D375a-6 SM

SEN05006-05
BULLDOZER D375A -6
SERIAL NUMBERS 60001 and up
Notice of revision
Notice of revision
5th. revision 2010/06
The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary ac-
tions must be taken to these pages according to the Q Page to be newly added Add
list below.
q Page to be replaced Replace
() Page to be deleted Discard
List of revised pages

Revision Revision Revision Revision
Mark Page Mark Page Mark Page Mark Page
number number number number
q 1 (05) 00-22 10-3 (04) 10-44
q 2 (05) 00-23 10-4 10-45
3 (04) 00-24 10-5 10-46
4 (04) 00-25 10-6 10-47
5 (04) 00-26 (04) 10-7 10-48
6 (04) 00-27 (04) 10-8 10-49
7 (04) 00-28 (04) 10-9 10-50
q 8 (05) 00-29 10-10 10-51
q 9 (05) 00-30 10-11 10-52
10 (02) 00-31 10-12 10-53
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50-35 (02) 50-87 (02) 50-139 (02) 50-191 (02)
50-36 (02) 50-88 (02) 50-140 (02) 50-192 (02)
50-37 (02) 50-89 (02) 50-141 (02) 50-193 (02)
50-38 (02) 50-90 (02) 50-142 (02) 50-194 (02)
50-39 (02) 50-91 (02) 50-143 (02) 50-195 (02)
50-40 (02) 50-92 (02) 50-144 (02) 50-196 (02)
50-41 (02) 50-93 (02) 50-145 (02) 50-197 (02)
50-42 (02) 50-94 (02) 50-146 (02) 50-198 (02)
50-43 (02) 50-95 (02) 50-147 (02) 50-199 (02)
50-44 (02) 50-96 (02) 50-148 (02) 50-200 (02)
50-45 (02) 50-97 (02) 50-149 (02) 50-201 (02)
50-46 (02) 50-98 (02) 50-150 (02) 50-202 (02)
50-47 (02) 50-99 (02) 50-151 (02) 50-203 (02)
50-48 (02) 50-100 (02) 50-152 (02) 50-204 (02)
50-49 (02) 50-101 (02) 50-153 (02) 50-205 (02)
50-50 (02) 50-102 (02) 50-154 (02) 50-206 (02)
50-51 (02) 50-103 (02) 50-155 (02) 50-207 (02)
50-52 (02) 50-104 (02) 50-156 (02) 50-208 (02)
50-53 (02) 50-105 (02) 50-157 (02) 50-209 (02)
50-54 (02) 50-106 (02) 50-158 (02) 50-210 (02)
50-55 (02) 50-107 (02) 50-159 (02) 50-211 (02)
50-56 (02) 50-108 (02) 50-160 (02) 50-212 (02)
50-57 (02) 50-109 (02) 50-161 (02) 50-213 (02)
50-58 (02) 50-110 (02) 50-162 (02) 50-214 (02)
D375A-6 7
(04)
Notice of revision

50-215 (02) 50-267 (02) 50-319 (02) 60-41
50-216 (02) 50-268 (02) 50-320 (02) 60-42
50-217 (02) 50-269 (02) 50-321 (02) 60-43
50-218 (02) 50-270 (02) 50-322 (02) 60-44
50-219 (02) 50-271 (02) 50-323 (02) 60-45
50-220 (02) 50-272 (02) 50-324 (02) 60-46
50-221 (02) 50-273 (02) 50-325 (02) 60-47
50-222 (02) 50-274 (02) 50-326 (02) 60-48
50-223 (02) 50-275 (02) 50-327 (02) 60-49
50-224 (02) 50-276 (02) 50-328 (02) 60-50
50-225 (02) 50-277 (02) 50-329 (02) 60-51
50-226 (02) 50-278 (02) 50-330 (02) 60-52
50-227 (02) 50-279 (02) 60-1 60-53 (04)
50-228 (02) 50-280 (02) 60-2 60-54
50-229 (02) 50-281 (02) 60-3 60-55 (04)
50-230 (02) 50-282 (02) 60-4 60-56
50-231 (02) 50-283 (02) 60-5 60-57
50-232 (02) 50-284 (02) 60-6 60-58
50-233 (02) 50-285 (02) 60-7 60-59
50-234 (02) 50-286 (02) 60-8 60-60
50-235 (02) 50-287 (02) 60-9 60-61
50-236 (02) 50-288 (02) 60-10 60-62
50-237 (02) 50-289 (02) 60-11 60-63
50-238 (02) 50-290 (02) 60-12 60-64
50-239 (02) 50-291 (02) 60-13 60-65
50-240 (02) 50-292 (02) 60-14 (04) 60-66
50-241 (02) 50-293 (02) 60-15 (04) 60-67
50-242 (02) 50-294 (02) 60-16 60-68
50-243 (02) 50-295 (02) 60-17 60-69
50-244 (02) 50-296 (02) 60-18 60-70
50-245 (02) 50-297 (02) 60-19 60-71
50-246 (02) 50-298 (02) 60-20 60-72 (04)
50-247 (02) 50-299 (02) 60-21 60-73 (04)
50-248 (02) 50-300 (02) 60-22 60-74
50-249 (02) 50-301 (02) 60-23 60-75
50-250 (02) 50-302 (02) 60-24 60-76
50-251 (02) 50-303 (02) 60-25 60-77
50-252 (02) 50-304 (02) 60-26 60-78
50-253 (02) 50-305 (02) 60-27 60-79 (04)
50-254 (02) 50-306 (02) 60-28 60-80
50-255 (02) 50-307 (02) 60-29 60-81
50-256 (02) 50-308 (02) 60-30 60-82
50-257 (02) 50-309 (02) 60-31 60-83
50-258 (02) 50-310 (02) 60-32 60-84
50-259 (02) 50-311 (02) 60-33 60-84-1 (04)
50-260 (02) 50-312 (02) 60-34 60-84-2 (04)
50-261 (02) 50-313 (02) 60-35 60-84-3 (04)
50-262 (02) 50-314 (02) 60-36 60-84-4 (04)
50-263 (02) 50-315 (02) 60-37 60-84-5 (04)
50-264 (02) 50-316 (02) 60-38 60-84-6 (04)
50-265 (02) 50-317 (02) 60-39 60-85
50-266 (02) 50-318 (02) 60-40 60-86
8 D375A-6
(05)
Notice of revision

60-87 80-42 (03) 2 (04)
60-88 (04) 80-43 (01) 3 (04)
60-89 80-44 (03) 4 (04)
60-90 (04) 80-45 (01) 5 (04)
60-91 80-46 (01) 6 (04)
60-92 80-47 (01) 7 (04)
60-93 80-48 (01) 8 (04)
60-94 (04) 80-49 (01) Colo-
q (05)
60-95 (04) 80-50 (01) phon
60-96 80-51 (01)
80-1 (01) 80-52 (01)
80-2 (01) 80-53 (01)
80-3 (01) 80-54 (03)
80-4 (01) 80-55 (01)
80-5 (01) 80-56 (01)
80-6 (01) 80-57 (01)
80-7 (01) 80-58 (01)
80-8 (01) 80-59 (01)
80-9 (01) 80-60 (01)
80-10 (01) 80-61 (01)
80-11 (01) 80-62 (01)
80-12 (01) 80-63 (01)
80-13 (01) 80-64 (01)
80-14 (01) 80-65 (01)
80-15 (01) 80-66 (01)
80-16 (01) 90-1
80-17 (01) 90-2
80-18 (01) 90-3
80-19 (01) 90-4
80-20 (03) 90-5
80-21 (01) 90-7 (04)
80-22 (03) 90-7-1 (04)
80-23 (03) 90-9
80-24 (01) 90-10
80-25 (01) 90-11
80-26 (03) 90-12
80-27 (03) 90-13
80-28 (01) 90-15
80-29 (01) 90-17
80-30 (01) 90-19
80-31 (01) 90-21
80-32 (03) 90-23
80-33 (01) 90-25
80-34 (03) 90-27
80-35 (01) 90-29
80-36 (01) 90-31
80-37 (01) 90-33
80-38 (03) 90-35
80-39 (01) 90-37
80-40 (01) 90-39
80-41 (01) 1 (04)
D375A-6 9
(05)
DRAFT
D375A-6
SEN05009-00
Bulldozer
Shop Manual
D375A-6
Machine model Serial number

D375A-6 60001 and up
00 Index and Foreword
D375A-6 00-1
Shop Manual
Table of contents
Table of contents
Notice of revision............................................................................................................................................. 1
00 Index and Foreword

Table of contents............................................................................................................................................. 00 - 2
Table of contents ......................................................................................................................................... 00 - 2
Foreword and general information .................................................................................................................. 00 - 5
Safety notice ................................................................................................................................................ 00 - 5
How to read the shop manual ...................................................................................................................... 00 - 10
Explanation of terms for maintenance standard .......................................................................................... 00 - 12
Handling of electric equipment and hydraulic components.......................................................................... 00 - 14
Handling of connectors newly used for engines .......................................................................................... 00 - 23
How to read electric wire code..................................................................................................................... 00 - 26
Precautions when carrying out work ............................................................................................................ 00 - 29
Method of disassembling and connecting push-pull type coupler................................................................ 00 - 32
Standard tightening torque table.................................................................................................................. 00 - 35
List of Abbreviation ...................................................................................................................................... 00 - 39
Conversion table .......................................................................................................................................... 00 - 43
01 Specification
Specification and technical data...................................................................................................................... 01 - 3
Specification drawing ................................................................................................................................... 01 - 3
Specifications............................................................................................................................................... 01 - 4
Weight table ................................................................................................................................................. 01 - 9
Table of fuel, coolant and lubricants ............................................................................................................ 01 - 11
10 Structure,function and maintenance standard

Engine and cooling system ............................................................................................................................. 10- 4
Cooling system ............................................................................................................................................ 10- 4
Cooling fan pump......................................................................................................................................... 10- 6
Cooling fan motor......................................................................................................................................... 10- 26
Power train ...................................................................................................................................................... 10- 32
Power train................................................................................................................................................... 10- 32
Overall drawing of power train unit .............................................................................................................. 10- 34
Power train hydraulic equipment arrangement drawing............................................................................... 10- 36
Damper and universal joint .......................................................................................................................... 10- 38
Torque converter and PTO .......................................................................................................................... 10- 40
Torque converter control valve .................................................................................................................... 10- 46
Main relief valve and torque converter relief valve....................................................................................... 10- 48
Lockup clutch ECMV and stator clutch ECMV............................................................................................. 10- 50
Scavenging pump ........................................................................................................................................ 10- 55
Transmission control.................................................................................................................................... 10- 56
PCCS lever .................................................................................................................................................. 10- 58
Transmission................................................................................................................................................ 10- 62
Transmission ECMV .................................................................................................................................... 10- 76
Transmission lubricating oil relief valve ....................................................................................................... 10- 81
Steering and brake control........................................................................................................................... 10- 82
Transfer unit, bevel gear shaft and steering ................................................................................................ 10- 84
Steering control valve .................................................................................................................................. 10- 90
Steering clutch ECMV and Steering brake ECMV ....................................................................................... 10- 92
Parking brake valve ..................................................................................................................................... 10- 99
Sudden stop prevention valve...................................................................................................................... 10- 101
Final drive .................................................................................................................................................... 10- 103
Undercarriage and frame ................................................................................................................................ 10- 108
Track frame.................................................................................................................................................. 10- 108
Idler cushion................................................................................................................................................. 10- 110
Track roller bogie ......................................................................................................................................... 10- 111
Main frame ................................................................................................................................................... 10- 112
Suspension .................................................................................................................................................. 10- 114
Hydraulic system ............................................................................................................................................. 10- 117
Work equipment hydraulic piping diagram................................................................................................... 10- 117
PPC control piping diagram ......................................................................................................................... 10- 121
00-2 D375A-6
(04)
Shop Manual
Table of contents
Work equipment control ............................................................................................................................... 10- 122

Hydraulic tank .............................................................................................................................................. 10- 124
Accumulator ................................................................................................................................................. 10- 126
PPC lock valve............................................................................................................................................. 10- 127
PPC valve .................................................................................................................................................... 10- 129
Piston valve.................................................................................................................................................. 10- 140
Quick drop valve .......................................................................................................................................... 10- 141
Pin puller switch ........................................................................................................................................... 10- 142
Pin puller solenoid valve .............................................................................................................................. 10- 143
Blade control lever (only for the machine with dual tilt specification)........................................................... 10- 145
Work equipment pump................................................................................................................................. 10- 146
Control valve ................................................................................................................................................ 10- 158
Self-pressure reducing valve ....................................................................................................................... 10- 173
Work equipment .............................................................................................................................................. 10- 180
Cylinder stay ................................................................................................................................................ 10- 180
Cab.................................................................................................................................................................. 10- 181
Cab mount ................................................................................................................................................... 10- 181
Cab .............................................................................................................................................................. 10- 182
Electrical system ............................................................................................................................................. 10- 184
Engine control .............................................................................................................................................. 10- 184
Engine control system.................................................................................................................................. 10- 185
CRI engine control system........................................................................................................................... 10- 194
Monitor system............................................................................................................................................. 10- 196
Machine monitor .......................................................................................................................................... 10- 198
Lamp system................................................................................................................................................ 10- 215
Engine preheat (electrical intake air heater) control .................................................................................... 10- 216
Palm command control system.................................................................................................................... 10- 217
Sensor.......................................................................................................................................................... 10- 220
Vehicle health monitoring system (VHMS) .................................................................................................. 10- 224
ORBCOMM system ..................................................................................................................................... 10- 230
20 Standard value table

Standard service value table ........................................................................................................................... 20 - 3
Standard value table for engine ................................................................................................................... 20 - 3
Standard value table for machine ................................................................................................................ 20 - 4
30 Testing and adjusting

Tools for testing, adjusting, and troubleshooting............................................................................................. 30 - 4
Tools for testing, adjusting, and troubleshooting ......................................................................................... 30 - 4
Engine and cooling system ............................................................................................................................. 30 - 6
Testing engine speed................................................................................................................................... 30 - 6
Testing intake air pressure (boost pressure) ............................................................................................... 30 - 8
Testing exhaust temperature ....................................................................................................................... 30 - 10
Testing exhaust gas color ............................................................................................................................ 30 - 12
Adjusting valve clearance ............................................................................................................................ 30 - 14
Measuring compression pressure................................................................................................................ 30 - 16
Testing blow-by pressure............................................................................................................................. 30 - 19
Testing engine oil pressure.......................................................................................................................... 30 - 21
Testing EGR valve and bypass valve drive oil pressure.............................................................................. 30 - 22
Handling of fuel system devices .................................................................................................................. 30 - 24
Releasing residual pressure from fuel system ............................................................................................. 30 - 25
Testing fuel pressure ................................................................................................................................... 30 - 26
Handling of reduced cylinder mode operation ............................................................................................. 30 - 27
Handling of no injection cranking operation ................................................................................................. 30 - 28
Testing leakage from pressure limiter and return rate from injector ............................................................ 30 - 29
Bleeding air from fuel circuit......................................................................................................................... 30 - 32
Testing fuel circuit for leakage ..................................................................................................................... 30 - 34
Replacing and adjusting alternator and air conditioner compressor belt ..................................................... 30 - 35
Measuring fan speed ................................................................................................................................... 30 - 36
Testing fan circuit oil pressure ..................................................................................................................... 30 - 37
Bleeding air from fan pump.......................................................................................................................... 30 - 38
Adjusting fuel control dial and decelerator pedal ......................................................................................... 30 - 39
D375A-6 00-3
(04)
Shop Manual
Table of contents
Power train ...................................................................................................................................................... 30 - 40

Testing power train oil pressure................................................................................................................... 30 - 40
Adjusting transmission output speed sensor ............................................................................................... 30 - 55
Simple test procedure for brake performance.............................................................................................. 30 - 56
Adjusting brake pedal and parking brake lever............................................................................................ 30 - 57
Adjusting position of pccs lever console ...................................................................................................... 30 - 60
Emergency escape method when there is failure in power train ................................................................. 30 - 61
Undercarriage and frame ................................................................................................................................ 30 - 63
Inspecting wear of sprocket ......................................................................................................................... 30 - 63
Testing and adjusting track shoe tension..................................................................................................... 30 - 64
Hydraulic system ............................................................................................................................................. 30 - 65
Measuring and adjusting work equipment oil pressure................................................................................ 30 - 65
Testing control circuit main pressure ........................................................................................................... 30 - 68
Testing PPC valve output pressure ............................................................................................................. 30 - 69
Adjusting play of PPC valve......................................................................................................................... 30 - 71
Testing output pressure of ripper pin-puller solenoid valve ......................................................................... 30 - 72
Checking location of cause of hydraulic drift of blade and ripper................................................................. 30 - 73
Testing leakage inside work equipment cylinder ......................................................................................... 30 - 74
Releasing remaining pressure in work equipment cylinders........................................................................ 30 - 75
Bleeding air from work equipment cylinders ................................................................................................ 30 - 76
Adjusting ripper lever position...................................................................................................................... 30 - 77
Work equipment .............................................................................................................................................. 30 - 78
Adjusting work equipment lock lever............................................................................................................ 30 - 78
Adjusting blade ............................................................................................................................................ 30 - 79
Cab and its attachments.................................................................................................................................. 30 - 81
Testing and adjusting operator's cab ........................................................................................................... 30 - 81
Electrial system ............................................................................................................................................... 30 - 86
Special functions of machine monitor (EMMS) ............................................................................................ 30 - 86
Handling of voltage circuit of engine controller ............................................................................................ 30 -143
Adjustment method when controller has been replaced .............................................................................. 30 -144
Preparation work for troubleshooting of electrical system ........................................................................... 30 -148
Inspection procedure of diode...................................................................................................................... 30 -152
Handling of optional devices ........................................................................................................................ 30 -153
Request for opening ORBCOMM terminal................................................................................................... 30 -154
Initialization procedures for VHMS controller............................................................................................... 30 -156
Using method of KOMTRAX functions of ORBCOMM terminal................................................................... 30 -176
Precautions for replacing VHMS controller .................................................................................................. 30 -179
Pm Clinic service............................................................................................................................................. 30 -185
Pm Clinic service ......................................................................................................................................... 30 -185
40 Troubleshooting
General Information on troubleshooting .......................................................................................................... 40 - 9
Points to remember when troubleshooting .................................................................................................. 40 - 9
Sequence of events in troubleshooting........................................................................................................ 40 - 10
Checks before troubleshooting .................................................................................................................... 40 - 11
Classification and procedures for troubleshooting ....................................................................................... 40 - 36
Failure codes table....................................................................................................................................... 40 - 39
Phenomena and troubleshooting numbers .................................................................................................. 40 - 45
Information in troubleshooting table............................................................................................................. 40 - 47
Troubleshooting method for disconnecting wiring harness of pressure sensor system............................... 40 - 49
Connectors table and arrangement drawing................................................................................................ 40 - 88
Connection table for connector pin numbers ............................................................................................... 40 - 52
T-branch box and T-branch adapter table ................................................................................................... 40 -102
Fuse locations table ..................................................................................................................................... 40 -105
Troubleshooting by failure code ...................................................................................................................... 40 -109
Failure code [AB00MA] Battery Charge Abnormal ...................................................................................... 40 -109
Failure code [1380MW] Lock up clutch: Slip................................................................................................ 40 -110
Failure code [1500L0] Transmission clutch: Abnormal ................................................................................ 40 -111
Failure code [15E0MW] Transmission clutch: Slip....................................................................................... 40 -111
Failure code [15SAL1] Forward clutch: Fill high .......................................................................................... 40 -112
Failure code [15SALH] Forward clutch: Fill Low .......................................................................................... 40 -114
Failure code [15SBL1] Reverse clutch: Fill high .......................................................................................... 40 -116
Failure code [15SBLH] Reverse clutch: Fill Low.......................................................................................... 40 -118
00-4 D375A-6
(04)
Shop Manual
Table of contents
Failure code [15SEL1] Speed 1st clutch: Fill high ....................................................................................... 40 -120
Failure code [15SELH] Speed 1st clutch: Fill Low ....................................................................................... 40 -122
Failure code [15SFL1] Speed 2nd clutch: Fill high ...................................................................................... 40 -124
Failure code [15SFLH] Speed 2nd clutch: Fill Low ...................................................................................... 40 -126
Failure code [15SGL1] Speed 3rd clutch: Fill high....................................................................................... 40 -128
Failure code [15SGLH] Speed 3rd clutch: Fill Low ...................................................................................... 40 -130
Failure code [15SJL1] L/U: Fill high ............................................................................................................. 40 -132
Failure code [15SJLH] L/U: Fill low.............................................................................................................. 40 -134
Failure code [1800MW] P/T clutch: Slip....................................................................................................... 40 -136
Failure code [2201L1] Right clutch: Fill high ................................................................................................ 40 -138
Failure code [2201LH] Right clutch: Fill low................................................................................................. 40 -140
Failure code [2202L1] Left clutch: Fill high .................................................................................................. 40 -142
Failure code [2202LH] Left clutch: Fill low ................................................................................................... 40 -144
Failure code [2300NR] Brake Themal Load Abnormality............................................................................. 40 -146
Failure code [2301L1] Right brake: Fill high ................................................................................................ 40 -148
Failure code [2301LH] Right brake: Fill low ................................................................................................. 40 -150
Failure code [2301NR] Steering Brake RH Themal Load Abnormality ........................................................ 40 -152
Failure code [2302L1] Left brake: Fill high................................................................................................... 40 -154
Failure code [2302LH] Left brake: Fill low.................................................................................................... 40 -156
Failure code [2302NR] Steering Brake LH Themal Load Abnormality......................................................... 40 -158
Failure code [7RFAKA] ECM ACC CUT RELAY: Disconnection................................................................. 40 -160
Failure code [7RFAKB] ECM ACC CUT RELAY: Short circuit .................................................................... 40 -162
Failure code [AA10NX] Air Cleaner Clogging .............................................................................................. 40 -164
Failure code [B@BAZG] Eng Oil Press Low................................................................................................ 40 -166
Failure code [B@BAZK] Eng Oil Level Low................................................................................................. 40 -167
Failure code [B@BCNS] Eng Water Overheat ............................................................................................ 40 -168
Failure code [B@BCZK] Eng Water Level Low ........................................................................................... 40 -169
Failure code [B@CENS] T/C Oil Overheat .................................................................................................. 40 -170
Failure code [B@HANS] Hyd Oil Overheat.................................................................................................. 40 -171
Failure code [B@HAZK] Hyd Oil Level Low................................................................................................. 40 -172
Failure code [CA111] ECM Critical Internal Failure ..................................................................................... 40 -174
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ........................................................................ 40 -176
Failure code [CA122] Chg Air Press Sensor High Error .............................................................................. 40 -178
Failure code [CA123] Chg Air Press Sensor Low Error ............................................................................... 40 -180
Failure code [CA131] Throttle Sensor High Error ........................................................................................ 40 -182
Failure code [CA132] Throttle Sensor Low Error ......................................................................................... 40 -184
Failure code [CA135] Eng Oil Press Sensor High Error .............................................................................. 40 -186
Failure code [CA141] Eng Oil Press Sensor Low Error ............................................................................... 40 -188
Failure code [CA144] Coolant Temp Sens High Error ................................................................................. 40 -190
Failure code [CA145] Coolant Temp Sens Low Error.................................................................................. 40 -192
Failure code [CA153] Chg Air Temp Sensor High Error .............................................................................. 40 -194
Failure code [CA154] Chg Air Temp Sensor Low Error ............................................................................... 40 -196
Failure code [CA187] Sens Supply 2 Volt Low Error ................................................................................... 40 -198
Failure code [CA212] Eng Oil Temp Sensor High Error .............................................................................. 40 -200
Failure code [CA213] Eng Oil Temp Sensor Low Error ............................................................................... 40 -202
Failure code [CA221] Ambient Press Sens High Error ................................................................................ 40 -204
Failure code [CA222] Ambient Press Sens Low Error ................................................................................. 40 -206
Failure code [CA227] Sens Supply 2 Volt High Error .................................................................................. 40 -208
Failure code [CA234] Eng Overspeed ......................................................................................................... 40 -209
Failure code [CA238] Ne Speed Sens Supply Volt Error............................................................................. 40 -210
Failure code [CA263] Fuel Temp Sensor High Error ................................................................................... 40 -212
Failure code [CA265] Fuel Temp Sensor Low Error .................................................................................... 40 -214
Failure code [CA271] IMV/PCV1 Short Error............................................................................................... 40 -216
Failure code [CA272] IMV/PCV1 Open Error............................................................................................... 40 -217
Failure code [CA273] PCV2 Short Error ...................................................................................................... 40 -218
Failure code [CA274] PCV2 Open Error ...................................................................................................... 40 -219
Failure code [CA322] Inj #1 (L#1) Open/Short Error.................................................................................... 40 -220
Failure code [CA342] Calibration Code Incompatibility................................................................................ 40 -232
D375A-6 00-4-1
(04)
Shop Manual
Table of contents
Failure code [CA351] Injectors Drive Circuit Error ....................................................................................... 40 -233

Failure code [CA352] Sens Supply 1 Volt Low Error ................................................................................... 40 -234
Failure code [CA386] Sens Supply 1 Volt High Error .................................................................................. 40 -236
Failure code [CA441] Battery Voltage Low Error ......................................................................................... 40 -237
Failure code [CA442] Battery Voltage High Error ........................................................................................ 40 -238
Failure code [CA449] Rail Press Very High Error ........................................................................................ 40 -239
Failure code [CA451] Rail Press Sensor High Error .................................................................................... 40 -240
Failure code [CA452] Rail Press Sensor Low Error..................................................................................... 40 -242
Failure code [CA553] Rail Press High Error ................................................................................................ 40 -244
Failure code [CA554] Rail Press Sensor In Range Error............................................................................. 40 -245
Failure code [CA559] Rail Press Low Error ................................................................................................. 40 -246
Failure code [CA689] Eng Ne Speed Sensor Error ..................................................................................... 40 -250
Failure code [CA731] Eng Bkup Speed Sens Phase Error.......................................................................... 40 -252
Failure code [CA757] All Continuous Data Lost Error.................................................................................. 40 -253
Failure code [CA778] Eng Bkup Speed Sensor Error.................................................................................. 40 -254
Failure code [CA1228] EGR Valve Servo Error 1 ........................................................................................ 40 -256
Failure code [CA1625] EGR Valve Servo Error 2 ........................................................................................ 40 -257
Failure code [CA1633] KOMNET Datalink Timeout Error............................................................................ 40 -258
Failure code [CA2185] Throt Sens Sup Volt High Error............................................................................... 40 -259
Failure code [CA2186] Throt Sens Sup Volt Low Error ............................................................................... 40 -260
Failure code [CA2249] Rail Press Very Low Error....................................................................................... 40 -261
Failure code [CA2271] EGR Valve Pos Sens High Error............................................................................. 40 -262
Failure code [CA2272] EGR Valve Pos Sens Low Error ............................................................................. 40 -264
Failure code [CA2351] EGR Valve Sol Current High Error.......................................................................... 40 -266
Failure code [CA2352] EGR Valve Sol Current Low Error........................................................................... 40 -268
Failure code [D110KB] Battery Relay: Drive Short Circuit ........................................................................... 40 -270
Failure code [D130KA] Neutral relay: Disconnection................................................................................... 40 -272
Failure code [D130KB] Neutral relay: Short circuit ...................................................................................... 40 -274
Failure code [D161KA] Back-up alarm releay: Disconnection ..................................................................... 40 -276
Failure code [D161KB] Back-up alarm releay: Short circuit......................................................................... 40 -278
Failure code [D182KZ] Preheater Relay Abnormality .................................................................................. 40 -280
Failure code [D190KA] ACC signal relay: Disconnection ............................................................................ 40 -282
Failure code [D190KB] ACC signal relay: Short circuit ................................................................................ 40 -284
Failure code [D1EFKA] Pre lub. motor relay: Disconnection ....................................................................... 40 -286
Failure code [D1EFKB] Pre lub. motor relay: Short circuit........................................................................... 40 -288
Failure code [DAFRKR] Monitor: Can communication lost (PT) .................................................................. 40 -290
Failure code [dAFRKR] Monitor: CAN communication lost (WE) ................................................................ 40 -291
Failure code [DAFRMC] CAN Discon (Monitor Detected) ........................................................................... 40 -292
Failure code [DB2RKR] ENG cont.: Can communication lost (PT).............................................................. 40 -297
Failure code [dB2RKR] ENG controller: CAN communication lost (WE) ..................................................... 40 -300
Failure code [DB90KT] WE controller: Abnormality in controller ................................................................. 40 -301
Failure code [DB91KK] WE controller: Source voltage reduction ................................................................ 40 -302
Failure code [DB92KK] WE controller: Output voltage reduction................................................................. 40 -304
Failure code [DB97KK] WE cont.: Sensor voltage 5 V (2) reduction ........................................................... 40 -306
Failure code [DB99KQ] WE controller: Type select signal........................................................................... 40 -308
Failure code [DB9RKR] WE controller: Can communication lost (PT)......................................................... 40 -309
Failure code [DBB0KK] VHMS controller:Source voltage reduction ............................................................ 40 -312
Failure code [DBB0KQ] VHMS connector connection abnormality ............................................................. 40 -314
Failure code [DBB3KK] VHMS controller: Source voltage reduction ........................................................... 40 -316
Failure code [DBB5KP] VHMS: Output sensor1 voltage reduction.............................................................. 40 -318
Failure code [DBB6KP] VHMS:Output sensor2 voltage reduction............................................................... 40 -320
Failure code [DBB7KP] VHMS:Output sensor3 voltage reduction............................................................... 40 -322
Failure code [DBBQKR] PT cont.: Can communication lost (VHMS) .......................................................... 40 -323
Failure code [DBE0KT] PT controller: Abnormality in controller .................................................................. 40 -323
Failure code [DBE1KK] PT controller: Source voltage reduction................................................................. 40 -324
Failure code [DBE2KK] PT controller: Output voltage reduction ................................................................. 40 -326
Failure code [DBE5KK] PT cont.: Sensor voltage 5 V (1) reduction ............................................................ 40 -328
Failure code [DBE6KK] PT cont.: Sensor voltage 24 V reduction ............................................................... 40 -330
Failure code [DBE7KK] PT cont.: Sensor voltage 5 V (2) reduction ............................................................ 40 -332
Failure code [DBE9KQ] PT controller: Type select signal ........................................................................... 40 -334
Failure code [DBERKR] PT controller: Can communication lost (WE) ........................................................ 40 -335
Failure code [DD12KA] Shift up Sw: Disconnection .................................................................................... 40 -338
Failure code [DD12KB] Shift up Sw: Short circuit ........................................................................................ 40 -340
00-4-2 D375A-6
(04)
Shop Manual
Table of contents
Failure code [DD13KA] Shift down Sw: Disconnection................................................................................ 40 -342

Failure code [DD13KB] Shift down Sw: Short circuit ................................................................................... 40 -344
Failure code [DD14KA] Parking lever Sw: Dissconnection.......................................................................... 40 -346
Failure code [DD14KB] Parking lever Sw: Short circuit ............................................................................... 40 -348
Failure code [DDB9L4] Reverse SW Signal disagreement.......................................................................... 40 -350
Failure code [DDE2KA] Pre lub. oil press sw: Disconnection ...................................................................... 40 -352
Failure code [DDK3L4] Forward SW Signal disagreement.......................................................................... 40 -354
Failure code [DDK5KA] Shift switch disconnection...................................................................................... 40 -356
Failure code [DDK5KB] Shift switch short circuit ......................................................................................... 40 -358
Failure code [DDN2LD] Blade tilt RH pressure SW abnormality ................................................................. 40 -360
Failure code [DDN3LD] Blade tilt LH pressure SW abnormality .................................................................. 40 -362
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection .................................................................. 40 -364
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit...................................................................... 40 -366
Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection....................................................................... 40 -368
Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit .......................................................................... 40 -370
Failure code [DDNALD] Blade lift up pressure SW abnormality .................................................................. 40 -372
Failure code [DDNBLD] Ripper lift up pressure SW abnormality................................................................. 40 -374
Failure code [DDNCLD] Ripper lift down pressure SW abnormality ............................................................ 40 -376
Failure code [DDNDLD] Ripper tilt in pressure SW abnormality.................................................................. 40 -378
Failure code [DDNELD] Ripper tilt back pressure SW abnormality ............................................................. 40 -380
Failure code [DDNFLD] Blade lift down pressure SW abnormality.............................................................. 40 -382
Failure code [DDNLKA] Weq lock Sw: Disconnection ................................................................................. 40 -384
Failure code [DDNLKB] Weq lock Sw: Short circuit..................................................................................... 40 -386
Failure code [DDT5KA] Neutral switch disconnection ................................................................................. 40 -388
Failure code [DDT5KB] Neutral switch short circuit ..................................................................................... 40 -390
Failure code [DDT5KQ] Lever SPEC selection signal disagreement .......................................................... 40 -392
Failure code [DDTSL1] S/C: Fill high ........................................................................................................... 40 -394
Failure code [DDTSLH] S/C: Fill low............................................................................................................ 40 -396
Failure code [DGE5KX] Ambient temp sensor abnormality ......................................................................... 40 -398
Failure code [DGS1KX] Hyd oil temp: signal abnormal ............................................................................... 40 -400
Failure code [DGT1KA] T/C oil temp sensor: Abnormal .............................................................................. 40 -402
Failure code [DGT1KX] T/C oil temp sensor: Abnormal .............................................................................. 40 -404
Failure code [DGT5KA] F exhaust temp sensor disconnection ................................................................... 40 -406
Failure code [DGT5KB] F exhaust temp sensor short circuit....................................................................... 40 -408
Failure code [DGT6KA] R exhaust temp sensor disconnection................................................................... 40 -410
Failure code [DGT6KB] R exhaust temp sensor short circuit ...................................................................... 40 -412
Failure code [DH21KA] Weq pressure sensor: Disconnection .................................................................... 40 -414
Failure code [DH21KB] Weq pressure sensor: Short circuit ........................................................................ 40 -416
Failure code [DHE5KB] ENG blow-by pressure sensor disconnection........................................................ 40 -418
Failure code [DHE5KY] ENG blow-by pressure sensor short circuit ........................................................... 40 -420
Failure code [DHT3KX] T/M oil pressure sensor abnormality...................................................................... 40 -422
Failure code [DHT5KA] T/C in-pressure sensor: Disconnection.................................................................. 40 -424
Failure code [DHT5KB] T/C in-pressure sensor: Short circuit ..................................................................... 40 -426
Failure code [DHT7KA] T/C out-pressure sensor: Disconnection................................................................ 40 -428
Failure code [DHT7KB] T/C out-pressure sensor: Short circuit ................................................................... 40 -430
Failure code [DK10KA] Fuel control Dial: Disconnection............................................................................. 40 -432
Failure code [DK10KB] Fuel control Dial: Short circuit ................................................................................ 40 -434
Failure code [DK30KA] ST lever 1: Disconnection ...................................................................................... 40 -436
Failure code [DK30KB] ST lever 1: Short circuit .......................................................................................... 40 -438
Failure code [DK30KX] ST lever: Out of normal range ................................................................................ 40 -440
Failure code [DK30KZ] ST lever: Disconnection or short circuit .................................................................. 40 -440
Failure code [DK30L8] ST lever: Signal mismatch ...................................................................................... 40 -441
Failure code [DK31KA] ST lever 2: Disconnection ...................................................................................... 40 -442
Failure code [DK31KB] ST lever 2: Short circuit .......................................................................................... 40 -444
Failure code [DK40KA] Brake potentiometer: Disconnection ...................................................................... 40 -446
Failure code [DK40KB] Brake potentiometer: Short circuit .......................................................................... 40 -448
Failure code [DK55KX] FR lever: Out of normal range................................................................................ 40 -450
Failure code [DK55KZ] FR lever: Disconnection or short circuit.................................................................. 40 -450
Failure code [DK55L8] FR lever: Signal mismatch ...................................................................................... 40 -451
Failure code [DK56KA] FR lever 1: Disconnection ...................................................................................... 40 -452
Failure code [DK56KB] FR lever 1: Short circuit.......................................................................................... 40 -454
Failure code [DK57KA] FR lever 2: Disconnection ...................................................................................... 40 -456
Failure code [DK57KB] FR lever 2: Short circuit.......................................................................................... 40 -458
D375A-6 00-4-3
(04)
Shop Manual
Table of contents
Failure code [DK60KA] Acceleration sensor: Disconnection ....................................................................... 40 -460

Failure code [DK60KB] Acceleration sensor: Short circuit........................................................................... 40 -462
Failure code [DKH1KA] Pitch angle sensor: Disconnection......................................................................... 40 -464
Failure code [DKH1KB] Pitch angle sensor: Short circuit ............................................................................ 40 -466
Failure code [DLF1KA] T/C out-speed sensor: Disconnection .................................................................... 40 -468
Failure code [DLM3KA] Fan rev. sensor: Disconnection ............................................................................. 40 -469
Failure code [DLM3MB] Fan control: Decline .............................................................................................. 40 -470
Failure code [DLT3KA] T/M out-speed sensor: Disconnection .................................................................... 40 -471
Failure code [DLT3KB] T/M out-speed sensor: Abnormal ........................................................................... 40 -472
Failure code [DW59KA] Blade dual selector SOL disconnection................................................................. 40 -473
Failure code [DW59KB] Blade dual selector SOL short circuit .................................................................... 40 -474
Failure code [DW59KY] Blade dual selector SOL hot short......................................................................... 40 -475
Failure code [DW5AKA] Blade pitch selector SOL disconnection ............................................................... 40 -476
Failure code [DW5AKB] Blade pitch selector SOL short circuit ................................................................... 40 -477
Failure code [DW5AKY] Blade pitch selector SOL Short circuit .................................................................. 40 -478
Failure code [DW7BKA] Fan rev EPC: Disconnection................................................................................. 40 -479
Failure code [DW7BKB] Fan rev EPC: Short circuit .................................................................................... 40 -480
Failure code [DWN3KA] Ssp solenoid: Disconnection................................................................................. 40 -481
Failure code [DWN3KB] Ssp solenoid: Short circuit .................................................................................... 40 -482
Failure code [DWN3KY] SSP solenoid: Short circuit ................................................................................... 40 -484
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection.................................................................... 40 -486
Failure code [DWN5KB] Fan pump solenoid 1: Short circuit ....................................................................... 40 -487
Failure code [DWN5KY] Fan pump solenoid 1: Short circuit ....................................................................... 40 -488
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection ................................................................... 40 -490
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit....................................................................... 40 -491
Failure code [DWNCKY] Fan pump solenoid 2: Short circuit....................................................................... 40 -492
Failure code [DXH1KA] Lock-up ECMV: Disconnection .............................................................................. 40 -494
Failure code [DXH1KB] Lock-up ECMV: Short circuit.................................................................................. 40 -495
Failure code [DXH1KY] Lock-up ECMV: Short circuit.................................................................................. 40 -496
Failure code [DXH4KA] 1st clutch ECMV: Disconnection............................................................................ 40 -498
Failure code [DXH4KB] 1st clutch ECMV: Short circuit ............................................................................... 40 -499
Failure code [DXH4KY] 1st clutch ECMV: Short circuit ............................................................................... 40 -500
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection .......................................................................... 40 -502
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit .............................................................................. 40 -503
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit .............................................................................. 40 -504
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection ........................................................................... 40 -506
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit............................................................................... 40 -507
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit............................................................................... 40 -508
Failure code [DXH7KA] R clutch ECMV: Disconnection.............................................................................. 40 -510
Failure code [DXH7KB] R clutch ECMV: Short circuit ................................................................................. 40 -511
Failure code [DXH7KY] R clutch ECMV: Short circuit ................................................................................. 40 -512
Failure code [DXH8KA] F clutch ECMV: Disconnection .............................................................................. 40 -514
Failure code [DXH8KB] F clutch ECMV: Short circuit.................................................................................. 40 -515
Failure code [DXH8KY] F clutch ECMV: Short circuit.................................................................................. 40 -516
Failure code [DXH9KA] Right clutch ECMV: Disconnection ........................................................................ 40 -518
Failure code [DXH9KB] Right clutch ECMV: Short circuit............................................................................ 40 -519
Failure code [DXH9KY] Right clutch ECMV: Short circuit............................................................................ 40 -520
Failure code [DXHAKA] Left clutch ECMV: Disconnection .......................................................................... 40 -522
Failure code [DXHAKB] Left clutch ECMV: Short circuit.............................................................................. 40 -523
Failure code [DXHAKY] Left clutch ECMV: Short circuit.............................................................................. 40 -524
Failure code [DXHBKA] Right brake ECMV: Disconnection ........................................................................ 40 -526
Failure code [DXHBKB] Right brake ECMV: Short circuit............................................................................ 40 -527
Failure code [DXHBKY] Right brake ECMV: Short circuit............................................................................ 40 -528
Failure code [DXHCKA] Left brake ECMV: Disconnection .......................................................................... 40 -530
Failure code [DXHCKB] Left brake ECMV: Short circuit.............................................................................. 40 -531
Failure code [DXHCKY] Left brake ECMV: Short circuit.............................................................................. 40 -532
Failure code [DXJBKA] S/C ECMV: Disconnection ..................................................................................... 40 -534
Failure code [DXJBKB] S/C ECMV: Short circuit......................................................................................... 40 -535
Failure code [DXJBKY] S/C ECMV: Short circuit......................................................................................... 40 -536
Failure code [DY2HKA] Pre lub. motor: Disconnection................................................................................ 40 -538
Failure code [F@BBZL] ENG blow-by pressure high level .......................................................................... 40 -540
Failure code [F@BYNR] F exhaust temp high level (2) ............................................................................... 40 -541
Failure code [F@BYNS] F exhaust temp high level (1) ............................................................................... 40 -542
00-4-4 D375A-6
(04)
Shop Manual
Table of contents
Failure code [F@BZNR] R exhaust temp high level (2)............................................................................... 40 -543

Failure code [F@BZNS] R exhaust temp high level (1) ............................................................................... 40 -544
Troubleshooting of electrical system (E-mode) ............................................................................................... 40 -545
Information contained in troubleshooting table ............................................................................................ 40 -545
E-1 Engine does not start (starting motor does not turn) ............................................................................. 40 -547
E-2 Preheater does not operate................................................................................................................... 40 -550
E-3 When starting switch is turned ON, machine monitor displays nothing................................................. 40 -554
E-4 When starting switch is turned ON (before starting engine), basic check item lights up....................... 40 -556
E-5 Precaution item lights up while engine is running ................................................................................. 40 -558
E-6 Emergency stop item lights up while engine is running......................................................................... 40 -560
E-7 Engine coolant temperature gauge does not indicate normally ............................................................ 40 -561
E-8 Fuel gauge does not indicate properly .................................................................................................. 40 -562
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally ....................................... 40 -564
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally ............................................. 40 -565
E-11 Contents of display by machine monitor are different from applicable machine ................................. 40 -566
E-12 Machine monitor does not display some items ................................................................................... 40 -566
E-13 Function switch does not work ............................................................................................................ 40 -566
E-14 Operation mode does not change ....................................................................................................... 40 -567
E-15 Gearshift mode does not change ........................................................................................................ 40 -567
E-16 Customize function does not operate normally ................................................................................... 40 -568
E-17 Customize memory function does not operate normally ..................................................................... 40 -568
E-18 Alarm buzzer does not sound or does not stop................................................................................... 40 -569
E-19 When starting switch is turned OFF, service meter is not displayed................................................... 40 -569
E-20 Machine monitor cannot be set in service mode ................................................................................. 40 -569
E-21 The ripper pin puller cylinder does not operate ................................................................................... 40 -570
E-22 Horn does not sound or does not stop ................................................................................................ 40 -572
E-23 Back-up alarm does not sound or does not stop................................................................................. 40 -574
E-24 Fan does not reverse .......................................................................................................................... 40 -576
E-25 The head lamp and rear lamp do not light up...................................................................................... 40 -577
E-26 Windshield wiper does not operate ..................................................................................................... 40 -584
E-27 Window washer does not operate ....................................................................................................... 40 -590
E-28 Electric priming pump does not operate or does not stop automatically ............................................. 40 -596
E-29 Orbcomm terminal does not operate normally (Data are not transmitted) .......................................... 40 -598
E-30 Gear cannot be shifted ........................................................................................................................ 40 -600
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................................... 40 -601
Information in troubleshooting table............................................................................................................. 40 -601
List of Failure Modes and Causes ............................................................................................................... 40 -602
H-1 Machine lacks power(or drawbar pull) .................................................................................................. 40 -604
H-2 Machine cannot travel (at 2nd or 3rd each speed)................................................................................ 40 -606
H-3 Machine cannot travel at any gear speeds ........................................................................................... 40 -607
H-4 Machine travels only in one direction, forward or reverse..................................................................... 40 -608
H-5 Large time lag at gear shifting or directional change ............................................................................ 40 -609
H-6 Machine connot turn.............................................................................................................................. 40 -610
H-7 Machine turns only to one side ............................................................................................................. 40 -611
H-8 Machine overruns at turnning................................................................................................................ 40 -612
H-9 Brake does not work ............................................................................................................................. 40 -612
H-10 Torque converter does not lock up...................................................................................................... 40 -613
H-11 Power train oil overheats..................................................................................................................... 40 -614
H-12 All work equipment operates too slow or lacks power ........................................................................ 40 -615
H-13 All work equipment does not operate.................................................................................................. 40 -616
H-14 Blade lift cylinder speed is too slow or lacks power ............................................................................ 40 -617
H-15 Blade tilt cylinder speed is too slow or lacks power ............................................................................ 40 -617
H-16 Ripper lift cylinder speed is too slow or lacks power........................................................................... 40 -618
H-17 Ripper tilt cylinder speed is too slow or lacks power........................................................................... 40 -618
H-18 Excessive hydraulic drift of blade lift cylinder...................................................................................... 40 -619
H-19 Excessive hydraulic drift of blade tilt cylinder...................................................................................... 40 -619
H-20 Excessive hydraulic drift of ripper lift cylinder ..................................................................................... 40 -620
H-21 Ripper pin puller cylinder does not operate (machine with giant ripper) ............................................. 40 -620
H-22 Blade pitch does not work (machine with dual tilt specification) ......................................................... 40 -621
H-23 Abnormal noise from around work equipment pump .......................................................................... 40 -621
H-24 Abnormal fan rotation(noise and/or vibration are abnormally large or engine overheats) .................. 40 -622
D375A-6 00-4-5
(04)
Shop Manual
Table of contents
Troubleshooting of engine (S-mode)............................................................................................................... 40 -624

Method of using troubleshooting chart......................................................................................................... 40 -624
S-1 Engine does not start easily .................................................................................................................. 40 -628
S-2 Engine does not start ............................................................................................................................ 40 -630
S-3 Engine does not rev up smoothly (response-up is poor)....................................................................... 40 -634
S-4 Engine stops during operation............................................................................................................... 40 -636
S-5 Engine does not rotate smoothly (hunting)............................................................................................ 40 -637
S-6 Engine lacks power (or output shortage)............................................................................................... 40 -638
S-7 Exhaust smoke is black (Incomplete combustion) ................................................................................ 40 -640
S-8 Oil is consumption is excessive(or exhaust smoke is blue) .................................................................. 40 -642
S-9 Engine oil becomes contaminated quickly ............................................................................................ 40 -643
S-10 Fuel consumption is excessive............................................................................................................ 40 -644
S-11 Oil mixes into coolant(coolant blows back or is reduced).................................................................... 40 -645
S-12 Engine pressure monitor lights up (drop in engine oil pressure) ......................................................... 40 -646
S-13 Oil level rises (Coolant or fuel mixes into oil) ...................................................................................... 40 -647
S-14 Coolant temperature rises too high (overheating) ............................................................................... 40 -649
S-15 Abnormal noise is heard...................................................................................................................... 40 -650
S-16 Vibration is excessive.......................................................................................................................... 40 -651
S-17 Air cannot be bled from fuel circuit (when air bleeding is performed after filter is replaced or fuel is used up
and then air is bled, engine does not start or it starts but stalls).................................................................. 40 -652
50 Disassembly and assembly

General information on disassembly and assembly........................................................................................ 50 - 4
How to read this manual .............................................................................................................................. 50 - 4
Coating materials list.................................................................................................................................... 50 - 6
Special tools list ........................................................................................................................................... 50 - 9
Sketches of special tools ............................................................................................................................. 50 - 16
Engine and cooling system ............................................................................................................................. 50 - 24
Removal and installation of fuel supply pump assembly ............................................................................. 50 - 24
Removal and installation of fuel injector assembly ...................................................................................... 50 - 28
Removal and installation of cylinder head assembly ................................................................................... 50 - 33
Removal and installation of radiator guard assembly .................................................................................. 50 - 49
Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler)................... 50 - 54
Removal and installation of radiator............................................................................................................. 50 - 59
Removal and installation of hydraulic oil cooler ........................................................................................... 50 - 61
Removal and installation of aftercooler........................................................................................................ 50 - 62
Removal and installation of engine assembly.............................................................................................. 50 - 63
Removal and installation of engine hood assembly..................................................................................... 50 - 70
Removal and installation of engine front seal .............................................................................................. 50 - 73
Removal and installation of engine rear seal ............................................................................................... 50 - 75
Removal and installation of fan drive assembly........................................................................................... 50 - 79
Removal and installation of fan motor assembly ......................................................................................... 50 - 81
Removal and installation of fuel tank assembly ........................................................................................... 50 - 83
Power train ...................................................................................................................................................... 50 - 86
Removal and installation of damper assembly ............................................................................................ 50 - 86
Disassembly and assembly of damper assembly ........................................................................................ 50 - 90
Removal and installation of power train unit assembly ................................................................................ 50 - 93
Disconnection and connection of power train unit assembly ....................................................................... 50 -100
Disassembly and assembly of PTO assembly............................................................................................. 50 -109
Disassembly and assembly of torque converter assembly .......................................................................... 50 -115
Disassembly and assembly of TORQFLOW transmission assembly .......................................................... 50 -125
Disassembly and assembly of steering case assembly............................................................................... 50 -153
Removal and installation of power train pump and lubrication pump assembly .......................................... 50 -169
Removal and installation of scavenging pump assembly ............................................................................ 50 -170
Removal and installation of final drive assembly ......................................................................................... 50 -171
Disassembly and assembly of final drive assembly..................................................................................... 50 -173
Undercarriage and frame ................................................................................................................................ 50 -186
Removal and installation of track frame assembly....................................................................................... 50 -186
Removal and installation of idler assembly.................................................................................................. 50 -191
Disassembly and assembly of idler assembly ............................................................................................. 50 -192
Removal and installation of recoil spring assembly ..................................................................................... 50 -196
Disassembly and assembly of recoil spring assembly................................................................................. 50 -201
Removal and installation of track roller assembly........................................................................................ 50 -203
00-4-6 D375A-6
(04)
Shop Manual
Table of contents
Disassembly and assembly of track roller assembly ................................................................................... 50 -206

Removal and installation of carrier roller assembly ..................................................................................... 50 -209
Disassembly and assembly of carrier roller assembly ................................................................................. 50 -210
Removal and installation of bogie assembly................................................................................................ 50 -214
Disassembly and assembly of bogie assembly ........................................................................................... 50 -219
Removal and installation of first bogie assembly ......................................................................................... 50 -221
Separation and connection of track shoe assembly .................................................................................... 50 -226
Overall disassembly and assembly of track shoe ........................................................................................ 50 -230
Link press press-fitting jig dimensions ......................................................................................................... 50 -247
Disassembly and assembly of one link assembly in the field ...................................................................... 50 -248
Disassembly and assembly of master link ................................................................................................... 50 -253
Removal and installation of pivot shaft assembly ........................................................................................ 50 -257
Removal and installation of equalizer bar .................................................................................................... 50 -258
Disassembly and assembly of equalizer bar bushing .................................................................................. 50 -262
Removal and installation of segment tooth .................................................................................................. 50 -264
Hydraulic system ............................................................................................................................................. 50 -266
Removal and installation of hydraulic tank assembly .................................................................................. 50 -266
Removal and installation of work equipment pump assembly ..................................................................... 50 -269
Removal and installation of fan pump assembly.......................................................................................... 50 -273
Removal and installation of control valve assembly .................................................................................... 50 -275
Disassembly and assembly of control valve assembly ................................................................................ 50 -277
Disassembly and assembly of blade PPC valve assembly.......................................................................... 50 -282
Disassembly and assembly of ripper PPC valve assembly ......................................................................... 50 -285
Disassembly and assembly of hydraulic cylinder assembly ........................................................................ 50 -287
Disassembly and assembly of ripper pin puller cylinder assembly .............................................................. 50 -295
Work equipment .............................................................................................................................................. 50 -298
Removal and installation of blade assembly................................................................................................ 50 -298
Disassembly and assembly of blade assembly ........................................................................................... 50 -300
Disassembly and assembly of giant ripper assembly .................................................................................. 50 -304
Cab and its attachments.................................................................................................................................. 50 -308
Removal and installation of ROPS guard .................................................................................................... 50 -308
Removal and installation of operator’s cab assembly.................................................................................. 50 -309
Removal and installation of floor frame assembly ....................................................................................... 50 -313
Removal and installation of air conditioner unit assembly ........................................................................... 50 -318
Electrical system ............................................................................................................................................. 50 -324
Removal and installation of transmission controller assembly and steering controller assembly................ 50 -324
Removal and installation of engine controller assembly .............................................................................. 50 -325
Removal and installation of VHMS controller assembly .............................................................................. 50 -327
Removal and installation of machine monitor assembly .............................................................................. 50 -328
60 Maintenance Standard
Engine and cooling system ............................................................................................................................. 60- 3
Engine mount............................................................................................................................................... 60- 3
Cooling fan pump......................................................................................................................................... 60- 5
Cooling fan motor......................................................................................................................................... 60- 12
Power train ...................................................................................................................................................... 60- 14
Power train unit ............................................................................................................................................ 60- 14
Damper and universal joint .......................................................................................................................... 60- 16
Torque converter and PTO .......................................................................................................................... 60- 19
Main relief valve and torque converter relief valve....................................................................................... 60- 22
Lockup clutch ECMV and stator clutch ECMV............................................................................................. 60- 23
Scavenging pump ........................................................................................................................................ 60- 24
Transmission control.................................................................................................................................... 60- 25
Transmission................................................................................................................................................ 60- 26
Transmission lubricating oil relief valve ....................................................................................................... 60- 30
Power train and lubrication pump ................................................................................................................ 60- 31
Transfer, bevel gear shaft and steering unit ................................................................................................ 60- 32
Steering control valve .................................................................................................................................. 60- 38
Steering clutch ECMV and steering brake ECMV........................................................................................ 60- 39
Parking brake valve ..................................................................................................................................... 60- 40
Final drive .................................................................................................................................................... 60- 41
Sprocket....................................................................................................................................................... 60- 44
D375A-6 00-4-7
(04)
Shop Manual
Table of contents
Undercarriage and frame ................................................................................................................................ 60- 46

Track frame.................................................................................................................................................. 60- 46
Idler cushion................................................................................................................................................. 60- 48
Idler .............................................................................................................................................................. 60- 50
Track roller ................................................................................................................................................... 60- 52
Carrier roller ................................................................................................................................................. 60- 54
Track roller bogie ......................................................................................................................................... 60- 55
Track shoe ................................................................................................................................................... 60- 56
Main frame ................................................................................................................................................... 60- 60
Suspension .................................................................................................................................................. 60- 62
Hydraulic system ............................................................................................................................................. 60- 67
PPC valve .................................................................................................................................................... 60- 67
Hydraulic cylinder......................................................................................................................................... 60- 72
Quick drop valve .......................................................................................................................................... 60- 75
Work equipment pump................................................................................................................................. 60- 76
Control valve ................................................................................................................................................ 60- 79
Self-pressure reducing valve ....................................................................................................................... 60- 85
Work equipment .............................................................................................................................................. 60- 87
Cylinder stay ................................................................................................................................................ 60- 87
Blade............................................................................................................................................................ 60- 88
Cutting edge and end bit.............................................................................................................................. 60- 92
Ripper .......................................................................................................................................................... 60- 94
80 Appendix
Air Conditioner................................................................................................................................................. 80 - 3
Caution about refrigerant ............................................................................................................................. 80 - 3
Air conditioner component ........................................................................................................................... 80 - 4
Configuration and function of refrigeration cycle.......................................................................................... 80 - 6
Outline of refrigeration cycle ........................................................................................................................ 80 - 7
Air conditioner unit ....................................................................................................................................... 80 - 10
Blower unit ................................................................................................................................................... 80 - 14
FRESH/RECIRC air changeover damper .................................................................................................... 80 - 15
Compressor ................................................................................................................................................. 80 - 16
Condenser ................................................................................................................................................... 80 - 17
Receiver drier............................................................................................................................................... 80 - 18
Air conditioner control panel ........................................................................................................................ 80 - 20
Procedure for testing and troubleshooting ................................................................................................... 80 - 22
Circuit diagram and arrangement of connector pins .................................................................................... 80 - 24
System diagram ........................................................................................................................................... 80 - 26
Part and connector locations ....................................................................................................................... 80 - 28
Testing temperature control ......................................................................................................................... 80 - 32
Testing FRESH/RECIC air changeover ....................................................................................................... 80 - 32
Testing relay ................................................................................................................................................ 80 - 34
Troubleshooting chart 1 ............................................................................................................................... 80 - 36
Troubleshooting chart 2 ............................................................................................................................... 80 - 38
Information in troubleshooting table............................................................................................................. 80 - 40
Troubleshooting for power supply system (Air conditioner does not operate) ............................................. 80 - 42
Troubleshooting for compressor system (Air is not cooled)......................................................................... 80 - 44
Troubleshooting for blower motor system (Air does not come out or air flow is abnormal) ......................... 80 - 48
Troubleshooting for temperature control...................................................................................................... 80 - 54
Troubleshooting for FRESH/RECIRC air changeover ................................................................................. 80 - 56
Troubleshooting with gauge pressure.......................................................................................................... 80 - 58
Connection of service tool............................................................................................................................ 80 - 60
Precautions for disconnecting and connecting ............................................................................................ 80 - 62
Handling of compressor oil .......................................................................................................................... 80 - 64
90 Diagrams and Drawings

Hydraulic diagrams and drawings ................................................................................................................... 90 - 3
Symbols used in hydraulic circuit diagrams ................................................................................................. 90 - 3
Power train hydraulic circuit diagram ........................................................................................................... 90 - 5
Hydraulic circuit diagram.............................................................................................................................. 90 - 7
Electrical diagrams and drawings.................................................................................................................... 90 - 9
Symbols use in electric circuit diagrams ...................................................................................................... 90 - 9
00-4-8 D375A-6
(04)
Shop Manual
Table of contents
Electrical circuit diagram .............................................................................................................................. 90 - 13
Index............................................................................................................................................................................ 1
D375A-6 00-4-9
(04)
DRAFT
Table of contents
00-4-10
00-14 D375A-6
(02)
DRAFT
Forword and general information
Safety notice

Safety notice
(Rev. 2009/5)
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific pur-
pose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with the
situation.
1. General precautions
k Mistakes in operation are extremely dan- 7) If welding repairs are needed, always have a
gerous. Read the Operation and Mainte- trained and experienced welder carry out the
nance Manual carefully before operating work. When carrying out welding work,
the machine. In addition, read this manu- always wear welding gloves, apron, shielding
al and understand its contents before goggles, cap and other clothes suited for
starting the work. welding work.
1) Before carrying out any greasing or repairs, 8) Before starting work, warm up your body
read all the safety labels stuck to the thoroughly to start work under good condi-
machine. For the locations of the safety tion.
labels and detailed explanation of precau- 9) Avoid continuing work for long hours and
tions, see the Operation and Maintenance take rests at proper intervals to keep your
Manual. body in good condition.
2) Decide a place in the repair workshop to Take rests in specified safe places.
keep tools and removed parts. Always keep
the tools and parts in their correct places. Safety points
Always keep the work area clean and make 1 Good arrangement
sure that there is no dirt, water, or oil on the 2 Correct work clothes
floor. Smoke only in the areas provided for 3 Following work standard
smoking. Never smoke while working. 4 Making and checking signals
Prohibition of operation and handling by unli-
3) When carrying out any operation, always 5
censed workers
wear safety shoes and helmet. Do not wear 6 Safety check before starting work
loose work clothes, or clothes with buttons Wearing protective goggles(for cleaning or grind-
missing. 7
ing work)
q Always wear safety glasses when hitting Wearing shielding goggles and protectors(for
8
parts with a hammer. welding work)
q Always wear safety glasses when grind- 9 Good physical condition and preparation
ing parts with a grinder, etc. Precautions against work which you are not used
10
to or you are used to too much
4) When carrying out any operation with 2 or
more workers, always agree on the operating
procedure before starting. Always inform
your fellow workers before starting any step
of the operation. Before starting work, hang
UNDER REPAIR warning tag in the oper-
ator's compartment.
5) Only qualified workers must carry out work
and operation which require license or quali-
fication.
6) Keep all tools in good condition, learn the
correct way to use them, and use the proper
ones of them. Before starting work, thor-
oughly check the tools, machine, forklift,
service car, etc.
D375A-6 00-5
DRAFT
Safety notice
2. Preparation work 5) When raising a heavy component (heavier

1) Before adding oil or making any repairs, park than 25 kg), use a hoist or crane. Before
the machine on a hard and level ground, and starting work, check that the slings (wire
apply the parking brake and block the wheels ropes, chains, and hooks) are free from
or tracks to prevent the machine from damage. Always use slings which have
moving. ample capacity and install them to proper
2) Before starting work, lower the work equip- places. Operate the hoist or crane slowly to
ment (blade, ripper, bucket, etc.) to the prevent the component from hitting any other
ground. If this is not possible, insert the lock part. Do not work with any part still raised by
pin or use blocks to prevent the work equip- the hoist or crane.
ment from falling. In addition, be sure to lock 6) When removing a cover which is under
all the control levers and hang warning tag on internal pressure or under pressure from a
them. spring, always leave 2 bolts in diagonal posi-
3) When disassembling or assembling, support tions. Loosen those bolts gradually and alter-
the machine with blocks, jacks, or stands nately to release the pressure, and then
before starting work. remove the cover.
4) Remove all mud and oil from the steps or 7) When removing components, be careful not
other places used to get on and off the to break or damage the electrical wiring.
machine. Always use the handrails, ladders Damaged wiring may cause electrical fires.
or steps when getting on or off the machine. 8) When removing piping, stop the fuel or oil
Never jump on or off the machine. If it is from spilling out. If any fuel or oil drips onto
impossible to use the handrails, ladders or the floor, wipe it up immediately. Fuel or oil
steps, use a stand to provide safe footing. on the floor can cause you to slip and can
even start fires.
3. Precautions during work 9) As a general rule, do not use gasoline to
1) Before disconnecting or removing compo- wash parts. Do not use it to clean electrical
nents of the oil, water, or air circuits, first parts, in particular.
release the pressure completely from the 10)Be sure to assemble all parts again in their
circuit. When removing the oil filler cap, a original places. Replace any damaged parts
drain plug, or an oil pressure pickup and parts which must not be reused with new
plug,loosen it slowly to prevent the oil from parts. When installing hoses and wires, be
spurting out. sure that they will not be damaged by contact
2) The coolant and oil in the circuits are hot with other parts when the machine is oper-
when the engine is stopped, so be careful not ated.
to get scalded. Wait for the oil and coolant to 11)When installing high pressure hoses and
cool before carrying out any work on the oil or tubes, make sure that they are not twisted.
water circuits. Damaged hoses and tubes are dangerous,
3) Before starting work, stop the engine. When so be extremely careful when installing
working on or around a rotating part, in partic- hoses and tubes for high pressure circuits. In
ular, stop the engine. When checking the addition, check that connections of them are
machine without stopping the engine correct.
(measuring oil pressure, revolving speed, 12)When assembling or installing parts, always
temperature, etc.), take extreme care not to tighten them to the specified torques. When
get or caught in rotating parts or moving installing protective parts such as guards, or
parts. parts which vibrate violently or rotate at high
4) Before starting work, remove the leads from speeds, be particularly careful to check that
the battery. Always remove the lead from the they are installed correctly.
negative (–) terminal first. 13)When aligning 2 holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
14)When measuring hydraulic pressure, check
that the measuring tools are correctly
installed.
15)Take care when removing or installing the end of the track.
tracks of track-type machines. When
removing the track, the track separates
suddenly, so never let anyone stand at either
00-6 D375A-6
DRAFT
Safety notice
16)If the engine is operated for a long time in a

place which is not ventilated well, you may
suffer from gas poisoning. Accordingly, open
the windows and doors to ventilate well.
4. Precautions for sling work and making

signals
1) Only one appointed worker must make
signals and co-workers must communicate
with each other frequently. The appointed
signaler must make specified signals clearly
at a place where he is well seen from the
operator's seat and where he can see the
working condition easily. The signaler must 8) When installing wire ropes to an angular
always stand in front of the load and guide load, apply pads to protect the wire ropes. If
the operator safely. the load is slippery, apply proper material to
q Do not stand under the load. prevent the wire rope from slipping.
q Do not step on the load. 9) Use the specified eyebolts and fix wire ropes,
2) Check the slings before starting sling work. chains, etc. to them with shackles, etc.
3) Keep putting on gloves during sling work. 10)Apply wire ropes to the middle portion of the
(Put on leather gloves, if available.) hook.
4) Measure the weight of the load by the eye q Slinging near the tip of the hook may
and check its center of gravity. cause the rope to slip off the hook during
5) Use proper sling according to the weight of hoisting. The hook has the maximum
the load and method of slinging. If too thick strength at the middle portion.
wire ropes are used to sling a light load, the
load may slip and fall.
6) Do not sling a load with 1 wire rope alone. If
it is slung so, it may rotate and may slip out of
the rope. Install 2 or more wire ropes
symmetrically.
k Slinging with 1 rope may cause turn-
ing of the load during hoisting, un-
twisting of the rope, or slipping of the
rope from its original winding position
on the load, which can result in a dan-
gerous accident.
7) Limit the hanging angle to 60 °, as a rule.
Do not sling a heavy load with ropes forming 11)Do not use twisted or kinked wire ropes.
a wide hanging angle from the hook. 12)When lifting up a load, observe the following.
When hoisting a load with 2 or more ropes, q Wind in the crane slowly until wire ropes
the force subjected to each rope will increase are stretched. When settling the wire
with the hanging angle. The table below ropes with the hand, do not grasp them
shows the variation of allowable load in kN but press them from above. If you grasp
{kg} when hoisting is made with 2 ropes, them, your fingers may be caught.
each of which is allowed to sling up to 9.8 kN q After the wire ropes are stretched, stop
{1,000 kg} vertically, at various hanging the crane and check the condition of the
angles. When the 2 ropes sling a load verti- slung load, wire ropes, and pads.
cally, up to 19.6 kN {2,000 kg} of total weight q If the load is unstable or the wire rope or
can be suspended. This weight is reduced to chains are twisted, lower the load and lift
9.8 kN {1,000 kg} when the 2 ropes make a it up again.
hanging angle of 120 °. If the 2 ropes sling a q Do not lift up the load at an angle.
19.6 kN {2,000 kg} load at a lifting angle of 13)When lowering a load, observe the following.
150 ° , each of them is subjected to a force as q When lowering a load, stop it temporarily
large as 39.2 kN {4,000 kg}. at 30 cm above the floor, and then lower
it slowly.
D375A-6 00-7
DRAFT
Safety notice
q Check that the load is stable, and then re- 7. Selecting wire ropes
move the sling. 1) Select adequate ropes depending on the
q Remove kinks and dirt from the wire weight of parts to be hoisted, referring to the
ropes and chains used for the sling work, table below.
and put them in the specified place. Wire ropes
(Standard "Z" twist ropes without galvanizing)
5. Precautions for using mobile crane (JIS G3525, No. 6, Type 6X37-A)
a Read the Operation and Maintenance Manu- Nominal diame-
Allowable load
al of the crane carefully in advance and oper- ter of rope
ate the crane safely. mm kN ton
10 8.8 0.9
12 12.7 1.3
6. Precautions for using overhead hoist crane 14 17.3 1.7
kWhen raising a heavy part (heavier than 25), use 16 22.6 2.3
a hoist, etc. In Disassembly and assembly, the 18 28.6 2.9
weight of a part heavier than 25 is indicated af- 20 35.3 3.6
ter the mark of 4.
25 55.3 5.6
30 79.6 8.1
1) Before starting work, inspect the wire ropes, 40 141.6 14.4
brake, clutch, controller, rails, over wind stop 50 221.6 22.6
device, ground fault circuit interrupter, crane 60 318.3 32.4
collision prevention device, and power appli-
a The allowable load is one-sixth of the
cation warning lamp, and check safety.
breaking strength of the rope used (Safe-
2) Observe the signals for sling work. ty coefficient: 6).
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east,
west, south, and north) and the directions of
the control buttons without fail.
5) Do not sling a load at an angle. Do not move
the crane while the slung load is swinging.
6) Do not raise or lower a load while the crane
is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and lift
up a load to a safe height.
10)Place the control switch on a position where
it will not be an obstacle to work and
passage.
11)After operating the hoist, do not swing the
control switch.
12)Remember the position of the main switch so
that you can turn off the power immediately in
an emergency.
13)If the hoist stops because of a power failure,
turn the power switch OFF. When turning on
a switch which was turned OFF by the
ground fault circuit interrupter, check that the
devices related to that switch are not in oper-
ation state.
14)If you find an obstacle around the hoist, stop
the operation.
15)After finishing the work, stop the hoist at the
specified position and raise the hook to at
least 2mabove the floor. Do not leave the
sling installed to the hook.
00-8 D375A-6
DRAFT
Safety notice
8. Precautions for disconnecting and

connecting hoses and tubes in air condi-
tioner circuit
1) Disconnection
k For the environment, the air condition-
er of this machine uses the refrigerant
(air conditioner gas: R134a) which has
fewer factors of the depletion of the
ozone layer. However, it does not
mean that you may discharge the re-
frigerant into the atmosphere as it is.
Be sure to recover the refrigerant
when disconnecting the refrigerant
gas circuit and then reuse it. a For tightening torque, see the precau-
a Ask a gualified person for collecting and tions for installation in each section of
filling operation of refrigerant (R134a). "Disassembly and assembly".
a Never release the refrigerant (R134a) to
the atmosphere.
k If the refrigerant gas gets in your eyes
or contacts your skin, you may lose
your sight and your skin may be fro-
zen. Accordingly, put on safety glass-
es, safety gloves and safety clothes
when recovering or adding the refrig-
erant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner circuit
hoses and tubes, take care that dirt, dust,
water, etc. will not enter them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings (1)
are fitted to their joints.
3] Check that each O-ring (1) is not
damaged or deteriorated.
4] When connecting the refrigerant piping,
apply compressor oil for refrigerant
(R134a) (DENSO: ND-OIL8, VALEO
THERMAL SYSTEMS: ZXL100PG
(equivalent to PAG46)) to its O-rings (1).
a Example of O-ring (Fitted to every
joint of hoses and tubes)
D375A-6 00-9
DRAFT
How to read the shop manual
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is
required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the "Chassis volume" and "Engine volume". For the engine unit, see the engine vol-
ume of the engine model mounted on the machine.
Composition of shop manual

