
Oil temperature: 45 50C BAL 180 2,033 334 308
{26 28}
(Engine speed: 1,900 rpm) 0.26
BAL 112 2,033 210 200
{2.7}
D375A-5 10-51
10 Structure, function and maintenance standard
MAINTENANCE STANDARD STEERING, BRAKE CONTROL
STEERING, BRAKE CONTROL

Regarding the transmission-related description
of the operation of the PCCS lever, refer to the
Transmission Control.
PCCS: Palm Command Control System
10-52 D375A-5
MAINTENANCE STANDARD STEERING, BRAKE CONTROL
1. Brake pedal Positions of lever and pedal

2. Safety lever 1: Neutral
3. PCCS lever (Steering) 2: Forward straight-travel
4. Limit switch 3: Reverse straight-travel
5. Steering controller 4: Left clutch OFF
6. Steering ECMV 5: Left clutch OFF
7. Brake valve Left brake ON
8. Parking brake lever (From safety lever) 6: Right clutch OFF
9. Cable 7: Right clutch OFF
10. Rod (From brake pedal) Right brake ON
11. Potentiometer 8: Brake RELEASE
9: Brake ON
:: Free
A: Lock
Outline
The PCCS lever (3) sends an electric signal to If you completely tilt the PCCS lever (3) leftward,
the steering controller (10). After receiving it, the the left steering clutch is turned OFF complete-
steering controller (10) sends a proportional cur- ly and the left steering brake is turned ON,
rent to the steering ECMV (6) to operate the causing the machine to make a sudden left
steering clutch and brake. swing.
The brake pedal (1) sends an electric signal to The safety bar (2) is connected to the parking
the steering controller (10) via the potentiometer brake lever (8) and it also serves as a parking
(11). After receiving it, the steering controller (10) brake.
sends a proportional current to the steering
ECMV (6) to operate the brake. In this case, the
right and left brakes operate at the same time to
activate braking. The rod (5) operates the brake
via the brake valve (9) for redundant use. (Only
at the time of complete braking)
If you slightly tilt the PCCS lever (3) leftward, the
left steering clutch is partially disengaged, caus-
ing the machine to make a slow left swing.
D375A-5 10-53
MAINTENANCE STANDARD TRANSFER, BEVEL GEAR SHAFT, STEERING
TRANSFER, BEVEL GEAR SHAFT, STEERING
1. Transmission unit
2. Input shaft
3. Steering unit
4. Breather
5. Parking brake valve
6. Left brake ECMV
7. Right brake ECMV
8. Transmission output rotation sensor
9. Filter
10. Left clutch ECMV
11. Right clutch ECMV
12. Sudden braking prevention valve
D375A-5 10-55
Transfer Bevel Gear Pinion
1. Input shaft Outline

2. Drive gear (35 teeth) The transfer bevel pinion is mounted at the rear
3. Transmission output rotation sensor part inside the steering case, which receives the
4. Rear cover power from the transmission output shaft by its
5. Bearing gauge input shaft (1). The transfer consists of the drive
6. Driven gear (33 teeth) gear (2) and the driven gear (6) to reduce the
7. Bevel pinion (23 teeth) power speed from the input shaft (1), transferring
8. Bevel gear (40 teeth) it to the bevel pinion (7). It is also provided with
the transmission output rotation sensor (3) to
send the pulse signal of the drive gear (2) to the
torque converter lock-up controller using an
electric signal.
10-56 D375A-5
Unit: mm
Standard clearance Clearance limit

1 Backlash of transfer gear Adjust or replace
0.24 0.63 0.75
Thickness of collar between Standard size Repair limit

2 Replace
transfer gear and bearing 24 23.6
Standard shim thickness for

3 2.0 Adjust
bearing cage mount
D375A-5 10-57
BEVEL GEAR SHAFT, STEERING CLUTCH, BRAKE
10-58 D375A-5
1. Clutch cage Outline

2. Clutch housing As steering clutches, wet-type, multiple disc
3. Clutch spring type, and spring-boosted types are adopted. If
4. Clutch piston you operate the PCCS lever, the controller out-
5. Torque pin puts a proportional solenoid current to hydrauli-
6. Clutch disc (One side: 9 sheets) cally operate the steering ECMV while
7. Clutch plate (One side: 9 sheets) interlocking with the brake.
8. Spacer As a lubrication method, forced lubrication is
9. Clutch stopper adopted, which makes oil from the power train oil
10. Clutch hub cooler flow through the passage in the steering
11. Bearing cage case to the housing and cage, and up to the disc
12. Bevel gear (Number of teeth: 40) plate.
13. Bevel gear shaft
14. Bevel gear shaft As steering brakes, wet-type, multiple disc type,
15. Bearing cage and spring-boosted types brakes are adopted. If
16. Pipe you operate the brake pedal and PCCS lever,
17. Brake stopper the controller outputs a proportional solenoid
18. Brake hub current to hydraulically operate the steering
19. Brake disc (One side: 9 sheets) valve ECMV while interlocking with the brake.
20. Spacer As a lubrication method, forced lubrication is
21. Brake plate (One side: 9 sheets) adopted, which makes oil from the power train oil
22. Torque pin cooler flow through the passage in the steering
23. Brake piston case to the housing and cage, and up to the disc
24. Brake case plate.
25. Brake spring When the engine is stopping, the steering brake
26. Brake cage is ON since the back pressure of the brake pis-
27. Sleeve ton lowers unless you press the brake pedal.
28. Output shaft Since the brake is released as the oil pressure in
the circuit goes up when the engine restarts, the
parking lock lever must be locked.
D375A-5 10-59
10-60 D375A-5
Unit: mm

Thickness of brake, clutch plate Replace
2.9 2.5
1
Tolerance Repair limit
Distortion of brake, clutch plate Repair or replace
Less than 0.3 0.4
Thickness of brake, clutch disc Replace
4.7 4.2
2
Tolerance Repair limit
Distortion of brake, clutch Repair or replace
Less than 0.3 0.4
Overall assembled thickness of Standard size Repair limit

3
brake plates and discs 68.4 64.7
4 68.4 65.4 Replace
clutch plates and discs
Backlash between brake, clutch Standard clearance Repair limit

5
disc and brake hub 0.17 0.52 1.0
Backlash between bevel gear and
6 0.3 0.4 0.75 Adjust or replace
pinion
Clearance between piston seal
7 0.5 0.8 0.8
ring groove and seal ring
Clearance between cage seal
8 0.5 0.8 0.8
ring groove and seal ring

Inside diameter of cage seal ring size Shaft Hole clearance limit
9
contact surface
0.5 +0.081 0.5
290
0.7 0 0.781
Inside diameter of piston seal ring 0.050 +0.046 0.050
10 245
contact surface 0.122 0 0.168
11 Brake belleville spring length load load
38.7 kN 33.9 kN
17.1 11.2 16.5
{3,950 kg} {3,460 kg}
37.9 kN 36.0 kN
12 Clutch belleville spring 17.6 11.35 17.0
{3,860 kg} {3,670 kg}
Standard Tolerance Standard Interference

Interference between bevel gear size Shaft Hole interference limit
13
and reamer bolt
+0.019 +0.027 0.026
16 0.02
+0.001 0 0.019
14 Runout of back face of bevel gear Repair limit: 0.05 (measure after installing to bevel gear) Repair or replace
Standard rotating torque: 4.9 5.9 Nm {0.5 0.6 kgm}
Preload of bevel gear shaft taper
15 (At tip of bevel gear teeth with bevel pinion and gear not Adjust
roller bearing
meshed: 23.5 28.4 N {2.4 2.9 kg})
Standard shim thickness for bear-
16 2.0 Adjust shim
ing cage
D375A-5 10-61
MAINTENANCE STANDARD STEERING ECMV
STEERING ECMV
(Electronic Control Modulation Valve)
10-62 D375A-5
1. ECMV (For left clutch) A. Left clutch operating pressure pick-up port
2. ECMV (For right clutch) B. Right clutch operating pressure pick-up port
3. Sudden braking prevention valve C. Left brake operating pressure pick-up port
4. Parking brake valve D. Right brake operating pressure pick-up port
5. ECMV (For left brake) E. To left clutch
6. ECMV (For right brake) F. To left lubrication
7. Filter G. To left brake
8. Valve seat H. To right clutch
J. To right lubrication
K. To right brake
L. Bevel gear shaft lubrication inlet
M. To pin puller solenoid valve
N. From pin puller solenoid valve
P. From pump
D375A-5 10-63
10-64 D375A-5
Outline
This machine employs four ECMV (electronic-
controlled modulation valve) on the steering con-
trol valve.
The steering control valve is provided on respec-
tive valve sheets as the assembly.
The steering control valve is situated in the cir-
cuit between the power train pump via the main
relief valve and the piston of the steering clutch
and the brake. It is configured with two pairs of
the steering ECMV (right and left) and the brake
ECMV (right and left).
Shifting the PCCS lever (steering and forward/
reverse) right or left disconnects the steering
clutch. Shifting it further turns ON the brake.
The controller sends the instruction to respective
ECMV to cause the gradual or sudden turn
whichever is designated by the operating posi-
tion of the PCCS lever (steering lever).
Depending on depth of the pedal depression, the
controller instructs ECMV to apply the right and
left brakes to stop the machine.
The controller that is electrically connected to the
PCCS lever and pedal performs above opera-
tions by switching the steering control valves
(each ECMV).
The steering control valves feed the oil from the
power train pump to the steering clutch and
brake to operate their disk clutches.
The sudden stop prevention valve disables sud-
den braking that can result when a failure is de-
tected in the electric systems.
Shifting the parking brake lever to the Lock po-
sition switches the port of the parking brake
valve, thereby draining the oil between the
ECMV for left-and-right brakes and the brake. As
the result, the machine brake is turned on.
The parking brake is also connected to the brake
pedal via the linkage.
D375A-5 10-65
MAINTENANCE STANDARD STEERING CLUTCH, STEERING BRAKE ECMV
STEERING CLUTCH, STEERING BRAKE ECMV

(Electronic control modulating valve)
A: To clutch or brake 1. Fill switch connector

P: From pump 2. Proportional solenoid connector
T: Drain 3. Pressure detection valve
Dr: Drain 4. Fill switch
P1: Clutch or brake pressure pick-up port 5. Proportional solenoid
P2: Pilot pressure pick-up port 6. Pressure control valve
10-66 D375A-5
Outline of ECMV
The ECMV (Electronic Control Modulating valve)
consists of a pressure control valve and a fill
switch.
Pressure control valve
This valve allows a proportional solenoid to re-
ceive a current sent from a steering controller
and converts it to oil pressure.
Fill switch
This component detects that a clutch is filled with
oil and has the following functions.
1) When the clutch is filled with the oil, at the
same time, a signal (fill signal) is output to
the controller and transmits filling termina-
tion.
2) While oil pressure is applied to the clutch,
the signal (fill signal) is output to the control-
ler and transmits the presence of oil pres-
sure.
ECMV and Proportional Solenoid

One proportional solenoid is mounted for each
ECMV. A thrust is generated according to the
command current of the controller.
The thrust generated by the proportional sole-
noid is actuated on a pressure control valve
spool and generates oil pressure. Accordingly,
by controlling an amount of the command cur-
rent, the thrust changes and the pressure control
valve is actuated, then a flow of oil and the oil
pressure is controlled.
Operation of ECMV
The ECMV is controlled using the command cur-
rent from the controller to the proportional sole-
noid and a fill switch output signal.
ECMV for Steering Clutch and Steering

Brake
Outline
This valve sets the steering clutch oil pressure or
the steering brake oil pressure to a set pressure
and switches a circuit to the clutch chamber and
the brake chamber.
D375A-5 10-67
Operation
1. In case of PCCS lever Neutral, brake pedal Released: Straight travel

(Left and right clutch ON, left and right brake Released, parking brake OFF)
In the position of PCCS lever Neutral and brake Further, the proportional solenoid valve (5) of the
pedal Released, because the solenoid valve (1) brake ECMV is energized and pushes the ball (6)
of the steering ECMV is deenergized, the sealing to the left direction, then closes the sealing portion.
portion of the ball (2) is opened. The oil that entered the pump port Pb enters the E
The oil from the power train pump enters the port port, pushes the valve (7) left, opens the Pb and B
Pc of the steering ECMV via the main relief valve. ports, and closes the B and Dr ports. The oil that
The oil that entered the port Pc passes through the entered the Pb port passes through the B port and
orifice a and passes through the sealing portion of flows into the back pressure port of the brake pis-
the ball (2), then is drained. ton. Subsequently, the piston moves to the left di-
The valve (3) is moved right by the tension of the rection waiting for the rise of the circuit oil pressure
spring (4) and closes the Pc and C ports, then and compresses the brake spring, then sets the
opens the C and Dr ports. At this time, the oil from brake Released.
the back pressure port of a clutch piston is drained In the parking brake OFF, the parking brake is
from the port C and the clutch is set to ON by the closed and the oil of the brake circuit is not drained.
tension of the clutch spring. The oil pressure of the
brake circuit is ensured by the orifice a.
10-68 D375A-5
2. When the PCCS lever is actuated halfway to the left: Slow swing
(Left clutch OFF, left brake Semi-released, right clutch ON, right brake Released, parking
brake OFF)
When the PCCS lever is actuated halfway to the proportional solenoid valve (5) in accordance with
left, the solenoid valve (1) of the left steering ECMV the stroke of the PCCS lever. When the current
is energized and pushes the ball (2) to the left direc- flows into the proportional solenoid (5), the sole-
tion, then closes the sealing portion. noid generates a thrust in proportion to the current.
The oil from the power train pump passes through The sum of the thrust of this solenoid, the thrust
the orifice a from the port Pc and enters F. Subse- caused by the brake port oil pressure, and the res-
quently, the oil pushes the valve (3) to the left and titution of the pressure control valve spring (8) is
opens the Pc and C ports, then closes the C and Dr balanced and pressure-adjusted.
ports. The oil of the C port flows into the clutch pis- Accordingly, if the stroke of the PCCS lever is
ton port and becomes the back pressure, then sets small, the oil pressure of the port B and later is also
the left clutch to OFF. specified high and the brake changes from Re-
Further, the proportional solenoid valve (5) of the leased to Semi-released. If the stroke is large,
left ECMV is energized and pushes the ball (6) to the oil pressure is specified low and the brake
the left direction, then closes the sealing portion. changes from Semi-released to ON.
The oil that entered the pump port Pb enters the E In the parking brake OFF, the parking brake valve
port and pushes the valve (7) to the left. is closed and the oil of the brake circuit is not
Besides, the oil pressure of the port B and later out- drained.
puts a command current from the controller to the
D375A-5 10-69
3. When the PCCS lever is actuated fully to the left: Sudden swing
(Left clutch OFF, left brake ON, right clutch ON, right brake Released, parking brake OFF)
When the PCCS lever is actuated fully to the left The left brake is set to ON by the tension of the
from the state of Section 2, the proportional so- brake spring.
lenoid valve (5) of the left brake ECMV is deen- In the parking brake OFF, the parking brake
ergized and sets the ball (6) free, then opens the valve is closed and the oil of the brake circuit is
sealing portion. not drained.
Because the oil of the port E passes through the
sealing portion and is drained, the valve (7) is
moved right by the tension of the spring (8).
At this time, the port Pb closes and the port B
and drain port Dr open.
The oil from the power train pump passes
through the orifice b from the port Pb and passes
through the sealing portion, then is drained. The
oil pressure of the clutch circuit is ensured by the
orifice b. On the other hand, the oil that flows into
the brake piston port and reached the back pres-
sure is drained from the port B to Dr.
10-70 D375A-5
4. In case of brake pedal Stepped on

(Clutch ON, brake ON, parking brake OFF)
When the brake pedal is stepped on, the propor- steering ECMVs is deenergized and the left and
tional solenoid valve (5) of the left and right right clutches are set to ON.
brake ECMVs is deenergized from energization Further, when the brake pedal is stepped on, the
by the pedal full actuation. parking brake valve linked using a linkage is ac-
A command current is output from the controller tuated and drains the oil of the brake circuit.
to the proportional solenoid valve (5) in accor-
dance with the actuation stroke of the brake ped-
al. When the current flows into the proportional
solenoid valve (5), the solenoid generates a
thrust that is proportional to the current. The sum
of the thrust of this solenoid, the thrust caused by
the oil pressure of the brake port, and the resti-
tution of the pressure control valve spring (8) is
balanced and oil pressure is specified, thereby
enabling adjustment of the effect of the brake.
Besides, because the PCCS lever is not actuat-
ed, the solenoid valve (1) of the left and right
D375A-5 10-71
5. In case of parking brake ON

(Clutch ON, brake ON, PCCS lever Neutral, braking pedal Released)
When the safety lever for the PCCS lever is set port A, port B, and drain port C, then the brake is
to the position of Locked, the parking brake set Released by oil pressure.
valve (1) moves to the left direction and the ports
A, B, and C open. Accordingly, the oil that flows
into the brake piston port and reached the back
pressure passes through the port C from the
ports A and B and is drained. The back pressure
of the brake piston port continues decreasing
and the brake is fully set to ON, then is held in
the state.
Further, because the ports A and B continue be-
ing opened together with the drain port C even if
the engine is restarted, the state of the brake
ON is held.
In the parking brake OFF, the parking brake
valve (1) moves right and is closed between the
10-72 D375A-5
MAINTENANCE STANDARD PARKING BRAKE VALVE
PARKING BRAKE VALVE
Unit: mm

Clearance between parking brake size Shaft Hole clearance limit
1 Replace
valve spool and valve body
0.020 +0.011 0.020
14 0.05
0.030 0 0.041
Sliding portion outside diameter Tolerance Repair limit Hard chrome

2 (spool) with dust sealing and V- 14 0.020 plating correction
packing 13.9 and replace
0.030

3 Parking brake valve spool spring length load load Replace
38.2 N 36.3 N
65 47.7 63.1
{3.9 kg} {3.71 kg}
D375A-5 10-73
MAINTENANCE STANDARD SUDDEN STOPS PREVENTION VALVE
SUDDEN STOPS PREVENTION VALVE
Outline
This sudden stops valve is installed to prevent a
vehicle from being braked suddenly when an er-
ror occurs in an electrical system.
When the sudden stops prevention valve (1) is
installed in the drain circuit of the brake ECMV
and the solenoid valve (2) of the brake ECMV is
deenergized, the oil of the brake circuit D is
drained and sudden braking is prevented from
being applied. Accordingly, when the solenoid
valve (3) of the sudden stops prevention valve
(1) is deenergized, the brake is set to Semi-re-
leased by throttling the brake drain circuit D that
works as the orifice a circuit.
10-74 D375A-5
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
Outline
The final drive is a single stage spur gear, single
stage planetary gear reduction type.
The lubrication is of splash type using the rota-
tion of the gears.
The final drive can be removed and installed as
a single unit.
Floating seal (1) is installed to the rotating sliding
portion of the sprocket to prevent the entry of dirt
or sand and to prevent leakage of lubricating oil.
D375A-5 10-75
10-76 D375A-5
1. Floating seal 8. Floating seal guard 15. First pinion

2. Sun gear 9. Cover 16. Final drive case
3. Carrier 10. Planetary pinion 17. Bearing cage
4. Hub 11. Ring gear 18. Boss
5. Cover 12. Cover 19. Shaft
6. Sprocket boss 13. First gear 20. Wear guard
7. Sprocket teeth 14. First gear hub 21. Pivot shaft
Unit: mm
Backlash between first pinion and Standard clearance Clearance limit

22
first gear 0.25 0.99 1.5
Backlash between sun gear and

23 0.22 0.81 1.5
planetary pinion
Backlash between planetary

24 0.25 0.81 1.5
pinion and ring gear
Outside diameter of oil seal Standard size Repair limit

25
contact surface of first pinion 115.0 114.9
Thickness of thrust collar in roller Replace

26 25.14 24.9
bearing of inner body
Thickness of thrust collar in roller

27 10.0 9.5
bearing of first gear boss
Dimensions from cover mounting

28 24.0 22.5
face to button head

Clearance between pinion shaft size Shaft Hole clearance limit
29
and carrier
0.036 0.024 0.023
85 0.1
0.058 0.059 0.034
Standard shim thickness of first

30 2
pinion bearing cage
Dimensions of final cover end 0 Adjust

31 7
surface and bearing end surface 0.2
32 Clearance of floating seal guard 4.1 5.3
D375A-5 10-77
PATH OF POWER TRANSMISSION
10-78 D375A-5
The power from the bevel gear and steering

clutch is transmitted to No. 1 pinion (15). It then
passes through No. 1 gear (13), which is
meshed with the No. 1 pinion, and is transmitted
to sun gear (2) to rotate it.
The rotation of sun gear (2) is transmitted to
planet pinion (10), but ring gear (11), which is
meshed with the planet pinion, is fixed to cover
(9), so the planet pinion rotates on its own axis
and moves around the sun gear along the ring
gear.
Then, the rotating force of sun gear (2) forms the
rotating force of carrier (3), which supports the
planet pinion, and is transmitted to sprocket hub
(4).
The direction of rotation of carrier (3) is the same
as that of sun gear (2).
The rotating force transmitted to sprocket hub (4)
is transmitted to sprocket teeth (7).
D375A-5 10-79
MAINTENANCE STANDARD TRACK FRAME
TRACK FRAME
1. Idler Outline
2. Recoil spring assembly The track roller adopts a K type bogie mount, thereby increasing
3. Carrier roller the actual ground contact area between a road surface and a
4. Track frame track shoe in an uneven ground and increasing drawbar pull.
5. Sprocket Because a rubber pad is mounted on a K type bogie, the shock
6. Sprocket cover from a road surface is absorbed.
7. Track roller bogie
8. Track roller Track roller bogie
9. Gap
10. Idler yoke
11. Cylinder Track roller flange type and bogie arrangement
12. Guide
No. 1 No. 2 No. 3 No. 4 No. 5 No. 6 No. 7
S D S D S D S
10-80 D375A-5
MAINTENANCE STANDARD TRACK FRAME
Unit: mm
Item Repair limit
Deformation of track frame outer Bend 7 (Per length 3,000) Correct or

4
sleeve Torsion 3 (Per level length 300) replace
Concave (Pipe portion) 12

Clearance between inner sleeve size clearance limit
Shaft Hole
13 and adjustment cylinder Replace
protruding portion 0.15 +0.3 0.15
60 2.0
0.35 0 0.65
Clearance between idler bogie Standard clearance Clearance limit

14 Adjust
and guide 0 0.5 3.0
15 Press fit force of cartridge pin 245 441 kN {25 45 ton}
D375A-5 10-81
MAINTENANCE STANDARD RECOIL SPRING
RECOIL SPRING
1. Yoke Outline
2. Nut Recoil spring (4) is used to adjust the track ten-
3. Retainer sion by pumping in or releasing grease from lu-
4. Recoil spring bricator (10) to move rod (5) forward or
5. Rod backward. The recoil spring (4) also acts to
6. Spring cylinder dampen any sudden shock brought to bear on
7. Retainer the idler.
8. Holder
9. Piston
10. Lubricator (for pumping in and releasing grease)
11. Grease chamber cylinder
10-82 D375A-5
MAINTENANCE STANDARD RECOIL SPRING
Unit: mm

4 Recoil spring length load load
499.7 kN 458.5 kN
1,416 1,230.5 1,440
{50,994 kg} {46,790 kg}
Standard Tolerance Standard Clearance Replace

Clearance between outer and size clearance limit
Shaft Hole
12 inner sleeve sides of outer sleeve
bushing 0.058 +0.317 0.118
380 0.8
0.228 +0.060 0.545
Clearance between adjustment 0.600

13 135
cylinder and bushing 1.000
Press fit force of outer sleeve

14 49.0 109.8 kN {5.0 11.2 ton}
bushing (outer sleeve side)
Press fit force of outer sleeve

15 91.2 322.6 kN {9.3 32.9 ton} Adjust
bushing (inner sleeve side)
Clearance between recoil spring

16 0 1.0
mounting nut and lockplate
D375A-5 10-83
MAINTENANCE STANDARD IDLER
IDLER
10-84 D375A-5
MAINTENANCE STANDARD IDLER
Unit: mm
Outside diameter of protruding Standard size Repair limit

1
portion 927
2 Outside diameter of tread 880 855

Rebuild or
3 Depth of tread 23.5
replace
4 Thickness of tread 32.5 20
5 Total width 294.4
6 Width of tread 79.0 87.5

Clearance between shaft and size Shaft Hole clearance limit
7 Replace bushing
busing
0.350 +0.198 0.297
155
0.413 0.053 0.611
Standard size Repair limit Rebuild or

8 Collar width of shaft
252 replace

Interference between shaft and size Shaft Hole interference limit
9 Replace ring
ring
+0.046 0.15 0.15
95 0.8
0 0.20 0.246

10 End play Adjust or replace
0.49 0.86
D375A-5 10-85
MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
Unit: mm
Outside diameter of flange Standard size Repair limit

1
(outside) 310
Outside diameter of flange
2 300
(inside)
Outside diame- Single flange 270 200

3
ter of tread Double flange 270 210
Thickness of Single flange 60 25

4
tread Double flange 60 30 Rebuild or
replace
5 Total width 358
6 Width of tread (Single flange) 82
7 Width of tread (Double flange) 82
Width of flange
8 29 14
(Outside double flange)
Width of flange
9 27 12
(Inside double flange)
10 Collar width of shaft 306

11 Replace bushing
bushing
0.350 +0.260 0.360
140
0.413 +0.010 0.673

12 Replace
ring
+0.046 0.13 0.130
75
0 0.18 0.226
13 End play Adjust or replace
0.44 0.91
10-86 D375A-5
MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
Unit: mm

1 Outside diameter of flange
242
2 Outside diameter of tread 210 185 Rebuild or

3 Width of tread 79 replace
4 Thickness of tread 40 27.5
5 Width of flange 23 12

6
ring
+0.245 +0.035
90 0.150 245
+0.185 0

Replace
7
support
0 +0.350
86 0 0.550
0.2 0

8 Axial play of roller
0.01 0.22
D375A-5 10-87
MAINTENANCE STANDARD TRACK ROLLER BOGIE
TRACK ROLLER BOGIE
1. Guide 6. Small bogie Outline

2. Gap 7. Track roller assembly The track roller is mounted on
3. Track roller assembly (Double) 8. Cover the small bogie (6) respectively
4. Large bogie 9. Cartridge pin so that the track roller and track
5. Rubber mount shoe can be touched constantly.
The vehicle body vibration from
a road surface is absorbed by
the rubber mount (5).
10-88 D375A-5
MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
Portion P shows the link on the side where the bushing is pressed fitted.
10-90 D375A-5
MAINTENANCE STANDARD TRACK SHOE
Unit: mm
Standard size Repair limit Reverse or

1 Link pitch
280.3 283.3 replace
2 Height of grouser 93 30 Lug welding,

3 Total height of shoe 116 53 rebuild or replace
Standard Reverse
4 Outside diameter of bushing size Light load Heavy load Reverse or

98.5 90 92.5 replace
5 Thickness of bushing 18.8 10.3 12.8

6 Height of link Rebuild or
181 163
replace
7 Thickness of link 56 38
Clearance between links One side Both side

8
(Busing press fir force) 1.4 2.8
Standard Tolerance Standard

Interference between bushing size Shaft Hole interference
9
and link
+0.622 +0.087 Adjust or replace
98 0.435 0.622
+0.522 0
Interference between regular pin +0.426 +0.127

10 60 0.239 0.373
and link +0.366 +0.053
Tightening torque Retightening angle

a. Regular link (Nm {kgm}) (Angle)
11 Shoe bolt
1,372 137 {140 14} 120 10
Retightening
b. Master link 686.4 68.6 {70 7} 180 10
D375A-5 10-91
MAINTENANCE STANDARD MAIN FRAME
MAIN FRAME
10-92 D375A-5
MAINTENANCE STANDARD MAIN FRAME
1. Main frame 6. Cage 11. Gap

2. Bracket 7. Clamp 12. Cushion
3. Gap 8. Seal 13. Bushing
4. Cushion 9. Cover 14. Flange
5. Plate 10. Coupling 15. Cushion spacer
Unit: mm

Interference between steering size Shaft Hole interference limit
16
case and bushing
+0.108 +0.052 0.004
275 Min. 0
+0.056 0 0.108
Clearance between steering 0.018 +0.057 0.018

17 332 0.2
frame and final cage 0.075 0 0.132
Clearance between bracket and +0.018 +0.046 0.018

18 70 0.1
cushion 0.012 0 0.058
Clearance between ripper beam 0.036 +0.166 0.064

19 120 1.5
mounting pin and bushing 0.090 +0.028 0.256
Clearance between ripper

0.036 +0.287 0.236
20 cylinder mounting pin and 100 1.5 Replace
0.090 +0.200 0.377
bushing
Clearance between radiator 0.030 +0.371 0.299

21 80 1.5
guard mounting pin and bushing 0.076 +0.269 0.477
Clearance between radiator 0.036 +0.369 0.303

22 90 1.0
guard mounting pin and bushing 0.090 +0.267 0.459
Clearance between equalizer bar 0.036 +0.243 0.137

23 120 1.0
shaft and bushing 0.090 +0.101 0.333
Amount of rubber protrusion on Standard size Repair limit

24
seal end surface 1 0.5
25 Free height of front mount rubber 105 103
26 Free height of rear mount rubber 58 56
Press fit force of ripper beam

27 44.1-117.6 kN {4.5 12 ton}
mounting bushing
Press fit force of ripper

28 58.8-171.6 kN {6 17.5 ton}
cylinder mounting bushing
Press fit force of radiator guard

29 98.0-181.4 kN {10 18.5 ton} Adjust
mounting bushing
Press fit force of radiator guard

30 58.8-137.3 kN {6 14 ton}
mounting bushing
Press fit force of equalizer bar

31 31.4-105.9 kN {3.2 10.8 ton}
shaft mounting bushing
D375A-5 10-93
MAINTENANCE STANDARD SUSPENSION
SUSPENSION
1. Equalizer 8. Cover Outline

2. Pivot shaft assembly 9. Seal For the track frame, the front is set upside down
3. Cover 10. Bushing centering around the pivot shaft (6) at the tail.
4. Thrust plate 11. Side pin Further, the equalizer (1) is swung centering around
5. Thrust plate 12. Center pin the center pin (12) and linked with the left and right
6. Pivot shaft 13. Busing track frames using the side pin (11).
7. Seal cage
10-94 D375A-5
Unit: mm

Clearance between center pin size Shaft Hole clearance limit
14
and bushing
0.036 +0.243 0.137
120 1.0
0.090 +0.101 0.333
Clearance between side pin and 0.048 +0.015 0.033

15 95 1.0 Replace bushing
bushing 0.078 0.015 0.093

Interference between side pin size Shaft Hole interference limit
16
boss and bushing
+0.045 0.028 0.055
160
+0.027 0.068 0.113
Press fit force of center pin

17 49.0-186.3 kN {5 9 ton}
bushing
18 Press fit force of side pin bushing 34.3-73.5 kN {3.5 7.5 ton}
D375A-5 10-95
1. Indicates the left of the blade single tilt specifications.

2. Indicates the right of the blade single tilt specifications.
Unit: mm

Interference between thrust size Shaft Hole interference limit
19
washer and seal +0.213 0.180 0.278
230
+0.098 0.226 0.439
Replace
Interference between thrust +0.140 0.061 0.161
20 165
washer and seal +0.100 0.124 0.264
Interference between pivot shaft +0.096 0.115 0.165
21 213
and seal +0.050 0.187 0.283
Clearance between pivot shaft size Shaft Hole clearance limit
22
and busing 0.145 +0.097 0.174
175 1.0 Replace bushing
0.208 +0.029 0.305
Clearance between pivot shaft 0.170 +0.072 0.170
23 210 1.0
and bushing 0.242 0 0.314
10-96 D375A-5
MAINTENANCE STANDARD WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM

BLADE SYSTEM
SEMI U + TILT
1. Blade tilt cylinder 6. Hydraulic tank

2. R.H. blade lift cylinder 7. Ripper Hi valve
3. Blade lift valve 8. Work equipment + PPC charge pump
4. Blade tilt, ripper Lo valve (SAR(4)140 + (3)071 + (1)022)
5. Hydraulic filter 9. L.H. blade lift cylinder
D375A-5 10-97
U-DOZER + DUAL TILT
1. Blade tilt cylinder 8. Hydraulic tank

2. R.H blade lift cylinder 9. Ripper Hi valve
3. Pitch solenoid valve 10. Work equipment + PPC charge pump
4. Dual tilt solenoid valve (SAR(4)140 + (3)071 + (1)022)
5. Blade lift valve 11. L.H. blade lift cylinder
6. Blade tilt, ripper Lo valve 12. Blade pitch cylinder
7. Hydraulic filter
10-98 D375A-5
RIPPER SYSTEM
MULTIPLE SHANK RIPPER
1. Ripper Hi valve
2. Ripper tilt cylinder
3. Ripper lift cylinder
D375A-5 10-99
GIANT RIPPER

2. Ripper Hi valve
3. Ripper tilt cylinder
4. Ripper lift cylinder
5. Pin puller cylinder
(from power train hydraulic circuit)
6. Solenoid valve
(for pin-puller)
10-100 D375A-5
MAINTENANCE STANDARD PPC CONTROL PIPING DIAGRAM
PPC CONTROL PIPING DIAGRAM

BLADE, RIPPER CONTROL
1. Blade lift valve 8. PPC charge pump (SAR(1)022)

2. Blade tilt, ripper Lo valve 9. Hydraulic pump (SAR(4)140 + (3)071)
3. PPC charge valve 10. Oil cooler (for PPC)
4. Accumulator
5. Ripper control PPC valve
6. Blade control PPC valve
7. PPC lock valve
D375A-5 10-101
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL
WORK EQUIPMENT CONTROL
The drawing shows a pitch dozer and pin puller installed vehicle.
10-102 D375A-5
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL
1. Work equipment safety lever

2. Blade control lever
3. Tilt/pitch selector switch
4. Ripper control lever
5. Pin puller switch
6. PPC lock valve
Lever positions
1: Blade HOLD
2: Blade LOWER
3: Blade FLOAT
4: Blade RAISE
5: Blade (left tilt/pitch)
6: Blade (right tilt/pitch)
7: Ripper HOLD
8: Ripper RAISE
9: Ripper LOWER
@: Ripper TILT IN
A: Ripper TILT BACK
B: FREE
C: LOCK
D: Pitch selector switch OFF
E: Pitch selector switch ON
F: Dual tilt selector switch OFF
G: Dual tilt selector switch ON
H: Pin puller switch PUSH IN
I: Pin puller switch PULL OUT
Outline
The work equipment control employs a PPC sys-
tem which uses a PPC valve to move the spools
of the control valve.
Work equipment safety lever (1) is interconnect-
ed with PPC lock valve (6), and when it is at the
LOCK position, the flow of oil in the PPC circuit
is stopped.
D375A-5 10-103
MAINTENANCE STANDARD HYDRAULIC TANK
HYDRAULIC TANK
1. Sight gauge Outline

2. Oil filler The hydraulic tank has an assembled type (ex-
3. Valve ternally installed) main control valve and a built-
4. Hydraulic filter in hydraulic filter. The tank capacity is 230 l and
5. Baffle tube the amount of oil inside the tank is set at 120 l.
6. Blade tilt, ripper Lo valve
7. Blade lift valve
P1. From large pump
A. To blade lift cylinder head
B. To blade lift cylinder bottom
P. From small pump
A1. To blade tilt cylinder bottom
B1. To blade tilt cylinder head
A2. To ripper tilt cylinder bottom
B2. To ripper lift cylinder head
A3. To ripper lift cylinder head
B3. To ripper lift cylinder bottom
T. From ripper Hi valve
10-104 D375A-5
MAINTENANCE STANDARD PPC CHARGE VALVE
PPC CHARGE VALVE
10-106 D375A-5
1. Strainer
2. Body Item Specified value
3. Piston
4. Valve Cracking pressure MPa {kg/cm2} 3.78 {38.5}
Relief valve
5. Spring Relief valve Set pressure MPa {kg/cm2} 4.46 {45.5}
6. Sleeve
7. Screw Oil cooler bypass 490 49
Cracking pressure KPa {kg/cm2}
8. Accumulator valve {5 0.5}
9. Accumulator check valve Accumulator 24.5 4.9
10. Oil cooler bypass valve Cracking pressure KPa {kg/cm2}
check valve {0.25 0.05}
C. Oil cooler Filter mesh size m 24 110
P. From PPC pump Strainer
P2. To valve Filtering area cm2 62.2
T. To hydraulic tank
Unit: mm

Clearance between relief valve size Shaft Hole clearance limit
11
and spool
0.040 +0.018 0.040
13 0.10
0.061 0 0.079
Clearance between check valve 0.032 +0.027 0.032

12 14 0.11
and body 0.059 0 0.086

Replace
13 Relief valve spring length load load
215.7 N 204.9 N
39.3 33.1 38.1
{22.0 kg} {20.9 kg}
37.3 N 35.3 N
14 Oil cooler bypass valve spring 26.3 19.1 25.4
{3.8 kg} {3.6 kg}
1.96 N 1.77 N
15 Accumulator check valve spring 20.6 19.1 20.0
{0.2 kg} {0.18 kg}
D375A-5 10-107
1. Adjustment screw
2. Lock nut
3. Sleeve
4. Main valve spring
5. Pilot piston
6. Main valve
Set pressure:
4.46 MPa {45.5 kg/cm2} (At 44.5 l/min)
Outline
The PPC charge valve acts to relieve the oil sent
from the pump when the PPC valve is at NEU-
TRAL.
It also acts to set the pressure sent to the PPC
valve to the set pressure.
Operation
Chamber A is connected to the pump circuit and
chamber C is connected to the tank drain circuit.
The oil passes through the orifice in the main
valve and fills chamber B.
When the pressure in chamber A rises, and the

x
differential pressure [ 4 (D2d2) pressure of
chamber A] caused by the difference in the area
of diameter D and d reaches the pressure set by
the main valve spring, the main valve opens. The
pressurized oil in chamber A then escapes to
chamber C, so the pressure in chamber A drops.
10-108 D375A-5
MAINTENANCE STANDARD ACCUMULATOR
ACCUMULATOR
FOR PPC VALVE
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications:
Type of gas: Nitrogen
Gas volume: 300 cc
Max. autuation pressure:
3.1 MPa {32 kg/cm2}
Min. autuation pressure:
1.2 MPa {12 kg/cm2}
Function
The accumulator is installed between the PPC
charge pump and the PPC valve. Even if the en-
gine is started with the work equipment still
raised, the pressure of the nitrogen gas com-
pressed inside the accumulator sends the pilot
pressure to the main control valve to actuate it
and enable the work equipment to move down
under its own weight.
Operation
After the engine is stopped, when the PPC valve
is at neutral, chamber A inside the bladder is
compressed by the oil pressure in chamber B.
When the PPC valve is operated, the oil pres-
sure in chamber B goes below 2.9 MPa {30 kg/
cm 2}, and the pressure of the nitrogen gas in
chamber A expands the bladder, so the oil in
chamber B acts the pilot pressure and actuates
the main control valve.
D375A-5 10-109
MAINTENANCE STANDARD PPC LOCK VALVE
PPC LOCK VALVE
1. Lever
2. End cap
3. Ball
4. Seat
5. Body
Outline
The PPC lock valve is installed in the PPC circuit
between the PPC charge valve and PPC valve.
If the work equipment safety lever is placed at
the LOCK position, the PPC lock valve is actuat-
ed together with the work equipment safety le-
ver. This stops the oil in the PPC circuit and
makes it impossible to operate the work equip-
ment.
10-110 D375A-5
MAINTENANCE STANDARD PPC VALVE
PPC VALVE
FOR BLADE LIFT, TILT
1. Spool 6. Nut (for lever joint) P. From PPC charge valve port P2
2. Metering spring 7. Joint (through PPC lock valve)
3. Centering spring 8. Plate T. To hydraulic tank
4. Piston 9. Retainer P1. To blade lift valve (LOWER) port PA
5. Disc 10. Body P2. To blade lift valve (RAISE) port PB
P3. To blade tilt valve (left tilt) port PA1
P4. To blade tilt valve (Right tilt) port PB1
10-112 D375A-5
Unit: mm

Free length Installed Installed Installed
Free length
11 Centering spring (for P1) O.D. length load load
94 N 75.2 N
34.0 15.5 31.9
{9.6 kg} {7.67 kg}
16.7 N 13.7 N
12 Metering spring (for P1, P2) 27.23 8.14 24.9
{1.7 kg} {1.4 kg}
96.1 N 76.5 N Replace spring
13 Centering spring (for P2) 43.2 15.5 31.9
{9.8 kg} {7.8 kg} if damaged or
111.8 N 89.4 N deformed
14 Centering spring (for P3, P4) 48.57 15.5 31.9
{11.4 kg} {9.1 kg}
16.7 N 13.7 N
15 Metering spring (for P3, P4) 26.53 8.15 24.9
{1.7 kg} {1.4 kg}
159.36 N 127.5 N
16 Detent spring (for P1) 20.39 19.5 13.1
{16.25 kg} {13 kg}
38.44 N 30.79 N
17 Detent spring (for P2) 45.36 7.5 26
{3.92 kg} {3.14 kg}
D375A-5 10-113
Operation
1) At neutral
(i) PPC valve for blade lift
Ports PA and PB of the blade lift control valve,
and ports P1 and P2 of the PPC valve are con-
nected to drain chamber D through fine control
hole f in spool(1).
(ii) PPC valve for blade tilt

Ports PA1 and PB1 of the blade tilt control valve,
and ports P3 and P4 of the PPC valve are con-
nected to drain chamber D through fine control
hole f in spool (1).
10-114 D375A-5
2) During fine control (neutral o fine control)

When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed; spool (1) is also pushed
by metering spring (2), and moves down.
When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same
time, it is connected to pump pressure chamber
PP, so pilot pressure oil from the charging pump
passes through fine control hole f and goes from
port P1 to port PB.
When the pressure at port P1 becomes higher,
spool (1) is pushed back and fine control hole f
is shut off from pump pressure chamber PP.
At almost the same time, it is connected to drain
chamber D to release the pressure at port P1.
When this happens, spool (1) moves up or down
so that the force of metering spring (2) is bal-
anced with pressure at port P1.
The relationship in the position of the spool (1)
and body (10) (fine control hole f is at a point
midway between drain hole D and pump pres-
sure chamber PP) does not change until retainer
(9) contacts spool (1).
Therefore, metering spring (2) is compressed
proportionally to the amount of movement of the
control level, so the pressure at port P1 also ris-
es in proportion to the travel in the control lever.
In this way the control valve spool moves to a po-
sition where the pressure in chamber PB (the
same as the pressure at port P1) and the force
of the control valve spool return spring are bal-
anced.
D375A-5 10-115
3) During fine control

(When control lever is returned)
When disc (5) starts to be returned, spool (1) is
pushed up to the force of centering spring (3)
and the pressure at port P1.
When this happens, fine control hole f is con-
nected to drain chamber D, and the pressure oil
at port P1 is released.
If the pressure at port P1 drops too far, spool (1)
is pushed down by metering spring (2), and fine
control hole f is shut off from drain chamber D. At
almost the same time it is connected to pump
pressure chamber PP, and the pump pressure is
supplied until the pressure at port P1 recovers to
a pressure that corresponds to the lever position.
When the spool of the control valve returns, oil in
drain chamber D flows in from fine control hole f'
in the valve on the side that is not working.
The oil passes through port P2 and enters cham-
ber PA to fill the chamber with oil.
4) At full stroke
When disc (5) pushed down piston (4), and re-
tainer (9) pushes down spool (1), fine control
hole f is shut off from drain chamber D, and is
connected with pump pressure chamber PP.
Therefore, the pilot pressure oil from the charg-
ing pump passes through fine control hole f and
flows to chamber PB from port P1, and pushes
the control valve spool.
The oil returning from chamber PA from port P2
through fine control hole f' and flows to drain
chamber D.
10-116 D375A-5
5) Blade operated to FLOAT

When piston (4) at port P1 (LOWER side) is
pushed by disc (5) and moves down, protrusion
a of the piston contacts ball (11) during the down-
ward stroke. (The detent starts to be actuated.)
If piston (4) is pushed further, ball (11) pushes up
collar (12), which is being held by detent spring
(13), and moves to the outside, so the ball pass-
es over protrusion a of the piston. At this point,
piston (4') at the opposite side is pushed up by
the spring (14).
As a result, the oil inside chamber F flows
through b and c and enters chamber E, and pis-
ton (4') follows disc (5). Passage d is intercon-
nected with port P1, so it is under more or less
the same pressure as port P1.
Chamber E is normally interconnected with drain
chamber D, but when ball (11) passes over pro-
trusion a of the poston, passage d and chamber
E (which were shut off) are interconnected and
pressurized oil flowa. At the same time, the con-
trol valve also moves to the FLOAT position, so
the blade circuit is set to the FLOAT condition.
The pressurized oil inside chamber E pushes up
piston (4'), so even of the lever is released, it is
held at the FLOAT position.
6) Blade released from FLOAT

When disc (5) is retuned from the FLOAT posi-
tion, it is pushed down by a force greater than
the pressure of the oil in chamber E.
For this reason, chamber E is shut off from pas-
sage d and is connected to the drain chamber.
Therefore, the oil pressure inside chamber E is
lost, and the FLOAT, position is released.
D375A-5 10-117
FOR RIPPER
1. Spool 7. Joint P. From PPC charge valve port P2

2. Metering spring 8. Plate (through PPC lock valve)
3. Centering spring 9. Retainer T. To hydraulic tank
4. Piston 10. Body P1. To ripper tilt valve (TILT BACK) port PB2
5. Disc 11. Filter P2. To ripper tilt valve (TILT IN) port PA2
6. Nut (for lever joint) P3. To ripper tilt valve (LOWER) port PA3
P4. To ripper tilt valve (RAISE) port PB3
10-118 D375A-5
Unit: mm

Free length Installed Installed Installed
Free length
12 Centering spring (for P3, P4) O.D. length load load
55.9 N 45.1 N Replace spring
50.4 15.5 34
{5.7 kg} {4.6 kg} if damaged or
deformed
16.7 N 13.7 N
13 Metering spring 26.6 7.5 24.9
{1.7 kg} {1.4 kg}
71.6 N 56.9 N
14 Centering spring (for P1, P2) 50.1 15.5 34
{7.3 kg} {5.8 kg}
D375A-5 10-119
Operation
1) At neutral
Ports PA2, PA3, PB2 and PB3 of the ripper con-
trol valve and ports P1, P2, P3, and P4 of the
PPC valve are connected to drain chamber D
Through fine control hole f of spool (1).
2) During fine control (neutral o fine control)

When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed; spool (1) is also pushed
by metering spring (2), and moves down.
When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same
time, it is connected to pump pressure chamber
PP, so pilot pressure oil from the charging pump
passes through fine control hole f and goes from
port P2 to port PA2.
When the pressure at port P2 becomes higher,
spool (1) is pushed back and fine control hole f
is shut off from pump pressure chamber PP.
At almost the same time, it is connected to drain
chamber D to release the pressure at port P2.
When this happens, spool (1) moves up or down
so that the force of metering spring (2) is bal-
anced with the pressure at port P2.
The relationship in the position of the spool (1)
and body (10) (fine control hole f is at a point
midway between drain hole D and pump pres-
sure chamber PP) does not change until retainer
(9) contacts spool (1).
Therefore, metering spring (2) is compressed
proportionally to the amount of movement of the
control lever, so the pressure at port P2 also ris-
es in proportion to the travel in the control lever.
In this way the control valve spool moves to a po-
sition where the pressure in chamber PA2 (the
same as the pressure at port P2) and the force
of the control valve spool return spring are bal-
anced.
10-120 D375A-5
3) During fine control

(When control lever is returned)
When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port P2.
When this happens, fine control hole f is con-
nected to drain chamber D, and the pressure oil
at port P2 is released.
If the pressure at port P2 drops too far, spool (1)
is pushed down by metering spring (2), and fine
control hole f is shut off from drain chamber D. At
almost the same time, it is connected to pump
pressure chamber PP, and the pump pressure is
supplied until the pressure at port P2 recovers to
a pressure that corresponds to the lever position.
When the spool of the control valve returns, oil in
drain chamber D flows in from fine control hole f'
in the valve on the side that is not working.
The oil passes through port P1 and enters cham-
ber PB1 to fill the chamber with oil.
4) At full stroke
When disc (5) pushed down piston (4), and re-
tainer (9) pushes down spool (1), fine control
hole f is shut off from drain chamber D, and is
connected with pump pressure chamber PP.
Therefore, the pilot pressure oil from the charg-
ing pump passes through fine control hole f and
flows to chamber PA1 from port P2, and pushes
the control valve spool.
The oil returning from chamber PB1 passes from
port P1 through fine control hole f' and flows to
drain chamber D.
D375A-5 10-121
MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
WORK EQUIPMENT CYLINDER

BLADE LIFT CYLINDER
BLADE TILT CYLINDER
PIN PULLER CYLINDER
10-122 D375A-5
Unit: mm

size Shaft Hole clearance limit
Blade 0.036 +0.270 0.097

90 0.693
Clearance between LIFT 0.090 +0.061 0.360
1
piston rod and bushing
Blade 0.036 +0.274 0.096
110
TILT 0.090 +0.060 0.364
Pin 0.065 +0.133 0.072 Replace

30 0.55
puller 0.117 +0.007 0.250
Clearance between
piston rod spherical Blade +0.300
2 100 (Ball) 1.0
surface and blade ball LIFT 0.300
portion
Clearance between
Blade 0.120 +0.035 0.120
3 cylinder support shaft 105 0.5
LIFT 0.207 0 0.242
bushing and yoke
Thickness of standard
Blade
4 shim between tip of 4.0 Adjust
LIFT
piston rod and cap

Clearance between size clearance limit
Shaft Hole
5 piston rod support shaft
and bushing Blade 0.200 +0.200 0.200
75 1.0
TILT 0.300 0 0.500
Clearance between
Blade 0.200 +0.174 0.300
6 cylinder bottom support 75 1.0
TILT 0.300 +0.100 0.474 Replace
shaft and bushing
Clearance between
Pin 0.100 +1.300
7 piston rod spherical 29 1.3 1.5
puller 0.200 +1.200
surface and cap
Clearance between
Pin 1.1
8 cylinder bottom support 26 0.1 1.0 1.3
puller 1.2
shaft and boss
D375A-5 10-123
RIPPER LIFT CYLINDER
RIPPER TILT CYLINDER
Unit: mm

size Shaft Hole clearance limit
Clearance between Ripper 0.036 +0.274 0.096

1 110 0.697
piston rod and bushing LIFT 0.123 +0.060 0.397
Ripper 0.036 +0.274 0.096

110 0.697
TILT 0.123 +0.060 0.397
Ripper 0.036 +0.207 0.156 Replace

Clearance between 100 1.0
LIFT 0.090 +0.120 0.297
2 piston rod support shaft
and bushing Ripper 0.036 +0.207 0.156
100 1.0
TILT 0.090 +0.120 0.297
Ripper 0.036 +0.207 0.156

Clearance between 100 1.0
LIFT 0.090 +0.120 0.297
3 cylinder bottom support
shaft and bushing Ripper 0.036 +0.207 0.156
100 1.0
TILT 0.090 +0.120 0.297
10-124 D375A-5
MAINTENANCE STANDARD PISTON VALVE
PISTON VALVE
(BLADE LIFT CYLINDER)
Outline
The piston valve is installed on the piston in the
blade lift cylinder. When the piston reaches its
stroke end, the valve releases the oil from the
hydraulic pump to reduce the oil pressure being
exerted on the piston.
In addition the piston valve relieves the shock
which occurs when the piston comes into contact
with the cylinder head or the bottom and serves
to reduce the subsequent surge pressure in the
cylinder by letting the oil escape from the cylin-
der before the piston reaches its stroke end.
Operation
1. Piston valve CLOSED

Pressurized oil from the hydraulic pump acts on
piston (2) and piston valve (3).
The piston valve (3) is pushed in the direction of
the arrow until piston valve seat (4) comes into
snug contact with the tapered section, thereby,
this causing the pressure in the cylinder to rise
and moving piston (2) in the direction of the ar-
row.
2. Piston valve OPEN

Just before piston rod (1) reaches the end of its
stroke, the tip of valve (6) contacts the cylinder
bottom, so valve (6) and piston valve (3) stop at
that position and do not move further. Only pis-
ton (2) moves further.
When this happens, the oil at the cylinder head,
which was sealed by piston valve (3), escapes
from piston valve seats (4) and (5), and the pres-
sure inside the cylinder stops rising.
D375A-5 10-125
MAINTENANCE STANDARD QUICK DROP VALVE
QUICK DROP VALVE

(BLADE LIFT CYLINDER)
Structure
The quick drop valve consists of valve body (1),
spool (2), check valve (3), and spring (4).
The quick drop valve serves to increase the
blade lowering speed and to reduce the occur-
rence of vacuum when the blade is lowering,
thereby shortening the time lag before digging is
started.
The blade lowering speed, which is generally de-
termined by the pump discharge, can be made
faster with the quick drop valve.
1. Valve body 3. Check valve
2. Spool 4. Spring
Operation
1. Start of lowering
When the blade lever is operated to LOWER, the
oil from the control valve enters the cylinder bot-
tom through port A and pushes the piston. In the
meantime, the oil in the cylinder head is pushed
out into the piston, enters valve port B, and flows
into the tank from port C.
2. While lowering
Pressurized oil from the cylinder head flows into
port C through port B.
At this time, the oil flow is restricted by an orifice
a provided along the way, causing a differential
pressure between front and back of orifice.
When the pressure of port B becomes greater
than the force of spring (4), it compresses the
spring and moves spool (2) and check valve (3)
to the right.
When the spool and the check valve have
moved, the circuit of port B and A is opend, part
of the oil flowing from the cylinder head to port C
enters the passage port A, and merged with the
oil from the control valve, and flows to the cylin-
der bottom.
Thus, the blade lowering speed increases in ac-
cordance with the amount of oil that flows to the
bottom of the cylinder and reduces the formation
of vacuum at the bottom of the cylinder.
10-126 D375A-5
MAINTENANCE STANDARD QUICK DROP VALVE
Unit: mm

Clearance between spool and size Shaft Hole clearance limit
1
valve body
0.011 +0.010 0.011
38.0 0.03
0.016 0 0.026

2 Valve spring length load load
136.3 N 122.6 N
75.2 55.9 67.7
{13.9 kg} {12.5 kg}
D375A-5 10-127
MAINTENANCE STANDARD PIN PULLER SWITCH
PIN PULLER SWITCH
Function
The pin puller solenoid valve is controlled by 1. Connector
turning the pin puller switch ON/OFF. 2. Wire
This changes the oil circuit to the pin puller cylin- 3. Switch
der and sets the shank mounting pin to the 4. Knob
PUSH IN or PULL OUT position.
10-128 D375A-5
MAINTENANCE STANDARD PIN PULLER SOLENOID VALVE
PIN PULLER SOLENOID VALVE
1. Plug A. To pin puller cylinder bottom

2. Spring B. To pin puller cylinder head
3. Spring retainer P. From power train pump
4. Valve body T. To steering case
5. Spool
6. Spring retainer
7. Spring
8. Push pin
9. Solenoid assembly
D375A-5 10-129
MAINTENANCE STANDARD PIN PULLER SOLENOID VALVE
Operation
1. Pin puller switch at PUSH IN position

When the pin puller switch is set to the PUSH IN
position, no electric current flows to solenoid (9)
and it is deenergized.
Then, ports P and A and ports B and T of spool
(5) open, and the oil from the power train pump
flows from port P to port A, and enters the bot-
tom end of pin puller cylinder (10).
When the oil enters the bottom end of the cylin-
der and the pressure in the circuit starts to rise,
the cylinder extends and pushes shank mount-
ing pin (11) into shank (12).
2. Pin puller switch at PULL OUT position

When the pin puller switch is set to the PULL
OUT position, electricity flows to solenoid (9) and
it is excited.
Then, the solenoid pushes out push pin (8) and
spool (5) moves to the left in the arrow direction.
At this point, ports P and A and ports B and T
close, and ports P and B and ports A and T
open, so the oil from the power train pump flows
from port P to port B and enters the head end of
pin puller cylinder (10).
When the oil enters the cylinder head end and
the pressure in the circuit rises, the cylinder re-
tracts and pulls shank mounting pin (11) out of
shank (12).
10-130 D375A-5
MAINTENANCE STANDARD BLADE CONTROL KNOB
BLADE CONTROL KNOB
1. Switch (Dual, single tilt switching) When the switch (2) is pressed and the lever is
2. Switch (Pitch) actuated, the blade is pitched. When the lever is
3. Cover set to the left, the blade is pitched back. When
4. Connector (Male) the lever is set to the right, the blade is pitch-
5. Connector (Female) damped.
When the switch (1) is set to the DUAL side
Outline and the lever is actuated, the blade is dually tilt-
By setting the blade control knob to the front and ed. When the lever is set to the left, the blade is
the rear or the left and the tight, the blade is dually tilted left. When the lever is set to the right,
raised or lowered and tilted left or right. Further, the blade is dually tilted right.
by setting the switch (1) to the DUAL side and Even if the switch (1) is switched to either DU-
setting the lever to the left and right, the dual tilt AL or SINGLE, the blade is pitched when the
actuation is performed. Also by setting the lever lever is set left and right pressing the switch (2).
to the left and right pressing (2), the pitch actua-
tion is performed.
D375A-5 10-131
MAINTENANCE STANDARD PITCH, DUAL TILT SOLENOID VALVE
PITCH, DUAL TILT SOLENOID VALVE

MACHINES EQUIPPED WITH DUAL TILT
1. Main spool assembly Function

2. Pilot solenoid assembly This valve is installed between the blade tilt,
3. Connector pitch cylinder and the blade tilt, ripper Lo valve.
A. To R.H. blade pitch (dual tilt) cylinder bottom It acts to open or close the hydraulic circuit to the
B. To R.H. blade pitch (dual tilt) cylinder head blade tilt or pitch cylinder according to the pitch
T1. To L.H. blade pitch (dual tilt) cylinder bottom or dual tilt switch signal.
T2. To L.H. blade pitch (dual tilt) cylinder head
P1, P2. From blade tilt control valve
P. From PPC charge valve
T. To hydraulic tank
10-132 D375A-5
MAINTENANCE STANDARD PITCH, DUAL TILT SOLENOID VALVE
Operation
Pitch switch ON
When pitch switch (1) is operated, electricity
flows to pitch solenoid valve (2) and it is excited.
When this happens, main spool (4) opens the
circuit between port T1 and B and between A
and P1, and the hydraulic circuit is connected to
the bottom end of left pitch cylinder (5) and to the
head end of right pitch cylinder (6). As a result,
both the right pitch cylinder and left pitch cylinder
are retracted and the blade is pitched to the rear.
Dual tilt switch ON

When dual pitch switch (2) is operated, electricity
flows to dual tilt solenoid valve (3) and it is excit-
ed. When this happens, main spool (4) opens
the circuit between port T2 and B and between
A and P2, and the hydraulic circuit is connected
to the head end of left tilt cylinder (5) and to the
bottom end of right tilt cylinder (6). As a result,
the left dual tilt cylinder is extended and the right
dual tilt cylinder is retracted to tilt the blade.
D375A-5 10-133
MAINTENANCE STANDARD WORK EQUIPMENT + PPC CHARGE PUMP
WORK EQUIPMENT + PPC CHARGE PUMP

SAR(4)140 + (3)071 + (1)022
10-134 D375A-5
MAINTENANCE STANDARD WORK EQUIPMENT + PPC CHARGE PUMP
Unit: mm
Type Standard clearance Clearance limit
SAR(4)-140 0.11 0.16 0.19

1 Side clearance
SAR(3)-071 0.10 0.15 0.19
SAR(1)-022 0.10 0.15 0.19
SAR(4)-140 0.060 0.140 0.20

Clearance between plain bearing
2 inside diameter and gear shaft SAR(3)-071 0.060 0.149 0.20
outside diameter
SAR(1)-022 0.060 0.144 0.20 Replace
Type Standard size Tolerance Repair limit
0
SAR(4)-140 21
0.5
3 Driving depth of pin 0
SAR(3)-071 14
0.5
0
SAR(1)-022 10
0.5
4 Spline shaft rotation torque 16.7 26.5 Nm {1.7 2.7 kgm}

discharge discharge
Type speed pressure amount amount
Delivery 20.6
SAR(4)-140 2,200 287 266
{210}
Oil: EO10-CD
Oil temperature: 45 50C 20.6
SAR(3)-071 2,200 137 125
{210}
4.9
SAR(1)-022 2,200 43 39
{50}
D375A-5 10-135
MAINTENANCE STANDARD MAIN CONTROL VALVE
MAIN CONTROL VALVE

BLADE LIFT VALVE
Outline
Demand valve (14) is assembled to the blade lift P1. From large pump
valve, and the oil from the two hydraulic pumps P2. From small pump
is merged by check valve (4). A. To blade lift cylinder head
With the demand valve, the oil from the large B. To blade lift cylinder bottom
pump becomes the pilot pressure, and at the T. To hydraulic tank
same time, the oil from the ripper circuit or the PA. From blade lift PPC valve port P2
blade lift circuit through shuttle valve (18B) also PB. From blade lift PPC valve port P1
becomes the pilot pressure, so the oil from the PL. From ripper Lo valve
two hydraulic pumps is used efficiently.
10-136 D375A-5
1. Check valve spring 9. Shuttle valve ball 17. Suction valve spring
2. Small pump circuit check valve 10. Shuttle valve seat (plug) 18. LOWER suction valve
3. Check valve 11. Retainer 19. Main relief, shuttle valve
4. Check valve spring 12. Return spring (for FLOAT) assembly
5. Valve body 13. Case 19A. Main relief valve
6. Return spring 14. Demand valve spring 19B. Shuttle valve
7. Blade lift valve 15. Demand valve
8. Shuttle valve seat (plug) 16. RAISE suction valve
D375A-5 10-137
Unit: mm

Free Installed Installed Free Installed
1 Spool return spring length length load length load
431.5 N 345.2 N
69.9 63
{44 kg} {35.2 kg}
400.1 N 319.7 N
2 Spool return spring 80.69 76.5
{40.8 kg} {32.6 kg}
588.4 N 470.7 N
3 Spool return spring (for floating) 43.82 32.5
{60 kg} {48 kg} Replace
9.8 N 7.9 N
4 Check valve spring 75.7 43.5 69.3
{1.0 kg} {0.8 kg}
44.1 N 35.3 N
{4.5 kg} {3.6 kg}
11.38 N 9.12 N
6 Suction valve spring 75.9 38.5 68.4
{1.16 kg} {0.93 kg}
235 N
7 Demand spool spring 74.5 55
{24 kg}
10-138 D375A-5
MAIN RELIEF, SHUTTLE VALVE
10-140 D375A-5
1. Valve body Overview

2. Piston The main relief valve exists in the blade lift circuit
3. Shuttle valve via the shuttle valve (3) and the circuit between
4. Shuttle valve spring the ripper circuit and the hydraulic tank, and the
5. Plug oil pressure of the blade lift circuit, that is, a large
6. Valve seat pump circuit is set to 20.6 MPa {210 kg/cm2}.
7. Main relief valve poppet The shuttle valve exists in the blade lift circuit
8. Main relief valve spring and the circuit between the ripper circuit and the
9. Sleeve demand valve via the main relief valve, and two
10. Main relief pressure adjustment screw circuits that applies the pilot pressure to the de-
PL. From shuttle valve inside ripper valve mand valve are selected. That is, either the
PB. From shuttle valve inside blade lift valve blade lift circuit or the ripper circuit is selected.
PD. Inside demand valve pilot port Besides, the shuttle valve connects the blade lift
T. To hydraulic tank circuit and the pilot port of the demand valve by
the tension of the spring (4) when work equip-
ment is not used (control lever Neutral).
Unit: mm

4 Shaft valve spring length length load length load
8.14 N 6.47 N Replace

42.7 22.0 38.6
{0.83 kg} {0.66 kg}
258.9 N 206.9 N
8 Main relief valve spring 41.1 32.6 39.4
{26.4 kg} {21.1 kg}
Height of main relief pressure

10 8 (1 turn of screw adjusts by 2.4 MPa {24.8 kg/cm2}) Adjust
adjustment screw
D375A-5 10-141
BLADE TILT, RIPPER LO VALVE
P. From small pump CO. To demand valve

A1. To blade tilt cylinder bottom PL. To shuttle valve inside blade lift valve
B1. To blade tilt cylinder head PA1. To blade tilt PPC valve P3 (left tilt)
A2. To ripper tilt cylinder bottom PA2. To ripper tilt PPC valve P2 (tilt in)
(through ripper Hi valve PA1) PA3. To ripper lift PPC valve P3 (lower)
B2. To ripper tilt cylinder head PB1. To blade tilt PPC valve P4 (right tilt)
(through ripper Hi valve PB1) PB2. To ripper tilt PPC valve P1 (tilt back)
A3. To ripper lift cylinder head PB3. To ripper lift PPC valve P4 (raise)
(through ripper Hi valve PB2)
B3. To ripper lift cylinder bottom
(through ripper Hi valve PA2)
10-142 D375A-5
1. Blade tilt valve 9. Sleeve 17. Check valve

2. Ripper tilt valve 10. Main relief valve body 18. Check valve spring
3. Ripper lift valve 11. Poppet spring 19. Valve seat
4. Valve body 12. Main relief valve poppet 20. Shuttle valve seat (plug)
5. Return spring 13. Valve seat 21. Shuttle valve ball
6. O-ring 14. Main relief valve spring 22. Shuttle valve seat
7. Case 15. Main relief valve
8. Main relief pressure 16. Valve seat
adjustment screw
D375A-5 10-143
Unit: mm

1 Spool return spring length length load length load
117.7 N 94.1 N
52.18 50.0
{12.0 kg} {9.6 kg}
6.9 N 5.5 N Replace
{0.7 kg} {0.56 kg}
31.4 N 25.1
3 Main relief valve spring 24.2 18.3 23.0
{3.2 kg} {2.56 kg}
258.9 N 206.9 N
4 Main relief valve poppet spring 41.1 32.6 39.4
{26.4 kg} {21.1 kg}
Height of main relief pressure
5 8 (1 turn of screw adjusts by 2.4 MPa {24.8 kg/cm2}) Adjust
adjustment screw
10-144 D375A-5
RIPPER HI VALVE
P. From small pump

PA1. From Lo valve tilt in
PB1. From Lo valve tilt back
PA2. From Lo valve ripper raise
PB2. From Lo valve ripper lower
A1-1. To L.H. tilt cylinder bottom
B1-1. To L.H. tilt cylinder head
A1-2. To R.H. tilt cylinder bottom
B1-2. To R.H. tilt cylinder head
A2-1. To L.H. lift cylinder bottom
B2-1. To L.H. lift cylinder head
A2-2. To R.H. lift cylinder bottom
B2-2. To R.H. lift cylinder head
D375A-5 10-145
1. Valve body 11. Plug

2. Shuttle valve seat 12. Check valve spring
3. Shuttle valve ball 13. Check valve
4. Valve body 14. Valve return spring
5. Plug 15. Plug
6. Fixed differential pressure valve spring 16. Ripper lift Hi valve
7. Fixed differential pressure valve 17. Suction valve spring
8. Fixed differential pressure valve 18. Suction valve
9. Fixed differential pressure valve 19. Ripper tilt Hi valve
10. Fixed differential pressure valve
10-146 D375A-5
Unit: mm

1 Hi valve return spring length length load length load
152.0 N 121.6 N
79.5 42.0 72.0
{15.5 kg} {12.4 kg}
30.2 N 24.1 Replace
{3.08 kg} {2.46 kg}
9.8 N 7.9 N
3 Suction valve spring 75.7 43.5 69.3
{1.0 kg} {0.8 kg}
Constant differential pressure 169.7 N 135.3 N
4 57.4 33.5 52.6
valve spring {17.3 kg} {13.8 kg}
D375A-5 10-147
Operation
1. Blade lever at HOLD, ripper lever at HOLD
10-148 D375A-5
When the blade is at the HOLD position, the When oil is drained
spool of the PPC valve directly connected to the In the condition already explained, if the hydrau-
control lever is not actuated; blade lift spool (5) lic pressure in the circuit rises, the surface pres-
closes the circuit from port B to ports C and D, sure (force pushing the demand valve to the left)
and opens the circuits of ports H and E and ports on port L of demand valve (1) becomes greater
J and F; blade tilt spool (16) close the circuit from than the combined force (force pushing the de-
port B3 to ports C3 and D3. mand valve to the right) of the surface pressure
Therefore, the circuits for blade lift cylinder (9) bearing on port M and tension of spring (2), it
and blade tilt cylinder (17) become closed cir- moves the demand valve to the left, opens the
cuits, and the cylinders are held in the same po- circuit between ports A and E, and ports R and
sition. F. The oil from the large and small pumps is then
If the ripper lever is placed at the HOLD position, relieved to ports E and F and is drained from port
the spool of the PPC valve directly connected to G to the hydraulic tank.
the control lever does not move; ripper tilt spool Therefore, both the large and small pumps are
(19) closes the circuit from port B4 to ports C4 put in an unload condition.
and D4, and ripper lift spool (21) closes the cir-
cuit from port B5 to ports C5 and D5. Therefore,
the circuits for ripper tilt cylinder (45) and ripper
lift cylinder (33) become closed circuits through
the two ripper valves, and the cylinders are kept
in the same position.
If the engine is started in this condition, the oil
from the large pump enters port A of the blade lift
valve. Some of the oil pushes open check valve
(3) and enters port B where it stops. The rest of
the oil passes through orifice a of demand valve
(1), and enters ports L and M. (The demand
valve is pushed to the right by the tension of
spring (2).)
The oil from the large pump flows to the blade lift
valve, but it also enters port A1 of the ripper Hi
valve, pushes open the two check valve (23) and
(35), then enters ports B1 and B2 and stops.
The oil from the small pump flows from port A2
of the ripper Lo valve and blade tilt valve to ports
A3, A4, and A5. Some of the oil pushes open
check valves (15), (18) and (20), then enters
ports B3, B4 and B5, and stops. The rest of the
oil flows from port A5, enters port R of the blade
lift valve, pushes open check valve (4), and flows
to port A where it merges with the oil from the
large pump.
D375A-5 10-149
2. Blade lever at RAISE (blade operating at high speed)
10-150 D375A-5
When the blade lever is moved fully to the

RAISE position, the spool of the PPC valve di-
rectly connected to the control lever is actuated.
When this happens, the pilot pressure entering
the PPC valve from the PPC pump is sent to port
PB of the blade lift valve. This pilot pressure
moves spool (5) to the left to the end of its stroke,
and fully opens the circuits between ports B and
C, ports C and H, and ports D and F.
When this happens, the oil from the two pumps
passes from ports A and B and enters port C.
Some of the oil flows to the head end of cylinder
(9), and the rest flows from ports H and H', push-
es shuttle valve (8) to the right and opens it,
flows to port K, and enters ports N, O, and P of
shuttle valve (10). It then enters port Q of de-
mand valve (1) and becomes the pilot pressure.
At the same time, the oil from the pump passes
through orifice a of demand valve (1), enters
ports L and M, and becomes the pilot pressure.
The oil at the bottom end of cylinder (9) flows
from port D to port F, and returns from port G to
the hydraulic tank. When the hydraulic pressure
in the circuit rises in this way, spool (5) opens the
circuit between ports B and C fully, so the resis-
tance of the oil flowing from port B to port C is
small, and there is little pressure difference gen-
erated between port B and port C.
Therefore, no pressure difference is generated
between port L and ports M and Q of the demand
valve. The surface pressure acting on the left
and right of the demand valve is equal, so the
demand valve is moved to the right by the ten-
sion of spring (2).
When this happens, the circuits between ports A
and E', and ports R and F' are closed, and all the
oil from both the large and small pumps flows to
the head end of the cylinder to increase the
speed of movement of the cylinder.
D375A-5 10-151
3. Blade lever at RAISE (blade operating at low speed)
10-152 D375A-5
When the blade lever is operated slightly to the If it is opened only slightly, the flow of oil beyond
RAISE position the spool of the PPC valve di- port C is throttled, so the oil flow is reduced, the
rectly connected to the control lever is actuated. hydraulic pressure becomes low, and the speed
When this happens, the pilot pressure entering of movement is slow.
the PPC valve from the PPC pump is sent to port In other words, the hydraulic pressure and oil
PB of the blade lift valve. This pilot pressure flow beyond port C is proportional, so this pro-
moves spool (5) slightly to the left to a point vides operation of the blade that follows the fine
where the pilot pressure and the force of the movement of the blade lever.
spring are in balance, and partially opens the cir-
cuit between ports B and C, ports C and H, and When cylinder is at stroke end
Ports D and F. If cylinder (9) moves to the end of its stroke from
When this happens, the oil from the two pumps the condition in items 2 and 3, the hydraulic pres-
passes from ports A and B, is throttled by spool sure in the whole circuit rises.
(5) and enters port C. Some of the oil flows to the Therefore, the hydraulic pressure beyond port C
head end of cylinder (9), and the rest flows from rises, and the oil entering the main relief valve
ports H and H', pushes shuttle valve (8) to the through shuttle valves (8) and (10) (that is, the oil
right and opens it, flows to port K, and enters at port P) pushes open poppet (13) and is re-
ports N, O, and P of shuttle valve (10). It then en- lieved to port T.
ters port Q of demand valve (1) and becomes the At this point, the circuit from port O to port P is
pilot pressure. throttled by orifice c, so the supply of oil to port P
At the same time, the oil from the pump passes is delayed. As a result, the hydraulic pressure of
through orifice a of demand valve (1), enters pilot port Q of demand valve (1) drops, and the
ports L and M, and becomes the pilot pressure. demand valve moves to the left.
The oil at the bottom end of cylinder (9) flows When this happens, the circuit between ports A
from port D to port F, and returns from port G to and E' and ports R and F' are opened, and the
the hydraulic tank. When the hydraulic pressure oil from the two pumps is relieved to prevent the
in the circuit rises in this way the situation is dif- hydraulic pressure from rising any further.
ferent from in item 2: spool (5) is throttling the cir- The hydraulic pressure at this point is 20.6 MPa
cuit between ports B and C, so the flow of oil {210 kg/cm2}.
from port B to port C is restricted, and a pressure
difference is generated between port B and port
C. The hydraulic pressure in the circuit up to port
B becomes higher.
Therefore, when the surface pressure acting on
port L of the demand valve becomes greater
than the combined force of the surface pressure
acting on port M, the surface pressure (low pres-
sure) acting on port Q, and the tension of spring
(2), the demand valve is moved to the left.
When this happens, the circuits between ports A
and E', and ports R and F' are opened, and the
oil from both the large and small pumps is re-
lieved to the hydraulic tank. This suppresses the
rise in the hydraulic pressure at ports A and B,
and the cylinder moves slowly.
As explained in the items above, the speed of
movement of the cylinder is determined by the
amount of opening of ports B and C, which cor-
responds to the movement of the lever. If it is
wide open, the flow of oil beyond port C increas-
es, the hydraulic pressure rises, and the speed
of movement becomes faster.
D375A-5 10-153
4. Blade lever at LEFT TILT
10-154 D375A-5
When the blade lever is moved to the LEFT TILT

position the spool of the PPC valve directly con-
nected to the control lever is actuated. When this
happens, the pilot pressure entering the PPC
valve from the PPC pump is sent to port PA1 of
the ripper Lo valve. This pilot pressure moves
spool (16) down, opens the circuits of ports B3
and C3 and ports D3 and F3, and closes the cir-
cuit of ports A2 and A3.
When this happens, the oil from the small pump
flows from ports A2, pushes open check valve
(15), flows from port B3, and enters port C3. It
flows to the bottom end of cylinder (17), and
when the hydraulic pressure in the circuit rises, it
extends the cylinder.
At this point, the oil at the head end of the cylin-
der returns from port D3 to port F3, and is
drained from port E3 to the hydraulic tank.
The oil from the large pump enters port A of the
blade lift valve, and actuates demand valve (1),
is relieved from port A to E, and is drained to the
hydraulic tank.
When the blade is operated, the circuit between
ports A2 and A3 is closed, so the oil does not en-
ter the ripper circuit, and it is impossible to oper-
ate the ripper.
In other words, the blade tilt circuit is given prior-
ity over the ripper circuit.
When cylinder is at stroke end

From the above condition, if cylinder (17) is
moved to the end of its stroke, the hydraulic
pressure in the whole circuit rises.
flows from port A2, and pushes open main relief
valve poppet (14). It is then relieved to port E2,
so the hydraulic pressure does not rise any fur-
ther.
The hydraulic pressure at this point is 20.6 MPa
{210 kg/cm2}.
D375A-5 10-155
5. Ripper lever at TILT IN (ripper Lo valve, shuttle valve actuated)
10-156 D375A-5
When the ripper lever is moved to the TILT IN po-

sition, the spool of the PPC valve directly con-
spool (19) down, opens the circuits between
ports B4 and C4, and ports D4 and F4, and ports
A3 and G4, and closes the circuit between ports
A3 and A4.
enters ports A2 and A3. Some of the oil pushes
open check valve (18), flows from port B4 into
port C4, and the flows to port H2 of the ripper Hi
valve. The rest of the oil passes through the
groove in spool (19), enters port G4, pushes
shuttle valve (22) down fully, then flows from port
H5 to port S of shuttle valve (10).
The oil entering port S passes through orifice b,
and pushes piston (11). The reaction moves
shuttle valve (10) to the left, closes the circuit be-
tween ports N and O, and opens the circuit be-
tween ports S and O.
The oil entering port O from port S then passes
through orifice c, and enters ports P and Q. It be-
comes the pilot pressure of demand valve (1),
and moves the demand valve to the right.
When this happens, the circuit between ports A
and E' is closed, so the oil from the large pump
is not drained to the hydraulic tank.
The whole amount of the oil flows to port A1 of
the ripper Hi valve.
D375A-5 10-157
6. Ripper lever at TILT IN (ripper Hi valve actuated)
10-158 D375A-5
As explained in item 5, the oil from the large

pump enters A1 of the ripper Hi valve, pushes
open check valves (23) and (35), flows to ports
B1 and B2, and stops.
The oil from the small pump flows from port C4
of the ripper Lo valve and enters port H2.
Some of the oil entering port H2 passes through
the passage inside valve (42), flows to port L2,
and pushes shuttle valve (44) fully to the right. It
then enters port O2, pushes spool (36) up, and
becomes the pilot pressure.
The rest of the oil is throttled by orifice g and en-
ters port D2.
Some of the oil entering port D2 passes through
the passage inside valve (42), flows to port J2,
and pushes shuttle valve (41) fully to the left. It
then enters port N2, pushes spool (36) down,
and becomes the pilot pressure.
The rest of the oil flows from port D2 to the bot-
tom end of ripper tilt cylinder (45).
When all the above hydraulic circuits are filled
with oil, the hydraulic pressure starts to rise.
From the condition previously explained, if the
hydraulic pressure continues to rise, the oil at
port H2 is throttled by orifice g and enters port
D2. Because of the resistance, the hydraulic
pressure at port H2 becomes higher than the
pressure beyond port D2.
Therefore, the hydraulic pressure at pilot port O2
of spool (36) becomes higher than the hydraulic
pressure at port N2, so when this pressure differ-
ence becomes greater than the tension of spring
(38), it pushes spool (36) up.
When this happens, the circuits between ports
B2 and D2, and ports C2 and F1 open, the oil
from the large pump flows from port B2 to port
D2, enters the bottom end of ripper tilt cylinder
(45), and merges with the oil from the small
pump to extend the cylinder.
Some of the oil at the head end of the cylinder re-
turns from port C2 to port F1, and is drained to
the hydraulic tank. The rest of the oil flows from
port C2, is throttled by orifice f of valve (39), and
returns to port G2. It then flows from port D4 of
the ripper Lo valve, returns to port F4, and is
drained to the hydraulic tank.
D375A-5 10-159
7. Ripper level at LOWER (ripper Lo valve, shuttle valve actuated)
10-160 D375A-5
When the ripper lever is moved to the LOWER

position, the spool of the PPC valve directly con-
spool (21) moves down, opens the circuits of
ports B5 and C5, and ports D5 and F5, and ports
A4 and G5 and closes the circuit of ports A4 and
A5.
enters ports A2, A3, and A4. Some of the oil
pushes open check valve (20), flows from port
B5 into port C5, and the flows to port H1 of the
ripper Hi valve. The rest of the oil passes through
the groove in the spool, enters port G5, pushes
shuttle valve (22) up fully, then flows from port
H5 to port S of shuttle valve (10).
The oil entering port S passes through orifice b,
and pushes piston (11). The reaction moves
shuttle valve (10) to the left, closes the circuit be-
tween ports N and O, and opens the circuit be-
tween ports S and O.
The oil entering port O from port S then passes
through orifice c, and enters ports P and Q. It be-
comes the pilot pressure of demand valve (1),
and moves the demand valve to the right.
and E is closed, so the oil from the large pump is
not drained to the hydraulic tank.
The whole amount of the oil flows to port A1 of
the ripper Hi valve.
D375A-5 10-161
8. Blade lever at HOLD, ripper lever at LOWER (ripper Hi valve actuated)
10-162 D375A-5
As explained in item 7, the oil from the large

pump enters A1 of the ripper Hi valve, pushes
open check valves (23) and (35), flows to ports
B1 and B2, and stops.
The oil from the small pump flows from port C5
of the ripper Lo valve and enters port H1.
Some of the oil entering port H1 passes through
the passage inside valve (30), flows to port M1,
and pushes shuttle valve (32) fully to the left. It
then enters port O1, pushes spool (24) up, and
becomes the pilot pressure.
The rest of the oil is throttled by orifice e and en-
ters port D1.
Some of the oil entering port D1 passes through
the passage inside valve (30), flows to port K1,
and pushes shuttle valve (29) fully to the right. It
then enters port N1, pushes spool (24) down,
and becomes the pilot pressure.
The rest of the oil flows from port D1 to the bot-
tom end of ripper tilt cylinder (33).
When all the above hydraulic circuits are filled
with oil, the hydraulic pressure starts to rise.
From the condition previously explained, if the
hydraulic pressure continues to rise, the oil at
port H1 is throttled by orifice e and enters port
D1. Because of the resistance, the hydraulic
pressure at port H1 becomes higher than the
pressure beyond port D1.
Therefore, the hydraulic pressure at pilot port O1
of spool (24) becomes higher than the hydraulic
pressure at port N1, so when this pressure differ-
ence becomes greater than the tension of spring
(25), it pushes spool (24) up.
When this happens, the circuits between ports
B1 and D1, and ports C1 and E1 open, the oil
from the large pump flows from port B1 to port
D1, enters the bottom end of ripper lift cylinder
(33), and merges with the oil from the small
pump to extend the cylinder.
Some of the oil at the head end of the cylinder re-
turns from port C1 to port E1, and is drained to
the hydraulic tank. The rest of the oil flows from
port C1, is throttled by orifice d of valve (27), and
returns to port G1. It then flows from port D5 of
the ripper Lo valve, returns to port E5, and is
drained to the hydraulic tank.
D375A-5 10-163
9. Ripper lever at LOWER (cylinder at stroke end)
10-164 D375A-5
From the condition in items 7 and 8. if cylinder

(33) is moved to the end of its stroke, the hydrau-
lic pressure in the whole circuit rises.
When this happens, in the same way as in item
4, the oil from the small pump flows from port A2
and pushes open main relief valve poppet (14).
It is then relieved to port E2, so the hydraulic
pressure does not rise any further.
{210 kg/cm2}.
The oil passing through shuttle valves (22) and
(10), and flowing from ports S and O to port P
also pushes open main relief valve poppet (13),
and is relieved to port T.
The circuit from port O to port P is throttled by or-
ifice c, so the supply of oil to port P is delayed.
As a result, the hydraulic pressure at pilot port Q
of demand valve (1) also drops, and the demand
valve moves to the left.
and E' opens, and the oil from the large pump is
relieved, so the hydraulic pressure in the circuit
of the large pump does not rise any further.
{210 kg/cm2}. When the hydraulic pressure in the
whole circuit is set at 20.6 MPa {210 kg/cm2}, the
pressure difference on both sides of orifice e of
valve (30) (that is, the difference in pressure be-
tween ports H1 and D1) disappears.
The pilot pressure at port O1 that is pushing
spool (24) up becomes the same pressure as the
pressure at port N1. When this happens, spool
(24) is pushed down by the tension of spring (25)
to a position where it is in balance with the ten-
sion of spring (26).
At this point, the circuits between ports B1 and
D1 and ports C1 and E1 are closed.
The oil from the large pump goes as far as port
B1, and stops. The oil at the head end of cylinder
(33) flows from port C1, passes through orifice d
of valve (27), and returns only to port G1.
D375A-5 10-165
MAINTENANCE STANDARD CYLINDER STAY
CYLINDER STAY
1. Yoke
2. Oil seal
3. Bushing
4. Bushing
Unit: mm

Clearance between cylinder yoke size Shaft Hole clearance limit
5
and bushing
0.085 +0.063 0.085
150 0.5
0.148 0 0.211
Replace
Clearance between cylinder yoke 0.072 +0.054 0.072
6 115 0.5
and bushing 0.126 0 0.180
Clearance between lift cylinder 0.120 +0.035 0.120

7 105 0.5
support shaft and bushing 0.207 0 0.242
10-166 D375A-5
MAINTENANCE STANDARD BLADE
BLADE
SEM-U DOZER
10-168 D375A-5
Unit: mm

Clearance between brace pin and size Shaft Hole clearance limit
1
brace
0.2 +0.3
75 0.3 0.6 2
0.3 +0.1
Clearance between brace pin and 0.2 +0.3 Replace

2 75 0.3 0.6 2
bracket 0.3 +0.1
Clearance between brace pin and 0.2 +0.3

3 75 0.2 0.6 1
bracket 0.3 0

4 75 0.2 0.5 1
bushing 0.3 0
Clearance between center brace 0.2 +0.3 Adjust shim or

5 170 0.2 0.6 1
and cap spherical surface 0.3 0 replace
Clearance between joint and 0.2 +0.3

6 200 0.3 1.0 3
bracket 0.7 +0.1
Clearance between frame pin 0.3 +0.3

7 100 0.3 0.8 3
and joint 0.5 0

8 100 0.5 1.0 2
and joint 0.5 +0.2
Clearance between straight

9 160 0.3 0.4 1
frame joint bushings
Clearance between trunnion and 0.5 +0.5

10 200 0.5 1.5 8
cap spherical surface 1.0 0

11 200 0.3 1.0 3 Replace
bracket 0.7 +0.1
Clearance between blade pin and 0.3 +0.3

12 100 0.3 0.8 3
joint 0.5 0

13 100 0.5 1.0 2
bracket 0.5 +0.2
Clearance between center link 0.3 +0.5

14 125 0.5 1.0 2
pin and blade bracket 0.5 +0.2

15 125 0.5 1.0 2
pin and center link 0.5 +0.2

16 280 0.3 0.7 2
and blade bracket 0.4 +0.1

17 170 0.2 0.6 1
spherical surface and cap 0.3 0 replace
D375A-5 10-169
U-DOZER
10-170 D375A-5
Unit: mm

Clearance between brace pin and size Shaft Hole clearance limit
1
brace
0.2 +0.3
75 0.3 0.6 2
0.3 +0.1
Clearance between brace pin and 0.2 +0.3 Replace

2 75 0.3 0.6 2
bracket 0.3 +0.1

3 75 0.2 0.6 1
bracket 0.3 0

4 75 0.2 0.5 1
bushing 0.3 0

5 170 0.2 0.6 1
and cap spherical surface 0.3 0 replace

6 200 0.3 1.0 3
bracket 0.7 +0.1

7 100 0.3 0.8 3
and joint 0.5 0

8 100 0.5 1.0 2
and bracket 0.5 +0.2
Clearance between straight

9 160 0.3 0.4 1
frame joint bushings
Clearance between trunnion and 0.5 +0.5

10 200 0.5 1.5 8
cap spherical surface 1.0 0

11 200 0.3 1.0 3 Replace
bracket 0.7 +0.1

12 100 0.3 0.8 3
joint 0.5 0

13 100 0.5 1.0 2
bracket 0.5 +0.2

14 125 0.5 1.0 2
pin and blade bracket 0.5 +0.2

15 125 0.5 1.0 2
pin and center link 0.5 +0.2

16 280 0.3 0.7 2
and blade bracket 0.4 +0.1

17 170 0.2 0.6 1
spherical surface and cap 0.3 0 replace
D375A-5 10-171
CUTTING EDGE, END BIT
Unit: mm

1 Height of end bit outside
478 380
Replace
2 Width of end bit 734 600
3 Height of end bit inside 393 300
4 Height of cutting edge 406 335 (264 after turned) Replace or turn
10-172 D375A-5
MAINTENANCE STANDARD RIPPER EQUIPMENT
RIPPER EQUIPMENT
VARIABLE MULTIPLE SHANK RIPPER
10-174 D375A-5
MAINTENANCE STANDARD RIPPER EQUIPMENT
GIANT RIPPER
Unit: mm
Standard Tolerance Standard Clearence

Clearance between bushing and size Shaft Hole clearance limit
1
bracket and arm mount pin
0.036 +0.208 0.161
120 1.5
0.090 +0.125 0.298
Clearance between bushing and 0.036 +0.208 0.161

2 120 1.5
beam and arm mount pin 0.090 +0.125 0.298
Clearance between cylinder 0.036 +0.207 0.156 Replace

3 100 1.5
mount pin and bushing 0.090 +0.120 0.207
Clearance between shank and Standard size Tolerance Repair limit

4
mount pin 82 0.3

5 Wear of point
420 255
6 Wear of protector 155 115
D375A-5 10-175
MAINTENANCE STANDARD CAB MOUNT
CAB MOUNT
1. Support Outline
2. Damper mount (Front) The cab mount is installed at two places in the
3. Damper mount (Rear) front and at two places in the rear, and the floor
frame and the cab are secured.
The cab mount adopts an oil seal type damper
mount and absorbs vibration.
10-176 D375A-5
MAINTENANCE STANDARD CAB
CAB
CAB ASEMBLY
1. Front wiper
2. Front glass
3. Rear wiper
4. Door
D375A-5 10-177
MAINTENANCE STANDARD CAB
ROPS GUARD
1. ROPS guard
10-178 D375A-5
MAINTENANCE STANDARD AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
1. Air conditioner compressor 10. Valve (hot water outlet)

2. Window defroster 11. Hot water return piping
3. Side defroster 12. Valve (hot water inlet)
4. Air conditioner unit 13. Refrigerant piping
5. Blower port A. Fresh air
6. Blower motor B. Recirculated air
7. Hot water pick-up piping C. Hot air/cold air
8. Condenser
9. Receiver tank
D375A-5 10-179
MAINTENANCE STANDARD ENGINE CONTROL
ENGINE CONTROL
1. Decelerator pedal Outline

2. Starter switch The throttle signal of the throttle dial enters the
3. Decelerator potentiometer steering controller and the transmission control-
4. Steering controller ler and is processed together with another infor-
5. Transmission controller mation, then sent to the engine controller as a
6. Fuel throttle dial throttle command. The engine controller controls
7. Battery the control valve unit and the fuel pump in accor-
8. Battery relay dance with the command.
9. Starter
10. Engine controller
11. Fuel pump
10-180 D375A-5
MAINTENANCE STANDARD ENGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM
Outline
The engine controller receives the manual signal The engine control system shares the informa-
of the second throttle and the third throttle signal tion about the engine controller with another con-
that is the control signal from a vehicle body and troller through networks and contributes to the
selects a low engine speed, then controls the optimum control between the engine and the ve-
control valve unit. hicle body.
The third throttle control signal includes the fol- As the auto decelerator function, the engine
lowing items: speed is temporarily set to 1,000 rpm when for-
(1) First throttle signal ward and reverse from F3, R3, and R2 are
(2) SSC (Shoe Slip Control) control switched. (For transmission clutch protection)
(3) Auto decelerators (F3, R3, R2)
The steering controller selects the lowest engine
speed from the information (1), (2), and (3) and
sends it to the engine controller as the third throt-
tle.
D375A-5 10-181
MAINTENANCE STANDARD DECELERATOR POTENTIOMETER
DECELERATOR POTENTIOMETER
1. Connector Outline
2. Lever The decelerator potentiometer is mounted on
3. Body the lower front of the operator cab and connect-
4. Potentiometer ed with the decelerator pedal using a linkage.
5. Coupling
6. Shaft When the decelerator pedal is actuated, the
7. Stopper shaft of the throttle potentiometer rotates via the
linkage and a resistance value is changed.
Fixed voltage is applied between the pins A to C
of the potentiometer and a voltage signal that
matches the actuation position of the decelerator
pedal is sent from the B pin to the engine control-
ler.
10-182 D375A-5
MAINTENANCE STANDARD HPI ENGINE CONTROL SYSTEM
HPI ENGINE CONTROL SYSTEM

HPI is an abbreviation of High Pressure Injection.
System drawing
Outline
The signals detected by various sensors are in-
put to the engine controller.
The input signals are operated arithmetically by
the controller. A signal is issued to each actuator
and controls a fuel injection level and fuel injec-
tion timing.
10-184 D375A-5
MAINTENANCE STANDARD HPI ENGINE CONTROL SYSTEM
1. Fuel tank OUTLINE OF HPI SYSTEM

2. Fuel filter The HPI system consists of injector assembly
3. Fuel pump assembly (5), control valve assembly (4), and fuel pump
3A. Gear pump assembly (3).
3B. Pump regulator Injector assembly (5) controls the amount of fuel
3C. Check valve injection and the injection timing by controlling
3D. Fuel pump actuator the amount of fuel passing through fuel orifice
3E. Fuel pump pressure sensor (5B).
4. Control valve assembly In order to control the fuel flow, it is necessary to
4A. Timing rail actuator valve control the fuel rail pressure and timig rail pres-
4B. Fuel leak throttle (220 cc/min) sure. To control these pressures, control valve
4C. Timing rail pressure sensor assembly (4) has 2 pressure sensors and 2 ac-
4D. Shut-off valve tuator valves built in. These carry out control so
4E. Fuel rail actuator valve that the fuel rail rail pressure and timing rail pres-
4F. Fuel leak throttle (110 cc/min) sure become the target value. Shut-off valve
4G. Fuel rail pressure sensor (4D), used to stop the engine, is installed in the
5. Injector assembly fuel rail line.
5A. Timing orifice Fuel pump assembly controls the basic pressure
5B. Fuel orifice of the fuel. The fuel supplied from fuel tank (1)
5C. Gravity check valve passes through fuel filter (2), is then sucked up
5D. Bypass orifice by gear pump (3A), and is supplied to control
5E. Injector valve assembly (4). The discharge pressure of
5F. Plunger the fuel pump is controlled to a suitable level by
5G. Gravity check valve adjusting the opening angle of fuel pump actua-
6. Fuel cooler tor (3D).
7. ECM controller
8. Engine speed sensor
9. Atmospheric pressure sensor
10. Boost pressure sensor
11. Boost temperature sensor
D375A-5 10-185
MAINTENANCE STANDARD MONITOR SYSTEM
MONITOR SYSTEM
The monitor system monitors the machine con- In the monitor panel, there are various mode se-
dition with sensors installed to various parts of lector switches of the SSC (Shoe Slip Control),
the machine, and quickly processes and dis- which are used to operate the machine control
plays obtained information on the monitor panel, system (with SSC).
to notify the operator of machine condition. The monitor panel has the functions of display-
The function of the monitor system is as follows. ing data and selecting the SSC mode (with
1) Function which turns on the alarm when the SSC).
machine has a trouble on the monitor. The CPU (Central Processing Unit) in it pro-
2) Function which constantly displays the cesses, displays, and outputs the information.
machine condition (coolant temperature, The display unit is LCD (Liquid Crystal Display)
torque converter oil temperature, fuel level, and the switches are seat switches.
hydraulic oil level, etc.) on the gauge.
3) Function of displaying error codes.
4) Function of monitoring the current and volt-
age of the sensors and solenoids.
10-186 D375A-5
MAINTENANCE STANDARD MONITOR SYSTEM
Processing in monitor panel (Common to all specifications)

Display of monitor panel
1. Contents and conditions of processing 2. Method 3. Flow of signals
1) Display of travel direction and gear speed. Transmission controller - Steering control-
F1, R3, etc. are notified by CAN according to informa- ler - Monitor panel
tion of transmission controller.
2) Display of engine speed in gauge number. CAN Engine speed sensor - Steering controller
The number of pulses the engine rotation is converted - Monitor panel
into a gauge number and notified to the monitor panel
by CAN.
3) Display of troubleshooting CAN Engine sensor/solenoid - Steering control-

When the machine has a trouble, the corresponding ler or transmission controller - Monitor
failure code is notified to the monitor panel by CAN. panel
Which one should be turned on, the buzzer or the cau-
tion lamp, is notified, too.
i) In normal state
User code
ii) In trouble history display mode
The service code (6-digit code) and the following Sensors and solenoids - Engine controller
items are displayed - Steering controller - Monitor panel
1. Time after first occurrence
2. Time after latest occurrence
3. Number of past occurrence
The monitor panel displays code on the hour meter
section.
Display of monitoring conditon

1) The communication conditions of each sensor, each CAN Each sensor - Steering controller or trans-
solenoid, and CAN are displayed. mission controller - Monitor panel
The item Nos. and device conditions are notified to the
monitor panel by CAN.
The monitor panel displays the items and each value Sensors - Engine controller - Steering
on its multi-information section. controller - Monitor panel
2) Each items is selected by using the cursor switches, Monitor panel - Controller - Monitor panel
selector switches, buzzer cancel switch, and shift UP/
DOWN switches.
Other items
1) Function selection mode (Displayed each time cancel CAN Steeging controller - Monitor panel
switch is turned to left)
i) Replacement periods of oil filter and oil are dis-
played.
ii) Engine speed, oil pressure in work equipment cir-
cuit, etc. are displayed.
iii) Failure codes related to electronic control are dis-
played.
iv) Brightness of display, etc. are adjusted.
2) Mode to change replacement periods of maintenance
mode
3) Mode to display failure codes related to the machine
such as overheating, abnormal coolant temperature, etc.
4) Mode to display service meter and information related
to load on machine
D375A-5 10-187
MAINTENANCE STANDARD MONITOR PANEL
MONITOR PANEL
Monitor portion
1. Engine coolant temperature gauge 13. Warming lamp

2. Power train oil temperature gauge 14. Filter, oil change interval lamp
3. Hydraulic oil temperature gauge 15. Display panel A (Speed range, Engine speed)
4. Fuel gauge 16. Display panel B (Multi-information)
5. Radiator coolant level check lamp 17. Dual/single tilt selector display lamp
6. Charge level monitor 18. Lock-up mode switch
7. Engine oil pressure caution lamp 19. Economy mode selector switch
8. Engine cooling water temperature caution lamp 20. Reverse slow mode selector switch
9. Power train oil temperature caution lamp 21. Shoe slip selection mode switch (with SSC)
10. Hydraulic oil temperature caution lamp 22. Rock selection mode selector switch (with SSC)
11. Engine preheating pilot lamp 23. Engine preheating pilot lamp
12. Maintenance caution lamp
Outline 2. Start-up inspection

The monitor potion consists of a monitor that is- 1) After all lighting of Section 1 is terminated, if
sues an alarm when an error occurred in a vehi- there is an error in a start-up inspection
cle, a gauge that always displays the state of the item, the item flashes.
vehicle, and the service meter. 2) If the engine is started, the check items
The monitor portion installs a microcomputer before starting go off. (If the engine running
and processes and displays signals from each is judged by the signal (CAN) from the
sensor. engine controller.)
Besides, the items displayed on the monitor 3. Cautions
portion and gauge portion are listed in the table Caution items are checked until the engine
on the next page. stops after the engine starts.
If an error occurs, the error is displayed by
Operation flashing and the alarm lamp synchronously
1. When the power turns on (When the starting flashes.
switch is ON) Further, if an emergency item flashes, the alarm
1) All items of the gauge and monitor portions buzzer also sounds synchronously.
come on for three seconds. Flashing of the monitor and alarm lamp is re-
2) The alarm lamp comes on for two seconds. peated. They come on and off for about 0.8 sec-
ond.
The flashing period of the monitor slightly chang-
es when atmospheric temperature is low (below
about 10C), but this case is not abnormal.
10-188 D375A-5
Monitor panel display

Display
Symbol Display item Display range Display method
category
Displays when engine is
stopped and starting
Check
switch is ON
Radiator coolant level Below low level
Display when normal: OFF
Display when abnormal:
Flashes
Displays when starting
switch is ON and engine is
Caution 1
running
Battery charge When charge is defective Display when normal: OFF
SAP00522 Display when abnormal:
Flashes
CAUTION lamp flashes
Engine oil pressure Below 49.0kPa {0.5kg/cm2}
Radiator coolant level Below low level
When at highest level (108C or Displays when starting

Engine coolant tempera-
above) on engine coolant tempera- switch is ON and engine is
ture
ture gauge running
Caution 2
Display when normal: OFF

Display when abnormal:
When at highest level (130C or Flashes
Torque converter oil tem-
above) on engine coolant tempera- CAUTION lamp flashes
perature
ture gauge Alarm buzzer sounds
Hydraulic oil level Below low level
When replacement time of filter or oil

Maintenance
has been passed
Lights according to
required time
determined by engine con-
troller based.
Preheating When preheating It also lights at the time of
manual preheat by setting
starting switch at preheat
Pilot
position (turning it counter-

clockwise).
Display lights at the time

of operation.
Dual tilt At the time of operation
It goes off at the time of
non-operation.
D375A-5 10-189
Display
Symbol Display item Display range Display method
category
Engine coolant tempera-

ture
Torque converter oil One place lights up to

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

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

From 0 to 99999
(Hours meter) is rotating
10-190 D375A-5
Switch portion
1. Switch functions
a) ON-OFF switching in lock-up mode
b) Economy mode setting OFF, mode 1, mode 2
c) ON-OFF switching in reverse slow mode
d) ON-OFF switching in SSC mode
e) SSC mode level setting Mode 1 to 5
a), b), and c) are mounted for all specifications and d) and e) are mounted for the SSC specifications.
SSC specifications
Without SSC specifications
2. Initial Setup at key ON Economy Mode Function

The function the operator desires according to In a field, such as a rock-bed place where many
the situation of an operating place is selected shoe slips are generated, the following power is out-
and all functions shall be set to the OFF state. put in each mode so that the frequency of decelera-
tor operation can decrease.
Economy mode 1 o Set to about 90% of the full
power.
Economy mode 2 o Set to about 70% of the full
power.
REVERSE slow mode o Set to about 80% of
the full travel speed at reverse time.
D375A-5 10-191
Sensors
Sensor and type Sensor system Normal time Abnormal time

Engine oil pressure Contact OFF ON
Engine water temperature Resistor
Torque converter oil
Resistor
temperature
Hydraulic oil temperature Contact ON OFF
Radiator water level Contact ON OFF
Fuel level Resistor
Engine oil pressure sensor
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
10-192 D375A-5
Engine Water Temperature Sensor

Torque converter oil temperature sensor
Hydraulic oil temperature sensor
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
Radiator water level sensor
1. Float 4. Wire
2. Sensor 5. Connector
3. Tube
D375A-5 10-193
Fuel level sensor
1. Connector Function
2. Float The fuel level sensor is installed to the bottom
3. Arm right of the front face of the fuel tank.
4. Body Float (2) moves up and down according to the
5. Spring fuel level. This movement of the float is transmit-
6. Contact ted by arm (3) and actuates a variable resis-
7. Spacer tance. This sends a signal to the monitor panel
to indicate the remaining fuel level. When the
display on the monitor panel reaches a certain
level, a warning lamp flashes.
10-194 D375A-5
MAINTENANCE STANDARD MODE SELECTION SYSTEM
MODE SELECTION SYSTEM

(SSC (Shoe slip control) system)
System drawing
Outline
The mode selection system automatically per- The lock-up control mode is the same mode as
forms the engine control that matches the work the conventional lock-up function and cannot
condition selected by the operator. It reduces a perform simultaneous selection with the above
fuel cost, makes the life of the track longer, and mode.
reduces the frequency of decelerator operation.
The engine control mode includes the economy
mode control used at dozing time, the SSC used
at ripping time, and the reverse slow mode con-
trol that can be used in both.
D375A-5 10-195
Mode selection function 4. The transmission controller sends the lock-up

signal to the lock-up solenoid valve. The applica-
This system comprises the mode selection panel
ble lock-up signal is decided based the entered
(with a built-in microcomputer) for the operation
gear speed information of the transmission con-
mode selection, steering controller (with a built-
troller.
in microcomputer) for the engine control and the
Refer to the Operation of Torque Converter
engine controller that, responding to the instruc-
Lock-up Control System.
tion from the steering controller, implements the
actual control by use of the control valve. The
system also comprises the transmission control-
Functions of the engine controller
ler that turns on or off the torque converter lock- 1. The engine controller controls the control valve
up responding to the signal from the transmis- unit responding to the manual instruction en-
sion output speed sensor plus various types of tered from the deceleration potentiometer or the
sensors. SSC instruction whichever designates a slower
Following describes the functions of respective engine speed (a higher voltage).
controllers.
Functions of the steering controller and

transmission controller
1. The steering controller computes the machine
bodys ground speed based on the input signal
from the acceleration sensor and then computes
the shoe speed by adding the signal from the
transmission output speed sensor to the ground
speed. The steering controller then calculates
the shoe slip rate based on above information.
2. Then the steering controller computes the draw-
bar pull using the input signals from the engine
speed sensor and the transmission output speed
sensor.
3. This controller calculates an optimum engine
speed using above 1 and 2 plus the set mode
signal and the speed information from the trans-
mission controller. This optimum value is then
sent from the speed controller to the engine con-
troller as the SSC instruction.
10-196 D375A-5
Operation of mode selection system

Work can be performed under the optimum conditions by simply or simultaneously selecting five modes in
accordance with the contents of work.
Mode Single Simulta-

Work neous Mode work condition Mode operation, characteristic
switch selection selection
ON/OFF switching is automatically per- 1. When the torque converter approaches to the
formed in accordance with a load. stall area or performs gear shaft operation,
Speed number F2, F3 lock-up is set to OFF. When the torque convert-
F1 er reaches a light lode, lock-up is set to ON.
of gear ratios R1, R2, R3
1,230 rpm 1,260 rpm 2. Can be used in all number of gear ratios.
speed side speed side

Lock-up
ON 3. Simultaneous selection disabled with another

or more or more
Low
mode
1,200 rpm 1,230 rpm
shaft speed
T/C output
OFF 4. Suitable for dozing work of comparatively a few

or more or more
load fluctuations
2,140 rpm
ON
or more
High
2,200 rpm
Dozing
OFF
or more
1. When F1 is shifted with the economy 1. When the economy mode ((1) or (2)) and SSC
mode switch (1) or (2) ON are set simultaneously, the F1 shift economy
control is performed. When the ripper lever is
actuated and the switch is turned on, the slip
Economy
control is performed.
2. The engine output can be suppressed in two
stages without performing the decelerator op-
eration of the engine.
Mode (1): 90% (at 1.5 km/h)
Mode (2): 65% (at 1.5 km/h)
3. At neutral time, the engine speed can be sup-
pressed partially
1. When R1, R2, and R3 are shifted 1. The engine speed can be suppressed without
Reverse slow
performing the decelerator operation of the en-

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

characteristic (refer to the rock-bed selection
Ripping
shown below) selected by the operator among

the index force characteristics set in five stages
and suppresses the generation of a slip.
3. The steering controller regards the index force
immediately before the slip (exceeding the
shoe ripping ratio of 30% is generated, as the
maximum, and performs the engine output
control. At this time, the steering controller per-
forms index characteristic down of about 30 to
80% and performs the engine outpuut control if
a ripper tilt or ripper up signal is input.
4. At neutral time, the engine speed is sup-
pressed partially.
Set to ON in connection with SSC 1. When the SSC is set to ON, the selection mode
Rock-bed
selection
3 comes on.
2. 1 3 5 is selected in accordance with the
state and load of the rock-bed.
When the above mode is set, the throttle lever and decelerator operations are enabled. In that case, the engine
output control is performed in accordance with the command having the smallest value among the control com-
mand, throttle command, and decelerator command.
D375A-5 10-197
Sensors
Engine speed sensor
Transmission output shaft speed sensor
1. Magnet
2. Terminal
3. Case
4. Boots
5. Connector
Acceleration sensor
1. Sensor portion
2. Wire
3. Connector
Outline
The acceleration sensor is mounted at the lower
front of the operator cab.
The acceleration sensor changes the position of
a ball inside the sensor in accordance with accel-
eration.
The coil that detects the position of this ball is
provided inside the sensor. This is amplified by
an amplifier to change voltage and the result is
sent to the SSC controller.
Refer to the drawing at the right for the sensor in-
put/output chatacteristics.
10-198 D375A-5
Pitch angle sensor
1. Body
2. Tube
3. Wire
4. Connector
The sensor is filled with electrolyte. If sensor

leans, the electrolyte surface slants. If electro-
lyte surface slants, the contact area of two elec-
trodes installed in the sensor with electrolyte
changes. As a result, electrostatic capacity be-
tween the two electrode changes. The change of
electrostatic capacity is output as a change of
voltage.
The input and output characteristics of the sen-
sor are shown in the figure at right.
D375A-5 10-199
MAINTENANCE STANDARD ELECTRICAL DEVICE
ELECTRICAL DEVICE
OPERATION OF LAMP SYSTEM
ELECTRICAL CIRCUIT OF LAMP SYSTEM
10-200 D375A-5
MAINTENANCE STANDARD ELECTRICAL DEVICE
OPERATION OF ELECTRICAL INTAKE AIR HEATER
ELECTRCAL CIRCUIT OF PREHEATING
D375A-5 10-201
MAINTENANCE STANDARD STEERING ELECTRONIC CONTROL
STEERING ELECTRONIC CONTROL
1. Monitor panel (Speed range display) 6. Steering control valve

2. Auto shift down switch 7. Transmission output shaft speed sensor
3. Engine controller 8. Transmission control valve
4. Transmission controller 9. Engine speed sensor
5. Steering controller
10-202 D375A-5
MAINTENANCE STANDARD STEERING ELECTRONIC CONTROL
Shift Mode Function

1. Function
If you shift the lever to the forward or reverse,
the gear speed selected from the shift mode is
turned on.
2. Type of Modes
1) F1-R1 (Manual mode)
2) F1-R2 (Shift mode 1)
3) F2-R2 (Shift mode 2)
3. Selecting method
Shift the PCCS lever to "N".
Select the shift mode using UP or DOWN
switch.
Up switch ON Up switch ON
Manual mode Shift mode 1 Shift mode 2
Down switch ON Down switch ON
4. Display
The selected shift mode is displayed on the
monitor panel.
Auto-shift-down function
1. Function
If the load is increased while the machine is
traveling or working at the 2nd or 3rd gear
speed, the gear speed is shifted down automat-
ically.
1) The drawbar pull (load on the machine) is
calculated from the engine speed, travel
speed, and throttle information from the
steering controller, and the gear speed is
shifted down automatically according to the
load and travel speed.
2) Once the gear speed is automatically
shifted down, it is not automatically shifted
up to the former position. (Gear speed can
be shifted up with the manual switch.)
3) This function is applicable to both forward
and reverse travels.
2. How to use
Turn the auto-shift-down switch (1) ON.
D375A-5 10-203
MAINTENANCE STANDARD VHMS CONTROLLER
VHMS CONTROLLER
10-204 D375A-5
Input and output signals

CN1 [CN 1] CN2 [CN2 A, B]
Input/ Input/
Pin No. Signal name Pin No. Signal name
Output Output
CN1-1 NC Input CN2-A1 Rack sensor (Right) Input
CN1-2 Sensor power supply (24V) Output CN2-A2 NC Input
CN1-3 Sensor power supply (12V) Output CN2-A3 F engine oil temperature Input
CN1-4 Sensor power supply (5V) Output CN2-A4 NC Input
CN1-5 Sensor power supply (5V) Output CN2-A5 Exhaust temperature (Right) Input
Power supply (Constant power supply) CN2-A6 NC Input
CN1-6 Input
(24V)
CN2-A7 Exhaust temperature (Left) Input
Power supply (Constant power supply)
CN1-7 Input CN2-A8 NC Input
(24V)
CN2-A9 NC Input
CN1-8 BR power supply (24V) Input
CN2-A10 Atmospheric temperature sensor Input
CN1-9 BR power supply (24V) Input
CN2-A11 NC Input
CN1-10 NC Input
CN2-A12 Sensor GND Input
CN1-11 GND Input
CN2-A13 Sensor GND Input
CN1-12 GND Input
CN2-A14 NC Input
CN1-13 NC
CN2-A15 Transmission, main Input
CN1-14 NC Input
CN2-A16 Oil pressure sensor Input
CN1-15 NC
CN2-A17 WAKE UP (Low)
CN1-16 NC
CN2-A18 Blow-by pressure Input
CN1-17 Start signal Input
CN2-B1 NC
CN1-18 NC
CN2-B2 NC Input
CN1-19 GND Input
CN2-B3 NC
CN1-20 GND Input
CN2-B4 NC Input
CN2-B5 NC Input
CN2-B6 NC
CN2-B7 NC Input
CN2-B8 NC
CN2-B9 GND Input
CN2-B10 NC Input
CN2-B11 NC Input
CN2-B12 CONNECTOR (GND) Input
D375A-5 10-205
CN3 [CN 3 A, B] CN4 [CN 4 A, B]

Input/ Input/
Pin No. Signal name Pin No. Signal name
Output Output
CN3-A1 CAB OUT D/L Sw Input CN4-A1 NC
CN3-A2 NC Input CN4-A2 NC
CN3-A3 NC Input Input/
CN4-A3 NC
Output
CN3-A4 NC Output
Input/
Model selection CN4-A4 CAN (1) H (KOM-NET/c)
CN3-A5 Input Output
(See ORB connection)
CN4-A5 CAN (0) SH Input
CN3-A6 NC Input
Input/
CN3-A7 Engine speed Input CN4-A6 CAN (0) SH
Output
Input/
CN3-A8 S-NET (+) CN4-A7 NC
Output
CN4-A8 NC
CN3-A9 CONNECTOR SEL2 (OPEN) Input
CN4-A9 GND Input
CN3-A10 NC Input
CN4-A10 RS232C RX0 (PC Tool) Input
CN3-A11 NC Input
CN4-A11 RS232C TX0 (PC Tool) Output
CN3-A12 NC Input
Input/
CN3-A13 NC Input CN4-A12 CAN (1) L (KOM-NET/c)
Output
CN3-A14 NC Input
CN4-A13 CAN (1) SH (KOM-NET/c) Input
CN3-A15 NC Input
Input/
CN4-A14 CAN (0) L
CN3-A16 NC Input Output
CN3-A17 GND Input CN4-B1 NC
Input/ CN4-B2 NC
CN3-A18 S-NET (+)
Output
CN4-B3 RS232C SH Input
CN3-B1 NC Input
CN4-B4 RS232C TX1 (Orbcom) Output
CN3-B2 NC
CN4-B5 NC
CN3-B3 NC
CN4-B6 NC
CN3-B4 NC
CN4-B7 NC
CN3-B5 NC
CN4-B8 NC
CN3-B6 Snap shot Sw data clear
CN4-B9 GND Input
CN3-B7 NC
CN4-B10 RS232C RX1 (Orbcom) Input
CN3-B8 NC
CN3-B9 NC
CN3-B10 NC
CN3-B11 NC
CN3-B12 NC Input
10-206 D375A-5
Sensors
Engine oil temperature sensor
Specifications
1. Type of sensor: Thermistor
2. Measurement range: 40 130C
80 130C (Assured
accuracy: 2C)
3. Max. power consumption: 0.5 mW
4. Pressure resistance: 4.9 MPa {50 kg/cm2}
5. Using temperature: 30C to +140C
6. Performance table
Temper- Resis- Temper- Resis- Temper- Resis-
ature tance ature tance ature tance
(C) (kz) (C) (kz) (C) (kz)
30 35.27 80 6.571 110 2.887
40 24.28 85 5.682 115 2.544
50 17.05 90 4.931 120 2.248
60 12.20 95 4.293 125 1.992
70 8.884 100 3.750 130 1.769
a: Heat sensing part of sensor Outside diameter

of mounting part: R1/4
Function
The engine oil temperature sensor is installed to the
engine oil filter. It inputs the change of the tempera-
ture as the change of the thermistor resistance to
the VHMS controller.
D375A-5 10-207
Exhaust temperature sensor/amplifier

Specifications
1. Rated voltage: DC 24 V
2. Sensed temperature range:100 1,000C
300 800C (Assured
accuracy: 10C)
3. Output voltage characteristics
(Ambient tempera-
ture: 20C) --- Refer-
ence values
Sensed
50 100 400 700 800
temperature (C)
Output voltage
1.191 1.397 2.626 3.899 4.316
(V)
4. Operating temperature range: 40 to +110C

5. Current consumption: Max. 30 mA
a. Heat sensing part of sensor Outside diameter

of mounting part: R1/8
b. Amplifier
c. Connector (Power supply side)
d. Connector (Sensor side)
Function
The exhaust temperature sensor/amplifier is a ther-
mocouple-type temperature sensor, which is
installed to the turbocharger inlet. It outputs the
exhaust temperature data to the VHMS controller.
Atmospheric temperature sensor

Specifications
1. Power consumption: Max. 0.5 mW

2. Pressure resistance: 0.98 MPa
{10 kg/cm2}
3. Sensed temperature range (ambient):
30 to +120C
4. Storage temperature range: 50 to +140C
5. Performance table
Sensed
temperature 20 10 0 10 20 50
(C)
Resistance
30.32 18.58 11.74 7.623 5.077 1.712
(kz)
a. Heat sensing part of sensor Outside diameter

of mounting part: 16 x 1.5
Function
The atmospheric temperature sensor inputs the
change of the atmospheric temperature as the
change of the thermistor resistance to the VHMS
controller.
10-208 D375A-5
Engine blow-by pressure sensor
1. Sensor Specifications and function

2. Connector Pressure range: 0 20 kPa
3. Atmospheric pressure intake tube {0 2,040 mmH2O}
Allowable pressure: 20 to 100 kPa
A. GND (Black) {2,040 to 10,200 mmH2O}
B. Power supply (Red) Source voltage: 5 0.25 V
C. Output (White) Output characteristics:See graph.
The blow-by pressure sensor is a fine relative
pressure sensor which measures the difference
between the pressure in the crankcase and the
atmospheric pressure.
The pressure in the crankcase is applied to the
tip side of the sensor and the atmospheric pres-
sure is applied to the wiring harness side.
Transmission main oil pressure sensor
1. Sensor
2. Connector
D375A-5 10-209
Torque converter speed sensor
1. Connector
2. Flange
3. Sensor
10-210 D375A-5
STRUCTURE, FUNCTION AND COMMUNICATION (ORB: ORBCOMM) CONTROLLER/
MAINTENANCE STANDARD ANTENNA
COMMUNICATION (ORB: ORBCOMM) CONTROLLER/ANTENNA

Controller
Specifications
1. Source voltage: DC 12 V DC 30 V
2. Size: W306 x D152 x H52 (mm)
Connectors
CN1A (ORB-A): AMP070-14
CN1B (ORB-B): AMP070-10
CN2: Communication antenna cable connector
Antenna
Specifications
1. Type: Helical whip antenna (1)
2. Impedance: 50 z
3. Input terminal: N-P type
4. Length: 165 20 mm
a. Communication antenna mounting part
Function
The communication controller transmits the data
collected and stored by the VHMS controller to the
computer center via the communication satellite.
D375A-5 10-211
20 TESTING AND ADJUSTING
STANDARD VALUE TABLES

STANDARD VALUE TABLE FOR ENGINE RELATED PARTS .............................................................. 20- 2
STANDARD VALUE TABLE FOR MACHINE RELATED PARTS ........................................................... 20- 3
TESTING AND ADJUSTING .................................................................................................................... 20-101
TROUBLESHOOTING.............................................................................................................................. 20-301
Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine
from the factory and is given for reference. It is used as a guideline for judging the progress of wear after
the machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of oper-
ation to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims
D375A-5 20-1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

Engine unit
Engine SA6D170E-3
Standard value for new
Category Item Unit Service limit value
machine
High idling 1,900 30 1,900 30
Engine speed Low idling rpm 720 30 720 30
Rated speed 1,800 1,800
Air supply kPa
At rated output Min. 107 {Min. 800} 93{700}
(boost pressure) {mmHg}
Whole speed range
Exhaust temperature C Max. 680 700
(ambient temperature: 20C)
At sudden acceleration Bosch Max. 4.0 6.0
Exhaust gas color
At high idling index Max. 1.0 2.0
Valve clearance Intake valve Max. 0.32 Max. 0.32
mm
(normal temperature) Exhaust valve Max. 0.62 Max. 0.62
MPa
Compression pres- Oil temperature: 40 - 60C Min. 2.9 {Min. 30} 2.1{21}
{kg/cm2}
sure (engine speed) (210 - 250) (210 - 250)
(rpm)
Water temperature: Within operating
kPa
Blow-by pressure range Max. 4.9 {Min. 500} 7.9{800}
{mmH2O}
At rated output
Water temperature: Within operating
range
At high idling
0.38 - 0.59{4.0 - 6.0} 0.21{2.1}
SAE30 or SAE15W-40 oil MPa
Oil pressure 0.34 - 0.54{3.5 - 5.5} 0.18{1.8}
SAE10W oil {kg/cm2}
At low idling
Min. 0.12 {Min. 1.2} 0.07{0.7}
SAE30 or SAE15W-40 oil
Min. 0.10{Min. 1.0} 0.05{0.5}
SAE10W oil
Oil temperature Whole speed range (inside oil pan) C 90 - 110 120
Deflection when pressed with finger
Fan belt tension mm Auto tension Auto tension
force of approx. 58.8 N {6 kg}
Alternator, air condi-
Deflection when pressed with finger When adjusting
tioner compressor mm New part: 19 - 21
force of approx. 98 N {10 kg} tension: 24 - 26
belt tension
When measuring the low idling speed after reducing speed suddenly from high speed, wait for several sec-
onds for the speed to stabilize before measuring.
20-2 D375A-5
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR MACHINE RELATED PARTS
STANDARD VALUE TABLE FOR MACHINE RELATED PARTS

Cat-
Standard value for Service limit
ego- Item Measurement conditions Unit
new machine value
ry
Deceleration speed Engine water temperature: Within operating 900 50 900 50
Torque converter stall range 1,520 50 1,430
Torque converter oil temperature: Within op-
Engine speed
erating range
Torque converter stall Hydraulic oil temperature: 45 - 55C rpm
+ work equipment re- Deceleration speed: Pedal depressed 1,300 60 1,160
lief speed Torque converter stall speed: F3
Torque converter stall + work equipment
speed: F3 + ripper RAISE
Engine stopped Neutral
30 5 Max. 8.0
Center of lever knob FORWARD
Direction
Neutral
30 5 30 5
PCCS lever
REVERSE
Full stroke (Neu- mm 40 5 40 5
tral - Left, right) (Play: Max. 3) (Play: Max. 3)
Steering Until clutch is
completely dis- 95 95
Control lever, pedal stroke
engaged
Engine stopped
Deceleration pedal mm 45 15 45 15
Center of lever knob
Engine at low idling
Full stroke 75 10 75 10
Center of lever knob
Brake pedal Stroke until oil mm
pressure be- 75 10 75 10
comes 0
Engine at low idling HOLD - RAISE,
72 10 72 10
Hydraulic oil temperature: FLOAT
Blade lever 45 - 55C mm
HOLD - Left,
Center of lever knob 53 10 53 10
right tilt
Engine at low idling HOLD - RAISE,
78 10 78 10
Hydraulic oil temperature: LOWER
Ripper lever 45 - 55C mm
HOLD - Tilt in,
Center of lever knob 81 10 81 10
tilt out
Engine stopped Neutral o 53.9 9.8 53.9 9.8
Center of lever knob FORWARD {5.5 1.0} {5.5 1.0}
Direction
Neutral o 53.9 9.8 53.9 9.8
REVERSE {5.5 1.0} {5.5 1.0}
Control lever, pedal operating effort
Until clutch is
14.7 4.9 14.7 4.9
completely dis-
{1.5 0.5} {1.5 0.5}
engaged
PCCS lever
Left
Until brake N
{kg} 26.5 4.9 26.5 4.9
takes effect and
{1.5 0.5} {1.5 0.5}
machine turns
Steering
Until clutch is
16.7 4.9 16.7 4.9
completely dis-
{1.7 0.5} {1.7 0.5}
engaged
Right
Until brake
29.4 4.9 29.4 4.9
takes effect and
{3.0 0.5} {3.0 0.5}
machine turns
Engine stopped N 49.0 9.8 49.0 9.8
Deceleration pedal
Center of pedal {kg} {5.0 1.0} {5.0 1.0}
D375A-5 20-3

Cat-
new machine value
ry
Engine at low idling N 460.6 49.0 460.6 49.0
Brake pedal
Center of pedal {kg} {47.0 5.0} {47.0 5.0}
Control lever, pedal operating effort
Engine at low idling HOLD 39.2 4.9 39.2 4.9

Hydraulic oil temperature: 45 - RAISE {4.0 0.5} {4.0 0.5}
55C
Center of lever knob HOLD N 83.3 9.8 83.3 9.8
Blade lever FLOAT {8.5 1.0} {8.5 1.0}
{kg}
HOLD
28.4 4.9 28.4 4.9
Left, right
{2.9 0.5} {2.9 0.5}
tilt
Engine at low idling HOLD
21.6 4.9 21.6 4.9
Hydraulic oil temperature: 45 - RAISE,
N {2.2 0.5} {2.2 0.5}
Ripper lever 55C LOWER
Center of lever knob {kg}
HOLD Tilt 20.6 4.9 20.6 4.9
in, tilt out {2.1 0.5} {2.1 0.5}
Torque converter oil tempera- 0.03 0.15 0.03 0.15
ture: Within operating range Low idling
Torque converter inlet {0.3 1.5} {0.3 1.5}
pressure 0.9 0.10 0.9 0.10
High idling
{9.0 1.0} {9.0 1.0}
0.01 0.15 0.01 0.15
Low idling
Torque converter outlet {0.1 1.5} {0.1 1.5}
pressure 0.39 0.64 0.39 0.64
High idling
MPa {4.0 6.5} {4.0 6.5}
{kg/cm2}
Low idling
Torque converter lock-
up clutch pressure 1.27 1.47 1.27 1.47
High idling
Power train oil pressure
{13.0 15.0} {13.0 15.0}

2.45 0.20 2.45 0.20
Low idling
Torque converter sta- {25.0 2.0} {25.0 2.0}
tor clutch pressure 2.65 0.20 2.65 0.20
High idling
{27.0 2.0} {27.0 2.0}
ture: Within operating range Low idling
Transmission main re- {26.0 1.5} {24.0 30.0}
lief pressure 2.70 0.15 2.45 2.94
High idling
{27.5 1.5} {25.0 30.0}
2.55 0.15 2.35 2.94
Low idling
Transmission F clutch MPa {26.0 1.5} {24.0 30.0}
pressure {kg/cm2} 2.70 0.15 2.45 2.94
High idling
{27.5 1.5} {25.0 30.0}
2.55 0.15 2.35 2.94
Low idling
Transmission R clutch {26.0 1.5} {24.0 30.0}
pressure 2.70 0.15 2.45 2.94
High idling
{27.5 1.5} {25.0 30.0}
20-4 D375A-5

Cat-
new machine value
ry
Low idling
Transmission 1st ture: Within operating range {23.0 2.0} {20.0 26.0}
clutch pressure 2.25 0.2 1.96 2.55
High idling
{23.0 2.0} {20.0 26.0}
2.55 0.15 2.35 2.94
Low idling
Transmission 2nd {26.0 1.5} {24.0 30.0}
clutch pressure MPa 2.70 0.15 2.45 2.94
High idling
{kg/cm2} {27.5 1.5} {25.0 30.0}
2.55 0.15 2.35 2.94
Low idling
Transmission 3rd {26.0 1.5} {24.0 30.0}
clutch pressure 2.70 0.15 2.45 2.94
High idling
{27.5 1.5} {25.0 30.0}
Transmission lubrica- 0.20 0.05 0.20 0.05
Power train oil pressure
High idling
tion pressure {2.0 0.5} {2.0 0.5}
Torque converter oil tempera- 2.55 0.15 Min. 2.4
Low idling
Steering left clutch ture: Within operating range {26.0 1.5} {Min. 24}
pressure 27.0 0.15 Min. 2.4
High idling
{27.5 1.5} {Min. 24}
2.50 0.15 Min. 2.4
Low idling
Steering left brake {25.5 1.5} {Min. 24}
High idling
MPa {27.0 1.5} {Min. 24}
{kg/cm2} 2.55 0.15 Min. 2.4
Low idling
Steering right clutch {26.0 1.5} {Min. 24}
High idling
{27.5 1.5} {Min. 24}
2.50 0.15 Min. 2.4
Low idling
Steering right brake {25.5 1.5} {Min. 24}
High idling
{27.0 1.5} {Min. 24}
Pin puller actuation Torque converter oil tempera- MPa 2.55 0.10 Min. 2.2
High idling
pressure ture: Within operating range {kg/cm2} {26.0 2.0} {Min. 22}
Flat ground 18.9 1.0 18.9 1.0
F1
Engine water tempera- (3.8 0.2) (3.8 0.2)
When lock-up switch is OFF
ture: Within operating 10.6 0.6 10.6 0.6

Power train performance
range F2
(6.8 0.3) (6.8 0.3)
Torque converter oil tem-
perature: Within operat- 6.1 0.3 6.1 0.3
F3
ing range Sec. (11.8 0.6) (11.8 0.6)
Travel speed
Engine at high idling (km/h) 15.0 0.8 15.0 0.8
R1
Run-up distance: 10 - 30 (4.8 0.2) (4.8 0.2)
m 8.3 0.4 8.3 0.4
Measuring distance: 20 R2
(8.7 0.4) (8.7 0.4)
m
4.9 0.3 4.9 0.3
R3
(14.7 0.7) (14.7 0.7)
D375A-5 20-5

Cat-
new machine value
ry
Flat ground 18.9 1.0 18.9 1.0
Engine water tempera- F1
{3.8 0.2} {3.8 0.2}
ture: Within operating
10.6 0.6 10.6 0.6
When lock-up switch is ON

range
Power train performance
F2
Torque converter oil tem- {6.8 0.3} {6.8 0.3}
perature: Within operat- 6.1 0.3 6.1 0.3
ing range F3
Sec. {11.8 0.6} {11.8 0.6}
Travel speed Engine at high idling
(km/h) 14.1 0.7 14.1 0.7
Run-up distance: R1
10 - 30 m {5.1 0.3} {5.1 0.3}
Measuring distance:
7.8 0.4 7.8 0.4
20 m R2
{9.2 0.5} {9.2 0.5}
4.6 0.3 4.6 0.3
R3
{15.8 0.8} {15.8 0.8}
+0.98
Hydraulic oil temperature: 19.6 0 Min. 18.6
45 - 55C Low idling
Blade lift relief pres- {200 +100 } {Min. 190}
Cylinder at stroke end
sure 20.6 0
+0.98
Min. 19.6
Standard value measured with High idling
oil pressure gauge {210 +100 } {Min. 200}
+0.98
19.6 0 Min. 18.6
Low idling
Blade tilt relief pres- {200 +100 } {Min. 190}
sure 20.6 0
+0.98
Min. 19.6
High idling
MPa {210 +100 } {Min. 200}
{kg/cm2} 19.6 0
+0.98
Min. 18.6
Low idling
Ripper lift relief pres- {200 +100 } {Min. 190}
sure 20.6 0
+0.98
Min. 19.6
High idling
{210 +100 } {Min. 200}
Work equipment oil pressure
+0.98
19.6 0 Min. 18.6
Low idling
Ripper tilt relief pres- {200 +100 } {Min. 190}
sure 20.6 0
+0.98
Min. 19.6
High idling
{210 +100 } {Min. 200}
Hydraulic oil temperature: 18.6 20.6 Min. 17.6
45 - 55C Low idling
Blade lift relief pres- {190 210} {Min. 180}
Cylinder at stroke end
sure 19.6 21.6 Min. 18.6
Standard value measured with High idling
monitor panel {200 220} {Min. 190}
18.6 20.6 Min. 17.6
Low idling
Blade tilt relief pres- {190 210} {Min. 180}
sure 19.6 21.6 Min. 18.6
High idling
MPa {200 220} {Min. 190}
{kg/cm2} 18.6 20.6 Min. 17.6
Low idling
Ripper lift relief pres- {190 210} {Min. 180}
sure 19.6 21.6 Min. 18.6
High idling
{200 220} {Min. 190}
18.6 20.6 Min. 17.6
Low idling
Ripper tilt relief pres- {190 210} {Min. 180}
sure 19.6 21.6 Min. 18.6
High idling
{200 220} {Min. 190}
20-6 D375A-5

Cat-
new machine value
ry
Control circuit oil pres- Hydraulic oil temperature: 45 - 55C

Work equipment
4.51 0.29 Min. 3.9

oil pressure
sure Engine at high idling {46.0 3.0} {Min. 40.0}

Circuit oil pressure: Lever at HOLD MPa
Output pressure: Lever at full stroke {kg/cm2}
PPC valve output pres-
sure
High idling 9 15 26
RAISE
Low idling 3.5 4.5 6
Blade lift Sec.