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

This section contains table of contents, and safety and basic information. If any revision of the shop man-
ual is made, the LIST OF REVISED PAGES will be added.
01. Specification
This section explains the specifications of the machine.
10. 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.
20. Standard value table

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

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

This section explains the special tools and procedures for removing, installing, disassembling, and assem-
bling each component, as well as precautions for them. In addition, tightening torque, and quantity and
weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60.Maintenance standard
This section gives maintenance standard values of each component. The maintenance standard sub-sec-
tion explains the criteria and remedies for disassembly and service.
80.Appendix
The section explains the equipment which can not be included in the other sections. This section explains
the structure, function, testing, adjusting, and troubleshooting fo the equipment.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
00-10 D375A-6
DRAFT
q Engine volume
This section explains the method of remanufacturing and repairing engine and replacing parts.
Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
Filing method
File the revised or added pages in the correct order of the page numbers printed in the LIST OF REVISED
PAGES.
q Revision number
When a manual is revised, revision number of each page is increased by 1.
(Example: (1),(2),(3)...)
q Revisions
The revised pages are shown in the LIST OF REVISED PAGES.
Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will be
used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving standards are

a Caution
necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when selecting hoisting
Weight
wire, or when working posture is important, etc.
3 Tightening torque Places that require special attention for tightening torque during assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5 Oil, coolant Places where oil, etc. must be added, and capacity.
6 Drain Places where oil, etc. must be drained, and quantity to be drained.
Units
In this shop manual, the units are indicated with International System of units (SI). For reference, convention-
ally used Gravitational System of units is indicated in parentheses { }.
D375A-6 00-11
DRAFT
Explanation of terms for maintenance standard

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

q To be accurate, the finishing size of parts is a
little different from one to another.
q To specify a finishing size of a part, a tempo-
rary standard size is set and an allowable dif-
ference from that size is indicated.
q The above size set temporarily is called the
"standard size" and the range of difference
from the standard size is called the "toler-
ance".
q The tolerance with the symbols of + or – is in-
dicated on the right side of the standard size.
Example:
Standard size Tolerance
- 0.022
120
- 0.126
a The tolerance may be indicated in the text
and a table as [standard size (upper limit of
tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of the

shaft to be fitted to that hole are indicated by
the same standard size and different toler-
ances of the hole and shaft. The tightness of
fit is decided by the tolerance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
- 0.030 + 0.046
60
- 0.076 0
00-12 D375A-6
DRAFT
2. Standard clearance and standard value 5. Clearance limit

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

dimension
q The size of a part changes because of wear
and deformation while it is used. The limit of
changed size is called the "repair limit".
q If a part is worn to the repair limit, it must be
replaced or repaired.
q The performance and function of a product
lowers while it is used. A value which the
product can be used without causing a prob-
lem is called the "allowable value" or "allow-
able dimension".
q If a product is worn to the allowable value, it
must be checked or repaired. Since the per-
missible value is estimated from various tests
or experiences in most cases, however, it
must be judged after considering the operat-
ing condition and customer's requirement.
D375A-6 00-13
DRAFT
Handling of electric equipment and hydraulic components
To maintain the performance of the machine over a long period, and to prevent failures or other troubles be-
fore they occur, correct "operation", "maintenance and inspection", "troubleshooting", and "repairs" must be
carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and "Han-
dling hydraulic components" (particularly gear oil and hydraulic oil).
Points to remember when handling electric equipment

1. Handling wiring harnesses and connectors
Wiring harnesses consist of wires 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 wires.
Compared with other electrical components
fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness
1) Defective contact of connectors (defective
contact between male and female connec-
tors)
Problems with defective contact are likely to
occur because the male connector is not
properly fitted into the female connector, or
because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces. The
corroded or oxidized contact surfaces may
become shiny again (and contact may
become normal) by connecting and discon-
necting the connector about 10 times.
2) Defective crimping or soldering of connectors
The pins of the male and female connectors
are connected to wires by crimping or
soldering. If excessive force is applied to the
wire, the joint is separated to cause defective
contact or the wire is broken.
00-14 D375A-6
DRAFT
3) Disconnections in wiring
If the harness is pulled to disconnect the
connector, or components are lifted with a
crane with the harness still connected, or a
heavy object hits the harness, the crimping of
the connector may separate, or the soldering
may be damaged, or the harness may be
broken.
4) High-pressure water entering connector

The connector is designed to make it difficult
for water to enter (drip-proof structure), but if
high-pressure water is sprayed directly on
the connector, water may enter the
connector, depending on the direction of the
water jet.
Accordingly, take care not to splash water
over the connector.
The connector is designed to prevent water
from entering, but at the same time, if water
does enter, it is difficult for it to be drained.
Therefore, if water should get into the
connector, the pins will be short-circuited by
the water, so if any water gets in, immediately
dry the connector or take other appropriate
action before passing electricity through it.
5) Oil or dirt stuck to connector
If oil or grease are stuck to the connector and
an oil film is formed on the mating surface of
the male and female pins, the oil will not let
the electricity pass, so there will be defective
contact. If there is oil or grease stuck to the
connector, wipe it off with a dry cloth or blow
it dry with compressed air and spray it with
electric contact cleaner.
a When wiping the joint portion of the con-
nector, be careful not to apply excessive
force or deform the pins.
a If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the com-
pressed air completely before cleaning
with compressed air.
D375A-6 00-15
DRAFT
3. Removing, installing, and drying connectors

and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors. For connectors held by a
screw, loosen the screw fully, then hold
the male and female connectors in each
hand and pull apart. For connectors
which have a lock stopper, press down
the stopper with your thumb and pull the
connectors apart.
a Never pull with one hand.
2] When removing from clips
q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is in-
stalled.
q When removing a connector from a

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

After removing any connector, cover it
with a vinyl bag to prevent any dust, dirt,
oil, or water from getting in the connector
portion.
a If the machine is left disassembled for
a long time, it is particularly easy for
improper contact to occur, so always
cover the connector.
00-16 D375A-6
DRAFT
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or water
stuck to the connector pins (joint portion).
Check that there is no deformation,
defective contact, corrosion, or damage
to the connector pins.
Check that there is no damage or
breakage to the outside of the connector.
a If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry
cloth. If any water has got inside the
connector, warm the inside of the con-
nector and harness with a dryer, but
be careful not to make them too hot as
this will cause short circuits.
a If there is any damage or breakage,
replace the connector.
2] Fix the connector securely.
Position the connectors correctly, and
then fit them securely. For connectors
with the lock stopper, push in the
connector until the stopper clicks into
position.
3] Correct any protrusion of the boot and
any misalignment of the wiring harness.
For connectors fitted with boots, correct
any protrusion of the boot. In addition, if
the wiring harness is misaligned, or the
clamp is out of position, adjust it to its
correct position.
a If the connector cannot be corrected
easily, remove the clamp and adjust
the position.
q If the connector clamp has been re-
moved, be sure to return it to its origi-
nal position. Check also that there are
no loose clamps.
D375A-6 00-17
DRAFT
3) DT connector (DT 8-pole, 12-pole)

Disconnection (Left of figure) q Disconnection q Connection (Example
While pressing both locks (a) and (b), pull out of incomplete setting of
female connector (2). (a))
Connection (Right of figure)
1] Push in female connector (2) horizontally
until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector (2)
while moving it up and down until the
locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled down
(not set completely) and lock (b) is set
completely.
(1): Male connector
(2): Female connector
(a),(b): Locks
00-18 D375A-6
DRAFT
4) Drying wiring harness

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

If water gets inside the connector, use a
dryer to dry the connector.
a Hot air from the dryer can be used, but
regulate the time that the hot air is
used in order not to make the connec-
tor or related parts too hot, as this will
cause deformation or damage to the
connector.
3] Carry out a continuity test on the connector.

After drying, leave the wiring harness
disconnected and carry out a continuity
test to check for any short circuits
between pins caused by water.
a After completely drying the connector,
blow it with electric contact cleaner
and reassemble.
D375A-6 00-19
DRAFT
4. Handling controller
1) The controller contains a microcomputer and
electronic control circuits. These control all of
the electronic circuits on the machine, so be
extremely careful when handling the
controller.
2) Do not place objects on top of the controller.
3) Cover the control connectors with tape or a
vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short time.
(Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
machine body, disconnect all wiring harness
connectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check all
the related connectors for half fit.
a Disconnect and connect the related con-
nectors several times to check.
3) Always connect any disconnected connec-
tors before going on to the next step.
a If the power is turned ON with the connec-
tors still disconnected, unnecessary ab-
normality warning will be issued.
4) When carrying out troubleshooting of circuits
(measuring the voltage, resistance, conti-
nuity, or current), wag the related wiring
harnesses and connectors several times and
check that there is no change in the reading
of the tester.
a If there is any change, there is probably
defective contact in that circuit.
00-20 D375A-6
DRAFT
Points to remember when handling hydraulic components

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

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

Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil 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.
D375A-6 00-21
DRAFT
5. Change hydraulic oil when the temperature is high

When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is still
warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain plug
in the circuit.) If any old oil is left, the 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
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried out
with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic components (pump,
control valve, etc.) or when running the machine,
carry out oil cleaning to remove the sludge or
contaminants in the hydraulic oil circuit. The oil
cleaning equipment is used to remove the ultra
fine (about 3 m) particles that the filter built in the
hydraulic components cannot remove, so it is an
extremely effective device.
00-22 D375A-6
DRAFT
Handling of connectors newly used for engines

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

(FRAMATOME-3,FRAMATOME-2) q 95–170,12V140 engines
q 95–170,12V140 engines q Various temperature sensors
q Various pressure sensors and NE speed Examples)
sensor Intake air temperature sensor in intake mani-
Examples) fold: TIM
Intake air pressure sensor in intake manifold: Fuel temperature sensor: TFUEL
PIM (125,170,12V140 engines) Oil temperature sensor: TOIL
Oil pressure sensor: POIL (125,170,12V140 Coolant temperature sensor: TWTR, etc.
engines)
Oil pressure switch (95,107,114 engines) Disconnect
Ne speed sensor of flywheel housing: Disconnect the connector by pulling lock (B) (on the
NE(95-170,12V140 engines) wiring harness side) of connector (2) outward.
Ambient pressure sensor: PAMB
(125,170,12V140 engines)
Disconnect
1) Slide lock L1 to the right.
2) While pressing lock L2, pull out connector (1)
toward you.
a Even if lock L2 is pressed, connector (1)
cannot be pulled out toward you, if part A
does not float. In this case, float part A
with a small screwdriver while press lock
L2 , and then pull out connector (1) to-
ward you.
Connect
Insert the connector straight until it "clicks".
Connect
D375A-6 00-23
DRAFT
Push lock type (1)

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

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

screwdriver [1] since you cannot insert your fin-
gers.
Connect
00-24 D375A-6
DRAFT
Push lock type (3) Turn-housing type (Round green connector)

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

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

(SUMITOMO-3)
a Pull the connector straight up.
Connect
D375A-6 00-25
How to read electric wire code
How to read electric wire code 0 -24

In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols.
The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L --- Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No.
of 0.85
Indicates color of wire by color code.

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

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

Type, symbol, and material of wire are shown in Table 1.
(Since the use of AV and AVS wires depends on size (nominal No.), their symbols
are not indicated on the diagram.)
1. Type, symbol, and material

AV and AVS are different only in thickness and outside diameter of the cover.CAVS has a circular
compressed conductor. It differs from that of AV and AVS in the outside diameter and thickness of the
cover.And AEX is similar to AV in thickness and outside diameter of the cover but different from AV and
AVS in material of the cover.
(Table 1)
Using tem-
Type Symbol Material Example of use
perature
Annealed copper for electric
Low-voltage Conductor
appliance General wiring
wire for automo- AV
(nominal No. 5 and above.)
bile Insulator Soft polyvinyl chloride
Thin-cover Annealed copper for electric
Conductor
low-voltage wire appliance General wiring
AVS -30 to +60
for automobile (nominal No. 3 and below.)
Insulator Soft polyvinyl chloride
(type 1)
Thin-cover Annealed copper for electric
Conductor
low-voltage wire appliance For mid- to small-size excavators
CAVS
for automobile (nominal No. 1.25 and below.)
Insulator Soft polyvinyl chloride
(type 2)
Annealed copper for electric General wiring in extremely cold
Heat-resistant Conductor
appliance district, wiring at high ambient tem-
low-voltage wire AEX -50 to +110
Heat-resistant crosslinked perature place
for automobile Insulator
polyethylene For wiring in a place of high atmo-
00-26 D375A-6
(04)
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diame- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
ter of strand
Conduc- Sectional area
tor 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
(mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –

Co
ver AV Standard – – – – – – – 4.6
D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diame- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
ter of strand
tor 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
(mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Co
ver AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Number of 7/Circular com- 11/Circular com- 16/Circular com-
strands/Diame- — — —
ter of strand pressed pressed pressed
tor — 0.56 — 0.88 — 1.29
(mm2)
(a) — 0.9 — 1.1 — 1.4

Co
ver CAVS Standard — 1.6 — 1.8 — 2.1
D
"f" of nominal No. denotes "flexible".
D375A-6 00-27
(04)
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow & Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second
color is the color of the marking.
Example: "GW" means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS/AV/CAVS AEX
Charge R WG – – – – R –
Ground B – – – – –- B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of cir-
Br BrW BrR BrY BrB – – –
cuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
00-28 D375A-6
(04)
DRAFT
Precautions when carrying out work
When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the work.
1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising component, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any component, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376 - 70210 02789 - 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
Part No.
number D d L
06 07049 - 00608 6 5 8
08 07049 - 00811 8 6.5 11
10 07049 - 01012 10 8.5 12
12 07049 - 01215 12 10 15
14 07049 - 01418 14 11.5 18
16 07049 - 01620 16 13.5 20
18 07049 - 01822 18 15 22
20 07049 - 02025 20 17 25
22 07049 - 02228 22 18.5 28
24 07049 - 02430 24 20 30
27 07049 - 02734 22.5 22.5 34
D375A-6 00-29
DRAFT
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified torque (KES) .
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q When coating with liquid gasket, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with liquid gasket.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with molybdenum disulfide lubricant (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When installing split flanges, fasten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, hydraulic pumps
and other hydraulic component removed for repair, always bleed the air as follows:
1] Start the engine and run at low idle.
2] Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder100 mm from the end of its stroke.
3] Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4] After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing work

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

Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see "Disassembly and assembly" .
00-30 D375A-6
DRAFT
3) Checking engine piping for damage and looseness

Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and
exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leak-
age.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage.
4) Checking muffler, exhaust pipe and their mounts for damage and looseness
1] Visually check the muffler, exhaust pipe and their mounts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounts for looseness.
If any part is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to "Troubleshooting" and "Disassembly and
assembly".
D375A-6 00-31
DRAFT
Method of disassembling and connecting push-pull type coupler
k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2) into
mating adapter (3). (Fig. 1)
a The adapter can be pushed in about 3.5
mm.
a Do not hold rubber cap portion (4).
2) With hose joint (2) pushed into adapter (3),
press rubber cap portion (4) against adapter
(3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull it
out. (Fig. 3)
a Since some hydraulic oil flows out, pre-
pare an oil container.
2. Connection
1) Hold hose adapter (1) or hose (5) and insert
it in mating adapter (3), aligning them with
each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter
perfectly, pull it back to check its connecting
condition. (Fig. 5)
a When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormal-
ity, however.
00-32 D375A-6
DRAFT
Type 2
1. Disconnection
1) Hold the tightening portion and push body (7)
straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal
portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1) and
2), pull out whole body (7) to disconnect it.
(Fig. 8)
2. Connection
q Hold the tightening portion and push body (7)
straight until sliding prevention ring (6) con-
tacts contact surface (a) of the hexagonal
D375A-6 00-33
DRAFT
Type 3
1. Disconnection
1) Hold the tightening portion and push body (9)
straight until sliding prevention ring (8)
contacts contact surface (b) of the hexagonal
2) While holding the condition of Step 1), push
cover (10) straight until it contacts contact
surface (b) of the hexagonal portion at the
male end. (Fig. 11)
3) While holding the condition of Steps 1) and
2), pull out whole body (9) to disconnect it.
(Fig. 12)
2. Connection
q Hold the tightening portion and push body (9)
straight until the sliding prevention ring (8)
contacts contact surface (b) of the hexagonal
00-34 D375A-6
DRAFT
Standard tightening torque table

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

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

mm mm Nm kgm
6 10 5.9 - 9.8 0.6 - 1.0
8 12 13.7 - 23.5 1.4 - 2.4
10 14 34.3 - 46.1 3.5 - 4.7
12 17 74.5 - 90.2 7.6 - 9.2
a Figure A a Figure B
Remarks: The widths across flats by thread diameter of flanged bolts (marked with "*") in Fig. A are the
ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
D375A-6 00-35
DRAFT
2. Table of tightening torques for split flanged bolts

a Unless there are special instructions, tighten split flanged bolts to the torque below.
mm mm Nm kgm
10 14 59 - 74 6.0 - 7.5
12 17 98 - 123 10.0 - 12.5
16 22 235 - 285 23.5 - 29.5
3. Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diameter Width across flats Tightening torque Nm {kgm}
Nominal No.
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}
03,04 20 84 – 132 {8.5 – 13.5} 103 {10.5}
Varies depending on
05,06 24 128 – 186 {13.0 – 19.0} 157 {16.0}
type of connector.
10,12 33 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Thread diameter Width across flats Tightening torque Nm {kgm}
Nominal No.
mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
00-36 D375A-6
DRAFT
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal
Nominal Width Nominal No.
Thread diame-
No. of across Thread size –Number of
Range Target ter (mm) (Ref-
hose flats (mm) threads, type
erence)
of thread
34 – 54 {3.5 – 5.5} 44 {4.5} - 9/16 - 18UNF 14.3
02 19
34 – 63 {3.5 – 6.5} 44 {4.5} 14 - -
22 54 – 93 {5.5 – 9.5} 74 {7.5} - 11/16 - 16UN 17.5
03
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 - -
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 13/16 - 16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 - 14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 - 3/16 - 12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 - -
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 - -
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 - -
6. Table of tightening torques for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be
used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer Width Tightening torque Nm {kgm} Face seal
diameter across Nominal No. –Number
Thread diameter (mm)
of pipe flats Range Target of threads, type of
(Reference)
(mm) (mm) thread
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16 – 18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16 – 16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16 – 16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1 – 14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1 – 3/16 – 12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are slso used, depending on the specification.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine
series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 - -
D375A-6 00-37
DRAFT
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine se-
ries to the torque below.
Thread size Tightening torque
mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 en-
gine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
00-38 D375A-6
DRAFT
List of Abbreviation
q This list of abbreviations is taken from the abbre- q Special abbreviations that appear infrequently
viations used in the text of the shop manual for are marked in the text with an *.
parts, components, and functions whose mean- q This list of abbreviations consists of two
ing is not immediately clear. The spelling is given parts.The first part is a list of abbreviations used
in full with an outline of the meaning. in the text of the manual, and the second part is
q Abbreviations that are used in general society a list of abbreviations used in circuit diagrams.
may not be included. text of the manual, and the second part is a list
List of abbreviations used in the shop manual

Purpose of use
Abbreviat- (major applicable machine(*), or
Full Spelling Explanation
ion component/
system)
With this function, when the tires skid (wheels
Travel and brake stop rotating), the brakes are released, and
A.B.S. Anti-skid Brake System
(HD, HM) when the wheels start to rotate, the brakes
are applied again.
Automatic Idling Setting This function automatically sets the idling
A.I.S.S. Engine
System speed.
Instead of a steering wheel, a lever is used to
Advanced Joystick Steering carry out the steering operations as well as to
A.J.S.S.
Steering System (WA) shift gear and change direction (forward or
reverse).
When the machine is traveling downhill, if the
Automatic Retarder Travel and brake accelerator pedal is released, this function
A.R.A.C.
Accelerator Control (HD, HM) automatically applies the retarder with a con-
stant braking force.
When the machine is traveling downhill, if the
accelerator pedal is released, this function
Automatic Retarder Travel and brake
A.R.S.C. automatically applies the retarder to ensure
Speed Control (HD, HM)
that the machine speed does not accelerate
above the speed set by the operator.
When the rear wheels spin on soft ground
Automatic Spin Regula- Travel and brake
A.S.R. surfaces, this function automatically uses the
tor (HD, HM)
optimum braking force to drive both wheels.
A device that can be fixed onto a machine in
ATT. Attachment Work equipment
order to enable it to do different jobs.
When the retarder is not being used, this
Breake Cooling oil con- Brake
B.C.V. valve bypasses part of the brake cooling oil to
trol Valve (HD)
reduce the load on the hydraulic pump.
Communication and electronic Communications standard standardized as
C.A.N. Controller Area Network
control ISO11898.
System that can simultaneously actuate multi-
Closed-center Load ple actuators regardless of the load (provides
C.L.S.S. Hydraulic
Sensing System better ease of combined operation than
O.L.S.S.).
Uses engine controller to carry out electronic
control of supply pump, common rail, and
C.R.I. Common Rail Injection Engine
injector. Functions to maintain optimum fuel
injection amount and fuel injection timing.
Electronic control device that uses the signals
Electronic Control Mod- from the sensors on the machine to indicate
E.C.M. Electronic control system
ule to the actuators the optimum actuation. (same
as ECU)
Proportional electromagnetic valve that grad-
Electronic Control Mod- Transmission
E.C.M.V. ually increases oil pressure to engage clutch
ulation Valve (WA, D, HD, etc.)
and reduces transmission shock.
System that ensures smooth high-speed
Electronically Con-
Travel travel by using hydraulic spring effect of accu-
E.C.S.S. trolled Suspension Sys-
(WA) mulator to absorb vibration of machine during
tem
travel.
D375A-6 00-39
DRAFT
Purpose of use
ion component/
system)
Electronic control device that uses the signals
from the sensors on the machine to indicate
E.C.U. Electronic Control Unit Electronic control system
to the actuators the optimum actuation. (same
as ECM)
Functions to recirculate part of exhaust gas to
Exhaust Gas Recircula- combustion chamber in order to reduce com-
E.G.R. Engine
tion bustion temperature, controls emission of
Nox.
System that allows data (filter, oil replacement
Equipment Manage- interval, abnormalities on machine, failure
E.M.M.S. Machine monitor
ment Monitoring System code, and failure history) from each sensor on
the machine to be checked on monitor.
Control system that moves an actuator in pro-
Electromagnetic Propor-
E.P.C. Hydraulic portion to the amperage of an electric current
tional Control
passing through the solenoid.
Forward-Neu-
F-N-R Operation Position of the gear shift lever or switch.
tral-Reverse
System that is used to determine the current
Global Positioning Sys- Communication location on the Earth of a ship, car, machine,
G.P.S.
tem (KOMTRAX, VHMS) etc. by receiving the radio wave signals trans-
mitted from the navigation satellites.
Steering function that uses a combination of
Hydrostatic Steering Steering hydraulic motor and bevel shaft to control dif-
H.S.S.
System (D) ference in travel speed of left and right tracks
to turn machine without using steering clutch.
Hydraulic transmission system that uses a
Hydro Static Transmis- Transmission combination of hydraulic pump and hydraulic
H.S.T.
sion (WA, D: Small size) motor to shift gear steplessly without using
gears.
Valve installed at inlet port of pump to adjust
fuel intake amount in order to control fuel dis-
I.M.A. Inlet Metering Actruator Engine
charge amount of supply pump. Same as
IMV.
fuel intake amount in order to control fuel dis-
I.M.V. Inlet Metering Valve Engine
charge amount of supply pump. Described as
IMV (IMA).
Image display device made up of a large
L.C.D. Liquid Crystal Display Machine monitor
number of pixels filled with liquid crystal.
Semiconductor element that emits light when
the voltage is applied in forward direction,
L.E.D. Light Emitting Diode Electronic parts
positive voltage to anode and negative volt-
age to cathode.
Function that senses differential pressure of
L.S. Load Sensing Hydraulic pump and controls discharge amount accord-
ing to load.
Service that allows transmission and recep-
Multimedia Messaging
M.M.S. Communication tion of short messages consisting of charac-
Service
ters or voice or images between cell phones.
Device actuated to open electric or hydraulic
N.C. Normally Closed Electronic and hydraulic circuits that are normally closed if not actu-
ated.
Device actuated to close electric or hydraulic
N.O. Normally Open Electronic and hydraulic
circuits that are normally open if not actuated.
Hydraulic system that can operate multiple
Open-center Load
O.L.S.S. Hydraulic actuators at the same time, regardless of the
Sensing System
load.
P.C. Pressure Control Hydraulic Controlling the oil pressure.
00-40 D375A-6
DRAFT
Purpose of use
ion component/
system)
System in which a controller instantly analy-
Palm Command Con- Steering ses data from each lever, pedal, and dial, and
P.C.C.S.
trol System (D) carries out optimum electronic control of the
engine and HST.
P.C.V. Pump Control Valve Engine fuel intake amount in order to control fuel dis-
charge amount of supply pump.
Proportional Pressure Control system that moves an actuator in pro-
P.P.C. Hydraulic
Control portion to the oil pressure.
Hydraulic
P.P.M. Piston Pump and Motor Piston pump and motor.
(PC, D, etc.)
A device to take off power of the engine in
P.T.O. Power Take Off Power train order to drive a hydraulic pump, an air com-
pressor, etc.
Power Tilt and power Work equipment Function that carries out hydraulic control of
P.T.P.
Pitch dozer (D) the tilt and pitch of the bulldozer blade.
International System of Units (abbreviated SI
from the French Le Systeme Internationale
d'Unites) is the modern form of the metric sys-
tem, and is the world's most widely used sys-
Le System International tem of measurement.
S.I. Unit
d' Unites There're seven base units: meter (m), kilo-
gram (kg), second (s), ampere (A), kelvin (K),
candela (cd), and mole (mol).
The derived units include Pascal (Pa), New-
ton (N), etc.
Solenoid is a loop of wire. However, as a mat-
ter of fact in engineering, it refers to an actua-
tor consists of a solenoid and an iron core that
SOL. Solenoid Electronic
is moved by the magnetic force when the
solenoid is energized. The word solenoid also
often refers to a solenoid valve.
Solenoid valve that switches over direction of
T.W.V. Two Way Valve Hydraulic and electronic
flow.
Communications system that transmits
machine data, such as the present position of
the machine, daily or aggregate hours of
Vehicle Health Monitor- Monitoring and communication operation, fuel consumption, radiator water
V.H.M.S.
ing System (PC, WA, D, HD: Large size) temperature, oil or filter replacement interval,
to make it possible to collect and check this
data from a distant place (Developed for use
on large machines used in mines).
*: Code for machine family
HD: Dump truck
HM: Articulate dump truck
WA: Wheel loader
D: Bulldozer
PC: Hydraulic excavator
D375A-6 00-41
DRAFT
List of abbreviations used in the circuit drawings

Abbreviation Full Spelling
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actruator
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
SW Switch
T/C Torque Converter
T/M Transmission
00-42 D375A-6
DRAFT
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 meth-
od of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

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

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to
the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.017 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
D375A-6 00-43
DRAFT
Conversion table
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 5 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.017 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1l= 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
00-44 D375A-6
DRAFT
Conversion table
Liters to U.K. Gallons

1l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
D375A-6 00-45
DRAFT
Conversion table
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
00-46 D375A-6
DRAFT
Conversion table
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade
values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 47 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

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

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

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

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

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
D375A-6 00-47
DRAFT
Conversion table
00-48 D375A-6
DRAFT
D375A-6
SEN05011-00
Bulldozer
Shop Manual
D375A-6

D375A-6 60001 and up
01 Specification
Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01 -
2
Specification drawing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01 -
3
Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01 -
4
Weight table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01 -
9
Table of fuel, coolant and lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01 -
11
D375A-6 01-1
DRAFT
Contents
Contents
01 Specification
Specification and technical data
Specification drawing ................................................................................................................................... 01 - 3
Specifications............................................................................................................................................... 01 - 4
Weight table ................................................................................................................................................. 01 - 9
Table of fuel, coolant and lubricants ............................................................................................................ 01 - 11
01-2 D375A-6
DRAFT
Specification drawing

Specification drawing
Sem i - U tilt dozer + Full - U tilt dozer + Semi - U tilt dozer + Full - U tilt dozer +
Item Unit
Giant ripper Giant ripper Multi - shank ripper Multi - shank ripper
Overall
A mm 10,485 10,845 10,195 10,555
length
Overall
4,265 4,265 4,265 4,265
B height mm
(4,285) (4,285) (4,285) (4,285)
(with ROPS)
C Overall width mm 4,774 5,215 4,774 5,215
D375A-6 01-3
DRAFT
Specifications
Specifications
Machine model D375A-6

Serial number 60001 and up
Machine weight
q Bare tractor 53,200
q Ditto with semi - U dozer 64,160
q Ditto with variable multi - shank ripper 70,960
q Ditto with ROPS cab + Air conditioner + Seat 72,230
Weight
belt + Perforated side cover + SSC kg

q Bare tractor with full - U dozer 65,665
q Ditto with variable giant ripper 71,865
q Ditto with ROPS cab + Air conditioner + Seat 73,135
belt + Perforated side cover + SSC
Min. turning radius m 4.2
Gradeability deg. 30
Stability (front, rear, left, right) deg. 35
Transmission speed ranges (man- Transmission speed ranges (auto-
1st 0 – 3.5
Forward
2nd 0 – 6.8
matic gear shift mode)
km/h
3rd (low speed) 0 – 8.0
3rd 0 – 11.8
1st 0 – 4.6
Reverse
2nd 0 – 8.9
km/h
3rd (low speed) 0 – 9.7
3rd 0 – 15.8
Forward
1st 0 – 3.5
2nd km/h 0 – 6.8
ual gear shift mode)
Performance
3rd 0 – 11.8
Reverse
1st 0 – 4.6
2nd km/h 0 – 8.7
3rd 0 – 14.7
q Bare tractor 107.87 {1.10}

q With semi - U dozer 129.45 {1.32}
Ground pressure (610 shoe)
q With full - U dozer 132.39 {1.35}

q With semi - U dozer and variable 143.18 {1.46}
multi-shank ripper
q Ditto with ROPS cab + Air conditioner 146.12 {1.49}
+ Seat belt + Perforated side cover +
kPa {kg/cm2}
SSC belt, perforated side cover, and
SSC
q With full-U dozer and variable giant 145.14 {1.48}
ripper
q Ditto with ROPS cab + Air conditioner 148.08 {1.51}
+ Seat belt + Perforated side cover +
SSC
01-4 D375A-6
Specification dimension drawings
Specifications

Overall length Serial number 60001 and up
Bare tractor 5,905

With semi-U dozer 7,780
With full-U dozer mm 8,140
With semi-U dozer + variable multi-shank ripper 10,195
With full-U dozer + variable multi-shank ripper 10,845
Dimensions
Overall height Overall width
Bare tractor 3,240

With semi-U dozer mm 4,695
With full-U dozer 5,140
To tip of exhaust pipe 4,265

mm
To top of air intake duct 3,525
Dimensions
Track gauge 2,500

Length of track on ground 3,980
mm
Track shoe width 610
Maximum ground clearance 662
Model SAA6D170E-5
Type 4-cycle, water-cooled, in-line vertical,
direct injection type with turbocharger
and aftercooler
mm
No. of cylinders – bore x stroke 6 - 170 x 170
l {cc}
Piston displacement 23.15 {23,150}
Flywheel horsepower (ISO 9249) kW {HP} /rpm 455 {609} / 1,800
Max. torque Nm {kgm} / rpm 2,730 {278} / 1,300
Performance
Engine
Max. high idle speed rpm 1,900

Min. low idle speed rpm 750
Min. fuel consumption ratio g/kWh 208 {155}
{g/HPh}
Starting motor 24 V, 7.5 kW x 2
Alternator 24 V, 60 A
Battery 12 V, 170 Ah x 2
Radiator core type Rectangle corrugated fin

3 - element, 1 - stage, 1 - phase (with
Torque converter
lockup clutch)
Planetary gear and multiple disc clutch
type, hydraulically actuated forced lubri-
Transmission
cated, forward 3 - speed, reverse 3 -
speed
Spiral bevel gear type, splash lubrication
Bevel gear shaft
Power train
type
Wet, multiple disc clutch type, spring -
Steering clutch loaded and hydraulically released (lever
operated), interconnected with brake
Wet, multiple disc clutch type, spring -
actuated, hydraulically released (pedal /
Steering brake
lever operated ), interconnected with
clutch
Single reduction spur gear single reduc-
Final drive tion , planetary gear , lubricating oil
splash lubrication type
D375A-6 01-5
(04)
DRAFT
Specifications

Undercarriage
Rigid, equalizer bar

Suspension
2 each side
Carrier roller
8 each side
Track roller
Assembly type, single grouser, 41 each side,
Track shoe
pitch: 280.0 mm , width: 610 mm
Power train + Lubricating oil pump (tandem) Gear type (BAL180 + 112)
Scavenging pump (tandem) Gear type (BAR63 + 277)
Variable swash plate type (LPV90 + 30)
Cooling fan pump MPa {kg/cm2} Max. delivery pressure: 18.1 {184}
l/min / rpm Theoretical delivery: 231/1,926
Fixed swash plate type (LMF 150)
Cooling fan motor
MPa {kg/cm2} Max. allowable working pressure: 18.1 {184}
Max. pressure MPa {kg/cm2} 27.5 {280}
Hydraulic
pump
Type Variable swash plate type (HPV190)

Delivery (engine speed at 1,800rpm) l/min 366
Machines with single tilt blade and 1 + 1 + 1 + 2 spool type, hydraulic assisted, PPC
variable ripper type
q For ripper tilt cylinder + Ripper tilt (in, back)
q For ripper lift cylinder + Ripper tilt (raise, lower)
q For blade tilt cylinder + Blade tilt
Control valve
q For blade lift cylinder + Blade lift × 2 (raise, lower)

q For blade lift cylinder
Machines with dual tilt blade and vari- 1 + 1 + 2 + 2 spool type, hydraulic assisted, PPC
able ripper type
Work equipment hydraulic system
q For ripper tilt cylinder + Ripper tilt (in, back)

q For ripper lift cylinder + Ripper lift (raise, lower)
q For blade tilt L.H cylinder + Blade tilt (single, dual and pitch)
q For blade tilt R.H cylinder + Blade tilt (dual and pitch)
q For blade lift cylinder + Blade lift × 2 (raise, lower)
q For blade lift cylinder
Type double acting piston

Dimensions of blade lift
Cylinder bore 140

cylinder
Piston rod outside diameter 90

Piston stroke mm 1,721
Max. between pins distance 2,495
Hydraulic cylinder
Min. between pins distance 774

Dimensions of blade tilt
Cylinder bore 200

cylinder

Piston stroke mm 240
Min. between pins distance 1,463
01-6 D375A-6
Specification dimension drawings
Specifications

Dimensions of blade dual
Cylinder bore 200
Piston rod outside diameter
110
(both right and left)
tilt cylinder
Piston stroke (both right and left) mm 185

Max. distance between pins
1,675
Min. distance between pins
1,490
Dimensions of ripper tilt cylinder Dimensions of ripper lift cylinder
Work equipment hydraulic system
Cylinder bore 200

Hydraulic cylinder

Cylinder bore 180

Hydraulic tank Box type (control valve externally installed)

Hydraulic semi-U tilt dozer
Type
Hydraulic full-U tilt dozer
Single tilt
Left: Brace type
Right: Tilt cylinder type
Blade supporting method Dual tilt
Left: Tilt cylinder type (for single tilt/dual tilt pitch)
Work equipment
Right: Tilt cylinder type (for dual tilt pitch)
Max. lift above ground mm 1,660

Performance
Max. drop below ground mm 715

Max. adjustment tilt mm 990
Semi-U dozer
Hydraulic oil tilt (single) mm 770

Blade cutting angle adjustment deg. ±5
Blade capacity m3 24.0 <SAE18.5>
4,774
Dimensions
Blade width mm 2,265 (with spill guard: 2,525)

Blade height mm 55
Blade cutting angle deg.
D375A-6 01-7
(04)
DRAFT
Specifications

Performance
Max.drop below ground mm 715

Max. adjustment tilt mm 1,080
Full - U dozer
Hydraulic oil tilt (single) mm 840

Blade cutting angle adjustment deg. ±5
Blade capacity m3 26.3 <SAE22.0>
Dimensions
Blade width mm 5,215

Blade height mm 2,265 (with spill guard: 2,525)
Blade cutting angle deg. 55
Full - U dozer + Pitch Semi - U dozer + Pitch
Performance
Max. hydraulic oil tilt mm 1,185

Max. pitch angle deg. Forward 4.7 / Backward 5.2
Work equipment
Dimensions
Max. hydraulic oil tilt mm 1,295

Max. pitch angle deg. Forward 4.7 / Backward 5.2
Dimensions Performance Dimensions Performance
Max. digging depth mm 1,140

Multi - shank ripper

Point digging angle deg. 45 (Stepless adjustment between 31.4 – 54.7)
Max. beam width mm 2,910

Shank positions No. of holes 2
Max. digging depth mm 1,485

Giant ripper
Point digging angle deg. 45 (Stepless adjustment between 31.6 – 55.0)
Max. beam width mm 1,600

Shank positions No. of holes 3
01-8 D375A-6
DRAFT
Weight table
Weight table
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Engine, damper assembly 3,320

q Engine assembly 3,065
q Damper assembly 185
q Engine mounting parts 70
Radiator assembly 465

Oil cooler assembly 92
Fuel tank assembly (When full) 580 (1,600)
Power train unit 4,220

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

Main frame assembly 5,541
Track group assembly (each side) 7,902

q Track frame 1,896
q Idler assembly 478
q Track roller assembly (each single flange x each side) 159 × 2
q Track roller assembly (each double flange x each side) 160 × 6
q Carrier roller assembly (each x each side) 71 × 2
q First bogie and track roller assembly 457
q Each of second – fourth bogie and track roller assembly 742 × 3
q Final bogie and track roller assembly 359
Track shoe assembly (610 mm ) 4,305 × 2

Pivot shaft 210 × 2
Equalizer bar assembly 500
Hydraulic tank assembly (excluding oil ) 236

Control valve (for single tilt) 119
Control valve (for dual tilt) 125
D375A-6 01-9
DRAFT
Weight table
Unit: kg
Semi-U dozer assembly (excluding oil)

q Single tilt 10,100
q Dual tilt 10,180
Reinforced type semi-U dozer assembly
q Dual tilt 18,650
Reinforced type Full-U dozer assembly
q Dual tilt 11,680
Semi-U blade assembly 6,750
Reinforced type semi-U blade assembly 7,220
Reinforced type Full-U blade assembly (with spill guard) 8,250
Straight frame 1,350 × 2
Tilt cylinder (excluding oil)
q Single tilt 275
q Dual tilt 270 × 2
Variable multi-shank ripper assembly (excluding oil) 6,755

q Shank assembly 470 × 3
q Ripper lift cylinder assembly 270 × 2
q Ripper tilt cylinder assembly 240 × 2
Variable giant ripper assembly (excluding oil) 6,155
q Shank assembly 650 × 1
q Ripper lift cylinder assembly 270 × 2
q Ripper tilt cylinder assembly 240 × 2
Radiator guard assembly (including cylinder yoke) 2,870
q Radiator guard 1,342
q Blade lift cylinder assembly 290 × 2
Radiator mask 140
Engine underguard 275
Power train underguard (Front) 220
Power train underguard (Rear) 320
Hood and side cover assembly (including air cleaner is con- 337
tained)
Fender (Left) 331
Fender (Right) 372
ROPS assembly 703
Floor frame assembly 591
Cab assembly 570
Operator seat assembly (with mechanical suspension) 64
Operator seat assembly (with air suspension) 58
01-10 D375A-6
DRAFT
Table of fuel, coolant and lubricants
For details of the notes (Note 1, Note 2 - - -) in the table, see Operation and Maintenance Manual.
D375A-6 01-11
DRAFT
Unit: l
D375A-6
Refilling points
Specified capacity Refill capacity
Engine oil pan 87 86
Damper case 2.1 2.1
Power train case 275 150
Final drive case

61 61
(both sides)
Hydraulic oil system
230
q Single tilt, without ripper
275 130
q Single tilt with variable rippers
280
q Dual tilt with variable rippers
Cooling system 120 -
Fuel tank 1,200 -
01-12 D375A-6
DRAFT
D375A-6
SEN05013-00
Bulldozer
Shop Manual
D375A-6

D375A-6 60001 and up
10 Structure and function
D375A-6 10-1
Table of contents
Table of contents 10-2

10 Structure, function and maintenance standard
Engine and cooling system ..................................................................................................... 10- 4
Cooling system .................................................................................................................... 10- 4
Cooling fan pump................................................................................................................. 10- 6
Cooling fan motor................................................................................................................. 10- 26
Power train.............................................................................................................................. 10- 32
Power train........................................................................................................................... 10- 32
Overall drawing of power train unit ...................................................................................... 10- 34
Power train hydraulic equipment arrangement drawing....................................................... 10- 36
Damper and universal joint .................................................................................................. 10- 38
Torque converter and PTO .................................................................................................. 10- 40
Torque converter control valve ............................................................................................ 10- 46
Main relief valve and torque converter relief valve............................................................... 10- 48
Lockup clutch ECMV and stator clutch ECMV..................................................................... 10- 50
Scavenging pump ................................................................................................................ 10- 55
Transmission control............................................................................................................ 10- 56
PCCS lever .......................................................................................................................... 10- 58
Transmission........................................................................................................................ 10- 62
Transmission ECMV ............................................................................................................ 10- 76
Transmission lubricating oil relief valve ............................................................................... 10- 81
Steering and brake control................................................................................................... 10- 82
Transfer unit, bevel gear shaft and steering ........................................................................ 10- 84
Steering control valve .......................................................................................................... 10- 90
Steering clutch ECMV and Steering brake ECMV ............................................................... 10- 92
Parking brake valve ............................................................................................................. 10- 99
Sudden stop prevention valve.............................................................................................. 10- 101
Final drive ............................................................................................................................ 10- 103
Undercarriage and frame ........................................................................................................ 10- 108
Track frame.......................................................................................................................... 10- 108
Idler cushion......................................................................................................................... 10- 110
Track roller bogie ................................................................................................................. 10- 111
Main frame ........................................................................................................................... 10- 112
Suspension .......................................................................................................................... 10- 114
Hydraulic system..................................................................................................................... 10- 117
Work equipment hydraulic piping diagram........................................................................... 10- 117
PPC control piping diagram ................................................................................................. 10- 121
Work equipment control ....................................................................................................... 10- 122
Hydraulic tank ...................................................................................................................... 10- 124
Accumulator ......................................................................................................................... 10- 126
PPC lock valve..................................................................................................................... 10- 127
PPC valve ............................................................................................................................ 10- 129
Piston valve.......................................................................................................................... 10- 140
Quick drop valve .................................................................................................................. 10- 141
Pin puller switch ................................................................................................................... 10- 142
Pin puller solenoid valve ...................................................................................................... 10- 143
Blade control lever (only for the machine with dual tilt specification)................................... 10- 145
Work equipment pump......................................................................................................... 10- 146
Control valve ........................................................................................................................ 10- 158
Self-pressure reducing valve ............................................................................................... 10- 173
Work equipment...................................................................................................................... 10- 180
Cylinder stay ........................................................................................................................ 10- 180
10-2 D375A-6
(04)
Table of contents
Cab ......................................................................................................................................... 10- 181

Cab mount ........................................................................................................................... 10- 181
Cab ...................................................................................................................................... 10- 182
Electrical system ..................................................................................................................... 10- 184
Engine control...................................................................................................................... 10- 184
Engine control system ......................................................................................................... 10- 185
CRI engine control system................................................................................................... 10- 194
Monitor system .................................................................................................................... 10- 196
Machine monitor .................................................................................................................. 10- 198
Lamp system ....................................................................................................................... 10- 215
Engine preheat (electrical intake air heater) control ............................................................ 10- 216
Palm command control system............................................................................................ 10- 217
Sensor ................................................................................................................................. 10- 220
Vehicle health monitoring system (VHMS) .......................................................................... 10- 224
ORBCOMM system ............................................................................................................. 10- 230
D375A-6 10-3
(04)
DRAFT
Engine and cooling system
Cooling system

Cooling system
10-4 D375A-6
DRAFT
Cooling system
A: Power train oil cooler inlet

B: Power train oil cooler outlet
C: Hydraulic oil cooler inlet
D: Hydraulic oil cooler outlet
1. Hydraulic oil cooler

2. Radiator cap
3. Pressure valve
4. Aftercooler outlet hose
5. Radiator inlet hose
6. Aftercooler inlet tube
7. Radiator
8. Aftercooler
9. Power train oil cooler
10. Radiator outlet hose
11. Drain plug (Power train oil cooler)
12. Cooling fan motor
13. Cooling fan
14. Reservoir tank
15. Drain plug (Radiator)
16. Reservoir tank cap
17. Reservoir tank sight gauge
Specifications
Radiator Power train oil cooler Hydraulic oil cooler Aftercooler
Rectangle corrugated Rectangle corrugated

Core type PTO-OL Rectangle straight fin
fin fin
Fin pitch(mm) 8.0/2 - 8.0/2 8.0/2
Total heat dissipation sur-

49.09 × 3 3.77 4.09 27.39 × 2
face(m2)
Cracking pressure of pres-
sure valve 88.3 ± 14.7
- - -
{0.9 ± 0.15}
(kPa {kg/cm2})
Cracking pressure of vac-
uum valve 0 – 4.9
- - -
{0 – 0.05}
(kPa {kg/cm2})
D375A-6 10-5
DRAFT
Cooling fan pump
Cooling fan pump

Model : LPV90 + 30
Appearance
1. LPV90 Hydraulic pump

2. LPV30 Hydraulic pump
10-6 D375A-6
DRAFT
Cooling fan pump
LPV90 Hydraulic pump

Appearance
D375A-6 10-7
DRAFT
Cooling fan pump
Sectional view
IM: Control current input connector 1. Shaft

PA: Pump discharge port 2. Cradle
PDI: Drain port 3. Case
PD2: Drain port (Plug) 4. Rocker cam
PDA: Breather 5. Shoe
PEN: Control pressure pickup port (Plug) 6. Piston
PEPC: EPC source pressure input port 7. Cylinder block
PS: Pump suction port 8. Valve plate
9. Spring
10. Servo piston
10-8 D375A-6
DRAFT
Cooling fan pump
Function
q The rotation and torque of the engine are trans- q The hydraulic balance is maintained properly on
mitted to the shaft of this pump. Then, this pump this face.
converts the rotation and torque into hydraulic q The oil is sucked into and discharged from each
pressure and discharges pressurized oil accord- cylinder in cylinder block (7) through valve plate
ing to the load. (8).
q The delivery of this pump can be changed by
changing the swash plate angle.
Structure
q Cylinder block (7) is connected to shaft (1)
through spline (c).
q Shaft (1) is supported by the front and rear bear-
ings (9).
q The tip of piston (6) has a spherical hollow in
which shoe (5) is being held by crimping.
q Piston (6) and shoe (5) form a spherical bearing.
q Shoe (5) is kept pressed against plane (A) of
rocker cam (4) and slids circularly.
q Rocker cam (4) pivots on cylindrical face (B) of
cradle (2) witch is fixed to case (3).
q Piston (6) in each cylinder of cylinder block (7)
reciprocates in the axial direction.
q Cylinder block (7) rotates relatively against valve
plate (8), while sealing the pressurized oil.
D375A-6 10-9
DRAFT
Cooling fan pump
Operation q If center line (X) of rocker cam (4) matches the

Operation of pump axis of cylinder block (7) (the swash plate angle
q Cylinder block (7) rotates together with shaft (1) = 0), the difference between volumes (E) and (F)
and shoe (5) slides on plane (A). in cylinder block (7) is 0.
q Rocker cam (4) moves along cylindrical face (B). q No oil is sucked or discharged and a pumping
As a result, angle (a) between center line (X) of action is not performed. (The swash plate angle
rocker cam (4) and the axis of cylinder block (7) is not set to 0 actually, however.)
changes.
q Angle (a) is called the swash plate angle.
q The pump delivery is in proportion of swash plate

angle (a).
q If angle (a) is made between center line (X) of
rocker cam (4) and the axis of cylinder block (7),
plane (A) works as a cam for shoe (5).
q Piston (6) reciprocates inside cylinder block (7)
and a difference is made between volumes (E)
and (F) of cylinder chamber in cylinder block (7).
q Each piston (6) sucks and discharges oil by (F) -
(E).
q If cylinder block (7) rotates and the volume of
chamber (E) is decreased, the oil is discharged
from chamber (E) during this process.
q The volume of chamber (F) is increased and the
oil is sucked in chamber (F) during this process.
10-10 D375A-6
DRAFT
Cooling fan pump
Control of delivery
q If swash plate angle (a) is increased, the differ-
ence between volumes (E) and (F) is increased,
or delivery (Q) is increased.
q Swash plate angle (a) is changed with servo pis-
ton (1).
q Servo piston (1) reciprocates straight according
to the signal pressure of the PC valve.
q This straight motion is transmitted to rocker cam
(4).
q Then, rocker cam (4) supported on the cylindri-
cal surface of cradle (2) is tilted in the axial direc-
tion.
q The pressure receiving area of the top of servo
piston (1) is different from that of the bottom.
Main pump discharge pressure (self-pressure)
(PA) is kept led in the pressure chamber on the
small-diameter piston side (upper side).
q PC valve output pressure (PEN) is led in the
pressure chamber on the large-diameter piston
side (lower side).
q The movement of servo piston (1) is controlled
according to the difference between pressure
(PA) on the small-diameter piston side and pres-
sure (PEN) on the large-diameter piston side
and the ratio of the pressure receiving area of
the small-diameter piston to that of the large-di-
ameter piston.
D375A-6 10-11
DRAFT
Cooling fan pump
PC valve, EPC valve, and servo piston
IM: Control current input connector PC valve

PA: Pump discharge port 4. Piston
PEPC: EPC source pressure input port 5. Seat
6. Spring
Servo piston 7. Spool
1. Servo piston 8. Sleeve
2. Lever 9. Plug
3. Spring
EPC valve
10. EPC valve
10-12 D375A-6
DRAFT
Cooling fan pump
Function
q The PC valve controls the servo piston so that
the delivery (swash plate angle) is related to the
current input to the EPC valve is as shown in the
figure below.
D375A-6 10-13
DRAFT
Cooling fan pump
When EPC output pressure is high [When EPC current (i) is large]
10-14 D375A-6
DRAFT
Cooling fan pump
Operation
q The relationship between the EPC valve input
current (i) and EPC valve output pressure (F) is
as shown in the figure below.
q If the EPC discharge pressure rises, spool (7) is

pushed to the left because of the difference in
sectional areas between parts (S1) and (S2) of
the spool (S1 > S2).
q Port (f) is connected to port (g) and the pump dis-
charge oil at pressure (PA) flows through port (g)
to port (f). Port (f) is disconnected from the drain
circuit.
q The pump discharge oil at pressure (PA) from
port (f) of the PC valve enters chamber (X) on
the large diameter side of servo piston (1).
q Pump pressure (PA) is also constantly applied to
chamber (Y) on the small diameter side of servo
piston (1). Since a larger force is applied to the
large diameter side because of the difference in
area between both ends of servo piston (1), how-
ever, servo piston (1) moves toward the mini-
mum swash plate angle side (upper side).
q If servo piston (1) moves up, piston (4) is moved
to the right through lever (2). Accordingly, spring
(6) is compressed and spool (7) moves to the
right.
q If spool (7) moves to the right and port (f) is dis-
connected from port (g), servo piston (1) stops
moving up.
q At this time, servo piston (1) stops at a place
higher (nearer to the minimum swash plate an-
gle) than when the EPC discharge pressure is
low.
D375A-6 10-15
DRAFT
Cooling fan pump
When EPC output pressure is low [When EPC current (i) is small]
10-16 D375A-6
DRAFT
Cooling fan pump
Operation
q If EPC current (i) reduces and the EPC output
pressure lowers, spool (7) is pushed to the right
by the force of spring (6).
q Port (g) is disconnected from port (f) and at the
same time port (f) is connected to the drain cir-
cuit.
q The oil in chamber (X) on the large diameter side
of servo piston (1) flows through port (f) of the
PC valve to the drain circuit.
q Servo piston (1) is moved toward the maximum
swash plate angle side (lower side) by the pres-
sure of chamber (Y) on the small diameter side.
D375A-6 10-17
DRAFT
Cooling fan pump
LPV30 Hydraulic pump

Appearance
IM: Control electric current input connector 1. piston pump

P1: Pump discharge port 2. Servo valve
PAEPC: EPC output pressure pickup port 3. Bleeder
PE: Servo piston control pressure input port 4. EPC value
PEPC: EPC valve source pressure input port
PH: Pump discharge pressure output port
PS: Pump suction port
TO: Drain port
10-18 D375A-6
DRAFT
Cooling fan pump
Sectional view
1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
11. Ball
D375A-6 10-19
DRAFT
Cooling fan pump
Function q The oil is sucked into and discharged from each

q The rotation and torque of the engine are trans- cylinder chamber of cylinder block (7) through
mitted to the shaft of this pump. Then, this pump valve plate (8).
converts the rotation and torque into hydraulic
energy and discharges hydraulic oil according to
the load.
q The discharge of this pump can be changed by
changing the swash plate angle in it.
Structure
q Cylinder block (7) is connected to shaft (1)
through splines (B).
q Shaft (1) is supported by the front and rear bear-
ings (12).
q The tip of piston (6) has a spherical hollow in
which shoe (5) is being held by crimping.
q Piston (6) and shoe (5) form a spherical bearing.
q Shoe (5) is kept pressed against plane (A) of
rocket cam (4) and slids circularly.
q Rocker cam (4) pivot on ball (11).
q Piston (6) in each cylinder of cylinder block (7)
reciprocates in the axial direction.
q Cylinder block (7) rotates relatively against valve
plate (8) sealing the hydraulic oil.
q The hydraulic balance on the valve plate is main-
tained properly.
10-20 D375A-6
DRAFT
Cooling fan pump
Operation
Operation of pump
q Cylinder block (7) rotates together with shaft (1) q If center line (X) of rocker cam (4) matches the
and shoe (5) slides on plane (A). axis of cylinder block (7) (the swash plate angle
q Rocker cam (4) pivots on ball (11). As a result, is 0), there is no difference between volumes (E)
angle (a) between center line (X) of rocker cam and (F) in cylinder block (7). The hydraulic oil is
(4) and the axis of cylinder block (7) changes. not sucked or discharged.
q Angle (a) is called the swash plate angle. (The swash plate angle is not set to 0 actually,
q If angle (a) is made between center line (X) of however.)
rocker cam (4) and the axis of cylinder block (7),
plane (A) works as a cam for shoe (5).
q Piston (6) reciprocates inside cylinder block (7)
and a difference is made between volumes (E)
and (F) in cylinder block (7)
q Each piston (6) sucks and discharges oil by (F) -
(E).
q If cylinder block (7) rotates and the volume of
chamber (E) is decreased, the oil is discharged
from chamber (E).
q The volume of chamber (F) is increased and the
oil is sucked in chamber (F).
q The pump delivery is in proportion to swash plate

angle (a) .
D375A-6 10-21
DRAFT
Cooling fan pump
Control of discharge
q If swash plate angle (a) is increased, the differ-
ence between volumes (E) and (F) is increased,
or delivery (Q) is increased.
q Swash plate angle (a) is changed with servo pis-
ton (10).
q Servo piston (10) reciprocates straight according
to the signal pressure of the servo valve.
q This linear motion is transmitted to rocker cam
(4).
q Then, rocker cam (4) supported on ball (11) piv-
ots on ball (11).
10-22 D375A-6
DRAFT
Cooling fan pump
Servo valve
P: EPC valve source pressure input port 1. Plug

PE: Servo piston control pressure output port 2. Lever
PH: Pump discharge pressure input port 3. Retainer
T: Drain port 4. Seat
5. Spool
6. Piston
7. Sleeve
D375A-6 10-23
DRAFT
Cooling fan pump
A: Drain side D: EPC output pressure side

B: Pump discharge pressure input side P: EPC source pressure input side
C: EPC output pressure receiving pressure
10-24 D375A-6
DRAFT
Cooling fan pump
Function Operation
q The servo valve controls the servo piston so that q The output oil of the EPC valve flows in the pis-
the delivery (swash plate angle) is related to the ton chamber (C) to push piston (6). Piston (6)
current input to the EPC valve as shown in the moves spool (5) to a position where the thrust is
figure below. balanced with the force of the spring.
q Then, port (PE) of the servo piston pressure pas-
sage is connected to the pump discharge pas-
sage by the notch of spool (5) and the oil at
pump discharge pressure is led to the servo pis-
ton.
q The servo piston raises the rocker cam. The po-
sition feedback is applied and the lever moves to
compress the spring.
q If spool (5) is pushed back, the pump discharge
pressure passage is disconnected from the ser-
vo piston circuit. The pressure in the servo piston
chamber lowers and the rocker cam returns to-
ward the position for the maximum swash plate
angle.
q The relationship between the EPC valve input
q These processes are repeated until the swash
current (i) and EPC valve output pressure (F) is
plate stabilizes at an angle where the EPC out-
as shown in the figure below.
put pressure is balanced with the force exerted
by the spring force.
q Accordingly, as the EPC output pressure in-
creases, the swash plate angle decreases. As
the EPC output pressure lowers, the swash plate
angle increases.
D375A-6 10-25
Cooling fan motor
Cooling fan motor 10-26

Type: LMF180 (150)
Appearance 10-26
P: From fan pump Specifications 10-26

T: To tank through cooler Type: LMF150
TC: To tank Capacity: 150 cm3/rev
Rated speed: 1,225 rpm
Rated flow: 184 l/min
Check valve cracking pressure:
68.6 kPa {0.7 kg/cm2}
10-26 D375A-6
(04)
DRAFT
Cooling fan motor
Sectional view
1. Output shaft 7. Valve plate

2. Case 8. End cover
3. Thrust plate 9. Center spring
4. Shoe 10. Suction safety valve
5. Piston 11. ON/OFF pilot valve
6. Cylinder block 12. Reversible valve spool
13. Speed sensor
D375A-6 10-27
DRAFT
Cooling fan motor
Hydraulic motor
Function
q This hydraulic motor is called a swash plate type
axial piston motor. It converts the energy of the
pressurized oil sent from the hydraulic pump into
rotary motion.
Principle of operation
q The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
This oil can flow into the cylinder chambers on
only one side (supply side) (Y - Y) line connect-
ing the top dead center and bottom dead center
of the stroke of piston (4)
q The oil sent to one side of cylinder block (5)
presses piston (4) [2 or 3 pieces] and generates
force (F1) [F1 = P × xD2/4].
q This force is applied to thrust plate (2). Since
thrust plate (2) is fixed at an angle of (a °) de-
grees to the output shaft (1), the force is divided
into components (F2) and (F3).
q The radial component (F3) generates torque [T
= F3 x ri] relative to the (Y - Y) line connecting the
top dead center and bottom dead center.
q The resultant of the torque [T = s (F3 × ri)] ro-
tates cylinder block (5) through the piston.
q Since this cylinder block (5) is splined to the out-
put shaft, the output shaft rotates to transmit the
torque.
10-28 D375A-6
DRAFT
Cooling fan motor
Suction safety valve When the pump is stopped

q If the engine is stopped and the shaft speed of
Function of suction valve the fan pump lowers to 0rpm, the pressurized oil
q If the fan pump stops, the hydraulic oil does not from the pump is not supplied to port (P) any
flow into the motor. Since the motor continues more. As the pressurized oil is not supplied to
revolution because of the force of inertia, howev- the (MA) side of the motor, the motor speed low-
er, the pressure on the outlet side of the motor ers gradually to stop.
rises. q If the motor shaft is revolved by the force of iner-
q When the oil stops flowing in from inlet port (P), tia while the oil flow in the port (P) is reducing,
suction safety valve (1) sucks in the oil on the the oil in port (T) on the outlet side is sent by suc-
outlet side and supplies it to port (MA), compen- tion safety valve (1) to the (MA) side to prevent
sating for the lack of oil on that side to prevent cavitation.
cavitation.
Operation
When pump is started
q If the pressurized oil from the pump is supplied
to port (P) and the pressure on (MA) side rises
and starting torque is generated in the motor, the
motor starts revolution.The pressurized oil on
the motor outlet (MB) side of the motor returns
through port (T) to the tank.
D375A-6 10-29
DRAFT
Cooling fan motor
Function as safety valve

q The pressure in port (P) of the fan motor may
rise abnormally as in starting engine.
q Suction safety valve (1) is installed to protect the
fan system circuit in such a case.
Operation
q If the pressure in port (P) rises above the crack-
ing pressure of suction safety valve (1), valve (2)
of suction safety valve (1) opens to release the
pressurized oil into port (T).
q By this operation, generation of abnormally high
pressure in port (P) is prevented.
10-30 D375A-6
DRAFT
Cooling fan motor
Operation of reversible valve
When the ON/OFF solenoid is de-energized When the ON/OFF solenoid is energized
q If ON/OFF solenoid (1) is "de-energized", the q If ON/OFF solenoid (1) is "energized", ON/OFF
pressurized oil from the pump is blocked by selector valve (2) switches to allow the pressur-
ON/OFF selector valve (2), and port (C) con- ized oil from the pump to flow through port (C) to
nects to the tank circuit. spool chamber (D).
q Spool (3) is pushed to the right by spring (4). q The pressurized oil in chamber (D) pushes valve
q Motor port (MA) connects to port (P) and pres- spool (3) to the left against spring (4) .
surized oil flows in to revolve the motor in normal q Motor port (MB) connects to port (P) and pres-
direction (clockwise). surized oil flows in to revolve the motor in re-
verse (counterclockwise).
D375A-6 10-31
DRAFT
Power train
Power train
Power train
Power train
Outline
q The power generated by engine (1) is transmit- Transfer (15) reduces the speed of the power
ted through universal joint (3) to torque converter transmitted, and then the combination of the
(8) while (2) reduces torsional vibration. The bevel pinion and bevel gear of the bevel gear
torque converter (8) that uses oil as a medium shaft unit reduces the speed further and divides
for power transmission transmits the power from the power at right angles to the left and right to
the engine to the input shaft (turbine shaft) of send to the respective steering clutches (10).
transmission (9) in accordance with the change Steering clutch (10) stops transmission of the
in load. power from the bevel gear shaft unit to the final
The torque converter is equipped with a lockup drive to steer the machine. Moving the PCCS
clutch, and when the speed of the output shaft of (steering) lever in the direction to which the
the transmission that receives the power from machine turns disengages the steering clutch on
the torque converter becomes higher, the lockup the side and the machine turns to the direction.
clutch is automatically engaged. When this The turning angle is adjusted by controlling
happens, the drive case and turbine are steering brake (11) installed to the outside of the
combined as a unit to transmit the power from steering clutch.
the engine directly to the transmission input Steering brake (11) is the same disc type as that
shaft. for the steering clutch. The power output from
Transmission (9) uses a combination of plane- the steering clutch goes to final drive (12) ,
tary gear mechanisms and hydraulic clutches to where the speed is reduced to drive sprocket
give three forward speeds and three reverse (13).
speeds. When a gear speed is selected with the Double-reduction type final drive (12) consists of
PCCS (gearshift) lever according to the change single-reduction spur gear train and
in load, two clutches are engaged to transmit the single-reduction planetary gear train. The
power from the torque converter to transfer (15) sprocket drives track shoe (14) to make the
through its output shaft. machine travel.
10-32 D375A-6
DRAFT
Power train
Power train
1. Engine (SAA6D170E-5) 10. Steering clutch

2. Damper 11. Steering brake
3. Universal joint 12. Final drive
4. Cooling fan pump (LPV90 + 30) 13. Sprocket
5. Power train pump (BAL180+112) 14. Track shoe
6. PTO 15. Transfer
7. Work equipment pump (HPV190) 16. Scavenging pump (BAR63+277)
8. Torque converter 17. Cooling fan motor (LMF150)
9. Transmission 18. Bevel gear and pinion gear
D375A-6 10-33
Power train
Overall drawing of power train unit
Overall drawing of power train unit 10-34
10-34 D375A-6
(04)
Power train
Overall drawing of power train unit
A: Torque converter inlet oil pressure pickup port N: Right steering clutch pressure pickup port (RC)
(IN) P: Transmission 1st clutch pressure pickup port
B: Torque converter outlet pressure pickup port (1ST)
(OUT) R: Main relief pressure pickup port (TM)
C: Lockup clutch pressure pickup port (LU) 1. Centralized pressure pickup port
D: Stator clutch oil pressure pickup port (SC) 2. Oil level gauge
E: Left steering clutch pressure pickup port (LC) 3. Oil filler pipe
F: Left steering brake pressure pickup port (LB) 4. Power train and lubrication pump
G: Transmission 2nd clutch pressure pickup port 5. PTO
(2ND) 6. Torque converter
H: Transmission R clutch pressure pickup port 7. Torque converter control valve
(REV) 8. Transmission control valve
J: Power train lubricating oil pressure pickup port 9. Transmission
(LUB) 10. Steering clutch and brake
K: Transmission 3rd clutch pressure pickup port 11. Steering control valve
(3RD) 12. Transmission lubricating oil filter
L: Transmission F clutch pressure pickup port 13. Power train oil filter
(FWD) 14. Power train oil strainer
M: Right steering brake pressure pickup port (RB) 15. Scavenging pump
Specification 10-35
q The power train unit consists of torque convert-
er, transmission unit, and steering unit by rough
classification.
Accordingly, after removing power train unit, it
can be divided into torque converter, transmis-
sion unit, and steering unit.
q The steering unit consists of transfer, bevel gear
shaft, steering clutch, and steering brake.
D375A-6 10-35
(04)
Power train
Power train hydraulic equipment arrangement drawing
Power train hydraulic equipment arrangement drawing 10-36
1. Oil cooler A: Torque converter lock-up pressure pickup port

2. Power train oil filter B: Torque converter stator clutch pressure pickup
3. Transmission lubricating oil filter port
4. Centralized pressure pickup port C: Left steering clutch pressure pickup port
5. Torque converter valve D: Left steering brake pressure pickup port
6. Transmission control valve (ECMV) E: Transmission 2nd clutch pressure pickup port
7. Steering control valve (ECMV) F: Transmission R clutch pressure pickup port
8. Power train oil tank G: Transmission 3rd clutch pressure pickup port
9. Power train oil strainer H: Transmission F clutch pressure pickup port
10. Power train pump (BAL180+112) J: Right steering brake pressure pickup port
11. Scavenging pump (BAR63+277) K: Right steering clutch pressure pickup port
12. Cooling fan pump (LPV90+30) L: Transmission 1st clutch pressure pickup port
M: Transmission 1st clutch pressure pickup port
N: Torque converter regulator pressure pickup port
P: Torque converter relief pressure pickup port
10-36 D375A-6
(04)
DRAFT
Power train
Power train hydraulic equipment arrangement drawing
D375A-6 10-37
DRAFT
Power train
Damper and universal joint
10-38 D375A-6
DRAFT
Power train
1. Outer body Outline

2. Engine flywheel q The damper protects the power train (such as
3. Output shaft the torque converter and transmission) by buff-
4. Coupling ering 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 couplings on the damper effciently
9. Breather (for damper bearing case) absorbs vibrations by rubber material's internal
10. Oil fitter pipe damping effects and deformation as well as fric-
11. Breather (for fly wheel housing) tional damping effects of the rubber material.
This arrangement also helps reducing number of
components used.
Operation
q The power of engine is transmitted from flywheel
(2) through outer body (1) to rubber couplings
(7). After absorption of torsional vibrations of the
engine by the rubber coupling, power is then
transmitted to the coupling (4) via output shaft
(3). Then, power is further transmitted from the
coupling to the torque converter input shaft
through universal joint (5).
D375A-6 10-39
DRAFT
Power train
Torque converter and PTO

a PTO: Abbreviation for Power Take Off
10-40 D375A-6
DRAFT
Power train
D375A-6 10-41
DRAFT
Power train
A: To transmission control valve 1. Cooling fan pump mounting location

B: To transmission lubrication circuit 2. Torque converter outlet oil pressure sensor
C: To transmission oil pan mounting location
D: From steering case 3. Work equipment pump mounting location
E: To power train oil filter 4.Power train and lubricating oil pump mounting
F: To transmission lubricating oil filter location
G: To transmission oil pan 5.Scavenging pump mounting location
H: To scavenging pump 6.Torque converter control valve
J: To scavenging pump 7. Torque converter outlet oil temperature
K: To power train oil filter sensor mounting port
L: To transmission lubricating oil filter 8.Coupling
M: To transmission control valve 9. Retainer
N: To transmission lubrication circuit 10. Input shaft (number of teeth: 61)
P: Torque converter outlet oil pressure pickup 11. Front housing
port (OUT) 12. PTO idler gear (number of teeth: 77)
R: To power train oil cooler 13.PTO idler gear shaft
14.Lockup clutch housing
15. Drive case
16.Turbine
17. Rear housing
18.Stator
19.Pump
20.Stator shaft
21. Guide
22.Retainer
23.Pump shaft
24.Transmission input shaft
25. Stator clutch hub gear
26.Stator clutch housing
27. Return spring
28. Stator clutch plate
29. Stator clutch disc
30. Stator clutch piston
31. Turbine boss
32. Lockup clutch plate
33. Lockup clutch disc
34. Lockup clutch piston
35.Scavenging pump drive gear (number of
teeth: 63)
36. Sleeve
37. Bearing race
38.Power train pump, lubricating oil pump and
cooling fan pump drive gear (number of teeth:
57)
39. Cover
40.Cover
41. Work equipment pump drive gear (number of
teeth: 57)
42.Cover
43. Strainer
10-42 D375A-6
Power train
Outline 10-43 Structure 10-43

q The torque converter is a 3-element, 1-stage q Pump (19) is united with coupling (8), input shaft
and 1-phase type, and is integral with the trans- (10), lockup clutch housing (14), and drive case
mission.The torque converter is equipped with a (15), and is rotated by the engine power.
wet double-disc clutch type lockup unit and a q Turbine (16) is united with the turbine boss (31)
stator clutch unit in order to reduce fuel con- and transmission input shaft (turbine shaft) (24)
sumption, to increase the operability, and to re- and is rotated by the oil from the pump.
duce captive consumption of the engine q Stator (18) is united with the stator shaft (20) and
horsepower. stator boss (25) and is fixed to rear housing (17)
q For higher efficiency of continuous light dozing through the stator clutch unit.
and leveling operation, the torque converter is q The lock-up clutch unit consists of clutch plate
locked up to transmit the engine power directly to (28) meshed with drive case (15), clutch discs
the transmission input shaft. Even when the (33) meshed with the turbine boss (31) and
torque converter is locked up (the pump is united clutch piston (30) that slides inside housing (14)
with the turbine), the oil is still supplied from the united with the drive case.
torque converter relief valve. q The stator clutch unit consists of clutch discs
The oil sent from the pump to the turbine returns (29) meshed with boss (25) splined to stator
to the stator. The flow of oil is obstructed by the shaft (20), clutch plate (28) supported on clutch
stator blades and becomes turbulent (it is housing (26) and rear housing (17) with the pins,
agitated), producing resistance against the rota- and clutch piston (30) that slides inside the rear
tion of the pump and turbine. housing.
To reduce the resistance against the rotation of q The PTO unit consists of input shaft (10), idler
the pump and turbine, the stator clutch is disen- gear (12), scavenging pump drive gear (35),
gaged simultaneously with lockup of the torque cooling fan pump and work equipment pump
converter, allowing the stator to rotate freely. As drive gear (41) and power train pump drive gear
the stator turns along with the pump and turbine, (38).
the oil returns from the turbine to the pump
smoothly with less resistance.
Conditions for lockup mode and torque converter

mode
Torque converter output shaft speed:
(rpm)
Gear speed
Torque converter
Lockup mode
mode
Min. 1,320 Min. 1,256
Forward 1st
Max. 1,830 Max. 1,830
Forward 2nd Min. 1,584 Max. 1,555
Forward 3rd Min. 1,350 Max. 1,320
Reverse 1st Min. 1,255 Max. 1,226
Reverse 2nd Min. 1,359 Max. 1,330
Reverse 3rd Min. 1,373 Max. 1,343
a While the transmission is shifting gears, the
torque converter comes into the torque convert-
er drive mode.
D375A-6 10-43
(04)
DRAFT
Power train
Power transmitting route
When lockup clutch is "disengaged" and stator When lockup clutch is "engaged" and stator
clutch is "engaged" clutch is "disengaged"
As drive case (4) and turbine (6) are disconnected from Drive case (4) is connected to turbine (6) and torque
each other, the torque converter works as an ordinary converter is locked up.
torque converter. Rear housing (9) and stator shaft (10) are connected to
Rear housing (9) and stator shaft (10) are connected to each other to fix stator (11).
each other to lock stator (11).
Engine power
Engine power O
O Coupling (1)
Coupling (1) O
O Input shaft (2), clutch housing (3), drive case (4) and
Input shaft (2), clutch housing (3), drive case (4) and pump (5) rotate together
pump (5) rotate together O
O Lockup clutch (9)
Oil is used as medium O
O Turbine (6) and boss (7)
Turbine (6) and boss (7) O
O Transmission input shaft (8)
Transmission input shaft (8)
10-44 D375A-6
DRAFT
Power train
Oil flow
q The oil flows through the main relief valve and its
pressure is regulated to the set pressure or be-
low by the torque converter relief valve. It then
flows in inlet port (A), goes through the oil pas-
sages of rear housing (1) and pump shaft (2),
and flows into pump (3) .
q The oil is given centrifugal force by pump (3) and
flows in turbine (4) to transfer its energy to tur-
bine (4).
q The oil from turbine (4) is sent to stator (5) and
flows into pump (3) again.However, a part of the
oil is sent from outlet port (B) to oil cooler through
turbine (4) and stator (5).
D375A-6 10-45
DRAFT
Power train
Torque converter control valve
A: From power train pump

B: Lockup clutch oil pressure pickup port (LC)
C: Stator clutch oil pressure pickup port (SC)
1. Main relief valve and torque converter relief valve

2. Stator clutch ECMV
3. Lockup clutch ECMV
4. Torque converter inlet oil pressure sensor
10-46 D375A-6
DRAFT
Power train
Outline
q The torque converter valve is installed at the top of the rear housing of the toque converter, and consists
of the following four types of valves.
q Two types of ECMV are installed; the identifications and differences are shown in the table below.
Identification Fill switch

Stamp of the nameplates Pressure control (Operation pressure: Operated
color
(A) valve clutches
(B) MPa{kg/cm2})
Equipped
A******* Yellow Without slit Stator
(0.26 {2.7})
Equipped
E******* Pink With slit Lockup
(0.26 {2.7})
Main relief valve Lockup clutch ECMV

q The main relief valve maintains each hydraulic q The lockup clutch modulating valve maintains
circuit pressure of the transmission, steering the clutch pressure at the set pressure or below
clutch, steering brake and the lockup clutch and to protect the lockup clutch circuit from abnor-
stator clutch of torque converter constantly at the mally high pressure, as well as increasing the
set pressure. clutch pressure gradually to the set pressure.
Set pressure : 2.63 – 2.92 MPa {26.8 – Set pressure: 1.3 MPa {13 kg/cm2}
29.8 kg/cm2 } (At rated engine speed)
Torque converter relief valve

q The torque converter relief valve maintains the
oil pressure at the torque converter inlet always
at the set pressure or below in order to protect
the torque converter from abnormally high pres-
sure.)
Set pressure: 1.00 MPa {10.2 kg/cm2} (cracking
pressure)
Stator clutch ECMV

q The stator clutch modulating valve maintains the
clutch pressure at the set pressure or below to
protect the stator clutch circuit from abnormally
high pressure, as well as increasing the clutch
pressure gradually to the set pressure.
Set pressure: 2.7 MPa {27 kg/cm2}
D375A-6 10-47
DRAFT
Power train
Main relief valve and torque converter relief valve
1. Valve body
2. Torque converter relief valve
3. Main relief valve
4. Cover
5. Piston
6. Piston
10-48 D375A-6
DRAFT
Power train
Operation of main relief valve Operation of torque converter relief valve
q The oil from the hydraulic pump flows through q The oil from the main relief valve flows through
the filter, port (A) of the torque converter valve, port (C) to the torque converter, and at the same
and orifice (a) of torque converter relief valve (1) time, also flows through orifice (b) of torque con-
to chambe (B). verter relief valve (3) to chamber (D) .
q When the oil pressure on the torque converter
exceeds the set pressure, the oil in chamber (D)
pushes piston (4), the reaction force of which
moves torque converter relief valve (3) to the
right to open port (C) and port (E).
Then the oil in port (C) is drained from port (E) to
the oil tank.
q When the oil pressure in the circuit exceeds the

set pressure, the oil in chamber (B) pushes pis-
ton (2), the reaction force of which moves spool
(1) to the left to open port (A) and port (C).
Above operation conducts the oil from port (C) to
the torque converter.
D375A-6 10-49
DRAFT
Power train
Lockup clutch ECMV and stator clutch ECMV

a ECMV: Abbreviation for Electronic Control Modulation Valve
a Don't try to disassemble it since the adjustment for maintaining the performance will be required.
A: To clutch
P: From pump
T: Drain
DR: Drain
P1: Clutch oil pressure pickup port
P2: Pilot oil pressure pickup port
1. Fill switch connector

2. Proportional solenoid connector
3. Oil pressure detection valve
4. Fill switch
5. Proportional solenoid
6. Oil pressure control valve
7. Nameplate
10-50 D375A-6
DRAFT
Power train
ECMV for lockup clutch Operation

When traveling with torque converter working
Outline
q This valve is used to switch the clutch in addition
to regulate the clutch oil pressure to the set pres-
sure.
It forms a modulation wave pattern, so the stator
clutch is engaged smoothly to reduce the shock
when shifting gear. In addition, it prevents gener-
ation of peak torque in the power train. As a
result, it provides a comfortable ride for the oper-
ator and greatly increases the durability of the
power train.
When changing from traveling in torque converter

drive mode to traveling in lockup drive mode
At gear shift (traveling in lockup drive mode)

q When traveling in torque converter drive mode,
current does not blow to proportional solenoid
(1).
Pressure control valve (3) drains the oil from
clutch port (A) through drain port (T), and lockup
clutch is "released".
Also at this time, fill switch (5) is turned "off"
because oil pressure is not applied to pressure
detection valve (4).
D375A-6 10-51
DRAFT
Power train
When traveling in lockup drive mode

(Traveling in torque converter drive mode to traveling in lockup drive mode)
During filling In pressure regulation
q When traveling in lockup drive mode, current q If current flows in proportional solenoid (1), the
flows in proportional solenoid (1), the oil pres- solenoid generates thrust in proportion to the
sure force balanced with the solenoid force is ap- current. This thrust of the solenoid is balanced
plied to chamber (B) and pushes pressure with the sum of the thrust generated by the oil
control valve (3) to the left. As a result, pump port pressure in clutch port and the reaction force of
(P) and clutch port (A) open. When the clutch is pressure control valve spring (2), and then the
filled with oil, oil pressure pickup port (4) actu- pressure is regulated.
ates and fill switch (5) is turned "ON". q While shifting gears, the lockup clutch oil pres-
sure is reduced temporarily to reduce the shock
when shifting gear.
Oil pressure at this time is controlled so that the
lockup piston pushing force balances with the
inside pressure of torque converter.
10-52 D375A-6
DRAFT
Power train
ECMV for stator clutch Operation

When traveling in lockup drive mode
Outline
q This valve is used to switch the clutch in addition
to regulate the clutch oil pressure to the set pres-
sure.
It forms a modulation wave pattern, so the stator
clutch is engaged smoothly to reduce the shock
when shifting gear. In addition, it prevents gener-
ation of peak torque in the power train. As a
result, it provides a comfortable ride for the oper-
ator and greatly increases the durability of the
power train.
Lockup drive mode travel to torque converter

drive mode travel
q When traveling in lockup drive mode, current

does not flow to proportional solenoid (1).
Pressure control valve (3) drains the oil from
clutch port (A) through drain port (T), and stator
clutch is "released".
because oil pressure is not applied to pressure
detection valve (4).
D375A-6 10-53
DRAFT
Power train
When traveling in torque converter drive mode

(Lockup drive mode travel o torque converter drive mode travel)
During filling In pressure regulation
q When traveling in torque converter drive mode q If current flows in proportional solenoid (1), the
current flows in proportional solenoid (1), the oil solenoid generates thrust in proportion to the
pressure force balanced with the solenoid force current. This thrust of the solenoid is balanced
is applied to chamber (B) and pushes pressure with the sum of the thrust generated by the oil
control valve (3) to the left.As a result, pump port pressure in clutch port and the reaction force of
(P) and clutch port (A) open. When the clutch is pressure control valve spring (2), and then the
filled with oil, oil pressure pickup port (4) actu- pressure is regulated.
ates and fill switch (5) is turned "ON".
10-54 D375A-6
DRAFT
Power train
Scavenging pump
Scavenging pump
Type: BAR(3) 63+277
A: Discharge port
B: Small pump suction port
C: Large pump suction port
1. Small pump
2. Large pump
D375A-6 10-55
DRAFT
Power train
Transmission control
a Regarding the steering-related description of
the PCCS lever, refer to the "Steering and brake
control".
a PCCS: Palm Command Control System
1. Brake pedal Lever position

2. Lock lever [1]: Neutral
3. PCCS lever (Steering, forward-reverse, gearshift) [2]: Forward
3A. Upshift switch (Gear upshifts each time this [3]: Reverse
switch is pressed) [4]: OFF
3B. Downshift switch (Gear downshifts each [5]: Upshift
time this switch is pressed) [6]: Downshift
4. Transmission neutral switch [7]: Free
5. Cable [8]: Lock
6. Transmission control valve
7. Power train controller
10-56 D375A-6
DRAFT
Power train
Outline
q The transmission is controlled with PCCS lever
(3).
The PCCS lever is used to perform steering
operation, directional changes and gear shift
operation.
q The machine has a safety mechanism that acti-
vates transmission neutral switch (4) to allow the
engine to start only when the lock lever (2) is set
to the "Lock" position.
D375A-6 10-57
Power train
PCCS lever
PCCS lever 10-58

a Don't try disassemble PCCS lever because, adjustments will be required for the characteristics of voltage
output and operating efforts.
1. Boot 5. Screw
2. Bracket 6. Lever
3. Plate 7. Connector
4. Bolt
10-58 D375A-6
(04)
Power train
PCCS lever
Function 10-59
Operating effort characteristics 10-59
Operation for forward and reverse travel Operation for left and right steering
q The control lever is held at 3 positions: "FOR- q Free return

WARD" , "NEUTRAL" and "REVERSE".
D375A-6 10-59
(04)
DRAFT
Power train
2. Output voltage characteristics

q The lever is installed to the left control stand and
the control lever (knob) is fixed directly onto it.
q The operating angle (stroke) of the control levers
sensed with potentiometers and signal voltages
are output to the transmission, steering control-
ler.
q A potentiometer is installed to detect each of lon-
gitudinal displacement and lateral displacement.
Each potentiometer outputs two signal voltages
which are opposite in phase as shown in the fig-
ure on the right.
10-60 D375A-6
Power train
PCCS lever
Gear shift of the machine 10-61

Since gear shift during travel is possible, there is no
need to stop the machine to shift gears.
Gear shift operation 10-61

Gear shift operation becomes available by pushing
switch (1) or (2) when Joystick (steering, directional
and gear shift lever) is in the FORWARD or RE-
VERSE position.
(1) The gear upshifts by one each time the "Upshift"
switch is pressed.
(2) The gear downshifts by one each time the"
Downshift" switch is pressed.
a If you carry out the gear shift, the gear speed is
indicated on the display panel.
<Ex.>
Neutral: Indicates "N".
Forward 2nd: Indicates "F2" on the display.
Reverse 3rd: Indicates "R3".
"P" is indicated when the lock lever is placed at
the "Lock" position.
D375A-6 10-61
(04)
DRAFT
Power train
Transmission
Transmission
10-62 D375A-6
DRAFT
Power train
Transmission
A: 1st clutch oil pressure pickup port

B: 3rd clutch oil pressure pickup port
C: R clutch oil pressure pickup port
D: 2nd clutch oil pressure pickup port
E: F clutch oil pressure pickup port

2. Front case
3. Rear case
4. Lubricating oil relief valve
D375A-6 10-63
DRAFT
Power train
Transmission
10-64 D375A-6
DRAFT
Power train
Transmission
5. Transmission input shaft Outline

6. Front cover q The transmission is a "forward 3-speed and re-
7. Sun gear for reverse clutch (34 teeth) verse 3-speed" transmission which consists of
8. Ring gear for reverse (hub) (91 teeth) the planetary gear trains and the disc clutches.
9. Planetary pinion for reverse clutch (25 teeth) q Transmission selects and locks two clutches out
10. Ring gear for reverse clutch (84 teeth) of the five sets of planetary gear trains and disc
11. Sun gear for forward clutch (41 teeth) clutches hydraulically by using the control valve
12. Planetary pinion for forward clutch (25 teeth) to select one travel direction and one gear
13. Ring gear for forward clutch ( 91 teeth) speed.
14. Ring gear for 3rd clutch (91 teeth) q The transmission transfers the power received
15. Planetary pinion for 3rd clutch (25 teeth) by the transmission input shaft to the output
16. Sun gear for 3rd clutch (41 teeth) shaft by changing the gear speed (forward
17. Ring gear for 2nd clutch (93 teeth) 1st-3rd or reverse 1st-3rd) with any combination
18. Planetary pinion for 2nd clutch (23 teeth) of the forword or reverse clutch, and one of three
19. 2nd sun gear(47 teeth ) speed clutches.
20. 1st clutch gear
21. 1st clutch piston No. of plates and discs used
22. 1st clutch piston housing Clutch No. Number of plates Number of discs
23. Output shaft R clutch 6 6
24. Spacer F clutch 5 6
25. Collar 3rd clutch 4 4
2nd clutch 3 3
26. 1st clutch spring
1st clutch 5 6
27. 2nd carrier
28. Plate
29. Carrier for forward and 3rd clutches Combinations of clutches at respective gear speeds
30. Piston housing for forward and 3rd speed gear and reduction ratio
31. Carrier for reverse clutch Clutches
Gear speed Reduction ratio
32. Carrier for reverse clutch engaged
33. Clutch piston Forward 1st F × 1st 3.220
Forward 2nd F × 2nd 1.745
34. Clutch spring
Forward 3rd F × 3rd 1.000
35. Clutch plate Neutral (*1) -
36. Clutch disc Reverse 1st R × 1st 2.471
37. Washer spring Reverse 2nd R × 2nd 1.339
38. Pin Reverse 3rd R × 3rd 0.769
39. Tie bolt *1: The 1st or 2nd clutch is filled with low-pressure
oil.
D375A-6 10-65
DRAFT
Power train
Transmission
Disc clutch
Structure Operation
When clutch is "engaged" (locked)
q The disc clutch consists of piston (2), plates (3),

discs (4), pin (5), return spring (6), and washer q The oil from ECMV is routed to the back of piston
spring (7) to fix ring gear (1). (2) through oil passage of clutch housing (8) and
q Inside teeth of disc (4) are engaged with outside pushes piston (2) leftward.
teeth of ring gear (1). q Piston (2) presses plate (3) closely against disc
q Plate (3) and clutch housing (8) are assembled (4) to stop rotation of disc (4) by using friction
with pin (5). force generated between them.
q Since inside teeth of disc (4) are engaged with
outside teeth of ring gear (1), the ring gear (1) is
locked.
When clutch is "disengaged" (released)
q When the supply of oil from ECMV is shut off,

piston (2) is returned rightward by the force of re-
turn spring (6).
q This relieves the frictional force between plates
(3) and discs (4), making the ring gear (1) free.
q Washer spring (7) installed at pin portions be-
tween the plates acts to speed up the return of
the piston when the clutch is disengaged, and
also to separate the plates and discs cleanly to
prevent drag turning.
10-66 D375A-6
DRAFT
Power train
Transmission
Oil passage in speed clutch
q When the PCCS lever is in the "Neutral" position

, the 1st or 2nd gear speed is kept selected.
q The piston chamber of the clutch corresponding
to the selected gear speed is filled with oil by
electronically controlling the oil circuit of each
clutch.
q When the PCCS lever is shifted from the "Neu-
tral" position to the "Forward" or "Reverse" posi-
tion, the pump is required to supply oil enough to
fill the piston chamber of the forward or reverse
clutch.
q When the gear speed is changed from "Forward
1st" to "Forward 2nd", the pump is required to
supply oil enough to press the plates and discs
of the 2nd clutch since the forward clutch has
been filled with the oil.
q The time lag at shifting gears is reduced by con-
trolling the oil circuit as explained above.
D375A-6 10-67
DRAFT
Power train
Transmission
Operation of transmission
Forward 1st
10-68 D375A-6
DRAFT
Power train
Transmission
F clutch ring gear (4) and 1st clutch gear (16) are locked hydraulically.
The power from torque converter
O
Input shaft (1)
O
F clutch sun gear (2)
O
F clutch planetary pinion (3)
O
F clutch and 3rd carrier (10)
O
3rd planetary pinion (11) o O
O O
3rd ring gear (12)
O O
2nd carrier (13)
O O
2nd planetary pinion (14)
O O
2nd ring gear (15) O
O O
1st clutch gear (16) 3rd sun gear (18)
O O
Output shaft (19)i i
D375A-6 10-69
DRAFT
Power train
Transmission
Forward 2nd
10-70 D375A-6
DRAFT
Power train
Transmission
F ring gear (4) of F clutch and 2nd ring gear (15) of 2nd clutch are locked hydraulically.
O
Input shaft (1)
O
O
O
F clutch and 3rd clutch carrier
O
3rd clutch planetary pinion (11) o O
O O
3rd clutch ring gear (12)
O O
2nd clutch carrier (13)
O O
2nd clutch planetary pinion (14)
O O
2nd clutch sun gear (17) 3rd clutch sun gear (18)
O O
D375A-6 10-71
DRAFT
Power train
Transmission
Forward 3rd
10-72 D375A-6
DRAFT
Power train
Transmission
F ring gear (4) of F clutch and 3rd ring gear (12) of 3rd clutch are locked hydraulically.
O
Input shaft (1)
O
O
O
F clutch and 3rd clutch carrier (10)
O
3rd clutch planetary pinion (11)
O
3rd clutch sun gear (18)
O
Output shaft (19)
D375A-6 10-73
DRAFT
Power train
Transmission
Reverse 1st
10-74 D375A-6
DRAFT
Power train
Transmission
R ring gear (7) of R clutch and 1st clutch gear (16) of 1st clutch are locked hydraulically.
O
Input shaft (1)
O
R clutch sun gear (5)
O
R clutch planetary pinion (6)
O
R clutch ring gear (9)
(R clutch carrier (8) is locked with R clutch
ring gear (7) = R clutch ring gear (9) rotation
direction is opposite to that of input shaft (1))
O
F clutch and 3rd clutch carrier
O
3rd clutch planetary pinion (11)o O
O O
3rd clutch ring gear (12)
O O
2nd clutch carrier (13)
O O
2nd clutch planetary pinion (14)
O O
2nd clutch ring gear (15)
O O
1st clutch gear (16) 3rd sun gear (18)
O O
D375A-6 10-75
DRAFT
Power train
Transmission ECMV
Transmission ECMV
a Don't try to disassemble it since adjustment for maintaining the performance will be required
10-76 D375A-6
DRAFT
Power train
Transmission ECMV
A: 1st clutch oil pressure pickup port

B: 3rd clutch oil pressure pickup port
C: R clutch oil pressure pickup port
D: 2nd clutch oil pressure pickup port
E: F clutch oil pressure pickup port
F: To clutch
P: From pump
T: Drain
1. 3rd clutch proportional solenoid

2. 1st clutch proportional solenoid
3. R clutch proportional solenoid
4. 2nd clutch proportional solenoid
5. F clutch proportional solenoid
6. 3rd clutch fill switch
7. 2nd clutch fill switch
8. 1st clutch fill switch
9. R clutch fill switch
10. F clutch fill switch
11. Connector for 1st clutch proportional solenoid
12. Connector for 3rd clutch proportional solenoid
13. Connector for R clutch proportional solenoid
14. Connector for 2nd clutch proportional solenoid
15. Connector for F clutch proportional solenoid
16. Connector for 3rd clutch fill switch
17. Connector for 2nd clutch fill switch
18. Connector for 1st clutch fill switch
19. Connector for R clutch fill switch
20. Connector for F clutch fill switch
21. Block
22. Pressure control valve
23. Oil pressure detection valve
24. Spring for pressure control valve
D375A-6 10-77
DRAFT
Power train
Transmission ECMV
Outline of ECMV ECMV and proportional solenoid

q The ECMV consists of a pressure control valve q For each ECMV, a proportional solenoid is in-
and a fill switch. stalled.
q Pressure control valve The proportional solenoid generates thrust
A proportional solenoid in this valve receives the shown below according to the command current
current sent from the controller and this valve from the controller.
converts it to oil pressure. The thrust generated by the proportional sole-
q Fill switch noid is applied to the pressure control valve
This switch detects that the clutch is filled with oil spool to generate oil pressure as shown in the
and has the following functions. figure below. Accordingly, controlling the
1. Outputs a signal (a fill signal) to the controller to command current that changes the thrust to
notify that filling is completed when the clutch is operate the pressure control valve allows for
filled with oil. controlling the oil flow and pressure to the clutch.
2. Keeps outputting signals (fill signals) to the Current - thrust characteristics of proportional
controller while oil pressure is applied to the solenoid
clutch to notify whether oil pressure is applied or
not .
Thrust - Oil pressure characteristics of propor-

tional solenoid
ECMV and fill switch

q For each ECMV, a fill switch is installed.
Phase A: Before shifting gear (oil is drained)
When the clutch is filled with oil, the fill switch is
Phase B: Filling phase
turned "ON" by the pressure of the clutch. The oil
Phase C: Pressure build-up phase
pressure starts to build up according to this
Phase D: Filling phase (during triggering)
signal.
Point E: Start of filling
Point F: Finish of filling
a The logic is so made that the controller does not
recognize completion of filling even if the fill
switch is turned "ON" during triggering (phase
D).
10-78 D375A-6
DRAFT
Power train
Transmission ECMV
Operation of ECMV Before shifting gear (oil is drained) (Phase A in

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

sent to the proportional solenoid (1), pressure
control valve (3) drains the oil from clutch port
(A) through drain port (T).
Phase A: Before shifting gear (oil is drained) because oil pressure is not applied to pressure
Phase B: Filling phase detection valve (4).
Phase C: Pressure build-up phase
Phase D: Filling phase (during triggering)
Point E: Start of filling
Point F: Finish of filling
a The logic is so made that the controller does not
recognize completion of filling even if the fill
switch is turned "ON" during triggering (phase
D).
q When gear is shifted with gear shift switch, the
clutch discs and plates are pressed by piston. If
high pressure is suddenly applied, the piston
suddenly engages the clutch, causing sudden
start of the machine and excessive shock.
ECMV reduces a shock at the start of the
machine by increasing the oil pressure applied
to the piston gradually to set pressure, and
allows the clutch to be smoothly "engaged". It
aims to increase durability of the components on
the power transmitting route and enhances an
operator comfort.
D375A-6 10-79
DRAFT
Power train
Transmission ECMV
Filling phase (Phase B in chart) Pressure adjustment (Range C in chart)
q When current is supplied to proportional sole- q When current flows through proportional sole-
noid (1) with no oil in the clutch, the force exerted noid (1), the solenoid generates thrust in propor-
by the oil pressure, that is equal to the thrust of tion to the current. The clutch circuit pressure
the solenoid, develops in chamber (B) and push- builds up until the thrust of the solenoid is bal-
es pressure control valve (3) to the right. As a re- anced with the sum of the force exerted by the oil
sult, pump port (P) and clutch port (A) are pressure in clutch port and the force of pressure
opened and oil starts filling the clutch. When the control valve spring (2), and then the pressure is
clutch is filled with oil, pressure detection value settled.
(4) actuates to turn "ON" fill switch (5).
10-80 D375A-6
DRAFT
Power train
Transmission lubricating oil relief valve
1. Lubricating oil pressure measurement plug Outline

2. Lubricating oil relief value spool q The lubricating oil relief valve is installed to the
3. Valve body right side face of the transmission, and acts to
prevent any abnormal pressure in the transmis-
sion lubricating oil.
Cracking pressure: 0.26 MPa {2.7 kg/cm2}
D375A-6 10-81
DRAFT
Power train
Steering and brake control

a Regarding the transmission-related description
of the operation of the PCCS lever, refer to the
"Transmission control".
a PCCS: Palm Command Control System
10-82 D375A-6
DRAFT
Power train
1. Brake pedal Positions of levers and pedals

2. Lock lever [1]: Neutral
3. PCCS lever(steering, forward-reverse, gear shift) [2]: Forward straight-travel
4. Power train controller [3]: Reverse straight-travel
5. Limit switch [4]: Left clutch OFF
6. Steering ECMV [5]: Left clutch OFF, Left brake ON
7. Brake valve [6]: Right clutch OFF
8. Parking brake lever (from lock lever) [7]: Right clutch OFF, Right brake ON
9. Cable [8]: Brake "released"
10. Rod (from brake pedal) [9]: Brake ON
11. Potentiometer [10]: Free
[11]: Lock
Outline
q PCCS lever (3) sends electric signals to power q If you completely tilt PCCS lever (3) leftward, the
train controller (4). After receiving the signals, left steering clutch is "disengaged" completely
power train controller (4) sends a proportional and the left steering brake is "applied" , causing
current to the steering ECMV (6) to operate the the machine to make a sharp left turn.
steering clutch and brake. q The lock lever (2) is connected to parking brake
q Brake pedal (1) sends electric signals to power lever (8) and serves as a parking brake lever.
train controller (4) through the potentiometer
(11). Upon receiving those signals, power train
controller (4) sends a proportional current to
steering ECMV (6) to operate the brake. In this
case, the right and left brakes operate at the
same time to activate braking. Rod (10), as an
emergency brake operating device, operates the
brake through brake valve (7). (only when the
brake pedal is depressed fully)
q If you completely tilt PCCS lever (3) If you slight-
ly tilt PCCS lever (3) leftward, the left steering
clutch is partially disengaged, causing the ma-
chine to make a gradual left turn.
D375A-6 10-83
DRAFT
Power train
Transfer unit, bevel gear shaft and steering

Machines without VHMS controller
1. Transmission 10. L.H. steering clutch ECMV

2. Input shaft 11. R.H. steering clutch ECMV
3. Steering unit 12. Sudden stop prevention valve
4. Breather
5. Parking brake valve
6. L.H. steering brake ECMV
7. R.H. steering brake ECMV
8. Transmission output shaft speed sensor
9. Filter
10-84 D375A-6
DRAFT
Power train
Machines equipped with VHMS controller
1. Transmission 10. L.H. steering clutch ECMV

2. Input shaft 11. R.H. steering clutch ECMV
3. Steering unit 12. Sudden stop prevention valve
4. Breather
5. Parking brake valve
6. L.H. steering brake ECMV
7. R.H. steering brake ECMV
9. Filter
D375A-6 10-85
DRAFT
Power train
Transfer unit and bevel pinion

1. Input shaft Outline

2. Drive gear (35 teeth) q The transfer unit and bevel pinion are installed at
3. Transmission output shaft speed sensor the rear part inside the steering case, and input
4. Rear cover shaft (1) receives the power from the transmis-
5. Bearing cage sion output shaft.
6. Driven gear (33 teeth) q The transfer unit consists of drive gear (2) and
7. Bevel pinion (23 teeth) driven gear (6) to reduce the power speed from
8. Bevel gear (40 teeth) input shaft (1), transferring it to bevel pinion (7).
q It is equipped with transmission output shaft
speed sensor (3) to send the electric signals of
speed of drive gear (2) to the power train control-
ler.
10-86 D375A-6
DRAFT
Power train
1. Input shaft Outline

2. Drive gear (35 teeth) q The transfer unit and bevel pinion are installed at
3. Transmission output shaft speed sensor the rear part inside the steering case, and input
4. Rear cover shaft (1) receives the power from the transmis-
5. Torque converter output speed sensor sion output shaft.
6. Bearing cage q The transfer unit consists of drive gear (2) and
7. Driven gear (33 teeth) the driven gear (7) to reduce the power speed
8. Bevel pinion (23 teeth) from the input shaft (1), transferring it to bevel
9. Bevel gear (40 teeth) pinion (8).
q It is equipped with transmission output shaft
speed sensor (3) to send the electric signals of
speed of drive gear (2) to the power train control-
ler.
D375A-6 10-87
DRAFT
Power train
Bevel gear shaft, steering clutch and brake
10-88 D375A-6
DRAFT
Power train
1. Output shaf Outline

2. Sleeve q The steering clutch is wet-type, multiple-disc,
3. Brake cage spring-applied type. If you operate the PCCS le-
4. Brake spring ver, the controller outputs a proportional sole-
5. Brake case noid current to hydraulically operate the steering
6. Brake piston clutch ECMV. The steering clutch works in con-
7. Torque pin junction with the steering brake.
8. Blake plate (each side: 9 plates) q The steering brake is wet type multiple-disc,
9. Spacer spring-applied type. If you operate the brake
10. Brake disc (each side: 9 discs) pedal and PCCS lever, the controller outputs a
11. Brake hub proportional solenoid current to hydraulically op-
12. Brake stopper erate the steering brake ECMV. The steering
13. Pipe brake works in conjunction with the steering
14. Bearing cage clutch.
15. Bevel gear shaft q When the engine is stopped, the steering brake
16. Bevel gear shaft is "applied" since the pressure acting on the
17. Bevel gear (40 teeth) back of the brake piston lowers, even if you do
18. Bearing cage not depress the brake pedal. Since the brake is
19. Clutch hub released as the oil pressure in the circuit goes up
20. Clutch stopper when the engine restarts, the parking brake le-
21. Spacer ver must be set to "LOCK" position.
22. Clutch plate (each side: 9 plates) q The lubrication method is forced lubrication type,
23. Clutch disc (each side: 9 discs) which makes oil from the power train oil cooler
24. Torque pin flow through the passage in the steering case to
25. Clutch piston the housing and cage, and up to the discs and
26. Clutch spring plates.
27. Clutch housing
28. Clutch cage
D375A-6 10-89
DRAFT
Power train
Steering control valve
10-90 D375A-6
DRAFT
Power train
A: Left clutch pressure pickup port Outline

B: Right clutch pressure pickup port q Four ECMV's are installed on the valve seat of
C: Left brake pressure pickup port the steering control valve to control the steering
D: Right brake pressure pickup port clutch and steering brake.
E: To left clutch q The steering control valve is located in the circuit
F: To left lubrication circuit between the power train pump and the pistons of
G: To left brake the steering clutch and steering brake. It con-
H: To right clutch sists of two sets of the steering clutch ECMV
J: To right lubrication circuit (L.H. and R.H.) and two sets of the steering
K: To right brake brake ECMV (L.H. and R.H.).
L: Bevel gear shaft lubricating oil inlet port q The steering control valve sends the oil from the
M: To pin puller solenoid valve power train pump to the both left and right sides
N: From pin puller solenoid valve of steering clutches and steering brakes to con-
P: From pump trol respective disc clutches and disc brakes.
q When the PCCS lever is leaned to the right or
1. Left steering clutch ECMV left, the steering clutch is disengaged. The steer-
2. Right steering clutch ECMV ing brake will operate by leaning further the
3. Sudden stop prevention valve PCCS lever.
4. Parking brake valve q The controller sends signals to each ECMV ac-
5. Left steering brake ECMV cording to the right or left travel of the PCCS le-
6. Right steering brake ECMV ver and controls the clutch and brake for the
7. Filter gradual or sharp turns.
8. Valve seat q When the brake pedal is depressed, the control-
ler sends the command current to the steering
brake ECMV according to the pedal travel to ap-
ply the L.H. and R.H. brakes to stop the ma-
chine.
q The controller that is connected electrically to
the PCCS lever and brake pedal operates the
steering clutch and steering brake by controlling
each ECMV.
q The sudden stop prevention valve is installed to
prevent the machine from stopping suddenly
when a failure occurs in the electrical system.
q When the parking brake lever is set in the "lock"
position, the parking brake valve port is switched
to drain the oil between the L.H. and R.H. steer-
ing brake ECMV and the brake piston to apply
the brake. The parking brake valve is connected
to the brake pedal by the linkage.
D375A-6 10-91
DRAFT
Power train
Steering clutch ECMV and Steering brake ECMV

a Don't try to disassemble ECMV since adjustment for maintaining the performance will be required.
A: To clutch or brake *1:

P: From pump Clutch to use ECMV
Stamp of the name
T: Drain plate
Dr: Drain Steering clutch, Steering
R*******
P1: Clutch or brake oil pressure pickup port brake
1. Fill switch connector Outline

2. Proportional solenoid connector q Each ECMV keeps the steering clutch pressure
3. Pressure detection valve and steering brake pressure to the set pressure
4. Fill switch and switches the circuit to the piston chamber of
5. Proportional solenoid the steering clutch and steering brake.
6. Pressure control valve
7. Nameplate (*1)
10-92 D375A-6
DRAFT
Power train
Outline of ECMV
q The ECMV consists of a pressure control valve
and a fill switch.
q Pressure control valve
A proportional solenoid in this valve receives a
current sent from the steering controller and this
valve converts it to an oil pressure.
q Fill switch
This is a switch to detect that a clutch or brake is
filled with oil and has the following functions.
1. At the moment when the clutch or brake is filled
with oil, the fill switch outputs the signal (fill
signal) to the controller to notify the finishing of
filling.
2. While the oil pressure is applied to the clutch or
brake, the fill switch outputs the signal (fill signal)
to the controller to notify the presence of the oil
pressure.
ECMV and proportional solenoid

q Each ECMV is equipped with a proportional so-
lenoid.
The solenoid generates thrust according to the
command current from the controller. The thrust
generated by the proportional solenoid acts on
the spool of the pressure control valve and the
valve generates the oil pressure. Accordingly,
controlling the command current that changes
the thrust to operate the pressure control valve
allows for controlling the oil flow and oil pressure.
ECMV and fill switch

q Each ECMV is equipped with a fill switch.
If the clutch is filled with oil, the fill switch is
turned "ON" by the pressure of the clutch. This
signal allows the oil pressure to build up.
Operation of ECMV
q ECMV is controlled by the command current
sent from the controller to the proportional sole-
noid and the fill switch output signal.
D375A-6 10-93
DRAFT
Power train
When PCCS lever is in "neutral" position, brake pedal is "released", and parking brake lever is in
"free" position: Straight travel
(L.H. and R.H. clutches are "engaged", L.H. and R.H. brakes are "released", and parking brake is "released".)
q When the PCCS lever is in "neutral" position and q The oil in port (Pb) of the brake ECMV flows in
the brake pedal is "released", proportional sole- port (E) and pushes valve (7) to the left to con-
noid (1) of the clutch ECMV is de-energized and nect port (Pb) to port (B) and disconnect port (B)
the sealing part by ball (2) is opened. from port (Dr). At this time, the oil flows in the
q The oil from the power train pump flows through port behind the brake piston. As the oil pressure
port (Pc) of the clutch ECMV to orifice (a), then it rises, the brake piston is pushed to the left to
is drained through the sealing part by ball (2). compress the brake spring, then the brake is
q Valve (3) is moved to the right by the force of “released”.
spring (4) to disconnect port (Pc) from port (C), q When the parking brake lever is in "free" posi-
and connect port (C) to port (Dr). At this time, the tion, as the parking brake valve is closed, the oil
oil from the port behind the clutch piston is in the brake circuit is not drained.
drained through port (C) and the clutch is "en-
gaged" by the force of the clutch spring.
q The oil pressure in the brake circuit, etc. is main-
tained by orifice (a).
q Proportional solenoid (5) of the brake ECMV is
energized and pushes ball (6) to the left to close
the sealing part.
10-94 D375A-6
DRAFT
Power train
When PCCS lever is "operated to the left halfway", brake pedal is "released", and parking brake lever
is in "free" position: Gradual left turn
(L.H. clutch is "disengaged", L.H. brake is "semi-released", R.H. clutch is "engaged", R.H. brake is "released",
and parking brake is "released".)
q When the PCCS lever is "operated halfway to q The oil in port (Pb) of the brake ECMV flows in
left" and the brake pedal is "released", propor- port (E) and pushes valve (7) to the left. The cir-
tional solenoid (1) of the L.H. clutch ECMV is en- cuit pressure after port (B) depends on the com-
ergized and the sealing part by ball (2) is closed. mand current output from the controller to
q The oil from the power train pump flows through proportional solenoid (5) according to the travel
port (Pc) of the clutch EMCV and orifice (a) to of the PCCS lever.
port (F) and pushes valve (3) to the left to con- q Proportional solenoid (5) generates the thrust in
nect port (Pc) to port (C) and disconnect port (C) proportion to the command current. When this
from port (Dr). At this time, the oil flows in the thrust is balanced with the sum of the force gen-
port behind the clutch piston. As the oil pressure erated by the pressure in the port behind the
rises, the clutch piston is pushed to the left to brake piston and the force of spring (8), the
compress the clutch spring, then the clutch is brake pressure that determines braking force is
"disengaged". set up.
q Proportional solenoid (5) of the brake ECMV is q Accordingly, if the travel of the PCCS lever is
energized and pushes ball (6) to the left to close short, the cricuit pressure after port (B) is set
the sealing part. high and the brake is turned from "released" to
"semi-released". If the travel of the PCCS lever
is long, the circuit pressure after port (B) is set
low and the brake is turned from "semi-released"
to "applied".
D375A-6 10-95
DRAFT
Power train
q When the parking brake lever is in "free" posi-

tion, as the parking brake valve is closed, the oil
in the brake circuit is not drained.
10-96 D375A-6
DRAFT
Power train
When PCCS lever is "operated fully to the left", brake pedal is "released", and parking brake lever is
in "free" position: Sharp left turn
(L.H. clutch is "disengaged", L.H. brake is "applied", R.H. clutch is "engaged", R.H. brake is "released", and
parking brake is "released".)
q When the PCCS lever is moved from "halfway to q The oil pressure in the clutch circuit, etc. is main-
left" to "fully to left" position, proportional sole- tained by orifice (b).
noid (5) of the L.H. brake ECMV is de-energized q When the parking brake lever is in "free" posi-
and the sealing part by ball (6) is fully opened. tion, as the parking brake valve is closed, the oil
q Since the oil in port (E) is drained through the in the brake circuit is not drained.
sealing part, valve (7) is moved to the right by the
force of spring (8) to disconnect port (Pb) from
(B) and connect port (B) to port (Dr). At this time,
the oil from the port behind the brake piston is
drained through port (B) and the brake is "ap-
plied" by the force of the brake spring.
q The oil from the power train pump flows through
port (Pb) of the brake ECMV and orifice (b), then
it is drained through sealing part by ball (6).
D375A-6 10-97
DRAFT
Power train
When PCCS lever is in "neutral", brake pedal is "depressed", and parking brake lever is in "free" po-
sition: Stop
(L.H. and R.H. clutches are "engaged", L.H. and R.H. brakes are "applied", and parking brake is "released".)
q When the brake pedal is depressed fully, propor-

tional solenoids (5) of L.H. and R.H. brake ECM-
Vs are de-energized to open the sealing part by
ball (6).
q The controller outputs the command current to
proportional solenoids (5)according to the brake
pedal travel.
q Proportional solenoid (5) generates the thrust in
proportion to the command current. When this
thrust is balanced with the sum of the thrust ex-
erted by the pressure in the port behind the
brake piston and the force of spring (8), the
brake pressure that determines the braking force
is set up.
q Since the PCCS lever is in "neutral" position,
proportional solenoid (1) of L.H. and R.H. clutch
ECMVs are de-energized and L.H. and R.H.
clutch are "engaged".
q When the brake pedal is depressed, the parking
brake valve connected to the pedal by the link-
age operates to connect the brake circuit to the
drain circuit, allowing the oil to drain.
10-98 D375A-6
DRAFT
Power train
Parking brake valve
Parking brake valve
1. Spool Outline
2. Valve body q The parking brake valve is installed to the steer-
ing control valve, and spool (1) operates with the
parking brake lever.
q When the parking brake lever is in “lock" posi-
tion, the brake is applied by draining the pressur-
ized oil for the L.H. and R.H. steering brakes.
D375A-6 10-99
DRAFT
Power train
Parking brake valve
When PCCS lever is in "neutral" position, brake pedal is "released", and parking brake lever is in
"lock" position : Parking
(L.H. and R.H. clutches are "engaged", L.H. and R.H. brakes are "applied", and parking brake is "applied".)
q When the parking brake lever is set to the "lock"

position, spool (1) is moved to the left to connect
ports (A) and (B) to port (C) .
q The oil in the port behind the brake piston is
drained from port (C) through ports (A) and (B) .
q The oil pressure in the port behind the brake pis-
ton continues to decrease, then the brake is fully
"applied" and kept "applied" .
q When the engine is started again, as ports (A)
and (B) are still connected to port (C) , the brake
is kept "applied" .
q When the parking brake lever is moved to "free"
position, spool (1) moves to the right to discon-
nect port (A) and (B) from (C) . Then the oil from
the brake ECMV flows to the port behind the
brake piston and the brake is "released".
10-100 D375A-6
DRAFT
Power train
Sudden stop prevention valve
Outline
q The sudden stop prevention valve is installed to
prevent the machine from stopping suddenly
when an abnormality takes place in the electric
system.
q Sudden stop prevention valve (1) is installed in
the drain circuit of the brake ECMV so that the
pressure of port (DR) does not drop suddenly
when brake ECMV coil (2) is de-energized, and
consequently the sudden braking can be avoid-
ed when coil (2) of brake ECMV is de-energized.
q If an abnormality takes place in the electric sys-
tem, coil (3) of the sudden stop prevention valve
(1) is de-energized. Then, the oil in port (DR) is
drained through orifice (a) so that the brake is
applied gradually.
D375A-6 10-101
DRAFT
Power train
10-102 D375A-6
DRAFT
Power train
Final drive
Final drive
Outline
q The final drive consists of a single-reduction
spur gear set and a singal-reduction planetary
gear train. The lubrication is of splash type using
the rotation of the gears.
The final drive can be removed and installed as
a single unit.
q Floating seal (1) is installed to the rotating por-
tion of the sprocket to prevent the entry of dirt or
sand and to prevent leakage of lubricating oil.
D375A-6 10-103
DRAFT
Power train
Final drive
10-104 D375A-6
DRAFT
Power train
Final drive
1. Floating seal
2. Sun gear
3. Carrier
4. Hub
5. Cover
6. Sprocket boss
7. Sprocket teeth
8. Floating seal guard
9. Cover
10. Planetary pinion
11. Ring gear
12. Cover
13. No.1 gear
14. No.1 gear hub
15. No.1 pinion
16. Final drive case
17. Bearing cage
18. Boss
19. Shaft
20. Wear guard
21. Pivot shaft
D375A-6 10-105
DRAFT
Power train
Final drive
Path of power transmission
10-106 D375A-6
DRAFT
Power train
Final drive
q The power from the bevel gear shaft and steer-

ing 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
planetary pinions (10), but ring gear (11), which
is meshed with the planetary pinions, is fixed to
cover (9), so the planetary pinions rotate along
the ring gear while moving around the sun gear.
Then, the rotating force of sun gear (2) functions
as the rotating force of carrier (3) , which
supports the planetary pinions, and is trans-
mitted to sprocket hub (4).
The rotating direction 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-6 10-107
DRAFT
Undercarriage and frame
Track frame

Track frame
1. Idler Outline
2. Recoil spring assembly q The track rollers are mounted on the K-shaped
3. Idler cushion bogies, thereby increasing the actual contact
4. Track frame area between ground and the track even on an
5. Sprocket uneven ground to increase drawbar pull.
6. Sprocket cover q Because a rubber pad is mounted on a
7. Track roller bogie K-shaped bogie, the shock from a road surface
8. Track roller is absorbed.
9. Cap
10. Idler yoke Track roller arrangement
11. Cylinder Track roller flange type
12. Guide 1st 2nd 3rd 4th 5th 6th 7th 8th
S D D D D D D S
S: Single flange type

D: Double flange type
10-108 D375A-6
DRAFT
Track frame
D375A-6 10-109
Idler cushion
Idler cushion 10-1 0
1. Yoke Outline 10-1 0

2. Nut Pumping in or discharging grease from lubricator
3. Retainer (10) moves rod (5) forward or backward to adjust
4. Recoil spring track tension. The recoil spring (4) acts to dampen
5. Rod any sudden shock brought to bear on the idler.
6. Spring cylinder
7. Retainer
8. Holder
9. Piston
10. Lubricator (for pumping in and discharging
grease)
11. Grease chamber cylinder
10-110 D375A-6
(04)
Track roller bogie
Track roller bogie 10-1 1
1. Guide Outline 10-1 1

2. Cap q The track roller is mounted on the miner bogie
3. Track roller assembly (double flange type) (6) so that the track roller and track shoe can be
4. Major bogie touched constantly.
5. Rubber mount q The vibration from a road surface is absorbed by
6. Miner bogie the rubber mount (5).
7. Track roller assembly
8. Cover
D375A-6 10-111
(04)
DRAFT
Main frame
Main frame
10-112 D375A-6
DRAFT
Main frame
1. Main frame
2. Bracket
3. Cap
4. Cushion
5. Plate
6. Cage
7. Clamp
8. Seal
9. Cover
10. Coupling
11. Cap
12. Cushion
13. Bushing
14. Flange
15. Cushion spacer
D375A-6 10-113
DRAFT
Suspension
Suspension
10-114 D375A-6
DRAFT
Suspension
1. Equalizer bar 11. Side pin

2. Pivot shaft assembly 12. Center pin
3. Cover 13. Bushing
4. Thrust plate
5. Thrust plate Outline
6. Pivot shaft q The track frame allows its front part to move up
7. Seal cage cover and down on the pivot shaft (6) at the tail con-
8. Cover nected to its rear part.
9. Seal The equalizer (1) can rock on the center pin (12)
10. Bushing and is connected to the left and right track
frames with side pins (11).
D375A-6 10-115
DRAFT
Suspension
*1 . Indicates the left suspension of single tilt specification machines.

*2 . Indicates the right suspension of single tilt specification machines.
Indicates the left and right suspension of dual tilt specification machines.
10-116 D375A-6
Hydraulic system
Work equipment hydraulic piping diagram
Hydraulic system 10-1 7

Work equipment hydraulic piping diagram 10-1 7
Blade system 10-1 7
Semi-U dozer + Single tilt
1. Blade tilt cylinder

2. R.H. blade lift cylinder
3. Control valve
4. Hydraulic tank
5. Work equipment pump (HPV190)
6. L.H. blade lift cylinder
D375A-6 10-117
(04)
DRAFT
Hydraulic system
q Full U - Dozer with dual tilt function
1. Blade tilt cylinder

2. R.H. blade lift cylinder
3. Control valve
4. Hydraulic tank
5. Work equipment pump (HPV190)
6. L.H. blade lift cylinder
7. Blade pitch cylinder
10-118 D375A-6
Hydraulic system
Ripper system 10-1 9
Variable multi-shank ripper (Figure shows a dual tilt specification machine)
1. Control valve
2. Ripper tilt cylinder
3. Ripper lift cylinder
D375A-6 10-119
(04)
Hydraulic system
Variable giant ripper (Figure shows a dual tilt specification machine)
1. Control valve
2. Steering control valve
3. Ripper tilt cylinder
4. Ripper lift cylinder
5. Pin puller cylinder (from power train hydraulic cir-
cuit)
6. Solenoid valve (for pin-puller)
10-120 D375A-6
(04)
Hydraulic system
PPC control piping diagram
PPC control piping diagram 10-121

Blade and ripper control 10-121
(Figure shows a dual tilt specification machine)
1. Accumulator
2. Check valve
3. Blade control PPC valve
4. Ripper control PPC valve
5. PPC lock valve
6. Cooling fan pump
7. Self-pressure reducing valve
8. Hydraulic pump
D375A-6 10-121
(04)
DRAFT
Hydraulic system
Work equipment control
q The drawing shows a dual tilt dozer and pin puller installed machine.
10-122 D375A-6
DRAFT
Hydraulic system
1. Work equipment lock lever

2. Blade control lever
3. Tilt/pitch selector switch (only for dual tilt dozer specification)
4. Ripper control lever (only for ripper installed machine)
5. Pin puller swith (only for giant ripper installed machine)
6. PPC lock valve
7. Work equipment lock switch
Lever positions
[1] : Blade "HOLD"
[2] : Blade "LOWER"
[3] : Blade "FLOAT"
[4] : Blade "RAISE"
[5] : Blade "LEFT TILT/*PITCH BACK"
[6] : Blade "RIGHT TILT/*PITCH DUMP"
* Activated when the pitch selector switch is turned
"ON" (dual tilt specification only)
[7] : Ripper "HOLD"
[8] : Ripper "RAISE"
[9] : Ripper "LOWER"
[10] : Ripper "TILT IN"
[11] : Ripper "TILT BACK"
[12] : FREE
[13] : LOCK
[14] : Dual tilt selector switch "OFF"
[15] : Dual tilt selector switch "ON"
[16] : Pitch selector switch "OFF" auto return
[17] : Pitch selector switch "ON"
[18] : Pin puller switch "PUSH OUT"
[19] : Pin puller switch "PUSH IN"
Outline
q The work equipment control employs a PPC sys-
tem which uses PPC valves to move respective
spools of the control valve.
q Work equipment lock lever (1) is interconnected
with PPC lock valve (6), and when it is set to the
"LOCK" position, the flow of oil in the PPC circuit
is stopped.
q Work equipment lock lever (1) is also interlocked
with work equipment lock switch (7). When work
equipment lock lever (1) is set to "LOCK" posi-
tion, work equipment lock switch (7) is turned
"OFF" and engine is ready to start.
When work equipment lock lever (1) is set to
"FREE" position, work equipment lock switch (7)
is turned "ON" and engine is not ready to start in
this circuit.
D375A-6 10-123
DRAFT
Hydraulic system
Hydraulic tank
Hydraulic tank
10-124 D375A-6
DRAFT
Hydraulic system
Hydraulic tank
1. Oil filler port cap

Specified value
2. Hydraulic oil filter element
3. Spring
Tank capacity (l) 210
4. Suction valve
5. Cover Hi (l) 144
6. Cover Hydrau-
7. Hydraulic tank lic tank Level inside
Center (l) 130
8. Strainer (suction) tank
9. Sight gauge Low (l) 112
10. Pressure valve and Breather
Cracking pressure of pres-
11. Drain valve 17 ± 2.5
sure valve
12. Drain plug {0.17 ± 0.025}
(kPa {kg/cm2})
13. Strainer (over flow) Breather
Operating pressure of vac-
uum valve 2 ± 0.3
{0.02 ± 0.003}
(kPa {kg/cm2})
Specified value
Cracking pressure 150 ± 30
(kPa{kg/cm2}) {1.5 ± 0.3}
Hydraulic Mesh size (mm) 30/8

oil filter
Filtering area (cm2) 17600
Filtering oil flow (l/min) 720

Strainer
Mesh size (mm) 40
(over flow)
Mesh size
105
Strainer (mm)
(suction) Filtration area
3,600
(cm2)
D375A-6 10-125
DRAFT
Hydraulic system
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
Gas volume: 300 cc
Max. working pressure: 3.1 MPa {32 kg/cm2}
Min. working pressure: 1.2 MPa {12 kg/cm2}
Function
q The accumulator is installed between the
self-pressure reducing valve and the PPC valve.
Even if the engine is stopped with the work
equipment raised, the pressure of the nitrogen
gas compressed inside the accumulator sends
the pilot pressure to the main control valve to ac-
tuate it and enable the work equipment to lower
under its own weight.
Operation
q After the engine is stopped, when the PPC valve
is at neutral, chamber (A) inside the bladder is
compressed by the oil pressure in chamber (B).
q When the PPC valve is operated, the oil pres-
sure in chamber (B) goes below 2.9 MPa
{30 kg/cm2}, and the pressure of the nitrogen
gas in chamber (A) expands the bladder, so the
oil in chamber (B) acts the pilot pressure and ac-
tuates the main control valve.
10-126 D375A-6
DRAFT
Hydraulic system
PPC lock valve
PPC lock valve

1. Lever
2. End cap
3. Ball
4. Sheet
5. Valve body
Outline
q The PPC lock valve is installed in the PPC circuit
between the PPC charge valve and PPC valve.
If the work equipment lock lever is placed at the
LOCK position, the PPC lock valve interlocked
with the work equipment lock lever is actuated to
stop the oil in the PPC circuit, preventing the
work equipment from moving.
D375A-6 10-127
DRAFT
Hydraulic system
PPC lock valve
10-128 D375A-6
DRAFT
Hydraulic system
PPC valve
PPC valve
Blade PPC valve

General view
P: From self-pressure reducing valve

P1: To blade lift valve(LOWER) PPC port
P2: To blade lift valve(RAISE) PPC port
P3: To blade tilt valve(LEFT TILT) PPC port
P4: To blade tilt valve(RIGHT TILT) PPC port
T: To hydraulic tank
D375A-6 10-129
DRAFT
Hydraulic system
PPC valve
Sectional view
1. Spool 8. Plate
2. Metering spring 9. Retainer
3. Centering spring 10. Valve body
4. Piston 11. Filter
5. Disc
6. Nut (for lever connection)
7. Joint
10-130 D375A-6
DRAFT
Hydraulic system
PPC valve
Operation
When in Neutral
Blade lift valve Blade tilt valve
q Ports (A) and (B) of the blade lift valve of the con- q Ports (C) and (D) of the blade tilt valve of the
trol valve and ports (P1) and (P2) of the PPC control valve and ports (P3) and (P4) of the PPC
valve are connected through fine control hole (f) valve are connected through fine control hole (f)
of spool (1) to drain chamber (D). of spool (1) to drain chamber (D).
D375A-6 10-131
DRAFT
Hydraulic system
PPC valve
When blade control lever is in fine control range

(Neutral o Fine control range)
q When piston (4) is pushed by disc (5), retainer
(9) is pushed, spool (1) is also pushed by meter-
ing spring (2), and moves down.
q Accordingly, fine control hole (f) is disconnected
from drain chamber (D) and connected to pump
pressure chamber (PP) almost simultaneously,
and then the pilot oil flows from port (P1) through
fine control hole (f) to port (B).
q 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).
q As a result, spool (1) moves up and down until
the force of metering spool (2) is balanced with
the force exerted by the pressure at port (P1).
q The positional relationship between spool (1)
and valve body (10) [where fine control hole (f) is
between drain chamber (D) and pump pressure
chamber (PP)] does not change until retainer (9)
comes in contact with spool (1).
q Since metering spring (2) is compressed in pro-
portion to the travel of the control lever, the pres-
sure in port (P1) rises in proportion to the travel
of the control lever.
q Accordingly, the control valve spool moves to a
position at which the pressure in port (B) [equal
to the pressure in port (P1)] is balanced with the
force of the control valve spool return spring.
10-132 D375A-6
DRAFT
Hydraulic system
PPC valve
When blade control lever is in fine control range When blade control lever is operated to stroke
(When blade control lever is returned) end
q When disc (5) begins to return, spool (1) is q When disc (5) pushes down piston (4) and re-
pushed up by the force of centering spring (3) tainer (9) pushes down spool (1), fine control
and the force exerted by the pressure at port hole (f) is disconnected from drain chamber (D)
(P1) . and connected to pump pressure chamber (PP).
q Because of this, fine control hole (f) is connected q Accordingly, the pilot oil flows through fine con-
to drain chamber (D), and the pressurized oil at trol hole (f) and port (P1) into port (B) and pushes
port (P1) is released. the control valve spool.
q When the pressure in port (P1) lowers too much, q The oil returning from port (A) flows through port
spool (1) is pushed down by metering spring (2) (P2) and fine control (f') into drain chamber (D).
and fine control hole (f) is disconnected from
drain chamber (D) and connected to pump pres-
sure chamber (PP) almost simultaneously.
Then, the oil at the pump pressure is supplied
until the pressure in port (P1) is restored to the
level corresponding to the position of the lever.
q When the control valve spool returns, the oil in
drain chamber (D) flows in through fine control
hole (f') of the valve which is not operated and
then flows through port (P2) into port (A) to sup-
ply oil.
D375A-6 10-133
DRAFT
Hydraulic system
PPC valve
When blade control lever is operated to "Float"

q When piston (4) for blade "Lower" side of port
(P1) is pushed down by disc (5), ball (11) touch-
es projection (a) of the piston in the middle of the
stroke (The detent starts to operate).
q When piston (4) is pushed down further, ball (11)
pushes up collar (12) supported on detent spring
(13) and moves outward to allow projection (a) of
the piston to pass.
q At this time, piston (4') on the opposite side is
pushed up by spring (14).
q As a result, the oil in chamber (F) flows through
ports (b) and (c) to chamber (E) , allowing piston
(4') to follow disc (5). Since passage (d) is con-
nected to port (P1), almost the same pressure is
applied to passage (d) and port (P1).
q Chamber (E) is normally connected to drain
chamber (D). When projection (a) of the piston
passes ball (11) , passage (d) is connected to
chamber (E) and the oil starts flowing to cham-
ber (E).
q At this time, the control valve moves to the
"Float" position and the circuit comes into "Float"
condition.
q Since piston (4') is pushed up by the force exert-
ed by the pressure in chamber (E) , the "Float"
condition is kept even if the lever is released.
When canceling "Float" condition
q Disc (5) is returned with a force large than the
force exerted by the pressure in chamber (E) to
cancel the "Float" condition.
q As a result, chamber (E) is disconnected from
passage (d) and connected to the drain cham-
ber. Accordingly, the pressure in chamber (E)
lowers to contact the "Float" condition.
10-134 D375A-6
DRAFT
Hydraulic system
PPC valve
Ripper PPC valve

General view
P: From self-pressure reducing valve

P1: To ripper tilt valve PPC port
P2: To ripper tilt valve PPC port
P3: To ripper lift valve PPC port
P4: To ripper lift valve PPC port
T: To tank
D375A-6 10-135
DRAFT
Hydraulic system
PPC valve
Sectional view
10-136 D375A-6
DRAFT
Hydraulic system
PPC valve
1. Spool
2. Piston
3. Disc
4. Nut (for lever connection)
5. Joint
6. Plate
7. Retainer
8. Valve body
9. Filter
D375A-6 10-137
DRAFT
Hydraulic system
PPC valve
Operation q As a result, spool (1) moves up and down so that

the force of metering spring (2) is balanced with
When ripper control lever is in Neutral the force exerted by pressure in port (P1). The
q Ports (A) and (B) of the control valve and ports positional relationship between spool (1) and
(P1) and (P2) of the PPC valve are connected to valve body (10) (where fine control hole (f) is be-
drain chamber (1) through fine control hole (f) in tween drain chamber (D) and pump pressure
spool (D). chamber (PP)) does not change until retainer (9)
comes in contact with spool (1).
q Since metering spring (2) is compressed in pro-
portion to the travel of the control lever, the pres-
sure in port (P1) rises in proportion to the travel
of the control lever.
q In this way, the control valve spool moves to a
position where the pressure of port (A) (same as
pressure at port (P1)) and the force of the return
spring of the control valve spool are balanced.
When ripper control lever is in fine control range