LOWER High idling 1.1 1.6 1.1 1.6
Hydraulic oil tempera-
ture: 45 - 55C
Blade: No load
Low idling 1.1 1.6 1.1 1.6
Ground level - Max.
height
Low idling 10 15 17
Work equipment speed
Left tilt
Work equipment
High idling 45 6
Blade tilt Sec.
Low idling 8 12 16
Right tilt

ture: 45 - 55C
Blade: No load High idling 34 5
Full left tilt - Full right tilt
Low idling
Left tilt
High idling
Blade dual tilt Sec.
Low idling
Right tilt

ture: 45 - 55C
Blade: No load
High idling
Full left tilt - Full right tilt
D375A-5 20-7

Cat-
new machine value
ry
Low idling
Dump
High idling
Blade pitch Sec.
Hydraulic oil tempera- Low idling
Back
ture: 45 - 55C
Blade: No load
Full dump - Full back High idling
Low idling 7 11 15
RAISE
High idling 2.5 3.5 5
Ripper lift Sec.
Hydraulic oil tempera- Low idling 23 23

LOWER
ture: 45 - 55C
Blade: No load
Ground level - Max. High idling 23 23
height
Work equipment
Low idling 12 18 24
Tilt in
High idling 4.5 5.5 7

Ripper tilt Sec.
Low idling 8 12 16
Tilt back

ture: 45 - 55C
Blade: No load High idling 34 6
Full tilt in - Full tilt out
Hydraulic oil temperature: Low idling Max. 8 12
45 - 55C
Lever at full stroke
Raise blade to maximum
Blade height, then lower blade and
measure time taken from point High idling Max. 1.8 2.0
where blade contacts ground to
point where idler comes off
Time lag
ground
Sec.
Hydraulic oil temperature: Low idling
45 - 55C
Lever at full stroke
Raise ripper to maximum
Ripper height, then lower ripper and
measure time taken from point High idling Max. 1.0 1.5
where ripper contacts ground
to point where sprocket comes
off ground
20-8 D375A-5

Cat-
new machine value
ry
Blade lift mm Max. 200/15 min 400/15 min
Hydraulic oil temperature: 45 - 55C

Engine stopped
Hydraulic drift for 15 minutes at bottom edge
of blade (change in height h)
Hydraulic drift of
chassis (blade mm Max. 50/5 min 100/5 min
lift)

Engine stopped
Work equipment
Hydraulic drift
Hydraulic drift for 5 minutes at center of idler

(change in height h)
Blade tilt mm Max. 50/5 min 80/5 min

Engine stopped
Retraction h of tilt cylinder
Ripper lift mm Max. 80/15 min 160/15 min

Engine stopped
Hydraulic drift for 15 minutes at tip of shank
(change in height h)
D375A-5 20-9

Cat-
new machine value
ry
Hydraulic drift
Hydraulic drift of
chassis (ripper mm Max. 30/5 min 60/5 min
lift)
Work equipment

Engine stopped
Hydraulic drift for 5 minutes at center of
sprocket (change in height h)
Engine at high idling
Oil leakage from cylinder
Blade tilt cylinder Hydraulic oil temperature: 45 - 55C Max. 3.0 12

Measure oil leakage during 1 minute at cyl-
inder relief
Ripper lift
cc/min Max. 3.6 12
cylinder
Ripper tilt
Max. 3.2 12
cylinder
20-10 D375A-5

TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING ................................................................ 20- 102
MEASURING ENGINE SPEED ....................................................................................................................... 20- 104
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) ..................................................................... 20- 107
MEASURING EXHAUST TEMPERATURE (ALL CYLINDERS) ...................................................................... 20- 108
MEASURING EXHAUST TEMPERATURE (EACH CYLINDER) ..................................................................... 20- 110
MEASURING EXHAUST COLOR .................................................................................................................... 20- 111
TROUBLESHOOTING FOR INJECTOR .......................................................................................................... 20- 112
ADJUSTING VALVE CLEARANCE ................................................................................................................. 20- 113
ADJUSTING INJECTOR SET LOAD ............................................................................................................... 20- 114
MEASURING COMPRESSION PRESSURE ................................................................................................... 20- 116
MEASURING BLOW-BY PRESSURE ............................................................................................................. 20- 118
MEASURING ENGINE OIL PRESSURE ......................................................................................................... 20- 119
HANDLING EQUIPMENT IN FUEL SYSTEM .................................................................................................. 20- 120
MEASURING FUEL CIRCUIT PRESSURE ..................................................................................................... 20- 121
VISUAL INSPECTION OF RETURN FUEL ..................................................................................................... 20- 123
ARRANGEMENT OF CONTROL DEVICES FOR HPI .................................................................................... 20- 124
BLEEDING AIR FROM FUEL CIRCUIT ........................................................................................................... 20- 126
ADJUSTING ENGINE SPEED SENSOR ......................................................................................................... 20- 128
REPLACING AND ADJUSTING FAN BELT .................................................................................................... 20- 129
TESTING AND ADJUSTING ALTERNATOR, AIR CONDITIONER COMPRESSOR BELT TENSION ........... 20- 130
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL .............................................................. 20- 131
MEASURING POWER TRAIN OIL PRESSURE ............................................................................................. 20- 133
ADJUSTING TRANSMISSION SPEED SENSOR ........................................................................................... 20- 143
SIMPLE PROCEDURE FOR TESTING BRAKE PERFORMANCE ................................................................. 20- 143
ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER ....................................................................... 20- 144
ADJUSTING POSITION OF PCCS LEVER CONSOLE .................................................................................. 20- 147
EMERGENCY ESCAPE METHOD WHEN THERE IS FAILURE IN POWER TRAIN ..................................... 20- 148
ADJUSTING IDLER CLEARANCE .................................................................................................................. 20- 150
CHECKING WEAR OF SPROCKET ................................................................................................................ 20- 150
TESTING AND ADJUSTING TRACK SHOE TENSION ................................................................................... 20- 151
TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE .............................................................. 20- 152
TESTING AND ADJUSTING CONTROL CIRCUIT MAIN PRESSURE ........................................................... 20- 157
MEASURING PPC VALVE OUTPUT PRESSURE .......................................................................................... 20- 159
ADJUSTING PLAY OF PPC VALVE ................................................................................................................ 20- 161
MEASURING OUTPUT PRESSURE OF RIPPER PIN-PULLER SOLENOID VALVE .................................... 20- 162
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER .............................. 20- 163
MEASURING LEAKAGE INSIDE WORK EQUIPMENT CYLINDER ............................................................... 20- 164
RELEASING REMAINING PRESSURE IN WORK EQUIPMENT CYLINDERS .............................................. 20- 165
BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS ............................................................................ 20- 165
ADJUSTING RIPPER LEVER POSITION ....................................................................................................... 20- 166
ADJUSTING SAFETY LOCK LEVER .............................................................................................................. 20- 167
ADJUSTING BLADE ........................................................................................................................................ 20- 168
ADJUSTMENT OF PCCS LEVER POTENTIOMETERS ................................................................................. 20- 170
CHECKING THE ADJUSTMENT OF PCCS LEVER ....................................................................................... 20- 172
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) ................................................................................. 20- 175
ADJUSTMENT METHOD OF REPLACED CONTROLLER ............................................................................ 20- 227
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL EQUIPMENT SYSTEM ................ 20- 229
HANDLING OF OPTIONAL DEVICES ............................................................................................................. 20- 232
INITIALIZATION PROCEDURES FOR VHMS CONTROLLER ....................................................................... 20- 233
PROCEDURES FOR EXECUTING QUICK PM .............................................................................................. 20- 238
PRECAUTIONS FOR REPLACING VHMS CONTROLLER ............................................................................ 20- 247
PM CLINIC SERVICE ...................................................................................................................................... 20- 248
UNDERCARRIAGE TROUBLESHOOTING REPORT .................................................................................... 20- 255
D375A-5 20-101
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING

Testing and
Symbol Part No. Part name Qty Remarks
adjusting item
Measuring intake air
pressure A 799-201-2202 Boost gauge kit 1 101 200 kPa {760 1,500 mmHg}
(boost pressure)
Measuring exhaust B 799-101-1502 Digital thermometer 1 99.9 1,299C

temperature 799-201-1150 Adapter connector 1 For Pm clinic specification
Measuring exhaust
temperature C 795-799-5510 Heat gun 1
(each cylinder)
1 799-201-9000 Handy smoke checker 1 Pollution level: 0 70%
Measuring exhaust (With standard color)
D
color 2 Purchased Smoke meter 1 (Pollution level 1/10 <Komfont_Plain>C
Bosch index)
Troubleshooting for
E 795-799-5510 Heat gun 1
injector
Adjusting valve Air intake side: 0.32 mm,
F Purchased Thickness gauge 1
clearance Exhaust side: 0.62 mm
0 6.9 MPa {0 70 kg/cm2}
1 795-502-1590 Compression gauge 1
KIT No.: 795-502-1205
795-611-1210 Adapter 6
6560-11-8410 O-ring 6 TOP
Measuring 6560-11-8310 O-ring 6 2ND
compression G 2
6560-11-8210 O-ring 6 3RD
pressure
6560-11-8510 O-ring 6 4TH
6560-11-7310 Gasket 6
795-799-5410 Adapter 1
3
795-799-5420 Remover 1
Measuring blow-by
H 799-201-1504 Blow-by checker 1
pressure
q Same as above Q
Measuring power
J
train oil pressure
19M-06-32820 Switch assembly 1
Emergency escape 1 7824-66-6430 Resistor 1
method when there is K
failure in power train 195-06-71220 Wiring harness 1
2 790-190-1600 Pump assembly 1
q Same as above Q1
799-101-5002 Hydraulic tester 1
Testing and adjusting 1
control circuit main L 790-261-1203 Digital hydraulic tester 1
pressure
2 799-101-5210 Nipple 1 Size: PT1/4
q Same as above Q1
1
790-261-1203 Digital hydraulic tester 1
Measuring PPC valve Oil pressure pickup adapt-
M 2 799-401-3100 1 Size: 02
output pressure er
Oil pressure pickup adapt-
3 799-401-3200 1 Size: 03
er
20-102 D375A-5
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
Testing and
Symbol Part No. Part name Qty Remarks
adjusting item
q Same as above Q1
Measuring output 1
pressure of ripper 790-261-1203 Digital hydraulic tester 1
P
pin-puller solenoid
Oil pressure pickup adapt-
valve 2 799-401-3200 1 Size: 03
er
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
1 {25, 60, 400, 600 kg/cm2}
Measuring engine oil
Q
pressure 790-261-1203 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
q Same as above Q1
1
Measuring fuel circuit 790-261-1203 Digital hydraulic tester 1
R
pressure 2 795-799-5550 Adapter 1
3 795-799-5560 Negative pressure gauge 1 0 0.1 MPa {0 1 kg/cm2}
q Same as above Q1
1
Testing and adjusting 790-261-1203 Digital hydraulic tester 1
work equipment oil S
pressure 790-261-1321 Adapter 1 Size: 18 1.5, PT1/8 3
2
07002-11823 O-ring 1
Measuring leakage
inside work T Purchased Mess cylinder 1
equipment cylinder
Measuring water
temperature and oil q Same as above B
temperature
Measuring operating 79A-264-0021 Push-pull scale 1 0 294 N {0 30 kg}
effort and pressing
force 79A-264-0091 Push-pull scale 1 0 490 N {0 50 kg}
Measuring stroke and

Purchased Scale 1
hydraulic drift
Measuring work
Purchased Stopwatch 1
equipment speed
Measuring voltage
Purchased Tester 1
and resistance
799-601-7400 T-adapter assembly 1
799-601-7360 Adapter 1 For relay (5-pin)
799-601-9000 T-adapter assembly 1 For heavy-duty wire connector
For heavy-duty wire connector
799-601-9300 T-adapter assembly 1
(For 24-pin and 40-pin types)
795-799-5520 Socket (S) 1 For speed sensor 1 and 2
For fuel temperature sensor
795-799-5530 Socket (C) 1
Troubleshooting for For coolant temperature sensor
sensors and wiring 795-799-5540 Socket (A) 1 For intake air temperature sensor
harnesses
Atmospheric pressure
Cable
795-799-5460 1 Fuel rail pressure sensor
(cummins No.: 3824774)
Timing rail actuator
Fuel pump actuator
Cable
795-799-5470 1 Fuel rail actuator
Timing rail actuator
Cable
795-799-5480 1 Boost pressure sensor
Fuel pump pressure sensor
D375A-5 20-103
(1)
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED
a Measure the engine speed under the following 3. Measuring high idling speed
condition. 1) Start the engine and set the fuel control dial
Engine coolant temperature: in the high idling position.
Within operating range 2) Set the PCCS lever and work equipment
Torque converter oil temperature: control lever in neutral and measure the
Within operating range engine speed.
Power train oil temperature:
Within operating range
4. Measuring decelerator pedal speed
1) Start the engine and set the fuel control dial
1. Preparation work in the high idling position.
Turn starting switch ON and set the monitor 2) Set the PCCS lever and work equipment
panel to the Monitoring Mode to prepare for control lever in neutral and press the decel-
measurement of the engine speed. erator pedal and measure the engine
a For the operating method, see SPECIAL speed.
FUNCTIONS OF MONITOR PANEL
(EMMS).
Monitoring code: 01002 (Engine speed)
Unit: rpm
2. Measuring low idling speed

1) Start the engine and set the fuel control dial
in the low idling position.
2) Set the PCCS lever and work equipment
control lever in neutral and measure the
engine speed.
20-104 D375A-5
5. Measuring torque converter stall speed 6. Measuring torque converter stall + work
1) Start the engine and set the fuel control dial equipment relief speed (Full stall speed)
in the low idling position. 1) Start the engine and set the fuel control dial
2) Press the brake pedal securely and set the in the low idling position.
parking brake lever in the FREE position 2) Keep pressing the brake pedal securely
and set the PCCS lever in the FORWARD and set the parking brake lever in the FREE
3rd gear speed position. position and set the PCCS lever in the
a Before going to the next step, check that FORWARD 3rd gear speed position.
the upper display unit of the monitor a Before going to the next step, check that
panel is set in the normal display state the upper display unit of the monitor
and it displays [F3]. panel is set in the normal display state
a Keep the steering in neutral. and it displays [F3].
3) Press the decelerator pedal and set the fuel a Set the PCCS lever in the steering neu-
control dial in the high idling position. tral position.
4) Return the decelerator pedal slowly to stall 3) Press the decelerator pedal and set the fuel
the torque converter with the engine at high control dial in the high idling position.
idling. 4) Return the decelerator pedal slowly to stall
k Keep pressing the brake pedal securely the torque converter with the engine at high
and keep your right foot on the decelera- idling.
tor pedal for safety until the work is fin- k Keep pressing the brake pedal securely
ished. and keep your right foot on the decelera-
5) Just after the power train oil temperature tor pedal for safety until the work is fin-
gauge reaches position "a" of the green ished.
range, return the direction of the PCCS 5) Operate the lever to move the ripper lift cyl-
lever into neutral. inder to the raising stroke end.
6) Just after the torque converter oil tempera-
ture gauge reaches position "a" of the
green range, return the direction of the
PCCS lever into neutral.
6) Repeat above steps 2) - 5) 3 times.

7) Perform steps 2) - 4) again and measure
the engine speed when the power train oil
temperature gauge reaches position "a" of
the green range. 7) Repeat above steps 2) - 5) 3 times.
a Immediately after finishing measure- 8) Perform steps 2) - 4) again and relieve the
ment, return the direction of the PCCS ripper circuit in the raising direction and
lever into neutral and lower the power measure the engine speed when the power
train oil temperature with the engine at train oil temperature gauge reaches posi-
high idling. tion "a" of the green range.
a Immediately after finishing measure-
ment, return the direction of the PCCS
lever into neutral and lower the power
train oil temperature with the engine at
high idling.
D375A-5 20-105
a The engine speed can be measured in

the "PM Clinic Auxiliary Mode" of the
monitor panel.
20-106 D375A-5
TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)

a Tools for measuring intake air pressure (boost 4. Run the engine at a mid-range speed or above
pressure) to bleed the oil from the hose.
a Insert the connection of the hose and pres-
Symbol Part No. Part Name sure gauge about half way, repeat the action
A 799-201-2202 Boost gauge kit to open the self-seal portion at the hose end,
and bleed the oil.
a A nipple (quick coupler) is installed to the intake a If Pm kit (A) is available, the air bleed cou-
air pressure (boost pressure) pickup port of the pling (790-261-1130) inside the kit can be
Pm clinic specification machine. used.
k Be careful not to touch any hot parts when re- a If there is oil inside the hose, the gauge will
moving or installing the measuring tools. not work, so always bleed the oil.
a Measure the intake air pressure (boost pressure) 5. Run the engine at high idling to stall the torque
under the following conditions. converter, and measure the intake air pressure
Coolant temperature: Within operating range (boost pressure).
Torque converter oil temperature: Within op- a For details of the procedure for stalling the
erating range t o r q u e c o n v e r t e r, s e e M E A S U R I N G
Hydraulic oil temperature: 45 - 55C TORQUE CONVERTER STALL SPEED.
a The intake air pressure (boost pressure)
1. Open the engine left side cover. should be measured with the engine running
at rated output. However, when measuring
2. Remove intake air pressure measurement plug in the field, a similar value can be obtained at
(1). torque converter stall speed.
3. Fit nipple (1) of boost gauge kit A, then connect 6. After completing the measurement, remove the
gauge (2). measuring equipment and set to the original con-
dition.
D375A-5 20-107
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE (ALL CYLINDERS)
MEASURING EXHAUST TEMPERATURE (ALL CYLINDERS)

a Measuring instrument for exhaust temperature 1. Open the engine right side cover, then remove
(all cylinders) the adiabatic cover.
Symbol Part No. Name 2. Remove exhaust temperature measurement

B 799-101-1502 Digital thermometer plug (1).
a Measuring instruments for exhaust temperature

(Pm clinic specification)
Since the exhaust temperature sensor is in-
stalled to the Pm clinic specification machine,
prepare an adapter connector to connect the ex-
haust temperature sensor and digital tempera-
ture gauge.
Symbol Part No. Part Name

B 799-101-1502 Digital temperature gauge
799-201-1150 Adapter connector
a Measure the exhaust temperature under the fol- 3. Fit sensor (1) of digital temperature gauge B,
lowing condition. then connect to meter (2).
Engine coolant temperature: a Clamp the wiring harness of the digital tem-
Within operating range perature gauge to prevent it from touching
Torque converter oil temperature: any hot part during measurement.
Within operating range
Hydraulic oil temperature:
45 - 55C
A. If the machine is equipped with the VHMS, check

the exhaust temperature with the monitor panel
since the machine is equipped with exhaust tem-
perature sensors for the VHMS.
Monitoring code (Front bank): 42601
Monitoring code (Rear bank): 42600
Unit: C
a For the operating method, see SPECIAL
FUNCTIONS OF MONITOR PANEL.
B. If the machine is not equipped with the VHMS,

measure the exhaust temperature according to
the following procedure.
k Remove and install the measuring instru-
ments after the exhaust manifold is cooled
down.
20-108 D375A-5
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE (ALL CYLINDERS)
4. Procedure when measuring the maximum value 2) From the above condition, cancel the hy-
during troubleshooting draulic pump relief and carry out only torque
Carry out actual work and measure the maxi- converter relief to lower the exhaust temper-
mum value during operation. ature. (Condition b in the diagram).
a Use the PEAK mode of the digital tempera- a If the exhaust temperature does not go
ture gauge. down but rises, use the procedure in
a The exhaust temperature varies greatly ac- Step 1) to make the set temperature
cording to the ambient temperature (tempera- higher.
ture of the engine intake air), so if any 3) When the exhaust temperature goes down
abnormal value is obtained, carry out tempera- and becomes stable, record the tempera-
ture compensation using the following formula. ture. (Condition c in the diagram).
Compensation value [C] = Measured k If the torque converter oil temperature gauge
value + 2 x (20 - ambient temperature) enters the red range, return the directional
lever immediately to the neutral position and
lower the torque converter oil temperature.
5. Procedure when measuring periodically or dur-

ing preventive maintenance
a If only torque converter stall is used, the
power train oil temperature will overheat be-
fore the exhaust temperature stabilizes, so
always use the following procedure when
measuring.
1) Use the following procedure to carry out full
stall and raise the exhaust temperature to
approx. 650C. (Condition a in the diagram).
i) Start the engine, set the fuel control dial
to the low idling position, then operate
the ripper lever to move the ripper lift cyl-
inder to the end of the RAISE stroke.
ii) Keep the brake pedal firmly depressed,
operate the PCCS lever to the F position 6. After completing the measurement, remove the
and set the speed to 3. measuring equipment and set to the original con-
iii) Depress the decelerator pedal and set dition.
the fuel control dial to high idling.
iv) Let the decelerator pedal back slowly,
run the engine at high idling, stall the
torque converter, and at the same time,
operate the ripper lever to RAISE relief.
k Keep the brake pedal depressed firmly
during operation. For safety reasons, al-
ways keep your right foot on the deceler-
ator pedal until the completion of the
measurement operation.
D375A-5 20-109
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE (EACH CYLINDER)
MEASURING EXHAUST TEMPERATURE (EACH CYLINDER)

a Tools for measuring exhaust temperature (each 5. Compensate the measured value for each cylin-
cylinder) der to judge which cylinder is defective.
a Compensation value
C 795-799-5510 Thermometer Cylinder No.1 No.2 No.3 No.4 No.5 No.6
Compen-
a If the engine output drops or there is any other sation +20C +5C 0C 0C +5C +20C
problem, if there is the possibility of defective value
combustion due to defective injection by the in-
jector, measure the exhaust temperature of each a Method of judgment
cylinder as follows to locate the cylinder with the Add up the temperatures after compensat-
defective injection (defective combustion). ing, then calculate the average temperature.
If the temperature of any cylinder is more
1. Open the engine right side cover. than 20C lower than the average, judge that
the cylinder is abnormal.
2. Stop the engine and leave it to cool down. (1) Measurement and judgment example 1
a When cooling the engine down, as a guide-
Cylinder No.1 No.2 No.3 No.4 No.5 No.6
line, wait for the temperature of the exhaust
manifold to cool down to a temperature of Measured
value 85C 62C 79C 112C 89C 82C
"ambient temperature + 20C".
Compen-
3. Start the engine and run it at low idling for at least sation 105C 67C 79C 112C 94C 102C
value
10 minutes.
a Run it for at least 10 minutes to stabilize the Average
value 93C
exhaust temperature.
No. 2 cylinder is more than 20C lower than
4. Using thermometer C, measure the temperature the average value, so judge that No. 2 cylin-
at the outlet of the exhaust manifold of each cyl- der is abnormal.
inder. (2) Measurement and judgment example 2:
a Measure the exhaust temperature at the top
or bottom of the exhaust manifold of each Cylinder No.1 No.2 No.3 No.4 No.5 No.6
cylinder. Measure at the same position for Measured 86C 96C 73C 91C 94C 103C
the all cylinders. value
Compen-
sation 106C101C 73C 91C 99C 123C
value
Average
value 99C

the average value, so judge that No. 3 cylin-
der is abnormal.
(3) Measurement and judgment example 3:
Cylinder No.1 No.2 No.3 No.4 No.5 No.6

Measured
value 85C 62C 79C 112C 89C 82C
Compen-
sation 105C 67C 79C 112C 94C 102C
value
Average 93C
value
No cylinder is more than 20C lower than the

average value, so judge that all cylinders are
normal.
20-110 D375A-5
TESTING AND ADJUSTING MEASURING EXHAUST COLOR
MEASURING EXHAUST COLOR

a Tools for measuring exhaust color

1 799-201-9000 Handy Smoke Checker
D Commercially
2 Smoke Meter
available
k Be careful not to touch any hot parts when re-

moving or installing the measuring tools.
a When measuring in the field where there is no air
or electric power supply, use Handy Smoke
Checker D1; when recording formal data, use
Smoke Meter D2.
a Measure the exhaust color under the following 2) Connect the air hose and the socket of the
conditions. probe hose and accelerator switch to Smoke
Coolant temperature: Within operating range Meter D2.
a Keep the pressure of the air supply be-
low 1.5 MPa (15 kg/cm2).
1. Measuring with Handy Smoke Checker D1 3) Connect the power cord to the AC100V
1) Install filter paper to Handy Smoke Checker socket.
D1. a Before connecting the cord, check that
2) Insert the exhaust gas suction port into the the power switch of the Smoke Meter is
exhaust pipe. OFF.
3) Start the engine. 4) Loosen the cap nut of the suction pump and
4) Accelerate the engine suddenly or run at fit the filter paper.
high idling, and operate the handle of Handy a Fit the filter paper securely so that the
Smoke Checker D1 at the same time to col- exhaust gas cannot leak.
lect the exhaust gas on the filter paper. 5) Turn the power switch of Smoke Meter D2
ON.
5) Remove the filter paper and compare it with

the scale supplied to judge the condition. 6) Start the engine.
6) After completing the measurement, remove 7) Accelerate the engine suddenly or run at
the measuring equipment and set to the orig- high idling, and depress the accelerator ped-
inal condition. al of Smoke Meter D2 at the same time to
collect the exhaust gas color on the filter.
8) Place the filter paper used to catch the ex-
2. Measuring with Smoke Meter D2 haust gas color on top of at least 10 sheets
1) Insert probe (1) of Smoke Meter D2 into the of unused filter paper inside the filter paper
outlet port of the exhaust pipe, and tighten holder, and read the value shown.
the clip to secure it to the exhaust pipe. 9) After completing the measurement, remove
the measuring equipment and set to the orig-
inal condition.
D375A-5 20-111
TESTING AND ADJUSTING TROUBLESHOOTING FOR INJECTOR
TROUBLESHOOTING FOR INJECTOR

a Tools for adjusting
E 795-799-5510 Heat gun
a If the engine power down and bad combustion

seems to be caused by defective fuel injection,
perform troubleshooting for the injector accord-
ing to the following procedure.
1. Stop the engine and wait for it to cool down.

a A guideline for judging if the engine has
cooled down is that the temperature of the
exhaust manifold is less than 20C above
6. Compensate the measured value for each cylin-
the ambient temperature.
der 12 minutes after starting the engine and
judge if there is any cylinder with a problem.
2. Make measurement marks a to the exhaust
a Compensation value
manifold outlets of the all cylinders. Unit: C
a Make the marks at the same points of the Cylinder No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
tops or bottoms of the exhaust manifolds of
Compensation
the all cylinders. +20 +5 0 0 +5 +20
value
a Method of judgement
After compensating, add up the values for
the exhaust gas temperature and calculate
the average value. Any cylinder that is more
than 20C lower than the average value can
be considered abnormal.
a Measurement and judgement example 1
the average value, so judge it as abnormal.
Unit: C
Cylinder No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
Measured value 85 62 79 112 89 82
3. Using heat gun E, measure the temperature at Compensated
105 67 79 112 94 102
value
the exhaust manifold outlet port of each cylinder
before starting the engine. Average value 93
a Apply the measurement light (center) of the a Measurement and judgement example 2
heat gun to mark a of each cylinder to pre- No. 3 cylinder is more than 20C lower than
vent dispersion of the measurement results the average value, so judge it as abnormal.
caused by difference of the measuring Unit: C
points.
Cylinder No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
Measured value 86 96 73 91 94 103
4. Run the engine at low idling speed.
Compensated
106 101 73 91 99 123
value
5. Using heat gun E, measure the temperature at
Average value 99
the exhaust manifold outlet port of each cylinder
3 minutes, 6 minutes, 9 minutes, and 12 minutes a Measurement and judgement example 3
after starting the engine. No cylinder is more than 20C lower than the
a Apply the measurement light (center) of the average value, so judge all cylinders as nor-
heat gun to mark a of each cylinder to pre- mal.
vent dispersion of the measurement results Unit: C
caused by difference of the measuring Cylinder No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
points. Measured value 70 88 88 93 86 72
Compensated
90 93 88 93 91 92
value
Average value 91
20-112 D375A-5
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

a Tools for adjusting valve clearance

Commercially
F Thickness gauge
available
1. Open the engine left side cover and right side

cover.
2. Remove all cylinder head covers (1).
4. Insert thickness gauge F2 into clearance b be-

tween rocker arm (3) and crosshead (4), and ad-
just the valve clearance with adjustment screw
(5).
a Insert the thickness gauge and turn the ad-
justment screw until the clearance is a slid-
ing fit.
5. Hold adjustment screw (5) in position, then tight-
3 Locknut:
en locknut (6).
3. Rotate the crankshaft in the normal direction, to
set the No. 1 cylinder at compression top dead
center, and align [1.6TOP] line a on the damper 57.8 - 77.4 Nm {5.9 - 7.9 kgm}
with pointer (2). a After tightening the locknut, check the valve
a Crank the engine with barring device (1) of clearance again.
the flywheel housing.
6. Rotate the crankshaft 120 each time in the nor-

a At compression top dead center, the rocker mal direction and repeat the procedure in Steps
arm of the No. 1 cylinder can be moved by 3 - 5 to adjust the valve clearance of each cylin-
hand an amount equal to the valve clear- der according to the firing order.
ance. If the rocker arm does not move, it is Firing order: 1-5-3-6-2-4
not at compression top dead center, so ro-
tate the crankshaft one more turn. 7. After completing the adjustment, set to the origi-
3 Cylinder head cover mounting bolt:

nal condition.
9.8 1.0Nm{1.0 0.1kgm}
D375A-5 20-113
TESTING AND ADJUSTING ADJUSTING INJECTOR SET LOAD
ADJUSTING INJECTOR SET LOAD

1. Open the engine left side cover and right side a Cylinder at compression top dead center and
cover. cylinder where injector is adjusted
2. Remove all cylinder head covers (1). Compression top

1 5 3 6 2 4
dead center
Injector to be
2 4 1 5 3 6
adjusted
3. Rotate the crankshaft in the normal direction,

align [1.6TOP] line a on the damper with pointer
(2), and set the No. 1 cylinder at compression
top dead center.
4. Loosen locknut (4) of the injector to be adjusted.
a Crank the engine with barring device (1) of
Completely loosen adjustment screw (3), then
the flywheel housing.
tighten it with your fingers.
a Check that the bearing at the tip of the rocker
arm and the ball at the push rod end are fit-
ted securely in the injector and push rod re-
spectively.
5. Tighten and loosen adjustment screw (3) repeat-
3 Adjustment screw:
edly in the following order, then tighten it finally.
1st pass: 29.4 - 34.3 Nm {3.0 - 3.5 kgm}

2nd pass: Loosen completely
3rd pass: 29.4 - 34.3 Nm {3.0 - 3.5 kgm}
4th pass: Loosen completely
a At compression top dead center, the rocker 5th pass: 29.4 - 34.3 Nm {3.0 - 3.5 kgm}
arm of the No. 1 cylinder can be moved by
hand and amount equal to the valve clear-
ance. If the rocker arm does not move, it is
not at compression top dead center, so ro-
tate the crankshaft one more turn.
a The cylinder where the injector is adjusted is
different from the cylinder at compression
top dead center, so check the chart below
when carrying out the operation.
20-114 D375A-5
TESTING AND ADJUSTING ADJUSTING INJECTOR SET LOAD
6. Hold adjustment screw (3) in position, then tight-
3 Locknut: 205.8 - 245 Nm {21 - 25 kgm}

en locknut (4).
7. After completing the adjusting, set to the original

condition.
9.8 1.0Nm{1.0 0.1kgm}
D375A-5 20-115
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE

a Measuring instruments for compression pres- 3. Remove rocker arm assemblies (1) of all the cyl-
sure inders.

1 795-502-1590 Compression gauge
795-611-1210 Adapter
6560-11-8410 O-ring (TOP)
6560-11-8310 O-ring (2ND)
2
G 6560-11-8210 O-ring (3RD)
6560-11-8510 O-ring (4TH)
6560-11-7310 Gasket
795-799-5410 Adapter
3
795-799-5420 Remover
4. Remove injector push rods (2) and injectors (3)
k When measuring the compression pressure, of all the cylinders.
take care not to burn yourself on the exhaust a Using remover G3, pull out each injector.
manifold, muffler, etc. or get caught in a rotating
part.
a Measure the compression pressure after the en-
gine is warmed up.
(Engine oil temperature: 40 60C)
a Since the compression pressure of all the cylin-
ders should be measured at the same time for
efficiency, preapre 6 adapter assemblies G2.
1. Open the right side cover and left side cover of

the engine.
2. Remove all cylinder head covers (5).

5. Install adapter assemblies G2 to the all cylinders
and secure them with the holders.
a Install the adapter assemblies with the forc-
ing screw holes directed in the diagonal di-
rection of the holders.
a Secure the adapter assemblies with the in-
3 Holder mounting bolt:

jector holders.
24.5 34.3 Nm {2.5 3.5 kgm}
20-116 D375A-5
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
6. Install rocker arm assemblies (1) and adjust the 8. Connect compression gauge G1 to adapter as-
valve clearance. sembly G2 of the cylinder to be measured.
2 Threads and seat of mounting bolt:
3 Mounting bolt:
Engine oil (EO30CD)
235.2 254.8 Nm {24 26 kgm}

a See ADJUSTING VALVE CLEARANCE.
9. Crank the engine with the starting motor and

measure the compression pressure.
a Read the gauge when its pointer is stabi-
lized.
10. After finishing measurement, remove the mea-

7. Disconnect the EG1 (POW) connector and EG2 suring instruments and return the removed parts.
(SIG) connector (4) of the engine. a Measure the stem length of the injector hold-
a After this step, the fuel pump does not supply er mounting bolt. If it is longer than 80 mm,
fuel to the injectors. replace the bolt.
2 Threads and seat of
holder mounting bolt:

Engine oil (EO30CD)
1st time:
24.5 34.3 Nm {2.5 3.5 kgm}
2nd time:
Tighten by 90 120
2 Threads and seat of rocker arm
assembly mounting bolt:
3 Rocker arm assembly mounting bolt:

Engine oil (EO30CD)
235.2 254.8 Nm {24 26 kgm}

a Adjust the valve clearance. For details, see
ADJUSTING VALVE CLEARANCE.
a Adjust the set load of the injector. For details,
see ADJUSTING SET LOAD OF INJEC-

TOR.
9.8 1.0 Nm {1 0.1 kgm}
D375A-5 20-117
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE

a Tools for measuring blow-by pressure
3) Run the engine at high idling and measure
Symbol Part No. Part Name the blow-by pressure when the torque con-
H 799-201-1504 Blow-by checker verter stalls.
a For details of the procedure for stalling
a Measure the blow-by pressure under the follow- the torque converter, see MEASURING
ing conditions. T O R Q U E C O N V E R T E R S TA L L
Engine coolant temperature: Within operat- SPEED.
ing range a The blow-by should be measured with
Torque converter oil temperature: Within op- the engine running at rated output. How-
erating range ever, when measuring in the field, a sim-
Hydraulic oil temperature: 45 - 55C ilar value can be obtained at torque
converter stall.
1. If the machine is equipped with the VHMS, check a If it is impossible to check at rated output
the blow-by pressure with the monitor panel or torque converter stall, measure at
since the machine is equipped with crankcase high idling.
pressure sensors for the VHMS. In this case, the blow-by value will be
Monitoring code: 42800 (Blow-by pressure) about 80% of the value at rated output.
Unit: kPa a Blow-by varies greatly according to the
a For the operating method, see SPECIAL condition of the engine. Therefore, if the
F U N C T I O N S O F M O N I T O R PA N E L blow-by value is considered abnormal,
(EMMS). check for problems connected with de-
fective blow-by, such as excessive oil
2. If the machine is not equipped with the VHMS, consumption, defective exhaust gas col-
measure the blow-by pressure according to the or, and prematurely dirty or deteriorated
following procedure. oil.
1) Open the engine left side cover and pull out

blow-by hose (1).
2) Install nozzle (1) of blow-by checker G to

blow-by hose (1), then connect to gauge (2).
4) After completing the measurement, remove

inal condition.
20-118 D375A-5
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRESSURE
a Measuring instruments for engine oil pressure 2. If the machine is not equipped with the VHMS,
measure the engine oil pressure according to the
Symbol Part No. Name following procedure.
799-101-5002 Hydraulic tester 1) Open the engine left side cover.
1
790-261-1203 Digital hydraulic tester
Q
Hydraulic tester 2) Remove oil pressure measurement plug (1).
2 799-401-2320
(0.98 MPa {10 kg/cm2})
a Measure the engine oil pressure under the fol-

lowing condition.
Engine coolant temperature: Within operat-
ing range
Engine oil temperature: Min 80C
1. If the machine is equipped with the VHMS, check

the engine oil pressure with the monitor panel
since the machine is equipped with engine oil
pressure sensors for the VHMS.
Monitoring code: 52200 (Engine oil pres-
sure) 3) Fit nipple (1) of hydraulic tester H1, then con-
Unit: kPa nect to hydraulic tester H2.
F U N C T I O N S O F M O N I T O R PA N E L
(EMMS).
4) Start the engine, and measure the oil pres-

sure at low idling and high idling.

inal condition.
D375A-5 20-119
TESTING AND ADJUSTING HANDLING EQUIPMENT IN FUEL SYSTEM
HANDLING EQUIPMENT IN FUEL SYSTEM

a Precautions for inspection and maintenance of
fuel system
The HPI type fuel injection system is constructed
of more precise components than the conven-
tional fuel injection pump and nozzle, so prob-
lems may occur if dirt or dust get in.
When carrying out inspection and maintenance
of the fuel system, pay more attention than usual
to prevent dirt or dust from getting in. If there is
any dirt stuck to any part, use clean fuel to wash
it off completely.
a Precautions when replacing fuel filter cartridge
Always use a genuine Komatsu part for the fuel
filter cartridge.
The HPI type fuel injection system is constructed
of more precise components than the conven-
tional fuel injection pump and nozzle, so a spe-
cial filter with high efficiency filtering ability is
used to prevent dirt or dust from getting in.
For this reason, if any filter is used as a substi-
tute for the genuine filter, there is danger that
problems will occur with the fuel system. To pre-
vent this, never use such filters.
20-120 D375A-5
TESTING AND ADJUSTING MEASURING FUEL CIRCUIT PRESSURE
MEASURING FUEL CIRCUIT PRESSURE

a Measuring instruments for fuel circuit pressure a Fuel pump inlet pressure
(Negative pressure):
Engine Fuel pump inlet
799-101-5002 Hydraulic tester Condition
1 speed pressure
790-261-1203 Digital hydraulic tester Max. 13.6 kPa When new
R
2 795-799-5550 Adapter High {Max. 102 mmHg} filter is used
3 795-799-5560 Negative pressure gauge idling Max. 27.1 kPa Normal
{Max. 203 mmHg} condition
1. Measuring fuel pump inlet pressure
(negative pressure)
1) Install adapter R2 to inlet pressure pickup
coupler (1) of the fuel pump.
4) After finishing measurement, remove the

measuring instruments and return the re-
moved parts.
2) Install nipple (1) of hydraulic tester R1 and

connect it to negative pressure gauge R3. 2. Measuring fuel pump outlet pressure
1) Install adapter R2 to outlet pressure pickup
coupler (2) of the fuel pump.
3) Run the engine at high idling and measure

the fuel pump inlet pressure.
a Check that the fuel pump inlet pressure 2) Install nipple (1) of hydraulic tester R1 and
is in the following range. connect it to oil pressure gauge (2).
a Use the oil pressure gauge of 2.5 MPa
{25 kg/cm2}.
D375A-5 20-121
TESTING AND ADJUSTING MEASURING FUEL CIRCUIT PRESSURE
4) Measure the fuel pump outlet pressure at

each engine speed.
a Check that the fuel pump outlet pressure
is in the following range.
a Fuel pump outlet pressure:
Engine Fuel pump outlet Sensor

voltage
speed pressure (Reference)
0.83 0.14 MPa
600 rpm 1.78 0.21 V
{8.45 1.41 kg/cm2}
0.93 0.14 MPa
700 rpm 1.94 0.21 V
{9.50 1.41 kg/cm2}
3) Start the engine, set the monitor panel in the 1.03 0.14 MPa
800 rpm 2.10 0.21 V
MONITORING MODE, and prepare for mea- {10.53 1.41 kg/cm2}
suring the engine speed. 1.14 0.14 MPa
900 rpm 2.26 0.21 V
a For the operating method, see SPECIAL {11.60 1.41 kg/cm2}
FUNCTIONS OF MONITOR PANEL 1.25 0.14 MPa
1,000 rpm 2.42 0.21 V
(EMMS). {12.70 1.41 kg/cm2}
Monitoring code: 01002 (Engine speed) 1.34 0.14 MPa
1,100 rpm 2.59 0.21 V
a The engine speed is displayed on the {13.70 1.41 kg/cm2}
service meter display section in 1 rpm. 1.46 0.14 MPa
1,200 rpm 2.76 0.21 V
{14.90 1.41 kg/cm2}
a The sensor voltage shown in the above

table is the voltage measured at the
PMPR connector of the fuel pump pres-
sure sensor. It is shown for reference.

moved parts.
20-122 D375A-5
TESTING AND ADJUSTING VISUAL INSPECTION OF RETURN FUEL
VISUAL INSPECTION OF RETURN FUEL

a The fuel used for control of the timing rail in the
fuel circuit and the excessive fuel that is not used
injected in the fuel rail are returned from the in-
jector through the fuel cooler to the fuel tank.
a If the engine does not revolve normally or fuel
consumption is abnormally high, inspect the spill
fuel according to the following procedure.
1. Disconnect fuel return hose before the fuel tank.

a Plug the hole of the fuel tank.
a Keep the spill hose open and receive the fuel
with an oil pan, etc.
2. Start the engine and check that the fuel flows out
of the spill hose smoothly.
a Spillage (Referene)
At low idling: 4 6 /min.
At high idling: 10 12 /min.
a If the spillage is extremely low, check the re-
turn piping and fuel cooler for clogging.
D375A-5 20-123
TESTING AND ADJUSTING ARRANGEMENT OF CONTROL DEVICES FOR HPI
ARRANGEMENT OF CONTROL DEVICES FOR HPI

Arrangement of control devices (for troubleshooting)
20-124 D375A-5
TESTING AND ADJUSTING ARRANGEMENT OF CONTROL DEVICES FOR HPI
Controller pump valve

1. Engine controller
2. Fuel pump assembly
3. Control valve assembly
Sensors
4. Atmospheric pressure sensor (AAPR)
5. Boost pressure sensor (IMPR)
6. Intake air temperature sensor (IMTP)
7. Oil pressure sensor (OPS)
8. Fuel temperature sensor (FLTP)
9. Water temperature sensor (CLTP)
10. Speed sensor (SP1, SP2)
11. Fuel pump pressure sensor (PMPR)
12. Fuel rail pressure sensor (RPR)
13. Timing rail pressure sensor (TRP)
Actuator
14. Fuel pump actuator (PUMP)
15. Fuel shut-off valve (FSO+, FSO)
16. Fuel rail actuator (RAIL)
17. Timing rail actuator (TIMG)
D375A-5 20-125
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
BLEEDING AIR FROM FUEL CIRCUIT
a If the engine does not start or is difficult to start a Add fuel from the inlet port a (8 places). Por-
after the following operations or conditions, tion b is the outlet port after filtering (clean
bleed the air from the fuel circuit as follows. side), so never add fuel from portion b.
When starting the engine for the first time
After cleaning the fuel tank
After adding fuel when the engine has stalled
After replacing the fuel filter (only when the
air is not bled easily)
1. Open the stop valve at the fuel tank supply side,

then open the engine right side cover.
a Check that there is ample fuel in the fuel
tank.
2. Remove fuel filter, fill it with fuel, then install it

again.
a Carry out this operation only if the fuel filter
has been replaced.
a If the fuel filter is not to be replaced, there is
danger of dirt getting in, so do not remove
the fuel filter.
20-126 D375A-5
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
3. Crank the engine with the starting motor, push

air bleed the valve (1), and bleed the air from the
vent circuit.
a There is no problem with starting even if
some air is in the circuit, so if the fuel flows
out the bleeding operation is completed.
4. Start the engine and run at low idling.
a The injector is an open circuit, so while the
engine is running the air remaining in the cir-
cuit is released from the injector to the inside
of the engine or the fuel tank.
a After the engine is started, the engine rota-
tion will be slightly unstable until the air re-
maining in the circuit is completely bled, so
continue to run the engine at low idling until
it stabilizes.
a If the engine will still not start after the above op-
eration, fill the fuel pump with fuel as follows.
1) Remove air bleed valve (1).
2) Fill with clean fuel through the hole in the
valve until it overflows.
a Amount of fuel to add: Approx. 30 cc (ref-
erence)
3 Air bleed plug: 12.7 Nm {1.3 kgm}

3) Install air bleed plug (1).
4) Crank the engine with the starting motor.
D375A-5 20-127
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED SENSOR

a If the engine speed sensor has been removed
and installed or the flywheel has been removed
or installed, adjust as follows.
1. Remove the floor inspection cover, then remove

engine speed sensor (1).
a Before adjusting, remove the engine speed
sensor, check that the tip of the sensor is not
scratched and that there are no iron particles
sticking to it, then install it again.
5. After completing the adjustment, switch the mon-

itor panel to the monitoring mode display, and
check that the engine speed is displayed normal-
ly.
a For details of the method of operation, see
SPECIAL FUNCTIONS OF MONITOR PAN-
EL (EMMS).
Monitoring code: 01002 (Engine speed)
2. Screw in engine speed sensor (1) until its tip

lightly touches the tooth tip of flywheel ring gear
(2).
a Before installing the sensor, check that its tip
is free from steel chips and flaws.
2 Threads:
Hydraulic sealant (No. 21028)
manufactured by LOCTITE
3. Return engine speed sensor (1) by 1/2 3/4

turns.
a Adjust clearance a between the engine
speed sensor tip and gear tooth tip to 0.75
1.25 mm.
4. Hold engine speed sensor (1) and tighten lock-
3 Locknut:
nut (3).
33.9 - 47.5 Nm {3.5 - 4.8 kgm}
20-128 D375A-5
TESTING AND ADJUSTING REPLACING AND ADJUSTING FAN BELT
REPLACING AND ADJUSTING FAN BELT

Replacing Adjusting
1. Open the engine right side cover. a If the fan belt whines during operation, or a gap
forms between the tension pulley lever and the
2. Loosen locknut (1), then turn adjustment screw adjustment screw, adjust as follows.
(2) back fully.
1. Screw in adjustment screw (2) until the tip con-
3. Use one of the following methods to loosen the tacts tension pulley lever (3).
belt tension.
1) Insert bar (1) (approx. 50 cm) into hole a 2. From this position, tighten adjustment screw (2)
(M12 x 1.75) in tension pulley lever (3), pull a further 2 turns, then secure in position with
3 Locknut:
strongly and keep the tension of the fan belt locknut (1).
loosened.
2) Remove adjustment screw (2), then screw it 245.0 - 308.7 Nm {25.0 - 31.5 kgm}
into hole b (M16 x 1.0) of bracket (4) and
loosen the tension.
a After replacing the belts, set the adjust-
ment screw back to its original condition.
4. Remove the old fan belts and replace them with

new belts.
D375A-5 20-129
TESTING AND ADJUSTING ALTERNATOR, AIR CONDITIONER
TESTING AND ADJUSTING COMPRESSOR BELT TENSION
TESTING AND ADJUSTING ALTERNATOR, AIR CONDITIONER

COMPRESSOR BELT TENSION
Testing
Measure deflection a when a point midway be-
tween the alternator pulley and the air condition-
er compressor pulley (or idler pulley) is pressed
with a finger.
a Pushing force: Approx. 98 N {approx. 10 kg}
Adjusting
a If the deflection is not correct, adjust as follows.
1. Loosen the 2 alternator mounting bolts and 1

lock bolt for the adjustment rod.
2. Loosen locknut (1), then turn adjustment nut (2)

to move alternator (3) and adjust the belt ten-
sion.
3. Tighten the 2 alternator mounting bolts and 1
3 Alternator mounting bolt (4):

lock bolt for the adjustment rod.
3 Alternator locknut (1):

65 - 85 Nm {6.7 - 8.7 kgm}
147 - 247 Nm {15 - 25 kgm}
20-130 D375A-5
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
1. Outline of fuel control system

The speed signals from the fuel control dial
and decelerator pedal (decelerator potenti-
ometer) are both input to the engine control-
ler (the signal from the fuel control dial
passes through the steering controller).
The controller gives priority to the lower of
these two speed signals and sends a com-
mand to the fuel control system (HPI system)
of the engine.
Adjustment of the engine speed is all carried
out by the linkage of the deceleration pedal.
D375A-5 20-131
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
2. Preparatory work 3. Adjusting deceleration pedal speed

1) Start the engine, switch the monitor panel to With the fuel control dial in the high idling posi-
the monitoring mode display, and prepare to tion, press decelerator pedal (2) until it touches
measure the engine speed. the stopper. Check that the decelerator pedal
a For details of the method of operation, speed is normal under this condition.
see SPECIAL FUNCTIONS OF MONI- Deceleration speed: 900 50 rpm
TOR PANEL (EMMS). a If the deceleration speed is not correct, ad-
Monitoring code: 01002 (Engine speed) just installed dimension a of rod (1).
a The engine speed is displayed on the Standard installed dimension a of rod: 124
service meter display section in 1 rpm. mm (reference)
4. High idling speed

Set the fuel control dial to the high idling position
and check that the high idling speed is correct.
High idling speed: 1900 25 rpm
a If the high idling speed is abnormal, adjust it
according to the following procedure.
If the engine speed is more than 1850 rpm:
To remove the play of the decelerator pedal,
use stopper bolt (3) to adjust the engine
speed to less than 1800 rpm, then adjust to
the high idling speed.
If the engine speed is less than 1850 rpm:
Use stopper bolt (3) to adjust to the high
idling speed.
2) Set the fuel control dial to the high idling po-

sition and check that the engine speed is at
least 1000 rpm.
a If the engine speed is less than 1000
rpm, extend installation dimension a of
rod (1) to raise the speed to above 1000
rpm.
20-132 D375A-5
TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURE
MEASURING POWER TRAIN OIL PRESSURE

a Tools for measuring power train oil pressure

799-101-5002 Hydraulic tester
1
790-261-1203 Digital type hydraulic tester
J
Hydraulic tester
2 799-401-2320
(0.98MPa {10kg/cm2})
k Stop the machine on level ground, lower the

work equipment completely to the ground, then
set the parking lever and safety lever to the
LOCK position.
a Measure the power train oil pressure under the
following condition.
erating range
a The portions for measuring the power train oil
pressure (central pressure detection portion, oil
filter) are installed inside the inspection cover on
the right side on the outside of the operators
cab.
a Table of pressure pick-up port positions and

gauges to use
Gauge
No. Stamp Measurement location
(MPa{kg/cm2})
Torque converter inlet port
1 IN 2.5 {25}
pressure
Torque converter outlet port
2 OUT 0.98{10}
pressure
Torque converter lock-up
3 LU 2.5 {25}
clutch pressure
Torque converter stator clutch
4 SC 5.9 {60}
pressure
Transmission main relief
5 TM 5.9 {60}
pressure
6 FWD Transmission F clutch pressure 5.9 {60}
7 R Transmission R clutch pressure 5.9 {60}
8 1ST Transmission 1st clutch pressure 5.9 {60}
Transmission 2nd clutch
9 2ND 5.9 {60}
pressure
Transmission 3rd clutch
10 3RD 5.9 {60}
pressure
11 LC Left steering clutch pressure 5.9 {60}
Left steering brake pressure
12 LB Output pressure of sudden 5.9 {60}
stop prevention valve
13 RC Right steering clutch pressure 5.9 {60}
Right steering brake pressure
14 RB Output pressure of sudden 5.9 {60}
stop prevention valve
Transmission lubricating
15 0.98{10}
pressure
D375A-5 20-133
1. Measuring torque converter inlet pressure 2. Measuring torque converter outlet pressure
(IN) (OUT)
1) Connect oil pressure gauge (1) of hydraulic 1) Connect hydraulic tester J2 to oil pressure
tester J1 to oil pressure measurement nipple measurement nipple (2).
(1). a Use a 0.98 MPa {10 kg/cm2} oil pressure
a Use a 2.5 MPa {25 kg/cm2} oil pressure gauge.
gauge.
2) Start the engine and set all the functions of

2) Start the engine and set all the functions of the PCCS lever to neutral.
the PCCS lever to neutral. 3) Measure the oil pressure with the engine at
3) Measure the oil pressure with the engine at low idling and high idling.
low idling and high idling.

4) After completing the measurement, remove the measuring equipment and set to the orig-
the measuring equipment and set to the original condition.
inal condition.
20-134 D375A-5
3. Measuring torque converter lock-up clutch 3) Set the parking brake lever in the FREE po-
pressure (LU) sition and turn the lock-up mode switch ON.
1) Connect oil pressure gauge (1) of hydraulic 4) Set the PCCS lever direction to F and the
tester J1 to oil pressure measurement nipple speed to the 1st, and rotate the transmission
(3). under no load.
a Use a 2.5 MPa {25 kg/cm2} oil pressure 5) Gradually raise the engine speed, and mea-
gauge. sure the oil pressure when the lock-up pilot
lamp lights up.
2) Start the engine and set the monitor panel in

the "Adjustment mode" and disengage both 6) After completing the measurement, remove
steering clutches. the measuring equipment and set to the orig-
a For the operating method, see "Special inal condition.
functions of monitor panel (EMMS)".
a Adjustment code: 5535 (Disengagement
of both steering clutches)
a The transmission speed is displayed on
the service meter display section (Unit:
rpm).
D375A-5 20-135
4. Measuring torque converter stator clutch 5. Measuring transmission main relief pressure
pressure (SC) (TM)
1) Connect oil pressure gauge (1) of hydraulic a If the machine is equipped with the VHMS,
tester J1 to oil pressure measurement nipple check the transmission main relief pressure
(4). with the monitor panel since the machine is
a Use a 5.8 MPa {60 kg/cm2} oil pressure equipped with a transmission main relief
gauge. pressure sensor for the VHMS.
Monitoring code: 43000
(Transmission main relief pressure)
Unit: MPa
(EMMS).
a If the machine is not equipped with the
VHMS, measure the transmission main relief
pressure according to the following proce-
dure.
1) Connect oil pressure gauge (1) of hydraulic
tester J1 to oil pressure measurement nipple
(5).
2) Start the engine and set all the functions of a Use a 5.8 MPa {60 kg/cm2} oil pressure
the PCCS lever to neutral. gauge.
3) Measure the oil pressure with the engine at
2) Start the engine and set all the functions of

the PCCS lever to neutral.
4) After completing the measurement, remove 3) Measure the oil pressure with the engine at
the measuring equipment and set to the orig- low idling and high idling.
inal condition.

inal condition.
20-136 D375A-5
6. Measuring transmission F clutch pressure 7. Measuring transmission R clutch pressure

(FWD) (R)
1) Connect oil pressure gauge (1) of hydraulic 1) Connect oil pressure gauge (1) of hydraulic
tester J1 to oil pressure measurement nipple tester J1 to oil pressure measurement nipple
(6). (7).
a Use a 5.8 MPa {60 kg/cm2} oil pressure a Use a 5.8 MPa {60 kg/cm2} oil pressure
gauge. gauge.
2) Start the engine and set the monitor panel in 2) Start the engine and set the monitor panel in
the "Adjustment mode" and disengage both the "Adjustment mode" and disengage both
steering clutches. steering clutches.
a For the display on the panel, see "3. a For the display on the panel, see "3.
Measuring torque converter lock-up Measuring torque converter lock-up
clutch pressure (LU)". clutch pressure (LU)".
a Adjustment code: 5535 (Disengagement a Adjustment code: 5535 (Disengagement
of both steering clutches) of both steering clutches)
3) Set the parking brake lever in the FREE po- 3) Set the parking brake lever in the FREE po-
sition. sition.
4) Keep pressing the brake pedal, set the 4) Keep pressing the brake pedal, set the
PCCS lever direction to F and the speed to PCCS lever direction to R and the speed to
the 3rd, and rotate the transmission under no the 3rd, and rotate the transmission under no
load. load.
5) Measure the oil pressure at low idling. 5) Measure the oil pressure at low idling.
6) After completing the measurement, remove 6) After completing the measurement, remove
the measuring equipment and set to the orig- the measuring equipment and set to the orig-
inal condition. inal condition.
D375A-5 20-137
8. Measuring transmission 1st clutch pressure 9. Measuring transmission 2nd clutch pressure
(1ST) (2ND)
1) Connect oil pressure gauge (1) of hydraulic 1) Connect oil pressure gauge (1) of hydraulic
tester J1 to oil pressure measurement nipple tester J1 to oil pressure measurement nipple
(8). (9).
a Use a 5.8 MPa {60 kg/cm2} oil pressure a Use a 5.8 MPa {60 kg/cm2} oil pressure
gauge. gauge.
2) Start the engine and set the monitor panel in 2) Start the engine and set the monitor panel in
the "Adjustment mode" and disengage both the "Adjustment mode" and disengage both
steering clutches. steering clutches.
a For the display on the panel, see "3. a For the display on the panel, see "3.
Measuring torque converter lock-up Measuring torque converter lock-up
clutch pressure (LU)". clutch pressure (LU)".
a Adjustment code: 5535 (Disengagement a Adjustment code: 5535 (Disengagement
of both steering clutches) of both steering clutches)
3) Set the parking brake lever in the FREE po- 3) Set the parking brake lever in the FREE po-
sition. sition.
4) Keep pressing the brake pedal, set the 4) Keep pressing the brake pedal, set the
PCCS lever direction to F and the speed to PCCS lever direction to F and the speed to
the 1st, and rotate the transmission under no the 2nd, and rotate the transmission under
load. no load.
5) Measure the oil pressure at low idling. 5) Measure the oil pressure at low idling.
20-138 D375A-5
10. Measuring transmission 3rd clutch pressure 11. Measuring left steering clutch pressure (LC)
(3RD) 1) Connect oil pressure gauge (1) of hydraulic
1) Connect oil pressure gauge (1) of hydraulic tester J1 to oil pressure measurement nipple
tester J1 to oil pressure measurement nipple (11).
gauge.
2) Start the engine and set the parking lever to

2) Start the engine and set the monitor panel in the FREE position.
the "Adjustment mode" and disengage both 3) Operate the PCCS lever steering fully to the
steering clutches. left.
a For the display on the panel, see "3. a Set the direction to the neutral position.
Measuring torque converter lock-up 4) Measure the oil pressure with the engine at
clutch pressure (LU)". low idling and high idling.
a Adjustment code: 5535 (Disengagement a Check that the oil pressure becomes 0
of both steering clutches) when the PCCS lever steering is re-
3) Set the parking brake lever in the FREE po- turned to neutral.
sition.
4) Keep pressing the brake pedal, set the
PCCS lever direction to F and the speed to
the 3rd, and rotate the transmission under no
load.
5) Measure the oil pressure at low idling.

inal condition.

inal condition.
D375A-5 20-139
12. Measuring left steering brake pressure (LB) 13. Measuring right steering clutch pressure
1) Connect oil pressure gauge (1) of hydraulic (RC)
tester J1 to oil pressure measurement nipple 1) Connect oil pressure gauge (1) of hydraulic
(12). tester J1 to oil pressure measurement nipple
a Use a 5.8 MPa {60 kg/cm2} oil pressure (13).
gauge. a Use a 5.8 MPa {60 kg/cm2} oil pressure
gauge.
2) Start the engine and set the parking lever to

the FREE position. 2) Start the engine and set the parking lever to
3) Measure the oil pressure with the engine at the FREE position.
low idling and high idling. 3) Operate the PCCS lever steering fully to the
a Check that the oil pressure becomes 0 right.
when the PCCS lever steering is operat- a Set the direction to the neutral position.
ed fully to the left. 4) Measure the oil pressure with the engine at
a Check that the oil pressure becomes 0 low idling and high idling.
when the brake pedal is depressed or a Check that the oil pressure becomes 0
the parking lever is operated to the when the PCCS lever steering is re-
LOCK position. turned to neutral.
20-140 D375A-5
14. Measuring right steering brake pressure (RB) 15. Measuring transmission lubrication pressure
1) Connect oil pressure gauge (1) of hydraulic 1) Connect hydraulic tester J2 to oil pressure
tester J1 to oil pressure measurement nipple measurement nipple (15).
gauge.
2) Start the engine and measure the oil pres-

2) Start the engine and set the parking lever to sure with the engine at high idling.
the FREE position.
3) Measure the oil pressure with the engine at
a Check that the oil pressure becomes 0
when the PCCS lever steering is operat-
ed fully to the right.
a Check that the oil pressure becomes 0
when the brake pedal is depressed or
the parking lever is operated to the
LOCK position.

inal condition.

inal condition.
D375A-5 20-141
16. Measuring output pressure of sudden stop

prevention valve
1) Connect oil pressure gauge (1) of hydraulic
tester J1 to oil pressure pickup nipples (12)
and (14).
a Use the oil pressure gauge of 5.9 MPa
{60 kg/cm2}.
(12): For steering left brake
3) Set the parking brake lever in the FREE po-

sition and set the PCCS lever in the ALL
NEUTRAL position.
4) Run the engine at low idling and measure
the oil pressure.
a If the output pressure of the sudden stop
prevention valve is as follows, it is nor-
mal.
(14): For steering right brake 1.13 1.57 MPa {11.5 16.0 kg/cm2}
2) Start the engine, set the monitor panel in the 5) After finishing measurement, remove the
ADJUSTMENT MODE, and set the sudden measuring instruments and return the re-
stop prevention valve in the operation mode. moved parts.
(EMMS).
a Adjustment code:
9995 (Electrical brake normal
ON mode)
a The electrical current of the brake pedal
potentiometer is displayed on the service
meter display section (Unit: mA).
20-142 D375A-5
ADJUSTING TRANSMISSION SPEED SENSOR
TESTING AND ADJUSTING SIMPLE PROCEDURE
ADJUSTING
FOR TESTING
TRANSMISSION
BRAKE SPEED
PERFORMANCE
SENSOR
ADJUSTING TRANSMISSION SIMPLE PROCEDURE FOR

SPEED SENSOR TESTING BRAKE
1. Remove the cover at the bottom of the fuel tank, PERFORMANCE
then remove transmission speed sensor (1).
a Carry out the simple test of the brake perfor-
a Before adjusting, remove the transmission
mance under the following conditions.
speed sensor, and check that the tip of the
sensor is not scratched and that there are no
erating range
iron particles sticking to it.
1. Stop the machine on a level surface and set the
blade and ripper to the travel posture.
2. Screw in transmission speed sensor (1) until its

tip lightly touches the tooth tip of gear (2).
2 Threads of sensor: 2. Start the engine and set the parking lever to the
Gasket sealant (LG-5) FREE position.
3. Return transmission speed sensor (1) by 1/2 1
turn. 3. With the engine at low idling, depress the brake
a Adjust clearance a between the engine pedal firmly, and set the PCCS lever direction to
speed sensor tip and gear tooth tip to 0.75 F and the speed to 2.
1.25 mm. k If it is set to 1, there will be excess load on
4. Hold transmission speed sensor (1) and tighten the brakes, so always carry out this test in
3 Nut: 49.0 - 68.6 Nm {5 - 7 kgm}

locknut (3). position 2.
a Set the steering to the neutral position.
4. Depress the decelerator pedal and set the fuel

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

raise the engine speed to high idling. Check that
the machine does not start to move.
k The torque converter is stalled, so keep the
brake pedal depressed firmly during the op-
eration. For safety reasons, always keep
your right foot on the decelerator pedal until
the completion of the measurement opera-
tion.
5. After completing the adjustment, switch the mon-
itor panel to the monitoring mode display, and
check that the transmission speed is displayed
normally.
a For details of the method of operation, see
SPECIAL FUNCTIONS OF MONITOR PAN-
EL (EMMS).
a Monitoring code: 31400 (Transmission speed)
D375A-5 20-143
TESTING AND ADJUSTING ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER
ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER

Adjusting brake pedal
Adjusting parking lever
20-144 D375A-5
Adjusting brake pedal 5. Initial setting of brake potentiometer

Turn the starting switch ON, set the monitor pan-
1. Adjusting travel of brake pedal el in the ADJUSTMENT MODE, and set the
Adjust installation dimension b of stopper bolt (2) brake potentiometer to the initial value.
so that the travel of brake pedal (1) is dimension a For the operating method, see SPECIAL
a. F U N C T I O N S O F M O N I T O R PA N E L
a When adjusting the travel of the brake pedal, (EMMS).
disconnect the brake rod from the pedal. a Adjustment code:
Pedal travel a: 74 mm 0005 (Brake potentiometer zero adjustment)
Stopper bolt installation dimension b: 42 mm
Adjusting parking lever
2. Adjusting installed length of brake rod
1) Install brake rod (3) and release brake pedal 6. Assembly and installation of lever assembly
(1) (do not depress it). 1) Assemble lever assembly (7) and adjust the
2) Adjust installed dimensions c and d of brake actuation of limit switch (8).
rod (3) with turnbuckle (5) so that the spool a When assembling the lever assembly,
of brake valve (4) is at the OFF position. disconnect the parking cable from the le-
a The locknut of the turnbuckle has a left- ver.
handed thread (reverse thread) at the Lever raised: OFF, lever lowered: ON
brake pedal end. Limit switch actuation travel: 3 mm
Installed dimension c: 32 mm 2) Install lever assembly (7).
3 Locknut:
Installed dimension d: 14 mm
7. Adjusting installed length of parking cable
34.3 58.8 Nm {3.5 6.0 kgm} 1) Connect parking cable (9) to the lever and
valve, then adjust installed dimensions f and
3. Checking travel of brake pedal g.
1) Depress brake pedal (1) and check that the Installed dimension f of cable: 112.8 mm
travel is as given in Step 1 above. Installed dimension g of cable: 114.0 mm
2) Depress brake pedal (1) and check that the 2) Operate parking lever (10) between the
pedal is stopped by stopper (6). FREE position and LOCK position, and ad-
3) Check that spool travel e of brake valve (4) just the position of rod end (11) so that spool
is within the correct range when brake pedal travel h of brake valve (4) is correct.
(1) is depressed. Spool travel h: 23.0 mm
Spool travel e: 19 23 mm
4. Checking brake oil pressure

1) Start the engine and set the monitor panel in
the ADJUSTMENT MODE.
(EMMS).
a Adjustment code:
9996 (Electrical brake release mode)
2) With the parking brake lever in the FREE po-
sition, press the brake pedal and check that
the brake oil pressures on both sides be-
come 0.
a For the measuring points of the brake oil
pressure, see MEASURING POWER
TRAIN OIL PRESSURE.
D375A-5 20-145
8. Checking brake oil pressure

Start the engine, set the parking brake lever in
the FREE position and LOCK position, and
check that the brake oil pressure becomes as
follows at the respective positions.
a For details of the method of measuring the
brake oil pressure, see MEASURING POW-
ER TRAIN OIL PRESSURE.
LOCK position: 0, FREE position: Specified
pressure
9. Checking limit switch

1) Turn the starting switch ON and set the mon-
itor panel in the MONITORING MODE.
(EMMS).
Monitoring code:
40910 (Steering controller switch input 1)
2) Set the parking brake lever in the FREE po-
sition and LOCK position and check that the
limit switch signals are input normally at the
respective positions.
20-146 D375A-5
TESTING AND ADJUSTING ADJUSTING POSITION OF PCCS LEVER CONSOLE
ADJUSTING POSITION OF PCCS LEVER CONSOLE
1. Set operators seat (1) facing the front (dozing

position).
2. In this condition, check that console (2) is paral-

lel to operators seat (1).
a If it is not parallel, adjust installed dimension
a of rod (3).
Standard installed dimension a: 179 mm
a The locknut at the rear of the turnbuckle has
a left-handed thread (reverse thread)
D375A-5 20-147
EMERGENCY ESCAPE METHOD WHEN THERE IS FAILURE IN POWER
TESTING AND ADJUSTING TRAIN
EMERGENCY ESCAPE METHOD WHEN THERE IS FAILURE IN

POWER TRAIN
a Tools for emergency escape a Insert switch assembly (1) inside the cab
through the cab window.
19M-06-32820 Switch assembly
1 7824-66-6430 Resistor
K
195-06-71220 Wiring harness
2 790-190-1600 Pump assembly
1. Emergency escape method using switch box

(using K1)
a If a problem occurs in the electrical system of
the power train control (direction, speed,
steering) and the machine does not move,
carry out the emergency escape as follows.
a With this procedure, it is necessary to be 3) Disconnect the neutral safety relay (NSF) in-
able to start the engine. If the engine will not side the fuse room, then connect pin (3) and
start, see EMERGENCY ESCAPE METHOD pin (5) of the connector at the wiring harness
USING BRAKE RELEASE DEVICE. end directly.
1) Connect switch assembly (1) and resistor (2) a With this operation, the neutral safety re-
to wiring harness (3) of emergency escape lay or transmission controller will not
device K1. work, so carry out this operation only if
k Resistor (2) controls the drive voltage of the engine will not start electrically.
the solenoid, so connect it before con- k With this method, if the engine starts, the
necting the wiring harness to the ma- neutral safety relay function will not
chine. work, so before starting the engine, set
k In order to prevent mistaken actuation, the parking lever to the LOCK position
set all the speed range switches of and all the PCCS lever functions to the
switch assembly (1) to the OFF position neutral position.
and the directional switch to the P posi- k With this method, start the engine only
tion. when carrying out the emergency es-
cape. In all other cases when the engine
does not start, always carry out trouble-
shooting and repair the cause.
2) Open the inspection cover on the left fender

and connect wiring harness (3) to PL1 con-
nector (1) and PL2 connector (2).
PL1 connector (1): Connect to male and 4) Start the engine and set the parking lever to
female ends the FREE position.
PL2 connector (2): Connect to male end 5) Operate switch assembly (1) and move the
a The female end of connector PL2 re- machine to a safe place.
mains disconnected, so cover it with vi- a The speed switch has an electric circuit
nyl. that gives priority to operation of the low
speed switch.
20-148 D375A-5
EMERGENCY ESCAPE METHOD WHEN THERE IS FAILURE IN POWER
TESTING AND ADJUSTING TRAIN
4) Connect the hose at the tip of pump assem-

2. Emergency escape method using brake re- bly K2 to the supply hose.
lease device (using K2) a Block the solenoid valve end with a plug.
a If the engine cannot be started, and the park- 5) Turn the starting switch ON and set the park-
ing brake cannot be released, carry out the ing lever to the FREE position.
emergency escape as follows. 6) Operate the volume pump to raise the brake
1) Assemble pump assembly K2. release oil pressure to the initial pressure.
Initial pressure: approx. 2.74 MPa {ap-
prox. 28 kg/cm2}
a An accumulator is installed in the circuit,
so it is necessary to operate the handle
30 - 50 times to raise the oil pressure.
a If the pressure does not go above the set
pressure, the set pressure of the relief
valve may be too low, so adjust it.
7) Tow the machine to a safe place.
a The brake release oil pressure will go
down gradually because of internal leak-
age, and the brake will be actuated after
approx. one minute, so carry out the op-
2) Set volume pump (1) of pump assembly K2 eration quickly.
on the outside of the operators cab. a When the brake release pressure goes
down to approx. 1.57 MPa {16 kg/cm2},
the brake is actuated. If this happens,
operate the volume pump again to raise
the brake release pressure to the initial
pressure.
3) Remove the cover at the bottom of the fuel

tank, then disconnect supply hose (3) of the
pin-puller solenoid valve.
D375A-5 20-149
ADJUSTING IDLER CLEARANCE
TESTING AND ADJUSTING ADJUSTING
CHECKING IDLER
WEAR OFCLEARANCE
SPROCKET
ADJUSTING IDLER CHECKING WEAR OF

CLEARANCE SPROCKET
a If there is wear of the idler side guide, top and a Copy the SPROCKET TOOTH BASIC DIMEN-
bottom guide, or guide plate, and the idler sways SION DRAWING on a clear paper or sheet, and
to the side or is at an angle, adjust as follows. place it directly on the sprocket to judge pass/fail
for the sprocket wear.
1. Travel for 1 - 2 m on flat ground, then measure
clearance a (outside, inside).
2. If clearance a is more than 3 mm, remove bolt (1)

and reduce shim (2) to adjust.
Standard clearance a on one side: 0 - 0.5
mm
Types of shim thickness: 0.5 mm, 1.0 mm
a When the machine is new, 10 mm thickness
of shim is installed on each side.
a When adjusting, reduce the shim thickness
3 Mounting bolt:
uniformly on the inside and outside.
824 - 1030 Nm {84 - 105 kgm}
20-150 D375A-5
TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING TRACK SHOE TENSION

Testing 3. If tension is too low:
1. Drive the machine forward and stop on a hori- Pump in grease through grease fitting (4).
zontal surface. a If the the track tension is poor, move the ma-
a Stop the machine without using the brake. chine backwards or forwards slowly.
2. Put straight steel rod (1) on top of the track be-

tween the idler and front carrier roller, and mea-
sure clearance a from the bottom of the steel rod
to the track shoe grouser.
Standard clearance a: 20 - 30 mm
Adjusting
a If the track shoe tension is not correct, adjust as
follows.
1. Remove cover (2).
2. If tension is too high:

Loosen plug (3) and release some of the grease.
k There is danger that the plug may fly out un-
der the high internal pressure of the grease,
3 Plug: 59 - 88 Nm {6 - 9 kgm}
so never loosen the plug more than 1 turn.
D375A-5 20-151
TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE
TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE

a Testing and adjusting instruments for work 3) Install adapter S2, nipple (1) of hydraulic
equipment oil pressure tester S1, and pressure sensor (9), and con-
nect them to oil pressure gauge (2).
Symbol Part No. Part Name a Use the oil pressure gauge of 39.2 MPa
799-101-5002 Hydraulic tester {400 kg/cm2}.
1
790-261-1203 Digital hydraulic tester
S
790-261-1321 Adapter
2
07002-11823 O-ring
Measuring (Measuring with oil pressure gauge)

a Meaure the work equipment oil pressure under
the following condition.
Hydraulic oil temperature: 45 55C
1. Measuring front pump relief pressure

1) Disconnect the blade lift cylinder hoses from
the cylinder and block the control valve side.
Flange for blocking: 4) Start the engine and reset the safety lock le-
07379-01260 (4 pieces) ver.
a Stop the cylinder side, too, with cork 5) Run the engine at low idling and high idling
stoppers, etc. and operate the blade lever to relieve the
2) Remove work equipment large pump pres- blade lift cylinder circuit. Measure the oil
sure sensor (9). pressure at this time.

moved parts.
20-152 D375A-5
2. Measuring center pump relief pressure 4) Run the engine at low idling and high idling
1) Remove work equipment small pump pres- and operate the blade lever or ripper lever to
sure sensor (10). relieve each cylinder circuit. Measure the oil
pressure at this time.
2) Install adapter S2, nipple (1) of hydraulic

tester S1, and pressure sensor (10), and 5) After finishing measurement, remove the
connect them to oil pressure gauge (2). measuring instruments and return the re-
a Use the oil pressure gauge of 39.2 MPa moved parts.
{400 kg/cm2}.
3) Start the engine and reset the safety lock le-

ver.
D375A-5 20-153
Measuring (Measuring with monitor panel) 1. Measuring front pump relief pressure
a Meaure the work equipment oil pressure under 1) Disconnect the blade lift cylinder hoses from
the following condition. the cylinder and block the control valve side.
Hydraulic oil temperature: 45 55C Flange for blocking:
a The unload pressure, main relief pressure, blade 07379-01260 (4 pieces)
tilt relief pressure, blade pitch relief pressure, a Stop the cylinder side, too, with cork
and blade raise relief pressure can also be mea- stoppers, etc.
sured in the "PM Clinic Auxiliary Mode" of the op- 2) Start the engine, set the monitor panel in the
erator mode of the monitor panel. MONITORING MODE, and prepare for mea-
a The pressures of both the front (F) and rear (R) suring the oil pressure.
pumps can be measured simultaneously in the a For the operating method, see SPECIAL
"Dual Display Monitoring Mode" of the service FUNCTIONS OF MONITOR PANEL
mode. (EMMS).
Monitoring code:
70700 (Work equipment front pump
oil pressure)
a The oil pressure is displayed on the ser-
vice meter display section in 1 kg/cm2.
ver.
4) Run the engine at low idling and high idling
and operate the blade lever to relieve the
blade lift cylinder circuit. Measure the oil
20-154 D375A-5
2. Measuring center pump relief oil pressure Adjusting

1) Start the engine, switch the monitor panel to
the monitoring mode display, and prepare to 1. Adjusting front pump relief pressure
measure the oil pressure. a If the front pump relief pressure is not cor-
a For details of the method of operation, rect, adjust main relief valve (1) of the blade
see SPECIAL FUNCTIONS OF MONI- lift valve as follows.
TOR PANEL (EMMS).
Monitoring code:
70702 (Work equipment center
pump oil pressure)
a The oil pressure is displayed on the ser-
vice meter display section in MPa.

ver.
3) Run the engine at low idling and high idling
and operate the blade lever or ripper lever to
relieve each cylinder circuit. Measure the oil
1) Remove the right side cover.
2) Remove cover (2).
3) Loosen locknut (3), then turn adjustment
screw (4) to adjust.
a Turn the adjustment screw as follows.
To INCREASE pressure, turn CLOCK-
WISE
To DECREASE pressure, turn COUN-
TERCLOCKWISE
a Amount of adjustment for one turn of ad-
justment screw:
3 Locknut :
Approx. 2.43 MPa (approx. 24.8 kg/cm2)
11.8 14.7 Nm {1.2 1.5 kgm}
3 Cover:
4) Install cover (2).
29.4 39.2 Nm {3 4 kgm}
5) After completion of the adjustment, repeat

the above procedure to check the oil pres-
sure again.
D375A-5 20-155
2. Adjusting center pump relief pressure 5) After completion of the adjustment, repeat
a If the center pump relief pressure are not the above procedure to check the oil pres-
correct, adjust main relief valve (5) of the sure again.
blade tilt and ripper Lo valve as follows.
1) Remove the right side cover.

To INCREASE pressure, turn CLOCK-
WISE
To DECREASE pressure, turn COUN-
TERCLOCKWISE
justment screw: Approx. 2.43 MPa (ap-
prox. 24.8 kg/cm2)
3 Cover: 29.4 - 39.2 Nm {3 - 4 kgm}

4) Install cover (6).
20-156 D375A-5
TESTING AND ADJUSTING TESTING AND ADJUSTING CONTROL CIRCUIT MAIN PRESSURE
TESTING AND ADJUSTING CONTROL CIRCUIT MAIN PRESSURE

a Tools for measuring control circuit main pres-
sure

1
L 790-261-1203 Digital type hydraulic tester
2 799-101-5210 Nipple (PT1/4)
Measuring
LOCK position.
4. Start the engine, run it at high idling, and mea-
a Measure the control circuit main pressure under sure the oil pressure when the blade lever and
the following conditions. ripper lever are placed at the HOLD position.
1. Open the right side cover.
2. Remove oil pressure measurement plug (1).
5. After completing the measurement, remove the

measuring equipment and set to the original con-
dition.
3. Fit nipple L2, then connect oil pressure gauge

(1) of hydraulic tester L1.
a Use a 5.8 MPa {60 kg/cm2} oil pressure
gauge.
D375A-5 20-157
TESTING AND ADJUSTING TESTING AND ADJUSTING CONTROL CIRCUIT MAIN PRESSURE
Adjusting
a If the control circuit main pressure is not correct,
adjust charge relief valve (2) as follows.

To INCREASE pressure, turn
CLOCKWISE
To DECREASE pressure, turn
COUNTERCLOCKWISE
3 Locknut:
justment screw: 0.77 MPa (7.8 kg/cm2)
54 - 74 Nm (5.5 - 7.5 kgm}
2) After completion of the adjustment, repeat

the above procedure to check the oil pres-
sure again.
20-158 D375A-5
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE

a Tools for measuring PPC valve output pressure

1
M Oil pressure pickup adapter

2 799-401-3100
(02 size)
Oil pressure pickup adapter
3 799-401-3200
(03 size)

4. Start the engine and set the safety lock lever to
LOCK position.
the FREE position.
a Check that the control circuit oil pressure is cor-
rect before measuring the PPC valve output 5. Run the engine at high idling, operate the control
pressure. lever of the circuit to be measured, and measure
a Measure the PPC valve output pressure under the oil pressure.
the following conditions. a Operate the control lever fully when measur-
Hydraulic oil temperature: 45 - 55C ing.
a For blade LOWER, operate to the FLOAT
1. Remove side cover of hydraulic tank. position.
2. Remove the oil pressure switch or oil pressure
measurement plug (1) of the circuit to be mea-
sured.
a For details of the circuit to be measured, see
the drawing on the next page.
a For circuits where there is no oil pressure
switch or oil pressure measurement plug in-
stalled, fit nipples M2, M3.

dition.
3. Fit nipple (1) of hydraulic tester M1, then connect

to oil pressure gauge (2).
gauge.
D375A-5 20-159
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE
20-160 D375A-5
TESTING AND ADJUSTING ADJUSTING PLAY OF PPC VALVE
ADJUSTING PLAY OF PPC VALVE

a If there is excessive play at the tip of the ripper
lever and blade lever, adjust the PPC valve as
follows.
a The diagram shows the PPC valve for the ripper.
Standard play dimension a:
0.5 - 3.0 mm at a point 200 mm from rotation
center of lever (both to front and rear, and to
left and right)
1. Remove boot (1).
2. Loosen locknut (2) and rotate disc (3) to adjust

the amount of play.
a When doing this, do not make the piston
move.
3. Secure disc (3) in position and tighten locknut
3 Locknut: 98 - 127 Nm {10 - 13 kgm}

(2).
4. Install boot (1).
D375A-5 20-161
MEASURING OUTPUT PRESSURE OF RIPPER PIN-PULLER SOLENOID
TESTING AND ADJUSTING VALVE
MEASURING OUTPUT PRESSURE OF RIPPER PIN-PULLER

SOLENOID VALVE
a Tools for measuring output pressure of ripper
pin-puller solenoid valve

1
P
Oil pressure pickup adapter
2 799-401-3200
(03 size)

LOCK position.
a Measure the output pressure of the ripper pin 4. Start the engine, run at high idling, and measure
puller solenoid valve under the following condi- the oil pressure when the ripper pin-puller switch
tions. is actuated.
Torque converter oil temperature: 45 - 55C
1. Disconnect pin-puller cylinder hoses (1) and (2).

dition.
2. Fit nipple P2, then connect the hoses again.
3. Fit nipple (1) of hydraulic tester P1, then connect

oil pressure gauge (2).
gauge.
20-162 D375A-5
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND
TESTING AND ADJUSTING RIPPER
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF

BLADE AND RIPPER
a If hydraulic drift occurs in the blade or ripper,
check as follows to see if the cause is in the cyl-
inder packing or in the control valve.
1. Set the cylinder to be inspected to the following
posture, then stop the engine.
1) Blade lift cylinder
Push the blade against the ground to raise
the front of the chassis.
a The blade lift cylinder has a built-in pis-
ton valve, so do not operate the cylinder
to the end of the stroke.
2. Operate the control lever in the direction to ex-

tend the cylinder rod, and check the movement
of the cylinder.
If the downward movement becomes faster,
the packing is defective.
If there is no change, the control valve is de-
fective.
a If there is no more pressure in the accumula-
tor, run the engine for approx. 10 seconds to
charge the accumulator.
2) Blade tilt cylinder [Reference:] If the cause of the hydraulic drift is in

Extend the tilt cylinder rod fully, then push the packing, the speed of downward
the blade against the ground to raise the movement in the above operation will
right side of the chassis. become faster for the following rea-
sons.
1) When the work equipment is set to the posture
given above, (holding pressure applied to the
bottom end), oil will leak from the bottom end to
the head end. However, the volume at the head
end is smaller than at the bottom end (by an
amount proportional to the volume of the rod), so
if the oil flows in from the bottom end, the internal
pressure at the head end will rise.
2) If the internal pressure at the head end rises, a
balance will be made in proportion to this at a
certain pressure (this differs according to the
amount of leakage). When the pressure be-
3) Ripper lift cylinder comes balanced, the speed of downward move-
Push the ripper against the ground to raise ment becomes slower.
the rear of the chassis. 3) In this condition, if the lever is operated as shown
above, the circuit at the head end is connected to
the drain circuit (the bottom end is closed by a
check valve), and the oil at the head end flows to
the drain circuit. As a result, the balance is lost
and the speed of downward movement increas-
es.)
D375A-5 20-163
TESTING AND ADJUSTING MEASURING LEAKAGE INSIDE WORK EQUIPMENT CYLINDER
MEASURING LEAKAGE INSIDE WORK EQUIPMENT CYLINDER

a Tools for measuring leakage from work equip- 3. Run the engine at high idling and apply the relief
ment cylinder pressure to the bottom end of the cylinder.
Blade tilt cylinder: Extract the cylinder to be
Symbol Part No. Part Name measured
Commercially Ripper lift cylinder: Lower ripper
T Measuring cylinder
available Ripper tilt cylinder: Tilt ripper to front
a Measure the oil leakage inside the hydraulic cyl-
4. Wait for 30 seconds, then measure the amount
inder under the following conditions.
of leakage over the next 1 minute.
a The blade lift cylinder has a built-in piston valve,
5. After completing the measurement, set to the
so the internal leakage cannot be measured.
original condition.
1. Fully extend the cylinder to be measured, and
set to the measurement posture.
1) Blade tilt cylinder:
Extract the cylinder to be measured to the
stroke end.
2) Ripper lift cylinder:
Remove the shank pin and lower the ripper
fully.
3) Ripper tilt cylinder:
Tilt the ripper fully to the front.
2. Disconnect the piping at the head end of the cyl-

inder and block the hose with an oil stopper plug.
a Remove the cover when disconnecting the
blade tilt cylinder hose.
k Be careful not to disconnect the hose at the
bottom end.
20-164 D375A-5
RELEASING REMAINING PRESSURE IN WORK EQUIPMENT CYLINDERS
TESTING AND ADJUSTING RELEASING REMAINING
BLEEDING
PRESSURE
AIR FROM
IN WORK EQUIPMENT CYLINDERS
RELEASING REMAINING BLEEDING AIR FROM WORK

PRESSURE IN WORK EQUIPMENT CYLINDERS
EQUIPMENT CYLINDERS a After removing or installing work equipment cyl-
inders or disconnecting and connecting hydrau-
a When disconnecting the piping between the con-
lic piping, bleed the air from the circuit as follows.
trol valve and work equipment cylinder, first re-
lease the remaining pressure inside the circuit as
1. Start the engine and run at idling for about 5 min-
follows.
utes.
1. Loosen the oil filler cap slowly to release the
2. Run the engine at low idling, and extend and re-
pressure inside the hydraulic tank.
tract the cylinders 4 - 5 times.
a Stop the piston rod about 100 mm before the
2. Set the safety lock lever to the FREE position,
end of the stroke. Never operate it to the re-
then operate the work equipment control levers
lief position.
to the front, rear, left, and right.
a When the levers are operated 2 - 3 times, the
3. Run the engine at high idling and repeat the pro-
pressure inside the accumulator is fully re-
cedure in Step 2.
leased.
4. Run the engine at low idling and operate the cyl-
3. Start the engine, run at low idling for approx. 5
inder to the end of the stroke to relieve the cir-
seconds, then stop the engine.
cuit.
4. Repeat the operation in Steps 2 and 3 above 2 -
3 times.
D375A-5 20-165
TESTING AND ADJUSTING ADJUSTING RIPPER LEVER POSITION
ADJUSTING RIPPER LEVER POSITION
a Use the following procedure to adjust the ripper 5) Loosen nut (3).
lever to the optimum position. 6) Turn knob (4) 180.
a It is possible to adjust the position of the ripper 7) Tighten nut (3) to hold knob (4) in position.
lever within a range of 40 mm to the front and
rear of the center of the lever shaft.
1. Adjusting within range of 40 mm from center to

rear
1) Loosen lock bolt (1).
2) Set lever (2) to the optimum position.
3) Tighten lock bolt (1) to hold lever (2) in posi-
tion.
2. Adjusting within range of 40 mm from center to

front
1) Loosen lock bolt (1).
2) Remove lever (2) and turn it 180.
3) Install lever (2) to lever (5), then set it to the
optimum position.
4) Tighten lock bolt (1) to hold lever (2) in posi-
tion.
20-166 D375A-5
TESTING AND ADJUSTING ADJUSTING SAFETY LOCK LEVER
ADJUSTING SAFETY LOCK LEVER
1. Adjust dimension a between the pins of rod (1).

Dimension a between pins: 444 mm
2. Connect rod (1) to safety lever (2) and PPC lock

valve (3).
3. Install connection pin (4) at the safety lock lever
end so that the split pin is at the outside of the
machine.
D375A-5 20-167
TESTING AND ADJUSTING ADJUSTING BLADE
ADJUSTING BLADE
a If the blade has been removed or disassembled, 2) Use shims to adjust the clearance at lift por-
adjust as follows. tion (2).
1. Procedure for adjusting with shims when as- Adjust- Standard

Standard
sembling ment loca- Clearance shim thick-
clearance
1) Use shims to adjust the clearance at center tion ness
portion (1). 2 b Max. 1 mm 4.0mm
Adjust- Standard
Standard
ment loca- Clearance shim thick-
clearance
tion ness
1 a See Note 4.5mm
Note: Adjust so that the play of the ball at the

spherical portion in the axial direction
is within 1 mm. Check that the ball ro-
tates smoothly.
20-168 D375A-5
TESTING AND ADJUSTING ADJUSTING BLADE
3) Use shims to adjust the clearance at trun-

nion portion (3) (shim adjustment type).
Adjust- Standard
Standard
ment loca- Clearance shim
clearance
tion thickness
1.560.65mm
3 c Total clear- 12mm
ance
2. Adjusting blade tilt

1) Adjust installation dimension d of brace (4)
with the handle.
Installation dimension d of brace (3):
1554 mm
2) Measure left and right tilt e1 and e2.
Right tilt e1: Approx. 700 mm
Left tilt e2: Approx. 700 mm
3) If the tilt is not the same on the left and right
sides, adjust installation dimension d of
brace (4) as follows to give the same tilt on
both sides.
e1 > e2: Carry out fine adjustment to
make installation dimension d longer
e1 < e2: Carry out fine adjustment to
make installation dimension d shorter
D375A-5 20-169
TESTING AND ADJUSTING ADJUSTMENT OF PCCS LEVER POTENTIOMETERS
ADJUSTMENT OF PCCS LEVER POTENTIOMETERS

When adjusting the lever assembly
independently X kz
1. Position lever in NEUTRAL (both forward & re-
verse, steering)
2. Using tester (2), measure resistance between
5 V pin and signal pin. (See table 1).
(ex. For ST1, measure resistance between pins
A (5 V) and H (SIG))
3. Using tester (2), measure resistance between
signal pin and GND pin. (See table 1).
(ex. For ST1, measure between pins H (SIG)
and G (GND))
4. Adjust resistance to be X = Y (tolerance: X Y Z
0.04 k) by slightly turning the potentiometer Y kz
body.
(Loosen screws (1) before adjusting)
5. Secure the potentiometer in place by tightening
screw (1).
Table 1
PIN No.
POTENTIOMETER No.
5V SIG GND
1 ST1 A H G
2 ST2 M E F
3 FR3 L K J
4 FR4 O P Q
20-170 D375A-5
TESTING AND ADJUSTING ADJUSTMENT OF PCCS LEVER POTENTIOMETERS
Related electrical circuit diagram
D375A-5 20-171
TESTING AND ADJUSTING CHECKING THE ADJUSTMENT OF PCCS LEVER
CHECKING THE ADJUSTMENT OF PCCS LEVER

1. Install the pre-adjusted PCCS lever to the machine.
(For details, see DISASSEMBLY AND ASSEMBLY OF PCCS LEVER.)
2. Position PCCS lever in NEUTRAL (both forward & reverse, steering)
3. Turn key switch ON.
4. Check the voltage of each potentiometer (ST1, 2 & FR3, 4) by using the monitoring mode of the monitor
panel.
(For details, see SPECIAL FUNCTION OF MONITOR PANEL EMMS.)
5. Voltage should be 2,500 50 mV for each potentiometer.
ADJUSTING IN ATTACHED CONDITION

1. Position PCCS lever in NEUTRAL (both forward & reverse, steering)
2. Using tester (4), adjust voltage by turning potentiometer slightly, so that the voltage becomes 2.5 V.
3. Tighten screw (2) at the position of voltage 2.5 V, and fix the potentiometer (1).
1. Potentiometer 5. T-adapter A. Wiring connection of adjustment for machine

power source.
2. Screw 6. Controller
3. PCCS lever 7. Machine power source B. Wiring connection of adjustment for external
power source.
4. Tester 8. External power source (5 V)
20-172 D375A-5
Disassembly and assembly of PCCS lever
DISASSEMBLY
1. Open armrest and remove screws (1) (4 places/
hexagon socket head).
2. Remove armrest & box assembly.
3. Remove screws (3).
D375A-5 20-173
5. Remove screws (5) (6 places).
6. Sling cover (6) and disconnect wiring for fuel di-

al.
7. Peel boot, remove bolts (7) (4 places/hexagon

socket head) and remove lever assembly (8).
8. Remove lever assembly (8) from console case

(11).
9. Loosen screw (9), then adjust voltage by turning
potentiometer (10) slightly.
ASSEMBLY
For assembly, procedure in reverse order.
20-174 D375A-5
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Special functions control portion 1 Special functions control portion 2

Special functions are displayed
portion (basic control) (switch control)
3. Service switch
1. Speed range display portion 8. Shift down switch
4. Buzzer cancel switch
2. Multi-information display prtion
5. Information switch
6. Auto shift down switch
7. Shift up switch
a EMMS: Equipment Management Monitoring System
D375A-5 20-175
Normal function and special functions of monitor panel (EMMS)

The monitor panel (EMMS) has the normal function and special functions and displays information of various
types at the gear speed display section at its center and the multi-information section.
Some items are displayed automatically according to the internal setting of the monitor panel and the others
are displayed according to the operation of the switches.
1. Normal function: Operation mode
With this function, the operator can display and change the items displayed normally.
2. Special function 1: Service mode
With this function, a serviceman can display and change the displayed items with special switches for test-
ing, adjusting, and troubleshooting.
Flow of modes and functions

Operator mode
Normal display (Default) 1 Maintenance mode Maintenance item: 12 items

[>] [<]
2 Pm clinic auxiliary mode Auxiliary menu: 4 items
Travel direction/Gear speed [U] [>] [<]
+ ( )
Shift mode/Service meter 3 Error code display mode
[>] [<]
[T] 4 Adjustment mode Adjustment menu: 6 items
[>] [<]
(Automatic) 1 Maintenance mode
Action code display function
[ON] & [U]( ) [T]

Service mode
Maintenance interval change

5 Maintenance item: 12 items
mode
[>] [<]
Electric system error code
6
display mode
[>] [<]
Mechanical system error code
7
display mode
[>] [<]
8 Adjustment mode Adjustment menu: 29 items
[>] [<]
9 Load memory display mode Display menu: 9 items
[>] [<]
10 Real-time monitoring mode
[>] [<]
11 Dual display monitoring mode
[>] [<] [ON]: Service switch
Snap shot mode [U]: Buzzer cancel switch (Left)
12
(Special mode for VHMS) [T]: Buzzer cancel switch (Right)
[>] [<] [ > ]: Information switch (Right)
Maintenance interval change [ < ]: Information switch (Left)
5 ( ): Min. 2.5 sec
mode
20-176 D375A-5
Operation and display in operator mode (Outline)

a In this section, only the outline of the operation
mode is described. For the details of the con-
tents and operation method of each function and
mode, see Operation Manual.
Normal display mode (Default)

The monitor panel displays the following information
normally.
Gear speed display section (1):
Left side: Travel direction (PNFR)
Right side: Gear speed (123)
Graphics: Engine speed
Multi-information section (2):
a Information is displayed in 2 lines of 16 charac-
ters each.
Left side:
Gear shift mode (F1-R1F1-R2F2-R2)
Right side:
Service meter (Unit: 0.1h)
a To change the normal display mode to the oper-
ator mode, hold buzzer cancel switch (4) in the
[U] position for 2.5 seconds.
1. Maintenance mode
(1-OIL, FILTER MAINTENANCE MODE)
In this mode, the time up to the next replace-
ment of oils and filters is displayed on the multi-
information section (2) and reset after the
replacement.
a Gear speed display section (1) keeps dis-
playing normally.
Order Display Item

1 01:ENG OIL Engine oil
2 02:ENG FLT Engine oil filter
3 03:BYPS FLT Bypass filter ( )
4 04:FUEL FLT Fuel filter
5 05:CORR FLT Corrosion resistor
6 06:P/L OIL Power train oil
7 07:P/L FLT Power train oil filter
8 08:HYD OIL Hydraulic oil
9 09:HYD FLT Hydraulic oil filter
10 10:CHG FLT HSS charge filter ( )
11 11:DAMP OIL Damper oil
12 12:F/D OIL Final drive oil
: Displayed on D375A-5 but not set.
D375A-5 20-177
2. Pm clinic auxiliary mode

(2-PM CLINIC MODE)
In this mode, the condition of the machine is
displayed on multi-information section (2) as an
auxiliary function of the periodic diagnoses such
as the Pm clinic, even if any measuring instru-
ment is not connected.
playing normally.
Order Display Item

1 01-ENG. SPEED Engine speed
Work equipment oil
2 02-H. PUMP PRES F
pressure 1
Work equipment oil
3 03-H. PUMP PRES R
pressure 2
4 04-BATTERY VOLT Battery voltage
3. Error code display mode

(3-FAULT CODE DISPLAY MODE)
In this mode, the contents of each fault in the
machine are displayed by a 6-character error
code on the multi-information section (2).
When the user or the operator needs to be noti-
fied of the error code of each fault, this mode is
applied.
playing normally.
a When a serviceman needs to check the er-
ror codes for troubleshooting, the Electric
system error code display mode and the
Mechanical system error code display mode
should be used for more detailed informa-
tion.
a Method of checking error code:
Turn buzzer cancel switch (4) to the [U]
position on the screen shown at right, and
the all error codes detected currently are
displayed at the interval of about 2 sec-
onds. (To finish displaying, turn the buzzer
cancel switch to the [ T ] position.)
20-178 D375A-5
Failure codes list

Cau- Cau-
Failure Con- Action
Failed part Trouble tion tion
code troller code
lamp buzzer
1500L0 Double engagement of clutch Double engagement (L0) TM CALL E03 q q
15SAL1 Forward clutch pressure * See separate list (L1) TM CALL E03 q q
15SALH Forward clutch pressure * See separate list (LH) TM CALL E03 q q
15SBL1 Reverse clutch pressure * See separate list (L1) TM CALL E03 q q
15SBLH Reverse clutch pressure * See separate list (LH) TM CALL E03 q q
15SEL1 1st clutch pressure * See separate list (L1) TM CALL E03 q q
15SELH 1st clutch pressure * See separate list (LH) TM CALL E03 q q
15SFL1 2nd clutch pressure * See separate list (L1) TM CALL E03 q q
15SFLH 2nd clutch pressure * See separate list (LH) TM CALL E03 q q
15SGL1 3rd clutch pressure * See separate list (L1) TM CALL E03 q q
15SGLH 3rd clutch pressure * See separate list (LH) TM CALL E03 q q
1800MW P/L clutch slip Slip (MW) TM E02 q q
2201L1 Right clutch pressure * See separate list (L1) ST CALL E04 q q
2201LH Right clutch pressure * See separate list (LH) ST CALL E04 q q
2202L1 Left clutch pressure * See separate list (L1) ST CALL E04 q q
2202LH Left clutch pressure * See separate list (LH) ST CALL E04 q q
2300NR Braking on slope Abnormal heating (NR) ST
2301L1 Right brake oil pressure * See separate list (L1) ST CALL E04 q q
2301LH Right brake oil pressure * See separate list (LH) ST CALL E04 q q
2302L1 Left brake oil pressure * See separate list (L1) ST CALL E04 q q
2302LH Left brake oil pressure * See separate list (LH) ST CALL E04 q q
AB00MA Abnormality in battery charge Malfunction (MA) Machine
B@BAZG Lowering of engine oil pressure Lowering of oil pressure (ZG) Machine
B@BCNS High engine coolant temperature Overheating (NS) Machine
B@BCZK Lowering of radiator coolant level Lowering of level (ZK) Machine
B@CENS Power train oil temperature Overheating (NS) Machine
Abnormality in hydraulic oil temperature
B@HANS Overheating (NS) Machine
sensor
C111KT Abnormality in engine controller Internal defect of controller (KT) ENG CALL E04 q q
C112LK Abnormality in timing rail actuator * See separate list (LK) ENG CALL E04 q q
C113KZ Abnormality in timing rail actuator current Disconnection or short circuit (KZ) ENG CALL E03 q q
Abnormality in engine speed sensor 2 sys-
C115KZ
tem
Disconnection or short circuit (KZ) ENG CALL E04 q q
Abnormally high signal of timing rail pres-
C116KX
sure sensor
Out of input signal range (KX) ENG CALL E04 q q
Abnormally low signal of timing rail pres-
C117KX
sure sensor
Abnormally high signal of fuel pressure sen-
C118KX
sor
Abnormally high signal of fuel pressure sen-
C119KX
sor
Abnormality in engine speed sensor 1 sys-
C121LC
tem
* See separate list (LC) ENG CALL E03 q q
Abnormally high signal of boost pressure
C122KX Out of input signal range (KX) ENG E01
sensor
Abnormally low signal of boost pressure
C123KX Out of input signal range (KX) ENG E01
sensor
Abnormally high level of throttle sensor sys-
C131KX
tem
Abnormally low level of throttle sensor sys-
C132KX
tem
Abnormally high signal of remote throttle
C133KX
sensor
Abnormally low signal of remote throttle
C134KX
sensor
D375A-5 20-179
Cau- Cau-
Failure Con- Action
code troller code
lamp buzzer
C135KX Abnormally high signal of engine oil sensor Out of input signal range (KX) ENG CALL E03 q q
C141KX Abnormally low signal of engine oil sensor Out of input signal range (KX) ENG CALL E03 q q
C143ZG Lowering of engine oil pressure Lowering of oil pressure (ZG) ENG
Abnormally high signal of engine coolant
C144KX
temperature sensor
Abnormally low signal of engine coolant
C145KX
temperature sensor
Abnormally high engine coolant tempera-
C151NS Overheating (NS) ENG
ture
C153KX Abnormally high signal of intake air sensor Out of input signal range (KX) ENG CALL E03 q q
C154KX Abnormally low signal of intake air sensor Out of input signal range (KX) ENG CALL E03 q q
Abnormally high signal of atmospheric
C221KX
pressure sensor
Abnormally low signal of atmospheric pres-
C222KX
sure sensor
C234N1 Engine overrun Overrun (N1) ENG
C254KZ Abnormality in fuel shut-off valve voltage Disconnection or short circuit (KZ) ENG E01
C259FS Abnormality in fuel shut-off valve Abnormality in valve (FS) ENG E01
C261NS Fuel temperature Overheating (NS) ENG
Abnormally high signal of fuel temperature
C263KX
sensor
Abnormally low signal of fuel temperature
C265KX
sensor
C316KZ Abnormality in fuel pump current Disconnection or short circuit (KZ) ENG CALL E03 q q
C318LK Abnormality in fuel pump * See separate list (LK) ENG CALL E03 q q
Abnormality in engine controller power sup-
C346KT
ply
Internal defect of controller (KT) ENG CALL E03 q q
C384LK Abnormality in pre-heater control system * See separate list (LK) ENG CALL E03 q q
C423L6 Abnormality in timing pressure * See separate list (L6) ENG CALL E03 q q
C441KK Abnormality in battery voltage Lowering of source voltage (Input) (KK) ENG E01
C442KG Abnormality in battery voltage Abnormality in voltage (KG) ENG E01
Abnormally high signal of fuel rail pressure
C451KX
sensor
Abnormally low signal of fuel rail pressure
C452KX
sensor
C455KZ Abnormality in fuel rail actuator current Disconnection or short circuit (KZ) ENG CALL E04 q q
C467LK Abnormality in timing actuator control * See separate list (LK) ENG CALL E03 q q
C468LK Abnormality in fuel rail actuator control * See separate list (LK) ENG CALL E03 q q
C514LK Abnormality in fuel rail actuator * See separate list (LK) ENG CALL E04 q q
C554L6 Abnormality in fuel rail pressure * See separate list (L6) ENG CALL E03 q q
D110KA BR relay holding 2 Disconnection (KA) ST
D110KB BR relay holding 1 Short circuit (KB) ST
D130KA N safety relay Disconnection (KA) TM E02 q q
D130KB N safety relay Short circuit (KB) TM E02 q q
D161KA Backup alarm relay Disconnection (KA) TM E01
D161KB Backup alarm relay Short circuit (KB) TM E01
D190KA ACC signal drive relay system Disconnection (KA) ST
D190KB ACC signal drive relay system Short circuit (KB)
D5ZRKA Disconnection in snap shot signal Disconnection (KA) ST
D5ZRKB Short circuit in snap shot signal Short circuit (KB) ST
Defective communication (Abnormal-
DAFRKR RTCDB abnormal S/T
ity in object component system) (KR)
MON CALL E03 q q
Abnormality in transmission controller
DAQ0KK
source voltage
Lowering of source voltage (Input) (KK) TM CALL E04 q q
Abnormality in transmission controller e2p
DAQ0KT Internal defect of controller (KT) TM E01
ROM
Abnormality in transmission controller 5-V
DAQ5KK
power supply
Lowering of source voltage (Input) (KK) TM CALL E03 q q
20-180 D375A-5
Cau- Cau-
Failure Con- Action
code troller code
lamp buzzer
Abnormality in transmission controller sen-
DAQ6KK Lowering of source voltage (Input) (KK) TM E01
sor power supply
Disagreement of model selection sig-
DAQ9KQ Abnormality in specification selection
nals (KQ)
TM CALL E04 q q
DAQRKR Abnormality in Knet communication (T/M)
TM CALL E03 q q
Detection of network abnormality by TM Defective communication (Abnormal-
DAQSKR TM E01
controller ity in object component system) (KR)
Abnormality in steering controller source
DB30KK
voltage
Lowering of source voltage (Input) (KK) ST CALL E04 q q
DB30KT Abnormality in steering controller e2p ROM Internal defect of controller (KT) ST E01
Abnormality in steering controller 5-V power
DB35KK
supply
Abnormality in steering controller sensor
DB36KK
power supply
Disagreement of model selection sig-
DB39KQ Abnormality in specification selection (S/T)
nals (KQ)
ST CALL E04 q q
DB3RKR Abnormality in Knet communication (S/T)
ST CALL E03 q q
Detection of network abnormality by S/T Defective communication (Abnormal-
DB3SKR ST E01
controller ity in object component system) (KR)
DBBRKR J1939 communication system E01
DD12KA Shift-up switch Disconnection (KA) TM E02 q q
DD12KB Shift-up switch Short circuit (KB) TM E02 q q
DD13KA Shift-down switch Disconnection (KA) TM E02 q q
DD13KB Shift-down switch Short circuit (KB) TM E02 q q
DD14KA Travel lock switch 2 Disconnection (KA) TM CALL E03 q q
DD14KB Travel lock switch 1 Short circuit (KB) TM CALL E03 q q
DD59KA Blade dual selector solenoid system Disconnection (KA) TM E01
DD59KB Blade dual selector solenoid system Short circuit (KB) TM E01
DD5AKA Blade pitch selector solenoid system Disconnection (KA) TM E02 q q
DD5AKB Blade pitch selector solenoid system Short circuit (KB) TM E02 q q
DDN2LD PPC tilt right oil pressure switch * See separate list (LD) TM E02 q q
DDN3LD PPC tilt left oil pressure switch * See separate list (LD) TM E02 q q
DDN7KA Work equipment knob switch down Disconnection (KA) TM E02 q q
DDN7KB Work equipment knob switch down Short circuit (KB) TM E02 q q
DDN9KA Work equipment knob switch up Disconnection (KA) TM E01
DDN9KB Work equipment knob switch up Short circuit (KB) TM E01
DDNALD Blade lift raise full oil pressure switch See list (LD) TM
Abnormality in PPC ripper raise oil pressure
DDNBLD * See separate list (LD) ST
switch
Abnormality in PPC ripper lower oil pres-
DDNCLD * See separate list (LD) ST
sure switch
Abnormality in PPC riper tilt oil pressure
DDNDLD * See separate list (LD) ST
switch
Abnormality in PPC ripper tilt-back oil pres-
DDNELD * See separate list (LD) ST
sure switch
DDNFLD PPC lift lower oil pressure switch * See separate list (LD) ST
DDQ2KA Travel lock switch 2 Disconnection (KA) ST CALL E03 q q
DDQ2KB Travel lock switch 1 Short circuit (KB) ST CALL E03 q q
dDQ2L4 Disagreement of travel lock Disagreement of ON/OFF signals (L4) TM CALL E03 q q
DDQ2L4 Disagreement of travel lock Disagreement of ON/OFF signals (L4) TM CALL E03 q q
Abnormality in hydraulic oil temperature
DGS1KX Out of input signal range (KX) TM
sensor
DH22KA Abnormality in hydraulic F pump sensor Disconnection (KA) TM
DH22KB Abnormality in hydraulic F pump sensor Short circuit (KB) TM
DH23KA Abnormality in hydraulic R pump sensor Disconnection (KA) TM
DH23KB Abnormality in hydraulic R pump sensor Short circuit (KB) TM
D375A-5 20-181
Cau- Cau-
Failure Con- Action
code troller code
lamp buzzer
DK10KA Abnormality in fuel control dial system Disconnection (KA) ENG CALL E03 q q
DK10KB Abnormality in fuel control dial system Short circuit (KB) ENG CALL E03 q q
DK30KA Swing potentiometer 1 Disconnection (KA) ST CALL E03 q q
DK30KB Swing potentiometer 1 Short circuit (KB) ST CALL E03 q q
DK30KX Travel lever swing Out of input signal range (KX) ST CALL E04 q q
DK30KZ Travel lever swing Disconnection or short circuit (KZ) ST CALL E04 q q
DK30L8 Swing signal deviation Disagreement of analog signals (L8) ST CALL E03 q q
DK31KA Swing potentiometer 2 Disconnection (KA) ST CALL E03 q q
DK31KB Swing potentiometer 2 Short circuit (KB) ST CALL E03 q q
DK40KA Brake potentiometer Disconnection (KA) ST CALL E03 q q
DK40KB Brake potentiometer Short circuit (KB) ST CALL E03 q q
DK55KX Travel lever forward/reverse Out of input signal range (KX) TM CALL E04 q q
DK55KZ Travel lever forward/reverse Disconnection or short circuit (KZ) TM CALL E04 q q
DK55L8 Forward/Reverse signal deviation Disagreement of analog signals (L8) TM CALL E03 q q
DK56KA Forward/Reverse potentiometer 1 Disconnection (KA) TM CALL E03 q q
DK56KB Forward/Reverse potentiometer 1 Short circuit (KB) TM CALL E03 q q
DK57KA Forward/Reverse potentiometer 2 Disconnection (KA) TM CALL E03 q q
DK57KB Forward/Reverse potentiometer 2 Short circuit (KB) TM CALL E03 q q
DK60KA Abnormality in acceleration sensor Disconnection (KA) ST E01
DK60KB Abnormality in acceleration sensor Short circuit (KB) ST E01
DKH1KA Pitch angle sensor Disconnection (KA) ST CALL E03 q q
DKH1KB Pitch angle sensor Short circuit (KB) ST CALL E03 q q
DKH1KX Pitch angle sensor Out of input signal range (KX) ST E01
Transmission controller engine speed sen-
dLE1KA Disconnection (KA) TM E01
sor
DLE1KA Steering controller engine speed sensor Disconnection (KA) ST E01
DLF1KA Torque converter speed sensor Disconnection (KA) TM
dLT3KA Transmission speed sensor Disconnection (KA) TM E01
DLT3KA Transmission speed sensor Disconnection (KA) ST E02 q q
DV00KB Caution buzzer Short circuit (KB) MON
DWN3KA Sudden stop prevent solenoid 1 Disconnection (KA) ST CALL E04 q q
DWN3KB Sudden stop prevent solenoid 2 Short circuit (KB) ST CALL E04 q q
DXH1KA Lockup SOL Disconnection (KA) TM E01
DXH1KB Lockup SOL Short circuit (KB) TM E01
DXH4KA 1st clutch ECMV Disconnection (KA) TM CALL E03 q q
DXH4KB 1st clutch ECMV Short circuit (KB) TM CALL E03 q q
DXH5KA 2nd clutch ECMV Disconnection (KA) TM CALL E03 q q
DXH5KB 2nd clutch ECMV Short circuit (KB) TM CALL E03 q q
DXH6KA 3rd clutch ECMV Disconnection (KA) TM CALL E03 q q
DXH6KB 3rd clutch ECMV Short circuit (KB) TM CALL E03 q q
DXH7KA Reverse clutch ECMV Disconnection (KA) TM CALL E03 q q
DXH7KB Reverse clutch ECMV Short circuit (KB) TM CALL E03 q q
DXH8KA Forward clutch ECMV Disconnection (KA) TM CALL E03 q q
DXH8KB Forward clutch ECMV Short circuit (KB) TM CALL E03 q q
DXH9KA Right clutch ECMV Disconnection (KA) ST CALL E03 q q
DXH9KB Right clutch ECMV Short circuit (KB) ST CALL E03 q q
DXHAKA Left clutch ECMV Disconnection (KA) ST CALL E03 q q
DXHAKB Left clutch ECMV Short circuit (KB) ST CALL E03 q q
DXHBKA Right brake ECMV Disconnection (KA) ST CALL E04 q q
DXHBKB Right brake ECMV Short circuit (KB) ST CALL E04 q q
DXHCKA Left brake ECMV Disconnection (KA) ST CALL E04 q q
DXHCKB Left brake ECMV Short circuit (KB) ST CALL E04 q q
20-182 D375A-5
Separate list: Phenomenon codes list