(Neutal o Fine control range)
q When piston (4) is pushed by disc (5), retainer
(9) is pushed and spool (1) is also pushed down
through metering spring (2).
q Accordingly, fine control hole (f) is disconnected
from drain chamber (D) and connected to pump
pressure chamber (PP) almost simultaneously,
and then the pilot oil flows from port (P1) through
fine control hole (f) to port (A).
q 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).
10-138 D375A-6
DRAFT
Hydraulic system
PPC valve
When ripper control lever is in fine control range When ripper control lever is operated to stroke
(When ripper control lever is returned) end
q When disc (5) begins to return, spool (1) is q When disc (5) pushes down piston (4) and re-
pushed up by the force of centering spring (3) tainer (9) pushes down spool (1), fine control
and the force exerted by the pressure at port hole (f) is disconnected from drain chamber (D)
(P1). and connected to pump pressure chamber (PP).
q Because of this, fine control hole (f) is connected q Accordingly, the pilot oil flows through fine con-
to drain chamber (D), and the pressurized oil at trol hole (f) and port (P1) into port (A) and pushes
port (P1) is released. the control valve spool.
q When the pressure at port (P1) goes down too q The oil returning from port (B) flows through port
far, spool (1) is pushed down by metering spring (P2) and fine control hole (f') into drain chamber
(2). Fine control hole (f) is shut off from drain (D).
chamber (D), and almost simultaneously, it is
connected to pump pressure chamber (PP). The
oil at pump pressure is supplied until the pres-
sure at port (P1) recovers to a pressure equiva-
lent to the position of the lever.
q When the spool of the control valve returns, the
oil in drain chamber (D) flows in through fine con-
trol hole (f') in the valve on the side that is not op-
erated. The oil passes through port (P2) and
enters port (B) to replenish the port with pressur-
ized oil.
D375A-6 10-139
DRAFT
Hydraulic system
Piston valve
Piston valve
For blade lift cylinder
Outline 2. Piston valve OPEN
q The piston valve is installed on the piston in the Just before piston rod (1) reaches the end of its
blade lift cylinder. When the piston reaches its stroke, the tip of valve (6) contacts the cylinder bot-
stroke end, the valve releases the oil from the tom, so valve (6) and piston valve (3) stop at that po-
work equipment pump to reduce the oil pressure sition and do not move further. Only piston (2)
being exerted on the piston. moves further.
In addition the piston valve relieves the shock When this happens, the oil at the cylinder head,
which occurs when the piston comes into which has been sealed in by piston valve (3), es-
contact with the cylinder head or the bottom and capes through piston valve seats (4) and (5), and
serves to reduce the subsequent surge pressure the pressure inside the cylinder stops rising.
in the cylinder by letting the oil escape from the
cylinder before the piston reaches its stroke end.
Operation
1. Piston valve CLOSED
Pressurized oil from the work equipment pump acts
on piston (2) and piston valve (3).
Then, piston valve (3) is pushed to the right and con-
tacts the tapered part of piston valve seat (4) to seal
in the oil. As a result, the pressure in the cylinder ris-
es to move piston (2) to the right.
10-140 D375A-6
DRAFT
Hydraulic system
Quick drop valve
Quick drop valve

For blade lift cylinder
Outline
q The quick drop valve installed to both right and
left blade lift cylinders serves to increase the
blade lowering speed and to reduce the occur-
rence of vacuum at the cylinder bottom end
when the blade is lowering, thereby shortening
the time lag between lever operation and start of
digging. The blade lowering speed, which is gen-
erally determined by the pump delivery, can be
made faster with the quick drop valve.
1. Valve body
2. Spool
3. Check valve
4. Spring
Operation
1. Start of lowering
When the blade control lever is operated to the
LOWER, the oil from the control valve flows through
port (A) to the cylinder bottom end and pushes the
piston.
The oil on the cylinder head end is pushed out by
the piston into port (B), and then flows through port
(C) and control valve to the hydraulic tank.
2. While lowering
Pressurized oil from the cylinder head end flows into
port (C) through port (B).
At this time, the oil flow is restricted by orifice (A)
provided along the way, causing a differential pres-
sure accross the 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 connecting parts (B) and (A) is made, part
of the oil flowing from the cylinder head end to port
(C) enters the passage that connects part (A) to the
cylinder bottom end, and merged with the oil from
the control valve, and flows to the cylinder bottom
end.
Thus, the blade lowering speed increases in accor-
dance with the amount of oil that flows to the bottom
of the cylinder and reduces the formation of vacuum
at the bottom end of the cylinder.
D375A-6 10-141
DRAFT
Hydraulic system
Pin puller switch
Pin puller switch
Function
q The pin puller solenoid valve is controlled by 1. Connector
turning the pin puller switch ON/OFF. This 2. Wire
switches the oil circuit to the pin puller cylinder 3. Switch
and sets the shank mounting pin to the PUSH IN 4. Knob
or PULL OUT position.
10-142 D375A-6
DRAFT
Hydraulic system
Pin puller solenoid valve
1. Plug A: To pin puller cylinder bottom end

2. Spring B: To pin puller cylinder head end
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-6 10-143
DRAFT
Hydraulic system
Operation
1. Pin puller switch at PUSH IN position 2. Pin puller switch at PULL OUT position
When the pin puller switch is set to the PUSH IN po- When the pin puller switch is set to the PULL OUT
sition, no electric current flows to solenoid (9) and it position, current flows to solenoid (9) and it is ener-
is de-energized. For spool (5), ports (P) and (B) con- gized. Then, the solenoid pushes out push pin (8)
nect to ports (A) and (T) respectively, and the oil and spool (5) moves to the left. At this point, ports
from the power train pump flows from port (P) to port (P) and (B) disconnect from ports (A) and (T) re-
(A), and enters the bottom end of pin puller cylinder spectively, and ports (P) and (A) connect to ports (B)
(10). The oil in the bottom end of the cylinder ex- and (T) respectively, so the oil from the power train
tends the cylinder to push shank mounting pin (11) pump flows from port (P) to port (B) and enters the
into shank (12) when the circuit pressure builds up head end of pin puller cylinder (10). The oil in the
sufficiently. cylinder head end retracts the cylinder to pull shank
mounting pin (11) out of shank (12) when the circuit
pressure builds up sufficiently.
10-144 D375A-6
DRAFT
Hydraulic system
Blade control lever (only for the machine with dual tilt specification)
Blade control lever (only for the machine with dual tilt specification)
1. Switch (Dual/single tilt selector) q When the switch (1) is set to the "DUAL" position
2. Switch (pitch) and the lever is moved to the left, the blade
3. Cover makes left dual tilt. Moving the lever to the right
4. Connector (male) makes the blade perform a right dual tilt.
5. Connector (female) q Even when switch (1) is set to either "DUAL" or
Outline "SINGLE" position, if the lever is moved to the
q Moving the blade control lever forward and back- left or right with the swith (2) kept pressed, the
ward or to the left or right raises and lowers the blade pitches backward and forward respective-
blade or tilt it left or right respectively. When the ly.
lever is moved to the left or right with swith (1) set
to the "DUAL" position, the blade makes a dual
tilt. When the lever is moved to the left or right
with swith (2) being pressed, the blade pitches.
q When switch (2) is kept pressed and the lever is
moved to the left, the blade pitches backward.
Moving the lever to the right pitches the blade
forward.
D375A-6 10-145
DRAFT
Hydraulic system
Work equipment pump
Work equipment pump

Type: HPV190
General view
10-146 D375A-6
DRAFT
Hydraulic system
Work equipment pump
Outline
q This pump consists of a variable displacement
swash plate type piston pump and LS valve.
PA: Pump discharge port

PB: Pump pressure inlet port
PD1: Case drain port
PD2: Drain plug
PEN: Control pressure pickup port
PLS: Load pressure inlet port
PLSC: Load pressure pickup port
PS: Pump suction port
1. Front pump
2. LS valve
D375A-6 10-147
DRAFT
Hydraulic system
Work equipment pump
Sectional view
1. Shaft
2. Cradle
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Servo piston
10-148 D375A-6
DRAFT
Hydraulic system
Work equipment pump
Function q Piston (6) carries out relative movement in the

q The pump converts the engine rotation transmit- axial direction inside each cylinder chamber of
ted to its shaft to oil pressure and oil flow, corre- cylinder block (7).
sponding to the load. q Cylinder block (7) seals the pressurized oil to
q It is possible to change the discharge amount by valve plate (8) and carries out relative rotation.
changing the swash plate angle. q This surface is designed so that the oil pressure
balance is maintained at a suitable level.
Structure q The oil inside the respective cylinder chambers
q Cylinder block (7) is supported by shaft (1) on of cylinder block (7) is sucked and discharged
splined area (12). through valve plate (8).
q Shaft (1) is supported by each bearing (13).
q Tip of piston (6) is concaved and shoe (5) is
crimped to it to form one unit.
q Piston (6) and shoe (5) constitute a spherical
bearing.
q Rocker cam (4) has flat surface (A), and shoe (5)
is always pressed against this surface while slid-
ing in a circular pattern.
q Rocker cam (4) conducts high pressure oil to cyl-
inder surface (2) with cradle (B), which is se-
cured to the case, and forms a static pressure
bearing when it slides.
D375A-6 10-149
DRAFT
Hydraulic system
Work equipment pump
Operation of pump
q Cylinder block (1) rotates together with shaft (7), q As center line (X) of rocker cam (4) matches the
and shoe (5) slides on flat surface (A). axial direction of cylinder block (7) (swash plate
q Rocker cam (4) moves along cylindrical surface angle (a) = 0), the difference between volumes
(B), so angle (4) between center line (X) of rock- (E) and (F) inside cylinder block (7) becomes 0.
er cam (7) and the axial direction of cylinder q Suction and discharge of pressurized oil is not
block (a) changes. carried out in this state. Namely pumping action
q (a) is called the swash plate angle. is not performed. (Actually, however, the swash
plate angle is not set to 0)
q With center line (X) of rocker cam (4) at a swash

plate angle (a) in relation to the axial direction of
cylinder block (7), flat surface (A) acts as a cam
in relation to shoe (5).
q Piston (6) slides on the inside of cylinder block
(7), so a difference between volumes (E) and
((F) is created inside cylinder block (7).
q A single piston (6) sucks and discharges the oil
by the amount (F) - (E).
q As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
q The volume of chamber (F) grows larger and, in
this process, the oil is sucked.
10-150 D375A-6
DRAFT
Hydraulic system
Work equipment pump
Control of delivery
q If the swash plate angle (a) becomes larger, the
difference between volumes (E) and (F) be-
comes larger and pump delivery (Q) increases.
q Servo piston (10) is used for changing swash
plate angle (a).
q Servo piston (10) carries out linear reciprocal
movement according to the signal pressure from
the PC and LS valves.
q This linear movement is transmitted to rocker
cam (4) through slider (14).
q Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) pivots on the surface
while continuing revolving movement.
q The area of servo piston (10) for receiving the
pressure are not identical on the left side and
right side. Main pump discharge pressure (self
pressure) (PP) is always brought to the pressure
chamber of the small diameter piston side.
q Output pressure (PEN) of the LS valve is brought
to the pressure chamber of the large diameter
piston side.
q The movement of servo piston (10) is controled
by the relationship of pressure between small di-
ameter piston side (PP) and large diameter side
(PEN) and by the ratio of the area receiving the
pressure between small diameter piston and
large diameter piston.
D375A-6 10-151
DRAFT
Hydraulic system
Work equipment pump
LS valve
PA: Pump port 1. Sleeve

PDP: Drain port 2. Piston
PLP:LS control pressure output port 3. Spool
PLS: LS pressure input port 4. Spring
PP: Pump port 5. Sheet
PPL: Drain port 6. Sleeve
PSIG: Drain port 7. Plug
8. Lock nut
Function
q The LS (load sensing) valve detects the load and
controls the pump delivery.
q This valve controls main pump delivery (Q) ac-
cording to differential pressure (dPLS) [= (PP) -
(PLS)], called the LS differential pressure [the
difference between main pump discharge pres-
sure (PP) and control valve outlet port pressure
(PLS)].
q Main pump discharge pressure (PP), pressure
(PLS) [called LS pressure] coming from the con-
trol valve output enter this valve.
q The relationship between LS differential pres-
sure (dPLS) [= (PP) - (PLS)], which is a diffential
pressure between main pump discharge pres-
sure (PP) and LS pressure (PLS) , and delivery
(Q) is as shown in the diagram.
10-152 D375A-6
DRAFT
Hydraulic system
Work equipment pump
Operation
When the control lever is operated to Neutral
q The LS valve is a three-way selector valve, with q According to the difference in the areas on servo
pressure (PLS) (LS pressure) from the inlet port piston (10), the servo piston is moved in the di-
of the control valve brought to spring chamber rection which makes the swash plate angle min-
(B), and pump discharge pressure (PP) brought imum.
to port (H) of sleeve (8)
q Magnitude of the force resulting from this LS
pressure (PLS), force of spring (4) and the pump
discharge pressure (self pressure) (PP) deter-
mine the position of spool (6).
q Before the engine is started, servo piston (10) is
pushed to the right. (See right drawing)
q If the control lever is at the neutral position when
the engine is started, LS pressure (PLS) will be
set to 0 MPa {0 kg/cm2}. (It is interconnected to
the drain circuit via the control valve spool)
q Spool (6) is pushed to the right, and port (C) and
port (D) will be connected.
q Pump pressure (PP) is conducted to the larger
diameter end from the port (K).
q The same pump pressure (PP) is conducted to
the smaller diameter end from the port (J).
D375A-6 10-153
DRAFT
Hydraulic system
Work equipment pump
Mechanism to make the pump delivery maximum
q When the difference between pump discharge

pressure (PP) and LS pressure (PLS), in other
words, LS differential pressure (dPLS) becomes
smaller [for example, when the area of opening
of the control valve becomes larger and pump
discharge pressure (PP) drops], spool (6) is
pushed to the left by the combined force of LS
pressure (PLS) and the force of spring (4).
q When spool (6) moves, port (D) and port (E) are
interconnected and connected to the PC valve.
q The pressure across circuits (D) and (K) be-
comes drain pressure (PT).
q The pressure at the large piston diameter end of
servo piston (10) becomes drain pressure (PT)
and pump discharge pressure (PP) always is
conducted to the small diameter end port (J) so
servo piston (10) is pushed to the left, and
moves the swash plate in the direction to make
the delivery larger.
10-154 D375A-6
DRAFT
Hydraulic system
Work equipment pump
Mechanism to make the pump delivery minimum
q When LS differential pressure (dPLS) becomes

larger [for example, when the area of opening of
the control valve becomes smaller and pump
pressure (PP) rises] because of the rightward
move (it reduces pump delivery) of servo piston
(10) , pump pressure (PP) pushes spool (6) to
the right.
q The movement of spool (6) transmits pump dis-
charge pressure (PP) to the large diameter end
of the piston through port (C) , port (D) and port
(K).
q Pump pressure (PP) is also conducted to port (J)
of the small diameter end of the piston, but be-
cause of the difference in area between the large
diameter end and the small diameter end on ser-
vo piston (10), it is pushed to the right. As the re-
sult, the servo piston (10) moves into the
direction to make the swash plate angle smaller.
D375A-6 10-155
DRAFT
Hydraulic system
Work equipment pump
When servo piston is balanced
q The symbols (A1), (A0) and (PEN) represent the q Force of spring (4) is adjusted in such that the
area receiving the pressure at the large diameter position of the balanced stop of this spool (6) is
end of the piston, the area receiving the pressure determined when (PP) - (PLS) = 1.96 MPa
at the small diameter end and the pressure con- {20 kg/cm2} at the median of the specified value.
ducted to the large diameter end of the piston,
respectively.
q When the force generated by main pump pres-
sure (PP) in the LS valve is balanced with the
combined force of spring (4) and LS pressure
(PLS) , and the relationship becomes (A0) ×
(PP) = (A1) × (PEN), servo piston (10) is
stopped in that position.
q The swash plate of the pump is held at the inter-
mediate position. [Spool (6) is stopped at a posi-
tion where the opening area from port (D) to port
(E) and the distance from port (C) to port (D) is
almost the same.]
q The relationship between the area receiving the
pressure at both ends of servo piston (10) is (A0)
: (A1) = 3 : 5 so the pressure applied accross the
piston when it is balanced becomes (PP):(PEN)
C 5:3.
10-156 D375A-6
DRAFT
Hydraulic system
Work equipment pump
D375A-6 10-157
Hydraulic system
Control valve
Control valve 10-158

6-spool valve for dual tilt 10-158
General view 10-158
10-158 D375A-6
(04)
DRAFT
Hydraulic system
Control valve
A1: To blade lift cylinder head

A3: To blade tilt right cylinder head
A4: To blade tilt left cylinder head
A5: To ripper cylinder head
A6: To ripper tilt cylinder bottom
B1: To blade lift cylinder bottom
B3: To blade tilt right cylinder bottom
B4: To blade tilt left cylinder bottom
B5: To ripper lift cylinder bottom
B6: To ripper tilt cylinder head
LS: To work equipment pump LS valve
LSI: LS pressure pickup port
P: From work equipment pump
PA1: From blade PPC valve port P1
PA5: From ripper PPC valve port P3
PB: PPC basic pressure
PB1: From blade PPC valve port P2
PB5: From ripper PPC valve port P4
P1: Pump pressure pick-up port
T: Drain port
D375A-6 10-159
DRAFT
Hydraulic system
Control valve
Sectional view (1/4)
1. Ripper tilt valve

2. Ripper lift valve
3. Blade right tilt valve
4. Blade left tilt valve
5. Blade lift valve
6. Blade lift spool
7. Blade lift spool
8. Blade left tilt spool
9. Blade right tilt spool
10. Ripper lift spool
11. Ripper tilt spool
12. Load check valve
13. Pressure compensation valve
10-160 D375A-6
DRAFT
Hydraulic system
Control valve
(2/4)
1. LS check valve
2. Preset plug
D375A-6 10-161
DRAFT
Hydraulic system
Control valve
(3/4)

2. LS relief valve
3. Unload valve
4. Suction valve
5. Check valve (built - in to spool)
10-162 D375A-6
DRAFT
Hydraulic system
Control valve
(4/4)
1. Suction safety valve

2. Check valve (built - in to spool)
3. Suction valve
4. Suction valve
D375A-6 10-163
Hydraulic system
Control valve
5-spool valve for single tilt 10-164

General view 10-164
10-164 D375A-6
(04)
Hydraulic system
Control valve

A3: To blade tilt cylinder head
A4: To ripper cylinder head
A5: To ripper tilt cylinder bottom
B3: To blade tilt cylinder bottom
B4: To ripper lift cylinder bottom
B5: To ripper tilt cylinder head
LS: To work equipment pump LS valve
LSI: LS pressure pickup port
P: From work equipment pump
PB: PPC basic pressure
P1: Pump pressure pick-up port
T: Drain port
D375A-6 10-164-1
(04)
Hydraulic system
Control valve
Sectional view (1/4) 10-164-2
1. Ripper tilt valve

2. Ripper lift valve
3. Blade tilt valve
4. Blade lift valve
5. Blade lift spool
6. Blade lift spool
7. Blade tilt spool
8. Ripper lift spool
9. Ripper tilt spool
10. Load check valve
10-164-2 D375A-6
(04)
Hydraulic system
Control valve
(2/4) 10-164-3
1. LS check valve
2. Preset plug
D375A-6 10-164-3
(04)
Hydraulic system
Control valve
(3/4) 10-164-

2. LS relief valve
3. Unload valve
4. Suction valve
5. Check valve (built-in to spool)
10-164-4 D375A-6
(04)
Hydraulic system
Control valve
(4/4) 10-164-5
1. Suction safety valve

2. Check valve (built-in to spool)
3. Suction valve
4. Suction valve
D375A-6 10-164-5
(04)
Hydraulic system
Control valve
Operation of control valve 10-164-6
Function 10-164-6
When the main spool is at the HOLD position, it
drains the excess oil discharged by the pump, and
prevents the pressure from being formed in the cir-
cuit from rising.
Operation 10-164-6
When set to "HOLD" position (operation of unload
valve) 10-164-6
q When the main spool is at the HOLD position,
the pump pressure passes from chamber (A)
through oriffice (4) to chamber (D). Chambers
(C) and (C') are connected to the drain circuit.
q When oil is supplied from the pump, the pressure
in chamber (D) rises, and spool (1) is pushed to
the right by pressure (FO) which is determined
by the cross-sectional area of piston (3) receiv-
ing the pressure.
q When (FO) becomes larger than set force (FS)
of spring (2), the spool moves to the right and
connects the passage between chamber (A) and
chamber (B), so the oil from the pump is drained.
q Therefore, spool (1) is balanced at a position that
matches the supply of oil from the pump.
q Actually, the amount of oil supplied from the
pump is small, so the pressure in the circuit is al-
most the same as the set force of spring (2).
10-164-6 D375A-6
(04)
Hydraulic system
Control valve
Control of flow rate 10-165

Work equipment valve
Use of the CLSS circuit (Closed - Center Load
Sensing System) makes it possible to control the oil
flow by adjusting the area of opening of the spool
driven by the PPC valve, regardless of the load.
When set to "HOLD" position (blade right tilt cylinder circuit on dual tilt specification machine) 10-165
q When the spool is set to the "HOLD" position, the q When this happens, the pump pressure is acting
pump pressure is sent from chamber (A) to pres- on the left end of spool (3) of the pressure com-
sure compensation valve spool (3) through its pensation valve, so it pushes against the force of
notch, and then conducted through chamber (B) spring (4) and moves rightward to the maximum
to chamber (C). stroke position.
q The oil in chamber (G) is drained through cham- q At this condition, the area of the opening for
ber (H) to chamber (F). spool (1) of the blade tilt valve is at its minimum.
D375A-6 10-165
(04)
Hydraulic system
Control valve
When set to "HOLD" position (blade tilt cylinder circuit on single tilt specification machine) 10-16
q When the spool is se to "HOLD" position, the

pump pressure is sent from chamber (A) through
chamber (B) to chamber (C).
q Pressure in chamber (H) is drained to chamber
(F).
q At this condition, the area of the opening for
spool (1) of the blade tilt valve is at its minimum.
10-166 D375A-6
(04)
Hydraulic system
Control valve
When set to RIGHT TILT position (blade right tilt cylinder circuit on dual tilt specification machine) 10-16 -1
q When the tilt lever is operated to right tilt posi- q dPLS = differential pressure between ports
tion, pilot pressure (PB1) acts on the right end of (L) and (K) = 1.96 {20 kg/cm2}
spool (1) through the PPC valve. q dPLS' = differential pressure between ports
q when the pressure becomes greater than the set (J) and (D)
force of spring (2), the spool (1) begins to move q dPLS C dPLS'
leftward. It is balanced at a position correspond-
ing to PPC output pressure (PB1.
D375A-6 10-166-1
(04)
Hydraulic system
Control valve
q Chamber (C) and chamber (D) are connected,

and the oil from the pump flows through ports
(A), (B), (C) and (D) to tilt cylinder (6).
q At the same time, the load pressure in chamber
(D) passes through LS orifice (5) and chamber
(H), and is sent to chamber (G). It is also sent
from the LS circuit (O) to pump servo valve (7).
q The condition of the pressure of spool (3) is
chamber (B) pressure C chamber (C) pressure,
and chamber (G) pressure C chamber (D) pres-
sure, so spool (3) is controlled by the differential
pressure of spool (1) (chamber (C) pressure -
chamber (D) pressure), and balances with the
force of spring (4).
q If the oil flow is too large, the differential pressure
of spool (1) becomes larger, so spool (3) moves
in the direction to throttle the oil flow.
q On the other hand, if the oil flow is too small,
spool (3) moves in the direction to increase the
oil flow.
q Pump servo valve (7) is controlled so that the dif-
ferential pressure [LS differentical pressure:
(dPLS)] between pump pressure (P) and LS
pressure (LS) remains constant.
q A suitable amount of oil flows to ensure that the
loss of pressure at the control valve (dPLS') is
equal to (dPLS).
q The loss of pressure in the control valve is deter-
mined by the area of the opening of the main
spool, so the oil flow matches the area of the
opening of the spool.
q The return oil flow from the tilt cylinder passes
through chamber (E) and chamber (F), and is
drained.
10-166-2 D375A-6
(04)
Hydraulic system
Control valve
When set to RIGHT TILT position (blade tilt cylinder circuit on single tilt specification machine) 10-167
q When the tilt lever is operated to right tilt posi- q dPLS = differential pressure between ports
tion, pilot pressure (PB3) acts on the right end of (K) and (J) = 1.96 {20 kg/cm2}
spool (1) through the PPC valve. q dPLS' = differential pressure between ports
q when the pressure becomes greater than the set (H) and (D)
force of spring (2), the spool (1) begins to move q dPLS C dPLS'
leftward. It is balanced at a position correspond-
ing to PPC output pressure (PB3.
D375A-6 10-167
(04)
Hydraulic system
Control valve
q Chamber (C) and chamber (D) are connected,

and the oil from the pump flows through ports
(A), (B), (C) and (D) to tilt cylinder (4).
q Part of the load pressure in chamber (D) is sent
through LS orifice chambers (3) and (G), and
part of it is also conducted through LS circuit (O)
to LS valve (5).
q LS valve (5) is controlled in such that the differ-
ential pressure [LS differential pressure: (dPLS)]
between pump pressure (P) and LS pressure
(LS) becomes constant.
q A suitable amount of oil flows to ensure that the
loss of pressure at the control valve (dPLS') is
equal to (dPLS).
q The loss of pressure in the control valve is deter-
mined by the area of the opening of the main
spool, so the oil flow matches the area of the
opening of the spool.
q The return oil flow from the tilt cylinder passes
through chamber (E) and chamber (F), and is
drained.
10-168 D375A-6
(04)
Hydraulic system
Control valve
When set to relief (blade lift, blade tilt, ripper lift, ripper tilt) 10-169
a The diagram shows the condition when work equipment LS valve (5) is relieved at blade tilt stroke end.
q dP1 = dP3 + dP4 = Differential pressure be- q dP4 = Differential pressure between ports (B)
tween ports (M) and (P) and (P)
q dP2 = Differential pressure between ports (P) q dLS = dP1 + dP2 = Differential pressure be-
and (N) tween ports (M) and (N) = 1.96 {20 kg/cm2}
q dP3 = Differential pressure between ports (M)
and (B)
D375A-6 10-169
(04)
Hydraulic system
Control valve
q If blade tilt valve (1) is moved, and the pressure

of tilt cylinder (8) becomes higher, work equip-
ment LS relief valve (5) will open and oil will be
drained from LS circuit (O).
(Ports (P), (F), (G), (J) and (K))
q As a result, there will be a drop in pressure in LS
passage (O) starting from LS sensing hole (F),
and (dP2) will become larger.
q For the same reason, if the pressure in chamber
(I) and (H) drops, spool (2) will push against
spring (3) and move to the right, and will make
the opening between chambers (B) and (C)
smaller, so the flow between chambers (B) and
(C) will be throttled and (dP4) will become larger.
q Because of the pump swash plate control, the
system circuit is balanced at a circuit pressure
which makes the pressure loss generated by the
flow at work equipment LS relief valve (5) (dP1)
+ (dP2) equal to LS differential pressure (dLS).
q When this happens, pump LS valve (6) detects
the differential pressure generated by LS relief
valve (5), and moves the pump swash plate from
the maximum to the minimum position.
q The swash plate is balanced at a position where
the LS differential pressure is 1.96 {20 kg/cm2}.
q When the pump is at the minimum swash plate
angle (minimum oil flow), if the minimum oil flow
is greater than the LS relief oil flow + leakage at
any part, the pressure resides in the pump circuit
[the pump and chambers (A) and chamber (B)]
through pressure compensation valve (7), so the
differential pressure rises.
q If this differential pressure goes above the set
pressure for unload valve (4), the unload valve is
actuated to relieve the excess oil flow and bal-
ance the circuit.
10-170 D375A-6
(04)
Hydraulic system
Control valve
Pitch system on dual tilt specification machine 10-171

a A dual tilt specification machine is configured with the dual tilt and pitch system circuits.
When single tilt operation is carried out 10-171
q In the single tilt mode, solenoid selector valve (1) q As a result, the right tilt cylinder does not move
is in the neutral position and connected to (PA4) and only the left tilt cylinder moves to carry out
and (PB4) of the control valve as shown in the the single tilt operation.
figure.
q PPC circuits (2) and (3) are separated from out-
put circuits (4) and (5) of the PPC valve.
D375A-6 10-171
(04)
Hydraulic system
Control valve
When dual tilt operation is carried out 10-172
q In the dual tilt mode, the position of solenoid se- q PPC circuit (3) connected to (PA3) of the control
lector valve (1) is changed as shown in the fig- valve is connected to output circuit (5) of the
ure. PPC valve.
q At this time, PPC circuit (2) connected to (PB3) q Accordingly, both tilt cylinders move in the oppo-
of the control valve is connected to output circuit site directions each other to carry out the dual tilt
(4) of the PPC valve. operation.
10-172 D375A-6
(04)
Hydraulic system
Control valve
When pitch operation is carried out 10-172-1
q In the pitch mode, the position of solenoid selec- q PPC circuit (3) connected to (PA3) of the control
tor valve (1) is changed as shown in the figure. valve is connected to output circuit (4) of the
q At this time, PPC circuit (2) connected to (PB3) PPC valve.
of the control valve is connected to output circuit q Accordingly, both tilt cylinders move in the same
(5) of the PPC valve. direction to carry out the pitch operation.
D375A-6 10-172-1
(04)
Hydraulic system
Control valve
10-172-2 D375A-6
(04)
DRAFT
Hydraulic system
Self-pressure reducing valve

General view
P1: From fan pump

P2: To fan motor
PR: To PPC valve and EPC valve, etc.
T: To tank
D375A-6 10-173
DRAFT
Hydraulic system
Sectional view
1. Valve (sequence valve) 6. Screw

2. Spring 7. Poppet
3. Valve (pressure reducing valve) 8. Spring (for pressure reducing valve pilot)
4. Spring (pressure reducing valve main) 9. Spring (safety valve)
5. Filter 10. Ball
10-174 D375A-6
DRAFT
Hydraulic system
Function
q The self-pressure reducing valves reduce the

discharge pressure of the fan pump and supplies
it to the PPC valve, the EPC valve, etc. as the
control pressure.
D375A-6 10-175
DRAFT
Hydraulic system
Operation
At engine stop (both pressure are low)
q Spring (6) pushes the poppet (5) the seat, and

port (PR) is disconnected from port (T).
q Spring (7) pushes the valve (8) to the left, and
port (P1) is connected to port (PR).
q Spring (3) pushes the valve (2) to the left, and
port (P1) is disconnected from port (P2) .
10-176 D375A-6
DRAFT
Hydraulic system
When the load pressure (P2) is lower than the output pressure (PR) of the self pressure reducing valve
q The force of spring (3) and the force of exerted q Therefore, differential pressure is developed
by the (PR) pressure [0MPa {0 kg/cm2} at the across hole (a) in spool (8) to move spool (8) in
time of engine stop] push valve (2) in the direc- the direction to block the opening between ports
tion to block the passage between the ports (P1) (P1) and (PR) . Thus this valve uses the area of
and (P2). When the hydraulic oil enters (P1) port, the opening to regulate pressure (P1) to a cer-
the value balances at a position where the ex- tain level (set pressure) and supplies it as pres-
pression [Force exerted by pressure (P1) C sure (PR).
Force of spring (3) + Force (area (d) × Pressure
(PR) ] holds, and the area of the opening be-
tween ports (P1) and (P2) is adjusted so that
pressure (P1) is maintained higher than pres-
sure (PR) .
q When the (PR) pressure rises above set pres-
sure, the poppet (5) opens and the hydraulic oil
flows through the route, from (PR) port, through
hole (a) in the spool (8), through the opening of
the poppet (5) , through to the tank port (T).
D375A-6 10-177
DRAFT
Hydraulic system
When load pressure (P2) is high
q When load pressure (P2) rises due to digging or q Therefore, differential pressure is developed
other operations, pump delivery increases and across hole (a) in spool (8) to move spool (8) to
pressure (P1) rises. When the expression {Force block the opening between ports (P1) and(PR) .
exerted by pressure (P1) > Force of spring (3) + Thus this valve uses the area of the opening to
Force [area (d) × pressure (PR)]} holds, and regulate pressure (P1) to a certain level (set
valve (2) moves downward to its stroke end. As pressure) and supplies it as pressure (PR).
a result, the opening between the ports (P1) and
(P2) increases, the passage resistance be-
comes smaller to reduce engine horsepower
loss.
q When pressure (PR) rises above the set pres-
sure, poppet (5) opens and hydraulic oil flows
through the route, from port (PR) , through hole
(a) in spool (8), and the opening of poppet (5) to
the tank port (T).
10-178 D375A-6
DRAFT
Hydraulic system
When abnormally high pressure is generated
q When the (PR) pressure of the self-pressure re-

ducing valve rises abnormally high, the ball (10)
separates from the seat against the spring (9) to
allow the oil from port (PR) to flow to port (T) so
as to reduce the pressure (PR). As a result, the
equipment (PPC valve, solenoid valve, etc.), to
which the oil pressure is supplied, is protected
from the abnormal high pressure.
D375A-6 10-179
DRAFT
Work equipment
Cylinder stay
Work equipment
Cylinder stay
1. Yoke
2. Oil seal
3. Bushing
4. Bushing
10-180 D375A-6
DRAFT
Cab and its attachments
Cab mount

Cab mount
1. Support Outline
2. Damper mount (front) q The cab mounts are installed at two places in the
3. Damper mount (rear) front section and at two places in the rear section
of the floor frame to secure the cab to the floor
frame.
q Oil-filled cab mounts are used to absorb vibra-
tion.
D375A-6 10-181
DRAFT
Cab
Cab
Cab assembly
1. Front wiper
2. Front glass
3. Rear wiper
4. Door
10-182 D375A-6
DRAFT
Cab
ROPS
1. ROPS
D375A-6 10-183
DRAFT
Electrical system
Engine control
Electrical system
Engine control
1. Decelerator pedal Outline

2. Deceleration potentiometer q The throttle signal of the fuel control dial is input
3. Starting switch to the power train controller and processed to-
4. Work equipment controller gether with the other information, then the result
5. Power train controller is sent as the throttle command to the engine
6. Fuel control dial controller. The engine controller controls the fuel
7. Battery supply pump according to the command.
8. Circuit breaker
9. Battery relay
10. Starting motor
11. Engine controller
12. Alternator
10-184 D375A-6
DRAFT
Electrical system
Engine control system
Outline q The information of the engine controller is pos-

q The engine throttle controller receives the fuel sessed jointly by the other controllers through
control dial signal of the 1st throttle, decelerator the network and used for the optimum control of
pedal signal of the 2nd throttle, and 3rd throttle the engine and power train.
signal which is the control signal from the power q The automatic deceleration is a function of low-
train controller, and then controls the fuel supply ering the engine speed temporarily when the
pump according to the command signal having travel direction is changed from F3, R3, F2 or R2
the lowest engine speed. (for protection of the transmission clutch).
The control signals of the 3rd throttle are as
follows.
1) Automatic-deceleration (F3, R3, F2, R2)
2) Neutral deceleration
3) Shoe slip control (if equipped)
q The power train controller calculates a proper
engine speed from information items (1), (2), etc.
and sends it as the 3rd throttle signal to the en-
gine throttle controller.
D375A-6 10-185
DRAFT
Electrical system
Engine controller
Outline
Engine controller mounted on engine
q Since the engine controller is mounted on the
engine, it is easy to be maintained.
q In order to secure the reliability of mounted en-
gine controller, engine controller cooler is in-
stalled to cool the engine controller by fuel.
q Rubber vibration isolator reduces vibration.
Common engine controller
q The common engine controller CM850 is adopt-
ed which is co-developed by Komatsu and Cum-
mins.
10-186 D375A-6
DRAFT
Electrical system
q Meanings of signal classes in the terminal table CN-CE01

shown below are as follows.
Pin No. Signal name Input/output
A: Power supply
B: Input 37 Sensor power source (5 V) A
C: Ground/Shield/Return 38 GND C
D: Output 39 NC (*) -
E: Communication
40 NC (*) -
CN-CE01 41 NC (*) -
Pin No. Signal name Input/output 42 NC (*) -

1 NC (*) - 43 NC (*) -
2 NC (*) - 44 Boost pressure sensor D
3 Ambient pressure sensor D 45 Injector #1 (+) B
4 Supply pump #1 (+) B 46 Injector #5 (+) B
5 Supply pump #1 (–) C 47 Sensor GND C
6 CAN (-) C 48 Ne sensor (–) C
7 NC (*) - 49 NC (*) -
8 CAN(+) B 50 NC (*) -
9 Supply pump #2 (+) B 51 Injector #2 (–) C
10 Supply pump #2 (–) C 52 Injector #3 (–) C
11 EGR valve (–) C 53 Injector #1 (–) C

12 NC (*) - 54 Injector #2 (+) B
13 Engine oil pressure sensor D 55 Injector #3 (+) B
14 NC (*) - 56 Injector #4 (+) B
15 Coolant temperature sensor D 57 Injector #6 (+) B
16 Sensor power source (5 V) A 58 Injector #4 (–) C
17 Engine oil temperature sensor D 59 Injector #6 (–) C
18 NC (*) - 60 Injector #5 (–) C
19 EGR valve position sensor D *: Never connect to NC, or malfunctions or failures
20 NC (*) - will occur.
21 NC (*) -
22 EGR valve (+) B
23 Boost temperature sensor D
24 NC (*) -
25 Common rail pressure sensor D
26 BKup sensor (+) D
27 NE sensor (+) D
28 NC (*) -
29 Bypass valve position sensor B
30 Fuel temperature sensor D
31 Bypass valve (+) D
32 NC (*) -
33 Sensor power source (5 V) A
34 NC (*) -
35 NC (*) -
36 NC (*) -
D375A-6 10-187
DRAFT
Electrical system
CN-CE02 CN-CE02
Pin No. Signal name Input/output Pin No. Signal name Input/output
1 NC (*) - 43 NC (*) -
2 NC (*) - 44 NC (*) -
3 NC (*) - 45 NC (*) -
4 NC (*) - 46 CAN(+) E
5 NC (*) - 47 CAN (-) E
6 NC (*) - 48 NC (*) -
7 NC (*) - 49 NC (*) -
8 NC (*) - 50 NC (*) -
9 Decelerator signal B *: Never connect to NC, or malfunctions or failures
10 NC (*) - will occure.
11 NC (*) -
CN-CE03
12 NC (*) - Pin No. Signal name Input/output
13 NC (*) - 1 GND C
14 NC (*) - 2 GND C
15 NC (*) - 3 Power source (+24 V constant) A
16 NC (*) - 4 Power source (+24 V constant) A
17 NC (*) - *: Never connect to NC, or malfunctions or failures
18 NC (*) - will occur.
19 NC (*) -
20 NC (*) -
21 NC (*) -
22 Sensor power source (5 V) A
23 GND C
24 NC (*) -
25 NC (*) -
26 NC (*) -
27 NC (*) -
28 NC (*) -
29 NC (*) -
30 NC (*) -
31 NC (*) -
32 NC (*) -
33 GND C
34 NC (*) -
35 NC (*) -
36 NC (*) -
37 CAN shield C
38 NC (*) -
39 Key switch (ACC) B
Electrical intake air heater relay
40 D
(+)
41 NC (*) -
Electrical intake air heater relay
42 C
return
10-188 D375A-6
DRAFT
Electrical system
Sensors
Fuel temperature sensor

q The fuel temperature sensor senses the fuel
temperature and sends it to the engine control-
ler. The sensor unit is a thermistor the resistance
of which changes according to the temperature.
q The engine controller applies voltage to the
thermistor and senses the temperature by the
voltage divided by the resistance in the comput-
er and the resistance of the thermistor.
D375A-6 10-189
DRAFT
Electrical system
EGR valve position sensor

q This sensor senses the opening and closing positions of the EGR valve .
q The following graph shows the output character-

istics of the position sensor.
10-190 D375A-6
DRAFT
Electrical system
NE speed sensor (Crank angle sensor) Bkup speed sensor (G sensor)

q If the signal hole made on the flywheel passes (Cylinder No. sensor)
the sensor, the magnetic line of force changes. q Similarly to the NE speed sensor, this sensor uti-
q If the magnetic line of force changes, the output lizes the pulses of 0 – 5 generated by the change
of the Hall element sensor changes linearly and of the magnetic line crossing the sensor unit.
it is converted into pulse of 0 – 5 by the wave q The disc gear installed to the central part of the
form shaping circuit in the sensor, and then out- camshaft of the high-pressure pump has teeth
put. (cut parts) around it at intervals of 60 °.
q In addition to the above teeth, one more tooth is
installed. Accordingly, 7 pulses are generated
every 2 revolutions of the engine.
q The standard pulse of the No. 1 cylinder is rec-
ognized by the combination of the NE speed
sensor pulse and Bkup speed sensor pulse.
Ambient pressure sensor

q This sensor is used to correct altitude.
Oil pressure sensor
D375A-6 10-191
DRAFT
Electrical system
Boost temperature sensor Coolant temperature sensor

q The boost temperature sensor senses the intake q The coolant temperature sensor senses the
air temperature (boost temperature) and sends it coolant temperature and sends it to the engine
to the engine controller. controller.
q The sensor unit is a thermistor the resistance of q The sensor unit is a thermistor the resistance of
which changes according to the temperature. which changes according to the temperature.
The engine controller applies voltage to the The engine controller applies voltage to the
thermistor and senses the temperature by the thermistor and senses the temperature by the
voltage divided by the resistance in the comput- voltage divided by the resistance in the comput-
er and the resistance of the thermistor. er and the resistance of the thermistor.
10-192 D375A-6
DRAFT
Electrical system
Deceleration potentiometer
1. Connector Outline
2. Lever q The deceleration potentiometer is installed to the
3. Body front lower part of the operator's cab and con-
4. Potentiometer nected to the decelerator pedal by linkage.
5. Coupling
6. Shaft q When the decelerator pedal is depressed, the
7. Stopper throttle potentiometer shaft is rotated by the link-
age and the potentiometer resistance changes.
Constant voltage is applied between pins (A)
and (C) of the potentiometer and an electric
signal is sent through pin (B) to the engine
controller according to the position of the decel-
erator pedal.
D375A-6 10-193
DRAFT
Electrical system
CRI engine control system
a "CRI" is an abbreviation for Common Rail Injection.
System diagram
10-194 D375A-6
DRAFT
Electrical system
1. NE speed sensor System configuration

2. Engine throttle controller
3. Injector assembly q The CRI system consists of fuel supply pump
3A. Orifice (9), common rail (10), injectors (3), engine throt-
3B. Control chamber tle controller (2) to control them, and sensors.
3C. Hydraulic piston q The fuel supply pump generates fuel pressure in
3D. Injector the common rail. The fuel pressure is controlled
3E. Nozzle by the fuel delivery from the supply pump. The
4. Orifice (for air bleeding) discharge rate is controlled by turning on and off
5. Fuel tank PCV (discharge control valve) (9A) of the fuel
6. Pre fuel filter supply pump according to the electric signals
7. Main fuel filter from the engine throttle controller.
8. Overflow valve The common rail receives the pressurized fuel
9. Fuel supply pump from the fuel supply pump and distributes it to
9A. PCV the cylinders.
9B. High pressure pump The fuel pressure is sensed by the common rail
9C. Priming pump fuel pressure sensor installed to the common rail
9D. Feed pump and controlled by the feedback method so that
9E. Bkup speed sensor (G sensor) the actual fuel pressure corresponds to the
10. Common rail command pressure set according to the engine
11. High pressure injection pipe speed and the load on the engine.
12. Flow damper The fuel pressure in the common rail is applied
13. Pressure limiter to the nozzle (3E) and control chamber (3B) of
14. Electric priming pump the injector through the high-pressure fuel pipe
15. Engine throttle controller cooler of each cylinder.
q The injector controls the fuel injection rate and
Outline fuel injection timing by energizing and de-ener-
q The signals detected by various sensors are in- gizing the TWV (2-way solenoid valve). If the
put to the engine controller. TWV is energized, the fuel circuit is so changed
q The engine controller processes input signals that the high-pressure fuel in the control cham-
and output command signals to each actuator to ber flows out through orifice (3A). As the result,
control the fuel injection rate and fuel injection the force exerted by the pressure of the
timing. high-pressure fuel on the nozzle side raises the
needle valve to start fuel injection. If the TWV is
de-energized, the fuel circuit is so change that
the pressure of the fuel applies to the control
chamber through the orifice. As a result, the nee-
dle valve lowers and finishes fuel injection. Ac-
cordingly, the fuel injection timing and fuel
injection rate are controlled respectively by the
timing to energize the TWV and the duration of
energizing the TWV.
D375A-6 10-195
DRAFT
Electrical system
Monitor system
Monitor system
q The monitor system monitors the machine con-

dition with the sensors installed to various parts
of the machine and processes and displays the
obtained information on the monitor panel quick-
ly to notify the operator of the machine condition.
The main display sections and functions of the
panel are as follows.
1. Monitor unit which turns on the alarm when the

machine has a trouble.
2. Gauge unit which constantly displays the
machine condition (coolant temperature, torque
converter oil temperature, fuel level, etc.)
3. Function of displaying error codes.
4. Function of monitoring the current and voltage of
the sensors and solenoids,
q The CPU (Central Processing Unit) in the moni-

tor panel displays and outputs various informa-
tion processed by the power train controller. The
display unit is LCD (Liquid Crystal Display)
10-196 D375A-6
Electrical system
Monitor system
Processing on machine monitor (common to all specifications) 10-197
Display of machine monitoer

Contents and conditions of processing Method Flow of signals
1. Display of travel direction and gear speed.
q F1, R3, etc. are notified by CAN according to information of power train CAN
controller.
2. Display of gauges of fuel level, engine coolant temperature, etc.
q Controller converts the sensor signals into gauge numbers and sends CAN
them to the machine monitor by CAN.
3. Display of problem
Each sensor, solenoid
q When the machine has a trouble, the corresponding failure code is noti-
O
fied to the machine monitor through CAN signal.
Controller
q The command to sound the buzzer or to light up the caution lamp is no-
O
tified, too.
Machine monitor
1) In standard screen
CAN
Action code, failure code
2) In abnormality record screen
The failure code (6-digit code) and the following items are displayed
q SMR at first occurrence
q SMR at latest occurrence
q Number of past occurrences
Display of monitoring condition

1. The communication conditions of each sensor, each solenoid, and CAN
are displayed. Each sensor
q The item Nos. and device conditions are notified to the machine monitor CAN O
by CAN. Controller
q The machine monitor displays the items and each value. O
2. Each items is selected by using the cursor switches and confirmation Machine monitor
CAN
switch.
Other items
1. Monitoring
2. Abnormality record
3. Maintenance record
4. Maintenance mode change
5. Phone number setting
6. Default
7. Adjustment
8. PM clinic
9. Cylinder cutout mode operation – –
10. No injection cranking
11. Fuel consumption display
12. Load memory display
13. VHMS setting
14. Snap shot
86. Setting of shoe slip control (if equipped)
87. Setting of pre-lubrication
88. Screen adjustment a
a Since this item is included in the service menu, it is not usually displayed.For details of the operating meth-
od, see "Special functions of monitor panel (EMMS)" section of Testing and adjusting.
D375A-6 10-197
(04)
DRAFT
Electrical system
Machine monitor
Machine monitor
Outline Precautions on the machine monitor display

q The machine monitor has the display function, q The liquid crystal display panel may have black
mode selection function and switch function for spots (which do not light up) or bright spots
electrical parts. (which stay on). Products having 10 or less black
q The machine monitor has a CPU (Central Pro- or bright spots conform the product specification;
cessing Unit) in it to process, display, and output such the condition is quite normal.
the information. q When the engine is started, the battery voltage
q The monitor display employs an LCD (Liquid may suddenly drop depending on the tempera-
Crystal Display). The switches are flat sheet ture and the battery condition. If this happens,
switches. the display on the machine monitor may momen-
tarily go out, but this does not indicate any ab-
normality.
q Continuous operation of the machine monitor
may display blue bright spots on the screen hav-
ing a black background; it is quite normal.
The screen normally displayed on the monitor
has a blue or white background. For this reason,
blue spots will not cause any problem (since the
liquid crystal lights up red, blue, and green spots
when displaying white).
10-198 D375A-6
DRAFT
Electrical system
Machine monitor
Input and output signals
CN-CM01 CN-CM03
Input/out Input/out
Pin No. Signal name Pin No. Signal name
put put
1 Battery power (+24 V constant) Input 1 RS232C CD for communication terminal Input
2 Battery power (+24 V constant) Input 2 RS232C RXD for communication terminal Input
3 Battery power GND - 3 RS232C SG for communication terminal -
4 Battery power GND - GND for communication terminal control sig-
4 -
Input/out nal
5 Wake-up
put 5 Communication terminal selection signal Input
6 Relay output Output 6 RS232C RTS for communication terminal Output
7 Chassis signal GND - 7 RS232C TXD for communication terminal Output
8 Hydraulic oil pressure - 8 RS232C DTR for communication terminal Output
9 Fuel level Input 9 RS232C DSR for communication terminal Input
10 NC (*) - 10 RS232C CTS for communication terminal Input
11 Battery charge Input 11 RS232C RI for communication terminal Input
12 Chassis analog signal GND - 12 GND for communication terminal power -
13 Light switch Input 13 Input CH1 for communication terminal status Input
14 Key switch (ACC) Input Output for communication terminal power
14 Output
15 Key switch (C) Input control
16 Preheating Input Output CH1 for communication terminal con-
15 Output
17 NC (*) - trol
18 NC (*) - Output CH2 for communication terminal con-
16 Output
trol
*: Never connect to NC, or malfunctions or failures 17 Input CH2 for communication terminal status Input
will occur. 18 Power supply for communication terminal Output
CN-CM02
Input/out CN-CM04
Pin No. Signal name Input/out
put Pin No. Signal name
1 NC (*) - put
2 NC (*) - 1 NC (*) -
3 Coolant level sensor Input 2 NC (*) -
4 NC (*) - 3 NC (*) -
5 NC (*) - 4 NC (*) -
6 NC (*) - 5 NC (*) -
7 Chassis signal GND - 6 NC (*) -
8 CAN terminating resistance - 7 NC (*) -
Input/out 8 NC (*) -
9 COMM_CAN_H_0 9 NC (*) -
put
10 NC (*) -
Input/out
10 COMM_CAN_L_0 11 NC (*) -
put
12 NC (*) -
11 NC (*) -
12 NC (*) - *: Never connect to NC, or malfunctions or failures
*: Never connect to NC, or malfunctions or failures will occur.
will occur.
CN-CM05
Input/out
Pin No. Signal name
put
1 Power supply for camera Output
2 Camera NTSC signal input 1 Input
5 Electric power supply GND for camera -
6 Camera signal GND1 -
D375A-6 10-199
DRAFT
Electrical system
Machine monitor
Monitor control portion
1. Gearshift mode selector switch 9. Fuel level gauge

2. Buzzer cancel switch 10. Gearshift mode and preset gearshift pattern
3. Operation mode switch 11. Guidance icon
4. Engine coolant temperature gauge 12. Function switch
5. Multi gauge 13. Customization switch
6. Pilot display 14. Customization memory switch
7. Service meter/clock
8. Mode display
10-200 D375A-6
Electrical system
Machine monitor
Machine monitor display 10-201

Display
Symbol Display item Contents Description
category
Displays when engine is stopped and
starting switch is set to ON position
Radiator coolant level Below "low" line
Display when normal: OFF
Display when abnormal: ON
When sensor is abnormal or

Display when normal: OFF
Oil pressure when wiring harness is dis-
connected
Displays when starting switch is set to

ON position and engine is running
Check
Battery charge condi-

When charge is defective Display when normal: OFF
tion
Display when abnormal: ON CAU-
TION lamp flashes
Displays when starting switch is
turned to ON position with engine
Engine oil level (if Lights up at low level or
stopped.
equipped) below
Display when abnormal: OFF Display
when normal: ON
Displays when starting switch is
turned to ON position with engine
Hydraulic oil level (if Lights up when oil level is
stopped.
equipped) below suction limit
Display when normal: ON Display
when abnormal: OFF
D375A-6 10-201
(04)
Electrical system
Machine monitor
Display
category
Lights when it becomes 49.0

Oil pressure
kPa {0.5 kg/cm2} and below
Lights when it becomes 7.8 V

Battery charge condi-
and below while engine is
tion
running
Lights when it becomes

Radiator coolant level
below "low" line
Engine coolant temperature

When highest gauge seg-
Engine coolant tem- ment is;
perature Above 102 °C: Symbol ON
Above 105 °C: Symbol ON +
buzzer sounds
Torque converter oil temper-
ature
Displays when starting switch is set to
When highest gauge seg-
Cautions
Torque converter oil ON position and engine is running

ment is;
temperature Display when normal: OFF
Above 120 °C: Symbol ON
Alarm buzzer sounds
buzzer sounds
Above 100 °C: Symbol ON

Hydraulic oil tempera-
ture
buzzer sounds
Lights up for 30 seconds

after starting key is turned to
ON position
Lights up in yellow from 30h
Maintenance
before the filter and oil
replacement time, and lights
up in red if replacement time
expires
Lights up when -7,470 ± 490

Air cleaner clogging Pa {-762 ± 50 mmH2O} is
reached.
Hydraulic oil level (if Lights up when oil level is

equipped) below suction limit
Lights according to required time

determined by engine controller.
It also lights up at the time of manual
Pilot
Preheating When preheating

preheat by setting the starting switch
at the preheat position (turning the
switch counterclockwise).
10-202 D375A-6
(04)
Electrical system
Machine monitor
Display
category
Engine coolant tem-

perature
Torque converter oil

Reads the temperature
temperature
Gauge

ture
Fuel level Reads the level
Service meter (Hours Progresses when the engine is run-

From 0 to 99999
meter) ning
D375A-6 10-203
(04)
Electrical system
Machine monitor
Gauge 10-204
The gauge pointer disappears when information on coolant temperature or hydraulic oil temperature cannot
be obtained due to disconnection of CAN.
Gauge Range Temperature or volume Indicator Buzzer sounds.
A1 105 Red Q
Engine coolant tem- A2 102 Red
A3 100 Off
perature
A4 85 Off
(°C)
A5 60 Off
A6 30 White
B1 130 Red Q
Power train oil temper- B2 120 Red
B3 118 Off
ature
B4 90 Off
(°C)
B5 50 Off
B6 0 White
C1 110 Red Q
Hydraulic oil tempera- C2 100 Red
C3 98 Off
ture
C4 70 Off
(°C)
C5 20 Off
C6 0 White
D1 1000 Off
D2 755 Off
Fuel level D3 550 Off
(l) D4 395 Off
D5 275 Off
D6 145 Red
10-204 D375A-6
(04)
Electrical system
Machine monitor
Machine speed 10-205 Battery voltage 10-205
1. 0 km/h 3. 10 km/h 1. 0 V 4. 25 V
2. 5 km/h 4. 15 km/h 2. 17 V 5. 30 V
3. 20 V 6. 31 V
Hydraulic pump oil pressure 10-205 Engine speed 10-205
1. 0 MPa 4. 30 MPa 1. 500 rpm 4. 2000 rpm

2. 10 MPa 5. 40 MPa 2. 1000 rpm 5. 2500 rpm
3. 20 MPa 6. 50 MPa 3. 1500 rpm 6. 3000 rpm
Engine oil pressure 10-205 Drawbar pull 10-205
1. 0 MPa 4. 0.4 MPa 1. 0 W 4. 0.6 W

2. 0.2 MPa 5. 0.5 MPa 2. 0.2 W 5. 0.8 W
3. 0.3 MPa 6. 0.7 MPa 3. 0.4 W 6. 1.0 W
D375A-6 10-205
(04)
Electrical system
Machine monitor
Guidance icon and function switch 10-206

The function of the function switches differ depending on the screen display. Each guidance icon shows the
function of the switch below it.
Switches with no guidance icon are disabled.
The functions shown by the guidance icons are as shown in the table below.
Switch
Symbol Item Function
power
F6 Enter Enters selected/set item.
F5 Return Returns to previous screen or condition.
F4 Select service meter/clock Switches service meter and clock display alternatively.
Selection of maintenance
F5 Switches to Maintenance List screen.
screen
F6 Select user mode screen Switches to Use Menu screen.
Selects item on left side (Selects right end item after left end
F3 Select item
item).
Selects item on right side (Selects left end item after right end
F4 Select item
item).
Selects item on lower side (Selects top item after bottom

F3 Select item
item)/Resets holding of monitoring.
Selects item on upper side (Selects bottom item after top

F4 Select item
item)/Holds monitoring.
Displays next page for selection (Selects top page after last
F1 Select item
page).
Displays previous page for selection (Selects last page after

F2 Select item
top page).
Returns selected item to default setting. (Used for screen

F2 Return to default setting
adjustment.)
Starts operation. (Used to start measurement of split fuel con-

F1 Start
sumption on fuel consumption display screen.)
Stops operation. (Used to stop measurement of split fuel con-

F1 Stop
sumption on fuel consumption display screen.)
F1/F2 Clear Clears selected / displayed item
F1 Set Executes setting
F2 Change of multi-gauge Changes display item for multi gauge
10-206 D375A-6
(04)
Electrical system
Machine monitor
Service meter and clock switching function10-207 Maintenance reminder function 10-207
Pressing F4 on the standard screen when the ser- Pressing F5 on the standard screen switches to the
vice meter is displayed in the top center of the Maintenance List screen.
screen switches the display to the clock, and doing
so when the clock is displayed switches the display
to the service meter.
F1: Displays the next page.

Displays the top page when the last page is dis-
played.
F2: Displays the previous page.
Displays the last page when the top page is dis-
played.
F3: Selects (highlights) an item one down.
F4: Selects (highlights) an item one up.
F5: Returns to the standard screen.
F6: Hold down the button to switch to the Mainte-
nance Time Reset screen.
No operation at least 30 sec.: Returns to the stan-
dard screen.
q On the Maintenance List screen, if the time re-
maining until maintenance for any item is less
than thirty hours, the remaining time display is
highlighted in yellow. If the time remaining until
maintenance becomes 0 hours, the remaining
time display is highlighted in red.
q On the Maintenance Time Reset screen, the re-
maining time for the selected item can be reset
and returned to the default.
D375A-6 10-207
(04)
Electrical system
Machine monitor
F5: Cancels the reset to return to the Maintenance q The defailt password is “000000”.
List screen. q Enabling the password lock on an attachment-
F6: Resets the remaining time and returns to the equipped machine locks the attachment setting
standard screen. screen at the same time.
No operation at least 30 sec.: Returns to the stan- a For information on changing the maintenance
dard screen. password, see "Function of changing mainte-
nance password" of "Testing and adjusting".
q The table below shows the maintenance items
and replacement intervals.
The time remaining to maintenance is reduced
as the machine is operated.
Replacement interval
No. Item
(Hours)
01 Engine oil 500
02 Engine oil filter 500
03 Fuel main filter 500
41 Fuel pre-filter 500
04 Hydraulic oil filter 2000
07 Damper case oil 2000
08 Finaldrive case oil 2000
10 Hydraulic oil 2000
19 P/L oil 1000
20 P/L oil filter 500
P/L: Power train
q The display of the maintenance monitor differs

according to the remaining time. The relation-
ship is as shown in the table below.
Display Condition
Remaining time for maintenance
Not displayed for all items is more than 30
hours.
Notice display (black There is one or more items with
symbol on yellow less than 30-hour remaining time
background) for maintenance.
Warning display There is one or more items with
(white symbol on red less than 0-hour remaining time
background) for maintenance.
q To prevent careless reset of the maintenance in-

terval, the screen is password protected.
10-208 D375A-6
(04)
Electrical system
Machine monitor
User mode 10-209

q Pressing F6 on the standard screen enters the
user mode, switching to the User Menu screen.
q In user mode, you can perform setting for items
relating to the machine monitor and machine
shown below.
Utility screen select
Multi-gauge
Screen adjustment
Time adjustment
Language setting
Reverse-interlok Enabled Mode (When cam-
era is set)
Fan reverse mode
Normal 10-209
Skipping pre-lubrication
q The standard screen is displayed.
Load display 10-209
q The horizontal axis indicates the time and the
vertical axis indicates the drawbar pull. The ma-
chine should be operated with the drawbar pull
kept in the green range.
q The graph on the screen is updated and scrolled
to the left at intervals of several seconds.
Body pitch display 10-209

q The horizontal axis indicates the time and the
vertical axis indicates the pitch angle of the body.
q The graph on the screen is updated and scrolled
to the left at intervals of several seconds.

F5: Returns to the normal screen.
F6: Switches to the setting screen for the selected
item.
No operation at least 30 sec.: Returns to the stan-
dard screen.
(In user mode, no switch operation at least 30 sec.
returns to the previous screen.)
Utility screen select 10-209

q If Utility Screen Select is selected with switch F6,
(1) Standard Display, (2) Load Display, or (3)
Body Pitch Display can be selected.
Multi gauge select 10-209
q Select the desired item with switch F3 or F4 and
q On this screen, the display item assigned to the
enter that item with switch F6.
gauge at the center can be selected.
D375A-6 10-209
(04)
Electrical system
Machine monitor
q Select desired item with switch F3 or F4 and en- F2: Returns all adjusted values to the defaults.
ter that item with switch F6. F3: Decreases the value indicated by the indicator
one graduation left.
F4: Increases the value indicated by the indicator
one graduation right.
F5: Cancels changes you made before entering
them with F6 and returns to the User Menu screen.
F6: Enter the changes and moves to the next item.
q For machines equipped with a camera, the
brightness, contrast, and illuminance of the cam-
era screen are also adjustable.
q Select Screen Adjustment from the User Menu
screen to switch to the screen for selecting a
camera screen you want to adjust.
q The following items can be selected.

Sellectable item for multi gauge
No. Selected item Remarks
1 PL oil temperature With caution
2 With caution
ture
3 Vehicle speed -
Hydraulic pump pres-
4 -
sure
5 Engine oil pressure With caution
6 Battery voltage -
7 Engine speed -
8 Traction force -
9 Clock - F3: Selects (highlights) an item one down.
Engine coolant temper-
10 For Utility Screen Select F4: Selects (highlights) an item one up.
ature
11 Fuel level For Utility Screen Select F5: Cancels changes you made before entering
F6: Moves to the setup screen of the selected (high-
Screen adjustment 10-210 lighted) item.
q Selecting the Screen Adjustment on the User q The adjustment methods for the camera screen
Menu screen and pressing F6 switches to the and standard screen are the same.
Screen Adjustment screen. q The background when adjusting the camera
q From this menu, you can adjust the brightness, screen is the No.1 camera image.
contrast, and luminance of the machine monitor
screen.
q When the light switch is set to "Night mode ON",
the night mode screen is adjustable.
q When the light switch is set to "Daytime mode
ON" or OFF, the daytime mode screen is adjust-
able.

F5: Cancels changes you made before entering
F6: Enter the changes and moves to the next item.
10-210 D375A-6
(04)
Electrical system
Machine monitor
Clock adjustment 10-21 F5: Cancels change you made before

q Select the Clock Adjustment on the User Menu entering them with F6 and returns to the User
screen and press F6 to switch to the Clock Ad- Menu screen.
justment screen. F6: Enters the changes and moves to the
q On this screen, you can change the setting of the Time setting.
time displayed on the standard screen.
a Summer time (daylight saving time) is a
system to lead a life according to the
one-hour advanced time in order to make
efficient use of daylight time.
Language setting 10-21

q Select the Language on the User Menu screen
and press F6 to switch to the Language setting
screen.
q From this menu, you can change the language to
be displayed on the monitor. Available languag-
es are as follows.
English, Japanese, Chinese, French, Spanish,
Portuguese, Italian, German, Russian, and
1) Time setting
Turkish
Adjust the clock time. If the item of Time is
not highlighted, press F6 to highlight it.
The hour display part is highlighted.
F3: Advances the hour display one hour.
F4: Sets the hour display back one hour.
F5: Cancels change you made before
entering it with F6 and returns to the User
Menu screen.
F6: Enters the change and moves to minute
setting.
The minute display part is highlighted.
F3: Advances the minute display one
minutes.
F4: Set the minute display back one minutes.
F5: Cancels the change you made before F3: Selects (highlights) an item one down.
entering it with F6 and returns to the User F4: Selects (highlights) an item one up.
Menu screen. F5: Cancels the change and returns to the User
F6: Enters the change and moves to the Menu screen.
12/24 Mode setting. F6: Enters the change to return to the User Menu
screen.
2) 12h/24h Mode
Specify 12-hour clock (AM/PM) or 24-hour
clock for time display. If the item of "12h/24h
Mode " is not highlighted, press F6 to high-
light it.
F3: Moves to the item one right.
F4: Moves to the item one left.
F5: Cancels the change you made and
returns to the User Menu screen.
F6: Enter the change and moves to Daylight
Saving Time setting.
3) Daylight Saving Time
Selecting ON for this sets the time forward 1
hour. Setting OFF returns to the ordinary
time.
F3: Moves to the item one right.
F4: Moves to the item one left.
D375A-6 10-211
(04)
Electrical system
Machine monitor
Setting of camera for reverse-interlock enabled mode

(applied to machines equipped with rear view cam-
era) 10-212
q When reversing the machine, the image of rear
view camera can be displayed on the multi mon-
itor.
q Turn "ON" the starting switch, select "Pre-lubri-
cation Skip Mode" on the screen (A) with F3 or
F4 key, then fix it with F6 key.
q Select "camera 1 or 2, 3, 1+2" with F3 or F4 key
while the screen (B) is displayed.
a If the connected camera is only one, "camera 1"
is only displayed on the menu.
q The selected camera is set by pushing F6 key,
and return to the screen (A).
q When shifting the travel lever to reverse, the
multi display switches to a view from camera
(screen (C) o(D))
q Function of the function keys

F5: Return to former screen.
F6: Fix the selection.
a The setting whether cameras are installed or not

can be done on the service menu.
Only the cameras set on the service menu are
available.
a This function is still available even though the
mode is terminated.
a While the view from camera is displayed, trav-
el/work equipment lock monitor is displayed on
the upper left of the screen (a), gear speed and
gearshift working mode etc. are displayed under
right of the screen (b) (screen (D)).
a The view range of camera is limited. Watch out
rear side carefully when traveling reverse.
a For safe reverse traveling, be careful to check
the rear side by using brake and deceleration
pedal.
10-212 D375A-6
(04)
Electrical system
Machine monitor
Fan reverse mode 10-213

q In this mode, the fan can be set to drive in re-
verse to clean the radiator core.
q While the starting switch is set to OFF, select the
menu with switch F3 or F4 and enter it with
switch F6.
q While screen (A) is displayed, press switch F6,
and the fan is ready to run in reverse.
q While screen (B) is displayed, start the engine.
Precautions for using fan reverse mode 10-213

q The rotation direction of the fan cannnot be
changed while the engine is running.
q When running the fan in reverse, set the lock le-
ver to the LOCK position.
q While the fan is running in reverse, the machine
cannot travel.
q When canceling the reverse mode, set the start-
ing switch to OFF position to stop the engine.
q When using this mode, warm up the engine suf-
ficiently. If the engine is not warmed up, the fan
may not supply sufficient air.
D375A-6 10-213
(04)
Electrical system
Machine monitor
Pre-lubrication skip mode (applied to machines Function of checking service meter 10-214
equipped with pre-lubrication) 10-214 q If you continuously pressing working mode se-
q This mode is used for starting engine without ac- lector switch (1) and buzzer cancel switch (2) at
tivating pre-lubrication. the same time when setting the starting switch to
q Turn "ON" the starting switch, select The item on the OFF position, the service meter will appear
the screen (A) with F3 or F4 key while engine is on the screen in 3 to 5 seconds.
not started, then fix it with F6 key.
q Press F6 on screen (B) to complete pre-lubrica-
tion skip.
After setting the mode, the display returns to
user menu automatically.
q Setting the starting switch to "START" position
initiates the starter rotation and starts up the en-
gine without turning on the pre-lubrication oper-
ation.
q When these switches are released, the LCD

goes out.
a Continuous operation of the machine monitor
may display blue bright spots on this screen; it is
quite normal.
10-214 D375A-6
(04)
Electrical system
Machine monitor
Function of checking display LCD 10-214-1

q Continuously pressing the buzzer cancel switch
(1) and F2 at the same time on the standard
screen causes all the LCD elements to light in
white. Release F2 and buzzer cancel switch in
order.
q One of the features of liquid crystal display panel
is that there may be black spots (spots that do
not light up) or white spots (spots that stay lit up)
on the screen. If there are fewer than ten black
or white spots, the monitor is normal.
q Pressing any function switch returns to the pre-

vious screen.
D375A-6 10-214-1
(04)
Electrical system
Machine monitor
10-214-2 D375A-6
(04)
DRAFT
Electrical system
Lamp system
Lamp system
Operation
Relate electric circuit diagram
D375A-6 10-215
DRAFT
Electrical system
Engine preheat (electrical intake air heater) control
Engine preheat (electrical intake air heater) control

Operation
Relate electric circuit diagram
10-216 D375A-6
DRAFT
Electrical system
Palm command control system
1. Machine monitor (Multi-information)

2. Gearshift mode switch
4. Power train controller
5. Engine speed sensor
7. Steering control valve
D375A-6 10-217
DRAFT
Electrical system
Gearshift mode function 6. Preset gearshift pattern(gear speed at start)

Outline 7. Mark of "Dozing 2" (which indicates manual
There are the auto gearshift mode and manual gear- gearshift mode)
shift mode in the gearshift mode. These modes are C:Shoe slip control mode (if equipped)
changed to each other each time gearshift mode 8. Gear speed used currently
switch (1) is pressed. 9. Preset gearshift pattern (gear speed at start)
1. Auto gearshift mode (Heavy duty dozing mode) 10. Mark of "Ripping "(which indicates shoe slip
q If a load is applied, the gear is shifted down control mode)
automatically. When the load is removed,
the gear is shifted up to the set maximum us-
able gear speed automatically.
q The torque converter lockup operates ac-
cording to loads and the maximum usable
gear speed is selected automatically. In this
mode, less fuel is consumed and more pro-
duction is obtained.
2. Manual gearshift mode (General dozing mode,
ripping mode)
q If a load is applied, the gear is shifted down
however, the gear is not shifted up automati-
cally.
3. Shoe slip control mode (if equipped)
q If a load is applied, the gear is shifted down
however, the gear is not shifted up automati-
cally.
q Automatic deceleration of the engine during
the ripping operation reduces operator's fa-
tigue and prevents grousers from useless
wearing caused by shoe slippage.
Gear shift operation

q Select a gear by pressing (a) or (b) on the PCCS
lever (steering / directional / gearshift lever).
(a): Shift-up switch
(b): Shift-down switch
Display of screen
The gearshift mode is displayed in the gearshift
mode display section of the monitor panel as shown
below.
A: Auto gearshift mode
1. Gear speed used currently
2. Preset gearshift pattern (gear speed at start)
or maximum usable gear speed
3. Mark of AUTO (which indicates auto gearshift
mode)
4. Mark of "Dozing 1" (which indicates automatic
gearshift mode)
B: Manual gearshift mode
5. Gear speed used currently
10-218 D375A-6
DRAFT
Electrical system
Setting preset gearshift pattern by using gear- a When the starting switch is set to ON position,
shift switches with travel control lever in neutral the auto gearshift mode ([F1 – R1]) is set. When
q Set the preset gearshift pattern (gear speed at the gearshift mode is changed, [F1 – R1] is se-
start) or the maximum usable gear speed (for lected initially.
only the auto gearshift mode) by using the gear- Changing gear speed by using gearshift switch-
shift switches with travel control lever in neutral. es during travel
A: Auto gearshift mode q The maximum usable gear speed (in the auto
Setting preset gearshift pattern (gear speed at gearshift mode) or the current gear speed (in the
start) or maximum usable gear speed manual gearshift mode) can be changed with the
gearshift switches while the machine is traveling.
A: Auto gearshift mode
Changing maximum usable gear speed
During forward travel: The maximum usable
gear speed can be set to F1 - F2.
During reverse travel: The maximum usable
gear speed can be set to R1 – R3.
Shift-up switch: Each time this switch is pressed,
the maximum usable gear speed is shifted up to
the next range.
Shift-down switch: Each time this switch is
pressed, the maximum usable gear speed is
shifted down to the next range.
Changing current gear speed
Setting preset gearshift pattern (gear speed at
During forward travel: The current gear speed
start)
can be set to F1 - F2.
During reverse travel: The current gear speed
can be set to R1 - R2.
Shift-up switch: Each time this switch is pressed,
the current gear speed is shifted up to the next
range.
pressed, the current gear speed is shifted down
to the next range.
C: Shoe slip control mode(if equipped)
Changing current speed
During forward travel: The current gear speed is
fixed to F1.
During reverse travel: The current gear speed
C:Shoe slip control mode (if equipped) can be set to R1 - R2.
Setting preset gearshift pattern (gear speed at Shift-up switch: Each time this switch is pressed,
start) the current gear speed is shifted up to the next
range.
pressed, the current gear speed is shifted down
to the next range.
D375A-6 10-219
Electrical system
Sensor
Sensor 10-2 0
Sensor name Type of sensor When normal When abnormal
Torque converter oil temperature
Resistive - -
sensor
Hydraulic oil temperature sensor Resistive - -
Coolant level sensor Contact ON (Closed) OFF (Open)
Fuel level sensor Resistive - -

Transmission output shaft R speed
Resistive - -
sensor
Pitch angle sensor Resistive - -
Acceleration sensor Resistive - -
Speed sensor Resistance — —
Engine oil level sensor Contact ON (Closed) OFF (Open)
Air cleaner clogging sensor Contact OFF (Closed) ON (Open)
Hydraulic oil level sensor Contact OFF (Closed) ON (Open)
Torque converter oil temperature sensor 10-2 0

Hydraulic oil temperature sensor 10-2 0
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
10-220 D375A-6
(04)
DRAFT
Electrical system
Sensor
Radiator coolant level sensor
1. Float 4. Wire
2. Sensor 5. Connector
3. Tube
Fuel level sensor
1. Connector Function
2. Float q The fuel level sensor is installed to the side face
3. Arm of the fuel tank. The float moves up and down
4. Body according to the fuel level. This movement of the
5. Spring float is transmitted by the arm to the variable re-
6. Contact sistor to change its resistance. This sends a sig-
7. Spacer nal 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.
D375A-6 10-221
DRAFT
Electrical system
Sensor
Transmission output shaft speed sensor
1. Magnet
2. Terminal
3. Case
4. Boot
5. Connector
Pitch angle sensor
1. Body
2. Tube
3. Wire
4. Connector
10-222 D375A-6
DRAFT
Electrical system
Sensor
Acceleration sensor
1. Sensor portion
2. Wire
3. Connector
Outline
q The acceleration sensor is installed under the
front of the operator's cab.
q The position of the ball inside the sensor chang-
es according to the acceleration.
The coil inside the sensor detects the position of
the ball. The change in the position is amplified
by the amp and is sent as a voltage change to
the power train controller.
q The input and output characteristics of the sen-
sor are shown in the figure on the right.
D375A-6 10-223
Electrical system
Sensor
Speed sensor 10-2 3-1
1. Sensor
2. O-ring
3. Connector
4. Wire
Function 10-2 3-1

q Speed sensor, which is installed in the case of
the cooling fan motor, detects gear speed as
pulse signals from cylinder block spline inside
the motor and sends them as converted electric
signals to the controller.
q Since the clearance between the sensor and
spline is controlled to the specified dimension,
adjustment at installation is not necessary.
10-223-1 D375A-6
(04)
Electrical system
Sensor
Engine oil level sensor 10-2 3-2
1. Connector 3. Float
2. Bracket 4. Switch
Air cleaner clogging sensor 10-2 3-2
1. Spring 4. Sensor
2. Switch 5. O-ring
3. Hose 6. Connector
Hydraulic oil level sensor
1. Float 4. Wire
2. Sensor 5. Connector
3. Tube
D375A-6 10-223-2
(04)
DRAFT
Electrical system
Vehicle health monitoring system (VHMS)

Outline
q The VHMS consists of the VHMS controller and If the "ORBCOMM terminal system" is installed
various sensors (some of which are used by oth- to the machine, it can transmit the data recorded
er systems, too) and records the operating con- in the VHMS by satellite communication to the
dition of the machine. It collects and records the administrator or the service department,
position information and operation information of allowing for remote machine management.
the machine, data from measuring instruments, q For the use of the VHMS, see "30 Testing and
etc. for later maintenance and service. The data adjusting" of this manual.
to be checked are downloaded to a personal
computer.
VHMS controller
Note 1. VHMS is an abbreviation of Vehicle Health Monitoring System.
10-224 D375A-6
DRAFT
Electrical system
Input and output signals

CN1 [CN 1] CN2 [CN2 A, B]
CN1-1 NC - CN2-A1 NC -
CN1-2 Sensor power supply (24 V) Output CN2-A2 NC -
CN1-5 Sensor power supply (5 V) Output CN2-A5 Exhaust temperature (Rear) Input
Power supply (Constant power
CN1-6 Input CN2-A6 NC -
supply) (24 V)
Power supply (Constant power
CN1-7 Input CN2-A7 Exhaust temperature (Front) Input
supply) (24 V)
CN1-8 BR power supply (24 V) Input CN2-A8 NC -
CN1-9 BR power supply (24 V) Input CN2-A9 CONNECTOR SEL0 (OPEN) Input
CN1-10 NC - CN2-A10 Ambient temperature Input
CN1-11 GND - CN2-A11 NC -
CN1-12 GND - CN2-A12 Sensor GND -
CN1-13 NC - CN2-A13 Sensor GND -
CN1-14 NC - CN2-A14 NC -
CN1-15 NC - CN2-A15 Transmission, main oil pressure Input
CN1-16 NC - CN2-A16 NC -
CN1-17 Start signal Input CN2-A17 WAKE UP (Low) Input
CN1-18 NC - CN2-A18 Blowby pressure Input
CN1-19 GND - CN2-B1 NC -
CN1-20 GND - CN2-B2 NC -
CN2-B3 NC -
CN2-B4 NC -
CN2-B5 NC -
CN2-B6 WAKE UP (Hi) Input
CN2-B7 NC -
CN2-B8 NC -
CN2-B9 GND -
CN2-B10 NC -
CN2-B11 NC -
CN2-B12 CONNECTOR SEL1 (GND) Input
D375A-6 10-225
DRAFT
Electrical system
CN3 [CN3 A, B] CN4 [CN4 A, B]

CN3-A1 NC - CN4-A1 NC -
CN3-A2 CAB out D/L Sw Input CN4-A2 NC -
CN3-A4 NC - CN4-A4 CAN (1) H (KOM-NET/c) Input/output
Model selection (See ORB connec-
CN3-A5 Input CN4-A5 CAN (0) shield (MMS) -
tion)
CN3-A6 NC - CN4-A6 CAN (0) H (MMS) Input/output
CN3-A9 CONNECTOR SEL2 (GND) Input CN4-A9 GND -
CN3-A10 NC - CN4-A10 RS232C RXD (PC Tool) Input
CN3-A11 NC - CN4-A11 RS232C TXD (PC Tool) Output
CN3-A12 NC - CN4-A12 CAN (1) L (KOM-NET/c) Input/output
CN3-A13 NC - CN4-A13 CAN (1) SH (KOM-NET/c) -
CN3-A14 NC - CN4-A14 CAN (0) L (MMS) Input/output
CN3-A15 NC - CN4-B1 NC -
CN3-A16 NC - CN4-B2 NC -
CN3-A17 NC - CN4-B3 GNG (Orbcomm) -
CN4-B4 RS232C TX1 (Orbcomm) Output

CN3-A18 NC -
CN4-B5 NC -
CN3-B1 NC -
CN4-B6 NC -
CN3-B2 NC -
CN4-B7 NC -
CN3-B3 NC -
CN4-B8 NC -
CN3-B4 NC -
CN4-B9 GND (Orbcomm) -
CN3-B5 NC -
CN4-B10 RS232C RX1 (Orbcomm) Input
CN3-B6 NC -
CN5
CN3-B7 NC - Pin No. Signal name Input/output
CN3-B8 NC - CN5-1 LAN TX+ Output
CN3-B9 NC - CN5-2 LAN TX- Output
CN3-B10 NC - CN5-3 LAN RX+ Input
CN3-B11 NC - CN5-4 LAN RT3 -
CN3-B12 CONNECTOR SEL3 (OPEN) Input

CN5-5 LAN RT4 -
CN5-6 LAN RX- Input
CN5-7 LAN RT1 -
CN5-8 LAN RT2 -
CN5-9 NC -
CN5-10 NC -
CN5-11 PWR (LAN5 V) Output
CN5-12 GND (LAN) -
10-226 D375A-6
DRAFT
Electrical system
Sensors Exhaust temperature sensor/amplifier
Engine oil temperature sensor Specification

Specification Rated voltage: 24V DC
Type of sensor: Thermistor Delectable temperature range: 100 – 1,000 °C
Measurement range : 40 – 130 °C 300 – 800 °C
80 – 130 °C (Assured accuracy: ±10 °C)
(Assured accuracy: ±2 °C) Output voltage characteristics
Max. power consumption:0.5 mW (Ambient temperature: 20 °C)
Pressure capacity: 4.9 MPa {50 kg/cm2} Reference values
Operating temperature: -30 °C – +140 °C Sensed tempera-
50 100 400 700 800
Performance table ture (°C)
Output voltage
Tem-pe Resis-ta Tem-pe Resis-ta Tem-pe Resis-ta 1.191 1.397 2.626 3.899 4.316
(V)
ra-ture nce ra-ture nce ra-ture nce
(°C) (kΩ) (°C) (kΩ) (°C) (kΩ) Operating temperature range: - 40 – +110 °C
30 35.27 80 6.571 110 2.887 Current consumption: Max. 30 mA
a. Heat sensing part of sensor
40 24.28 85 5.682 115 2.544 Outside diameter of mounting part: R1/8
b. Amplifier
50 17.05 90 4.931 120 2.248 c. Connector (power supply side)
60 12.20 95 4.293 125 1.992 d. Connector (sensor side)
70 8.884 100 3.750 130 1.769 Function

The exhaust temperature sensor/amplifier is a ther-
a. Heat sensing part of sensor mocouple-type temperature sensor, which is in-
Outside diameter of mounting part: R1/4 stalled to the turbocharger inlet. It outputs the
exhaust temperature data to the VHMS controller.
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-6 10-227
DRAFT
Electrical system
Ambient temperature sensor

Specification
Power consumption: Max. 0.5 mW
Pressure capacity: 0.98 MPa {10 kg/cm2}
Delectable temperature range (ambient):
- 30 – + 120 °C
Storage temperature range: - 50 – + 140 °C
Performance table
Detected
tempera- -20 -10 0 10 20 50
ture (°C)
Resistance
30.32 18.58 11.74 7.623 5.077 1.712
(kΩ)
a. Heat sensing part of sensor
Outside diameter of mounting part: 16 × 1.5
Function
The ambient temperature sensor inputs the change
of the ambient temperature as the change of the
thermistor resistance to the VHMS controller.
10-228 D375A-6
DRAFT
Electrical system
Engine blowby pressure sensor
1. Sensor Specifications and function

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

1. Sensor
2. Connector
D375A-6 10-229
DRAFT
Electrical system
ORBCOMM system
ORBCOMM system
Outline
q The ORBCOMM terminal system is a communi-
cation system to use the satellite communication
service of ORBCOMM Co., Ltd. (USA). If this
system is installed to the machine, the data re-
corded in the VHMS controller and various infor-
mation obtained through the network in the
machine can be transmitted by the satellite com-
munication.
q It is required to sign up for the ORBCOMM termi-
nal system before using its functions.
For details, including the sign-up test, see "30
Testing and adjusting" of this manual.
q The ORBCOMM terminal system may or may
not be installed to the machine, depending on
the user's purchase specification.
10-230 D375A-6
DRAFT
Electrical system
ORBCOMM system
ORBCOMM terminal system
1. Communication antenna connection

18 NC
2. DRC connector connection (40 poles)
19 NC
Outline
q The ORBCOMM terminal obtains various kinds 20 NC
of machine information from the network signals
21 NC
and input signal in the machine and transmits
them via the wireless communication antenna. It 22 NC
contains a CPU (Central Processing Unit) and
has wireless communication function. 23 NC
q This terminal has a LED lamp unit and a 7-seg-
ment display lamp unit used for inspection and 24 NC
troubleshooting. 25 NC
Input/Output signal
q DRC conector 26 NC
1 NC 27 NC
2 NC 28 NC
3 NC 29 DOUT (GND)
4 COMM 232C RXD 30 NC
5 COMM 232C TXD 31 NC
6 NC 32 NC
7 NC 33 NC
8 NC 34 NC
9 NC 35 NC
10 NC 36 ACC Input
11 RS232C GND 37 DIS_SEL0 (GND)
12 NC 38 DIS_SEL0 (GND)
13 NC 39 Constant power supply (24 V)
14 NC 40 Constant power supply (24 V)
15 NC
16 NC
17 NC
D375A-6 10-231
DRAFT
Electrical system
ORBCOMM system
Antenna
Specification
Type: Helical whip antenna (1)
Impedance: 50 Ω
Input terminal: M-P type
Length: 165 ± 20 mm
a. Communication antenna mounting part
Function
Transmits data collected and stored by the VHMS
controller to the computer center via communica-
tions satellites.
10-232 D375A-6
DRAFT
D375A-6
SEN05175-00
BULLDOZER
Shop Manual
D375A-6

D375A-6 60001 and up

Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-
2
Standard value table for engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-
3
Standard value table for machine- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-
4
D375A-6 20-1
(01)
DRAFT
Contents
Contents
Standard service value table ............................................................................................................................ 20- 3
Standard value table for engine .................................................................................................................... 20- 3
Standard value table for machine ................................................................................................................. 20- 4
20-2 D375A-6
(01)
DRAFT
Standard service value table
Standard value table for engine

Standard value table for engine
Engine SAA6D170E-5
Standard value for Permissible
Item Measurement conditions Unit
new machine value
High idle 1,900 (0/-50) 1,900 (0/-50)
Engine speed Low idle rpm 750 ± 50 750 ± 50
Rated speed 1,800 1,800
kPa Min. 155 Max. 141
Boost pressure At rated horsepower
{mmHg} {Min. 1,160} {Max. 1,060}
Whole speed range (Ambient temper-
Exhaust temperature °C Max. 700 Min. 730
ature: 20 °C)
At sudden acceleration Max. 2.5 Min. 3.5
Exhaust gas color Bosch index
At high idle Max. 1.0 Min. 2.0
Valve clearance Intake valve 0.32 ―
mm
(Normal temperature) Exhaust valve 0.62 ―
EGR valve and bypass At low speed Min. 1.18
―
valve drive oil pressure MPa {Min. 12}
(Oil temperature: 40 – {kg/cm2} Min. 1.43
60 °C) At high idle ―
{Min. 14.6}
Compression pressure Engine oil temperature: 40 – 60 °C MPa Min. 2.94 Max. 2.1
(SAE15W-40 or SAE30 {kg/cm2} {Min. 30} {Max. 21}
oil) (Engine speed) (rpm) (210 – 250) ―
Blowby pressure At rated horsepower
kPa Max. 3.43 Min. 9.41
(SAE15W-40 or SAE30 (Coolant temperature: Within operat-
{mmH2O} {Max. 350} {Min. 960}
oil) ing range)
SAE0W30E0S Min. 392.27 Max. 235.36
Oil pressure At high idle SAE5W40E0S kPa {Min. 4.0} {Max. 2.4}
(Oil temperature: 90 – SAE10W30DH
110 °C) SAE15W40DH {kg/cm2} Min. 117.68 Max. 78.45
At low speed
SAE30DH {Min. 1.2} {Max. 0.8}
Oil temperature Whole speed range (inside oil pan) °C 90 – 110 Min. 120
Deflection when pressed with finger

Alternator belt tension mm (Auto tension) ―
force of approximately 58.8 N {6 kg}
Air conditioner com- Deflection when pressed with finger
mm (Auto tension) ―
pressor belt tension force of approximately 98 N {10 kg}
D375A-6
(03) 20-3
DRAFT
Standard value table for machine

Standard
Cate- Permissible
Item Measuring condition Unit value for new
gory value
machine
q Working mode: P-mode

Decelerator pedal
q Gear shift mode: Manual 900 ± 50 900 ± 50
low speed
q Engine coolant temperature: Within operating
range
Engine speed
q Torque converter oil temperature: Within operat-

ing range
Torque converter
q Hydraulic oil temperature: 45 – 55 °C rpm 1,530 ± 50 1,450
stall speed
q Decelerator pedal low speed:
Pedal pressed
q Torque converter stall speed: F3
Torque converter q Torque converter + Work equipment speed:
stall + Work equip- F3 + Ripper RAISE 1,500 ± 50 1,400
ment relief speed q Measure with adjustment ID: 0530 (Stall mode)
q Engine stopped Neutral o For-

q Center of lever knob 30 ± 5 Max. 8.0
Forward and ward
reverse Neutral o
PCCS Lever
30 ± 5 30 ± 5
Reverse
All stroke mm 40 ± 5
40 ± 5
(Neutral – (Play: Max.
(Play: Max. 3)
Right/Left) 3)
Steering
Until clutch is
fully disen- 9±5 9±5
gaged
Control lever/pedal stroke
q Engine stopped
Decelerator pedal q Center of pedal mm 45 ± 15 45 ± 15
q Engine low idle

q Center of pedal Full stroke 75 ± 5 75 ± 5
Brake pedal Until oil pres- mm
sure becomes 54 ± 5 54 ± 5
zero
q Engine low idle
q Hydraulic oil temperature: 45 – Neutral – Raise 60 ± 10 60 ± 10
55 °C
Blade control lever q Center of lever knob Neutral – Float mm 85 ± 10 85 ± 10
Neutral –
53 ± 10 53 ± 10
Left/Right tilt
q Engine low idle Neutral –
q Hydraulic oil temperature: 45 – Raise/Lower 78 ± 10 78 ± 10
Ripper control lever 55 °C mm
q Center of lever knob Neutral – Tilt
81 ± 10 81 ± 10
forward/back
20-4 D375A-6
(03)
DRAFT
Standard
Cate- Permissible
gory value
machine
q Engine stopped Neutral o For- 56.9 ± 6.9 56.9 ± 6.9
q Center of lever knob ward {5.8 ± 0.7} {5.8 ± 0.7}
Forward and
reverse Neutral o 56.9 ± 6.9 56.9 ± 6.9
Reverse {5.8 ± 0.7} {5.8 ± 0.7}
Control lever/pedal operating effort
Until clutch is
12.8 ± 3.9 12.8 ± 3.9
PCCS lever
fully disen-
{1.3 ± 0.4} {1.3 ± 0.4}
Left gaged N
{kg} 16.7 ± 4.9 16.7 ± 4.9
At stroke end
{1.7 ± 0.5} {1.7 ± 0.5}
Steering
Until clutch is
13.7 ± 3.9 13.7 ± 3.9
fully disen-
{1.4 ± 0.4} {1.4 ± 0.4}
Right gaged
19.6 ± 4.9 19.6 ± 4.9
At stroke end
{2 ± 0.5} {2 ± 0.5}
q Engine stopped N 49.0 ± 9.8 49.0 ± 9.8
Decelerator pedal q Center of pedal {kg} {5.0 ± 1.0} {5.0 ± 1.0}
q Engine low idle N 460.6 ± 49.0 460.6 ± 49.0
Brake pedal q Center of pedal {kg} {47.0 ± 5.0} {47.0 ± 5.0}
q Engine low idle Neutral o
Control lever/pedal operating effort
39.2±5.9 39.2±5.9
q Hydraulic oil temperature: 45 – Raise {4.0±0.6} {4.0±0.6}
55 °C
q N 82.3 ± 9.8 82.3 ± 9.8
Blade control lever Center of lever knob Neutral o Float
{kg} {8.4 ± 1.0} {8.4 ± 1.0}
Neutral – 28.4 ± 4.9 28.4 ± 4.9
Left/Right tilt {2.9 ± 0.5} {2.9 ± 0.5}
q Engine low idle Neutral – 21.6 ± 4.9 21.6 ± 4.9
q Hydraulic oil temperature: 45 – Raise/Lower {2.2 ± 0.5} {2.2 ± 0.5}
55 °C N
Ripper control lever
q Center of lever knob Neutral – Tilt {kg} 20.6 ± 4.9 20.6 ± 4.9
forward/back {2.1 ± 0.5} {2.1 ± 0.5}
q Fan 100 % mode
Min. speed q Hydraulic oil temperature: Min. Engine low idle 350 ± 100 ―
40 °C rpm
Engine high
Fan
Max. speed 1,210 ± 25 Max. 1,110

idle
Engine high MPa 15.7 ± 2.5 15.7 ± 2.5
Circuit oil pressure
idle {kg/cm2} {160 ± 25} {160 ± 25}
D375A-6
(03) 20-5
DRAFT
Standard
Cate- Permissible
gory value
machine
q Power train oil temperature: 0.03 – 0.25 0.03 – 0.25
Within operating range Engine low idle
Torque converter {0.3 – 2.5} {0.3 – 2.5}
inlet pressure Engine high 0.69 – 1.05 0.69 – 1.05
idle {7.0 – 10.7} {7.0 – 10.7}
0.03 – 0.20 0.03 – 0.20
Engine low idle
outlet pressure Engine high 0.44 – 0.70 0.44 – 0.70
idle MPa {4.5 – 7.0} {4.5 – 7.0}
{kg/cm2}
Torque converter Engine low idle ― ―
lockup clutch pres-
sure Engine high 1.29 – 1.54 1.29 – 1.54
idle {13.2 – 15.7} {13.2 – 15.7}
2.25 – 2.87 2.25 – 2.87
Engine low idle
Power train oil pressure

stator clutch pres-
sure Engine high 2.55 – 2.87 2.55 – 2.87
idle {26.0 – 29.3} {26.0 – 29.3}
q Power train oil temperature: 2.38 – 3.07
2.48 – 2.87
Within operating range Engine low idle {24.3 –
Transmission main {25.3 – 29.3}
31.3}
relief pressure
Engine high 2.68 – 2.87 2.58 – 3.07
idle {27.3 – 29.3} {26.3 – 31.3}
q Adjustment ID: 5535 2.25 – 2.84 2.06 – 3.13
Measure in (both Engine low idle
Transmission F {23.0 – 29.0} {21.0 – 31.9}
steering clutch disen-
clutch pressure Engine high 2.55 – 2.87 2.35 – 3.16
gage modes)
idle MPa {26.0 – 29.3} {23.9 – 32.2}
{kg/cm2} 2.25 – 2.84 2.06 – 3.13
Engine low idle
Transmission R {23.0 – 29.0} {21.0 – 31.9}
idle {26.0 – 29.3} {23.9 – 32.2}
2.06 – 2.35 1.86 – 2.55
Engine low idle
Transmission 1st {21.0 – 24.0} {18.9 – 26.0}
idle {21.0 – 24.0} {18.9 – 26.0}
20-6 D375A-6
(03)
DRAFT
Standard
Cate- Permissible
gory value
machine
q Adjustment ID: 5535 2.25 – 2.84 2.06 – 3.13
Measure in (both Engine low idle
Transmission 2nd {23.0 – 29.0} {21.0 – 31.9}
steering clutch disen-
clutch pressure gage modes) Engine high 2.55 – 2.87 2.30 – 3.16
idle {26.0 – 29.3} {23.4 – 32.2}
MPa 2.25 – 2.84 2.06 – 3.13
Engine low idle
Transmission 3rd {kg/cm2} {23.0 – 29.0} {21.0 – 31.9}
idle {26.0 – 29.3} {23.4 – 32.2}
Transmission lubri- q Power train oil temperature: Engine high 0.08 – 0.25 0.08 – 0.25
cating oil pressure Within operating range idle {0.8 – 2.5} {0.8 – 2.5}
q Power train oil temperature: 2.25 – 2.84 2.2 – 3.04
Power train oil pressure
Within operating range Engine low idle

Steering left clutch {23.0 – 29.0} {22.4 – 31.0}
pressure Engine high 2.55 – 2.87 2.4 – 3.07
idle {26.0 – 29.3} {24.4 – 31.3}
2.25 – 2.84 2.2 – 3.04
Engine low idle
Steering left brake {23.0 – 29.0} {22.4 – 31.0}
idle MPa {26.0 – 29.3} {24.4 – 31.3}
{kg/cm2} 2.25 – 2.84 2.2 – 3.04
Engine low idle
Steering right clutch {23.0 – 29.0} {22.4 – 31.0}
idle {26.0 – 29.3} {24.4 – 31.3}
2.25 – 2.84 2.2 – 3.04
Engine low idle
Steering right brake {23.0 – 29.0} {22.4 – 31.0}
idle {26.0 – 29.3} {24.4 – 31.3}
Pin puller operating q Power train oil temperature: Engine high MPa 2.55 ± 0.10 Min. 2.2
Within operating range
pressure idle {kg/cm2} {26.0 ± 1.0} {Min. 22}
q Flat ground 20.6 ± 1.0 20.6 ± 1.0
q Engine coolant tempera- F1
{3.5 ± 0.2} {3.5 ± 0.2}
ture: Within operating
range 10.6 ± 0.6 10.6 ± 0.6
F2
q Power train oil tempera- {6.8 ± 0.3} {6.8 ± 0.3}
9.0 ± 0.4 9.0 ± 0.4
Automatic gear shift mode
Power train performance
range F3L
{8.0 ± 0.4} {8.0 ± 0.4}
q Engine high idle
q Run up distance: 10 - 30 6.1 ± 0.3 6.1 ± 0.3
F3
m sec {11.8 ± 0.6} {11.8 ± 0.6}
Travel speed q Measurement distance: {km/h} 15.7 ± 0.8 15.7 ± 0.8
20 m R1
{4.6 ± 0.2} {4.6 ± 0.2}
8.1 ± 0.4 8.1 ± 0.4
R2
{8.9 ± 0.4} {8.9 ± 0.4}
7.4 ± 0.3 7.4 ± 0.3
R3L
{9.7 ± 0.5} {9.7 ± 0.5}
4.9 ± 0.3 4.9 ± 0.3
R3
{15.8 ± 0.7} {15.8 ± 0.7}
D375A-6
(03) 20-7
DRAFT
Standard
Cate- Permissible
gory value
machine
q Flat ground 20.6 ± 1.0 20.6 ± 1.0
q Engine coolant tempera- F1
{3.5 ± 0.2} {3.5 ± 0.2}
10.6 ± 0.6 10.6 ± 0.6
Power train performance
range
Manual gear shift mode

F2
q Power train oil tempera- {6.8 ± 0.3} {6.8 ± 0.3}
ture: Within operating 6.1 ± 0.3 6.1 ± 0.3
range F3
sec {11.8 ± 0.6} {11.8 ± 0.6}
Travel speed q Engine high idle
{km/h} 15.7 ± 0.7 15.7 ± 0.7
q Run up distance: 10 - 30 R1
m {4.6 ± 0.3} {4.6 ± 0.3}
q Measurement distance: 8.2 ± 0.4 8.2 ± 0.4
20 m R2
{8.7 ± 0.4} {8.7 ± 0.4}
4.9 ± 0.3 4.9 ± 0.3
R3
{14.7 ± 0.7} {14.7 ± 0.7}
q Hydraulic oil temperature: 45 –
55 °C Engine low idle ― ―
Unload pressure q Cylinder stroke end
2.45
Engine high 2.45 (+1.37/0)
(+1.37/0)
idle {25 (+14/0)}
{25 (+14/0)}
26.4 – 28.4 26.4 – 29.4
Engine low idle
Blade tilt relief pres- {270 – 290} {270 – 300}
sure Engine high 27.4 – 29.4 27.4 – 29.4
idle {280 – 300} {280 – 300}
Work equipment oil pressure
MPa 26.4 – 28.4 26.4 – 29.4

Engine low idle
Ripper lift relief {270 – 290} {270 – 300}
{kg/cm2}
idle {280 – 300} {280 – 300}
26.4 – 28.4 26.4 – 29.4
Engine low idle
Ripper tilt relief {270 – 290} {270 – 300}
idle {280 – 300} {280 – 300}
25.48 ± 1.27 25.48 ± 1.27
LS pressure Engine low idle
{260 ± 13} {260 ± 13}
(Load sensing pres-
sure) Engine high 25.48 ± 1.27 25.48 ± 1.27
idle {260 ± 13} {260 ± 13}
Control circuit oil q Hydraulic oil temperature: 45 – 55 °C 3.43 – 4.12 3.43 – 4.12
pressure q Engine high idle MPa {35 – 42} {35 – 42}
PPC valve output q Circuit oil pressure: Lever in neutral {kg/cm2} 3.43 – 4.12 Min. 3.33
pressure q Output pressure: Lever at stroke end {35 – 42} {Min. 34}
20-8 D375A-6
(03)
DRAFT
Standard
Cate- Permissible
gory value
machine
Engine low idle 7 – 13 20
Raise
Engine high
3.7 – 4.7 6
idle
Blade lift sec
q Hydraulic oil tempera- Engine low idle 1.3 – 1.7 1.3 – 1.8
Lower
ture: 45 – 55 °C
q Apply no load to blade.
q Between ground level Engine high
1.3 – 1.7 1.3 – 1.8
and rising end of blade idle
Engine low idle 2–4 6

L.H. tilt
Engine high
2.5 – 3.5 5
idle
Blade tilt sec
q Hydraulic oil tempera- Engine low idle 2–4 6

R.H. tilt
ture: 45 – 55 °C
Work equipment speed
q Apply no load to blade. Engine high

Work equipment
q Between left tilt end and 2.5 – 3.5 5

idle
right tilt end

L.H. tilt
Dual tilt specification
Engine high
2.5 – 3.5 5
idle
sec
R.H. tilt
q Hydraulic oil tempera-

ture: 45 – 55 °C
2.5 – 3.5 5
q Between left tilt end and idle
Blade
right tilt end
dual tilt
L.H. tilt
Single tilt specification
Engine high
2.5 – 3.5 5
idle
sec
q Hydraulic oil tempera- Engine low idle 2–4 5

R.H. tilt
ture: 45 – 55 °C
q Between left tilt end and 2.5 – 3.5 5
idle
right tilt end
D375A-6
(03) 20-9
DRAFT
Standard
Cate- Permissible
gory value
machine
Dump
Engine high
2.5 – 3.5 5
idle
ture: 45 – 55 °C
Blade pitch sec
Back
q Between dump end and
back end Engine high
2.5 – 3.5 5
idle
*G 4–6
Engine low idle 7
RAISE
*M 4–6
Engine high *G 2–3
5
idle *M 2.5 – 3.5
Ripper lift sec
Engine low idle 1.5 – 2.5 1.5 – 2.5
LOWER
ture: 45 – 55 °C
q Apply no load to ripper.
Engine high
q Between ground level 1.5 – 2.5 1.5 – 2.5
Work equipment
idle
and rising end of ripper

Tilt in
Engine high
4.5 – 5.5 7
idle
Ripper tilt sec
Tilt back
ture: 45 – 55 °C
q Between forward tilt end Engine high
2.8 – 3.8 6
and backward tilt end idle
q Hydraulic oil temperature: 45 –

55 °C Engine low idle Max. 8 12
q Lever full stroke
Blade q Start lowering operation at blade
max. raising position and mea- Engine high
sure time from when blade idle Max. 1.8 2.0
Time lag
reaches ground until idler rises.

q
Hydraulic oil temperature: 45 – sec
55 °C
Engine low idle ― ―
q Lever full stroke
q Start lowering operation at ripper
Ripper
max. raising position and mea-
*G Max. 1.0 *G 1.5
sure time from when ripper Engine high
reaches ground until sprocket idle
*M Max. 1.5 *M 2
rises.
* G: Variable giant ripper specification, M: Variable multi-shank ripper specification
20-10 D375A-6
(03)
DRAFT
Standard
Cate- Permissible
gory value
machine
Hydraulic drift Max. 65 mm 130 mm per

mm
of lifted blade per 5 minutes 5 minutes
q Hydraulic oil temperature: 45 – 55 °C

q Engine stopped
q Measuring reduction of blade bottom height "h"
(for 5 minutes).
Hydraulic drift
Max. 50 mm 100 mm per
of machine mm
per 5 minutes 5 minutes
lifted by blade

Work equipment
Hydraulic drift
q Engine stopped
q Measure reduction of idler center height "h" (for 5
minutes).
Hydraulic drift
Max. 50 mm 80 mm per 5
of machine mm
per 5 minutes minutes
tilted by blade

q Engine stopped
q Measuring reduction of track shoe bottom height
"h" (for 5 minutes).
Hydraulic drift Max. 25 mm 50 mm per 5

mm
of lifted ripper per 5 minutes minutes

q Engine stopped
q Measuring reduction of height of bottom end of
shank "h" (for 5 minutes).
D375A-6
(03) 20-11
DRAFT

Standard
Cate- Permissible
Item Measurement condition Unit value for new
gory vable
machine
Hydraulic drift
Hydraulic drift
Max. 30 mm 60 mm per 5
of machine mm
per 5 minutes minutes
lifted by ripper
Work equipment

q Engine stopped
q Measure reduction of sprocket center height
"h" (for 5 minutes).
q Engine running at low idle
Cylinder internal leak-
Blade tilt cyl-

q Hydraulic oil temperature: 45 – 55 °C Max. 3.0 12
inder
q Relieve cylinder and measure leakage for 1
Ripper lift cyl- minute.
age
cc/min Max. 3.6 12

inder
Ripper tilt cyl-

Max. 3.2 12
inder
20-12 D375A-6
(01)
DRAFT
D375A-6
SEN05176-00
BULLDOZER
Shop Manual
D375A-6

D375A-6 60001 and up

Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 -
2
Tools for testing, adjusting, and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 -
4
Testing intake air pressure (boost pressure) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 -
8
Testing exhaust gas color - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 -
12
Adjusting valve clearance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 -
14
Measuring compression pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 -
16
Testing blow-by pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 -
19
Testing engine oil pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 -
21
Handling of fuel system devices- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 -
24
Releasing residual pressure from fuel system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 -
25
Bleeding air from fuel circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 -
31
Testing fuel pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 -
26
D375A-6 30-1
(01)
DRAFT
Contents
Contents
Tools for testing, adjusting, and troubleshooting.............................................................................................. 30 - 4
Tools for testing, adjusting, and troubleshooting .......................................................................................... 30 - 4
Testing engine speed.................................................................................................................................... 30 - 6
Testing intake air pressure (boost pressure) ................................................................................................ 30 - 8
Testing exhaust temperature ........................................................................................................................ 30 - 10
Testing exhaust gas color ............................................................................................................................. 30 - 12
Adjusting valve clearance ............................................................................................................................. 30 - 14
Measuring compression pressure................................................................................................................. 30 - 16
Testing blow-by pressure.............................................................................................................................. 30 - 19
Testing engine oil pressure........................................................................................................................... 30 - 21
Testing EGR valve and bypass valve drive oil pressure............................................................................... 30 - 22
Handling of fuel system devices ................................................................................................................... 30 - 24
Releasing residual pressure from fuel system .............................................................................................. 30 - 25
Testing fuel pressure .................................................................................................................................... 30 - 26
Handling of reduced cylinder mode operation .............................................................................................. 30 - 27
Handling of no injection cranking operation .................................................................................................. 30 - 27
Testing leakage from pressure limiter and return rate from injector ............................................................. 30 - 28
Bleeding air from fuel circuit.......................................................................................................................... 30 - 31
Testing fuel circuit for leakage ...................................................................................................................... 30 - 33
Replacing and adjusting alternator and air conditioner compressor belt ...................................................... 30 - 34
Measuring fan speed .................................................................................................................................... 30 - 35
Testing fan circuit oil pressure ...................................................................................................................... 30 - 36
Bleeding air from fan pump........................................................................................................................... 30 - 37
Adjusting fuel control dial and decelerator pedal .......................................................................................... 30 - 38
Power train ....................................................................................................................................................... 30 - 40
Testing power train oil pressure.................................................................................................................... 30 - 40
Adjusting transmission output speed sensor ................................................................................................ 30 - 52
Simple test procedure for brake performance............................................................................................... 30 - 53
Adjusting brake pedal and parking brake lever............................................................................................. 30 - 54
Adjusting position of pccs lever console ....................................................................................................... 30 - 57
Emergency escape method when there is failure in power train .................................................................. 30 - 58
Undercarriage and frame ................................................................................................................................. 30 - 60
Inspecting wear of sprocket .......................................................................................................................... 30 - 60
Testing and adjusting track shoe tension...................................................................................................... 30 - 61
Hydraulic system .............................................................................................................................................. 30 - 62
Measuring and adjusting work equipment oil pressure................................................................................. 30 - 62
Testing control circuit main pressure ............................................................................................................ 30 - 65
Testing PPC valve output pressure .............................................................................................................. 30 - 66
Adjusting play of PPC valve.......................................................................................................................... 30 - 68
Testing output pressure of ripper pin-puller solenoid valve .......................................................................... 30 - 69
Checking location of cause of hydraulic drift of blade and ripper.................................................................. 30 - 70
Testing leakage inside work equipment cylinder .......................................................................................... 30 - 71
Releasing remaining pressure in work equipment cylinders......................................................................... 30 - 72
Bleeding air from work equipment cylinders ................................................................................................. 30 - 72
Adjusting ripper lever position....................................................................................................................... 30 - 73
Work equipment ............................................................................................................................................... 30 - 74
Adjusting work equipment lock lever............................................................................................................. 30 - 74
Adjusting blade ............................................................................................................................................. 30 - 75
Cab and its attachments................................................................................................................................... 30 - 77
Testing and adjusting operator's cab ............................................................................................................ 30 - 77
Electrial system ................................................................................................................................................ 30 - 82
Special functions of machine monitor (EMMS) ............................................................................................. 30 - 82
Handling of voltage circuit of engine controller ............................................................................................. 30 -139
Adjustment method when controller has been replaced ............................................................................... 30 -140
30-2 D375A-6
(01)
DRAFT
Contents
Preparation work for troubleshooting of electrical system ............................................................................ 30 -144

Inspection procedure of diode....................................................................................................................... 30 -148
Handling of optional devices ......................................................................................................................... 30 -149
Request for opening ORBCOMM terminal.................................................................................................... 30 -150
Initialization procedures for VHMS controller................................................................................................ 30 -152
Using method of KOMTRAX functions of ORBCOMM terminal.................................................................... 30 -172
Precautions for replacing VHMS controller ................................................................................................... 30 -175
Pm Clinic service.............................................................................................................................................. 30 -181
Pm Clinic service .......................................................................................................................................... 30 -181
D375A-6 30-3
(01)
DRAFT
Tools for testing, adjusting, and troubleshooting

Sym-
Testing/Adjusting item Part No. Part Name Q'ty Remarks
bol
Measuring intake air
pressure (boost pres- A 799-201-2202 Boost gauge kit 1 -101 – 200 kPa {-760 – 1,500 mmHg}
sure)
Measuring exhaust gas B 799-101-1502 Digital thermometer 1 -99.9 – 1,299°C
temperature ― 799-201-1150 Adapter connector 1 For Pm clinic specification
1 799-201-9001 Handy smoke checker 1
Checking exhaust gas
C Commercially- Bosch index: Level 0 – 9
color 2 Smoke meter 1
available
Commercially- Intake side: 0.32 mm, Exhaust side:
Adjusting valve clearance D Clearance gauge 1
available 0.62 mm
1 795-502-1590 Compression gauge 1 0 – 7 MPa {0 – 70 kg/cm2}
Testing compression 795-611-1220 Adapter 1
E 2 6261-71-6150 Gasket 1
pressure
795-799-5410 Adapter 1
3
795-799-5420 Remover 1
Testing blow-by pressure F 799- 201-1504 Blow-by checker 1
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Pressure gauge: 60 MPa {600
Testing engine oil pres- 790-261-1204 Digital hydraulic tester 1
sure kg/cm2}
G 2 799-401-2320 Gauge 1 Pressure gauge: 1.0 MPa {10 kg/cm2}
799-101-5230 Nipple 1
3
6215-81-9720 O-ring 1
Testing drive pressure of 795T-690-1110 Block 1
EGR valve and bypass 4 01435-00835 Bolt 2
valve 07000-E2012 O-ring 3
1 *As common as G1
790-261-1204 Digital hydraulic tester 1
Testing fuel pressure H 2 799-401-2320 Gauge 1 *As common as G2
799-101-5160 Nipple 1 R 1/8
3 795-471-1450 Adapter 1 M8 × 1.25
07005-00812 Gasket 1
1 6167-11-6640 Spacer 1 Inside diameter: 10 mm
2 6206-71-1770 Joint 1 Joint diameter: 10 mm
Commercially-
3 Hose 1 f 5 mm (Inside diameter) x 2 – 3 m
available
Testing fuel return rate Commercially-
J 4 Hose 1 f 16 mm (Inside diameter) x 2 – 3 m
and leakage available
Commercially-
5 Measuring cylinder 1
available
Commercially-
6 Stopwatch 1
available
Testing power train oil 1 *As common as G1
K 790-261-1204 Digital hydraulic tester 1
pressure
2 799-401-2320 Gauge 1 *As common as G2
19M-06-32820 Switch assembly 1
Emergency escape
1 7824-66-6430 Resistor 1
method when power train L
195-06-71220 Wiring harness 1
has trouble
2 790-190-1601 Pump assembly 1
Measuring and adjusting 799-101-5002 Hydraulic tester 1
1 *As common as G1
work equipment oil pres- 790-261-1204 Digital hydraulic tester 1
M 799-101-5220 Nipple 2 M10 × 1.25
sure, Testing control cir-
2
cuit main pressure 07002-11023 O-ring 2
Testing PPC valve out- 799-101-5002 Hydraulic tester 1
N 1 *As common as G1
put pressure 790-261-1204 Digital hydraulic tester 1
30-4 D375A-6
(03)
DRAFT

Testing ripper pin puller sole- 1 *As common as G1
P 790-261-1204 Digital hydraulic tester 1
noid valve output pressure
2 799-401-3200 Adapter 1 Size 03
Testing internal leakage of Commercially-
Q Measuring cylinder 1
work equipment cylinder available
1 *As common as G1
Testing fan circuit oil pres- 790-261-1204 Digital hydraulic tester 1
S
sure 2 790-301-1330 q Flange 1 Size: 10
3 07372-21055 Bolt 4
4 07000-13035 O-ring 1
Testing operation force and 79A-264-0021 Push - pull scale 1 0 – 294 N {0 – 30 kg}
T
pedal force 79A-264-0091 Push - pull scale 1 0 – 490 N {0 – 50 kg}
Measuring stroke and Commercially-
U Ruler 1
hydraulic drift available
Measuring work equipment Commercially-
V Stopwatch 1
speed available
Measuring voltage and Commercially-
W Multimeter 1
resistance available
1 799-608-3211 Discket 1
Initial setting of VHMS con-
Z 2 799-608-3220 Wiring harness 1
troller
Commercially- Lap top type personal OS: Windows 98/2000/Me/XP/VISTA
3 1
available computer Terminal "RS232C" is with it
799-601-7400 T-adapter assembly 1 AMP040 Connector
799-601-7500 T-adapter assembly 1 AMP040 Connector
799-601-9000 T-adapter assembly 1 DT, HD30 connector
799-601-9300 T-adapter assembly 1 DRC26-24, 40-pin
799-601-7360 Adapter 1 Relay (5 pins)
799-601-3450 Adapter 1 VHMS download harness
799-601-4100 T-adapter assembly 1 Connected with engine
795-799-5530 q T-adapter 1 Engine coolant, oil, fuel temperature
795-799-5540 q T-adapter 1 Boost temperature sensor
799-601-4130 q T-adapter 1 Ne sensor
Diagnosis sensor and har-
– 799-601-4150 q T-adapter 1 Oil pressure sensor
ness
799-601-4211 q T-adapter 1 Controller (50 poles)
799-601-4240 q Socket 1 Ambient pressure sensor
799-601-4250 q Socket 1 Boost pressure sensor
799-601-9020 q T-adapter 1 EGR EGR valve, injector
799-601-9040 q T-adapter 1 EGR valve potentiometer sensor
799-601-9420 q T-adapter 1 Common rail pressure sensor
799-601-9430 q T-adapter 1 Supply pump PCV
799-601-9030 T-adapter 1 G sensor
D375A-6 30-5
(01)
DRAFT
Testing engine speed

3. Measuring high idle speed
k Stop the machine on level ground, lower the 1) Start the engine and set the fuel control dial
work equipment to the ground, stop the en- in the high idle (MAX) position.
gine, and set the parking brake lever and 2) Set the PCCS lever, blade control lever, and
work equipment lock lever in the lock posi- ripper control lever in neutral and measure
tion. the engine speed.
a Measure the engine speed under the following a The parking brake lever and work equip-
conditions. ment lock lever may be kept in the LOCK
q Coolant temperature:
position.
q Power train oil temperature:
4. Measuring decelerator pedal speed
1) Start the engine and set the fuel control dial
q Hydraulic oil temperature: 45 – 55°C
in the high idle (MAX) position.
q Gear shift mode: Manual
2) Set the PCCS lever, blade control lever, and
ripper control lever in neutral, press the
decelerator pedal to the stroke end, and
1. Preparation work
measure the engine speed.
Measure the engine speed with the Adjustment
a The parking brake lever and work equip-
function in the service mode of the machine
ment lock lever may be kept in the LOCK
monitor.
position.
a For the operating method, see "Special func-
tions of machine monitor (EMMS)".
q Adjustment ID: 0530 (Stall mode)
5. Measuring torque converter stall speed
a When stalling the torque converter for a pur- 1) Start the engine and set the fuel control dial
pose other than measuring the engine in the low idle (MIN) position.
speed, be sure to use this adjustment code, 2) Operate the shiftup (UP) switch of the PCCS
too. lever and set the preset mode display section
to [F3-R3].
a The preset mode display section (at the
right bottom of the screen) can be set to
[F3-R3] only while the Adjustment func-
tion is selected.
3) While pressing the brake pedal securely, set
the parking brake lever in the free position
and set the direction of PCCS lever in the
forward position.
a Before going to the next step, check that
[F3] is displayed in the gear speed display
section (at the right bottom of the screen).
a Keep the steering unit in neutral.
4) Press the decelerator pedal and set the fuel
control dial in the high idle (MAX) position.
2. Measuring low idle speed
5) Return the decelerator pedal slowly to stall
1) Start the engine and set the fuel control dial
the torque converter with the engine at high
in the low idle (MIN) position.
idle.
k Keep pressing the brake pedal secure-
2) Set the PCCS lever, blade control lever, and
ripper control lever in neutral and measure
ly and keep your right foot on the de-
the engine speed.
celerator pedal for safety until the
a The parking brake lever and work equip-
work is finished.
ment lock lever may be kept in the LOCK
6) Right after the power train oil temperature
position.
gauge (T/C TEMPERATURE) indicates 118
°C, return the PCCS lever to the neutral
position.
30-6 D375A-6
(03)
DRAFT
a The top of the green range of the power 2) Operate the shiftup (UP) switch of the PCCS
train oil temperature gauge indicates lever and set the preset mode display section
about 118 – 120 °C. to [F3-R3].
7) Repeat above steps 3) – 6) 3 times. a The preset mode display section (at the
8) Perform steps 3) - 5) again and measure the right bottom of the screen) can be set to
engine speed when the power train oil [F3-R3] only while the Adjustment func-
temperature gauge (T/C TEMPERATURE) tion is selected.
indicates 118 °C. 3) Set the work equipment lock lever in the free
a Immediately after finishing measuring, reposition and operate the ripper control lever
turn the PCCS lever to the neutral posi- to set the ripper lift cylinder to the raise stroke
tion and lower the power train oil end.
temperature with the engine at high idle. 4) While pressing the brake pedal securely, set
6. Measuring torque converter stall speed and set the direction of PCCS lever in the
(Inspection on Pm clinic screen) forward position.
1) Start the engine and set the fuel control dial a Before going to the next step, check that
in the low idle (MIN) position. [F3] is displayed in the gear speed display
2) Switch the machine monitor to the "Pm clinic" section (at the right bottom of the screen).
function display of the service mode. a Keep the steering unit in neutral.
a For the operating method, see "Special 5) Press the decelerator pedal and set the fuel
functions of machine monitor (EMMS)". control dial in the high idle (MAX) position.
6) Return the decelerator pedal slowly to stall
the torque converter with the engine at high
idle.
k Keep pressing the brake pedal secure-
work is finished.
7) Right after the power train oil temperature
gauge (T/C TEMPERATURE) indicates 118
°C, return the PCCS lever to the neutral
position.
a The top of the green range of the power
train oil temperature gauge indicates
about 118 – 120 °C.
3) Operate the shiftup (UP) switch of the PCCS
lever and set the preset mode display section 8) Repeat above steps 4) – 7) 3 times.
to [F2-R2]. 9) Perform steps 4) - 6) again, operate the
4) While pressing the brake pedal securely, set ripper control lever to relieve the ripper raise
the parking brake lever in the free position system, and measure the engine speed
and set the direction of PCCS lever in the when the power train oil temperature gauge
forward position. (T/C TEMPERATURE) indicates 118 °C.
a Immediately after finishing measuring, re-
5) Shift to 3rd gear by operating the shift-up
turn the PCCS lever to the neutral posi-
(UP) switch of PCCS lever.
tion and lower the power train oil
temperature with the engine at high idle.
a Keep the steering unit in neutral. 8. Measuring torque converter stall + Work
equipment relief speed (Full stall speed)
6) Repeat the measuring process in a similar
(Inspection on Pm clinic screen)
way by following Step 4) and later of "5.
Measuring torque converter stall speed". 1) Start the engine and set the fuel control dial
in the low idle (MIN) position.
7. Measuring torque converter stall + work equip- 2) Switch the machine monitor to the "Pm clinic"
ment relief speed (Full stall speed) function display of the service mode.
1) Start the engine and set the fuel control dial a For the operating method, see "Special
in the low idle (MIN) position. functions of machine monitor (EMMS)".
D375A-6
(03) 30-7
DRAFT
3) Operate the shift up (UP) switch of the PCCS

lever and set the preset mode display section
to [F2-R2].
forward position.
(UP) switch of PCCS lever.
6) Repeat the measuring process in a similar
way by following Step 5) and later of "7.
Measuring torque converter stall + Work
equipment relief speed (Full stall speed)".
30-8
30-7-1 D375A-6
(03)
DRAFT
D375A-6 30-7-2
(03)
DRAFT
Testing intake air pressure (boost pressure)
Testing intake air pressure (boost 2) Test the boost pressure when the torque
pressure) converter is stalled at high idle speed.
a For the torque converter stall procedure,
see Step 3) and later in "6. Measuring
a Testing instruments of intake air pressure (boost torque converter stall speed (Inspection
pressure) on Pm clinic screen)" of "Testing engine
Symbol Part No. Part name speed".
A 799-201-2202 Boost gauge kit
2. Testing with boost gauge kit
k Stop the machine on level ground, lower the 1) Open the engine left cover.
work equipment to the ground, stop the en- 2) Remove boost pressure pickup plug (1) at
gine, and set the parking brake lever and the rear of the air intake manifold.
work equipment lock lever in the lock posi-
tion.
k When installing and removing the testing in-
strument, take care not to touch a hot part of
the engine.
a A nipple (quick coupler) is installed to the intake
air pressure (boost pressure) pickup port of the
Pm clinic specification machine.
a Measure the intake air pressure (boost pres-
sure) under the following condition.
q Coolant temperature:
q Hydraulic oil temperature: 45 – 55°C 3) Install nipple [1] of boost gauge kit A and
q Working mode: P-mode connect gauge [2].
a Normally, the intake air pressure (boost pres-
sure) should be tested while the engine is run-
ning at the rated output. In the field, however, an
approximate value can be obtained by stalling
the torque converter.
1. Testing using machine monitor (Pm clinic)

1) Turn the starting switch to the ON position
and switch the machine monitor to the "Pm
clinic" function display of the service mode.
a For the operating method, see "Special
functions of machine monitor (EMMS)".
a The VHMS specification machine is
shown as an example in the figure.
4) Run the engine at middle or higher speed

and bleed oil from the hose.
30-10
30-8 D375A-6
(03)
DRAFT
Testing intake air pressure (boost pressure)
a Install the connecting parts of the gauge

and hose about a half and open the
self-seal on the hose side repeatedly, and
the oil will be drained.
a If Pm kit (A) is available, you use the
air-bleeding coupling (790-261-1130) in
that kit.
a If oil is left in the hose, the gauge does not
work. Accordingly, be sure to drain the oil.
5) Switch the machine monitor to the "Adjust-

ment" function display of the service mode.
q Adjustment code: 0530 (Stall mode)
6) Test the intake air pressure (boost pressure)

while the engine is running at high idle and
the torque converter is stalling.
see "5. Measuring torque converter stall
speed" of "Testing engine speed".
7) After finishing measuring, remove all test

tools in order to return the machine status as
it was.
q Remove the gasket sealant remaining on
the threads of the removed plug with a
wire brush and apply new adhesive or
gasket sealant to the plug before install-
ing.
2 Plug: LT-2 or LG-5
3 Plug: 9.8 – 19.6 Nm {1.0 – 2.0 kgm}
D375A-6 30-9
(03) 30-11
DRAFT
Testing exhaust temperature
a Checking tools for exhaust gas temperature

Sym-
Part No. Part name
bol
B 799-101-1502 Digital thermometer
a Checking tools for exhaust gas temperature (for

Pm clinic specification machine)
Because each Pm clinic specification machine
has an exhaust gas temperature sensor,
prepare an adapter for the electrical connection
between the exhaust gas temperature sensor
and the digital temperature gauge.
Sym-
Part No. Part name
bol
B 799-101-1502 Digital thermometer
― 799-201-1150 Adapter connector
k Stop the machine on level ground, lower the

work equipment to the ground, stop the en-
gine, and set the parking brake lever and
tion.
k Remove and install the testing tools after the
4) Procedure for measuring at maximum
exhaust manifold temperature has lowered.
temperature while troubleshooting
a Test the exhaust temperature under the follow-
Check the maximum exhaust gas tempera-
ing conditions.
ture during actual operations.
q Engine coolant temperature: Within operat-
a Use the digital temperature gauge in the
ing range
PEAK mode.
a The exhaust gas temperature largely de-
pends on the ambient air temperature (in-
take air temperature of engine).
Accordingly, if any abnormal value is ob-
tained, correct it using the following calcu-
lation.
1. Measuring with the digital temperature q Corrected value [°C] = Measured
gauge value + 2 x (20 - Ambient temperature)
1) Open the engine right side cover, and
remove the heat insulation cover. 2. Periodic measurement procedure using the
preventive maintenance service (Pm clinic)
2) Remove the exhaust gas temperature a If the torque converter alone has stalled, the
inspection plug. torque converter oil will overheat before the
exhaust gas temperature stabilizes. There-
3) Install sensors [1] of digital temperature fore, check the exhaust gas temperature ac-
gauge B and connect them to meter [2]. cording to the following procedure.
a Clamp the wiring harness of the digital 1) Turn the starting switch to the ON position
thermometer not to come into contact and switch the machine monitor to the
with any hot parts during measuring. "Adjustment" function display of the service
mode.
functions of machine monitor (EMMS)"
section.
30-12
30-10 D375A-6
(03)
DRAFT
k When the power train oil temperature

(T/C TEMPERATURE) reaches 118 °C,
return the PCCS lever to the neutral
position immediately and lower the
power train oil temperature while the
engine is running at high idle speed.
2) Run the engine to warm it up.

a The standard warm-up operation is as fol-
lows.
q Low idle: 3 minutes
q Run at a medium speed: 1 minute
q High idle: 1 minute
3) Set the fuel control dial to the low idle (MIN) 11)After finishing measuring, remove all test
position. tools in order to return the machine status as
4) Operate the shiftup (UP) switch of the PCCS it was.
to [F3-R3]. 3. Testing for VHMS specifications
a The preset mode display section (at the 1) Turn the starting switch to the ON position
right bottom of the screen) can be set to and switch the machine monitor to the "Pm
[F3-R3] only while the Adjustment func- clinic" function display of the service mode.
tion is selected. a For the operating method, see "Special
5) Set the work equipment lock lever in the free functions of machine monitor (EMMS)".
position and operate the ripper control lever
to set the ripper lift cylinder to the raise stroke
end.
forward position.
7) Press the decelerator pedal and set the fuel
8) Slowly release the decelerator pedal and
stall the torque converter at engine high idle 2) Run the engine to warm it up.
speed. Relieve the ripper raise system, and a The standard warm-up operation is as fol-
measure the maximum exhaust gas temper- lows.
ature when the power train oil temperature q Low idle: 3 minutes
(T/C TEMPERATURE) shows 118 °C. q Run at a medium speed: 1 minute
k Keep pressing the brake pedal secure- q High idle: 1 minute
work is finished.
9) Depress the decelerator pedal again.
10)Repeat Steps 8) and 9) several times and
record the highest exhaust gas temperature.
D375A-6 30-11
(03) 30-13
DRAFT
3) Set the fuel control dial to the low idle (MIN)

position.
4) Operate the shiftup (UP) switch of the PCCS
to [F2-R2].
forward position.
(UP) switch of the PCCS lever.
7) Repeat the measuring process in the similar
way by following Step 5) and later of "2. Peri-
odic measurement procedure using the
preventive maintenance service (Pm clinic)".
30-14
30-11-1 D375A-6
(03)
DRAFT
D375A-6 30-11-2
(03) 30-15
DRAFT
Testing exhaust gas color
Testing exhaust gas color 2. Checking with smoke meter C2

1) Insert probe [1] of the smoke meter C2 into
the outlet of the exhaust pipe and fix it to the
a Checking tools for exhaust gas color
exhaust pipe using a clip.
Symbol Part No. Part name
1 799-201-9001 Handy smoke checker
— Commercially
2 Smoke meter
available

tion.
k Be careful not to touch any hot part when re-
moving or installing the checking tools.
a If an air source and an electric power source are
not available in the field, use a handy smoke
checker C1. When recording official data, use a
smoke meter C2. 2) Connect the probe hose, receptacle of the
a Check the exhaust gas color under the following accelerator switch, and air hose to the smoke
condition. meter C2.
q Engine coolant temperature: Within operat- a Limit the supplied air pressure to 1.5 MPa
ing range {15 kg/cm2}.
q Working mode: P-mode 3) Connect the power cable to an AC recep-
q Gear shift mode: Manual tacle.
a Before connecting the cable, check that
1. Checking with a handy smoke checker C1 the power switch of the smoke meter is
1) Stick a sheet of filter paper to smoke checker turned OFF.
C1. 4) Loosen the cap nut of the suction pump and
2) Insert the exhaust gas intake pipe into the fit the filter paper.
exhaust pipe. a Fit the filter paper securely so that the ex-
3) Start the engine. haust gas will not leak.
4) Accelerate the engine suddenly or run it at 5) Turn on the power switch of smoke meter C2.
high idle and operate the handle of smoke
checker C1 so that the filter paper will absorb
the exhaust gas.
5) Remove the filter paper and compare it with

the attached scale.
6) After finishing checking, remove all test tools.
30-12 D375A-6
(03)
DRAFT
Testing exhaust gas color
6) Start the engine.

7) Accelerate the engine suddenly or run at high
idle, and depress the accelerator switch of
smoke meter C2 at the same time to collect
the exhaust gas color on the filter.
8) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated
value.
9) After testing, remove measuring tools and
reset the machine to its original status.
D375A-6 30-13
(01)
DRAFT
Adjusting valve clearance
a Adjusting tool for valve clearance

Sym-
Part No. Part name
bol
Commercially
D Feeler gauge
available

tion.
1. Remove the engine hood.
2. Remove cylinder head cover.

a Remove covers (1) and (2), bracket (3) and 6
cylinder head covers (4). For details, see
Disassembly and assembly volume, "Re-
moval and installation of cylinder head as-
sembly".
4. When the No. 1 cylinder is at the compression

top dead center, adjust the valve clearance indi-
cated by q of the valve layout plan.
a Loosen locknut (8) of adjustment screw (7),
insert feeler gauge D between crosshead (9)
and rocker arm (10), and rotate adjustment
screw (7) so that the feeler gauge will be
hitched a little.
3. Remove inspection hole plug (5) from the front a Valve clearance
side of the timing gear case and rotate the crank- q Air intake valve: 0.32 mm
shaft forward to set notch (a) of the supply pump q Exhaust valve: 0.62 mm
drive gear to the center of the inspection hole.
a Rotate the engine with the cranking device 5. While fixing adjustment screw (7), tighten
(6) on the rear left of engine. lock-nut (8).
a On the right of figure upper, the com- 3 Locknut:
pres-sion top dead center of No. 1 cylinder is 57.8 – 77.4 Nm {5.9 – 7.9 kgm}
shown and on the right, the top dead cen-ter a After tightening the lock nut, check the valve
of No. 6 cylinder is shown. clearance again.
a When the No. 1 cylinder is at the com-
pres-sion top dead center, the rocker arm
can be moved by the valve clearance with the
hand.
30-14 D375A-6
(01)
DRAFT
6. Rotate the crackshaft forward one turn and

adjust the valve clearance indicated by Q of the
valve layout plan.
a The adjustment method is the same as
above.
7. After finishing adjustment, return the removed-

parts.
3 Cylinder head cover mounting bolt :
{No. 1, 3, 4, 5, 6 cylinders}
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
{No.2 cylinder}
58.8 – 73.5 Nm {6 – 7.5 kgm}
D375A-6 30-15
(01)
DRAFT
Measuring compression pressure

a Remove the terminal on the injector side and
a Testing tools for compression pressure the mounting bolt on the rocker housing side,
Sym- and remove the injector wiring harness from
Part No. Part name the injector.
bol
1 795-502 1590 Compression gauge a Loosen the 2 terminal nuts alternately.
795-611-1220 Adapter
2
E 6261-71-6150 Gasket 5. Remove injector holder (7), and remove injector
795-799-5410 Adapter
4 (8).
795-799-5420 Remover

tion.
k When testing the compression pres-sure,
take care not to burn yourself on the exhaust
manifold, muffler, etc. or get caught in a ro-
tating part.
a Measuring the compression pressure under the
following condition.
(Engine oil temperature:40 – 60°C)
a Insert the pin (indicated by the arrow) at the
1. Remove the engine hood.
end of the tool E3 into hole (a) of adaptor (9),
and pull out the injector by moving the weight
2. Remove cylinder head cover. of tool E3 up and down.
a Remove covers (1) and (2), bracket (3) and
cylinder head cover (4) to test the compres-
sion pressure. For details, see Disassembly
and assembly volume, "Removal and instal-
lation of cylinder head assembly".
3. Adjust the valve clearance of the cylinder to be

inspected. For details, see "Adjusting valve
clearance".
4. Disconnect fuel high-pressure tube (5) and

injector wiring harness (6).
30-16 D375A-6
(01)
DRAFT
6. Install adapter E2 to the mounting hole on the 2) Fit adaptor (9) to injector (8), and press it in
injector and the compression gauge E1. as a unit to the cylinder head by hand.
a Fit the gasket to the injector end without fail
a Fix the adapter with the injector holder.
3 Holder mounting bolt :
58.8 – 73.5 Nm {6 – 7.5 kgm}
a Apply a little amount of engine oil to the con-
necting parts of the adapter and gauge so
that air will not leak easily.
3) Install holder (7) and tighten bolt (13) and

washer (14) temporarily.
2 Spherical surface of washer: Engine
oil
4) Install the fuel high-pressure tube, and
temporarily tighten sleeve nut (5).
5) Fully tighten bolt (13).
7. Turn the starting switch to the ON position and 3 Bolt:
switch the machine monitor to "Cylinder Cut-Out 58.8 – 73.5 Nm {6 – 7.5 kgm}
Operation" function display of the service mode. 6) Fully tighten sleeve nut (5).
a For the operating method, see Special func- 3 Sleeve nut :
tions of machine monitor (EMMS). 39.2 - 44.1 Nm {4 - 4.5 kgm}
k Be sure to set all the injectors in the no-in-
jection state so that the engine will not
start.
a Install the injector wiring harness according

to the following procedure
1) Assemble injector wiring harness (6) from the
8. Rotate the engine with the starting motor and inside of rocker arm housing and fix the
test the compression pressure. connector side with plate (15).
a Read the pressure gauge pointer when it is
stabilized.
9. After testing, remove measuring tools and reset
the machine to its original status.
a Install the injector and fuel high-pressure
tube according to the following procedure.
1) Install gasket (10) and O-rings (11) and (12).
a Take care not to install O-ring (11) to the
groove (b).
2 O-ring: Engine oil
D375A-6 30-17
(03) 30-21
DRAFT
2) Fit spacer (16) and fix it with bolt (17).