Phenome- Phenome-
Detail of phenomenon Detail of phenomenon
non code non code
Run and stop of engine do not agree with sig-
KA Disconnection L6
nals
KB Short circuit L8 Analog signals do not agree
KK Lowing of source voltage (input) LC Revolving speed signals do not agree
KP Lowering of output voltage LD Switch is pressed for long time
While command signal current is ON, fill signal
KQ Disagreement of model selection signals LH
is OFF
Defective communication (Objective compo- Feedback signal does not agree with output sig-
KR LK
nent abnormality) nal
KT Internal defect of controller MA Malfunction
KX Out of input signal range MB Lowering of function
KZ Disconnection or short circuit MW Slip
L0 Double engagement N1 Over ran
L1 While command current is OFF, fill signal is ON NR Abnormal heating
L2 Fuel pressure is too high NS Overheating
L3 Uncontrollability NX Clogging
L4 ON and OFF signals do not agree ZG Lowering of oil pressure
ZK Lowering of level
a "Controller" in the table indicates classification of the controller in charge of system check, monitor panel,
and code.
MON: Failure code of electric system checked by monitor panel
ENG: Failure code of electric system checked by engine controller
T/M: Failure code of electric system checked by transmission controller
S/T: Failure code of electric system checked by steering controller
Machine:Failure code of mechanical system
4. Adjustment mode (4-USER ADJUST MODE)

In this mode, the display condition of the moni-
tor panel can be adjusted and the fan speed (for
cleaning the radiator) can be changed on the
multi-information section (2).
playing normally.
Order Display Item

Adjustment of LCD
1 01:LCD BRIGHTNES
brightness
Adjustment of dis-
2 02:DSP BRIGHTNES
play brightness
Adjustment of dis-
3 03:DSP CONTRAST
play contrast
D375A-5 20-183
Action code display function

If a fault notifies the operator, occurs during work,
an action code and a phone number are displayed
on the multi-information section (2).
a Gear speed display section (1) keeps displaying
normally.
a The phone No. is displayed for only important
action codes. The display shown at right is an
example. (The form of the displayed phone No.
depends on the form of the input No.)
a If an important action code is displayed, the cau-
tion lamp flashes and the caution buzzer
sounds.
<Reference>
An action code is displayed only when a serious
fault occurs.
Even if an action code is not displayed, a fault may
have occurred. If you feel any abnormality, be sure
to check for a error code in the Electric system
error code display mode and Mechanical system
error code display mode of the service mode.
Action codes table
Action
Indication method of fault Contents of fault Remedy
code
Torque converter is not locked up. Automatic function stops or normal

E01 Only action code is dis- Blade dual tilt mechanism does not function stops partially but machine
played. work. can work.
Call your Komatsu distributor for repair.
Action code is displayed. Gear is not shifted up or down. Stop engine and start it again, and you
E02 Caution lamp flashes. Blade tilt is not limited. can operate machine without limiting
Caution buzzer sounds. Blade pitch mechanism does not work. function. You must take care, however.
Call your Komatsu distributor for repair.
Engine coolant temperature is defec-
tive.
Action code is displayed. Usable gear speeds are limited.
CALL E03 Caution lamp flashes. Engine speed does not rise fully. Move machine to safe place.
Caution buzzer sounds. Gear shifting shocks become large. Call your Komatsu distributor for repair.
Steering performance lowers.
Brake shocks become large.
Action code is displayed. Engine cannot be controlled.
CALL E04 Caution lamp flashes. Machine cannot travel. Stop machine immediately.
Caution buzzer sounds. Machine stops. Call your Komatsu distributor for repair.
20-184 D375A-5
Operation and display in service mode

Method of changing to service mode
a When using the service mode, change the
screen by the following special operation.
1) Special operation of switches

Set the monitor panel in the service mode by
operating service switch (3) and buzzer cancel
switch (4).
a Keeping the service switch in the ON posi-
tion, hold the buzzer cancel switch in the
[U] position for 2.5 seconds.
a If the monitor panel is set in the service
mode, [1C] is displayed on the gear speed
display section (1).
a Each time the monitor panel is set in the
service mode, the Maintenance interval
change mode is displayed first.
2) Selecting and executing mode to be used

Select the mode to be used with information
switch (5) and execute it with buzzer cancel
switch (4).
[ > ]: Next mode No.
[ < ]: Previous mode No.
[U]: Execute mode.
a For the details of operation in each mode,
see the following pages.
Gear
3) Finishing mode and function Order speed Display and item
The current mode and function can be finished display
by either of the following method, regardless of 5-EXCHG, INTVAL. SET MODE
the current mode and hierarchy. 1 1C
Maintenance interval change mode
(1) When continuing the operation in another
mode or function or in the operator mode: 6-ELEC. FAULT CODE MODE
2 EE
Return to the mode screen or function Electric system fault code display mode
screen to be used next by operating buzzer 7-MACHINE FAULT CODE MODE
cancel switch (4). 3 bE Mechanical system fault code display
[T]: Screen returns. mode
(2) When finishing the all operation: 8-SERVICE ADJUST MODE
Turn off the starting switch. 4 Cb
Adjustment mode
9-LOAD MEMORY DISPLEY MODE
5 Ld
Load memory display mode
10-REAL TIME MONITORING MODE
6 5R
Real time monitoring mode
11-DUAL DISPLAY MONITORING MODE
7 dR
Dual display monitoring mode
12-SNAP SHOT MODE
8 55
Snap shot mode *
* VHMS specification only
D375A-5 20-185
5. Maintenance interval change mode

(5-EXCHG. INTVAL. SET MODE)
In this mode, you can check and set the mainte-
nance interval times of various filters and oils
which are the bases of the maintenance display
function in the operator mode.
1) Selecting and executing mode

i) Select Maintenance interval change
mode on the mode selection screen.
a If the mode is selected, code (1C) is
displayed on gear speed display
section (1) and the title is displayed
on multi-information section (2).
ii) Display the maintenance item selection
screen by operating buzzer cancel
switch (4).
[U]: Execute mode.
2) Selecting and displaying mintenance item

i) Operate information switch (5) on the
maintenance item selection screen to
select a maintenance item.
[ > ]: Next code
[ < ]: Previous code
ii) Display the maintenance item selection
switch (4).
[U]: Execute item.
3) Contents of information section

The following items are displayed on the
information section.
(1) Code
(2) Maintenance item
(3) Replacement interval time (Set time)
a The items shown at right are examples.
a If the replacement interval does not
need to be changed, finish the operation
on this screen.
a If the replacement interval needs to be
changed, go to step 4).
20-186 D375A-5
4) Changing replacement interval time

i) Change the set time by operating infor-
mation switch (5), shift-up switch (7),
and shift-down switch (8).
[ > ]: Move cursor to right.
[ < ]: Move cursor to left.
[UP]: Increase number.
[DOWN]: Decrease number.
a If you do not use the maintenance

function, set the all times to 0.
ii) If the input time is correct, enter the

change of setting by operating buzzer
cancel switch (4).
[U]: Enter change.
a If the change is finished normally,
the information display screen ap-
pears after the screen shown at
right.
a If the change is not finished normal-

ly, the information display screen
before the change appears after the
screen shown at right. In this case,
execute the above operation again.
D375A-5 20-187
(1)
Maintenance items list
Replacement interval
Order Display Item 1st time 2nd time and after
(Must not be changed) (May be changed)
1 01:ENG OIL Engine oil 0500 h 0500 h
2 02:ENG FLT Engine oil filter 0500 h 0500 h
3 03:FUEL FLT Fuel filter 0500 h 0500 h
4 04:HYD FLT Hydraulic oil filter 0250 h 2000 h
5 06:CORR RES Corrosion resistor 1000 h 1000 h
6 18:BYPS FLT Bypass filter * 0h 0h
7 07:DAMP OIL Damper oil 2000 h 2000 h
8 08:F/D OIL Final drive oil 0250 h 000 h
9 10:HYD OIL Hydraulic oil 0250 h 2000 h
10 19:POWL OIL Power train oil 0250 h 1000 h
11 20:POWL FLT Power train oil filter 0250 h 0500 h
12 12:HSS FLT Charge filter * 0h 0h
* Displayed on D375A-5 but not set.
a The first interval time cannot be changed. If it needs to be changed for a particular reason, assume that the
first maintenance has been finished in the maintenance mode of the operator mode, then change the 2nd
and after interval times.
20-188 D375A-5
6. Electric system error code display mode

(6-ELEC. ERROR CODE MODE)
In this mode, you can check the past electric
system error codes.

i) Select Electric system error code display
mode on the mode selection screen.
a If the mode is selected, code (EE) is
ii) Display the error code display screen
by operating buzzer cancel switch (4).
[U]: Execute mode.
2) Display in the case where no codes are

recorded
If no error codes have been output up to
now, the information section displays as
shown at right.
3) Display in the case where 1 or more codes

are recorded
If any error code has been output up to
shown at right.
(1) Record No. (Up to 20)
(2) Error code (Code being output currently
is flashing)
(3) Number of past occurrences
(4) Time measured by service meter after
first occurrence
last occurrence
a For the details of displayed error codes,
see the ERROR CODES TABLE in the
operator mode.
D375A-5 20-189
a Flashing and lighting of error code

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

recorded.
When multiple codes are recorded, they
can be displayed one by one by operating
information switch (5).
[ > ]: Next code
a The error codes are displayed from the
oldest one in order of length of time after
they were output.
5) Method of deleting error code

While a error code to be deleted, operate
shift-up switch (7) or shift-down switch (8).
[UP] or [DOWN]: Delete error code.
a A error code which is being output cur-
rently (which is flashing) cannot be de-
leted.
20-190 D375A-5
(1)
7. Mechanical system error code display mode

(7-MACHINE ERROR CODE MODE)
In this mode, you can check the past mechani-
cal system error codes.

i) Select Mechanical system error code
display mode on the mode selection
screen.
a If the mode is selected, code (bE) is
ii) Display the error code display screen
by operating buzzer cancel switch (4).
[U]: Execute mode.
2) Display in the case where no codes are

recorded
If no error codes have been output up to
shown at right.
3) Display in the case where 1 or more codes

are recorded
If any error code has been output up to
shown at right.
(1) Record No. (Up to 20)
(2) Error code (Code being output currently
is flashing)
(3) Number of past occurrences
first occurrence
last occurrence
a For the details of displayed error codes,
see the ERROR CODES TABLE in the
operator mode.
D375A-5 20-191
a Flashing and lighting of error code

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

recorded.
When multiple codes are recorded, they
can be displayed one by one by operating
information switch (5).
[ > ]: Next code
a The error codes are displayed from the
oldest one in order of length of time after
they were output.
5) Method of deleting error code

The mechanical system error codes cannot
be deleted.
20-192 D375A-5
8. Adjustment mode
(8-SERVICE ADJUST MODE)
In this mode, you can adjust the control system
and various devices of the machine.

i) Select Adjustment mode on the mode
selection screen.
a If the mode is selected, code (Cb) is
ii) Display the adjustment code input
switch (4).
[U]: Execute mode.
2) Selecting adjustment items

On the adjustment code input screen, input
the 4-digit code of the item to be adjusted
by operating information switch (5), shift-up
switch (7), and shift-down switch (8).
a If the 4-digit code is input, the informa-
tion of that code is displayed automati-
cally.
3) Contents of display on adjustment screen

(1) Code
(2) Adjustment item
(3) Related information
a For the detailed information and adjust-
ment procedure, see ADJUSTMENT
MODE TABLE AND ADJUSTMENT
PROCEDURE.
D375A-5 20-193
(1)
a If an incorrect code is input, the adjust-

ment code input screen appears again
after the screen shown at right. In this
case, execute the above operation
again.
4) When operating machine in adjustment

mode
If the parking brake lever is set in the FREE
position, gear speed display section (1) dis-
plays normally and the machine can be
operated normally.
a To select another screen, return the
parking brake lever to the LOCK posi-
tion and perform the necessary proce-
dure.
5) Automatic selection of adjustment item

(Limited function)
After one of some adjustment items is select-
ed, if the information switch is operated, the
next adjustment item is selected automati-
cally, even if the code of the next adjustment
item is not input.
[ > ]: Code is increased
[ < ]: Code is decreased
a This function is applied to only the items
having numbers in the Automatic selec-
tion column of the Adjustment mode ta-
ble. Those items are selected in the
order of their numbers.
a Note that this operation is not effective
while the parking brake lever is in the
RESET position.
a You may return to the screen for input-
ting codes and enter a code without us-
ing this function.
20-194 D375A-5
Adjustment modes list and adjustment procedure
Disassembly Sending
Code Adjustable item Related information
and assembly in order
(1) 0001 INP TEL NO. Phone No. input mode Numerals and symbols
(2) 0002 S/T S. CODE Steering controller specification set Code q 1
(3) 0003 T/M S. CODE Transmission controller specification set Code q 2
(4) 0004 BODY TYPE Machine specification set Code q 3
(5) 0005 BRAKE BASE Brake potentiometer zero point adjustment Voltage q 4
(6) 0009 PITCH SENS. Pitch angle sensor initialization Voltage 5
(8) 1012 S/T N-SET Steering lever neutral set Voltage
(9) 1013 S/T M. L-SET Steering lever left set Voltage
(10) 1014 S/T M. R-SET Steering lever right set Voltage
(11) 1015 BRKLH. OFST Left brake oil pressure offset (set) Oil pressure
(12) 1016 BRKRH. OFST Right brake oil pressure offset (set) Oil pressure
(13) 1031 BR AUTO-SET Brake automatic adjustment mode Oil pressure
(14) 2223 R SLOW CUT Reverse slow stop set DEACTIVE or ACTIVE
(15) 5535 CLUTCH OPEN Clutch disengagement mode Revolving speed
(16) 5536 CL AUTO-SET Clutch automatic adjustment mode Oil pressure
(17) 5537 CLT LH. OFST Left clutch oil pressure offset (set) Oil pressure
(18) 5538 CLT RH. OFST Right clutch oil pressure offset (set) Oil pressure
(19) 9995 LOCK BRAKE Electric brake constantly ON mode Voltage
(20) 9996 MECHA BRAKE Electric brake release mode Voltage
(21) 9997 HI IDLE SET High idling limit mode Revolving speed
(22) 9998 SFT INHIBIT 3rd speed cut set Permit
k After assembling the machine or replacing each controller, be sure to adjust the items marked with q in the
Disassembly and assembly column of the above table. (For the adjustment procedure, see ADJUSTMENT
PROCEDURE AFTER REPLACEMENT OF CONTROLLER.)
D375A-5 20-195
(1)
(1) 0001: Phone number input mode

This code inputs or changes a phone number to
be displayed simultaneously when the user
code is displayed.
The lower part displays a phone number and
symbols.
Available characters: 0 1 2 3 4 5 6 7 8 9 : ; < > ?
Instructions for use:
By operating the information switch (5), shift up
switch (7), and shift down switch (8), input a
phone number and symbols.
[ > ]: Moves the cursor rightward.
[ < ]: Moves the cursor leftward.
[UP]: Advance the numeric character or
character (in the order of available charac-
ters).
[DOMN]: Reverse the numeric character or
character (in the reverse order of available
characters).
a Sixteen digits of numeric characters are pro-
vided. To avoid confusion, input symbols
other than numeric characters at digits you
will not use.
a 0 (zero) is input at all places of the lower part
before shipment from our factory. (No phone
number is displayed under this condition.)
a The setting is enabled even after ending this
code.
(2) 0002: Steering controller specification set

This code is used to initialize the specification
codes recognized by the steering controller and
the set values of the memory in the controller.
The specification code is displayed on the lower
line.
Adjustment method
1) Set buzzer cancel switch (4) in the [U]
position and check that the caution buzzer
sounds.
2) Check that the displayed specification code
has changed from [6*6] to [666].
a If specification code [666] is not displayed,
the controller wiring harness or the control-
ler unit may be defective.
a Even if this code is turned off, the setting is
effective.
20-196 D375A-5
(1)
(3) 0003: Transmission controller specification set

This code is used to initialize the specifica-
tion codes recognized by the transmission
controller and the set values of the memory
in the controller.
The specification code is displayed on the
lower line.
Adjustment method (HSS specification):
sounds.
2) Check that the displayed specification code
has changed from [5*5] to [555].
a If specification code [555] is not dis-
played, the controller wiring harness or
the controller unit may be defective.
a Even if this code is turned off, the setting
is effective.
(4) 0004: Machine specification set

This code is used to have the machine specifica-
tion recognized by the controllers which com-
pose the system.
The machine specification code is displayed on
the lower line.
Adjustment method:
a Since this code is reset when Transmission
controller specification set is executed, ad-
just it after that.
1) Select the code of the machine specifica-
tion by setting shift up switch (7), and shift
down switch (8).
a Be sure to select SSC power setting 1
as the SSC type.
No. Type of work equipment Specification
position and check that the caution buzzer 000 Single tilt
sounds. 001 Single tilt SSC specification
k If the machine specification is different from 002 Single tilt SSCL specification
the setting in the controller, the machine may 010 Dual tilt
move abnormally or an error may be made.
011 Dual tilt SSC specification
Accordingly, be sure to match the setting to
the machine specification. 012 Dual tilt SSCL specification
effective.
D375A-5 20-197
(1)
(5) 0005: Brake potentiometer zero-point adjust-

ment
This code is used to adjust the zero point of the
brake pedal potentiometer.
The deviation from the standard value is indicat-
ed by voltage on the lower line (Indication range:
0 5000).
Adjustment method:
1) Check that the brake pedal is in neutral (it is
not pressed).
position and check that the alarm buzzer
sounds.
a This adjustment is performed to have the
zero point of the potentiometer recognized
by the controller. It is not performed to adjust
the effect of the brake.
a Even if this adjustment is performed, the in-
dication on the lower line does not change.
effective.
(6) 0009: Pitch angle sensor initial set

This code is used to adjust the zero point and in-
stallation error of the pitch angle sensor.
The deviation from the standard neutral position
is displayed by voltage on the lower line (Display
range: 0 5000).
Adjustment method:
Set buzzer cancel switch (4) in the [U] position
and check that the caution buzzer sounds.
effective.
20-198 D375A-5
(8) 1012: Steering lever neutral set

This code is used to adjust the steering neutral
position of the PCCS lever.
The deviation of the steering. potentiometer
from the standard neutral position is displayed
by voltage on the lower line (Display range: 0
5000).
Adjustment method:
Set buzzer cancel switch (4) in the [U] position
effective.
(9) 1013: Steering lever left set

This code is used to adjust the maximum left
steering position of the PCCS lever.
The deviation of the steering potentiometer from
the standard maximum left position is displayed
by voltage on the lower line (Display range: 0
5000).
Adjustment method:
1) Set the PCCS lever to the left steering
stroke end.
sounds.
effective.
(10)1014: Steering lever right set

This code is used to adjust the maximum right
steering position of the PCCS lever.
The deviation of the steering potentiometer from
the standard maximum right position is dis-
played by voltage on the lower line (Display
range: 0 5000).
Adjustment method:
1) Set the PCCS lever to the right steering
stroke end.
sounds.
effective.
20-200 D375A-5
(11) 1015: Left brake oil pressure offset

This code is used to adjust the left brake oil pres-
sure manually.
The offset oil pressure (Unit: 0.01 MPa) is dis-
played on the lower line (If it has been adjusted,
its value is displayed. It can be adjusted further
within the allowable range).
Adjustment method:
a The allowable adjustment range is 0.3
MPa {3 kg/cm2} (Displayed value: 300)
1) Operate the shift switch to set the offset oil
pressure.
Shiftup switch (7): Increase oil pressure
Shiftdown switch (8): Decrease oil pres-
sure
a The offset pressure is increased or de-
creased by 0.05 MPa {0.5 kg/cm2} (Dis-
played value: 50).
sounds.
effective.
(12)1016: Right brake oil pressure offset

This code is used to adjust the right brake oil
pressure manually.
Adjustment method:
pressure.
sure
played value: 50).
2) Hold the buzzer cancel switch for 1 second
effective.
D375A-5 20-201
(1)
(13)1031: Brake automatic adjustment

This code is used to automatically adjust the
change of the performance caused by disper-
sion and wear of the brake parts to keep the
brake control performance.
The brake command oil pressure (Unit: 0.01
MPa) is displayed on the lower line.
k Since the machine moves forward by 1 2 m
during this adjustment, perform the adjustment
on a flat place where the safety around the ma-
chine can be secured.
Adjustment method 1 (Preparation work)
a Perform the adjustment while the torque
converter oil temperature is in the operating
range.
1) Start the engine and select this code.
2) Set the parking brake lever in the FREE
position.
3) Turn the auto shiftdown switch OFF.
4) Run the engine at low idling.
5) Press and hold the brake pedal and decel-
erator pedal.
6) Set the PCCS lever in the FORWARD 2nd
gear speed position.
a Keep the PCCS lever in the steering
neutral position.
7) Release the decelerator pedal and brake
pedal gradually and check that the machine
does not move.
k If the machine moves, there is abnormal-
ity. In this case, stop the adjustment im-
mediately.
a After checking that the machine does
not move, go to adjustment method 2
below.
Adjustment method 2 (Adjustment of left brake)

stroke end.
2) Check that the displayed command oil pres-
sure changes automatically.
3) Check that the caution buzzer sounds after
the machine moves forward by 1 2 m and
stops.
4) Return the PCCS lever to the steering neu-
tral position.
a After adjusting the left brake, go to ad-
justment method 3 below.
a The corrected oil pressure of the left
brake can be checked by adjustment
code [1015].
20-202 D375A-5
Adjustment method 3 (Adjustment of right brake)

stroke end.
3) Check that the caution buzzer sounds after
the machine moves forward by 1 2 m and
stops.
tral position.
a The corrected oil pressure of the right
brake can be checked by adjustment
code [1016].
effective.
(14)2223: Reverse slow stop set

This code is used to turn off the reverse slow
function forcibly, regardless of the operation of
the switches on the monitor panel.
The state of the reverse slow function is dis-
played on the lower line by letters.
Adjustment method:
Operate information switch (5) to change the
setting.
[ < ] [ > ]: Change display
[DEACTIVE]: Turn reverse slow function
OFF
[ACTIVE]: Turn reverse slow function ON
a Once the reverse slow function is turned
OFF, the reverse speed is not lowered, even
if the reverse slow mode switch on the mon-
itor panel is turned ON.
effective.
D375A-5 20-203
(15)5535: Both steering clutches disengagement

This code is used to engage the transmission
clutch without driving the machine for testing,
adjusting, troubleshooting, Pm Clinic, etc.
The transmission speed (Unit: rpm) is displayed
on the lower line.
Using method:
While this code is displayed, the function is effec-
tive and steering clutches on both sides are dis-
engaged. Accordingly, the machine does not
travel even if the PCCS lever is operated.
a If this code is turned off, the function be-
comes ineffective.
(16)5536: Steering clutch automatic adjustment
This code is used to automatically adjust the
change of the performance caused by disper-
sion and wear of the steering clutch parts to
keep the steering control performance.
The clutch command oil pressure (Unit: 0.01 kg/
cm2) is displayed on the lower line.
Adjustment method 1 (Preparation work)
a Perform the adjustment while the torque
converter oil temperature is in the operating
range.
1) Start the engine and select this code.
2) Set the parking brake lever in the FREE
position.
3) Turn the auto shiftdown switch OFF.
4) Run the engine at low idling.
5) Press and hold the brake pedal and decel-
erator pedal.
6) Set the PCCS lever in the FORWARD 3rd
gear speed position.
a Keep the PCCS lever in the steering
neutral position.
7) Release the decelerator pedal and brake
pedal gradually and check that the machine
does not move.
k If the machine moves, there is abnormal-
ity. In this case, stop the adjustment im-
mediately.
a After checking that the machine does
not move, go to adjustment method 2
below.
Adjustment method 2 (Adjustment of left clutch)
stroke end.
3) Check that the engine speed rises and the
caution buzzer sounds.
tral position.
a After adjusting the left clutch, go to ad-
justment method 3 below.
a The corrected oil pressure of the left
clutch can be checked by adjustment
code [5537].
20-204 D375A-5
Adjustment method 3 (Adjustment of right

clutch)
stroke end.
3) Check that the engine speed rises and the
caution buzzer sounds.
tral position.
a The corrected oil pressure of the right
clutch can be checked by adjustment
code [5538].
effective.
(17)5537: Left steering clutch oil pressure offset

This code is used to adjust the left clutch oil
pressure manually.
Adjustment method:
pressure.
sure
played value: 50).
sounds.
effective.
D375A-5 20-205
(1)
(18)5538: Right steering clutch oil pressure offset

This code is used to adjust the right clutch oil
pressure manually.
Adjustment method:
pressure.
sure
played value: 50).
sounds.
effective.
(19)9995: Electric brake constantly ON mode

This code is used to see if the sudden stop pre-
vent valve operates normally.
The voltage of the brake potentiometer is dis-
played on the lower line.
Using method:
While this code is displayed, the function is
effective and the electric brake is constantly
turned on.
comes ineffective.
(20)9996: Electric brake release mode

This code is used to check the operation of the
mechanical brake.
The voltage of the brake potentiometer is dis-
played on the lower line.
Using method:
While this code is displayed, the function is
effective and the electric brake is constantly
turned off.
comes ineffective.
20-206 D375A-5
(1)
(21)9997: High idling limit mode

This code is used to limit the high idling speed.
The engine speed (set value) is displayed on the
lower line.
Possible limiting range: High idling speed 400
rpm
Using method:
1) Set information switch (5) in the [ > ] or [ < ]
position to select the limit speed.
sounds.
a Once the high idling speed is limited, the en-
gine speed does not reach the original high
idling speed, even if the fuel control dial is
operated.
effective.
(22)9998: Gear speed limit mode

This code is used to prevent the gear from shift-
ing up to the 3rd gear speed.
Available gear speeds are displayed on the low-
er line by bits (in the order of the 3rd, 2nd, and
1st from the left).
Using method:
Operate information switch (5) and buzzer can-
cel switch (4) to limit or reset the maximum gear
speed.
[ > ]: Move cursor to right
[ < ]: Move cursor to left
[U] Change setting
Display of lower line [o]: Gear speed is effec-
tive
Display of lower line [ ]: Gear speed is inef-
fective
a Once a gear speed is limited, the gear does
not shift up to that gear speed, even if the
shiftup switch is operated.
effective.
D375A-5 20-207
9. Load memory display mode

(9-LOAD MEMORY DISPLAY MODE)
In this mode, you can check the load on the
machine, forward odometer, and reverse odom-
eter.

i) Select Load memory display mode on
the mode selection screen.
a If the mode is selected, code (Ld) is
ii) Display the adjustment code input
switch (4).
[U]: Execute mode.
2) Changing information screen No. Display Item

Change the information screen by operating
1000 rpm service
information switch (5). 1 01-1000 rpm SMR
data
[ > ]: Next screen.
[ < ]: Previous screen. Forward travel
2 02-FOWARD ODO M
distance
Reverse travel
3 03-REVERSE ODO M
distance
4 04-F1 ODO Meter F1 travel distance
7 07-R1 ODO Meter R1 travel distance
3) Display of 1,000rpm service meter (01)

This code is used to display the service
meter which integrates the operation hours
only while the engine speed is higher than
1,000rpm.
a The data cannot be reset.
20-208 D375A-5
4) Display of forward odometer (02)

On this screen, the integrated forward travel
distance is displayed.
5) Display of reverse odometer (03)

On this screen, the integrated reverse travel
distance is displayed.
6) Display of F1 odometer (04)

On this screen, the integrated F1 (Forward
1st gear) travel distance is displayed.

2nd gear) travel distance is displayed.
D375A-5 20-209

3rd gear) travel distance is displayed.
9) Display of R1 odometer (07)

On this screen, the integrated R1 (Reverse
1st gear) travel distance is displayed.

2nd gear) travel distance is displayed.

3rd gear) travel distance is displayed.
20-210 D375A-5
12) Moving machine with saved load displayed

position, gear speed display unit (1) is set in
the normal display mode again and the
machine can operate normally.
parking brake lever to the LOCK posi-
tion temporarily, and then start the oper-
ation.
D375A-5 20-211
10. Real-time monitoring mode

(10-REAL TIME MONITORING MODE)
In this mode, the speeds, oil pressures, oil tem-
peratures, currents, voltages, etc. can be moni-
tored by using the signals from sensors,
switches, and solenoids installed various parts
of the machine.
a This mode is used to monitor 1 item. When
monitoring 2 items simultaneously, use the
Dual display monitoring mode.

i) Select Real-time monitoring mode on
the mode selection screen.
a If the mode is selected, code (5R) is
ii) Display the monitoring code input
switch (4).
[U]: Execute mode.
2) Selecting and entering monitored items

i) On the code input screen, input the 5-
digit code of the item to be monitored
by operating information switch (5),
shift-up switch (7), and shift-down
switch (8).
ii) After inputting the code, display the

monitoring screen by operating buzzer
cancel switch (4).
[ ]: Enter input code.
a If the input code is normal, the mon-
itoring screen shown at right ap-
pears.
20-212 D375A-5
(1)
a If the input code is abnormal, the

code input screen appears again af-
ter the screen shown at right.
3) Contents of display on monitoring screen

(Right figure shows examples)
(1) Code
(2) Monitoring item
(3) Information
(4) Unit (Not displayed for some items)
a For the details, see the MONITORING
MODE TABLE.
4) Function of holding monitoring information

If an information item such as the engine
speed is not stabilized and cannot be read
easily in the monitoring mode, it can be held
and released by operating buzzer cancel
switch (4).
[U]: Hold and release.
a While the monitored item is held, the let-
ter H is displayed at the left end of the
lower line.
5) When operating machine in monitoring mode

position, gear speed display section dis-
operated normally.
parking brake lever to the FREE posi-
dure.
D375A-5 20-213
6) Automatic selection of monitoring item

(Limited function)
After one of some monitoring items is
selected, if the information switch is oper-
ated, the next monitoring item is selected
automatically, even if the code of the next
monitoring item is not input.
[ > ]: Code is increased
[ < ]: Code is decreased
a This function is applied to only the items
having numbers in the Automatic selec-
tion column of the Monitoring mode ta-
ble. Those items are selected in the
order of their numbers.
a Note that this operation is not effective
while the parking brake lever is in the
RESET position.
a You may return to the screen for input-
ting codes and enter a code without us-
ing this function.
20-214 D375A-5
Monitoring items list
Mode
Tran-
No. Code Monitoring item Unit Display range Remarks
sition
Order
1 01002 ENG.SPEED Engine speed rpm 0 3000 1
2 51100 FUEL DIAL Fuel control dial command rpm 0 100 2
3 50002 DECEL PEDAL
Deceleration command rpm 0 3000 3
4 60300 SSC ORDER SSC opening ratio rpm 0 150
Transmission controller FR potentiometer 1
7 50200 T/M LEVR 1 mV 0 5000 4
voltage
Transmission controller FR potentiometer 2
8 50201 T/M LEVR 2 mV 0 5000 5
voltage
9 50300 S/T LEVR 1 Steering potentiometer 1 voltage mV 0 5000 6
10 50301 S/T LEVR 2 Steering potentiometer 2 voltage mV 0 5000 7
11 50400 BRAKE PEDL Brake potentiometer voltage mV 0 5000 8
15 31619 BRAKE L.H.F Left brake ECMV output current (F/B) mA 0 1000 9
16 31618 BRAKE R.H.F Right brake ECMV output current (F/B) mA 0 1000 10
17 90600 CLT L.H.F Left CLT output current (F/B) mA 0 1000 11
18 90601 CLT R.H.F Right CLT pump output current (F/B) mA 0 1000 12
19 31622 F CLUTCH F Forward clutch ECMV output current (F/B) mA 0 1000 13
20 31616 R CLUTCH F Reverse clutch ECMV output current (F/B) mA 0 1000 14
21 31612 1 CLUTCH F 1st ECMV output current (F/B) mA 0 1000 15
22 31613 2 CLUTCH F 2nd ECMV output current (F/B) mA 0 1000 16
23 31614 3 CLUTCH F 3rd ECMV output current (F/B) mA 0 1000 17
High temperature side of engine coolant tem-
24 04102 WATER HIGH C 0 150 18
perature
26 30100 T/C TEMP. Torque converter oil temperature C 0 150 19
27 04200 FUEL LEVEL Fuel level sensor voltage mV 0 5000 20
29 31400 T/M OUT Transmission controller transmission speed rpm 0 5000 21
Steering controller sudden stop prevent sole-
30 31628 E.BRAKE SL mA 0 1000 22
noid voltage
31 31627 L/U SOL. Transmission controller lockup solenoid current mA 0 1000 23
32 50900 N-SAFTY Transmission controller neutral safety relay mV 0 30000 24
33 40001 VEHICLE SP Theoretical travel speed km/h 0 20.0 25
34 60000 TRACTION Theoretical traction force W 02 26
35 32900 BODY ANGLE Steering controller pitch angle sensor -30 30 27
36 03200 BATTERY Battery voltage mV 0 30000 28
44 60100 BODY ANGLE Steering controller pitch angle sensor voltage mV 0 150 29
45 60200 ACCELERATN Steering controller acceleration sensor voltage mV 0 100
(See detailed
47 04401 HYD. TEMP. Hydraulic oil temperature C bit
information)
(See detailed
48 40910 S/T-SW1 Steering controller switch input 1 bit bit
information)
(See detailed
information)
(See detailed
50 40912 S/T-SW3 Steering controller oil pressure switch input 3 bit bit
information)
(See detailed
51 00200 HPI-SW4 Steering controller HPI input 4 bit bit
information)
(See detailed
information)
(See detailed
information)
(See detailed
54 31521 S/T FILL Steering controller fill switch input bit bit
information)
55 31621 BRAKE L.H. Left brake ECMV current command value mA 0 1000
D375A-5 20-215
Mode
Tran-
sition
Order
56 31620 BRAKE R.H. Right brake ECMV current command value mA 0 1000
57 90602 CLT L.H.0 Left clutch current command value mA 0 1000
58 90603 CLT R.H.0 Right clutch current command value mA 0 1000
(See detailed
59 40914 S/T SOL.1 Steering controller ON/OFF output bit bit
information)
Steering controller engine controller drive com-
61 60500 ENG.CON.PLT mV 0 30000
mand voltage
Steering controller engine controller drive volt-
62 60600 BR HOLD mV 0 10000
age
(SSC specifi-
63 70100 SLIP FLAG Slip flag bit bit
cation only)
Char-
64 20200 MON.PROGRM Tachometer module program No.
acter
Char-
65 20201 T/M.PROGRM Transmission controller program No.
acter
Char-
66 20202 S/T.PROGRM Steering controller program No.
acter
Char-
67 60700 S/T MODE Steering condition code
acter
Char-
68 60800 FILL MODE Fill condition setting variable
acter
Char-
69 60909 MOD.MODE Modulation condition setting
acter
Char-
70 70000 CHG.P.MODE Gear shifting point condition setting variable
acter
Transmission controller transmission speed
71 70200 T/M OUT mV 0 5000
sensor voltage
(See detailed
72 40905 T/M-SW1 Transmission controller switch input 1 bit bit
information)
(See detailed
73 40906 T/M-SW2 Transmission controller switch input 2 bit bit
information)
(See detailed
74 31520 T/M-FILL Transmission controller fill switch input bit bit
information)
75 31608 Frd CLUTCH Forward clutch ECMV current command value mA 0 1000
76 31606 Rev CLUTCH Reverse clutch ECMV current command value mA 0 1000
77 31602 1 st CLUTCH 1st clutch ECMV current command value mA 0 1000
78 31603 2nd CLUTCH 2nd clutch ECMV current command value mA 0 1000
79 31604 3rd CLUTCH 3rd clutch ECMV current command value mA 0 1000
(See detailed
80 40909 T/M SOL.2 Transmission controller ON/OFF output bit bit
information)
81 70400 BACK ALRM Transmission controller backup alarm voltage mV 0 30000
(See detailed
94 40907 T/M OP SIG Transmission controller blade knob switch input bit bit
information)
Transmission controller blade oil pressure (See detailed
95 40908 T/M SW2 bit bit
switch input information)
(See detailed
96 70300 B. KNOB SW Transmission controller blade knob switch input bit bit
information)
Transmission controller work equipment front
97 70700 HYD.PUMP 1 MPa 0 50
pump oil pressure
Transmission controller work equipment front
98 70701 HYD.PUMP 1 mV 0 5000
pump oil pressure sensor voltage
Transmission controller work equipment center
99 70702 HYD.PUMP 2 MPa 0 50
pump oil pressure
Transmission controller work equipment center
100 70703 HYD.PUMP 2 mV 0 5000
pump oil pressure sensor voltage
20-216 D375A-5
Mode
Tran-
sition
Order
102 31625 PITCH SOL. Transmission controller pitch solenoid current mA 0 1000
103 70600 DUAL SOL. Transmission controller dual solenoid voltage mA 0 1000
(See detailed
106 90001 T/M SOL.4 Transmission ON/OFF output 4 bit bit
information)
107 01000 ENG.SPEED Steering engine speed rpm 0 30000
108 14200 FUEL TEMP HPI fuel temperature C 0 150
109 14300 FUEL SUMP Fuel consumption L 0 2000
2-digit
110 20300 VHMS VHMS LED monitor LED 0.0. F.F hexadecimal
number
111 31200 T/M IN Transmission controller torque converter speed rpm 0 3000
112 36500 BOOST PRES Boost pressure MPa 0 100
113 37301 FUEL RATE HPI fuel consumption L/h 0 1000
114 37400 ATMPHERI P Atmospheric pressure kPa 0 50
115 37501 ATM TEMP Atmospheric temperature C -200 200
116 42600 EXH TEMP L Exhaust temperature C 0 1000
117 42601 EXH TEMP R Exhaust temperature C 0 1000
118 42700 ENGOIL TEMP Engine oil temperature C ?0 150
119 42800 BLOWBY PRS Blow-by pressure kPa ?0 10
120 43000 T/M PRESS Transmission main pressure MPa 0 10
121 51000 FINL.THRTL Final regulation rpm 0 150
122 52000 2ND THROTL HPI 2nd throttle speed rpm 0 3000
123 52200 ENGOIL PRS Engine oil pressure kPa 0 10
(See detailed
124 70305 T/M RIPPER2 Ripper lever knob switch input bit bit
information)
125 92100 F1 SMR F1 integrated travel time h 0 4294967295
128 92200 R1 SMR R1 integrated travel time h 0 4294967295
131 99901 TRIG T F Trigger time F msec 0 100
132 99902 TRIG T R Trigger time R msec 0 200
133 99903 TRIG T 1 Trigger time 1 msec 0 200
Char-
136 99906 TM SFT Transmission shift
acter
(See detailed
137 99907 LU Transmission shift condition bit bit
information)
138 99908 TM IN TRQ Transmission input torque Nm 0 1000
139 99909 DOZING h Dozing time h 0 4294967295
140 99910 RIPPING h Ripping time h 0 4294967295
141 99911 PATH NUM Number of paths path 0 4294967295
142 99913 TC IN TRQ Torque converter input torque Nm 0 1000
143 99914 H.P 1 TRQ Work equipment pump 1 input torque Nm 0 1000
144 99915 H.P 2 TRQ Work equipment pump 2 input torque Nm 0 1000
145 99917 BR L PRESS Brake left pressure MPa 05
146 99918 BR R PRESS Brake right pressure MPa 05
147 99919 CL L PRESS Clutch left pressure MPa 05
148 99920 CL R PRESS Clutch right pressure MPa 05
D375A-5 20-217
Detailed information on bit display codes
Examples of display of bit information

a The display position of the bit information in the
Real-time monitoring mode (Display of only 1
item) is different from that in the Dual display
monitoring mode (Simultaneous display of 2
items).
a The bit information is displayed by [ ] for OFF
and [o] for ON in the places (1) (8).
a The state of each item shown below is the con-
dition for turning on the bit.
00200: Steering controller HPI signal 1

(1): (Unused)
(2): (Unused)
(3): (Unused)
(4): (Unused)
(5): Engine oil pressure switch: ON
(6): Fuel temperature switch: ON
(7): (Unused)
(8): (Unused)
31520: Input state of transmission fill switch

(1): Forward clutch fill switch: ON
(2): Reverse clutch fill switch: ON
(3): 1st clutch fill switch: ON
(4): 2nd clutch fill switch: ON
(5): 3rd clutch fill switch: ON
(6): (Unused)
(7): (Unused)
(8): (Unused)
31521: Input state of steering fill switch

(1): Left brake fill switch: ON
(2): Left clutch fill switch: ON
(3): (Unused)
(4): (Unused)
(5): Right clutch fill switch: ON
(6): Right brake fill switch: ON
(7): (Unused)
(8): (Unused)
20-218 D375A-5
40906: Transmission controller input signal 2

(1): Automatic gear shift-down switch: ON
(2): (Unused)
(3): (Unused)
(4): (Unused)
(5): (Unused)
(6): (Unused)
(7): (Unused)
(8): (Unused)
40907: Blade lever knob switch input signal

(1): ACC signal switch: ON
(2): (Unused)
(3): R signal: ON
(4): (Unused)
(5): (Unused)
(6): (Unused)
(7): (Unused)
(8): (Unused)
40908: Blade lever oil pressure switch input signal

(1): Blade lift raise oil pressure switch: ON
(2): Blade lift lower oil pressure switch: ON
(3): Blade left tilt oil pressure switch: ON
(4): Blade right tilt oil pressure switch: ON
(5): (Unused)
(6): (Unused)
(7): (Unused)
(8): (Unused)

(1): (Unused)
(2): (Unused)
(3): (Unused)
(4): Backup alarm relay: ON
(5): Neutral safety relay: ON
(6): Lockup: ON
(7): (Unused)
(8): (Unused)
D375A-5 20-219

(1): Automatic gear shift-down switch: ON
(2): (Unused)
(3): (Unused)
(4): (Unused)
(5): (Unused)
(6): (Unused)
(7): (Unused)
(8): (Unused)

(1): ACC signal switch: ON
(2): (Unused)
(3): R signal: ON
(4): (Unused)
(5): (Unused)
(6): (Unused)
(7): (Unused)
(8): (Unused)
40908: Blade lever oil pressure switch input signal

(1): Blade lift raise oil pressure switch: ON
(2): Blade lift lower oil pressure switch: ON
(3): Blade left tilt oil pressure switch: ON
(4): Blade right tilt oil pressure switch: ON
(5): (Unused)
(6): (Unused)
(7): (Unused)
(8): (Unused)

(1): (Unused)
(2): (Unused)
(3): (Unused)
(4): Backup alarm relay: ON
(5): Neutral safety relay: ON
(6): Lockup: ON
(7): (Unused)
(8): (Unused)
20-220 D375A-5
40910: Steering controller input signal 1

(1): (Unused)
(2): (Unused)
(3): (Unused)
(4): (Unused)
(5): Parking brake lever switch: FREE
(6): Parking brake lever switch: LOCK
(7): (Unused)
(8): (Unused)

(1): (Unused)
(2): User switch: U position
(3): Information switch: < position
(4): Information switch: > position
(5): (Unused)
(6): (Unused)
(7): VHMS (VHMS specification machine)
(8): (Unused)
40912: Steering controller oil pressure switch input

signal 3
(1): (Unused)
(2): (Unused)
(3): (Unused)
(4): (Unused)
(5): Ripper lift raise oil pressure switch:
ON (Operated)
(6): Ripper lift lower oil pressure switch:
ON (Operated)
(7): Ripper tilt in oil pressure switch: ON (Operated)
(8): Ripper tilt out oil pressure switch: ON (Oper-
ated)

(1): ACC signal: ON
(2): Turbo timer switch: ON
(3): Engine low idling signal: ON
(4): Monitoring signal: ON
(5): (Unused)
(6): (Unused)
(7): (Unused)
(8): (Unused)
D375A-5 20-221
40914: Steering controller output signal

(1): Pre-lubrication drive: ON
(2): Snap shot switch: ON
(3): (Unused)
(4): Engine controller: ON
(5): Battery relay drive: ON
(6): Sudden stop prevent solenoid: ON
(7): (Unused)
(8): (Unused)

(1): Electrical intake air heater signal: ON
(2): C signal: ON
(3): (Unused)
(4): Night lighting signal: ON
(5): (Unused)
(6): Pre-lubrication oil pressure signal: ON
(7): (Unused)
(8): (Unused)
70100: SSC slip flag

(1): Shoe slip ratio: Min. 30%
(2): (Unused)
(3): (Unused)
(4): (Unused)
(5): (Unused)
(6): (Unused)
(7): (Unused)
(8): (Unused)

(1): Blade lever tilt switch: SINGLE
(2): Blade lever tilt switch: DUAL
(3): Blade lever pitch switch: ON
(4): Blade lever pitch switch: OFF
(5): (Unused)
(6): (Unused)
(7): (Unused)
(8): (Unused)
20-222 D375A-5
90001: Transmission controller output signal

(1): Dual tilt solenoid: ON
(2): Pitch solenoid: ON
(3): (Unused)
(4): (Unused)
(5): (Unused)
(6): (Unused)
(7): (Unused)
(8): (Unused)
99907: Transmission shift

(1): Forward clutch: ON
(2): Revease clutch: ON
(3): 1st clutch: ON
(4): 2nd clutch: ON
(5): 3rd clutch: ON
(6): During modulating
(7): Lockup solenoid: ON
(8): In neutral
D375A-5 20-223
11. Dual display monitoring mode

(11-DUAL DISPLAY MONITORING MODE)
In this mode, 2 monitored items can be dis-
played simultaneously.
a Note that only codes and monitoring infor-
mation are displayed in this mode since the
usable display columns are limited. (Item
names and units cannot be displayed.)

i) Select Dual display monitoring mode
on the mode selection screen.
a If the mode is selected, code (dR) is
ii) Display the monitoring code input
switch (4).
[U]: Execute mode.
2) Selecting and entering monitored items

i) On the code input screen, input the 5-
digit codes of the items to be monitored
to the upper and lower lines by operat-
ing information switch (5), shift-up
switch (7), and shift-down switch (8).
ii) After inputting the codes, display the

monitoring screen by operating buzzer
cancel switch (4).
[U]: Enter input code.
a If the input codes are normal, the
monitoring screen shown at right
appears.
20-224 D375A-5
(1)
a If the input codes are abnormal, the

code input screen appears again af-
ter the screen shown at right.
3) Contents of display on monitoring screen

(Right figure shows examples)
(1) Code 1
(2) Information 1
(3) Code 2
(4) Information 2
a For the details, see the Monitoring
mode table.
4) When operating machine in monitoring

mode
position, gear speed display section (1) dis-
operated normally.
parking brake lever to the FREE posi-
dure.
D375A-5 20-225
12. Snap shot mode (12-SNAPSHOT MODE)

The VHMS specification has the manual snap
shot function and automatic snap shot function.
While the manual snap shot function is turned
ON, various data in 7 minutes 30 seconds for
the Pm clinic, testing, and adjusting can be
saved in the VHMS controller.
1) Select "Snap shot mode" on the mode
selection screen.
a If the mode is selected, code (55) is dis-
played on gear speed display unit (1) and
the title is displayed on multi-information unit
(2).
For details of the operating method in the
snap shot mode, see EXECUTION
METHOD OF QUICK PM.
(1) Manual snap shot function
To collect data periodically for the Pm
clinic, the machine must be operated as
specified by the Quick Pm. When data
is required and collected for testing, ad-
justing, etc., the operations of the ma-
chine are not limited.
To use the data saved with the manual
snap shot function, a personal computer
must be connected. For the procedure
for connecting the personal computer,
see "Initialization procedure for VHMS
controller". (The personal computer
may be connected either before or after
the snap shot operation.)
(1) Automatic snap shot function
While the automatic snap shot function
is turned ON, if an item which the VHMS
controller monitors constantly becomes
abnormal (if the corresponding failure
code is displayed), the snap shot data of
that item in 7 minutes 30 seconds are
saved in the VHMS controller automati-
cally.
Since the VHMS controller automatical-
ly performs the automatic snap shot
function according to the monitoring
item data, the operator does not need to
operate the monitor.
How to collect snap shot data
If the value of a monitoring item data
becomes abnormal, that data is
recorded and saved for 7 minutes 30
seconds from 5 minutes 30 seconds
ago.
a The data is recorded at 10 second inter-
vals for the first 5 minutes, and at 1 sec-
ond intervals for 2 minutes 30 seconds
after the first 5 minutes.
20-226 D375A-5
TESTING AND ADJUSTING ADJUSTMENT METHOD OF REPLACED CONTROLLER
ADJUSTMENT METHOD OF REPLACED CONTROLLER
a After the machine is assembled or transmission

controller or steering controller is replaced, ad-
just the system according to the following proce-
dure.
k If the system is not adjusted, the machine may
not operate normally and may move suddenly.
Accordingly, be sure to adjust it.
a Precautions for replacing a controller:
If a controller is replaced, the memory of the oil
and filter maintenance mode is reset. According-
ly, take a record of the next replacement periods
of the oils and filters.
a Precautions for replacing a controller:
When replacing a controller, stop the machine in
a safe place and turn the starting switch off. 4. Turning power on again
Turn the starting switch off and on, then reset
the monitor panel in the Adjustment Mode of
1. Setting system in service mode the service mode.
Turn the starting switch on and set the monitor
panel in the Adjustment mode of the service
mode. 5. Adjusting machine specification
Select Machine specification set (0004) and
adjust the machine specification.
2. Adjusting steering controller
Select Steering controller specification set
(0002) and adjust the steering controller.
a Execute this code only when the transmis-
sion controller is also replaced.
6. Adjusting brake potentiometer

Select Brake potentiometer initial set (0005)
and adjust the brake potentiometer.
3. Adjusting transmission controller

Select Transmission controller specification set
(0003) and adjust the transmission controller.
a Execute this code only when the steering
controller is also replaced.
D375A-5 20-227
TESTING AND ADJUSTING ADJUSTMENT METHOD OF REPLACED CONTROLLER
7. Turning power on again

Turn the starting switch off and on.
8. Checking error codes

1) Set the monitor panel in the Electric sys-
tem error code display mode of the service
mode.
2) See if any error code is currently being out-
put. If any error code is not being output,
delete all the error codes.
a If any error code is being output, remove its
cause by troubleshooting and execute steps
7 and 8 again.
a Precautions after replacing controller:

If any controller is replaced, the service meter in
the oil and filter maintenance mode is reset to 0.
As a result, the replacement period displayed
on the monitor panel may be different from the
actual operating hours. To solve this problem,
determine the first replacement periods of the
oils and filters after the replacement of the con-
troller according to the replacement periods
recorded before the replacement of the control-
ler.
20-228 D375A-5
PREPARATION WORK FOR TROUBLESHOOTING FOR
TESTING AND ADJUSTING ELECTRICAL EQUIPMENT SYSTEM

ELECTRICAL EQUIPMENT SYSTEM
a When performing troubleshooting for an electri- 2. Engine controller

cal circuit related to the monitor panel, engine 1) Remove engine left side cover (3).
controller, transmission controller, steering con-
troller, or VHMS terminal, expose the related
connectors according to the following proce-
dure.
1. Monitor panel
2) Remove the 2 mounting bolts and pull out
monitor panel (2) toward the operators
seat.
2) Insert or connect the troubleshooting T-

adapter to connector ECMA and connector
ECMB of engine controller (4).
a The connectors are held by screws, so
loosen the screws before disconnecting.
a When returning the connectors to their
original position, tighten the screws to
3 Screw: 2.82 Nm {0.288 kgm}

the specified torque.
3) Insert or connect T-adapters in or to con-

nectors S01, S02, S03, and S04 of monitor
panel (2).
D375A-5 20-229
3. Transmission controller 4. Steering controller

1) Remove cover (5). 1) Remove cover (5).
2) Insert or connect the troubleshooting T- 2) Insert or connect the troubleshooting T-

adapter to connector TMCN1, connector adapter to connector NGICN1, connector
TMCN2, and connector TMCN3 of transmis- NGICN2, and connector NGICN3 of steering
sion controller (6). controller (7).
a If it is difficult to remove or install the con- a If it is difficult to remove or install the con-
nectors, remove the controller from the nectors, remove the controller from the
floor frame when carrying out the opera- floor frame when carrying out the opera-
tion. tion.
a The connectors are held by screws, so a The connectors are held by screws, so
loosen the screws before disconnecting. loosen the screws before disconnecting.
a When returning the connectors to their a When returning the connectors to their
original position, tighten the screws to original position, tighten the screws to
3 Screw: 2.82 Nm {0.288 kgm} 3 Screw: 2.82 Nm {0.288 kgm}

the specified torque. the specified torque.
20-230 D375A-5
5. VHMS controller 6. ORBCOMM terminal

1) Open the floor left side cover and remove 1) Open the right side cover of operators seat
cover (8). and insert or connect T-adapters in or to
connectors CM29 and CM30 of ORB-
COMM terminal (10).
a If it is difficult to remove and install the
connectors, remove the terminal for the
ease of work.
2) Insert or connect T-adapters in or to con-

nectors V1, V2A, V2B, V3A, and V3B of
VHMS controller (9).
a If it is difficult to remove and install the
connectors, remove the controller for
the ease of work.
D375A-5 20-231
TESTING AND ADJUSTING HANDLING OF OPTIONAL DEVICES
HANDLING OF OPTIONAL DEVICES
a D375A-5 has connectors to install optional de- 5. Connecting MMS device

vices in its fuse box. When installing any option- When connecting an MMS device, connect it to
al device, receive the necessary signals and the connector (MMS) above the VHMS control-
power through those connectors without modify- ler.
ing the wiring harness. a For the terminals, see below.
1. Connecting the ACC signal of starting switch

If the ACC signal (ON signal) of the starting
switch is necessary for a optional device such
as the turbocharger timer, connect it through
the following connector pin.
Pin (B) of CN-ESD (3-pole heavy duty wire
connector)
a A 20A fuse is installed on the upstream side
of this connector pin.
2. Inputting engine low-idling command

If it is required to keep the engine speed at low
idling for an optional device such as the engine
protector, connect the following connector pin to
the chassis ground.
Pin (C) of CN-ESD (3-pole heavy duty wire
connector)
a While this connector pin is connected to the
chassis ground, the engine speed is kept at
low idling, regardless of the fuel control dial
position.
3. Connecting C signal of starting switch

If the C signal (starting signal) of the starting
switch is necessary for a optional device such
as the pre-lubricator, connect it through the fol-
lowing connector pin.
CN-PRS (2-pole heavy duty wire connector)
a Remove the connector installed when the
machine is shipped, and connector pin (1) to
the starting signal to be final output by the
pre-lubricator and connector pin (2) to the
input signal from the starting switch.
4. Connecting external power source

If an external power source is necessary, con-
nect it through the following connectors.
CN-800 (Plug connector)
CN-801 (Plug connector)
a A 20A fuse is installed on the upstream side
of each of these connectors.
a AUX1 is used for the machine with air sus-
pension seat (if equipped).
20-232 D375A-5
(1)
TESTING AND ADJUSTING INITIALIZATION PROCEDURES FOR VHMS CONTROLLER
INITIALIZATION PROCEDURES FOR VHMS CONTROLLER
a Initialization tools for VHMS controller a For location of the VHMS controller and OR-
BCOMM terminal, refer to the "TESTING
Symbol Part No. Part name
AND ADJUSTING 5".
799-608-3101 Service kit
1 799-608-3211 Diskette
2. Connection of personal computer
W 799-608-3220 Wiring harness 1) Make sure the starting switch is turned to
Notebook type personal com- the OFF position.
k Be sure to connect and disconnect the
Commercially
2 puter (OS: Windows98/2000/
available
NT/Me/XP) personal computer while the starting
switch is turned to the OFF position.
a Before starting operation after completion of lo- 2) Connect the personal computer W2 and the
cal assembly or before resuming operation after download connectors DL1 and VDW with
storage for a long period, initialize the VHMS wiring harness [1] of service kit W1.
controller according to the following procedure. a The download connectors are installed
a Machine data collected with the VHMS controller to the following places.
are stored and managed in WebCARE data- VDW: Inside of cab (Left rear lower
base. To process the data smoothly on the We- part)
bCARE, it is necessary to set the VHMS DL1: Left rear side of chassis (Left
controller consistently. If it is not set correctly, fender rear light box)
data will not be taken into the WebCARE and a Connect the personal computer to the
data in the VHMS controller may not be utilized. RS232C terminal.
Be sure to perform the initialization.
a For method of installation for the VHMS Initiali-
zation Program to a personal computer, refer to
the Operation and Maintenance Manual con-
tained in the W1 service kit package.
a The initialization procedures cover both "ORB-
COMM Specification" and "ORBCOMMLESS
Specification". In case of "ORBCOMMLESS"
Specification", omit the procedures necessary
for "ORBCOMM Specification" only.
a During the initialization work, make necessary
confirmations for each work according to the
"VHMS Initialization Work Checklist".
1. Check of machine information, engine infor-

mation, and controller information
a This step applied to works on the whole ma-
chine.
Check and record the machine information,
engine information, VHMS controller informa-
tion, and ORBCOMM terminal information.
Information to be checked
No. Information Remarks
1 Machine model
2 Machine serial No. 5 digits
3 Engine serial No. 6 digits
4 Transmission serial No. 6 digits
5 VHMS controller serial No. 5 digits
ORBCOMM terminal serial No.
6 11 digits
[For only ORBCOMM specification]
D375A-5 20-233
4. Startup of VHMS initialization tool

1) Switch on the personal computer and start
the OS.
2) Click the icon of [VHMS Initialization Tool]
on the personal computer screen to start
the VHMS initialization tool.
3) Input the 10-digit service ID in [Service ID].

a Service ID: 782613100
4) Select [Data clear and Set up] in the [Select
Function] column.
5) Press the [OK] button to shift to the setup
screen.
3. Performance check of VHMS controller

1) Set the starting switch to the ON position.
2) Select "Service mode" and "Real-time mon-
itoring mode" in order on the monitor panel.
3) Input ID = 20300.
4) If the central part of the lower line of the
multi-information display unit counts up, the
VHMS controller is normal.
20-234 D375A-5
(1)
5. Performance check of ORBCOMM terminal

Decimal point
[For only ORBCOMM specification] Indication
at right bottom
1) Judge the operation of the ORBCOMM con-
troller by the state of the dot at the right bot- Power is not applied to ORBCOMM
OFF
controller.
tom of the LED digit of the VHMS controller.
2) The dot at the right bottom of the LED digit ON Satellite is not captured.
of the VHMS controller can be checked in ORBCOMM controller does not
the multi-information display unit of the Quick flashing have transmission data.Satellite is
monitor by the following method. captured.
i) Set the starting switch to the ON posi-
ORBCOMM controller has transmis-
tion. Slow flashing
sion data.Satellite is captured.
ii) For monitor panel specification: Refer-
ring to 10 "Real-time monitoring mode"
or 11 "Dual display monitoring mode" 6. Initialization of VHMS controller
above, input ID = 20300. [Machine information]
1) Open the [Machine information] tab.
a The [Machine information] tab is dis-
played first in the [Data clear and Set
up] menu.
2) Check all the data.
3) At least 3 minutes after starting the VHMS,

check the decimal point at the right bottom
of the LED of the VHMS controller or the
decimal point at the right bottom of the cen-
tral part of the lower line of the multi-infor-
mation display unit.
3) When information in the [Date/Time] box is

not correct, change it according to the fol-
lowing procedures:
i) Click on [Edit] (1) located in the right
lower part of the [Date/Time] box to dis-
play the correction screen.
ii) Correct the information, then click [OK].
D375A-5 20-235
4) When information in the [Machine informa- [For ORBCOMM specification only]

tion] box is not correct, change it according a Set the ORBCOMM terminal after the date
to the following procedures: of opening the terminal.
i) Click on [Edit] (2) located in the right 1) Open the VHMS Setting Tool according to
lower part of the [Machine information] the procedure for "Start of VHMS initializa-
box to display the correction screen. tion tool".
ii) Correct the information, then click [OK]. 2) Open the [Communication Setting] tab.
5) After checking and changing all the data in

[Machine information], click on the [Apply]
(3) to apply the settings.
a Click [Apply] (3), the screen for checking
the settings will appear. Recheck the
settings and click [OK] when all the set- 3) To change setting in [SHORT FAULT
tings are correct. HISTRY], follow the procedure below:
a In case of the ORBCOMM Specifica- i) Select [SHORT FAULT HISTRY] on the
tion, execute [Communication Setting] screen and click [Edit] (5) located in the
and settle it. left lower part of the [File Transfer Set-
ting] block to display the setting screen.
ii) Change the settings, then click [OK].
a At initialization, select [Occurrence] at
[Timing] screen, and set the function to
[ON].
6) After checking/changing the data of

4) To change setting in [SHORT TREND
[Machine Information], click [Exit] (4) to fin-
ANALYSIS], follow the procedures below:
ish [VHMS Initialization Tool].
i) Select [SHORT TREND ANALYSIS] on
the screen and click [Edit] (5) located in
the left lower part of the [File Transfer
Setting] block to display the setting
screen.
ii) Change the settings, then click [OK].
20-236 D375A-5
a At initialization, select [20h] at [SMR]

screen, and set the function to [ON].
5) To change the setting of [Satellite Setting],

follow the procedure below: (Important)
[Exit]
i) Click [Edit] (6) in the [Satellite Setting]
7) After checking/changing the data of [Com-
block to display the setting screen.
munication Setting], click [Exit] (8) to finish
ii) Bring GCC Code to the applicable area,
[VHMS Initialization Tool].
then click [OK].
GCC Code and Application Area

Code Applicable Area
1 U.S.A.
120 Italy
121 Malaysia
122 Korea
123 Brazil
130 Japan
6) After checking and changing all data in the

[Communication Setting], click [Apply] (7) to
apply the settings.
a Click [Apply] (3), the screen for checking
the settings will appear. Recheck the
settings and click [OK] when all the set-
tings are correct.
D375A-5 20-237
TESTING AND ADJUSTING PROCEDURES FOR EXECUTING QUICK PM
PROCEDURES FOR EXECUTING QUICK PM
a The Quick Pm means the Pm Clinic executed

with the snap shot function of the monitor panel.
k Stop the machine on a flat place.
1. Start the engine.
2. Set the monitor panel to display the service

menu.
a For the operating method, see "Special
functions of monitor panel".
3. Mode selection and excution

1) Select "Snap shot mode" on the mode
selection screen.
a If the mode is selected, code (55) is dis-
played in gear speed display unit (1) and the
title is displayed in multi-information unit (2).
2) Set the buzzer cancel switch in the [U]
position.
3) "READY" is displayed as shown in the fig-

ure and the system is ready to start.
4) If the buzzer cancel switch is set in the [U]

position, the snap shot function starts.
a After the snap shot function is started, the
elapsed time is displayed.
a On the lower line, 1 " " is added every 30
seconds. While multiple " " are displayed,
the one at the right end flashes.
a To interrupt the snap shot function, set the
buzzer cancel switch in the [t] position.
20-238 D375A-5
5) After starting the snap shot function, oper-

ate the machine according to Table 1.
a Check that the engine coolant and torque
converter oil temperatures are in operating
range.
a After 10 " " are displayed (After 5 minutes),
"#" is added up to 5.
" ": The data sampling interval is 10
seconds.
"#": The data sampling interval is 1 sec-
ond.
Operation of machine
Time (sec)
Finish
Start
Fuel
No.
State of machine Steer- Decelera- Brake Parking

Transmission Work equipment control
ing tor pedal pedal brake
dial
1 0:00 1:00 60 N LH N LOW HI Released Released
Low idling
2 1:00 2:00 60 N RH N LOW HI Released Released
3 2:00 3:00 60 High idling N N N HI HI Released Released
4 3:00 4:00 60 Deceleration slow N N N HI LOW Released Released
Work equipment
5 4:00 5:00 30 N N HI HI Released Released
relief & high idling
Ripper lift
Work equipment
6 5:00 6:00 30 N N LOW HI Released Released
relief & low idling
NoF1oF2oF3o
Torque converter
9 5:00 5:30 30 NoR1oR2oR3 N N LOW HI ON Released
stall & low idling
oN
Torque converter NoF3 (Shift to F3, LOWo
10 5:30 6:00 30 stall (F3) & high then run engine at N N HI Shift to F3, ON Released
idling (Note 1) full throttle) then HI
11 6:00 6:30 30 High idling N N N HI HI Released Released
Torque converter NoF3 (Shift to F3, LOWo
12 6:30 7:00 30 stall + Work equip- then run engine at N Ripper lift HI Shift to F3, ON Released
ment relief high idling) then HI
High idlingo HIo
13 7:00 7:30 30 N N N HI Released ON
Low idling (Note 2) LOW
(Note 1): Press the brake pedal fully and shift the gear to F3, then run the engine at full throttle.
(Note 2): Keep running the engine at low idling until the oil temperature is lowered to the normal level.
a While the torque converter is stalled and the 1st gear speed is selected, do not heighten the engine speed
to high idling.
a After stalling the torque converter, watch the power train oil temperature gauge and take care not to over-
heat the power train oil.
(The torque converter stall time of 30 seconds is a reference time. When the power train oil temperature
gauge reaches the top of the green range, return the transmission to the N (Neutral) position and run the
engine at high idling to lower the oil temperature.)
D375A-5 20-239
6) The screen shown below appears 7 min- 8) Open the data of the Quick Pm and trans-
utes 30 seconds after the snap shot is late them into a graph.
started, and then the initial screen appears a Set the time to the X-axis and set the follow-
5 seconds after. (End of snap shot) ing items to the Y-axis.
Engine Speed
Fuel Inject
Boost Press
Blowby Press
Exhaust Temp RB (Exhaust tempera-
ture of front bank: 1, 2, 3)
Exhaust Temp LB (Exhaust tempera-
ture of rear bank: 1, 2, 3)
Engine Oil Press
Engine Oil Temp
Eng Coolant Temp
Ambient Temp
Demand Eng Speed
(Engine speed demanded by controller)
Important T/C Oil Temp
The data of the Quick Pm is recorded on once. (Torque converter oil temperature)
If the Quick Pm is executed again, the current T/M Main Press
data are overwritten. Accordingly, be sure to (Transmission main relief pressure)
save the data in the personal computer after T/M Output Speed
executing the Quick Pm. (Transmission output speed)
Shift Position
7) Using the analysis tool, read the data of the (Transmission, travel, gear speed)
Quick Pm. S/T Clutch Pos.
a For the usage of the analysis tool, see the (Steering clutch position)
operation manual. S/T Brake Pos. (Steering brake posi-
tion)
Hydr Oil Temp
(Hydraulic oil temperature)
Pump 1 Press
(Work equipment pump 1 oil pressure)
Pump 2 Press
(Work equipment pump 2 oil pressure)
Body Pitch Angle (Pitch angle)
20-240 D375A-5
9) Check "Click position graphic value dis-

play".
D375A-5 20-241
10) Click a point in the graph, and the value of

each measurement item at that point on the
X-axis is displayed under the graph.
(Example of displayed graph: This is differ-
ent from the actual graph.)
20-242 D375A-5
11) Enter the above value in the Pm Clinic Inspection Sheet.

a The relationship between the data necessary for the Pm Clinic and the measurement conditions is as
follows.
Measurement items
Work equipment pump (Front, Center)

Transmission main relief pressure
Steering right clutch fill switch
Steering right brake fill switch

Steering left clutch fill switch
Steering left brake fill switch

State of machine
Front clutch fill switch
Rear clutch fill switch

Exhaust temperature
2nd clutch fill switch
3rd clutch fill switch

Engine oil pressure
1st clutch fill switch

Blow-by pressure
Engine speed
Engine at low idling Q Q Q Q Q Q Q

Engine at high idling Q Q Q
Deceleration slow Q
Work equipment relief & engine at full throttle Q Q
Work equipment relief & engine at slow Q
Torque converter stall & engine at slow Q Q Q Q Q Q Q Q
Torque converter stall (F3) & engine at full throttle Q Q Q
Engine at full throttle
Torque converter stall & relief Q
Engine at high idling o Engine at low idling Q Q
D375A-5 20-243
4. Downloading of Set Data 5. Check of Downloaded Data

1) Turn the starting switch to the ON position. a This step applies to works in the cab (on the
2) Click the icon of [VHMS Technical Analysis personal computer).
Tool] on the personal computer to start the 1) Check the set data with [View] function.
VHMS analysis tool. a For the operation procedures, refer to
the Operation and Maintenance Manual
for VHMS Technological Analysis Tool.
a Make sure that the [MFA0] code at the
time of snapshot is displayed in [Fault
History].
a Make sure that the SNAPSHOT data
has been recorded.
a Input [User Name] and [Password].

a For the operation procedures, refer to
the Operation and Maintenance Manual
for VHMS Technological Analysis Tool.
2) After having checked the set data, termi-

nate [VHMS Technical Analysis Tool].
6. Disconnection of Personal Computer

1) Make sure the starting switch is turned to
the OFF position.
k Be sure to turn off the starting switch be-
fore connecting or disconnecting the per-
3) Use the [Download] function to download sonal computer.
the data recorded in the VHMS controller to 2) Terminate the OS of the personal computer
the personal computer. and switch off the personal computer.
a For the operation procedures, refer to 3) Disconnect the wiring harness [1] of the
the Operation and Maintenance Manual service kit W1 from the download connec-
for VHMS Technological Analysis Tool. tors VDW and DL1.
a Make sure that the downloading has
completed before proceeding to the
next step.
7. Communication to Komatsu
After having completed Steps 1 to 15 success-
fully, please send the check sheet and the
VHMS data to VHMS/WebCARE Support Cen-
ter of Komatsu, Tokyo.
a Since Komatsu has to arrange the setting
for satellite communication on the receiving
side, please be sure to inform Komatsu of
the completion of the setting.
a Fax the check sheet to Komatsu.
a Send the VHMS data by Notes (LAN) or E-
mail (WAN).
Contact VHMS/WebCARE Support

Center by
Telephone: 81-3-5561-2765
FAX: 81-3-5561-4766
E-mail: webcare@komatsu.co.jp
20-244 D375A-5
D375A-5 20-245
20-246 D375A-5
TESTING AND ADJUSTING PRECAUTIONS FOR REPLACING VHMS CONTROLLER
PRECAUTIONS FOR REPLACING VHMS CONTROLLER
a Tools for replacing VHMS controller

2) Open the [Communication Setting] tab and
Symbol Part No. Name check and record all the information.
799-608-3101 Service kit (For only ORBCOMM specification)
1 799-608-3211 Diskette
799-608-3220 Wiring harness
W
Notebook type per-
Commercially sonal computer
2
available (OS: Windows98/2000/
NT/Me/XP)
a When the VHMS controller needs to be re-

placed, set it before removing it and the installed
new VHMS controller according to the following
procedure.
a Machine data collected with the VHMS controller
are stored and managed in WebCARE data-
base. To process the data smoothly on the We-
bCARE, it is necessary to set the VHMS
controller consistently. If it is not set correctly,
data will not be taken into the WebCARE and 3) After checking and recording all the data,
data in the VHMS controller may not be utilized. press the [Exit] button at the right lower part
Accordingly, be sure to carry out the initializa- of the screen to finish the "VHMS Initializa-
tion. tion Tool".
a During the initialization work, make necessary
confirmations for each work according to the [Work after replacing VHMS controller]
"VHMS Initialization Work Check Sheet". a After replacing the VHMS controller, carry out in-
itialization according to the "Initialization Proce-
[Work before replacing VHMS controller] dure for VHMS Controller".
1. Downloading of remaining a Change the data to the information recorded be-
Use the [Download] function to download the fore the VHMS controller was replaced. (Input
data currently recorded in the VHMS controller the date and time when the VHMS controller
to the personal computer. was replaced.)
a For the operation procedures, refer to the a After completing the setting after the replace-
"initialization procedure for VHMS control- ment, send the check sheet to VHMS/Web-
ler". CARE Support Center of Komatsu, Tokyo.
a Send the check sheet to Komatsu by fax.
2. Checking and recording set information a Send the data downloaded before and after re-
1) Open the [Machine information] tab and placing the VHMS controller by Notes (LAN) or
check and record all the information. E-mail (WAN).
Komatsu VHMS/WebCARE Support Center
2-3-6, Akasaka Minato-ku Tokyo, Japan

FAX: 81-3-5561-4766 (from outside of Japan)
FAX: 03-5561-4766 (Domestic user)
E-mail: webcare@komatsu.co.jp
D375A-5 20-247
TESTING AND ADJUSTING PM CLINIC SERVICE
Pm CLINIC SERVICE
Model Serial No Service meter
D375A-5 h
User name Date of clinic Serviceman
Specifications
Blade Rear attachment Shoe width
Semi-U blade Multi-shank ripper 610 mm
U-blade Variable giant ripper 710 mm
Dual tilt blade Counterweight ( kg) 810 mm
Operating conditions
Quarry, mine Construction Type of soil (specific gravity ) Type of work
Coal Construction, Rock Dozing %
Gold civil engineering Gravel Side cutting %
Limestone Roads Sand Ripping %
Tunnels Clay Travel %
Existence of abnormalities
Oil, water level check
Engine coolant level When necessary
Engine oil level Power train Damper case
Hydraulic oil level Final drive ( )
Engine coolant temperature Max. range Power train oil temperature Max. range Ambient temperature
Max.
Min.
Height above sea level
m
Operators opinion
Visual check results
Service code history
E h E h
Content: Content:
E h E h
Content: Content:
20-248 D375A-5
Pm-clinic
TESTING AND ADJUSTING measuring points for D375A-5 (1/3)
PM CLINIC SERVICE
Reference items of measurement procedure (Pages)

q1. Engine speed: Measuring engine speed (20-104 106 page)
q2. Blow-by pressure: Measuring blow-by pressure (20-118 page)
q3. Engine oil pressure: Measuring engine oil pressure (20-119 page)
q4. Boost pressure: Measuring intake air pressure (boost pressure) (20-107 page)
q5. Exhaust temperature: Measuring exhaust temperature (20-108 110 page)
D375A-5 20-249
Pm-clinic
PM CLINIC SERVICE

q6. Items related to torque converter: Measuring power train oil pressure (20-133 142 page)
q7. Items related to transmission: Measuring power train oil pressure (20-133 142 page)
q8. Items related to steering: Measuring power train oil pressure (20-133 142 page)
20-250 D375A-5
Pm-clinic
PM CLINIC SERVICE

q9. Items related to work equipment: Testing and adjusting work equipment oil pressure (20-152 156 page)
q10. Items related to work equipment: Testing and adjusting control circuit main pressure (20-157 158 page)
D375A-5 20-251
TESTING AND ADJUSTING PMNo
Serial CLINIC SERVICE
Pm CLINIC CHECK SHEET D375A-5
Work order No. Date Service meter Serviceman
h
Item Measurement conditions Unit Standard value for new machine Service limit value Measurement results Pass Fail
Low idling 690 - 750 690 - 750
Decel Deceleration pedal depressed 850 - 950 850 - 950
Engine speed High idling rpm 1870 - 1930 1870 - 1930
Torque converter stall 1470 - 1570 Min. 1430
Torque converter stall + work equipment relief 1240 - 1360 Min. 1160
kPa Max. 4.9 Max. 7.9
Blow-by pressure Torque converter stall
Engine
<mmAq> <Max. 500> <Max. 800>

Min. 100 50
Engine at low idling <Min. 1.0> <0.5>
SAE10W
340 - 540 180
Engine oil Engine at high idling kPa <3.5 - 5.5> <1.8>
pressure <kg/cm2> Min. 120 70
<Min. 1.2> <0.7>
SAE15W-40 SAE30
Engine at high idling 380 - 590 210
<4.0 - 6.0> <2.1>
kPa Min. 107 Min. 93
Boost pressure Torque converter stall <mmHq> <Min. 700>
<Min. 800>
No. 1, 2 & 3
Exhaust temperature Torque converter stall Max. 680 700
No. 4, 5 & 6
When measuring the oil pressure of the torque converter and transmission, use the adjustment mode of the monitor and set to "Both steering clutches release mode (Co mode)".
(Check that the left and right steering clutches are released.) When measuring the pressure of each transmission clutch, check only with the engine at low idling to ensure safety.
0.03 - 0.15 0.03 - 0.15
Inlet oil pressure <0.3 - 1.5> <0.3 - 1.5>
Outlet oil pressure 0.01 - 0.15 0.01 - 0.15
<0.1 - 1.5> <0.1 - 1.5>
0-0 0-0
Lock-up clutch pressure <0 - 0> <0 - 0>
Transmission:
Torque converter
2.25 - 2.65 2.25 - 2.65

Stator clutch pressure Neutral <23.0 - 27.0> <23.0 - 27.0>
Oil temperature: 0.8 - 1.0 0.8 - 1.0
Inlet oil pressure <8.0 - 10.0> <8.0 - 10.0>
70-90 MPa
<kg/cm2> 0.39 - 0.64 0.39 - 0.64
Outlet oil pressure <4.0 - 6.5> <4.0 - 6.5>
Lock-up clutch pressure 0-0 0-0
<0 - 0> <0 - 0>
2.45 - 2.85 2.45 - 2.85
Stator clutch pressure <25.0 - 29.0> <25.0 - 29.0>
Lock-up clutch pressure 1.27 - 1.47 1.27 - 1.47
Transmission: F1 Raise engine speed, <13.0 - 15.0> <13.0 - 15.0>
when lock-up lamp
(Co mode) lights up 0-0 0-0
Stator clutch pressure <0 - 0> <0 - 0>
Engine at low idling 2.40 - 2.70 2.35 - 2.94
<24.5 - 27.5> <24.0 - 30.0>
Main relief pressure
2.55 - 2.85 2.45 - 2.94
Transmission: Engine at high idling <26.0 - 29.0> <25.0 - 30.0>
Neutral Engine at low idling
Lubricating oil
Transmission
pressure 0.15 - 0.25 0.15 - 0.25

Engine at high idling <1.5 - 2.5> <1.5 - 2.5>
F clutch pressure T/M: F3 Engine at low idling MPa 2.40 - 2.70 2.35 - 2.94
(Co mode) <kg/cm2> <24.5 - 27.5> <24.0 - 30.0>
R clutch pressure T/M: R3 2.40 - 2.70 2.35 - 2.94
Engine at low idling <24.5 - 27.5> <24.0 - 30.0>
(Co mode)
T/M: F1 2.05 - 2.45 1.96 - 2.55
1st clutch pressure (Co mode) Engine at low idling <20.0 - 26.0>
<21.0 - 25.0>
T/M: F2 2.40 - 2.70 2.35 - 2.94
2nd clutch pressure (Co mode) Engine at low idling
<24.5 - 27.5> <24.0 - 30.0>
3rd clutch pressure T/M: F3 Engine at low idling 2.40 - 2.70 2.35 - 2.94
(Co mode) <24.5 - 27.5> <24.0 - 30.0>
20-252 D375A-5
TESTING AND ADJUSTING PMNo
Pm CLINIC CHECK SHEET D375A-5
Work order No Date Service meter Serviceman
h
2.40 - 2.70 Min. 2.4
Left clutch pressure <24.5 - 27.5> <Min. 24.0>
Engine at low idling Min. 2.4
Left brake pressure 2.35 - 2.65
Transmission: <24.0 - 27.0> <Min. 24.0>
Steering clutch & brake
Neutral 2.55 - 2.85 Min. 2.4

Left clutch pressure <Min. 24.0>
<26.0 - 29.0>
Engine at high idling 2.50 - 2.80 Min. 2.4
Left brake pressure MPa <Min. 24.0>
<25.5 - 28.5>
<kg/cm2> 2.40 - 2.70 Min. 2.4
Right clutch pressure
<24.5 - 27.5> <Min. 24.0>
Engine at low idling Min. 2.4
2.35 - 2.65
Right brake pressure Transmission: <24.0 - 27.0> <Min. 24.0>
Neutral 2.55 - 2.85 Min. 2.4
Right clutch pressure <Min. 24.0>
<26.0 - 29.0>
Engine at high idling 2.50 - 2.80 Min. 2.4
Right brake pressure <25.5 - 28.5> <Min. 24.0>
Brake performance Engine at high idling, F2, brake actuated Machine must not move
Ripper lift 18.6 - 20.6 Min. 17.6
Front pump <Min. 180>
relief Engine at low <190 - 210>
Hydraulic components
Blade tilt relief idling

18.6 - 20.6 Min. 17.6
Center pump <Min. 180>
(single tilt only) <190 - 210>
Ripper lift MPa 19.6 - 21.6 Min. 18.6

Front pump <kg/cm2>
relief <200 - 220> <Min. 190>
Engine at high
Center pump Blade tilt relief 19.6 - 21.6 Min. 18.6
(single tilt only) idling <200 - 220> <Min. 190>
Control circuit main Neutral 4.22 - 4.80 Min. 3.9

pressure <43 - 49> <Min. 40>
q Pump oil pressure is standard value measured by monitor panel. When using an oil pressure gauge, see TESTING AND ADJUSTING STANDARD VALUES.
Engine at low idling 9 - 15 Max.17
Blade RAISE
Engine at high idling 3.5 - 4.5 Max. 6
Single tilt (left g right) Engine at low idling 8 - 12 Max.16

Engine at high idling 3-4 Max. 5
Sec.
Dual tilt (left g right) Engine at low idling 10 - 15 Max.16
Engine at high idling 4-5 Max. 6
Ripper tilt (in g out) Engine at low idling 8 - 12

3-4
Max.16
Max. 6
Hydraulic drift
Hydraulic oil temperature
Blade lift cylinder Engine stopped Max. 100 Max. 150

mm/5 min.
Ripper lift cylinder Max. 15 Max. 30
Visual inspection of final drive drain plug Engine stopped There must be no excessive metal particles
Always fill in the record when repairing, adjusting, or replacing main parts.
Date Service meter Repair record Date Service meter Repair record
D375A-5 20-253
TESTING AND
PmADJUSTING
CLINIC PMNo
UNDERCARRIAGE CHECK SHEET

D375A-5
Work order No. Date Service meter Serviceman
h
Measure the bushing temperature immediately after operations

Left side of machine
Measurement
results Pass Fail
Right side of machine

Measurement
results Pass Fail
Opening of track link Left track A: Clearance between links

Pin No. 1.4
Right track A: Clearance between links

Pin No. 1.4
20-254 D375A-5
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)
(Program form No.: SELA195001)
Y Komatsu
Undercarriage Inspection Customer name:
Address:
Model D375A-5 Serial# Equip# Work Order No

Location SMR Wet,AR,HD or Dry Wet
Soil condition Dealer Shoe width (mm)
Working condition Inspector Shoe type SINGLE
Insp.Date(yy/mm/dd) (yyyy/m/d) Wear type NORMAL
New 100% Measured Wear SMR Hours on Comments/Observation
Wear mm % New Rebuilt Parts:
LH 1121.2 1141.2
LINK PITCH
R
M L L=l/4 RH 1121.2 1141.2
LH 280.30 285.30
master pin M
master l
i 1.3 RH 280.30 285.30
LH 181.0 163.0
H
RH 181.0 163.0
LINK HEIGHT1.3
New Turned
BUSHIN d1 LH 98.5 90.0
G New Turned
d
D is the smallest d RH 98.5 90.0
ofd1,,d2 and,d3 1
GROUSER HIGHT LH 93.0 30.0
H
0 RH 93.0 30.0
CARRIER
CARRIER LH 210.0 185.0
Front
RH 210.0 185.0
D LH 210.0 185.0
Rear
1.3 RH 210.0 185.0
IDLER
IDLER LH 23.5 36.0
Front
H RH 23.5 36.0
LH 23.5 36.0
Rear
1.3 RH 23.5 36.0
1 LH 270.0 200.0
2 LH 270.0 200.0
3 LH 270.0 200.0
4 LH 270.0 200.0
5 LH 270.0 200.0
6 LH 270.0 200.0
7 LH 270.0 200.0
TRACK ROLLER 8 LH 270.0 200.0
9 LH 270.0 200.0
10 LH 270.0 200.0
D 1 RH 270.0 200.0
h1 2 RH 270.0 200.0
h2
3 RH 270.0 200.0
D=2(h1- 4 RH 270.0 200.0
5 RH 270.0 200.0
6 RH 270.0 200.0
7 RH 270.0 200.0
8 RH 270.0 200.0
9 RH 270.0 200.0
1.3 10 RH 270.0 200.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3 h3 h2
1.3 RH 0.0 6.0
Remarks:
D375A-5 20-255
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)
(Program form No.: SELA195001)
Y Komatsu
Undercarriage Inspection Customer name:
Address:
Model D375A-5 Serial# Equip# Work Order No

Location SMR Wet,AR,HD or Dry Wet
Soil condition Dealer Shoe width (mm)
Working condition Inspector Shoe type SINGLE
Insp.Date(yy/mm/dd) (yyyy/m/d) Wear type IMPACT
New 100% Measured Wear SMR Hours on Comments/Observation
Wear mm % New Rebuilt Parts:
LH 1121.2 1133.2
LINK PITCH
R
M L L=l/4 RH 1121.2 1133.2
LH 280.30 283.30
master pin M
master l
i 1.3 RH 280.30 283.30
LH 181.0 163.0
H
RH 181.0 163.0
LINK HEIGHT1.3
New Turned
BUSHI d1 LH 98.5 92.5
NG New Turned
d
D is the smallest d RH 98.5 92.5
ofd1,,d2 and,d3 1
GROUSER HIGHT LH 93.0 30.0
H
0 RH 93.0 30.0
CARRIER
CARRIER LH 210.0 185.0
Front
RH 210.0 185.0
D LH 210.0 185.0
Rear
1.3 RH 210.0 185.0
IDLER
IDLER LH 23.5 36.0
Front
H RH 23.5 36.0
LH 23.5 36.0
Rear
1.3 RH 23.5 36.0
1 LH 270.0 200.0
2 LH 270.0 200.0
3 LH 270.0 200.0
4 LH 270.0 200.0
5 LH 270.0 200.0
6 LH 270.0 200.0
7 LH 270.0 200.0
TRACK ROLLER 8 LH 270.0 200.0
9 LH 270.0 200.0
10 LH 270.0 200.0
D 1 RH 270.0 200.0
2 RH 270.0 200.0
h2 h1
3 RH 270.0 200.0
D=2(h1- 4 RH 270.0 200.0
5 RH 270.0 200.0
6 RH 270.0 200.0
7 RH 270.0 200.0
8 RH 270.0 200.0
9 RH 270.0 200.0
1.3 10 RH 270.0 200.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3 h3 h2
1.3 RH 0.0 6.0
Remarks:
20-256 D375A-5
TROUBLESHOOTING
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING ...................................................................... 20-302

SEQUENCE OF EVENTS IN TROUBLESHOOTING ............................................................................. 20-303
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE .................................................... 20-304
CHECKS BEFORE TROUBLESHOOTING ............................................................................................. 20-312
CLASSIFICATION OF AND PROCEDURE FOR TROUBLESHOOTING ............................................... 20-313
CONNECTOR ALLOCATION DRAWING ............................................................................................... 20-317
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ................................................................. 20-328
T-BRANCH BOX AND T-BRANCH TABLE ............................................................................................. 20-350
TROUBLESHOOTING WHEN ERROR CODE IS DISPLAYED (ERROR CODE) .................................. 20-401

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .............................................................. 20-701
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) .............................. 20-801
TROUBLESHOOTING OF THE ENGINE BODY (S-MODE) ................................................................... 20-901
D375A-5 20-301
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative () terminal of the battery first.
When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 3) Other inspection items.

to disassemble the components. 4) Other maintenance items can be checked ex-
If components are disassembled immediately any ternally, so check any item that is considered
failure occurs: to be necessary.
Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be disas- Confirm the extent of the failure yourself, and
sembled. judge whether to handle it as a real failure or as
It will become impossible to find the cause a problem with the method of operation, etc.
of the failure. When operating the machine to reenact the
It will also cause a waste of manhours, parts, or troubleshooting symptoms, do not carry out
oil or grease, and at the same time, will also lose any investigation or measurement that may
the confidence of the user or operator. make the problem worse.
For this reason, when carrying out troubleshoot- 5. Troubleshooting
ing, it is necessary to carry out thorough prior Use the results of the investigation and inspec-
investigation and to carry out troubleshooting in tion in Items 2 4 to narrow down the causes of
accordance with the fixed procedure. failure, then use the troubleshooting flowchart to
2. Points to ask user or operator locate the position of the failure exactly.
1) Have any other problems occurred apart from The basic procedure for troubleshooting is
the problem that has been reported? as follows.
2) Was there anything strange about the ma- 1) Start from the simple points.
chine before the failure occurred? 2) Start from the most likely points.
3) Did the failure occur suddenly, or were there 3) Investigate other related parts or infor-
problems with the machine condition before mation.
this? 6. Measures to remove root cause of failure
4) Under what conditions did the failure occur? Even if the failure is repaired, if the root cause of
5) Had any repairs been carried out before the the failure is not repaired, the same failure will
failure? occur again.
When were these repairs carried out? To prevent this, always investigate why the prob-
6) Has the same kind of failure occurred be- lem occurred. Then, remove the root cause.
fore?
3. Check before troubleshooting
1) Check for symptoms of any abnormality in
the machine.
2) Check the CHECKS BEFORE STARTING items.
20-302 D375A-5
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
Office, shop Jobsite

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

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

shop manual to find locations of possible Step
causes.
Repair at jobsite
Hurray !
It's repalred
Step 3
Preparation of troubleshooting tools
TEW00185
1) Look at the table of troubleshooting tools in
the shop manual and prepare the necessary Step 7
tools. Pinpoint locations of failure (carry out
T-adapter troubleshooting)
Hydraulic pressure gauge kit, etc. Decide action to take
2) Look in the parts book and prepare the nec-
essary replacement parts. 1) Before starting troubleshooting, locate and
TEW00186 repair simple failures.
Check before starting items
Other check items
2) See the Troubleshooting Section of the shop
manual, select a troubleshooting flowchart
that matches the symptoms, and carry out
troubleshooting.
TEW00187
Step 6
Re-enacting failure
Drive and operate the machine to confirm

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

chine before the failure occurred?
Did the failure occur suddenly?
Had any repairs been carried out before the
TEW00189 failure?
TEW00190
D375A-5 20-303
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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

ELECTRIC EQUIPMENT
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are more
likely to be affected by the direct effects of rain,
water, heat, or vibration. Furthermore, during
inspection and repair operations, they are fre-
quently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
TEW00191
Main failures occurring in wiring harness

(1) Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.
(2) Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
are in contact at the crimped terminal or
soldered portion, but if there is excessive
force brought to bear on the wiring, the plat-
ing at the joint will peel and cause improper
connection or breakage.
20-304 D375A-5
(3) Disconnections in wiring

If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.
TEW00194
(4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, depending on the direction of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
for it to be drained. Therefore, if water should
get into the connector, the pins will be short-
TEW00195
circuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing elec-
tricity through it.
(5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con- TEW00196
tact restorer.
a When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
a If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before clean-
ing with compressed air.
D375A-5 20-305
2) Removing, installing, and drying connectors and

wiring harnesses
Disconnecting connectors
(1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connec-
tors 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 con-
nectors apart.
a Never pull with one hand.
(2) When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
a If the connector is twisted up and down
or to the left or right, the housing may
break.
TBW00484
(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.
TEW00198
20-306 D375A-5
Connecting connectors
(1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation, de-
fective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
aIf 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 wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
aIf there is any damage or breakage, re-
place the connector.
(2) Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
TEW00200
(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 po-
sition.
a If the connector cannot be corrected eas-
ily, remove the clamp and adjust the
position.
(4) If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps. TBW00487
Since the DT 8-pole and 12-pole heavy duty wire

connectors have 2 latches respectively, push them
in until they click 2 times.
1. Male connector, 2. Female connector
Normal locking state (Horizontal): a, b, d
Incomplete locking state (Diagonal): c
D375A-5 20-307
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 wa-
ter or using steam. If the connector must be
washed in water, do not use high-pressure water
or steam directly on the wiring harness.
If water gets directly on the connector, do as fol-

lows:
(1) Disconnect the connector and wipe off the
water with a dry cloth.
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 dry-
er to dry the connector.
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 dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
After completely drying the connector,
blow it with contact restorer and reas-
semble.
20-308 D375A-5
3) Handling control box

(1) The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
(2) Do not open the cover of the control box un-
less necessary.
(3) Do not place objects on top of the control

box.
(4) Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with
your hand.
(5) During rainy weather, do not leave the con-
trol box in a place where it is exposed to rain.
(6) Do not place the control box on oil, water, or

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

1) Always turn the power OFF before disconnecting or connecting connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
If there is any change, there is probably defective contact in that circuit.
D375A-5 20-309
5. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hy-

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

Avoid adding hydraulic oil, replacing filters, or re-
pairing the machine in rain or high winds, or plac-
es where there is a lot of dust.
2) Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and maintenance of hydraulic equipment
should be carried out in a specially prepared
dustproof workshop, and the performance
should be confirmed with special test equipment.
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. If the opening is left open or is blocked with
a rag, there is danger or dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this.
Do not simply drain oil out on to the ground, col-
lect 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 refill-

ing operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil fill-
er 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.
20-310 D375A-5
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 possi-
ble of the old hydraulic oil must be drained out.
(Do not 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 contami-
nants 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 re-
move 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 sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the machine,
carry out oil cleaning to remove the sludge or
contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove the
ultrafine (about 3) particles that the filter built
into the hydraulic equipment cannot remove, so
it is an extremely effective device.
D375A-5 20-311
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Judgement
Item Action
Value
1. Check fuel level Add fuel
2. Check for impurities in fuel Clean, drain
Lubricating oil, coolant
3. Check hydraulic oil level Add oil

Checks before starting
4. Check oil level in damper case Add oil

5. Check power train oil level Add oil
6. Check engine oil level (engine oil pan level) Add oil
7. Check coolant level Add water
8. Check dust indicator for clogging Clean or replace
9. Check travel of brake pedal Adjust
mechanical equipment
Electrical
10. Check for looseness, corrosion of battery terminal, wiring Tighten or replace
11. Check for looseness, corrosion of alternator terminal, wiring Tighten or replace
12. Check for looseness, corrosion of starting motor terminal, wiring Tighten or replace
equipment
Hydraulic,
13. Check for abnormal noise, smell Repair

14. Check for oil leakage Repair
15. Carry out air bleeding Bleed air
Other check items
16. Check battery voltage (engine stopped) 20 - 30 V Replace

17. Check battery electrolyte level Add or replace
Electrical equipment
18. Check for discolored, burnt, exposed wiring Replace

19. Check for missing wiring clamps, hanging wire Repair
20. Check for water leaking on wiring (pay particularly careful attention Disconnect connector
to water leaking on connectors or terminals) and dry
21. Check for water on wiring Replace
22. Check alternator voltage (engine running at 1/2 throttle or above) After running for Replace
several minutes:
27.5 - 29.5 V
23. Check operating sound of battery relay (starting switch ON, OFF) Replace
20-312 D375A-5
TROUBLESHOOTING CLASSIFICATION OF AND PROCEDURE FOR TROUBLESHOOTING
CLASSIFICATION OF AND PROCEDURE FOR

TROUBLESHOOTING
Classification of troubleshooting
Mode Contents
Service code Troubleshooting when service code is displayed
E mode Troubleshooting for electric system
H mode Troubleshooting for hydraulic and mechanical systems
S mode Troubleshooting of the engine body
Procedure for troubleshooting

If a possible fault is detected in the machine, narrow the troubleshooting Nos. according to the following proce-
dure, then go to the related troubleshooting section.
1. Procedure for troubleshooting when user code is displayed on monitor panel:

If a user code is displayed on the monitor panel, display the service code in the service code display mode
of the monitor panel (EMMS).
Carry out the troubleshooting for the displayed "service code".
The service code becomes "E" when a fault is detected. Accurately, even if it is "P" when the starting
switch is turned ON, the fault may not have been repaired. (Some faults are detected by simply turning
the starting switch ON, however.)
If the service code is recorded, be sure to perform the procedure for reproducing it to see if the corre-
sponding fault has been repaired. (For the method of reproducing the service code, see the trouble-
shooting for the service code.)
2. Procedure for troubleshooting when service code is recorded:

If a user code is not displayed on the monitor panel, check the service code in the service code display mode
of the monitor panel (EMMS).
If the service code is recorded, carry out the troubleshooting for that "service code".
The service code becomes "E" when a fault is detected. Accurately, even if it is "P" when the starting
switch is turned ON, the fault may not have been repaired. (Some faults are detected by simply turning
the starting switch ON, however.)
If the service code is recorded, be sure to perform the procedure for reproducing it to see if the corre-
sponding fault has been repaired. (For the method of reproducing the service code, see the trouble-
shooting for the service code.)
3. Procedure for troubleshooting when user code is not displayed and service code is not recorded
If a service code is not recorded on the monitor panel (EMMS), the machine may have a fault in its electric,
hydraulic, or mechanical system and may not able to detect it by the self-diagnosis.
In this case, check the possible fault again and select the related faults from the table of "Possible faults and
troubleshooting Nos. for them" and carry out troubleshooting for the related items in the "E mode", "H mode"
or "S mode".
D375A-5 20-313
Phenomena considered to be failures and troubleshooting No.
Troubleshooting
No. Phenomena considered to be failures
Trouble code E mode H mode S mode
Action code, trouble code related
1 Action code is displayed on monitor panel Check trouble code
2 Trouble code is displayed in trouble code display mode q
Engine related
3 Engine starting is poor (always takes time to start) S-1
4 Engine does not turn E-1 S-2 1)
Engine turns but no exhaust
5 S-2 2)
Engine does not start smoke comes out
Exhaust smoke comes out but
6 S-2 3)
engine does not start
7 Engine pickup is poor (response is poor) S-3
8 Engine stops during operation S-4
9 Engine turns irregularly (hunting) S-5
10 Lack of output or no power S-6
11 Exhaust color is black (incomplete combustion) S-7
12 Oil consumption is excessive or exhaust color is blue S-8
13 Oil quickly becomes dirty S-9
14 Fuel consumption is excessive S-10
15 Oil mixed in cooling water, blows back, water level goes down S-11
16 Oil level rises S-13
17 There is abnormal noise S-15
18 Excessive vibration S-16
19 Preheating does not work E-2
Power train related
20 No power (no drawbar pull) H-1 S-6
21 Does not travel (when in 2nd or 3rd) H-2
22 Does not move off in any speed range H-3
23 Moves in only one direction (forward or reverse) H-4
Excessive time lag when shifting gear or shifting between
24 H-5
forward and reverse
25 Cannot turn (steering) H-6
26 Turns in only one direction (steering) H-7
27 Overruns when turning (steering) H-8
28 Brakes do not work H-9
29 Torque converter does not lock up H-10
30 Torque converter oil overheats H-11
Work equipment related
31 All work equipment speeds are slow H-12
32 No work equipment moves H-13
33 Blade RAISE speed is slow or lacks power H-14
34 Blade LOWER speed is slow or lacks power H-15
35 Ripper RAISE speed is slow or lacks power H-16
36 Ripper LOWER speed is slow or lacks power H-17
37 Excessive hydraulic drift of blade lift H-18
38 Excessive hydraulic drift of blade tilt H-19
39 Excessive hydraulic drift of ripper lift H-20
40 Ripper pin-puller cylinder does not work E-3 H-21
41 Blade pitch does not work H-22
42 Abnormal noise from around hydraulic pump H-23
20-314 D375A-5
Troubleshooting
No. Phenomena considered to be failures
Trouble code E mode H mode S mode
Monitor panel related (operator mode: normal screen)
Nothing lights up on monitor panel when starting switch is
43 E-4
turned ON
All lamps on monitor panel stay on and do not go out when
44 E-5
starting switch is turned ON
45 Basic check items flash when starting switch is turned ON E-6
46 Caution items flash when engine is running E-7
47 Warning items flash when engine is running E-8
48 Preheating lamp does not light up E-9
49 Engine water temperature gauge display is not normal E-10
50 Torque converter oil temperature gauge display is not normal E-11
51 Fuel gauge display is not normal E-12
52 Travel speed, engine speed, shift mode display is not normal E-13
53 Service meter display is not normal E-14
54 Switch module cannot be operated E-15
55 Warning lamp does not flash or does not go out E-16
56 Alarm buzzer does not sound or does not stop E-17
57 Alarm buzzer cannot be canceled E-18
Monitor panel related (service mode: special for function screen)
58 Does not switch to service mode E-19
Others
59 Backup alarm does not sound E-20
Panel night lighting, front lamp, working lamp, rear lamp do
60 E-21
not light up
61 Air conditioner does not work E-22
D375A-5 20-315
TROUBLESHOOTING CONNECTOR ALLOCATION DRAWING
CONNECTOR ALLOCATION DRAWING

(3-dimensional allocation drawing)
TABLE OF CONNECTORS The address shows the approximate position in
the connector 3-dimensional allocation drawing
Connector Connector No. of

Place of use Address
No. type pins
101 18-14 14 Intermediate connector (Engine side connector No. VHL) F-1
1939 9 Engine controller communication connector
201 DT 4 Intermediate connector C-1
202 DT 4 Intermediate connector A-4
203 DT 2 Right front lamp A-5
204 DT 2 Left front lamp D-1
205 Terminal 1 Horn B-2
206 DT 4 Intermediate connector E-1
206 Terminal GND N-4
212 3 Buzzer cancel switch N-6
214 DT-B 12 Intermediate connector N-3
215 DT-C 12 Intermediate connector N-2
216 DT-D 12 Intermediate connector N-2
217 DT 2 Alarm buzzer P-1
218 4 Rear lamp switch N-5
219 4 Front lamp & working lamp switch N-4
221 DT 2 Left working lamp G-2
223 DT 2 Left rear lamp J-4
224 DT 2 Ripper pin-puller solenoid valve I-3
241 DT 12 Intermediate connector D-8
242 DT 2 Right working lamp A-5
243 DT 2 Right rear lamp J-9
244 DT 2 Backup alarm K-9
262 X 2 Horn switch Q-8
263 X 2 Ripper pin-puller switch R-8
264 DT 4 Intermediate connector R-8
265 Terminal 1 Horn switch
266 Terminal 1 Horn switch
351 DT 2 Air conditioner compressor Y-3
360 DT 6 Window washer motor (left rear) K-5
369 DT 6 Window washer motor (right front) J-4
375 4 Warning lamp N-5
405 DT 2 Radiator water level switch B-2
422 DT 2 Intermediate connector K-5
423 DT 2 Fuel level sensor I-4
431 DT 3 Intermediate connector K-8
452 DT 2 Hydraulic oil temperature sensor e-5
453 DT 2 Torque converter oil temperature sensor h-3
653 DT 2 Torque converter lock-up solenoid valve e-5
701 Terminal 1 Battery relay terminal BR
702 Terminal 1 Battery relay terminal M
703 Terminal 1 Battery relay terminal B
D375A-5 20-317

No. type pins
1-pin
800 1 Spare power source N-9
connector
1-pin
801 1 Spare power source N-9
connector
AAPR 3 Atmospheric pressure sensor C-8
ADH 4 Heater switch N-4
ARC X 2 Air conditioner condenser H-3
ATM0 DT 2 Atmospheric temperature sensor C-7
ATM1 DT 2 Intermediate connector
ASD 4 Auto shift down switch N-5
BB1 5 Front lamp relay M-8
BB3 5 Working lamp relay M-8
BKA 5 Backup alarm relay M-8
BLD DT 2 Blade lower oil pressure switch P-7
BLU DT 2 Blade raise oil pressure switch P-7
BRK DT 3 Brake potentiometer Q-1
BUZ 3 Buzzer cancel switch N-6
CAN 12 Intermediate connector d-4
CAN 3 CAN Terminal resistance V-7
CB1 2 Circuit breaker M-9
CLTP 2 Engine water temperature sensor Y-6
CM29 AMP-070 10 Intermediate connector (ORBCOMM controller) W-9
CM30 AMP-070 14 Intermediate connector (ORBCOMM controller) W-9
CN1 AMP 12 Monitor panel O-7
CN2 AMP 8 Monitor panel P-7
CN4 M 2 Monitor panel O-6
1-pin
CN-1 1 Lamp outlet connector [cab] H-9
connector
CN-2 Terminal 1 Rear right speaker [cab] H-9
CN-3 Terminal 1 Rear right speaker [cab] H-9
CN-4 4 Rear wiper motor [cab] G-9
CN-5 Terminal 1 Rear left speaker [cab] G-9
CN-6 Terminal 1 Rear left speaker [cab] G-9
CN-9 6 Front wiper motor [cab] E-8
CN-10 9 Radio [cab] I-9
CN-11 6 Left wiper switch [cab] E-9
CN-12 6 Front wiper switch [cab] E-9
CN-13 6 Right wiper switch [cab] F-9
CN-14 6 Rear wiper switch [cab] F-9
CN-15 2 Lamp switch [cab] F-9
CN-17 4 Right door wiper motor [cab] E-8
CN-18 4 Left door wiper motor [cab] I-7
CN-19 M 4 Intermediate connector G-2
CN-20 DT 1 Cab power source connector [cab] T-1
CN-21 DT 1 Cab power source connector [cab] T-1
CN-22 Terminal 2 Cigar lighter [cab] K-6
20-318 D375A-5

No. type pins
CN-23 4 Converter [cab] G-9
CN-24 2 Intermediate connector [cab] K-6
1-pin
CN-25 1 Rotating lamp outlet connector [cab] I-9
connector
CN-26 2 Rotating lamp switch [cab] F-9
CN-81 2 Room lamp [cab] E-8
COT DT 3 CAN terminal resistance W-4
CUR 3 Cursor switch N-6
DCL DT 3 Decelerator pedal potentiometer R-1
DL1 DT 6 Intermediate connector N-1
DLCO 6 Data link crossover connector d-6
DLK HD10-6 6 Intermediate connector Q-1
ECMA 40 Engine controller d-2
ECMB 40 Engine controller b-8
EDIS DT 2 Dust indicator F-2
EG1 24-21 21 Intermediate connector (Engine side connector No. POW) d-5
ENBP DT 3 Blow-by pressure d-6
ENGT DT 2 Engine oil temperature sensor d-4
EG2 24-31 31 Intermediate connector (Engine side connector No. SIG) d-5
ESD DT 3 Connector for option O-7
EX1L DT 3 Exhaust temperature left amplifier W-5
EX1R DT 3 Exhaust temperature right amplifier W-5
EX2L DT 2 Exhaust temperature left amplifier W-4
EX2R DT 2 Exhaust temperature right amplifier W-5
EXHL DT 2 Exhaust temperature left sensor c-8
EXHR DT 2 Exhaust temperature right sensor c-8
F1T DT 2 1st clutch ECMV (fill switch) g-7
F2T DT 2 2nd clutch ECMV (fill switch) g-7
F3T DT 2 3rd clutch ECMV (fill switch) f-6
FD1 24-23 23 Intermediate connector W-3
FD5 DT-A 12 Intermediate connector V-2
FD6 24-31 31 Intermediate connector W-4
FFT DT 2 F clutch ECMV (fill switch) I-3
FLB DT 2 Left steering brake ECMV (fill switch) I-3
FLC DT 2 Left steering clutch ECMV (fill switch) h-7
FLTP 2 Fuel temperature sensor a-7
FRB DT 2 Right steering brake ECMV (fill switch) J-7
FRC DT 2 Right steering clutch ECMV (fill switch) h-7
FRT DT 2 F clutch ECMV (fill switch) g-7
FS1 Fuse box 1 N-9
FS2 Fuse box 2 N-9
FS4 Fuse box 4 O-9
FSB 24-31 31 Intermediate connector S-1
FSO- Terminal 1 Fuel shut off valve Y-5
FSO+ Terminal 1 Fuel shut off valve Y-5
GND Terminal GND C-7
GND Terminal GND (engine) Y-3
GND Terminal GND (engine) Y-3
GND1 Terminal GND H-3, N-4
GND4 Terminal GND A-2
HEAT DT 2 Intermediate connector d-5
D375A-5 20-319

No. type pins
IMPR 3 Boost pressure sensor Z-6
IMTP 2 Intake air temperature sensor Z-7
JC01 6 Junction connector d-3
JC02 8 Junction connector c-3
JC03 8 Junction connector a-2
JC11 6 Junction connector b-2
JC12 6 Junction connector b-2
KEY M 6 Starting switch O-6
LINK 6 Data link crossover connector d-4
LPP DT 3 Work equipment large pump pressure sensor D-8
M26 6 Air conditioner unit O-1
MMS DT-C 12 Intermediate connector (MMS wiring harness) W-6
NGICN1 24 Steering controller U-8
NGICN2 40 Steering controller T-9
NGICN3 40 Steering controller T-9
NSF 5 Neutral safety relay M-7
NSW DT 3 Travel lock switch O-9
OBC DT-A 12 Intermediate connector W-9
OLPR 3 Engine oil pressure sensor Y-3
P03 DT 6 Work equipment knob switch Q-7
P04 DT-A 2 Intermediate connector D-8
PAS DT 4 Tilt angle sensor F-2
PL1 24-23 23 Intermediate connector W-2
PL2 24-31 31 Intermediate connector W-3
PL3 DT-B 12 Intermediate connector V-2
PMPR 3 Fuel pump pressure sensor Z-2
PPR 5 Pump power relay M-7
PRE DT 2 Prelube O-7
PRR 5 Pre lub relay O-1
PRS DT 2 Prelube O-8
PUMP 3 Fuel pump actuator Z-2
PWR DT 1 Intermediate connector U-2
RAIL 3 Fuel rail actuator Y-3
RHR 5 Preheater relay N-7
RPD DT 2 Ripper LOWER oil pressure switch Q-8
RPR 3 Fuel rail pressure sensor d-3
RPU DT 2 Ripper RAISE oil pressure switch R-8
RTI DT 2 Ripper tilt in oil pressure R-8
RTO DT 2 Ripper tilt-back oil pressure switch Q-8
S01 AMP 12 Monitor panel O-7
S02 M 2 Monitor panel N-5
S03 AMP 16 Monitor panel O-6
S04 AMP-070 12 Monitor panel O-7
S13 DT-A 12 Intermediate connector N-3
S1T DT 2 1st clutch CMV (solenoid valve) F-6
S21 3 SSC initial setting jumper N-5
S24 Terminal 6 Service switch P-1
20-320 D375A-5

No. type pins
S25 X 4 Data write connector (steering controller) U-8
S26 X 4 Data write connector (transmission controller) V-8
S2T DT 2 2nd clutch CMV (solenoid valve) g-7
S3T DT 2 3rd clutch CMV (solenoid valve) f-6
SDR 5 Engine controller power relay N-7
SFT DT 2 F clutch CMV (solenoid valve) h-3
SLB DT 2 Left steering brake ECMV (solenoid valve) J-5
SLC DT 2 Left steering clutch ECMV (solenoid valve) I-7
SOL1 DT 2 Solenoid valve for pitch B-6
SOL2 DT 2 Solenoid valve for dual C-7
SP1 2 Engine speed sensor (master) d-6
SP2 2 Engine speed sensor (backup) d-6
SPP DT 3 Work equipment small pump pressure sensor E-8
SRB DT 2 Right steering brake ECMV (solenoid valve) J-6
SRC DT 2 Right steering clutch ECMV (solenoid valve) h-7
SRT DT 2 F clutch ECMV (solenoid valve) g-6
SS3 DT 3 Acceleration sensor F-2
STB DT 2 Sudden stop valve solenoid I-7
SX8 Terminal GND H-3
TC1 DT 2 Torque converter outlet speed sensor j-6
TIMG 3 Timing rail actuator a-8
TL1 24-23 23 Fuel control dial, full monolever unit S-1
TLS DT 2 Blade tilt left oil pressure switch P-7
TM1 DT 2 Transmission outlet speed sensor j-7
TMCN1 24 Transmission controller V-7
TMMD DT 3 Transmission main oil pressure sensor e-6
TMV 24-23 23 Intermediate connector g-7
TPR 3 Timing rail pressure sensor d-4
TRS DT 2 Blade tilt right oil pressure sensor P-7
TST DT 2 For writing
USB DT 1 Intermediate connector U-1
V1 070 20 VHMS controller W-2
V23 DT 3 CAN terminal resistance V-6
V25 DT 4 Download plug W-6
V2A 070 18 VHMS controller W-2
V2B 070 12 VHMS controller W-2
V3A 070 18 VHMS controller W-1
V3B 070 12 VHMS controller W-1
V4A 070 14 VHMS controller X-1
V4B 070 10 VHMS controller X-1
VDA 18-14 14 Download box K-5
VDB DT-A 8 Intermediate connector (Floor) W-3
VEG 18-14 14 Intermediate connector E-1, d-5
VF1 DT-A 12 Intermediate connector (VHMS controller box) W-5
VF2 24-31 31 Intermediate connector V-1
D375A-5 20-321
3-DIMENSIONAL ALLOCATION DRAWING
20-322 D375A-5
D375A-5 20-323
20-324 D375A-5
D375A-5 20-325
20-326 D375A-5
D375A-5 20-327
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
X Type Connector
Number
of Pins T-adapter Part
Male (Female housing) Female (Male housing)
Number
1 Part number: 08055-00181 Part number: 08055-00191 799-601-7010
2 799-601-7020
Part number: 08055-00282 Part number: 08055-00292
3 799-601-7030
4 799-601-7040

Terminal part number: 79A-222-3370 Terminal part number: 79A-222-3390
Wire size: 0.85 Wire size: 0.85

Quantity: 20 pieces Quantity: 20 pieces
Grommet: black Grommet: black

Grommet: red Grommet: red
20-328 D375A-5
SWP Type Connector

Number
Number
6 799-601-7050
8 799-601-7060
12 799-601-7310
14 799-601-7070
D375A-5 20-329
SWP Type Connector

Number
of Pins T-adapter
Part Number
16 799-601-7320

Terminal part number: Terminal part number:

Grommet: black Grommet: black
Terminal part number: Terminal part number:

Grommet: red Grommet: red
20-330 D375A-5
M Type Connector
Number
Number
1 Part number: 08056-00171 Part number: 08056-00181 799-601-7080
2 799-601-7090
3 799-601-7110
4 799-601-7120
6 799-601-7130
8 799-601-7340
D375A-5 20-331
S Type Connector
Number
Number
8 799-601-7140
10
799-601-7150
(white)
12
799-601-7350
(white)
16
799-601-7330
(white)
20-332 D375A-5
S Type Connector
Number
Number
10

(blue)
12
799-601-7160
(blue)
16
799-601-7170
(blue)
D375A-5 20-333
MIC Type Connector

Number
Number
Body part number: 79A-222-2640 Body part number: 79A-222-2630
7
(Quantity: 5 pieces) (Quantity: 5 pieces)
11
5 799-601-2710

9 799-601-2950

13 799-601-2720

20-334 D375A-5
MIC Type Connector

Number
Number
17 799-601-2730

21 799-601-2740


D375A-5 20-335
AMP040 Type Connector

Number
of Pins T-adapter
Part Number
8 799-601-7180
Housing part number: 79A-222-3430

(Quantity: 5 pieces)
12 799-601-7190

16 799-601-7210

20 799-601-7220

Terminal part number: 79A-222-3470 (for all numbers of pins).
20-336 D375A-5
AMP070 Type Connector

Number
Number
9JS02245 9JS02246
10 799-601-7510
Part number: 7821-92-7330
12 799-601-7520
14 799-601-7530
18 799-601-7540
20 799-601-7550
D375A-5 20-337
(1)
L Type Connector
Number
Number
PA Type Connector
Number
Number
BENDIX (MS) Type Connector

Number
Number
10 799-601-3460
20-338 D375A-5
KES1 Automobile Type Connector

Number
Number
Part number: 08027-10210 (Natural color) Part number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
08027-10420 (Black) 08027-10470 (Black)
08027-10620 (Black) 08027-10670 (Black)
D375A-5 20-339
KES1 Automobile Type Connector

Number
Number
08027-10820 (Black) 08027-10870 (Black)
20-340 D375A-5
F Type Connector
Number
Number
D375A-5 20-341
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector
(shell
size T-adapter Part
Body (plug) Body (receptacle)
code) Number
Pin (male terminal) Pin (female terminal)
799-601-9210
Part number: 08191-11201, 08191-11202 Part number: 08191-14101, 08191-14102

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male terminal)
799-601-9210

08191-11205, 08191-12206 08191-13105, 08191-13106
799-601-9220

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220

08191-22205, 08191-22206 08191-23105, 08191-23106
20-342 D375A-5
(shell
size T-adapter Part
code) Number
799-601-9230
18-20 Part number: 08191-31201, 08191-31202 Part number: 08191-34101, 08191-34102

799-601-9230

799-601-9240

799-601-9240
D375A-5 20-343
(shell
size T-adapter Part
code) Number
799-601-9250

799-601-9250

799-601-9260

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260

08191-62205, 08191-62206 08191-63105, 08191-63106
20-344 D375A-5
(shell
size T-adapter Part
code) Number
799-601-9270

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part number: 08191-81201, 08191-81202, Part number: 08191-84101, 08191-84102,

08191-81203, 08191-81204, 08191-84103, 18191-84104,
24-23 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part number: 08191-82201, 08191-82202, Part number: 08191-83101, 08191-83102,

08191-82203, 08191-82204, 08191-83103, 18191-83104,
08191-82205, 08191-82206 08191-83105, 08191-83106
D375A-5 20-345
(1)
(shell
size T-adapter Part
code) Number
799-601-9290

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290

08191-92205, 08191-92206 08191-93105, 08191-93106
20-346 D375A-5
DT Series connector
Number
Number
2 799-601-9020
Part number: 08192-12200 (normal type) Part number: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
D375A-5 20-347
DT Series connector
Number
Number
8GR:799-601-9060
8B :799-601-9070
8
8G :799-601-9080
8BR :799-601-9080
12GR:799-601-9110
12B :799-601-9120
12
12G :799-601-9130
12BR :799-601-9140
20-348 D375A-5
DTM Series connector
Number
Number
2 799-601-9010
DTHD Series connector

Number
Number
Part number: 08192-31200 (Contact size #12) Part number: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
D375A-5 20-349
DRC26 Series connector

No. of
pins T-adapter
Part No.
24 799-601-9360
Part No.: 7821-93-3110
40
799-601-9350
(A)
Part No.: 7821-93-3120
40
799-601-9350
(B)
Part No.: 7821-93-3130
20-350 D375A-5
(1)
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
T-BRANCH BOX AND T-BRANCH TABLE

The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part
number of Harness Checker Assy.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
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
Connector type or
Part No. No. of pins

part name
799-601-2600 Measurement box Econo-21P

799-601-3100 Measurement box MS-37P
799-601-3200 Measurement box MS-37P
799-601-3300 Measurement box Econo-24P
799-601-3360 Plate For MS box
799-601-3410 BENDIX (MS) 24P
799-601-3420 BENDIX (MS) 24P
799-601-3430 BENDIX (MS) 17P
799-601-3440 BENDIX (MS) 17P
799-601-3450 BENDIX (MS) 5P
799-601-3460 BENDIX (MS) 10P
799-601-3510 BENDIX (MS) 5P
799-601-3520 BENDIX (MS) 14P
799-601-3530 BENDIX (MS) 19P
799-601-2910 BENDIX (MS) 14P
799-601-3470 Case
799-601-2710 MIC 5P
799-601-2720 MIC 13P
799-601-2730 MIC 17P
799-601-2740 MIC 21P
799-601-2950 MIC 9P
799-601-2750 ECONO 2P
799-601-2760 ECONO 3P
799-601-2770 ECONO 4P
799-601-2780 ECONO 8P
799-601-2790 ECONO 12P
799-601-2810 DLI 8P
799-601-2820 DLI 12P
799-601-2830 DLI 16P
799-601-2840 Additional cable
799-601-2850 Case
799-601-7010 X 1P
799-601-7020 X 2P
799-601-7030 X 3P
799-601-7040 X 4P
799-601-7050 SWP 6P
799-601-7060 SWP 8P
799-601-7310 SWP 12P
799-601-7070 SWP 14P
799-601-7320 SWP 16P
799-601-7080 M 1P
799-601-7090 M 2P
799-601-7110 M 3P
799-601-7120 M 4P
799-601-7130 M 6P
799-601-7340 M 8P
799-601-7140 S 8P
799-601-7150 S 10P-White
D375A-5 20-351
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
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
Connector type or
Part No. No. of pins

part name
799-601-7160 S 12P-Blue
799-601-7170 S 16P-Blue
799-601-7330 S 16P-White
799-601-7350 S 12P-White
799-601-7180 AMP040 8P
799-601-7190 AMP040 12P
799-601-7210 AMP040 16P
799-601-7220 AMP040 20P
799-601-7230 Short connector X-2
799-601-7240 Case
799-601-7270 Case
799-601-7510 070 10P
799-601-7520 070 12P
799-601-7530 070 14P
799-601-7540 070 18P
799-601-7550 070 20P
799-601-7360 Relay connector 5P
799-601-7370 Relay connector 6P
799-601-7380 JFC connector 2P
799-601-9010 DTM 2P
799-601-9020 DT 2P
799-601-9030 DT 3P
799-601-9040 DT 4P
799-601-9050 DT 6P
799-601-9060 DT 8P-Gray
799-601-9070 DT 8P-Black
799-601-9080 DT 8P-Green
799-601-9090 DT 8P-Brown
799-601-9110 DT 12P-Gray
799-601-9120 DT 12P-Black
799-601-9130 DT 12P-Green
799-601-9140 DT 12P-Brown
799-601-9210 HD30 18-8
799-601-9220 HD30 18-14
799-601-9230 HD30 18-20
799-601-9240 HD30 18-21
799-601-9250 HD30 24-9
799-601-9260 HD30 24-16
799-601-9270 HD30 24-21
799-601-9280 HD30 24-23
799-601-9290 HD30 24-31
799-601-9310 Plate For HD30
799-601-9320 Measurement box For DT, HD
799-601-9330 Case
799-601-9340 Case
799-601-9350 DRC26 40P
799-601-9360 DRC26 24P
799-601-9410 For NE, G sensor 2P
799-601-9420 For fuel, boost press. 3P
799-601-9430 PVC socket 2P
20-352 D375A-5
(1)
TROUBLESHOOTING 20 TROUBLESHOOTING
TROUBLESHOOTING WHEN
ERROR CODE IS DISPLAYED
(ERROR CODE)
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ........................................................... 20-406

ERROR CODE [1500LO] (TRANSMISSION CLUTCH DOUBLE ERROR) .......................................... 20-408
ERROR CODE [15SAL1] (DEFECTIVE DISENGAGEMENT OF TRANSMISSION FORWARD CLUTCH)
20-409
ERROR CODE [15SALH] (DEFECTIVE ENGAGEMENT OF TRANSMISSION FORWARD CLUTCH)
20-410
ERROR CODE [15SBL1] (DEFECTIVE DISENGAGEMENT OF TRANSMISSION REVERSE CLUTCH)
20- 411
ERROR CODE [15SBLH] (DEFECTIVE ENGAGEMENT OF TRANSMISSION REVERSE CLUTCH) 20-412
ERROR CODE [15SELH] (DEFECTIVE DISENGAGEMENT OF TRANSMISSION 1ST CLUTCH) .... 20-413
ERROR CODE [15SELH] (DEFECTIVE ENGAGEMENT OF TRANSMISSION 1ST CLUTCH) .......... 20-414
ERROR CODE [15SFL1] (DEFECTIVE DISENGAGEMENT OF TRANSMISSION 2ND CLUTCH) ... 20-415
ERROR CODE [15SFLH] (DEFECTIVE ENGAGEMENT OF TRANSMISSION 2ND CLUTCH) ......... 20-416
ERROR CODE [15SGL1] (DEFECTIVE DISENGAGEMENT OF TRANSMISSION 3RD CLUTCH) ... 20-417
ERROR CODE [15SGLH] (DEFECTIVE ENGAGEMENT OF TRANSMISSION 3RD CLUTCH) ......... 20-418
ERROR CODE [1800MW] (SLIP OF POWER TRAIN CLUTCH) ........................................................... 20-419
ERROR CODE [2201L1] (DEFECTIVE DISENGAGEMENT OF RIGHT STEERING CLUTCH) ........ 20-420
ERROR CODE [2201LH] (DEFECTIVE ENGAGEMENT OF RIGHT STEERING CLUTCH) .............. 20-421
ERROR CODE [2202L1] (DEFECTIVE DISENGAGEMENT OF LEFT STEERING CLUTCH) ........... 20-422
ERROR CODE [2202LH] (DEFECTIVE ENGAGEMENT OF LEFT STEERING CLUTCH) ................. 20-423
ERROR CODE [2300NR] (BRAKE ABNORMAL HEATING) ................................................................ 20-424
ERROR CODE [2301L1] (DEFECTIVE DISENGAGEMENT OF RIGHT STEERING BRAKE) ........... 20-425
ERROR CODE [2301LH] (DEFECTIVE ENGAGEMENT OF RIGHT STEERING BRAKE) ................. 20-426
ERROR CODE [2301NR] (RIGHT STEERING BRAKE ABNORMAL HEATING) ................................ 20-427
ERROR CODE [2302L1] (DEFECTIVE DISENGAGEMENT OF LEFT STEERING BRAKE) ............. 20-428
ERROR CODE [2302LH] (DEFECTIVE ENGAGEMENT OF LEFT STEERING BRAKE) ................... 20-429
ERROR CODE [2302NR] (LEFT STEERING BRAKE ABNORMAL HEATING) ................................... 20-430
ERROR CODE [AB00MA] (ALTERNATOR MALFUNCTION) ............................................................... 20-430
ERROR CODE [B@BAZG] (ENGINE OIL PRESSURE REDUCTION) ................................................... 20-431
ERROR CODE [B@BCNS] (RADIATOR COOLANT OVERHEAT) ......................................................... 20-432
ERROR CODE [B@BCZK] (RADIATOR COOLANT LEVEL REDUCTION) ........................................... 20-432
ERROR CODE [B@CENS] (POWER TRAIN OIL OVERHEAT) ............................................................. 20-433
ERROR CODE [B@HANS] (HYDRAULIC OIL OVERHEAT) .................................................................. 20-433
ERROR CODE [C111KT] (ABNORMALITY IN ENGINE CONTROLLER MEMORY) .......................... 20-434
ERROR CODE [C112LK] (ABNORMALITY IN TIMING RAIL ACTUATOR) ......................................... 20-434
ERROR CODE [C113KZ] (ABNORMAL CURRENT IN TIMING RAIL ACTUATOR SYSTEM) ............ 20-435
ERROR CODE [C115KZ] (ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEMS) ................... 20-436
ERROR CODE [C116KZ] (ABNORMALLY HIGH LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM)
20-438
ERROR CODE [C117KX] (ABNORMALLY LOW LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM)
20-439
ERROR CODE [C118KX] (ABNORMALLY HIGH LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM)
20-440
ERROR CODE [C119KX] (ABNORMALLY LOW LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM)
20-441
ERROR CODE [C121LC] (ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEMS) ................... 20-441
ERROR CODE [C122KX] (ABNORMALLY HIGH LEVEL IN BOOST PRESSURE SENSOR SYSTEM)
20-442
D375A-5 20-401
TROUBLESHOOTING
ERROR CODE [C123KX] (ABNORMALLY LOW LEVEL IN BOOST PRESSURE SENSOR SYSTEM)
20-443
ERROR CODE [C131KX] (ABNORMALLY HIGH LEVEL IN THROTTLE SENSOR SYSTEM) ........... 20-444
ERROR CODE [C132KX] (ABNORMALLY LOW LEVEL IN THROTTLE SENSOR SYSTEM) ............ 20-445
ERROR CODE [C133KX] (ABNORMALLY HIGH LEVEL IN REMOTE THROTTLE SENSOR SYSTEM)
20-446
ERROR CODE [C134KX] (ABNORMALLY LOW LEVEL IN REMOTE THROTTLE SENSOR SYSTEM)
20-447
ERROR CODE [C135KX] (ABNORMALLY HIGH LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM)
20-448
ERROR CODE [C141KX] (ABNORMALLY LOW LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM)
20-449
ERROR CODE [C143ZG] (LOWERING OF ENGINE OIL PRESSURE) ............................................... 20-449
ERROR CODE [C144KX] (ABNORMALLY HIGH LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR
SYSTEM) ..................................................................................................... 20-450
ERROR CODE [C145KX] (ABNORMALLY LOW LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR
SYSTEM) ..................................................................................................... 20-451
ERROR CODE [C151NS] (RISE OF ENGINE COOLANT TEMPERATURE) ....................................... 20-451
ERROR CODE [C153KX] (ABNORMALLY HIGH LEVEL IN AIR INTAKE TEMPERATURE SENSOR
SYSTEM) ..................................................................................................... 20-452
ERROR CODE [C154KX] (ABNORMALLY LOW LEVEL IN AIR INTAKE TEMPERATURE SENSOR
SYSTEM) 20- 453
ERROR CODE [C221KX] (ABNORMALLY HIGH LEVEL IN ATMOSPHERIC PRESSURE SENSOR
SYSTEM) 20- 454
ERROR CODE [C222KX] (ABNORMALLY LOW LEVEL IN ATMOSPHERIC PRESSURE SENSOR
SYSTEM) ..................................................................................................... 20-455
ERROR CODE [C234N1] (OVER-SPEED) ........................................................................................... 20-455
ERROR CODE [C254KZ] (ABNORMAL VOLTAGE OF FUEL SHUT-OFF VALVE) ............................. 20-456
ERROR CODE [C259FS] (ABNORMALITY IN FUEL SHUT-OFF VALVE) ........................................... 20-457
ERROR CODE [C261NS] (ABNORMAL RISE OF FUEL TEMPERATURE) ......................................... 20-457
ERROR CODE [C263KX] (ABNORMALLY HIGH LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM)
20-458
ERROR CODE [C265KX] (ABNORMALLY LOW LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM)
20-459
ERROR CODE [C316KZ] (ABNORMAL CURRENT OF FUEL PUMP ACTUATOR) ............................ 20-460
ERROR CODE [C318LK] (ABNORMALITY IN FUEL PUMP ACTUATOR) .......................................... 20-461
ERROR CODE [C346KT] (ABNORMALITY IN POWER-DOWN UNIT OF ENGINE CONTROLLER) . 20-462
ERROR CODE [C384LK] (ABNORMALITY IN PREHEATER CONTROL SYSTEM) ........................... 20-464
ERROR CODE [C423L6] (ABNORMALITY IN IN-RANGE OF TIMING RAIL PRESSURE SENSOR SYSTEM)
20-466
ERROR CODE [C441KK] (ABNORMALLY LOW LEVEL IN BATTERY VOLTAGE SYSTEM) ............. 20-468
ERROR CODE [C442KG] (ABNORMALLY HIGH LEVEL IN BATTERY VOLTAGE SYSTEM) ............ 20-468
ERROR CODE [C451KX] (ABNORMALLY HIGH LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM)
20-469
ERROR CODE [C452KX] (ABNORMALLY LOW LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM)
20-470
ERROR CODE [C455KZ] (ABNORMAL CURRENT OF FUEL RAIL ACTUATOR) .............................. 20-471
ERROR CODE [C467LK] (ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL) ...................... 20-472
ERROR CODE [C468LK] (ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL) .......................... 20-472
ERROR CODE [C514LK] (ABNORMALITY IN FUEL RAIL ACTUATOR) ............................................ 20-473
ERROR CODE [C554L6] (ABNORMALITY IN IN-RANGE OF FUEL RAIL PRESSURE SENSOR SYSTEM)
20-474
ERROR CODE [D110KA] (DISCONNECTION IN BATTERY RELAY SYSTEM) .................................. 20-476
ERROR CODE [D110KB] (SHORT CIRCUIT IN BATTERY RELAY SYSTEM) .................................... 20-477
ERROR CODE [D130KA] (DISCONNECTION IN NEUTRAL SAFETY RELAY SYSTEM) ................... 20-478
ERROR CODE [D130KB] (SHORT CIRCUIT IN NEUTRAL SAFETY RELAY SYSTEM) ..................... 20-480
ERROR CODE [D161KA] (DISCONNECTION IN BACK-UP ALARM RELAY SYSTEM) ..................... 20-482
20-402 D375A-5
TROUBLESHOOTING
ERROR CODE [D161KB] (SHORT CIRCUIT IN BACK-UP ALARM RELAY SYSTEM) ....................... 20-484
ERROR CODE [D190KA] (DISCONNECTION IN ACC SIGNAL DRIVE RELAY SYSTEM) ................ 20-486
ERROR CODE [D190KB] (SHORT CIRCUIT IN ACC SIGNAL DRIVE RELAY SYSTEM) .................. 20-487
ERROR CODE [D5ZRKA] (DISCONNECTION IN SNAP SHOT SIGNAL) ............................................ 20-488
ERROR CODE [D5ZRKB] (SHORT CIRUIT IN SNAP SHOT SIGNAL) ................................................ 20-489
ERROR CODE [DAFRKR] (DEFECTIVE OF MONITOR PANEL CAN COMMUNICATION) ................. 20-490
ERROR CODE [DAQ0KK] (ABNORMALITY IN TRANSMISSION CONTROLLER POWER SUPPLY SYSTEM)
20-492
ERROR CODE [DAQ0KT] (ABNORMALITY IN TRANSMISSION CONTROLLER ROM) ..................... 20-494
ERROR CODE [DAQ5KK] (ABNORMALITY IN TRANSMISSION CONTROLLER 5 V POWER SUPPLY
SYSTEM) ..................................................................................................... 20-496
ERROR CODE [DAQ6KK] (ABNORMALITY IN TRANSMISSION CONTROLLER 24 V POWER SUPPLY
SYSTEM) ..................................................................................................... 20-498
ERROR CODE [DAQ9KQ] (ABNORMALITY IN SELECTION OF TRANSMISSION CONTROLLER
SPECIFICATION) 20- 499
ERROR CODE [DAQRKR] (DEFECTIVE OF TRANSMISSION CONTROLLER CAN COMMUNICATION
(ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM)) ...................... 20-500
ERROR CODE [DAQSKR] (DEFECTIVE OF TRANSMISSION CONTROLLER S-NET COMMUNICATION
ERROR CODE [DB30KK] (ABNORMALITY IN STEERING CONTROLLER POWER SUPPLY SYSTEM)
20-504
ERROR CODE [DB30KT] (ABNORMALITY IN STEERING CONTROLLER ROM) .............................. 20-506
ERROR CODE [DB35KK] (ABNORMALITY IN STEERING CONTROLLER 5 V POWER SUPPLY SYSTEM)
20-508
ERROR CODE [DB36KK] (ABNORMALITY IN STEERING CONTROLLER 24 V POWER SUPPLY SYSTEM)
20-510
ERROR CODE [DB39KQ] (ABNORMALITY IN SELECTION OF STEERING CONTROLLER
SPECIFICATION) ........................................................................................ 20- 511
ERROR CODE [DB3RKR] (DEFECTIVE OF STEERING CONTROLLER CAN COMMUNICATION
ERROR CODE [DB3SKR] [ABNORMALITY IN NETWORK SYSTEM (STEERING)] ........................... 20-514
ERROR CODE [DBBRKR] (ABNORMALITY IN J1939 COMMUNICATION SYSTEM) ......................... 20-515
ERROR CODE [DD12KA] (DISCONNECTION IN SHIFT-UP SWITCH SYSTEMS) ............................. 20-516
ERROR CODE [DD12KB] (SHORT CIRCUIT IN SHIFT-UP SWITCH SYSTEMS) ............................... 20-518
ERROR CODE [DD13KA] (DISCONNECTION IN SHIFT-DOWN SWITCH SYSTEMS) ...................... 20-520
ERROR CODE [DD13KB] (SHORT CIRCUIT IN SHIFT-DOWN SWITCH SYSTEMS) ........................ 20-522
ERROR CODE [DD14KA] (DISCONNECTION IN PARKING BRAKE LEVER SWITCH SYSTEMS) ... 20-524
ERROR CODE [DD14KB] (SHORT CIRCUIT IN PARKING BRAKE LEVER SWITCH SYSTEMS) ..... 20-526
ERROR CODE [DD59KA] (DISCONNECTION IN BLADE DUAL SELECTOR SOLENOID SYSTEM) 20-528
ERROR CODE [DD59KB] (SHORT CIRCUIT IN BLADE DUAL SELECTOR SOLENOID SYSTEM) .. 20-529
ERROR CODE [DD5AKA] (DISCONNECTION IN BLADE PITCH SELECTOR SOLENOID SYSTEM) 20-530
ERROR CODE [DD5AKB] (SHORT CIRCUIT IN BLADE PITCH SELECTOR SOLENOID SYSTEM) . 20-531
ERROR CODE [DDN2LD] (SHORT CIRCUIT IN BLADE TILT RIGHT OIL PRESSURE SWITCH SYSTEM)
20-532
ERROR CODE [DDN3LD] (SHORT CIRCUIT IN BLADE TILT LEFT OIL PRESSURE SWITCH SYSTEM)
20-533
ERROR CODE [DDN7KA] (DISCONNECTION IN BLADE PITCH SWITCH SYSTEMS) ...................... 20-534
ERROR CODE [DDN7KB] (SHORT CIRCUIT IN BLADE PITCH SWITCH SYSTEMS) ........................ 20-536
ERROR CODE [DDN9KA] (DISCONNECTION IN BLADE TILT SWITCH SYSTEMS) ......................... 20-538
ERROR CODE [DDN9KB] (SHORT CIRCUIT IN BLADE TILT SWITCH SYSTEMS) ........................... 20-540
ERROR CODE [DDN1LD] (BLADE LIFT RAISE FULL OIL PRESSURE SWITCH: REFER TO TABLE (LD))
20-542
ERROR CODE [DDNALD] (ABNORMALITY IN BLADE LIFT RAISE FULL OIL PRESSURE SWITCH)
20-543
ERROR CODE [DDNBLD] (SHORT CIRCUIT IN RIPPER LIFT RAISE OIL PRESSURE SWITCH SYSTEM)
20-544
D375A-5 20-403
TROUBLESHOOTING
ERROR CODE [DDNCLD] (SHORT CIRCUIT IN RIPPER LIFT LOWER OIL PRESSURE SWITCH SYSTEM)
20-545
ERROR CODE [DDNDLD] (SHORT CIRCUIT IN RIPPER TILT-IN OIL PRESSURE SWITCH SYSTEM)
20-546
ERROR CODE [DDNELD] (ABNORMALITY IN RIPPER TILT BACK OIL PRESSURE SWITCH) ........ 20-547
ERROR CODE [DDNFLD] (ABNORMALITY IN BLADE LIFT LOWER FULL OIL PRESSURE SWITCH)
20-548
ERROR CODE [DDQ2KA] (DISCONNECTION IN PARKING BRAKE LEVER SWITCH SYSTEMS) .... 20-550
ERROR CODE [DDQ2KB] (SHORT CIRCUIT IN PARKING BRAKE LEVER SWITCH SYSTEMS) ...... 20-552
ERROR CODE [dDQ2L4] (DISAGREEMENT OF PARKING BRAKE LEVER SWITCH SYSTEM SIGNALS)
20-554
ERROR CODE [DDQ2L4] (DISAGREEMENT OF PARKING BRAKE LEVER SWITCH SYSTEM SIGNALS)
20-555
ERROR CODE [DGS1KX] (DEFECTIVE OF HYDRAULIC OIL TEMPERATURE SENSOR) ................ 20-556
ERROR CODE [DH22KA] (DISCONNECTION IN FRONT PUMP OIL PRESSURE SENSOR SYSTEM)
20-557
ERROR CODE [DH22KB] (SHORT CIRCUIT IN FRONT PUMP OIL PRESSURE SENSOR SYSTEM)
20-558
ERROR CODE [DH23KA] (DISCONNECTION IN CENTER PUMP OIL PRESSURE SENSOR SYSTEM)
20-559
ERROR CODE [DH23KB] (SHORT CIRCUIT IN CENTER PUMP OIL PRESSURE SENSOR SYSTEM)
20-560
ERROR CODE [DK10KA] (DISCONNECTION IN FUEL CONTROL DIAL SYSTEM) .......................... 20-561
ERROR CODE [DK10KB] (SHORT CIRCUIT IN FUEL CONTROL DIAL SYSTEM) ............................ 20-562
ERROR CODE [DK30KA] (DISCONNECTION IN STEERING POTENTIOMETER 1 SYSTEM) .......... 20-564
ERROR CODE [DK30KB] (SHORT CIRCUIT IN STEERING POTENTIOMETER 1 SYSTEM) ............ 20-566
ERROR CODE [DK30KX] [ABNORMALITY IN BOTH STEERING POTENTIOMETER SYSTEMS (1)]
20-567
ERROR CODE [DK30KZ] [ABNORMALITY IN BOTH STEERING POTENTIOMETER SYSTEMS (2)]
20-567
ERROR CODE [DK30L8] (DEVIATION OF STEERING POTENTIOMETER SYSTEM SIGNALS) ...... 20-568
ERROR CODE [DK31KA] (DISCONNECTION IN STEERING POTENTIOMETER 2 SYSTEM) .......... 20-569
ERROR CODE [DK31KB] (SHORT CIRCUIT IN STEERING POTENTIOMETER 2 SYSTEM) ............ 20-570
ERROR CODE [DK40KA] (DISCONNECTION IN BRAKE POTENTIOMETER SYSTEM) ................... 20-572
ERROR CODE [DK40KB] (SHORT CIRCUIT IN BRAKE POTENTIOMETER SYSTEM) ..................... 20-574
ERROR CODE [DK55KX] (FORWARD-REVERSE POTENTIOMETER INPUT SIGNAL IS OUT OF NORMAL
RANGE) ....................................................................................................... 20-575
ERROR CODE [DK55KZ] (DISCONNECTION OR SHORT CIRCUIT IN FORWARD-REVERSE
POTENTIOMETER) ..................................................................................... 20-575
ERROR CODE [DK55L8] (DISCREPANCY OF FORWARD-REVERSE POTENTIOMETER) ............. 20-576
ERROR CODE [DK56KA] (DISCONNECTION IN FORWARD-REVERSE POTENTIOMETER 1) ....... 20-577
ERROR CODE [DK56KB] (SHORT CIRCUIT IN FORWARD-REVERSE POTENTIOMETER 1) ......... 20-578
ERROR CODE [DK57KA] (DISCONNECTION IN FORWARD-REVERSE POTENTIOMETER 2 SYSTEM)
20-580
ERROR CODE [DK57KB] (SHORT CIRCUIT IN FORWARD-REVERSE POTENTIOMETER 2 SYSTEM)
20-582
ERROR CODE [DK60KA] (DISCONNECTION IN ACCELERATION SENSOR SYSTEM) ................... 20-583
ERROR CODE [DK60KB] (SHORT CIRCUIT IN ACCELERATION SENSOR SYSTEM) ..................... 20-584
ERROR CODE [DKH1KA] (DISCONNECTION IN PITCH ANGLE SENSOR SYSTEM) ....................... 20-586
ERROR CODE [DKH1KB] (SHORT CIRCUIT IN PITCH ANGLE SENSOR SYSTEM) ......................... 20-588
ERROR CODE [DKH1KX] (DISCONNECTION OR SHORT CIRCUIT IN PITCH ANGLE SENSOR SYSTEM)
20-589
ERROR CODE [dLE1KA] (DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) .................... 20-590
ERROR CODE [DLE1KA] (DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) .................... 20-591
ERROR CODE [DLF1KA] (DISCONNECTION IN TORQUE CONVERTER OUTPUT SPEED SENSOR)
20-592
ERROR CODE [dLT3KA] (DISCONNECTION IN TRANSMISSION SPEED SENSOR SYSTEM) ...... 20-594
20-404 D375A-5
TROUBLESHOOTING
ERROR CODE [DLT3KA] (DISCONNECTION IN TRANSMISSION SPEED SENSOR SYSTEM) ...... 20-596
ERROR CODE [DV00KB] (SHORT CIRCUIT IN CAUTION BUZZER) ................................................. 20-598
ERROR CODE [DWN3KA] (DISCONNECTION IN SUDDEN STOP PREVENTION SOLENOID SYSTEM)
20-599
ERROR CODE [DWN3KB] (SHORT CIRCUIT IN SUDDEN STOP PREVENTION SOLENOID SYSTEM)
20-600
ERROR CODE [DXH1KA] (DISCONNECTION IN TORQUE CONVERTER LOCK-UP SOLENOID SYSTEM)
20-601
ERROR CODE [DXH1KB] (SHORT CIRCUIT IN TORQUE CONVERTER LOCK-UP SOLENOID SYSTEM)
20-602
ERROR CODE [DXH4KA] (DISCONNECTION IN TRANSMISSION 1ST CLUTCH ECMV (E-POCV)
SYSTEM) 20- 603
ERROR CODE [DXH4KB] (SHORT CIRCUIT IN TRANSMISSION 1ST CLUTCH ECMV (E-POCV) SYSTEM)
20-604
ERROR CODE [DXH5KA] (DISCONNECTION IN TRANSMISSION 2ND CLUTCH ECMV (E-POCV)
SYSTEM) 20- 605
ERROR CODE [DXH5KB] (SHORT CIRCUIT IN TRANSMISSION 2ND CLUTCH ECMV (E-POCV) SYSTEM)
20-606
ERROR CODE [DXH6KA] (DISCONNECTION IN TRANSMISSION 3RD CLUTCH ECMV (E-POCV)
SYSTEM) 20- 607
ERROR CODE [DXH6KB] (SHORT CIRCUIT IN TRANSMISSION 3RD CLUTCH ECMV (E-POCV) SYSTEM)
20-608
ERROR CODE [DXH7KA] (DISCONNECTION IN TRANSMISSION REVERSE CLUTCH ECMV (E-POCV)
SYSTEM) 20- 609
ERROR CODE [DXH7KB] (SHORT CIRCUIT IN TRANSMISSION REVERSE CLUTCH ECMV (E-POCV)
SYSTEM) 20- 610
ERROR CODE [DXH8KA] (DISCONNECTION IN TRANSMISSION FORWARD CLUTCH ECMV (E-POCV)
SYSTEM) 20- 611
ERROR CODE [DXH8KB] (SHORT CIRCUIT IN TRANSMISSION FORWARD CLUTCH ECMV (E-POCV)
SYSTEM) 20- 612
ERROR CODE [DXH9KA] (DISCONNECTION IN RIGHT STEERING CLUTCH ECMV (E-POCV) SYSTEM)
20-613
ERROR CODE [DXH9KB] (SHORT CIRCUIT IN RIGHT STEERING CLUTCH ECMV (E-POCV) SYSTEM)
20-614
ERROR CODE [DXHAKA] (DISCONNECTION IN LEFT STEERING CLUTCH ECMV (E-POCV) SYSTEM)
20-615
ERROR CODE [DXHAKB] (SHORT CIRCUIT IN LEFT STEERING CLUTCH ECMV (E-POCV) SYSTEM)
20-616
ERROR CODE [DXHBKA] (DISCONNECTION IN RIGHT STEERING BRAKE ECMV (E-POCV) SYSTEM)
20-617
ERROR CODE [DXHBKB] (SHORT CIRCUIT IN RIGHT STEERING BRAKE ECMV (E-POCV) SYSTEM)
20-618
ERROR CODE [DXHCKA] (DISCONNECTION IN LEFT STEERING BRAKE ECMV (E-POCV) SYSTEM)
20-619
ERROR CODE [DXHCKB] (SHORT CIRCUIT IN LEFT STEERING BRAKE ECMV (E-POCV) SYSTEM)
20-620
D375A-5 20-405
TROUBLESHOOTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
a The troubleshooting list and related circuit diagram summarize the following information. Understand their
contents well to advance troubleshooting.
Action code Error code

Trouble Trouble that appeared on machine
Panel display Panel display
Contents of
State where the monitor panel or controller detects the trouble
trouble
Action of
Action to be taken to protect the system and equipment when the monitor panel or controller detects a
monitor panel or
trouble
controller
Problem that
Problem that appears as an abnormality in the main unit by the action taken by the monitor panel or con-
appears on
troller (above)
machine
Related
Information related to a detected trouble or troubleshooting
information
Cause Standard value in normal state/Remarks on troubleshooting

<Described contents>
Standard value in normal state required to judge the assumed
cause (good or not)
1 Remarks required to judge whether the cause is good
<Phenomenon of defective harness>

Disconnection in wiring
The connector connection is defective or the wiring harness is dis-
connected.
2 Grounding fault
A harness not connected to the ground (earth) circuit comes into
contact with the ground (earth) circuit.
Defective hot short
A harness not connected to the power (24V) circuit comes into con-
Possible causes tact with the power (24V) circuit.
Cause by which a trouble
and standard Defective short
is assumed to be detected
value in normal 3 A harness of an independent circuit abnormally comes into contact
(The order number indi-
state with one of another circuit.
cates a serial number, not
a priority sequence.)
<Notes on troubleshooting>
1) Method of indicating connector numbers and handling T-junction
For troubleshooting, insert or connect the T-junction adapter as
shown below unless especially specified.
4 When male or female is not indicated for a connector number,
disconnect the connector, and insert the T-junction adapter in both
the male and female.
When male or female is indicated for a connector number, dis-
connect the connector, and insert the T-junction adapter in only ei-
ther the male or female.
2) Pin number description sequence and tester lead handling
5 For troubleshooting, connect the plus (+) and minus () leads as
shown below unless especially specified.
Connect the plus (+) lead to a pin or harness indicated in the front.
Connect the minus () lead to a pin or harness indicated in the rear.
20-406 D375A-5
TROUBLESHOOTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Related circuit diagram
This is the excerpted circuit diagram related to trouble

Connector No.: Indicates (Model-No. of pins) (Color).
Arrow ( ): Roughly indicates mounting place on machine.
TROUBLE CODE TABLE

a Regarding trouble code provided with instruction Refer to table, check it against table below.
Trouble Trouble
Detail of trouble Detail of trouble
code code
AL Air leakage L4 ON and OFF signals do not agree
KA Disconnection L6 Run and stop of engine do not agree with signals
KB Short circuit L8 Analog signals do not agree
KK Lowing of source voltage (input) LC Revolving speed signals do not agree
KM Mistake in operation or setting LD Switch is pressed for long time
KP Lowering of output voltage LH Command current is ON and fill signal is OFF
KQ Disagreement of model selection signals Feedback signal does not agree with output
LK
Defective communication signal
KR
(Objective component abnormality) NR Abnormal heating
KT Internal defect of controller NX Clogging
KX Out of input signal range MA Malfunction
KY Short circuit with power source line MB Lowering of function
KZ Disconnection or short circuit MW Slip
L0 Double engagement NS Overheating
L1 Command current is OFF and fill signal is ON ZG Lowering of oil pressure
L2 Fuel pressure is too high ZK Lowering of level
L3 Uncontrollability ZL Overpressure
D375A-5 20-407
TROUBLESHOOTING ERROR CODE [1500LO] (TRANSMISSION CLUTCH DOUBLE ERROR)
ERROR CODE [1500LO] (TRANSMISSION CLUTCH DOUBLE ERROR)
Action code Error code Transmission clutch double error (Connection error)
Trouble (Disconnection error)
CALL03 1500LO (Transmission controller system)
Of the error codes related to the transmission clutch, the following codes were displayed at the same
time. (Connection error)
(1) Either [DXH4KA] or [DXH4KB] and either [DXH5KA] or [DXH5KB]
Of the error codes related to the transmission clutch, the following codes were displayed at the same
time. (Disconnection error)
(2) Either [DXH8KA] or [DXH8KB] and either [DXH7KA] or [DXH7KB]
Contents of trouble (3) [DXH6KA] and [DXH6KB]
(4) [15SFL1] and [15SGL1]
(5) [15SAL1] and [15SBL1]
(6) [15SELH], [15SFLH] and [15SGLH]
(7) [15SEL1] and [15SFL1]
(8) [15SEL1] and [15SGL1]
(9) [15SFL1] and [15SGL1]
Flashed caution lamp and turns on caution busser.
Action of controller
Limits operation of engine and tansmission.
The auto shift down function does not start.
Problem that Once machine is stopped, engine speed is limited to medium (half).
appears on machine Once machine is stopped, running is limited to F3 and R3.
Once machine is stopped, it cannot travel any more.
Related information Method of reproducing error code: Engine start + Run
Possible causes Confirm the error codes displayed at the same time, then carry out troubleshooting for the codes.
and standard val- [15SAL1], [15SALH], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1], [15SFLH], [15SGL1],
ue in normal state 1 [15SGLH]
[DXH4KA], [DXH4KB], [DXH5KA], [DXH5KB], [DXH6KA], [DXH6KB], [DXH7KA], [DXH7KB],
[DXH8KA], [DXH8KB]
20-408 D375A-5
ERROR CODE [15SAL1] (DEFECTIVE DISENGAGEMENT OF TRANSMISSION
TROUBLESHOOTING FORWARD CLUTCH)
ERROR CODE [15SAL1] (DEFECTIVE DISENGAGEMENT OF TRANSMISSION FORWARD

CLUTCH)
Action code Error code Defective disengagement of transmission forward clutch

Trouble
CALL E03 15SAL1 (Transmission controller system)
When outputting of signal to transmission forward clutch solenoid circuit is stopped, fill switch signal
Contents of trouble
is not turned OFF.
Flashes caution lamp and turns on caution buzzer.
Action of controller Judges that transmission is in N (Neutral) when it is set in reverse position.
Limits operation of engine and transmission.
appears on machine Once machine is stopped, travel is limited to F1.
Inputting from forward clutch fill switch (ONOFF) can be checked in monitoring mode.
(Code 31520: Transmission fill switch input)
Related information Method of reproducing error code: Start engine and set transmission in neutral.
When troubleshooting by operating clutch, set system in adjustment mode (Code: 5535) so that ma-
chine will not start.

aPrepare with starting switch OFF, then start engine and carry out
troubleshooting.
Defective forward clutch fill
1 switch FFT (male) PCCS lever Resistance
(Internal short circuit) Between (1) chassis N Min. 1 M
ground F (Forward) Max. 1
aPrepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis without turning starting switch ON.
Possible causes
2 ground in wiring harness Short circuit of wiring harness between
and standard val- Max.
(Contact with ground circuit) TMCN1 (female) (5) FFT (female) (1) with Resistance
ue in normal state 1 M
chassis ground
troubleshooting.
Defective transmission con- TMCN1 PCCS lever Voltage
3
troller
Between (5) chassis N 20 30 V
ground F (Forward) Max. 1 V
If electric system does not have abnormality, hydraulic system may
4 Defective hydraulic system
have. Carry out related troubleshooting (H-mode).
Circuit diagram related to transmission forward clutch ECMV (E-POCV)
D375A-5 20-409
ERROR CODE [15SALH] (DEFECTIVE ENGAGEMENT OF TRANSMISSION FORWARD
TROUBLESHOOTING CLUTCH)
ERROR CODE [15SALH] (DEFECTIVE ENGAGEMENT OF TRANSMISSION FORWARD

CLUTCH)
Action code Error code Defective engagement of transmission forward clutch

Trouble
CALL E03 15SALH (Transmission controller system)
When signal is output to transmission forward clutch solenoid circuit, fill switch signal is not turned
Contents of trouble
ON.
Action of controller Judges that transmission is in N (Neutral) when it is set in forward position.
appears on machine Once machine is stopped, travel is limited to R1.
Inputting from forward clutch fill switch (ONOFF) can be checked in monitoring mode.
Related information Method of reproducing error code: Start engine and drive forward.

troubleshooting.
Defective forward clutch fill
1 switch FFT (male) PCCS lever Resistance
ground F (Forward) Max. 1
Disconnection in wiring har- aPrepare with starting switch OFF, then carry out troubleshooting
Possible causes ness without turning starting switch ON.
2
and standard val- (Disconnection in wiring or de- Wiring harness between TMCN1 (female) (5)
ue in normal state fective contact in connector) FFT (female) (1) Resistance Max. 1
troubleshooting.
3
troller
Between (5) chassis N 5 11 V
ground F (Forward) Max. 1 V
20-410 D375A-5
ERROR CODE [15SBL1] (DEFECTIVE DISENGAGEMENT OF TRANSMISSION
TROUBLESHOOTING REVERSE CLUTCH)
ERROR CODE [15SBL1] (DEFECTIVE DISENGAGEMENT OF TRANSMISSION REVERSE

CLUTCH)
Action code Error code Defective disengagement of transmission reverse clutch

Trouble
CALL E03 15SBL1 (Transmission controller system)
When outputting of signal to transmission reverse clutch solenoid circuit is stopped, fill switch signal
Contents of trouble
is not turned OFF.
Action of controller Judges that transmission is in N (Neutral) when it is set in forward position.
Inputting from reverse clutch fill switch (ONOFF) can be checked in monitoring mode.
When troubleshooting by operating clutch, set system in adjustment mode (Code: 55355) so that
machine will not start.

troubleshooting.
Defective reverse clutch fill
1 switch FRT (male) PCCS lever Resistance
ground R (Reverse) Max. 1
Possible causes
and standard val-
(Contact with ground circuit) TMCN1 (female) (24) FRT (female) (1) with Resistance Max. 1
ue in normal state
chassis ground
troubleshooting.
3
troller
Between (24) N 5 11 V
chassis ground R (Reverse) Max. 1 V
Circuit diagram related to transmission reverse clutch ECMV (E-POCV)
D375A-5 20-411
ERROR CODE [15SBLH] (DEFECTIVE ENGAGEMENT OF TRANSMISSION REVERSE
ERROR CODE [15SBLH] (DEFECTIVE ENGAGEMENT OF TRANSMISSION REVERSE

CLUTCH)
Action code Error code Defective engagement of transmission reverse clutch

Trouble
CALL E03 15SBLH (Transmission controller system)
When signal is output to transmission reverse clutch solenoid circuit, fill switch signal is not turned
Contents of trouble
ON.
Action of controller Judges that transmission is in N (Neutral) when it is set in reverse position.
Inputting from reverse clutch fill switch (ONOFF) can be checked in monitoring mode.
Related information Method of reproducing error code: Start engine and drive in reverse.

troubleshooting.
Defective reverse clutch fill
1 switch FRT (male) PCCS lever Resistance
ground R (Reverse) Max. 1
2
ue in normal state fective contact in connector) FRT (female) (1) Resistance Max. 1
troubleshooting.
3
troller
chassis ground R (Reverse) Max. 1 V
20-412 D375A-5
ERROR CODE [15SELH] (DEFECTIVE DISENGAGEMENT OF TRANSMISSION 1ST
ERROR CODE [15SELH] (DEFECTIVE DISENGAGEMENT OF TRANSMISSION 1ST

CLUTCH)
Action code Error code Defective disengagement of transmission 1st clutch

Trouble
CALL E03 15SELH (Transmission controller system)
When outputting of signal to transmission 1st clutch solenoid circuit is stopped, fill switch signal is not
Contents of trouble
turned OFF.
appears on machine Once machine is stopped, travel is limited to F1 and R1.
Inputting from 1st clutch fill switch (ONOFF) can be checked in monitoring mode.

troubleshooting.
Defective 1st clutch fill
1 switch F1T (male) PCCS lever Resistance
(Internal short circuit) Between (1) chassis Other than F1R1 Min. 1 M
ground F1R1 Max. 1
Possible causes
and standard val-
(Contact with ground circuit) TMCN1 (female) (23) F1T (female) (1) with Resistance Min. 1 M
ue in normal state
chassis ground
troubleshooting.
3
troller
Between (23) Other than F1R1 5 11 V
chassis ground F1R1 Max. 1 V
Circuit diagram related to transmission 1st clutch ECMV (E-POCV)
D375A-5 20-413
ERROR CODE [15SELH] (DEFECTIVE ENGAGEMENT OF TRANSMISSION 1ST
ERROR CODE [15SELH] (DEFECTIVE ENGAGEMENT OF TRANSMISSION 1ST CLUTCH)
Action code Error code Defective engagement of transmission 1st clutch

Trouble
CALL E03 15SELH (Transmission controller system)
Contents of trouble When signal is output to transmission 1st clutch solenoid circuit, fill switch signal is not turned ON.
Auto shift-down function does not work.
Problem that
Once machine is stopped, engine speed is limited to medium (half).
appears on machine
Once machine is stopped, travel is limited to F2 and R2.
Inputting from 1st clutch fill switch (ONOFF) can be checked in monitoring mode.
Related information Method of reproducing error code: Start engine and drive in F1 or R1.

troubleshooting.
Defective 1st clutch fill
ground F1R1 Max. 1
2
ue in normal state fective contact in connector) F1T (female) (1) Resistance Max. 1
troubleshooting.
3
troller
20-414 D375A-5
ERROR CODE [15SFL1] (DEFECTIVE DISENGAGEMENT OF TRANSMISSION 2ND
ERROR CODE [15SFL1] (DEFECTIVE DISENGAGEMENT OF TRANSMISSION 2ND

CLUTCH)
Action code Error code Defective disengagement of transmission 2nd clutch

Trouble
CALL E03 15SFL1 (Transmission controller system)
When outputting of signal to transmission 2nd clutch solenoid circuit is stopped, fill switch signal is
Contents of trouble
not turned OFF.
Problem that
appears on machine
Inputting from 2nd clutch fill switch (ONOFF) can be checked in monitoring mode.

troubleshooting.
Defective 2nd clutch fill
ground F2R2 Max. 1
Possible causes
(Contact with ground circuit) TMCN1 (female) (17) F2T (female) (1) with Resistance
chassis ground
troubleshooting.
3
troller
Circuit diagram related to transmission 2nd clutch ECMV (E-POCV)
D375A-5 20-415
ERROR CODE [15SFLH] (DEFECTIVE ENGAGEMENT OF TRANSMISSION 2ND
ERROR CODE [15SFLH] (DEFECTIVE ENGAGEMENT OF TRANSMISSION 2ND CLUTCH)
Action code Error code Defective engagement of transmission 2nd clutch

Trouble
CALL E03 15SFLH (Transmission controller system)
Contents of trouble When signal is output to transmission 2nd clutch solenoid circuit, fill switch signal is not turned ON.
Inputting from 2nd clutch fill switch (ONOFF) can be checked in monitoring mode.

troubleshooting.
Defective 2nd clutch fill
ground F2R2 Max. 1
2
troubleshooting.
3
troller
20-416 D375A-5
ERROR CODE [15SGL1] (DEFECTIVE DISENGAGEMENT OF TRANSMISSION 3RD
ERROR CODE [15SGL1] (DEFECTIVE DISENGAGEMENT OF TRANSMISSION 3RD

CLUTCH)
Action code Error code Defective disengagement of transmission 3rd clutch

Trouble
CALL E03 15SGL1 (Transmission controller system)
When outputting of signal to transmission 3rd clutch solenoid circuit is stopped, fill switch signal is not
Contents of trouble
turned OFF.
Problem that
appears on machine
Inputting from 3rd clutch fill switch (ONOFF) can be checked in monitoring mode.

troubleshooting.
Defective 3rd clutch fill
ground F3R3 Max. 1
Possible causes
and standard val-
(Contact with ground circuit) TMCN1 (female) (11) F3T (female) (1) with Resistance Max. 1
ue in normal state
chassis ground
troubleshooting.
3
troller
Circuit diagram related to transmission 3rd clutch ECMV (E-POCV)
D375A-5 20-417
ERROR CODE [15SGLH] (DEFECTIVE ENGAGEMENT OF TRANSMISSION 3RD
ERROR CODE [15SGLH] (DEFECTIVE ENGAGEMENT OF TRANSMISSION 3RD CLUTCH)
Action code Error code Defective engagement of transmission 3rd clutch

Trouble
CALL E03 15SGLH (Transmission controller system)
Contents of trouble When signal is output to transmission 3rd clutch solenoid circuit, fill switch signal is not turned ON.
Inputting from 3rd clutch fill switch (ONOFF) can be checked in monitoring mode.

troubleshooting.
Defective 3rd clutch fill
ground F3R3 Max. 1
2
troubleshooting.
3
troller
20-418 D375A-5
TROUBLESHOOTING ERROR CODE [1800MW] (SLIP OF POWER TRAIN CLUTCH)
ERROR CODE [1800MW] (SLIP OF POWER TRAIN CLUTCH)
Action code Error code Slip of power train clutch

Trouble
E02 1800MW (Transmission controller system)
When torque converter is locked up, transmission speed calculated from engine speed is different
Contents of trouble
more than 200 rpm from real speed.
Action of controller Flashes caution lamp and turns on caution buzzer.
Problem that
appears on machine
Engine speed (rpm) and transmission speed (rpm) can be checked in monitoring mode.
(Code 01002: Engine speed A, Code 01004: Engine speed B Code 31400: Transmission speed)
Related information Method of reproducing error code: Start engine, turn lock-up switch ON, and drive machine.
chine will not start traveling.

Slip of power train clutch Since slip of clutch is detected, check cause and damage of machine
1
(When system is normal) and repair.
Defective engine speed sen- See if error codes [C121LC], [DLE1KA], and [dLE1KA] are displayed.
Possible causes 2
sor system If they are displayed, carry out troubleshooting for them.
and standard val-
ue in normal state Defective transmission See if error codes [dLT3KA] and [DLT3KA] are displayed. If they are
3
speed sensor system displayed, carry out troubleshooting for them.
Since trouble is in system, troubleshooting cannot be carried out.
Defective transmission con-
4 (If there is not visible trouble in machine, controller may be used as it
troller
is.)
D375A-5 20-419
ERROR CODE [2201L1] (DEFECTIVE DISENGAGEMENT OF RIGHT STEERING
ERROR CODE [2201L1] (DEFECTIVE DISENGAGEMENT OF RIGHT STEERING CLUTCH)
User code Error code Defective disengagement of right steering clutch

Trouble
CALL E04 2201L1 (Steering controller system)
When outputting of signal to right steering clutch solenoid circuit is stopped, fill switch signal is not
Contents of trouble
turned OFF.
Limits operation of engine, transmission, and brake.
appears on machine Once machine is stopped, it cannot travel any more.
Inputting from right steering clutch fill switch (ONOFF) can be checked in monitoring mode.
(Code 31521: Steering fill switch input)
Related information
Method of reproducing error code:
Start engine, release parking brake lever, and operate PCCS lever (to steer to right).

troubleshooting.
Defective right steering
1 clutch fill switch FRC (male) PCCS lever Resistance
ground Right steering Max. 1
Possible causes
(Contact with ground circuit) NGICN3 (female) (39) FRC (female) (1) with Resistance
chassis ground
troubleshooting.
3 Defective steering controller NGICN3 PCCS lever Voltage
chassis ground Right steering Max. 1 V
Circuit diagram related to right steering clutch ECMV (E-POCV)
20-420 D375A-5
TROUBLESHOOTING ERROR CODE [2201LH] (DEFECTIVE ENGAGEMENT OF RIGHT STEERING CLUTCH)
ERROR CODE [2201LH] (DEFECTIVE ENGAGEMENT OF RIGHT STEERING CLUTCH)
User code Error code Defective engagement of right steering clutch

Trouble
CALL E04 2201LH (Steering controller system)
Contents of trouble When signal is output to right steering clutch solenoid circuit, fill switch signal is not turned ON.
Inputting from right steering clutch fill switch (ONOFF) can be checked in monitoring mode.
Related information (Code 31521: Steering fill switch input)
Method of reproducing error code: Start engine.

troubleshooting.
1 clutch fill switch FRC (male) PCCS lever Resistance
2
and standard val- (Disconnection in wiring or de- Wiring harness between NGICN3 (female)
ue in normal state fective contact in connector) (39) FRC (female) (1) Resistance Max. 1
troubleshooting.
D375A-5 20-421
ERROR CODE [2202L1] (DEFECTIVE DISENGAGEMENT OF LEFT STEERING
ERROR CODE [2202L1] (DEFECTIVE DISENGAGEMENT OF LEFT STEERING CLUTCH)
User code Error code Defective disengagement of left steering clutch

Trouble
When outputting of signal to left steering clutch solenoid circuit is stopped, fill switch signal is not
Contents of trouble
turned OFF.
Inputting from left steering clutch fill switch (ONOFF) can be checked in monitoring mode.
(Code 31521: Steering fill switch input)
Related information
Start engine, release parking brake lever, and operate PCCS lever (to steer to left).

troubleshooting.
Defective left steering clutch
1 fill switch FLC (male) PCCS lever Resistance
(Internal short circuit) Between (1) chassis N (Neutral) Min. 1 M
ground Left steering Max. 1
Possible causes
(Contact with ground circuit) NGICN3 (female) (29) FLC (female) (1) with Resistance
chassis ground
troubleshooting.
Between (29) N (Neutral) 5 11 V
chassis ground Left steering Max. 1 V
Circuit diagram related to left steering clutch ECMV (E-POCV)
20-422 D375A-5
TROUBLESHOOTING ERROR CODE [2202LH] (DEFECTIVE ENGAGEMENT OF LEFT STEERING CLUTCH)
ERROR CODE [2202LH] (DEFECTIVE ENGAGEMENT OF LEFT STEERING CLUTCH)
User code Error code Defective engagement of left steering clutch

Trouble
Contents of trouble When signal is output to left steering clutch solenoid circuit, fill switch signal is not turned ON.
Inputting from left steering clutch fill switch (ONOFF) can be checked in monitoring mode.

troubleshooting.
Defective left steering clutch
1 fill switch FLC (male) PCCS lever Resistance
2
and standard val- (Disconnection in wiring or de- Wiring harness between NGICN3 (female) Max.
ue in normal state fective contact in connector) (29) FLC (female) (1) Resistance
1 M
troubleshooting.
D375A-5 20-423
TROUBLESHOOTING ERROR CODE [2300NR] (BRAKE ABNORMAL HEATING)
ERROR CODE [2300NR] (BRAKE ABNORMAL HEATING)
Action code Error code Brake thermal load: abnormal heating (NR)
Trouble
2300NR (Steering controller system)
Contents of The steering controller multiplied the continuous operating times of the pitch angle sensor, travel speed
trouble sensor, and brake potentiometer, and then judged that the brake was heating abnormally.
Action of
None in particular.
controller
Problem that
appears on
machine
Related
information

Possible causes
and standard 1 Improper braking during downslope travel (Machine traveled down with brake pedal pressed)
value in normal
state 2 Defective steering controller When the operation in cause 1 is not performed
20-424 D375A-5
ERROR CODE [2301L1] (DEFECTIVE DISENGAGEMENT OF RIGHT STEERING
TROUBLESHOOTING BRAKE)
ERROR CODE [2301L1] (DEFECTIVE DISENGAGEMENT OF RIGHT STEERING BRAKE)
User code Error code Defective disengagement of right steering brake

Trouble
When outputting of signal to right steering brake solenoid circuit is stopped, fill switch signal is not
Contents of trouble
turned OFF.
Brake is kept applied lightly during travel.
Problem that
appears on machine
Inputting from right steering brake fill switch (ONOFF) can be checked in monitoring mode.
Method of reproducing error code: Start engine and release parking brake lever.

troubleshooting.
1 brake fill switch FRB (male) PCCS lever Resistance
Possible causes
and standard val-
(Contact with ground circuit) NGICN2 (female) (25) FRB (female) (1) with Resistance Max. 1
ue in normal state
chassis ground
troubleshooting.
Circuit diagram related to right steering brake ECMV (E-POCV)
D375A-5 20-425
TROUBLESHOOTING ERROR CODE [2301LH] (DEFECTIVE ENGAGEMENT OF RIGHT STEERING BRAKE)
ERROR CODE [2301LH] (DEFECTIVE ENGAGEMENT OF RIGHT STEERING BRAKE)
User code Error code Defective engagement of right steering brake

Trouble
Contents of trouble When signal is output to right steering brake solenoid circuit, fill switch signal is not turned ON.
Problem that
appears on machine
Inputting from right steering brake fill switch (ONOFF) can be checked in monitoring mode.

troubleshooting.
1 brake fill switch FRB (male) PCCS lever Resistance
2
ue in normal state fective contact in connector) (25) FRB (female) (1) Resistance Max. 1
troubleshooting.
20-426 D375A-5
TROUBLESHOOTING ERROR CODE [2301NR] (RIGHT STEERING BRAKE ABNORMAL HEATING)
ERROR CODE [2301NR] (RIGHT STEERING BRAKE ABNORMAL HEATING)
Action code Error code Right steering brake thermal load: Abnormal heating (NR)
Trouble
Contents of The steering controller multiplied the continuous operating times of the pitch angle sensor and right
trouble steering potentiometer, and then judged that the right steering brake was heating abnormally.
Action of
None in particular.
controller
Problem that
appears on
machine
Related
information

Possible causes
Improper steering during downslope travel (Machine traveled down and was steered to right continu-
and standard 1
ously)
value in normal
D375A-5 20-427
TROUBLESHOOTING ERROR CODE [2302L1] (DEFECTIVE DISENGAGEMENT OF LEFT STEERING BRAKE)
ERROR CODE [2302L1] (DEFECTIVE DISENGAGEMENT OF LEFT STEERING BRAKE)
User code Error code Defective disengagement of left steering brake

Trouble
When outputting of signal to left steering brake solenoid circuit is stopped, fill switch signal is not
Contents of trouble
turned OFF.
Problem that
appears on machine
Inputting from left steering brake fill switch (ONOFF) can be checked in monitoring mode.
Method of reproducing error code: Start engine and release parking brake lever.

troubleshooting.
Defective left steering brake
1 fill switch FLB (male) PCCS lever Resistance
Possible causes
(Contact with ground circuit) NGICN2 (female) (35) FLB (female) (1) with Resistance
chassis ground
troubleshooting.
Circuit diagram related to left steering brake ECMV (E-POCV)
20-428 D375A-5
TROUBLESHOOTING ERROR CODE [2302LH] (DEFECTIVE ENGAGEMENT OF LEFT STEERING BRAKE)
ERROR CODE [2302LH] (DEFECTIVE ENGAGEMENT OF LEFT STEERING BRAKE)
User code Error code Defective engagement of left steering brake

Trouble
Contents of trouble When signal is output to left steering brake solenoid circuit, fill switch signal is not turned ON.
Problem that
appears on machine
Inputting from left steering brake fill switch (ONOFF) can be checked in monitoring mode.

troubleshooting.
Defective left steering brake
1 fill switch FLB (male) PCCS lever Resistance
2
ue in normal state fective contact in connector) (35) FLB (female) (1) Resistance Max. 1
troubleshooting.
D375A-5 20-429
ERROR CODE [2302NR] (LEFT STEERING BRAKE ABNORMAL HEATING)
TROUBLESHOOTING ERROR CODE [2302NR] (LEFT
ERROR STEERING
CODE BRAKE
[AB00MA] ABNORMAL
(ALTERNATOR HEATING)
MALFUNCTION)
ERROR CODE [2302NR] (LEFT STEERING BRAKE ABNORMAL HEATING)
Action code Error code Left steering brake thermal load: Abnormal heating (NR)
Trouble
The steering controller multiplied the continuous operating times of the pitch angle sensor and travel
Contents of
speed sensor, and then judged that the brake was heating abnormally (The machine traveled down with
trouble
the foot brake pressed).
Action of
None in particular.
controller
Problem that
appears on
machine
Related
information

Possible causes
Improper steering during downslope travel (Machine traveled down and was steered to left continu-
and standard 1
value in normal ously)
ERROR CODE [AB00MA] (ALTERNATOR MALFUNCTION)

Trouble Alternator: Malfunction (MA) (Mechanical system)
AB00MA
Contents of
During rotation of engine, charge level caution lamp flashes.
trouble
Action of
controller
Problem that
appears on If machine is operated as it is, battery may be discharged.
machine
Related
information

Defective battery charge It is suspected that problem causing defective battery charge is occur-
Possible causes
1 (When system is in normal ring at present or occurred in past. Investigate cause and damage con-
and standard
state) dition, and correct it.
value in normal
state Carry out troubleshooting of charge level caution lamp system in accor-
Defective charge level cau-
2 dance with During running of engine, emergency caution item flashes
tion lamp system
in E mode.
20-430 D375A-5
TROUBLESHOOTING ERROR CODE [B@BAZG] (ENGINE OIL PRESSURE REDUCTION)
ERROR CODE [B@BAZG] (ENGINE OIL PRESSURE REDUCTION)

Trouble Engine oil: Oil pressure reduction (ZG) (Mechanical system)
B@BAZG
Contents of
During rotation of engine, engine oil pressure caution lamp flashes.
trouble
Action of
Turns on caution buzzer. (Function of monitor panel)
controller
Problem that
appears on If machine is operated as it is, engine may be damaged.
machine
Related
information

Engine oil pressure reduc- It is suspected that problem causing engine oil pressure reduction is
Possible causes
1 tion (When system is in nor- occurring at present or occurred in past. Investigate cause and damage
and standard
mal state) condition, and correct it.
value in normal
state Carry out troubleshooting of engine oil pressure caution lamp system in
Defective engine oil pres-
2 accordance with During running of engine, emergency caution item
sure caution lamp system
flashes in E mode.
D375A-5 20-431
ERROR CODE [B@BCNS] (RADIATOR COOLANT OVERHEAT)
TROUBLESHOOTING ERROR
ERROR CODE
CODE [B@BCNS]
[B@BCZK] (RADIATOR
(RADIATOR COOLANT
COOLANT LEVELOVERHEAT)
REDUCTION)
ERROR CODE [B@BCNS] (RADIATOR COOLANT OVERHEAT)

Trouble Radiator coolant: Overheat (NS) (Mechanical system)
B@BCNS
Contents of
During rotation of engine, engine water temperature caution lamp flashes.
trouble
Action of
controller
Problem that
machine
Related
information

Engine water temperature It is suspected that problem causing engine water temperature overheat
Possible causes
1 overheat (When system is is occurring at present or occurred in past. Investigate cause and dam-
and standard
in normal state) age condition, and correct it.
value in normal
state Defective engine water tem- Carry out troubleshooting of engine water temperature caution lamp
2 perature caution lamp sys- system in accordance with During running of engine, emergency cau-
tem tion item flashes in E mode.
ERROR CODE [B@BCZK] (RADIATOR COOLANT LEVEL REDUCTION)

Trouble Radiator coolant: Level reduction (ZK) (Mechanical system)
B@BCZK
Contents of
When turning starting switch ON, radiator coolant caution lamp flashes.
trouble
Action of
controller
Problem that
machine
Related
Method of reproducing error code: Turn starting switch ON.
information

Radiator coolant level It is suspected that problem causing radiator coolant level reduction is
Possible causes
1 reduction (When system is occurring at present or occurred in past. Investigate cause and damage
and standard
in normal state) condition, and correct it.
value in normal
state Carry out troubleshooting of radiator coolant level caution lamp system
Defective radiator coolant
2 in accordance with When turning starting switch ON, basic check item
level caution lamp system
flashes in E mode.
20-432 D375A-5
ERROR CODE [B@CENS] (POWER TRAIN OIL OVERHEAT)
TROUBLESHOOTING ERROR CODE
ERROR[B@CENS] (POWER
CODE [B@HANS] TRAIN OIL
(HYDRAULIC OILOVERHEAT)
OVERHEAT)
ERROR CODE [B@CENS] (POWER TRAIN OIL OVERHEAT)

Trouble Power train oil: Overheat (NS) (Mechanical system)
B@CENS
Contents of
During rotation of engine, power train oil temperature caution lamp flashes.
trouble
Action of
controller
Problem that
appears on If machine is operated as it is, power train may be damaged.
machine
Related
information

Power train oil temperature It is suspected that problem causing power train oil temperature over-
Possible causes
1 overheat (When system is heat is occurring at present or occurred in past. Investigate cause and
and standard
in normal state) damage condition, and correct it.
value in normal
state Defective power train oil Carry out troubleshooting of power train oil temperature caution lamp
2 temperature overheat cau- system in accordance with During running of engine, emergency cau-
tion lamp system tion item flashes in E mode.
ERROR CODE [B@HANS] (HYDRAULIC OIL OVERHEAT)

Trouble Hydraulic oil: Overheat (NS) (Mechanical system)
B@HANS
Contents of
During rotation of engine, hydraulic oil caution lamp flashes.
trouble
Action of
controller
Problem that
appears on If machine is operated as it is, work equipment circuit units may be damaged.
machine
Related
information

Hydraulic oil temperature It is suspected that problem causing hydraulic oil temperature overheat
Possible causes
1 overheat (When system is is occurring at present or occurred in past. Investigate cause and dam-
and standard
in normal state) age condition, and correct it.
value in normal
state Defective hydraulic oil tem- Carry out troubleshooting of hydraulic oil temperature caution lamp sys-
2 perature caution lamp system in accordance with During running of engine, emergency caution
tem item flashes in E mode.
D375A-5 20-433
ERROR CODE [C111KT] (ABNORMALITY IN ENGINE CONTROLLER MEMORY)
TROUBLESHOOTING ERROR CODE [C111KT] (ABNORMALITY
ERROR CODE IN ENGINE IN
[C112LK] (ABNORMALITY CONTROLLER MEMORY)
TIMING RAIL ACTUATOR)
ERROR CODE [C111KT] (ABNORMALITY IN ENGINE CONTROLLER MEMORY)
User code Error code Abnormality in engine controller memory

Trouble
CALL E04 C111KT (Engine controller system)
Contents of trouble Memory in controller has trouble or processor in controller has communication trouble.
Problem that
Engine cannot be started.
appears on machine
Related information Method of reproducing error code: Turn starting switch ON.

Reset according to following procedure. If error code E is displayed at
Possible causes
this time, engine controller is defective.
and standard val-
ue in normal state 1 Defective engine controller 1)Keep starting switch at OFF position for 5 seconds.
2)Run engine at low idling.
3)Check error code.
ERROR CODE [C112LK] (ABNORMALITY IN TIMING RAIL ACTUATOR)
Action code Error code Abnormality in timing rail actuator

Trouble
CALL E04 C112LK (Engine controller system)
Displayed fuel value of timing rail is excessively different from actual timing fuel.
Contents of trouble Judgment value (for reference):
Error is above 400 mm3/st or below 750 mm3/st (When water temperature is below 0C).
Limits engine speed to 1,500 rpm.
Problem that
Engine speed lowers.
appears on machine
Related information Method of reproducing error code: Start engine.

Check displayed error codes. If code related to engine controller is
1 Defective related systems
displayed, carry out troubleshooting for it first.
Clogging, looseness, break-
Check fuel filter/piping directly for clogging, looseness, breakage, and
2 age, or leakage of fuel filter/
Possible causes leakage.
piping
and standard val-
3 Defective timing rail actuator Check timing rail actuator directly for defective operation.
ue in normal state
Clogging of timing rail actua-
4 Check timing rail actuator screen directly for clogging.
tor screen
5 Breakage of injector O-ring Check injector O-ring directly for breakage.
If causes 1 5 are not detected, engine controller may be defective.
6 Defective engine controller
(Since trouble is in system, troubleshooting cannot be carried out.)
20-434 D375A-5
ERROR CODE [C113KZ] (ABNORMAL CURRENT IN TIMING RAIL ACTUATOR
TROUBLESHOOTING SYSTEM)
ERROR CODE [C113KZ] (ABNORMAL CURRENT IN TIMING RAIL ACTUATOR SYSTEM)
User code Error code Abnormal current in timing rail actuator system
Trouble
CALL E03 C113KZ (Engine controller system)
Current in timing rail actuator is out of normal range.
Contents of trouble
Normal range (for reference): 0.40 0.35 A (When engine is stopped)
Problem that Engine output lowers.
appears on machine Exhaust gas becomes white.
Special cable (795-799-5460) is necessary for troubleshooting for timing rail actuator.
Related information
Method of reproducing error code: Turn starting switch ON (or start engine).

without turning starting switch ON.
Defective timing rail actuator TIMG (male) Resistance
1
(Internal trouble)
Between (A) (C) 79
Between (A), (C) chassis ground Min. 100 k
Disconnection in wiring har- without turning starting switch ON.
ness
Wiring harness between ECMA (female) (1)
2 (Disconnection in wiring or Resistance Max. 10
TIMG (female) (A)
defective contact in connec-
tor) Wiring harness between ECMA (female) (20)
Resistance Max. 10
TIMG (female) (C)
Possible causes
and standard val- aPrepare with starting switch OFF, then carry out troubleshooting
ue in normal state without turning starting switch ON.
Short circuit in wiring har- Short circuit of wiring harness between ECMA
ness (female) (1) TIMG (female) (A) with wiring Resistance Min. 1 M
3
(with another wiring har- harness around it
ness) Short circuit of wiring harness between ECMA
(female) (20) TIMG (female) (C) with wiring Resistance Min. 1 M
harness around it
ECMA (female) Resistance
Between (1) (20) 79
Wiring harness between (1), (20)
Min. 1 M
wiring harness around it
Circuit diagram related to timing rail actuator
D375A-5 20-435
(1)
TROUBLESHOOTING ERROR CODE [C115KZ] (ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEMS)
ERROR CODE [C115KZ] (ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEMS)
User code Error code Abnormality in engine speed sensor 2 systems

Trouble
Contents of trouble Signal is not input to either of engine speed sensor circuit 2 systems.
Outputs speed signal of 0 rpm.
Problem that
Engine stops.
appears on machine
Inputting from engine speed sensor (rpm) can be checked in monitoring mode.
(Code 01002: Engine speed)
Related information
Special cable (795-799-5520) is necessary for troubleshooting for engine speed sensor.

Defective engine speed sen- SP1 (male), SP2 (male) Resistance

1 sor Between (A) (B) 1 k 2 k
(Internal trouble) Between (A) (A) Max. 10
Between (B) (B) Max. 10
Between (A) chassis ground Min. 10 M
Damage of engine speed
2 Check engine speed sensor directly.
sensor
Disconnection in wiring har- Resistance Max. 10
SP1 (female) (A)
ness
3 (Disconnection in wiring or Wiring harness between ECMA (female) (28)
Resistance Max. 10
SP1 (female) (B)
Resistance Max. 10
SP2 (female) (A)
Resistance Max. 10
SP2 (female) (B)
Possible causes
Short circuit of wiring harness between ECMA
(female) (27) SP1 (female) (A) with wiring Resistance Min. 1 M
harness around it
ness (female) (28) SP1 (female) (B) with wiring Resistance Min. 1 M
4
(female) (37) SP2 (female) (A) with wiring Resistance Min. 1 M
harness around it
(female) (38) SP2 (female) (B) with wiring Resistance Min. 1 M
harness around it
troubleshooting.
Between (27) (28) 1 k 2 k
5 Defective engine controller Between (27), (28) chassis
Min. 1 M
ground
Between (37) (38) 1 k 2 k
Between (37), (38) chassis
Min. 1 M
ground
20-436 D375A-5
TROUBLESHOOTING ERROR CODE [C115KZ] (ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEMS)
Circuit diagram related to engine speed sensor
D375A-5 20-437
ERROR CODE [C116KZ] (ABNORMALLY HIGH LEVEL IN TIMING RAIL PRESSURE
TROUBLESHOOTING SENSOR SYSTEM)
ERROR CODE [C116KZ] (ABNORMALLY HIGH LEVEL IN TIMING RAIL PRESSURE

SENSOR SYSTEM)
User code Error code Abnormally high level in timing rail pressure sensor system
Trouble
CALL C116KZ (Engine controller system)
Contents of trouble Signal voltage of timing rail pressure sensor circuit is above 4.78 V.
Action of controller Opens and controls timing rail.
Problem that Engine makes abnormal combustion sound or discharges white smoke, then its speed is set to
appears on machine 1,500 rpm.
Special cable (795-799-5480) is necessary for troubleshooting for timing rail pressure sensor.
Related information

aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective timing rail pres-
1 sure sensor TPR Voltage
(Internal trouble) Between (A) (B) 4.75 5.25 V
Between (C) (B) 0.42 0.58 V
Disconnection in wiring har-
ness Resistance Max. 10
TPR (female) (A)
2 (Disconnection in wiring or
defective contact in connec- Wiring harness between ECMA (female) (18) Resistance Max. 10
TPR (female) (B)
tor)
Resistance Max. 10
Possible causes TPR (female) (C)
(female) (5) TPR (female) (A) with wiring Resistance Min. 1 M
Short circuit in wiring har-
harness around it
ness
3 Short circuit of wiring harness between ECMA
(with another wiring har-
(female) (18) TPR (female) (B) with wiring Resistance Min. 1 M
ness) harness around it
(female) (33) TPR (female) (C) with wiring Resistance Min. 1 M
harness around it
4 Defective engine controller ECMA Voltage
Between (5) (18) 4.75 5.25 V
Between (33) (18) 0.42 0.58 V
Circuit diagram related to engine speed sensor
20-438 D375A-5
(1)
ERROR CODE [C117KX] (ABNORMALLY LOW LEVEL IN TIMING RAIL PRESSURE
ERROR CODE [C117KX] (ABNORMALLY LOW LEVEL IN TIMING RAIL PRESSURE

SENSOR SYSTEM)
User code Error code Abnormally low level in timing rail pressure sensor system
Trouble
CALL E04 C117KX (Engine controller system)
Contents of trouble Signal voltage of timing rail pressure sensor circuit is below 0.30 V.
Action of controller Opens and controls timing rail.
Problem that Engine makes abnormal combustion sound or discharges white smoke, then its speed is set to
appears on machine 1,500 rpm.
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard val-
ue in normal state Carry out troubleshooting for error code [C116KX].
D375A-5 20-439
ERROR CODE [C118KX] (ABNORMALLY HIGH LEVEL IN FUEL PUMP PRESSURE
ERROR CODE [C118KX] (ABNORMALLY HIGH LEVEL IN FUEL PUMP PRESSURE

SENSOR SYSTEM)
User code Error code Abnormally high level in fuel pump pressure sensor system
Trouble
Contents of trouble Signal voltage of fuel pump pressure sensor circuit is above 4.78 V.
Opens and controls fuel pump.
Problem that
appears on machine
Special cable (795-799-5480) is necessary for troubleshooting for fuel pump pressure sensor.
Related information

Defective fuel pump pres- carry out troubleshooting.
1 sure sensor PMPR (male) Voltage
Between (C) (B) 0.42 0.58 V
PMPR (female) (A)
defective contact in connec- Wiring harness between ECMA (female) (18)
Resistance Max. 10
PMPR (female) (B)
tor)
Resistance Max. 10
Possible causes PMPR (female) (C)
Short circuit in wiring har- (female) (5) PMPR (female) (A) with wiring Resistance Min. 1 M
harness around it
ness
ness) (female) (18) PMPR (female) (B) with wiring Resistance Min. 1 M
harness around it
(female) (32) PMPR (female) (C) with wiring Resistance Min. 1 M
harness around it
4 Defective engine controller ECMA (female) Resistance
Between (5) (18) 4.75 5.25 V
Between (32) (18) 0.42 0.58 V
Circuit diagram related to fuel pump pressure sensor
20-440 D375A-5
(1)
ERROR CODE [C119KX] (ABNORMALLY LOW LEVEL IN FUEL PUMP PRESSURE SENSOR
ERROR CODE [C119KX] (ABNORMALLY LOW LEVEL IN FUEL PUMP PRESSURE SYSTEM)
TROUBLESHOOTING SENSOR
ERROR CODE [C121LC] (ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM)
1 SYSTEMS)
ERROR CODE [C119KX] (ABNORMALLY LOW LEVEL IN FUEL PUMP PRESSURE

SENSOR SYSTEM)
User code Error code Abnormally low level in fuel pump pressure sensor system
Trouble
Contents of trouble Signal voltage of fuel pump pressure sensor circuit is below 0.30 V.
Opens and controls fuel pump.
Problem that
appears on machine

and standard val-
ERROR CODE [C121LC] (ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEMS)
User code Error code Abnormality in engine speed sensor 1 systems

Trouble
CALL E03 C121LC (Engine controller system)
Contents of trouble Signal is not input to both of engine speed sensor circuit 2 systems.
Problem that
appears on machine
Inputting from engine speed sensor (rpm) can be checked in monitoring mode.
Related information (Code 01002: Engine speed)

and standard val-
ue in normal state Carry out troubleshooting for error code [C115KZ].
D375A-5 20-441
ERROR CODE [C122KX] (ABNORMALLY HIGH LEVEL IN BOOST PRESSURE
ERROR CODE [C122KX] (ABNORMALLY HIGH LEVEL IN BOOST PRESSURE SENSOR

SYSTEM)
User code Error code Abnormally high level in boost pressure sensor system
Trouble
E01 C122KX (Engine controller system)
Contents of trouble Signal voltage of boost pressure sensor circuit is above 4.72 V.
Problem that When machine is accelerated sharply, exhaust gas color is bad.
appears on machine Engine output rises.
Special cable (795-799-5480) is necessary for troubleshooting for boost pressure sensor.
Related information

Defective boost pressure carry out troubleshooting.
1 sensor IMPR (male) Voltage
Between (C) (B) 0.42 0.58 V
IMPR (female) (A)
Resistance Max. 10
IMPR (female) (B)
tor)
Resistance Max. 10
Possible causes IMPR (female) (C)
Short circuit in wiring har- (female) (6) IMPR (female) (A) with wiring Resistance Min. 1 M
harness around it
ness
ness) (female) (17) IMPR (female) (B) with wiring Resistance Min. 1 M
harness around it
(female) (35) IMPR (female) (C) with wiring Resistance Min. 1 M
harness around it
Between (6) (17) 4.75 5.25 V
Between (35) (17) 0.42 0.58 V
Circuit diagram related to boost pressure sensor
20-442 D375A-5
(1)
ERROR CODE [C123KX] (ABNORMALLY LOW LEVEL IN BOOST PRESSURE
ERROR CODE [C123KX] (ABNORMALLY LOW LEVEL IN BOOST PRESSURE SENSOR

SYSTEM)
User code Error code Abnormally low level in boost pressure sensor system
Trouble
E01 C123KX (Engine controller system)
Contents of trouble Signal voltage of boost pressure sensor circuit is below 0.30 V.
Problem that
Engine output lowers.
appears on machine

and standard val-
D375A-5 20-443
ERROR CODE [C131KX] (ABNORMALLY HIGH LEVEL IN THROTTLE SENSOR
ERROR CODE [C131KX] (ABNORMALLY HIGH LEVEL IN THROTTLE SENSOR SYSTEM)
User code Error code Abnormally high level in throttle sensor system
Trouble
Contents of trouble Signal voltage of throttle sensor (deceleration potentiometer) circuit is above 4.80 V.
Keeps engine speed at constant level.
Problem that
Engine output and speed rise suddenly.
appears on machine
Inputting from deceleration potentiometer to steering controller (Voltage) can be checked in monitor-
ing mode.
Related information
(Code 50002: Deceleration potentiometer voltage)

Defective deceleration po- DCL (male) Resistance
1 tentiometer
Between (A) (C) 4.0 6.0 k
(Internal trouble)
Between (A) (B) 0.25 7.0 k
Between (B) (C) 0.25 7.0 k
Wiring harness between ECMB (female) (26)
DCL (female) (A)
defective contact in connec- Wiring harness between ECMB (female) (11)
Resistance Max. 10
DCL (female) (C)
tor)
Possible causes Wiring harness between ECMB (female) (29)
Resistance Max. 10
and standard val- DCL (female) (B)
ue in normal state aPrepare with starting switch OFF, then carry out troubleshooting
Short circuit of wiring harness between ECMB
Short circuit in wiring har- (female) (26) DCL (female) (A) with wiring Resistance Min. 1 M
harness around it
ness
3 Short circuit of wiring harness between ECMB
ness) (female) (11) DCL (female) (C) with wiring Resistance Min. 1 M
harness around it
(female) (29) DCL (female) (B) with wiring Resistance Min. 1 M
harness around it
ECMB Voltage
Between (29) (11) 0.30 4.80 V
Circuit diagram related to deceleration potentiometer
20-444 D375A-5
ERROR CODE [C132KX] (ABNORMALLY LOW LEVEL IN THROTTLE SENSOR
ERROR CODE [C132KX] (ABNORMALLY LOW LEVEL IN THROTTLE SENSOR SYSTEM)
User code Error code Abnormally low level in throttle sensor system
Trouble
Contents of trouble Signal voltage of throttle sensor (deceleration potentiometer) circuit is below 0.30 V.
Problem that
Engine speed and output lower suddenly.
appears on machine
Inputting from deceleration potentiometer to steering controller (Voltage) can be checked in monitor-
ing mode.
Related information
(Code 50002: Deceleration potentiometer voltage)

and standard val-
D375A-5 20-445
ERROR CODE [C133KX] (ABNORMALLY HIGH LEVEL IN REMOTE THROTTLE
ERROR CODE [C133KX] (ABNORMALLY HIGH LEVEL IN REMOTE THROTTLE SENSOR

SYSTEM)
User code Error code Abnormally high level in remote throttle sensor system
Trouble
Contents of trouble Signal voltage of remote throttle sensor (SSC command) circuit is above 4.80 V.
Problem that
Engine speed rises suddenly.
appears on machine
Outputting of SSC command to steering controller (Voltage) can be checked in monitoring mode.
Related information (Code 51000: Final regulation)

ness without turning starting switch ON.
1
(Disconnection in wiring or de- Wiring harness between ECMB (female) (30)
fective contact in connector) NGICN2 (female) (11) Resistance Max. 10

Short circuit in wiring har- without turning starting switch ON.
ness
2 Short circuit of wiring harness between ECMB
ness) (female) (30) NGICN2 (female) (11) with wir- Resistance Min. 1 M
ing harness around it
Possible causes
and standard val- Reset according to following procedure, then check displayed error
ue in normal state code to see which controller is defective.
When P (reset) is displayed: Steering controller is defective.
When E (detection) is displayed: Engine controller is defective.
1)With starting switch turned OFF, exchange steering controller and
Defective engine controller transmission controller.
3 2)Turn starting switch ON.
or steering controller
3)Set monitor panel in adjustment mode (service mode) and execute
adjustment codes [0002] and [0003].
4)Turn starting switch OFF and ON.
5)Set monitor panel in error code display mode and check displayed
code.
aAfter checking, return controllers to original states.
Circuit diagram related to SSC command
20-446 D375A-5
ERROR CODE [C134KX] (ABNORMALLY LOW LEVEL IN REMOTE THROTTLE
ERROR CODE [C134KX] (ABNORMALLY LOW LEVEL IN REMOTE THROTTLE SENSOR

SYSTEM)
User code Error code Abnormally low level in remote throttle sensor system
Trouble
Contents of trouble Signal voltage of remote throttle sensor (SSC command) circuit is below 0.30 V.
Problem that
Engine speed lowers suddenly.
appears on machine
Outputting of SSC command to steering controller (Voltage) can be checked in monitoring mode.
Related information (Code 51000: Final regulation)

and standard val-
D375A-5 20-447
ERROR CODE [C135KX] (ABNORMALLY HIGH LEVEL IN ENGINE OIL PRESSURE
ERROR CODE [C135KX] (ABNORMALLY HIGH LEVEL IN ENGINE OIL PRESSURE

SENSOR SYSTEM)
User code Error code Abnormally high level in engine oil pressure sensor system
Trouble
Contents of trouble Signal voltage of engine oil pressure sensor circuit is above 4.88 V.
Problem that
appears on machine
Special cable (795-799-5470) is necessary for troubleshooting for engine oil pressure sensor.
Related information

Defective engine oil pres- carry out troubleshooting.
1 sure sensor OLPR Voltage
Between (C) (B) 0.42 0.58 V
OLPR (female) (A)
Resistance Max. 10
OLPR (female) (B)
tor)
Resistance Max. 10
Possible causes OLPR (female) (C)
Short circuit in wiring har- (female) (6) OLPR (female) (A) with wiring Resistance Min. 1 M
harness around it
ness
ness) (female) (17) OLPR (female) (B) with wiring Resistance Min. 1 M
harness around it
(female) (24) OLPR (female) (C) with wiring Resistance Min. 1 M
harness around it
Between (6) (17) 4.75 5.25 V
Between (24) (17) 0.42 0.58 V
Circuit diagram related to engine oil pressure sensor
20-448 D375A-5
ERROR CODE [C141KX] (ABNORMALLY LOW LEVEL IN ENGINE OIL PRESSURE SENSOR
ERROR CODE [C141KX] (ABNORMALLY LOW LEVEL IN ENGINE OIL PRESSURE SYSTEM)
TROUBLESHOOTING SENSOR
ERROR CODE [C143ZG] (LOWERING OF ENGINE SYSTEM)
OIL PRESSURE)
ERROR CODE [C141KX] (ABNORMALLY LOW LEVEL IN ENGINE OIL PRESSURE

SENSOR SYSTEM)
User code Error code Abnormally low level in engine oil pressure sensor system
Trouble
CALL03 C141KX (Engine controller system)
Contents of trouble Signal voltage of engine oil pressure sensor circuit is below 0.31 V.
Problem that
appears on machine

and standard val-
ERROR CODE [C143ZG] (LOWERING OF ENGINE OIL PRESSURE)
User code Error code Lowering of engine oil pressure

Trouble
C143ZG (Engine controller system)
Engine oil pressure sensor detected pressure lower than pressure set in controller.
Criterion (for reference): Max. 0.05 MPa {0.5 kg/cm2} at 600 rpm
Max. 0.09 MPa {0.9 kg/cm2} at 1,000 rpm
Contents of trouble
Action of controller Limits fuel injection rate to 50% after 10 seconds.
Problem that
appears on machine

Possible causes 1 Defective related systems
and standard val-
ue in normal state Defective engine oil pres-
2 Carry out troubleshooting for error codes [C135KX] and [C141KX].
sure sensor system
3 Defective engine See S mode.
D375A-5 20-449
ERROR CODE [C144KX] (ABNORMALLY HIGH LEVEL IN ENGINE COOLANT
TROUBLESHOOTING TEMPERATURE SENSOR SYSTEM)
ERROR CODE [C144KX] (ABNORMALLY HIGH LEVEL IN ENGINE COOLANT

TEMPERATURE SENSOR SYSTEM)
User code Error code Abnormally high level in engine coolant temperature sensor system
Trouble
Contents of trouble Signal voltage of engine coolant temperature sensor circuit is above 4.95 V.
Problem that
appears on machine
Special cable (795-799-5530) is necessary for troubleshooting for engine coolant temperature sen-
Related information sor.

Defective engine coolant without turning starting switch ON.
1 temperature sensor
CLTP Resistance
(Internal trouble)
Between (A) (B) 600 36 k
ness
CLTP (female) (A)
Resistance Max. 10
Possible causes CLTP (female) (B)
ness (female) (22) CLTP (female) (A) with wiring Resistance Min. 1 M
3
(female) (17) CLTP (female) (B) with wiring Resistance Min. 1 M
harness around it
Between (24) (17) 600 36 k
Circuit diagram related to engine coolant temperature sensor
20-450 D375A-5
ERROR CODE [C145KX] (ABNORMALLY LOW LEVEL IN ENGINE COOLANT TEMPERATURE
ERROR CODE [C145KX] (ABNORMALLY LOW LEVEL IN ENGINE COOLANT
SENSOR SYSTEM)
TROUBLESHOOTING TEMPERATURE
ERROR CODE [C151NS] (RISE OF SENSOR
ENGINE COOLANT SYSTEM)
TEMPERATURE)
ERROR CODE [C145KX] (ABNORMALLY LOW LEVEL IN ENGINE COOLANT

TEMPERATURE SENSOR SYSTEM)
User code Error code Abnormally low level in engine coolant temperature sensor system
Trouble
Contents of trouble Signal voltage of engine coolant temperature sensor circuit is below 0.21 V.
Problem that
appears on machine

and standard val-
ERROR CODE [C151NS] (RISE OF ENGINE COOLANT TEMPERATURE)
User code Error code Rise of engine coolant temperature

Trouble
C151NS (Engine controller system)
Engine coolant temperature sensor detected temperature higher than temperature set in controller.
Contents of trouble
Criterion (for reference): Min. 105C
Action of controller Limits fuel injection rate to 50% after 10 seconds.
Problem that
appears on machine

and standard val-
ue in normal state Defective engine coolant
temperature sensor system
D375A-5 20-451
ERROR CODE [C153KX] (ABNORMALLY HIGH LEVEL IN AIR INTAKE
TROUBLESHOOTING TEMPERATURE SENSOR SYSTEM)
ERROR CODE [C153KX] (ABNORMALLY HIGH LEVEL IN AIR INTAKE TEMPERATURE

SENSOR SYSTEM)
User code Error code Abnormally high level in air intake temperature sensor system
Trouble
Contents of trouble Signal voltage of air intake temperature sensor circuit is above 4.88 V.
Problem that
appears on machine
Special cable (795-799-5540) is necessary for troubleshooting for air intake temperature sensor.
Related information

Defective air intake tempera- without turning starting switch ON.
1 ture sensor
IMTP (female) Resistance
(Internal trouble)
Between (A) (B) 36 600
ness
IMTP (female) (A)
Resistance Max. 10
Possible causes IMTP (female) (B)
ness (female) (23) IMTP (female) (A) with wiring Resistance Min. 1 M
3
(female) (17) IMTP (female) (B) with wiring Resistance Min. 1 M
harness around it
Between (23) (17) 36 600
Circuit diagram related to air intake temperature sensor
20-452 D375A-5
ERROR CODE [C154KX] (ABNORMALLY LOW LEVEL IN AIR INTAKE TEMPERATURE
ERROR CODE [C154KX] (ABNORMALLY LOW LEVEL IN AIR INTAKE TEMPERATURE

SENSOR SYSTEM)
User code Error code Abnormally low level in air intake temperature sensor system
Trouble
Contents of trouble Signal voltage of air intake temperature sensor circuit is below 0.08 V.
Problem that
appears on machine

and standard val-
D375A-5 20-453
ERROR CODE [C221KX] (ABNORMALLY HIGH LEVEL IN ATMOSPHERIC PRESSURE
ERROR CODE [C221KX] (ABNORMALLY HIGH LEVEL IN ATMOSPHERIC PRESSURE

SENSOR SYSTEM)
User code Error code Abnormally high level in atmospheric pressure sensor system
Trouble
Contents of trouble Signal voltage of atmospheric pressure sensor circuit is above 4.78 V.
Problem that
appears on machine
Special cable (795-799-5460) is necessary for troubleshooting for atmospheric pressure sensor.
Related information

Defective atmospheric pres-
1 sure sensor AAPR Voltage
Between (C) (B) 0.42 0.58 V
AAPR (female) (A)
Resistance Max. 10
AAPR (female) (B)
tor)
Resistance Max. 10
Possible causes AAPR (female) (C)
Short circuit in wiring har- (female) (6) AAPR (female) (A) with wiring Resistance Min. 1 M
harness around it
ness
ness) (female) (17) AAPR (female) (B) with wiring Resistance Min. 1 M
harness around it
(female) (34) AAPR (female) (C) with wiring Resistance Min. 1 M
harness around it
Between (6) (17) 4.75 5.25 V
Between (34) (17) 0.42 0.58 V
Circuit diagram related to atmospheric pressure sensor
20-454 D375A-5
ERROR CODE [C222KX] (ABNORMALLY LOW LEVEL IN ATMOSPHERIC PRESSURE
SENSOR
ERROR CODE [C222KX] (ABNORMALLY LOW LEVEL IN ATMOSPHERIC SYSTEM)
PRESSURE
TROUBLESHOOTING ERROR CODE [C234N1] (OVER-SPEED)
SENSOR SYSTEM)
ERROR CODE [C222KX] (ABNORMALLY LOW LEVEL IN ATMOSPHERIC PRESSURE

SENSOR SYSTEM)
User code Error code Abnormally low level in atmospheric pressure sensor system
Trouble
Contents of trouble Signal voltage of atmospheric pressure sensor circuit is below 0.20 V.
Problem that
appears on machine

and standard val-
ERROR CODE [C234N1] (OVER-SPEED)
User code Error code Over-speed

Trouble
C234N1 (Engine controller system)
Engine speed sensor detected speed higher than speed set in controller.
Contents of trouble
Criterion (for reference): Min. 2,400 rpm
Action of controller Closes fuel rail actuator fully (Cuts out fuel).
Problem that
appears on machine

Possible causes
and standard val- 1 Defective related systems
ue in normal state
D375A-5 20-455
TROUBLESHOOTING ERROR CODE [C254KZ] (ABNORMAL VOLTAGE OF FUEL SHUT-OFF VALVE)
ERROR CODE [C254KZ] (ABNORMAL VOLTAGE OF FUEL SHUT-OFF VALVE)
User code Error code Abnormal voltage of fuel shut-off valve

Trouble
E01 C254KZ (Engine controller system)
Contents of trouble Voltage (Resistance) of fuel shut-off valve circuit is above 6.0 V (below 20 ).
Action of controller Turns off power for fuel shut-off valve.
Problem that
Engine stops.
appears on machine

Defective fuel shut-off valve FSO (Valve side) Resistance
1
(Internal trouble)
Between (+) () 23 40
Between (+) chassis ground 100 k
ness
FSO (wiring harness side) (+)
Possible causes tor) Wiring harness between FSO (wiring harness
Resistance Max. 10
and standard val- side) () chassis ground
ness (female) (30) FSO (wiring harness side) (+) Resistance Min. 1 M
3
(with another wiring har- with wiring harness around it
ness) Short circuit of wiring harness between FSO
(wiring harness side) () chassis ground Resistance Min. 1 M
with wiring harness around it
ECMA Resistance
Between (30) chassis ground 23 40
Circuit diagram related to fuel shut-off valve
20-456 D375A-5
ERROR CODE [C259FS] (ABNORMALITY IN FUEL SHUT-OFF VALVE)
TROUBLESHOOTING ERROR CODECODE
ERROR [C259FS] (ABNORMALITY
[C261NS] IN FUEL
(ABNORMAL RISE SHUT-OFF
OF FUEL VALVE)
TEMPERATURE)
ERROR CODE [C259FS] (ABNORMALITY IN FUEL SHUT-OFF VALVE)
User code Error code Abnormality in fuel shut-off valve

Trouble
CALL E04 C259FS (Engine controller system)
Contents of trouble Fuel shut-off valve cannot be closed (Engine does not stop when electric power is turned off).
Turns off power for fuel shut-off valve.
Problem that
Engine cannot be stopped.
appears on machine

2 Trouble in fuel shut-off valve Check inside of fuel shut-off valve directly.
Possible causes
and standard val- Clogging, looseness, break-
ue in normal state 3 age, or leakage of fuel filter/
leakage.
piping
4 Trouble in injector Check inside of injector directly.
ERROR CODE [C261NS] (ABNORMAL RISE OF FUEL TEMPERATURE)
User code Error code Abnormal rise of fuel temperature

Trouble
C261NS (Engine controller system)
Fuel temperature sensor detected temperature lower than temperature set in controller.
Contents of trouble
Criterion (for reference): Min. 76C
Action of controller Limits engine speed to 800 rpm after 30 seconds.
Problem that
appears on machine

and standard val-
ue in normal state Defective fuel temperature
sensor system
D375A-5 20-457
ERROR CODE [C263KX] (ABNORMALLY HIGH LEVEL IN FUEL TEMPERATURE
ERROR CODE [C263KX] (ABNORMALLY HIGH LEVEL IN FUEL TEMPERATURE SENSOR

SYSTEM)
User code Error code Abnormally high level in fuel temperature sensor system
Trouble
Contents of trouble Signal voltage of fuel temperature sensor circuit is above 4.95 V.
Problem that
appears on machine
Special cable (795-799-5530) is necessary for troubleshooting for fuel temperature sensor.
Related information

Defective fuel temperature without turning starting switch ON.
1 sensor
FLTP (female) Resistance
(Internal trouble)
Between (A) (B) 600 36 k
ness
FLTP (female) (A)
Resistance Max. 10
Possible causes FLTP (female) (B)
ness (female) (26) FLTP (female) (A) with wiring Resistance Min. 1 M
3
(female) (17) FLTP (female) (B) with wiring Resistance Min. 1 M
harness around it
Between (26) (17) 600 36 k
Circuit diagram related to fuel temperature sensor
20-458 D375A-5
ERROR CODE [C265KX] (ABNORMALLY LOW LEVEL IN FUEL TEMPERATURE
ERROR CODE [C265KX] (ABNORMALLY LOW LEVEL IN FUEL TEMPERATURE SENSOR

SYSTEM)
User code Error code Abnormally low level in fuel temperature sensor system
Trouble
Contents of trouble Signal voltage of fuel temperature sensor circuit is below 0.21 V.
Problem that
appears on machine

and standard val-
D375A-5 20-459
TROUBLESHOOTING ERROR CODE [C316KZ] (ABNORMAL CURRENT OF FUEL PUMP ACTUATOR)
ERROR CODE [C316KZ] (ABNORMAL CURRENT OF FUEL PUMP ACTUATOR)
User code Error code Abnormal current of fuel pump actuator

Trouble
Current of fuel pump actuator circuit is out of normal range.
Contents of trouble
Problem that
appears on machine
Special cable (795-799-5470) is necessary for troubleshooting for fuel pump actuator.
Related information

Defective fuel pump actuator PUMP (male) Resistance
1
(Internal trouble)
Between (A) (C) 79
ness
PUMP (female) (A)
Resistance Max. 10
PUMP (female) (C)
Possible causes
ness (female) (11) PUMP (female) (A) with wiring Resistance Min. 1 M
3
(female) (40) PUMP (female) (C) with wiring Resistance Min. 1 M
harness around it
Between (11) (40) 79
Between (11), (40) another
Min. 1 M
wiring harness
Circuit diagram related to fuel pump actuator
20-460 D375A-5
TROUBLESHOOTING ERROR CODE [C318LK] (ABNORMALITY IN FUEL PUMP ACTUATOR)
ERROR CODE [C318LK] (ABNORMALITY IN FUEL PUMP ACTUATOR)
User code Error code Abnormality in fuel pump actuator

Trouble
Displayed pressure of fuel pump is excessively different from actual value.
Contents of trouble
Criteria for difference (for reference): 0.21 MPa {2.1 kg/cm2} (when water temperature is 38C)
Problem that
Engine speed is unstable.
appears on machine

leakage.
piping
Suction of air caused by low Air may be sucked because of lowering of fuel level in tank. If fuel level
3
fuel level in tank gauge is in red range, supply fuel.
Suction resistance of fuel filter may be large. Check fuel filter directly.
Possible causes
When new Max. 13.6 kPa
and standard val- Large suction resistance of
4 Fuel pump Engine high filter is used {Max. 102 mmHg}
ue in normal state fuel filter
inlet pressure idling Normal Max. 27.1 kPa
condition {Max. 203 mmHg}
Trouble in fuel pump actua-
5 Fuel pump actuator may malfunction. Check it directly.
tor
Defective electric system of
fuel pump pressure sensor
7 Trouble in injector Inside of injector may be defective. Check it directly.
D375A-5 20-461
ERROR CODE [C346KT] (ABNORMALITY IN POWER-DOWN UNIT OF ENGINE
TROUBLESHOOTING CONTROLLER)

CONTROLLER)
User code Error code Abnormality in power-down unit of engine controller

Trouble
CALL E03 C346KT (Engine controller system)
Contents of trouble Data recorded in power-down unit of engine controller has error.
Problem that Power-down data (maintenance information, current controller information, engine operating hours,
appears on machine etc.) are lost.
Charge level of battery (Voltage) can be checked in monitoring mode.
Related information (Code 03200: Battery voltage)

If fusible link is broken, circuit probably has short circuit with chassis
1 Defective fusible link (34 A)
ground.
Defective fuse
2 If fuse is broken, circuit probably has short circuit with chassis ground.
(FS1-1, FS1-4)
Disconnection in wiring har- Wiring harness between ECMB (female) (3)
FS1-3 outlet
defective contact in connec- Wiring harness between ECMA (female) (4),
Resistance Max. 10
tor) (5) FS1-4 outlet
Wiring harness between FS1 inlet fusible
Resistance Max. 10
link battery relay terminal B
Possible causes aPrepare with starting switch OFF, then carry out troubleshooting
and standard val- without turning starting switch ON.
ue in normal state
(female) (3) FS1-3 outlet with wiring harness Resistance Min. 1 M
Short circuit in wiring har- around it
ness
ness) (female) (4), (5) FS1-4 outlet with wiring har- Resistance Min. 1 M
ness around it
Wiring harness between FS1 inlet fusible
link battery relay terminal B with wiring har- Resistance Min. 1 M
ness around it
5 Defective engine controller ECMA, ECMB Voltage
Between ECMB (3), (4), (5)
17.3 34.7 V
ECMA (7), (8)
20-462 D375A-5
TROUBLESHOOTING CONTROLLER)
Circuit diagram related to engine controller power supply
D375A-5 20-463
TROUBLESHOOTING ERROR CODE [C384LK] (ABNORMALITY IN PREHEATER CONTROL SYSTEM)
ERROR CODE [C384LK] (ABNORMALITY IN PREHEATER CONTROL SYSTEM)
User code Error code Abnormality in preheater control system

Trouble
Contents of trouble Disconnection or short circuit was detected in preheater control circuit.
Problem that
appears on machine

Defective preheater relay without turning starting switch ON.
1
(Internal trouble) RHR (male) Resistance
Between (1) (2) 200 400
ness
RHR (female) (1)
tor) Wiring harness between RHR (female) (2)
Resistance Max. 10
chassis ground
and standard val- without turning starting switch ON.
ue in normal state
ness (female) (2) RHR (female) (1) with wiring Resistance Min. 1 M
3
ness) Short circuit of wiring harness between RHR
(female) (2) chassis ground with wiring har- Resistance Min. 1 M
ness around it
Between (2) another wiring
Min. 1 M
harness
20-464 D375A-5
TROUBLESHOOTING ERROR CODE [C384LK] (ABNORMALITY IN PREHEATER CONTROL SYSTEM)
Circuit diagram related to preheater control
D375A-5 20-465
ERROR CODE [C423L6] (ABNORMALITY IN IN-RANGE OF TIMING RAIL PRESSURE

SENSOR SYSTEM)
User code Error code Abnormality in in-range of timing rail pressure sensor system
Trouble
CALL E03 C423L6 (Engine controller system)
Timing rail pressure sensor detected abnormal pressure.
Contents of trouble
Criterion (for reference): Min. 2.42 MPa {24.65 kg/cm2} when starting switch is turned on
Limits high idling speed to 1,500 rpm.
Problem that
appears on machine
Special cable (799-795-5460) is necessary for troubleshooting for timing rail pressure sensor.
Related information

Defective timing rail pres-
1 sure sensor TIMG (male) Voltage
Between (C) (B) 0.42 0.58 V
Disconnection in wiring har- Wiring harness between ECMA (female) (5)
TPR (female) (A)
Resistance Max. 10
tor) TPR (female) (B)
Resistance Max. 10
TPR (female) (C)
Possible causes Short circuit of wiring harness between ECMA
and standard val- (female) (5) TPR (female) (A) with wiring Resistance Min. 1 M
ue in normal state Short circuit in wiring har- harness around it
ness
ness) (female) (18) TPR (female) (B) with wiring Resistance Min. 1 M
harness around it
(female) (33) TPR (female) (C) with wiring Resistance Min. 1 M
harness around it
When new Max. 13.6 kPa
Large suction resistance of
4 Fuel pump Engine high filter is used {Max. 102 mmHg}
fuel filter
inlet pressure idling Normal Max. 27.1 kPa
condition {Max. 203 mmHg}
5 Defective engine controller ECMA (female) Resistance
Between (5) (18) 4.75 5.25 V
Between (33) (18) 0.42 0.58 V
20-466 D375A-5
Circuit diagram related to timing rail pressure sensor
D375A-5 20-467
ERROR CODE
ERROR CODE[C441KK] (ABNORMALLY
[C441KK] (ABNORMALLY LOW
LOW LEVEL
LEVEL IN BATTERY
IN BATTERY VOLTAGE
VOLTAGE SYSTEM)
TROUBLESHOOTING ERROR CODE [C442KG] (ABNORMALLY HIGH LEVEL IN BATTERY VOLTAGESYSTEM)
SYSTEM)
ERROR CODE [C441KK] (ABNORMALLY LOW LEVEL IN BATTERY VOLTAGE SYSTEM)
User code Error code Abnormally low level in battery voltage system
Trouble
E01 C441KK (Engine controller system)
Contents of trouble Voltage of controller power supply circuit is below 12 V.
Problem that
appears on machine

and standard val-
ue in normal state Carry out troubleshooting for error code [C346KT].
ERROR CODE [C442KG] (ABNORMALLY HIGH LEVEL IN BATTERY VOLTAGE SYSTEM)
User code Error code Abnormally high level in battery voltage system
Trouble
E01 C442KG (Engine controller system)
Contents of trouble Voltage of controller power supply circuit is below 38 V.
Problem that
appears on machine

and standard val-
ue in normal state Carry out troubleshooting for error code [C346KT].
20-468 D375A-5
ERROR CODE [C451KX] (ABNORMALLY HIGH LEVEL IN FUEL RAIL PRESSURE
ERROR CODE [C451KX] (ABNORMALLY HIGH LEVEL IN FUEL RAIL PRESSURE

SENSOR SYSTEM)
User code Error code Abnormally high level in fuel rail pressure sensor system
Trouble
Contents of trouble Signal voltage of fuel rail pressure sensor circuit is above 4.78 V.
Opens and controls fuel rail.
Problem that
appears on machine
Special cable (795-799-5460) is necessary for troubleshooting for fuel rail pressure sensor.
Related information

Defective fuel rail pressure without turning starting switch ON.
1 sensor RPR Voltage
Between (C) (B) 0.42 0.58 V
RPR (female) (A)
Resistance Max. 10
RPR (female) (B)
tor)
Resistance Max. 10
Possible causes RPR (female) (C)
Short circuit in wiring har- (female) (5) RPR (female) (A) with wiring Resistance Min. 1 M
harness around it
ness
ness) (female) (18) RPR (female) (B) with wiring Resistance Min. 1 M
harness around it
(female) (31) RPR (female) (C) with wiring Resistance Min. 1 M
harness around it
Between (5) (18) 4.75 5.25 V
Between (31) (18) 0.42 0.58 V
Circuit diagram related to fuel rail pressure sensor
D375A-5 20-469
ERROR CODE [C452KX] (ABNORMALLY LOW LEVEL IN FUEL RAIL PRESSURE
ERROR CODE [C452KX] (ABNORMALLY LOW LEVEL IN FUEL RAIL PRESSURE SENSOR
SYSTEM)
User code Error code Abnormally low level in fuel rail pressure sensor system
Trouble
CALL C452KX (Engine controller system)
Contents of trouble Signal voltage of fuel rail pressure sensor circuit is below 0.15 V.
Reduces current for fuel rail actuator to 0 A.
Problem that
appears on machine

and standard val-
20-470 D375A-5
TROUBLESHOOTING ERROR CODE [C455KZ] (ABNORMAL CURRENT OF FUEL RAIL ACTUATOR)
ERROR CODE [C455KZ] (ABNORMAL CURRENT OF FUEL RAIL ACTUATOR)
User code Error code Abnormal current of fuel rail actuator

Trouble
Current of fuel rail actuator circuit is out of normal range.
Contents of trouble
Problem that
appears on machine
Special cable (795-799-5470) is necessary for troubleshooting for fuel rail actuator.
Related information
Method of reproducing error code: Turn starting switch ON or start engine.

Defective fuel rail actuator RAIL (male) Resistance
1
(Internal trouble)
Between (A) (C) 79
ness
RAIL (female) (A)
Resistance Max. 10
RAIL (female) (C)
Possible causes
ness (female) (3) RAIL (female) (A) with wiring Resistance Min. 1 M
3
(female) (10) RAIL (female) (C) with wiring Resistance Min. 1 M
harness around it
Between (3) (10) 79
Between (3), (10) another wiring
Min. 1 M
harness
Circuit diagram related to fuel rail actuator
D375A-5 20-471
ERROR CODE [C467LK] (ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL)
TROUBLESHOOTING ERROR CODE [C467LK]
ERROR (ABNORMALITY
CODE [C468LK] IN TIMING
(ABNORMALITY RAIL
IN FUEL ACTUATOR
RAIL ACTUATORCONTROL)
CONTROL)
ERROR CODE [C467LK] (ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL)
User code Error code Abnormality in timing rail actuator control

Trouble
Displayed timing rail fuel value is so different from quantity of actual timing fuel that target value can-
Contents of trouble
not be obtained.
Problem that
appears on machine

and standard val-
ue in normal state Carry out troubleshooting for error code [C112LK].
ERROR CODE [C468LK] (ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL)
User code Error code Abnormality in fuel rail actuator control

Trouble
Displayed injection rate of fuel rail is so different from actual injection rate that target value cannot be
Contents of trouble
obtained.
Limits maximum injection rate to 217 mm3/st.
Problem that
appears on machine

Possible causes leakage.
piping
and standard val-
3 Trouble in fuel rail actuator Fuel pump actuator may have trouble in it. Check it directly.
ue in normal state
Clogging of fuel rail actuator
4 Fuel rail actuator screen may be clogged. Check it directly.
screen
5 Breakage of injector O-ring Injector O-ring may be broken. Check it directly.
20-472 D375A-5
TROUBLESHOOTING ERROR CODE [C514LK] (ABNORMALITY IN FUEL RAIL ACTUATOR)
ERROR CODE [C514LK] (ABNORMALITY IN FUEL RAIL ACTUATOR)
User code Error code Abnormality in fuel rail actuator

Trouble
CALL C514LK (Engine controller system)
Displayed injection rate of fuel rail is excessively different from actual injection rate.
Contents of trouble
Criterion (for reference): Difference is 600 mm3/st for 50 msec or 250 mm3/st for 200 msec.
Problem that
appears on machine

and standard val-
ue in normal state Carry out troubleshooting for error code [C468LK].
D375A-5 20-473
ERROR CODE [C554L6] (ABNORMALITY IN IN-RANGE OF FUEL RAIL PRESSURE

SENSOR SYSTEM)
User code Error code Abnormality in in-range of fuel rail pressure sensor system
Trouble
CALL E05 C554L6 (Engine controller system)
Fuel rail pressure sensor detected abnormal pressure.
Contents of trouble
Criterion (for reference): Min. 0.17 MPa {1.76 kg/cm2} when starting switch is turned on
Problem that
appears on machine
Special cable (799-795-5460) is necessary for troubleshooting for fuel rail pressure sensor.
Related information

Defective fuel rail pressure
1 sensor RPR Voltage
Between (C) (B) 0.42 0.58 V
Disconnection in wiring har- Wiring harness between ECMA (female) (5)
RPR (female) (A)
Resistance Max. 10
tor) RPR (female) (B)
Resistance Max. 10
RPR (female) (C)
Possible causes without turning starting switch ON.
and standard val- Short circuit of wiring harness between ECMA
ue in normal state (female) (5) RPR (female) (A) with wiring Resistance Min. 1 M
Short circuit in wiring har- harness around it
ness
ness) (female) (18) RPR (female) (B) with wiring Resistance Min. 1 M
harness around it
(female) (31) RPR (female) (C) with wiring Resistance Min. 1 M
harness around it
Large suction resistance of
4 Negative suction pressure
fuel filter 27 kPa {203 mmHg}
(Tank side)
Between (5) (18) 4.75 5.25 V
Between (31) (18) 0.42 0.58 V
20-474 D375A-5
Circuit diagram related to fuel rail pressure sensor
D375A-5 20-475
TROUBLESHOOTING ERROR CODE [D110KA] (DISCONNECTION IN BATTERY RELAY SYSTEM)
ERROR CODE [D110KA] (DISCONNECTION IN BATTERY RELAY SYSTEM)
User code Error code Disconnection in battery relay system

Trouble
D110KA (Steering controller system)
Contents of trouble When signal is output to battery relay circuit, current does not flow.
Action of controller Stops outputting to battery relay circuit.
Problem that
Trouble may occur in writing data in each controller ROM (non-volatile memory).
appears on machine
Outputting to battery relay (Voltage) can be checked in monitoring mode.
Related information (Code 60600: Battery relay drive voltage)
Method of reproducing error code: Turn starting switch ON and OFF.

Defective battery relay without turning starting switch ON.
1
(Internal disconnection) Battery relay Continuity
Between terminals BR E There is continuity.
ness
Wiring harness between NGICN3 (female) (4)
chassis ground
Possible causes defective contact in connec-
and standard val- tor) Wiring harness between battery relay terminal
Resistance Max. 1
ue in normal state E chassis ground
Short circuit with power carry out troubleshooting.
3 source in wiring harness Short circuit of wiring harness between
(Contact with 24 V circuit) NGICN3 (female) (4) battery relay terminal Voltage Max. 1 V
BR with chassis ground
4 Defective steering controller
NGICN3 (female) Continuity
Between (4) chassis ground There is continuity.
Circuit diagram related to battery relay
20-476 D375A-5
TROUBLESHOOTING ERROR CODE [D110KB] (SHORT CIRCUIT IN BATTERY RELAY SYSTEM)
ERROR CODE [D110KB] (SHORT CIRCUIT IN BATTERY RELAY SYSTEM)
User code Error code Short circuit in battery relay system

Trouble
D110KB (Steering controller system)
Contents of trouble When signal is output to battery relay circuit, abnormal current flowed.
Action of controller Stops outputting to battery relay circuit.
Problem that
Trouble may occur in writing data in each controller ROM (non-volatile memory).
appears on machine
Outputting to battery relay (Voltage) can be checked in monitoring mode.
Related information (Code 60600: Battery relay drive voltage)
Method of reproducing error code: Turn starting switch ON and OFF.

Defective battery relay Battery relay Continuity/Resistance
1
(Internal short circuit) Between terminals BR E There is continuity.
Between terminal BR chassis
Min. 1 M
ground
and standard val- Short circuit with chassis without turning starting switch ON.
ue in normal state 2 ground in wiring harness Short circuit of wiring harness between
(Contact with ground circuit) NGICN3 (female) (4) battery relay terminal Resistance Min. 1 M
BR with chassis ground
3 Defective steering controller NGICN3 Starting switch Voltage
Between (4) chassis
ON 20 30 V
ground
Circuit diagram related to battery relay
D375A-5 20-477
TROUBLESHOOTING ERROR CODE [D130KA] (DISCONNECTION IN NEUTRAL SAFETY RELAY SYSTEM)
ERROR CODE [D130KA] (DISCONNECTION IN NEUTRAL SAFETY RELAY SYSTEM)
User code Error code Disconnection in neutral safety relay system

Trouble
E02 D130KA (Transmission controller system)
Contents of trouble When GND signal for neutral safety relay circuit is turned off, 24 V is not generated.
Stops outputting GND signal for neutral safety relay circuit.
Problem that
appears on machine
Outputting to neutral safety relay (Voltage) can be checked in monitoring mode.
(Code 50900: Neutral safety relay drive voltage)
Related information
Turn starting switch ON and operate parking brake lever (LOCK position).
aThis error code detects abnormality on primary side (coil side) of neutral safety relay and cannot de-
tect abnormality on secondary side (contact side).

Defective circuit breaker If circuit breaker is turned OFF, circuit probably has short circuit with
1
(CB3) chassis ground.
Defective neutral safety re- without turning starting switch ON.
2 lay
NSF (Male) Resistance
(Internal disconnection)
Between (1) (2) 200 400
ness
Wiring harness between TMCN2 (female) (8)
NSF (female) (2)
Possible causes tor) Wiring harness between NSF (female) (1)
Resistance Max. 1
and standard val- CB3 (1)
Short circuit with chassis Short circuit of wiring harness between
4 ground in wiring harness TMCN2 (female) (8) NSF (female) (2) with Resistance Min. 1 M
(Contact with ground circuit) chassis ground
Short circuit of wiring harness between NSF
Resistance Min. 1 M
(female) (1) CB3 (1) with chassis ground
Defective transmission con- TMCN2 Parking brake lever Voltage
5
troller
Between (8) chassis When locked Max. 1 V
ground When free 20 30 V
20-478 D375A-5
TROUBLESHOOTING ERROR CODE [D130KA] (DISCONNECTION IN NEUTRAL SAFETY RELAY SYSTEM)
Circuit diagram related to neutral safety relay
D375A-5 20-479
TROUBLESHOOTING ERROR CODE [D130KB] (SHORT CIRCUIT IN NEUTRAL SAFETY RELAY SYSTEM)
ERROR CODE [D130KB] (SHORT CIRCUIT IN NEUTRAL SAFETY RELAY SYSTEM)
User code Error code Short circuit in neutral safety relay system
Trouble
E02 D130KB (Transmission controller system)
Contents of trouble When GND signal for neutral safety relay circuit is turned off, abnormal current flowed.
Stops outputting GND signal for neutral safety relay circuit.
Problem that
appears on machine
Outputting to neutral safety relay (Voltage) can be checked in monitoring mode.
(Code 50900: Neutral safety relay drive voltage)
Related information
Turn starting switch ON and operate parking brake lever (LOCK position).
aThis error code detects abnormality on primary side (coil side) of neutral safety relay and cannot de-

Defective neutral safety re- without turning starting switch ON.
1 lay
NSF (male) Resistance
(Internal short circuit)
Between (1) (2) 200 400
Possible causes Short circuit with power carry out troubleshooting.
and standard val- 2 source in wiring harness Short circuit of wiring harness between
ue in normal state (Contact with 24 V circuit) TMCN2 (female) (8) NSF (female) (2) with Voltage Max. 1 V
chassis ground
Defective transmission con- TMCN2 Parking brake lever Voltage
3
troller
Between (8) chassis When locked Max. 1 V
ground When free 20 30 V
20-480 D375A-5
TROUBLESHOOTING ERROR CODE [D130KB] (SHORT CIRCUIT IN NEUTRAL SAFETY RELAY SYSTEM)
Circuit diagram related to neutral safety relay
D375A-5 20-481
TROUBLESHOOTING ERROR CODE [D161KA] (DISCONNECTION IN BACK-UP ALARM RELAY SYSTEM)
ERROR CODE [D161KA] (DISCONNECTION IN BACK-UP ALARM RELAY SYSTEM)
User code Error code Disconnection in back-up alarm relay system

Trouble
E01 D161KA (Transmission controller system)
Contents of trouble When GND signal for back-up alarm relay circuit is turned off, 24 V is not generated.
Action of controller Stops outputting to back-up alarm relay circuit.
Problem that
Back-up alarm does not sound.
appears on machine
Outputting to back-up alarm relay (Voltage) can be checked in monitoring mode.
(Code 70400: Back-up alarm relay drive voltage)
Related information Method of reproducing error code: Turn starting switch ON and set parking brake lever in neutral.
aThis error code detects abnormality on primary side (coil side) of back-up alarm relay and cannot de-

1 Defective fuse FS4-1 If fuse is broken, circuit probably has short circuit with chassis ground.
Defective back-up alarm re- without turning starting switch ON.
2 lay
BKA (male) Resistance
Between (1) (2) 200 400
ness
BKA (female) (2)
tor) Wiring harness between BKA (female) (1)
Resistance Max. 1
Possible causes FS4-1 outlet
Short circuit of wiring harness between
Short circuit with chassis
TMCN2 (female) (18) BKA (female) (2) with Resistance Min. 1 M
4 ground in wiring harness
chassis ground
(Contact with ground circuit)
Short circuit of wiring harness between BKA
(female) (1) FS4-1 outlet with chassis Resistance Min. 1 M
ground
5
troller
Between (18) Neutral 20 30 V
chassis ground Reverse Max. 1 V
20-482 D375A-5
TROUBLESHOOTING ERROR CODE [D161KA] (DISCONNECTION IN BACK-UP ALARM RELAY SYSTEM)
Circuit diagram related to back-up alarm
D375A-5 20-483
TROUBLESHOOTING ERROR CODE [D161KB] (SHORT CIRCUIT IN BACK-UP ALARM RELAY SYSTEM)
ERROR CODE [D161KB] (SHORT CIRCUIT IN BACK-UP ALARM RELAY SYSTEM)
User code Error code Short circuit in back-up alarm relay system
Trouble
E01 D161KB (Transmission controller system)
Contents of trouble When GND signal for back-up alarm relay circuit was output, abnormal current flowed.
Action of controller Stops outputting to back-up alarm relay circuit.
Problem that
Back-up alarm does not sound.
appears on machine
Outputting to back-up alarm relay (Voltage) can be checked in monitoring mode.
(Code 70400: Back-up alarm relay drive voltage)
Related information Method of reproducing error code: Turn starting switch ON and operate PCCS lever (in reverse).
aThis error code detects abnormality on primary side (coil side) of back-up alarm relay and cannot de-

Defective back-up alarm re- without turning starting switch ON.
1 lay
BKA (male) Resistance
Between (1) (2) 200 400
and standard val- 2 source in wiring harness
ue in normal state (Contact with 24 V circuit) Short circuit of wiring harness between
Voltage Max. 1 V
TMCN2 (female) (18) BKA (female) (2)
3
troller
Between (18) Neutral 20 30 V
chassis ground Reverse Max. 1 V
20-484 D375A-5
TROUBLESHOOTING ERROR CODE [D161KB] (SHORT CIRCUIT IN BACK-UP ALARM RELAY SYSTEM)
Circuit diagram related to back-up alarm
D375A-5 20-485
TROUBLESHOOTING ERROR CODE [D190KA] (DISCONNECTION IN ACC SIGNAL DRIVE RELAY SYSTEM)
ERROR CODE [D190KA] (DISCONNECTION IN ACC SIGNAL DRIVE RELAY SYSTEM)
User code Error code Disconnection in ACC signal drive relay system
Trouble
D190KA (Steering controller system)
Contents of trouble When signal is output to ACC signal drive circuit, current does not flow.
Action of controller Stops outputting to ACC signal drive relay circuit.
Problem that
Turbocharger timer function does not work (if equipped).
appears on machine
Outputting to ACC signal drive relay (Voltage) can be checked in monitoring mode.
(Code 60500: Engine controller relay drive voltage)
Related information
Turn starting switch ON and OFF (when turbocharger timer is in operation).
aThis error code detects abnormality on primary side (coil side) of ACC signal drive relay and cannot
detect abnormality on secondary side (contact side).

Defective ACC signal drive without turning starting switch ON.
1 relay
SDR (male) Resistance
Between (1) (2) 200 400
ness
Wiring harness between NGICN3 (female)
Possible causes (18) SDR (female) (1)
and standard val- tor) Wiring harness between SDR (female) (2)
ue in normal state Resistance Max. 1
chassis ground
3 source in wiring harness
(Contact with 24 V circuit) Short circuit of wiring harness between
Voltage Max. 1 V
NGICN3 (female) (18) SDR (female) (1)
Defective transmission con- without turning starting switch ON.
4
troller SGICN3 (female) Resistance
Circuit diagram related to ACC signal drive relay
20-486 D375A-5
TROUBLESHOOTING ERROR CODE [D190KB] (SHORT CIRCUIT IN ACC SIGNAL DRIVE RELAY SYSTEM)
ERROR CODE [D190KB] (SHORT CIRCUIT IN ACC SIGNAL DRIVE RELAY SYSTEM)
User code Error code Short circuit in ACC signal drive relay system
Trouble
D190KB (Steering controller system)
Contents of trouble When signal is output to ACC signal drive circuit, abnormal current flowed.
Action of controller Stops outputting to ACC signal drive relay circuit.
Problem that
Turbocharger timer function does not work (if equipped).
appears on machine
Outputting to ACC signal drive relay (Voltage) can be checked in monitoring mode.
(Code 60500: Engine controller relay drive voltage)
Related information
Turn starting switch ON and OFF (when turbocharger timer is in operation).
aThis error code detects abnormality on primary side (coil side) of ACC signal drive relay and cannot
detect abnormality on secondary side (contact side).

Defective ACC signal drive without turning starting switch ON.
1 relay
SDR (male) Resistance
Between (1) (2) 200 400
Possible causes
and standard val-
(Contact with ground circuit) NGICN3 (female) (18) SDR (male) (1) with Resistance Min. 1 M
chassis ground
3
troller TMCN3 (female) Resistance
Circuit diagram related to ACC signal drive relay
D375A-5 20-487
TROUBLESHOOTING ERROR CODE [D5ZRKA] (DISCONNECTION IN SNAP SHOT SIGNAL)
ERROR CODE [D5ZRKA] (DISCONNECTION IN SNAP SHOT SIGNAL)
Action code Error code Snap shot switch: Disconnection (KA)

Trouble
D5ZRKA (Steering controller system)
Contents of
When the snap shot switch circuit is disconnected from the chassis ground, 24 V is not generated.
trouble
Action of
None in particular.
controller
Problem that
appears on
machine
Related
Enter the snap shot mode and apply a trigger.
information

Disconnection in wiring aPrepare with starting switch OFF, then carry out troubleshooting with-
harness (Disconnection in out turning starting switch ON.
1
wiring harness or defective Wiring harness between STCN2 (female) (9)
contact in connector) Voltage Max. 1 V
and V3B (female) (6)
aPrepare with starting switch OFF, then carry out troubleshooting with-
Short circuit with chassis out turning starting switch ON.
2 ground in wiring harness Between wiring harness between STCN2
Possible causes (Contact with ground circuit) (female) (9) and V3B (female) (6) and chassis Resistance Min. 1 Mz
and standard ground
value in normal aPrepare with starting switch OFF, then turn starting switch ON and
state carry out troubleshooting.
STCN2 Snap shot switch Voltage
Trigger Max. 1 V
Between (9) and
chassis ground Out of period just
20 30 V
after trigger
4 Defective VHMS controller
V3B Voltage
Between (6) and chassis ground 20 30 V
Circuit diagram related to snap shot switch
20-488 D375A-5
TROUBLESHOOTING ERROR CODE [D5ZRKB] (SHORT CIRUIT IN SNAP SHOT SIGNAL)
ERROR CODE [D5ZRKB] (SHORT CIRUIT IN SNAP SHOT SIGNAL)
Action code Error code Snap shot switch: Short circuit (KB)
Trouble
D5ZRKB (Steering controller system)
Contents of
When the snap shot switch circuit is disconnected from the chassis ground, 24 V is not generated.
trouble
Action of
None in particular.
controller
Problem that
appears on
machine
Related
Enter the snap shot mode and apply a trigger.
information

1 source in wiring harness Between wiring harness between STCN2
(Contact with 24-V circuit) (female) (9) and V3B (female) (6) and chassis Voltage Max. 1 V
ground
Possible causes aPrepare with starting switch OFF, then turn starting switch ON and
and standard carry out troubleshooting.
value in normal STCN2 Snap shot switch Voltage
state Trigger Max. 1 V
Between (9) and
chassis ground Out of period
20 30 V
just after trigger
3 Defective VHMS controller
V3B Voltage
Between (6) and chassis ground 20 30 V
Circuit diagram related to snap shot switch
D375A-5 20-489
TROUBLESHOOTING ERROR CODE [DAFRKR] (DEFECTIVE OF MONITOR PANEL CAN COMMUNICATION)
ERROR CODE [DAFRKR] (DEFECTIVE OF MONITOR PANEL CAN COMMUNICATION)
Action code Error code Monitor panel CAN communication: Defective communication (KR)
Trouble
CALL E03 DAFRKR (Monitor panel system)
Contents of
Monitor panel cannot recognize steering controller with CAN communication circuit.
trouble
Action of Flashes caution lamp and turns on caution buzzer.
controller Limits operation of engine and transmission.
System may not operate normally.
Problem that
appears on
machine
Display may show error code [dAFRKR] and [daFRKR] simultaneously.
Related
information

out turning starting switch ON.
Wiring harness between S04 (female) (1), (2)
Disconnection in wiring har- STCN2 (female) (32), TMCN2 (female) (32),
Resistance Max. 1 z
ness (Disconnection in wir- V23 (female) (A), CAN (female) (A), V4A
1
ing or defective contact in (female) (4)
connector) Wiring harness between S04 (female) (3) (4)
STCN2 (female) (22), TMCN2 (female) (22)
Resistance Max. 1 z
V23 (female) (B) CAN (female) (B), V4A
(female) (12)
Short circuit of wiring harness between S04
(female) (1), (2) STCN2 (female) (32),
TMCN2 (female) (32) V23 (female) (A), Resistance Min. 1 Mz
CAN (female) (A), V4A (female) (4) with chas-
sis ground
Possible causes (female) (3), (4) STCN2 (female) (22),
and standard TMCN2 (female) (22), V23 (female) (B) Resistance Min. 1 Mz
value in normal CAN (female) (B), V4A (female) (12) with
state chassis ground
TMCN2 (female) (32) V23 (female) (A) CAN Voltage Max. 1 V
Hot short circuit in wiring
(female) (A), V4A (female) (4) with chassis
3 harness (Contact with 24 V
ground
circuit)
TMCN2 (female) (22) V23 (female) (B) CAN Voltage Max. 1 V
(female) (B), V4A (female) (12) with chassis
ground
Defective CAN terminal out turning starting switch ON.
4
resistance V23 (male), CAN (male) Resistance
Between (A) (B) 120 z
If no problem is found in causes 1 to 4, it is suspected that monitor panel
Defective monitor panel or
5 or steering controller is defective. (Troubleshooting cannot be carried
defective steering controller
out since it is internal defect.)
20-490 D375A-5
TROUBLESHOOTING ERROR CODE [DAFRKR] (DEFECTIVE OF MONITOR PANEL CAN COMMUNICATION)
Circuit diagram related to CAN communication
D375A-5 20-491
ERROR CODE [DAQ0KK] (ABNORMALITY IN TRANSMISSION CONTROLLER POWER
TROUBLESHOOTING SUPPLY SYSTEM)

SUPPLY SYSTEM)
User code Error code Abnormality in transmission controller power supply system
Trouble
CALL E04 DAQ0KK (Transmission controller system)
Contents of trouble Source voltage of transmission controller is below 17 V.
Monitor panel may not display normally.
Problem that Relays and solenoids may not be driven and system may not operate normally as result.
appears on machine Once machine is stopped, engine speed is limited to medium (half).
Charge level (Voltage) of battery can be checked in monitoring mode.