3) Alternately tighten nuts (18) on the injector
side.
3 Nut:
2 ± 0.2 Nm {0.2 ± 0.02 kgm}
a Tighten the cylinder head cover mounting

bolt with the following torque.
{No. 1, 3, 4, 5, 6 cylinders}
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
{No.2 cylinder}
58.8 - 73.5 Nm {6 - 7.5 kgm}
30-18 D375A-6
(01)
DRAFT
Testing blow-by pressure

a Measuring tools for blow-by pressure 3) Turn the starting switch to the ON position
Sym- and switch the machine monitor to the
Part No. Part name
bol "Adjustment" function display of the service
F 799-201-1504 Blow-by checker mode.
k Stop the machine on level ground, lower the a For the operating method, see "Special
work equipment to the ground, stop the en- functions of machine monitor (EMMS)".
tion.
a Measure the blow-by pressure under the follow-

ing condition.
ing range
4) Run the engine at high idle and test the

1. Testing with blowby kit blow-by pressure when the torque converter
1) Open the engine left side cover and pull out stalls.
blow-by hose (1). a For the torque converter stall procedure,
2) Install nozzle [1] and hose [2] of blowby speed" of "Testing engine speed".
checker F to blowby hose (1) and connect a Blow-by varies greatly according to the
them to gauge [3]. condition of the engine. Therefore, if the
blow-by value is considered abnormal,
check for problems connected with defec-
tive blow-by, such as excessive oil con-
sumption, defective exhaust gas color,
and prematurely dirty or deteriorated oil.
it was.
D375A-6 30-19
(03) 30-23
DRAFT
2. Testing for VHMS specifications

2) Test the blowby pressure when the torque

converter is stalled at high idle speed.
see Step 3) and later in "6. Measuring
torque converter stall speed (Inspection
on Pm clinic screen)" of "Testing engine
speed".
30-24
30-20 D375A-6
(03)
DRAFT
Testing engine oil pressure
Testing engine oil pressure 2. Measuring with oil pressure gauge

1) Open the engine left cover.
a Measuring tools for engine oil pressure 2) Remove oil pressure test plug (1).
Sym-
Part No. Part name
bol
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
G 3 799-401-2320 Gauge
799-101-5230 Nipple
4
6215-81-9720 O-ring

tion.
3) Install nipple G3 and connect it to gauge G2.
a A nipple (quick coupler) is installed into the hy-
draulic oil inspection port of the engine for the
Pm clinic specification machine.
a Measure the engine oil pressure under the fol-
lowing condition.
q Engine oil temperature: Min. 70 °C
ing range
1. Checking with machine monitor (Pm clinic)

1) Turn the starting switch ON and set the
machine monitor to the "Pm clinic" function
display of the service mode. 4) Run the engine and measure the engine oil
a For the operating method, see "Special pressure at low idle and also at high idle.
2) Run the engine and measure the engine oil 5) After finishing measuring, remove all test
pressure at low idle and also at high idle. tools in order to return the machine status as
it was.
D375A-6 30-21
(03) 30-25
DRAFT
Testing EGR valve and bypass valve drive oil pressure
Testing EGR valve and bypass

valve drive oil pressure
a Measuring instruments for EGR valve and by-

pass valve drive pressure
Sym-
Part No. Part name
bol
1
G 795T-690-1110 Block
4 01435-00835 Bolt
07000-E2012 O-ring
k Stop the machine on level ground, lower the 5. Install the nipple (component part of G1) into
work equipment to the ground, stop the en- measurement hole (a) (size: PT 1/8) of tool G4
gine, and set the parking brake lever and and connect gauge [1] of hydraulic tester G1.
work equipment lock lever in the lock posi- Reference: The oil pressure to be measured will
tion. be a maximum of approximately 3 MPa
{30 kg/cm2}.
a Drive oil pressure for EGR and bypass valve will
be checked under the following condition.
q Engine oil temperature: 40 – 60 °C
1. Open the left side cover.
2. Remove flange mounting bolts (2) and clamp

mounting bolt (3) of oil supply tube (1) that drives
the EGR valve on the EGR valve side.
3. Install tool G4 on the oil supply portion of the

EGR valve.
3 Mounting bolt (4) (component part of G4):
27 – 34 Nm {2.8 – 3.5 kgm}
4. Install oil supply tube (1) that drives the EGR

valve on the top of tool G4 and tighten flange
mounting bolts (2) on the EGR valve side.
3 Flange mounting bolt (2):
27 – 34 Nm {2.8 – 3.5 kgm}
30-26
30-22 D375A-6
(03)
DRAFT
Testing EGR valve and bypass valve drive oil pressure
6. Start the engine and measure the oil pressure at

low idle and high idle.
7. After testing, remove measuring tools and reset

the machine to its original status.
a Replace the flange O-ring on the EGR valve
side with new one.
3 Flange mounting bolt (2):
27 - 34 Nm {2.8 - 3.5 kgm}
3 Clamp mounting bolt (3):
58.8 - 73.5 Nm {6 - 7.5 kgm}
D375A-6 30-23
(01)
DRAFT
Handling of fuel system devices
Handling of fuel system devices
a Precautions for checking and maintaining fuel

system
The common rail fuel injection system (CRI)
consists of more precise parts than the conven-
tional fuel injection pump and nozzle. If foreign
matter enters this system, it can cause a trouble.
When testing and maintaining the fuel system,
take care more than the past. If dust, etc. sticks
to any part, wash that part thoroughly with clean
fuel.
a Precautions for replacing fuel filter cartridge
Be sure to use Komatsu genuine fuel filter
cartridge.
The fuel injection pump and nozzle of the
common rail type fuel injection system (CRI) are
consisted of more precision parts than those
used for the current pumps and nozzles. This
system, therefore, employs a special filter with
highly efficient filtering performance to prevent
mixing of foreign substances. Thus, substituting
it with a non-genuine filter could cause troubles
in the fuel system. It is strictly prohibited to use
such part.
30-24 D375A-6
(01)
DRAFT
Releasing residual pressure from fuel system
Releasing residual pressure from

fuel system
a Pressure is generated in the low-pressure circuit

and high-pressure circuit of the fuel system while
the engine is running.
Low pressure circuit: Feed pump – Fuel main
filter – Fuel supply pump
High-pressure circuit: Fuel supply pump –
Common rail – Fuel injector
a The pressure in both low-pressure circuit and
high-pressure circuit lowers to a safety level au-
tomatically 30 seconds after the engine is
stopped.
a Before the fuel circuit is tested and its parts are
removed, the residual pressure in the fuel circuit
must be released completely. Accordingly ob-
serve the following.
k Before testing the fuel system or removing
its parts, wait at least 30 seconds after stop-
ping the engine until the residual pressure in
the fuel circuit is released. (Do not start the
work just after stopping the engine since
there is residual pressure.)
D375A-6 30-25
(01)
DRAFT
Testing fuel pressure
Testing fuel pressure 3. Install nipple H3 and connect it to gauge H2.
a Measuring tools for fuel pressure

Sym-
Part No. Part name
bol
1
2 799-401-2320 Gauge
H
799-101-5160 Nipple (R 1/8)
3 795-471-1450 Adapter (M8 x 1.25)
07005-00812 Gasket

work equipment to the ground, stop the en- 4. Start the engine and inspect the fuel pressure
gine, and set the parking brake lever and with the engine running at high idle or at the
work equipment lock lever in the lock posi- equivalent of rated output speed (stall load).
tion. a If the fuel pressure is in the following range, it
is normal.
a Test only the fuel pressure in the low-pressure Engine speed Fuel pressure
circuit from the feed pump through the engine At high idle or at the 0.15 – 0.3 MPa
controller cooler and fuel filter to the supply equivalent of rated out-
put speed {1.5 – 3 kg/cm2}
pump.
k Since the pressure in the high-pressure cir-
cuit from the supply pump through the com-
mon rail to the injector is very high, it cannot
be measured.
a Test the fuel pressure under the following condi-
tions.
1. Open the engine left cover.
2. Remove plug (1).
5. After finishing measuring, remove all test tools in

order to return the machine status as it was.
30-30
30-26 D375A-6
(03)
DRAFT
Handling of reduced cylinder mode operation
Handling of reduced cylinder Handling of no injection cranking

mode operation operation
a Reduced cylinder mode operation means to run a No-injection cranking means to crank the engine
the engine with the fuel injectors of 1 or more cyl- with the starting motor while all the injections are
inders disabled electrically to reduce the number stopped electrically. The purpose and effect of
of effective cylinders. The purposes and effects this operation are as follows.
of this operation are as follows. q When a machine or engine has been stored for
a long time, implementing the no-injection crank-
1. This operation is used to find out a cylinder ing before starting the engine lubricates the en-
which does not output power normally (or, gine parts and thus prevents its seizure.
combustion in it is abnormal). a Do not use the no injection cranking function for
any purpose other than that mentioned above.
2. When a cylinder is selected for the reduced a For the no injection cranking procedure, see
cylinder mode operation, if the engine speed and "Special functions of machine monitor
output do not change from the normal operation (EMMS)"section.
(all-cylinder operation), that cylinder has 1 or
more defects.
q Leakage through cylinder head gasket
q Defective injection
q Defective piston, piston ring, and cylinder lin-
er
q Defective valve mechanism (Moving valve
system)
q Defect in electrical system
3. Since the common rail fuel injection system

controls the injector of each cylinder electroni-
cally, the operator can perform the cylinder cut
out mode operation easily with switches to find
out a defective cylinder.
a To implement reduced cylinder mode opera-
tion, see "Special functions of monitor panel
(EMMS)".
a Use the reduced cylinder mode for only the
purpose of troubleshooting.
D375A-6 30-27
(03) 30-31
DRAFT
Testing leakage from pressure limiter and return rate from injector
a Testing instruments for fuel return rate and leak- a Test the fuel return rate and leakage under the
age following conditions.
Symbol Part No. Part name q Working mode: P-mode
1 6167-11-6640 Spacer q Gear shift mode: Manual
2 6206-71-1770 Joint
Commercially
3 Hose
available
Commercially
J 4 Hose
available
Commercially
5 Measuring cylinder
available
Commercially
6 Stopwatch
available
a Prepare an oil pan of about 20 l to receive the oil
that will flow out during the testing process..

tion.
30-28
30-32 D375A-6
(03)
DRAFT
1. Preparation work
1) Remove tube (3) between common rail (1)
and block (2).
2) Insert spacer J1 on block (2) side and tighten
the removed joint bolt again.
3 Joint bolt:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
a Fit the gaskets to both ends of the spacer.
2. Testing leakage from pressure limiter

1) Route inspection hose J3 in such that it may
be free from slack and then insert its end to
the oil pan (saucer).
and switch the machine monitor to "Adjust-
ment" function display of the service mode.
3) Insert joint J2 to common rail (1) side and a For the operating method, see "Special
tighten the currently removed joint bolt again. functions of machine monitor (EMMS)".
3 Joint bolt:
17.7 – 22.6 Nm {1.8 – 2.3 kgm}
a Be sure to fit the gaskets to both ends of
the joint.
4) Connect inspection hose J3 to the tip of joint
J2.
a Bind the connecting part of the test hose
with a wire, etc. to prevent it from coming
off.
a The above is the preparation work for
testing the leakage from the pressure lim-
iter.
3) Run the engine at high idle and stall the

torque converter. After the engine speed is
stabilized, measure the return rate in 1
minute with measuring cylinder J5.
a You may test for 20 seconds and judge by
multiplying the result by 3.
a If the leakage from the pressure limiter is
in the following range, it is normal.
Engine speed Leakage
(rpm) (spill) (cc/min)
Equivalent to rated oper-
Max. 10
ation
D375A-6 30-29
(03) 30-33
DRAFT

a You may test for 20 seconds and judge by
multiplying the result by 3.
a If the supply pump is not supplying fuel,
the engine speed may not rise. In this
case, record the engine speed, too, dur-
ing the test.
a If the return rate (spill) from the injector is
in the following range, it is normal.
Engine speed
(Equivalent to rated output Return (Spill) limit
operation load) (spill) (cc/min)
4) After finishing testing, stop the engine. (rpm)
1,600 960
3. Testing return rate from injector 1,700 1,020
1,800 1,080
1) Remove the hose (4) at spill outlet and
1,900 1,140
connect inspection hose J4 in stead. Then
2,000 1,200
insert the hose end to the oil pan (saucer).
2) Turn the starting switch to the ON position 4) After finishing testing, stop the engine.
and switch the machine monitor to "Adjust-
ment" function display of the service mode. 4. Work after finishing testing
q Adjustment code: 0530 (Stall mode) After finishing all testing, remove the testing
a For the operating method, see "Special tools and return the removed parts.
3) Run the engine at high idle and stall the

torque converter. After the engine speed is
stabilized, measure the return rate in 1
minute with measuring cylinder J5.
30-34
30-30 D375A-6
(03)
DRAFT
Bleeding air from fuel circuit

3. Open the engine left cover.
work equipment to the ground, stop the en- 4. Open air bleeding valve (2).
tion.
a Bleed air from the fuel circuit in the following cas-
es according to this procedure.
q When the fuel filter is replaced
q When fuel is used up
q When the engine is started for the first time
after the fuel piping or supply pump is re-
placed
a When the fuel filter is replaced, don't feed fuel to
the filters, including both the main and pre-filter.
k While the electric priming pump is in opera-
tion, pressure is applied to the fuel circuit. Do
not loosen the air bleeding plug at this time,
since the fuel may spout out. 5. Set electric priming pump switch (3) inside the
engine compartment to the "ON" position.
1. Set the starting switch to OFF position. a Lamp (4) will start flashing and operation of
the electric priming pump will be started.
2. Check that supply valve (1) of the fuel tank is in
the "OPEN" position.
D375A-6 30-31
(01)
DRAFT
a The built-in timer of this switch automatically 2) While the electric priming pump is operating,
starts or stops operation of the electric prim- crank the engine with the starting motor.
ing pump. (See the figure below) a If the engine does not start, wait for about
a Operation of the electric priming pump is 2 minutes and then repeat steps 1) and
stopped as long as flashing of the lamp is 2).
continued. It is not an error. a Do not rotate the starting motor for more
a Shifting the switch to “OFF” while the lamp than 20 seconds continuously.
is flashing turns off the lamp and stops the 3) If the engine starts, run it at low idle for 5
electric priming pump, too. minutes to bleed all air from the fuel circuit.
6. After the specified time (about 7 minutes), lamp

(4) goes off automatically and the electric
priming pump stops.
a When the fuel filter alone was replaced,
above completes bleeding air..
7. When fuel is not provided in the fuel circuit such

as when run out of fuel occurred or when
replacement of the fuel pipe or supply pump was
done, set switch (3) to “ON” again after the elec-
tric priming pump is automatically stopped.
8. Bleeding air, in this case, completes as lamp (4)

went off.
9. Close air bleeding valve (2).
10. Start the engine with the starting motor.

a Do not rotate the starting motor for more than
20 seconds continuously.
a The air in the high-pressure circuit is bled au-
tomatically if the engine is cranked.
11. If the engine starts, run it at low idle for 5 minutes

to bleed all air from the fuel circuit.
a If the engine does not start, the air may have
not been bled from the low pressure circuit. In
this case, try to start the engine again accord-
ing to the following procedure.
a Work with air bleeding valve (2) closed.
a If you failed to start the engine, wait for about
2 minutes and then try to start again.
1) Set electric priming pump switch (3) to the
"ON" position.
30-32 D375A-6
(01)
DRAFT
Testing fuel circuit for leakage
Testing fuel circuit for leakage

8. Run the engine at high idle and load it.
k Very high pressure is generated in the a Relieve by tilting the blade or raising the rip-
high-pressure circuit of the fuel system. If per.
fuel leaks while the engine is running, it is
dangerous since it can catch fire. 9. Check the fuel piping and devices for fuel
After checking the fuel system or removing its leakage.
parts, check it for fuel leakage according to the a Check mainly around the high-pressure cir-
following procedure. cuit parts coated with the color checker for
a Clean and degrease the engine and the parts fuel leakage.
around it in advance so that you can check it a If fuel leakage is recognized, repeat the pro-
easily for fuel leakage. cedure from step 1 after repairing the leak-
age.
1. Spray color checker (developer) over the fuel a If no fuel leakage is detected, check is com-
supply pump, common rail, fuel injector, and pleted.
joints of the high-pressure piping.
2. Start the engine, keep its speed below 1,000

rpm, and stop it when its speed stabilizes.
3. Check the fuel piping and devices for fuel

leakage.
a Check mainly around the high-pressure cir-
cuit parts coated with the color checker for
fuel leakage.
a If fuel leakage is recognized, repeat the pro-
cedure from step 1 after repairing the leak-
age.
4. Run the engine at low idle.

leakage.
fuel leakage.
age.
6. Run the engine at high idle.

leakage.
fuel leakage.
age.
D375A-6 30-33
(01)
DRAFT
Replacing and adjusting alternator and air conditioner compressor belt
Replacing and adjusting alternator and air conditioner compressor belt

tion.
a The auto-tensioner is provided for the alternator

and air conditioner compressor belt. Thus, test-
ing and adjustment of the belt is usually not nec-
essary.
a Following describes the auto-tensioner adjust-
ment procedure to be employed for the belt re-
placement.
1. Open the engine left side cover.
2. Loosen locknut (1), tighten push bolt (2) fully and

then loose in tension pulley (4).
3. Replace belt (5).
4. After replacing the belt, loosen push bolt (2) until

its installed length (a) is 90 mm.
5. Tighten locknut (1).
30-34 D375A-6
(01)
DRAFT
Measuring fan speed
Measuring fan speed

tion.
a Measure the fan motor speed under the follow-
ing condition.
1. Start the engine and set the machine monitor to

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

idle, measure the fan speed
3. After finishing measurement, remove the

measuring instruments and return the removed
parts.
a If the starting switch is turned to the OFF po-
sition, the fan 100% mode is reset.
D375A-6 30-35
(01)
DRAFT
Testing fan circuit oil pressure
Testing fan circuit oil pressure

4. Install nipple [2] of hydraulic tester S1 and
a Testing instruments for fan circuit oil pressure connect it to oil pressure gauge [1].
Symbol Part No. Part name a For an analog oil pressure gauge, the pres-
1
799-101-5002 Hydraulic tester sure must be 40 MPa {400 kg/cm2}.
S 2 790-301-1330 q Flange
4 07372-21055 Bolt
6 07000-13035 O-ring

tion.
a Test the fan circuit oil pressure under the follow-
ing condition.
q Gear shift mode: Manual 5. Start the engine and switch the machine monitor
to "Adjustment" function display of the service
1. Open the radiator mask. mode.
q Adjustment ID: 1005 (Fan 100% mode)
2. Remove bolt (1) and disconnect tube (2). a For the operating method, see "Special func-
a If this adjustment code is displayed, the fan
speed is kept at 100% speed in accordance
with the engine speed, regardless of the
state of the machine.
3. Install oil pressure testing flange S2 and then

install tube (2) again with bolt S3.
q The stem of oil pressure testing bolt S3 is 15
mm longer.
6. While running the engine at high idle, measure

the fan circuit oil pressure.
7. After measuring, remove measuring tools and

reset the machine to its original status.
30-36 D375A-6
(01)
DRAFT
Bleeding air from fan pump
Bleeding air from fan pump
a If the fan pump is removed and installed or its

piping is disconnected and connected, bleed air
from the pump case according to the following
procedure.
a Before bleeding air, check that the hydraulic oil
level is proper.
1. Remove the floor mat.
2. Remove left footrest (1).
3. Loosen air bleeders (2) and (3), and leave them

for 15 minutes.
4. After 15 minutes, run the engine at low idle.
5. When oil flows from air bleeders, tighten air

bleeders (2) and (3).
D375A-6 30-37
(01)
DRAFT
Adjusting fuel control dial and decelerator pedal
1. Outline of fuel control system [1] Fuel control dial (2nd throttle signal)
q The following signals are inputted as rotation [2] Engine controller
command signals to the engine controller. [3] Power train controller
q Decelerator pedal potentiometer signal [4] Decelerator pedal (1st throttle signal)
q 3rd throttle signal [5] Decelerator potentiometer
The engine controller controls the fuel control [6] Engine (CRI system)
system of the engine (CRI system) according [7] Machine control signal (3rd throttle signal)
to the lowest engine speed signal among [8] Rod
those input signals.
q Adjust the deceleration slow speed by adjust- 2. Preparation work
ing the decelerator pedal linkage. a Set the working mode to P mode and set the
gear shift mode to Manual.
1) Start the engine and switch the machine
monitor to "Pm clinic" function display of the
service mode.
30-42
30-38 D375A-6
(03)
DRAFT
3. Adjusting the speed when using decelerator

pedal
With the fuel control dial in the high idle position,
depress decelerator pedal (4) until it touches the
stopper. Check that the engine speed is normal
under this condition.
q Engine speed: 900 ± 50 rpm
a If the engine is not running at the correct
speed, adjust installed dimension (a) of rod
(8).
q Standard installed dimension (a) of rod: 123
mm (reference)
4. Adjusting high idle speed

Return the decelerator pedal, set the fuel control
dial to the high idle position, and check that the
engine is running at the correct high idle speed.
q High idle speed: 1,900 (0/-50) rpm
a If the high idle speed is abnormal, adjust it
according to the following procedure.
q If the engine speed is high:
To remove the play of the decelerator pedal,
use stopper bolt (9) to adjust the engine
speed to less than 1,800 rpm, then adjust to
the high idle speed.
q If the engine speed is low:
Use stopper bolt (9) to adjust to the high idle
speed.
5. After finishing all adjustment, return the removed

parts.
D375A-6 30-39
(03) 30-43
DRAFT
Power train
Testing power train oil pressure
Power train
a Testing instruments for power train oil pressure

1
K 790-261-1204 Digital hydraulic tester
3 799-401-2320 Gauge
tion.
a Test the power train oil pressure under the fol-
lowing condition.
q Power train oil temperature: Within operating
range
q Working mode: P mode
a The portions for testing the power train oil pres-
sure (central pressure detection portion) are in-
side the inspection cover on the right side on the
outside of the cab.
a Table of pressure pick-up port positions and

gauges to use
Gauge
No. Mark Oil pressure to check
(MPa {kg/cm2})
1 IN T/C IN 2.5 {25}
2 OUT T/C OUT 1.0 {10}
Torque converter lock-up
3 LU 2.5 {25}
clutch pressure
4 SC T/C S/C 6 {60}
Transmission main relief
5 T/M 6 {60}
pressure
Transmission F clutch
6 FWD 6 {60}
pressure
Transmission R clutch
7 REV 6 {60}
pressure
Transmission 1st clutch
8 1ST 6 {60}
pressure
Transmission 2nd clutch
9 2ND 6 {60}
pressure
Transmission 3rd clutch
10 3RD 6 {60}
pressure
Left steering clutch pres-
11 LC 6 {60}
sure
Left steering brake pres-
sure
12 LB 6 {60}
Output pressure of sudden
stop prevention valve
Right steering clutch pres-
13 RC 6 {60}
sure
Right steering brake pres-
sure
14 RB 6 {60}
Output pressure of sudden
stop prevention valve
Transmission lubricating
15 LUB 1.0 {10}
oil pressure
30-44
30-40 D375A-6
(03)
DRAFT
Power train
1. Testring torque converter inlet pressure (IN) 2. Testing torque converter outlet pressure
(Testing with oil pressure gauge) (OUT)
1) Connect oil pressure gauge [1] of hydraulic (Testing with oil pressure gauge)
tester K1 to oil pressure test nipple (1). 1) Connect gauge K2 to oil pressure test nipple
a When using an analogue oil pressure (2).
gauge, use one of 2.5 MPa {25kg/cm2}.
2) Start the engine and set the PCCS lever in

2) Start the engine and set the PCCS lever in the fully neutral position.
the fully neutral position. 3) est the torque converter outlet port pressure
3) Test the torque converter inlet port pressure with the engine at low idle and high idle.
with the engine at low idle and high idle.

4) After finishing measuring, remove all test tools in order to return the machine status as
tools in order to return the machine status as it was.
it was.
D375A-6 30-41
(03) 30-45
DRAFT
Power train
3. Measuring torque converter inlet pressure

and outlet pressure
[Checking with machine monitor (Pm clinic)]

the fully neutral position.
a The test may be performed with the park-
ing brake lever in the LOCK position.
3) While running the engine at low idle and high
idle, measure the inlet pressure and outlet
pressure of the torque converter.
30-46
30-41-1 D375A-6
(03)
DRAFT
Power train
D375A-6 30-41-2
(03) 30-47
DRAFT
Power train
4. Testing torque converter lock-up clutch 3) Set the gearshift mode and preset range as
pressure (LU) follows with the gearshift mode selector
1) Connect oil pressure gauge [1] of hydraulic switch and shiftup or shiftdown switch.
tester K1 to oil pressure test nipple (3). q Gear shift mode: Automatic gear shift
a For an analog oil pressure gauge, the q Preset range: F2-R2
pressure must be 2.5 MPa {25 kg/cm2}. 4) With the brake pedal depressed, set the
PCCS lever to F and the gear speed to the
2nd.
5) Gradually release the brake pedal.
6) With the decelerator pedal depressed, set
the fuel control dial to the MAX position.
7) Gradually release the decelerator pedal and
raise the engine speed.
8) Test the torque converter lock-up clutch
pressure when the engine speed reaches
near the high idle.
a The test cannot be made at a low engine
speed.
it was.
2) Start the engine, set the machine monitor to

"Adjusting" function of the service mode, and
disengage both steering clutches.
q Adjustment ID:
5535 (Both steering clutch disengage
mode)
section.
30-48
30-42 D375A-6
(03)
DRAFT
Power train
5. Testing torque converter stator clutch pres- 6. Testing transmission main relief pressure
sure (SC) (T/M)
1) Connect oil pressure gauge [1] of hydraulic [Testing using oil pressure gauge]
tester K1 to oil pressure test nipple (4). 1) Connect oil pressure gauge [1] of hydraulic
a When using an analog oil pressure tester K1 to oil pressure test nipple (5).
gauge, use one of 6 MPa {60 kg/cm2}. a When using an analog oil pressure
gauge, use one of 6 MPa {60 kg/cm2}.

the fully neutral position. 2) Start the engine and set the PCCS lever in
a The test may be performed with the park- the fully neutral position.
ing brake lever in the LOCK position. a The test may be performed with the park-
3) Test the torque converter stator clutch pres- ing brake lever in the LOCK position.
sure with the engine at low idle and high idle. 3) Test the transmission main relief pressure

tools in order to return the machine status as 4) After finishing measuring, remove all test
it was. tools in order to return the machine status as
it was.
D375A-6 30-43
(03) 30-49
DRAFT
Power train
[Checking with machine monitor (for VHMS

specification)]

the fully neutral position.
a The test may be performed with the park-
ing brake lever in the LOCK position.
3) Test the transmission main relief pressure
30-50
30-43-1 D375A-6
(03)
DRAFT
Power train
D375A-6 30-43-2
(03) 30-51
DRAFT
Power train
7. Testing transmission F clutch pressure

(FWD)
1) Connect oil pressure gauge [1] of hydraulic
tester K1 to oil pressure pickup plug (6).
a When using an analog oil pressure

it was.
2) Start the engine and set the parking brake

lever in the FREE position.
ment" function display of the service mode
and disengage both steering clutches.
q Adjustment ID:
5535 (Disengage mode for both steering
clutches)
4) Set the gearshift mode and preset range as

follows with the gearshift mode selector
switch and shiftup or shiftdown switch.
q Gear shift mode: Manual gear shift
q Preset range: F1-R1
5) While pressing the brake pedal, set the direc-
tion of PCCS lever in the forward position.
a Check that [F1] is displayed in the gear
speed display section.
6) Check the F clutch pressure with the engine
at low and high idle.
30-52
30-44 D375A-6
(03)
DRAFT
Power train
8. Testing transmission R clutch pressure 6) Check the R clutch pressure with the engine
(REV) at low and high idle.
tester K1 to nipple (7) for checking oil pres-
sure.

it was.

q Adjustment ID:
clutches)

5) While pressing the brake pedal, set the
PCCS lever in the backward position.
a Check that [R1] is displayed in the gear
D375A-6 30-45
(03) 30-53
DRAFT
Power train
9. Testing transmission 1st clutch pressure 6) Check the 1st clutch pressure with the
(1st) engine at low and high idle.
sure.

it was.

q Adjustment ID:
clutches)

tion of PCCS lever in the forward position.
30-54
30-46 D375A-6
(03)
DRAFT
Power train
10. Testing transmission 2nd clutch pressure 6) Check the 2nd clutch pressure with the
(2nd) engine at low and high idle.
sure.

it was.

q Adjustment ID:
clutches)

tion of PCCS lever in the forward position and
shift the gear to 2nd using the shiftup switch.
D375A-6 30-47
(03) 30-55
DRAFT
Power train
11. Testing transmission 3rd clutch pressure 6) Check the 3rd clutch pressure with the
(3rd) engine at low and high idle.
sure.

it was.

q Adjustment ID:
clutches)

tion of PCCS lever in the forward position and
shift the gear to 3rd using the shiftup switch.
30-56
30-48 D375A-6
(03)
DRAFT
Power train
12. Testing left steering clutch pressure (LC) 13. Testing left steering brake pressure (LB)
1) Connect oil pressure gauge [1] of hydraulic 1) Connect oil pressure gauge [1] of hydraulic
tester K1 to oil pressure test nipple (11). tester K1 to oil pressure test nipple (12).
a When using an analog oil pressure a When using an analog oil pressure
gauge, use one of 6 MPa {60 kg/cm2}. gauge, use one of 6 MPa {60 kg/cm2}.
2) Start the engine and set the parking brake 2) Start the engine and set the parking brake
lever in the FREE position. lever in the FREE position.
3) Operate the PCCS lever steering fully to the 3) Test the left steering brake pressure with the
left. engine at low idle and high idle.
a Set the direction to the neutral position. a Check that the oil pressure becomes 0
4) Test the left steering clutch pressure with the when the PCCS lever steering is operat-
engine at low idle and high idle. ed fully to the left.
a Check that the oil pressure becomes 0 a Check that the oil pressure becomes 0
when the PCCS lever steering is returned when the brake pedal is depressed fully
to neutral. or the parking brake lever is operated to
the LOCK position.

it was.
D375A-6 30-49
(03) 30-57
DRAFT
Power train
14. Testing right steering clutch pressure (RC) 15. Testing right steering brake pressure (RB)
1) Connect oil pressure gauge [1] of hydraulic 1) Connect oil pressure gauge [1] of hydraulic
tester K1 to oil pressure test nipple (13). tester K1 to oil pressure test nipple (14).
a When using an analog oil pressure a When using an analog oil pressure
gauge, use one of 6 MPa {60 kg/cm2}. gauge, use one of 6 MPa {60 kg/cm2}.
2) Start the engine and set the parking brake 2) Start the engine and set the parking brake
lever in the FREE position. lever in the FREE position.
3) Operate the PCCS lever steering fully to the 3) Test the right steering brake pressure with
right. the engine at low idle and high idle.
a Set the direction to the neutral position. a Check that the oil pressure becomes 0
4) Test the right steering clutch pressure with when the PCCS lever steering is operat-
the engine at low idle and high idle. ed fully to the right.
a Check that the oil pressure becomes 0 a Check that the oil pressure becomes 0
when the PCCS lever steering is returned when the brake pedal is depressed fully
to neutral. or the parking brake lever is operated to
the LOCK position.

it was.
30-58
30-50 D375A-6
(03)
DRAFT
Power train
16. Testing transmission lubrication pressure 17. Testing of output pressure of sudden stop
1) Connect gauge K2 to oil pressure test nipple prevention valve (Sudden stop prevention
(15). valve operation mode)
tester K1 to oil pressure pickup nipples (12)
and (14).
q (12): For steering left brake
2) Start the engine and test the transmission

lubricating pressure with the engine at high
idle.
q (14): For steering right brake

it was.
2) Start the engine, switch the machine monitor

to "Adjusting" function of the service mode
and deactivate the sudden stop prevention
valve and right and left brake ECMV.
q Adjustment ID: 9996 (Sudden stop pre-
vention valve operation mode)
section.
D375A-6 30-51
(03) 30-59
DRAFT
Power train
3) Set the parking brake lever in the FREE posi-

tion and set the PCCS lever in the ALL
NEUTRAL position.
4) Test the output pressure of the sudden stop
prevention valve with the engine at low idle.
a If the output pressure of the sudden stop
prevention valve is as follows, it is normal.
q 1.13 – 1.57 MPa {11.5 – 16.0 kg/cm }
2

it was.
30-60
30-51-1 D375A-6
(03)
DRAFT
Power train
D375A-6 30-51-2
(03) 30-61
DRAFT
Power train
Adjusting transmission output speed sensor
Adjusting transmission output speed sensor
k Stop the machine on level ground, lower the 6. Hold sensor (2) and tighten locknut (4).
work equipment to the ground, stop the en- a Take care that the speed sensor is not
gine, and set the parking brake lever and dragged.
work equipment lock lever in the lock posi- 3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm}
tion.
1. Remove cover (1) under the fuel tank.
7. After finishing adjustment, return the removed

parts.
2. Remove transmission output speed sensor (2). 8. Start the engine, set the machine monitor to
a Before adjusting, remove the sensor, and "Adjusting" function of the service mode, and
check that the tip of the sensor is not disengage both steering clutches.
scratched and that there are no iron particles q Adjustment ID:
sticking to it. 5535 (Disengage mode for both steering
clutches)
a Set the working mode to P mode and set the
gear shift mode to Manual.
9. Operate the PCCS lever in the direction of

forward or reverse position, and check the trans-
mission speed is displayed normally.
3. Look through the sensor mounting hole and

check that a tooth tip of gear (3) is at the center
of the hole.
a If the tooth tip is not at the center of the hole,
adjust it by starting the engine and moving
the machine forward or in reverse.
4. Screw in sensor (2) until its tip lightly touches the

tooth tip of gear (3).
2 Threads of sensor: Gasket sealant (LG-5)
5. Return sensor (2) by 1/2 - 1 turn.

a Clearance (a) between the sensor tip and
gear tooth tip becomes 0.75 – 1.50 mm.
30-52 D375A-6
(01)
DRAFT
Power train
Simple test procedure for brake performance
Simple test procedure for brake k Since the torque converter is stalled, keep
performance pressing the brake pedal securely and
keep your right foot on the decelerator
pedal for safety until the work is finished.
tion.
a Carry out the simple performance test of the
brake under the following condition.
1. Set the blade and ripper in the travel posture on

a level place.
2. Start the engine and set the parking brake lever

in the FREE position.
3. Set the gearshift mode and preset range as

follows with the gearshift mode selector switch
and shiftup or shiftdown switch.
4. While pressing the brake pedal, set the direction

of PCCS lever in the forward position.
k If this test is carried out in the 1st gear po-
sition, the brake will be overloaded. Ac-
cordingly, be sure to carry out in the 2nd
gear speed.
5. Press the decelerator pedal and set the fuel

6. Return the decelerator pedal slowly and check

that the machine does not start when the engine
speed reaches the high idle speed.
D375A-6 30-53
(03) 30-63
DRAFT
Power train
Adjusting brake pedal and parking brake lever
Adjusting brake pedal
Adjusting parking brake lever
30-54 D375A-6
(01)
DRAFT
Power train
Adjusting brake pedal

1. Adjusting travel of brake pedal
Adjust installation dimension b of stopper bolt (2)
so that the travel of brake pedal (1) is dimension
a.
a When adjusting the travel of the brake pedal,
disconnect the brake rod from the pedal.
q Pedal stroke a: 75 mm
q Stopper bolt installation dimension b: 42 mm
2. Adjusting installed length of brake rod

1) Keep the parking brake lever in the release
position.
2) Install brake rod (3) and release brake pedal
(1) (do not depress it). 5. Checking brake oil pressure
3) Adjust installed dimensions c and d of brake 1) Start the engine and switch the machine
rod (3) with turnbuckle (5) so that the spool of monitor to the "Adjustment" function display
brake valve (4) is at the OFF position. of the service mode.
a The locknut of the turnbuckle has a q Adjustment ID: 9995 (Control brake re-
left-handed thread (reverse thread) at the lease mode)
brake pedal end. a For the operating method, see "Special
q Stopper bolt installation dimension c: 32 functions of machine monitor (EMMS)".
mm a The function of this mode is used to can-
q Stopper bolt installation dimension d: 14 cel electrical control of brake oil pressure
mm and makes it possible to check the brake
3 Locknut: oil pressure mechanically.
34.3 – 58.8 Nm {3.5 – 6.0 kgm} a Set the working mode to P mode and set
4) Check that clearance x between yoke (12) the gear shift mode to Manual.
and pin (13) is approximately 1 mm.
3. Checking travel of brake pedal

1) Depress brake pedal (1) and check that the
travel is as given in Step 1 above.
2) Depress brake pedal (1) and check that the
pedal is stopped by stopper (6).
3) Check that spool travel e of brake valve (4) is
within the correct range when brake pedal (1)
is depressed.
q Spool travel e: 19 – 23 mm
4. Adjusting brake potentiometer

Turn the starting switch ON and set the machine
monitor to Adjusting function of the service 2) With the parking brake lever in the FREE
mode. position, depress the brake pedal fully and
q Adjustment ID: 0005 check that the brake oil pressure on both
(Brake pedal potentiometer initial correction) sides of left and right becomes 0.98 MPa {10
a For the operating method, see "Special func- kg/cm2} or less.
tions of machine monitor (EMMS)". a For details of the method of testing the
a Set the working mode to P mode and set the brake oil pressure, see "Testing power
gear shift mode to Manual. train oil pressure".
a When the brake pedal is depressed, if the
brake oil pressure does not drop below
0.98 MPa {10 kg/cm2}, adjust its linkage
again.
D375A-6 30-55
(03) 30-65
DRAFT
Power train
a If the linkage is adjusted normally, the a Set the working mode to P mode and set
brake pedal potentiometer may be adjust- the gear shift mode to Manual.
ed wrongly or broken. (Adjust the poten-
tiometer only when necessary.)
Adjusting parking brake lever side

1. Assembly and installation of lever assembly
1) Assemble lever assembly (7) and adjust the
operation of limit switch (8).
a When assembling the lever assembly,
disconnect the parking cable from the le-
ver.
q Lever raised: OFF, lever lowered: ON
q Operation stroke of limit switch: 3 mm
2) Install lever assembly (7).
2. Adjusting installed length of parking brake 2) Check that the limit switch signal is input
cable normally when parking brake lever (10) is set
1) Connect parking brake cable (9) to the lever in the FREE position and LOCK position.
and valve, then adjust installed dimensions f q FREE position:
f and g. Travel lock NC OFF, Travel lock NO ON
q Cable installation dimension (f): 112.8 q LOCK position:
mm Travel lock NC ON, Travel lock NO OFF
q Cable installation dimension (g): 114.0
mm
2) Operate parking brake lever (10) between
the free and lock positions, and adjust rod
end (4) so that spool stroke h of brake valve
(11) is normal.
q Spool stroke (h): 23.0 mm
3) Check that clearance y between rod end (11)
and pin (14) is approximately 0.5 mm.
a When tightening the lock nuts of brake yoke
(12) and rod end (11), exercise care so that
the yoke and rod end will not interfere with
pins (13) and (14).
q The operating effort of the parking brake
lever may increase.
3. 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 testing the brake
oil pressure, see "Testing power train oil
pressure".
2
q LOCK position: 0 MPa {0 kg/cm }, FREE po-
sition: Specified pressure
4. Checking limit switch

1) Turn the starting switch ON and set the
machine monitor to Monitoring function of the
service mode.
q Monitoring code: 40905 (P/T SW Input 3)
30-66
30-56 D375A-6
(03)
DRAFT
Power train
Adjusting position of pccs lever console
Adjusting position of pccs lever console
1. Set operator’s seat (1) facing the front (dozing

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

parallel to operator’s seat (1).
a If it is not parallel, adjust installed dimension
(a) of rod (3).
q Standard installed dimension (a): 179 mm
a The locknut at the rear of the turnbuckle has
a left-handed thread (reverse thread)
D375A-6 30-57
(01)
DRAFT
Power train
Emergency escape method when there is failure in power train
Emergency escape method when q PL2 connector (2): Connect to male end
there is failure in power train a The female end of connector PL2 re-
mains disconnected, so cover it with vinyl.
a Tools for emergency escape a Insert switch assembly [1] inside the cab
Symbol Part No. Part name through the cab window.
19M-06-32820 Switch assembly
1 7824-66-6430 Resistor
L
195-06-71220 Wiring harness
2 790-190-1601 Pump assembly
1. Emergency escape method using switch box

(Use L1)
a If the machine cannot be moved because of
a trouble in the electrical system of the power
train control unit (travel direction, gear speed,
steering), carry out the emergency escape
a With this procedure, it is necessary to be able
to start the engine. If the engine will not start,
see "Emergency escape method using brake
3) Disconnect the neutral safety relay (NSF)
release device".
inside the fuse room, then connect pin [3] and
1) Connect switch assembly [1] and resistor [2]
pin [5] of the connector at the wiring harness
to wiring harness [3] of emergency escape
end directly.
k With this method, if the engine starts,
device L1.
k Resistor [2] controls the drive voltage
the neutral safety relay function will
of the solenoid, so connect it before
not work, so before starting the en-
connecting the wiring harness to the
gine, set the parking brake lever to the
machine.
k In order to prevent mistaken actuation,
LOCK position and all the PCCS lever
functions to the neutral position.
k With this method, start the engine only
set all the speed range switches of
switch assembly [1] to the OFF posi-
when carrying out the emergency es-
tion and the directional switch to the P
cape. In all other cases when the en-
position.
gine does not start, always carry out
troubleshooting and repair the cause.
2) Open the inspection cover on the left fender

and connect wiring harness [3] to PL1
connector (1) and PL2 connector (2).
q PL1 connector (1): Connect to male and
female ends 5) Operate switch assembly [1] and move the
machine to a safe place.
a The speed switch has an electric circuit
that gives priority to operation of the low
speed switch.
k Take care that the L.H. and R.H. steer- verse.
ing directions are opposite when re-
30-58 D375A-6
(01)
DRAFT
Power train
Emergency escape method when there is failure in power train
2. Emergency escape method with brake releasing

device (Use L2) 4) Connect end hose of pump assembly L2 to
a If the engine cannot be started and the park- the supply hose. (Use the nipple of face seal
ing brake cannot be released, carry out the type.)
emergency escape according to the following a Block the solenoid valve side with plug.
procedure. Plug: 02789-00315
1) Assemble pump assembly L2. 5) Turn the starting switch ON and set the
parking brake lever in the FREE position.
6) Operate the vacuum pump to raise the brake
releasing oil pressure to the initial pressure.
2
q Initial pressure: 2.74 MPa {28 kg/cm }
a Since an accumulator is installed in the
circuit, the handle must be operated 30 -
50 times to raise the oil pressure.
a If the oil pressure does not rise above a
certain level, the relief valve may be set to
low pressure. In this case, adjust the set
pressure of the relief valve.
7) Tow the machine to a safe place.
a The brake releasing oil pressure lowers
gradually because of internal leakage and
2) Install volume pump [4] of pump assembly L2 the brake is applied again about 1 minute
to the outside of the operator’s cab. after. Therefore, work immediately.
a When the brake release oil pressure
drops to about 1.57 MPa {16 kg/cm2}, the
brake is applied. In such a case, increase
the brake release oil pressure to its initial
level by operating the vacuum pump
again.
3) Remove the fuel tank undercover and

disconnect supply hose (3) of the pin puller
solenoid valve.
D375A-6 30-59
(01)
DRAFT
Inspecting wear of sprocket

Inspecting wear of sprocket
a Use the "Full-scale dimensions drawing of

sprocket profile" in "Sprocket" in "maintenance
standard" as a gauge for testing wear of the
sprocket.
a Make a copy of the "Full-scale dimensions draw-

ing of sprocket profile" on a transparent paper or
sheet and apply it directly to the sprocket to see
if the sprocket can be used.
30-60 D375A-6
(01)
DRAFT
Testing and adjusting track shoe tension
Testing and adjusting track shoe tension

Testing 2. If tension is too high:
1. Drive the machine forward and stop on a hori- Loosen plug (3) and release some of the grease.
zontal surface. k There is danger that the plug may fly out
a Stop the machine without using the brake. under the high internal pressure of the
grease, so never loosen the plug more
2. Put straight steel rod (1) on top of the track than 1 turn.
between the idler and front carrier roller, and test 3 Plug: 59 – 88 Nm {6 – 9 kgm}
clearance (a) from the bottom of the steel rod to
the track shoe grouser. 3. If tension is too low:
q Standard clearance (a): 20 – 30 mm Pump in grease through grease fitting (4).
a If the track shoe is not tensed well, drive the
machine forward and in reverse slowly.
a After finishing adjustment, check the tension
again according to the above procedure.
Adjustment
a If the track shoe tension is abnormal, adjust it ac-
cording to the following procedure.
1. Remove cover (2).
D375A-6 30-61
(01)
DRAFT
Hydraulic system
Measuring and adjusting work equipment oil pressure
Hydraulic system
Measuring and adjusting work
equipment oil pressure
a Measuring and adjusting instruments for work

equipment oil pressure
1
M
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring

gine, and set the parking brake lever and 3) Run the engine at high idle and set the blade
work equipment lock lever in the lock posi- control lever and ripper control lever in
tion. neutral and measure the unload pressure.
a Open the cover of the main control valve (both a The work equipment lock lever may be
sides). set in the LOCK position.
k Do not operate the work equipment
Testing when analog oil pressure gauge (6
a Measure the work equipment oil pressure under
MPa {60 kg/cm2}) is mounted. (This is
the following condition.
required to protect the gauge from be-
ing damaged.)
a The unload pressure, work equipment oil pres-
sure can be checked with the monitoring func-
tion of the service mode of the machine monitor
(See 3).
1. Measuring unload pressure

1) Remove P oil pressure pickup plug (1) from
the control valve.

it was.
2. Measuring work equipment oil pressure

1) Remove P oil pressure pickup plug (1) and
LS oil pressure pickup plug (2) from the
control valve.
2) Mount nipple M2, and connect it to oil pres-

sure gauge [1] of hydraulic tester M1.
30-72
30-62 D375A-6
(03)
DRAFT
Hydraulic system
2) Mount nipple M2, and connect it to oil pres- 5) After finishing measuring, remove all test
sure gauge [1] of hydraulic tester M1. tools in order to return the machine status as
a When using analog oil pressure gauges, it was.
use ones of 40 MPa {400 kg/cm2}.
3. Testing using machine monitor (Pm clinic)
a The VHMS specification is shown as an
example in the figure.
3) Start the engine and set the work equipment

lock lever in the free position.
4) Run the engine at high idle, operate the blade
control lever and ripper control lever to
relieve each cylinder at a stroke end, and
measure the work equipment relief pressure
and work equipment LS relief pressure.
a The work equipment relief oil pressure is
displayed at P stamp side (plug-1 side), 2) Start the engine and measure each oil pres-
but work equipment LS relief oil pressure sure.
is displayed at LS stamp side (plug-2 a The measuring condition of each oil pres-
side). sure is the same with 1 – 2 above.
a Hydraulic pressure displayed at P stamp
side of control valve can be measured,
but hydraulic pressure at LS stamp side
(work equipment LS relief pressure) can-
not be measured.
D375A-6 30-63
(03) 30-73
DRAFT
Hydraulic system
Adjustment 4) After finishing measurement, check the work

1. Adjusting unload pressure equipment oil pressure according to the
a The unload pressure cannot be adjusted. above measuring method.
2. Adjusting work equipment oil pressure

a If the work equipment oil pressure is abnor-
mal, adjust it with work equipment LS relief
valve (3) according to the following proce-
dure.
a This figure shows a dual tilt model, 6-spool
valve. (The single tilt model has a 5-spool
valve.)
1) While fixing adjustment nut (4), loosen

locknut (5).
2) Adjust the pressure by rotating adjustment
nut (4).
a If the adjustment nut is
q rotated to the right, the pressure is
heightened.
q rotated to the left, the pressure is low-
ered.
a Quantity of adjustment per turn of adjust-
ment nut:
Approx. 19.6 MPa {200 kg/cm2}
3) While fixing adjustment nut (4), tighten
locknut (5).
3 Locknut: 39 – 49 Nm {4 – 5 kgm}
30-74
30-64 D375A-6
(03)
DRAFT
Hydraulic system
Testing control circuit main pressure
Testing control circuit main pressure

4. After finishing measurement, remove the
Tools for testing control circuit main pressure measuring tools and return the removed parts.
799 - 101 - 5002 Hydraulic tester Adjusting
M 1
790 - 261 - 1204 Digital hydraulic tester a The self pressure reducing valve cannot be ad-
justed.
Testing
k Stop the machine on level ground, lower the work
equipment to the ground, stop the engine, and set
the parking brake lever and work equipment lock
lever in the lock position.
a Test the control circuit main pressure under the
following conditions.
1. Open the cover of the main control valve (both

sides).
2. Connect oil pressure gauge [1] of hydraulic

tester M1.
a When using an analog oil pressure gauge,
use one of 6 MPa {60 kg/cm2}.
a Inspection nipple (1) is equipped.
3. Start the engine, run it at high idle, and test the

oil pressure when the blade lever and ripper
lever are placed at the HOLD position.
D375A-6 30-65
(01)
DRAFT
Hydraulic system
Testing PPC valve output pressure
a Tools for testing PPC valve output pressure 4. Start the engine and set the work equipment lock
Symbol Part No. Part name lever in the Free position.
N 1
5. Run the engine at high idle, operate the control
lever of the circuit to be tested, and test the oil
k Stop the machine on level ground, lower the work pressure.
equipment to the ground, stop the engine, and set a Operate the control lever fully when testing.
the parking brake lever and work equipment lock a For blade LOWER, operate to the FLOAT po-
lever in the lock position. sition.
a Check that the control circuit oil pressure is cor-
rect before testing the PPC valve output pres- 6. After finishing measurement, remove the
sure. measuring tools and return the removed parts.
a Test the PPC valve output pressure under the
following conditions.
1. Open the cover of the main control valve (both

sides).
2. Remove the oil pressure switch (1) of the circuit

to be tested.
a For details of the position to be tested, see
the drawing on the next page.
3. Fit nipple [1] (R1/8) of hydraulic tester N1, then

connect to oil pressure gauge [2].
a When using an analog oil pressure gauge,
use one of 6 MPa {60 kg/cm2}.
30-66 D375A-6
(01)
DRAFT
Hydraulic system
A. Blade RAISE E. Ripper TILT (In)

B. Blade TILT (Right) F. Ripper RAISE
C. Blade LOWER G. Ripper TILT (Back)
D. Blade TILT (Left) H. Ripper LOWER
D375A-6 30-67
(01)
DRAFT
Hydraulic system
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.
q Standard play (a):
1 - 6 mm at the position 400 mm away from lever
rotation center
(both to front and rear, and to left and right)
q Standard play (b): 0.03 – 0.30 mm (full stroke)
a Exchange the joint (4) when lever end play is
longer than 24 mm at neutral position must be
joint may have damaged.
1. Remove boot (1).
2. Loosen locknut (2) and rotate disc (3) to adjust

the amount of play.
a Do not move the pistons at this time.
3. Secure disc (3) in position and tighten locknut

(2).
3 Lock nut: 69 – 88 Nm {7 – 9 kgm}
4. Apply grease (G2-LI) to sliding area of joint (4)

and to contact area of disc and piston.
2 Sliding area of the joint: G2-LI
2 Contact area of the disc and piston: G2-LI
5. Install boot (1).
30-78
30-68 D375A-6
(03)
DRAFT
Hydraulic system
Testing output pressure of ripper pin-puller solenoid valve
a Tools for testing output pressure of ripper

pin-puller solenoid valve
799 - 101 - 5002 Hydraulic tester
1
790 - 261 - 1204 Digital type hydraulic tester
P
Oil pressure pickup adapter
2 799 - 401 - 3200
(03 size)

work equipment completely to the ground,
then set the parking brake lever and work
equipment lock lever to the LOCK position.
a Test the output pressure of the ripper pin puller
solenoid valve under the following conditions.
4. Start the engine, run at high idle, and test the oil
Within operating range pressure when the ripper pin-puller switch is
actuated.
1. Disconnect pin-puller cylinder hoses (1) and (2).
5. After completing the test remove the testing

equipment and set to the original condition.
2. Fit adapter P2, then connect the hoses again.
3. Fit nipple P1 of hydraulic tester [1], then connect

oil pressure gauge [2].
a Use a 6 MPa {60 kg/cm2} oil pressure gauge.
D375A-6 30-69
(01)
DRAFT
Hydraulic system
Checking location of cause of hydraulic drift of blade and 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 piston
valve, so do not operate the cylinder to
2. Operate the control lever in the direction to
the end of the stroke.
extend the cylinder rod, and check the move-
ment of the cylinder.
q If the downward movement becomes faster,
the packing is defective.
q 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.
[Reference:] If the cause of the hydraulic drift is

in the packing, the speed of downward move-
ment in the above operation will become faster
for the following reasons.
1) When the work equipment is set to the
2) Blade tilt cylinder posture given above, (holding pressure
Extend the tilt cylinder rod fully, then push the applied to the bottom end), oil will leak from
blade against the ground to raise the right the bottom end to the head end. However,
side of the chassis. 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
becomes balanced, the speed of downward
movement becomes slower.
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
3) Ripper lift cylinder head end flows to the drain circuit. As a
Push the ripper against the ground to raise result, the balance is lost and the speed of
the rear of the chassis. downward movement increases.)
30-80
30-70 D375A-6
(03)
DRAFT
Hydraulic system
Testing leakage inside work equipment cylinder
Testing leakage inside work equipment cylinder

3. Run the engine at high idle and apply the relief
a Tools for testing leakage from work equipment pressure to the bottom end of the cylinder.
cylinder q Blade tilt cylinder: Extract the cylinder to be
Symbol Part No. Part name tested
Commercially q Ripper lift cylinder: Lower ripper
L Measuring cylinder
available q Ripper tilt cylinder: Tilt ripper to front
a Test the oil leakage inside the hydraulic cylinder 4. Wait for 30 seconds, then test the amount of
under the following conditions. leakage over the next 1 minute.
a The blade lift cylinder has a built-in piston valve, 5. After finishing measurement, return the removed
so the internal leakage cannot be tested. parts.
1. Fully extend the cylinder to be tested, and set to

the test posture.
1) Blade tilt cylinder
Extract the cylinder to be tested to the stroke
end.
2) Ripper lift cylinder
Pull out the shank pin and lower the ripper to
the end.
3) Ripper tilt cylinder
Tilt the ripper fully to the front.
2. Disconnect hose on the cylinder head side and

block the hose side with a plug.
a Remove the hose cover of the blade tilt cylin-
der.
k Take care not to disconnect the hose on
the bottom side.
D375A-6 30-71
(01)
DRAFT
Hydraulic system
Releasing remaining pressure in work equipment cylinders
Releasing remaining pressure Bleeding air from work equipment

in work equipment cylinders cylinders
a When disconnecting the piping between the con- a If the work equipment cylinder was removed and
trol valve and work equipment cylinder, release installed or its piping was disconnected and con-
the residual pressure in the circuit according to nected, bleed air from its circuit according to the
the following procedure. following procedure.
1. Start the engine, and lower the blade and ripper 1. Run the engine at low idle for about five minutes.
to the ground.
2. Running the engine at low idle, extend and
2. Stop the engine. retract the cylinder to be bled 4 – 5 times.
a Stop the piston rod about 100 mm before the
3. Loosen the hydraulic tank cap gradually to end of the stroke. Never operate it to the re-
release the residual pressure in the tank. lief position.
4. Set the work equipment lock lever in the FREE 3. Running the engine at high idle and carry out the
position, and move the work equipment control operation in 2.
lever (for blade and ripper) front, back, left and
right. 4. Running the engine at low idle, move the
a After the levers are operated 2 – 3 times, the cylinder to the stroke end to relieve the oil.
residual pressure in the accumulator is fully
released.
5. Fully close the oil filler cap of hydraulic tank.
30-82
30-72 D375A-6
(03)
DRAFT
Hydraulic system
Adjusting ripper lever position
Adjusting ripper lever position
a Use the following procedure to adjust the ripper

lever to the optimum position.
a It is possible to adjust the position of the ripper
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.
5) Loosen nut (3).
6) Turn knob (4) 180 °.
7) Tighten nut (3) to hold knob (4) in position.
D375A-6 30-73
(03) 30-83
DRAFT
Work equipment
Adjusting work equipment lock lever
Work equipment
Adjusting work equipment lock lever
k Stop the machine on level ground, lower the a For the operating method, see "Special func-
work equipment to the ground, stop the en- tions of machine monitor (EMMS)".
gine, and set the parking brake lever and a Set the working mode to P mode and set the
work equipment lock lever in the lock posi- gear shift mode to Manual.
tion.
a Tighten the locknut of the rod securely and bend
the cotter pin securely.
a Remove the control valve cover.
1. Set work equipment lock lever (1) in the LOCK

position.
2. Set and install limit switch (2) to sliding surface

(a) of lever (3).
a Just set the roller of the limit switch to the
sliding surface. Do not move it.
3. Set work equipment lock lever (1) in the FREE
position and check that limit switch (2) operates
normally. 5. Check that the limit switch signal is input
q Stroke of limit switch: 2.5 – 3 mm
normally when work equipment lock lever (1) is
set in the FREE position and LOCK position.
4. Turn the starting switch ON and set the machine q FREE position:
monitor to Monitoring function of the service Work equipment lock NC OFF, Work equip-
mode. ment lock NO ON
a Monitoring code: q LOCK position:
70300 (Blade Sw Input) Work equipment lock NC ON, Work equip-
ment lock NO OFF
30-84
30-74 D375A-6
(03)
DRAFT
Work equipment
Adjusting blade
Adjusting blade
a If the blade has been removed or disassembled,

adjust as follows.
1. Procedure for adjusting with shims when assem-

bling
1) Use shims to adjust the clearance at center
portion (1) and (2).
Adjust- Standard
Adjusted Standard
ment shim thick-
clearance clearance
location ness
1 a
See Note 4.5 mm
2 b
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 rotates
smoothly.
D375A-6 30-75
(01)
DRAFT
Work equipment
Adjusting blade
2) Use shims to adjust the clearance at trunnion

portion (3).
Adjust- Adjusted Standard
Standard clear-
ment loca- clear- shim thick-
ance
tion ance ness
1.56 ± 0.65 mm
3 c 12 mm
Total clearance
2. Adjusting blade tilt

(Only single tilt specification machine)
1) Adjust installation dimension (d) of brace (4)
with the handle.
q Dimension (d) of installed brace: 1,587
mm
2) Test left and right tilt (e1) and (e2).
[Semi-U dozer]
q Right tilt (e1): Approx. 770 mm
q Left tilt (e2): Approx. 770 mm
[Full-U dozer]
q Right tilt (el): Approx. 840 mm
q Left tilt (el): Approx. 840 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.
q (e1) > (e2): Carry out fine adjustment to
make installation dimension d longer
q (e1) < (e2): Carry out fine adjustment to
make installation dimension d shorter
30-76 D375A-6
(01)
DRAFT
Testing and adjusting operator's cab

Check after installing cab assembly

1. Testing pressure in cab
a Test the operator's cab according to the fol-
lowing conditions.
q Engine speed: High idle
q Blower speed: High (Hi)
q Fresh/Recirculation switch: Fresh air position
1) Start the engine and switch the machine
monitor to "Adjustment" function display of
the service mode.
q Adjustment code: 1005 (Fan 100% mode)
functions of machine monitor (EMMS)". a Secure the end of hose [1] to the opera-
a If this adjustment code is displayed, the tor's seat with tape.
fan speed is kept at 100% speed in accor-
dance with the engine speed, regardless
of the state of the machine.
6) Seal the mounting holes of lock lever (1) with

tape (2).
2) Prepare a transparent vinyl hose.
q Outside diameter: 10 mm,
Length: 3000 mm
3) Secure the inside end of the hose to the top
of the back seat with a tape.
4) Pour coolant in the hose up to about half.
5) Remove slide glass lever lock (1) and insert
the other end of vinyl hose [1].
D375A-6 30-77
(01)
DRAFT
7) Set the coolant level in the vinyl hose out of

the cab to that in the cab.
8) Run the engine at high idle and test coolant
level difference (c).
a [a] side: Inside of cab (Pressurized)
[b] side: Out of cab (Atmospheric pres-
sure)
q Criteria
Measuring value (c) X 8 mm {0.08 kPa {8
mmH2O})
a If the tested value is lower than the stan-
dard value, check the following.
q Plug of control box
q Clogging of air filters (recirculation
and fresh air filters) in the air condi-
tioner
q Seals between the cab and the floor
frame
2. Check of sealing performance

1) Close the all openings of the cab.
2) Throw water onto the area near the cab
(hatched area) at a rate of about 19 l/min for
10 minutes.
q At this time, it is not necessary to splash
pressurized coolant.
3) Splash coolant horizontally from a hose over
sealing surface (3).
4) Check around the dashboard carefully.
a If coolant leaks, caulk the leaking part and
check again.
30-88
30-78 D375A-6
(03)
DRAFT
3. Testing and adjusting door lock 2) Check the relationship between the door
Close the door and check the relationship latch and striker (on both sides).
between the operator's cab and door. If there is q Close door (5) and check the engaging
any fault, repair it. condition of latch (6) and striker (7).
1) Check the installed height of damper rubber q Normal:
(4). Deviation (a) is 0.5 mm or less.
(Check both sides, 4 pieces on each) a Check deviation (a) between latch center
q Stick adhesive tape [1] to the contact face (y) and striker center (x) from (A) direc-
of damper rubber (4), open and close the tion.
door 2 – 3 times. Then, check the contact
face of adhesive tape [1] against the op-
erator's cab.
Normal:
When the door is closed, the damper
rubbers come in contact lightly.
Abnormal:
When the door is closed, the damper
rubbers do not come in contact or come in
contact so strongly that the adhesive
tapes are removed.
D375A-6 30-79
(03) 30-89
DRAFT
3) Adjusting height of damper rubber

q Loosen the mounting bolt of damper rub-
ber (4).
q The shim can be removed or installed
without removing the mounting bolt.
q Increase or decrease the number of shim
(8) installed at the bottom of damper rub-
ber (4) to properly adjust the height of
damper rubber (4).
a Open the door and check the engag-

ing condition of the open latch and
striker.
q Check that the claw of open latch (9)
does not ride over the bent part of
striker (10).
q Check that the body of open latch (9)
does not interfere with striker (10).
4) Adjusting height of latch and striker

1] Temporarily tighten the mounting bolt of
striker (7), open and close the door 2 - 3
times to align latch (6) and striker (7) to
each other.
2] Check the engaging condition of latch (6)
and striker (7).
3] Securely tighten the mounting bolt of
striker (7).
4] Open and close the door and check that it
is locked and unlocked smoothly. If the
door is not locked and unlocked smoothly
(if the knob is heavy), perform the adjust-
ment procedure from the first.
a Operating effort of door unlock lever:
68.6 ± 19.6 N {7 ± 2 kg}
5) Apply grease (G2-LI) to latch (6).
a If latch (6) is not sufficiently greased, the
knob becomes heavy.
4. Testing open lock

Lock the door open and check the relationship
between the operator cab and door. If there is
any fault, repair it.
1) Check of condition
2] Check the installed height of the stopper
1] Check the relationship between open lock rubbers.
latch (9) and striker (10) from the direction (Check both sides, 2 pieces on each.)
of (B). q Lock the door open and shake it in the
forward and reverse directions to see
if it has any play.
q Check that the operating effort of un-
lock lever is not heavy.
30-90
30-80 D375A-6
(03)
DRAFT
2) Adjusting 2] Adjusting installed height of stopper

1] Adjusting latch and striker rubber
q Loosen the adjustment nut of striker 1] Loosen locknut (12) of stopper rubber
(10) and adjust striker (10) so that it (11).
will not interfere with or ride over open 2] If there is any play, adjust stopper
latch (9), then tighten the nut. rubber (11) until dimension (c) is as
q If interference cannot be eliminated by follows.
adjusting striker (10), loosen the a If the door is not locked easily or the
mounting bolt of open latch (9) and unlock lever is heavy, return stopper
adjust open latch (9). rubber (11) in the range that the door
q Push the door. If it moves until clear- does not have any play.
ance (b) between striker (10) and q Dimension (c) of stopper rubber
open latch (9) is reduced to "0", loosen above cab:
mounting nut (12) of stopper rubber 35 ± 0.5 mm
(11) and extend stopper rubber (11) in q Dimension (c) of stopper rubber under
the pushing direction to adjust. cab:
32 ± 0.5 mm
q Operating effort of door unlock lever:
68.6 ± 19.6 Nm {7 ± 2 kgm}
3] After adjusting, tighten locknut (12).
D375A-6 30-81
(01)
DRAFT
Electrial system
Special functions of machine monitor (EMMS)
Electrial system
30-82 D375A-6
(01)
DRAFT
Electrial system
Upper section of machine monitor (Display section)

(a): Multi-display
a The figure shows an example of display of sym-
bols and gauges in the ordinary display mode
(The contents of display depend on the condition
of the machine and operating method).
a When the engine is started, the battery voltage
may lower suddenly, depending on the ambient
temperature and the condition of the battery.
In this case, the machine monitor goes off for a
moment. This phenomenon is not a failure,
however.
Upper section of machine monitor (Switch section)

[F1]: F1 function switch
a The function of each function switch is indicated
by graphic mark in the multi-display (a) above
that function switch.
a If the graphic mark of a function switch is not dis-
played, that function switch is not working.
Lower section of machine monitor (Switch section)

[1]: Numeral 1 input switch/Operation mode selector
switch
[2]: Numeral 2 input switch/Gearshift mode selector
switch
[3]: Numeral 3 input switch/Customize switch
[4]: Numeral 4 input switch/Buzzer cancel switch
[5]: Numeral 5 input switch
[6]: Numeral 6 input switch/Customize memory
switch
Switch having no numerals: Unused
a Each switch has the function indicated by graph-
ic mark and the function of inputting a numeral.
a The machine monitor automatically judges
which function of each switch is currently effec-
tive, according to the display condition of
multi-display (a).
D375A-6 30-83
(01)
DRAFT
Electrial system
t Ordinary functions and special functions of machine monitor