1
2 Defective fusible link (96A)
ground.
Disconnection in wiring har- Wiring harness between TMCN3 (female) (1),
(11) CB3 (1)
defective contact in connec- Wiring harness between CB3 (2) fusible link
Resistance Max. 1
tor) battery relay terminal M
Wiring harness between TMCN3 (female)
Possible causes Resistance Max. 1
(21), (31), (32), (33) chassis ground
and standard val-
TMCN3 (female) (1), (11) CB3 (1) with chas- Resistance Min. 1 M
sis ground
Short circuit of wiring harness between CB3
(2) fusible link battery relay terminal M with Resistance Min. 1 M
chassis ground
5 TMCN3 Voltage
troller
Between (1), (11) (21), (31),
20 30 V
(32), (33)
20-492 D375A-5
Circuit diagram related to transmission controller power supply
D375A-5 20-493
TROUBLESHOOTING ERROR CODE [DAQ0KT] (ABNORMALITY IN TRANSMISSION CONTROLLER ROM)
ERROR CODE [DAQ0KT] (ABNORMALITY IN TRANSMISSION CONTROLLER ROM)
User code Error code Abnormality in transmission controller ROM

Trouble
E01 DAQ0KT (Transmission controller system)
Contents of trouble Information in transmission controller ROM (non-volatile memory) is abnormal.
Action of controller Sets internal adjustment values to default.
Problem that
Gear shifting feeling of transmission may become bad.
appears on machine

Possible causes
and standard val- Since trouble is in system, troubleshooting cannot be carried out.
ue in normal state 1 (If there is not visible trouble in machine, controller may be used as it
troller
is.)
20-494 D375A-5
ERROR CODE [DAQ5KK] (ABNORMALITY IN TRANSMISSION CONTROLLER 5 V
TROUBLESHOOTING POWER SUPPLY SYSTEM)
ERROR CODE [DAQ5KK] (ABNORMALITY IN TRANSMISSION CONTROLLER 5 V POWER

SUPPLY SYSTEM)
User code Error code Abnormality in transmission controller 5 V power supply system
Trouble
CALL03 DAQ5KK (Transmission controller system)
Voltage of 5 V power supply circuit for sensors of transmission controller is below 4.5 V or above 5.5 V.
Contents of trouble
Abnormal current flowed in 5 V power supply circuit for sensors of transmission controller.
Action of controller Stops 5 V power supply circuit from outputting if abnormal current flows.
Problem that
appears on machine

TL1 (male) Resistance
Defective forward-reverse Between (L) (J) 2 k 20%
1 potentiometer Sensor 1 (FR3) Between (L) chassis
(Internal short circuit) Min. 1 M
ground
Between (O) (Q) 2 k 20%
Sensor 2 (FR4) Between (O)
Min. 1 M
chassis ground
(Contact with ground circuit) TMCN1 (female) (22) TL1 (female) (L) or Resistance Min. 1 M
TL1 (female) (O) with chassis ground
(Contact with 24 V circuit) TMCN1 (female) (22) TL1 (female) (L) or Voltage Max. 1 V
TL1 (female) (O) with chassis ground
Defective transmission con- carry out troubleshooting.
4
troller TMCN1 Voltage
Between (22) (21) 4.5 5.5 V
20-496 D375A-5
Circuit diagram related to transmission controller 5 V power supply
D375A-5 20-497

POWER SUPPLY SYSTEM)
User code Error code Abnormality in transmission controller 24 V power supply system
Trouble
E01 DAQ6KK (Transmission controller system)
Voltage of 24 V power supply circuit for sensors of transmission controller is below 17 V or above 20 V.
Contents of trouble
Abnormal current flowed in 24 V power supply circuit for sensors of transmission controller.
Problem that
Work equipment oil pressure cannot be monitored in error mode.
appears on machine

When connector shown at right is disconnected, if error
Defective work equipment
code changes to P (to indicate that trouble is repaired),
large pump oil pressure sen- LPP
1 trouble is in system.
sor connector
aPrepare with starting switch OFF, then turn starting
switch ON and carry out troubleshooting.
Defective work equipment
code changes to P (to indicate that trouble is repaired),
small pump oil pressure sen- SPP
2 trouble is in system.
sor connector
Possible causes aPrepare with starting switch OFF, then turn starting
and standard val- switch ON and carry out troubleshooting.
(Contact with ground circuit) TMCN1 (female) (16) LPP (female) (B) or Resistance Min. 1 M
SPP (female) (B) with chassis ground
4
Between (16) (21) 20 30 V
20-498 D375A-5
ERROR CODE [DAQ9KQ] (ABNORMALITY IN SELECTION OF TRANSMISSION
TROUBLESHOOTING CONTROLLER SPECIFICATION)
ERROR CODE [DAQ9KQ] (ABNORMALITY IN SELECTION OF TRANSMISSION

CONTROLLER SPECIFICATION)
User code Error code Abnormality in selection of transmission controller specification

Trouble
CALL E04 DAQ9KQ (Transmission controller system)
Internal setting of transmission controller specification is different from specification setting signal
Contents of trouble
(Transmission controller cannot recognize specification setting normally).
Action of controller Stops transmission controller from outputting all signals.
Machine does not move at all.
Problem that
appears on machine

After adjustment mode is executed, if error code display again (in-
Defective adjustment of dicate that trouble is repaired), system is normal.
1
transmission controller Adjustment code 0003
Transmission controller specification set
Possible causes Disconnection in wiring har- aPrepare with starting switch OFF, then carry out troubleshooting
and standard val- ness without turning starting switch ON.
2
ue in normal state (Disconnection in wiring or de- Wiring harness between TMCN3 (female) (10)
fective contact in connector) chassis ground Resistance Max. 1
3
Between (10) chassis ground Max. 1 V
Circuit diagram related to transmission controller specification selection signal
D375A-5 20-499
ERROR CODE [DAQRKR] (DEFECTIVE OF TRANSMISSION CONTROLLER CAN
TROUBLESHOOTING COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM))

COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM))
Action code Error code Transmission controller CAN communication: Defective communication
Trouble (Abnormality in objective component system) (KR)
CALL E03 DAQRKR (Transmission controller system)
Contents of Transmission controller cannot recognize monitor panel, steering controller, engine controller, or VHMS
trouble controller with CAN communication circuit.
Problem that System may not operate normally.
appears on Once machine is stopped, engine speed is limited to medium (half).
machine Once machine is stopped, travel is limited to F1 and R1.
Related
information

Wiring harness between S04 (female) (1), (2)
Disconnection in wiring har- STCN2 (female) (32), TMCN2 (female) (32)
Resistance Max. 1 z
ness (Disconnection in wir- V23 (female) (A) CAN (female) (A), V4A
1
ing or defective contact in (female) (4)
connector) Wiring harness between S04 (female) (3), (4)
STCN2 (female) (22), TMCN2 (female) (22),
Resistance Max. 1 z
V23 (female) (B), CAN (female) (B), V4A
(female) (12)
TMCN2 (female) (32), V23 (female) (A), Resistance Min. 1 Mz
sis ground
Possible causes (Contact with ground circuit)
and standard
value in normal
TMCN2 (female) (22), V23 (female) (B) Resistance Min. 1 Mz
state
CAN (female) (B), V4A (female) (12) with
chassis ground
TMCN2 (female) (32), V23 (female) (A), Voltage Max. 1 V
3 harness
sis ground
(Contact with 24 V circuit)
TMCN2 (female) (22), V23 (female) (B), Voltage Max. 1 V
chassis ground
4
20-500 D375A-5

Possible causes Defective monitor panel,
defective engine controller, If no problem is found in causes 1 to 4, it is suspected that monitor panel,
and standard
defective transmission con- engine controller, transmission controller, steering controller or VHMS
value in normal 5
state troller, defective steering controller is defective. (Troubleshooting cannot be carried out since it is
controller or VHMS control- internal defect.)
ler
D375A-5 20-501
ERROR CODE [DAQSKR] (DEFECTIVE OF TRANSMISSION CONTROLLER S-NET

Action code Error code Transmission controller S-NET communication: Defective communica-
Trouble tion (Abnormality in objective component system) (KR)
E01 DAQSKR (Transmission controller system)
Contents of trouble Transmission controller cannot recognize S-NET.
Action of controller Takes no particular action.
Problem that
appears on Machine may not acquire switch signal of monitor panel, not allowing normal operation of system.
machine

Disconnection in wiring har- aPrepare with starting switch OFF, then carry out troubleshooting with-
ness (Disconnection in wir- out turning starting switch ON.
1
ing or defective contact in Wiring harness between TMCN2 (female) (21)
connector) Resistance Max. 1 z
S01 (female) (8)
2 ground in wiring harness Short circuit of wiring harness between TMCN2
(Contact with ground circuit) (female) (21) S01 (female) (8) with chassis Resistance Min. 1 Mz
ground
Possible causes aPrepare with starting switch OFF, then turn starting switch ON and
and standard Hot short circuit in wiring carry out troubleshooting.
value in normal 3 harness Short circuit of wiring harness between TMCN2
state (Contact with 24 V circuit) (female) (21) S01 (female) (8) with chassis Voltage Max. 1 V
ground
Defective monitor panel carry out troubleshooting.
4
(Switch module) S01 Voltage
Between (8) chassis ground 69V
5
Between (21) (31) 69V
20-502 D375A-5
Circuit diagram related to S-NET COMMUNICATION
D375A-5 20-503
ERROR CODE [DB30KK] (ABNORMALITY IN STEERING CONTROLLER POWER
ERROR CODE [DB30KK] (ABNORMALITY IN STEERING CONTROLLER POWER SUPPLY

SYSTEM)
User code Error code Abnormality in steering controller power supply system
Trouble
CALL E04 DB30KK (Steering controller system)
Contents of trouble Source voltage of steering controller is below 17 V.
Problem that Relays and solenoids may not be driven and system may not operate normally as result.
appears on machine Once machine is stopped, engine speed is limited to medium (half).
Charge level (Voltage) of battery can be checked in monitoring mode.

1
2 Defective fusible link (96A)
ground.
Disconnection in wiring har- Wiring harness between NGICN3 (female)
(1), (11) CB1 (1)
defective contact in connec- Wiring harness between CB1 (2) fusible link
Resistance Max. 1
tor) battery relay terminal M
(21), (31), (32), (33) chassis ground
and standard val-
NGICN3 (female) (1), (11) CB1 (1) with Resistance Min. 1 M
chassis ground
Short circuit of wiring harness between CB1
(2) fusible link battery relay terminal M with Resistance Min. 1 M
chassis ground
5 Defective steering controller NGICN3 Voltage
Between (1), (11) (21), (31),
20 30 V
(32), (33)
20-504 D375A-5
ERROR CODE [DB30KK] (ABNORMALITY IN STEERING CONTROLLER POWER
Circuit diagram related to steering controller power supply
D375A-5 20-505
TROUBLESHOOTING ERROR CODE [DB30KT] (ABNORMALITY IN STEERING CONTROLLER ROM)
ERROR CODE [DB30KT] (ABNORMALITY IN STEERING CONTROLLER ROM)
User code Error code Abnormality in steering controller ROM

Trouble
E02 DB30KT (Steering controller system)
Contents of trouble Information in steering controller ROM (non-volatile memory) is abnormal.
Sets internal adjustment values to default.
Problem that Steering performance may lower.
appears on machine Braking performance may lower.

Possible causes
and standard val- Since trouble is in system, troubleshooting cannot be carried out.
ue in normal state 1 Defective steering controller (If there is not visible trouble in machine, controller may be used as it
is.)
20-506 D375A-5
ERROR CODE [DB35KK] (ABNORMALITY IN STEERING CONTROLLER 5 V POWER

SUPPLY SYSTEM)
User code Error code Abnormality in steering controller 5 V power supply system
Trouble
Voltage of 5 V power supply circuit for sensors of steering controller is below 4.5 V or above 5.5 V.
Contents of trouble
Abnormal current flowed in 5 V power supply circuit for sensors of steering controller.
Problem that
appears on machine

Defective fuel control dial code changes to P (to indicate that trouble is repaired), Fuel control
1 trouble is in system. dial
(Internal short circuit) aDisconnect connector with starting switch OFF, then connector
turn starting switch ON and carry out troubleshooting.
Defective brake potentiome- code changes to P (to indicate that trouble is repaired),
BRK
2 ter trouble is in system.
aDisconnect connector with starting switch OFF, then connector
Defective acceleration sen- code changes to P (to indicate that trouble is repaired),
SS3
3 sor trouble is in system.
aDisconnect connector with starting switch OFF, then connector
TL1 (male) Resistance
Defective steering potenti- Between (A) (G) 2 k 20%
4 ometer Sensor 1 (ST1) Between (A) chassis
Possible causes Min. 1 M
(Internal short circuit) ground
and standard val-
ue in normal state Between (M) (F) 2 k 20%
Sensor 2 (ST2) Between (M)
Min. 1 M
chassis ground
5 ground in wiring harness NGICN1 (female) (22) TL1 (female) (A), TL1
(Contact with ground circuit) (female) (M), fuel control dial connector (fe- Resistance Min. 1 M
male) (1), BRK (female) (C), or SS3 (female)
(8) with chassis ground
Short circuit with power Short circuit of wiring harness between
6 source in wiring harness NGICN1 (female) (22) TL1 (female) (A), TL1
(Contact with 24 V circuit) (female) (M), fuel control dial connector (fe- Voltage Max. 1 V
male) (1), BRK (female) (C), or SS3 (female)
(8) with chassis ground
NGICN1 Voltage
Between (22) (21) 4.5 5.5 V
20-508 D375A-5
D375A-5 20-509

SUPPLY SYSTEM)
User code Error code Abnormality in steering controller 24 V power supply system
Trouble
Voltage of 24 V power supply circuit for sensors of steering controller is below 17 V or above 30 V.
Contents of trouble
Abnormal current flowed in 24 V power supply circuit for sensors of steering controller.
Problem that
appears on machine

Defective machine inclina- code changes to P (to indicate that trouble is repaired),
PAS
1 tion angle sensor trouble is in system.
connector
(Internal short circuit) aDisconnect connector with starting switch OFF, then
(Contact with ground circuit) NGICN1 (female) (16) PAS (female) (C) with Resistance Min. 1 M
chassis ground
NGICN1 Voltage
Between (16) (21) 20 30 V
Circuit diagram related to steering controller 24 V power supply
20-510 D375A-5
ERROR CODE [DB39KQ] (ABNORMALITY IN SELECTION OF STEERING
TROUBLESHOOTING CONTROLLER SPECIFICATION)
ERROR CODE [DB39KQ] (ABNORMALITY IN SELECTION OF STEERING CONTROLLER

SPECIFICATION)
User code Error code Abnormality in selection of steering controller specification

Trouble
CALL E04 DB39KQ (Steering controller system)
Internal setting of steering controller specification is different from specification setting signal (Steer-
Contents of trouble
ing controller cannot recognize specification setting normally).
Action of controller Stops steering controller from outputting all signals.
Machine does not move at all.
Problem that
appears on machine

After adjustment mode is executed, if error code changes to P (to in-
Defective adjustment of dicate that trouble is repaired), system is normal.
1
steering controller Adjustment code:
5A [Check of specification code (Steering controller)]
and standard val- 2 (Disconnection in wiring or
ue in normal state defective contact in connec- Wiring harness between NGICN3 (female) Resistance Max. 1
tor) (20) chassis ground
NGICN3 Voltage
Between (20) chassis ground Max. 1 V
Circuit diagram related to steering controller specification selection signal
D375A-5 20-511
ERROR CODE [DB3RKR] (DEFECTIVE OF STEERING CONTROLLER CAN

Action code Error code Defective of steering controller CAN communication

Trouble (Abnormality in objective component system)
CALL E03 DB3RKR (Steering controller system)
Contents of Steering controller cannot recognize monitor panel, transmission controller, engine controller, or VHMS
trouble controller with CAN communication circuit.
Problem that System may not operate normally.
appears on Once machine is stopped, engine speed is limited to medium (half).
machine Once machine is stopped, travel is limited to F1 and R1.
Related
information

Between wiring harness between S04 (female)
Disconnection in wiring har- (1), (2) STCN2 (female) (32), TMCN2
Resistance Max. 1 z
ness (Disconnection in wir- (female) (32) V23 (female) (A), CAN
1
ing or defective contact in (female) (A), V4A (female) (4)
connector) Wiring harness between S04 (female) (3) (4)
STCN2 (female) (22), TMCN2 (female) (22),
Resistance Max. 1 z
V23 (female) (B), CAN (female), V4A
(female) (12)
TMCN2 (female) (32), V23 (female) (A), Resistance Min. 1 Mz
sis ground
Possible causes (Contact with ground circuit)
and standard
value in normal
TMCN2 (female) (22), V23 (female) (B), Resistance Min. 1 Mz
state
chassis ground
aPrepare with starting switch OFF, turn starting switch ON and carry out
troubleshooting.
(female) (1), (2), STCN2 (female) (32),
TMCN2 (female) (32), V23 (female) (A), Voltage Max. 1 V
sis ground
circuit)
TMCN2 (female) (22), ECN2 (female) (22), Voltage Max. 1 V
V23 (female) (B), CAN (female) (B), V4A
(female) (12) with chassis ground
4
20-512 D375A-5
D375A-5 20-513
TROUBLESHOOTING ERROR CODE [DB3SKR] [ABNORMALITY IN NETWORK SYSTEM (STEERING)]
ERROR CODE [DB3SKR] [ABNORMALITY IN NETWORK SYSTEM (STEERING)]
User code Error code Abnormality in network system (steering)

Trouble
CALL E03 DB3SKR (Steering controller system)
Contents of trouble Steering controller detected abnormality in S-NET.
Shoe slip control (SSC) function may not work.
Problem that
appears on machine
Error code [dB3RKR] may be displayed simultaneously.

ness
Wiring harness between S03 (female) (9)
NGICN2 (female) (21)
tor) Wiring harness between S03 (female) (8)
Resistance Max. 1
2 ground in wiring harness Short circuit of wiring harness between S03
(Contact with ground circuit) (female) (9) S01 (female) (8) or NGICN2 (fe- Resistance Min. 1 M
male) (21) with chassis ground
Possible causes
and standard val- aPrepare with starting switch OFF, then turn starting switch ON and
ue in normal state Short circuit with power carry out troubleshooting.
3 source in wiring harness Short circuit of wiring harness between S03
(Contact with 24 V circuit) (female) (9) S01 (female) (8) or NGICN2 (fe- Voltage Max. 1 V
Defective monitor panel carry out troubleshooting.
4
(tachometer module) S03 Voltage
Between (9) (8) 69V
NGICN2 Voltage
Between (21) (31) 69V
20-514 D375A-5
TROUBLESHOOTING ERROR CODE [DBBRKR] (ABNORMALITY IN J1939 COMMUNICATION SYSTEM)
ERROR CODE [DBBRKR] (ABNORMALITY IN J1939 COMMUNICATION SYSTEM)
User code Error code Abnormality in J1939 communication system

Trouble
CALL E04 DBBRKR (Steering controller system)
Contents of trouble Steering controller cannot receive communication signal of J1939 communication.
Action of controller Cannot receive communication information from engine controller.
Monitoring mode of engine controller system cannot be used.
Problem that
Error codes of engine controller system cannot be recorded.
appears on machine
Engine information cannot be displayed on monitor panel normally.
J1939 communication is communication circuit between engine controller and steering controller. Al-
Related information though transmission controller is connected to this circuit, it does not communicate.

1
(Disconnection in wiring or de- Wiring harness between NGICN2 (female)
fective contact in connector) (22) ECMB (female) (22) Resistance Max. 1
Reset according to following procedure, then check displayed error

code to see which controller is defective.
Possible causes When P (reset) is displayed: Steering controller is defective.
and standard val- When E (detection) is displayed: Engine controller is defective.
ue in normal state 1)With starting switch turned OFF, exchange steering controller and
Defective steering controller transmission controller.
2 2)Turn starting switch ON.
or engine controller
3)Set monitor panel in adjustment mode (error mode) and execute ad-
justment codes [0002] and [0003].
4)Turn starting switch OFF and ON.
5)Set monitor panel in error code display mode and check displayed
code.
aAfter checking, return controllers to original states.
Circuit diagram related to J1939 communication
D375A-5 20-515
TROUBLESHOOTING ERROR CODE [DD12KA] (DISCONNECTION IN SHIFT-UP SWITCH SYSTEMS)
ERROR CODE [DD12KA] (DISCONNECTION IN SHIFT-UP SWITCH SYSTEMS)
User code Error code Disconnection in shift-up switch systems

Trouble
E02 DD12KA (Transmission controller system)
Contents of trouble Signals of both shift-up switch circuit systems are turned OFF simultaneously.
Assumes that switch is not pressed.
Problem that Transmission gear cannot be shifted up.
appears on machine Auto shift-down function does not work.
NO and NC signals of both switch systems are for detecting operation and error respectively.
Inputting from shift-up switch (ONOFF) can be checked in monitoring mode.
Related information
(Code 40905: Transmission controller input 1)
Method of reproducing error code: Turn starting switch ON and operate shift-up switch.

Shift-up switch
Defective shift-up switch TL1 (male)
OFF (Pressed) ON (Released)
1 (Internal disconnection or
short circuit) Resistance between
Max. 1 Min. 1 M
(N) (U)
Resistance between
Min. 1 M Max. 1
(N) (B)
TL1 (female) (U)
defective contact in connec- Wiring harness between TMCN2 (female) (37)
Resistance Max. 1
TL1 (female) (B)
Possible causes tor)
Wiring harness between TMCN1 (female) (4),
and standard val- Resistance Max. 1
(10) TL1 (female) (N)
ue in normal state
TMCN1 (female) (6) TL1 (female) (U) with Voltage Max. 1 V
chassis ground
TMCN2 (female) (37) TL1 (female) (B) with Voltage Max. 1 V
chassis ground
Shift-up switch
TMCN1, TMCN2
Defective transmission con- OFF (Released) ON (Pressed)
4
troller Voltage between TMCN1
Max. 1 V 5 11 V
(6) TMCN1 (4), (10)
Voltage between TMCN2
5 11 V Max. 1 V
(37) TMCN1 (4), (10)
20-516 D375A-5
TROUBLESHOOTING ERROR CODE [DD12KA] (DISCONNECTION IN SHIFT-UP SWITCH SYSTEMS)
Circuit diagram related to shift-up switch and shift-down switch
D375A-5 20-517
TROUBLESHOOTING ERROR CODE [DD12KB] (SHORT CIRCUIT IN SHIFT-UP SWITCH SYSTEMS)
ERROR CODE [DD12KB] (SHORT CIRCUIT IN SHIFT-UP SWITCH SYSTEMS)
User code Error code Short circuit in shift-up switch systems

Trouble
E02 DD12KB (Transmission controller system)
Contents of trouble Signals of both shift-up switch circuit systems are turned ON simultaneously.
Problem that Transmission gear cannot be shifted up.
Inputting from shift-up switch (ONOFF) can be checked in monitoring mode.
Related information
Method of reproducing error code: Turn starting switch ON and operate shift-up switch.

Shift-up switch
Defective shift-up switch TL1 (male)
Max. 1 Min. 1 M
(N) (U)
Resistance between
Min. 1 M Max. 1
(N) (B)
TMCN1 (female) (6) TL1 (female) (U) with Resistance Min. 1 M
chassis ground
Possible causes TMCN2 (female) (37) TL1 (female) (B) with Resistance Min. 1 M
and standard val- chassis ground
ue in normal state
TMCN1 (female) (6) TL1 (female) (U) with Voltage Max. 1 V
chassis ground
TMCN2 (female) (37) TL1 (female) (B) with Voltage Max. 1 V
chassis ground
Shift-up switch
TMCN1, TMCN2
4
Max. 1 V 5 11 V
(6) TMCN1 (4), (10)
5 11 V Max. 1 V
(37) TMCN1 (4), (10)
20-518 D375A-5
TROUBLESHOOTING ERROR CODE [DD12KB] (SHORT CIRCUIT IN SHIFT-UP SWITCH SYSTEMS)
D375A-5 20-519
TROUBLESHOOTING ERROR CODE [DD13KA] (DISCONNECTION IN SHIFT-DOWN SWITCH SYSTEMS)
ERROR CODE [DD13KA] (DISCONNECTION IN SHIFT-DOWN SWITCH SYSTEMS)
User code Error code Disconnection in shift-down switch systems

Trouble
Contents of trouble Signals of both shift-down switch circuit systems are turned ON or OFF simultaneously.
Problem that Transmission gear cannot be shifted down.
Inputting from shift-down switch (ONOFF) can be checked in monitoring mode.
Related information
Method of reproducing error code: Turn starting switch ON and operate shift-down switch.

Shift-up switch
Defective shift-down switch TL1 (male)
Max. 1 Min. 1 M
(D) (V)
Resistance between
Min. 1 M Max. 1
(D) (C)
TL1 (female) (V)
Resistance Max. 1
TL1 (female) (C)
Possible causes tor)
Wiring harness between TMCN1 (female) (4),
(10) TL1 (female) (D)
ue in normal state
TMCN3 (female) (19) TL1 (female) (V) with Voltage Max. 1 V
chassis ground
TMCN3 (female) (29) TL1 (female) (C) with Voltage Max. 1 V
chassis ground
Shift-up switch
TMCN1, TMCN3
4
Max. 1 V 5 11 V
(19) TMCN1 (4), (10)
5 11 V Max. 1 V
(29) TMCN1 (4), (10)
20-520 D375A-5
TROUBLESHOOTING ERROR CODE [DD13KA] (DISCONNECTION IN SHIFT-DOWN SWITCH SYSTEMS)
D375A-5 20-521
TROUBLESHOOTING ERROR CODE [DD13KB] (SHORT CIRCUIT IN SHIFT-DOWN SWITCH SYSTEMS)
ERROR CODE [DD13KB] (SHORT CIRCUIT IN SHIFT-DOWN SWITCH SYSTEMS)
User code Error code Short circuit in shift-down switch systems

Trouble
Contents of trouble Signals of both shift-down switch circuit systems are turned ON or OFF simultaneously.
Problem that Transmission gear cannot be shifted down.
Inputting from shift-down switch (ONOFF) can be checked in monitoring mode.
Related information
Method of reproducing error code: Turn starting switch ON and operate shift-down switch.

Shift-up switch
Defective shift-down switch TL1 (male)
Max. 1 Min. 1 M
(D) (V)
Resistance between
Min. 1 M Max. 1
(D) (C)
Possible causes
and standard val-
TMCN3 (female) (19) TL1 (female) (V) with Resistance Min. 1 M
ue in normal state 2 ground in wiring harness
chassis ground
TMCN3 (female) (29) TL1 (female) (C) with Resistance Min. 1 M
chassis ground
Shift-up switch
TMCN1, TMCN3
3
Max. 1 V 5 11 V
(19) TMCN1 (4), (10)
5 11 V Max. 1 V
(29) TMCN1 (4), (10)
20-522 D375A-5
TROUBLESHOOTING ERROR CODE [DD13KB] (SHORT CIRCUIT IN SHIFT-DOWN SWITCH SYSTEMS)
D375A-5 20-523
ERROR CODE [DD14KA] (DISCONNECTION IN PARKING BRAKE LEVER SWITCH
TROUBLESHOOTING SYSTEMS)

SYSTEMS)
User code Error code Disconnection in parking brake lever switch systems
Trouble
CALL E03 DD14KA (Transmission controller system)
Contents of trouble Signals of both parking brake lever switch circuit systems are turned ON or OFF simultaneously.
Action of controller Assumes that parking brake lever is at FREE position.
aSince parking brake switch signal is used by both transmission controller and steering controller, re-
lated codes may be displayed simultaneously, depending on troubled part.
(Related codes: DDQ2L4, DDQ2KA)
Related information NO and NC signals of both switch systems are for detecting operation and error respectively.
Inputting from parking brake switch (ONOFF) can be checked in monitoring mode.
Method of reproducing error code: Turn starting switch ON and operate parking brake lever.
When only error code [DD14KA] is displayed

ness
circuit branching point
tor) Wiring harness between TMCN2 (female) (12)
Resistance Max. 1
Possible causes circuit branching point
ue in normal state carry out troubleshooting.
Parking brake lever
TMCN2
Defective transmission con- At FREE At LOCK
2
troller Between (18)
Max. 1 V 5 11 V
chassis ground
Between (12)
5 11 V Max. 1 V
chassis ground
When error codes [DD14KA] and [DDQ2KA] are displayed simultaneously

Defective parking brake le-
ver switch Parking brake lever
1 NSW
(Internal disconnection or At FREE At LOCK
short circuit) Between (A) (B) Max. 1 Min. 1 M
Between (A) (B) Min. 1 M Max. 1
Wiring harness between NSW (female) (B)
Possible causes ness Resistance Max. 1
circuit merging point
and standard val- 2 (Disconnection in wiring or
ue in normal state Wiring harness between NSW (female) (C)
defective contact in connec- Resistance Max. 1
tor)
Wiring harness between NSW (female) (A)
Resistance Max. 1
chassis ground
Short circuit with power Short circuit of wiring harness between NSW
(female) (B) TMCN1 (female) (18) Voltage Max. 1 V
NGICN2 (female) (5) with chassis ground
Short circuit of wiring harness between NSW
(female) (C) TMCN1 (female) (12) Voltage Max. 1 V
20-524 D375A-5
Circuit diagram related to parking brake switch
D375A-5 20-525
ERROR CODE [DD14KB] (SHORT CIRCUIT IN PARKING BRAKE LEVER SWITCH

SYSTEMS)
User code Error code Short circuit in parking brake lever switch systems
Trouble
CALL E03 DD14KB (Transmission controller system)
Contents of
Signals of both parking brake lever switch circuit systems are turned ON or OFF simultaneously.
trouble

Assumes that parking brake lever is at FREE position.
Problem that
appears on
machine
(Related codes: DDQ2KB, DDQ2L4)
Related
information Inputting from parking brake switch (ONOFF) can be checked in monitoring mode.

Defective parking brake le-
Parking brake lever
ver switch NSW
1
Between (A) (B) Min. 1 M Max. 1
Short circuit with chassis Short circuit of wiring harness between NSW
Possible causes (female) (B) TMCN1 (female) (18) Resistance Min. 1 M
and standard val- 2 ground in wiring harness
ue in normal state (Contact with ground circuit)
(female) (C) TMCN1 (female) (12) Resistance Min. 1 M
Parking brake lever
TMCN2
Defective transmission con- At FREE At LOCK
3
troller Between (18)
Max. 1 V 5 11 V
chassis ground
Between (12)
5 11 V Max. 1 V
chassis ground
20-526 D375A-5
D375A-5 20-527
ERROR CODE [DD59KA] (DISCONNECTION IN BLADE DUAL SELECTOR SOLENOID
ERROR CODE [DD59KA] (DISCONNECTION IN BLADE DUAL SELECTOR SOLENOID

SYSTEM)
User code Error code Disconnection in blade dual selector solenoid system
Trouble
Contents of trouble When signal is output to blade dual selector solenoid circuit, current does not flow.
Action of controller Stops outputting to blade dual selector solenoid circuit.
Problem that Blade dual tilt mechanism does not work (When dual tilt operation is performed, single tilt mechanism
appears on machine works).
Outputting to blade dual selector solenoid (Voltage) can be checked in monitoring mode.
Related information (Code 70400: Blade dual solenoid drive voltage)
Method of reproducing error code: Turn starting switch ON and perform blade dual tilt operation.

Defective blade dual selec- without turning starting switch ON.
1 tor solenoid
SOL2 (male) Resistance
Between (1) (2) 10 40
ness
SOL2 (female) (1)
and standard val- tor) Wiring harness between SOL (female) (2)
Resistance Max. 1
ue in normal state chassis ground
(Contact with 24 V circuit) TMCN3 (female) (17) SOL2 (female) (1) Voltage Max. 1 V
with chassis ground
4
Circuit diagram related to blade dual selector solenoid
20-528 D375A-5
ERROR CODE [DD59KB] (SHORT CIRCUIT IN BLADE DUAL SELECTOR SOLENOID
ERROR CODE [DD59KB] (SHORT CIRCUIT IN BLADE DUAL SELECTOR SOLENOID

SYSTEM)
User code Error code Short circuit in blade dual selector solenoid system
Trouble
Contents of trouble When signal was output to blade dual selector solenoid circuit, abnormal current flowed.
Action of controller Stops outputting to blade dual selector solenoid circuit.
Outputting to blade dual selector solenoid (Voltage) can be checked in monitoring mode.
Related information (Code 70400: Blade dual solenoid drive voltage)
Method of reproducing error code: Turn starting switch ON and perform blade dual tilt operation.

Defective blade dual selec-
1 tor solenoid SOL2 (male) Resistance
(Internal short circuit) Between (1) (2) 10 40
Between (1) chassis ground Min. 1 M
(Contact with ground circuit) TMCN3 (female) (17) SOL2 (female) (1) Resistance Min. 1 M
with chassis ground
3
Circuit diagram related to blade dual selector solenoid
D375A-5 20-529
ERROR CODE [DD5AKA] (DISCONNECTION IN BLADE PITCH SELECTOR SOLENOID
ERROR CODE [DD5AKA] (DISCONNECTION IN BLADE PITCH SELECTOR SOLENOID

SYSTEM)
User code Error code Disconnection in blade pitch selector solenoid system
Trouble
E02 DD5AKA (Transmission controller system)
Contents of trouble When signal is output to blade pitch selector solenoid circuit, current does not flow.
Stops outputting to blade pitch selector solenoid circuit.
Problem that
Blade does not pitch (When pitching operation is performed, blade tilts).
appears on machine
Outputting to blade pitch selector solenoid (Voltage) can be checked in monitoring mode.
Related information (Code 31625: Blade pitch solenoid drive voltage)
Method of reproducing error code: Turn starting switch ON and perform blade pitch operation.

Defective blade pitch selec- without turning starting switch ON.
1 tor solenoid
SOL1 (male) Resistance
Between (1) (2) 10 40
ness
SOL1 (female) (1)
and standard val- tor) Wiring harness between SOL1 (female) (2)
Resistance Max. 1
ue in normal state chassis ground
(Contact with 24 V circuit) TMCN3 (female) (37) SOL1 (female) (1) Voltage Max. 1 V
with chassis ground
4
Circuit diagram related to blade pitch selector solenoid
20-530 D375A-5
ERROR CODE [DD5AKB] (SHORT CIRCUIT IN BLADE PITCH SELECTOR SOLENOID
ERROR CODE [DD5AKB] (SHORT CIRCUIT IN BLADE PITCH SELECTOR SOLENOID

SYSTEM)
User code Error code Short circuit in blade pitch selector solenoid system
Trouble
E02 DD5AKB (Transmission controller system)
Contents of trouble When signal was output to blade pitch selector solenoid circuit, abnormal current flowed.
Stops outputting to blade pitch selector solenoid circuit.
Problem that
appears on machine
Outputting to blade pitch selector solenoid (Voltage) can be checked in monitoring mode.
Related information (Code 31625: Blade pitch solenoid drive voltage)
Method of reproducing error code: Turn starting switch ON and perform blade pitch operation.

Defective blade pitch selec-
1 tor solenoid SOL1 (male) Resistance
(Contact with ground circuit) TMCN3 (female) (37) SOL1 (female) (1) Resistance Min. 1 M
with chassis ground
3
Circuit diagram related to blade pitch selector solenoid
D375A-5 20-531
ERROR CODE [DDN2LD] (SHORT CIRCUIT IN BLADE TILT RIGHT OIL PRESSURE
TROUBLESHOOTING SWITCH SYSTEM)
ERROR CODE [DDN2LD] (SHORT CIRCUIT IN BLADE TILT RIGHT OIL PRESSURE
SWITCH SYSTEM)
User code Error code Short circuit in blade tilt right oil pressure switch system
Trouble
E02 DDN2LD (Transmission controller system)
Contents of trouble Signal of blade tilt right oil pressure switch circuit was kept turned ON for 180 seconds.
Judges that oil pressure switch is turned OFF.
Problem that When pitch and dump operation or right dual tilt operation is performed, right single tilt mechanism
appears on machine operates.
Inputting from blade tilt right oil pressure switch (ONOFF) can be checked in monitoring mode.
(Code 40908: Blade lever oil pressure switch input)
Related information
Turn starting switch ON (Error code is reproduced after 180 seconds).

After reproductive operation, if error code P is still displayed (to indi-
Defective operation of lever
1 cate that trouble is repaired), lever may have been so operated that
(Electric system is normal)
error would be detected.
troubleshooting.
Defective blade tilt right oil
2 pressure switch TRS (male) Blade lever Resistance
(Internal short circuit) Neutral Min. 1 M
Between (1) (2)
Possible causes Right tilt Max. 1
ue in normal state Short circuit with chassis without turning starting switch ON.
(Contact with ground circuit) TMCN2 (female) (6) TRS (female) (1) with Resistance Max.
1 M
chassis ground
troubleshooting.
Defective transmission con- TMCN2, TMCN1 Blade lever Voltage
4
troller
Between TMCN2 (6) Neutral 5 11 V
TMCN1 (4), (10) Right tilt Max. 1 V
Circuit diagram related to blade tilt right oil pressure switch
20-532 D375A-5
ERROR CODE [DDN3LD] (SHORT CIRCUIT IN BLADE TILT LEFT OIL PRESSURE
ERROR CODE [DDN3LD] (SHORT CIRCUIT IN BLADE TILT LEFT OIL PRESSURE SWITCH
SYSTEM)
User code Error code Short circuit in blade tilt left oil pressure switch system
Trouble
E02 DDN3LD (Transmission controller system)
Contents of trouble Signal of blade tilt left oil pressure switch circuit was kept turned ON for 180 seconds.
Judges that oil pressure switch is turned OFF.
Problem that When pitch and dump operation or right dual tilt operation is performed, left single tilt mechanism op-
appears on machine erates.
Inputting from blade tilt left oil pressure switch (ONOFF) can be checked in monitoring mode.
(Code 40908: Blade lever oil pressure switch input)
Related information

troubleshooting.
Defective blade tilt left oil
2 pressure switch TLS (male) Blade lever Resistance
Between (1) (2)
Possible causes Left tilt Max. 1
(Contact with ground circuit) TMCN2 (female) (16) TLS (female) (1) with Resistance Max.
1 M
chassis ground
troubleshooting.
Defective transmission con- TMCN2, TMCN1 Blade lever Voltage
4
troller
TMCN1 (4), (10) Left tilt Max. 1 V
Circuit diagram related to blade tilt left oil pressure switch
D375A-5 20-533
TROUBLESHOOTING ERROR CODE [DDN7KA] (DISCONNECTION IN BLADE PITCH SWITCH SYSTEMS)
ERROR CODE [DDN7KA] (DISCONNECTION IN BLADE PITCH SWITCH SYSTEMS)
User code Error code Disconnection in blade pitch switch systems

Trouble
E02 DDN7KA (Transmission controller system)
Contents of trouble Signals of both blade pitch switch circuit systems are turned ON or OFF simultaneously.
Problem that
appears on machine
Inputting from blade pitch switch (ONOFF) can be checked in monitoring mode.
Related information
(Code 70300: Blade lever knob switch input)
Method of reproducing error code: Turn starting switch ON and operate blade pitch switch.

Blade pitch switch
P03 (male)
Defective blade pitch switch OFF (Released) ON (Pressed)
1
(Internal disconnection) Resistance between
Max. 1 Min. 1 M
(1) (5)
Resistance between
Min. 1 M Max. 1
(1) (2)
Disconnection in wiring har- Wiring harness between TMCN2 (female) (15)
P03 (female) (5)
Resistance Max. 1
tor) P03 (female) (2)
Possible causes Wiring harness between TMCN1 (female) (4),
(10) P03 (female) (1)
ue in normal state
Short circuit with power
TMCN2 (female) (15) P03 (female) (5) with Voltage Max. 1 V
chassis ground
chassis ground
Blade pitch switch
TMCN1, TMCN2
4
troller
Max. 1 V 5 11 V
(15) TMCN1 (4), (10)
5 11 V Max. 1 V
(5) TMCN1 (4), (10)
20-534 D375A-5
TROUBLESHOOTING ERROR CODE [DDN7KA] (DISCONNECTION IN BLADE PITCH SWITCH SYSTEMS)
Circuit diagram related to blade tilt switch and blade pitch switch
D375A-5 20-535
TROUBLESHOOTING ERROR CODE [DDN7KB] (SHORT CIRCUIT IN BLADE PITCH SWITCH SYSTEMS)
ERROR CODE [DDN7KB] (SHORT CIRCUIT IN BLADE PITCH SWITCH SYSTEMS)
User code Error code Short circuit in blade pitch switch systems
Trouble
E02 DDN7KB (Transmission controller system)
Contents of trouble Signals of both blade pitch switch circuit systems are turned ON or OFF simultaneously.
Problem that
appears on machine
Inputting from blade pitch switch (ONOFF) can be checked in monitoring mode.
Related information
Method of reproducing error code: Turn starting switch ON and operate blade pitch switch.

Blade pitch switch
P03 (male)
Defective blade pitch switch OFF (Released) ON (Pressed)
1
(Short circuit) Resistance between
Max. 1 Min. 1 M
(1) (5)
Resistance between
Min. 1 M Max. 1
(1) (2)
Possible causes Short circuit of wiring harness between
and standard val- Short circuit with chassis
TMCN2 (female) (15) P03 (female) (5) with Resistance Min. 1 M
chassis ground
chassis ground
Blade pitch switch
TMCN1, TMCN2
3
troller
Max. 1 V 5 11 V
(15) TMCN1 (4), (10)
5 11 V Max. 1 V
(5) TMCN1 (4), (10)
20-536 D375A-5
TROUBLESHOOTING ERROR CODE [DDN7KB] (SHORT CIRCUIT IN BLADE PITCH SWITCH SYSTEMS)
D375A-5 20-537
TROUBLESHOOTING ERROR CODE [DDN9KA] (DISCONNECTION IN BLADE TILT SWITCH SYSTEMS)
ERROR CODE [DDN9KA] (DISCONNECTION IN BLADE TILT SWITCH SYSTEMS)
User code Error code Disconnection in blade tilt switch systems

Trouble
E02 DDN9KA (Transmission controller system)
Contents of trouble Signals of both blade tilt switch circuit systems are turned ON or OFF simultaneously.
Assumes that switch is at SINGLE position.
Inputting from blade tilt switch (ONOFF) can be checked in monitoring mode.
Related information
Method of reproducing error code: Turn starting switch ON and operate blade tilt switch.

Blade tilt switch
P03 (male)
Defective blade tilt switch SINGLE DUAL
1
(Internal disconnection) Resistance between
Max. 1 Min. 1 M
(3) (6)
Resistance between
Min. 1 M Max. 1
(3) (4)
Disconnection in wiring har- Wiring harness between TMCN2 (female) (35)
P03 (female) (6)
Resistance Max. 1
tor) P03 (female) (4)
Possible causes Wiring harness between TMCN1 (female) (4),
(10) P03 (female) (3)
ue in normal state
Short circuit with power
chassis ground
chassis ground
Blade tilt switch
TMCN1, TMCN2
Defective transmission con- SINGLE DUAL
4
troller
Max. 1 V 5 11 V
(35) TMCN1 (4), (10)
5 11 V Max. 1 V
(25) TMCN1 (4), (10)
20-538 D375A-5
TROUBLESHOOTING ERROR CODE [DDN9KA] (DISCONNECTION IN BLADE TILT SWITCH SYSTEMS)
D375A-5 20-539
TROUBLESHOOTING ERROR CODE [DDN9KB] (SHORT CIRCUIT IN BLADE TILT SWITCH SYSTEMS)
ERROR CODE [DDN9KB] (SHORT CIRCUIT IN BLADE TILT SWITCH SYSTEMS)
User code Error code Short circuit in blade tilt switch systems
Trouble
E02 DDN9KB (Transmission controller system)
Contents of trouble Signals of both blade tilt switch circuit systems are turned ON or OFF simultaneously.
Assumes that switch is at SINGLE position.
Inputting from blade tilt switch (ONOFF) can be checked in monitoring mode.
Related information
Method of reproducing error code: Turn starting switch ON and operate blade tilt switch.

Blade tilt switch
P03 (male)
Defective blade tilt switch SINGLE DUAL
1
(Short circuit) Resistance between
Max. 1 Min. 1 M
(3) (6)
Resistance between
Min. 1 M Max. 1
(3) (4)
Possible causes Short circuit of wiring harness between
and standard val- Short circuit with chassis
chassis ground
chassis ground
Blade tilt switch
TMCN1, TMCN2
Defective transmission con- SINGLE DUAL
3
troller
Max. 1 V 5 11 V
(35) TMCN1 (4), (10)
5 11 V Max. 1 V
(25) TMCN1 (4), (10)
20-540 D375A-5
TROUBLESHOOTING ERROR CODE [DDN9KB] (SHORT CIRCUIT IN BLADE TILT SWITCH SYSTEMS)
D375A-5 20-541
ERROR CODE [DDN1LD] (BLADE LIFT RAISE FULL OIL PRESSURE SWITCH: REFER
TROUBLESHOOTING TO TABLE (LD))
ERROR CODE [DDN1LD] (BLADE LIFT RAISE FULL OIL PRESSURE SWITCH: REFER TO
TABLE (LD))
Action code Error code Blade lift raise full oil pressure switch: Refer to table (LD)
Trouble
DDN1LD (Transmission controller system)
Contents of
The signal of the blade lift raise full oil pressure switch circuit is kept turned ON for 180 seconds.
trouble
Action of
Recognizes that the oil pressure switch is turned OFF.
controller
Problem that
appears on The data of the VHMS may become abnormal.
machine
The input state (ON/OFF) from the blade lift raise full oil pressure switch can be checked in the moni-
Related
toring mode. (Code 40908: Ripper lever oil pressure switch input signal)
information
Method of reproducing error code: Turn the starting switch ON (Error is reproduced after 180 seconds).

Wrong operation of lever If the service code lamp still lights up (resetting is still urged) after the
1 (When electrical system is resetting operation is performed, it is suspected that the lever was oper-
normal) ated to cause an error.
aPrepare with starting switch OFF, then start engine and carry out trou-
Defective blade lift raise full bleshooting.
2 oil pressure switch BLU (male) Blade lever Resistance
(Internal short circuit) Neutral Min. 1 Mz
Possible causes Between (1) and (2)
Raise Max. 1 z
and standard
value in normal aPrepare with starting switch OFF, then carry out troubleshooting with-
state Short circuit with chassis out turning starting switch ON.
(Contact with ground circuit) (female) (36) and BLU (female) (1) and chassis Resistance Min. 1 Mz
ground
bleshooting.
Defective transmission
4 TMCN1, TMCN2 Ripper lever Voltage
controller
and TMCN1 (10) Tilt in Max. 1 V
Circuit diagram related to blade lift raise full oil pressure switch
20-542 D375A-5
ERROR CODE [DDNALD] (ABNORMALITY IN BLADE LIFT RAISE FULL OIL
TROUBLESHOOTING PRESSURE SWITCH)
ERROR CODE [DDNALD] (ABNORMALITY IN BLADE LIFT RAISE FULL OIL PRESSURE
SWITCH)
Action code Error code Abnormality in blade lift raise full oil pressure switch
Trouble
DDNALD (Transmission controller system)
Contents of
The signal of the blade lift raise full oil pressure switch circuit is kept turned ON for 180 seconds.
trouble
Action of
controller
Problem that
appears on The data of the VHMS may become abnormal.
machine
The input state (ON/OFF) from the blade lift raise full oil pressure switch can be checked in the moni-
Related
toring mode. (Code 40908: Oil pressure switch input signal)
information

Defective blade lift raise full bleshooting.
2 oil pressure switch BLU (male) Blade lever Resistance
Raise Max. 1 z
and standard
(Contact with ground circuit) (female) (36) and BLU (female) (1) and chassis Resistance Min. 1 Mz
ground
bleshooting.
controller
and TMCN1 (10) Blade Raise Max. 1 V
Circuit diagram related to blade lift raise full oil pressure switch
D375A-5 20-543
ERROR CODE [DDNBLD] (SHORT CIRCUIT IN RIPPER LIFT RAISE OIL PRESSURE
ERROR CODE [DDNBLD] (SHORT CIRCUIT IN RIPPER LIFT RAISE OIL PRESSURE
SWITCH SYSTEM)
User code Error code Short circuit in ripper lift raise oil pressure switch system
Trouble
E02 DDNBLD (Steering controller system)
Contents of trouble Signal of ripper lift raise oil pressure switch circuit was kept turned ON for 60 seconds.
Action of controller Judges that oil pressure switch is turned OFF.
Problem that
Shoe slip control (SSC) function does not work normally.
appears on machine
Inputting from ripper lift raise oil pressure switch (ONOFF) can be checked in monitoring mode.
(Code 40912: Oil pressure switch input)
Related information

troubleshooting.
Defective ripper lift raise oil
2 pressure switch RPU (male) Ripper lever Resistance
Between (1) (2)
Possible causes Raise Max. 1
(Contact with ground circuit) NGICN2 (female) (3) RPU (female) (1) with Resistance Max.
1 M
chassis ground
troubleshooting.
4 Defective steering controller NGICN2, NGICN1 Ripper lever Voltage
Between NGICN2 (3) Neutral 5 11 V
NGICN1 (4), (10) Raise Max. 1 V
Circuit diagram related to ripper lift raise oil pressure switch
20-544 D375A-5
ERROR CODE [DDNCLD] (SHORT CIRCUIT IN RIPPER LIFT LOWER OIL PRESSURE
ERROR CODE [DDNCLD] (SHORT CIRCUIT IN RIPPER LIFT LOWER OIL PRESSURE
SWITCH SYSTEM)
User code Error code Short circuit in ripper lift lower oil pressure switch system
Trouble
E02 DDNCLD (Steering controller system)
Contents of trouble Signal of ripper lift lower oil pressure switch circuit was kept turned ON for 60 seconds.
Problem that
appears on machine
Inputting from ripper lift lower oil pressure switch (ONOFF) can be checked in monitoring mode.
(Code 40912: Oil pressure switch input 3)
Related information

troubleshooting.
Defective ripper lift lower oil
2 pressure switch RPD (male) Ripper lever Resistance
Between (1) (2)
Possible causes Lower Max. 1
(Contact with ground circuit) NGICN1 (female) (24) RPD (female) (1) with Resistance Max.
1 M
chassis ground
troubleshooting.
4 Defective steering controller NGICN1 Ripper lever Voltage
Between NGICN1 Neutral 5 11 V
(24) (4), (10) Lower Max. 1 V
Circuit diagram related to ripper lift lower oil pressure switch
D375A-5 20-545
ERROR CODE [DDNDLD] (SHORT CIRCUIT IN RIPPER TILT-IN OIL PRESSURE
ERROR CODE [DDNDLD] (SHORT CIRCUIT IN RIPPER TILT-IN OIL PRESSURE SWITCH
SYSTEM)
User code Error code Short circuit in ripper tilt-in oil pressure switch system
Trouble
E02 DDNDLD (Steering controller system)
Contents of trouble Signal of ripper tilt-in oil pressure switch circuit was kept turned ON for 60 seconds.
Problem that
appears on machine
Inputting from ripper tilt-in oil pressure switch (ONOFF) can be checked in monitoring mode.
(Code 40912: Oil pressure switch input)
Related information

troubleshooting.
Defective ripper tilt-in oil
2 pressure switch RTI (male) Ripper lever Resistance
Between (1) (2)
Possible causes Tilt-in Max. 1
(Contact with ground circuit) NGICN1 (female) (18) RTI (female) (1) with Resistance Max.
1 M
chassis ground
troubleshooting.
4 Defective steering controller NGICN1 Ripper lever Voltage
Between NGICN1 Neutral 5 11 V
(18) (4), (10) Tilt-in Max. 1 V
Circuit diagram related to ripper tilt-in oil pressure switch
20-546 D375A-5
ERROR CODE [DDNELD] (ABNORMALITY IN RIPPER TILT BACK OIL PRESSURE
TROUBLESHOOTING SWITCH)
ERROR CODE [DDNELD] (ABNORMALITY IN RIPPER TILT BACK OIL PRESSURE

SWITCH)
Action code Error code Abnormality in ripper tilt back oil pressure switch
Trouble
DDNELD (Transmission controller system)
Contents of
The signal of the ripper tilt back oil pressure switch circuit is kept turned ON for 60 seconds.
trouble
Action of
controller
Problem that
The shoe slip control (SSC) function does not operate normally.
appears on
The tilt back speed of the ripper lowers.
machine
The input state (ON/OFF) from the ripper tilt back oil pressure switch can be checked in the monitoring
Related
mode. (Code 40912: Ripper lever oil pressure switch input signal)
information

Defective ripper tilt back oil bleshooting.
2 pressure switch RT8 (male) Ripper lever Resistance
Tilt back Max. 1 z
and standard
3 ground in wiring harness Between wiring harness between TMCN2
(Contact with ground circuit) (female) (38) and RT8 (female) (1) and chassis Resistance Min. 1 Mz
ground
bleshooting.
controller
and TMCN1 (10) Tilt back Max. 1 V
Circuit diagram related to ripper tilt back oil pressure switch
D375A-5 20-547
ERROR CODE [DDNFLD] (ABNORMALITY IN BLADE LIFT LOWER FULL OIL
TROUBLESHOOTING PRESSURE SWITCH)
ERROR CODE [DDNFLD] (ABNORMALITY IN BLADE LIFT LOWER FULL OIL PRESSURE
SWITCH)
Action code Error code Abnormality in blade lift lower full oil pressure switch
Trouble
DDNFLD (Transmission controller system)
Contents of
The signal of the blade lift lower full oil pressure switch circuit is kept turned ON for 60 seconds.
trouble
Action of
controller
Problem that
appears on The lift lower speed of the blade lowers.
machine
The input state (ON/OFF) from the blade lift lower full oil pressure switch can be checked in the moni-
Related
toring mode. (Code 40908: Oil pressure switch input signal)
information

Defective blade lift lower full bleshooting.
2 oil pressure switch BLD (male) Blade lever Resistance
Lower full Max. 1 z
and standard
value in normal
(Contact with ground circuit) (female) (26) and BLD (female) (1) and chassis Resistance Min. 1 Mz
ground
bleshooting.
controller
TMCN2 (26) Neutral 5 11 V
TMCN1 (10) Tilt in Max. 1 V
Circuit diagram related to blade lift lower full oil pressure switch
20-548 D375A-5
ERROR CODE [DDQ2KA] (DISCONNECTION IN PARKING BRAKE LEVER SWITCH

SYSTEMS)
User code Error code Disconnection in parking brake lever switch systems
Trouble
CALL E03 DDQ2KA (Steering controller system)
Contents of trouble Signals of both parking brake lever switch circuit systems are turned OFF simultaneously.
Problem that
Travel lock does not work (Mechanical parking brake and pedal work normally.)
appears on machine
(Related codes: DD14KA, dDQ2L4, DDQ2L4)
Related information
(Code 40910: Steering controller switch input 1)
When only error code [DDQ2KA] is displayed
ness
tor) Resistance Max. 1
Possible causes (15) circuit branching point
Parking brake lever
NGICN2
At FREE At LOCK
Between (5) chassis
Max. 1 V 5 11 V
ground
Between (15)
5 11 V Max. 1 V
chassis ground
When error codes [DDQ2KA] and [DD14KA] are displayed simultaneously
Defective parking brake le- without turning starting switch ON.
1 NSW
Between (A) (C) Min. 1 M Max. 1
ness Wiring harness between NSW (female) (B)
Resistance Max. 1
Wiring harness between NSW (female) (C)
defective contact in connec- circuit merging point Resistance Max. 1
tor)
chassis ground
and standard val-
(female) (B) NGICN2 (female) (5) TMCN1 Resistance Min. 1 M
(female) (C) NGICN2 (female) (15) Resistance Min. 1 M
TMCN1 (female) (12) with chassis ground
(female) (B) NGICN2 (female) (5) TMCN1 Voltage Max. 1 V
(female) (C) NGICN2 (female) (15) Voltage Max. 1 V
20-550 D375A-5
D375A-5 20-551
ERROR CODE [DDQ2KB] (SHORT CIRCUIT IN PARKING BRAKE LEVER SWITCH

SYSTEMS)
User code Error code Short circuit in parking brake lever switch systems
Trouble
CALL E03 DDQ2KB (Steering controller system)
Contents of trouble Signals of both parking brake lever switch circuit systems are turned ON simultaneously.
Problem that
Travel lock does not work (Mechanical parking brake and pedal work normally.)
appears on machine
(Related codes: DD14KB, dDQ2L4, DDQ2L4)
Related information
When only error code [DDQ2KB] is displayed
ness
Parking brake lever
NGICN2
At FREE At LOCK
Between (5) chassis
Max. 1 V 5 11 V
ground
Between (15)
5 11 V Max. 1 V
chassis ground
When error codes [DDQ2KB] and [DD14KA] are displayed simultaneously
Defective parking brake le- without turning starting switch ON.
1 NSW
Between (A) (C) Min. 1 M Max. 1
ness Wiring harness between NSW (female) (B)
Resistance Max. 1
Wiring harness between NSW (female) (C)
defective contact in connec- circuit merging point Resistance Max. 1
tor)
chassis ground
and standard val-
(female) (B) NGICN2 (female) (5) TMCN1 Resistance Min. 1 M
(female) (C) NGICN2 (female) (15) Resistance Min. 1 M
(female) (B) NGICN2 (female) (5) TMCN1 Voltage Max. 1 V
(female) (C) NGICN2 (female) (15) Voltage Max. 1 V
20-552 D375A-5
D375A-5 20-553
ERROR CODE [DDQ2L4] (DISAGREEMENT OF PARKING BRAKE LEVER SWITCH
TROUBLESHOOTING SYSTEM SIGNALS)
ERROR CODE [dDQ2L4] (DISAGREEMENT OF PARKING BRAKE LEVER SWITCH

SYSTEM SIGNALS)
User code Error code Disagreement of parking brake lever switch system signals
Trouble
CALL E03 dDQ2L4 (Transmission controller system)
Switch input signal of transmission controller disagrees with communication signal from steering con-
Contents of trouble
troller.
aSince parking brake switch signal is used by both transmission controller and steering controller and
information is exchanged by CAN communication, related codes may be displayed simultaneously,
depending on troubled part.
(Related codes: DB3KR, DD14KA, DD14KB, DDQ2KA, DDQ2KB, DDQ2L4)
Related information
(Code 40905: Transmission controller switch input 1)

Defective CAN communica- See if CAN error codes are displayed. If they are displayed, carry out
1
tion system troubleshooting for them first.
Possible causes See if error codes [DD14KA], [DD14KB], [DDQ2KA] and [DDQ2KB]
and standard val- Defective parking brake le- are displayed. If they are displayed, carry out troubleshooting for them
ue in normal state 2
ver switch signal system first.
(Error code [DDQ2L4] is same as [dDQ2L4].)
3 Since trouble is in system, troubleshooting cannot be carried out.
troller
20-554 D375A-5
TROUBLESHOOTING SYSTEM SIGNALS)

SYSTEM SIGNALS)
User code Error code Disagreement of parking brake lever switch system signals
Trouble
CALL E03 DDQ2L4 (Steering controller system)
Switch input signal of steering controller disagrees with communication signal from steering control-
Contents of trouble
ler.
aSince parking brake switch signal is used by both transmission controller and steering controller and
information is exchanged by S-NET communication, related codes may be displayed simultaneously,
depending on troubled part.
Related information (Related codes: DB3SKR, DD14KA, DD14KB, dDQ2L4, DDQ2KA, DDQ2KB)

Defective S-NET communi- See if error code [DB3SKR] is displayed. If they are displayed, carry
1
cation system out troubleshooting for them first.
Possible causes
and standard val- See if error codes [DD14KA], [DD14KB], [DDQ2KA], [DDQ2KB] are
ue in normal state Defective parking brake le- displayed. If they are displayed, carry out troubleshooting for them
2
ver switch signal system first.
(Error code [dDQ2L4] is same as [DDQ2KA].)
3 Defective steering controller Since trouble is in system, troubleshooting cannot be carried out.
D375A-5 20-555
TROUBLESHOOTING ERROR CODE [DGS1KX] (DEFECTIVE OF HYDRAULIC OIL TEMPERATURE SENSOR)
ERROR CODE [DGS1KX] (DEFECTIVE OF HYDRAULIC OIL TEMPERATURE SENSOR)
Action code Error code Defective of hydraulic oil temperature sensor

Trouble
DGS1KX (Transmission controller system)
Contents of
Hydraulic oil temperature sensor signal is out of normal range.
trouble
Action of
Does not take any particular action.
controller
Problem that
appears on Hydraulic oil temperature gauge of monitor panel may not display normally.
machine
Hydraulic oil temperature (temperature) can be checked in monitoring mode.
Related
(Code 04401: Hydraulic oil temperature)
information
Method of reproducing error code: Turn starting switch ON or start engine.

Defective hydraulic oil tem- out turning starting switch ON.
perature sensor (Internal
1 452 (male) Resistance
disconnection or short cir-
Between (1) (2) 3.5 k 90 kz
cuit)
Between (1) chassis ground Min. 1 Mz
Disconnection in wiring har- out turning starting switch ON.
ness (Disconnection in wir- Wiring harness between TMCN2 (female) (14)
2 Resistance Max. 1 z
ing or defective contact in 452 (female) (1)
connector) Wiring harness between TMCN2 (female) (21)
Resistance Max. 1 z
452 (female) (2)
Possible causes
and standard aPrepare with starting switch OFF, then carry out troubleshooting with-
value in normal Short circuit with chassis out turning starting switch ON.
state 3 ground in wiring harness Short circuit of wiring harness between TMCN2
(Contact with ground circuit) (female) (14) 452 (female) (1) with chassis Resistance Min. 1 Mz
ground
aPrepare with starting switch OFF, turn starting switch ON and carry out
Short circuit with power troubleshooting.
4 source in wiring harness Short circuit of wiring harness between TMCN2
(Contact with 24 V circuit) (female) (14) 452 (female) (1) with chassis Voltage Max. 1 V
ground
Defective transmission con- TMCN2 (female) Resistance
5
troller
Between (14) (21) 1 k 50 kz
Between (14) chassis ground Min. 1 Mz
Circuit diagram related to hydraulic oil temperature sensor
20-556 D375A-5
ERROR CODE [DH22KA] (DISCONNECTION IN FRONT PUMP OIL PRESSURE
ERROR CODE [DH22KA] (DISCONNECTION IN FRONT PUMP OIL PRESSURE SENSOR

SYSTEM)
User code Error code Disconnection in front pump oil pressure sensor system
Trouble
DH22KA (Transmission controller system)
Contents of trouble Signal voltage of work equipment front pump oil pressure sensor circuit is below 0.5 V.
Action of controller Does not take any particular action.
Problem that
Oil pressure of work equipment front pump cannot be monitored.
appears on machine
Outputting from work equipment front pump oil pressure sensor (Voltage) can be checked in monitor-
ing mode.
Related information
(Code 70701: Voltage of work equipment front pump oil pressure sensor)

Defective sensor 24 V power See if error code [DAQ6KK] is displayed. If it is displayed, carry out
1
supply system troubleshooting for it first.
Defective front large pump carry out troubleshooting.
2 oil pressure sensor
LPP Voltage
(Internal trouble)
Between (C) (A) 0.5 6.0 V
ness
Possible causes 3 (Disconnection in wiring or Resistance Max. 1
LPP (female) (B)
and standard val- defective contact in connec-
ue in normal state tor) Wiring harness between TMCN1 (female) (9)
Resistance Max. 1
LPP (female) (C)
(Contact with ground circuit) TMCN1 (female) (9) LPP (female) (C) with Resistance Min. 1 M
chassis ground
5
Between (9) (21) 0.5 6.0 V
Circuit diagram related to front large pump oil pressure sensor
D375A-5 20-557
ERROR CODE [DH22KB] (SHORT CIRCUIT IN FRONT PUMP OIL PRESSURE SENSOR
ERROR CODE [DH22KB] (SHORT CIRCUIT IN FRONT PUMP OIL PRESSURE SENSOR
SYSTEM)
User code Error code Short circuit in front pump oil pressure sensor system
Trouble
DH22KB (Transmission controller system)
Contents of trouble Signal voltage of work equipment front pump oil pressure sensor circuit is above 6.0 V.
Problem that
Oil pressure of work equipment front pump cannot be monitored.
appears on machine
Outputting from work equipment front pump oil pressure sensor (Voltage) can be checked in monitor-
ing mode.
Related information
(Code 70701: Voltage of work equipment front pump oil pressure sensor)

1
Defective front large pump carry out troubleshooting.
LPP Voltage
(Internal trouble)
Possible causes
(Contact with 24 V circuit) TMCN1 (female) (9) LPP (female) (C) with Voltage Max. 1 V
chassis ground
4
Between (9) (21) 0.5 6.0 V
Circuit diagram related to front large pump oil pressure sensor
20-558 D375A-5
ERROR CODE [DH23KA] (DISCONNECTION IN CENTER PUMP OIL PRESSURE
ERROR CODE [DH23KA] (DISCONNECTION IN CENTER PUMP OIL PRESSURE SENSOR

SYSTEM)
User code Error code Disconnection in center rear pump oil pressure sensor system
Trouble
DH23KA (Transmission controller system)
Contents of trouble Signal voltage of work equipment rear pump oil pressure sensor circuit is below 0.5 V.
Problem that
Oil pressure of work equipment rear pump cannot be monitored.
appears on machine
Outputting from work equipment rear pump oil pressure sensor (Voltage) can be checked in monitor-
ing mode.
Related information
(Code 70703: Voltage of work equipment rear pump oil pressure sensor)

1
Defective center small pump carry out troubleshooting.
SPP Voltage
(Internal trouble)
ness
SPP (female) (B)
ue in normal state tor) Wiring harness between TMCN1 (female) (3)
Resistance Max. 1
SPP (female) (C)
(Contact with ground circuit) TMCN1 (female) (3) SPP (female) (C) with Resistance Min. 1 M
chassis ground
5
Between (3) (21) 0.5 6.0 V
Circuit diagram related to center small pump oil pressure sensor
D375A-5 20-559
ERROR CODE [DH23KB] (SHORT CIRCUIT IN CENTER PUMP OIL PRESSURE
ERROR CODE [DH23KB] (SHORT CIRCUIT IN CENTER PUMP OIL PRESSURE SENSOR
SYSTEM)
User code Error code Short circuit in center rear pump oil pressure sensor system
Trouble
DH23KB (Transmission controller system)
Contents of trouble Signal voltage of work equipment rear pump oil pressure sensor circuit is above 6.0 V.
Problem that
Oil pressure of work equipment rear pump cannot be monitored.
appears on machine
Outputting from work equipment rear pump oil pressure sensor (Voltage) can be checked in monitor-
ing mode.
Related information
(Code 45: Voltage of work equipment rear pump oil pressure sensor)

1
Defective center small pump carry out troubleshooting.
SPP Voltage
(Internal trouble)
Possible causes
(Contact with 24 V circuit) TMCN1 (female) (3) SPP (female) (C) with Voltage Max. 1 V
chassis ground
4
Between (3) (21) 0.5 6.0 V
Circuit diagram related to center small pump oil pressure sensor
20-560 D375A-5
TROUBLESHOOTING ERROR CODE [DK10KA] (DISCONNECTION IN FUEL CONTROL DIAL SYSTEM)
ERROR CODE [DK10KA] (DISCONNECTION IN FUEL CONTROL DIAL SYSTEM)
User code Error code Disconnection in fuel control dial system

Trouble
CALL E03 DK10KA (Steering controller system)
Contents of trouble Signal voltage of fuel control dial circuit is below 0.30 V.
Action of controller Continues controlling with signal of decelerator pedal potentiometer.
Inputting from fuel control dial (Voltage) can be checked in monitoring mode.
Related information (Code 51100: Command of fuel control dial)

Defective sensor 5 V power See if error code [DB35KK] is displayed. If it is displayed, carry out
1
Defective fuel control dial TL1 (male) Resistance
Between (R) (T) 4.0 6.0 k
short circuit)
Between (R) (S) 0.25 7.0 k
Between (S) (T) 0.25 7.0 k
Possible causes ness
and standard val- Wiring harness between NGICN1 (female)
ue in normal state (22) TL1 (female) (R)
tor) Wiring harness between NGICN1 (female) (8)
Resistance Max. 1
TL1 (female) (S)
(Contact with ground circuit) NGICN1 (female) (8) TL1 (female) (S) with Resistance Min. 1 M
chassis ground
5
troller NGICN1 Voltage
Between (8) (21) 0.30 4.33 V
Circuit diagram related to fuel control dial
D375A-5 20-561
TROUBLESHOOTING ERROR CODE [DK10KB] (SHORT CIRCUIT IN FUEL CONTROL DIAL SYSTEM)
ERROR CODE [DK10KB] (SHORT CIRCUIT IN FUEL CONTROL DIAL SYSTEM)
User code Error code Short circuit in fuel control dial system
Trouble
CALL E03 DK10KB (Steering controller system)
Contents of trouble Signal voltage of fuel control dial circuit is above 4.55 V.
Action of controller Continues controlling with signal of decelerator pedal potentiometer.
Inputting from fuel control dial (command rotation) can be checked in monitoring mode.
Related information (Code 51100: Command of fuel control dial)

1
Defective fuel control dial TL1 (male) Resistance
Between (R) (T) 4.0 6.0 k
short circuit)
Possible causes Between (R) (S) 0.25 7.0 k
and standard val- Between (S) (T) 0.25 7.0 k
ue in normal state
Voltage Max. 1 V
NGICN1 (female) (8) TL1 (female) (S)
4
Between (8) (21) 0.30 4.33 V
Circuit diagram related to fuel control dial
20-562 D375A-5
ERROR CODE [DK30KA] (DISCONNECTION IN STEERING POTENTIOMETER 1
ERROR CODE [DK30KA] (DISCONNECTION IN STEERING POTENTIOMETER 1 SYSTEM)
User code Error code Disconnection in steering potentiometer 1 system

Trouble
Contents of trouble Signal voltage of steering potentiometer 1 (ST1) is below 0.5 V or above 4.5 V.
Action of controller Continues controlling with signal of steering potentiometer 2 system (ST2).
Inputting from steering potentiometer 1 (ST1) (Voltage) can be checked in monitoring mode.
Related information (Code 50300: Voltage of steering potentiometer 1)
Method of reproducing error code: Turn starting switch ON and operate PCCS lever (Steering).

1
Defective steering potenti-
ometer 1 TL1 (male) Resistance
2
(Internal disconnection or Between (A) (G) 2 k 20%
short circuit) Between (H) (A)
Between (H) (G)
ue in normal state (22) TL1 (female) (A)
Resistance Max. 1
TL1 (female) (H)
(Contact with ground circuit) NGICN1 (female) (2) TL1 (female) (H) with Resistance Min. 1 M
chassis ground
NGICN1 Voltage
Between (2) (21) 0.5 4.5 V
20-564 D375A-5
Circuit diagram related to steering potentiometer
D375A-5 20-565
ERROR CODE [DK30KB] (SHORT CIRCUIT IN STEERING POTENTIOMETER 1
ERROR CODE [DK30KB] (SHORT CIRCUIT IN STEERING POTENTIOMETER 1 SYSTEM)
User code Error code Short circuit in steering potentiometer 1 system

Trouble
Contents of trouble Signal voltage of steering potentiometer 1 (ST1) is above 4.5 V.

1
2
(Internal disconnection or Between (A) (G) 2 k 20%
short circuit) Between (H) (A)
Possible causes
and standard val- Between (H) (G)
ue in normal state aPrepare with starting switch OFF, then turn starting switch ON and
(Contact with 24 V circuit) NGICN1 (female) (2) TL1 (female) (H) with Voltage Max. 1 V
chassis ground
NGICN1 Voltage
Between (2) (21) 0.5 4.5 V
Circuit diagram related to steering potentiometer
20-566 D375A-5
ERROR CODE [DK30KX] [ABNORMALITY IN BOTH STEERING POTENTIOMETER
TROUBLESHOOTING SYSTEMS (1)]
ERROR CODE [DK30KX] [ABNORMALITY IN BOTH STEERING POTENTIOMETER

SYSTEMS (1)]
User code Error code Abnormality in both steering potentiometer systems (1)
Trouble
CALL E04 DK30KX (Steering controller system)
Error codes [DK30KA] and [DK30KB] are displayed simultaneously for steering potentiometer sys-
Contents of trouble
tems 1 and 2.
Inputting from steering potentiometers (Voltage) can be checked in monitoring mode.
(Code 50300: Voltage of steering potentiometer 1)
Related information

and standard val-
ue in normal state Carry out troubleshooting for error codes [DK30KA] and [DK30KB].
ERROR CODE [DK30KZ] [ABNORMALITY IN BOTH STEERING POTENTIOMETER

SYSTEMS (2)]
User code Error code Abnormality in both steering potentiometer systems (2)
Trouble
CALL DK30KZ (Steering controller system)
Either of steering potentiometers 1 and 2 is abnormal when starting switch is turned ON, then error
Contents of trouble
codes [DK30KA] and [DK30KB] are displayed simultaneously.
Inputting from steering potentiometers (Voltage) can be checked in monitoring mode.
Related information

and standard val-
D375A-5 20-567
ERROR CODE [DK30L8] (DEVIATION OF STEERING POTENTIOMETER SYSTEM
TROUBLESHOOTING SIGNALS)
ERROR CODE [DK30L8] (DEVIATION OF STEERING POTENTIOMETER SYSTEM

SIGNALS)
User code Error code Deviation of steering potentiometer system signals

Trouble
CALL E03 DK30L8 (Steering controller system)
Contents of trouble Total signal voltages of steering potentiometers 1 (ST1) and 2 (ST2) is below 4.41 V or above 5.59 V.
Action of controller Continues controlling with normal signal of steering potentiometer 1 (ST1) system or 2 (ST2) system.

and standard val-
20-568 D375A-5
ERROR CODE [DK31KA] (DISCONNECTION IN STEERING POTENTIOMETER 2 SYSTEM)
User code Error code Disconnection in steering potentiometer 2 system

Trouble
Contents of trouble Signal voltage of steering potentiometer 2 (ST2) is below 0.5 V.

Defective sensor power sup- See if error code [DB35KK] is displayed. If it is displayed, carry out
1
ply system troubleshooting for it first.
2
(Internal disconnection or Between (M) (F) 2 k 20%
short circuit) Between (E) (M)
Between (E) (F)
ue in normal state (22) TL1 (female) (M)
tor) Wiring harness between NGICN1 (female)
Resistance Max. 1
(19) TL1 (female) (E)
(Contact with ground circuit) NGICN1 (female) (19) TL1 (female) (E) with Resistance Min. 1 M
chassis ground
NGICN1 Voltage
Between (19) (21) 0.5 4.5 V
CIRCUIT DIAGRAM RELATED TO STEERING POTENTIOMETERS
D375A-5 20-569
ERROR CODE [DK31KB] (SHORT CIRCUIT IN STEERING POTENTIOMETER 2
ERROR CODE [DK31KB] (SHORT CIRCUIT IN STEERING POTENTIOMETER 2 SYSTEM)
User code Error code Short circuit in steering potentiometer 2 system

Trouble
Contents of trouble Signal voltage of steering potentiometer 2 (ST2) is above 4.5 V.

Defective sensor power sup- See if error code [DB35KK] is displayed. If it is displayed, carry out
1
ply system troubleshooting for it first.
2
(Internal disconnection or Between (M) (F) 2 k 20%
short circuit) Between (E) (M)
Possible causes
and standard val- Between (E) (F)
(Contact with 24 V circuit) NGICN1 (female) (19) TL1 (female) (E) with Voltage Max. 1 V
chassis ground
NGICN1 Voltage
Between (19) (21) 0.5 4.5 V
Circuit diagram related to steering potentiometers
20-570 D375A-5
TROUBLESHOOTING ERROR CODE [DK40KA] (DISCONNECTION IN BRAKE POTENTIOMETER SYSTEM)
ERROR CODE [DK40KA] (DISCONNECTION IN BRAKE POTENTIOMETER SYSTEM)
User code Error code Disconnection in brake potentiometer system

Trouble
Contents of trouble Signal voltage of brake potentiometer circuit is below 0.5 V.
Action of controller Stops controlling with brake potentiometer signal.
Brake control performance of brake pedal lowers.
Problem that
appears on machine
Inputting from brake potentiometer (Voltage) can be checked in monitoring mode.
Related information (Code 50400: Voltage of brake potentiometer)
Method of reproducing error code: Turn starting switch ON and operate brake pedal.

1
Defective brake potentiome-
ter BRK (male) Resistance
2
(Internal disconnection or Between (A) (C) 4.0 6.0 k
short circuit) Between (A) (B) 0.25 7.0 k
Between (B) (C) 0.25 7.0 k
3 (Disconnection in wiring or Resistance
ue in normal state (22) BRK (female) (C)
Resistance
BRK (female) (B)
(Contact with ground circuit) NGICN1 (female) (3) BRK (female) (B) with Resistance Min. 1 M
chassis ground
NGICN1 Voltage
Between (3) (B) 0.5 4.5 V
20-572 D375A-5
TROUBLESHOOTING ERROR CODE [DK40KA] (DISCONNECTION IN BRAKE POTENTIOMETER SYSTEM)
Circuit diagram related to brake potentiometer
D375A-5 20-573
TROUBLESHOOTING ERROR CODE [DK40KB] (SHORT CIRCUIT IN BRAKE POTENTIOMETER SYSTEM)
ERROR CODE [DK40KB] (SHORT CIRCUIT IN BRAKE POTENTIOMETER SYSTEM)
User code Error code Short circuit in brake potentiometer system

Trouble
Contents of trouble Signal voltage of brake potentiometer circuit is below 0.5 V or above 4.5 V.
Action of controller Stops controlling with brake potentiometer signal.
Brake control performance of brake pedal lowers.
Problem that
appears on machine
Inputting from brake potentiometer (Voltage) can be checked in monitoring mode.
Related information (Code 50400: Voltage of brake potentiometer)
Method of reproducing error code: Turn starting switch ON and operate brake pedal.

1
Defective brake potentiome-
ter BRK (male) Resistance
2
(Internal disconnection or Between (A) (C) 4.0 6.0 k
short circuit) Between (A) (B) 0.25 7.0 k
Possible causes
and standard val- Between (B) (C) 0.25 7.0 k
(Contact with 24 V circuit) NGICN1 (female) (3) BRK (female) (B) with Voltage Max. 1 V
chassis ground
NGICN1 Voltage
Between (3) (B) 0.5 4.5 V
Circuit diagram related to brake potentiometer
20-574 D375A-5
ERROR CODE [DK55KX] (FORWARD-REVERSE POTENTIOMETER INPUT SIGNAL IS OUT OF
NORMAL RANGE)
ERROR CODE
ERROR CODE[DK55KX]
[DK55KZ](FORWARD-REVERSE POTENTIOMETER
(DISCONNECTION OR SHORT INPUT SIGNAL IS
CIRCUIT IN FORWARD-REVERSE
TROUBLESHOOTING OUT OF NORMAL RANGE)
POTENTIOMETER)
ERROR CODE [DK55KX] (FORWARD-REVERSE POTENTIOMETER INPUT SIGNAL IS OUT

OF NORMAL RANGE)
Action code Error code Forward-reverse potentiometer Input signal is out of normal range
Trouble
CALL E04 DK55KX (Transmission controller system)
Contents of Either of error codes [DK56KA] and [DK56KB] of forward-reverse potentiometer systems 1 and 2 and
trouble either of error codes [DK57KA] and [DK57KB] are displayed simultaneously.
controller Limits operation of engine, transmission, and brake.
Problem that
appears on
machine
Input (Voltage) from forward-reverse potentiometers can be checked in monitoring mode.
(Code 50200: Voltage of forward-reverse potentiometer 1)
Related
information
Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/re-
verse travel).

and standard
value in normal Carry out troubleshooting for error codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].
state
ERROR CODE [DK55KZ] (DISCONNECTION OR SHORT CIRCUIT IN FORWARD-REVERSE

POTENTIOMETER)
Action code Error code Disconnection or short circuit forward-reverse potentiometer

Trouble
CALL E04 DK55KZ (Transmission controller system)
When starting switch is turned ON, either of forward-reverse potentiometer systems 1 and 2 is abnor-
Contents of
mal, then either of error codes [DK56KA] and [DK56KB] and either of error codes [DK57KA] and
trouble
[DK57KB] are displayed simultaneously.
controller Limits operation of engine, transmission, and brake.
Problem that
appears on
machine
Related Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse
information travel).

and standard
state
D375A-5 20-575
ERROR CODE [DK55L8] (DISCREPANCY OF FORWARD-REVERSE
TROUBLESHOOTING POTENTIOMETER)
ERROR CODE [DK55L8] (DISCREPANCY OF FORWARD-REVERSE POTENTIOMETER)
Action code Error code Discrepancy of forward-reverse potentiometer

Trouble
CALL E03 DK55L8 (Transmission controller system)
Contents of Total signal voltage of each of forward-reverse potentiometer 1 system (FR3) and 2 system (FR4) is be-
trouble low 4.41 V or above 5.59 V.
Action of Continues controlling with signal of normal one of forward-reverse potentiometer 1 system (FR3) and 2
controller (FR4).
Problem that
appears on
machine
Related
information
Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse
travel).

and standard
state
20-576 D375A-5
ERROR CODE [DK56KA] (DISCONNECTION IN FORWARD-REVERSE
TROUBLESHOOTING POTENTIOMETER 1)
ERROR CODE [DK56KA] (DISCONNECTION IN FORWARD-REVERSE POTENTIOMETER 1)
Action code Error code Disconnection in forward-reverse potentiometer 1

Trouble
CALL E03 DK56KA (Transmission controller system)
Contents of
Signal voltage of forward-reverse potentiometer 1 system (R) is below 0.5 V.
trouble
Action of
Continues controlling with signal of forward-reverse potentiometer 2 system (F).
controller
Problem that
appears on
machine
Input (Voltage) from forward-reverse potentiometer 1 (R) can be checked in monitoring mode. (Code
Related 50200: Voltage of forward-reverse potentiometer 1)
information Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse
travel).

Defective 5 V sensor power See if error code [DAQ5KK] is displayed. If it is displayed, carry out trou-
1
source system bleshooting for it first.
Defective forward-reverse out turning starting switch ON.
potentiometer 1 (Internal TL2 (male) Resistance
2
disconnection or short cir- Between (L) (J) 2 kz20%
cuit) Between (K) (L)
Between (K) (J)
Possible causes Disconnection in wiring har- out turning starting switch ON.
and standard ness (Disconnection in wir- Wiring harness between TMCN1 (female) (22)
value in normal 3 Resistance Max. 1 z
ing or defective contact in TL2 (female) (L)
state connector) Wiring harness between TMCN1 (female) (2)
Resistance Max. 1 z
TL2 (female) (K)
4 ground in wiring harness Short circuit of wiring harness between TMCN1
(Contact with ground circuit) (female) (2) TL2 (female) (K) with chassis Resistance Min. 1 Mz
ground
5
Between (2) (21) 0.5 4.5 V
Circuit diagram related to forward-reverse potentiometer
D375A-5 20-577
ERROR CODE [DK56KB] (SHORT CIRCUIT IN FORWARD-REVERSE
TROUBLESHOOTING POTENTIOMETER 1)
ERROR CODE [DK56KB] (SHORT CIRCUIT IN FORWARD-REVERSE POTENTIOMETER 1)
Action code Error code Short circuit in forward-reverse potentiometer 1

Trouble
CALL E03 DK56KB (Transmission controller system)
Contents of
Signal voltage of forward-reverse potentiometer 1 system (R) is above 4.5 V.
trouble
Action of
Continues controlling with signal of forward-reverse potentiometer 2 system (L).
controller
Problem that
appears on
machine
Input (Voltage) from forward-reverse potentiometer 1 (R) can be checked in monitoring mode. (Code
Related 50200: Voltage of forward-reverse potentiometer 1)
information Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse
travel).

Defective 5 V sensor power See if error code [DAQ5KK] is displayed. If it is displayed, carry out trou-
1
source system bleshooting for it first.
Defective forward-reverse out turning starting switch ON.
potentiometer 1 (Internal TL2 (male) Resistance
2
disconnection or short cir- Between (L) (J) 2 kz20%
Possible causes cuit) Between (K) (L)
and standard Between (K) (J)
value in normal aPrepare with starting switch OFF, then turn starting switch ON and
state Short circuit with power carry out troubleshooting.
3 source in wiring harness Short circuit of wiring harness between TMCN1
(Contact with 24 V circuit) (female) (2) TL2 (female) (3) with chassis Resistance Max. 1 V
ground
4
Between (2) (21) 0.5 4.5 V
Circuit diagram related to forward-reverse potentiometer
20-578 D375A-5
TROUBLESHOOTING POTENTIOMETER 2 SYSTEM)
ERROR CODE [DK57KA] (DISCONNECTION IN FORWARD-REVERSE POTENTIOMETER 2

SYSTEM)
User code Error code Disconnection in forward-reverse potentiometer 2 system

Trouble
CALL E03 DK57KA (Transmission controller system)
Contents of trouble Signal voltage of forward-reverse potentiometer 2 (FR4) is below 0.5 V.
Action of controller Continues controlling with signal of forward-reverse potentiometer 1 system (FR3).
Inputting from forward-reverse potentiometer 2 (FR4) (Voltage) can be checked in monitoring mode.
(Code 50201: Voltage of froward-reverse potentiometer 2)
Related information
Turn starting switch ON and operate PCCS lever (Forward-Reverse travel).

1
Defective forward-reverse
potentiometer 2 TL1 (male) Resistance
2
(Internal disconnection or Between (O) (Q) 2 k 20%
short circuit) Between (P) (O)
Between (P) (Q)
and standard val- Wiring harness between TMCN1 (female) (22)
ue in normal state TL1 (female) (O)
tor) Wiring harness between TMCN1 (female) (19)
Resistance Max. 1
TL1 (female) (P)
(Contact with ground circuit) TMCN1 (female) (19) TL1 (female) (P) with Resistance Min. 1 M
chassis ground
5
Between (19) (21) 0.5 4.5 V
20-580 D375A-5
Circuit diagram related to forward-reverse potentiometers
D375A-5 20-581
ERROR CODE [DK57KB] (SHORT CIRCUIT IN FORWARD-REVERSE
ERROR CODE [DK57KB] (SHORT CIRCUIT IN FORWARD-REVERSE POTENTIOMETER 2

SYSTEM)
User code Error code Short circuit in forward-reverse potentiometer 2 system

Trouble
CALL E03 DK57KB (Transmission controller system)
Contents of trouble Signal voltage of forward-reverse potentiometer 2 (FR4) is above 4.5 V.
Action of controller Continues controlling with signal of forward-reverse potentiometer 1 system (FR3).
Inputting from forward-reverse potentiometer 2 (FR4) (Voltage) can be checked in monitoring mode.
(Code 50201: Voltage of froward-reverse potentiometer 2)
Related information
Turn starting switch ON and operate PCCS lever (Forward-Reverse travel).

1
Defective forward-reverse
potentiometer 2 TL1 (male) Resistance
2
(Internal disconnection or Between (O) (Q) 2 k 20%
short circuit) Between (P) (O)
Possible causes
and standard val- Between (P) (Q)
(Contact with 24 V circuit) TMCN1 (female) (19) TL1 (female) (P) with Voltage Max. 1 V
chassis ground
4
Between (19) (21) 0.5 4.5 V
Circuit diagram related to forward-reverse potentiometers
20-582 D375A-5
TROUBLESHOOTING ERROR CODE [DK60KA] (DISCONNECTION IN ACCELERATION SENSOR SYSTEM)
ERROR CODE [DK60KA] (DISCONNECTION IN ACCELERATION SENSOR SYSTEM)
User code Error code Disconnection in acceleration sensor system

Trouble
E01 DK60KA (Steering controller system)
Contents of trouble Signal voltage of acceleration sensor is below 0.3 V.
Action of controller Stops shoe slip control (SSC) function.
Problem that
Even if shoe slips, engine speed does not change.
appears on machine
Inputting from acceleration sensor (Voltage) can be checked in monitoring mode.
Related information (Code 60200: Voltage of acceleration sensor)

1
Defective acceleration sen- carry out troubleshooting.
2 sor
SS3 Voltage
(Internal trouble)
Between (2) (3) 0.75 4.25 V
ness
(22) SS3 (female) (1)
ue in normal state tor) Wiring harness between NGICN1 (female) (1)
Resistance Max. 1
SS3 (female) (2)
(Contact with ground circuit) NGICN1 (female) (1) SS3 (female) (2) with Resistance Min. 1 M
chassis ground
5
Between (1) (21) 0.75 4.25 V
Circuit diagram related to acceleration sensor
D375A-5 20-583
TROUBLESHOOTING ERROR CODE [DK60KB] (SHORT CIRCUIT IN ACCELERATION SENSOR SYSTEM)
ERROR CODE [DK60KB] (SHORT CIRCUIT IN ACCELERATION SENSOR SYSTEM)
User code Error code Short circuit in acceleration sensor system

Trouble
E01 DK60KB (Steering controller system)
Contents of trouble Signal voltage of acceleration sensor is below 0.3 V or above 4.7 V.
Action of controller Stops shoe slip control (SSC) function.
Problem that
Even if shoe slips, engine speed does not change.
appears on machine
Inputting from acceleration sensor (Voltage) can be checked in monitoring mode.
Related information (Code 60200: Voltage of acceleration sensor)

1
Defective acceleration sen- carry out troubleshooting.
2 sor
SS3 Voltage
(Internal trouble)
Possible causes Between (2) (3) 0.75 4.25 V
Voltage Max. 1 V
NGICN1 (female) (1) SS3 (female) (2)
4
Between (1) (21) 0.75 4.25 V
Circuit diagram related to acceleration sensor
20-584 D375A-5
TROUBLESHOOTING ERROR CODE [DKH1KA] (DISCONNECTION IN PITCH ANGLE SENSOR SYSTEM)
ERROR CODE [DKH1KA] (DISCONNECTION IN PITCH ANGLE SENSOR SYSTEM)
User code Error code Disconnection in pitch angle sensor system

Trouble
CALL E03 DKH1KA (Steering controller system)
Contents of trouble Signal voltage of pitch angle sensor circuit is below 0.15 V.
Action of controller Cannot recognize angle of inclination.
Gear shift shock occur at slopes, or steering shock occur at level.
Problem that
appears on machine
aSince pitch angle sensor signal is input to both steering controller and transmission controller, related
codes may be displayed simultaneously, depending on troubled part.
(Related code: DKH1KX)
Related information
Inputting from pitch angle revolution sensor (Voltage) can be checked in monitoring mode.
(Code 60100: Pitch angle sensor voltage)
When only error code [DKH1KX] is displayed

1
Possible causes (Disconnection in wiring or de- Wiring harness between NGICN2 (female)
fective contact in connector) (13) circuit branching point Resistance Max. 1
and standard val-
2
troller NGICN2 Resistance
Between (13) chassis ground 0.15 4.85 V
When error codes [DKH1KA] and [DKH1KX] are displayed simultaneously

1
Defective pitch angle sensor carry out troubleshooting.
2
(Internal trouble) PAS Voltage
Between (B) (A) 0.15 4.85 V
and standard val- Disconnection in wiring har- without turning starting switch ON.
ue in normal state ness Wiring harness between PAS (female) (B)
3 Resistance Max. 1
(Disconnection in wiring or de- circuit branching point
fective contact in connector) Wiring harness between PAS (male) (C)
Resistance Max. 1
4 ground in wiring harness Short circuit of wiring harness between PAS
(Contact with ground circuit) (female) (B) TMCN1 (female) (13) Resistance Min. 1 M
20-586 D375A-5
TROUBLESHOOTING ERROR CODE [DKH1KA] (DISCONNECTION IN PITCH ANGLE SENSOR SYSTEM)
Circuit diagram related to pitch angle sensor
D375A-5 20-587
TROUBLESHOOTING ERROR CODE [DKH1KB] (SHORT CIRCUIT IN PITCH ANGLE SENSOR SYSTEM)
ERROR CODE [DKH1KB] (SHORT CIRCUIT IN PITCH ANGLE SENSOR SYSTEM)
User code Error code Short circuit in pitch angle sensor system
Trouble
CALL E03 DKH1KB (Steering controller system)
Contents of trouble Signal voltage of pitch angle sensor circuit is above 4.85 V.
Steering function and braking function may lower.
Problem that
appears on machine
aSince pitch angle sensor signal is input to both steering controller and transmission controller, related
codes may be displayed simultaneously, depending on troubled part.
(Related code: DKH1KX)
Related information
(Code A8: Pitch angle sensor voltage)
When only error code [DKH1KB] is displayed

1
Possible causes (Disconnection in wiring or de- Wiring harness between NGICN2 (female)
fective contact in connector) (13) circuit branching point Resistance Max. 1
and standard val-
2
troller NGICN2 Resistance
When error codes [DKH1KB] and [DKH1KX] are displayed simultaneously

1
Defective pitch angle sensor carry out troubleshooting.
Possible causes 2
(Internal trouble) PAS Voltage
and standard val-
ue in normal state Between (B) (A) 0.15 4.85 V
3 ground in wiring harness Short circuit of wiring harness between PAS
(Contact with ground circuit) (female) (B) TMCN1 (female) (13) Resistance Min. 1 M
20-588 D375A-5
ERROR CODE [DKH1KX] (DISCONNECTION OR SHORT CIRCUIT IN PITCH ANGLE
ERROR CODE [DKH1KX] (DISCONNECTION OR SHORT CIRCUIT IN PITCH ANGLE

SENSOR SYSTEM)
User code Error code Disconnection or short circuit in pitch angle sensor system)
Trouble
E01 DKH1KX (Steering controller system)
Contents of trouble Signal voltage of pitch angle sensor circuit is below 0.15 V or above 4.85 V.
Action of controller Stops auto shift-down function.
Problem that Gear shifting feeling of transmission may become bad.
Related information (Code 60100: Pitch angle sensor voltage)
When only error code [DKH1KX] is displayed

Possible causes defective contact in connec- Wiring harness between TMCN2 (female) (1) Resistance Max. 1
and standard val- tor) circuit branch point
ue in normal state
2
D375A-5 20-589
TROUBLESHOOTING ERROR CODE [DLE1KA] (DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM)
ERROR CODE [dLE1KA] (DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM)
User code Error code Disconnection in engine speed sensor system

Trouble
E01 dLE1KA (Transmission controller system)
Contents of trouble Engine speed signal is not input from engine controller.
Action of controller Cannot recognize engine speed.
Inputting from engine speed sensor (Voltage) can be checked in monitoring mode.
Related information (Code 01002: Engine speed sensor input signal)
When only error code [dLE1KA] is displayed

ness
and standard val- tor) Wiring harness between TMCN2 (female) (39)
Resistance Max. 1
ue in normal state circuit branching point
Defective transmission con- troubleshooting.
2
Between (40) (39) Approx 3.3 V
When error codes [dLE1KA] and [DLE11A] are displayed simultaneously

ness
and standard val- tor) Wiring harness between EG2 (male) (30)
Resistance Max. 1
ECMB Voltage
Between (25) chassis ground
Circuit diagram related to engine speed sensor signal
20-590 D375A-5
TROUBLESHOOTING ERROR CODE [DLE1KA] (DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM)
ERROR CODE [DLE1KA] (DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM)
User code Error code Disconnection in engine speed sensor system

Trouble
E01 DLE1KA (Steering controller system)
Contents of trouble Engine speed signal is not input from engine controller.
Action of controller Cannot recognize engine speed.
Problem that Tachometer graphic section is not displayed.
appears on machine Steering performance may lower.
Inputting from engine speed sensor (Voltage) can be checked in monitoring mode.
Related information (Code 01000: Engine speed sensor input signal)
When only error code [DLE1KA] is displayed

ness
and standard val- tor) Wiring harness between NGICN2 (female)
Resistance Max. 1
ue in normal state (39) circuit branching point
troubleshooting.
NGICN2 Voltage
Between (40) (39) Approx 3.3 V
When error codes [DLE1KA] and [dLE1KA] are displayed simultaneously

ness
and standard val- tor) Wiring harness between EG2 (male) (30)
Resistance Max. 1
troubleshooting.
ECMB Voltage
Between (25) chassis ground
Circuit diagram related to engine speed sensor signal
D375A-5 20-591
ERROR CODE [DLF1KA] (DISCONNECTION IN TORQUE CONVERTER OUTPUT
TROUBLESHOOTING SPEED SENSOR)
ERROR CODE [DLF1KA] (DISCONNECTION IN TORQUE CONVERTER OUTPUT SPEED

SENSOR)
Action code Error code Disconnection in torque converter output speed sensor
Trouble
CALL E01 DLF1KA (Transmission controller system)
Contents of
Signals from the torque converter output speed sensor are not input.
trouble
Action of
None in particular.
controller
Problem that
appears on The torque converter speed cannot be monitored.
machine
The input state (rpm) from the torque converter output speed sensor can be checked in the monitoring
Related
mode. (Code 31200: Torque converter speed)
information
Method of reproducing error code: Start the engine + Drive the machine actually.

Defective torque converter out turning starting switch ON.
output speed sensor TC1 (male) Resistance
1
(Internal disconnection or
short circuit) Between (1) and (2) 500 1,000 z
Between (1) and chassis ground Min. 1 Mz
Disconnection in wiring out turning starting switch ON.
harness (Disconnection in Wiring harness between TMCN2 (female) (20)
Possible causes wiring harness or defective and TC1 (female) (1)
and standard contact in connector) Wiring harness between TMCN2 (female) (39)
Resistance Max. 1 z
value in normal and TC1 (female) (2)
state aPrepare with starting switch OFF, then carry out troubleshooting with-
(Contact with ground circuit) (female) (20) and TC1 (female) (1) and chassis Resistance Min. 1 Mz
ground
4 TMCN2 (female) Resistance
controller
Between (20) and (39) 500 1,000 z
Between (20) and chassis ground Min. 1 Mz
Circuit diagram related to torque converter output speed sensor
20-592 D375A-5
ERROR CODE [DLT3KA] (DISCONNECTION IN TRANSMISSION SPEED SENSOR
ERROR CODE [dLT3KA] (DISCONNECTION IN TRANSMISSION SPEED SENSOR

SYSTEM)
User code Error code Disconnection in transmission speed sensor system

Trouble
E01 dLT3KA (Transmission controller system)
Contents of trouble Signal is not input from transmission speed sensor
Action of controller Cannot recognize transmission output speed.
Inputting from transmission speed sensor (Voltage) can be checked in monitoring mode.
(Code 70200: Transmission speed sensor input signal)
Related information Method of reproducing error code: Start engine and drive machine.
When troubleshooting by operating transmission, set system in adjustment mode (Code: 5535) so
that machine will not start.
When only error code [dLT3KA] is displayed

ness
Possible causes Wiring harness between TMCN2 (female) (29)
and standard val- circuit branching point
ue in normal state
2
troller
Between (30) (29) 500 1,000
When error codes [DLT3KA] and [dLT3KA] are displayed simultaneously

Defective transmission without turning starting switch ON.
speed sensor TM1 (male) Resistance
1
short circuit) Between (1) (2) 500 1,000
Possible causes Disconnection in wiring har- without turning starting switch ON.
and standard val- ness
Wiring harness between TM1 (female) (1)
ue in normal state 2 (Disconnection in wiring or Resistance Max. 1
tor) Wiring harness between TM1 (male) (2) cir-
Resistance Max. 1
cuit branching point
3 ground in wiring harness Short circuit of wiring harness between TM1
(Contact with ground circuit) (female) (1) TMCN2 (female) (30) Resistance Min. 1 M
20-594 D375A-5
Circuit diagram related to transmission speed sensor
D375A-5 20-595

SYSTEM)
User code Error code Disconnection in transmission speed sensor system

Trouble
E01 DLT3KA (Steering controller system)
Contents of trouble Signal is not input from transmission speed sensor
Action of controller Cannot recognize transmission output speed.
Problem that
Steering performance may lower.
appears on machine
aSince transmission speed signal is input to both steering controller and transmission controller, relat-
ed codes may be displayed simultaneously, depending on troubled part.
(Related code: E0932)
Inputting from transmission speed sensor (Voltage) can be checked in monitoring mode.
Related information
(Code 31400: Transmission speed sensor input signal)
Method of reproducing error code: Start engine and drive machine.
When troubleshooting by operating transmission, set system in adjustment mode (Code: 5535) so
that machine will not start.
When only error code [DLT3KA] is displayed

ness
(30) circuit branching point
Possible causes Wiring harness between NGICN2 (female)
and standard val- (29) circuit branching point
ue in normal state
2 Defective steering controller NGICN2 (female) Resistance
Between (30) (29) 500 1,000
When error codes [DLT3KA] and [dLT3KA] are displayed simultaneously

Defective transmission without turning starting switch ON.
speed sensor TM1 (male) Resistance
1
short circuit) Between (1) (2) 500 1,000
Possible causes Disconnection in wiring har- without turning starting switch ON.
and standard val- ness
Wiring harness between TM1 (female) (1)
ue in normal state 2 (Disconnection in wiring or Resistance Max. 1
tor) Wiring harness between TM1 (male) (2) cir-
Resistance Max. 1
cuit branching point
3 ground in wiring harness Short circuit of wiring harness between TM1
(Contact with ground circuit) (female) (1) NGICN2 (female) (30) Resistance Min. 1 M
20-596 D375A-5
Circuit diagram related to transmission speed sensor
D375A-5 20-597
TROUBLESHOOTING ERROR CODE [DV00KB] (SHORT CIRCUIT IN CAUTION BUZZER)
ERROR CODE [DV00KB] (SHORT CIRCUIT IN CAUTION BUZZER)
Action code Error code Short circuit in caution buzzer

Trouble
E01 DV00KB (Monitor panel system)
Contents of
Abnormal current flowed when caution buzzer circuit output ground signal.
trouble
Action of Flashes caution lamp.
controller Stops caution buzzer circuit from outputting ground signal.
Problem that
appears on Caution buzzer does not sound.
machine
Related Method of reproducing error code: Turn starting switch ON (When it is turned ON, buzzer sounds for 1
information second).

Defective caution buzzer out turning starting switch ON.
1
(Internal short circuit) 217 (male) Resistance
Between (1) (2) 200 z
and standard 2 source in wiring harness Short circuit of wiring harness between 217
value in normal (Contact with 24 V circuit) (female) (1) S03 (female) (18) with chassis Voltage Max. 1 V
state ground
S03 Caution buzzer Voltage
3 Defective monitor panel
When turned OFF 20 30 V
Between (18)
chassis ground When turned ON
Max. 3 V
(sounding)
Circuit diagram related to caution buzzer
20-598 D375A-5
ERROR CODE [DWN3KA] (DISCONNECTION IN SUDDEN STOP PREVENTION
TROUBLESHOOTING SOLENOID SYSTEM)
ERROR CODE [DWN3KA] (DISCONNECTION IN SUDDEN STOP PREVENTION SOLENOID

SYSTEM)
User code Error code Disconnection in sudden stop prevention solenoid system
Trouble
CALL E04 DWN3KA (Steering controller system)
Contents of trouble When signal is output to sudden stop prevention solenoid circuit, current does not flow.
Problem that
appears on machine
Outputting to sudden stop prevention solenoid (Voltage) can be checked in monitoring mode.
Related information (Code 31521: Sudden stop prevention solenoid drive voltage)

Defective sudden stop pre- without turning starting switch ON.
1 vention solenoid
STB (male) Resistance
Between (1) (2) 5 25
ness
STB (female) (1)
Resistance Max. 1
ue in normal state (13) STB (female) (2)
(Contact with 24 V circuit) NGICN3 (female) (7) STB (female) (1) with Voltage Max. 1 V
chassis ground
NGICN3 (female) Resistance
Between (7) (13) 5 25
Circuit diagram related to sudden stop prevention solenoid
D375A-5 20-599
ERROR CODE [DWN3KB] (SHORT CIRCUIT IN SUDDEN STOP PREVENTION
ERROR CODE [DWN3KB] (SHORT CIRCUIT IN SUDDEN STOP PREVENTION SOLENOID

SYSTEM)
User code Error code Short circuit in sudden stop prevention solenoid system
Trouble
CALL E04 DWN3KB (Steering controller system)
Contents of trouble When signal is output to sudden stop prevention solenoid circuit, abnormal current flowed.
Problem that
appears on machine
Outputting to sudden stop prevention solenoid (Voltage) can be checked in monitoring mode.
Related information (Code 31628: Sudden stop prevention solenoid drive electric current)

Defective sudden stop pre-
1 vention solenoid STB (male) Resistance
(Contact with ground circuit) Short circuit of wiring harness between Resistance Max. 1
Possible causes NGICN3 (female) (7) STB (female) (1)
Short circuit in wiring har-
ness Short circuit of wiring harness between
3
(with another wiring har- NGICN3 (female) (7) STB (female) (1) with
ness) Resistance Max. 1
wiring harness between NGICN3 (female)
(13) STB (female) (2)
Between (7) (13) 5 25
Circuit diagram related to sudden stop prevention solenoid
20-600 D375A-5
ERROR CODE [DXH1KA] (DISCONNECTION IN TORQUE CONVERTER LOCK-UP
ERROR CODE [DXH1KA] (DISCONNECTION IN TORQUE CONVERTER LOCK-UP

SOLENOID SYSTEM)
User code Error code Disconnection in torque converter lock-up solenoid system
Trouble
E01 DXH1KA (Transmission controller system)
Contents of trouble Current does not flow when signal is output to torque converter lock-up solenoid.
Action of controller Stops outputting to torque converter lock-up solenoid.
Problem that
Torque converter lock-up solenoid does not work.
appears on machine
Outputting to torque converter lock-up solenoid (Voltage) can be checked in monitoring mode.
(Code 31627: Lock-up solenoid drive voltage)

Defective torque converter without turning starting switch ON.
1 lock-up solenoid
653 (male) Resistance
Between (1) (2) 30 80
ness
Possible causes 653 (female) (1)
ue in normal state Resistance Max. 1
653 (female) (2)
(Contact with 24 V circuit) Short circuit of TMCN3 (female) (38) 653 (fe-
Voltage Max. 1 V
4
Between (38) (23) 30 80
Circuit diagram related to torque converter lock-up solenoid
D375A-5 20-601
ERROR CODE [DXH1KB] (SHORT CIRCUIT IN TORQUE CONVERTER LOCK-UP
ERROR CODE [DXH1KB] (SHORT CIRCUIT IN TORQUE CONVERTER LOCK-UP

SOLENOID SYSTEM)
User code Error code Short circuit in torque converter lock-up solenoid system
Trouble
E01 DXH1KB (Transmission controller system)
Contents of trouble Abnormal current flowed when signal is output to torque converter lock-up solenoid.
Action of controller Stops outputting to torque converter lock-up solenoid.
Problem that
Torque converter lock-up solenoid does not work.
appears on machine
Outputting to torque converter lock-up solenoid (Voltage) can be checked in monitoring mode.
(Code 31627: Lock-up solenoid drive voltage)

Defective torque converter
1 lock-up solenoid 653 (male) Resistance
(Contact with ground circuit) TMCN3 (female) (38) 653 (female) (1) with Resistance Min. 1 M
Possible causes
chassis ground
and standard val-
3
(with another wiring har- TMCN3 (female) (38) 653 (female) (1) with
ness) Resistance Min. 1 M
wiring harness between TMCN3 (female) (23)
653 (female) (2)
4
troller
Between (38) (23) 30 80
Circuit diagram related to torque converter lock-up solenoid
20-602 D375A-5
ERROR CODE [DXH4KA] (DISCONNECTION IN TRANSMISSION 1ST CLUTCH ECMV
TROUBLESHOOTING (E-POCV) SYSTEM)
ERROR CODE [DXH4KA] (DISCONNECTION IN TRANSMISSION 1ST CLUTCH ECMV

(E-POCV) SYSTEM)
User code Error code Disconnection in transmission 1st clutch ECMV (E-POCV) system
Trouble
CALL E03 DXH4KA (Transmission controller system)
Contents of trouble When signal is output to transmission 1st clutch solenoid circuit, current does not flow.
Action of controller Stops outputting to transmission 1st clutch solenoid circuit.
Problem that
appears on machine
Outputting to 1st clutch solenoid (Current) can be checked in monitoring mode.
(Code 31602, 31612: 1st clutch ECMV (E-POCV) output current)

Defective 1st clutch solenoid without turning starting switch ON.
1
(Internal short circuit) S1T (male) Resistance
Between (1) (2) 5 15
ness
S1T (female) (1)
Resistance Max. 1
ue in normal state S1T (female) (2)
(Contact with 24 V circuit) TMCN3 (female) (15) S1T (female) (1) with Voltage Max. 1 V
chassis ground
4
Between (15) (13) 5 15
D375A-5 20-603
ERROR CODE [DXH4KB] (SHORT CIRCUIT IN TRANSMISSION 1ST CLUTCH ECMV
ERROR CODE [DXH4KB] (SHORT CIRCUIT IN TRANSMISSION 1ST CLUTCH ECMV

(E-POCV) SYSTEM)
User code Error code Short circuit in transmission 1st clutch ECMV (E-POCV) system
Trouble
CALL E03 DXH4KB (Transmission controller system)
Contents of trouble When signal was output to transmission 1st clutch solenoid circuit, abnormal current flowed.
Action of controller Stops outputting to transmission 1st clutch solenoid circuit.
Problem that
appears on machine
Outputting to 1st clutch solenoid (Current) can be checked in monitoring mode.
(Code 31602, 31612: 1st clutch ECMV (E-POCV) output current)

Defective 1st clutch solenoid S1T (male) Resistance
1
Between (1) (2) 5 15
Possible causes (Contact with ground circuit) TMCN3 (female) (15) S1T (female) (1) with Resistance Min. 1 M
chassis ground
and standard val-
3
(with another wiring har- TMCN3 (female) (15) S1T (female) (1) with
Resistance Min. 1 M
ness) wiring harness between TMCN3 (female) (13)
S1T (female) (2)
4
troller
Between (15) (13) 5 15
20-604 D375A-5
ERROR CODE [DXH5KA] (DISCONNECTION IN TRANSMISSION 2ND CLUTCH ECMV
ERROR CODE [DXH5KA] (DISCONNECTION IN TRANSMISSION 2ND CLUTCH ECMV

(E-POCV) SYSTEM)
User code Error code Disconnection in transmission 2nd clutch ECMV (E-POCV) system
Trouble
Contents of trouble When signal is output to transmission 2nd clutch solenoid circuit, current does not flow.
Action of controller Stops outputting to transmission 2nd clutch solenoid circuit.
Outputting to 2nd clutch solenoid (Current) can be checked in monitoring mode.
(Code 31603, 31613: 2nd clutch ECMV (E-POCV) output current)

Defective 2nd clutch sole- without turning starting switch ON.
1 noid
S2T (male) Resistance
Between (1) (2) 5 15
ness
2 (Disconnection in wiring or Wiring harness between TMCN3 (female) (36) Resistance Max. 1
S2T (female) (1)
Resistance Max. 1
chassis ground
4
Between (36) (3) 5 15
D375A-5 20-605
ERROR CODE [DXH5KB] (SHORT CIRCUIT IN TRANSMISSION 2ND CLUTCH ECMV
ERROR CODE [DXH5KB] (SHORT CIRCUIT IN TRANSMISSION 2ND CLUTCH ECMV

(E-POCV) SYSTEM)
User code Error code Short circuit in transmission 2nd clutch ECMV (E-POCV) system
Trouble
Contents of trouble When signal was output to transmission 2nd clutch solenoid circuit, abnormal current flowed.
Action of controller Stops outputting to transmission 2nd clutch solenoid circuit.
Outputting to 2nd clutch solenoid (Current) can be checked in monitoring mode.
(Code 31603, 31613: 2nd clutch ECMV (E-POCV) output current)

Defective 2nd clutch sole- without turning starting switch ON.
1 noid S2T (male) Resistance
chassis ground
and standard val-
3
S2T (female) (2)
4
troller
Between (36) (3) 5 15
20-606 D375A-5
ERROR CODE [DXH6KA] (DISCONNECTION IN TRANSMISSION 3RD CLUTCH ECMV
ERROR CODE [DXH6KA] (DISCONNECTION IN TRANSMISSION 3RD CLUTCH ECMV

(E-POCV) SYSTEM)
User code Error code Disconnection in transmission 3rd clutch ECMV (E-POCV) system
Trouble
Contents of trouble When signal is output to transmission 3rd clutch solenoid circuit, current does not flow.
Action of controller Stops outputting to transmission 3rd clutch solenoid circuit.
Outputting to 3rd clutch solenoid (Current) can be checked in monitoring mode.
(Code 31604, 31614: 3rd clutch ECMV (E-POCV) output current)

Defective 3rd clutch sole- without turning starting switch ON.
1 noid
S3T (male) Resistance
Between (1) (2) 5 15
ness
2 (Disconnection in wiring or Wiring harness between TMCN3 (female) (5) Resistance Max. 1
S3T (female) (1)
Resistance Max. 1
chassis ground
4
Between (5) (13) 5 15
D375A-5 20-607
ERROR CODE [DXH6KB] (SHORT CIRCUIT IN TRANSMISSION 3RD CLUTCH ECMV
ERROR CODE [DXH6KB] (SHORT CIRCUIT IN TRANSMISSION 3RD CLUTCH ECMV

(E-POCV) SYSTEM)
User code Error code Short circuit in transmission 3rd clutch ECMV (E-POCV) system
Trouble
Contents of trouble When signal was output to transmission 3rd clutch solenoid circuit, abnormal current flowed.
Action of controller Stops outputting to transmission 3rd clutch solenoid circuit.
Outputting to 3rd clutch solenoid (Current) can be checked in monitoring mode.
(Code 31604, 31614: 3rd clutch ECMV (E-POCV) output current)

Defective 3rd clutch sole- without turning starting switch ON.
1 noid S3T (male) Resistance
chassis ground
and standard val-
3
S3T (female) (2)
4
troller
Between (5) (13) 5 15
20-608 D375A-5
ERROR CODE [DXH7KA] (DISCONNECTION IN TRANSMISSION REVERSE CLUTCH
TROUBLESHOOTING ECMV (E-POCV) SYSTEM)
ERROR CODE [DXH7KA] (DISCONNECTION IN TRANSMISSION REVERSE CLUTCH

ECMV (E-POCV) SYSTEM)
User code Error code Disconnection in transmission reverse clutch ECMV (E-POCV) system
Trouble
Contents of trouble When signal is output to transmission reverse clutch solenoid circuit, current does not flow.
Action of controller Stops outputting to transmission reverse clutch solenoid circuit.
Outputting to reverse clutch solenoid (Current) can be checked in monitoring mode.
(Code 31606, 31616: Reverse clutch ECMV (E-POCV) output current)

Defective reverse clutch so- without turning starting switch ON.
1 lenoid
SRT (male) Resistance
Between (1) (2) 5 15
ness
SRT (female) (1)
Resistance Max. 1
ue in normal state SRT (female) (2)
(Contact with 24 V circuit) TMCN3 (female) (25) SRT (female) (1) with Voltage Max. 1 V
chassis ground
4
Between (25) (3) 5 15
D375A-5 20-609
ERROR CODE [DXH7KB] (SHORT CIRCUIT IN TRANSMISSION REVERSE CLUTCH
ERROR CODE [DXH7KB] (SHORT CIRCUIT IN TRANSMISSION REVERSE CLUTCH ECMV

(E-POCV) SYSTEM)
User code Error code Short circuit in transmission reverse clutch ECMV (E-POCV) system
Trouble
Contents of trouble When signal was output to transmission reverse clutch solenoid circuit, abnormal current flowed.
Action of controller Stops outputting to transmission reverse clutch solenoid circuit.
Outputting to reverse clutch solenoid (Current) can be checked in monitoring mode.
(Code 31606, 31616: Reverse clutch ECMV (E-POCV) output current)

Defective reverse clutch so- without turning starting switch ON.
1 lenoid SRT (male) Resistance
Possible causes (Contact with ground circuit) TMCN3 (female) (25) SRT (female) (1) with Resistance Min. 1 M
chassis ground
and standard val-
3
(with another wiring har- TMCN3 (female) (25) SRT (female) (1) with
SRT (female) (2)
4
troller
Between (25) (3) 5 15
20-610 D375A-5
ERROR CODE [DXH8KA] (DISCONNECTION IN TRANSMISSION FORWARD CLUTCH
ERROR CODE [DXH8KA] (DISCONNECTION IN TRANSMISSION FORWARD CLUTCH

User code Error code Disconnection in transmission forward clutch ECMV (E-POCV) system
Trouble
Contents of trouble When signal is output to transmission forward clutch solenoid circuit, current does not flow.
Action of controller Stops outputting to transmission forward clutch solenoid circuit.
Outputting to forward clutch solenoid (Current) can be checked in monitoring mode.
(Code 31608, 31618: Forward clutch ECMV (E-POCV) output current)
chine will not travel forward.

Defective forward clutch so- without turning starting switch ON.
1 lenoid
SFT (male) Resistance
Between (1) (2) 5 15
ness
SFT (female) (1)
Resistance Max. 1
ue in normal state SFT (female) (2)
(Contact with 24 V circuit) TMCN3 (female) (35) SFT (female) (1) with Voltage Max. 1 V
chassis ground
4
Between (35) (13) 5 15
D375A-5 20-611
ERROR CODE [DXH8KB] (SHORT CIRCUIT IN TRANSMISSION FORWARD CLUTCH
ERROR CODE [DXH8KB] (SHORT CIRCUIT IN TRANSMISSION FORWARD CLUTCH

User code Error code Short circuit in transmission forward clutch ECMV (E-POCV) system
Trouble
Contents of trouble When signal was output to transmission forward clutch solenoid circuit, abnormal current flowed.
Action of controller Stops outputting to transmission forward clutch solenoid circuit.
Outputting to forward clutch solenoid (Current) can be checked in monitoring mode.
(Code 31608, 31622: Forward clutch ECMV (E-POCV) output current)
chine will not travel forward.

Defective forward clutch so- without turning starting switch ON.
1 lenoid SFT (male) Resistance
Possible causes (Contact with ground circuit) TMCN3 (female) (35) SFT (female) (1) with Resistance Min. 1 M
chassis ground
and standard val-
3
(with another wiring har- TMCN3 (female) (35) SFT (female) (1) with
SFT (female) (2)
4
troller
Between (35) (13) 5 15
20-612 D375A-5
ERROR CODE [DXH9KA] (DISCONNECTION IN RIGHT STEERING CLUTCH ECMV
ERROR CODE [DXH9KA] (DISCONNECTION IN RIGHT STEERING CLUTCH ECMV

(E-POCV) SYSTEM)
User code Error code Disconnection in right steering clutch ECMV (E-POCV) system
Trouble
CALL E03 DXH9KA (Steering controller system)
Contents of trouble When signal is output to right steering clutch solenoid circuit, current does not flow.
Action of controller Stops outputting to right steering clutch solenoid circuit.
Machine cannot be steered to right.
Problem that
appears on machine
Outputting to right steering clutch solenoid (Current) can be checked in monitoring mode.
(Code 90603: Right steering clutch ECMV (E-POCV) output current)
Related information
Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to right).

Defective right steering without turning starting switch ON.
1 clutch solenoid
SRC (male) Resistance
Between (1) (2) 5 15
ness
2 (Disconnection in wiring or Wiring harness between NGICN3 (female) Resistance Max. 1
(35) SRC (female) (1)
Resistance Max. 1
ue in normal state (23) SRC (female) (2)
(Contact with 24 V circuit) NGICN3 (female) (35) SRC (female) (1) with Voltage Max. 1 V
chassis ground
Between (35) (23) 5 15
D375A-5 20-613
ERROR CODE [DXH9KB] (SHORT CIRCUIT IN RIGHT STEERING CLUTCH ECMV
ERROR CODE [DXH9KB] (SHORT CIRCUIT IN RIGHT STEERING CLUTCH ECMV

(E-POCV) SYSTEM)
User code Error code Short circuit in right steering clutch ECMV (E-POCV) system
Trouble
CALL E03 DXH9KB (Steering controller system)
Contents of trouble When signal was output to right steering clutch solenoid circuit, abnormal current flowed.
Action of controller Stops outputting to right steering clutch solenoid circuit.
Machine cannot be steered to right.
Problem that
appears on machine
Outputting to right steering clutch solenoid (Current) can be checked in monitoring mode.
(Code 90603: Right steering clutch ECMV (E-POCV) output current)
Related information
Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to right).

1 clutch solenoid SRC (male) Resistance
Possible causes (Contact with ground circuit) NGICN3 (female) (35) SRC (female) (1) with Resistance Min. 1 M
chassis ground
and standard val-
3
(with another wiring har- NGICN3 (female) (35) SRC (female) (1) with
(23) SRC (female) (2)
Between (35) (23) 5 15
20-614 D375A-5
ERROR CODE [DXHAKA] (DISCONNECTION IN LEFT STEERING CLUTCH ECMV
ERROR CODE [DXHAKA] (DISCONNECTION IN LEFT STEERING CLUTCH ECMV

(E-POCV) SYSTEM)
User code Error code Disconnection in left steering clutch ECMV (E-POCV) system
Trouble
CALL E03 DXHAKA (Steering controller system)
Contents of trouble When signal is output to left steering clutch solenoid circuit, current does not flow.
Action of controller Stops outputting to left steering clutch solenoid circuit.
Machine cannot be steered to left.
Problem that
appears on machine
Outputting to left steering clutch solenoid (Current) can be checked in monitoring mode.
(Code 90602: Left steering clutch ECMV (E-POCV) output current)
Related information
Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to left).

Defective left steering clutch without turning starting switch ON.
1 solenoid
SLC (male) Resistance
Between (1) (2) 5 15
ness
2 (Disconnection in wiring or Wiring harness between NGICN3 (female) Resistance Max. 1
(25) SLC (female) (1)
Resistance Max. 1
ue in normal state (23) SLC (female) (2)
(Contact with 24 V circuit) NGICN3 (female) (25) SLC (female) (1) with Voltage Max. 1 V
chassis ground
Between (25) (23) 5 15
D375A-5 20-615
ERROR CODE [DXHAKB] (SHORT CIRCUIT IN LEFT STEERING CLUTCH ECMV
ERROR CODE [DXHAKB] (SHORT CIRCUIT IN LEFT STEERING CLUTCH ECMV (E-POCV)
SYSTEM)
User code Error code Short circuit in left steering clutch ECMV (E-POCV) system
Trouble
CALL E03 DXHAKB (Steering controller system)
Contents of trouble When signal was output to left steering clutch solenoid circuit, abnormal current flowed.
Action of controller Stops outputting to left steering clutch solenoid circuit.
Machine cannot be steered to left.
Problem that
appears on machine
Outputting to left steering clutch solenoid (Current) can be checked in monitoring mode.
(Code 90602: Left steering clutch ECMV (E-POCV) output current)
Related information
Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to left).

Defective left steering clutch without turning starting switch ON.
1 solenoid SLC (male) Resistance
Possible causes (Contact with ground circuit) NGICN3 (female) (25) SLC (female) (1) with Resistance Min. 1 M
chassis ground
and standard val-
3
(with another wiring har- NGICN3 (female) (25) SLC (female) (1) with
(23) SLC (female) (2)
Between (25) (23) 5 15
20-616 D375A-5
ERROR CODE [DXHBKA] (DISCONNECTION IN RIGHT STEERING BRAKE ECMV
ERROR CODE [DXHBKA] (DISCONNECTION IN RIGHT STEERING BRAKE ECMV

(E-POCV) SYSTEM)
User code Error code Disconnection in right steering brake ECMV (E-POCV) system
Trouble
CALL E04 DXHBKA (Steering controller system)
Contents of trouble When signal is output to right steering brake solenoid circuit, current does not flow.
Action of controller Stops outputting to right steering brake solenoid circuit.
Problem that
appears on machine
Outputting to right steering brake solenoid (Current) can be checked in monitoring mode.
Related information (Code 31620: Right steering brake ECMV (E-POCV) output current)
Method of reproducing error code: Turn starting switch ON and release parking brake lever.

1 brake solenoid
SRB (male) Resistance
Between (1) (2) 5 15
ness
2 (Disconnection in wiring or Wiring harness between NGICN3 (female)
Resistance Max. 1
(15) SRB (female) (1)
Resistance Max. 1
ue in normal state (13) SRB (female) (2)
(Contact with 24 V circuit) NGICN3 (female) (15) SRB (female) (1) with Voltage Max. 1 V
chassis ground
Between (15) (13) 5 15
D375A-5 20-617
ERROR CODE [DXHBKB] (SHORT CIRCUIT IN RIGHT STEERING BRAKE ECMV
ERROR CODE [DXHBKB] (SHORT CIRCUIT IN RIGHT STEERING BRAKE ECMV (E-POCV)
SYSTEM)
User code Error code Short circuit in right steering brake ECMV (E-POCV) system
Trouble
CALL E04 DXHBKB (Steering controller system)
Contents of trouble When signal was output to right steering brake solenoid circuit, abnormal current flowed.
Action of controller Stops outputting to right steering brake solenoid circuit.
Limits operation of engine, transmission, brake.
Problem that
appears on machine
Outputting to right steering brake solenoid (Current) can be checked in monitoring mode.
Related information (Code 31620: Right steering brake ECMV (E-POCV) output current)

1 brake solenoid SRB (male) Resistance
(Contact with ground circuit) NGICN3 (female) (15) SRB (female) (1) with Resistance Min. 1 M
Possible causes
chassis ground
and standard val-
3
(with another wiring har- NGICN3 (female) (15) SRB (female) (1) with
(13) SRB (female) (2)
Between (15) (13) 5 15
20-618 D375A-5
ERROR CODE [DXHCKA] (DISCONNECTION IN LEFT STEERING BRAKE ECMV
ERROR CODE [DXHCKA] (DISCONNECTION IN LEFT STEERING BRAKE ECMV (E-POCV)

SYSTEM)
User code Error code Disconnection in left steering brake ECMV (E-POCV) system
Trouble
CALL E04 DXHCKA (Steering controller system)
Contents of trouble When signal is output to left steering brake solenoid circuit, current does not flow.
Action of controller Stops outputting to left steering brake solenoid circuit.
Problem that
appears on machine
Outputting to left steering brake solenoid (Current) can be checked in monitoring mode.
Related information (Code 31621: Left steering brake ECMV (E-POCV) output current)

Defective left steering brake without turning starting switch ON.
1 solenoid
SLB (male) Resistance
Between (1) (2) 5 15
ness
2 (Disconnection in wiring or Wiring harness between NGICN3 (female) (5)
Resistance Max. 1
SLB (female) (1)
Resistance Max. 1
ue in normal state (13) SLB (female) (2)
(Contact with 24 V circuit) NGICN3 (female) (5) SLB (female) (1) with Voltage Max. 1 V
chassis ground
Between (5) (13) 5 15
D375A-5 20-619
ERROR CODE [DXHCKB] (SHORT CIRCUIT IN LEFT STEERING BRAKE ECMV
ERROR CODE [DXHCKB] (SHORT CIRCUIT IN LEFT STEERING BRAKE ECMV (E-POCV)
SYSTEM)
User code Error code Short circuit in left steering brake ECMV (E-POCV) system
Trouble
CALL E04 DXHCKB (Steering controller system)
Contents of trouble When signal was output to left steering brake solenoid circuit, abnormal current flowed.
Action of controller Stops outputting to left steering brake solenoid circuit.
Problem that
appears on machine
Outputting to left steering brake solenoid (Current) can be checked in monitoring mode.
Related information (Code 31261: Left steering brake ECMV (E-POCV) output current)

Defective left steering brake without turning starting switch ON.
1 solenoid SLB (male) Resistance
(Contact with ground circuit) NGICN3 (female) (5) SLB (female) (1) with Resistance Min. 1 M
Possible causes
chassis ground
and standard val-
3
(with another wiring har- NGICN3 (female) (5) SLB (female) (1) with
(13) SLB (female) (2)
Between (5) (13) 5 15
20-620 D375A-5
TROUBLESHOOTING OF ELECTRICAL SYSTEM

(E-MODE)
INFORMATION IN TROUBLESHOOTING TABLE ................................................................................. 20-702

E-1 THE ENGINE DOES NOT START ............................................................................................... 20-703
E-2 PREHEAT DOES NOT OPERATE (MANUAL PREHEATING FUNCTION) ................................ 20-705
E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE ................................................. 20-707
E-4 THE MONITOR PANEL DOES NOT COME ON AT ALL
WHEN THE STARTING SWITCH IS TURNED ON. .................................................................... 20-708
E-5 WHEN THE STARTING SWITCH IS TURNED ON,
THE MONITOR PANEL COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT. ........ 20-709
E-6 WHEN THE STARTING SWITCH IS ON, THE BASIC CHECK ITEM FLASHES ....................... 20-710
E-7 WHEN THE ENGINE IS OPERATING, THE CAUTION ITEM FLASHES ................................... 20-711
E-8 WHEN THE ENGINE IS OPERATING, THE EMERGENCY ALARM ITEM FLASHES ............... 20-713
E-9 THE PREHEATING LAMP DOES NOT COME ON ..................................................................... 20-716
E-10 THE DISPLAY OF THE ENGINE WATER TEMPERATURE GAUGE IS NOT NORMAL ........... 20-717
E-11 AT THE SELECTING TIME OF DUAL TILT,
THE DUAL/SINGLE TILT SELECTOR LAMP DOES NOT COME ON.
(DUAL TILT-MOUNTED MACHINE) ............................................................................................ 20-718
E-12 AT THE LOCKING-UP OF THE TORQUE CONVERTER,
THE TORQUE CONVERTER LOCK-UP DISPLAY LAMP DOES NOT COME ON. ................... 20-718
E-13 THE DISPLAY OF THE TORQUE CONVERTER OIL TEMPERATURE GAUGE IS NOT NORMAL
..................................................................................................................................................... 20-719
E-14 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY. ............ 20-720
E-15 THE DISPLAY OF THE FUEL GAUGE IS NOT NORMAL .......................................................... 20-721
E-16 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL. ............................. 20-722
E-17 INDICATION OF THE SHIFT MODE SERVICE METER IS ABNORMAL. .................................. 20-722
E-18 THE SWITCH MODULE CANNOT BE OPERATED .................................................................... 20-723
E-19 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT. ...................................... 20-724
E-20 THE ALARM BUZZER DOES NOT SOUND OR STOP .............................................................. 20-725
E-21 THE ALARM BUZZER CANNOT BE CANCELLED. .................................................................... 20-726
E-22 THE OPERATOR MODE CANNOT BE OPERATED. ................................................................. 20-727
E-23 THE SERVICE MODE CANNOT BE OPERATED. ...................................................................... 20-728
E-24 INSTRUMENT PANEL NIGHT LAMP, HEADLAMP,
WORKING LAMP AND REAR LAMP DO NOT COME ON ......................................................... 20-730
E-25 AIR CONDITIONER DOES NOT OPERATE ............................................................................... 20-734
D375A-5 20-701
TROUBLESHOOTING INFORMATION IN TROUBLESHOOTING TABLE
INFORMATION IN TROUBLESHOOTING TABLE

The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before carrying out troubleshooting, understand that information fully.
Trouble Trouble in machine
Related information Information related to detected trouble or troubleshooting
<Contents of description>
Standard value in normal state to judge possible causes
Remarks on judgment
1
<Troubles in harness>
Disconnection
Connector is connected imperfectly or harness is broken.
Short circuit with chassis ground
Harness which is not connected to chassis ground circuit is in con-
tact with chassis ground circuit.
Short circuit with power source
2 Harness which is not connected to power source (24 V) circuit is in
contact with power source (24 V) circuit.
Short circuit
Independent harnesses are in contact with each other abnormally.
Possible causes Possible causes of trouble
and standard val- (Given numbers are refer-
ue in normal state <Precautions for troubleshooting>
ence numbers, which do not
(1)Method of indicating connector No. and handling of T-adapter
indicate priority)
Insert or connect T-adapter as explained below for troubleshooting,
unless otherwise specified.
3 If connector No. has no marks of male and female, disconnect
connector and insert T-adapters in both male side and female
side.
If connector No. has marks of male and female, disconnect
connector and connect T-adapter to only male side or female
side.
(2)Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative () lead of tester as ex-
plained below for troubleshooting, unless otherwise specified.
4 Connect positive (+) lead to pin No. or harness entered on front
side.
Connect negative () lead to pin No. or harness entered on rear
side.
Related electrical circuit diagram
Part of electric circuit diagram related to trouble

Connector No.: Indicates (Model Number of pins) and (Color).
Arrows (): Indicate rough location of connector in machine.
20-702 D375A-5
TROUBLESHOOTING E-1 THE ENGINE DOES NOT START
E-1 THE ENGINE DOES NOT START
Trouble The engine does not start.

Because the neutral safety function is provided in the engine starting circuit, the engine can be started
only when the parking lever is in the lock position.
Related information
If the Monitor panel does not come on or the Operating sound of the battery relay is not heard when
the starting switch is ON, a main power system abnormality is assumed. So inspect it.

Battery voltage Battery specific gravity
1 Insufficient battery capacity
Min. 24 V Min. 1.26
aPrepare the engine with the starting switch OFF and diagnose it
with the starting switch OFF as is.
Starting switch failure Key (male) Switch position Resistance value
2
OFF Min. 1 M
Between (5) and (3)
START Max. 1
with the engine start.
Neutral safety relay failure
3 If the engine is started by the engine starting operation by replacing
this relay with another relay with the starting switch OFF, the neutral
safety relay (NSF) is faulty.
Diode failure with the starting switch ON.
4
(Internal short circuit) Alternator Voltage
Between R terminal and ground Max. 1 V
with the engine start.
Starter Voltage
Power: Between B terminal
Possible causes 20 30 V
and ground
and standard val- Starter failure
ue in normal state 5 Charge: Between R terminal
(Internal fault) Max. 1 V
and ground
Start: Between C terminal
20 30 V
and ground
If each voltage of power, charge, or start is normal and the starter is
not turned, the starter is faulty.
Harness disconnection fail- with the starting switch OFF as is.
ure Between the harnesses between key (female) Resistance
6 Max. 1
(Disconnection/connector (3) and NSF (female) (3) value
contact failure) Between harnesses between NSF (female) Resistance
Max. 1
(5) and top and bottom starter C terminal value
with the starting switch ON.
Between alternator R terminal and top and
bottom starter C terminal, between alternator
Harness hot short-circuiting R terminal and D03 (female) (2), between al-
7 failure ternator R terminal and S03 (female) (4), be-
(24 V circuit and contact) tween alternator R terminal and CN1 (female) Voltage Max. 1 V
(4), and between harness and ground
(Note: If hot short-circuiting occurs, the charge
level lamp comes on when the starting switch
is ON.)
D375A-5 20-703
TROUBLESHOOTING E-1 THE ENGINE DOES NOT START
Engine start/charge-related circuit diagram
20-704 D375A-5
TROUBLESHOOTING E-2 PREHEAT DOES NOT OPERATE (MANUAL PREHEATING FUNCTION)
E-2 PREHEAT DOES NOT OPERATE (MANUAL PREHEATING FUNCTION)
Trouble Preheat does not operate.

aThis troubleshooting describes the procedures when the electrical intake air heater mounting unit is
not heated (if only the preheating lamp does not come on, execute the diagnosis indicating that the
Preheating lamp does not come on.)
Related information Preheat includes the Automatic preheating function and the Manual preheating function. Even if
which function is operated, the preheating lamp comes on.
If the Monitor panel does not come on or No operating sound of the battery relay is heard when
the starting switch is ON, a main power system abnormality is assumed. So inspect it.

Starting switch failure Key (male) Switch position Resistance value
1
OFF Min. 1 M
Between (5) and (2)
HEAT Max. 1
If the fuse is damaged by fire, the possibility of a ground fault having
2 Fuse (FS4-4) failure
occurred in the circuit is great.
Preheater relay failure with HEAT.
3
(Internal disconnection) If the engine is preheated by the heat operation by replacing this relay
with the starting switch OFF, the preheater relay (RHR) is faulty.
with HEAT.
Preheater Voltage
Power: Between power sup-
Heater relay failure ply terminal and 20 30 V
4
(Internal fault) ground
Possible causes Signal: Between signal termi-
20 30 V
nal and ground
and standard val-
ue in normal state If each voltage of power and signal is normal and no operation sound
is heard, the heater relay is faulty.
Electrical intake air heater with the starting switch OFF as is.
5 failure
Electrical intake air heater Continuity
(Internal fault)
Between terminals Continue
Between harnesses between FS4-5 exit and Resistance
Max. 1
Harness disconnection fail- RHR (female) (5) value
ure Between RHR (female) (3) and key (female)
6 Resistance
(Disconnection/connector (2), and between harnesses RHR (female) (3) Max. 1
contact failure) value
and heater relay
Between harnesses between battery relay M
Resistance
terminal and starter and between the batter Max. 1
value
relay M terminal and heater relay
Harness ground fault with the starting switch OFF as is.
7
(GND circuit and contact) Between FS4-5 (exit side)-related harnesses Resistance
Min. 1 M
and between grounds value
D375A-5 20-705
TROUBLESHOOTING E-2 PREHEAT DOES NOT OPERATE (MANUAL PREHEATING FUNCTION)
Engine preheat-related circuit diagram
20-706 D375A-5
TROUBLESHOOTING E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE
E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE
Trouble The ripper pin puller cylinder does not operates.

Related information

If the fuse is damaged by fire, the possibility of a ground fault having
1 Fuse (FS4-1) failure
occurred in the circuit is great.
Pin puller switch failure with the starting switch OFF as is.
2 (Internal disconnection/short 263 (male) Switch Resistance value
circuit) Draw-in Max. 1
Between (1) and (2)
Pull-in Min. 1 M
Pin puller solenoid failure with the starting switch OFF as is.
3 (Internal disconnection/short 224 (male) Resistance value
circuit) Between (1) and (2) 10 80
Between (1) and groud Min. 1 M
Possible causes with the starting switch Off as is.
and standard val- Between harnesses between FS4-1 exit and Resistance
Harness disconnection fail- Max. 1
ue in normal state 263 (female) (1) value
ure
4
(Disconnection/connector Between harnesses between 263 (female) (2) Resistance
Max. 1
contact failure) and 224 (female) (1) value
Between harnesses between 224 (female) (2) Resistance
Max. 1
and ground value
Harness ground fault Between FS4-1 (exit side)-related harnesses Resistance
5 Min. 1 M
(GND circuit and contact) and between grounds value
Between harness and ground between 263 Resistance
Min. 1 M
(female) (2) and 224 (female) (1) value
Harness hot short-circuiting with the starting switch ON.
6 failure
(24 V circuit and contact) Between harness and ground between 263
Voltage Max. 1 V
(female) (2) and 224 (female) (1)
Ripper pin puller solenoid-related circuit diagram
D375A-5 20-707
E-4 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING
TROUBLESHOOTING SWITCH IS TURNED ON.
E-4 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING
SWITCH IS TURNED ON.
Trouble The monitor panel does not come on at all when the starting switch is turned ON.
Related When the starting switch is turned ON, the gear speed indicator, the multi information section, the gauge
information section and the lamp section come on for 2 sec.

Defective circuit breaker When the circuit breaker is cut off, the circuit may have possibly been
1
(CB2) short-circuited with ground.
aPrepare with the starting switch OFF, then carry out troubleshooting
Disconnection of wiring har- without turning the starting switch ON.
ness (Disconnection in wir- Wiring harness between S03 (female) (1) (2)
ing or defective contact in and CB2 outlet
Possible causes connector) Wiring harness between S03 (female) (3) (4)
and standard Resistance Max. 1 z
and ground
value in normal
state Ground fault of wiring har-
without turning the starting switch ON.
3 ness (Contact with ground
Between wiring harness related to CB2 (outlet
circuit) Resistance Min. 1 Mz
side) and ground
aPrepare with the starting switch OFF, then turn the starting switch ON
Defective monitor panel and carry out troubleshooting.
4
(Gauge/lamp module) S03 Voltage
Between (1) (2) and (3) (4) 20 30 V
Circuit diagram related to monitor panel electric power supply
20-708 D375A-5
E-5 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL
TROUBLESHOOTING COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT.
E-5 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL
COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT.
When the starting switch is turned ON, the monitor panel completely remains lighted and does not go
Trouble
out.
Related When the starting switch is turned ON, the gear speed indicator, the multi information section, the gauge
information section and the lamp section come on for 2 sec. and go out.

and standard
Defective monitor panel
value in normal 1 This internal defect cannot be diagnosed.
(Gauge/lamp module)
state
D375A-5 20-709
TROUBLESHOOTING E-6 WHEN THE STARTING SWITCH IS ON, THE BASIC CHECK ITEM FLASHES
E-6 WHEN THE STARTING SWITCH IS ON, THE BASIC CHECK ITEM FLASHES
Trouble The radiator water level lamp flashes.

Related information The basic check item flashes when an abnormality is detected before the engine starts.

Radiator water level de-
Because the radiator water level decrease is detected, inspect the ra-
1 crease
diator water level (the lamp flashes below the specified level).
(When system is normal)
Radiator water level failure 405 (male) Radiator water level Resistance value
2
At normal time Max. 1
Between (1) and (2)
At decreased time Min. 1 M
Possible causes
and standard val-
ue in normal state
ure Between harnesses between S03 (female) Resistance
3 Max. 1
(Disconnection/connector (11) and 405 (female) (1) value
contact failure) Between harnesses between 405 (female) (2) Resistance
Max. 1
and ground value
Monitor panel failure S03 Radiator water level Voltage
4
(Caution module)
Between (11) and At normal time Max. 1V
ground At decreased time 20 20 V
Radiator water level sensor-related circuit diagram
20-710 D375A-5
TROUBLESHOOTING E-7 WHEN THE ENGINE IS OPERATING, THE CAUTION ITEM FLASHES
E-7 WHEN THE ENGINE IS OPERATING, THE CAUTION ITEM FLASHES
Trouble The charge level lamp flashes.

Related information The caution item flashes if an abnormality is detected when the engine is operating.

Alternator failure starting the engine.
1 (Insufficient power genera- Alternator Engine speed Voltage
tion) Between R terminal Above intermediate
20 30 V
and ground speed (half)
Harness disconnection fail- aPrepare the engine with the starting switch OFF and diagnose it
ure with the starting switch OFF as is.
2
(Disconnection/connector Between harnesses between S04 (female) (9) Resistance
contact failure) Max. 1
and alternator R terminal value
Possible causes aPrepare the engine with the starting switch OFF and diagnose it
and standard val- with the starting switch OFF as is.
ue in normal state Between S04 (9) and S03 (female) (4), Be-
tween S04 (female) (9) and alternator R termi-
Harness ground fault
3 nal, between S04 (female) (9) and top and
(GND circuit and contact) Resistance
bottom starter R terminal, between S04 (fe- Min. 1 M
value
male) (9) and NGICN3 (female), between har-
ness and ground between S04 (female) (9)
and battery relay BR terminal
Monitor panel failure
4 S04 Engine speed Voltage
(Caution module)
Between (9) and Above intermediate
20 30 V
ground speed (half)
D375A-5 20-711
TROUBLESHOOTING E-7 WHEN THE ENGINE IS OPERATING, THE CAUTION ITEM FLASHES
Engine start/charge-related circuit diagram
20-712 D375A-5
E-8 WHEN THE ENGINE IS OPERATING, THE EMERGENCY ALARM ITEM
TROUBLESHOOTING FLASHES
E-8 WHEN THE ENGINE IS OPERATING, THE EMERGENCY ALARM ITEM FLASHES
Trouble (1) The fuel temperature lamp flashes.

The emergency alarm item flashes if an abnormality is detected when the engine is operating and
Related information
sounds the alarm buzzer.

Fuel temperature rises ab- Inspect the fuel temperature since abnormal increase of fuel temper-
1 normally ature has been detected. (When fuel temperature exceeds the speci-
(When system is normal) fied temperature: Lamp flashes.)
Possible causes
and standard val- Fuel temperature sensor
2 system failure Execute the service codes [C261NS], [C263KX] and [C265KX].
ue in normal state
(Engine controller system)
If there is an abnormality in Causes 1 and 2, a monitor panel failure is
3 assumed (because the monitor panel is internally faulty, it cannot be
(Caution module)
diagnosed).
Trouble (2) Engine oil pressure lamp flashes.

The emergency alarm item flashes if an abnormality is detected when the engine is operating and
Related information
sounds the alarm buzzer.

Engine oil pressure de-
Because the engine oil pressure decrease is detected, inspect the en-
1 crease
gine oil pressure (below specified pressure: Lamp flashes).
(When system is normal)
Possible causes
and standard val-
ue in normal state 2 system failure Execute the service codes [C135KX] [C141KX], and [C143ZG].
(engine controller system)
If there is an abnormality in Causes 1 and 2, a monitor panel failure is
(Caution module)
diagnosed).
D375A-5 20-713
Trouble (3) The engine water temperature caution lamp flashes.

When any abnormality is detected during engine operation, the relevant emergency warning item will
Related sound the alarm buzzer.
information The engine water temperature caution lamp flashes or goes out as it links with indication on the engine
water temperature gauge.

As overheated engine water was detected, check the engine water tem-
Overheated engine water
perature. (When the water temperature is over 102C, the lamp flashes.
1 temperature (when the sys-
When the water temperature is over 108C, the lamp flashes and the
tem is normal)
buzzer sounds.)
Check the indication on the engine water temperature gauge. If the indi-
cation is abnormal, carry out the troubleshooting of Indication on the
engine water temperature gauge is abnormal.
aWater temperatures are guides for selecting
indications.
Possible causes
and standard
The engine water tempera-
value in normal
ture sensor system is defec- Water temperature
state 2
tive. (Engine controller gauge
system)
White range/
Water temperature Red range
Green range
lamp
Goes out. Flashes.
Defective monitor panel When Causes 1 and 2 are not applicable, the monitor panel is supposed
3
(Gauge/lamp module) to be defective. (This is an internal defect, which cannot be troubleshot.)
Trouble (4) The power train oil temperature caution lamp flashes.
information The power train oil temperature caution lamp flashes or goes out as it links with indication on the power
train oil temperature gauge.

Overheated oil temperature As an overheated power train oil temperature was detected, check the
1 of power train (when the power train oil temperature. (When the oil temperature is over 130C,
system is normal) the lamp flashes.)
Check the indication on the power train oil temperature gauge. If the
indication is abnormal, carry out the troubleshooting of Indication on the
power train oil temperature gauge is abnormal.
aOil temperatures are guides for selecting in-
dications.
Possible causes
and standard
The power train oil tempera-
value in normal
2 ture sensor system is defec- Oil temperature gauge
state
tive. (Monitor panel system)
White range/
Red range
Oil temperature lamp Green range
Goes out. Flashes.
3
20-714 D375A-5
Trouble (5) The hydraulic oil temperature caution lamp flashes.

information The hydraulic oil temperature caution lamp flashes or goes out as it links with indication on the hydraulic
oil temperature gauge.

Overheated hydraulic oil As an overheated hydraulic oil temperature was detected, check the
1 temperature (when the sys- hydraulic oil temperature. (When the oil temperature is over 130C, the
tem is normal) lamp flashes.)
Check the indication on the engine water temperature gauge. If the indi-
cation is abnormal, carry out the troubleshooting of Indication on the
hydraulic oil temperature gauge is abnormal.
aOil temperatures are guides for selecting in-
dications.
Possible causes
and standard
The hydraulic oil tempera-
value in normal
2 ture sensor system is defec- Oil temperature gauge
state
tive. (Monitor panel system)
White range/
Red range
Oil temperature lamp Green range
Goes out. Flashes.
3
D375A-5 20-715
TROUBLESHOOTING E-9 THE PREHEATING LAMP DOES NOT COME ON
E-9 THE PREHEATING LAMP DOES NOT COME ON
Trouble The preheating lamp does not come on.

aThis troubleshooting describes the procedures when the preheating lamp does not come on (if the
electrical intake air heater mounting portion is not heated, execute the diagnosis indicating that the
Related information Preheat lamp does not operate.
Preheat includes the Automatic preheat function and the Manual preheat function. Even if which
function operates, the preheating lamp comes on.

1
(Disconnection/connector Between harnesses between S03 (female) (9) Resistance
and heater relay terminal value
Possible causes Harness ground fault with the starting switch OFF as is.
and standard val- 2
(GND circuit and contact) Between harness and ground between S03 Resistance
ue in normal state Min. 1 M
(female) (9) and heater relay terminal value
Monitor panel failure S03 Starting switch Voltage
3
(Caution module)
Between (9) and ON Max. 1 V
ground HEAT 20 30 V
Engine preheat-related circuit diagram
20-716 D375A-5
E-10 THE DISPLAY OF THE ENGINE WATER TEMPERATURE GAUGE IS NOT
TROUBLESHOOTING NORMAL
E-10 THE DISPLAY OF THE ENGINE WATER TEMPERATURE GAUGE IS NOT NORMAL
Trouble The display of the engine water temperature gauge is nor normal.
The signal of the engine water temperature gauge is received by the communication from the engine
Related information
controller.

Engine water temperature
Possible causes 1 system failure Execute the diagnosis of the service codes [C144KX] and [C145KX].
and standard val- (Engine controller system)
ue in normal state If there is an abnormality in Cause 1, a monitor panel abnormality is
(Caution module)
diagnosed).
D375A-5 20-717
E-11 AT THE SELECTING TIME OF DUAL TILT, THE DUAL/SINGLE TILT
SELECTOR LAMP DOES NOT COME ON. (DUAL TILT-MOUNTED MACHINE)
E-11 AT THE
E-12 SELECTING
AT THE TIMEOFOF
LOCKING-UP DUAL
THE TILT,CONVERTER,
TORQUE THE DUAL/SINGLE TILT
THE TORQUE
TROUBLESHOOTING SELECTOR LAMP DOES NOT COME ON. (DUAL TILT-MOUNTED MACHINE)
CONVERTER LOCK-UP DISPLAY LAMP DOES NOT COME ON.
E-11 AT THE SELECTING TIME OF DUAL TILT, THE DUAL/SINGLE TILT SELECTOR
LAMP DOES NOT COME ON. (DUAL TILT-MOUNTED MACHINE)
At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on. (Dual tilt-mounted
Trouble
machine)
Before troubleshooting the blade, make sure that the dual tilt can operate. (When the blade does not
Related
operate normally, the electrical system on the machine side or the hydraulic/mechanical system is sup-
information
posed to be out of order. So, troubleshoot the relevant system.)

and standard
value in normal 1 This is an internal defect, which cannot be troubleshot.
(Gauge/lamp module)
state
E-12 AT THE LOCKING-UP OF THE TORQUE CONVERTER, THE TORQUE CONVERTER

LOCK-UP DISPLAY LAMP DOES NOT COME ON.
Trouble At the locking-up of the torque converter, the torque converter lock-up display lamp does not come on.
Before troubleshooting the torque converter, make sure that the lock-up is operating. (When the lock-
Related
up does not operate normally, the electrical system on the machine side or the hydraulic/mechanical
information
system is supposed to be out of order. So, troubleshoot the relevant system.)

and standard
(Gauge/lamp module)
state
20-718 D375A-5
E-13 THE DISPLAY OF THE TORQUE CONVERTER OIL TEMPERATURE
TROUBLESHOOTING GAUGE IS NOT NORMAL
E-13 THE DISPLAY OF THE TORQUE CONVERTER OIL TEMPERATURE GAUGE IS NOT
NORMAL
Trouble The display of the torque converter oil temperature gauge is not normal.
Related information

Torque converter oil temper- Torque converter oil
453 (male) Resistance value
ature sensor failure temperature
1
(Internal disconnection/short Approx. 80 k
circuit) Between (1) and (2)
approx. 3.8 k
10 100C
Between (1) and
Min. 1 M
ground
ure Between harnesses between S04 (female) Resistance
2 Max. 1
Possible causes contact failure) Between harnesses between 453 (female) (2) Resistance
Max. 1
and standard val- and ground value
ue in normal state aPrepare the engine with the starting switch OFF and diagnose it
3
(GND circuit and contact) Between harness and ground between S04 Resistance
Min. 1 M
4 failure
(24 V circuit and contact) Between harness and ground beytween S04
Voltage Max. 1 V
Monitor panel failure Torque converter oil
5 S04 (female) Resistance value
(Caution module) temperature
Between (12) and Approx. 80 k
10 100C
ground approx. 3.8 k
Torque converter oil temperature-related circuit diagram
D375A-5 20-719
E-14 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE
TROUBLESHOOTING NORMALLY.
E-14 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY.
Trouble The hydraulic oil temperature gauge does not indicate normally.
Signals of the hydraulic oil temperature sensor are received from the transmission controller through
Related communication.
information When any abnormality occurred in the hydraulic oil temperature sensor system, the failure code
[DGS1KX] is displayed sometimes.

The hydraulic oil tempera- without turning the starting switch ON.
ture sensor is defective.
1 SDS (male) Resistance
Between (1) and (2) 3.5 k 90 kz
short circuit)
Between (1) and ground Min. 1 Mz
Disconnection of wiring har- without turning the starting switch ON.
ness (Disconnection in wir- Wiring harness between TMCN1 (female) (14)
ing or defective contact in and SDS (female) (1)
connector) Wiring harness between TMCN1 (female) (21)
Resistance Max. 1 z
and SDS (female) (2)
Possible causes
and standard Ground fault of wiring har-
value in normal 3 ness (Contact with ground
state Between wiring harness (between TMCN1
(female) (14) and SDS (female) (1)) and ground
Hot short circuit of wiring
and carry out troubleshooting.
Between wiring harness (between TMCN1
circuit) Voltage Max. 1 V
(female) (14) and SDS (female) (1)) and ground
5 TMCN1 (female) Resistance
troller
Between (14) and (21) 3.5 k 90 kz
Between (14) and ground Min. 1 Mz
6 This is an internal defect, which cannot be troubleshot.
(Gauge/lamp module)
Circuit diagram related to hydraulic oil temperature sensor
20-720 D375A-5
TROUBLESHOOTING E-15 THE DISPLAY OF THE FUEL GAUGE IS NOT NORMAL
E-15 THE DISPLAY OF THE FUEL GAUGE IS NOT NORMAL
Trouble The display of the fuel gauge is not normal.

Related information

Fuel level sensor failure with the starting switch OFF as is.
1 (Internal disconnection/short 423 (male) Remaining fuel level Resistance value
circuit) Between (1) and (2) Full Max. approx. 12
(ground) Empty Approx. 85 110
2
(Disconnection/connector Between harnesses between S04 (female) Resistance
Max. 1
contact failure) (10) and 423 (female) (1) value
Possible causes aPrepare the engine with the starting switch OFF and diagnose it
and standard val- Harness ground fault with the starting switch OFF as is.
3
ue in normal state (GND circuit and contact) Between harness and ground between S04 Resistance
Min. 1 M
4 failure
Between harness and ground between S04
(24 V circuit and contact) Voltage Max. 1 V
Monitor panel failure S04 (female) Remaining fuel level Resistance value
5
(Caution module)
Between (10) and Full Max. approx. 12
ground Empty Approx. 85 110
Fuel level sensor-related circuit diagram
D375A-5 20-721
E-16 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL.
TROUBLESHOOTING E-16 INDICATIONS OF GEAR
E-17 INDICATION OFSPEED AND
THE SHIFT ENGINE
MODE SPEED
SERVICE AREISABNORMAL.
METER ABNORMAL.
E-16 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL.
Trouble Indications of gear speed and engine speed are abnormal.

Related Signals of gear speed and engine speed are received from the transmission controller and the engine
information controller through communication.

and standard
(Gauge/lamp module)
state
E-17 INDICATION OF THE SHIFT MODE SERVICE METER IS ABNORMAL.
Trouble (1) During engine operation, the service meter does not advance.
Related The service meter measures time according to engine drive signals (alternator voltage and engine oil
information pressure).

When the battery charge level caution lamp flashes during engine oper-
1 Defective alternator system ation, carry out the troubleshooting of While the engine is operating,
Possible causes
caution items flash.
and standard
The engine oil pressure When the engine oil pressure caution lamp flashes during engine oper-
value in normal
2 sensor system is defective. ation, carry out the troubleshooting of While the engine is operating,
state
(Engine controller system) emergency warning items flash.
3 This is an internal defect, which cannot be troubleshot.
(Gauge/lamp module)
Trouble (2) Shift mode and service meter are not displayed at all.
Related
information

and standard
(Gauge/lamp module)
state
20-722 D375A-5
TROUBLESHOOTING E-18 THE SWITCH MODULE CANNOT BE OPERATED
E-18 THE SWITCH MODULE CANNOT BE OPERATED
Trouble (1) Even if the switch is operated, the lamp is not switched.
Related information

and standard val- Monitor panel failure
1 Because the monitor panel is internally faulty, it cannot be diagnosed.
ue in normal state (Switch module)
Trouble (2) Even if the switch is operated, the system setting is not switched.
Related information The signal of the switch module is sent to each controller by communication.

1
Possible causes (Disconnection/connector Between harnesses between S013 (female) Resistance
and standard val- (8) and circuit merging point value
ue in normal state aPrepare the engine with the starting switch OFF and diagnose it
Monitor panel failure with the engine start.
2
(Switch module) S01 Voltage
Between (8) and ground 69V
S-NET communication-related circuit diagram
D375A-5 20-723
TROUBLESHOOTING E-19 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT.
E-19 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT.
Trouble The warning lamp does not flash or does not go out.
Related
information

and standard
(Gauge/lamp module)
state
20-724 D375A-5
TROUBLESHOOTING E-20 THE ALARM BUZZER DOES NOT SOUND OR STOP
E-20 THE ALARM BUZZER DOES NOT SOUND OR STOP
Trouble The alarm buzzer does not sound or stop.

If a short circuit occurs in the alarm lamp system, a service code is displayed. In other failures, any
Related information
service code cannot be displayed.

If the circuit breaker is disconnected, the possibility of a ground fault
1 Circuit breaker (CB2) failure
having occurred in the circuit is great.
Alarm lamp failure with the starting switch OFF as is.
2 (Internal disconnection/short 217 (male) Resistance value
circuit) Between (1) and (2) 200
Between (2) and ground Min. 1 M
ure Between harnesses between CN2 (female) Resistance
Possible causes 3 Max. 1
and standard val-
contact failure) Between harnesses between 217 (female) (2) Resistance
ue in normal state Max. 1
and CB2 exit value
4
(GND circuit and contact) Between CB2 (exit side)-related harnesses Resistance
Min. 1 M
and grounds value
Monitor panel failure S03 Alarm buzzer Voltage
5
(Caution module) At stoppage time 20 30 V
Between (8) and
ground At operating
Max. 3 V
(sounding) time
Alarm buzzer-related circuit diagram
D375A-5 20-725
TROUBLESHOOTING E-21 THE ALARM BUZZER CANNOT BE CANCELLED.
E-21 THE ALARM BUZZER CANNOT BE CANCELLED.
Trouble The alarm buzzer cannot be cancelled.

Related
information

BUZ (male) Buzzer cancel switch Resistance
Defective buzzer cancel
1 switch (Internal disconnec- OFF (0) Min. 1 Mz
Between (1) and (2)
tion or short circuit) Max. 1 z
OFF (0) Min. 1 Mz
Between (1) and (3)
Max. 1 z
Disconnection of wiring har- Wiring harness between STCN2 (36) and BUZ
Resistance Max. 1 z
ness (Disconnection in (female) (2)
2
wiring or defective contact Wiring harness between STCN2 (26) and BUZ
Possible causes Resistance Max. 1 z
in connector) (female) (3)
and standard
Wiring harness between BUZ (female) (1) and
value in normal Resistance Max. 1 z
STCN1 (female) (10)
state
Ground fault of wiring har-
Between wiring harness (between STCN2 (36)
3 ness (Contact with ground Resistance Min. 1 Mz
and BUZ (female) (2)) and ground
circuit)
Resistance Min. 1 Mz
and BUZ (female) (3)) and ground
and carry out the troubleshooting.
STCN2 Buzzer cancel switch Voltage
4 Defective steering controller Between STCN2 (36) OFF (0) 20 30 V
STCN1 (10) Max. 1 V
Between STCN2 (26) OFF (0) 20 30 V
STCN1 (10) Max. 1 V
Circuit diagram related to buzzer cancel switch
20-726 D375A-5
TROUBLESHOOTING E-22 THE OPERATOR MODE CANNOT BE OPERATED.
E-22 THE OPERATOR MODE CANNOT BE OPERATED.
Trouble The operator mode cannot be operated.

Related
information

Defective buzzer cancel Since the buzzer cancel switch system is supposed to be out of order,
1
switch system carry out the troubleshooting of The alarm buzzer cannot be cancelled.
Defective information switch CUR (male) Information switch Resistance
2 (Internal short circuit or dis- OFF (0) Min. 1 Mz
Between (1) and (2)
connection) Max. 1 z
OFF (0) Min. 1 Mz
Between (1) and (3)
Max. 1 z
Disconnection of wiring har- Wiring harness between STCN2 (16) and CUR
Resistance Max. 1 z
ness (Disconnection in wir- (female) (2)
Possible causes 3
ing or defective contact in Wiring harness between STCN2 (6) and CUR
and standard
connector) (female) (3)
value in normal
state Wiring harness between CUR (female) (1) and
Resistance Max. 1 z
STCN1 (female) (10)
4 ness (Contact with ground Resistance Min. 1 Mz
and CUR (female) (2)) and ground
circuit)
Resistance Min. 1 Mz
and CUR (female) (3)) and ground
STCN2 Buzzer cancel switch Voltage
5 Defective steering controller Between STCN2 (16) OFF (0) 20 30 V
STCN1 (10) Max. 1 V
Between STCN2 (6) OFF (0) 20 30 V
STCN1 (10) Max. 1 V
Circuit diagram related to information switch
D375A-5 20-727
TROUBLESHOOTING E-23 THE SERVICE MODE CANNOT BE OPERATED.
E-23 THE SERVICE MODE CANNOT BE OPERATED.
Trouble The service mode cannot be operated.

Related
information

Defective buzzer cancel Since the buzzer cancel switch system is supposed to be out of order,
1
switch system carry out the troubleshooting of The alarm buzzer cannot be cancelled.
Defective information switch Since the information switch system is supposed to be out of order, carry
2
system out the troubleshooting of The operator mode cannot be cancelled.
Defective circuit breaker When the circuit breaker is cut off, a ground fault may have possibly
3
(CB6) occurred in the circuit.
Defective service switch without turning the starting switch ON.
4 (Internal short circuit or dis- S24 Service switch Resistance
connection) Between (1) and (2), OFF Min. 1 Mz
Between (4) and (5) ON Max. 1 z
Disconnection of wiring har- Wiring harness between CB6 outlet and S24 (1) Resistance Max. 1 z
Possible causes ness (Disconnection in wir- Wiring harness between S24 (6) and ground Resistance Max. 1 z
5
and standard ing or defective contact in Wiring harness between S03 (female) (16) and
connector) Resistance Max. 1 z
value in normal S24 (2)
state Wiring harness between STCN1 (female) (6)
Resistance Max. 1 z
and S24 (4)
6 ness (Contact with ground
Between wiring harness related to CB6 (outlet
side) and ground
7 S03 Service switch Voltage
(Gauge/lamp module)
Between (16) and OFF Max. 1 V
ground ON 20 30 V
8 Defective steering controller STCN1 Service switch Voltage
Between (6) and OFF 20 30 V
ground ON Max. 1 V
20-728 D375A-5
TROUBLESHOOTING E-23 THE SERVICE MODE CANNOT BE OPERATED.
Circuit diagram related to service switch
D375A-5 20-729
E-24 INSTRUMENT PANEL NIGHT LAMP, HEADLAMP, WORKING LAMP AND
TROUBLESHOOTING REAR LAMP DO NOT COME ON
E-24 INSTRUMENT PANEL NIGHT LAMP, HEADLAMP, WORKING LAMP AND REAR
LAMP DO NOT COME ON
Trouble (1) Any of the instrument panel night lamp, headlamp, working lamp and rear lamp do not come on.
Related information

When the fuse is blown, there is a high possibility that the circuit was
1 Defective fuse (FS2-5)
short-circuited with ground.
aSet the starting switch to OFF for preparation and troubleshoot
Disconnection of harness while keeping it to OFF.
2 (Disconnection, defective
contact of connector) Harness between FS2-5 (outlet side) and cir- Resistance
Max. 1
cuit branched portion value
while keeping it to OFF.
Possible causes Between harness related to FS2-5 (outlet Resistance
and standard val- Min. 1 M
side) and ground value
ue in normal state
Between harnesses (between 219 (female)
(3) and CN4 (female) (1), between 219 (fe-
Ground fault of harness male) (3) and S03 (female) (1), between 219
3 Resistance
(contact with GND circuit) (female) (3) and S02 (female) (1), between Min. 1 M
value
219 (female) (3) and S01 (female) (10) and
between 219 (female) (3) and BB1 (female)
(1)) and ground
Between harnesses (between 218 (female)
Resistance
(3) and 223 (female) (1) and between 218 (fe- Min. 1 M
value
male) (3) and 243 (female) (1)) and ground
Trouble (2) Any of the instrument panel night lamp, headlamp, working lamp and rear lamp do not come on.
Related information

Headlamp and working lamp while keeping it to OFF.
1 switches 219 (male) Switch Resistance value
(Internal disconnection) OFF Min. 1 M
Between (2) and (3)
ON Max. 1
Possible causes aSet the starting switch to OFF for preparation and troubleshoot
and standard val- while keeping it to OFF.
ue in normal state Harness between 219 (female) (2) and circuit Resistance
Max. 1
branched portion value
Disconnection of harness
2 (Disconnection, defective Harnesses between 219 (female) (3) and BB1
Resistance
(female) (1) and between 219 (female) (3) and Max. 1
contact of connector) value
BB3 (female) (1)
Harnesses between BB1 (female) (2) and
Resistance
ground and between BB3 (female) (2) and Max. 1
value
ground
20-730 D375A-5
Trouble (3) Only the instrument panel night lamp does not come on.
Related information

Defective night lamp The night lamp is supposed to be defective. Check if the light bulb is
1
(Burnt bulb) burned out.
aSet the starting switch to OFF for preparation Resistance
Max. 1
and troubleshoot while keeping it to OFF. value
Harness between S01 (female) (10) and cir- Resistance
Max. 1
cuit branched portion value
Disconnection of harness
2 (Disconnection, defective Harness between S02 (female) (1) and circuit Resistance
Max. 1
contact of connector)
Possible causes Harness between S02 (female) (2) and Resistance
Max. 1
and standard val- ground value
ue in normal state Harness between S03 (female) (8) and circuit Resistance
Max. 1
Set the starting switch to OFF for preparation and set it to ON for
troubleshooting.
3 Between S01 (10) and
(Switch module)
(2) Light switch ON 20 30 V
Between S01 (1) and (2)
Defective monitor panel troubleshooting.
4
(Tachometer module)
Between S03 (6) and (2) Light switch ON 20 30 V
Trouble (4) Only the headlamp does not come on.

Related information

Defective headlamp The headlamp is supposed to be defective. Check if the light bulb is
1
Defective circuit breaker When the circuit breaker is cut off, there is a high possibility that the
2
(CB5) circuit was short-circuited with ground.
troubleshooting.
Defective headlamp relay
3 When the starting switch is set to OFF, replace the relay with another
relay. Set the starting switch to ON and set the light switch to ON. If
the headlamp comes on, the headlamp relay (BB1) is defective.
Possible causes Set the starting switch to OFF for preparation and troubleshoot
and standard val-
ue in normal state Disconnection of harness Harness between CB5 outlet and BB1 (fe- Resistance
Max. 1
4 (Disconnection, defective male) (3) value
contact of connector) Harnesses between BB1 (female) (5) and 203
Resistance
(female) (1) and between BB1 (female) (5) Max. 1
value
and 204 (female) (1)
Set the starting switch to OFF for preparation and troubleshoot
Ground fault of harness Between harness related to CB5 (outlet side) Resistance
Min. 1 M
5 and ground value
(contact with GND circuit)
Between harnesses (between BB1 (female)
Resistance
(5) and 203 (female) (1), between BB1 (fe- Min. 1 M
value
D375A-5 20-731
Trouble (5) Only the working lamp does not come on. (Both right and left, or one side only)
Related information

Defective working lamp The working lamp is supposed to be defective. Check if the light bulb
1
(Burnt bulb) is burned out.
When the fuse is blown, there is a high possibility that the circuit was
2 Defective fuse (FS2-4)
short-circuited with ground.
aSet the starting switch to OFF for preparation and set it to ON for
Defective working lamp re- troubleshooting.
3 lay When the starting switch is set to OFF, replace the relay with another
(Internal disconnection) relay. Set the starting switch to ON and set the light switch to ON. If
the working lamp comes on, the working lamp relay (BB3) is defective.
Possible causes
and standard val-
ue in normal state Disconnection of harness Harness between FS2-4 outlet and BB3 (fe- Resistance
Max. 1
4 (Disconnection, defective male) (3) value
contact of connector) Harnesses between BB3 (female) (5) and 221
Resistance
(female) (1) and between BB3 (female) (5) Max. 1
value
and 241 (female) (1)
Between harness related to FS2-4 (outlet Resistance
Ground fault of harness Min. 1 M
5 side) and ground value
(contact with GND circuit)
Between harnesses (between BB3 (female)
Resistance
(5) and 221 (female) (1), between BB3 (fe- Min. 1 M
value
Trouble (6) Only the rear lamp does not come on. (Both right and left, or one side only)
Related information

Defective rear lamp The rear lamp is supposed to be defective. Check if the light bulb is
1
aSet the starting switch to OFF for preparation and set it to ON for
troubleshooting.
Defective rear lamp switch 218 (male) Switch Resistance value
2
Possible causes OFF Min. 1 M
and standard val- Between (2) and (3)
ON Max. 1
ue in normal state aSet the starting switch to OFF for preparation and troubleshoot
Disconnection of harness Harness between 18 (female) (2) and circuit Resistance
Max. 1
3 (Disconnection, defective branched portion value
contact of connector) Harnesses between 218 (female) (3) and 223
Resistance
(female) (1) and between 218 (female) (3) and Max. 1
value
243 (female) (1)
20-732 D375A-5
Circuit diagram related to instrument panel night lamp, headlamp, working lamp and rear lamp
D375A-5 20-733
TROUBLESHOOTING E-25 AIR CONDITIONER DOES NOT OPERATE
E-25 AIR CONDITIONER DOES NOT OPERATE
Trouble (1) No airflow occurs

Related information

Defective circuit breaker When the circuit breaker is cut off, there is a high possibility that the
1
(CB4) circuit was short-circuited with ground.
Defective blower main relay while keeping it to OFF.
2
(coil side) CN-R1 (male) Resistance value
Between (1) and (2) 240 40
Defective blower main relay troubleshooting.
3
(contact side) CN-R1 Voltage
Between (6C) and ground 20 30 V
Defective blower Hi relay while keeping it to OFF.
4
Between (1) and (2) 240 40
Defective blower Hi relay troubleshooting.
5
(contact side) Set the starting switch to ON and set the blower Hi switch to ON. If the
motor rotates, the relay is normal.
Defective blower Mi relay while keeping it to OFF.
6
Between (1) and (2) 240 40
Defective blower Mi relay troubleshooting.
7
(contact side) Set the starting switch to ON and set the blower Mi switch to ON. If the
Possible causes Set the starting switch to OFF for preparation and set it to ON for
and standard val- troubleshooting.
ue in normal state 8 Defective blower motor
Set the starting switch to ON and set the blower Lo switch to ON. If the
Harness between CR-R3 (female) (0B), CN-
Resistance
AC1 (female) (0C), CN-R (female) (0D) or Max. 1
value
CCN-R2 (female) (0E) and ground
Harness between CN-B (female) (10A) and Resistance
Max. 1
CN-R (female) (10B) value
Harnesses between CN-B (female) (11A) and
Resistance
CN-R2 (female) (11B) and between CN-B (fe- Max. 1
value
male) (11A) and CN-R (female) (11C)
Disconnection of harness Harnesses between CB4 outlet and CNAC1
9 (Disconnection, defective (female) (13C), between CB4 outlet and CN-
Resistance
contact of connector) R1 (female) (13D), between CB4 outlet and Max. 1
value
CN-R2 (female) (13E) and between CB4 out-
let and CN-R3 (female) (13H)
Harness between CN-R1 (female) (14A) and Resistance
Max. 1
CN-AC1 (female) (14B) value
Max. 1
Max. 1
When cases 1 to 9 are not applicable, the control panel is supposed to be
10 Defective control panel
defective.
Mistake of failure phenome- When any specific cause cannot be determined, failure phenomena might
11
non have been mistaken. Execute the troubleshooting of No cooling.
20-734 D375A-5
Trouble (2) No cooling

Related information

troubleshooting.
1 Defective pressure switch CN-P Blower switch Voltage
Between (26A) and
ON 20 30 V
ground
Defective compressor clutch while keeping it to OFF.
2 relay
CN-R4 (male) Resistance value
(coil side)
Between (1) and (2) 240 40
Defective compressor clutch troubleshooting.
3 relay
CN-R4 Voltage
(contact side)
Between (9B) and ground 20 30 V
Condenser relay troubleshooting.
4
(contact side) CN-R5 Voltage
Between (7B) and ground 20 30 V
5 Defective thermistor
CN-AC1 (male) Resistance value
Between (15B) and (16C) Max. 3,500
Defective condenser blower while keeping it to OFF.
6
resistor Condenser blower resistor Resistance value
Possible causes Between terminals 2.8 5%
and standard val- Set the starting switch to ON for troubleshooting.
ue in normal state 7 Defective condenser motor
Set the air conditioner switch to ON. If the motor rotates, it is normal.
Start the engine for troubleshooting.
Defective compressor mag-
8 The compressor magnet clutch is supposed to be defective. Check it
net clutch
directly.
9 Defective compressor
The compressor is supposed to be defective. Check it directly.
Harnesses between CB4 outlet and CN-R5
Resistance
(female) (6B) and between CB4 outlet and Max. 1
value
CN-R4 (female) (6D)
Harness between CN-R5 (female) (7B) and Resistance
Max. 1
ARC (female) (2) value
Harness between CN-R4 (female) (9B) and Resistance
Max. 1
Disconnection of harness 351 (female) (1) value
10 (Disconnection, defective Harnesses between CB4 outlet and CN-R4 Resistance
Max. 1
contact of connector) (female) (131) value
Harness between CN-T (female) (15A) and Resistance
Max. 1
Harness between CN-P (female) (19A) and Resistance
Max. 1
CN-R4 (female) (19C) value
Harness between CN-P (female) (26A) and Resistance
Max. 1
Harness between ARC (female) (1) and Resistance
Max. 1
ground value
When cases 1 to 10 are not applicable, the control panel is supposed
11 Defective control panel
to be defective.
D375A-5 20-735
Circuit diagram related to air conditioner
20-736 D375A-5
TROUBLESHOOTING OF
HYDRAULIC AND MECHANICAL SYSTEM
(H-MODE)
INFORMATION IN TROUBLESHOOTING TABLE ................................................................................. 20-802

H-1 NO FORCE (NO DRAWBAR PULL) ................................................................................................ 20-803
H-2 NO TRAVEL (AT 2ND OR 3RD SPEED) ........................................................................................ 20-804
H-3 NO TRAVEL AT ALL GEAR SPEEDS ............................................................................................. 20-805
H-4 LARGE TIME LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE SHIFTING ............. 20-806
H-5 LARGE TIME LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE SHIFTING ............. 20-807
H-6 STEERING IS NOT POSSIBLE ....................................................................................................... 20-808
H-7 STEERING IS POSSIBLE ONLY ON ONE SIDE ............................................................................ 20-808
H-8 STEERING OVERRUN OCCURS ................................................................................................... 20-809
H-9 BRAKE DOES NOT WORK ............................................................................................................. 20-809
H-10 TORQUE CONVERTER IS NOT LOCK-UP .................................................................................. 20-810
H-11 TORQUE CONVERTER OIL IS OVERHEATED ............................................................................ 20-810
H-12 ALL WORK EQUIPMENT OPERATES SLOWLY ......................................................................... 20- 811
H-13 ALL WORK EQUIPMENT DOES NOT OPERATE ........................................................................ 20-812
H-14 BLADE LIFT RAISING SPEED IS SLOW OR THE BLADE LIFT HAS NO POWER ..................... 20-813
H-15 BLADE TILT RAISING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER .................... 20-813
H-16 RIPPER LIFT RAISING SPEED IS SLOW OR THE RIPPER LIFT HAS NO POWER ................. 20-814
H-17 RIPPER TILTING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER ............................ 20-814
H-18 HYDRAULIC DRIFT OF BLADE LIFT IS LARGE .......................................................................... 20-815
H-19 HYDRAULIC DRIFT OF BLADE TILT IS LARGE .......................................................................... 20-815
H-20 HYDRAULIC DRIFT OF RIPPER LIFT IS LARGE ........................................................................ 20-816
H-21 RIPPER PIN PULLER CYLINDER DOES NOT OPERATE .......................................................... 20-816
H-22 BLADE PITCH DOES NOT OPERATE ......................................................................................... 20-817
H-23 ABNORMAL NOISE OCCURS AROUND THE WORK EQUIPMENT PUMP ............................... 20-817
D375A-5 20-801
TROUBLESHOOTING INFORMATION IN TROUBLESHOOTING TABLE
INFORMATION IN TROUBLESHOOTING TABLE

The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before carrying out troubleshooting, understand that information fully.
Trouble Trouble in machine
Related information Information related to detected trouble or troubleshooting
2
Possible causes Possible causes of trouble
and standard val- <Contents of description>
(Given numbers are refer-
Standard value in normal state to judge possible causes
ue in normal state ence numbers, which do not
Remarks on judgment
indicate priority)
3
20-802 D375A-5
TROUBLESHOOTING H-1 NO FORCE (NO DRAWBAR PULL)
H-1 NO FORCE (NO DRAWBAR PULL)
Trouble No force (No drawbar pull)

Related information Before troubleshooting, check that the power train oil level is normal.

1 Defective power train pump The power train pump is supposed to be defective. Check it directly.
Set the starting switch to OFF for preparation and idle the engine at
a high speed for troubleshooting (after checking that the transmis-
sion main relief pressure is normal).
Internal defect of torque con-
2 Torque converter Torque converter
verter PCCS lever
inlet pressure outlet pressure
0.8 1.0 MPa 39.2 63.7 MPa
Full neutral
{8.0 10.0 kg/cm2} {4.0 6.5 kg/cm2}
Incorrect pressure set to a high speed for troubleshooting.
3 transmission main relief
PCCS lever Transmission main relief pressure
valve
Full neutral 2.45 2.94 MPa {25.0 30.0 kg/cm2}
Defective operation of trans- while keeping it to OFF.
4
mission main relief valve Check it directly that the spring free length (120.3 mm) is normal and
that the spool moves smoothly.
a low speed for troubleshooting (after checking that the transmis-
Transmission clutch Clutch pressure
Defective operation of trans- FWD 2.35 2.94 MPa {24.0 30.0 kg/cm2}
5
mission valve (ECMV)
REV 2.35 2.94 MPa {24.0 30.0 kg/cm2}
1ST 1.96 2.55 MPa {20.0 26.0 kg/cm2}
Possible causes
2ND 2.35 2.94 MPa {24.0 30.0 kg/cm2}
and standard val-
ue in normal state 3RD 2.35 2.94 MPa {24.0 30.0 kg/cm2}
a high speed for troubleshooting.
Internal defect of transmis-
6 Measuring conditions Engine speed
sion
F3 stall 1,430 rpm
F3 stall + Work equipment relief 1,160 rpm
Move the machine to a flat ground and start the engine for trouble-
shooting.
Defective operation (drag-
7 Idle the engine at a low speed and operate F2. Unless the machine
ging) of brake
moves, the brake is being dragged. (Execute the troubleshooting of
Brake does not work.)
PCCS lever Left stroke end Right stroke end
Min. 2.4 MPa 0
Left clutch pressure
{Min. 24 kg/cm2} {0}
0 Min. 2.4 MPa
8 Defective steering clutch Right clutch pressure
{0} {Min. 24 kg/cm2}
0 Min. 2.4 MPa
Left brake pressure
{0} {Min. 24 kg/cm2}
Min. 2.4 MPa 0
Right brake pressure
{Min. 24 kg/cm2} {0}
When the oil pressure is abnormal, execute the troubleshooting of
Steering is not possible.
D375A-5 20-803
TROUBLESHOOTING H-2 NO TRAVEL (AT 2ND OR 3RD SPEED)
H-2 NO TRAVEL (AT 2ND OR 3RD SPEED)
Trouble No travel (at 2nd or 3rd speed)

Before troubleshooting, check that the power train oil level is normal.
Related information
Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.)

Internal defect of torque con- Torque converter Torque converter
1 PCCS lever
verter inlet pressure outlet pressure
0.8 1.0 MPa 39.2 63.7 MPa
Full neutral
{8.0 10.0 kg/cm2} {4.0 6.5 kg/cm2}
a low speed for troubleshooting.
Defective operation of trans- Transmission clutch Clutch pressure
2
2ND 2.35 2.94 MPa {24.0 30.0 kg/cm2}
3RD 2.35 2.94 MPa {24.0 30.0 kg/cm2}
Internal defect of transmis- The inside of transmission clutch (2nd speed, 3rd speed) is supposed
3
sion clutch to be defective. Check it directly.
4 Defective operation (dragging) is supposed, check linkage valves.
ging) of parking brake
Possible causes
and standard val- Move the machine to a flat ground and start the engine for trouble-
ue in normal state shooting.
ging) of brake
Min. 2.4 MPa 0
{Min. 24 kg/cm2} {0}
0 Min. 2.4 MPa
Defective steering clutch, Right clutch pressure
6 {0} {Min. 24 kg/cm2}
brake
0 Min. 2.4 MPa
Left brake pressure
{0} {Min. 24 kg/cm2}
Min. 2.4 MPa 0
{Min. 24 kg/cm2} {0}
When the oil pressure is abnormal, execute the troubleshooting of
Steering is not possible.
20-804 D375A-5
TROUBLESHOOTING H-3 NO TRAVEL AT ALL GEAR SPEEDS
H-3 NO TRAVEL AT ALL GEAR SPEEDS
Trouble No travel at all gear speeds


Incorrect pressure set to a high speed for troubleshooting.
valve
3
Defective operation of trans- FWD 2.35 2.94 MPa {24.0 30.0 kg/cm2}
4
REV 2.35 2.94 MPa {24.0 30.0 kg/cm2}
1ST 1.96 2.55 MPa {20.0 26.0 kg/cm2}
2ND 2.35 2.94 MPa {24.0 30.0 kg/cm2}
3RD 2.35 2.94 MPa {24.0 30.0 kg/cm2}
Possible causes Internal defect of transmis- The inside of transmission clutch (2nd speed, 3rd speed) is supposed
and standard val- 5
sion clutch to be defective. Check it directly.
ue in normal state
Move the machine to a flat ground and idle the engine at a high
speed for troubleshooting (after checking that the transmission
main relief pressure is normal).
6 Defective operation of brake
Brake pedal Brake oil pressure (right and left)
Release Min. 2.4 MPa {Min. 24 kg/cm2}
Step on 0 {0}
Min. 2.4 MPa 0
Defective seal of steering {Min. 24 kg/cm2} {0}
7
clutch 0 Min. 2.4 MPa
Right clutch pressure
{0} {Min. 24 kg/cm2}
0 Min. 2.4 MPa
Left brake pressure
{0} {Min. 24 kg/cm2}
Min. 2.4 MPa 0
{Min. 24 kg/cm2} {0}
Internal defect of steering The inside of the steering clutch is supposed to be defective, check it
8
clutch directly.
D375A-5 20-805
H-4 LARGE TIME LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE
TROUBLESHOOTING SHIFTING
H-4 LARGE TIME LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE SHIFTING
Trouble Large time lag at gear speed shifting or forward-reverse shifting


Incorrect pressure set to
valve
When the oil pressure is abnormal, clean the valve and then check the
oil pressure again.
3
Possible causes sion main relief pressure is normal).
and standard val-
ue in normal state Defective operation of trans-
4 FWD 2.35 2.94 MPa {24.0 30.0 kg/cm2}
REV 2.35 2.94 MPa {24.0 30.0 kg/cm2}
1ST 1.96 2.55 MPa {20.0 26.0 kg/cm2}
2ND 2.35 2.94 MPa {24.0 30.0 kg/cm2}
3RD 2.35 2.94 MPa {24.0 30.0 kg/cm2}
Defective seal of transmis- When the cause 4 is not applicable, the clutch seal is supposed to be
5
sion clutch defective. Check it directly.
Internal defect of transmis- The inside of the transmission clutch is supposed to be defective,
6
sion clutch check it directly.
shooting.
ging) of brake
20-806 D375A-5
H-5 LARGE TIME LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE
TROUBLESHOOTING SHIFTING
H-5 LARGE TIME LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE SHIFTING
Trouble Large time lag at gear speed shifting or forward-reverse shifting


Defective operation of trans- PCCS lever Transmission main relief pressure
2
mission main relief valve Full neutral 2.45 2.94 MPa {25.0 30.0 kg/cm2}
When the oil pressure is abnormal, clean the valve and then check the
oil pressure again.
Possible causes Defective operation of trans-
3 FWD 2.35 2.94 MPa {24.0 30.0 kg/cm2}
and standard val- mission valve (ECMV)
ue in normal state REV 2.35 2.94 MPa {24.0 30.0 kg/cm2}
1ST 1.96 2.55 MPa {20.0 26.0 kg/cm2}
2ND 2.35 2.94 MPa {24.0 30.0 kg/cm2}
3RD 2.35 2.94 MPa {24.0 30.0 kg/cm2}
Defective seal of transmis- When the cause 3 is not applicable, the clutch seal is supposed to be
4
sion clutch defective. Check it directly.
Internal defect of transmis- The inside of the transmission clutch is supposed to be defective,
5
sion clutch check it directly.
shooting.
ging) of brake
D375A-5 20-807
H-6 STEERING IS NOT POSSIBLE
TROUBLESHOOTING H-7 STEERING H-6
IS POSSIBLE
STEERINGONLY ONPOSSIBLE
IS NOT ONE SIDE
H-6 STEERING IS NOT POSSIBLE
Trouble Steering is not possible.

Related information

Start the engine for preparation and idle it at a low speed for trou-
bleshooting.
1 Defective operation of brake Lift the machine with the blade and the ripper and steer the wheel for
F3 travel (or R3 travel). If the track shoe stops, the brake is defective.
(Execute the troubleshooting of Brake does not work.)
Possible causes Min. 2.4 MPa 0
and standard val- {Min. 24 kg/cm2} {0}
ue in normal state Defective operation of steer-
2 0 Min. 2.4 MPa
ing clutch valve (ECMV) Right clutch pressure
{0} {Min. 24 kg/cm2}
0 Min. 2.4 MPa
Left brake pressure
{0} {Min. 24 kg/cm2}
Min. 2.4 MPa 0
{Min. 24 kg/cm2} {0}
Defective seal of steering When the cause 2 is not applicable, the clutch seal is supposed to be
3
clutch defective. Check it directly.
4
clutch directly.
H-7 STEERING IS POSSIBLE ONLY ON ONE SIDE
Trouble Steering is possible only on one side.

Related information

Min. 2.4 MPa 0
{Min. 24 kg/cm2} {0}
Defective operation of steer-
1 0 Min. 2.4 MPa
Possible causes ing clutch valve (ECMV) Right clutch pressure
{0} {Min. 24 kg/cm2}
and standard val-
ue in normal state 0 Min. 2.4 MPa
Left brake pressure
{0} {Min. 24 kg/cm2}
Min. 2.4 MPa 0
{Min. 24 kg/cm2} {0}
Defective seal of steering When the cause 1 is not applicable, the clutch seal is supposed to be
2
clutch defective. Check it directly.
3
clutch directly.
20-808 D375A-5
H-8 STEERING OVERRUN OCCURS
TROUBLESHOOTING H-9 BRAKE
H-8 STEERING DOES NOT
OVERRUN WORK
OCCURS
H-8 STEERING OVERRUN OCCURS
Trouble Steering overrun occurs.

Related information

Start the engine for preparation and idle it at a low speed for trou-
bleshooting.
Possible causes 1 Defective operation of brake Lift the machine with the blade and the ripper and steer the wheel for
and standard val- F3 travel (or R3 travel). If the track shoe stops, the brake is defective.
ue in normal state (Execute the troubleshooting of Brake does not work.)
When the track shoe does not stop in the troubleshooting of the cause
2 1, the steering clutch is defective. (Execute the troubleshooting of
ing clutch
Steering is not possible.)
H-9 BRAKE DOES NOT WORK
Trouble Brake does not work.

Related information

Step on the brake pedal, shift the gear to F2 and idle the engine at a
1 Degradation of brake
high speed. When the machine moves, the brake performance is de-
graded.
Defective operation of brake The brake pedal and the brake valve are supposed not to work nor-
2
pedal mally. Check them directly.
Possible causes PCCS lever Left stroke end Right stroke end
and standard val- Min. 2.4 MPa 0
ue in normal state {Min. 24 kg/cm2} {0}
3 0 Min. 2.4 MPa
ing brake valve (ECMV) Right clutch pressure
{0} {Min. 24 kg/cm2}
0 Min. 2.4 MPa
Left brake pressure
{0} {Min. 24 kg/cm2}
Min. 2.4 MPa 0
{Min. 24 kg/cm2} {0}
When the brake seal is not normal in the troubleshooting of the cause
4 Defective brake seal
3, the brake seal is supposed to be defective. Check it directly.
5 Internal defect of brake The inside of the brake is supposed to be defective. Check it directly.
D375A-5 20-809
H-10 TORQUE CONVERTER IS NOT LOCK-UP
TROUBLESHOOTING H-11H-10
TORQUE CONVERTER
TORQUE OIL IS OVERHEATED
CONVERTER NOT LOCK-UP
H-10 TORQUE CONVERTER IS NOT LOCK-UP
Trouble The torque converter is not lock-up.

Related information

Defective operation of a high speed for troubleshooting.
2 torque converter lock-up Torque converter Clutch pressure
valve Min. 1.27 1.47 MPa
At lock-up time
{Min. 13.0 15.0 kg/cm2}
Possible causes
Defective seal of lock-up When the troubleshooting of the case 2 is not normal, the lock-up
and standard val- 3
clutch clutch seal is supposed to be defective. Check it directly.
ue in normal state
Internal defect of lock-up The inside of the lock-up clutch is supposed to be defective. Check it
4
clutch directly.
Internal defect of torque con-
5 Measuring conditions Engine speed
verter
F3 stall 1,430 rpm
F3 stall + Work equipment relief 1,160 rpm
H-11 TORQUE CONVERTER OIL IS OVERHEATED
Trouble The torque converter oil is overheated.

Before troubleshooting, check that the indication of the torque converter oil temperature gauge
agrees with actual temperature of the torque converter oil. (When the indication does not agree with
Related information
actual temperature, execute the troubleshooting of The indication of torque converter oil temperature
gauge is abnormal.)

Engine output is supposed to have increased abnormally. Trouble-
1 Rise of engine output
shoot referring to the shop manual for engine.
Defective power train pump The power train pump is supposed to be defective, or air is supposed
2
or air entry in suction circuit to have entered from the suction circuit. Check them directly.
Internal defect of torque con- Torque converter Torque converter
3 PCCS lever
Possible causes verter inlet pressure outlet pressure
and standard val- 0.8 1.0 MPa 39.2 63.7 MPa
Full neutral
ue in normal state {8.0 10.0 kg/cm2} {4.0 6.5 kg/cm2}
Defective operation (slide) of The inside of the transmission clutch is supposed to be defective (the
4
transmission clutch clutch slides). Check it directly.
Defective operation (drag- Idle the engine at a low speed and operate F2. Unless the machine
5
ging) of brake moves, the brake is being dragged. (Execute the troubleshooting of
Defective operation (slide) of The inside of the steering clutch is supposed to be defective (the
6
steering clutch clutch slides). Check it directly.
20-810 D375A-5
TROUBLESHOOTING H-12 ALL WORK EQUIPMENT OPERATES SLOWLY
H-12 ALL WORK EQUIPMENT OPERATES SLOWLY
Trouble All work equipment operates slowly.

Related information Before troubleshooting, check that the hydraulic tank oil level is normal.

Defective PTO (work equip- The work equipment pump drive of the PTO is supposed to be defec-
1
ment pump drive) tive. Check it directly.
Defective work equipment The work equipment large pump is supposed to be defective. Check
2
large pump it directly.
Defective work equipment The work equipment small pump is supposed to be defective. Check
3
small pump it directly.
4 Defective PPC charge pump The PPC charge pump is supposed to be defective. Check it directly.
Improper pressure set to a high speed for troubleshooting.
5 main relief valve for blade lift
Blade lever Main relief pressure
valve
Raise Min. 19.6 MPa {Min. 200 kg/cm2}
Internal defect of main relief The inside of the main relief valve for blade lift valve is supposed to be
Possible causes 6
valve for blade lift valve defective. Check it directly.
and standard val-
ue in normal state Improper pressure set to a high speed for troubleshooting.
7 main relief valve for blade tilt
ripper Lo valve
Internal defect of main relief
The inside of the main relief valve for blade tilt ripper Lo valve is sup-
8 valve for blade tilt ripper Lo
posed to be defective. Check it directly.
valve
9
charge relief valve Work equipment lever Control relief pressure
Full neutral Min. 3.9 MPa {Min. 40.0 kg/cm2}
Internal defect of charge re- The inside of the charge relief valve is supposed to be defective.
10
lief valve Check it directly.
11 Internal leak of PPC valve Internal leak of PPC valve is supposed. Check it directly.
D375A-5 20-811
TROUBLESHOOTING H-13 ALL WORK EQUIPMENT DOES NOT OPERATE
H-13 ALL WORK EQUIPMENT DOES NOT OPERATE
Trouble All work equipment does not operate.

Related information Before troubleshooting, check that the hydraulic tank oil level is normal.

Defective PTO (work equip- The work equipment pump drive of the PTO is supposed to be defec-
1
ment pump drive) tive. Check it directly.
Defective work equipment The work equipment large pump is supposed to be defective. Check
2
large pump it directly.
Defective work equipment The work equipment small pump is supposed to be defective. Check
3
small pump it directly.
4 Defective PPC charge pump The PPC charge pump is supposed to be defective. Check it directly.
5 main relief valve for blade lift
valve
Internal defect of main relief The inside of the main relief valve for blade lift valve is supposed to be
6
Possible causes valve for blade lift valve defective. Check it directly.
and standard val- Set the starting switch to OFF for preparation and idle the engine at
ue in normal state Improper pressure set to a high speed for troubleshooting.
7 main relief valve for blade tilt
ripper Lo valve
Internal defect of main relief
The inside of the main relief valve for blade tilt ripper Lo valve is sup-
8 valve for blade tilt ripper Lo
posed to be defective. Check it directly.
valve
9
charge relief valve Work equipment lever Control relief pressure
Full neutral Min. 3.9 MPa {Min. 40.0 kg/cm2}
Internal defect of charge re- The inside of the charge relief valve is supposed to be defective.
10
lief valve Check it directly.
Defective operation of PPC The PPC lock valve is supposed to operate abnormally. Check the le-
11
lock valve ver linkage or the lock valve directly.
20-812 D375A-5
H-14 BLADE
H-14 LIFT RAISING
BLADE SPEED IS
LIFT RAISING SLOWISOR
SPEED THE OR
SLOW BLADE
THELIFT HASLIFT
BLADE NO HAS
POWER
NO
TROUBLESHOOTING H-15 BLADE TILT RAISING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER
H-14 BLADE LIFT RAISING SPEED IS SLOW OR THE BLADE LIFT HAS NO POWER
Trouble Blade lift raising speed is slow or the blade lift has no power.
Before troubleshooting, check that the hydraulic tank oil level is normal.
Check if the blade has been modified.
Related information
In case of large hydraulic drift of the blade lift, execute the troubleshooting of Hydraulic drift of blade
lift is large.

Defective operation of PPC a high speed for troubleshooting.
1
valve Blade lever PPC valve output pressure
Raising stroke end Min. 3.9 MPa {Min. 40 kg/cm2}
Possible causes Defective operation of blade The spool of the blade lift control valve is suppose to operate abnor-
2
and standard val- lift control valve (spool) mally. Check it directly.
ue in normal state The suction valve of the blade lift control valve is suppose to operate
Defective operation of blade abnormally. Check it directly.
3 lift control valve It is also acceptable to replace the suction valve on the head side
(suction valve) with the one on the bottom side to check change of the phenome-
non as another method.
Air is supposed to enter the blade lift cylinder. Bleed air and check the
4 Air entry in blade lift cylinder
change of phenomenon.
H-15 BLADE TILT RAISING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER
Trouble Blade tilt raising speed is slow or the blade tilt has no power.
Related information
lift is large.

1
Possible causes valve Blade lever PPC valve output pressure
and standard val- Tilt stroke end Min. 3.9 MPa {Min. 40 kg/cm2}
ue in normal state Defective operation of blade The spool of the blade tilt control valve is suppose to operate abnor-
2
tilt control valve (spool) mally. Check it directly.
Air is supposed to enter the blade tilt cylinder. Bleed air and check the
3 Air entry in blade tilt cylinder
D375A-5 20-813
H-16 RIPPER
H-16 LIFT RAISING
RIPPER SPEED IS
LIFT RAISING SLOWISOR
SPEED THE OR
SLOW RIPPER
THE LIFT HASLIFT
RIPPER NO HAS
POWER
NO
TROUBLESHOOTING H-17 RIPPER TILTING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER
H-16 RIPPER LIFT RAISING SPEED IS SLOW OR THE RIPPER LIFT HAS NO POWER
Trouble Ripper lift raising speed is slow or the ripper lift has no power.
Check if the ripper has been modified.
Related information
lift is large.

1
valve Ripper lever PPC valve output pressure
Raising stroke end Min. 3.9 MPa {Min. 40 kg/cm2}
Possible causes Defective operation of ripper The spool of the ripper lift control valve (Lo, Hi) is suppose to operate
2
and standard val- lift control valve (spool) abnormally. Check it directly.
ue in normal state The constant differential pressure valve of the ripper lift control valve
Defective operation of ripper
(Hi) is suppose to operate abnormally. Check it directly.
lift control valve
3 It is also acceptable to replace the constant differential pressure
(constant differential pres-
valve on the head side with the one on the bottom side to check
sure valve)
change of the phenomenon as another method.
Air is supposed to enter the ripper lift cylinder. Bleed air and check the
4 Air entry in ripper lift cylinder
H-17 RIPPER TILTING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER
Trouble Ripper tilting speed is slow or the ripper has no power.

Related information

1
valve Ripper lever PPC valve output pressure
Tilt end Min. 3.9 MPa {Min. 40 kg/cm2}
Possible causes Defective operation of ripper The spool of the ripper tilt control valve (Lo, Hi) is suppose to operate
2
and standard val- tilt control valve (spool) abnormally. Check it directly.
ue in normal state The constant differential pressure valve of the ripper tilt control valve
Defective operation of ripper
(Hi) is suppose to operate abnormally. Check it directly.
tilt control valve
3 It is also acceptable to replace the constant differential pressure
(constant differential pres-
valve on the head side with the one on the bottom side to check
sure valve)
change of the phenomenon as another method.
Air is supposed to enter the ripper tilt cylinder. Bleed air and check the
4 Air entry in ripper tilt cylinder
20-814 D375A-5
H-18 HYDRAULIC DRIFT OF BLADE LIFT IS LARGE
TROUBLESHOOTING H-19
H-18 HYDRAULIC DRIFT OF BLADE TILT
LIFT IS LARGE
H-18 HYDRAULIC DRIFT OF BLADE LIFT IS LARGE
Trouble Hydraulic drift of the blade lift is large

Related information
Before troubleshooting, check that no oil leaks from the work equipment circuit.

Start the engine for preparation and stop it for troubleshooting.
Follow the procedures below for the troubleshooting. When the hy-
draulic drift speed becomes fast, the spool seal of the blade lift control
Possible causes Defective seal of blade lift valve is defective:
1 1)Stretch the blade lift on the ground and push up the front of the ma-
and standard val- control valve (spool)
chine.
ue in normal state
2)Stop the engine and release the safety lock lever.
3)Move the blade lever to the lift lowering side, and check the phe-
nomenon.
Defective seal of blade lift The seal of the blade lift cylinder is supposed to be defective. Check
2
cylinder it directly.
H-19 HYDRAULIC DRIFT OF BLADE TILT IS LARGE
Trouble Hydraulic drift of the blade tilt is large

Related information

draulic drift speed becomes fast, the spool seal of the blade tilt control
Defective seal of blade tilt valve is defective:
1
Possible causes control valve (spool) 1)Stretch the blade tilt on the ground and push up the right side of the
and standard val- machine.
ue in normal state 2)Stop the engine and release the safety lock lever.
3)Move the blade tilt to the right tilt side, and check the phenomenon.
Defective seal of blade tilt a high speed for troubleshooting.
2
cylinder Blade tilt cylinder Leakage from cylinder
Right tilt stroke end 12 cc/min
D375A-5 20-815
H-20 HYDRAULIC DRIFT OF RIPPER LIFT IS LARGE
TROUBLESHOOTING H-21 RIPPER PIN PULLER DRIFT
H-20 HYDRAULIC CYLINDER DOES NOT
OF RIPPER LIFT OPERATE
IS LARGE
H-20 HYDRAULIC DRIFT OF RIPPER LIFT IS LARGE
Trouble Hydraulic drift of the ripper lift is large

Related information

draulic drift speed becomes fast, the spool seal of the ripper lift control
Defective seal of blade lift valve (Hi) is defective:
1 1)Stretch the ripper lift on the ground and push up the rear of the ma-
Possible causes control valve (spool)
chine.
and standard val-
2)Stop the engine and release the safety lock lever.
ue in normal state 3)Move the ripper lever to the lift lowering side, and check the phe-
nomenon.
Defective seal of ripper lift a high speed for troubleshooting.
2
cylinder Ripper lift cylinder Leakage from cylinder
Lowering stroke end 12 cc/min
H-21 RIPPER PIN PULLER CYLINDER DOES NOT OPERATE
Trouble Ripper pin puller cylinder does not operate.

Related information Before troubleshooting, check that transmission main relief pressure is normal.

Possible causes Defective operation of pin Pin puller operating
1 Pin puller switch Measuring position
and standard val- puller solenoid pressure
ue in normal state Push-in Cylinder bottom side Min. 2.4 MPa
Pull-in Cylinder head side {Min. 24 kg/cm2}
Internal defect of pin puller The inside of the pin puller cylinder is supposed to be defective.
2
cylinder Check it directly.
20-816 D375A-5
H-22 BLADE PITCH DOES NOT OPERATE
TROUBLESHOOTING H-23 ABNORMAL NOISE OCCURSH-22
AROUND THE
BLADE WORK
PITCH EQUIPMENT
DOES PUMP
NOT OPERATE
H-22 BLADE PITCH DOES NOT OPERATE
Trouble Blade pitch does not operate.

Related information

Defective operation of blade Operate both the blade pitch and the blade tilt. When only the pitch
Possible causes 1 pitch selection solenoid operation is not possible, the pitch selection solenoid valve is operat-
and standard val- valve ing abnormally.
ue in normal state Operate both the blade pitch and the blade tilt. When both the pitch
Defective operation of blade
2 operation and the tilt operation are not possible, the pitch cylinder (tilt
pitch cylinder
cylinder) is operating abnormally.
H-23 ABNORMAL NOISE OCCURS AROUND THE WORK EQUIPMENT PUMP
Trouble Abnormal noise occurs around the work equipment pump.

Related information Before troubleshooting, check that the oil level in the hydraulic tank is normal.

1 Improper oil is used Improper oil is supposed to be used. Check it directly.
Clogging of hydraulic tank The hydraulic tank strainer is supposed to be clogged. Check it direct-
Possible causes 2
strainer ly.
and standard val-
ue in normal state Air is supposed to have entered the suction circuit of the work equip-
3 Air entry in suction circuit
ment pump. Check the piping directly.
Internal defect of work The inside of the work equipment pump is supposed to be defective.
4
equipment pump Check it directly.
D375A-5 20-817
TROUBLESHOOTING OF THE ENGINE BODY

(S-MODE)
POINTS TO REMEMBER WHEN TROUBLESHOOTING ...................................................................... 20-902

METHOD OF USING TROUBLESHOOTING CHARTS .......................................................................... 20-903
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) ............................. 20-906
S-2 ENGINE DOES NOT START ......................................................................................................... 20-909
1) Engine does not turn ................................................................................................................ 20-909
2) Engine turns but no exhaust smoke comes out (fuel is not being injected) ............................. 20-910
3) Exhaust smoke comes out but engine does not start (fuel is being injected) ........................... 20-912
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) ........................................ 20-914
S-4 ENGINE STOPS DURING OPERATIONS ..................................................................................... 20-916
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) ............................................................. 20-918
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) ......................................................................... 20-920
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) ................................................... 20-922
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) .................................... 20-924
S-9 OIL BECOMES CONTAMINATED QUICKLY ................................................................................ 20-925
S-10 FUEL CONSUMPTION IS EXCESSIVE ........................................................................................ 20-926
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 20-927
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) ............................... 20-928
S-13 OIL LEVEL RISES .......................................................................................................................... 20-929
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) ........................................... 20-930
S-15 ABNORMAL NOISE IS MADE ....................................................................................................... 20-931
S-16 VIBRATION IS EXCESSIVE .......................................................................................................... 20-932
D375A-5 20-901
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING

k Stop the machine in a level place, and check that the safety pins and blocks are securely fitted, and the park-
ing brake is securely applied.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is still hot, boiling water may spurt out and cause serious
burns. Always wait for the water temperature to go down before removing the radiator cap.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative () terminal of the battery first.
k When removing a plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand
the structure and function. However, a short cut to effective troubleshooting is to ask the operator various ques-
tions to form some idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not 3. Checks before troubleshooting

hurry to disassemble the components 1) Is there any sign of abnormality in the ma-
If components are disassembled immediately chine or engine?
any failure occurs: 2) Always carry out the Checks before starting.
Parts that have no connection with the failure 3) Carry out other checks if necessary.
or other unnecessary parts will be disassem- 4) Other maintenance items can be checked
bled. externally, so check any item that is consid-
It will become impossible to find the cause of ered to be necessary.
the failure. 5) Check for any error display on the controller.
It will also cause a waste of man-hours, parts, or
oil or grease, and at the same time, will also lose 4. Confirming failure
the confidence of the user or operator. Confirm the extent of the failure yourself, and
For this reason, when carrying out troubleshoot- judge whether to handle it as a real failure or as
ing, it is necessary to carry out thorough prior in- a problem with the method of operation, etc.
vestigation and to carry out troubleshooting in a When operating the machine to re-enact the
accordance with the fixed procedure. troubleshooting symptoms, do not carry out
any investigation or measurement that may
2. Points to ask user or operator make the problem worse.
1) Have any other problems occurred apart
from the problem that has been reported? 5. Troubleshooting
2) Was there anything strange about the ma- Use the results of the investigation and inspec-
chine before the failure occurred? tion in Items 2 4 to narrow down the causes of
3) Did the failure occur suddenly, or were there failure, then use the troubleshooting matrix or
problems with the machine condition before flowchart to locate the position of the failure ex-
this? actly.
4) Under what conditions did the failure occur? a The basic procedure for troubleshooting is
5) Had any repairs been carried out before the as follows.
failure? When were these repairs carried 1) Start from the simple points.
out? 2) Start from the most likely points.
6) Has the same kind of failure occurred be- 3) Investigate other related parts or informa-
fore? tion.
6. Measures to remove root cause of failure

Even if the failure is repaired, if the root cause of
the failure is not repaired, the same failure will
occur again.
To prevent this, always investigate why the prob-
lem occurred. Then, remove the root cause.
20-902 D375A-5
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make fi-
nal confirmation.
[Questions]
Sections (A) + (B) in the chart on the right corre-
sponds to the items where answers can be ob-
tained from the user. The items in (B) are items
that can be obtained from the user, depending
on the users level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under (C) in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information (A) that he has obtained from the
user and the results of (C) that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with Q, and of these, causes that have a high prob- (A)
ability are marked with w.

Check each of the [Questions] and [Check items]
in turn, and marked the Q or w in the chart for items
where the problem appeared. The vertical column (B)
(Causes) that has the highest number of points is the (C)
most probable cause, so start troubleshooting for
that item to make final confirmation of the cause.
As a rule, do not use it when calculating the points
for locating the cause, but it can be included if nec-
essary to determine the order for troubleshooting.
Use the E in the Cause column as reference for
[Degree of use (Operated for long period)] in the
[Questions] section as reference.
D375A-5 20-903
Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms
have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became
weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)

General causes why exhaust smoke is black
Insufficient intake of air
Defective condition of fuel injection
Excessive injection of fuel
20-904 D375A-5
Five causes
Step 1
Clarify the relationship between the three symptoms in

the [Questions] and [Check items] section and the five
Cause items in the vertical column.
Three symptoms
Step 2
Add up the total of and marks where the horizontal
limes for the three symptoms and the vertical columns for
the causes intersect.
(1) Clogged air cleaner element:
(2) Defective contact of valve, valve seat:
(3) Leakage of air between turbocharger
and head:
(4) Worn piston ring, cylinder liner:
(5) Defective timing rail pressure sensor:
Step 3
The calculation in Step 2 show that the closest
relationship is with [Worn piston ring, cylinder liner].
Follow this column down to the troubleshooting area and
carry out the troubleshooting item marked .
The Remedy is given as [Clean], so carry out cleaning,
and the exhaust gas color should return to normal.
D375A-5 20-905
TROUBLESHOOTING S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)
General causes why starting performance is poor Causes

Defective electrical system
Defective preheating circuit (when starting in low temperatures)

Insufficient supply of fuel
Improper selection of fuel
Defective HPI sensor
Defective HPI actuator
Defective contact of valve, valve seat
Clogged timing rail actuator screen

Loose piping, fuel filter, entry of air
Defective or deteriorated battery

Worn piston ring, cylinder liner
Defective alternator regulator

Clogged air cleaner element
Defective injector check ball

Clogged fuel filter, strainer
Cut, worn injector O-ring

Defective shut-off valve
Clogged fuel tank cap
Defective fuel pump
Defective alternator
Defective injector
Confirm recent repair history
Degree of use of machine Operated for long period
Starting performance became worse gradually
Engine starts easily when warm
Questions
Non-specified fuel is being used

Replacement of filters has not been carried out according to Operation Manual
Engine oil must be added more frequently
Charge caution lamp lights up
When preheating, preheating indicator lamp does not light up
Dust indicator is red
Air breather hole in fuel tank cap is clogged
Starting motor cranks engine slowly
When engine is Little fuel comes out even when injection pump sleeve nut is loosened
cranked with
starting motor, Little fuel comes out even when fuel filter air bleed plug is loosened
Check items
When exhaust manifold is touched immediately after starting engine, temperature

of some cylinders is low
Engine does not pick up smoothly, and combustion is irregular
There is hunting from engine (rotation is irregular)
Blow-by gas is excessive
Difficult to stop engine
Inspect air cleaner element directly

When compression pressure is measured, it is found to be low
Inspect fuel filter, strainer directly
When negative pressure at inlet port of fuel pump is measured, it is found to be high
When pressure at outlet port of fuel pump is measured, it is found to vary
When pressure at outlet port of fuel pump is measured, it is found to be low
Inspect fuel pump directly
Troubleshooting
Inspect fuel shut-off valve directly

Inspect timing rail actuator screen directly
When temperature of exhaust gas of each cylinder is measured, there are some
cylinders that are low
Inspect injector directly
When specific gravity of electrolyte and voltage of battery are measured, one of
them is low
When starting switch is turned to HEAT, heater mount does not become warm
Is voltage 26 - 30V between alternator terminal B and terminal E with Yes
engine at low idling? No
Inspect sensor directly (Output voltage and resistance)
Inspect actuator directly (Resistance and filter for clogging)
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
20-906 D375A-5
TROUBLESHOOTING S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)
Causes
1. If the following service codes are displayed, carry out
the troubleshooting in Service code. (If any of the fol-
lowing service codes is not displayed, they are not
probably the cause of the trouble. In this case, inspect
Defective intake manifold temperature sensor the other devices for the cause.)
[EC514]: Abnormality in fuel rail actuator
1)
1) [EC112]: Abnormality in timing rail actuator
1)
Defective atmospheric pressure sensor
Defective fuel pump actuator (Marked

Defective timing rail actuator (Marked
Defective fuel pump pressure sensor
Defective timing rail pressure sensor
[EC318]: Abnormality in fuel pump actuator

Defective water temperature sensor
Defective fuel rail actuator (Marked

Defective fuel rail pressure sensor
Defective boost pressure sensor
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
D375A-5 20-907
TROUBLESHOOTING S-2 ENGINE DOES NOT START
S-2 ENGINE DOES NOT START
1) Engine does not turn Causes
General causes why engine does not turn

Internal parts of engine seized
a See Troubleshooting S-4.
Defective electrical system
Problem in power train (troubleshooting in chassis volume)
Defective safety relay or safety switch

Defective battery terminal connection
Defective starting circuit wiring

Broken flywheel ring gear
Defective starting switch
Defective starting motor

Defective battery relay
Questions
Condition of horn when starting Horn does not sound

switch is turned ON Horn volume is low
Battery electrolyte is low
Battery terminal is loose
When starting switch is turned to ON, there is no clicking sound from battery relay
When starting switch is turned to START, starting pinion does not move out
Check items
Speed of rotation is low

When starting switch is turned Makes grating noise
to START, starting pinion moves
out, but Soon disengages again
Makes rattling noise and does not turn
Inspect flywheel ring gear directly

Troubleshooting
When specific gravity of electrolyte and voltage of battery are measured, one of them is low
When terminal B and terminal C of starting switch are connected, engine starts
Turn starting switch
There is no 24V between battery relay terminal B and terminal E
OFF, connect cord,
and carry out When terminal B and terminal C of starting motor are connected, engine starts
troubleshooting at When terminal B and terminal C of safety relay are connected, engine starts
1.
ON
When terminal of safety switch and terminal B of starting motor are connected, engine starts
Replace
Replace
Replace
Replace
Replace
Replace
Correct

Remedy
1. Carry out troubleshooting in chassis volume
D375A-5 20-909
2) Engine turns but no exhaust smoke comes out (fuel is not being injected) Causes
General causes why engine turns but no exhaust smoke comes out
Fuel is not being supplied
Supply of fuel is extremely small
Improper selection of fuel (particularly in winter)

Defective fuel shut-off valve wiring

Clogged timing actuator screen
Broken fuel pump drive shaft
Defective fuel shut-off valve
Insufficient fuel in tank
Questions
Exhaust smoke suddenly stopped coming out (when starting again)

Starts when engine is warm
When fuel tank is inspected, it is found to be empty
Rust and water are found when fuel tank is drained
When fuel filter is drained, fuel does not come out
Check items
There is leakage from fuel piping

Wiring of fuel shut-off valve is loose
Cylinder block ground wiring is loose
When engine is cranked with Fuel pump outlet port coupler is pushed, almost no fuel comes out
starting motor, and Fuel pump outlet port coupler is pushed, air comes out together with fuel
Troubleshooting
Inspect fuel pump drive shaft directly

Inspect fuel shut-off valve directly
When starting switch is turned to START, voltage [24V] is not generated between fuel shut-off valve connector
pins
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
Add
20-910 D375A-5
Causes
the other devices for the cause.)
Defective intake manifold temperature sensor

1)
1)
[EC112]: Abnormality in timing rail actuator
1)


Defective water temperature sensor

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
D375A-5 20-911
3) Exhaust smoke comes out but engine does not start (fuel is being Causes
injected)
Defective dynamic valve system (valve, rocker arm, etc.)

General causes why exhaust smoke comes out but engine does not start
Lack of rotating force due to defective electrical system
Improper selection of fuel and oil
Defective preheating heater circuit


Clogged timing actuator screen

Defective fuel pump
Defective injector
Suddenly failed to start
Questions
Starts when engine is warm

When preheating, preheating indicator lamp does not light up
When fuel filter is drained, no fuel comes out
Check items

Starting motor cranks engine slowly
When engine is cranked, abnormal noise is generated around cylinder head
When engine is Fuel pump outlet port coupler is pushed, almost no fuel comes out
cranked with starting
motor, and Fuel pump outlet port coupler is pushed, air comes out together with fuel

Inspect dynamic valve system directly
Troubleshooting
When fuel filter, strainer directly

When temperature of exhaust gas of each cylinder is measured, there are some cylinders that are low
When specific gravity of electrolyte and voltage of battery are measured, one of them is low
When starting switch is at HEAT, heater mount does not become warm
Inspect fuel rail actuator directly
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Remedy
20-912 D375A-5
Replace Defective atmospheric pressure sensor
Replace Defective boost pressure sensor
Replace Defective fuel rail pressure sensor
D375A-5
Replace Defective timing rail pressure sensor
Replace Defective fuel pump pressure sensor
Replace Defective water temperature sensor
Causes
Replace Defective intake manifold temperature sensor

Replace Defective fuel rail actuator (Marked 1)
TROUBLESHOOTING
Replace Defective timing rail actuator (Marked 1)

Replace Defective fuel pump actuator (Marked 1)
Replace Clogged fuel rail actuator

S-2 ENGINE DOES NOT START
20-913
TROUBLESHOOTING S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)
General causes why engine does not pick up smoothly Causes

Defective condition of fuel spray
Improper fuel used
Abnormality in fuel control system
Defective contact of valve and valve seat


Normal output is not applied
Failure boost pressure sensor

o See Troubleshooting S-6

Improper valve clearance

Seized turbocharger
Defective fuel pump

Defective injector
Engine pick-up suddenly became worse
Questions

Rust and water are found when fuel is drained
When engine is cranked Fuel pump outlet port coupler is pushed, almost no fuel comes out
with starting motor, and Fuel pump outlet port coupler is pushed, air comes out together with fuel
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Check items
Blue under light load

Color of exhaust gas
Black
Clanging sound is heard from around cylinder head
Noise of interference is heard from around turbocharger
High idling speed under no load is normal, but speed suddenly drops when load is applied

When turbocharger is rotated by hand, it is found to be heavy
Inspect valve clearance directly
Troubleshooting

When temperature of injector of each cylinder is measured, there are some cylinders that are low
When intake air pressure (boost pressure) is measured, it is found to be normal
Inspect for air leakage
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Clean
Remedy
20-914 D375A-5
TROUBLESHOOTING S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)
Causes
Air leakage from piping between turbocharger and cylinder head lowing service codes is not displayed, they are not
1)
1)

1)


Replace
Replace
Replace
Replace
Replace
D375A-5 20-915
TROUBLESHOOTING S-4 ENGINE STOPS DURING OPERATIONS
S-4 ENGINE STOPS DURING OPERATIONS
General causes why engine stops during operations Causes

Seized parts inside engine
Failure in power train (troubleshooting in chassis volume)

There is overheating
Broken dynamic valve system (valve, rocker arm, etc.)
Broken, seized main bearing, connecting rod bearing
Broken auxiliary equipment (pump, compressor, etc.)

Problem in power train (troubleshooting in chassis volume)

Broken, seized piston, connecting rod
Broken fuel pump drive shaft

Broken, seized gear train
Defective injector
Abnormal noise was heard and engine stopped suddenly
Engine overheated and stopped
Condition when engine stopped
Engine stopped slowly
Questions
There was hunting and engine stopped

Fuel level caution lamp lights up
Metal particles are found when oil is drained
Does not turn at all
When it is attempted
Check items
Turns in opposite direction

to turn by hand using
barring tool Moves amount of gear backlash
Fuel pump shaft does not turn
Engine turns, but stops when load is applied to machine

Inspect piston, connecting rod directly
Inspect main bearing, connecting rod directly
Inspect gear train directly
Troubleshooting

Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed
1.

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Remedy
Add
20-916 D375A-5
TROUBLESHOOTING S-4 ENGINE STOPS DURING OPERATIONS
Causes 1. If the following service codes are displayed, carry out

1)
1)

1)


Defective fuel shut-off valve

Clogged fuel inlet circuit
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
D375A-5 20-917
TROUBLESHOOTING S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
General causes why engine does not rotate smoothly Causes

Air in fuel system
Defective governor mechanism
High resistance, clogged fuel return circuit

Defective actuation of timing rail actuator
Defective actuation of fuel rail actuator

Defective injector check ball


Defective fuel pump
Defective injector
Questions
Occurs at a certain speed range

Occurs at low idling
Condition of hunting
Occurs even when speed is raised
Occurs on slopes
Rust, water are found when fuel tank is drained
Leakage from fuel piping
Check items
Engine speed sometimes rises too far
Engine is difficult to stop

Troubleshooting

When flow of spill fuel is checked visually, it is found to be low
Inspect fuel rail actuator screen directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
20-918 D375A-5
Replace Defective atmospheric pressure sensor
Replace Defective boost pressure sensor
Replace Defective fuel rail pressure sensor
D375A-5
Replace Defective timing rail pressure sensor
Replace Defective fuel pump pressure sensor
Replace Defective fuel pump actuator (Marked 1)
Causes
Defective in throttle sensor

Replace Defective in speed sensor
TROUBLESHOOTING
Replace Clogged fuel rail actuator screen

Replace Clogged timing rail actuator screen
inspect the other devices for the cause.)
1. If the following service code is displayed, carry out the
troubleshooting in Service code. (If it is not displayed,
it is not probably the cause of the trouble. In this case,
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
20-919
TROUBLESHOOTING S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)
a Measure the engine speed and judge if the problem is in the engine Causes
or on the machine.
General causes why engine lacks output
Improper fuel used

(if non-specified fuel is used, output drops)
Improper adjustment of valve clearance

There is overheating

Seized turbocharger, interference



Defective fuel pump

Defective injector
Suddenly
Power was lost
Questions
Gradually
Dust indicator lamp is red
Black
Check items

Engine pickup is poor and combustion is irregular
High idling speed of engine is low

Troubleshooting

Check part No. of controller calibration data
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Remedy
20-920 D375A-5
TROUBLESHOOTING S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)
Causes 1. If the following service codes are displayed, carry out

1)
1)

1)

High resistance or clogged fuel circuit

Defective controller calibration data

Defective throttle sensor

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean

D375A-5 20-921
TROUBLESHOOTING S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)
General causes why exhaust smoke is black Causes

Leakage of air between turbocharger and cylinder head

1)
Improper adjustment of valve clearance

Failure timing rail pressure sensor

Seized turbocharger, interference

Crushed, clogged muffler

Defective fuel pump
Defective injector
Suddenly became black
Color of exhaust gas Gradually became black
Questions

Suddenly
Power was lost
Gradually
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
Check items

Exhaust noise is abnormal
Engine pickup is poor and combustion is irregular
Inspect air cleaner directly

Troubleshooting

When muffler is removed, exhaust sound improves
Inspect between turbocharger and cylinder head directly
Abnormality in timing rail pressure sensor system is indicated ( 2)
Inspect sensor directly (Output voltage)
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Remedy
20-922 D375A-5
TROUBLESHOOTING S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)

2. If a service code of the timing rail pressure sensor sys-
tem is displayed, carry out the troubleshooting in Ser-
vice code.
D375A-5 20-923
TROUBLESHOOTING S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)
a To prevent the oil from leaking up or down in the turbocharger, Causes

do not run the engine at idling for more than 20 minutes contin-
uously (both low and high idling).
General causes why oil consumption is excessive
Worn seal at turbine end

Abnormal combustion of oil
Worn seal at blower end

External leakage of oil
Worn, damaged valve (stem, guide, seal)

Wear of parts in lubrication system
Leakage from oil pan or cylinder head

Clogged breather or breather hose
Dust sucked in from intake system
Leakage from oil filter or oil cooler

Leakage from oil drain plug

Too much engine oil added
Worn, broken rear oil seal
Leakage from oil piping

Broken piston ring
Broken oil cooler

Turbocharger
Questions

Oil consumption suddenly increased
Engine oil becomes contaminated quickly
Oil level is above H level on gauge
Outside of engine is dirty with oil
There are loose piping clamps in intake system
Inside of turbocharger intake pipe is dirty with oil
Check items
Inside of exhaust pipe is dirty with oil

There is oil in engine cooling water
Oil level in clutch chamber or damper chamber rises
Exhaust smoke is blue under light load
Excessive
Amount of blow-by gas
None
When intake manifold is removed, dust is found inside

Excessive play of turbocharger shaft
Troubleshooting
When intake manifold is removed, inside is found to be dirty with oil

Inspect breather element directly
Inspect rear oil seal directly
There is external leakage of oil from engine
Pressure-tightness test of oil cooler shows there is leakage
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
20-924 D375A-5
TROUBLESHOOTING S-9 OIL BECOMES CONTAMINATED QUICKLY
S-9 OIL BECOMES CONTAMINATED QUICKLY
General causes why oil becomes contaminated quickly Causes

Entry of exhaust gas into oil due to internal wear
Clogging of lubrication passage
Defective combustion
Improper fuel used
Operation under excessive load
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
Oil change interval is too long
Clogged breather, breather tube

Worn valve (stem, guide, seal)
Defective oil filter safety valve

Too much engine oil added
Exhaust smoke is black

Clogged oil cooler
Clogged oil filter
Questions

Non-specified oil is being used
Oil level is above H level on gauge
When oil filter is inspected, metal particles are found
When exhaust pipe is removed, inside is found to be dirty with oil
Even when engine oil temperature rises, oil filter caution lamp lights up (machines equipped with caution lamp)
Check items
Engine oil temperature rises quickly

Black
Excessive
Amount of blow-by gas
None
Inspect turbocharger lubrication drain tube directly
Troubleshooting S-7
Troubleshooting
Excessive play of turbocharger shaft

Inspect breather element directly
Carry out
Inspect oil cooler directly
Inspect oil filter directly
Inspect safety valve directly
Replace
Replace
Replace
Replace
Correct
eplace
Clean
Clean
Clean

Remedy
D375A-5 20-925
TROUBLESHOOTING S-10 FUEL CONSUMPTION IS EXCESSIVE
S-10 FUEL CONSUMPTION IS EXCESSIVE
General causes why fuel consumption is excessive Causes

Leakage of fuel
High resistance, clogged fuel return circuit

Failure timing rail pressure sensor
Leakage of fuel inside head cover

Failure fuel rail pressure sensor

Defective fuel pump
Defective injector
Questions
More than for other machines of same model

Condition of fuel consumption Gradually increased
Suddenly increased
There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Check items
Black
Exhaust smoke color
White
Inspect inside of head cover directly

Troubleshooting

Abnormality in fuel rail pressure sensor system is indicated ( 1)
Abnormality in timing rail pressure sensor system is indicated ( 1)
When flow of return fuel is checked visually, it is found to be low
Inspect sensor directly (Output voltage)
Replace
Replace
Replace
Replace
Replace
Replace
Replace
1. If a service code of the fuel rail pressure sensor system or timing rail pressure sensor
Correct
Clean
Clean
system is displayed, carry out the troubleshooting in "Service code". Remedy
20-926 D375A-5
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL
TROUBLESHOOTING GOES DOWN
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN
General causes why oil is in cooling water Causes

Internal leakage in lubrication system
Broken power train oil cooler (troubleshooting in chassis volume)

Internal leakage in cooling system
Damaged cylinder liner O-ring, holes caused by pitting

Insufficient protrusion of cylinder liner
Broken cylinder head, head gasket
Internal cracks in cylinder block
Broken oil cooler core, O-ring

Broken water pump seal
Questions
Suddenly increased
Oil level
Gradually increased
Hard water is being used as cooling water (or corrosion resistor valve is closed)
Excessive air bubbles inside radiator, spurts back
Check items
Engine oil level has risen, oil is cloudy white

Hydraulic oil, transmission oil on machine side is cloudy white
When hydraulic oil, transmission oil on machine side is drained, water is found
Troubleshooting
Carry out pressure-tightness test of cylinder head

Inspect cylinder block, liner directly
Inspect cylinder liner directly
Carry out pressure-tightness test of oil cooler
Inspect water pump directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
D375A-5 20-927
TROUBLESHOOTING S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)
General causes why oil pressure caution lamp lights up Causes

Leakage, clogging, wear of lubricating system
Defective oil pressure control
Improper selection of fuel (insufficient viscosity)
Deterioration of oil due to overheating
Clogged, broken oil pump suction pipe

Broken oil pump suction pipe brazing
Leaking, crushed hydraulic piping

Clogged oil pan suction strainer
Defective oil pump relief valve
Defective oil pressure sensor

Defective oil level sensor
Worn crankshaft journal
Lack of oil in oil pan
Defective oil pump
Clogged oil cooler

Clogged oil filter
Water, fuel in oil

Questions
Non-specified oil is being used

Engine oil pressure caution lamp lights up
Lights up at low idling
Lights up at low, high idling
Condition when oil pressure lamp lights up
Lights up on slopes
Sometimes lights up
Oil level caution lamp lights up (machines equipped with caution lamp)
Check items
There is crushing, external leakage from hydraulic piping

Oil level in oil pan is low
Oil is cloudy white or smells of diesel oil
When oil is drained, metal particles are found
When oil filter is inspected, metal particles are found
Carry out Troubleshooting
Inspect suction strainer, pipe directly
Troubleshooting
Oil pump rotation is heavy, there is play

Inspect relief valve, regulator valve directly
When engine oil level sensor is replaced, oil pressure lamp goes out
(machines equipped with oil level sensor)
S-13
When oil pressure is measured, it is found to be normal

Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Adjust
Clean
Clean
Clean
Clean

Add
20-928 D375A-5
TROUBLESHOOTING S-13 OIL LEVEL RISES
S-13 OIL LEVEL RISES
a If there is oil in the cooling water, carry out Troubleshooting S-11. Causes
General causes why oil level rises
Clogged water pump drain hole (breather hole), defective seal

Cooling water in oil (milky white)
Defective auxiliary equipment (pump, compressor) seal

Fuel in oil (diluted, and smells of diesel fuel)
Entry of water or oil from other component
Defective cylinder head injector sleeve

Broken, broken rear oil seal face

Broken oil cooler core, O-ring
Cracks inside cylinder block
Defective thermostat seal

Broken aftercooler core
Worn fuel pump seal

Questions

Fuel must be added more frequently
Engine oil smells of diesel fuel
There is oil in cooling water
When engine is first started, drops of water come from muffler
When radiator cap is removed and engine is run at low idling, an abnormal number of bubbles
appear, or water spurts back
Check items
Exhaust smoke is white

Water pump drain hole (breather hole) is clogged
When water pump drain hole (breather hole) is cleaned, water comes out
Oil level goes down in clutch or damper chamber
Oil level goes down in hydraulic tank
Carry out pressure-tightness test of aftercooler
Troubleshooting
Inspect rear oil seal directly

Carry out pressure-tightness test of oil cooler
Inspect water pump directly
Inspect thermostat directly
Inspect injector directly
Inspect pump auxiliary equipment (pump, compressor) directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
D375A-5 20-929
TROUBLESHOOTING S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
General causes why water temperature becomes too high Causes

Lack of cooling air (deformation, damage of fan)
Rise in power train oil temperature (troubleshooting in chassis volume)

Drop in heat dissipation efficiency
Rise in oil temperature in power train

(troubleshooting in chassis volume)
Defective radiator cap (pressure valve)
Defective water temperature gauge

Defective operation of thermostat

Fan belt slipping, worn fan pulley
Clogged, crushed radiator fins
Cracks inside cylinder block
Clogged, broken oil cooler
Clogged radiator core

Lack of cooling water
Broken water pump

Questions
Suddenly overheated
Condition of overheating
Always tends to overheat
Rises quickly
Water temperature gauge
Does not go down from red range
Radiator water level caution lamp lights up (machines equipped with caution lamp)
Engine oil level has risen, oil is cloudy white
Cloudy white oil is floating on cooling water
Excessive air bubbles inside radiator, water spurts back
When light bulb is held behind radiator, no light passes through
Radiator shroud, inside of underguard are clogged with dirt or mud
Check items
Water is leaking because of cracks in hose or loose clamps

When belt tension is inspected, it is found to be loose
Fan belt whines under sudden load
Cooling water flows out from overflow hose
Power train oil temperature enters red range faster than engine water temperature

Inspect oil cooler directly
Troubleshooting
Inspect radiator core directly

When temperature difference between top and bottom radiator tanks is measured, it is found to
be slight
Carry out function test on radiator cap (cracking pressure)
When temperature difference between top and bottom radiator tanks is measured, it is found to
be excessive
Carry out function test on thermostat (cracking temperature)
1.
When water temperature is measured, it is found to be normal

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Add
20-930 D375A-5
TROUBLESHOOTING S-15 ABNORMAL NOISE IS MADE
S-15 ABNORMAL NOISE IS MADE
a Judge if the noise is an internal noise or an external noise. Causes

General causes why abnormal noise is made
Air leakage from auxiliary equipment (pump, compressor)

Abnormality due to defective parts
Broken dynamic valve system (valve, rocker arm, etc.)