The machine monitor has the ordinary function and special functions and displays information of various types
on the multi-display
Some items are displayed automatically according to the internal setting of the machine monitor and the oth-
ers are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The items in this mode are displayed ordinarily. The operator can display and set them by operating the
switches (Display and setting of some items need special operations of the switches).
2. Special functions: Service mode
The items in this mode are not displayed ordinarily. Each serviceman can display them by operating the
switches specially.
This mode is used for special setting, testing, adjusting, or troubleshooting.
Page page
Operator mode (Outline) Service mode
30-85 30-94
A Display of KOMATSU logo 30-85 01 Monitoring 30-95
Mechanical system "Abnor-
A Display of check before starting 30-85 30-100
02 Abnormality mality Record"
Display of warning after check before start- Record Electrical system "Abnormal-
A 30-86 30-101
ing ity Record"
A Display of ending of maintenance interval 30-86 03 Maintenance Record 30-103
A Display of check of preset 30-86 04 Maintenance Mode Change 30-104
A Display of ordinary screen 30-87 05 Phone Number Entry 30-105
A Display of end screen 30-87 Key-on Mode 30-107
B Selection of operation mode 30-87 Unit 30-108
Setting of maintenance pass-
OSpecial operations
B Selection of gearshift mode 30-87 06 Default 30-109

word
B Customizing operation 30-88 Setting of camera 30-110
B Operation of customize memory 30-88 Setting of ECO display 30-111
B Operation to cancel alarm buzzer 30-88 07 Adjustment 30-112
Selection of dual tilt
B 30-88 08 PM clinic 30-131
(Dual tilt specification)
Operation to display camera mode (if cam-
B 30-88 09 Cylinder Cut-Out 30-133
era is installed)
B Operation to display clock and service 30-89 10 No Injection 30-134
B Check of maintenance information 30-89 11 Fuel Consumption 30-136
B Setting and display of user mode 30-89 12 Display of saved load 30-137
C Display of caution monitor 30-90 13 Setting of VHMS 30-138
Display function of action code and failure
C 30-90 14 Snap shot (Machine equipped with VHMS) 30-138
code
O (Special operation)
Function of checking display of LCD (Liquid
D 30-92
Crystal Display)
D Function of checking service meter 30-92
Function of changing maintenance pass-
D 30-93
word
a Classification of operator mode

A: Display/Function from time when starting switch is turned ON to time when screen changes to ordinary
screen and display after starting switch is turned OFF
B: Display/Function when switch of machine monitor is operated
C: Display/Function when certain condition is satisfied
D: Display/Function which needs special operation of switch
30-84 D375A-6
(01)
DRAFT
Electrial system
t Operator mode (Outline) Display of KOMATSU logo

a Only outline of the operator mode is described in When the starting switch is turned ON, the KOMAT-
this section. SU logo is displayed for 2 seconds.
For details of contents/operation of each func- After the KOMATSU logo is displayed for 2 seconds,
tion/display, see "the Structure, function and the screen changes to "Display of screen to input
maintenance standard, or Operation and Main- password" or "Display of check before starting".
tenance Manual".
a The following are the displays or functions of the
operator mode explained in this section (includ-
ing some items which need special operations).
Display pat-
tern
a b c d
Display of KOMATSU logo 1 1 1 1
Display of check before starting 3 2 2 2
Display of warning after check
- - 3 -
before starting
Display of ending of maintenance
- - - 3
interval
Display of check of preset 4 4 4 4
Display of ordinary screen 5 4 5 5
Display of check before starting
Display of end screen
Selection of operation mode When the screen changes to the check-before-start-
Selection of gearshift mode ing screen, the check before starting is carried out
Customizing operation for 2 seconds.
Operation of customize memory a If any abnormality is detected by the check be-
Operation to cancel alarm buzzer fore starting, the screen changes to "Display of
Selection of dual tilt (Dual tilt specification) warning after check before starting" or "Display
Operation to display camera mode (if camera is
of ending of maintenance interval".
installed)
Operation to display clock and service meter a If no abnormality is detected by the check before
Check of maintenance information starting, the screen changes to "Display of check
Setting and display of user mode of preset".
Display of caution monitor a The monitors (3 pieces) displayed on the screen
Display function of action code and failure code are the items under the check before starting.
O(Special operation)
Function of checking display of LCD (Liquid Crystal
Display)
Function of checking service meter
Function of changing maintenance password
a Display pattern of operator mode
The contents of display from the time when
starting switch is turned ON to time when screen
changes to ordinary screen depends on the
setting and condition of the machine.
a: When engine start lock is set effective
b: When engine start lock is set ineffective
c: When there is abnormal item in
check-before-starting items
d: When there is maintenance item which is not
maintained after specified interval
D375A-6 30-85
(01)
DRAFT
Electrial system
Display of warning after check before starting Display of ending of maintenance interval
If any abnormality is detected by the check before When the check before starting is carried out, if a
starting, the warning monitor is displayed on the maintenance item is near or after the end of the set
screen. interval, the maintenance monitor is displayed for 30
a The following figure shows that the radiator cool- seconds to urge the operator to maintenance.
ant level monitor (a) is warning of low radiator a This screen is displayed only when the mainte-
coolant level. nance function is effective. The color of the
maintenance monitor (yellow or red) indicates
the length of the time after the maintenance in-
terval.
a Set or change the maintenance function in the
service mode.
Display of check of preset

If the check before starting is finished normally, the
screen to check the preset (gear speed at start) is
displayed for 2 seconds.
a After display of check of preset is finished, the
screen changes to "Display of ordinary screen".
30-86 D375A-6
(01)
DRAFT
Electrial system
Display of ordinary screen Selection of operation mode

If the machine monitor starts normally, the ordinary While the ordinary screen is displayed, press the op-
screen is displayed. eration mode selector switch, and the operation
a Service meter (a) or a clock is displayed at the mode monitor (a) changes.
center upper section of the screen (The service a Each time the switch is pressed, the operation
meter or clock is selected with [F4]). mode changes between [P (Power)] and [E
a Power train oil temperature gauge (b) is dis- (Economy)].
played on the multi-gauge section (It is turned
ON and OFF with the user mode function or
[F2]).
a ECO gauge (c) is displayed at the right end of
the screen (It is turned ON and OFF in the ser-
vice mode).
Selection of gearshift mode

While the ordinary screen is displayed, press the
gearshift mode selector switch, and the gearshift
mode monitor (a) in the gear speed display section
changes.
a Each time the switch is pressed, the gearshift
Display of end screen mode changes among [Automatic gearshift],
When the starting switch is turned OFF, the end [Manual gearshift] and [Shoe slip control] (Op-
screen is displayed for 5 seconds. tional) in order.
a If the automatic gearshift mode is selected, "AU-
TO" symbol (b) is displayed in the gear speed
display section. If the manual gearshift mode or
shoe slip control mode is selected, "MAN" sym-
bol is displayed.
D375A-6 30-87
(03) 30-97
DRAFT
Electrial system
Customizing operation Selection of dual tilt (Dual tilt specification)

While the ordinary screen is displayed, press the Select the blade dual tilt mode by changing the
customize switch, and you can change the setting of blade control lever knob switch while the ordinary
the machine. screen is displayed.
a If the customize memory switch is operated a If the dual tilt mode is turned ON, dual tilt mode
while the above screen is displayed, up to 5 set- monitor (a) is displayed. If the former is turned
tings can be saved. OFF, the latter is put out.
Operation of customize memory Operation to display camera mode (if camera is in-
While the ordinary screen is displayed, press the stalled)
customize memory switch, and you can select the When a camera is installed, if [F3] is pressed, the
recorded setting of customization. multi-display changes to the camera image.
a Set the connection of the camera in the service
mode.
Operation to cancel alarm buzzer

While the alarm buzzer is sounding, if the buzzer
cancel switch is pressed, the alarm buzzer stops. a Up to 3 cameras can be connected. If the cam-
a Even if the buzzer cancel switch is pressed, the era mode is selected, however, only the image of
screen does not change. camera 1 is always displayed.
30-88 D375A-6
(01)
DRAFT
Electrial system
a If a caution is generated in the camera mode, the Check of maintenance information

caution monitor is displayed at the left upper of While the maintenance monitor or ordinary screen is
the screen. displayed, press [F5], and the maintenance table
a When an error that there is a user code occurs in screen is displayed.
the camera mode, if the machine stops for 10
seconds, the screen changes to the ordinary
screen and displays the error information.
a When two or more cameras are connected, the
image of one of them or the images of two of
them can be displayed.
a If 2-camera image display [F4] is selected, the
image of camera 1 is displayed on the left side of
the screen and the image of camera 2 is dis-
played on the right side. The image of camera 3
is displayed only singly.
a If the images of 2 cameras are displayed simul-
taneously, images are displayed at intervals of 1
second on the right and left screen.
a To reset the time left after finishing maintenance,
more operations are necessary.
Operation to display clock and service meter
(See "Maintenance history" section in service
While the ordinary screen is displayed, press [F4],
mode)
and section (a) changes to the service meter and
clock alternately.
a When the clock is selected, adjust the time, set
12-hour or 24-hour display, and set the summer
time with the user mode function.
a Display of service meter
Setting and display of user mode

While the ordinary screen is displayed, press [F6],
and the user menu screen is displayed.
a Display of clock
D375A-6 30-89
(03) 30-99
DRAFT
Electrial system
a There are following items in the user menu. Display of action code and failure code
If an abnormality which displays an action code and
Utility screen select a failure code occurs on the ordinary screen or cam-
Multi gauge select era mode screen, all the information of the abnor-
mality is displayed.
Screen adjustment (a): Action code (3 digits)
(b): Failure code (5 or 6 digits)
Time adjustment
(c): Telephone mark
Language setting (d): Telephone No.
a This screen is displayed only when an abnormal-
Reverse interlock selection mode ity (failure code) for which a user code is set oc-
curs.
Fan reverse mode
a The telephone mark and telephone No. are dis-
Prelub skip played only when the telephone No. is registered
in the service mode.
a If multiple abnormalities occur simultaneously,
all the codes are displayed repeatedly in order.
a Since the information of the displayed failure
code is recorded in the fault history in the service
mode, check the details in the service mode.
Display of caution monitor

If an abnormality which displays a caution monitor
occurs on the ordinary screen or camera mode
screen, the caution monitor is displayed large for a
moment and then displayed at (a) in the screen.
a On the camera mode screen, the caution moni-
tor flashes at the left upper of the screen when
the caution is generated.
30-90 D375A-6
(01)
DRAFT
Electrial system
a Remedies given by displayed action codes to operator to take are as follows (Excerpt from the Operation
and Maintenance Manual).
Action
Method of indicating trouble Examples of trouble Remedy given to operator to take
code
q Although all or a part of automatic
q Backup alarm does not sound. function stops, machine can be op-
q Action code and failure
E01 q Fan speed is always at maxi- erated.
code are displayed.
mum. q Ask your Komatsu distributor for re-
pair.
q If operator stops and restarts en-
q Gear is not shifted up or down. gine, machine can be operated with-
q Action code and failure q Engine boost pressure is about any functions being limited.
E02 code are displayed. normal. However, operator has to pay atten-
q Alarm buzzer sounds. q Exhaust gas color is bad when tion.
temperature is low. q Ask your Komatsu distributor for re-
pair.
q Engine coolant temperature
sensor is abnormal.
q Usable gear speeds are limited.
code are displayed. q Move machine to safe place.
q Engine speed does not rise ful-
E03 q Telephone No. is dis- q Ask your Komatsu distributor for re-
ly.
played (if set). pair.
q Gear shift shock is large.
q Alarm buzzer sounds.
q Steering performance lowers.
q Braking shock is increased.
code are displayed. q Engine cannot be controlled. q Stop machine immediately.
E04 q Telephone No. is dis- q Machine cannot travel. q Ask your Komatsu distributor for re-
played (if set). q Machine stops. pair.
q Alarm buzzer sounds.
D375A-6 30-91
(03) 30-101
DRAFT
Electrial system
Function of checking display of LCD (Liquid Crystal Function of checking service meter
Display) To check the service meter while the starting switch
While the ordinary screen is displayed, if the follow- is turned OFF, operate the numeral input switches
ing numeral input switch and function switch are op- as follows. At this time, only the service meter sec-
erated as follows, all the LCD (Liquid Crystal tion displays.
Display) lights up in white. q Operation of switches (simultaneous): [4] + [1]
q Operation of switches (simultaneous): [4] + [F2] a Since there is some time lag in start of the LCD,
a When finishing the operation of the switches, re- hold down the switches until the LCD displays
lease [F2] first. normally.
a If there is a display error in the LCD, only that a After the machine monitor is used continuously,
part is indicated in black. blue points (points which do not go off) may be
a The LCD panel sometimes has black points seen on this screen. This phenomenon does not
(points which are not lighted) and bright points indicate a failure or a defect.
(points which do not go off) for the reason of its
characteristics.
If the number of the bright points and black
points does not exceed 10, those points are not
a failure or a defect.
a To return to the former screen, press the function
switch.
30-92 D375A-6
(01)
DRAFT
Electrial system
Function of changing maintenance password (If it has only 3 or less digits or has 7 or more
When changing the maintenance password used for digits, it is not accepted).
the maintenance setting function, follow these pro- q [F5]: Delete input numeral/Return to ordinary
cedures. screen
q [F6]: Confirm input numeral
1. While the ordinary screen is displayed, perform
the following operation with the numeral input
switches.
q Operation of switches (While pressing [4],
perform the operation in order):
[4 ]+ [5]o [5] o [5]
a This operation of the switches is not accept-
ed until 10 minutes pass after the starting
switch is turned on.
4. After the "New Password" screen is displayed

again, input a new password again with the
numeral input switches and confirm it with the
function switch.
q [F5]: Delete input numeral/Return to ordinary
screen
a If a password different from the password in-
put before is input, the message to input
2. After the "Password" screen is displayed, input again is displayed.
the current password with the numeral input
switches and confirm it with the function switch.
q [F5]: Delete input numeral/Return to ordinary
screen
a Default password: [000000]
a If the input password is correct, the screen
changes to the next screen.
a If the input password is incorrect, the mes-
sage to input the password again is dis-
played.
5. If the screen to notify completion of setting is

displayed and then the ordinary screen is
displayed, the password is changed successfully
3. After the New password input screen is

displayed, input a new password with the
numeral input switches and confirm it with the
function switch.
a Set a new password of 4 – 6 digits
D375A-6 30-93
(01)
DRAFT
Electrial system
t Service mode a The items which can be selected in the ser-

To change the operator mode to the service mode, vice menu are as follows.
perform the following operation. 01 Monitoring
This operation is always required when you use the Mechanical system "Abnor-
service mode. 02 Abnormality mality Record"
Record Electrical system "Abnormal-
1. Check of display of screen and operation of ity Record"
03 Maintenance Record
switches
04 Maintenance Mode Change
While the ordinary screen is displayed, perform 05 Phone Number Entry
the following operation with the numeral input Key-on Mode
switches. Setting of unit
q Operation of switches (While pressing [4], Setting of maintenance pass-
06 Default
perform the operation in order): word
[4]+[1]o[2]o[3] Setting of camera
Setting of ECO display
a This operation of the switches is accepted
07 Adjustment
only while the ordinary screen is displayed. 08 PM clinic
09 Cylinder Cut-Out
10 No Injection
11 Fuel Consumption
12 Display of saved load
13 Setting of VHMS
14 Snap shot (Machine equipped with VHMS)
a Items with 2-digit codes are the menus dis-
played on the Service menu screen. The
items on their right are the menus on the next
hierarchy.
2. Selection of the service menu

When the "Service Menu" screen is displayed,
the service mode is selected. Select a service
menu you use with the function switches or
numeral input switches.
q [F3]: Move to lower menu
q [F4]: Move to upper menu
q [F5]: Return to ordinary screen (operator
mode)
q [F6]: Confirm selection
a You may enter a 2-digit code with the numer-
al input switches to select the menu of that
code and confirm it with [F6].
30-94 D375A-6
(01)
DRAFT
Electrial system
Monitoring
The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed to
many parts of the machine and the information from
the controllers which are controlling switches, etc.
1. Selecting menu
Select "01 Monitoring" on the "Service Menu"
screen.
3. Deciding monitoring items

After selecting monitoring items, execute moni-
toring with the function switch or numeral input
switch.
a Execution with function switch: Doubleclick
or hold down [F6] (about 2 seconds).
a Execution with numeral input switch: Input
[99999] and press [F6].
a When monitoring only 2 items, for example,
select them and confirm with [F6]. If [F6] is
2. Selecting monitoring items pressed once more at this time, monitoring is
After the "Monitoring selection menu screen" is executed.
displayed, select items to be monitored with the a If monitoring items are selected up to the limit
function switches or numeral input switches. number, monitoring is executed automatical-
q [F1]: Go to next page (screen) ly.
q [F2]: Go to previous page (screen)
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Delete input numeral/Return to service
menu screen
a Selection with function switches: Select an
item with [F3] or [F4] and confirm it with [F6].
a Selection with numeral input switches: Enter
a 5-digit code, and the item of that code is se-
lected directly. Confirm that item with [F6].
a If the color of the selected box changes from
yellow to red, selection of the item of that box
is confirmed.
a Up to 6 monitoring items can be selected at a
time. You may not able to set up to 6 items,
however, depending on the display form of
those items.
D375A-6 30-95
(01)
DRAFT
Electrial system
4. Executing monitoring 6. Changing machine setting mode

After the "Executing monitoring screen" is To change the setting of the "P/E Mode", "Fan
displayed, perform the necessary operation of Rev." mode, or "Working" mode during moni-
the machine and check the monitoring informa- toring, operate the corresponding switch under
tion. the current condition, and the mode setting
a Monitoring information is indicated by value, screen is displayed.
ON/OFF, or special display. While this screen is displayed, if the corre-
a The unit of display can be set to SI unit, met- sponding switch is operated further, the corre-
ric unit, or inch unit with the Default function sponding mode is changed.
in the service mode. a After finishing changing the setting, press
[F6] to MPareturn to the monitoring informa-
tion screen.
a If the setting is changed during monitoring,
the new setting is held even after the screen
returns to the ordinary screen after monitor-
ing is finished.
5. Holding monitoring information

The monitoring information can be held and
reset with the function switches.
q [F3]: Reset holding
q [F4]: Hold (displayed data)
q [F5]: Return to monitoring selection menu
screen
30-96 D375A-6
(01)
DRAFT
Electrial system
Monitoring items list

Code Unit (Default: SI) Component
Monitoring item (displayed on screen) Remarks
No. SI Metric Imperial in charge
50300 S/T Lever 1 Potentio mV mV mV P/T
50301 S/T Lever 2 Potentio mV mV mV P/T
50400 Brake Pedal Potentio mV mV mV P/T
31619 Brake LH ECMV(F/B) mA mA mA P/T
31618 Brake RH ECMV(F/B) mA mA mA P/T
90600 S/T Clutch LH ECMV(F/B) mA mA mA P/T
90601 S/T Clutch RH ECMV(F/B) mA mA mA P/T
31628 S.S.P Solenoid mA mA mA P/T
32900 Pitch Angle ° ° ° P/T
60100 Pitch Angle Sensor mV mV mV P/T
60600 BR Hold Relay mV mV mV P/T
03001 Fuel Dial Throttle % % % P/T
03000 Fuel Dial Sensor mV mV mV P/T
S/T Clutch LH Fill Sw ON • OFF P/T
S/T Brake LH Fill Sw ON • OFF P/T
31521 S/T Fill Sw Input
S/T Clutch RH Fill Sw ON • OFF P/T
S/T Brake RH Fill Sw ON • OFF P/T
50200 T/M Lever 1 Potentio mV mV mV P/T
50201 T/M Lever 2 Potentio mV mV mV P/T
31622 T/M Clutch F ECMV(F/B) mA mA mA P/T
31616 T/M Clutch R ECMV(F/B) mA mA mA P/T
31612 T/M Clutch 1st ECMV(F/B) mA mA mA P/T
31613 T/M Clutch 2nd ECMV(F/B) mA mA mA P/T
31614 T/M Clutch 3rd ECMV(F/B) mA mA mA P/T
30100 T/C Oil Temperature C C F P/T
31400 T/M Out Speed r/min rpm rpm P/T
32601 T/C In Pressure MPa kg/cm2 psi P/T
32602 T/C In Pressure Sensor mV mV mV P/T
32603 T/C Out Pressure MPa kg/cm2 psi P/T
32604 T/C Out Pressure Sensor mV mV mV P/T
31642 L/U ECMV(F/B) mA mA mA P/T
90700 S/C ECMV(F/B) mA mA mA P/T
40001 Vehicle speed km/h km/h MPH P/T
60000 Traction W W W P/T
70200 T/M Out Speed Sensor mV mV mV P/T
31624 Fan Pump Solenoid(F/B) mA mA mA P/T
10000 Fan Speed r/min rpm rpm P/T
SUNC ON • OFF P/T
SUNO ON • OFF P/T
SDNC ON • OFF P/T
40905 P/T SW Input 3
SDNO ON • OFF P/T
PNC ON • OFF P/T
PNO ON • OFF P/T
F ON • OFF P/T
R ON • OFF P/T
40906 T/M Fill Sw Input 1 1st ON • OFF P/T
2nd ON • OFF P/T
3rd ON • OFF P/T
L/U ON • OFF P/T
31520 T/M Fill Sw Input 2
S/C ON • OFF P/T
D375A-6 30-97
(03) 30-107
DRAFT
Electrial system

Back-up alarm ON • OFF P/T
N-safty ON • OFF P/T
40909 P/T SW Output
Pre-lub Motor ON • OFF P/T
Pre-heater ON • OFF P/T
70700 Hydraulic Pump Pressure 1 MPa kg/cm2 psi W/E
70701 Hydraulic Pressure Sensor 1 mV mV mV W/E
60200 Acceleration Sensor Voltage mV mV mV P/T
60300 SSC Command Speed r/min rpm rpm P/T
31200 Trque Converter Output Speed r/min rpm rpm P/T
43001 T/M Main Oil Pressure MPa kg/cm2 psi WHMS
40910 P/T SW Input 2 ON • OFF P/T
W/E Lock Switch (NO) ON • OFF W/E
W/E Lock SW (NC) ON • OFF W/E
W/E Knob Upper SW
ON • OFF W/E
(NO)
70300 Blade Sw Input W/E Knob Upper SW
ON • OFF W/E
(NC)
W/E Knob Lower SW
ON • OFF W/E
(NO)
W/E Knob Lower SW
ON • OFF W/E
(NC)
Blade Lift Raise
Blade Leber Oil Blade Lift Lower
90802 ON • OFF W/E
Press. Swith Blade Left Tilt
Blade Right Tilt
31634 Fan Pump Solenoid 2 (F/B) mA mA mA W/E
10007 Fan Speed r/min rpm rpm W/E
Ripper Lift Raise
Ripper Leber Oil Ripper Lift Lower
40982 ON • OFF W/E
Press. Switch Ripper Tilt in
Ripper Tilt Out
01501 LS Solenoid (F/B) mA mA mA W/E
HYD. Oil Level
ENG Low Idle
40981 W/E SW Input C-sig ON • OFF W/E
R-sig
Acc
ENG Hold
40983 W/E SW Output Fan Reverse Solenoid ON • OFF W/E
ENG Shut Down
37501 Ambient Temperature C C F WHMS
42610 Exhaust Temperature, front C C F WHMS
42611 Exhaust Temperature, rear C C F WHMS
42612 Exhaust Temp. sensor, front V V V WHMS
42613 Exhaust Temp. sensor, rear V V V WHMS
42801 Blow-by Pressure kPa kg/cm2 psi WHMS
20300 VHMS LED Monitor — WHMS
Orbcomm Con. Power
Orbcomm Commu-
99003 Satellite Condition ON • OFF WHMS
nication Status
Data Transmission
20227 Monitor Ass'y P/N — MON
20402 Monitor serial No — MON
30-108
30-98 D375A-6
(03)
DRAFT
Electrial system

20228 Monitor Prog P/N — MON
20242 P/T Con Ass'y P/N — P/T
20404 P/T Con Serial No — P/T
20243 P/T Con Prog P/N — P/T
20244 W/E Con Ass'y P/N — W/E
20405 W/E Con Serial No — W/E
20245 W/E Con Prog P/N — W/E
04200 Fuel Level Sensor Volt V V V MON
04300 Battery charge volt V V V MON
04401 Hyd Oil Temperature C C F MON
04402 Hyd Temp Sens Volt V V V MON
18900 ECM Internal Temp C C F ENG
37200 Engine oil pressure Mpa kg/cm2 psi ENG
00201 Machine ID — ENG
20216 ECM Build Version — ENG
20217 ECM Calibration Data Ver — ENG
20400 ECM Serial No — ENG
01002 Engine Speed r/min rpm rpm ENG
36700 Engine Torque Ratio % % % ENG
31701 Decel Pedal Position % % % ENG
31703 Decel Pedal Pos Sens Volt mV mV mV ENG
17500 Engine Power Mode — ENG
36400 Rail Pressure MPa kg/cm2 psi ENG
36401 Rail Pressure Sens Volt V V V ENG
36200 Rail Press Command MPa kg/cm2 psi ENG
36300 Injection Timing Command CA CA CA ENG
04107 Coolant Temperature C C F ENG
04105 Coolant Temp Sens Volt V V V ENG
37400 Ambient Pressure Mpa kg/cm2 psi ENG
37401 Ambient Press Sens Volt V V V ENG
Indicated in abso-
lute pressure
36500 Charge Pressure-Abs Mpa kg/cm2 psi ENG
(including ambi-
ent pressure)
36501 Charge Press Sens Volt V V V ENG
03203 Battery Power Supply V V V ENG
37300 Fuel Rate l/h l/h gal/h ENG
31706 Final Throttle Position % % % ENG
18500 Charge Temperature C C F ENG
18501 Charge Temp Sens Volt V V V ENG
18600 Inject Fueling Command mg/st mg/st mg/st ENG
17201 PCV Close Timing CA CA CA ENG
18700 Engine Output Torque Nm kgm lbft ENG
37201 Eng Oil Press Sens Volt V V V ENG
14200 Fuel Temperature C C F ENG
14201 Fuel Temp Sens Volt V V V ENG
42700 ENG Oil Temperature C C F ENG
42701 ENG Oil Temp. sensor mV mV mV ENG
17903 EGR Inlet Pressure-A Mpa kg/cm2 psi ENG
18001 EGR In Press Sens Volt mV mV mV ENG
18100 EGR Valve Position mm mm mm ENG
18101 EGR Valve Pos Sens Volt mV mV mV ENG
D375A-6 30-99
(03) 30-109
DRAFT
Electrial system

18200 BPS Valve Position mm mm mm ENG
18201 BPS Valve Pos Sens Volt mV mV mV ENG
Acc ON • OFF P/T
40912 P/T SW Input 1 R-sig ON • OFF P/T
C-sig ON • OFF P/T
a Entry order of monitoring items in table
The monitoring items are entered in the order of display on the "Monitoring" screen for item selection.
a Unit
The display unit can be set to SI, Metric, or Imperial unit freely (use "Unit" menu of "Default" in the
service menu to select the unit.).
"CA" in the display unit is an abbreviation for crankshaft angle.
"mg/st" in the display unit is an abbreviation for milligram/stroke.
a Component in charge
MON: The machine monitor is in charge of detection of the monitoring information.
ENG: The engine controller is in charge of detection of the monitoring information.
P/T: The power train controller is in charge of detection of the monitoring information.
W/E: The work equipment controller is in charge of detection of the monitoring information.
VHMS: The VHMS controller is in charge of detection of the monitoring Information.
30-110
30-99-1 D375A-6
(03)
DRAFT
Electrial system
D375A-6 30-99-2
(03) 30-111
DRAFT
Electrial system
"Abnormality Record" (Mechanical system "Abnor- 3. Information displayed on "Abnormality Record"

mality Record") screen
The machine monitor classifies and records the ab- On the "Mechanical Systems" screen, the
normalities which occurred in the past or which are following information is displayed.
occurring at present into the mechanical system ab- (a): Sequential order from latest occur-
normality or electrical system abnormality. rence/Total number of records
To check the mechanical system abnormality re- (b): Failure code
cord, perform the following procedures. (c): Contents of trouble
1. Selecting menu (d): Occurrence number
Select "02 Abnormality Record" on the "Service (e): Service meter reading at first occurrence
Menu" screen. (f): Service meter reach at last occurrence
q [F1]: Move to next page (screen) (if dis-
played)
q [F2]: Move to previous page (screen) (if dis-
played)
q [F5]: Return to "Abnormality Record" screen
a If no "Abnormality Record" is recorded, "No
Abnormality Record" is displayed.
a If the number of occurrence time is 1 (first oc-
currence), the service meter reading at the
first occurrence and that at the last occur-
rence are the same.
a If [E] is displayed on the left of a failure code,
the abnormality is still occurring or resetting
of it has not been confirmed.
2. Selecting sub menu
a For all the failure codes that the machine
After the "Abnormality Record" screen is
monitor can record, see Troubleshooting,
displayed, select "01 Mechanical Systems" with
"Failure codes table".
the function switches or numeral input switches.
q [F5]: Return to service menu screen
al input switches to select the record of that
4. Deleting "Abnormality Record"

The contents of the mechanical system "Abnor-
mality Record" cannot be deleted.
30-100 D375A-6
(01)
DRAFT
Electrial system
"Abnormality Record" (Electrical system "Abnormali- 3. Information displayed on "Abnormality Record"

ty Record") screen
The machine monitor classifies and records the ab- On the "Electrical Systems" screen, the following
normalities which occurred in the past or which are information is displayed.
occurring at present into the mechanical system ab- (a): Sequential order from latest occur-
normality or electrical system abnormality. rence/Total number of records
To check the electrical system abnormality record, (b): Failure code
perform the following procedures. (c): Contents of trouble
1. Selecting menu (d): Occurrence number
Select "02 Abnormality Record" on the "Service (e): Service meter reading at first occurrence
Menu" screen. (f): Service meter reach at last occurrence
q [F1]: Move to next page (screen) (if dis-
played)
q [F2]: Move to previous page (screen) (if dis-
played)
q [F5]: Return to "Abnormality Record" screen
a If no "Abnormality Record" is recorded, "No
Abnormality Record" is displayed.
a If the number of occurrence time is 1 (first oc-
currence), the service meter reading at the
first occurrence and that at the last occur-
rence are the same.
a If [E] is displayed on the left of a failure code,
the abnormality is still occurring or resetting
After the "Abnormality Record" screen is
of it has not been confirmed.
displayed, select "02 Electrical Systems" with
a For all the failure codes that the machine
the function switches or numeral input switches.
monitor can record, see Troubleshooting,
"Failure codes table".
al input switches to select the record of that
4. Deleting "Abnormality Record"

1) While the "Electrical Systems" screen is
displayed, perform the following operation
with the numeral input switches.
q Operation of switches (While pressing [4],
perform the operation in order):
[4]+[1]o[2]o[3]
a Operate the switches similarly to the pro-
cedure for changing the ordinary display
to the service mode.
D375A-6 30-101
(01)
DRAFT
Electrial system
2) Check that the screen is set in the reset 4) If the screen to notify completion of reset is
mode, and then reset the items one by one or displayed and then the "Electrical Systems"
together with the function switches. (reset mode) screen is displayed, the reset of
a If the screen is set in the reset mode, the abnormality record is completed.
[CLEAR] graphic mark is indicated at a After a while, the screen returns to the
[F2]. "Electrical Sys. Error Reset" screen.
q [F2]: Delete all items
q [F5]: Return to "Abnormality Record"
screen
q [F6]: Delete selected item
a To delete items one by one: Select the
item to be deleted with [F3] or [F4] and
press [F6].
a To delete all items together: Press [F2],
and all the items are deleted, regardless
of selection of the items.
a If [E] is displayed on the left of a failure
code, the deleting operation is accepted
but the information is not deleted.
3) After the "Electrical Sys. Error Reset" screen

is displayed, operate the function switches.
q [F5]: Return to "Electrical Sys. Error Re-
set" screen (Delete mode)
q [F6]: Execute deletion
a The following figure shows the screen
displayed when the items are reset one
by one (which is a little different from the
screen displayed when all the items are
reset together).
30-102 D375A-6
(01)
DRAFT
Electrial system
Maintenance Record a The following items can be selected in the

The machine monitor records the maintenance in- maintenance record.
formation of the filters, oils, etc., which the operator
01 Engine Oil Change
can display and check by the following operations.
When maintenance is carried out, if the data are re- 02 Engine Oil Filter Change
set in the operator mode, the number of the times of
maintenance is recorded in this section. 03 Fuel Main Filter Change
41 Fuel Pre Filter Change

1. Selecting menu
Select "03 Maintenance Record" on the "Service 04 Hyd Oil Filter Change
Menu" screen.
06 Corrosion Resistor Change
07 Damper case service
08 Replacement interval of final drive case oil
10 Hydraulic oil change
19 Replacement of power train oil
20 Replacement of power train oil filter
3. Items displayed on Maintenance Record screen.

The following items are displayed.
(a): Maintenance items
(b): Number of times of change up to now
2. Selecting maintenance record item (c): Service meter reading (SMR) at previous
After the "Maintenance Record" screen is change
displayed, select an item to be checked with the
function switches or numeral input switches.
q [F1]: Go to next page (screen)
q [F2]: Go to previous page (screen)
al input switches to select the item of that
code.
D375A-6 30-103
(03) 30-115
DRAFT
Electrial system
Maintenance Mode Change

The operating condition for maintenance func- 00 Maintenance Mode On/Off
tion in the operation mode can be set and 01 Engine Oil Change Int
changed with this menu.
q Set function effective or ineffective 02 Eng Oil Filter Change Int
q Change set replacement interval (by items)
03 Fuel Main Filter Change Int
q Initialize all set change intervals
41 Fuel Pre Filter Change Int

1. Selecting menu
Select "04 Maintenance Mode Change" on the 04 Hyd Oil Filter Change Int
Service menu screen. 07 Check and replacement interval of damper
case oil
08 Replacement interval of final drive case oil
10 Replacement interval of hydraulic oil
19 Replacement interval of power train oil
20 Replacement interval of power train oil filter
99 Use Default Value
3. Contents of setting of ON/OFF of maintenance

mode
After selecting "00 Maintenance Mode On/Off", if
the screen is displayed, set ON or OFF with the
2. Selecting sub menu function switches.
After the "Maintenance Mode Change" screen is q ON: Functions of all maintenance items are
displayed, select an item to change the setting set effective in operator mode
with the function switches or numeral input q OFF: Functions of all maintenance items are
switches. set ineffective in operator mode
q [F1]: Go to next page (screen) q [F3]: Move to lower item
q [F2]: Go to previous page (screen) q [F4]: Move to upper item
q [F3]: Move to lower item q [F5]: Cancel selection and return to Mainte-
q [F4]: Move to upper item nance mode screen
q [F5]: Return to service menu screen q [F6]: Confirm selection and return to Mainte-
q [F6]: Confirm selection nance mode screen
a You may enter a 2-digit code with the numer- a Even if ON/OFF of each item has been set, if
al input switches to select the record of that the above setting is changed, it is applied.
4. Contents of setting of each maintenance item

a The following items can be selected on the After selecting each maintenance item, if the
Change of maintenance mode screen. screen is displayed, set the item with the function
switches.
30-104 D375A-6
(01)
DRAFT
Electrial system
q Default: Maintenance interval set in machine a If this operation is executed, the set values of
monitor (Recommended by manufacturer all the maintenance items are set to default
and not changeable). values.
q Set: Maintenance interval which can be set q [F5]: Return to Maintenance Mode Change
freely. Maintenance functions in operator screen
mode operate on basis of this set time (which q [F6]: Execute default setting
is increased or decreased by 25 hours). a A while after [F6] is pressed, the initialization
q ON: Maintenance function of this item is set completion screen is displayed. Then, if the
effective in operator mode. "Maintenance Mode Change" screen is dis-
q OFF: Maintenance function of this item is set played, initialization is completed.
ineffective in operator mode.
q [F3]: Select Reduce set value (Upper) or OFF
(Lower).
q [F4]: Select Increase set value (Upper) or ON
(Lower).
q [F5]: Cancel setting before confirmation and
return to Maintenance Mode Change screen.
q [F6]: Confirm setting of upper or lower line.
a After the setting of the upper and lower lines
is confirmed with [F6] and the screen chang-
es to the Maintenance mode change screen
with [F5], the setting is effective.
Phone Number Entry

The telephone No. displayed when the user
code/failure code is displayed in the operator mode
can be input and changed according to the following
procedure.
If a telephone No. is not input with this function, no
telephone No. is displayed in the operator mode.
1. Selecting menu
Select "05 Phone Number Entry" on the "Service
Menu" screen.
5. Function of All Default Value

After selecting "99 Use Default Value", if the
screen is displayed, set with the function
switches.
D375A-6 30-105
(01)
DRAFT
Electrial system
2. Registering and changing telephone No.

After the "Phone Number Entry" screen is
displayed, register or change the telephone No.
q [F2]: Delete all input No.
q [F3]: Move to left position (if not blank)
q [F4]: Move to right position (if not blank)
q [F5]: Delete input digit/Return to service
menu
q [F6]: Confirm input
a Up to 14 digits can be input from the left. In-

put nothing in the surplus positions.
a If one of the input digits is wrong, move to
that digit (and its background changes to or-
ange) and overwrite it with the correct digit.
a If [F6] is pressed without inputting a digit,
there is not information of phone No. Accord-
ingly, no phone No. is displayed in the oper-
ator mode.
30-106 D375A-6
(01)
DRAFT
Electrial system
Default setting (Key-on Mode) q Default Value (ALL OFF): Default setting of
Check and change various settings related to the all mode items (Power: P, other 3 items:
machine monitor and the machine with the "De- OFF) is displayed when starting switch is
fault". turned ON
The function of Key-on Mode is used to set the initial q [F3]: Move to lower item
mode displayed on the machine monitor when the q [F4]: Move to upper item
starting switch is turned ON. q [F5]: Cancel selection and return to the "De-
fault" screen
1. Selecting menu q [F6]: Confirm selection and return to default
Select "06 Default" on the "Service Menu" screen
screen. a When the machine is delivered, Mode at Pre-
vious key-off.

After the "Default" screen is displayed, select "01
Key-on Mode" with the function switches or
a Select this item similarly to an item on the
"Service Menu" screen.
a This function sets the following 4 mode items
(which are the items set with the customize
switch in the operator mode).
q Power: P/E
q Reverse slow mode: ON/OFF
q Work equipment fine control: ON/OF
q Blade slow down: ON/OFF
3. Selecting mode
After the "Key-on Mode" screen is displayed,
select the mode to be set with the function
switches.
q Mode at previous key-OFF: Final mode in
previous operation is displayed when starting
switch is turned ON
D375A-6 30-107
(01)
DRAFT
Electrial system
Default setting (Setting of unit)

Check and change various settings related to the
machine monitor and the machine with the "De-
fault".
The unit selecting function is used to select the unit
of the data displayed for monitoring, etc.
1. Selecting menu
Select "06 Default" on the "Service Menu"
screen.

Unit" with the function switches or numeral input
switches.
3. Selecting unit
After the "Unit" screen is displayed, select the
unit to be set with the function switches.
q [F5]: Cancel selection and return to the "De-
fault" screen
q [F6]: Confirm selection and return to default
screen
a When the machine is delivered, the SI unit
system is set.
30-108 D375A-6
(01)
DRAFT
Electrial system
Default setting (Setting of maintenance password)

fault".
The function of setting maintenance password is
used to set the display of the password screen when
the functions related to the maintenance are used in
the operator mode.
1. Selecting menu
screen.
4. Displaying maintenance password screen

When the following operation is performed, the
password screen is displayed in the operator
mode.
q The ordinary screen is changed to the main-
tenance mode (with [F5]) and then the "Main-
tenance table" screen is changed to the
"Maintenance interval reset" screen.
5. Changing maintenance password

The password can be changed by operating the
switches specially in the operator mode.
2. Selecting sub menu a See "Function of changing maintenance
After the "Default" screen is displayed, select "03 password" in the operator mode.
Maintenance Password" with the function a Default password: [000000]
switches or numeral input switches. a If the password setting is changed from "En-
a Select this item similarly to an item on the able" to "Disable", the password is reset to
"Service Menu" screen. the default.
a When "Enable" is set again, be sure to set a
new password.
a The maintenance password is different from
the engine start lock password.
3. Selecting Enable/Disable
After the Maintenance Password screen is
displayed, select the setting with the function
switches.
q Disable: Password screen is not displayed
q Enable: Password screen is displayed
fault" screen
screen
D375A-6 30-109
(01)
DRAFT
Electrial system
Default setting (Setting of camera) a After "Camera" screen is displayed, camera

Check and change various settings related to the 1 can be always set.
machine monitor and the machine with the "De- When 2 or more cameras are connected, if
fault". camera 1 is set, the screen changes to
The camera setting function is used to set default setting of camera 2 automatically.
setting and removal of a camera. a After confirming the setting of each line with
[F6], return to the "Default" screen with [F5],
1. Selecting menu and the setting is effective.
Select "06 Default" on the "Service Menu" a If a camera is connected but not set normally
screen. with this function, the graphic mark of camera
is not displayed at [F3] in the operator mode.
Accordingly, the image of the camera cannot
be used.
a If 2 or more cameras are connected, be sure
to set the use of them from camera 1 in order.
a The function of displaying 2 images simulta-
neously is effective when use of camera 1
and camera 2 is set.
a When a camera is installed, check that the
displayed image is not inverted horizontally
in the operator mode.

Camera" with the function switches or numeral
input switches.
3. Selecting camera setting

After the "Camera" setting screen is displayed,
select the setting with the function switches.
q OFF: Camera is not connected
q Original image: Image of connected camera
is displayed in original position
(as in mirror, used as back monitor)
q Reverse image: Image of connected camera
is displayed in reverse position (as seen di-
rectly, used as front or side monitor)
q [F3]: Move to left item
q [F4]: Move to right item
q [F5]: Cancel setting before confirmation and
return to Default screen
q [F6]: Confirm selection in each line
30-110 D375A-6
(01)
DRAFT
Electrial system
Default setting (Setting of ECO display)

fault".
The ECO display setting function is used to set the
display of the ECO gauge.
1. Selecting menu
screen.
a Display of ECO gauge (a)

ECO Display" with the function switches or
3. Selecting display setting

After the "ECO Display" screen is displayed,
select the setting with the function switches.
q ON: Display ECO
q OFF: Do not display ECO
q [F3]: Move to left item
q [F4]: Move to right item
fault" screen
screen
a If ECO display is turned ON, ECO is dis-
played when the screen changes to the ordi-
nary screen.
D375A-6 30-111
(01)
DRAFT
Electrial system
Adjusting
The operator can adjust various items related to the
machine with the machine monitor.
When using an adjustment item, select it according
to the following procedure.
1. Selecting menu
Select "07 Adjustment" in the "Service menu"
screen.
3. Displaying adjustment screen

After the "Adjustment" screen for the adjustment
ID is displayed, you can start adjustment.
a In the figure, adjustment ID [0002] is selected
and displayed as an example.
a "000", "00", and "0" on the left of the adjust-
ment ID must be filled but they are not dis-
played on the adjustment screen.
a The functions given to function switches [F3]
2. Selecting adjustment items – [F6] depend on the adjustment item.
After the "Adjustment" screen is displayed, input a For the method of operating each adjustment
the 4-digit adjustment ID of the adjustment item item, see the explanation of its adjustment
to be used with the numeral input switches. ID.
q [F5]: Cancel adjustment and return to Ser-
vice menu screen
q [F6]: Confirm input adjustment ID and go to
Adjustment screen
a For the adjustment ID's and their adjustment
items, see the adjustment items table.
a lf the input adjustment ID is incorrect, the

message of "Not Available" is displayed and
the ID input screen does not change (another
ID can be input again with the numeral input
switches while this screen is displayed).
30-112 D375A-6
(01)
DRAFT
Electrial system
Adjustment items table

Adjustment
Adjustment item Remarks
ID
0002 Power train controller initialization
0004 Work equipment specification setting
0005 Brake pedal potentiometer initial correction
0007 Engine decelerator cutting Resetting auto-decelerating function
0009 Pitch angle sensor initial correction
0010 Fan 70% mode
0031 Work equipment controller initialization
0036 Shoe slip control specification code setting
0041 Travel lever code setting Setting and resetting uni-direction lever
Recommended mode of torque con-
0530 Stall mode
verter stall
1005 Fan 100 % mode
1012 Steering lever neutral position adjustment
1013 Steering lever leftmost position adjustment
1014 Steering lever rightmost position adjustment
1015 Right brake oil pressure offset
1016 Left brake oil pressure offset
2021 Power train controller voltage check mode
2022 Work equipment controller voltage check mode
5535 Both steering clutch disengage mode
5537 Left steering clutch oil pressure offset
5538 Right steering clutch oil pressure offset
6001 R1 reverse slow set speed Fine adjustment of reverse slow mode
7842 Transmission clutch IP and fill time automatic initial correction
7843 Transmission clutch IP manual initial correction
7845 Transmission clutch IP learning display
7847 Transmission clutch fill time manual initial correction
Control brake: Brake ECMV (Right and
9995 Control brake release mode
left)
9996 Sudden stop prevent valve operation mode
9997 High idle cut mode
9998 Max. gear speed setting mode
D375A-6 30-113
(03) 30-125
DRAFT
Electrial system
Adjustment ID: 0002 (Power train controller Adjustment ID: 0004 (Work equipment specifica-
initialization) tion setting)
q This adjustment code is used to initialize the q This adjustment code is used to make the
specification code recognized by the power work equipment controller recognize the type
train controller and the set values of the of the work equipment.
memory in the controller. a After the work equipment controller or the
a After the power train controller is replaced, work equipment is replaced, be sure to carry
be sure to carry out this adjustment once. out this adjustment once.
q Functions of function switches q Functions of function switches

[F3]: Unused [F3]: Increase specification value [CODE]
[F4]: Unused [F4]: Decrease specification value [CODE]
[F5]: Return to adjustment item selecting [F5]: Return to adjustment item selecting
screen (ID inputting screen) screen (ID inputting screen)
[F6]: Save setting [F6]: Save setting
q Operating method: q Operating method:

1] Press [F6] and check that the alarm 1] Press [F3] or [F4] to select the specifica-
buzzer sounds. tion value [CODE] of the work equipment
2] Check that the displayed specification concerned.
code [CODE] has changed from [1x1] to CODE Type of work equipment
[111]. 0 Dual tiltdozer
a If specification code [111] is not dis- 1 Single tiltdozer
played, the controller unit may be defec- 2] Press [F6] and check that the alarm
tive. buzzer sounds.
a Even if this adjustment code is turned off, k If the specification of the work equipment
the setting is effective. is different from the setting in the control-
ler, the work equipment may move unex-
pectedly or an error may be made.
Accordingly, be sure to match the con-
troller to the work equipment.
a Even if this adjustment code is turned off, the
setting is effective.
30-114 D375A-6
(01)
DRAFT
Electrial system
Adjustment ID: 0005 (Brake pedal potentiometer Adjustment ID: 0007 (Engine decelerator cutting)
initial correction)
q This adjustment code is used to stop the au-

q This adjustment code is used to make the to-deceleration function of the engine and
power train controller recognize the zero check the high idle speed of the engine unit.
point of the brake pedal potentiometer. a The engine can be operated and tested with
a After the power train controller or brake pedal only the auto-decelerator turned off with this
potentiometer is replaced or the brake pedal adjustment code.
linkage is disconnected and connected, be a Use this adjustment code for testing, adjust-
sure to carry out this adjustment once. ing, or troubleshooting when necessary.

[F3]: Unused [F3]: Unused
[F6]: Save corrected value [F6]: Unused

1] Check that the brake pedal is in the When this adjustment code is displayed, its
neutral position (it is not pressed at all) function is effective and the auto-decelera-
and keep it in that position. tion function is stopped.
2] Press [F6] and check that the alarm a After this adjustment code is turned OFF,
buzzer sounds. its function is ineffective.
a Even if the adjustment is carried out, the
displayed value does not change.
a Even if this adjustment code is turned off,
the correction is effective.
a This adjustment code is used to make the
controller recognize the zero point of the
potentiometer. It is not used to adjust the
braking force.
D375A-6 30-115
(01)
DRAFT
Electrial system
Adjustment ID: 0009 (Pitch angle sensor initial Adjustment ID: 0010 (Fan 70% mode)
correction)
q This adjustment code is used to forcibly set

q This adjustment code is used to make the the cooling fan speed to about 70%.
power train controller recognize the zero a Use this adjustment code for testing, adjust-
point of the pitch angle sensor and to correct ing, or troubleshooting when necessary.
the installation error.
a After the power train controller is replaced or q Functions of function switches
the pitch angle sensor is removed and in- [F3]: Increase adjustment value [FAN 70 %
stalled or replaced, be sure to carry out this SPEED MODE]
adjustment once. [F4]: Decrease adjustment value [FAN 70 %
SPEED MODE]
q Functions of function switches [F5]: Return to adjustment item selecting
[F3]: Unused screen (ID inputting screen)
[F5]: Return to adjustment item selecting
screen (ID inputting screen) q Operating method:
[F6]: Save corrected value The function is effective at the time when this
adjustment is displayed and the cooling fan
q Operating method: speed is controlled to about 70% of the
1] Check that the machine is level. maximum speed.
2] Press [F6] and check that the alarm a After this adjustment code is turned OFF,
buzzer sounds. its function is ineffective.
a If the adjustment is performed, displayed
item [BODY PITCH ANGLE] changes to
[0.0°] (No other displayed item chang-
es).
the correction is effective.
30-116 D375A-6
(01)
DRAFT
Electrial system
Adjustment ID: 0031 (Work equipment controller Adjustment ID: 0036 (Shoe slip control specifica-
initialization) tion code setting)
q This adjustment code is used to initialize the q This adjustment code is used to change the
specification code recognized by the work rocky terrain specification setting when the
equipment controller and the set values of shoe slip control is used.
the memory in the controller.
a After the work equipment controller is re- a When the shoe slip control operates, if shoe
placed, be sure to carry out this adjustment slip is not restrained even if the rocky terrain
once. specification is set to "5", change the set val-
ue.
q Functions of function switches
[F3]: Unused q Functions of function switches
[F4]: Unused [F3]: Return
[F5]: Return to adjustment item selecting [F4]: Go
screen (ID inputting screen) [F5]: Return to adjustment item selecting
[F6]: Save setting screen (ID inputting screen)
[F6]: Confirm selection
q Operating method:
1] Press [F6] and check that the alarm q Operating method:
buzzer sounds. 1] Change the setting from [SSC SPEC H]
2] Check that the displayed specification to [SSC SPEC L] by pressing [F3] or [F4].
code [CODE] has changed from [2x2] to 2] Press [F6] to define the selection.
[222]. a At this time, check that alarm buzzer
a If specification code [222] is not dis- sounds.
played, the controller wiring harness or a Even if this adjustment code is turned off,
the controller unit may be defective. the setting is effective.
the setting is effective.
D375A-6 30-117
(01)
DRAFT
Electrial system
Adjustment ID: 0041 (Travel lever code setting)
q This adjustment code is used to correct the

set value of the travel lever code recognized
by the power train controller when it is differ-
ent from the lever that is actually installed.
a If the power train controller is replaced while
a non-standard travel lever (for example, a
uni-direction lever) is installed, be sure to
perform this adjustment once.
[F3]: Unused
[F4]: Unused
screen (ID inputting screen)
[F6]: Save setting
q Operating method:
1] Perform adjustment ID "0002" (Initializa-
tion of power train controller) and "0031"
(Initialization of work equipment
controller).
a After the above operation has been
carried out, an error is displayed.
2] Enter adjustment ID "0041".
3] Press [F6] and check that the alarm
buzzer sounds.
4] Check that the displayed specification
code [CODE] has changed from [1x1] to
[111].
a If specification code [111] is not dis-
played, the controller unit may be de-
fective.
a Even if this adjustment code is turned
off, the setting is effective.
30-130
30-117-1 D375A-6
(03)
DRAFT
Electrial system
D375A-6 30-117-2
(03) 30-131
DRAFT
Electrial system
Adjustment ID: 0530 (Stall mode) Adjustment ID: 1005 (Fan 100% mode)
q This adjustment code is used to set the fan q This adjustment code is used to set the cool-
speed in the 100% mode automatically and ing fan speed to about 100% forcibly.
make it possible to set the preset (gear speed It is also used to set the adjustment value of
at start) to [F3-R3] to stall the torque convert- the maximum speed.
er. a Use this adjustment code for testing, adjust-
a The preset (gear speed at start) can be set to ing, or troubleshooting when necessary.
[F3-R3] only while this adjustment code is se- a Functions of function switches
lected. [F3]: Increase adjustment value [FAN 100 %
a Use this adjustment code for testing, adjust- SPEED MODE]
ing, or troubleshooting when necessary. [F4]: Decrease adjustment value [FAN 100 %
q Functions of function switches SPEED MODE]
[F3]: Unused [F5]: Return to adjustment item selecting
[F5]: Return to adjustment item selecting [F6]: Save adjustment value
[F6]: Unused q Operating method:
a When this adjustment code is displayed,
q Mode setting information within screen its function is effective and the cooling fan
[P-AUTO SFT MODE]: Automatic Gearshift speed is controlled to about 100% of the
In P Mode maximum speed.
[E-AUTO SFT MODE]: Automatic Gearshift 1] increase Or decrease the adjustment
In E Mode value by pressing [F3] or [F4].
[P-MANUAL SFT MODE]: Manual Gearshift 2] when confirming the adjustment value,
In P Mode press [F6] and check that the alarm
[E-MANUAL SFT MODE]: Manual Gearshift buzzer sounds.
In E Mode a When using this adjustment code, be
a When using this adjustment code, be sure to sure to keep the hydraulic oil temperature
select "P-MANUAL SFT MODE". above 45°C.(If the hydraulic oil temper-
q Operating method: ature drops below 40°C, the fan speed
when this adjustment code is displayed, its fluctuates)
function is effective and the preset (gear a After this adjustment code is turned OFF,
speed at start) is set to [F3-R3]. its function is ineffective but the set ad-
k This adjustment code does not stall the justment value is effective.
torque converter automatically. Accord-
ingly, operate the levers and pedals se-
curely when stalling the torque converter
(For the procedure for stalling the torque
converter, see Measuring engine speed).
a When using this adjustment code, be sure to
keep the hydraulic oil temperature above 45
°C.(If the hydraulic oil temperature drops
below 40°C, the fan speed fluctuates)
a After this adjustment code is turned OFF, its
function is ineffective.
30-132
30-118 D375A-6
(03)
DRAFT
Electrial system
Adjustment ID: 1012 (Steering lever neutral posi- Adjustment ID: 1013 (Steering lever leftmost
tion adjustment) position adjustment)
q This adjustment code is used to make the q This adjustment code is used to make the
power train controller recognize the neutral power train controller recognize the leftmost
position of the steering potentiometer of the position of the steering potentiometer of the
PCCS lever. PCCS lever.
a After the power train controller or PCCS lever a After the power train controller or PCCS lever
is replaced, be sure to carry out this adjust- is replaced, be sure to carry out this adjust-
ment once. ment once.

[F6]: Save adjustment value [F6]: Save adjustment value

1] Check that the PCCS lever is in the 1] Operate the PCCS lever in the steering
neutral position of the steering direction direction to the left stroke end and keep it
and keep it in that position. there.
2] Press [F6] and check that the alarm 2] Press [F6] and check that the alarm
buzzer sounds. buzzer sounds.
a Even if the adjustment is carried out, the a Even if the adjustment is carried out, the
displayed value does not change. displayed value does not change.
a Even if this adjustment code is turned off, a Even if this adjustment code is turned off,
the adjustment is effective. the adjustment is effective.
a This adjustment code is used to make the a This adjustment code is used to make the
controller recognize the neutral position controller recognize the leftmost position
of the potentiometer. It is not used to ad- of the potentiometer. It is not used to ad-
just the steering force. just the steering force.
D375A-6 30-119
(01)
DRAFT
Electrial system
Adjustment ID: 1014 (Steering lever rightmost Adjustment ID: 1015 (Right brake oil pressure
position adjustment) offset)
q This adjustment code is used to make the q This adjustment code is used to adjust the
power train controller recognize the rightmost right brake oil pressure manually.
position of the steering potentiometer of the a Use this adjustment code for work when nec-
PCCS lever. essary.
a After the power train controller or PCCS lever
is replaced, be sure to carry out this adjust- q Functions of function switches
ment once. [F3]: Increase adjustment value
[F4]: Decrease adjustment value
q Functions of function switches [F5]: Return to adjustment item selecting
[F4]: Unused [F6]: Save adjustment value
screen (ID inputting screen) q Information displayed on screen
[F6]: Save adjustment value The offset oil pressure is displayed and the
adjustment value is increased or decreased
q Operating method: by 0.0098 MPa {0.1 kg/cm2} (The value
1] Operate the PCCS lever in the steering displayed on the screen is multiplied by 100).
direction to the right stroke end and keep a The default adjustment value is 0 MPa {0
it there. kg/cm2}.
2] Press [F6] and check that the alarm a The adjustment range is -0.294 - 0.294
buzzer sounds.
MPa {-3 - 3 kg/cm2}.
a Even if the adjustment is carried out, the
displayed value does not change.
q Operating method:
1] Increase or decrease the adjustment
the adjustment is effective.
value by pressing [F3] or [F4].
a This adjustment code is used to make the
controller recognize the rightmost posi- 2] Press [F6] and check that the alarm
tion of the potentiometer. It is not used to buzzer sounds.
adjust the steering force. a If an adjustment has been performed, the
adjustment value is displayed. It can be
adjusted again within the allowable
range.
a It is not necessary to operate the brake
during adjustment. After finishing adjust-
ment, however, operate the brake and
check that there is not a problem in the
actual brake performance.
30-134
30-120 D375A-6
(03)
DRAFT
Electrial system
Adjustment ID: 1016 (Left brake oil pressure Adjustment ID: 2021 (Power train controller
offset) voltage check mode)
q This adjustment code is used to adjust the q This adjustment code is used to check the
left brake oil pressure manually. constant power supply voltage and switch
a Use this adjustment code for work when nec- power supply voltage applied to the power
essary. train controller.
a Use this adjustment code for testing, adjust-
q Functions of function switches ing, or troubleshooting when necessary.
[F3]: Increase adjustment value
[F4]: Decrease adjustment value q Functions of function switches
[F5]: Return to adjustment item selecting [F3]: Unused
screen (ID inputting screen) [F4]: Unused
[F6]: Save adjustment value [F5]: Return to adjustment item selecting
q Information displayed on screen [F6]: Unused
The offset oil pressure is displayed and the
adjustment value is increased or decreased q Information displayed on screen
by 0.0098 MPa {0.1 kg/cm2} (The value [PT CONTROLLER UNSWITCH POWER]:
displayed on the screen is multiplied by 100). Constant power supply voltage
a The default adjustment value is 0 MPa {0 [PT CONTROLLER ACC POWER]: Switch
power supply voltage
kg/cm2}.
a The adjustment range is -0.294 – 0.294
q Operating method:
MPa {-3 – 3 kg/cm2}. When this adjustment code is displayed, its
function is effective and the constant power
q Operating method: supply voltage and switch power supply
1] Increase or decrease the adjustment voltage are displayed simultaneously.
value by pressing [F3] or [F4]. a After this adjustment code is turned OFF,
2] Press [F6] and check that the alarm its function is ineffective.
buzzer sounds.
a It is not necessary to operate the brake
ment, however, operate the brake and
check that there is not a problem in the
actual brake performance.
a If an adjustment has been performed, the
range.
D375A-6 30-121
(03) 30-135
DRAFT
Electrial system
Adjustment ID: 2022 (Work equipment controller Adjustment ID: 5535 (Both steering clutch disen-
voltage check mode) gage mode)
q This adjustment code is used to check the q This adjustment code is used to disengage
constant power supply voltage and switch both steering clutches with the parking brake
power supply voltage applied to the work ON.
equipment controller.
a Use this adjustment code for testing, adjust- a Used to check the torque converter lockup
ing, or troubleshooting when necessary. operation, lockup operating pressure and
transmission clutch operating pressure.
[F3]: Unused q Functions of function switches
[F6]: Unused
q Information displayed on screen
[WE CONTROLLER UNSWITCH POWER]: q Operating method:
Constant power supply voltage When this adjustment code is displayed, its
[WE CONTROLLER ACC POWER]: Switch function is effective and both steering
power supply voltage clutches are disengaged.
a After this adjustment code is turned OFF,
q Operating method: its function is ineffective.
When this adjustment code is displayed, its
function is effective and the constant power
supply voltage and switch power supply
voltage are displayed simultaneously.
a After this adjustment code is turned OFF,
its function is ineffective.
30-122 D375A-6
(01)
DRAFT
Electrial system
Adjustment ID: 5537 (Left steering clutch oil pres- a It is not necessary to steer the machine
sure offset) during adjustment. After finishing adjust-
ment, however, steer the machine and
check that there is no problem in the ac-
tual steering performance.
q This adjustment code is used to manually ad-

just the pressure of the left steering clutch.
q If a machine has been operated for a long pe-
riod of time, the clutch oil pressure may be
out of the standard pressure range because
of wear of the clutch disc and the machine
may not make a smooth gradual turn.
In this case, this adjustment is effective to
adjustment of oil pressure for smooth gradual
turn.
a Use this adjustment code for work when nec-
essary.

[F5]: Return to adjustment item selection
[F6]: Save adjustment value

by 0.0098 MPa {0.1 kg/cm2} (The value
displayed on the screen is multiplied by 100).
a The default adjustment value is 0 MPa {0
kg/cm2}.
MPa {-3 – 3 kg/cm2}.
q Operating method:
buzzer sounds.
range.
D375A-6 30-123
(03) 30-137
DRAFT
Electrial system
Adjustment ID: 5538 (Right steering clutch oil a It is not necessary to steer the machine
pressure offset) during adjustment. After finishing adjust-
ment, however, steer the machine and
check that there is no problem in the ac-
tual steering performance.
q This adjustment code is used to manually ad-

just the pressure of the left steering clutch.
q If a machine has been operated for a long pe-
riod of time, the clutch oil pressure may be
out of the standard pressure range because
of wear of the clutch disc and the machine
may not make a smooth gradual turn.
In this case, this adjustment is effective to
adjustment of oil pressure for smooth gradual
turn.
a Use this adjustment code for work when nec-
essary.

[F5]: Return to adjustment item selection

by 0.0098 MPa {0.1 kg/cm2} (The value
displayed on the screen is multiplied by 100).
a The default adjustment value is 0 MPa {0
kg/cm2}.
MPa {-3 – 3 kg/cm2}.
q Operating method:
buzzer sounds.
range.
30-138
30-124 D375A-6
(03)
DRAFT
Electrial system
Adjustment ID: 6001 (R1 reverse slow set speed) Adjustment ID: 6002 (R2 reverse slow set speed)
q This adjustment code is used to adjust the q This adjustment code is used to adjust the
engine speed applied to travel at gear speed engine speed applied to travel at gear speed
R1 with the reverse slow mode ON. R2 with the reverse slow mode ON.
a Use this adjustment code for work when nec- a Use this adjustment code for work when nec-
essary. essary.

[F3]: Increase adjustment value [F3]: Increase adjustment value
[F4]: Decrease adjustment value [F4]: Decrease adjustment value
[F6]: Save adjustment value [F6]: Save adjustment value
q Information displayed on screen q Information displayed on screen

The lower speed (reduced from the high idle The lower speed (reduced from the high idle
speed of 1,900 rpm) is displayed and the speed of 1,900 rpm) is displayed and the
adjustment value is increased or decreased adjustment value is increased or decreased
in 50 rpm units. in 50 rpm units.
a The adjustment value at shipment is 300 a The adjustment value at shipment is 300
rpm. rpm.
(Setting at shipment: 1,900 - 300 = 1,600 (Setting at shipment: 1,900 - 300 = 1,600
rpm) rpm)

1] Increase or decrease the adjustment 1] Increase or decrease the adjustment
value by pressing [F3] or [F4]. value by pressing [F3] or [F4].
2] Press [F6] and check that the alarm 2] Press [F6] and check that the alarm
buzzer sounds. buzzer sounds.
a If the set speed has been adjusted, the a If the set speed has been adjusted, the
adjustment value is displayed. It can be adjustment value is displayed. It can be
adjusted again within the allowable adjusted again within the allowable
range. range.
a It is not necessary to drive the machine a It is not necessary to drive the machine
during adjustment. After finishing adjust- during adjustment. After finishing adjust-
ment, however, drive the machine at R1 ment, however, drive the machine at R2
with the reverse slow mode ON and with the reverse slow mode ON and
check that there is not a problem in the check that there is not a problem in the
actual travel speed. actual travel speed.
a Even if this adjustment code is turned off, a Even if this adjustment code is turned off,
the adjustment is effective. the adjustment is effective.
D375A-6 30-125
(01)
DRAFT
Electrial system
Adjustment ID: 6003 (R3 reverse slow set Adjustment ID: 7842 (Transmission clutch IP and
speed) fill time automatic initial correction)
q This adjustment code is used to adjust the q This adjustment code is used to make the
engine speed applied to travel at gear speed power train controller recognize the mechan-
R3 with the reverse slow mode ON. ical condition of the transmission.
a Use this adjustment code for work when nec- a After the power train controller or transmis-
essary. sion is replaced, be sure to carry out this ad-
justment once.
[F3]: Increase adjustment value q Functions of function switches
[F4]: Decrease adjustment value [F3]: Unused
[F6]: Save adjustment value screen (ID inputting screen)
The lower speed (reduced from the high idle q Conditions for correction work
speed of 1,900 rpm) is displayed and the 1] [ENGINE SPEED]: 1,700 – 1,950 rpm
adjustment value is increased or decreased 2] [T/C TEMPERATURE]: 65 – 85°C
in 50 rpm units. 3] Parking brake lever: LOCK position
a The adjustment value at shipment is 300
4] PCCS lever: Neutral position
rpm (Display: 30).
a When using this adjustment code, keep
(Setting at shipment: 1,900 - 300 = 1,600
the above conditions (In particular, in-
rpm)
crease the power train oil temperature
sufficiently before starting adjustment).
q Operating method:
1] Increase or decrease the adjustment q Operating method:
1] Stall the torque converter so that the
2] Press [F6] and check that the alarm torque converter oil temperature will be
buzzer sounds. stabilized in the range of 65 – 85°C.
a If the set speed has been adjusted, the
2] Fix the engine speed in the range of 1,700
– 1,900 rpm.
3] Set the PCCS lever in the neutral position
range.
and set the parking brake lever in the lock
a It is not necessary to drive the machine
position.
ment, however, drive the machine at R2 4] Input adjustment ID [7842] directly with
with the reverse slow mode ON and the numeral input switches and press
check that there is not a problem in the [F6].
actual travel speed. 5] Press [F6] again.
a Even if this adjustment code is turned off, a IP correction is started automatically.
the adjustment is effective. a Which clutch is being adjusted is dis-
played in section "a".
30-126 D375A-6
(01)
DRAFT
Electrial system
6] If [End of teaching. Press F6] is displayed Adjustment ID: 7843 (Transmission clutch IP
in section "a", press [F6] again. manual initial correction)
a The buzzer sounds and the adjust-
ment value is saved.
a This work takes 3 - 5 minutes to com-
plete.
q This adjustment code is used to carry out cor-

rection manually when the correction is not
carried out normally by the operation of IP
automatic correction (Adjustment ID: 7842.
a Use this adjustment code after the IP correc-
tion work, if necessary.

a If [F2] is pressed while [F1] is pressed, all
the correction values are set to 0.
q Functions of shift up/down switches

You can select a clutch to be corrected
manually with the shift-up and shift-down
switches.
q Conditions for correction work

Same as the conditions for IP automatic
correction (Adjustment ID: 7842).
q Operating method:
1] Start the engine and keep its speed in the
specified range of condition with the fuel
control dial.
2] Select a clutch to be corrected manually
with the shift-up or shift-down switches.
buzzer sounds.
a The machine does not move during the
correction work.
D375A-6 30-127
(01)
DRAFT
Electrial system
Adjustment ID: 7845 (Transmission clutch IP Adjustment ID: 7847 (Transmission clutch fill
learning display) time manual initial correction)
q This adjustment code is used to check the in- q This adjustment code is used to carry out cor-
formation of correction made by the opera- rection manually when the correction is not
tion of IP automatic correction (Adjustment carried out normally by the operation of fill
ID: 7842) or IP manual correction (Adjust- time automatic correction (Adjustment ID:
ment ID: 7843). 7842).
a Use this adjustment code for testing, adjust- a Use this adjustment code after the fill time
ing, or troubleshooting when necessary. correction work, if necessary.
[F3]: Change display [F3]: Increase adjustment value
[F4]: Change display [F4]: Decrease adjustment value
[F6]: Unused [F6]: Save adjustment value
a If [F2] is pressed while [F1] is pressed, all the
q Operating method: correction values are set to 0.
When this adjustment code is displayed, its q Functions of shift up/down switches
function is effective and the correction infor- You can select a clutch to be corrected
mation is displayed. manually with the shift-up and shift-down
a After this adjustment code is turned OFF, switches.
its function is ineffective. a The value displayed when the clutch is se-
lected is correction information set automati-
cally or manually before.
q Conditions for correction work
Same as the conditions for fill time automatic
correction (Adjustment ID: 7842).
q Operating method:
1] Start the engine and keep its speed in the
specified range of condition with the fuel
control dial.
2] Select a clutch to be corrected manually
with the shift-up or shift-down switches.
buzzer sounds.
a The machine does not move during the
correction work.
30-128 D375A-6
(01)
DRAFT
Electrial system
Adjustment ID: 9995 (Control brake release Adjustment ID: 9996 (Sudden stop prevent valve
mode) operation mode)
q This adjustment code is used to release the q This adjustment code is used to stop the sud-
control brake (right and left brake ECMV) to den stop prevent solenoid valve and right
check the operation of the backup brake and left brake ECMV to check the operation
(brake pedal solenoid valve). of the sudden stop prevent valve.
a Use this adjustment code for testing, adjust- a Use this adjustment code for testing, adjust-
ing, or troubleshooting when necessary. ing, or troubleshooting when necessary.