Abnormal combustion noise
Defect inside muffler (dividing board out of position)

Air sucked in from intake system
Leakage of air between turbocharger and head
Excessive wear of piston ring, cylinder liner
Deformed cooling fan, fan belt interference

Seized turbocharger, internal interference
Defective adjustment of valve clearance
Missing, seized gear bushing

Improper gear train backlash
Seized crankshaft bearing
Defective injector
Gradually occurred
Questions
Condition of abnormal noise

Suddenly occurred
Seal on injection pump has come off
Metal particles are found in oil filter
Leakage of air between turbocharger and head, loose clamp
Vibrating noise is heard from around muffler
Check items
Black
Engine pickup is poor and combustion is abnormal
Abnormal noise is loud when accelerating engine
Troubleshooting
When muffler is removed, abnormal noise disappears

Inspect crankshaft bearing directly
Inspect front gear and rear gear directly
Inspect cooling fan, belt directly
When temperature of exhaust gas of each cylinder is measured, there are some cylinders that are low
Inspect piping of pump auxiliary equipment (pump, compressor, etc.) directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Adjust
D375A-5 20-931
TROUBLESHOOTING S-16 VIBRATION IS EXCESSIVE
S-16 VIBRATION IS EXCESSIVE
a If there is abnormal noise together with the vibration, carry out Trouble- Causes
shooting S-15 also.
Defective dynamic valve system (valve, rocker arm, etc. stuck)

General causes why vibration is excessive
Internal damage in clutch chamber or damper chamber

Defective parts (abnormal wear, breakage)
Improper alignment between engine and chassis
Loose engine mounting bolts, broken cushion

Abnormal combustion
Worn front support spigot joint portion

Worn main bearing, connecting rod
(troubleshooting for machine)

Improper gear train backlash
Defective vibration damper
Worn cam bushing
Clogged injector
Questions
Suddenly increased
Condition of vibration
Gradually increased
Seal on injection pump has come off
Metal particles are found in oil filter
Metal particles are found when oil is drained
Check items
Oil pressure is low at low idling

Vibration occurs at mid-range speed
Vibration follows engine speed
Exhaust smoke is black

Inspect main bearing, connecting rod directly
Troubleshooting
Inspect cam bushing directly

Inspect front gear train and rear gear train directly
Inspect vibration damper directly
Injection pump test shows that injection amount is incorrect
Inspect front support spigot joint directly
Inspect engine mounting bolts, cushions directly
Inspect clutch chamber or damper chamber directly (troubleshooting for machine)
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Remedy
20-932 D375A-5
30 DISASSEMBLY AND ASSEMBLY
30 DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL ................. 30- 5 REMOVAL AND INSTALLATION OF

Removal and installation of assemblies 30- 5 DAMPER ASSEMBLY ................................. 30- 39
Disassembly and assembly of Special tools .......................................... 30- 39
assemblies ........................................... 30- 6 Removal ................................................ 30- 39
PRECAUTIONS WHEN CARRYING Installation ............................................. 30- 41
OUT OPERATION ...................................... 30- 7 DISASSEMBLY AND ASSEMBLY OF
SPECIAL TOOL LIST ................................. 30- 9 DAMPER ..................................................... 30- 43
SKETCHES OF SPECIAL TOOLS ............. 30- 18 Disassembly of damper assembly ........ 30- 43
REMOVAL AND INSTALLATION OF Disassembly of damper cover assembly 30- 43
FUEL PUMP ASSEMBLY ........................... 30- 19 Assembly of damper assembly ............. 30- 44
Removal ............................................... 30- 19 Assembly of damper cover assembly ... 30- 45
Installation ............................................ 30- 19 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION POWER TRAIN UNIT ASSEMBLY ............. 30- 46
OF ENGINE FRONT SEAL ........................ 30- 20 Removal ................................................ 30- 46
Special tools ......................................... 30- 20 Installation ............................................. 30- 49
Removal ............................................... 30- 20 DISCONNECTION OF
Installation ............................................ 30- 20 POWER TRAIN UNIT ASSEMBLY ............. 30- 50
REMOVAL AND INSTALLATION OF CONNECTION OF POWER TRAIN UNIT
ENGINE REAR SEAL ................................. 30- 22 ASSEMBLY ................................................. 30- 55
Special tools ......................................... 30- 22 DISASSEMBLY AND ASSEMBLY OF
Removal ............................................... 30- 22 PTO ASSEMBLY ........................................ 30- 57
Installation ............................................ 30- 22 Disassembly .......................................... 30- 57
REMOVAL AND INSTALLATION OF Assembly .............................................. 30- 60
CYLINDER HEAD ASSEMBLY .................. 30- 24 DISASSEMBLY AND ASSEMBLY OF
Special tools ......................................... 30- 24 TORQUE CONVERTER ASSEMBLY ......... 30- 64
Removal ............................................... 30- 24 Special tools .......................................... 30- 64
Installation ............................................ 30- 27 Disassembly .......................................... 30- 64
REMOVAL AND INSTALLATION OF Assembly .............................................. 30- 68
FUEL TANK ASSEMBLY ............................ 30- 29 DISASSEMBLY AND ASSEMBLY OF
Removal ............................................... 30- 29 TORQFLOW TRANSMISSION
Installation ............................................ 30- 29 ASSEMBLY ................................................. 30- 74
REMOVAL AND INSTALLATION OF Special tools .......................................... 30- 74
RADIATOR ASSEMBLY ............................. 30- 30 Disassembly .......................................... 30- 74
Removal ............................................... 30- 30 Assembly .............................................. 30- 89
Installation ............................................ 30- 31 DISASSEMBLY AND ASSEMBLY OF
REMOVAL AND INSTALLATION OF STEERING CASE ASSEMBLY .................. 30-106
RADIATOR GUARD ASSEMBLY ............... 30- 32 Disassembly .......................................... 30-106
Special tools ......................................... 30- 32 Assembly .............................................. 30- 112
Removal ............................................... 30- 32 REMOVAL AND INSTALLATION OF
Installation ............................................ 30- 34 POWER TRAIN, LUBRICATION
REMOVAL AND INSTALLATION OF PUMP ASSEMBLY ..................................... 30-123
ENGINE ASSEMBLY .................................. 30- 35 Removal ................................................ 30-123
Special tools ......................................... 30- 35 Installation ............................................. 30-123
Removal ............................................... 30- 35
Installation ............................................ 30- 38
D375A-5 30-1
(1)
c c
REMOVAL AND INSTALLATION OF DISASSEMBLY AND ASSEMBLY OF

SCAVENGING PUMP ASSEMBLY ............ 30-124 BOGIE ASSEMBLY ..................................... 30-169
Removal ................................................ 30-124 Special tools .......................................... 30-169
Installation ............................................. 30-124 Disassembly .......................................... 30-169
REMOVAL AND INSTALLATION OF Assembly ............................................... 30-170
FINAL DRIVE ASSEMBLY ......................... 30-125 REMOVAL AND INSTALLATION OF
Special tools .......................................... 30-125 1ST BOGIE ASSEMBLY ............................. 30-171
Installation ............................................. 30-125 Removal ................................................ 30-171
DISASSEMBLY AND ASSEMBLY OF Installation ............................................. 30-173
FINAL DRIVE ASSEMBLY ......................... 30-126 Sketch of special tool ............................ 30-176
Special tools .......................................... 30-126 .............................................................. 30-177
Disassembly .......................................... 30-126 EXPANDING AND ASSEMBLY TRACK
Assembly .............................................. 30-132 SHOE INSTALLATION ................................ 30-179
REMOVAL AND INSTALLATION OF Check before expanding track
TRACK FRAME ASSEMBLY ...................... 30-141 shoe assembly ...................................... 30-179
Removal ................................................ 30-141 Expanding track shoe assembly ............ 30-180
Installation ............................................. 30-142 Expanding track shoe assembly ............ 30-180
REMOVAL AND INSTALLATION OF Installation of track shoe assembly ....... 30-181
IDLER ASSEMBLY ..................................... 30-143 WHOLE DISASSEMBLY AND ASSEMBLY
Removal ................................................ 30-143 OF TRACK SHOE ....................................... 30-182
Installation ............................................. 30-143 Special tools .......................................... 30-182
DISASSEMBLY AND ASSEMBLY OF Whole disassembly ............................... 30-183
IDLER ASSEMBLY ..................................... 30-144 Whole assembly .................................... 30-185
Special tools .......................................... 30-144 1. When recycling for lubricated
Disassembly .......................................... 30-144 track ................................................ 30-185
Assembly .............................................. 30-145 2. When recycling for grease-
Sketch of special tool ............................ 30-148 filled track ........................................ 30-194
REMOVAL AND INSTALLATION OF DIMENSIONS TABLE OF FITTING
RECOIL SPRING ASSEMBLY .................... 30-149 JIG OF LINK PRESS ................................... 30-199
Special tools .......................................... 30-149 DISASSEMBLY AND ASSEMBLY OF
Removal ................................................ 30-149 1 LINK IN THE FIELD .................................. 30-200
DISASSEMBLY AND ASSEMBLY OF Disassembly .......................................... 30-200
RECOIL SPRING ASSEMBLY .................... 30-153 Assembly ............................................... 30-202
Special tools .......................................... 30-153 DISASSEMBLY AND ASSEMBLY OF
Disassembly .......................................... 30-153 MASTER LINK ............................................. 30-204
Assembly .............................................. 30-154 Special tools .......................................... 30-204
REMOVAL AND INSTALLATION Disassembly .......................................... 30-205
TRACK ROLLER ASSEMBLY .................... 30-155 Assembly ............................................... 30-206
Special tools .......................................... 30-155 REMOVAL AND INSTALLATION OF
Removal ................................................ 30-155 PIVOT SHAFT ASSEMBLY ......................... 30-209
Sketch of special tool ............................ 30-158 Removal ................................................ 30-209
DISASSEMBLY AND ASSEMBLY OF Installation ............................................. 30-209
TRACK ROLLER ASSEMBLY .................... 30-159 Sketch of special tool ............................ 30-210
Special tools .......................................... 30-159 REMOVAL AND INSTALLATION OF
Disassembly .......................................... 30-159 EQUALIZER BAR ........................................ 30- 211
Assembly .............................................. 30-160 Special tools .......................................... 30- 211
Sketch of special tool ............................ 30-162 Removal ................................................ 30- 211
REMOVAL AND INSTALLATION OF Installation ............................................. 30-213
BOGIE ASSEMBLY .................................... 30-163 DISASSEMBLY AND ASSEMBLY OF
Special tools .......................................... 30-163 EQUALIZER BAR BUSHING ...................... 30-214
Installation ............................................. 30-165 Disassembly .......................................... 30-214
Sketch of special tool ............................ 30-168 Assembly ............................................... 30-215
Sketch of special tool ............................ 30-216
30-2 D375A-5
c c
REMOVAL AND INSTALLATION OF DISASSEMBLY AND ASSEMBLY OF

SEGMENT TOOTH .................................... 30-217 GIANT RIPPER ASSEMBLY ...................... 30-249
Removal ............................................... 30-217 Disassembly .......................................... 30-249
Installation ............................................ 30-217 Assembly .............................................. 30-250
REMOVAL AND INSTALLATION OF REMOVAL AND INSTALLATION OF
HYDRAULIC TANK ASSEMBLY ................ 30-218 ROPS GUARD ............................................ 30-252
Removal ............................................... 30-218 Removal ................................................ 30-252
Installation ............................................ 30-220 Installation ............................................. 30-252
REMOVAL AND INSTALLATION OF REMOVAL AND INSTALLATION OF
WORK EQUIPMENT AND PPC OPERATOR'S CAB ASSEMBLY ................ 30-253
PUMP ASSEMBLY ..................................... 30-221 Removal ................................................ 30-253
Removal ............................................... 30-221 Installation ............................................. 30-254
Installation ............................................ 30-221 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF FLOOR FRAME .......................................... 30-257
BLADE LIFT VALVE ASSEMBLY .............. 30-222 Special tools .......................................... 30-257
Removal ............................................... 30-222 Removal ................................................ 30-257
Installation ............................................ 30-223 Installation ............................................. 30-260
DISASSEMBLY AND ASSEMBLY OF REMOVAL AND INSTALLATION OF
BLADE LIFT VALVE ASSEMBLY .............. 30-224 DASHBOARD ASSEMBLY ......................... 30-262
Assembly .............................................. 30-224 Special tools .......................................... 30-262
DISASSEMBLY AND ASSEMBLY OF Removal ................................................ 30-262
BLADE TILT AND RIPPER LOW Installation ............................................. 30-263
VALVE ASSEMBLY .................................... 30-226 REMOVAL AND INSTALLATION OF
Assembly .............................................. 30-227 MONITOR PANEL ASSEMBLY .................. 30-264
DISASSEMBLY AND ASSEMBLY OF Removal ................................................ 30-264
RIPPER HIGH VALVE ASSEMBLY ........... 30-228 Installation ............................................. 30-264
Assembly .............................................. 30-229 REMOVAL AND INSTALLATION OF
DISASSEMBLY AND ASSEMBLY OF AIR CONDITIONER UNIT ASSEMBLY ...... 30-265
PPC CHARGE VALVE ASSEMBLY ........... 30-230 Removal ................................................ 30-265
Assembly .............................................. 30-230 Installation ............................................. 30-267
DISASSEMBLY AND ASSEMBLY OF
BLADE PPC VALVE ASSEMBLY .............. 30-231
Assembly .............................................. 30-231
RIPPER PPC VALVE ASSEMBLY ............. 30-233
Assembly .............................................. 30-233
HYDRAULIC CYLINDER ASSEMBLY ....... 30-234
Special tools ......................................... 30-234
Disassembly ......................................... 30-234
Assembly .............................................. 30-237
RIPPER PIN PULLER CYLINDER
ASSEMBLY ................................................ 30-240
Special tools ......................................... 30-240
Disassembly ......................................... 30-240
Assembly .............................................. 30-241
REMOVAL AND INSTALLATION OF
BLADE ASSEMBLY ................................... 30-243
Removal ............................................... 30-243
Installation ............................................ 30-244
BLADE ASSEMBLY ................................... 30-245
Disassembly ......................................... 30-245
Assembly .............................................. 30-247
D375A-5 30-3
c c
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
HOW TO READ THIS MANUAL

ASSEMBLIES
Special tools Installation of parts

Special tools that are deemed necessary for re- Except where otherwise instructed, install parts
moval or installation of parts are listed. is the reverse order of removal.
List of the special tools contains the following Instructions and precautions for installing parts
kind of information. are shown with q 1 mark in the INSTALLATION
1) Necessity Section, identifying which step the instructions
: Special tools which cannot be substitut- are intended for.
ed, should always be used. Marks shown in the INSTALLATION Section
z Special tools which are very useful if stand for the following.
available, can be substituted with com- This mark indicates safety-related pre-
mercially available tools. cautions which must be followed when
2) Distinction of new and existing special tools doing the work.
N: Tools with new part numbers, newly This mark gives guidance or precau-
developed for this model. tions when doing the procedure.
R: Tools with upgraded part numbers, re- 2 This mark stands for a specific coating
3 This mark indicates the specified

modeled from already available tools agent to be used.
for other models.
Blanks: Tools already available for other torque.
5
models, used without any modifica-
tion. This mark indicates an amount of oil or
3) Circle mark (c) in sketch column: water to be added.
A circle mark means that a sketch of the spe-
cial tool is presented in the section of
Sketches of special tools
Sketches for Special Tools.
Part No. of special tools starting with 79*T Various special tools are illustrated for the con-
means that they are locally made parts and as venience of local manufacture.
such not interchangeable with those made by
Komatsu in Japan e.g. 79*T---xxx---xxxx.
Removal of parts
The REMOVAL Section contains procedures,
precautions and the amount of oil or water to be
drained.
Various symbols used in the REMOVAL Section
are explained and listed below.
This mark indicates safety-related pre-
cautions which must be followed when
doing the work.
This mark gives guidance or precautions
when doing the procedure.
q1 This mark shows that there are instruc-
tions or precautions for installing parts.
6 This mark shows oil or water to be
drained.
4 Mass of a part or component.
D375A-5 30-5
c c
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL

ASSEMBLIES
Special tools Assembly

Special tools which are deemed ncessary for Section titled ASSEMBLY contain procedures,
disassembly and assembly are listed in this sec- precautions and the know-how for the work, as
tion. well as the amount of oil or water to be added.
List of the special tools contains the following Various symbols used in the ASSEMBLY Sec-
kind of information. tion are explained and listed below.
1) Neccessity This mark indicates safety-related pre-
: Special tools which cannot be substitut- cautions which must be followed when
ed, should always be used. doing the work.
z Special tools which are very useful if This mark gives guidance or precau-
available, can be substituted with com- tions when doing the procedure.
mercially available tools. 2 This mark stands for a specific coating
3 This mark indicates the specified

2) Distinction of new and existing special tools agent to be used.
N: Tools with new part numbers, newly
developed for this model. torque.
5
R: Tools with upgraded part numbers, re-
modeled from already available tools This mark indicates an amount of oil or
for other models. water to be added.
Blanks: Tools already available for other
models, used without any modifica-
Sketches of special tools
tion.
3) Circle mark (c) in sketch column: Various special tools are illustrated for the con-
A circle mark means that a sketch of the spe- venience of local manufacture.
cial tool is presented in the section of
Sketches for Special Tools.
Part No. of special tools starting with 79*T
means that they are locally made parts and as
such not interchangeable with those made by
Komatsu in Japan e.g. 79*T---xxx---xxxx.
Disassembly
The DISASSEMBLY Section contains proce-
dures, precautions and the amount of oil or water
to be drained.
Various symbols used in the DISASSEMBLY
Section are explained and listed below.
This mark indicates safety-related pre-
cautions which must be followed when
doing the work.
This mark gives guidance or precautions
when doing the procedure.
q1 This mark shows that there are instruc-
tions or precautions for installing parts.
6 This mark shows oil or water to be
drained.
4 Mass of a part or component.
30-6 D375A-5
c c
PRECAUTIONS WHEN CARRYING
DISASSEMBLY AND ASSEMBLY OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general pre-
cautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
If the coolant contains antifreeze dispose of it correctly.
After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
When draining oil, prepare a container of adequate size to catch the oil.
Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
Check the number of thickness of the shims, and keep in a safe place.
When raising components, be sure to use lifting equipment of ample strength.
When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering
after removal.
Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Nut (elbow end)
number
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
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 (mm)
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
D375A-5 30-7
c c
PRECAUTIONS WHEN CARRYING
DISASSEMBLY AND ASSEMBLY OUT OPERATION
2. Precautions when carrying out installation work

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

If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the water level again.
If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then check the oil level again.
If the piping or hydraulic equipment has been removed, always bleed the air from the system after reassem-
bling the parts. For details, see TESTING AND ADJUSTING, Bleeding air.
Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
30-8 D375A-5
c c
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

Tools with part number 79cT-ccc-cccc cannot be supplied (they are items to be locally manufac-
tured).
Necessity: : Cannot be substituted, should always be installed (used).
z: Extremely useful if available, can be substituted with commercially available part.
New/remodel: N: Tools with new part numbers, newly developed for this model.
R: Tools with upgraded part numbers, remodeled from items already available for other mod-
els.
Blank: Tools already available for other models, used without any modification.
Tools marked c in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPE-
CIAL TOOLS).
Necessity
Sketch
remodel
New/
Qty
Component Symbol Part No. Part name Nature work remarks
795-902-1410 Sleeve 1
1
01050-32240 Bolt 3 Removal, installation of engine front
795-902-1430 Push tool 1 seal
3
01050-32235 Bolt 3
795-902-1420 Sleeve 1
2 795-902-1450 Bolt 2
Removal, installation of engine rear
A 01582-02016 Nut 2
seal
Engine assembly 795-902-1440 Push tool 1
4
01050-32050 Bolt 4
5 790-331-1110 Wrench 1 Tightening of cylinder head bolt
791-451-1000 Remover 1
Removal, installation of radiator
6 790-101-2102 Puller (294 kN {30 ton}) 1
guard assembly
790-101-1102 Pump 1
795-799-5410 Adapter 1 Removal, installation of injector as-
A
795-799-5420 Remover 1 sembly
Torque converter 790-413-1010 Bracket 1 Disassembly, assembly of torque

C
assembly 790-501-5000 Repair stand (100 V) 1 converter assembly
790-415-1011 Bracket 1 Disassembly, assembly of torqu-

1
750-501-5000 Repair stand (100 V) 1 flow transmission assembly
2 791-615-1130 Push tool 1 Removal, installation of snap ring

791-615-1200 Ring assembly 1
791-615-1210 Ring 1
3 135-A90-1150 Bolt 1 Installation of No. 3 ring gear
Torquflow transmission 01580-01008 Nut 1

D
assembly 01641-51032 Washer 2
791-615-1101 Ring assembly 1
791-615-1111 Ring 1
4 135-A90-1150 Bolt 1 Installation of No. 1 ring gear
01580-01008 Nut 1
01641-51032 Washer 2
5 799-301-1600 Oil leak tester 1 Operation check of clutch piston
D375A-5 30-9
c c
Necessity
Sketch
remodel
New/
Qty
Removal, installation of final drive

1 790-337-1001 Sling tool 1
assembly
791-580-3200 Remover 1
Separation of sprocket hub assem-
2 790-101-2102 Puller (294 kN {30 ton}) 1
bly and bearing
790-101-1102 Pump 1
791-580-3300 Installer 1
Press fitting of sprocket hub bearing
3 790-101-2102 Puller (294 kN {30 ton}) 1
assembly
790-101-1102 Pump 1
4 790-431-1071 Installer 1 N Installation of floating seal
Final drive assembly J 791-580-3400 Remover 1

5 790-101-2102 Puller (294 kN {30 ton}) 1 Disassembly of hub shaft assembly
790-101-1102 Pump 1
791-580-3500 Installer 1
Press fitting of hub shaft bearing as-
6 790-101-2102 Puller (294 kN {30 ton}) 1
sembly
790-101-1102 Pump 1
790-431-1230 Remover & installer 1
Removal, installation of planetary
7 790-101-2102 Puller (294 kN {30 ton}) 1
gear shaft
790-101-1102 Pump 1
8 790-431-1250 Guide 1 Installation of gear assembly
791T-630-2210 Plate 1 c
792-530-1630 Stud 2
790-101-2510 Block 1
790-101-2570 Washer 2
1 Press fitting of bushing
01580-01613 Nut 2
Idler assembly L 01643-31645 Washer 2
790-101-2102 Puller (294 kN {30 ton}) 1
790-101-1102 Pump 1
2 791-515-1520 Installer 1 Installation of floating seal
3 791-685-8310 Push tool 1 Press fitting of seal guide
4 791-601-1000 Oil pump 1 Filling of oil
791-730-1110 Bolt 4
1 Removal of pin
01580-12722 Nut 4
791-685-8501 Compressor 1
Recoil spring assembly M
790-101-1600 Cylinder (686 kN {70 ton}) 1 Disassembly, assembly of recoil
2
790-101-1102 Pump 1 spring assembly
791-635-3160 Extension 1
8 791T-630-2220 Plate 1 c Press fitting of bushing
10 791T-630-2230 Push tool 1 c Press fitting of seal guide
790-401-1700 Sling tool 1
Track roller assembly L 790-401-1761 Adapter 1
12 Sling track roller assembly
790-401-1540 Shackle 2
790-401-1770 T-Bolt 2
791T-630-2320 Plate 3 N c
13 01011-62700 Bolt 6 Secure bogie assembly
01673-32780 Washer 6
30-10 D375A-5
c c
Necessity
Sketch
remodel
New/
Qty
791T-630-2320 Plate 3 N c
13 01011-62700 Bolt 6 Secure bogie assembly
01673-32780 Washer 6
1 791-830-1620 Plate 1 N
2 791-830-1630 Spacer 1 N
3 791-830-1640 Screw 3 N
14 4 01580-12722 Nut 3
5 01630-32780 Washer 3
6 790-101-4000 Puller (490 kN {50 ton}) 1
7 790-101-1102 Pump 1
1 791-830-1650 Plate 1 N Removal of shaft, ring
2 791-830-1660 Spacer 1 N
3 796-670-1120 Plate 1
4 790-434-1070 Screw 1 N
Bogie assembly L 15
5 01580-13629 Nut 2
6 01643-33690 Washer 1
7 790-101-4000 Puller (490 kN {50 ton}) 1
8 790-101-1102 Pump 1
1 791-830-1620 Plate 1 N
2 791-830-1640 Screw 3 N
3 01580-12722 Nut 3
16 Press fitting of pin assembly
4 01643-32780 Washer 3
5 790-101-4000 Puller (490 kN {50 ton}) 1
6 790-101-1102 Pump 1
Align the pin hole of the track frame
17 791T-630-2290 Guide 2 N c
and bogie
1 791-830-1620 Plate 1 N
2 791-830-1630 Spacer 1 N
3 791-830-1640 Screw 3 N
14 4 01580-12722 Nut 3
5 01630-32780 Washer 3
6 790-101-4000 Puller (490 kN {50 ton}) 1
7 790-101-1102 Pump 1
No. 1 bogie assembly L 1 791-830-1650 Plate 1 N Removal of shaft, ring
2 791-830-1660 Spacer 1 N
3 796-670-1120 Plate 1
4 790-434-1070 Screw 1 N
15
5 01580-13629 Nut 2
6 01643-33690 Washer 1
7 790-101-4000 Puller (490 kN {50 ton}) 1
8 790-101-1102 Pump 1
D375A-5 30-11
c c
Necessity
Sketch
remodel
New/
Qty
1 791-830-1620 Plate 1 N
2 791-830-1640 Screw 3 N
3 01580-12722 Nut 3
16 Press fitting of pin assembly
4 01643-32780 Washer 3
5 790-101-4000 Puller (490 kN {50 ton}) 1
6 790-101-1102 Pump 1
Align the pin hole of the track frame
17 791T-630-2290 Guide 2 N c
and bogie
1 791-630-1860 Bracket (L.H) 1 N
No. 1 bogie assembly L
2 791-630-1870 Bracket (R.H) 1 N
20 Setting of installation position
3 01010-62760 Bolt 2
4 01643-32780 Washer 2
791T-630-1900 Sling tool z 1
791T-630-1910 Tube 1 c
791T-630-1920 Plate 1 c
07283-38973 Clip 1
21 Installation of track roller assembly
04530-11628 Eye bolt 1
01643-31645 Washer 1
01643-31232 Washer 2
01582-01210 Nut 2
1 791-646-7351 Push tool 1 Removal of small plug
2 791-660-7460 Pin brush 1 Cleaning of pin hole
3 791-646-7900 Push tool (for large plug) 1 Press fitting of large plug
791-701-3000 Seal checker
4 or 2 Supply oil
791-601-1000 Oil pump
5 791-932-1110 Push tool (for small plug) 1 Press fitting of small plug
6 791-632-1021 Installer 1 Installation of seal assembly
Remover & installer assem-
1 791-632-1100 1
bly
2 791-632-1130 Adapter 1
3 790-434-1610 Guide 1
4 01010-51440 Bolt 2
Track shoe R 5 791-685-9510 Frame 1
6 791-685-9530 Rod 1
7 791-685-9520 Frame 1
8 791-685-9550 Nut 3
Disassembly, assembly of track
7
9 04530-12030 Eye bolt 1 shoe
10 791-685-9560 Bolt 4
11 791-126-0150 Adapter 1
12 791-685-9540 Rod 1
13 791-632-1140 Adapter 1
14 791-680-5520 Guide 1
15 01010-51030 Bolt 1
16 791-632-1150 Pusher 1
17 791-685-9620 Extension 1
30-12 D375A-5
c c
Necessity
Sketch
remodel
New/
Qty
18 791-632-1180 Adapter 1
19 791-680-5543 Adapter 1
20 791-632-1160 Guide 1
21 791-680-5551 Guide 1
22 791-680-9630 Adapter 1
Disassembly, assembly of track
7 23 791-632-1160 Guide 1
shoe
24 195-32-61210 Bolt 2
25 790-101-4300 Cylinder (1,470 kN {150 ton}) 1
26 790-101-1102 Pump 1
27 790-101-4200 Cylinder (294 kN {30 ton}) 1
28 791-680-1630 Spencer 1
1 791-632-1300 Push tool assembly 1 N
2 791-632-1260 Ring 1
3 791-632-1270 Shaft 1
4 791-632-1220 Adapter (small) 1
5 791-632-1230 Ring 1
8 6 791-632-1240 Washer 1
7 791-685-5730 Bar 1
8 791-632-1250 Urethan 1
9 791-632-1280 Spring 1
10 01252-30605 Bolt 1
Track shoe R 11 01580-01210 Nut 1

2 791-632-1260 Ring 1 Assembly of link
3 791-632-1270 Shaft 1
4 798-632-1210 Adapter (large) 1
5 791-632-1230 Ring 1
9 6 791-632-1240 Washer 1
7 791-685-5730 Bar 1
8 791-632-1250 Urethan 1
9 791-632-1280 Spring 1
10 01252-30655 Bolt 1
11 01580-01210 Nut 1
10 2 791-685-5730 Bar 1
3 01580-01210 Nut 1
1 791-646-7351 Push tool 1
2 791-660-7460 Pin brush 1
3 791-646-7900 Push tool (for large plug) 1
791-701-3000 Seal checker Disassembly, assembly of one link
4 or 2 in the field
791-601-1000 Oil pump
5 791-932-1110 Push tool (for small plug) 1
6 791-632-1021 Installer 1
D375A-5 30-13
c c
Necessity
Sketch
remodel
New/
Qty

1 791-632-1100 1
bly
2 791-632-1130 Adapter 1
3 790-434-1610 Guide 1
4 01010-51440 Bolt 2
5 791-685-9510 Frame 1
6 791-685-9520 Rod 1
7 791-685-9520 Frame 1
8 791-685-9550 Nut 3
9 04530-12030 Eye bolt 1
10 791-685-9560 Bolt 4
11 791-126-0150 Adapter 1
12 791-685-9540 Rod 1
13 791-632-1140 Adapter 1
Disassembly, assembly of one link
7 14 791-680-5520 Guide 1
in the field
15 01010-51030 Bolt 1
16 791-632-1150 Pusher 1
17 791-685-9620 Extension 1
18 791-632-1180 Adapter 1
19 791-680-5543 Adapter 1
20 791-632-1170 Guide 1
21 791-680-5551 Guide 1
22 791-680-9630 Adapter 1
23 791-632-1160 Guide 1
Track shoe R
24 195-32-61210 Bolt 1
25 790-101-4300 Cylinder (1,470 kN {150 ton}) 1
26 790-101-1102 Pump 1
27 790-101-4200 Cylinder (294 kN {30 ton}) 1
28 791-680-1630 Spacer 1 N
1 791-646-7351 Push tool 1
2 791-660-7460 Pin brush 1
3 791-646-7900 Push tool (for large plug) 1
791-701-3000 Seal checker
4 or 2
791-601-1000 Oil pump
5 791-932-1110 Push tool (for small plug) 1
6 791-632-1021 Installer 1
1 791-632-1100 1
bly
2 791-632-1130 Adapter 1 Disassembly, assembly of master
link
3 790-434-1610 Guide 1
4 01010-51440 Bolt 2
5 791-685-9510 Frame 1
7
6 791-685-9530 Rod 1
7 791-685-9520 Frame 1
8 791-685-9550 Nut 3
9 04530-12030 Eye bolt 1
10 791-685-9560 Bolt 4
11 791-126-0150 Adapter 1
30-14 D375A-5
(1) cc
Necessity
Sketch
remodel
New/
Qty
12 791-685-9540 Rod 1
13 791-632-1140 Adapter 1
14 791-680-5520 Guide 1
15 01010-51030 Bolt 1
16 791-632-1150 Pusher 1
17 791-685-9620 Extension 1
18 791-632-1180 Adapter 1
19 791-630-5543 Adapter 1
7 20 791-632-1160 Guide 1
21 791-680-5551 Guide 1
22 791-680-9630 Adapter 1
23 791-632-1160 Guide 1
24 195-32-61210 Bolt 2
25 790-101-4300 Cylinder (1,470 kN {150 ton}) 1
26 790-101-1102 Pump 1
27 790-101-4200 Cylinder (294 kN {30 ton}) 1
28 791-680-1630 Spacer 1
2 791-632-1260 Ring 1
3 791-632-1270 Shaft 1
4 791-632-1220 Pin (small) 1 Disassembly, assembly of master
Track shoe R
5 791-632-1230 Ring 1 link
8 6 791-632-1240 Washer 1
7 791-685-5730 Bar 1
8 791-632-1250 Urethan 1
9 791-632-1280 Spring 1
10 01252-30605 Bolt 1
11 01580-01210 Nut 1
2 791-632-1260 Ring 1
3 791-632-1270 Shaft 1
4 798-632-1210 Pin (large) 1
5 791-632-1230 Ring 1
9 6 791-632-1240 Washer 1
7 791-685-5730 Bar 1
8 791-632-1250 Urethan 1
9 791-632-1280 Spring 1
10 01252-30655 Bolt 1
11 01580-01210 Nut 1
10 2 791-632-1260 Bar 1
3 01580-01210 Nut 1
D375A-5 30-15
c c
Necessity
Sketch
remodel
New/
Qty
1 791T-650-2330 Sleeve 1 N c
2 791T-650-2340 Plate 1 N c
3 790-201-3310 Bolt 2
4 790-101-2510 Block 1
Removal, installation of pivot shaft
Pivot shaft assembly P 5 790-101-2570 Washer 2
assembly
6 01580-01613 Nut 2
7 01643-31645 Washer 2
8 790-105-2300 Jack assembly 1
9 790-101-1102 Pump 1
791-650-1300 Remover z 1
791-735-1123 Sleeve 1
790-434-1050 Screw 1
Removal, installation of equalizer
Equalizer bar N 1 01580-02419 Nut 1
bar
01643-32460 Washer
790-101-2102 Puller (294 kN {30 ton}) z 1
790-101-1102 Pump z 1
1 791T-650-2410 Bracket 1 N c
2 791T-650-2420 Bracket 1 N c
3 790-438-1110 Screw 1
Disassembly, assembly of equaliz-
Equalizer bar bushing N 2 4 791-112-1180 Nut 2
er bar for bushing
5 790-101-2540 Washer 2
6 790-101-2102 Puller (294 kN {30 ton}) 1
7 791-101-1102 Pump 1
Cylinder Disassembly, assembly of hydraulic
1 790-502-1003 z 1
Repair stand cylinder assembly
790-201-1702 Push tool KIT 1
790-201-1841 Push tool 1
2 790-201-1861 Push tool 1 Press fitting of bushing
790-101-5021 Clip 1
01010-50816 Bolt 1
790-201-1500 Push tool KIT 1
790-201-1650 Plate 1
3 790-201-1670 Plate 1 Press fitting of seal
790-101-5021 Clip 1
Hydraulic cylinder
U 01010-50816 Bolt 1
assembly
4 790-720-1000 Expander 1
796-720-1680 Ring 1
07281-01589 Clamp 1
796-720-1720 Ring 1 Installation of piston ring
5
07281-02429 Clamp 1
796-720-1690 Ring 1
07281-02169 Clamp 1
790-102-2302 Wrench
or 1
6 790-330-1100 Multi wrench Tightening of cylinder head
790-101-1102 Pump 1
30-16 D375A-5
c c
Necessity
Sketch
remodel
New/
Qty
Cylinder Disassembly, assembly of ripper

1 790-502-1003 z 1
Repair stand pin puller cylinder assembly
790-201-1702 Push tool KIT 1
790-201-1721 Push tool 1
2 Press fitting of bushing
790-101-5021 Clip 1
01010-50816 Bolt 1
790-201-1500 Push tool KIT 1
790-201-1530 Plate 1
Ripper pin puller cylinder 3 Press fitting of dust seal
U 790-101-5021 Clip 1
assembly
01010-50816 Bolt 1
4 790-720-1000 Expander 1
796-720-1630 Ring 1 Installation of piston ring
5
07281-00709 Clamp 1
790-102-2302 Wrench
or 1
6 790-330-1100 Multi wrench Tightening of cylinder head
790-101-1102 Pump
799-703-1200 Service tool KIT 1
799-703-1100 Vacuum pump (100 V) 1
Extraction and charging the refrig-
Air conditioner assembly X 799-703-1110 Vacuum pump (220 V) 1
erant gas
799-703-1120 Vacuum pump (240 V) 1
799-703-1401 Gas leak detector 1
D375A-5 30-17
(1) cc
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

Note: komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
L1 Plate
L8 Plate
30-18 D375A-5
(1) cc
L10 Push tool

.
L13 Plate
D375A-5 30-18-1
(1) c c
L17 Guide
L21 Sling tool
9JS02244
30-18-2 D375A-5
c (1) c
L21 Tube
L21 Plate
D375A-5 30-18-3
(1) c c
P1 Sleeve
P2 Plate
30-18-4 D375A-5
c (1) c
N2-1 Bracket
N2-2 Bracket
D375A-5 30-18-5
(1) c c
DISASSEMBLY AND ASSEMBLY FUEL PUMP ASSEMBLY
REMOVAL AND
INSTALLATION OF
FUEL PUMP ASSEMBLY
REMOVAL INSTALLATION
1. Close fuel supply valve. Carry out installation in the reverse order to re-
moval.
2. Remove engine left side covers (1) and (2).
Bleed air from fuel circuit.
1) Remove air bleed valve (1).
2) Fill with clean fuel through hole in valve until
it overflows.
Amount of fuel: Approx. 300 cc (refer-
ence)
3 Air bleed valve:

3) Install air bleed valve (1).
12.7 Nm {1.3 kgm}

4) Crank engine with starting motor.
3. Disconnect fuel tubes (3) and (4).

4. Remove fuel hose (5).
5. Disconnect wiring connector (6).
6. Remove clamps (7) and (8).
7. Loosen fuel pump mounting bolt (9) and remove
fuel pump assembly (10).
D375A-5 30-19
c c
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY OF ENGINE FRONT SEAL
REMOVAL AND
INSTALLATION
OF ENGINE FRONT SEAL
SPECIAL TOOLS INSTALLATION
Sym- Ne- Q'ty New/Re- Sketc Carry out installation in the reverse order to re-
Part No. Part name
bol cessity model h moval.
795-902-1410 Sleeve 1 q1
1
01050-32240 Bolt 3 Align the crankshaft pulley with the dowel pin
A
795-902-1430 Push tool 1 when installing.
3
01050-32235 Bolt 3 Tighten the mounting bolts in the order
3 Crankshaft pulley mounting bolt:

shown in the diagram below.
REMOVAL 1st step:

1. Remove radiator guard assembly. For details, 73.5 19.6Nm {7.5 2kgm}
see REMOVAL OF RADIATOR GUARD AS- 2nd step:
SEMBLY. 245 19.6Nm {25 2kgm}
2. Remove crankshaft pulley (1). q1 3rd step:
637 19.6Nm {65 2kgm}
3. Remove front seal (2). q2

q2
Procedure for assembling standard seal
Fill the lip portion with approx. 5 cc of lithium
grease (G2-LI).
Using tool A3, press fit front seal (2) to front
cover (3).
After press fitting, check installation dimen-
sion a.
Front seal installation dimension a:
66 mm (standard)
30-20 D375A-5
(1) cc
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY OF ENGINE FRONT SEAL
Procedure of assembling front seal with sleeve

(for repair)
1) Using tool A1, guide bolt 1 , and nut 2 ,
press fit sleeve (4) to crankshaft (5).
Tighten 3 nuts 2 uniformly.
Press fit until tool A1 contacts the end
face of the crankshaft.
After press fitting, check that sleeve in-
stallation dimension b is the specified di-
mension.
Sleeve installation dimension b:
68 0.1mm
2) Using tool A3, press fit front seal (6) to front

cover (3).
Fill the lip portion with approx. 5 cc lithi-
um grease (G2-LI).
After press fitting, check installation di-
mension c.
Front seal installation dimension c:
66 mm (standard)
D375A-5 30-21
(1)c c
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
REMOVAL AND
INSTALLATION OF
ENGINE REAR SEAL
SPECIAL TOOLS 5. Remove rear seal (2).
Sym- Part No. Part name Ne- Q'ty New/Re- Sketc
bol cessity model h
795-902-1420 Sleeve 1
2 795-902-1450 Bolt 2
A 01582-02016 Nut 2
795-902-1440 Push tool 1
4
01050-32050 Bolt 4
REMOVAL
1. Remove damper assembly. For details, see RE-
MOVAL OF DAMPER ASSEMBLY.
2. Remove 1 mounting bolt of flywheel (1) and in-
stall guide bolt 1 . INSTALLATION
3. Using eyebolts 2 , sling flywheel (1), then re- q1
move remaining mounting bolts. q1 Coat the thread and seat of the flywheel
mounting bolts with anti-friction compound
4. Move flywheel towards you, then lift off.
(LM-P).
The spigot portion of the flywheel is shallow
Secure the flywheel and the housing with
and it may suddenly fall, so be careful not to
q2
stopper 3 , then tighten the mounting bolts.
get your fingers caught.
4 Flywheel: 45kg
30-22 D375A-5
c c
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
Tighten the flywheel mounting bolts in the order q2
3 Flywheel mounting bolt:

shown in the diagram below. Procedure for assembling standard seal.
Using tool A4, press fit the rear seal (2) until
1st step: 98 19.6Nm {10 2kgm} it contacts the flywheel housing.
2nd step: 294 19.6Nm {30 2kgm}
3rd step: 539 19.6Nm {55 2kgm} Assembly procedure for seal with sleeve (for
maintenance)
1) Using tool A2, guide bolt 5 , and nut 6 ,
press fit sleeve (3) to crankshaft (4).
Tighten 2 nuts 6 uniformly.
Press fit until tool A2 contacts the crank.
After press fitting, check that mounting
dimension a of sleeve is the specified di-
mension.
Sleeve mounting dimension a: 27
1mm
After installing the flywheel, use dial gauge 4 to

measure the radial and face runout of the fly-
wheel.
Face runout: Max. 0.15 mm
Radial runout: Max. 0.20 mm
2) Using tool A4, press fit rear seal (5) until it

contacts flywheel housing (6).
D375A-5 30-23
(1)c c
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
REMOVAL AND
INSTALLATION OF
CYLINDER HEAD ASSEMBLY
SPECIAL TOOLS 5. Disconnect water tube (3).
Sym- Ne- Q'ty New/Re- Sketc 6. Remove wiring (4) and wiring clamp.
Part No. Part name
bol cessity model h
795-799-5410 Adapter 1
A
795-799-5420 Remover 1
A5 790-331-1110 Wrench 1
REMOVAL
Disconnect the cable from the negative () termi-
nal of the battery.
1. Drain coolant.
2. Remove hood assembly. For details, see RE-
MOVAL OF HOOD ASSEMBLY.
3. Remove engine right side cover (1). 7. Remove air cleaner dust discharge tube, hose,
and clamp (5).
8. Remove dust indicator hose (6).
9. Remove suction tube (7).
10. Remove left and right air cleaner assembly
mounting bolts (8).
11. Remove hose (9) and tube (10) between turbo-
charger and aftercooler.
12. Lift off air cleaner assembly (11).
4 Air cleaner assembly: 45 kg
4. Remove engine left side cover (2).
30-24 D375A-5
c c
13. Remove alternator (12). 21. Remove adiabatic cover (24).

14. Remove U-bolt, and disconnect bracket (13) and
water tube (14).
15. Remove tube (15).
22. Lift off muffler assembly (25).
16. Remove fuel tube (16), fuel hose (17), and fuel
filter assembly (18).
17. Disconnect corrosion hose (19), and remove
corrosion resistor assembly (20).
18. Disconnect electrical intake air heater wiring
(21).
19. Disconnect fuel tube (22). q1
20. Lift off aftercooler assembly (23). q2
23. Disconnect turbocharger inlet lubrication tube

(26) and outlet tube (27), then disconnect ex-
haust temperature wiring.
D375A-5 30-25
c c
24. Sling turbocharger assembly and exhaust mani- 29. Remove crosshead (34) and push rod (35).
fold (28) as one unit, then loosen mounting bolts q6
and remove. q3
4 Turbocharger,
30. Using tool A, remove injector assembly (36).
q7
exhaust manifold assembly: 60kg
31. Remove mounting bolts, then remove rocker

25. Remove air cleaner bracket and wiring clamp. arm housing (37). q8
26. Remove spill hose (30).

27. Remove cylinder head cover (32). q4
32. Loosen cylinder head mounting bolts (38), then

using eyebolts, remove cylinder head assembly
(39). q9
28. Remove rocker arm assembly (33). q5 4 Cylinder head assembly: 60kg
Loosen the locknut, then loosen the adjust-
ment screws 2 or 3 turns.
30-26 D375A-5
c c
q4
INSTALLATION
Carry out installation in the reverse order to re-
moval. 31.85 2.45Nm {3.25 0.25kgm}
q1 q5
3 Delivery tube sleeve nut: Clean the hole of the mounting bolts and install.
92.5 2.5Nm {9.45 0.25kgm} Check that the ball portion of the adjustment
screw is fitted securely in the socket portion of
q2
3 Rocker arm mounting bolt:
the push rod.
Tighten the aftercooler mounting bolts in the or-
3 Mounting bolt: 3 Locknut: 67.62 9.8Nm {6.9 1kgm}

der shown in the diagram below. 98 4.9Nm {10 0.5kgm}
66.15 7.35Nm {6.75 0.75kgm}

q6
Adjust the crosshead as follows.
1) Loosen the locknut, then turn back the ad-
justment screw.
2) Hold down the top surface of the crosshead
lightly, and screw in the adjustment screw.
3) After the adjustment screw contacts the
valve stem, screw it in a further 20.
4) Tighten the locknut to hold the adjustment
3 Locknut:
screw in position.
58.8 5.88Nm {6 0.6kgm}
q7
q3 3 Injector mounting bolt:
Tighten the turbocharger and exhaust manifold 1st step : 29.4 4.9Nm {3 0.5kgm}
mounting bolts in the order shown in the diagram 2nd step : Tighten 90 - 120
3 Turbocharger,
below.
q8
3 Rocker arm housing mounting bolt:
exhaust manifold as-
sembly mounting bolt:
110.35 12.25Nm {11.25 1.25kgm} 98 4.9Nm {10 0.5kgm}
D375A-5 30-27
c c
q9 After tightening, make one punch mark a on the

Check that there is no dirt or dust on the cylinder main bolt head (if the bolt is new, do not make
head mounting surface or inside the cylinder. any punch mark).
Check that the grommet does not come out
when installing the gasket.
Tighten the cylinder head mounting bolts in the
order shown in the diagram.
2 Mounting bolt:
3 Cylinder head mounting bolts (1

Anti-friction compound (LM-P)
- 7 ):
1st step:
245 9.8Nm {25 1kgm}
2nd step:
382.5 9.8Nm {39 1kgm}
3rd step:
Make marks with paint on bolt
and head, then tighten a fur- Refilling with water
ther 90 - 120. Add water through water filler to the specified
(The mounting bolts may be level. Run the engine to circulate the water
tightened to the above angle through the system. Then check the water level
again.
3 Mounting bolts (8
with tool A5.)
-9)
98.1 4.9Nm {10 0.5kgm}
30-28 D375A-5
c c
DISASSEMBLY AND ASSEMBLY FUEL TANK ASSEMBLY
REMOVAL AND
INSTALLATION OF
FUEL TANK ASSEMBLY
REMOVAL 5. Disconnect fuel return hose (7) and hose clamp
(8).
nal of the battery.
1. Remove covers (1) and (2).
6. Lift off fuel tank assembly (9).

4 Fuel tank assembly:
2. Disconnect wiring connector (CN-422) (3). Approx. 500 kg (when empty)

Approx. 1350 kg (when full)
3. Close fuel supply valve and disconnect fuel sup-
ply hose (4).
4. Disconnect brackets (5) and (6).
INSTALLATION
3 Fuel tank mounting bolt:

moval.
927 98Nm {94.5 10kgm}
D375A-5 30-29
c c
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY
REMOVAL AND
INSTALLATION OF
RADIATOR ASSEMBLY
REMOVAL 8. Disconnect sub tank hose (7).
Disconnect the cable from the negative () termi- 9. Disconnect radiator water level sensor connec-
nal of the battery. tor (CN-405) (8).
1. Drain coolant. 10. Remove windbreaker plate (9).
2. Remove inspection cover (17). 11. Using eyebolts, sling radiator assembly, then re-
move 2 each of left and right top mount bolts
3. Disconnect front lamp connector (CN-202) (1). (10).
4. Using eyebolts, lift off radiator top cover (2).
4 Radiator top cover: 76kg
12. Remove 2 covers (11).

13. Open guard (12).
5. Disconnect radiator inlet hose (3) and aeration
hose (4).
6. Remove ground wiring (CN-GND4) (5).
7. Disconnect wiring clamps (6) (4 places), and
move wiring towards left side of radiator.
30-30 D375A-5
c c
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY
14. Remove windbreaker plate (13). INSTALLATION

3 Radiator inlet hose clamp:

moval.
3 Aeration hose clamp:

882 98Ncm {90 10kgcm}
333.2 49Ncm {34 5kgcm}
Refilling with water

Add water through water filler to the specified level.
Run the engine to circulate the water through the
system. Then check the water level again.
15. Disconnect radiator outlet tube (14).

16. Remove bottom mount bolt (15).
17. Lift off radiator assembly (16).

4 Radiator assembly: 390kg
D375A-5 30-31
c c
REMOVAL AND INSTALLATION OF RADIATOR
DISASSEMBLY AND ASSEMBLY GUARD ASSEMBLY
REMOVAL AND
INSTALLATION OF RADIATOR
GUARD ASSEMBLY
SPECIAL TOOLS 2. Disconnect hose (2).
New/
Release the remaining pressure in the hy-
Sym- Ne- Sketc draulic circuit. For details, see TESTING
Part No. Part name Q'ty Remod-
bol cessity h
el AND ADJUSTING, Releasing remaining
791-451-1000 Remover 1 pressure in hydraulic circuit.
Puller Fit a blind plug to prevent any dirt or dust
A 6 790-101-2102 1
(294kN {30ton})
from entering.
790-101-1102 Pump 1
REMOVAL
1. Remove cap (1) of blade lift cylinder.
Check the number and thickness of the
shims, and keep in a safe place.
Start the engine, and retract the piston rod,
then tie the piston rod with wire to prevent it
from coming out.
3. Sling blade lift cylinder assembly (3), then fit cyl-

inder holder and secure to radiator guard.
4. Drain coolant.
30-32 D375A-5
c c
6. Disconnect radiator inlet hose (4). 10. Open engine underguard.

Disconnect at the radiator end and move it
11. Remove right undercover of radiator guard, then
towards the engine.
remove radiator outlet tube (11).
7. Disconnect aeration hose (5) and hose (6) from Loosen the clamp at the hose portion, then
reserve tank. remove the tube.
Disconnect at the radiator end, then remove
2 clamps and move towards the engine.
12. Disconnect wiring connector (12) (CN-21), and

remove cover (13).
8. Disconnect PPC oil cooler piping (7) and (8).
13. Disconnect blade piping (14) and (15).
9. Disconnect fuel cooler piping (9) and (10).
D375A-5 30-33
c c
14. Loosen tension of tension pulley (16) and re- 17. Lift off radiator guard assembly (20).
move fan belt (17). Be careful not to damage the wiring and pip-
ing when removing.
4 Radiator guard assembly: 2,700kg
15. Sling radiator and guard assembly, remove lock

bolt, then using tool A6, push rear pin (18) to in-
side radiator guard, and remove.
INSTALLATION
16. Remove lock plate, and using tool A6, pull front
pin (19) to outside of radiator guard, and remove. Carry out installation in the reverse order to re-
moval.

Standard shim thickness: 4mm

882 98Ncm {90 10kgcm}
3Radiator outlet hose clamp:

333.2 49Ncm {34 5kgcm}
882 98Ncm {90 10kgcm}

30-34 D375A-5
c c
DISASSEMBLY AND ASSEMBLY ENGINE ASSEMBLY
REMOVAL AND
INSTALLATION OF
ENGINE ASSEMBLY
SPECIAL TOOLS 5. Remove air cleaner dust discharge tube hose
clamp (3).
Sym- Ne- New/ Sketc
Part No. Part name Q'ty Remod- 6. Remove air cleaner band (4).
bol cessity el h
799-703-1200 Service tool kit 1 7. Remove air supply tube clamp (5), then remove
799-703-1100 Vacuum pump 1 air supply tube (6).
799-703-1110 Vacuum pump 1 8. Disconnect dust indicator hose (7).
X
799-703-1120 Vacuum pump 1
9. Lift off air cleaner assembly (8).
4 Air cleaner assembly: 22kg
Gas leak
799-703-1401 1
detecter
REMOVAL
nal of the battery.1.
1. Drain coolant.
2. Remove engine hood assembly.
3. Remove engine right side cover (1).
10. Disconnect ground connection wiring (9).

11. Disconnect starting motor wiring (10).
12. Close heater valve (11), and move engine to
rear.
4. Remove engine left side cover (2).
D375A-5 30-35
(1) cc
13. Remove torque converter oil cooler connector 16. Disconnect fuel supply hose (18).
(12). 17. Disconnect fuel return hose (19) and remove
14. Disconnect radiator outlet tube (13). hose clamp.
15. Disconnect air conditioner hoses (16) and (17). 18. Disconnect wiring connectors (CN-101) (20),
Air conditioner gas (R134a) is completely ex- (CU-EG1) (21), and (CU-EG2) (22).
tracted from an air conditioner circuit.
Fit blind plugs to prevent dirt, dust, or mois-
ture from getting inside the hoses.
Disconnect all clamps of hoses (16) and
(17).
19. Disconnect radiator inlet hose (23).

Disconnect aeration hose (24).
30-36 D375A-5
(1) cc
20. Remove fan net (22). 26. Lift off bracket assembly (32).
21. Loosen tension of tension pulley (23) and re- 4 Bracket assembly: 170kg
move fan belt (24).
27. Remove damper case oil level gauge (33).

22. Remove right covers (25) and (26).
28. Remove bracket (34).
23. Remove left covers (27) and (28).
29. Sling universal joint (35), remove mounting bolts,

then lift off.
25. Disconnect wiring connectors (CN206) (30) and
(CN-201) (31).
D375A-5 30-37
c c
30. Remove front mount bolt (36) and rear mount INSTALLATION
bolt (37).
Be careful to prevent the entry of moisture, dust
31. Raise engine assembly (38), and remove right or dirt into the air conditioner circuit hoses when
rear mount cap (39). installing.
4 Engine assembly: 3,200kg Check that there are O-rings at the portion of the
air conditioner hoses connecting to the piping,
then tighten. Coat the O-rings thoroughly with
compressor oil (Showa-Shell Suniso 4G or 5G).
32. Move engine assembly (38) to above chassis

and operate chain block to raise front of engine
3 Air conditioner gas piping tightening

assembly and set assembly at an angle.
33. Pass chassis parts through front and rear of en- torque
gine assembly (38), then rotate engine assembly
(38) 90 to right of chassis and remove. Thread size Tightening torque
When removing, be careful not to damage
the wiring and hoses. 16 1.5 13.23 1.47Nm {1.35 0.15kgm}
22 1.5 22.05 2.45Nm {2.25 0.25kgm}
24 1.5 31.85 2.45Nm {3.25 0.25kgm}
M6 bolt
5.39 1.47Nm {0.55 0.15kgm}
(receiver portion)
M6 bolt
9.8 1.96Nm {1.0 0.2kgm}
(compressor portion)

882 98Ncm {90 10kgcm}
3 Universal joint mounting bolt:

333.2 49Ncm {34 5kgcm}
3 Engine mount bolt:

176.4 19.6Nm {18 2kgm}
926.1 102.9Nm {94.5 1kgm}

Charging air conditioner with gas

Using tool X, charge the air conditioner circuit with
air conditioner gas (R134a).
30-38 D375A-5
c c
DISASSEMBLY AND ASSEMBLY DAMPER ASSEMBLY
REMOVAL AND
INSTALLATION OF
DAMPER ASSEMBLY
SPECIAL TOOLS 5. Remove right covers (5) and (6).
New/ Sketc 6. Remove left covers (7) and (8).
Sym- Ne-
Part No. Part name Q'ty Remod-
bol cessity el h 7. Remove cover (9).
799-7.3-1200 Service tool kit 1
799-703-1100 Vacuum pump 1
799-703-1110 Vacuum pump 1
X
799-703-1120 Vacuum pump 1
Gas leak de-
799-703-1401 1
tector
REMOVAL
nal of the battery.
8. Disconnect wiring connector (CN-206) (10).
2. Disconnect ground connection wiring (1).
3. Disconnect starting motor wiring (2).
4. Close heater valve, then remove heater hose
clamp, and disconnect heater hoses (3) and (4).
q1
D375A-5 30-39
(1) cc
9. Disconnect air conditioner hoses (11) and (12). 13. Open power train underguard (front).
Air conditioner gas (R134a) is completely ex- 14. Sling universal joint (27), then remove mounting
q2
tracted from an air conditioner circuit. bolts, and lift off.D
4 Universal joint: 45kg
Fit blind plugs to prevent dirt, dust, or mois-
ture from getting inside the hoses.
10. Lift off bracket (13).
4 Bracket assembly: 170kg
15. Remove drain plug and drain oil from damper

case.
6 Damper case: Approx. 2.1
11. Remove damper case oil level gauge (25).
16. Remove holder (28) and coupling (29). q3
17. Remove retainer (30).
30-40 D375A-5
(1) cc
18. Using eyebolts 1 , sling damper cover (31), then INSTALLATION

use forcing screws to remove. q4
To prevent the damper cover from coming moval.
out suddenly, set guide bolt 2 (=200mm). q1
4 Damper cover: 75kg Install the hoses without twisting or interfer-
ence.
19. Using eyebolts 3 , remove damper assembly
q5
Be careful to prevent the entry of moisture,
(32). dust or dirt into the air conditioner circuit hos-
To prevent the damper assembly from comes when installing.
i n g o u t s u d d e n l y, s e t g u i d e b o l t 4 Check that there are O-rings at the portion of
(=200mm). the air conditioner hoses connecting to the
4 Damper assembly: 70kg piping, then tighten.
Coat the O-rings thoroughly with compres-
sor oil (Showa-Shell Suniso 4G or 5G).
20. Remove bearing (33) from flywheel.

q6
3 Air conditioner gas piping tightening
torque
Thread size Tightening torque
16 1.5 13.23 1.47Nm {1.35 0.15kgm}
22 1.5 22.05 2.45Nm {2.25 0.25kgm}
24 1.5 31.85 2.45Nm {3.25 0.25kgm}
q2
176.4 19.6Nm {18 2kgm}
q3
2 Holder mounting bolt thread portion:

Thread tightener (LT-2)
276.85 31.85Nm {28.25 3.25kgm}
D375A-5 30-41
c c
q4
Using guide bolt 2 (=200 mm), dtermine
the position of the damper cover.
q5
Using guide bolt 4 (=200 mm), dtermine
the position of the damper assembly.
q6
Fill approx.50% (approx. 11 g) of the hatched
portion a in the diagram with grease (G2-LI).
Refilling with oil

Fill with oil to the specified level.
Charging air conditioner with gas

Using tool X, charge the air conditioner cir-
cuit with air conditioner gas (R134a).
30-42 D375A-5
c c
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF DAMPER
DISASSEMBLY AND
ASSEMBLY OF DAMPER
DISASSEMBLY OF DAMPER ASSEMBLY 6. Remove seal (7) from flanges (2) and (5).
1. Set damper assembly to block 1 .
2. Remove mounting nut (1), then using forcing
screws 2 , remove flange (2).
DISASSEMBLY OF DAMPER COVER

ASSEMBLY
7. Remove bearing (8) and oil seal (9) from cover
3. Remove shaft (3). (10).
4. Remove rubber (4). 8. Remove oil seal (11) from retainer (12).
5. Using forcing screws 2 , remove flange (5) from

body (6).
D375A-5 30-43
c c
ASSEMBLY OF DAMPER ASSEMBLY 3. Set flange and body assembly to block, then set
shaft (3) in position.
1. Install seals (7) to flanges (2) and (5).
Install the seal with the lip facing the inside 4. Assemble rubber (4).
as shown in the diagram. When assembling the rubber, coat the whole
surface of the rubber, the outside circumfer-
ence of the shaft, and the inside circumfer-
ence of the body with grease (G2-LI).
After assembling to the rubber, fill approx.
30% of the clearance (16 places) between
the flange and body with grease (G2-LI).
2. Align bolt holes with body (6) and install flange

(5).
2 Mating surface of flange:
Gasket sealant (LG-4)
Check that there are no dents, rust, oil or
grease, or water on the mating surface, then
5. Install flange (2).
2 Mating surface of flange:
coat both faces of the flange and body with
gasket sealant.
Check that there are no dents, rust, oil or
grease, or water on the mating surface, then
coat both faces of the flange and body with
gasket sealant.
6. Set bolt in position, and tighten mounting nut (1).
30-44 D375A-5
c c
ASSEMBLY OF DAMPER COVER ASSEM- 9. Using push tool 5 , press fit oil seal (9) to cover
BLY (10).
7. Using push tool 3 , press fit oil seal (11) to re- 2 Oil seal press-fitting surface:
tainer (12). Gasket sealant (LG-1)
2 Oil seal press-fitting surface: Coat the inside surface of the retainer thinly
Gasket sealant (LG-1) with gasket sealant and wipe off any sealant
that is squeezed out.
2 Lip of oil seal: Grease (G2-LI)
Coat the inside surface of the retainer thinly
with gasket sealant and wipe off any sealant
that is squeezed out.
8. Using push tool 4 , press fit bearing (8) to cover

(10).
D375A-5 30-45
c c
REMOVAL AND INSTALLATION OF POWER
DISASSEMBLY AND ASSEMBLY TRAIN UNIT ASSEMBLY
REMOVAL AND
INSTALLATION OF POWER
TRAIN UNIT ASSEMBLY
REMOVAL 9. Disconnect wiring connectors (CN-PL1) (7),
(CN-PL2) (8), and (CN-PL3)(9).
1. Drain oil from hydraulic tank and power train
case. 10. Loosen locknut and remove from bracket.
6
Hydraulic tank: Approx. 120
6
Power train case: 150
2. Remove floor frame assembly. For details, see

REMOVAL OF FLOOR FRAME ASSEMBLY.
3. Remove fuel tank. For details, see REMOVAL
OF FUEL TANK ASSEMBLY.
4. Remove 2 clamps (1) of hydraulic and PPC
pump inlet tube coupling.
Move the coupling towards the power train
unit and disconnect the tube.
5. Disconnect PPC drain hose (2).
11. Disconnect torque converter oil cooler hose (10).
Disconnect at the pump inlet tube end, and
move it to the right side of the chassis.
6. Disconnect 2 PPC oil cooler hoses (3), then dis-
connect clamps (2 places).
Move the 2 hoses together to the outside of
the oil level gauge, then move them to the
right side of the chassis.
7. Disconnect hydraulic and PPC pump outlet hose
(4).
Disconnect at the pump end.
8. Disconnect wiring connectors (CN-241) (5) and
(CN-404) (6), then disconnect clamps (2 places).
12. Disconnect right rear lamp connector (CN-243)

(11), then disconnect clamps at top of frame (3
places) and at bottom of frame (1 place).
13. Remove frame (12).
30-46 D375A-5
c c
14. Disconnect torque converter oil cooler hose (13), 18. Disconnect universal joint (18) at torque convert-
then disconnect bracket at frame end. er end.
Move the hose towards the front of the chas- After disconnecting, move it towards the
sis. damper end.
15. Disconnect ripper low valve hose (14), then dis-
connect bracket (1 place) on top of steering
case.
Move the hose towards the power train unit
end.
16. Disconnect 2 pin puller solenoid hoses (15), then
disconnect clamp.
Disconnect the hose at the steering case
end, and move it towards the ripper end.
19. Remove cover (19), then using eyebolts, pull out

left and right drive shaft (30).
If the shaft does not come out, push up the
shoe grouser from the ground surface with a
jack and move the sprocket backwards or
forwards to adjust to a position where the
shaft can be removed, then pull the shaft out.
Pull the shaft out to a point where it contacts
the sprocket.
17. Disconnect clamps (16) and (17) and remove

bracket.
Move the hose towards the right side of the
chassis.
D375A-5 30-47
c c
20. Remove right floor frame rear mount (21). 22. Remove left and right rear mount caps (24).
Remove at this point because the right floor
frame rear mount will interfere when the
power train unit is raised.
23. Loosen left and right rear coupling clamps (25).

Move the clamps towards the main frame,
open the joint of the coupling, then move the
21. Remove left floor frame mount (22) and right seal towards the main frame.
floor frame mount (23).
The front mount of the power train unit is
tightened together with the front mount of the
floor frame.
4 Left floor frame mount: 38kg
Right floor frame mount: 37kg
30-48 D375A-5
c c
24. Lift off power train unit assembly (26). Refilling with oil (power train case, hydraulic
Check that all the wiring and piping has been tank)
disconnected before removing the power Add oil through oil filler to the specified level.
train unit assembly. Run the engine to circulate the oil through
4 Power train unit assembly: 4,200kg the system. Then check the oil level again.
5 Power train case: Approx.150

Hydraulic tank: Approx.120
INSTALLATION
moval.

176.4 19.6Nm {18 2kgm}
If the shaft does not go in, push up the shoe

grouser from the ground surface with a jack
and move the sprocket backwards or for-
wards to adjust to a position where the shaft
meshes, then assemble the shaft.
3 Rear mount cap mounting bolt:
3 Rear coupling clamp mounting bolt:

367.5 61.25Nm {43.75 6.25kgm}
6.85 1.96Nm {0.7 0.2kgm}
When installing the power train unit assem-

bly, pay attention to the mating surface of the
coupling and be careful not to damage the
coupling seal at the rear mount.
D375A-5 30-49
c c
DISCONNECTION OF POWER
TRAIN UNIT ASSEMBLY
1. Draining oil 6. Disconnect 14 pressure detection hoses (5) and
Before setting power train unit assembly in posi- remove central pressure detection bracket (6) as
tion, drain oil from oil pan. one unit.
Before removing, mark all the hoses with
2. Raise power train unit assembly (1) and set to
tags to prevent mistakes in the mounting po-
block 1 .
sition when installing.
Set blocks under the front of the oil pan, un-
der the transmission rear case, and under
the steering case.
7. Remove oil level gauge (7).

8. Remove oil filler pipe (8).
3. Remove brake rod (2).
4. Remove parking brake cable (3).
Measure the dimension of the mounting
bracket portion.
5. Remove control cable and bracket assembly (4).
Disconnect the directional control cable and
speed control cable together with the lever at
the control valve end.
30-50 D375A-5
c c
9. Lift off filter assembly (9) together with bracket. 12. Lift off scavenging pump assembly (12).
4 Filter assembly: 120kg 4 Scavenging pump assembly: 41kg
10. Lift off strainer assembly (10) together with suc-

tion tube.
4 Strainer assembly:50kg
13. Lift off front mount (13).

4 Front mount: 150kg
11. Lift off power train and lubrication pump assem-

bly (11).
4 Power train, lubrication pump assembly:
50kg
14. Remove outlet hose of hydraulic and PPC pump.

15. Lift off hydraulic and PPC pump assembly (14)
together with inlet tube.
4 Work equipment, PPC pump assembly:
65kg
D375A-5 30-51
c c
16. Disconnect hydraulic hoses (35) and (36) of ser- 20. Remove block from under oil pan, and sling oil
vo valve (34). pan (17).
17. Disconnect bolts (37) and (38). 21. Remove mounting bolts, then remove oil pan
(17).
18. Remove 3 bolts (39), then remove servo valve
In addition to the mounting bolts at the front,
(34).
rear, left, and right, there are also bolts in-
stalled inside the holes at 4 places under the
oil pan.
4 Oil pan: 110kg
19. Disconnect steering control rod (15) at control

valve end, and remove together with lever as-
sembly (16).
22. Remove bearing cage (18) together with torque

converter speed sensor.
23. Remove case (19).
30-52 D375A-5
c c
24. Remove shaft (20). 28. Set PTO, torque converter, and transmission as-
sembly (22) with PTO side at top, then set on
block 3 .
25. Set block 2 under PTO.

26. Sling steering case assembly (21), and remove
29. Remove coupling (23).
block from under steering case.
30. Remove retainer (24).
27. Remove mounting bolts, then remove steering

case assembly (21).
4 Steering case assembly: 1,750kg
31. Remove snap ring (25), then remove spacer
(26).
D375A-5 30-53
c c
32. Using eyebolts, lift off PTO assembly (27).

4 PTO assembly: 290kg
33. Lift off torque converter assembly (28).

4 Torque converter assembly: 550kg
30-54 D375A-5
c c
DISASSEMBLY AND ASSEMBLY CONNECTION OF POWER TRAIN UNIT ASSEMBLY
CONNECTION OF POWER
TRAIN UNIT ASSEMBLY
Carry out connection in the reverse order to dis- Check that the tip of shaft (20) is fitted securely
connection. in drum (31) of bearing cage (18).
Bend the cotter pin securely.

Set the installation dimension of the bracket to
the dimension measured when removing.
Adjust the limit switch and the lever of the direc-
tional control linkage as follows.
1) Set lever (29) to N position and insert.
2) Set up and down lever (29) at a height where
roller of up and down limit switch (30) con-
tacts groove in lever (29), then tighten tem-
porarily.
3) Move lever (29) to F and R positions and
check that roller is pushed in securely [F: top
limit switch], [R: bottom limit switch], then Check that shaft (20) is fitted securely in boss
tighten lever (29) fully. (32) at the tip of the transmission input shaft.
Bend the cotter pin securely.
D375A-5 30-55
c c
DISASSEMBLY AND ASSEMBLY CONNECTION OF POWER TRAIN UNIT ASSEMBLY
3 Steering case mounting bolt: 3) Select shim thickness.

276.85 31.85Nm {28.25 3.25kgm} Shim thickness = a + 0 - 0.05 mm
Types of shim thickness = 0.15 mm, 0.2 mm,
Adjust the retainer shim as follows. 0.5 mm
1) Without fitting shim, install retainer (24) and 4) Assemble selected shim thickness and tight-
tighten 6 mounting bolts to following torque. en mounting bolts of retainer (24) to speci-
2 Oil seal: Grease (G2-LI)
3 Mounting bolt:
fied torque.
3 Mounting bolt: 9.8Nm {1kgm} 66.15 7.35Nm {6.75 0.75kgm}

2) Using clearance gauge, measure clearance
Check that the number and thickness of
a between retainer (24) and PTO housing
the shims is the same on both the left
(33).
and right sides.
Assemble the shims (34) as shown in the
diagram below so that they do not block
the forcing screw tap H hole in the retain-
er.
Measure clearance a at 4 places (A, B, C, D)

around the circumference and calculate the av-
erage.
Coat portion P of the PTO shaft with anti-friction

compound (LM-P) and the spline portion Q with
grease (G2-LI).
30-56 D375A-5
c c
DISASSEMBLY AND ASSEMBLY PTO ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF
PTO ASSEMBLY
DISASSEMBLY 3) Using puller 2 , remove bearings (5) and (6)
from gear (7).
1. PTO lubrication tube
Sling PTO assembly and remove lubrication
tube (1).
Remove 3 lubrication tubes on the opposite
side, then set the torque converter side at
the bottom and lower the assembly.
3. Power train pump gear assembly

1) Using forcing screws 1 , pull out cover as-
sembly (8) and remove.
2) Using puller, remove gear assembly (10)
from cover (9).
2. Hydraulic, PPC pump gear assembly
1) Using forcing screws 1 , pull out cover as-
sembly (2) and lift off.
2) Using puller 2 , remove gear assembly (3)
from cover (4).
D375A-5 30-57
c c
3) Using puller 2 , remove bearings (11) and 5. Idler gear assembly

(12) from gear (13). 1) Remove plate (17).
4) Turn over PTO case, and remove cover (14). 2) Turn over PTO case, then using forcing
screws 1 , remove shaft assembly (18).
4. Scavenging pump gear
The bearing outer race and gear assem-
1) Remove snap ring (15) at bottom of PTO
bly will come out from the bottom of the
case, then remove gear (16).
PTO case, so set a wooden block and
take care not to cause damage.
3) Remove plug (19), then using forcing
screws, push out bearing inner race (20).
After removing the bearing, install the
plug.
30-58 D375A-5
c c
4) Remove bearing outer races (21) and (22) 3) Remove bearing outer race (29).
from gear (23). 4) Remove sleeve (30).
6. PTO race 7. Bearing

1) Remove race assembly (24) and bearing Remove snap ring (31), then remove bearing
outer race (25) as one unit. (32).
2) Remove bearing inner races (26) and (27)

from race (28).
D375A-5 30-59
c c
ASSEMBLY 3) Using push tool, press fit bearing inner races

(27) and (26) to race (28).
Wash all parts clean and check that there are no
scratches or dirt before assembling.
Check that the snap ring is fitted securely in the
groove.
1. Bearing
1) Using push tool, press fit bearing (32) to
case.
Drop approx. 6 cc of engine oil
(SAE10W-CD or SAE30-CD) on the
bearing, and rotate it 10 times.
2) Install snap ring (31).
4) Install race assembly (24).

2 Inside surface of race:
5) Using push tool, press fit bearing outer race
(25).
2. PTO case
1) Install sleeve (30) to case.
Install the sleeve with the chamfered
portion on the inside circumference fac-
ing down.
Expand fit the sleeve.
2) Using push tool, press fit bearing outer race
(29).
30-60 D375A-5
c c
3. Idler gear 4) Turn over PTO case and install gear assem-
1) Using push tool 3 , press fit bearing outer bly (33).
races (22) and (21) to gear (23). 5) Press fit bearing spacer (34) and bearing in-
ner race (35).
2) Using push tool 4 , press fit bearing inner

race (20) to shaft.
3) Fit O-ring and install shaft assembly (18).
6) Install plate (17).

2 Mounting bolt:
3 Mounting bolt:
110.35 12.25Nm {11.25 1.25kgm}
4. Scavenging pump gear

1) Install gear (16).
2 Spline portion: Grease (G2-LI)
D375A-5 30-61
c c
2) nstall snap ring (15) from bottom of PTO 3) Using push tool 6 , press fit gear assembly
case. (10) to cover (9).
5. Power train pump gear assembly 2 Gear spline portion:
1) Fit O-ring and install cover (14). Grease (G2-LI)
4) Fit O-ring, then raise cover assembly (8) and
install to case.
If the cover assembly is stiff and it is dif-
ficult to insert into the case, tap uniformly
around the circumference with a plastic
hammer to install.
2) Using push tool 5 , install bearings (11) and

(12) to gear (13).
6. Hydraulic, PPC pump gear assembly

1) Using push tool 5 , press fit bearings (5) and
(6) to gear (7).
30-62 D375A-5
c c
2) Using push tool 6 , press fit gear assembly 7. Lubrication tube

(3) to cover (4). Sling PTO assembly, and install lubrication tube
At one end, the end face of the bearing (1).
is level with the end face of the gear. In- Install the 3 lubrication tubes on the opposite
stall so that this end is facing the cover. side also.
2 Gear spline portion:
Grease (G2-LI)
3) Fit O-ring, then raise cover assembly (2) and
install to case.
If the cover assembly is stiff and it is dif-
ficult to insert into the case, tap uniformly
around the circumference with a plastic
hammer to install.
D375A-5 30-63
c c
DISASSEMBLY AND ASSEMBLY OF TORQUE
DISASSEMBLY AND ASSEMBLY CONVERTER ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF TORQUE
CONVERTER ASSEMBLY
SPECIAL TOOLS 1. Torque converter valve assembly
Remove torque converter valve assembly (1).
Sym- Ne- New/Re- Sketc
bol Part No. Part name cessity Q'ty model h 2. Draining oil
790-413-1010 Bracket 1 Remove 2 drain plugs (2) and drain oil from
C Repair pump case.
790-501-5000 stand 1 After draining the oil, tighten the plugs.
(100V)
3. Lock-up clutch, drive case assembly
DISASSEMBLY 1) Leaving 2 mounting bolts (3), remove other
mounting bolts, then set with input shaft at
Preparatory work top and remove remaining 2 mounting bolts.
Set torque converter assembly (56) to tool C.
2) Using eyebolts 1 , remove lock-up clutch

and drive case assembly (4).
3) Disassemble lock-up clutch and drive case
assembly as follows.
i) Remove 2 seal rings (5).
ii) Using forcing screws 2 , remove input
shaft (6).
30-64 D375A-5
c c
iii) Remove snap ring (7), then remove plate vii) Remove seal ring (13) from piston.
(8). viii) Remove seal ring (14) from housing.
iv) Set with clutch housing at bottom, then
using forcing screws 3 , remove turbine
(9).
ix) Using push tool 5 , remove bearing (15)

from housing.
v) Set with clutch housing at top, then using

eyebolts 4 , remove housing and piston
assembly (10).
When the assembly is removed, the
piston will come out, so support it by
hand when removing.
vi) Remove piston (11) from housing (12).
x) Remove 2 discs (16) and 1 plate (17)

from drive case (18).
Store the discs and plates in a flat
place to prevent them from becom-
ing deformed.
D375A-5 30-65
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4. Stator assembly 5. Pump assembly

1) Remove snap ring (19), then remove stator 1) Remove snap ring (25).
assembly (20). 2) Remove pump assembly (26).
2) Disassemble stator assembly as follows. 3) Disassemble pump assembly as follows.
i) Remove snap ring (21), then remove i) Remove retainer (27).
race (22) from stator (23). ii) Remove bearing and guide assembly
(28) from pump (29).
ii) Remove snap ring (24) from stator (23).

iii) Remove bearing outer race (30) from
guide (31).
6. Stator clutch housing
Set with stator clutch housing side at top, then
remove stator clutch housing (32).
30-66 D375A-5
c c
7. Spring 2) Remove seal ring (42) from piston.

Remove spring (33). 3) Remove seal ring (43) from case.
8. Spring, discs, plate
Remove spring (34), 2 discs (35), and 1 plate
(36).
Store the discs and plates in a flat place to
prevent them from becoming deformed.
12. Stator shaft assembly

1) Tap stator shaft assembly (44) with plastic
hammer to remove from case (45).
2) Disassemble stator shaft assembly as fol-
lows.
i) Using push tool 6 , remove shaft as-
9. Pin
sembly (45) from stator shaft assembly.
Remove pin (37).
10. Inner gear
Remove snap ring (38), then remove inner gear
(39).
11. Piston
1) Remove piston (40) from case (41).
D375A-5 30-67
c c
ii) Remove snap ring (47), then remove ASSEMBLY

bearing inner race (48), bushing (49),
and seal shaft (50) from shaft.
iii) Remove seal ring (51), then remove
Check that the snap ring is fitted securely in the
plate (54).
groove.
iv) Remove snap ring (35), then remove
plate (54).
Preparatory work
Set case (41) to tool C.
v) Using push tool 7 , remove bearing

(55). 1. Stator shaft assembly
1) Assemble stator shaft assembly as follows.
i) Using push tool, press fit bearing (55) to
stator shaft (52).
ii) Install plate (54) and secure with snap
ring (53).
iii) Install seal ring (51).
After installing the seal ring, coat with
grease (G2-LI) and fit securely to
shaft.
30-68 D375A-5
c c
iv) Install seal ring (50) to shaft. 2) Tap stator shaft (52) with plastic hammer to
After installing the seal ring, coat with press fit bearing portion to case.
grease (G2-LI) and fit securely to the 3) Set shaft (46) to stator shaft, then using push
shaft. tool, press fit bearing portion.
v) Using push tool 9 , press fit bushing 4) Turn over case, and tighten mounting bolts
(49). of shaft from case end.
Be careful not to deform the bushing 2 Outer circumference of seal ring:
when press fitting.
3 Mounting bolt:
Grease (G2-LI)
66.15 7.35Nm {6.75 0.75kgm}
vi) Using push tool 0, press fit bearing in-

ner race (48).
vii) Install snap ring (47) and secure bearing
inner race. 2. Piston
1) Install seal ring (43) to case.
2 Outer circumference of seal ring:
Grease (G2-LI)
The seal ring must be installed facing in
the correct direction. Assemble as
shown in the diagram.
2) Install seal ring (42) to piston.
2 Outer circumference of seal ring:
Grease (G2-LI)
D375A-5 30-69
c c
The seal ring must be installed facing in 7. Stator clutch housing

the correct direction. Assemble as Install stator clutch housing (32).
shown in the diagram. Check that the spring is fitted securely in the
piston and housing holes.
2 Mounting bolt:
3 Mounting bolt:
110.35 12.25Nm {11.25 1.25kgm}
8. Pump assembly
1) Assemble pump assembly as follows.
i) Using push tool, press fit bearing outer
race (30) to guide (31).
Drop approx.6 cc of engine oil
3) Install piston (40) to case (41).
2 Mating surface of seal ring:
Grease (G2-LI)
3. Inner gear
Install inner gear (39), and secure with snap ring
(38).
4. Pin
Install pin (37).
5. Plate, discs, spring
Install 1 plate (36), 2 discs (35), and spring (34).
6. Spring
Install spring (33).
30-70 D375A-5
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9. Stator assembly
ii) Set bearing and guide assembly (28) to 1) Assemble stator assembly as follows.
pump (29), then tap with plastic hammer i) Install snap ring (24) to stator (23).
to press fit bearing portion.
iii) Install retainer (27).
2 Mounting bolt:
3 Mounting bolt: 66.15 7.35Nm

{6.75 0.75kgm}
2) Install pump assembly (26).
When installing the pump, be careful not
to damage the seal ring assembled to
the shaft.
ii)
Assemble race (22) in stator (23), then
secure with snap ring (21).
2) Install stator assembly (20) to stator shaft,
then secure with snap ring (19).
D375A-5 30-71
c c
10. Lock-up clutch, drive case assembly iii) Install seal ring (14) to housing.
1) Assemble lock-up clutch and drive case as- 2 Outer circumference of seal
sembly as follows. ring: Grease (G2-LI)
i) Set turbine (9) to block A , then set drive
iv) Install seal ring (13) to piston.
2 Outer circumference of seal
case (18) to turbine.
ring: Grease (G2-LI)
ii) Install 2 discs (16) and 1 plate (17).
v) Install piston (11) to housing (12).

2 Mating surface of seal ring:
Grease (G2-LI)
When installing, be careful not to
damage the seal ring.
vi) Using eyebolts 4 , install housing and
piston assembly (10).
2 Mounting bolt:
3 Mounting bolt:
110.35 12.25Nm
{11.25 1.25kgm}
30-72 D375A-5
c c
vii) Using push tool, press fit bearing (15). 3) Tighten mounting bolts (3).
viii) Install plate (8) and secure with snap ring Check that drain plug (2) has been tight-
3 Mounting bolt:
(7). ened.
ix) Install input shaft (6).
2 Mounting bolt:
3 Drain plug:
53.9 4.9Nm {5.5 0.5kgm}
3 Mounting bolt:
11.25 1.45Nm {1.15 0.15kgm}
277.0 31.9Nm
{28.5 3.25kgm} 11. Torque converter valve assembly
x) Install 2 seal rings (5). Install torque converter valve assembly (1).
Tighten the mounting bolts equally to prevent
3 Mounting bolt:
unbalanced tightening.
49.0 4.9Nm {5.0 0.5kgm}
2) Using eyebolts 1 , install lock-up clutch and

drive case assembly (4).
Align the tturbine oil groove (marked a)
and drain plug (2) when installing.
D375A-5 30-73
c c
DISASSEMBLY AND ASSEMBLY OF TORQFLOW
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF TORQFLOW
TRANSMISSION ASSEMBLY
SPECIAL TOOLS 2. Control valve assembly
1) Remove tube.
bol Part No. Part name cessity Q'ty model h 2) Remove cover (2), then remove sleeve in-
790-415-1011 Bracket 1 side.
Repair
1
750-501-5000 stand 1
(100V)
2 791-615-1130 Push tool 1
Ring as-
791-615-1200 1
sembly
791-615-1210 Ring 1
3
135-A90-1150 Bolt 1
D 01580-01008 Nut 1
01641-51032 Washer 2
Ring as-
791-615-1101 1
sembly
791-615-1111 Ring 1
4
135-A90-1150 Bolt 1
01580-01008 Nut 1
4) Remove control valve assembly (4) as one
01641-51032 Washer 2
unit with seat.
Oil leak
5 799-301-1600
tester
1 Remove the 4 mounting bolts marked *.
Do not remove any other bolts.
DISASSEMBLY
1. Preparatory work
Set transmission assembly (1) to tool D1.
3. Lubrication valve assembly

Remove lubrication valve assembly (5).
30-74 D375A-5
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4. Front case 3) Using eyebolts 2 , lift off input shaft and No.
1) Set input shaft end at top and stand trans- 1 carrier assembly (8).
mission assembly. 4) Turn over input shaft and No. 1 carrier as-
2) Using eyebolts, remove front case (6). sembly, and remove seal ring (9).
5) Disassemble input shaft and No. 1 carrier

5. Input shaft, No. 1 carrier assembly assembly as follows.
1) Remove 17 tie bolts (7). i) Remove snap ring (10), then remove No.
2) Using forcing screws 1 , disconnect input 2 sun gear (11).
shaft and No. 1 carrier assembly (8). ii) Remove spacer and bearing assembly
Tighten the forcing screws uniformly, and (12).
be careful not to twist the input shaft and
No. 1 carrier assembly.
D375A-5 30-75
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iii) Using push tool, remove ball bearings vi) Using eyebolts 3 , sling housing and No.
(13) and (14) from spacer (15). 1 carrier assembly (18) and set on block.
Put the tip of the input shaft in con-
tact with the ground and separate the
housing and No. 1 carrier assembly
from the block by approx. 20 mm.
vii) Remove snap ring (19).
iv) Remove No. 1 sun gear (16).

v) Remove spacer (17).
viii) Tap housing with plastic hammer and

drop housing and No. 1 carrier assembly
(20) on block to remove input shaft as-
sembly (21).
ix) Using press, remove ball bearing (22)
from input shaft (23).
30-76 D375A-5
c c
x) Remove snap ring (24) from housing and xiv) Using push tool 5 , remove ball bearing
No. 1 carrier assembly (20). (28) from housing.
xi) Set housing and No. 1 carrier assembly xv) Remove spacer (29) from No. 1 carrier
on block, then using push tool 4 , re- assembly (26).
move housing (25) from No. 1 carrier as-
sembly (26).
xvi) Turn over No. 1 carrier assembly, re-

move snap ring (30), then remove collar
xii) Remove snap ring (27) from housing (31).
(25). xvii) Turn over No. 1 carrier assembly, pull out
xiii) Turn over housing and set on block, then shaft (33) partially from carrier (32), re-
remove seal ring (146). move ball (34), then remove shaft (33).
Keep the ball in a safe place and be
careful not to lose it.
D375A-5 30-77
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xviii) Remove gear (34) and thrust washer 7. No. 1 clutch ring gear
(35) from carrier. Remove No. 1 clutch ring gear (41).
xix) Remove needle bearing (36) from gear
(34).
8. No. 1 housing
1) Using eyebolts 5 , remove No. 1 housing
6. No. 1 discs, plates, springs assembly (42).
1) Remove 12 springs (37).
2) Remove 6 discs (38), 6 springs (40), and 5
plates (39) in turn, then remove guide plate.
Store the discs and plates in a flat place
to prevent them from becoming de-
formed.
30-78 D375A-5
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2) Disassemble No. 1 housing assembly as fol- 9. No. 2 discs, plates, springs

lows. 1) Remove 12 springs (47).
i) Remove piston (43) from housing (44). 2) Remove 6 discs (48), 5 plates (49), and 6
springs (50) in turn.
formed.
ii) Remove seal ring (45) from piston (43).

iii) Remove seal ring (46) from housing
(44).
3) Remove 17 sleeves (51).
D375A-5 30-79
c c
4) Remove seal ring (52) from No. 2 and No. 3 2) Disassemble No. 1 ring gear and No. 2, No.
carrier. 3 carrier assembly as follows.
5) Remove 6 torque pins (53). i) Remove seal rings (57) and (58).
6) Remove 12 guide pins (54). ii) Remove ring (59).
10. No. 1 ring gear, No. 2, No. 3 carrier assembly iii) Pull out shaft (61) partially from carrier
1) Using eyebolts 6 , lift off No. 1 ring gear and (60), remove ball (62), then remove shaft
No. 2, No. 3 carrier assembly (55). (61).
Keep the ball in a safe place and be
careful not to lose it.
30-80 D375A-5
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iv) Remove gear (63) and thrust washer 12. No. 2, No. 3 housing assembly
(64) from carrier. 1) Using eyebolts 7 , remove No. 2 and No. 3
v) Remove needle bearing (65) from gear housing assemblies (68) as one unit with top
(63). and bottom pistons.
No. 2, No. 3 carrier (60) and No. 1 Tie the bottom piston with wire to prevent
ring gear (66) are secured by an in- it from falling out.
ternal embedded ring, so they can-
not be disassembled.
2) Disassemble No. 2 and No. 3 housing as-

semblies as follows.
11. No. 2 ring gear i) Remove pistons (69) and (70) from
Remove No. 2 ring gear (67). housing (71).
D375A-5 30-81
c c
ii) Remove seal ring (72) from piston (69). 13. No. 3 discs, plates, springs
iii) Remove seal ring (73) from piston (70). 1) Remove guide plate, then remove 12 springs
(76).
2) Remove 4 discs (77), 4 springs (79), and 3
plates (78) in turn.
formed.
iv) Remove seal rings (74) and (75) from

housing (71).
14. No. 3, No. 4 clutch plate

Using eyebolts 8 , remove plate (80).
30-82 D375A-5
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15. No. 4 discs, plates, springs 2) Disassemble No. 4 housing assembly as fol-
1) Remove 3 discs (81), 3 springs (83), and 2 lows.
plates (82) in turn, then remove guide plate i) Remove piston (86) from housing (87).
(147).
formed.
2) Remove 6 torque pins (84).
ii) Remove seal ring (88) from piston (86).

iii) Remove seal ring (89) from housing
(87).
16. No. 4 housing assembly

1) Using eyebolts 9 , remove housing assem-
bly (85) as one unit with piston.
D375A-5 30-83
c c
17. No. 3 ring gear, No. 4 carrier, No. 5 clutch as- 5) Set No. 4 carrier end at top and stand trans-
sembly mission assembly.
1) Rotate tool D1, and set transmission facing 6) Using eyebolts 0 , sling No. 3 ring gear and
sideways. No. 4 carrier, No. 5 clutch assembly (95),
2) Remove plate (90). then tap bottom part of output shaft with a
3) Remove snap ring (91), then remove plate copper hammer and remove.
(92).
7) Disassemble No. 3 ring gear and No. 4 car-

4) Remove snap ring (93), then remove spacer rier, No. 5 clutch assembly as follows.
(94). i) Remove 2 seal rings (56) from housing.
ii) Remove seal ring (118) from input shaft.
30-84 D375A-5
c c
iii) Remove snap ring (96), then remove No. vi) Using eyebolts A , remove No. 3 ring
3 sun gear (97). gear and No. 4 carrier assembly (101) as
iv) Remove collar and bearing assembly one unit with No. 4 sun gear.
(98). vii) Remove No. 4 sun gear (102) from No. 3
ring gear and No. 4 carrier assembly
(101).
v) Using push tool, remove ball bearing

(99) from collar (100).
viii) Turn over No. 3 ring gear and No. 4 car-
rier assembly and remove hub (103).
ix) Remove seal rings (104) and (105) from
hub (103).
D375A-5 30-85
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x) Remove snap ring (106), then remove xv) Turn over carrier (109) and remove snap
collar (107) from No. 3 ring gear and No. ring (115).
4 carrier assembly (101). xvi) Turn over carrier, then using push tool,
xi) Remove seal ring (108) from collar remove ball bearing (116).
(107). No. 3 ring gear (117) and No. 4 carri-
er (109) are secured by an internal
embedded ring, so they cannot be
disassembled.
xii) Pull out shaft (110) partially from carrier

(109), remove ball (111), then remove
shaft (110).
Keep the ball in a safe place and be xvii) Set output end of output shaft at top, and
careful not to lose it. put output shaft and housing assembly
xiii) Remove gear (112) and thrust washer (118) on top of block.
(113) from carrier. xviii) Using forcing screws, disconnect input
xiv) Remove needle bearing (114) from gear shaft and housing assembly (118), then
(112). use eyebolts B to remove.
Tighten the forcing screws uniformly
and disconnect the output shaft and
housing.
30-86 D375A-5
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xix) Remove 6 discs (119), 6 springs (121), xxi) Set housing assembly (123) to press,
and 5 plates (120) from housing (122) in then using tool D2, tighten spring, and
turn. remove snap ring (125).
Store the discs and plates in a flat Operate the press slowly and push
place to prevent them from becom- up the springs uniformly.
ing deformed. xxii) Remove retainer (126) and spring (127)
from housing (128).
xx) Set output shaft and housing assembly

to press, then using push tool C , re- xxiii) Remove piston (129) from housing, then
move housing assembly (123) from out- remove seal ring (130) from piston (129).
put shaft assembly (124).
To prevent the housing assembly
from falling out, set block D under
the housing assembly.
D375A-5 30-87
c c
xxiv)Remove seal ring (131) from housing 18. Rear case assembly
(128). 1) Remove collar (138) from rear case (139).
xxv) Remove snap ring (132) from housing.
xxvi)Using push tool, remove ball bearing
(133) from housing.
2) Remove seal ring (140) from collar (138).
xxvii) Remove snap ring (134), then remove

needle bearing (135) from input shaft
(124).
xxviii)Turn over output shaft, remove snap
ring (136), then remove roller bearing
(137) from output shaft.
3) Turn over rear case, remove snap ring (141),

then remove ball bearing (142).
30-88 D375A-5
c c
ASSEMBLY 2) Turn over rear case (139) and install to collar

(138).
Wash all parts clean, dry them (especially the oil
Be careful not to get the seal ring caught.
holes), check that there are no scratches or dirt,
then coat the sliding parts with engine oil before
assembling.
Coat each spline portion with grease (G2-LI).
1. Preparatory work
Set rear case (139) to tool D1.
3. Output shaft assembly

1) Using push tool, press fit needle bearing
(135) to output shaft (124), then secure with
snap ring (134).
2) Using push tool, press fit ball bearing (142)

to output shaft.
2. Rear case assembly
1) Install seal ring (149) to collar (138).
Install the seal ring in the direction shown
in the diagram below.
2 Seal ring: Grease (G2-LI)
D375A-5 30-89
c c
3) Install spacer (94) and secure with snap ring 8) Install plate (92) and secure with snap ring
(93). (91).
2 Mounting bolt:
3 Mounting bolt:
66.15 7.35Nm {6.75 0.75kgm}

5) Install seal ring (118).
4. No. 3 ring gear, No. 4 carrier, No. 5 clutch as-

sembly
1) Assemble No. 3 ring gear, No. 4 carrier, and
No. 5 clutch assembly as follows.
When No. 3 ring gear, No. 4 carrier is
supplied as an individual part.
Using tool D3, compress ring (143), then
set No. 3 ring gear (117) on top of No. 4
carrier (109), and tap No. 3 ring gear
6) Turn over rear case (139) and set output (117) with a plastic hammer to assemble.
shaft assembly (124) in position, then using Check that the ring is fitted securely
push tool, press fit bearing portion. in the groove.
30-90 D375A-5
c c
i) Using push tool, press fit ball bearing v) Install seal ring (108) to collar (107).
(116) to carrier (109), and secure with 2 Seal ring: Grease (G2-LI)
snap ring (115).
vi) Align collar (107) with dowel pin, then in-
stall No. 3 ring gear and No. 4 carrier as-
sembly (101) and secure with snap ring
(106).
Knock in the dowel pin portion with a
plastic hammer until there is no
clearance at the mating surface.
ii) Turn over carrier.

iii) Assemble needle bearing (114) to gear
(112), then fit thrust washers (113) to
both ends and set carrier in position.
iv) Fit ball (111) and install shaft (110) to car-
rier.
Check that the gear rotates smooth-
ly. vii) Install seal rings (105) and (104) to hub
(103).
viii) Install hub (103) to No. 3 ring gear and
No. 4 carrier assembly (101).
Be careful not to get the seal ring
caught.
D375A-5 30-91
c c
ix) Using eyebolts E , install housing (122) xi) Using push tool, press fit ball bearing
to No. 3 ring gear and No. 4 carrier as- (133) to housing (128), and secure with
sembly. snap ring (132).
x) Install 6 discs (119), 6 springs (121), and xii) Install seal ring (131) to housing.
5 plates (120) in turn. Install the seal ring in the direction
shown in the diagram below.
2 Seal ring:
Grease (G2-LI)
30-92 D375A-5
c c
xiii) Install seal ring (130) to piston (129). xvii) Using eyebolts F , install housing as-
Install the seal ring in the direction sembly (123).
shown in the diagram below. 2 Mounting bolt:
3 Mounting bolt:
xiv) Install piston (129) to housing (128).
Be careful not to get the seal ring 176.4 19.6Nm {18 2kgm}
caught.
xviii) Install 2 seal rings (56) to housing.
xv) Set spring (127) and retainer (126) to

housing.
Set the 3 springs as shown in the di- 2) Turn over rear case (139), and No. 3 ring
agram below. gear, No. 4 carrier, and No. 5 clutch assem-
xvi) Set housing assembly (123) to press, bly (95).
and using tool D2, compress spring, then 3) Using eyebolts 0 , set No. 3 ring gear, No. 4
install snap ring (125). carrier assembly, and No. 5 clutch assembly
Spring installed load: (95) to rear case and output shaft.
2,175N {222kg} Be careful not to get the seal ring caught.
D375A-5 30-93
c c
4) Using push tool G , press fit bearing portion 6. No. 3 sun gear
of No. 3 ring gear, No. 4 carrier, and No. 5 1) Using push tool, press fit ball bearing (99) to
clutch assembly (95) to output shaft. collar (100).
5. No. 4 sun gear 2) Install collar and bearing assembly (98).

Install No. 4 sun gear (102). Install with the flanged side of the collar
at the top.
3) Install No. 3 sun gear (97) and secure with
snap ring (96).
30-94 D375A-5
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7. No. 4 housing assembly 4) Using eyebolts 9 , align dowel pin and install
1) Install seal ring (89) to housing (87). No. 4 housing assembly (85).
Install the seal ring in the direction shown Knock in the dowel pin portion with a
in the diagram below. plastic hammer until there is no clear-
2 Seal ring: Grease (G2-LI) ance at the mating surface.
2) Install seal ring (88) to piston (86).
8. No. 4 discs, plates, springs

1) Install 6 torque pins (84).
Length of torque pin: 162mm
2) Fit guide plate (147), and install 3 discs (81),
3 springs (83), and 2 plates (82) in turn.
3) Install piston (86) to housing (87).
D375A-5 30-95
c c
9. No. 3, No. 4 clutch plate 11. No. 1 ring gear, No. 3 housing assembly
Using eyebolts 8 , align plate (80) with dowel 1) Install seal rings (74) and (75) to housing
pin and install. (71).
Knock in the dowel pin portion with a plastic Install the seal ring in the direction shown
hammer until there is no clearance at the in the diagram below.
mating surface. 2 Seal ring: Grease (G2-LI)

1) Install 4 discs (77), 3 springs (79), and 3 2) Install seal ring (73) to piston (70).
plates (78) in turn. Install the seal ring in the direction shown
2) Install 12 guide pins (54).
Length of guide pin: 360mm
3) Fit 12 springs (76) and install guide plate. 3) Install seal ring (72) to piston (69).
Free length of spring: 97mm Install the seal ring in the direction shown
30-96 D375A-5
c c
4) Install pistons (70) and (69) to housing (71). 12. No. 2 ring gear
Be careful not to get the seal ring caught. Install ring gear (67).
Tie piston (70) with thin wire to prevent it
from falling out when the housing is
raised.
13. No. 1 ring gear, No. 2, No. 3 carrier assembly

1) Assemble No. 1 ring gear and No. 2, No. 3
carrier assembly as follows.
5) Align dowel pin and install housing assembly When No. 1 ring gear and No. 2, No. 3
(68). carrier is supplied as an individual part.
Knock in the dowel pin portion with a Using tool D4, compress ring (144), then
plastic hammer until there is no clear- set No. 1 ring gear (66) on top of No. 2,
ance at the mating surface. No. 3 carrier (60), and tap No. 1 ring gear
(66) with a plastic hammer to assemble.
Check that the ring is fitted securely
in the groove.
D375A-5 30-97
c c
i) Assemble needle bearing (65) to gear iii) Install ring (59) to carrier.
(63), then fit thrust washers (64) to both Check that the ring is fitted securely
sides and set to carrier (60). in the groove.
iv) Install seal rings (58) and (57) to carrier.
Center seal ring (58) with the carrier
and secure in position with grease
(G2-LI).
ii) Fit ball (62) and install shaft (61) to carri-

er.
Check that the gear rotates smooth-
ly.
2) Using eyebolts 6 , install No. 1 ring gear and

No. 2, No. 3 carrier assembly (55).
30-98 D375A-5
c c
3) Using push tool H , press fit bearing portion 3) Install 17 sleeves (51).
of No. 1 ring gear and No. 2, No. 3 carrier as-
sembly (55).
Set the sleeve with the slit at the bottom

and install it in the bolt hole marked q.
1) Install 6 torque pins (53).
Length of torque pin:199mm
2) Install seal ring (52) to No. 2, No. 3 carrier.
4) Install 12 springs (47).

Free length of spring: 70mm
5) Install 6 discs (48), 6 springs (50), and 5
Align the notches in the oil groover on
the outside circumference of the discs.
D375A-5 30-99
c c
15. No. 1 housing assembly 4) Using eyebolts 5 , align dowel pin and install
1) Install seal ring (46) to housing (44). housing (42).
Install the seal ring in the direction shown Check that the spring is fitted securely in
in the diagram below. the hole in the housing.
2 Seal ring: Grease (G2-LI) Knock in the dowel pin portion with a
plastic hammer until there is no clear-
2) Install seal ring (45) to piston (43). ance at the mating surface.
16. No. 1 clutch ring gear

Install No. 1 clutch ring gear (41).
3) Install piston (43) to housing (44).

30-100 D375A-5
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17. No. 1 discs, plates, springs ii) Fit ball (34) and install shaft (33) to carri-
1) Fit guide plate and install 12 springs (37). er.
Free length of spring: 66mm iii) Install collar (31) to carrier and secure
2) Install 6 discs (38), 6 springs (40), and 5 with snap ring (30).
iv) Using push tool I , press fit ball bearing

18. Input shaft, No. 1 carrier assembly (28) to plate (25), then secure with snap
1) Assemble input shaft and No. 1 carrier as- ring (27).
sembly as follows.
i) Assemble needle bearing (36) to gear
(34), then fit thrust washers (35) to both
ends and set to carrier (32).
D375A-5 30-101
c c
v) Turn over plate and install seal ring viii) Using press, install ball bearing (22) to
(146). input shaft assembly (23).
Align the center of the plate and use ix) Set housing and No. 1 carrier assembly
grease (G2-LI) to hold the seal ring in (20) to block.
position. x) Using eyebolts 3 , install input shaft as-
vi) Install spacer (29) to No. 1 carrier assembly (18) to housing and No. 1 carrier
sembly (26). assembly.
vii) Set plate (25) to No. 1 carrier (26), then xi) Install snap ring (19).
using push tool J , press fit bearing por-
tion and secure with snap ring (24).
30-102 D375A-5
c c
xii) Set input shaft and No. 1 carrier assem- xv) Install spacer and bearing assembly
bly facing sideways, and install spacer (12).
(17). Install the small diameter bearing
xiii) Install No. 1 sun gear (16). facing the No. 1 sun gear.
xvi) Install No. 2 sun gear (11) and secure
with snap ring (10).
xiv) Using push tool, press fit ball bearings

(13) and (14) to spacer (15).
xvii) Install seal ring (9) to No. 1 carrier.
Align with the center of the carrier
and use grease (G2-LI) to hold the
seal ring in position.
2) Turn over input shaft and No. 1 carrier as-
sembly (8), then using eyebolts 2 , set to
No. 1 housing.
Check that the tip of the input shaft does
not interfere with the output shaft bear-
ing, and lower slowly.
D375A-5 30-103
c c
3) Tighten 4 tie bolts (12) uniformly on diago- 20. Front case

nally opposite sides. Fit O-ring and use eyebolts to install front case
3 Tie bolt:
4) Tighten remaining bolts (12). (6).
Check that the front case does not interfere
259.7 14.7Nm {26.5 1.5kgm} and lower gradually.
21. Output shaft bearing

19. Air check 1) Set output shaft end at top and stand trans-
Using tool D5, check stroke of each clutch pis- mission assembly.
ton. 2) Using push tool, press fit roller bearing (137)
Air pressure: 490-588KPa {5-6kg/cm2} to output shaft, and secure with snap ring
Standard stroke of piston (136).
Be careful not to hit or damage the bear-
Piston No. 1 No. 2 No. 3 No. 4 No. 5
ing cage or roller.
Stroke (mm) 6.7 7.0 5.6 4.7 7.0 Use a push tool of a size that pushes
only the outer race.
30-104 D375A-5
c c
22. Lubrication valve assembly 2) Install cover (3).

Install lubrication valve assembly (5). Remove plug (145) and check that the
linkage pin on the inside of the cover is
meshed with the yoke of the control
valve spool.
After checking, install plug (145).
3) Fit O-ring and install sleeve, then install cov-
er (2).
4) Install tube.
23. Control valve assembly

1) Install control valve assembly (4) as one unit
3 Mounting bolt:
with seat.
49.0 4.9Nm {5.0 0.5kgm}
D375A-5 30-105
c c
DISASSEMBLY AND ASSEMBLY OF STEERING
DISASSEMBLY AND ASSEMBLY CASE ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF STEERING
CASE ASSEMBLY
DISASSEMBLY iii) Using forcing screws 1 , remove sleeve
(7).
1. Steering control valve assembly
iv) Using puller 2 , pull out bearing inner
1) Remove steering control valve assembly (1).
4 Steering control valve assembly:
race (8) from sleeve.
25kg
2) Remove seat (2).
2. Clutch, brake assembly

1) Using eyebolts, sling clutch and brake as-
sembly, then remove mounting bolts, and re-
move clutch and brake assembly (3).
Remove the clutch and brake assembly
on the opposite side in the same way.
When pulling out the clutch and brake
assembly, be careful not to damage the
discs and plates.
v) Turn over clutch and brake assembly,

then using eyebolts 3 , disconnect
clutch assembly (9) and brake assembly
(10).
2) Disconnect clutch and brake assembly as

follows.
i) Remove plate (4), then remove collar
(5).
ii) Remove plate (6).
30-106 D375A-5
c c
3) Disassemble clutch assembly as follows. vi) Remove outer race (18) from plate.
i) Remove stopper (11). vii) Remove bearing and cage assembly
ii) Remove discs (12), springs (13), and (19).
ing deformed.
viii) Remove plate (21) and nut (22) from

cage (20).
ix) Remove bearing and inner race (23),
spacers (24) and (25), and bearing outer
iii) Remove torque pin (15). race (26).
iv) Using eyebolts, remove clutch hub (16).
v) Using forcing screws 4 , remove plate
(17).
D375A-5 30-107
c c
x) Using eyebolts, remove clutch cage (27). xvi) Using eyebolts 6 , remove brake hub
xi) Remove seal ring (28) from clutch cage. (33).
xii) Remove piston (29). xvii) Remove bearing (34) from brake hub.
xiii) Remove seal ring (30) from piston.
4) Disassemble brake assembly as follows.

xiv) Remove bearing outer race (31) from i) Remove stopper (35).
clutch cage. ii) Remove discs (36), springs (37), and
xv) Remove belleville spring (32). plates (38) in turn.
ing deformed.
30-108 D375A-5
c c
iii) Using eyebolts 7 , remove brake cage 3. Shafts

(39). Remove left and right shafts (46).
iv) Remove bearing outer race (40) and
4. Lubrication tube
seal ring (41) from brake cage.
Remove lubrication tube (47).
v) Remove torque pin (42).

5. Pipes
vi) Remove piston (43).
1) Remove left and right pipes (48).
vii) Remove seal ring (44) from piston.
2) Remove pipe (49).
viii) Remove belleville spring (45).
D375A-5 30-109
c c
6. Transfer, gear housing assembly v) Using puller 0 , remove both bearing in-
1) Fit guide bolt 8 , raise with eyebolts 9 , then ner races (55).
remove housing assembly (50). vi) Remove lubrication tube (56).
2) Disassemble transfer gear housing assem-
bly as follows.
i) Set transfer gear housing assembly on
block.
ii) Remove lubrication tube (51).
vii) Using eyebolts A , remove pinion hous-

ing assembly (57).
Check the number and thickness of
the shims, and keep in a safe place.
viii) Using forcing screws, remove cover
iii) Using push tool, remove bearing (53). (58).
iv) Remove drive gear (54). ix) Remove holder (59).
30-110 D375A-5
c c
x) Push pinion shaft with press, then pull xv) Remove bearing (70) from case.
out pinion gear (60). xvi) Remove bearing (71) from case.
xi) Remove holder, then using puller B , re-
move bearing inner race (61) from pinion
gear (60).
xii) Remove cage and bearing assembly
(62).
7. Right cage
1) Turn over steering case so that right cage is
at top.
2) Remove cage and bearing assembly (72).
xiii) Remove collar (63) from gear (64). shims, and keep in a safe place.
xiv) Using push tool C , remove bearing out- 3) Remove bearing outer race from cage and
er races (65) and (69), bearing inner rac- bearing assembly.
es (66) and (67), and collar (68). 4) Using eyebolts D , remove cage (73).
D375A-5 30-111
c c
8. Bevel gear, shaft assembly 2) Remove bearing outer race (80) from cage
1) Using eyebolts, remove bevel gear and shaft and bearing assembly.
assembly.
2) Disassemble bevel gear and shaft assembly
as follows.
i) Pull out reamer bolt, then remove bevel
gear (75) from shaft (76).
ASSEMBLY
Coat the rotating portion of the bearing with en-
ii) Using puller E , remove bearing inner gine oil and rotate it several times.
races (77) and (78) from shaft. Coat the sliding parts with engine oil, then as-
semble.
9. Left cage Check that the snap ring is fitted securely in the
1) Turn over steering case so that left side of groove.
steering case is at top, then remove cage
and bearing assembly (79). 1. Left cage
Check the number and thickness of the 1) Using push tool, press fit bearing outer race
shims, and keep in a safe place. (80).
2) Assemble shims, and install cage and bear-
ing assembly (79).
3 Cage,
Standard shim thickness: 2mm
bearing assembly mounting
bolt: 176.4 19.6Nm {18 2kgm}
30-112 D375A-5
c c
2. Bevel gear, shaft assembly 2) Assemble shim and install cage and bearing
1) Assemble bevel gear and shaft assembly as assembly (72).
3 Cage,
follows. Standard shim thickness: 2mm
i) Using push tool F , press fit bearing in- bearing assembly mounting
ner races (78) and (77). bolt:
ii) ii) Set bevel gear (75) to shaft (76) and 176.4 19.6Nm {18 2kgm}
3 Reamer bolt:
tighten reamer bolt.
274.4 29.4Nm {28 3kgm}

2) Using eyebolts, install bevel gear and shaft
assembly (74).
4. Adjusting preload
Adjust shim thickness at cage to adjust rotating
force of bevel gear shaft.
Rotate the bevel gear 2 - 3 times and put the
push-pull scale in contact with the tip of the
3. Right cage tooth.
1) Using eyebolts D , install cage (73). Rotating force (with bevel gear not meshed):
4.9 - 5.88 N {0.5 - 0.6 kg}
(Rotating torque: 23.52 - 28.42 Nm
{2.4 - 2.9 kgm})
D375A-5 30-113
c c
5. Transfer, gear housing assembly vi) Using push tool H , press fit inner race
1) Assemble transfer and gear housing assem- (61) to pinion gear (60).
3
bly as follows. vii) Install holder.
i) Using push tool F , press fit transfer Holder mounting bolt:
gear bearing (71) to case. 276.85 31.85Nm {28.25 3.25kgm}
ii) Using push tool G , press fit pinion bear-
ing (70) to case. viii) Install gear (64) and collar (63) to pinion
gear.
iii) Using push tool, press fit bearing outer

ix) Using push tool I , press fit cage and
race (69) to cage.
bearing assembly (62).
iv) Assemble bearing inner races (67) and
3
x) Install holder (59).
(66) and collar (68).
v) Using push tool, press fit bearing outer Holder mounting bolt:
race (65). 276.85 31.85Nm {28.25 3.25kgm}
30-114 D375A-5
c c
xi) Tighten mounting bolts of cover (58) in xiii) Tighten mounting bolts of cover (58) in
3 Mounting bolt:
the order given in diagram and to tight- order given in diagram.
ening torque given below, and temporari-
3 Mounting bolt: 49Nm {5kgm}

ly assemble cover (58).
66.15 7.35Nm {6.75 0.75kgm}
xiv) Assemble shims to pinion housing as-

xii) Check clearance A between cover and sembly (57), then use eyebolts A to in-
cage, and check that it is as given below. stall.
Clearance A : 0.48 0.27mm Standard shim thickness: 2mm
Check that the variation around the xv) Install lubrication tube (56).
whole circumference is less than
0.05 mm and that the bearing is com-
pletely press fitted and is not at an
angle.
D375A-5 30-115
c c
xvi) Using push tool J , press fit bearing in- 2) Fit guide bolt 8 to steering case, then using
ner race (55) to both sides of drive gear. eyebolts 9 , install transfer and gear hous-
3 Mounting bolt:
xvii) Set drive gear (54) to case. ing assembly (50).
276.85 31.85Nm
{28.25 3.25kgm}
6. Lubrication tube
Install lubrication tube (47).
xviii) Using push tool K , press fit bearing

(53).
xix) Install bearing assembly (52) to case.
xx) Install lubrication tube (51) as one unit
with block.
7. Adjusting backlash, tooth contact

1) Adjusting backlash
Testing
Put the probe of dial gauge L in contact with
the tooth face at the tip of the bevel gear, fix
the bevel pinion in position, and read the
scale when the bevel gear is moved back-
ward and forward.
Standard value of backlash:
0.3-0.4mm
Measure at 3 places on diametrically op-
posite sides.
30-116 D375A-5
c c
Adjusting 2) Adjusting tooth contact

If the result of the measurement shows that Testing
the backlash is not correct, adjust as follows. i) Coat the tooth face of the bevel pinion
i) When backlash is too small: lightly with red lead (minium), then rotate
Adjust the shim thickness at the bevel the bevel gear forward and backward
pinion end and move the bevel pinion in and inspect the pattern left on the teeth.
direction A.
Or, adjust the shim thickness at the bear-
ing cage of the bevel gear shaft and
move the bevel gear in direction B.
ii)
The standard value for the tooth contact
is as follows
(from small end of pinion)
a) Width of tooth contact: 30 - 75 %
ii)
When backlash is too large: b) Center of tooth contact: 25 - 50 %
Adjust the shim thickness at the bevel c) Position of tooth contact: 25 - 50 %
pinion end and move the bevel pinion in When preload is applied to the taper roll-
direction C. er bearing supporting the bevel gear, it
Or, adjust the shim thickness at the bear- should be within the standard value with
ing cage of the bevel gear shaft and only the bevel pinion meshed and under
move the bevel gear in direction D. no load.
When adjusting the shim thickness at the The tooth contact should be at the center
bearing cage of the bevel gear shaft, do of the tooth height and there should be
not change the preload of the bearing. no strong contact at the root of the gear
Adjust by moving shims from one side to tooth.
the opposite side. Always keep the In addition, the contact should be more
same total thickness of shims. or less the same for forward and reverse.
D375A-5 30-117
c c
Adjusting ii)
When bevel pinion is too close to center
If the result of the inspection shows that the of bevel gear:
correct tooth contact is not being obtained, Contact is at the big end of the convex
adjust again as follows. tooth face of the bevel gear and the small
i) When bevel pinion is too far from center end of the concave tooth face.
line of bevel gear: [Adjusting]
Contact is at the small end of the convex Follow the same procedure as in Step i)
tooth face of the bevel gear and at the but move the bevel pinion in direction A
big end of the concave tooth face. and the bevel gear in direction B.
[Adjusting] When adjusting the movement in and out
Adjust the shim thickness at the bevel of the bevel gear, do not change the pre-
pinion end and move the bevel pinion in load of the bearing. Adjust by moving
direction A. shims from one side to the opposite side.
Or, adjust the shim thickness at the bear- Always keep the same total thickness of
ing cage of the bevel gear shaft and shims.
move the bevel gear in direction B.
After adjusting, check the tooth contact
pattern and backlash again.
8. Pipes
1) Install pipe (49).
2) Install left and right pipes (48).
30-118 D375A-5
c c
3
9. Clutch, brake assembly vi) Using eyebolts 7 install brake cage (39).
1) Assemble brake assembly as follows. Mounting bolt:
i) Install belleville spring (45). 110.25 12.25Nm {11.25 1.25kgm}
Install the belleville springs back to
back. vii) Install plates (38), springs (37), and
ii) Install seal ring (44) to piston (43). discs (36).
Check that there is no dirt or damage
to the mating faces of the discs and
plates, and coat thinly with engine oil
before assembling.
iii) Install piston (43).

iv) Install torque pin (42).
v) Using push tool, install seal ring (41) and
bearing outer race (40) to brake cage.
3
viii) Install stopper (35).
Mounting bolt:
276.85 31.85Nm {28.25 3.25kgm}
2) Assemble clutch assembly as follows.
i) Using push tool, install bearing (34) to
brake hub.
D375A-5 30-119
c c
ii) Using eyebolts 6 , install brake hub (33) ix) Install bearing inner race (26), spacers
to clutch housing. (25) and (24), and bearing inner race
iii) Install belleville spring (32). (23) to cage (20).
Install the belleville springs back to x) Tighten nut (22), and install plate (21).
back. Use a push tool, hold the cage in a
press, and use a hook wrench to
tighten the nut.
iv) Install outer race (31) to clutch cage.

v) Install seal ring (30) to piston.
vi) Install piston (29).
vii) Install seal ring (28) to clutch cage.

viii) Using eyebolts, install clutch cage (27) to
housing.
30-120 D375A-5
c c
xi) Install bearing and cage assembly (19). xvii) Install plates (14), springs (13), and
xii) Using push tool, install outer race (18) to discs (12) in turn.
plate. Check that there is no dirt or damage
to the mating faces of the discs and
plates, and coat thinly with engine oil
before assembling.
3
xviii) Install stopper (11).
Mounting bolt:
276.85 31.85Nm
{28.25 3.25kgm}
3
xiii) Install plate (17).
Mounting bolt:
110.25 12.25Nm {11.25 1.2kgm}
xiv) Set guide bolt to housing.
xv) Using eyebolts, install clutch hub (16).
Check that the rotating force of the
housing is less than 29.4N {3 kg} and
that it rotates smoothly. 3) Connect clutch and brake assembly as fol-
xvi) Install torque pin (15). lows.
i) Using eyebolts C , install brake assem-
bly (10) to clutch assembly (9).
ii) Using push tool D , press fit bearing in-
ner race (8) to sleeve.
D375A-5 30-121
c c
iii) Set sleeve (7) to clutch and brake as- 10. Shafts
sembly. Install left and right shafts (46).
If the bevel gear is locked in position and it is
difficult to insert the shaft, release the steer-
ing brake before inserting.
Remove plug (81), then remove mounting
bolt (82), and screw the mounting bolt into
the plug hole to compress the clutch spring
and release the brake.
3
iv) Install plate (6).
Mounting bolt:
110.25 12.25Nm
{11.25 1.25kgm}
v) Fit collar (5) and install plate (4).
4) Using eyebolts, install clutch and brake as-
3 Mounting bolt:
sembly.
276.85 31.85Nm 1) Install seat (2).
{28.25 3.25kgm} 2) Raise steering control valve assembly (1)
3 Mounting bolt:
and install.
49.0 4.9Nm
{5.0 0.5kgm}
30-122 D375A-5
c c
REMOVAL AND INSTALLATION OF POWER TRAIN,
DISASSEMBLY AND ASSEMBLY LUBRICATION PUMP ASSEMBLY
REMOVAL AND
INSTALLATION OF POWER
TRAIN, LUBRICATION PUMP
ASSEMBLY
REMOVAL
1. Remove power train underguard (front).
4 Power train underguard (front): 280kg
3. Disconnect tube (2).

4. Lift off power train and lubrication pump assem-
bly (3).
4 Power train, lubrication pump assembly:
50kg
INSTALLATION
moval.
D375A-5 30-123
c c
REMOVAL AND INSTALLATION OF SCAVENGING
DISASSEMBLY AND ASSEMBLY PUMP ASSEMBLY
REMOVAL AND INSTALLA-

TION OF SCAVENGING PUMP
ASSEMBLY
REMOVAL
1. Remove power train underguard (front).
4 Power train underguard (front): 280kg
2. Disconnect inlet tube (1).

The oil in the piping will leak out, so use a
container to catch it.
3. Disconnect outlet tube (2).
4. Remove scavenging pump assembly (3).
INSTALLATION
moval.
Refilling with oil (power train case)

Add oil through oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.
30-124 D375A-5
c c
REMOVAL AND INSTALLATION OF FINAL DRIVE
DISASSEMBLY AND ASSEMBLY ASSEMBLY
REMOVAL AND
INSTALLATION OF FINAL
DRIVE ASSEMBLY
SPECIAL TOOLS 5. Remove 3 bolts of final drive, and install tool J1.
6. Sling final drive assembly (5), then remove
q2
bol Part No. Part name cessity Q'ty model h mounting bolts and lift off.
4 Final drive assembly: 2,300kg
J 1 790-337-1001 Lifting tool 1
REMOVAL
1. Remove track shoe assembly. For details, see
REMOVAL OF TRACK SHOE ASSEMBLY.
2. Raise chassis with jack or ripper, then set stand
1 under frame.
3. Remove covers (1) and (2).
INSTALLATION
moval.
q1
If the shaft does not go in, push up the shoe
grouser from the ground surface with a jack
and move the sprocket backwards or for-
wards to adjust to a position where the shaft
4. Remove cover (3), then using eyebolts, pull out
q1
meshes, then assemble the shaft.
q2
drive shaft (4).
2 Final drive assembly mounting bolt:

If the shaft does not come out, push up the
shoe grouser from the ground surface with a
3 Final drive assembly mounting bolt:

jack and move the sprocket backwards or Thread tightener (LT-2)
forwards to adjust to a position where the
shaft can be removed, then pull the shaft out. 1,720 190Nm {175 20kgm}
Pull the shaft out to a point where it contacts
the sprocket.
Refilling with oil (final drive case)
5 Final drive case: 65
(SAE 30CD)
D375A-5 30-125
c c
DISASSEMBLY AND ASSEMBLY OF FINAL
DISASSEMBLY AND ASSEMBLY DRIVE ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF FINAL
DRIVE ASSEMBLY
SPECIAL TOOLS DISASSEMBLY
Sym- Ne- New/Re- Sketc 1. Draining oil
bol Part No. Part name cessity Q'ty model h Remove drain plug and drain oil from final drive
791-580-3200 Remover 1 case.
6
Puller
2 790-101-2102 (294 kN 1

Final drive case: Approx.61
{30 ton})
2. Sprocket
790-101-1102 Pump 1
1) Set final drive assembly to block (height: ap-
791-580-3300 Installer 1
prox. 50 mm).
Puller 2) Remove sprocket (1).
3 790-101-2102 (294 kN 1
{30 ton})
790-101-1102 Pump 1
4 790-431-1071 Installer 1 N
791-580-3400 Remover 1
Puller
5 790-101-2102 (294 kN 1
J
{30 ton})
790-101-1102 Pump 1
791-580-3500 Installer 1
Puller
6 790-101-2102 (294 kN 1
{30 ton})
790-101-1102 Pump 1
Remover
790-431-1230 1
& installer 3. Cover
7
Puller Using eyebolts 1 , remove cover (2).
790-101-2102 (294 kN 1
{30 ton})
790-101-1102 Pump 1
8 790-431-1250 Guide 1
30-126 D375A-5
c c
4. Hub 2) Using tool J2, disconnect sprocket hub as-

1) Remove plate (3). sembly (6) and bearing (7).
2) Using eyebolts 2 , lift off hub (4). 3) Using eyebolts 3 , remove sprocket hub as-
sembly (6).
5. Sprocket hub assembly

1) Remove holder (5).
4) Remove bearing inner race (8) from sprocket

hub assembly.
D375A-5 30-127
c c
5) Turn over sprocket hub assembly, and re- 2) Disassemble cover assembly as follows.
move floating seal cover (9) and bearing out- i) Remove floating seal cover (15).
er races (10) and (11). ii) Remove floating seal (16) from floating
6) Remove floating seal (12) from floating seal seal cover.
cover. Be careful not to damage the floating
Be careful not to damage the floating seal and keep it in a safe place.
seal and keep it in a safe place.
iii) Remove spacer (17) and bearing inner

6. Wear guard race (18).
Lift off wear guard (13).
7. Cover assembly
1) Using eyebolts 4 , lift off cover assembly
(14).
30-128 D375A-5
c c
iv) Remove plate, then remove ring gear iv) Remove planetary gear (23), bearing in-
(19). ner races (24A) and (24B), and spacer
(24C).
8. Carrier assembly
1) Using eyebolts 5 , remove carrier assembly
(20).
v) Remove bearing outer race (24D).
2) Disassemble carrier assembly as follows.

i) Set carrier assembly to block (approx.
100mm).
ii) Remove holder (21).
iii) Using tool J7, remove planetary gear
shaft (22).
9. Sun gear
1) Remove plate (25), button (26), and sun
gear (27).
D375A-5 30-129
c c
10. Hub, shaft assembly 3) Disassemble hub assembly as follows.

1) Remove plate (28). i) Remove gear (32) from hub (33).
ii) Remove hub (33) from boss (34).
iii) Using puller, remove bearing outer race
(35) from boss (34).
2) Using tool J5, pull out hub assembly (29)

and bearing inner race (30) from shaft as-
sembly (31).
4) Using eyebolts 6 , pull out shaft assembly
(31) from case.
5) Disassemble shaft assembly as follows.
i) Remove collar (36).
ii) Remove bearing inner race (37) and col-
lar (38).
30-130 D375A-5
c c
11. Cage assembly 12. Gear assembly

1) Using eyebolts 7 , remove cage assembly 1) Remove gear assembly (44).
(39). 2) Using puller 9 , remove bearing inner races
2) Remove shims (40). (45) and (46) from gear.
13. Outer race, oil seals

1) Using puller 0 , remove bearing outer race
3) Disassemble cage assembly as follows. (48).
i) Using puller 8 , remove bearing outer 2) Remove oil seals (49) and (50) from case.
race (41).
ii) Remove oil seals (42) and (43).
D375A-5 30-131
c c
ASSEMBLY 2) Using push tool C , press fit bearing outer

race (48).
Wash all parts clean, check that there are no
dents or dirt, then coat the sliding parts with en-
gine oil before assembling.
1. Oil seals, bearing outer race
1) Using push tools A and B , install oil seals
(50) and (49).
Install the bottom seal with the side re-
ceiving the pressure at the bottom and
the top seal with the side receiving the
pressure at the top.
2 Press-fitting surface of oil seal:
Coat the inside surface of the case thinly 2. Gear assembly
with gasket sealant and wipe off any 1) Using push tool D , press fit bearing inner
sealant that is squeezed out. races (46) and (45) to gear.
2) Set tool J8 to case, and install gear assem-
bly (44).
Leave tool J8 in position. (Remove it af-
ter installing the cage.)
30-132 D375A-5
c c
3. Cage assembly ii) Using push tool E , press fit bearing out-
1) Assemble cage assembly as follows. er race (41).
i) Using push tools A and B , install oil
seals (43) and (42).
Install the bottom seal with the side
receiving the pressure at the bottom
and the top seal with the side receiv-
ing the pressure at the top.
2 Lip of oil seal:
Grease (G2-LI)
2 Press-fitting surface of oil seal:
Coat the inside surface of the case
thinly with gasket sealant and wipe
off any sealant that is squeezed out.
2) Using eyebolts 7 , set cage assembly (39)
to case, then tighten portions C and D uni-
3 Mounting bolt: 14.7Nm {1.5kgm}

formly with mounting bolts.
D375A-5 30-133
c c
3) In this condition, use thickness gauge F as a + b [mm] No. of shims to use

shown in the diagram below and measure Total shim
Less thickness
clearances a and b between cage A and From t = 0.1 t = 0.5 t = 1.0
than c [mm]
case B.
4) Use table to set thickness c of shim to insert. 1.6 1.8 1 1.0
5) Assemble shims selected in Step 4), then
1.8 2.0 1 1 1.1
3 Mounting bolt:
tighten 4 cage mounting bolts.
2.0 2.2 2 1 1.2
227.3 80.85Nm
{23.25 8.25kgm} 2.2 2.4 3 1 1.3
Rotate the gear and tighten uniformly, 2.4 2.6 4 1 1.4
then remove tool J8. 2.6 2.8 1 1 1.5
2.8 3.0 1 1 1 1.6
3.0 3.2 2 1 1 1.7
3.2 3.4 3 1 1 1.8
3.4 3.6 4 1 1 1.9
3.6 3.8 2 2.0
3.8 4.0 1 2 2.1
4.0 4.2 2 2 2.3
4.2 4.4 3 2 2.3
4.4 4.6 4 2 2.4
4.6 4.8 1 2 2.5
4.8 5.0 1 1 2 2.6
5.0 5.2 2 1 2 2.7
5.2 5.4 3 1 2 2.8
5.4 5.6 4 1 2 2.9
5.6 5.8 5 1 2 3.0
30-134 D375A-5
c c
4. Hub, shaft assembly ii) Set boss (34) to hub (33).

1) Assemble shaft assembly as follows. 4) Set shaft assembly (31) and hub assembly
i) Install collar (38). (29) in position, then using tool J6, press fit
ii) Using push tool (17), press fit bearing in- bearing portion (30).
ner race (37).
iii) Install collar (38).
5) Tighten mounting bolts of hub assembly
3 Mounting bolt:
(29).
2) Using eyebolts 6 , install shaft assembly
(31) to case. 276.85 31.85Nm
3) Assemble hub assembly as follows. {28.25 3.25kgm}
i) Using push tool, press fit bearing outer
2 Mounting bolt:
race (35) to boss (34).
3 Mounting bolt:
548.8 58.8Nm {56 6kgm}
3 Mounting bolt:
7) Install gear (32).
539 49Nm {55 5kgm}
D375A-5 30-135
c c
5. Sun gear i) Install ring and spacer to planetary gear,

1) Install sun gear (27) to hub assembly. then using push tool H , press fit top and
2) Install button (26) and plate (25). bottom bearing outer races (24D).
6. Carrier assembly ii) Assemble spacer (24C) and bearing in-

1) Assemble carrier assembly as follows. ner races (24B) and (24A) to planetary
The bearing for the planetary gear con- gear (23), and set to carrier.
sists of a set, so match the distinguishing
marks on the inner race, outer race, and
spacer when assembling.
q1.Distinguishing mark for bearing
q2.Distinguishing mark for bearing
spacer
30-136 D375A-5
c c
iii) Using tool J7, press fit planetary gear ii) Using tool J3, press fit bearing inner race
shaft (22). (18).
Align the bearing and spacer hole, iii) Install spacer (17).
then gradually press fit the shaft.
3 Mounting bolt:
iv) Install holder (21).
548.8 58.8Nm {56 6kgm}

After tightening the bolts, check that
the gear rotates smoothly.
iv) Using tool J4, press fit floating seal (16)

to floating seal cover.
Remove all oil and grease from the
O-ring and O-ring contact surface,
and dry before installing.
After installing the floating seal,
check that the angle of the seal is
2) Using eyebolts 5 , install carrier assembly
less than 1 mm.
(20).
7. Cover assembly
1) Assemble cover assembly as follows.
i) Fit ring gear (19), and install plate.
Install the plate so that the cham-
fered side is at the top.
D375A-5 30-137
c c
v) Install floating seal cover (15). 2) Using eyebolts 4 , raise cover assembly
Fit a cork plug in the forcing tap. (14) and install.
Coat the mating faces with Three Bond
1216.
8. Wear guard
Raise wear guard (13) and install.
Install the floating seal cover with the

notch facing down as shown in the
diagram below.
9. Sprocket hub assembly

1) Using tool J4, install floating seal (12) to
floating seal cover.
Remove all oil and grease from the O-
ring and O-ring contact surface, and dry
before installing.
After installing the floating seal, check
that the angle of the seal is less than 1
mm.
30-138 D375A-5
c c
2) Using push tool, press fit bearing outer races 5) Using eyebolts 3 , sling sprocket hub as-
(11) and (10). sembly (6) and set to cover.
3) Install floating seal cover (9). Check that there is no dirt on the sliding
surface of the floating seal, then coat
thinly with engine oil.
4) Set bearing (8) to sprocket hub assembly.
6) Using tool J3, press fit bearing portion (7).

Rotate the sprocket hub assembly while
press fitting.
D375A-5 30-139
c c
7) Install holder (5). 11. Cover

2 Mounting bolt: Using eyebolts 1 , install cover (2).
3 Mounting bolt:
276.85 31.85Nm
{28.25 3.25kgm}
12. Sprocket
Install sprocket (1).
2 Mounting bolt:
3 Mounting bolt:
10. Hub
1) Using eyebolts 2 , lift off hub (4). 1,813 98Nm {185 10kgm}
13. Refilling with oil
Tighten drain plug and add engine oil through oil
filler to the specified level.
5 Final drive case: Approx. 61
Carry out the final check of the oil level after
installing the final drive assembly to the
chassis, and check that the oil is at the spec-
ified level.
30-140 D375A-5
c c
REMOVAL AND INSTALLATION OF TRACK
DISASSEMBLY AND ASSEMBLY FRAME ASSEMBLY
REMOVAL AND
INSTALLATION OF TRACK
FRAME ASSEMBLY
REMOVAL 6. Remove covers (3) and (4).
1. Expand the track shoe assembly. For details, 7. Remove cover (5).
see EXPANDING TRACK SHOE ASSEMBLY.
2. Raise the machine body with a jack or the ripper
and set stands 1 under the frame to float the
rear part of the machine body.
3. Set hydraulic jack 2 under the center of the
equalizer bar to float the front part of the ma-
chine body.
4. Sling the track frame assembly temporarily.
8. Apply a pad to pin (6) from rear and drive out the
pin with a hammer.
If the equalizer bar hole and track frame hole
are not aligned, the pin cannot be removed
easily. Adjust the hanging height of the track
frame properly.
5. Loosen front bolt (1) and rear bolt (2).
9. Remove the mounting bolts and cover (7) from

the track frame.
D375A-5 30-141
c c
REMOVAL AND INSTALLATION OF TRACK
DISASSEMBLY AND ASSEMBLY FRAME ASSEMBLY
10. Remove cover (8). INSTALLATION

For the right track frame, disconnect the 4
hoses for the blade tilt cylinder from the cov-
moval.
er.
11. Remove seal (9) and washer (10) together. 2 Inside surface of bushing : Grease (G2-LI)
Perform this procedure for only the right
Before installing the pin, adjust the height of the
track frame.
track frame and align the center of the equalizer
12. Remove washer (11) and spacer (12). bar hole and track frame hole.
Set the pin with the grease hole facing the out-
side of the machine.
Fit pin (4) and bushing (3), install cover (2), then
install the cover and cushion.
After removing the grease from the press fitting
surface of the seal, coat with gasket sealant (LG-
6).
Be careful not to install with the seal displaced in
the direction of twisting.
Be careful not to install the track frame with seal
(14) displaced in the direction of twisting.
Refilling with oil (pivot case)

5 Pivot case : 18 (SAE30)
13. Lift off track frame assembly (13).
Receive the oil flowing out of the pivot case
with an oil pan, etc.
6 Pivot case: 18
4 Track frame: 7,260 kg
30-142 D375A-5
c c
DISASSEMBLY AND ASSEMBLY IDLER ASSEMBLY
REMOVAL AND
INSTALLATION OF
IDLER ASSEMBLY
1. Remove track shoe assembly. For details, see Carry out installation in the reverse order to re-
REMOVAL OF TRACK SHOE ASSEMBLY moval.
To prevent danger, never stand in front of the
idler yoke assembly. For both the left and right idler assemblies,
install with the oil filler plug facing the left
2. Remove scraper (1). side of the machine.
Remove the inside scraper also. Tighten the idler cap mounting bolts in the
3. Remove cover (2). following order.
Remove the inside cover also. Tightening order: 1) 2 bolts at a
2) 2 bolts at b
3) 2 bolts at a
4) Tighten all bolts to
specified torque.
2 Mounting bolt:
3 Mounting bolt :
1641.5 171.5 Nm
{167.5 17.5 kgm}
After tightening the idler cap mounting bolts,
check that clearance c between the bottom
of the idler cap and the yoke is 0.
4. Sling idler assembly and remove idler cap (3).

For both the left and right idler assemblies,
there is a ball assembled to the left idler cap,
so keep it in a safe place and be careful not
to lose it.
5. Lift off idler assembly (4).
4 Idler assembly : 478 kg
D375A-5 30-143
c c
DISASSEMBLY AND
ASSEMBLY OF
IDLER ASSEMBLY
SPECIAL TOOLS 4. Turn over idler assembly (1).
Sym- Ne- New/Re- Sketc 5. Remove mounting bolts, then using eyebolts 3
bol Part No. Part name cessity Q'ty model h , remove shaft (5) as one unit with retainer.
791T-630-2210 Plate 1 c
6. Using puller 4 , remove seal guides (2) and (6),
792-530-1630 Stud 2
and plate (8).
790-101-2510 Block 1
790-101-2570 Washer 2
1 01580-01613 Nut 2
01643-31645 Washer 2
L
Puller
790-101-2102 (294kN 1
{30ton})
790-101-1102 Pump 1
2 791-515-1520 Installer 1
3 791-685-8310 Push tool 1
4 791-601-1000 Oil pump 1
DISASSEMBLY
1. Remove oil filler plug and drain oil. 7. Remove seal guides (2) and (6) from retainers
6 Idler: 0.95 - 1.05 (3) and (7).
2. Set idler assembly (1) on blocks 1 .

3. Remove mounting bolts, then using forcing
screws 2 , remove seal guide (2) as one unit
with retainer (3) and plate (4).
30-144 D375A-5
c c
8. Remove floating seal (9) from seal guides (2) ASSEMBLY

and (6).
Be careful not to damage the floating seal
and keep it in a safe place.
1. Set bushing (11) and tool L1 to idler (12), and
9. Remove floating seal (10) from seal guides (3)
press fit bushing (11).
and (7).
First, use a plastic hammer to center the
bushing, then press fit it with a puller.
Press fit the bushing so that press-fitting di-
mension a from the end face of the idler to
the top face of the bushing is the dimension
below.
Press-fitting dimension a: 17 0.5 mm
10. Remove bushing (11) from idler (12).
2. Using tool L2, install floating seal (10) to retain-

ers (3) and (6).
3. Fit O-ring and install retainer (3) and plate (4) to
idler.
Check that the plate rotates smoothly by
hand.
D375A-5 30-145
c c
4. Using eyebolts 3 , set idler (12) to shaft (5). 8. Set seal guide (2) to shaft, then using tool L3,
Set block (approx. 140 mm) under the idler. press fit seal guide (2).
Press-fitting force of seal guide:
5. Turn over idler assembly.
Tie the shaft with wire to prevent it from fall- 43 - 71 kN {4.4 - 7.2 ton})
ing out.
6. Fit O-ring and install retainer (7) and plate (8) to
idler.
Press fit the seal guide so that press-fitting

dimension b from the end face of the shaft to
the top face of the seal guide is the dimen-
7. Using tool L2, install floating seal (8) to seal sion below.
guides (2) and (6). Press-fitting dimension b: 102 0.2 mm
Turn over the idler assembly and repeat the
procedure above to press fit seal guide (6)
on the opposite side.
30-146 D375A-5
c c
9. Using tool L4, charge with specified amount of

oil, then tighten oil filler plug.
6
3 Oil filler plug:

Idler: 0.95 - 1.05
206 49 Nm {21 5 kgm}
D375A-5 30-147
c c
SKETCH OF SPECIAL TOOL

Note: We will not be liable for any result caused by a special tool made according to this drawing.
L1 Plate
30-148 D375A-5
c c
REMOVAL AND INSTALLATION OF RECOIL
DISASSEMBLY AND ASSEMBLY SPRING ASSEMBLY
REMOVAL AND
INSTALLATION OF RECOIL
SPRING ASSEMBLY
SPECIAL TOOLS 6. Remove covers (4).
Remove both the inside and outside covers.
bol Part No. Part name cessity Q'ty model h
791-730-1110 Bolt 4
M 1
01580-12722 Nut 4
REMOVAL
1. Remove track shoe assembly. For details, see
REMOVAL OF TRACK SHOE ASSEMBLY.
To prevent danger, never stand in front of the
idler yoke assembly.
2. Drain oil from recoil cylinder chamber using oil
pump.
6 Recoil cylinder chamber : Approx. 50
7. Using tool M1, remove pins (5).
3. Using eyebolt 1 , remove cover (1). Remove both the inside and outside pins.
4 Cover : 40 kg
8. Lift off idler and recoil spring assembly (6).

Using a lever block, keep the assembly hor-
4. Remove cover (2). izontal, and be careful not to damage the oil
5. Lift off trunnion (3). seal at the track frame end.
4 Trunnion : 75 kg 4 Idler, recoil spring assembly : 2,180 kg
D375A-5 30-149
c c
9. Disconnect recoil cylinder assembly (8) from

idler yoke assembly (7) as follows.
1) Pit idler yoke assembly (7) in contact with
ground, then raise recoil cylinder assembly
(8).
When doing this, check that there is no
damage to the weld of recoil cylinder as-
sembly (7).
Wrap cloth around the chrome plated
bushing to protect it.
3) When the bolts are loosened, the torque will

suddenly drop. Check that the installed load
of the recoil spring is not applying any push-
ing force on the mounting bolts, then remove
all bolts.
If the torque increases (the installed load
of the recoil spring is applied) during the
loosening operation, stop the loosening
operation and disassemble as follows.
If the torque does not drop during steps
2) Loosen idler yoke mounting bolts (9) gradu- 2) and 3) described above, and the
ally in turn on diagonally opposite sides. torque when the bolts are loosened re-
To prevent danger, never stand in front of mains large, there is probably damage to
the idler yoke assembly. recoil spring set bolts (10), or nut (11) at
the tip of the shaft has fallen off, so there
The recoil spring inside the recoil cylin-
is danger that the idler yoke assembly
der is applying a pushing force of ap-
may fly off to the front. For this reason,
prox. 500 kN (approx. 51 tons) on the
disassemble as follows.
idler yoke, so be careful not to loosen the
mounting bolts suddenly. Loosen the When disconnecting the idler yoke as-
mounting bolts gradually until clearance sembly and recoil cylinder assembly, do
a between the flange of the recoil cylin- not stand in front of the idler yoke assem-
der and idler yoke is 8 12 mm. bly or behind the recoil cylinder assem-
bly until safety has been confirmed and
the recoil spring assembly has been re-
moved.
30-150 D375A-5
c c
i) Prepare the following parts. v) When recoil spring is fully extended and
Bolt 1 (6) : 791-730-1110 torque has completely dropped in loos-
Nut 2 (6) : 01580-12722 ening direction of nut 2 , remove bolt 1
Washer 3 (6) : 01643-32780 (use .
again) When clearance b is approx. 230
mm, the spring is fully extended.
ii) Remove 6 bolts marked q, then install

bolts 1 , nuts 2 , and washers 3 . 10. Remove ring (12).
Check that dimension L is less than
30 mm.
Screw in bolts 1 until they contact
the bottom of the yoke thread.
iii) Remove remaining 12 bolts (those not
marked q).
iv) Hold bolts 1 with a wrench to prevent
them from turning, and loosen 2 nuts 2
simultaneously on diagonally opposite
sides.
Be careful not to let the road bear on
only one bolt.
11. Pump in grease through lubricator (13), and re-

move cylinder (14) and piston assembly (15).
D375A-5 30-151
c c
12. Disassemble piston assembly (15) as follows. INSTALLATION

1) Remove wear ring (16) from piston.
2) Remove snap ring (17), then remove pack-
3 Cover mounting bolt:

moval.
ing (18).
277 32 Nm {28.25 3.25 kgm}
Before installing the pin, align the center of the

hole in the track frame and the dowel pin at the
recoil cylinder end with a bar.
Using a lever block, keep horizontal and be care-
ful not to damage the oil seal at the track frame
end when installing.
Adjust the clearance. For details, see TESTING
AND ADJUSTING, Adjusting clearance of idler.
If the recoil spring set bolt is broken or the nut at
the tip of the shaft has fallen off, see ASSEMBLY
OF RECOIL SPRING ASSEMBLY when assem-
13. Remove recoil spring assembly (19).
4 Recoil spring assembly : 550 kg
bling.
2 Idler yoke assembly mounting bolt :
3 Idler yoke assembly mounting bolt :

1641.5 171.5 Nm {167.5 17.5 kgm}
To prevent air from accumulating inside the cyl-

inder, fill with grease as follows.
1) Fill the inside of the cylinder with approx. 1.3
of grease.
2) Set with the cylinder drain hole facing up,
then loosen the lubricator.
3) Push the piston until it contacts the stopper.
This will push out the air and any extra
grease.
14. Remove holder (20) from recoil spring assembly.
30-152 D375A-5
c c
DISASSEMBLY AND ASSEMBLY OF RECOIL
DISASSEMBLY AND
ASSEMBLY OF RECOIL
SPRING ASSEMBLY
SPECIAL TOOLS 2. Apply hydraulic pressure slowly to compress
spring, then remove lock plate (2) and remove
bol Part No. Part name cessity Q'ty model h nut (3).
791-685-8501
Compres-
1 3. Release hydraulic pressure gradually and re-
sor
lieve tension of spring.
Cylinder
M 2 790-101-1600 (686kN 1
{70ton})
790-101-1102 Pump 1
791-635-3160 Extension 1
DISASSEMBLY
1. Remove recoil spring assembly (1) with tool M2.
The spring is under high installed load, so be
careful to set it correctly.
Installed load of spring:
Approx. 500 kN {approx. 51 ton}
4. Remove rear pilot (5), spacer (6), bolt (7), and

front pilot (8) from spring (4).
D375A-5 30-153
c c
DISASSEMBLY AND ASSEMBLY OF RECOIL
ASSEMBLY 2. Apply hydraulic pressure slowly to compress

spring, and set so that installed length of spring
1. Assemble front pilot (8), bolt (7), spacer (6), and
is specified value.
rear pilot (5) to spring (4), then set in tool M2.
Installed length a of spring : 1,230.5 mm
Installed load of spring :
Approx. 500 kN {approx. 51 ton}
The spring is under high installed load, so be

careful to set all parts correctly.
3. Fit nut (3), then install lock plate (2).
Make clearance b of 0 - 10 mm between the
nut and lock plate to prevent the nut from
protruding from the end face of bolt (7).
Bring lock plate (2) and bolt (7) into tight con-
tact, and secure in position.
2 Lock plate mounting bolt :
4. Gradually release hydraulic pressure to com-
pletely relieve tension of spring, then remove re-
coil spring assembly (1) from tool M2.
30-154 D375A-5
c c
REMOVAL AND INSTALLATION TRACK
DISASSEMBLY AND ASSEMBLY ROLLER ASSEMBLY
REMOVAL AND
INSTALLATION TRACK
ROLLER ASSEMBLY
SPECIAL TOOLS 4. Set steel plate 1 on track shoe, and operate
blade and ripper to lower chassis to a point
bol Part No. Part name cessity Q'ty model h where track roller assembly contacts steel plate.
790-401-1700 Lifting tool 1 Run the engine at low idling and operate the
790-401-1761 Adapter 1
blade and ripper slowly.
12
790-401-1540 Shackle 2
L 790-401-1770 T-Bolt 2
791T-630-2320 Plate 3 N c
13 01011-62700 Bolt 6
01673-32780 Washer 6
REMOVAL
1. Loosen track shoe tension. For details, see RE-
MOVAL OF TRACK SHOE ASSEMBLY.
2. Install tool L13 and secure bogie assembly (1).
q1
3. Operate blade and ripper, and jack up chassis to 5. Remove mounting bolts, and leave track roller
a point where track roller assembly (2) comes up assembly (2) on steel plate 1 .
from track shoe.
6. Operate blade and ripper, and jack up chassis to
a point where track roller assembly (2) separates
from bogie.
D375A-5 30-155
c c
7. Using a crane and bar, pull out track roller as- INSTALLATION
sembly (2) from steel plate to outside of body.
4 Track roller assembly:
moval.
150 kg (single flange)
160 kg (double flange) q1
After removing tool L3, replace mounting bolts of

cover (3) with normal parts.
927 103 Nm {94.5 10.5 kgm}
Note that the installation location differs for

the single flange track roller assembly and
double flange track roller assembly.
S: Single flange
D: Double flange
Install the track roller assembly with the oil
filler plug on the outside.
30-156 D375A-5
c c
After fitting the track shoe assembly tempo-
3 Track roller assembly mounting bolt:

rarily, align the position of dowel pin (4).
1,325 145 Nm {135 15 kgm}
When using assembly tool

Set tool L12 to bottom of track roller assembly,
then raise track roller assembly (2) and set to
track frame.
D375A-5 30-157
c c

L13 Plate
30-158 D375A-5
c c
DISASSEMBLY AND ASSEMBLY OF TRACK
DISASSEMBLY AND
ASSEMBLY OF TRACK
ROLLER ASSEMBLY
SPECIAL TOOLS 6. Using press, remove seal guide (6) as one unit
bol Part No. Part name cessity Q'ty model h 7. Remove seal guides (2) and (6) from retainers
8 791T-630-2220 Plate 1 c (3) and (7).
9 791-670-1020 Installer 1
L
10 791T-630-2230 Push tool 1 c
11 791-601-1000 Oil pump 1
DISASSEMBLY
1. Remove oil filler plug and drain oil.
6 Track roller: 1.4 - 1.5
2. Set track roller assembly (1) to block 1 .
3. Remove mounting bolts, then using forcing
screws 2 , remove seal guide (2) as one unit
4. Turn over track roller assembly. 8. Remove floating seal (9) from seal guides (2)
5. Remove mounting bolts, then using eyebolts 3 and (6).
, remove shaft (4) as one unit with retainer. Be careful not to damage the floating seal
9. Remove floating seal (10) from retainers (3) and
(7).
D375A-5 30-159
c c
10. Remove bushing (11) from roller (12). 2. Set shaft (5) to roller.
3. Using tool L9, install floating seal (10) to retain-
ers (3) and (7).
4. Fit O-ring and install retainers (3) and (7), and
plates (4) and (8) to roller.
Check that the plate rotates smoothly by
hand.
ASSEMBLY
1. Set roller (12) to press, then using tool L8, press
fit bushing (11).
First, use a plastic hammer to center the
bushing, then press fit it with a puller. 5. Using tool L9, install floating seal (9) to seal
Press fit the bushing so that press-fitting di- guides (2) and (6).
mension a from the end face of the idler to 6. Using tool L10, press fit seal guide (2) to shaft.
the top face of the bushing is the dimension
below.
Press-fitting dimension a: 17 0.5 mm
30-160 D375A-5
c c
Press-fitting force of seal guide:

36 - 63 kN {3.7 - 6.4 ton})
Press fit the seal guide so that press-fitting
dimension b from the end face of the shaft to
the top face of the seal guide is the dimen-
sion below.
Press-fitting dimension b: 77 0.2 mm
7. Using tool L11, charge with specified amount of

oil, then tighten oil filler plug.
5
3 Oil filler plug:
Track roller: 1.4 - 1.5 (SAE140)
206 49 Nm {21 5 kgm}
D375A-5 30-161
c c

L8 Plate
L10 Push tool
30-162 D375A-5
c c
DISASSEMBLY AND ASSEMBLY BOGIE ASSEMBLY
REMOVAL AND
INSTALLATION OF
BOGIE ASSEMBLY
SPECIAL TOOLS REMOVAL
Ne- New/Re- Sketc 1. Loosen the track shoe tension. For details, see
Symbol Part No. Part name Q'ty
cessity model h EXPANDING TRACK SHOE ASSEMBLY.
791T-630-2320 Plate 3 N c
13 01011-62700 Bolt 6
01673-32780 Washer 6
1 791-830-1620 Plate 1 N
2 791-830-1630 Spacer 1 N
3 791-830-1640 Screw 3 N
4 01580-12722 Nut 3
14
5 01630-32780 Washer 3
Puller
6 790-101-4000 (490kN 1
{50ton})
7 790-101-1102 Pump 1
1 791-830-1650 Plate 1 N
2 791-830-1660 Spacer 1 N
2. Install tool L13 and secure the bogie assembly.
3 796-670-1120 Plate 1
4 790-434-1070 Screw 1 N
L
15 5 01580-13629 Nut 2
6 01643-33690 Washer 1
Puller
7 790-101-4000 (490kN 1
{50ton})
8 790-101-1102 Pump 1
1 791-830-1620 Plate 1 N
2 791-830-1640 Screw 3 N
3 01580-12722 Nut 3
16 4 01643-32780 Washer 3
Puller
5 790-101-4000 (490kN 1
{50ton})
6 790-101-1102 Pump 1
17 791T-630-2290 Guide 2 N c
18 791-530-1510 Installer 1
19 791-601-1000 Oil pump 1
D375A-5 30-163
c c
3. Operate the blade and ripper to raise the ma-

chine body until the track roller is floated above
the track link.
Set a block between the track roller and track
link so that the machine body will not lower.
4. Set block 1 out of the track shoe according to
the height of the track link.
5. Set steel plate 2 on the track shoe and block 1 .
6. Operate the blade and ripper to lower the ma-
chine body until the track roller of the bogie as-
sembly (1) comes in contact with steel plate 2 .
Operate the blade and ripper slowly with the 3) Remove floating seals (5) from the ends of
engine at low idling speed. rings (4) and (7).
Keep the floating seals so that they will
not be damaged.
4) Set tool L15.

5) Pull out spacer (6) and rings (7) and (8).
Pulling out force:
205.8 - 382.2 kN {21 - 39 tons}
8. Remove the shaft and ring.

1) Set tool L14.
2) Push shaft (3) and ring (4) simultaneously to
the opposite side.
Pushing force:
137.2 - 274.4 kN {14 - 28 tons}
30-164 D375A-5
c c
6) Remove spacer (6). INSTALLATION

7) Remove spacer (9) and floating seal (10) be-
1. Assemble the pin assembly.
tween rings (7) and (8).
1) Using tool L18, install floating seals (5) to
rings (4) and (7) and install floating seal (10)
not be damaged.
to the opposite side of ring (7) and ring (8).
8) Remove the shaft and rings from the bogie
When installing the floating seals, thor-
on the opposite side according to steps 1) -
oughly degrease the O-rings and the O-
7) above.
ring contact surfaces of the mating parts.
Check that the slant of each floating seal
is within 1mm.
9. Remove tool L13.

10. Place bogie assembly (1) on steel plate 2 .
2) Press fit shaft (3) to ring (8).
3) Install spacer (9).
chine body until the bogie assembly can be
4) Press fit ring (7) to shaft (3).
pulled out.
Set a block between the track roller and track
2 Apply Anti-friction compound (LM-
12. Sling bogie assembly (1) and slide it out on steel P) to parts "a" (about 10 mm) of
plate 2 and remove it. rings (8) and (4).
4 Bogie assembly: 720 kg
D375A-5 30-165
c c
2. Apply lever block 3 between the guard of bogie 2) Press fit pin assembly.
assembly (1) and that of the bogie assembly on Insert the pin assembly with arrow "a" on
the opposite side and slide bogie assembly (1) its end face up (in the mounting state on
on the steel plate to the mounting position. the machine body).
Push in the pin assembly with cover (2).
Press fit the pin assembly to machined
surface "b" of the bogie.
2 Apply Anti-friction compound (LM-
P) to the all outside surface of the
pin.
Total press fitting force for pin assembly:
245 - 441 kN {25 - 45 tons}
3. Align the pin holes of the track frame and bogie

and set guide tool L17.

Using tool L19, supply the specified quantity of
oil.
Oil supply pressure: 0.49 MPa {5 kg/cm2}
5 Pin assembly: 95 - 115 cc (GO-140)
4. Press fit the pin assembly.

1) Set tool L16 and cover (2).
30-166 D375A-5
c c
6. Press fit the pin assembly on the opposite side

according to steps 3 - 4 above.
7. Tighten the mounting bolts of pin assembly cov-
ers (2). (Install 2 covers, outside and inside

ones.)
927 103 Nm {94.5 10.5 kgm}

8. Adjust the track shoe tension. For details, see
TESTING AND ADJUSTING, Testing and adjust-
ing track shoe tension.
D375A-5 30-167
c c

L13 Plate
L17 Guide
30-168 D375A-5
c c
DISASSEMBLY AND
ASSEMBLY OF
BOGIE ASSEMBLY
SPECIAL TOOLS 2. Remove cover (3).
Ne- New/Re- Sketc
cessity model h
1 791-830-1620 Plate 1 N
2 791-830-1640 Screw 3 N
3 01580-12722 Nut 3
16 4 01643-32780 Washer 3
L Puller
5 790-101-4000 (490kN 1
{50ton})
6 790-101-1102 Pump 1
19 791-601-1000 Oil pump 1
DISASSEMBLY
3. Disassemble the pin assembly according to the
1. Track roller assembly
procedure in Removal of bogie assembly.
Turn over bogie assembly (1) and lift off 2 track
(Step 8)
roller assemblies (2).
4. Disconnection of bogie
Disconnect inner bogie (4) and outer bogie (5).
D375A-5 30-169
c c
ASSEMBLY 4. Refilling with oil

1. Assembly of pin assembly
oil.
Assemble the pin assembly according to the pro-
5 Pin assembly: 90 - 115 cc (GO-140)
cedure in Installation of bogie assembly.
(Steps 3 - 5)
2. Set inner bogie (4) to outer bogie (5).
3. Press fitting of pin assembly
2) Press fit the pin assembly.
Insert the pin assembly with arrow "a" on
its end face up (in the mounting state on
the machine body).
surface "b" of the bogie and secure level
difference "b" of 5 mm between the bo-
gie and pin assembly.
2 Anti-friction compound (LM-P) to
the all outside surface of the pin. 5. Press fit the pin assembly on the opposite side
Total press fitting force for pin assembly: according to steps 3 - 4 above.
245 - 441 kN {25 - 45 tons} After press fitting the pin assembly, rock the
smaller bogie.
6. Tighten the mounting bolts of pin assembly cov-
ers (3).

(Install 2 covers, outside and inside ones.)
824 - 1,030 Nm {84 - 105 kgm}
7. Track roller assembly

Sling 2 track roller assemblies (2) and install
them to bogie assembly (1).
2 Track roller mounting bolt:
3 Track roller mounting bolt:

1,180 - 1,470 Nm {120 - 150 kgm}
30-170 D375A-5
c c
REMOVAL AND INSTALLATION OF 1ST
REMOVAL AND
INSTALLATION OF 1ST
BOGIE ASSEMBLY
SPECIAL TOOLS REMOVAL
Ne- New/Re- Sketc 1. Loosen the track shoe. For details, see EX-
cessity model h PANDING TRACK SHOE ASSEMBLY.
1 791-830-1620 Plate 1 N
2 791-830-1630 Spacer 1 N
chine body until the track roller of the 2nd bogie
3 791-830-1640 Screw 3 N
assembly is floated above the track link.
4 01580-12722 Nut 3
14 Set a block between the track roller and track
5 01630-32780 Washer 3
Puller
6 790-101-4000 (490 kN 1 3. Install eyebolts to the pad mounting bolts (M12 x
{50 ton})
2 pieces) at the rear of first bogie assembly (1)
7 790-101-1102 Pump 1 and pull up first bogie assembly (1).
1 791-830-1650 Plate 1 N
2 791-830-1660 Spacer 1 N
3 796-670-1120 Plate 1
4 790-434-1070 Screw 1 N
15 5 01580-13629 Nut 2
6 01643-33690 Washer 1
Puller
7 790-101-4000 (490 kN 1
{50 ton})
8 790-101-1102 Pump 1
1 791-830-1620 Plate 1 N
2 791-830-1640 Screw 3 N
3 01580-12722 Nut 3
L
16 4 01643-32780 Washer 3
4. Insert a steel plate between the track shoe and
Puller
5 790-101-4000 (490 kN 1 roller and loosen the roller cap bolts (2) by about
{50 ton}) 20 mm. (Loosen both inside and outside bolts.)
6 790-101-1102 Pump 1 5. Hit the end of shaft (3) with a hammer to remove
17 791T-630-2290 Guide 2 N c track roller assembly (4).
18 790-434-1350 Installer 1 Take care not to break the dowel pin inserted
19 791-601-1000 Oil pump 1 before the track roller assembly.
1 791-630-1860
Bracket
1 N
(Insertion allowance for dowel pin: 5 - 6 mm)
(L.H) 6. Remove roller cap bolts (2) and place track roller
20 2 791-630-1870
Bracket
1 N assembly (4) on the steel plate and pull it out.
(R.H)
3 01010-62760 Bolt 2 4Track roller assembly: 150 kg
4 01643-32780 Washer 2
791T-630-1900 Sling tool z 1
791T-630-1910 Tube 1 c
791T-630-1920 Plate 1 c
07283-38973 Clip 1
21
04530-11628 Eye bolt 1
01643-31645 Washer 1
01643-31232 Washer 2
01582-01210 Nut 2
D375A-5 30-171
c c
7. Using tool L20, sling and hold 1st bogie (5). 3) Remove floating seals (9) from the end faces
of rings (8) and (12).
not be damaged.
9. Pull out the shaft and ring.

1) Set tool L14.
4) Set tool L15.
2) Push shaft (7) and ring (8) simultaneously to
the opposite side.
Pushing force:
137.3 - 274.6 kN {14 - 28 tons}
When the ring is pushed out, it interferes
with the idler. To prevent this, supply
grease to the track tension adjuster in
advance to push out the idler cushion as-
sembly forward.
30-172 D375A-5
c c
5) Pull out spacer (11) and rings (12) and (13). INSTALLATION
Pulling out force:
1. Assemble the pin assembly.
205.8 - 382.2 kN {21 - 37 tons}
1) Using tool L18, install floating seals (9) to
6) Remove spacer (11).
rings (8) and (12) and install floating seal
7) Remove spacer (14) and floating seal (10)
(10) to the opposite side of ring (12) and ring
between rings (12) and (13).
(13).
When installing the floating seals, thor-
not be damaged.
oughly degrease the O-rings and the O-
ring contact surfaces of the mating parts.
Check that the slant of each floating seal
is within 1mm.
10. Lower bogie (5) on the steel plate and pull it out.
4 Bogie assembly: 110 kg
2) Press fit shaft (7) to ring (13).
2 Apply Anti-friction compound
(LM-P) to parts "a" (about 10 mm)
of rings (13) and (8).
D375A-5 30-173
c c
2. Place bogie assembly (5) on steel plate 1 and 2) Press fit pin assembly .
slide it to the center. Insert the pin assembly with arrow "a" on
3. Using tool L20, set the bogie in position. its end face up (in the mounting state on
the machine body).
surface "b" of the bogie and secure level
difference "b" of 5 mm between the bo-
gie and pin assembly.
2 Apply Anti-friction compound
(LM-P) to the all outside surface of
the pin.
Total press fitting force for pin assembly:
245 - 441 kN {25 - 45 tons}
4. Align the pin holes of the track frame and bogie

and set guide tool L17.

oil.
5. Press fit the pin assembly. 5 Pin assembly: 95 - 115 cc (GO-140)
30-174 D375A-5
c c
7. Press fit the pin assembly on the opposite side

according to steps 5 - 6 above.
8. Install covers (6).
(Install 2 covers, outside and inside ones.)
9. Install eyebolts to the pad mounting bolts (M12 x
2 pieces) of bogie (5) and pull up and hold the
bogie.
13. Adjust the track shoe tension. For details, see

testing and adjusting, TESTING AND ADJUST-
ING TRACK SHOE TENSION.
10. Using tool L21, insert the shaft in track roller as-
sembly (4), then sling and set it on the track
shoe, balancing it.
4 Track roller assembly: 150 kg
11. Lower the machine body slowly. When the clear-

ance between bogie (5) and shaft (3) becomes
about 20 mm, install cap (15) and secure it with
bolt (2) temporarily.
12. Align the dowel pin hole and tighten bolt (2) se-
curely.
2 Cap mounting bolt:
3 Cap mounting bolt:

1,180 - 1,470 Nm {120 - 150 kgm}
D375A-5 30-175
c c

L17 Guide
L21 Tube
30-176 D375A-5
c c
L21 Plate
D375A-5 30-177
c c
EXPANDING AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY TRACK SHOE INSTALLATION

TRACK SHOE INSTALLATION
CHECK BEFORE EXPANDING TRACK 1. Sling the end of the master link and move the
SHOE ASSEMBLY machine slowly in reverse to expand track shoe
assembly (4).
Since it may be very dangerous to expand the
Length of track shoe: Approx. 12.5 m
track shoe assembly, check the following items
in advance.
Do not loosen the lubricator more than 1 turn.
Loosen lubricator (1) of the adjustment cylin-
der to discharge the grease and move the
machine in reverse a little and check that the
track shoe is loosened.
After the shoe is loosened, perform EX-
PANDING TRACK SHOE ASSEMBLY
(NORMAL).
If the track shoe is not loosened by the
above work, the track frame may have an in-
ternal trouble (damage of the recoil spring or
recoil spring set bolt, fall of the shaft end nut,
etc.)
If the track shoe is not loosened, perform
EXPANDING TRACK SHOE ASSEM-
BLY (WHEN TRACK FRAME HAS IN-
TERNAL TROUBLE).
D375A-5 30-179
c c
EXPANDING TRACK SHOE ASSEMBLY EXPANDING TRACK SHOE ASSEMBLY

(When track frame has internal trouble). (Normal)
If any abnormality is detected by CHECK BE- If any abnormality is not detected by CHECK BE-
FORE EXPANDING TRACK SHOE ASSEM- FORE EXPANDING TRACK SHOE ASSEM-
BLY, perform the following procedure. BLY, perform the following procedure.
If the track shoe is removed while the track frame 1. Set the master link in position.
has an internal trouble, it may spring back. Even Set the master link above the idler (a little af-
if the track shoe is removed, the idler may jump ter the idler center).
out, and that can cause a serious result. Accord- Set a block (1) and (2) between the front side
ingly, expand the track shoe according to the fol- of the idler and carrier roller so that the mat-
lowing procedure. ing part of the master link will not open until
1. Remove the work equipment. For details, see the master bolt is pulled out.
REMOVAL OF WORK EQUIPMENT ASSEM-
BLY.
2. Loosen lubricator (1) and move the machine for-
ward and in reverse to discharge the grease.
Do not loosen lubricator (1) more than 1 turn.
Check that the all grease has been dis-
charged.
2. Loosen the track shoe.

Do not loosen lubricator (1) more than 1 turn.
Loosen all of them by 1 - 2 turns first until
they are turned lightly, then pull them out. Do
not loosen and pull out the bolts 1 by 1.
If the bolts are turned forcibly before they be-
come light, the threads of them and master
link may be damaged.
30-180 D375A-5
c c
3. Move the machine slowly forward against large INSTALLATION OF TRACK SHOE
block 1 or a wall (or the blade of another ma- ASSEMBLY
chine of the similar size of the machine to be re-
Carry out installation in the reverse order to EX-
paired, if available) to press the track shoe on
PANDING.
q1
the idler side. When the recoil spring is distort-
ed, stop and apply the brake.
Adjust the track shoe tension. For details,
At this time, set the master link between the idler
see testing and adjusting, TESTING AND
and front carrier roller.
ADJUSTING TRACK SHOE TENSION.
For safe work, apply a lever block between the
Tighten the all 4 bolts with fingers until the
carrier roller support and link.
master link mating faces are fitted.
4. Remove track shoe (5) and disconnect master If the bolts are tightened forcibly before the
link (6). master link mating faces are fitted, the
5. Move the machine slowly in reverse to expand threads of the bolts and master link may be
track shoe assembly. damaged.
q2
Tighten the shoe mounting bolts for the mas-
ter link in the following order.
2 Shoe mounting bolt:
Anti-seizure agent (Maruzen
3 Shoe mounting bolt:

MOLYMAX No. 2 or equivalent)
1st time:
686 68.6 Nm {70 7 kgm}
2nd time:
Retighten by 180 10
D375A-5 30-181
c c
WHOLE DISASSEMBLY AND
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRACK SHOE

ASSEMBLY OF TRACK SHOE
SPECIAL TOOLS
Ne- New/Re- Sketc Ne- New/Re- Sketc
Symbol Part No. Part name Q'ty Symbol Part No. Part name Q'ty
cessity model h cessity model h
1 791-646-7351 Push tool 1 26 790-101-1102 Pump 1
2 791-660-7460 Pin brush 1 Cylinder
7 27 790-101-4200 (294kN 1
Push tool
3 791-646-7900 (For large 1 {30ton})
plug) 28 791-680-1630 Spacer 1
791-701-3000 Seal Push tool
1 791-632-1300 1 N
or checker assembly
4 2
2 791-632-1260 Ring 1
791-601-1000 Oil pump
3 791-632-1270 Shaft 1
Push tool
5 791-932-1110 (For small 1 Adapter
4 791-632-1220 1
plug) (small)
6 791-632-1021 Installer 1 8 5 791-632-1230 Ring 1
Remover 6 791-632-1240 Washer 1
1 791-632-1100 and installer 1
7 791-685-5730 Bar 1
assembly
8 791-632-1250 Urethan 1
2 791-632-1130 Adapter 1
9 791-632-1280 Spring 1
3 790-434-1610 Guide 1
10 01252-30605 Bolt 1
4 01010-51440 Bolt 2
R 11 01580-01210 Nut 1
5 791-685-9510 Frame 1
Push tool
6 791-685-9530 Rod 1 1 791-632-1200 1 N
assembly
7 791-685-9520 Frame 1 2 791-632-1260
R Ring 1
8 791-685-9550 Nut 3
3 791-632-1270 Shaft 1
9 04530-12030 Eyebolt 1
Adapter
4 791-632-1210 1
10 791-685-9560 Bolt 4 (large)
11 791-126-0150 Adapter 1
9 5 791-632-1230 Ring 1
12 791-685-9540 Rod 1 6 791-632-1240 Washer 1
7 13 791-632-1140 Adapter 1 7 791-685-5730 Bar 1
14 791-680-5520 Guide 1 8 791-632-1250 Urethan 1
15 01010-51030 Bolt 1 9 791-632-1280 Spring 1
16 791-632-1150 Pusher 1 10 01252-30655 Bolt 1
17 791-685-9620 Extension 1 11 01580-01210 Nut 1
18 791-632-1180 Adapter 1 Push tool
1 791-632-1290 2 N
19 791-680-5543 Adapter 1 assembly
10
20 791-632-1160 Guide 1 2 791-685-5730 Bar 1
21 791-680-5551 Guide 1 3 01580-01210 Nut 1
22 791-680-9630 Adapter 1
23 791-632-1160 Guide 1
24 195-32-61210 Bolt 2
Cylinder
25 790-101-4300 (1,470kN 1
{150ton})
30-182 D375A-5
c c
WHOLE DISASSEMBLY
When disassembling the track shoe, see "Parts
judgment guide, Undercarriage, Lubricated
track" and "Parts judgment guide, Undercar-
riage, Reversing procedure for pin bushing".
1. Removal of shoe
Sling the shoe assembly and set it with the shoe
up on the floor and remove the shoe by using a
shoe bolt impact wrench.
If a shoe bolt is not loosened after it is un-
screwed by 1 turn (If its torque is not reduced
to 0), loosen the other bolts first, and it will be
removed smoothly.
If a shoe bolt is turned forcibly while its
torque is not 0, it and link will adhere to each
other and they will need to be repaired.
When moving the shoe assembly, take care
not to damage the master link.
If it is obliged to cut a shoe nut with gas, keep
the seal temperature below 80C to prevent
thermal deterioration of the seal and take
measures to prevent the spatters from enter-
ing through the clearances among the links.
2) Operate the left cylinder to pull out the pin

and bushing from the left link simultaneously.
Check the pulling out force of the pin and
bushing which will be reversed and as-
sembled again, then pull out them simul-
taneously.
The wedge link is broken with a bang.
This sound does not indicate abnormali-
ty.
2. Disassembly of link
1) Set the link assembly on a link press and hit
it with a hammer so that the bushing will be
fitted to the jaw.
If the link tread, outside of the bushing,
etc. are worn, adjust the height of the jaw
or guide plate and align the pin and
bushing with the disassembly jig so that
the link hole will not be damaged during
disassembly work.
If the pin and bushing are not aligned
well, the link hole may be damaged and
the pin and bushing may be broken dur-
ing disassembly work.
Using tool R1, drive the small plug of the
pin inward after the disassembly work so
that the workplace will not become dirty.
D375A-5 30-183
c c
3) Return the left cylinder and operate the right 2) Measure the outside diameter of the press
cylinder to pull out the pin and bushing from fitting parts of the pin and bushing and the in-
the right link simultaneously. side diameter of the pin and bushing fitting
parts of the link with a micrometer and a cyl-
inder gauge to see if the allowable fitting al-
lowance is obtained. When using the pin,
bushing, and link for a lubricated track, how-
ever, secure the standard fitting allowance
between the pin and link.
If the allowable fitting allowance is not
obtained, replace the parts with new one.
For the dimensional criteria, see MAIN-
TENANCE STANDARD.
4) Return the right cylinder and take out the

links, pins, bushings, and spacers on both
sides and feed the next 1 set of the link as-
sembly to the jaw.
If the bushing ends and sealing surfaces
are damaged, oil will leak. Accordingly,
handle them carefully.
Since the broken wedge link has sharp
edges, take care not to cut your hands
with them.
3. Inspection
Check the parts for the following items to see if
they can be used for a lubricated track or a
grease-filled track, then examine them generally
and determine to use them for a lubricated track
or grease-filled track.
For judgment of reuse of the parts, see
"Parts judgment guide, Undercarriage, Lu-
bricated track".
1) Check the parts visually for damage. If a part
seems to be damaged, check it by dye pen-
etrant test or magnaflux inspection. If it has
any crack, it cannot be used again. Discard
it.
30-184 D375A-5
c c
2) When reusing the pin, chamfer its end cor-

ners smoothly with a grinder. Remove the
nodules sticking to the press fitting parts with
the grinder, too.
If the ends are worn and sharpened, they
may scuff the press fitting parts and
cause oil leakage.
3) If the link, pin, bushing, and spacer are dirty,
clean them. Remove the nodules sticking to
the link and bushing with the grinder, too.
Since these parts rust easily, clean them
just before assembling them.
Do not polish the bushing ends. If they
are polished, oil may leak.
Precautions for storage
1) Store the seal without removing it from the
link so that the counterbore portion will not
be rusted and take care not to damage the
seal lip.
2) Apply rust-preventive oil to the pin and bush-
ing fitting parts, shoe mating surface, and
master link mating surface of the link.
3) When storing, apply rust-preventive oil to the
all surfaces of the pin, bushing, and spacer.
Take care not to damage the ends of the
bushing in particular.
WHOLE ASSEMBLY
For the whole assembly of the track shoe, see
"Parts judgment guide, Undercarriage, Revers-
ing procedure for pin bushing".
1. WHEN RECYCLING FOR LUBRICATED

TRACK
1. Preparation work
1) Cleaning seal assembly
Remove the seal assembly from the link and
divide it into the seal ling and load ring, then
clean them.
Since the seal ring and load ring are de-
teriorated easily by the cleaning liquid
(trichloroethylene etc.), clean them
quickly. After cleaning them, wipe off the
cleaning agent from them.
D375A-5 30-185
c c
4) If the large plug was pulled out, drive it in by 5) Installation of seal assembly
using tool R3. Clean the counterbore portion of the link
In this case, clean the pin hole in advance by carefully and push in the seal to the bottom
using tool R2. by using tool R6.
i) Insert the plug through the plug insertion If oil is sticking to the counterbore portion
window into the guide hole. of the link or seal assembly, the seal will
ii) Push the bar with the hand until the plug turn and its sealing performance will low-
stops. er. Accordingly, do not apply any oil.
iii) Push the plug with the bar to press the When inserting the seal in the counter-
guide against the pin. bore portion, take care that oil not stick to
iv) Drive in the bar with a hammer. the seal and counterbore portion.
Driving distance "a" from pin end:
11 2 mm
If the chamfered part of the pin hole
has been worn, chamfer it with a
small-sized grinder (grindstone tip
angle: 45- 60) so that the plug will
not be damaged.
Coat the plug with GO90 and drive it
with the small diameter end ahead.
30-186 D375A-5
c c
6) Adjust the dimensions of the press fitting jig 7) Adjust the relief pressure of the link press so
of the link press to keep the projection of the that the pressing force of the press will not
pin and bushing constant and keep the in- exceed the standard value.
stalled dimensions of the seal within the If the pressing force is too strong, the
standard range. spacer will be pressed forcibly against
For the standard dimensions, see DI- the bushing. As a result, the spacer may
MENSIONS TABLE OF FITTING JIG OF be broken and it and bushing may be
LINK. worn abnormally.
If the pin end (part P) or link sides (parts Pushing force of pin and bushing: 980
Q and R) are worn, add the dimensions kN {170 tons}
of the worn parts when adjusting the Pushing force = 1.8 x Average pressure
standard dimensions so that the projec- (Adjust the relief pressure of the link
tions of the pins and bushings on both press to set the pushing force.)
sides will be even.
2. Assembly of link
1) Apply oil (GO90) to the mating surfaces of
the pin and bushing with a clean brush and
assemble them, then set them before the jaw
of the link press.
When reusing (reversing) the bushing,
set the worn outside surface of the bush-
ing on the shoe fitting side of the link (set
the bushing with the worn outside sur-
face up on the link press).
D375A-5 30-187
c c
2) Press fit the master links on both bushing 4) Turn over the master links and check that
sides to the bushing with the shoe fitting fac- they are press fitted in parallel.
es up. 5) Measure the projections of the bushing on
At this time, use the master links on the both sides with a depth gauge.
pin side as supports. Adjust the press fitting jig of the link
Press fitting force for bushing: press so that the projections on both
196 - 343 kN {20 - 35 tons} sides will be even.
3) Using the shoe bolt hole pitch gauge, press 6) Send the master links and set the next pin
fit the master links until the distance between and bushing.
the shoe bolt holes of both links is the stan- When reusing a pin, install it so that its
dard value. side hole will be the link tread side simi-
Remove the all steel chips caused by larly to a new one. If it is not installed so,
press fitting of the bushing with com- its strength may be lowered. According-
pressed air. ly, indicate the direction of the side hole
on the end face to prevent a mistake.
30-188 D375A-5
c c
7) Apply gasket sealant (198-32-19890) to the 9) Set the right jig on the receiving side and the
pin fitting hole of the links to prevent oil from left one on the pushing side and press fit the
oozing out of the scuffed parts of the pin fit- pin and bushing simultaneously.
ting parts. If the pin and bushing have play when
they are press fitted, the seal may come
off the link. To prevent this, press fit
smoothly. If the seal comes off the link,
stop press fitting and set the seal to the
link correctly, then start press fitting
again.
Press fitting force for pin and bushing:
392 - 686 kN {40 - 70 tons}
8) Set the right link and install the spacer to the

pin.
Check that the seal surface and bushing
end are free from dirt and apply oil
(GO90) to them with a clean cloth or
brush.
When installing the spacer, wipe it with a
clean cloth.
10) Using the spacer for fine adjustment, press
fit the pin and bushing until the pin end is fit-
ted to the bottom of the receiving jig.
Adjust the depth of the receiving jig hole
so that the projections of the pin on both
sides will be even.
D375A-5 30-189
c c
11) Set the left link and install the spacer to the 13) Press fit until the link, spacer, and bushing
pin. are fitted together.
Apply oil similarly to the right link. Actually, you cannot see from outside if
the above parts are fitted.
Accordingly, control the hydraulic pres-
sure of the link press. Set the relief pres-
sure to a proper level and heighten the
hydraulic pressure to that level.
For setting of the relief pressure, see
PREPARATION WORK.
Check that adjacent 2 links can turn
around each other.
12) Set the left jig on the receiving side and the
right one on the pushing side and press fit
the left link.
When press fitting, take care that both
seals and spacers will not come off.
Press fitting force for link:
392 - 686 kN {40 - 70 tons}
14) Using a shoe bolt hole pitch gauge, measure

the distance between the shoe bolt holes
and check that the result is within the stan-
dard range.
If the distance between the shoe bolt
holes is longer than the standard range,
disassemble and check for abnormality,
then press fit again.
If the distance between the shoe bolt
holes is shorter than the standard range
and the shoe cannot be installed, the
spacer or bushing end may be worn
more than the allowable limit. In this
case, disassemble and replace the
parts.
30-190 D375A-5
c c
15) Install the ring to jig R8. 18) Using jig R10, push in the ring.
Pushing force for ring:
294 - 372 kN {30 - 38 tons}
16) Match the jig to the pin hole and push it in un-
til the ring is inserted in the pin groove.
A sound is made when the ring is insert-
ed in the pin groove. 19) After each link is assembled, bleed air from
the pin by using tool R4 and check the seal-
ing performance.
Keep the degree of vacuum inside the
pin at 86.7 - 93.3 kPa {650 - 700 mmHg}
for 5 seconds and check that the pres-
sure does not change.
If the pressure changes, disassemble
and check the seal. If the seal is free
from abnormality, assemble again.
17) Using jig R9, insert the ring in the pin groove
on the opposite side similarly.
D375A-5 30-191
c c
20) Using tool R4, supply oil (G090) until the oil 21) After supplying oil, drive in the small plug to
supply pressure rises to 196.1 - 294.2 kPa {2 the specified position, using tool R4.
- 3 kg/cm2}. Apply G090 around the small plug.
Drive in the plug to the following depth.
Driving depth from end face: 7.5 1 mm
In a cold or very cold district, supply Ko-

matsu genuine oil (150-09-19270 or 195-
32-61990) having better low-tempera- 22) Assemble the master link on the pin side at
ture characteristics instead of G090. last.
If the oil pressure is heightened too Check that the master links on both
much, it has bad effects on the seal. sides are press fitted in parallel.
Take care.
Supply oil so that depth L of the hollow of
the pin hole will be in the following range
when the link is left with the small plug
side up (when the link assembly is
placed on its side) for 30 minutes.
Dimension L: 40 - 70 mm
30-192 D375A-5
c c
3. Installation of shoe 2) When installing a double track, place the as-

1) Set the link assembly on the bed and install sembled double shoes on a level place in 1
the shoe with a shoe bolt impact wrench and line with the shoe side up. Pull pin-side mas-
3 Shoe bolt (Regular link)

a torque wrench. ter link (1) and bushing-side master link (2)
together and set them to each other by the
Initial torque: mating faces. Place shoe (3) on the links
1,372 137.2 Nm {140 14 kgm} and check that shoe bolt (4) can be tightened
Retightening angle: 120 10 easily until the mating faces of the links are
2 Shoe bolt:
fitted together, then connect the links with
the master bolts.
2 Shoe bolt:
3 Shoe bolt (Master link)

Initial torque:
686 68.6 Nm {70 7 kgm}
Retightening angle: 180 10
Tighten the bolts in the order of 1 - 4 .
D375A-5 30-193
c c
2. WHEN RECYCLING FOR GREASE- 3) Drive in the large and small plugs by using
FILLED TRACK tools R3 and R5.
i) Insert each plug through the plug inser-
1. Preparation work
tion window into the guide hole (Apply oil
1) Cleaning seal assembly
to the plug).
Remove the seal assembly from the link
ii) Push the bar with the hand until the plug
and divide it into the seal ling and load
stops.
ring, then clean them.
iii) Push the plug with the bar to press the
Since the seal ring and load ring are
guide against the pin.
deteriorated easily by the cleaning
iv) Drive in the bar with a hammer.
liquid, clean them quickly. After
Driving distance "a" from pin end:
cleaning them, wipe off the cleaning
Small plug: 7.5 1 mm
agent from them.
Large plug: 11 2 mm
If the plugs were not pulled out when
the shoe was disassembled, reuse
them as they are.
2) When reusing the pin, chamfer its end cor-

ners carefully with a grinder so that it will be
press fitted smoothly.
30-194 D375A-5
c c
4) If the outside of the pin, surfaces of the spac- 2. Assembly of link

er, and ends and inside of the bushing are 1) Apply lithium grease (G2-LI) to the mating
dirty, clean them. surfaces of the pin and bushing and assem-
5) Apply grease to the outside of the pin and ble them, then set them before the jaw of the
surfaces of the spacer. link press.
6) Installation of seal assembly When reusing (reversing) the bushing,
Clean the counterbore portion of the link set the worn outside surface of the bush-
carefully and push in the seal to the bot- ing on the shoe fitting side of the link (set
tom by using tool R6. the bushing with the worn outside sur-
If grease is sticking to the counter- face up on the link press).
bore portion of the link or seal as-
sembly, the seal will turn and its
sealing performance will lower. Ac-
cordingly, do not apply any oil.
2) Press fit the master links on both bushing

sides to the bushing with the shoe fitting fac-
es up.
At this time, use the master links on the
7) Adjust the dimensions of the press fitting jig pin side as supports.
of the link press to keep the projection of the Press fitting force for bushing:
pin and bushing constant and keep the in- 196 - 343 kN {20 - 35 tons}
stalled dimensions of the seal within the
standard range.
For the standard dimensions, see DI-
MENSIONS TABLE OF FITTING JIG OF
LINK PRESS.
If the pin end (part P) or link sides (parts
Q and R) are worn, add the dimensions
of the worn parts when adjusting the
standard dimensions so that the projec-
tions of the pins and bushings on both
sides will be even.
D375A-5 30-195
c c
3) Using the shoe bolt hole pitch gauge, press If the outside of the pin is worn, install it
fit the master links until the distance between so that the un-worn surface will be on the
the shoe bolt holes of both links is the stan- traction side. In this case, install the pin
dard value. so that its side hole will be the link tread
Remove the all steel chips caused by side, too.
press fitting of the bushing with com-
pressed air.
4) Turn over the master links and check that
they are press fitted in parallel.
7) Set both links and operate both pushing jigs

to press fit the pin and bushing simulta-
neously.
If the pin and bushing have play when
5) Measure the amount of protrusion of the left they are press fitted, the seal may come
and right bushing with a depth gauge. off the link. To prevent this, press fit
Adjust the press fitting jig of the link smoothly. If the seal comes off the link,
press so that the projections on both stop press fitting and set the seal to the
sides will be even. link correctly, then start press fitting
again.
Pushing force of pin and bushing: 980
kN {100 tons}
Pushing force 1.8 x Average pressure
(Adjust the relief pressure of the link
press to set the pushing force.)
6) Send the master links and set the next pin

and bushing.
When reusing a pin, install it so that its
side hole will be the link tread side simi-
larly to a new one. If it is not installed so,
its strength may be lowered. According-
ly, indicate the direction of the side hole
on the end face to prevent a mistake.
30-196 D375A-5
c c
8) Using a shoe bolt hole pitch gauge, measure 11) Using jig R10, push in the ring.
the distance between the shoe bolt holes. Pushing force for ring:
When the distance is in the standard range, 294 - 372 kN {30 - 38 tons}
stop press fitting.
12) Assemble the master link on the pin side at

9) Install the ring to jig R8. last.
Check that the master links on both
sides are press fitted in parallel.
3. Shoe (regular link portion)
Set the link assembly on the bed and install the
shoe with a shoe bolt impact wrench and a
torque wrench.
2 Shoe bolt :
Lubricant containing molybdenum
3 Shoe bolt (Regular link):

disulfide (LM-P)
Initial torque: 1,372 137.2 Nm

{140 14 kgm}
10) Match the jig to the pin hole and push it in un-
til the ring is inserted in the pin groove.
Using jig R9, install the ring on the opposite
side similarly.
A sound is made when the ring is insert-
ed in the pin groove.
D375A-5 30-197
c c
4. Assembly of 1/2 track

Place the assembled 2 shoes on a level place in
1 line with the shoe side up. Pull pin-side master
link (1) and bushing-side master link (2) together
and set them to each other by the mating faces.
Place shoe (3) on the links and check that shoe
bolt (4) can be tightened easily until the mating
faces of the links are fitted together, then con-
nect the links with the master bolts.
2 Shoe bolt:
Lubricant containing molybdenum

disulfide (LM-P)
Initial torque:
686 68.6 Nm {70 7 kgm}
Tighten the bolts in the order of 1 - 4 .
30-198 D375A-5
c c
DIMENSIONS TABLE OF FITTING
DISASSEMBLY AND ASSEMBLY JIG OF LINK PRESS
DIMENSIONS TABLE OF FITTING JIG OF LINK PRESS
Unit: mm
Dimensions of jig
a 4.2
b 2.0
c 52.1
Precaution
The link receiving faces of the jaw (1) must be verti-
cal.
Replaceable wear plate (2) type shown below is de-
sirable.
D375A-5 30-199
c c
DISASSEMBLY AND ASSEMBLY 1 LINK IN THE FIELD
DISASSEMBLY AND
ASSEMBLY OF
1 LINK IN THE FIELD
SPECIAL TOOLS
Symbol Part No. Part name Ne- Q'ty New/Re- Sketc Symbol Part No. Part name Ne- Q'ty New/Re- Sketc
1 791-646-7351 Push tool 1 21 791-680-5551 Guide 1
2 791-660-7460 Pin Brush 1 22 791-680-9630 Adapter 1
Push tool 23 791-632-1160 Guide 1
3 791-646-7900 1
(L burash)
24 195-32-61210 Bolt 2
791-701-3000 Seal Cylinder
checker
4 2 R 7 25 790-101-4300 (1,470kN 1
{150ton})
791-601-1000 Oil pump
26 790-101-1102 Pump 1
Push tool
5 791-932-1110 1 Cylinder
(S burash)
27 790-101-4200 (294kN 1
6 791-632-1021 Installer 1
{30ton})
Remover 28 791-680-1630 Spacer 1 N
assembly
2 791-632-1130 Adapter 1
DISASSEMBLY
3 790-434-1610 Guide 1
4 01010-51440 Bolt 2 1. Install tool R7-2 to link (1) with tool R7-24 and in-
5 791-685-9510 Frame 1
stall tool R7-3 with tool R7-4.
R
Use the shoe bolts for tool R7-24.
6 791-685-9530 Rod 1
7 791-685-9520 Frame 1
8 791-685-9550 Nut 3
9 04530-12030 Eye bolt 1
7 10 791-685-9560 Bolt 4
11 791-126-0150 Adapter 1
12 791-685-9540 Rod 1
13 791-632-1140 Adapter 1
14 791-680-5520 Guide 1
15 01010-51030 Bolt 1
16 791-632-1150 Pusher 1
17 791-685-9620 Extention 1
18 791-632-1180 Adapter 1
19 791-680-5543 Adapter 1
20 791-632-1170 Guide 1
30-200 D375A-5
(1) cc
2. Assemble tools R7-25 and R7-5 - R7-11, then If the cylinder reaches the stroke end, con-
sling and set them on the shoe. nect tool R7-17 and repeat the work.
3. Insert tool R7-12 from the cylinder side and in- 5. Set tools R7-27 and R7-28 to the center on the
stall it with 2 tools R7-8. roller tread side of the link to be disassembled
and connect tool R7-26. Apply hydraulic pres-
sure to open the link by 5 - 6 mm and disconnect
it.
4. Set tools R7-13 - R7-16 and connect them by

tool R7-26. Apply hydraulic pressure and pull
out pin (2).
6. Repeat steps 1 - 4 to pull out pin (3) on the op-
posite side.
D375A-5 30-201
c c
7. Repeat step 5 to remove link (4). 2) Set tool R7-19 to the pin-side end of the link
and press fit pin (7).
Set the pin with its side hole on the link
tread side.
Press fitting force of pin:
206 - 323 kN {21 - 33 tons}
ASSEMBLY
1. Assemble the link sub-assembly according to
the following procedure.
1) Set tool R7-18 to the bushing-side end of link
(5) and press fit bushing (6).
2. Set link sub-assembly (8) to the link to be con-
Press fitting force of bushing:
nected.
196 - 294 kN {20 - 35 tons}
3. Set link (9) on the opposite side and support it

with tool R7-20.
30-202 D375A-5
c c
4. Similarly to the disassembly procedure, set tools 7. Set link (11) to be connected to link (10) and con-
R7-25, R7-5 - R7-12, and R7-17 to the link. nect them with tool R7-23, then remove tools R7-
27 and R7-28.
5. Use R7-19 and R7-21 to press fit the pin. Use
tools R7-22, R7-18, and R7-21 to press fit the
bushing. Press fit the pin and bushing alternate-
ly.
Press fit the pin first. After the bushing is en-
gaged with the link, remove tool R7-20 in-
stalled in step 3, then press fit the bushing.
206 - 323 kN {21 - 33 tons}
Press fitting force of bushing:
196 - 294 kN {20 - 30 tons}
8. Similarly to the disassembly procedure, set tools

R7-2 - R7-12 and press fit pin (12) to the link.
2 Pin fitting hole of link:
Gasket sealant (198-32-19890)
Set the pin with its side hole on the link tread
side.
412 - 646 kN {42 - 66 tons}
If the cylinder reaches the stroke end, insert
tools R7-17 and R7-14 - R7-16 and repeat
6. Similarly to the disassembly procedure, push the work.
open link (10) to be connected by using tools R7-
27 and R7-28.
D375A-5 30-203
c c
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF MASTER LINK
DISASSEMBLY AND
ASSEMBLY OF MASTER LINK
SPECIAL TOOLS
Ne- New/Re- Sketc Ne- New/Re- Sketc
Symbol Part No. Part name Q'ty Symbol Part No. Part name Q'ty
1 791-646-7351 Push tool 1 26 790-101-1102 Pump 1
2 791-660-7460 Pin brush 1 Cylinder
7 27 790-101-4200 (294kN 1
Push tool
3 791-646-7900 (For large 1 {30ton})
plug) 28 791-680-1630 Spacer 1
791-701-3000 Seal Push tool
1 791-632-1300 1 N
or checker assembly
4 2
2 791-632-1260 Ring 1
791-601-1000 Oil pump
3 791-632-1270 Shaft 1
Push tool
5 791-932-1110 (For small 1 4 791-632-1220 Pin (small) 1
plug) 5 791-632-1230 Ring 1
6 791-632-1021 Installer 1 8
6 791-632-1240 Washer 1
Remover 7 791-685-5730 Bar 1
assembly 8 791-632-1250 Urethan 1
2 791-632-1130 Adapter 1 9 791-632-1280 Spring 1
3 790-434-1610 Guide 1 10 01252-30605 Bolt 1
4 01010-51440 Bolt 2 R 11 01580-01210 Nut 1
5 791-685-9510 Frame 1 Push tool
1 791-632-1300 1 N
assembly
6 791-685-9530 Rod 1
2 791-632-1260 Ring 1
7 791-685-9520 Frame 1
R 3 791-632-1270 Shaft 1
8 791-685-9550 Nut 3
4 791-632-1210 Pin (large) 1
9 04530-12030 Eyebolt 1
5 791-632-1230 Ring 1
10 791-685-9560 Bolt 4 9
6 791-632-1240 Washer 1
11 791-126-0150 Adapter 1
7 791-685-5730 Bar 1
12 791-685-9540 Rod 1
8 791-632-1250 Urethan 1
7 13 791-632-1140 Adapter 1
9 791-632-1280 Spring 1
14 791-680-5520 Guide 1
10 01252-30655 Bolt 1
15 01010-51030 Bolt 1
11 01580-01210 Nut 1
16 791-632-1150 Pusher 1
Push tool
17 791-685-9620 Extension 1 1 791-632-1290 2 N
assembly
18 791-632-1180 Adapter 1 10
2 791-685-5730 Bar 1
19 791-680-5543 Adapter 1 3 01580-01210 Nut 1
20 791-632-1160 Guide 1
21 791-680-5551 Guide 1
22 791-680-9630 Adapter 1
23 791-632-1160 Guide 1
24 195-32-61210 Bolt 2
Cylinder
25 790-101-4300 (1,470kN 1
{150ton})
30-204 D375A-5
c c
DISASSEMBLY Master link type

1) Cutting and removal of master link on bush-
For the method of using tool R7, see DISAS-
SEMBLY OF 1 LINK IN THE FIELD. ing side with gas
Cut the parts marked with gas and re-
1. Removal of track shoe assembly move the parts marked . Move master
Remove the track shoe assembly from the track links (5) and (6) in the direction of and to
frame. For details, see EXPANDING TRACK pull them out. Then, push pins (8) and (9)
SHOE ASSEMBLY. out of regular link (7) in the directions of
2. Disassembly of shoe and with a press.
Disconnect the all master links and divide the Necessary special tools:
shoes into 4 parts. 1. Gas cutting machine
2. Tool R7
3. Removal of master link
Master pin type
1) Cutting of regular link with gas
move the parts marked .
Necessary special tool: Gas cutting ma-
chine
2) Removal of master link on pin side

move the parts marked . Push pin (10)
out of link (11) in the direction of with a
press. Then, pull pin (10) and link (12) to-
gether out of bushing (13).
Necessary special tools:
2) Removal of regular link 1. Gas cutting machine
Push pin (1) in the direction of with a press 2. Tool R7
to remove it from link (2), then pull pin (1) and
link (3) together out of bushing (4).
D375A-5 30-205
c c
ASSEMBLY 2. Installation of link at bushing end

1) Expand the center of the link tread with tool
For the method of using tool R7, see DISAS-
R7 as shown in the figure. (Expand the link
SEMBLY of 1 link in the field.
end by 10 mm.)
1. Assembly of link at bushing end
1) Press fit bushing-side master link (1) at
bushing end to bushing (2) with a press.
When press fitting both master links,
take care that they will be in parallel with
each other.
Do not damage the mating surfaces of
the master links and end faces of the
bushing.
Unit: mm
L1 184 0.7
L2 253.4 0.7
D1 Drill 33 in diameter 2) Set spacer (3) and seal assembly (4) to the
counterbore of the link of the connecting
D2 30 2.0 part.
3) Match the pin hole and bushing hole to each

other and connect the pin and bushing with
guide pin 1 .
30-206 D375A-5
c c
4) Press fit pin (5) with tool R7 and install at Adjust the end play of the connecting
bushing end master link (1). part (the thrust play between the links
2 Apply gasket sealant (198-32- before and after the pin) to 0 - 0.13 mm.
19890) to the pin hole of the link. Take care that dirt and sand will not stick
to the seal, spacer, end of bushing, and
Set the pin with its side hole on the link tap-hole mating face of the master link.
tread side.
5) Using tools R7, R8, R9, and R10, install the 3. Assembly of at pin end link
ring. 1) Set spacer (3) and seal assembly (4) to the
counterbore of the master link.
6) Install the shoe to the link of the connecting

part. 2) Pass pin (9) through bushing (8) and set and
7) Drive large plug (6) with tool R3 and supply press fit pin-side master links (10) at pin end
oil with tool R4, then drive small plug (7) with from both sides with tool R7.
tool R5. 3) Using tools R7, R8, R9, and R10, install the
ring.
4) Drive large plug (11) with tool R3 and supply
oil with tool R4, then drive small plug (12)
with tool R5.
When press fitting both master links,

take care that they will be in parallel with
each other (Bushing side and pin side).
Do not damage the mating surfaces of
the master links and end faces of the
bushing.
D375A-5 30-207
c c
4. Connection of master links

Place the assembled 2 shoes on a level place in
1 line with the shoe side up. Pull master link (13)
at pin end and bushing-side master link (14) to-
gether and set them to each other by the mating
faces. Place the shoe on the links and check
that the shoe bolt can be tightened easily until
the mating faces of the links are fitted together,

then connect the links with the master bolts.
Initial torque:
686 68.6 Nm {70 7 kgm}
30-208 D375A-5
c c
DISASSEMBLY AND ASSEMBLY PIVOT SHAFT ASSEMBLY
REMOVAL AND
INSTALLATION OF
PIVOT SHAFT ASSEMBLY
SPECIAL TOOLS 3. Remove seal (2) and cover (3). q2

bol Part No. Part name cessity Q'ty model h
1 791T-650-2330 Sleeve 1 N c
2 791T-650-2340 Plate 1 N c
3 790-201-3310 Bolt 2
4 790-101-2510 Block 1
5 790-101-2570 Washer 2
P
6 01580-01613 Nut 2
7 01643-31645 Washer 2
Jack
8 790-105-2300 1
assembly
9 790-101-1102 Pump 1
1. Track frame assembly Carry out installation in the reverse order to re-
Remove the track frame assembly. For de- moval.
q1
tails, see REMOVAL OF TRACK FRAME
ASSEMBLY.
2. Sling pivot shaft assembly (1) temporarily and 2 Press fitting face of pivot shaft:
remove the mounting bolts. Using forcing screw Anti-friction compound (LM-P)
1 , pull out the pivot shaft assembly. q1 q2
4 Pivot shaft assembly: 390 kg
Using tool P, press fit seal (2) to the pivot
shaft.
2 Press fitting face of seal:
Check that press fitting dimension "a" of the
seal from the shaft end is in the standard
range.
Press fitting dimension "a":
655 1.0 mm
D375A-5 30-209
c c
DISASSEMBLY AND ASSEMBLY PIVOT SHAFT ASSEMBLY

P1 Sleeve
P2 Plate
30-210 D375A-5
c c
DISASSEMBLY AND ASSEMBLY EQUALIZER BAR
REMOVAL AND
INSTALLATION OF
EQUALIZER BAR
SPECIAL TOOLS 3. Remove seal (2) and washer (3) together. q 1
Perform this procedure for only the right
bol Part No. Part name cessity Q'ty model h track frame.
791-650-1300 Remover z 1 4. Remove washer (4) and spacer (5).
791-735-1123 Sleeve 1 Receive the oil flowing out of the pivot case
790-434-1050 Screw 1 with an oil pan, etc.
01580-02419 Nut 1 6 Pivot case: 18
N 1
01643-32460 Washer
Puller 5. Set hydraulic jack 1 (490 kN (50 tons}) under
790-101-2102 (294kN z 1 the radiator guard.
{ton})
790-101-1102 Pump z 1
REMOVAL
1. Remove the engine underguard and power train
underguard (front).
4 Engine underguard: 290 kg
Power train underguard (front): 280 kg

For the right track frame, disconnect the 4
hoses for the blade tilt cylinder.
Since the whole machine body will be raised
by using the blade, plug the hoses on the tilt 6. Remove cover (6).
cylinder side securely.
7. Remove cover (7) and loosen bolt (8).
D375A-5 30-211
c c
8. Loosen clamping bolt (9) of the rear equalizer 12. Disconnect lubrication tube (12).
q4
bar side pin.
13. Remove 2 lock plates (13).
q2 q3
q5
9. Remove side pin (10).
14. Using tool N1, remove center pin (14).
If the equalizer bar hole is not aligned with
If the equalizer bar hole is not aligned with
the track frame hole, the pin cannot be pulled
the main frame hole, the pin cannot be pulled
out easily. Accordingly, adjust the height of
out easily. Accordingly, adjust the height of
the equalizer bar with hydraulic jack 1 .
the main frame with hydraulic jack 1 .
10. Repeat steps 6 - 9 and remove the side pin on

the opposite side.
11. Operate hydraulic jack 1 slowly to lower the ma-
chine body until the equalizer bar touches both
track frames.
30-212 D375A-5
c c
15. Operate the blade to raise the front part of the INSTALLATION
machine body and set stand 3 under the radia-
tor guard.
moval.
q1
After removing the grease from the pressfit-
ting surface of the seal, coat with gasket
sealant (LG-6).
Be careful not to install with the seal dis-
placed in the direction of twisting.
q2
2 Inside surface of bushing :
Grease (G2-LI)
Before installing the pin, operate hydraulic
jack 1 to adjust the height of the main frame
and align the center of the equalizer bar hole
16. Sling equalizer bar (15) and remove it over the and track frame hole.
main frame and track frame. Set the pin with the grease hole facing the
After removing the equalizer bar, do not low- outside of the machine.
er the machine body. q3
4 Equalizer bar assembly: 500 kg Fit pin and bushing, install cover, then install
the cover and cushion.
Tighten bolt (8), then tighten cover mounting
bolt.
q4
3 Lock plate mounting bolt :
549 59 Nm {56 6 kgm}
q5
2 Equalizer bar bushing and main frame
bushing : Grease (G2-LI)
Before installing the pin, operate the crane to
align the center of the main frame hole and
the equalizer bar hole.
Refilling with oil (pivot case)

5 Pivot case : 18 (SAE30)
D375A-5 30-213
c c
DISASSEMBLY AND ASSEMBLY OF EQUALIZER
DISASSEMBLY AND ASSEMBLY BAR BUSHING
DISASSEMBLY AND
ASSEMBLY OF EQUALIZER
BAR BUSHING
SPECIAL TOOLS 2. Guide bushing
1) Remove seal (2).
Ne- New/Re- Sketc
Symbol Part No. Part name
cessity
Q'ty
model h 2) Remove snap ring (3).
1 791T-650-2410 Bracket 1 N c
2 791T-650-2420 Bracket 1 N c
3 790-438-1110 Screw 1
4 791-112-1180 Nut 2
N 2
5 790-101-2540 Washer 2
Puller
6 790-101-2102 (294kN 1
{30ton})
7 790-101-1102 Pump 1
DISASSEMBLY
1. Center bushing
1) Remove center bushing (1). 3) Set tool N2 and remove side bushing (4)
from equalizer bar (5).
30-214 D375A-5
c c
ASSEMBLY 2) Install snap ring (3).

After installing the snap ring, fill parts "c"
1. Side bushing
before and after the side bushing with
1) Set side bushing (4) and tool N2 and press fit
grease (G2-LI).
2 Amount of grease to be supplied to
side bushing (4) to equalizer bar (5).
2 Outside of side bushing:
Anti-friction compound (LM-P) side bushing: 0.3
Press fit the side bushing in the direction 3) Using a press, press fit seal (2).
shown below. Press fitting force for seal:
9.8 - 29.4 kN {1 - 3 tons}
Press fit the seal so that its metallic part
will not be projected from the equalizer
bar end.
2 Seal lip: Grease (G2-LI)
i)Set split (mating) face "a" of the outer

bushing on the level.
ii) Set grease holes "b" of the inner
bushing and outer bushing diagonally.
Press fitting force for side bushing:
34.3 - 73.5 kN {3.5 - 7.5 tons} 2. Center bushing
Using the press, press fit bushing (1).
2 Outside of center bushing:
Press fitting force for center bushing:
4.9 - 186.2 kN {5 - 19 tons}
D375A-5 30-215
c c

N2-1 Bracket
N2-2 Bracket
30-216 D375A-5
c c
DISASSEMBLY AND ASSEMBLY SEGMENT TOOTH
REMOVAL AND
INSTALLATION OF
SEGMENT TOOTH
1. Stop the machine in a position where the seg- Carry out installation in the reverse order to re-
ment tooth can be removed (between the chute moval.
and track frame).
2. Remove covers (1) and (2). 2 Seat of segment tooth mounting nut:
3 Segment tooth mounting nut:

1,813 98 Nm {185 10 kgm}
3. Remove the mounting bolts and segment tooth

(3).
Before removing the all mounting bolts, in-
sert bar 1 in the upper mounting bolt hole
and move and remove the segment tooth
outward.
4 Segment tooth: 35 kg
D375A-5 30-217
c c
REMOVAL AND INSTALLATION OF HYDRAULIC
DISASSEMBLY AND ASSEMBLY TANK ASSEMBLY
REMOVAL AND
INSTALLATION OF
HYDRAULIC
TANK ASSEMBLY
REMOVAL 5. Disconnect the 2 PPC hoses and 3 main hoses
(5) from the blade lift valve.
Lower the work equipment to the ground and re-
The PPC hoses are classified by the color
q1
lease the residual pressure from the piping, re-
bands.
f e r r i n g t o T E S T I N G A N D A D J U S T I N G,
Releasing residual pressure from hydraulic cir-
cuit. Then, loosen the hydraulic oil filler cap to
release the internal pressure of the hydraulic
tank.
1. Drain the oil from the hydraulic tank.
6 Hydraulic tank: 230
2. Remove operator's cab right cover (1).
6. Open hydraulic tank front cover (6) and discon-

nect hoses (7) and (8) from the blade lift valve.
Move the disconnected hoses toward the op-
erator's cab.
3. Disconnect PPC charge valve (2) from the hy-

draulic tank.
Move the PPC charge valve toward the floor
frame.
30-218 D375A-5
c c
7. Disconnect 6 PPC hoses (9), 4 rear main hoses 10. Lift off hydraulic tank assembly (16).
(10), and 4 front main hoses/tubes (11) from the 4 Hydraulic tank assembly: 380 kg q3
blade tilt and ripper Lo valve.
bands. q2
8. Disconnect return hose (12) and suction tube
(13) from the hydraulic tank.
9. Remove hydraulic tank front cover (14) and dis-

connect return hose (15).
D375A-5 30-219
c c
INSTALLATION 3 Hydraulic tank mounting bolt:

Carry out installation in the reverse order to re- 151.9 24.5 Nm {15.5 2.5 kgm}
moval. q3
Refilling with oil (Hydraulic tank)
q1 q2 Add oil through the oil filler to the specified level.
The connecting positions of the PPC hoses Run the engine to circulate the oil through the
are indicated by the band colors on their system. Then, check the oil level again.
quick couplers. When connecting them,
confirm them by the band colors. Bleeding air
Bleeding the air from the piping.
For details, see TESTING AND ADJUSTING,
Bleeding air from hydraulic cylinder.
Distinguishing color bands

(View from operators cad)
A. Transparent
B. Red/White
C. Black/Blue
D. Brown
E. Black
F. Green
G. White
H. Yellow
30-220 D375A-5
c c
REMOVAL AND INSTALLATION OF WORK
DISASSEMBLY AND ASSEMBLY EQUIPMENT AND PPC PUMP ASSEMBLY
REMOVAL AND
INSTALLATION OF WORK
EQUIPMENT
AND PPC PUMP ASSEMBLY
REMOVAL 7. Sling work equipment pump assembly (5) tem-
porarily and remove the mounting bolts, then re-
move the work equipment pump assembly.
4 Work equipment and PPC pump
Releasing residual pressure from hydraulic cir- assembly: 45 kg
tank.
nal of the battery.
2. Remove the floor frame assembly. For details,

see REMOVAL OF FLOOR FRAME ASSEM-
BLY.
3. Disconnect hydraulic oil temperature sensor
connector (CN-452) (1).
INSTALLATION
4. Disconnect 2 hoses (2).
5. Disconnect 4 delivery hoses (3). moval.
3 Suction tube clamp bolt:

6. Disconnect suction tube (4).
Remove the 2 clamps and move the cou-
pling toward the pump to disconnect the suc- 26.95 2.45 Nm {2.75 0.25 kgm}
tion tube.
Add oil through the oil filler to the specified level.
system. Then, check the oil level again.
D375A-5 30-221
c c
REMOVAL AND INSTALLATION OF BLADE
DISASSEMBLY AND ASSEMBLY LIFT VALVE ASSEMBLY
REMOVAL AND
INSTALLATION OF BLADE
LIFT VALVE ASSEMBLY
REMOVAL 4. Open hydraulic tank front cover (4) and discon-
nect hoses (5) and (6).
Releasing residual pressure from hydraulic cir-
tank.
2. Remove operator's cab right cover (1).
5. Sling work blade lift valve (7) temporarily and re-

move the mounting bolts. Then, remove the
blade lift valve assembly.
4 Blade lift valve assembly: 60 kg
3. Disconnect 2 PPC hoses (2) and 3 main hoses

(3).
bands. q1
30-222 D375A-5
c c
REMOVAL AND INSTALLATION OF BLADE
DISASSEMBLY AND ASSEMBLY LIFT VALVE ASSEMBLY
INSTALLATION
moval.
q1
The connecting positions of the PPC hoses
are indicated by the band colors on their
confirm them by the band colors.

A. Transparent
B. Red/White

Bleeding air
Bleed air from the piping. For details, see TEST-
ING AND ADJUSTING, Bleeding air from hy-
draulic cylinders.
D375A-5 30-223
c c
DISASSEMBLY AND ASSEMBLY BLADE LIFT VALVE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF BLADE LIFT VALVE

ASSEMBLY
This chapter deals only with precautions to be 4. Assembly of main relief and shuttle valve as-
followed when reassembling the Blade Lift Valve sembly
Assembly. Fit the O-ring and main relief and shuttle valve
assembly (18).
ASSEMBLY Tighten the mounting bolts in the order of 1
3 Mounting bolt:
-4.
Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with engine
oil before installing. 1st time:
34.3 4.9 Nm {3.5 0.5 kgm}
1. Assembly of shuttle valve assembly
2nd time:
3 Plug:
Install ball (31) and fit the O-ring and plug (30).
66.15 7.35 {6.75 0.75 kgm}
34.3 4.9 Nm {3.5 0.5 kgm}
2. Assembly of check valve assembly

Install valve (29) and spring (28) and fit the O-
3 Plug:367.5 24.5 Nm {37.5 2.5 kgm}

ring and plug (27).
3. Assembly of suction valve assembly

Install valve (26) and spring (25) and fit the O-
3 Plug:514.5 24.5 Nm {52.5 2.5 kgm}

ring and plug (24).
30-224 D375A-5
c c
DISASSEMBLY AND ASSEMBLY BLADE LIFT VALVE ASSEMBLY
If the main relief valve was disassembled,

adjust it after installing the valve assembly to
the machine body, referring to TESTING
AND ADJUSTING, Measuring and adjusting
work equipment oil pressure.
5. Assembly of demand valve assembly
1) Install seal (17), spool (16), O-ring, and case
3 Mounting bolt:
(15).
186.2 9.8 Nm {19 1 kgm}
3 Mounting bolt:
2) Install spring (14) and case (13).
186.2 9.8 Nm {19 1 kgm}

6. Assembly of main spool assembly
1) Install spool (12), O-ring, and case (11).
2) Install retainer (10), spring (9), O-ring, and
case (8).
3) Install retainer (7), spacer (6), spring (5), re-
tainer (4), and washer (3) and tighten bolts
3 Mounting bolt:
(2).
110.25 12.25 Nm
{11.25 1.25 kgm}
Tighten the bolts with the spool installed
in the body.
4) Install the O-ring and case (1).
D375A-5 30-225
c c
DISASSEMBLY AND ASSEMBLY OF BLADE TILT
DISASSEMBLY AND ASSEMBLY AND RIPPER LOW VALVE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF BLADE TILT AND RIPPER

LOW VALVE ASSEMBLY
30-226 D375A-5
c c
DISASSEMBLY AND ASSEMBLY OF BLADE TILT
DISASSEMBLY AND ASSEMBLY AND RIPPER LOW VALVE ASSEMBLY
This chapter deals only with precautions to be

followed when reassembling the Blade Tilt and
Ripper Low Valve Assembly.
ASSEMBLY
Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with engine
oil before installing.
1. Assembly of shuttle valve assembly
1) Install ball (20) and seat (19) to plug (18).
3 Plug:
2) Install the O-ring and plug (18).
34.3 4.9 Nm {3.5 0.5 kgm}
2. Assembly of check valve assembly

1) Install valve (17) and spring (16).
2) Install the O-ring, seat (15), and bar (14) and
tighten bolts (13).
3. Assembly of main relief valve assembly
Install the O-ring and main relief valve assembly
3 Main relief valve assembly:

(12).
83.3 14.7 Nm {8.5 1.5 kgm}

If the main relief valve was disassembled,
adjust it after installing the valve assembly to
the machine body, referring to TESTING
AND ADJUSTING, Measuring and adjusting
work equipment oil pressure.
4. Assembly of spool assembly
1) Install spool (10) to body (11).
2) Set retainer (9), spacers (8) and (7), spring
(6), retainer (5), and washer (4) and tighten
bolts (3).
Tighten the bolts with the spool installed
3 Mounting bolt:
in the body.
34.3 4.9 Nm {3.5 0.5 kgm}

D375A-5 30-227
c c
DISASSEMBLY AND ASSEMBLY RIPPER HIGH VALVE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF RIPPER HIGH VALVE

ASSEMBLY
30-228 D375A-5
c c
DISASSEMBLY AND ASSEMBLY RIPPER HIGH VALVE ASSEMBLY
This chapter deals only with precautions to be 5. Assembly of constant-differential pressure

followed when reassembling the Ripper High valve assembly
Valve Assembly. 1) Install spool (9).
2) Set retainer (8), spring (7), and retainer (6) to
ASSEMBLY the spool and install plug (5).
Clean the all parts and check them for dirt or Be sure to tighten the plug with the spool in-
damage. Coat their sliding surfaces with engine stalled in the valve.
oil before installing.
3 Plug: 34.3 4.9 Nm {3.5 0.5 kgm}

6. Install ball (4), O-ring, and plug (3).
1. Install valve (23), spring (22), seat (21), O-ring,
3 Plug:
and plug (20).
7. Install the O-ring and blocks (2) and (1).
514.5 24.5 Nm {52.5 2.5 kgm}
2. Install check valve (19), spring (18), O-ring, and
3 Plug: 127.4 19.6 Nm {13 2 kgm}

plug (17).
3. Assembly of ripper lift high valve assembly

1) Install spool (16).
2) Set retainer (15) and spring (14) to the spool
3 Plug:
and install the O-ring and plug (13).
66.15 7.35 {6.75 0.75 kgm}

3) Set retainer (12) and spring (11) to the spool
3 Plug:
and install the O-ring and plug (10).
66.15 7.35 {6.75 0.75 kgm}

Be sure to tighten the plugs with the
spool installed in the valve.
4. Assembly of ripper tilt high valve assembly

Assemble the ripper tilt high valve assembly ac-
cording to the assembly procedure for the ripper
lift high valve assembly.
D375A-5 30-229
c c
DISASSEMBLY AND ASSEMBLY OF PPC CHARGE
DISASSEMBLY AND ASSEMBLY VALVE ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF PPC CHARGE
VALVE ASSEMBLY
followed when reassembling the PPC Charge
Valve Assembly.
ASSEMBLY
Check the all parts for dirt or damage. Coat their
sliding surfaces with engine oil before installing.
1. Install plugs (13) and (12).
2. Install poppet (11) and spring (10) to valve body
(1), then tighten plug (9).
When installing the spring, check its free
length.
Free length of spring: 25.3 mm
3. Install poppet (8) and spring (7) to valve body
(1), then tighten plug (6).
When installing the spring, check its free
length.
Free length of spring: 20.6 mm
4. Install strainer (5) and plug (4).
Tighten the strainer to the following torque
3 Strainer:
and caulk it by 2 places.
7.35 0.49 Nm {0.75 0.05 kgm}
3 Relief valve:
5. Tighten relief valve (3) into valve body (1).
53.9 4.9 Nm {5.5 0.5 kgm}
6. Install accumulator (2) to valve body (1).
30-230 D375A-5
c c
DISASSEMBLY AND ASSEMBLY OF BLADE PPC
DISASSEMBLY AND
ASSEMBLY OF BLADE PPC
VALVE ASSEMBLY
followed when reassembling the Blade PPC
Valve Assembly.
ASSEMBLY
1. Install the blade RAISE valve
1) Install the blade RAISE valve
2) Install the blade RAISE valve
Install spring (37) with its small seat di-
ameter (inside diameter) end on the
shim (38) side.
3) Install spring (36), retainer (35), piston (34),
spring (33), and piston (32).
When installing piston (34), apply grease
(G2-LI) to the outside of the piston and
the inside of the body hole.
(G2-LI) to the inside of the body hole.
2. Install the blade LOWER valve.
1) Install valve (31) to body (18).
2) Install shim (30) and spring (29) to valve
(31).
shim (30) side.
3) Install spring (28), retainer (27), piston (26),
shim (25), retainer (24), ball (23), collar (22),
spring (21), spacer (20), and piston (19).
3. Install the blade tilt valve.
1) Install valve (17) to body (18).
2) Install shim (16) and spring (15) to valve
(17).
shim (16) side.
D375A-5 30-231
c c
DISASSEMBLY AND ASSEMBLY OF BLADE PPC
3) Install spring (14), retainer (13), and pistons

(12) and (11).
3 Orifice:
4. Install orifice (10).
11.8-14.7 Nm {1.2-1.5 kgm}
5. Install the O-ring and plate (9).

6. Install the O-ring and body (8).
7. Install the O-ring to collar (7) and install them to
body (8), then install seal (6).
3 Mounting bolt:
8. Install plate (5).
11.8-14.7 Nm {1.2-1.5 kgm}
9. Install joint (4).

When installing the joint, apply adhesive (LT-
3 Joint:
2) to the female threads hole of body (8).
44.1 4.9 Nm {3.5 0.5 kgm}

Apply grease (G2-LI) to the rocking part of
the joint.
10. Install boot (3) and disc (2) and secure them with
nut (1).
Apply grease (G2-LI) to the contact surfaces
3 Nut:
of disc (2) and pistons (32), (19), and (11).
112.7 14.7 Nm {11.5 1.5 kgm}

After installing the disc, adjust its height, re-
ferring to TESTING AND ADJUSTING, Ad-
justing PPC valve.
30-232 D375A-5
c c
DISASSEMBLY AND ASSEMBLY OF RIPPER
DISASSEMBLY AND ASSEMBLY PPC VALVE ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF RIPPER
PPC VALVE ASSEMBLY
followed when reassembling the Ripper PPC
Valve Assembly.
ASSEMBLY
1. Install valve (13) to body (14).
2. Install shim (12) and spring (11) to valve (13).
Install spring (11) with its small seat diameter
(inside diameter) end on the shim (12) side.
3. Install spring (10), retainer (9), and piston (8).
Springs (10) having different number of turns
are used for the following hydraulic ports.
Take care when installing them.
Port Total number of turns
P1, P2 9
P3, P4 10.5
Each port position is stamped on the under-

side of the valve body.
2 Piston: Grease (G2-LI)
When installing piston (8), apply grease to
the outside of the piston and the inside of the
body hole.
4. Install the O-ring to collar (7) and install them to
body (14), then install seal (6).
3 Mounting bolt:
5. Install plate (5).
13.72 1.96 Nm {1.4 0.2 kgm}
6. Install joint (4).

2 Rocking part of joint: Grease (G2-LI)
2 Joint: Thread tightener (LT-2)
3 Joint: 44.1 5 Nm {4.5 0.5 kgm}
Observe the tightening torque for the joint.
7. Install boot (3) and disc (2) and secure them with
3 Nut: 112.7 14.7 Nm {11.5 1.5 kgm}

nut (1).
After installing the disc, adjust its height, re-

ferring to TESTING AND ADJUSTING, Ad-
justing PPC valve.
D375A-5 30-233
c c
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC
DISASSEMBLY AND ASSEMBLY CYLINDER ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
Sym- Ne- New/Re- Sketc 1. Cylinder tube
bol Part No. Part name cessity Q'ty model h Remove the cylinder tube.
Cylinder re-
1 790-502-1003 z 1 2. Quick drop valve assembly
pair stand
Push tool Perform this procedure for only the blade lift
790-201-1702 1
kit cylinder.
790-201-1841 Push tool 1 1) Remove quick drop valve assembly (1).
2
790-201-1861 Push tool 1
790-101-5021 Clip 1
01010-50816 Bolt 1
Push tool
790-201-1500 1
kit
790-201-1650 Plate 1
3
790-201-1670 Plate 1
790-101-5021 Clip 1
U
01010-50816 Bolt 1
4 790-720-1000 Expander 1
796-720-1680 Ring 1
07281-01589 Clamp 1
796-720-1720 Ring 1
5
07281-02429 Clamp 1 2) Disassemble the quick drop valve assembly
796-720-1690 Ring 1 according to the following procedure.
07281-02169 Clamp 1
i) Remove elbow (2).
ii) Remove spring (3), washer (4), and
790-102-2302 Wrench
valves (5) and (6), then pull out collar (7).
1
6 790-330-1100 Multi-
wrench
790-101-1102 Pump 1
30-234 D375A-5
c c
3. Piston rod assembly 2) Remove spacer (11).

1) Set cylinder assembly (8) to tool U1. 3) Remove the piston assembly.
2) Remove head assembly (9). 4) Remove backup rings (13) and (14) and O-
3) Pull out piston rod assembly (10). ring (15).
Put an oil pan under the cylinder to re- 5) Remove retainer (16).
ceive the oil.
6) Disassemble the piston assembly according

4. Piston assembly to the following procedure.
1) Set piston rod assembly (10) to tool U1. i) Remove wear ring (17).
ii) Remove piston ring (18).
D375A-5 30-235
c c
5. Cylinder head assembly ii) Remove snap ring (22) and tool (23).
1) Remove cylinder head assembly (19) from iii) Remove packing (24) and bushing (25).
the piston rod.
2) Disassemble the cylinder head assembly ac-

cording to the following procedure.
i) Remove O-ring (20) and backup ring
(21).
30-236 D375A-5
c c
ASSEMBLY v) Install backup ring (21) and O-ring (20).

Apply engine oil to the sliding surfaces of each
part and install the packings, dust seals, and O-
rings, taking care not to damage them.
1. Cylinder head assembly
1) Assemble the cylinder head assembly ac-
2) Install cylinder head assembly (19) to the

piston rod.
i) Using tool U2, press fit bushing (25) to

the head.
ii) Install packing (24).
iii) Using tool U3, press fit seal (23).
iv) Install snap ring (22).
D375A-5 30-237
c c
2. Piston assembly 2) Install retainer (16).

1) Assemble the piston assembly according to 3) Install the O-ring and backup rings (14) and
the following procedure. (13).
i) Using tool U4, expand piston ring (18). Apply grease to the O-ring and backup
Set the piston ring to the tool and rings so that the backup rings will not
turn the handle of the tool by 8 - 10 open.
turns to expand the piston ring. 4) Install piston assembly (12).
ii) Remove piston ring (18) from tool U4 5) Install spacer (11) and tighten the mounting
and install it to the piston. bolts.
2 Mounting bolt:
3 Mounting bolt:
Blade lift:
66.5 7.5 Nm {6.75 0.75 kgm}
Blade tilt, ripper lift, ripper tilt:
176.5 19.5 Nm {18 2 kgm}
iii) Set tool U5 and shrink piston ring (18).

iv) Install wear ring (17) to the piston.
3. Piston rod assembly

1) Set cylinder (8) to tool U1.
30-238 D375A-5
c c
2) Install piston rod (10) to cylinder (8). 2) Install quick drop valve assembly (1).
Apply grease to the sealing part of the
piston. 5. Cylinder tube
Push in the piston rod fully. Install the cylinder tube.
3) Push head assembly (9) in the cylinder and
tighten the mounting bolts.
Apply grease to the backup rings.
4. Quick drop valve assembly

Perform this procedure for only the blade lift
cylinder.
1) Assemble the quick drop valve assembly ac-
i) Install collar (7), valves (6) and (5),
washer (4), and spring (3).
D375A-5 30-239
c c
DISASSEMBLY AND ASSEMBLY OF RIPPER PIN
DISASSEMBLY AND ASSEMBLY PULLER CYLINDER ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF RIPPER PIN
PULLER
CYLINDER ASSEMBLY
Sym- Ne- New/Re- Sketc 1. Cylinder assembly
bol Part No. Part name cessity Q'ty model h 1) Set pin puller cylinder assembly (1) to tool
1 790-502-1003
Cylinder re-
z 1 U1.
pair stand
2) Using tool U6, remove cylinder head assem-
Push tool bly (2).
790-201-1702 1
kit
3) Remove piston rod (3) and cylinder head as-
2 790-201-1721 Push tool 1
sembly (2) together.
790-101-5021 Clip 1
Put an oil pan under the cylinder to re-
01010-50816 Bolt 1 ceive the oil.
Push tool
790-201-1500 1
kit
3 790-201-1530 Plate 1
U
790-101-5021 Grip 1
01010-50816 Bolt 1
4 790-720-1000 Expander 1
796-720-1630 Ring 1
5
07281-00709 Clamp 1
Wrench
790-102-2302
1
6 790-330-1100 Multi-
wrench
790-101-1102 Pump
2. Cylinder head assembly

1) Remove cylinder head assembly (2) from
piston rod (3).
30-240 D375A-5
c c
2) Remove O-ring (5) and backup ring (6). ASSEMBLY

3) Remove O-ring (7).
Apply engine oil to the sliding surfaces of each
4) Remove snap ring (8) and dust seal (9).
part and install the packings, dust seals, and O-
5) Remove rod packing (10) and bushing (11).
rings, taking care not to damage them.
1) Using tool U4, expand piston ring (12).
Set the piston ring to the tool and turn the
handle of the tool by 8 - 10 turns to expand
the piston ring.
2) Remove piston ring (12) from the tool and in-
stall it to piston rod (3).
3) Using tool U5, shrink piston ring (12).

Remove piston ring (12) from piston rod (3).
D375A-5 30-241
c c
2. Cylinder head assembly 6) Install cylinder head assembly (2) to piston

1) Using tool U2, press fit bushing (11) to cylin- rod (3).
der head (4).
3. Cylinder assembly
2) Using tool U3, press fit dust seal (9) to cylin- 1) Set the cylinder to tool U1 and support it with
der head (4). block 1 .
2) Install piston rod (3) and cylinder head as-
sembly (2) together.
Apply grease to the sealing part of the
piston.
Apply grease to the backup ring.
Push in the piston fully.
3) Using tool U6, tighten cylinder head assem-
3 Cylinder head assembly:

bly (2).
441 44.1 Nm {45 4.5 kgm}
3) Install snap ring (8) and rod packing (10).

4) Install O-ring (7).
5) Install backup ring (6) and O-ring (4).
30-242 D375A-5
c c
DISASSEMBLY AND ASSEMBLY BLADE ASSEMBLY
REMOVAL AND
INSTALLATION OF
BLADE ASSEMBLY
REMOVAL
Lower the work equipment to a level place and
set blocks 1 under both straight frames (6) se-
curely.
1. Remove cap (1) from the lift cylinder. q1
Check the quantity and thickness of the in-
serted shims.
3. Remove both covers (3).

4. Disconnect hose (4).
Plug the openings so that dirt will not enter
the piping.
5. Remove both trunnion caps (5).
6. Remove blade assembly (6). q2
Start the engine and move the machine in re-
verse slowly to disconnect the blade assem-
bly from the trunnion.
2. Sling lift cylinder assembly (2) temporarily. Start

the engine and retract the piston rod fully. Install
the cylinder fixing tool and fix the cylinder to the
radiator guard.
Bind the piston rod with wires so that it will
not come out.
Similarly, disconnect the cylinder on the op-
posite side from the blade.
Release the residual pressure from the piping,
referring to TESTING AND ADJUSTING, Re-
leasing residual pressure from hydraulic circuit.
Then, loosen the hydraulic oil filler cap to release
the internal pressure of the hydraulic tank.
D375A-5 30-243
c c
INSTALLATION
moval.
q1
Referring to TESTING AND ADJUSTING,
Adjusting semi-U tiltdozer, adjust the shims.
q2
Adjust height "b" and width "c" of both
straight frames to the following values with
block 1 , etc.
Trunnion height "b": Approx. 863 mm
Frame width "c": Approx. 3,484 mm

30-244 D375A-5
c c
DISASSEMBLY AND
ASSEMBLY OF
BLADE ASSEMBLY
DISASSEMBLY 3. Sling tilt cylinder assembly (4) temporarily and
remove the lock plate and pin (5).
Set blocks 1 and stands 2 securely under both
straight frames and blade to stabilize the blade. 4. Remove the lock plate and pin (6) and lift off tilt
cylinder assembly (4).
4 Tilt cylinder assembly: 380 kg
1. Remove right frame covers (1) and (2).

2. Disconnect tilt cylinder hose (3).
5. Set block 3 under right center brace (7) and re-
move the mounting bolts of cap (8) on the center
frame side.
Check the quantity and thickness of the
shims inserted under the cap.
D375A-5 30-245
c c
6. Sling right straight frame (9) temporarily and dis- 11. Sling center brace (15) temporarily and remove
connect right center brace (7). the mounting bolts and cap (16) and lift off both
center braces (15) and (7).
7. Remove the lock plate and pin (10) and lift off
Check the quantity and thickness of the
right straight frame (9).
4 Straight frame: 1,150 kg
shims inserted under the cap.
4 Center brace: 220 kg
8. Sling tilt brace (11) temporarily and remove the

12. Sling blade (17) and bring down the blade.
4 Blade: 4,900 kg
lock plate and pin (12).
9. Remove the lock plate and pin (13) and lift off tilt
brace (11).
4 Tilt brace: 200 kg
10. Disconnect the left center brace and remove left

straight frame (14) similarly to steps 5 - 7 above.
30-246 D375A-5
c c
ASSEMBLY 3. Sling right straight frame (9) and install pin (10)
and secure it with the lock plate.
4 Straight frame: 220 kg
Check the thickness and quantity of the shims
removed from each part during disassembly and
insert those shims to their original position.
4. Sling right straight frame (9) temporarily and set
For adjustment of the shims, see TESTING AND
the ball of right center brace (7) to right straight
ADJUSTING, Adjusting blade.
frame (9).
1. Sling blade (17) and put a block, stand, etc. un-
der it securely to stabilize it.
4 Blade: 4,900 kg
5. Insert the shims under cap (8) of right center

brace (7) and tighten the mounting bolts.
Standard shim thickness: 4.5 mm
2. Sling center brace (15) and set the shims and
tighten the mounting bolts of cap (16).
Set a block under the center brace according
to the height of the straight frame.
Standard shim thickness: 4.5 mm
4 Center brace: 220 kg
Install center brace (7) on the opposite side
similarly.
D375A-5 30-247
c c
6. Sling tilt cylinder assembly (4) and install pin (6) 10. Install left straight frame (14) similarly to steps 3
and secure it with the lock plate. - 5 above and connect the left center brace.
4 Tilt cylinder assembly: 380 kg 11. Sling tilt brace (11) and install pin (13) and se-
cure it with the lock plate.
4 Tilt brace: 200 kg
7. Install pin (5) and secure it with the lock plate.
12. Install pin (12) and secure it with the lock plate.
8. Connect tilt cylinder hose (3).

9. Install right frame covers (2) and (1).
13. Supplying grease
After finishing the assembly work, supply suffi-
cient amount of grease to the parts shown in the
following figure.
2 Each part of work equipment:
Grease (G2-LI)
30-248 D375A-5
c c
DISASSEMBLY AND ASSEMBLY OF GIANT
DISASSEMBLY AND ASSEMBLY RIPPER ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF GIANT
RIPPER ASSEMBLY
DISASSEMBLY Start the engine and retract the piston rod
fully and lower it onto the lift cylinder.
1. Drive the machine over block 1 and lower the
blade to the ground. After stopping the engine, release the resid-
ual pressure from the piping, referring to
Lock the brake securely.
TESTING AND ADJUSTING, Releasing re-
2. Sling the shank temporarily and operate the pin sidual pressure from hydraulic circuit. Then,
puller switch to pull out the shank pin. loosen the hydraulic oil filler cap to release
the internal pressure of the hydraulic tank.
3. Raise the ripper fully and lower and remove
shank (1) slowly. 7. Disconnect 4 lift cylinder hoses (4), 4 tilt cylinder
4 Shank: 470 kg hoses (5), and 2 pin puller cylinder hoses (6).
4. Set stand 2 between the arm and beam.
8. Sling tilt cylinder assembly (7) temporarily and

remove pin (8) and lift off tilt cylinder assembly
5. Sling the lift cylinder assembly and remove pin (7).
(2).
Start the engine and retract the piston rod
fully and lower it onto the arm.
6. Sling the tilt cylinder assembly and remove pin
(3).
D375A-5 30-249
c c
9. Sling lift cylinder assembly (9) temporarily and ASSEMBLY

remove pin (10) and lift off lift cylinder assembly
1. Sling and set arm (13) in position and install both
(9).
4 Lift cylinder assembly: 350 kg
pins (14) and secure them with the lock plates.
4 Arm: 1,000 kg
Set a stand under the arm.
10. Sling beam (11) temporarily and remove both

pins (12) and lift off beam (11).
4 Beam: 2,000 kg
2. Sling and set beam (11) in position and install
both pins (12) and secure them with the lock
plates.
4 Beam: 2,000 kg
Set a stand under the beam.
11. Sling arm (13) temporarily and remove both pins

(14) and lift off arm (13).
4 Arm: 1,000 kg
30-250 D375A-5
c c
3. Sling and set lift cylinder assembly (9) in position 6. Sling the tilt cylinder assembly temporarily. Start
and install pin (10) and secure it with the lock the engine and extend the piston rod to align it
plate. with the pin hole. Install pin (3) and secure it with
4 Lift cylinder assembly: 350 kg the lock plate.
7. Sling the lift cylinder assembly temporarily. Start
the engine and extend the piston rod to align it
with the pin hole. Install pin (2) and secure it with
the lock plate.
8. Drive the machine over block 1 and lower the
blade to the ground.
Lock the brake securely.
4. Sling and set tilt cylinder assembly (7) in position

and install pin (8) and secure it with the lock
plate.
9. Raise the ripper a little and remove stand 2 .

10. Raise the ripper fully. Pass a wire through the
shank holder and raise shank (1) slowly to align
it with the pin hole. Operate the pin puller switch
to insert the shank pin.
11. Raise the blade and lower the machine body
from block 1 .
12. Bleed air from the cylinders. For details, see
TESTING AND ADJUSTING, Bleeding air from
hydraulic cylinders.
5. Connect 2 pin puller cylinder hoses (6), 4 tilt cyl-
inder hoses (5), and 4 lift cylinder hoses (4).
D375A-5 30-251
c c
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF ROPS GUARD
REMOVAL AND
INSTALLATION OF ROPS
GUARD
REMOVAL
1. Sling ROPS guard (1) and remove 12 mounting
bolts (2). q1
2. Lift off ROPS guard (1). q2
4 ROPS guard: 766 kg
INSTALLATION
moval.
q1
3 ROPS guard mounting bolt:
1,715 196 Nm {175 20 kgm}
q2
Install the ROPS guard so that the fire extin-
guisher seats (3 pieces) will be on the right
of the machine body.
30-252 D375A-5
c c
REMOVAL AND INSTALLATION OF OPERATOR'S
DISASSEMBLY AND ASSEMBLY CAB ASSEMBLY
REMOVAL AND
INSTALLATION OF
OPERATOR'S CAB
ASSEMBLY
REMOVAL 6. Remove garnishes (7), (8), and (9).
nal of the battery.
1. Remove the ROPS guard. For details, see Re-
moval of ROPS guard.
2. Remove the operator's cab left cover.
3. Disconnect wiring connectors (CN-19) (2) and
(CN-20, CN-21) (3).
Pull out the wires from inside of the opera-
tor's cab.
4. Disconnect 4 window washer hoses (4). q1
Pull out the hoses from inside of the opera-
tor's cab.
7. Remove covers (10) on both sides and covers
(12) and (13).
5. Remove steps (5) and covers (6).

8. Remove angle (14) and in-cab angle (15).
D375A-5 30-253
c c
9. Remove 19 mounting bolts and lift off operator's INSTALLATION

cab assembly (16).
4 Operator's cab assembly: 420 kg
Before installing the cab, loosen the mounting
bolts of angle bar (14) and in-cab angle bar (15).
1. Seal
1) Fit seal (17) to guide plate (18) of the air con-
ditioner box.
2 Part A on outside of seal
(Sealing face against cab):
Grease (G2-LI)
2) Sling operator's cab assembly (16) and stick

seal (19) to the mating face of the former.
30-254 D375A-5
c c
2. Operators cab assembly Check that clearance a between cab-

1) Lower the operators cab assembly to the side air conditioner duct (22) and monitor
floor slowly. (23) is the same on both sides.
Take care not to shift or damage the seal. Furthermore, check that seals (25) of
Check that the air conditioner duct seal cab-side air conditioner ducts (22-1) are
on the cab side is fitted to the air condi- fitted to both faces C of dashboard-side
tioner duct on the dashboard side and no air conditioner duct (26) and are not shift-
clearance is made. ed laterally.
Lower the cab carefully, since the clear-
ance between the air conditioner duct on
the cab side and the monitor is little.
2) Tighten the mounting bolts temporarily.
Note that the bolt length and washer at
the door inlet are different.
Check that the seal between air condi-
tioner bracket (20) and cab (21) is fitted
securely.
Check the joint B of the seal and floor
frame for gap.
If there is a clearance, remove the cab,
and then install it correctly. If the clear-
ance is little, fill it with sealant, however.
D375A-5 30-255
c c
If the clearance between cab-side air

conditioner duct (22-1) and monitor (23)
is not the same on both sides, loosen
mounting screws (27) of the cab-side air
conditioner duct and adjust the duct so
that the clearance will be the same on
both sides.
If cab-side air conditioner duct and dash-
board-side air conditioner duct are shift-
ed laterally, adjust their positions
similarly to the above.
3) Securely tighten the mounting bolts tight-

ened temporarily in step 2).
4) Securely tighten the mounting bolts of angle
bar (14) and in-cab angle bar (15).
After the above work, carry out installation from

step 7 in reverse order to removal.
q1
When connecting the window washer hoses,
match the colors of their bands.
30-256 D375A-5
c c
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF FLOOR FRAME
REMOVAL AND
INSTALLATION OF FLOOR
FRAME
SPECIAL TOOLS 5. Disconnect 2 air conditioner hoses (7). q1
Air conditioner gas (R134a) is completely ex-
bol cessity model h tracted from an air conditioner circuit.
Service Disconnect the hoses from the air condition-
799-703-1200 1
tool kit er and move them toward the engine.
Vacuum Plug the hoses to prevent dirt, water, etc. will
799-703-1100 1
pump not enter them.
X 799-703-1110
Vacuum
1 Take care not to damage or miss the O-rings.
pump
Vacuum
6. Disconnect 2 heater hoses (8).
799-703-1120 1 Close the heater valve at the engine end.
pump
Gas leak
799-703-1401 1
detector
REMOVAL
1. Remove the operator's cab assembly. For de-
tails, see REMOVAL OF OPERATOR'S CAB
ASSEMBLY.
2. Remove covers (1), (2), (3), and (4).
7. Remove fresh air duct clamp (9) and duct (10).
3. Remove step cover (5).

4. Lift off operator's seat (6).
Remove the seat and undercover together.
4 Operator's seat: 108 kg
D375A-5 30-257
(1) cc
8. Disconnect blade PPC hoses (15), (16), (17), 12. Remove window washer hose clamp (33).
(18), and (19). q2
Move the hoses together toward the floor
frame.
9. Disconnect ripper PPC hoses (20), (21), (22),
(23), and (24). q3
Move the hoses together toward the floor
frame.
10. Disconnect PPC hose (25).
13. Disconnect parking brake cable (34) from the le-

ver and remove it from the bracket.
Before disconnecting the cable, check its in-
stalled length. q4
14. Disconnect brake pedal linkage (35) from the
turnbuckle. q5
Before disconnecting the linkage, check the
installed length of the brake rod.
The turnbuckle has opposite threads.
11. Remove wiring connectors CN-FD5 (26), CN-
BWR (27), CN-USB (28), CN-FSB (29), CN-TL1
(30), CN-19 (31), and CN-SX8 (32).
Disconnect CN-TL1 from inside of the floor.
30-258 D375A-5
c c
15. Remove armrest (36). 19. Disconnect ground wire (40).

16. Remove right console (37). 20. Remove 4 left front mounting bolts (41). q7
q8
Disconnect wiring connectors (CN-262, CN-
21. Remove 4 right front mounting bolts (42).
263) inside the console.
Before removing the console, remove the le-
ver boot from the console.
17. Remove left console cover (38).
22. Lift off floor frame assembly (45).

4 Floor frame assembly: 600 kg
Using a chain block, sling the floor frame as-
sembly slowly, balancing it carefully.
18. Remove 4 rear mounting bolts (39) from each
q6
After removing the floor frame assembly, re-
side.
move the spacers on the right front floor
mount.
D375A-5 30-259
c c
INSTALLATION q2 q3
The connecting positions of the PPC hoses
are indicated by the band colors on their
moval.
q1
confirm them by the band colors.
Connect the hoses so carefully that they will
not be twisted.
When installing the air conditioner circuit
hoses, take care that dirt, dust, or water will
not enter them.
When connecting the air conditioner hoses,
check that the O-rings are fitted to their
adapters.
Apply sufficient amount of compressor oil
(Showa-Shell Suniso 4G or 5G) to the O-
rings.

A. Transparent
B. Red/White
C. Black/Blue
D. Brown
E. Black
F. Green
G. White
H. Yellow
3 Tightening torque for air conditioner

refrigerant piping
16 1.5 12.23 1.47Nm {1.35 0.15kgm}
22 1.5 22.05 2.45Nm {2.25 0.25kgm}
24 1.5 31.85 2.45Nm {3.25 0.25kgm}
M6 bolt (for receiver) 5.39 1.47Nm {0.55 0.15kgm}
M6 bolt
9.8 1.96Nm {1.0 0.2kgm}
(for compressor)
30-260 D375A-5
c c
q4
Adjust the parking brake lever linkage. For
details, see TESTING AND ADJUSTING,
Adjusting PCCS (Steering, Forward/Reverse
travel, Gear shifting), parking brake lever
linkage.
q5
Adjust the brake pedal linkage. For details,
see TESTING AND ADJUSTING, Adjusting
3 Brake pedal linkage turnbuckle:

brake pedal linkage.
45.56 12.25 Nm
{4.76 1.25 kgm}
q6 q7
3 Rear mounting bolt:
3 Front mounting bolt:

338.1 39.2 Nm {34.5 4kgm}
338.1 39.2 Nm {34.5 4kgm}
q8
Charging air conditioner with refrigerant
gas
Using tool X, charge the air conditioner cir-
cuit with refrigerant (R134a).
Add water through the water filler to the
specified level. Run the engine to circulate
the water through the system. Then, check
the water level again.
D375A-5 30-261
c c
DISASSEMBLY AND ASSEMBLY DASHBOARD ASSEMBLY
REMOVAL AND
INSTALLATION OF
DASHBOARD ASSEMBLY
SPECIAL TOOLS 3. Disconnect 2 air conditioner hoses (2). q1
bol cessity model h tracted from an air conditioner circuit.
Service Disconnect the hoses from the air condition-
799-703-1200 1
tool kit er and move them toward the engine.
Vacuum Plug the hoses to prevent dirt, water, etc. will
799-703-1100 1
pump not enter them.
X 799-703-1110
Vacuum
1 Take care not to damage or miss the O-rings.
pump
Vacuum
799-703-1120 1 Close the heater valve on the engine side.
pump
Gas leak
799-703-1401 1
detector
REMOVAL
tails, see Removal of operator's cab assembly.
5. Disconnect wiring connectors (CN-213) (4),

(CN-214) (5), (CN-215) (6), (CN-216) (7), and
(CN-DL1) (8).
6. Remove fresh air duct band (9) and duct (10).
30-262 D375A-5
(1) cc
DISASSEMBLY AND ASSEMBLY DASHBOARD ASSEMBLY
7. Lift off dashboard assembly (9). 3 Tightening torque for air conditioner
4 Dashboard assembly: 95 kg refrigerant piping
16 1.5 12.23 1.47Nm {1.35 0.15kgm}
22 1.5 22.05 2.45Nm {2.25 0.25kgm}
24 1.5 31.85 2.45Nm {3.25 0.25kgm}
M6 bolt
9.8 1.96Nm {1.0 0.2kgm}
(for compressor)
Charging air conditioner with refrigerant gas

Using tool X, charge the air conditioner circuit
INSTALLATION with refrigerant (R134a).
Carry out installation in the reverse order to re- Add water through the water filler to the specified
moval. level. Run the engine to circulate the water
q1
through the system. Then, check the water level
again.
not be twisted.
not enter them.
adapters.
(Showa-Shell Suniso 4G or 5G) to the O-
rings.
D375A-5 30-263
c c
REMOVAL AND INSTALLATION OF MONITOR
DISASSEMBLY AND ASSEMBLY PANEL ASSEMBLY
REMOVAL AND
INSTALLATION OF MONITOR
PANEL ASSEMBLY
REMOVAL
nal of the battery.
1. Remove mounting bolts, then open monitor pan-
el assembly (1).
2. Disconnect connectors (CN-1, CN-2, CN-3, CN-

4, CN-5, CN-S01, CN-S02) (2).
3. Remove monitor panel assembly.
INSTALLATION
moval.
30-264 D375A-5
c c
REMOVAL AND INSTALLATION OF AIR
DISASSEMBLY AND ASSEMBLY CONDITIONER UNIT ASSEMBLY
REMOVAL AND
INSTALLATION OF AIR
CONDITIONER UNIT
ASSEMBLY
SPECIAL TOOLS 5. Disconnect wiring connectors (CN-213) (6),
(CN-214) (7), (CN-215) (8), (CN-216) (9), and
bol Part No. Part name cessity Q'ty model h (CN-DL1) (10).
Service
799-703-1200 1
tool kit
Vacuum
799-703-1100 1
pump
Vacuum
X 799-703-1110 1
pump
Vacuum
799-703-1120 1
pump
Gas leak
799-703-1401 1
detector
REMOVAL
tails, see Removal of operator's cab assembly.
2. Remove covers (1), (2), and (3). 6. Remove covers (11) and (12).
3. Disconnect 2 air conditioner hoses (4). q1

7. Remove steps (13) and covers (14).
tracted from an air conditioner circuit. 8. Remove panel (15) and cover (16).
Disconnect the hoses from the air condition-
er and move them toward the engine.
Plug the hoses to prevent dirt, water, etc. will
not enter them.
Take care not to damage or miss the O-rings.
Close the heater valve on the engine side.
D375A-5 30-265
(1) cc
9. Remove ducts (17) and (18). 12. Disconnect bracket (22) and clamp (23).
10. Remove monitor (19) and cover (20). 13. Disconnect relays (CN-R1) (24), (CN-R2) (25),
and (CN-R3) (26) in the right part of the dash-
board and connector (CN-M26) (27).
11. Remove inside filter (21).
14. Remove air conditioner unit (28).

15. Remove blower motor (29).
30-266 D375A-5
c c
INSTALLATION Charging air conditioner with refrigerant gas

Using tool X, charge the air conditioner circuit
with refrigerant (R134a).
moval.
q1
Add water through the water filler to the specified
level. Run the engine to circulate the water
not be twisted.
through the system. Then, check the water level
again.
not enter them.
adapters.
(Showa-Shell Sniso 4G or 5G) to the O-
rings.
3 Tightening torque for air conditioner

refrigerant piping
16 1.5 12.23 1.47Nm {1.35 0.15kgm}
22 1.5 22.05 2.45Nm {2.25 0.25kgm}
24 1.5 31.85 2.45Nm {3.25 0.25kgm}
M6 bolt
9.8 1.96Nm {1.0 0.2kgm}
(for compressor)
D375A-5 30-267
c c
90 OTHERS
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM .................................................................................. 90- 2

POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM .................................................................................. 90- 3
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (TILTDOZER) ................................................... 90- 4
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (TILTDOZER) ................................................... 90- 5
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (DUAL TILTDOZER) ........................................ 90- 6
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (DUAL TILTDOZER) ........................................ 90- 7
ELECTRICAL CIRCUIT DIAGRAM (1/7) ................................................................................................... 90- 9
ELECTRICAL CIRCUIT DIAGRAM (2/7) ................................................................................................... 90- 11
ELECTRICAL CIRCUIT DIAGRAM (3/7) ................................................................................................... 90-13
DIAGRAM FOR ELECTRICAL CIRCUIT OF AIR CONDITIONER ........................................................... 90-23
ELECTRIC CIRCUIT DIAGRAM OF INSIDE CAB .................................................................................... 90-24
D375A-5 90-1
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
1. Oil tank 37. R.H steering clutch

2. Power train oil strainer 38. R.H steering brake
3. Power train pump (BAL180) 39. L.H steering brake
4. Power train oil filter 40. L.H steering clutch
Set pressure: 0.29 MPa {3.0 kg/cm2} 41. Brake prevention valve
5. Transmission lubrication pump (BAL112) 42. Transmission lubrication valve
6. Power train lubricating oil filter Set pressure: 0.26 MPa {2.7 kg/cm2}
7. Main relief valve 43. Transmission lubrication
Set pressure: 2.65 0.1 MPa {27.0 1.0 kg/cm2} 44. PTO lubrication
8. Modulating relief valve (ECMV) for R clutch 45. Scavenging pump (BAR63 + 277)
9. Modulating relief valve (ECMV) for F clutch 46. Solenoid valve (for ripper pin puller)
10. Modulating relief valve (ECMV) for 3rd clutch 47. Pin puller cylinder
11. Modulating relief valve (ECMV) for 2nd clutch 48. Steering case
12. Modulating relief valve (ECMV) for 1st clutch A. Torque converter lockup pressure pick-up port
13. Fill switch B. Torque converter stator clutch pressure pick-up
Operating pressure: 0.26 MPa {2.7 kg/cm2} port
14. 1st clutch C. L.H steering clutch operating pressure pick-up
15. 2nd clutch port
16. 3rd clutch D. L.H steering brake operating pressure pick-up
17. R clutch port
18. F clutch E. Transmission 2nd clutch operating pressure pick-
up port
19. Pilot filter
F. Transmission R clutch operating pressure pick-
20. Torque converter relief valve
up port
Set pressure: 0.88 0.1 MPa {9.0 1.0 kg/cm2}
G. Transmission 3rd clutch operating pressure pick-
21. Torque converter
up port
Set pressure: 1.3 +0.1 +1 2
0 MPa {13 0 kg/cm }
H. Transmission F clutch operating pressure pick-up
22. Oil cooler
port
23. Steering clutch/brake lubrication
J. R.H steering brake operating pressure pick-up
24. Torque converter case port
25. Torque converter lockup valve K. R.H steering clutch operating pressure pick-up
26. Lockup clutch modulating valve port
Set pressure: 1.3 +0.1 MPa {13 +1 kg/cm2} L. Transmission 1st clutch operating pressure pick-
0 0
27. Torque converter lockup solenoid valve up port
28. Torque converter lockup clutch M. Transmission main relief pressure pick-up port
29. Stator clutch modulating valve N. Torque converter regulator pressure pick-up port
Set pressure: 2.65 0.1 MPa {27.0 1.0 kg/cm2} P. Torque converter relief pressure pick-up port
30. Stator clutch lubrication
31. Stator clutch
32. Parking brake valve
33. R.H steering ECMV
34. R.H brake ECMV
35. L.H brake ECMV
36. L.H steering ECMV
90-2 D375A-5
90
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
D375A-5 90-3
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (TILTDOZER)
TILTDOZER
1. Hydraulic tank 13E. Ripper lift constant differential pressure
1A. Oil filler cap valve
2. Strainer 13F. Shuttle valve
3. PPC charge pump (SAR(1) 022) 13G. Shuttle valve
4. PPC charge valve 13H. Suction valve (for ripper lift)
Set pressure: 4.46 MPa {45.5 kg/cm2} 13J. Ripper tilt HI valve
5. Accumulator 13K. Ripper tilt constant differential pressure
6. Oil cooler (for PPC) valve
7. PPC lock valve 13L. Ripper tilt constant differential valve
8. Blade control PPC valve 13M. Shuttle valve
8A. For blade lift 13N. Shuttle valve
8B. For blade tilt 14. Quick drop valve
9. Ripper control PPC valve 15. R.H blade lift cylinder
9A. For ripper lift 16. L.H blade lift cylinder
9B. For ripper tilt 17. Blade tilt cylinder
10. Work equipment pump (SAR(4) 140 + (3) 071) 18. R.H ripper tilt cylinder
11. Blade control valve 19. R.H ripper lift cylinder
11A. Demand valve 20. L.H ripper lift cylinder
11B. Main relief valve 21. L.H ripper tilt cylinder
Set pressure: 20.6 MPa {210 kg/cm2} 22. Hydraulic oil filter
11C. Shuttle valve Set pressure: 0.15 MPa {1.5 kg/cm2}
11D. Check valve
11E. Check valve
11F. Blade lift valve
11G. Suction valve (for blade lift)
11H. Shuttle valve
12. Blade tilt, ripper LO valve
12A. Main relief valve
Set pressure: 20.6 MPa {210 kg/cm2}
12B. Check valve
12C. Blade tilt valve
12D. Check valve
12E. Ripper tilt valve
12F. Check valve
12G. Ripper lift valve
12H. Shuttle valve
13. Ripper HI valve
13A. Check valve
13B. Check valve
13C. Ripper lift (HI) valve
13D. Ripper lift constant differential pressure
valve
90-4 D375A-5
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
TILTDOZER
For details of the pin puller cylinder, see POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM.
D375A-5 90-5
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (DUAL TILTDOZER)
DUAL TILTDOZER
1. Hydraulic tank 13E. Ripper lift constant differential pressure
1A. Oil filler cap valve
2. Strainer 13F. Shuttle valve
3. PPC charge pump (SAR(1) 022) 13G. Shuttle valve
4. PPC charge valve 13H. Suction valve (for ripper lift)
Set pressure: 4.46 MPa {45.5 kg/cm2} 13J. Ripper tilt HI valve
5. Accumulator 13K. Ripper tilt constant differential pressure
6. Oil cooler (for PPC) valve
7. PPC lock valve 13L. Ripper tilt constant differential pressure
valve
8. Blade control PPC valve
13M. Shuttle valve
8A. For blade lift
13N. Shuttle valve
8B. For blade tilt
14. Quick drop valve
9. Ripper control PPC valve
15. R.H blade lift cylinder
9A. For ripper lift
16. L.H blade lift cylinder
9B. For ripper tilt
17. Pitch selector solenoid valve
10. Work equipment pump (SAR(4) 140 + (3) 071)
18. Dual tilt selector solenoid valve
11. Blade lift control valve
19. Blade tilt cylinder
11A. Demand valve
20. Blade pitch cylinder
11B. Main relief valve
Set pressure: 20.6 MPa {210 kg/cm2} 21. R.H ripper tilt cylinder
11C. Shuttle valve 22. R.H ripper lift cylinder
11D. Check valve 23. L.H ripper lift cylinder
11E. Check valve 24. L.H ripper tilt cylinder
11F. Blade lift valve 25. Hydraulic oil filter
Set pressure: 0.15 MPa {1.5 kg/cm2}
11G. Suction valve (for blade lift)
11H. Shuttle valve
12. Blade tilt, ripper LO valve
12A. Main relief valve
Set pressure: 20.6 MPa {210 kg/cm2}
12B. Check valve
12C. Blade valve
12D. Check valve
12E. Ripper tilt valve
12F. Check valve
12G. Ripper lift valve
12H. Shuttle valve
13. Ripper HI valve
13A. Check valve
13B. Check valve
13C. Ripper lift (HI) valve
13D. Ripper lift constant differential pressure
valve
90-6 D375A-5
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
DUAL TILTDOZER
For details of the pin puller cylinder, see POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM.
D375A-5 90-7
ELECTRICAL CIRCUIT DIAGRAM (1/7)
D375A-5 90-9
D375A-5 90-11
D375A-5 90-13
D375A-5 90-15
D375A-5 90-17
D375A-5 90-19
D375A-5 90-21
DIAGRAM FOR ELECTRICAL CIRCUIT OF AIR CONDITIONER
D375A-5 90-23
ELECTRIC CIRCUIT DIAGRAM OF INSIDE CAB
90-24 D375A-5

SM D375a-5 VHMS

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SEBM036101

Machine model Serial number

D375A-5 (VHMS Specification) 18052 and up

D375A-5 mounts the SA6D170E-3 engine.

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ...... 10-1

20 TESTING AND ADJUSTING ............................................................. 20-1

30 DISASSEMBLY AND ASSEMBLY ................................................... 30-1

90 OTHERS ............................................................................................ 90-1

The affected pages are indicated by the use of the

q Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

List of revised pages

Time of Time of Time of Time of Time of

q 00-1 (1) 10-16 10-47 10-76

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

Slinging near the edge of the hook may cause

If a part cannot be smoothly removed from the

The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

Used to prevent rubber gaskets, rub-

Holtz Used as heat-resisting sealant for re-

Used as lubricant for sliding portion

SYG2-400CA Used for normal temperature, light

Molybdenum Used for heavy load portion

SUNSTAR Used as primer for cab side

"S" is used for high-tempera-

SUNSTAR Used to seal joints of glass

STANDARD TIGHTENING TORQUE

6 10 11.8 14.7 1.2 1.5

16 24 235 285 23.5 29.5

27 41 1150 1440 118 147

6 10 5.9 9.8 0.6 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 4.9 2.5 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque (Nm {kgm})

02 14 35 63 {3.5 6.5} 44 {4.5}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque (Nm {kgm})