When this adjustment code is displayed, its When this adjustment code is displayed, its
function is effective and the control brake function is effective and the sudden stop
(right and left brake ECMV) is kept released. prevent solenoid valve and right and left
a After this adjustment code is turned OFF, brake ECMV are kept stopped.
its function is ineffective. a After this adjustment code is turned OFF,
its function is ineffective.
D375A-6 30-129
(01)
DRAFT
Electrial system
Adjustment ID: 9997 (High idle cut mode) Adjustment ID: 9998 (Max. gear speed setting
mode)
q This adjustment code is used to limit the high

idle speed. q This adjustment code is used to limit the
a Use this adjustment code for work when nec- maximum transmission gear speed.
essary. q The limited gear speed is applied in both au-
tomatic gearshift mode and manual gearshift
q Functions of function switches mode.
[F3]: Increase adjustment value [HI IDLE a Use this adjustment code for work when nec-
RPM SET MODE] essary.
[F4]: Decrease adjustment value [HI IDLE
RPM SET MODE] q Functions of function switches
[F5]: Return to adjustment item selecting [F3]: Increase adjustment value [MAX
screen (ID inputting screen) SHIFT]
[F6]: Save adjustment value [F4]: Decrease adjustment value [MAX
SHIFT]
q Operating method: [F5]: Return to adjustment item selecting
1] Increase or decrease the adjustment screen (ID inputting screen)
value by pressing [F3] or [F4]. [F6]: Save adjustment value
buzzer sounds. q Operating method:
a To reset the high idle speed limit, set it to 1] Increase or decrease the adjustment
the original high idle speed (1,900 rpm) value by pressing [F3] or [F4].
that was set at the time the machine was 2] Press [F6] and check that the alarm
shipped. buzzer sounds.
a The adjustment value is increased or de- a When resetting the limitation of the maxi-
creased in 50 rpm units. mum gear speed, set the adjustment val-
a Even if this adjustment code is turned off, ue to the maximum gear speed (3RD)
the setting is effective. which is the initial setting at shipment.
a Setting with this adjustment code be-
comes effective only after the starting
switch is turned to OFF position and then
to ON position again.
30-130 D375A-6
(01)
DRAFT
Electrial system
PM clinic q 3rd screen

The machine monitor can check the condition of
the machine without connecting testing tools to
assist the Pm Clinic and other periodic inspec-
tions.
1) Selecting menu
Select "08 PM CLINIC" on the Service menu
screen.
q 4th screen (The figure shows VHMS in-

stallation specification)
2) Information displayed on Pm Clinic screen

The Pm Clinic function displays the following
information on 6 pages.
q 1st screen
q 5th screen
q 2nd screen (The figure shows VHMS in-

q 6th screen (The figure shows VHMS in-

D375A-6 30-131
(01)
DRAFT
Electrial system
q [F1]: Change screen

q [F2]: Change screen
q [F3]: Reset holding
q [F4]: Hold (displayed data)
3) Holding displayed information

The displayed information can be held and
released with [F3] and [F4].
30-132 D375A-6
(01)
DRAFT
Electrial system
Cylinder Cut-Out operation

The operator can perform Cylinder Cut-Out
operation with the machine monitor.
Reduced cylinder mode operation means to run
the engine with 1 or more fuel injectors disabled
electrically to reduce the number of effective
cylinders. This operation is used to find out a
cylinder which does not output power normally
(combustion in it is abnormal).
1) Selecting menu
Select "09 Cylinder Cut-Out" on the "Service
Menu" screen.
3) Resetting disabled cylinder
When changing a cylinder to be disabled or
when reduced cylinder mode operation is
finished, select a disabled cylinder to be
reset with the function switches.
a This operation may be performed while
the engine is running.
a When [F6] is pressed, if background (a) of
the selected cylinder No. becomes light
blue, the cylinder is reset.
a If the machine monitor rests a disabled
cylinder but the engine controller cannot
reset that disabled cylinder, the back-
2) Selecting cylinder to be disabled ground of the cylinder No. becomes red.
After the "Cylinder Cut-Out" screen is a The reduced cylinder mode operation is
displayed, select a cylinder to be Cut-Out not automatically reset after the screen
with the function switches. returns to the operator mode. According-
q [F1]: Move selection mark (R) to left ly, be sure to perform the resetting opera-
q Move selection mark (R) to right tion after the reduced cylinder mode
q [F3]: Reset holding operation is finished.
q [F4]: Hold
q [F5]: Return to service menu screen 4) Function of holding displayed information
q [F6]: Confirm selection If [F4] is pressed during the reduced cylinder
a This operation may be performed while mode operation, the displayed information is
the engine is running. newly held (c) (The real-time information is
a When [F6] is pressed, if background (a) of kept displayed on the left side).
the selected cylinder No. becomes white, a While the information is held, if [F3] is
the cylinder is disabled. pressed, the holding function is reset.
a If the machine monitor disables a cylinder a The holding function is effective, regard-
but the engine controller cannot disable less of setting of the reduced cylinder
that cylinder, the background of the cylin- mode operation.
der No. becomes yellow.
a One or more cylinders can be disabled.
D375A-6 30-133
(01)
DRAFT
Electrial system
[Reference] Display of No Injection

q If a normally operating cylinder is dis- If the engine is operated after long storage of the
abled, the following phenomena occur. machine, it may be worn or damaged because of
1) Lowering of engine speed insufficient lubrication with oil. To prevent this,
2) Increase of final injection rate the function to lubricate the engine before
command (quantity) starting it by cranking it without injecting fuel is
q If the engine is running near the high idle, installed.
however, the engine speed may not lower Set the no-injection cranking while the engine is
for the reason of engine control. stopped.
q In this case, lower the engine speed with
the fuel control dial and judge by increase 1) Selecting menu
of the injection rate command. Select "10 No Injection" on the "Service
Menu" screen.
2) Preparation for no injection cranking

When the “No injection” screen is displayed,
the machine monitor checks automatically if
no injection cranking can be performed.
If no injection cranking can be performed, the
screen changes to the next screen automati-
cally.
a If no injection cranking cannot be per-
formed because the engine is running or
the communication is abnormal, the
screen does not change from the follow-
ing screen. In this case, depress [F5] to
return to the "Service Menu" screen and
solvethe problem.
30-134 D375A-6
(01)
DRAFT
Electrial system
3) Display of confirmation screen 5) Finishing no injection cranking

The confirmation screen for no injection After completing the no injection cranking
cranking is displayed. Select with the func- operation, press [F6], and finish of no injec-
tion switch. tion cranking is displayed and the screen
q [F5]: returns to the "2. Preparation of No Injection
Do not perform (Return to Service menu cranking" screen automatically
screen)
q [F6]: Perform
6) Prohibiting no injection cranking

If the operator tries to perform the no injection
4) Starting no injection cranking cranking while the engine is running, the
If no injection cranking (Fuel injection in no message that the engine is running is
cylinders) becomes effective, that is displayed and the no injection cranking is not
displayed on the screen. Under this condi- set effective.
tion, crank the engine with the starting motor. a Depress [F5] to return to the "Service
a While the screen is changing to the fol- Menu" screen, stop the engine, and se-
lowing screen, the screen of "Being pre- lect no injection cranking again.
pared" is displayed.
a Limit the cranking time to 20 seconds to
protect the starting motor.
D375A-6 30-135
(01)
DRAFT
Electrial system
Display of Fuel Consumption 3) Display and function during measurement

This function calculates the hourly fuel Clock mark (a) flashes during measurement.
consumption from the actual fuel consumption in a While the fuel consumption is being mea-
a measuring period and indicates it. sured, the operator can work with the op-
erator mode and other functions.
1) Selecting menu Measurement is not finished until this
Select "11 Fuel Consumption" on the screen is displayed again and [F1] is
"Service Menu" screen. pressed (Even if the starting switch is
turned OFF, this function is kept effective,
although fuel consumption is measured
only while the engine is running).
2) Starting measurement
After the screen of "Fuel Consumption" is
displayed, start measurement with the func-
tion switches. 4) Finishing measurement
q [F1]: START Press [F1], and measurement is finished and
q [F2]: CLEAR the data are displayed on the finishing date
q [F5]: Return to service menu screen and time side.
a When the screen of "Fuel Consumption"
is displayed, if a data is indicated, it is the 5) Displaying fuel consumption
data of the previous measurement. This If the measurement is finished, the hourly
data is not an obstacle to new measure- fuel consumption calculated from the fuel
ment and can be deleted by pressing consumption calculated by the engine
[F2]. controller and the elapsed time are
a If [F1] is pressed, the data is displayed on displayed.
the starting date and time side and mea-
surement starts.
a The display unit of the fuel changes ac-
cording to the unit set with the initializa-
tion (unit setting) function.
SI and meter: l/h, inch: gal/h
30-136 D375A-6
(01)
DRAFT
Electrial system
Display of saved load q [F1]: Change screen

This function displays the data accumulated q [F2]: Change screen
since the machine started operation. q [F5]: Return to service menu screen
(It displays the data saved in the controller.) q 2nd screen
1] F1 travel distance
1) Selecting menu The cumulative travel distance in F1
Select "12 Display of saved load" on the (theoretical value) is displayed.
"Service Menu" screen. 2] F2 travel distance
The cumulative travel distance in F2
(theoretical value) is displayed
3] F3 travel distance
The cumulative travel distance in F3
(theoretical value) is displayed.
4] R1 travel distance
The cumulative travel distance in R1
2) Information displayed on Display of saved (theoretical value) is displayed.
load screen
The following Information is displayed 2
screens of the "Display of saved load"
screen.
q 1st screen
1] 1000 rpm service meter
The number of cumulative operation
hours at engine speed higher than 1,000
rpm is displayed.
2] Forward travel distance
The cumulative forward travel distance
3] Reverse travel distance
The cumulative reverse travel distance
D375A-6 30-137
(01)
DRAFT
Electrial system
Setting of VHMS Snap shot (VHMS specification)

This function is used to set installation of VHMS. This function sends a snap shot trigger
If VHMS is installed when shipped, this setting command to the VHMS controller to execute the
has been completed. snap shot.
1) Selecting menu VHMS specification has a manual snap shot
Select "13 Setting of VHMS" on the "Service function and an auto snap shot function.
Menu" screen. A manual snap shot can save the data for seven
minutes and 30 seconds into the VHMS
controller in order for them to be used for trouble-
shooting purposes.
1) Selecting menu
Select "14 Snap shot" on the "Service Menu"
screen.
2) Setting of installation of VHMS

After the "Setting of VHMS" screen is
displayed, select "ON" with the function
switch.
To reset the setting of VHMS, select "OFF".
a Perform setting securely to prevent incor-
rect display and partial disability of the
VHMS function. 2) Operating method of manual snap shot
After the "Snap shot" screen is displayed,
start measuring data with the function switch.
If [F1] is pressed to start measurement,
display of [START] goes off. If measurement
is finished, [START] is displayed again.
a The elapsed measurement time is indi-
cated in minute and second, and prog-
ress is indicated with a bar graph.
a If [F5] is pressed during measurement,
the screen returns to the service menu
screen but measurement is continued.
q [F3]: Select "ON"

q [F4]: Select "OFF"
q [F1]: Start measurement

30-152
30-138 D375A-6
(03)
DRAFT
Electrial system
Handling of voltage circuit of engine controller
Handling of voltage circuit of engine controller
1. Disconnecting or connecting operation of the

connector between the engine controller and the
engine shall be performed only when the starting
switch is in the OFF position.
k Before connecting the harness connec-
tor, be sure to completely remove sand,
dust, water, etc., from inside of controller
side connector.
2. Do not start the engine while the T adapter is

inserted or connected to the connector between
the engine controller and the engine for diag-
nosis.
a The allowed starting switch position is either
OFF or ON. It must not be set to START po-
sition.
D375A-6 30-139
(01)
DRAFT
Electrial system
Adjustment method when controller has been replaced

6) Select "07 Adjustment" in the "Service
a After machine is assembled or the power train menu".
controller or the work equipment controller is re-
placed, adjust the system according to the fol-
lowing procedure.
k If the system is not adjusted, the machine
may not operate normally but may move un-
expectedly. 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. Accord-
ingly, take a record of the next replacement
periods of the oils and filters.
a Precautions for replacing a controller:
Stop the machine in a safe place and turn the
starting switch to the OFF position.
a Since the controller performs the finishing pro-
cess for about 30 seconds after the starting 7) Input adjustment ID [0002] directly with the
switch is turned to the OFF position and the bat- numeral input switches. (Initial setting of
tery relay is turned OFF, do not remove the con- power train controller)
troller immediately. 8) Press [F6].
a The buzzer sounds and the specification
1. Controller initial setting selection is saved.
a Confirm that the displayed specification
1) Connect all the wiring harnesses and control-
code has changed from [1 x 1] to [111].
lers.
2) Turn the starting switch to the ON position.
a The buzzer sounds and the machine
monitor indicates an error.
3) Turn the starting switch to the OFF position
and wait for approx. 30 seconds.
a It takes approx. 30 seconds to shut down
the controller completely after the battery
relay is turned OFF.
again.
a The machine monitor lights up, the buzz-
er sounds, and an error is indicated.
5) While pressing numeral input switch [4],
press [1], [2] and [3] in order to set the
machine monitor in the service mode.
30-140 D375A-6
(01)
DRAFT
Electrial system
9) Press [F5] to return to the adjustment ID input

screen.
10) Input adjustment ID [0031] directly with the
numeral input switches. (Initial setting of
work equipment controller)
11) Press [F6].
a The buzzer sounds and the specification
selection is saved.
a Ensure that the displayed specification
code has changed from [2 x 2] to [222].
3) Press [F3] to select "ON" and press [F6] to

settle the selection.
12) Press [F5] to return to the adjustment ID

input screen.
13) Turn the starting switch to the OFF position
and wait for approx. 30 seconds.
a It takes approx. 30 seconds to shut down
the controller completely after the battery
relay is turned OFF. 3. Shoe slip control setting
14) Turn the starting switch to the ON position a Set this item after the machine monitor was
again. replaced, too.
a The machine monitor lights up and dis- 1) Input "86" with the numeral input switches
plays normally. and press [F6] in the "Service menu" screen.
a The engine can be started now. 2) Press [F3] to select "ON" and press [F6] to
2. VHMS device setting (VHMS specification)
a Set this item after the machine monitor was
replaced, too.
a Since the VHMS device is not installed in the
default setting, be sure to set this item if the
machine has the VHMS specification.
1) Set the machine monitor in the service mode.

2) Select "13 VHMS Setting" in the "Service
menu" screen.
D375A-6 30-141
(01)
DRAFT
Electrial system
4. Prelube setting
a Set this item after the machine monitor was
replaced, too.
1) Input "87" with the numeral input switches
and press [F6] in the "Service menu" screen.
2) Press [F3] to select "ON" and press [F6] to
4) Check to see if there is any failure code being

indicated. If there is not any, delete all the
recorded failure codes.
a If any active failure codes exist, eliminate
the cause of the incident by troubleshoot-
ing then carry out steps 5 and 6 again.
5. Turning power on again a Precautions after replacing controller:

Turn the starting switch to the OFF position and If any controller is replaced, the service
turn it to the ON position again about 1 minute meter in the oil and filter maintenance
after (the battery relay is turned OFF). mode is reset to 0.
As a result, the replacement period
displayed on the monitor panel may be
6. Checking failure codes
different from the actual operating hours.
1) Set the machine monitor in the service mode.
To solve this problem, determine the first
2) Select "02 Failure history" on the "Service replacement periods of the oils and filters
menu" screen. after the replacement of the controller
according to the replacement periods
recorded before the replacement of the
controller.
3) Press [F3] or [F4] to select "02 Electrical

system failure history" and press [F6] to
30-142 D375A-6
(01)
DRAFT
Electrial system
7. Work equipment specification selection

1) Select "07 Adjustment" in the "Service menu" 11. IP correction value check (Check of correction
screen. value of electric current)
a For details, see "Adjustment" function of
"Special functions of machine monitor
(EMMS)".
q Adjustment ID: 7845
12. Trigger teaching value check

(EMMS)".
13. Steering lever neutral position adjustment

(EMMS)".
2) Input adjustment ID [0004] directly with the
numeral input switches and press [F6].
3) Press [F3] or [F4] to select Dual tilt or Single
14. Steering lever leftmost position adjustment
tilt.
4) Press [F6] to settle the selection.
a The buzzer sounds and the work equip-
(EMMS)".
ment specification is saved.
15. Steering lever rightmost position adjustment

(EMMS)".
16. Shoe slip control specification setting

(EMMS)".
17. Travel lever code setting

8. Brake pedal potentiometer initial correction (For machines with non-standard travel lever
a For details, see "Adjustment" function of only)
"Special functions of machine monitor a For details, see "Adjustment" function of
(EMMS)". "Special functions of machine monitor
q Adjustment ID: 0005 (EMMS)".
9. Pitch angle sensor standard setting
(EMMS)".
10. IP automatic correction and trigger auto-

matic initial teaching
(EMMS)".
D375A-6 30-143
(03) 30-157
DRAFT
Electrial system
Preparation work for troubleshooting of electrical system
a When performing troubleshooting for an electri- 3) Insert or connect test T-adapters into or to
cal circuit related to the machine monitor, engine connectors CM01 and CM02 on the back
controller, work equipment controller, power side of the machine monitor.
train controller, VHMS controller, or ORBCOMM
terminal, expose the related connectors accord-
ing to the following procedure.
1. Machine monitor
1) Remove cover (1).
1) Open covers (4) and (5) on the left side of the
engine.
2) Remove 4 mounting bolts (2) and pull out

machine monitor (3) toward this side.
30-144 D375A-6
(01)
DRAFT
Electrial system
2) Remove engine controller covers (6) and (7).
3) Insert or connect the diagnostic T-adapter in

or to the connector (ENG, EGC2, EGC3) of
engine controller (8).
a When disconnecting the connector, loos-
en its screw.
a When returning the connector to the pre-
vious condition, tighten the screw to the
following torque.
3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
k In order to prevent malfunction and mis-

taken system error warning, be sure to
completely remove foreign object (b)
such as sand, dust, water, etc., from in-
side of controller side connector (a) with
air blow etc., before connecting it to the
harness connector.
D375A-6 30-145
(01)
DRAFT
Electrial system
Preparation work for troubleshooting for electrical equipment system
3. Work equipment controller 4. Power train controller

1) Slide the operator's seat to the front end and 1) Slide the operator's seat to the front end and
fold the seat back forward. fold the seat back forward.
2) Remove cover (9). 2) Remove cover (9).
3) Remove the mounting bolts of work equip- 3) Remove the mounting bolts of power train
ment controller (10). controller (11).
4) Insert or connect test T-adapters into or to 4) Insert or connect test T-adapters into or to
connectors WECN1, WECN2 and WECN3. connectors PTCN1, PTCN2 and PTCN3.
a Since the connectors are secured with a Since the connectors are secured with
screws, loosen those screws before dis- screws, loosen those screws before dis-
connecting. connecting.
a When returning the connector to the pre- a When returning the connector to the pre-
vious condition, tighten the screw to the vious condition, tighten the screw to the
following torque. following torque.
3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm} 3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
30-160
30-146 D375A-6
(03)
DRAFT
Electrial system
Preparation work for troubleshooting for electrical equipment system
5. VHMS controller (VHMS specification) 2) Remove the mounting bolts of ORBCOMM

1) Open the cover on the left side of the floor terminal (16) and pull out the terminal.
and remove cover (12).
2) Insert or connect troubleshooting T-adapters
intoV1?V2A?V2B?V3A?V3B?V4A?V4B
connectors of VHMS controller (13).
a If it is difficult to remove and install the
connectors, remove the controller for the
ease of work.
3) Insert or connect test T-adapter into or to

connector KOM1.
a Since the connectors are secured with
screws, loosen those screws before dis-
connecting.
a When returning the connector to the pre-
vious condition, tighten the screw to the
following torque.
3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
6. ORBCOMM terminal
1) Remove seat belt buckle (14) and remove
cover (15).
D375A-6 30-147
(03) 30-161
DRAFT
Electrial system
Inspection procedure of diode
Inspection procedure of diode

2. When using analog tester
a The direction of continuity of diode is marked on 1) Set the tester in the resistance range.
the surface of the diode. 2) Apply the leads of the tester as explained-
below and check the movement of the
pointer.
1] Set red (+) test lead to diode anode (P)
side and black (–) test lead to cathode (N)
side.
2] Set red (+) test lead to diode cathode (N)
side and black (–) test lead to anode (P)
side.
3) Evaluate the condition of the diode by the
movement of the pointer.
q Needle does not deflect with connection i)
but deflects with connection ii): Normal.
(However deflection range (resistance
1. When using digital tester value) varies depending on the type of
1) Set the tester in the diode range and read the tester and testing range.)
indicated value. q Needle deflects with both connection i)
a When an ordinary circuit tester is used, and ii): Defective (internal short circuit)
the voltage of the internal battery is indi- q Needle does not deflect with either con-
cated. nection 1] or 2]: Defective (internal dis-

2) Put the red probe (+) of the test lead to the connection)
anode (P) of and the black probe (–) to the
cathode (N) of diode, and confirm the indi-
cated value.
3) Evaluate the condition of the diode by the
indicated value.
q Indicated value remains unchanged:
Conduction is absent (Failure)
q The indicated value changes: The diode
has conductivity (Normal) (See a below.)
Note: In the case of silicon diode, the value
between 460 – 600 mV is displayed.
q Displayed value becomes 0 or near 0 :
Short-circuiting of diode internal part (de-
fect)
30-148 D375A-6
(01)
DRAFT
Electrial system
Handling of optional devices
Handling of optional devices

4. Connecting C signal of starting switch
a D375A-6 has connectors to install optional de- When starting switch signal C (starting signal) is
vices in its fuse box. When installing any optional necessary to an optional device such as prelube
device, receive the necessary signals and power device, take it out of the following connector pin.
through those connectors without modifying the q CN-PRS (2-pole heavy duty wire connector)
wiring harness. a Remove the connector installed when the
a For the locations of the connectors, see Trouble- machine was delivered and connect pin (1) to
shooting, "Connector list and three-dimensional the final starting signal output point of the
layout". prelube device and connect pin (2) to the in-
put signal point from the starting switch.
1. Connecting the ACC signal of starting switch
If the ACC signal (ON signal) of the starting 5. Connecting external power source
switch is necessary for a optional device such as If an external power source is necessary,
the turbocharger timer, connect it through the connect it through the following connectors.
following connector pin. q CN-800 (Plug connector):
q Pin (B) of CN-ESD (3-pole heavy duty wire Used for device in cab
connector) q CN-810 (Plug connector):
a A 20A fuse is installed on the upstream side Used for device out of cab
of this connector pin. a A 20A fuse is installed on the upstream side
of these connectors.
2. Input of engine stop signal
If the engine needs to be stopped with the
starting switch in the ON position for an optional
device such as the engine emergency stop
system, use the circuit of the following connector
pin.
q Pin [A] of CN-ESD (3-pole heavy duty wire
connector)
a Before using this circuit, be sure to notify your
Komatsu distributor.
3. Inputting engine low-idle command

If it is required to keep the engine speed at low
idle for an optional device such as the engine
protector, use the circuit of the following
connector pin.
q Pin (C) of CN-ESD (3-pole heavy duty wire
connector)
a Before using this circuit, be sure to notify your
Komatsu distributor.
D375A-6 30-149
(01)
DRAFT
Electrial system
Request for opening ORBCOMM terminal
a If the machine is equipped with ORBCOMM, fill

in the "Request for opening VHMS ORBCOMM
terminal" and send it by fax or mail to "KOMAT-
SU KOMTRAX SUPPORT CENTER" before ini-
tializing the VHMS controller.
a Initialize the VHMS controller after the opening
notification is received from "KOMATSU
KOMTRAX SUPPORT CENTER".
a If the ORBCOMM antenna is installed and the
starting switch is turned to the ON position be-
fore the opening notification is received, the OR-
BCOMM terminal transmits radio waves and
ORBCOMM CO. LTD. sends out the stop signal
automatically. In this case, complicated proce-
dures and some time are required to open the
ORBCOMM terminal service again.
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Initialization procedures for VHMS controller

1. Check of machine information, engine informa-
a Initialization tools for VHMS controller tion and controller information
Sym- a This step is a work performed on the whole
Part No. Part name
bol machine.
1 799-608-3211 Discket Check and record the machine information,
799-608-322 engine information, VHMS controller infor-
2 Wiring harness
0 mation and ORBCOMM terminal information.
Z Notebook type personal com-
Commer- NO Information to be checked
puter
3 cially avail- 1 Model name
:Windows98/2000/Me/XP/VISTA
able 2 Machine serial No.
(*) [With RS232C terminal] 3 Current service meter reading
*:VHMS setting tool Ver.3.06.00.03 or later, VHMS 4 Engine serial No.
analysis tool Ver.3.05.00.00 or later. 5 Transmission serial No.
6 VHMS controller serial No.
ORBCOMM terminal serial No.
a Before starting full operation after completion of 7
[Only for machines equipped with ORBCOM]
local assembly or before resuming operation af-
ter storage for a long period, initialize the VHMS
controller according to the following procedure. a VHMS controller (1) is in the control box on
a Machine data collected with the VHMS controller the left side of the floor and ORBCOMM ter-
are stored and managed in WebCARE data- minal (2) is in the control box on the right side
base. To process the data smoothly on the We- of the floor.
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
data in the VHMS controller may not be utilized.
Accordingly, be sure to carry out the initializa-
tion.
a For the method of installing the VHMS Initializa-
tion Program to the personal computer, refer to
the Operation and Maintenance Manual con-
tained in the package of diskette Z1.
a Since the service menu of the machine monitor
will be used in the following procedure, read
"Special functions of machine monitor (EMMS)"
and understand the operating procedure in ad-
vance.
a The initial setting procedure is described in the
ORBCOM installation specification and the OR-
BCOM-less specification. When using the ORB-
COM installation specification, implement the
procedures needed for VHMS alone, bypassing
those prepared only for ORBCOM installation
specification.
a During the initialization work, confirm each work
according to the "VHMS Initialization Work
Checklist".
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2. Connection of personal computer

1) Make sure that the starting switch is in the
OFF position.
k Be sure to turn off the starting switch
before connecting or disconnecting
the personal computer.
2) Connect personal computer Z3 and down-
load connectors (VDW) and (DL1) by wiring
harness Z2.
a The download connectors are installed to
the following places.
q VDW: Under left rear of operator seat
q DL1: Right rear of machine body (Side
of backup lamp)
3. Check of operation and satellite capturing condi-
a Connect the personal computer to the
tion of VHMS controller
RS232C terminal.
a This step is a work performed in the opera-
tor's cab.
a Check of satellite capturing condition is nec-
essary o only [ORBCOMM specification].
[Method of checking with monitoring func-

tion](Monitoring code: 99003)
2) Set the machine monitor to display the
service menu.
3) Select "01 Monitoring".

a Execute initialization of VHMS from the
connector in the cab.
a Use the ground download connector for
only downloading.
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4) Input monitoring code 99003 directly with the 2) At least 3 minutes after the starting switch is
numeral input switches. turned to the ON position, check the commu-
a The communication condition of the OR- nication condition of the ORBCOMM terminal
BCOMM terminal is displayed. by the display condition of the decimal point
(indicated with the arrow) of the machine
monitor.
[Method of checking with monitoring function]

(Monitoring code: 20300)
1) Input monitoring code 20300 directly with the Deci-
numeral input switches. mal Condition
a The procedure up to inputting of the mon- point
q Power is not supplied to ORBCOMM con-
itoring code is the same as the above sec-
troller.
tion. OFF
q Communication line to VHMS controller is
abnormal.
q Satellite is not captured.
q Power is supplied to ORBCOMM controller.
ON
q Communication line to VHMS controller is
normal.
q Power is supplied to ORBCOMM controller.
Blink- q Communication line to VHMS controller is
ing normal.
q Satellite is captured.
[Method of checking with VHMS controller]

2) The 7-segment LED (indicated with the
arrow) of the VHMS controller flashes and
rotates, and then counts up.
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3) Confirm that the ORBCOMM terminal has

captured the communication satellite by
checking that the decimal point (indicated
with the arrow) of the 7-segment LED is
flashing.
a The ORBCOMM terminal may take time
to capture the satellite, depending on the
strength of the signals from the satellite.
4. Startup of VHMS initialization tool

tor's cab (on the personal computer). 5. Initialization of VHMS controller (Tool before
1) Turn on the personal computer and start the Ver. 3.5.2.1)
OS. a This step is a work performed in the opera-
2) Click the icon of [VHMS Initialization Tool] on tor's cab (on the personal computer).
the personal computer screen to start the a When initializing, do not change the data of
VHMS initialization tool. service meter [SMR].
[Machine Information]
Important 1) Open the [Machine information] tab.
a The setting screen varies with the version a The [Machine information] tab is dis-
No. of the VHMS setting tool. played first in the [Data clear and Set up]
a When using a tool before Ver. 3.5.2.1 menu.
(CD-ROM), set the VHMS in step 5. 2) Check all the data.
a When using an updated tool (Ver. 3.5.2.1
or after), set the VHMS in step 6.
a It is recommended to download the latest
VHMS setting tool from the WebCARE
and update your tool.
(Related material: Servicemate
SMP-623)
3) Input the 10-digit service ID in [Service ID].
a Service ID: 7826147000
4) Select [Data clear and Set up] in the [Select
Function] column.
5) Press the [OK] button to go to the setup
screen.
3) If information in the [Date/Time] box is not

correct, change it according to the following
procedures:
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1] Press [Edit] button (1) on the right lower

part of the [Date/Time] box to display the
correction screen.
2] Correct the information and press the
[OK] button.
4) If information in the [Machine information]

box is not correct, change it according to the
following procedures:
1] Press the [Edit] button (2) on the right
lower part of the [Machine information]
box to display the correction screen.
2] Correct the information and press the
[OK] button.
5) After checking/changing all the data in

[Machine information], press [Apply] button
(3) to settle the setting.
a Press the [Apply] button (3), and the
screen for checking the setting will ap-
pear. Check the setting again and press
the [OK] button if the setting is correct.
a In case of the ORBCOMM Specification,
execute [Communication Setting] first
and then settle the setting.
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[Communication Setting] (For 9) To change setting in [SHORT TREND ANAL-

ORBCOMM specification only) YSIS], follow the procedures below:
a Execute this setting after requesting for 1] Select [SHORT TREND ANALYSIS] on
opening of the ORBCOM terminal and fin- the screen and press [Edit] button on the
ishing the opening procedure. left lower part of the [File Transfer Setting]
6) Open the [Communication Setting] tab. block to display the setting screen.
7) Check all the data. 2] Change the setting and then press the
[OK] button.
a At initialization, input [20h] to [SMR]
and set the function to [ON].
8) To change the setting in [SHORT FAULT

HISTRY], follow the procedure below: 10)To change the setting of [Satellite Setting],
1] Select [SHORT FAULT HISTRY] on the follow the procedure below.
screen and press [Edit] button (5) on the 1] Press the [Edit] button in the [Satellite
left lower part of the [File Transfer Setting] Setting] block to display the setting
block to display the setting screen. screen.
2] Change the setting and then press the 2] Set the GCC Code to the applicable area
[OK] button. and then press the [OK] button.
a At initialization, select [Occurrence] at
[Timing] and set the function to [ON].
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GCC
Area Remarks
Code
N.America (*1)
*1: Except U.S. Territories in
1 C.S.Americas
Micronesia and Midway Island
Faroe Islands
Europe (*2)
Middle East
Asia (*3) *2: Except Faroe Islands
120
Africa *3: Except Japan
Oceania
CIS
130 Japan
a If the combination of the country name
and code in the list box displayed by the
setting tool is different from the above ta-
ble, select the GCC code in the table or 6. Initialization of VHMS controller (Ver. 3.5.2.1
input the value through the keyboard. or after)
11)After checking/changing all the data in a This step is a work performed in the opera-
[Communication Setting], press [Apply] tor's cab (on the personal computer).
button to settle the setting. a When initializing, do not change the data of
a If the [Apply] button is pressed, the service meter [SMR].
screen for checking the setting appears. 1) Select [VHMS Setting] and press the "Next"
Check the setting again and press the button.
[OK] button if the setting is correct.
2) Select [Set up & All clear] and press the

"Next" button.
12)After checking/changing the data of [Machine

Information] and [Communication Setting],
press the [Exit] button at the right lower part
of the screen to finish [VHMS Initialization
Tool].
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3) Check the machine information. If it does not 4) Select the time zone.
need to be corrected, press the "Next" 5) Input the local time.
button. 6) If the DST (Daylight Saving Time) is used
now, select it and press the "Next" button.
a If the DST is selected, the clock is ad-
vanced 1 hour automatically, thus the
time must be corrected again.
a If the VHMS was installed additionally,

the information of [Serial No.] etc. must
be input.
7) Set the GCC Code to the applicable area and

then press the "Next" button.
GCC
Area Remarks
Code
N.America (*1)
*1: Except U.S. Territories in
1 C.S.Americas
Micronesia and Midway Island
Faroe Islands
Europe (*2)
Middle East
Asia (*3) *2: Except Faroe Islands
120
Africa *3: Except Japan
Oceania
CIS
130 Japan
a If the combination of the country name
and code in the list box displayed by the
setting tool is different from the above ta-
ble, select the GCC code in the table or
input the value through the keyboard.
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8) The contents of the setting are displayed

finally. If there is not a problem, press the
"Apply" button.
9) The system asks you if you save the data

before changing the setting. If you do not
need to save, select "NO".
10)After finishing the work of changing the

contents of initialization, press the "OK"
button to finish the program.
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7. Downloading of set data 2) When using download connector (VDW) in

1) Connect personal computer Z3 and down- the cab, set the starting switch in the ON
load connectors (VDW) in the cab or ground position.
download connector (DL1) by wiring harness 3) When using ground download connector
Z2. (DL1), turn switch (3) ON.
a The green LED lights up.
4) Operate the icon of [VHMS Technical Anal-

ysis Tool] on the personal computer to start
the VHMS technical analysis tool.
a Download connector (VDW) in the cab is

installed to the left rear lower part of the a Input [User Name] and [Password].
operator's seat. a For the operation procedures, refer to the
Operation and Maintenance Manual for
VHMS Technical Analysis Tool.
a The ground download connector DL1 is 5) Use the [Download] function to download the
installed to the side of the backup lamp at data recorded in the VHMS controller to the
the rear right of the machine. personal computer.
a For the operation procedures, refer to the
a Make sure that downloading has complet-
ed before proceeding to the next step.
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8. Check of downloaded data 3) If the data was downloaded in the cab,

a This step is a work performed in the opera- disconnect wiring harness Z2 from download
tor's cab (on the personal computer). connector (VDW).
1) Check the set data with the [View] function.
a For the operation procedures, refer to the
a Make sure that the [MFA0] code at the
time when the snapshot was operated is
displayed in [Fault History].
a Make sure that the snap shot data is re-
corded.
4) If the data was downloaded on the ground,

turn switch (3) OFF and disconnect wiring
harness Z2 from download connector (DL1).
2) After checking the set data, terminate [VHMS

Technical Analysis Tool].
9. Disconnection of Personal Computer

1) Make sure that the starting switch is in the
OFF position.
k Be sure to turn off the starting switch
before connecting or disconnecting
the personal computer.
2) Finish the OS of the personal computer and
then turn the personal computer OFF.
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10. Report to Komatsu

After completing steps 1 to 9 successfully, send
the "VHMS/WebCARE setting notification form"
to VHMS/WebCARE Support Center of
Komatsu, Tokyo.
a Since Komatsu has to set the receiving side
of the satellite communication, be sure to in-
form Komatsu of the completion of the set-
ting.
a Send the VHMS data by Notes (LAN) or
E-mail (WAN).
a When using the KOMTRAX functions on the
machine equipped with the ORBCOMM,
complete the sign-up test on the machine
side and enter the use of the KOMTRAX
functions in the "VHMS/WebCARE setting
notification form".
Komatsu VHMS/WebCARE Support Center
2-3-6, Akasaka Minato-ku Tokyo, Japan
FAX: 81-3-5561-4766 (from outside of Japan)
E-mail: webcare@komatsu.co.jp
30-178
30-168 D375A-6
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Date of setting:
DB/branch
[For storage] name:
VHMS initial setting work check sheet Data entered by:
Setting step Check item Result
Model name
Serial No.
Check of nameplates of chassis and
1 Engine serial No.
components
Transmission controller serial No.
VHMS controller serial No.
Connection of personal computer and

2 Is connection made securely? yes no
VHMS controller
Is operation normal?
3 Check of operation VHMS controller yes no
(Decimal counting up must be displayed after rotation.)
4 Starting of VHMS initialization Tool Is setting tool set in "Data Clear and Set up" mode? yes no
Is model name correct? yes no

Initialization of VHMS controller Is machine serial No. input correctly? yes no
(Setting of machine information) Is engine serial No. input correctly? yes no
5
Set basic information of machine to Is today's date displayed? yes no
VHMS controller in this step. Does clock indicate present time? yes no
Is SMR input correctly? yes no
6 Saving of set items Is LED (7-segment) turned OFF? yes no
7 Check of VHMS function Does LED operate normally? yes no
Are service mode "SNAPSHOT" selected and is switch

8 Execution of Quick Pm Clinic yes no
pressed?
9 Saving operation of VHMS Is LED (7-segment) turned OFF? yes no
10 Downloading Does LED operate normally? yes no
Are all files downloaded? yes no

Hour, min-
The time downloaded (Reference wrist watch)
ute:
11 Check of downloaded data [Check of data]
Is there MFA0 error in Fault History? yes no
Are SMR and time in Fault History matched to set values? yes no
Are all data of Snap Shot prepared? yes no
12 Saving operation of VHMS Is LED (7-segment) turned OFF? yes no
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[For keeping] Date of setting:

DB/branch name:
ORBCOMM Station Establishment Check
Sheet Data entered by:
Setting step Check item Result
Model name
Serial No.
Check of nameplates of chassis Engine serial No.
1
and components Transmission serial No.
VHMS controller serial No.
ORBCOMM controller serial No.
Connection of personal computer

2 Is connection made securely? yes no
and VHMS controller
Check of operation VHMS control- Is operation normal?

3 yes no
ler (Counting up must be displayed after rotation.)
4 Starting of VHMS Initialization Tool Is setting tool set in "Set up" mode? yes no
Enter set value of S.Fault History.

Execution of communication On Off
Number of communication (Default: 8) hrs
Initial setting of VHMS controller Enter set value of S. Trend Analysis.
1. Setting of communication Execution of communication On Off
(Machine information and PLM Interval (Default: 20H) hrs
5
have been set) Enter set value of S. Payload data (If PLM is installed).
Execution of communication On Off
Time to start collection
Collection interval (Number of days) day
2. Setting of start of communica-
Is GCC code set? (130 for Japan) yes no
tion
6 Saving of set items Is LED (7-segment) turned OFF after saving operation? yes no
Check of operation of ORBCOMM How is display of decimal point on VHMS monitor (7-segment)?
7 yes no
controller (Off, On, long/short flashing)
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Using method of KOMTRAX functions of ORBCOMM terminal
a The ORBCOMM terminal equipped with the a The ORBCOMM terminal executes the
KOMTRAX function can display the machine on sign-up test and judges the result by it-
the control screen of the KOMTRAX system. self. The criterion is as follows.
a Whether the ORBCOMM terminal has the q The starting switch is in the ON position.
KOMTRAX functions can be checked by the part q The VHMS controller can communicate
No. of the ORBCOMM terminal. with the ORBCOMM terminal (They are
a When using the KOMTRAX functions, perform connected normally).
the following procedure. q A valid GCC code is set to the VHMS con-
1. Make the request for opening the ORBCOMM troller.
terminal and receive the opening notification. q The ORBCOMM terminal is receiving the
a See "Request for opening ORBCOMM termi- signals from the ORBCOMM communica-
nal". tion satellite. (The ORBCOMM antenna is
connected.)
2. Initialize the VHMS controller and set the GCC q Positioning of the machine with the is
code of the machine location. completed (The GPS antenna is connect-

a See "Initialization procedure for VHMS con- ed.)
troller". 4) Check that LED1 is lighting.
a At this time, the sign-up test is completed.
3. Perform the sign-up test on the machine side. a Once the sign-up test is completed, the
a Perform the sign-up test in an open outdoor ORBCOMM terminal cannot be returned
place. to the original state.
a If the sign-up test is performed in an indoor
place where the satellite radio waves are
blocked, it may not be completed.
a It may take time to complete the sign-up test,
depending on the condition of receiving sig-
nals from the ORBCOMM communication
satellite and GPS satellite.
1) Check that the VHMS controller, ORBCOMM
terminal, ORBCOMM antenna and JPS
antenna are connected to the wiring harness
of the machine.
3) Wait until LED1 lights up.
a LED1 keeps flashing until the sign-up test
is completed.
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[LED display] [State]

(1) LED-green KOMTRAX state Waiting for server trigger: Lighting
Normal operating state: Turning off
(2) LED-green ORBCOMM satellite capture Satellite not captured: Lighting
Satellite captured (No transmission data): Quick flashing
Satellite captured (There is transmission data): Slow flashing
Power OFF: Turning off
(3) LED-yellow VHMS start recognition VHMS start recognized: Lighting
VHMS stop recognized: Turning off
(4) LED-green ORBCOMM MODEM power ON: Lighting
OFF: Turning off
(5) LED-red Unused Kept Turning off
(6) LED-red Unused Kept Turning off
(7) 7-segment LED Number of mails waiting to be sent (Max. of 9)
(8) Dot GPS satellite capture state Satellite not captured: Turning off
Satellite captured: Lighting
* Flashing interval
Quick flashing: Period of 1 sec (Lighting for 0.5 sec and Turning off for 0.5 sec repeatedly)
Slow flashing: Cycle of 4 sec (Lighting for 2 sec and Turning off for 2 sec repeatedly)
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4. Apply for starting to use.

1) Notify the VHMS/WebCARE operations
administrator of the following information of
the machine which has completed the station
set-up check.
q Model, model No. and serial No. of ma-
chine
q Part No. and serial No. of ORBCOMM ter-
minal
q Reading of service meter when sign-up
test was completed (0.1 h unit)
2) Fill in the "VHMS/WebCARE setting notifica-
tion form" and enter "Use" in the column of
"Use of KOMTRAX Service".
3) Send the "VHMS/WebCARE setting notifica-
tion form" to VHMS/WebCARE Support
Center in Komatsu Head Office.
E-mail: webcare@komatsu.co.jp
4) The KOMTRAX operations administrator

registers the machine using the KOMTRAX
client personal computer.
a For the registration procedure, see the
"Global KOMTRAX Web Reference Man-
ual (For Key Person)".
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Precautions for replacing VHMS controller

2. Check, saving and writing of information set in
a Tools for replacing VHMS controller VHMS controller (Before Ver. 3.5.2.1)
Sym- a This step is a work performed in the opera-
Part No. Part name
bol tor's cab (on the personal computer).
1 799-608-3211 Discket a Transfer the set data of the VHMS controller
3 799-608-3220 Wiring harness to be replaced to the personal computer and
Notebook type personal com- then write it in the newly installed VHMS con-
Z
Commercially puter
4 troller.
available :Windows98/2000/Me/XP/VIST
A (*) [With RS232C terminal]
2-1. Check and saving of information set in
*:VHMS setting tool Ver.3.06.00.03 or later, VHMS VHMS controller to be replaced.
analysis tool Ver.3.05.00.00 or later. 1) Connect the personal computer and start the
a When the VHMS controller needs to be re- VHMS technical analysis tool.
placed, set it before removing it and the installed a See "Initialization procedures for VHMS
new VHMS controller according to the following controller".
procedure. 2) Select "Save/Load" and press the "OK"
a Machine data collected with the VHMS controller button.
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
data in the VHMS controller may not be utilized.
Accordingly, be sure to carry out the initializa-
tion.
a During the initialization work, confirm each work
according to the "VHMS Initialization Work
Checklist".
[Work before replacing VHMS controller]

1. Downloading of remaining data
tor's cab (on the personal computer).
a Using the [Download] function, download the
data currently recorded in the VHMS control-
ler to the personal computer.
a For the operating procedures, see Initializa-
tion procedures for VHMS controller, "8. 3) Check all the information before replacing
Downloading of set data". the VHMS controller.
4) Select [Save] from [File] in the menu.
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2-2. Writing of set information in new VHMS

controller
1) Connect the personal computer again and
start the VHMS technical analysis tool.
a See "Initialization procedures for VHMS
controller".
2) Select "Save/Load" and press the "OK"
button.
5) Check the information again and press the

"OK" button to save it.
3) Select [Load] from [File] in the menu.

6) Select [Exit] from [File] in the menu to finish
the VHMS setting tool.
7) Disconnect the personal computer.
a See Initialization procedures for VHMS
controller, "9. Disconnection of Personal
Computer".
8) Turn the personal computer OFF.
9) Replace the VHMS controller.
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4) The saved information is displayed. Press 7) After setting the time, press the "OK" button.
the "OK" button.
8) Press the [Apply] button, and the contents of

the setting are displayed. Check the contents
again and press the [OK] button if there is not
a problem.
5) The saved information is displayed on

another screen.
6) Press the [Edit] button to set the time.
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9) The system asks you if you will save the 3. Check, saving and writing of information set in
previous data. Press the "NO" button. VHMS controller (Ver.3.5.2.1 or later)
a Usually, you do not need to save the pre- a This step is a work performed in the oper-
vious data. ator's cab (on the personal computer).
a Transfer the set data of the VHMS con-
troller to be replaced to the personal com-
puter and then write it in the newly
installed VHMS controller.
3-1. Check and saving of information set in

VHMS controller to be replaced.
1) Connect the personal computer and start the
VHMS technical analysis tool.
controller".
2) Select [When VHMS needs to be replaced]
and press the "Next" button.
10)Select [Exit] from [File] in the menu to finish

the VHMS setting tool.
3) Select [Save Current Setting before replace-

ment of VHMS controller] and press the
"Next" button.
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4) Check all the information before replacing 3) Select [Use Previous setting after replace-
the VHMS controller and press the "Save" ment of VHMS controller] and press the
button. "Next" button.
5) Select [Exit] from [File] in the menu to finish 4) The saved information is displayed. Press
the VHMS setting tool. the "Next" button.
6) Disconnect the personal computer.
a See Initialization procedures for VHMS
controller, "9. Disconnection of Personal
Computer".
7) Turn the personal computer OFF.
8) Replace the VHMS controller.
3-2. Writing of set information in new VHMS

controller
1) Connect the personal computer again and
start the VHMS technical analysis tool.
controller".
2) Select [When VHMS needs to be replaced]
and press the "Next" button.
5) Set the time and press the "Apply" button.
D375A-6 30-179
(01)
DRAFT
Electrial system
6) The system asks you if you will save the [Work after replacing VHMS controller]
previous data. Press the "NO" button. a After replacing the VHMS controller, carry out
a Usually, you do not need to save the pre- initialization according to the "Initialization Pro-
vious data. cedure for VHMS Controller".
a Change the data to the information recorded be-
fore the VHMS controller was replaced. (Input
the date and time when the VHMS controller was
replaced.)
a After completing the setting after the replace-
ment, send the check sheet to VHMS/Web-
CARE Support Center of Komatsu, Tokyo.
a Send the data downloaded before and after re-
placing the VHMS controller by Notes (LAN) or
E-mail (WAN).
7) The above completes modification of the E-mail: webcare@komatsu.co.jp

setting. Press [OK] button to end the VHMS
initial setting tool.
30-180 D375A-6
(01)
DRAFT
Pm Clinic service
Pm Clinic service
Pm Clinic service
Pm Clinic service
Model Serial No. Service meter
D375A–6 #60001– h
User name Date of inspection Serviceman

/ /
Specifications
Blade Blade tilt Attachment Shoe width
□ Semi U blade □ Single tilt blade □ Multi–shank ripper □ 610 mm
□ U blade □ Dual tilt blade □ Variable giant ripper □ 710 mm
□ □ Counter weight ( kg) □ 810 mm
□ Others □ Others
Operating conditions
Quarry, mine Construction Type of soil (specific gravity) Type of work
□ Coal □ Construction, civil engineering □ Rock □ Dozing %
□ Gold □ Roads □ Gravel □ Side cutting %
□ Limestone □ Tunnels □ Sand □ Ripping %
□ □ □ Clay □ Travel %
Existence of abnormalities
Oil, coolant level check
□ Engine coolant level When necessary
□ Engine oil level □ Power train □ Damper case
□ Hydraulic oil level □ Final drive □( )
Ambient temperature Height above sea level

Max.
°C m
Min.
Operator's opinion
Visual check results
Failure code history

[ ] h [ ] h
Content: Content:
[ ] h [ ] h
Content: Content:
Operating mode
q Working mode: P- or E-mode
q Gear shift mode: Auto or Manual
q Preset: F ,R
Comment
D375A-6 30-181
(03) 30-191
DRAFT
Pm Clinic service
Pm Clinic service
Pm Clinic measurement item or specification of the D375A–6
Measuring methods:
Q: Measurement with machine monitor
E: Measurement by gauge. (sensor or quick copuler)
×: Need installation sensor or quick copuler
Engine
Specifica-
Engine speed Engine oil pressure Exhaust temperature Blow–by Boost pressure
tions
STD Q Q × × Q
Pm clinic Q Q E × Q
WHMS Q Q Q Q Q
Power train oil circuit

Specifica-
T/C IN T/C OUT T/C S/C L/U Steering Brake
tions
STD Q Q E E E E
Pm clinic Q Q E E E E
WHMS Q Q E E E E
Power train oil circuit

Transmission Transmission
Specifica-
main relief 1st 2nd 3rd F R lubricating oil
tions
pressure pressure
STD E E E E E E E
Pm clinic E E E E E E E
WHMS Q E E E E E E
Work equipment circuit Fan circuit

Specifica-
Control source pressure Pump pressure Engine speed
tions
STD E E Q
Pm clinic E Q Q
WHMS E Q Q
30-192
30-182 D375A-6
(03)
DRAFT
Pm Clinic service
Pm Clinic service
Testing points for Pm clinic (1/3)
For the measurement procedures, see the following pages.

*1. Engine speed: "Testing of engine speed"
*2. Blow–by pressure: "Testing of blow–by pressure"
*3. Engine oil pressure: "Check of engine oil pressure"
*4. Boost pressure: "Testing of boost pressure"
*5. Exhaust gas temperature: "Check of exhaust gas temperature"
D375A-6 30-183
(03) 30-193
DRAFT
Pm Clinic service
Pm Clinic service

*6. Measurement related to torque converter: "Testing of power train oil pressure"
*7. Measurement related to transmission: "Testing of power train oil pressure"
*8. Measurement related to steering brake "Testing of power train oil pressure"
30-184 D375A-6
(01)
DRAFT
Pm Clinic service
Pm Clinic service

*9. Hydraulic pressure of work equipment: "Testing of work equipment oil pressure"
*10. Source pressure of control circuit: "Testing of control circuit source pressure"
*11. Fan speed: "Check of fan speed"
D375A-6 30-185
(03) 30-195
DRAFT
Pm Clinic service
Pm Clinic service
Pm Clinic check sheet D375A–6 Serial No.
Work order No. Date of inspection Service meter Serviceman

/ / h
Standard
Service limit Test
Item Test conditions Unit value for new OK NG Remarks
value results
machine
Low idle 700 – 800 i
Deceleration pedal
Decel 850 – 950 i
depressed
Engine speed High idle rpm 1,850 – 1,900 i
Torque converter stall (Adjustment ID: 0530) 1,480– 1,580 1,450
Torque converter stall + Work equipment relief
1,450 – 1,550 1,400
(ripper raise) (Adjustment ID: 0530)
kPa Max. 3.43 Min. 9.41
Blowby pressure At torque converter stall
Engine
{mmH2O} {Max. 350} {Min. 960}

SAE0W30E0S Min. 117.68 Max. 78.45
Low idle SAE5W40E0S {Min. 1.2} {Max. 0.8}
SAE10W30DH kPa
Engine oil pressure
SAE15W40DH {kg/cm2} Min. 392.27 Max. 235.36
High idle Oil temperature: {Min. 4.0} {Max. 2.4}
Min. 70 °C
kPa Min. 155 Max. 141
Boost pressure At torque converter stall
{mmHg} {Min. 1,160} {Max. 1.060}
Torque converter stall + No. 1, 2 , 3 cylinder
Exhaust temperature °C Max. 700 Min. 730
Work equipment relief No. 4, 5, 6 cylinder
k For torque converter lockup clutch pressure, set both of the steering clutches to the disengage mode on the machine
monitor and check the pressure.
Standard
Service limit Test
Item Test conditions Unit value for new OK NG Remarks
value results
machine
0.03 – 0.25 i
Inlet oil pressure
{0.3 – 2.5} i
0.03 – 0.20 i
Outlet oil pressure
{0.3 – 2.0} i
Engine low idle
Lockup clutch pres- 0–0 i
sure {0 – 0} i
Torque converter
Stator clutch pres- 2.25 – 2.87 i

sure {23.0 – 29.3} i
Transmission: Neutral MPa 0.69 – 1.05 i
Inlet oil pressure
{kg/cm2} {7.0– 10.7} i
0.44 – 0.70 i
Outlet oil pressure
{4.5 – 7.0} i
Engine high idle
Lockup clutch pres- 0–0 i
sure {0 – 0} i
Stator clutch pres- 2.55 – 2.87 i
sure {26.0 – 29.3} i
Lockup clutch pres- Transmission: F2 1.29 – 1.54 i
Engine high idle
sure (Adjustment ID: 5535) {13.2 – 15.7} i
k For each of the transmission clutch pressures, set both of the steering clutches to the disengage mode on the machine
monitor and check the pressures only in low idle for safety.
Standard Service limit Test
Item Test conditions Unit OK NG Remarks
value for new value results
2.48 – 2.87 2.38 – 3.07
Engine low idle
{25.3 – 29.3} {24.3 – 31.3}
Main relief pressure
2.68 – 2.87 2.58 – 3.07
Transmission: Neutral Engine high idle
{27.3 – 29.3} {26.3 – 31.3}
Lubricating oil pres- 0.08 – 0.25 i
Engine high idle
sure {0.8 – 2.5} i
Transmission
Transmission: F1 2.25 – 2.84 2.06 – 3.13

F clutch pressure Engine low idle MPa
(Adjustment ID: 5535) {23.0 – 29.0} {21.0 – 31.9}
R clutch pressure
Transmission: R1
Engine low idle {kg/cm2} 2.25 – 2.84 2.06 – 3.13
(Adjustment ID: 5535) {23.0 – 29.0} {21.0 – 31.9}
Transmission: F1 2.06 – 2.35 1.86 – 2.55
1st clutch pressure Engine low idle
(Adjustment ID: 5535) {21.0 – 24.0} {18.9 – 26.0}
Transmission: F2 2.25 – 2.84 2.06 – 3.13
2nd clutch pressure Engine low idle
(Adjustment ID: 5535) {23.0 – 29.0} {21.0 – 31.9}
Transmission: F3 2.25 – 2.84 2.06 – 3.13
3rd clutch pressure Engine low idle
(Adjustment ID: 5535) {23.0 – 29.0} {21.0 – 31.9}
30-196
30-186 D375A-6
(03)
DRAFT
Pm Clinic service
Pm Clinic service

/ / h
Standard value
Service limit Test
Item Test conditions Unit for new OK NG Remarks
value results
machine
2.25 – 2.84 2.2 – 3.04
Left clutch pressure
{23.0 – 29.0} {22.4 – 31.0}
Engine low idle
2.25 – 2.84 2.2 – 3.04
Left brake pressure
{23.0 – 29.0} {22.4 – 31.0}
Transmission: Neutral
2.55 – 2.87 2.4 – 3.07
Steering clutch & brake

{26.0 – 29.3} {24.4 – 31.3}
Engine high idle
2.55 – 2.87 2.4 – 3.07
Left brake pressure MPa {26.0 – 29.3} {24.4 – 31.3}
Right clutch pressure {kg/cm2} 2.25 – 2.84 2.2 – 3.04
{23.0 – 29.0} {22.4 – 31.0}
Engine low idle
2.25 – 2.84 2.2 – 3.04
Right brake pressure
{23.0 – 29.0} {22.4 – 31.0}
Transmission: Neutral
2.55 – 2.87 2.4 – 3.07
Right clutch pressure
{26.0 – 29.3} {24.4 – 31.3}
Engine high idle
2.55 – 2.87 2.4 – 3.07
{26.0 – 29.3} {24.4 – 31.3}
Brake performance Engine at high idle, F2, brake actuated Machine must not move
Standard value
Service limit Test
value results
machine
Work equipment
Control lever in NEU- 2.45 – 3.82 2.45 – 3.82
pump Engine high idle
Hydraulic system
TRAL position {25 – 39} {25 – 39}

(Unload pressure)
MPa 27.5 – 29.4 Min. 26.5
Engine low idle
Work equipment Ripper lift relief or {280 – 300} {Min. 270}
pump blade tilt relief {kg/cm2} 27.5 – 29.4 Min. 26.5
{280 – 300} {Min. 270}
Engine high idle
Control circuit source Control lever in NEU- 3.43 – 4.12 Min. 3.1
pressure TRAL position {35 – 42} {Min. 32}
Standard value
Service limit Test
value results
machine
Min. speed Engine low idle 250 – 450 ―
Fan
Fan 100 % mode rpm

Max. speed Engine high idle 1,185 – 1,235 Max. 1,110
Standard value
Service limit Test
value results
machine
Blade RAISE
Engine high idle 3.7 – 4.7 6

Blade tilt (left and right tilt)
[Single tilt model]

[Dual tilt model, Dual setting]
sec
Blade dump
[Dual tilt specification]

[Dual tilt model, Single setting]

Ripper tilt (ino out)
D375A-6 30-187
(03) 30-197
DRAFT
Pm Clinic service
Pm Clinic service

/ / h
Standard
value for Service Test
new limit value results
machine
Hydraulic drift
Blade lift cylinder Engine stopped Max. 65 i

Hydraulic oil tem-
mm/5min.
perature:
Ripper lift cylinder 45 – 55 °C Max. 25 i
Standard
value for Service Test
new limit value results
machine
There must be no exces-
Visual inspection of final drive drain plug Engine stopped ―
sive metal particles
Always fill in the record when repairing, adjusting, or replacing main parts.
Date Service meter Repair record Date Service meter Repair record
30-198
30-188 D375A-6
(03)
DRAFT
Pm Clinic service
Pm Clinic service
D375A-6 30-189
(01)
DRAFT
Pm Clinic service
Pm Clinic service
30-190 D375A-6
(01)
DRAFT
Pm Clinic service
Pm Clinic service
D375A-6 30-191
(01)
DRAFT
Pm Clinic service
Pm Clinic service
30-192 D375A-6
(01)
DRAFT
D375A-6
SEN01868-02
BULLDOZER
Shop Manual
D375A-6

D375A-6 60001 and up
40 Troubleshooting
D375A-6 40-1
(01)
DRAFT
Contents
Contents
40 Troubleshooting
General Information on troubleshooting ........................................................................................................... 40 - 9
Points to remember when troubleshooting ................................................................................................... 40 - 9
Sequence of events in troubleshooting......................................................................................................... 40 - 10
Checks before troubleshooting ..................................................................................................................... 40 - 11
Classification and procedures for troubleshooting ........................................................................................ 40 - 36
Failure codes table........................................................................................................................................ 40 - 39
Phenomena and troubleshooting numbers ................................................................................................... 40 - 45
Information in troubleshooting table.............................................................................................................. 40 - 47
Troubleshooting method for disconnecting wiring harness of pressure sensor system................................ 40 - 49
Connection table for connector pin numbers ................................................................................................ 40 - 52
Connectors table and arrangement drawing................................................................................................. 40 - 88
T-branch box and T-branch adapter table .................................................................................................... 40 -102
Fuse locations table ...................................................................................................................................... 40 -105
Troubleshooting by failure code ....................................................................................................................... 40 -109
Failure code [1380MW] Lock up clutch: Slip................................................................................................. 40 -109
Failure code [1500L0] Transmission clutch: Abnormal ................................................................................. 40 -110
Failure code [15E0MW] Transmission clutch: Slip........................................................................................ 40 -111
Failure code [15SAL1] Forward clutch: Fill high ........................................................................................... 40 -112
Failure code [15SALH] Forward clutch: Fill Low ........................................................................................... 40 -114
Failure code [15SBL1] Reverse clutch: Fill high ........................................................................................... 40 -116
Failure code [15SBLH] Reverse clutch: Fill Low........................................................................................... 40 -118
Failure code [15SEL1] Speed 1st clutch: Fill high ........................................................................................ 40 -120
Failure code [15SELH] Speed 1st clutch: Fill Low ........................................................................................ 40 -122
Failure code [15SFL1] Speed 2nd clutch: Fill high ....................................................................................... 40 -124
Failure code [15SFLH] Speed 2nd clutch: Fill Low ....................................................................................... 40 -126
Failure code [15SGL1] Speed 3rd clutch: Fill high........................................................................................ 40 -128
Failure code [15SGLH] Speed 3rd clutch: Fill Low ....................................................................................... 40 -130
Failure code [15SJL1] L/U: Fill high .............................................................................................................. 40 -132
Failure code [15SJLH] L/U: Fill low............................................................................................................... 40 -134
Failure code [1800MW] P/T clutch: Slip........................................................................................................ 40 -136
Failure code [2201L1] Right clutch: Fill high ................................................................................................. 40 -138
Failure code [2201LH] Right clutch: Fill low.................................................................................................. 40 -140
Failure code [2202L1] Left clutch: Fill high ................................................................................................... 40 -142
Failure code [2202LH] Left clutch: Fill low .................................................................................................... 40 -144
Failure code [2300NR] Brake Themal Load Abnormality.............................................................................. 40 -146
Failure code [2301L1] Right brake: Fill high ................................................................................................. 40 -148
Failure code [2301LH] Right brake: Fill low .................................................................................................. 40 -150
Failure code [2301NR] Steering Brake RH Themal Load Abnormality ......................................................... 40 -152
Failure code [2302L1] Left brake: Fill high.................................................................................................... 40 -154
Failure code [2302LH] Left brake: Fill low..................................................................................................... 40 -156
Failure code [2302NR] Steering Brake LH Themal Load Abnormality.......................................................... 40 -158
Failure code [7RFAKA] ECM ACC CUT RELAY: Disconnection.................................................................. 40 -160
Failure code [7RFAKB] ECM ACC CUT RELAY: Short circuit ..................................................................... 40 -162
Failure code [AA10NX] Air Cleaner Clogging ............................................................................................... 40 -164
Failure code [AB00MA] Battery Charge Abnormal ....................................................................................... 40 -166
Failure code [B@BAZG] Eng Oil Press Low................................................................................................. 40 -166
Failure code [B@BAZK] Eng Oil Level Low.................................................................................................. 40 -167
Failure code [B@BCNS] Eng Water Overheat ............................................................................................. 40 -168
Failure code [B@BCZK] Eng Water Level Low ............................................................................................ 40 -169
Failure code [B@CENS] T/C Oil Overheat ................................................................................................... 40 -170
Failure code [B@HANS] Hyd Oil Overheat................................................................................................... 40 -171
Failure code [B@HAZK] Hyd Oil Level Low.................................................................................................. 40 -172
Failure code [CA111] ECM Critical Internal Failure ...................................................................................... 40 -174
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ......................................................................... 40 -176
Failure code [CA122] Chg Air Press Sensor High Error ............................................................................... 40 -178
40-2 D375A-6
(01)
DRAFT
Contents
Failure code [CA123] Chg Air Press Sensor Low Error ................................................................................ 40 -180
Failure code [CA131] Throttle Sensor High Error ......................................................................................... 40 -182
Failure code [CA132] Throttle Sensor Low Error .......................................................................................... 40 -184
Failure code [CA135] Eng Oil Press Sensor High Error ............................................................................... 40 -186
Failure code [CA141] Eng Oil Press Sensor Low Error ................................................................................ 40 -188
Failure code [CA144] Coolant Temp Sens High Error .................................................................................. 40 -190
Failure code [CA145] Coolant Temp Sens Low Error................................................................................... 40 -192
Failure code [CA153] Chg Air Temp Sensor High Error ............................................................................... 40 -194
Failure code [CA154] Chg Air Temp Sensor Low Error ................................................................................ 40 -196
Failure code [CA187] Sens Supply 2 Volt Low Error .................................................................................... 40 -198
Failure code [CA212] Eng Oil Temp Sensor High Error ............................................................................... 40 -200
Failure code [CA213] Eng Oil Temp Sensor Low Error ................................................................................ 40 -202
Failure code [CA221] Ambient Press Sens High Error ................................................................................. 40 -204
Failure code [CA222] Ambient Press Sens Low Error .................................................................................. 40 -206
Failure code [CA227] Sens Supply 2 Volt High Error ................................................................................... 40 -208
Failure code [CA234] Eng Overspeed .......................................................................................................... 40 -209
Failure code [CA238] Ne Speed Sens Supply Volt Error.............................................................................. 40 -210
Failure code [CA263] Fuel Temp Sensor High Error .................................................................................... 40 -212
Failure code [CA265] Fuel Temp Sensor Low Error ..................................................................................... 40 -214
Failure code [CA271] IMV/PCV1 Short Error................................................................................................ 40 -216
Failure code [CA272] IMV/PCV1 Open Error................................................................................................ 40 -217
Failure code [CA273] PCV2 Short Error ....................................................................................................... 40 -218
Failure code [CA274] PCV2 Open Error ....................................................................................................... 40 -219
Failure code [CA322] Inj #1 (L#1) Open/Short Error..................................................................................... 40 -220
Failure code [CA342] Calibration Code Incompatibility................................................................................. 40 -232
Failure code [CA351] Injectors Drive Circuit Error ........................................................................................ 40 -233
Failure code [CA352] Sens Supply 1 Volt Low Error .................................................................................... 40 -234
Failure code [CA386] Sens Supply 1 Volt High Error ................................................................................... 40 -236
Failure code [CA441] Battery Voltage Low Error .......................................................................................... 40 -237
Failure code [CA442] Battery Voltage High Error ......................................................................................... 40 -238
Failure code [CA449] Rail Press Very High Error ......................................................................................... 40 -239
Failure code [CA451] Rail Press Sensor High Error ..................................................................................... 40 -240
Failure code [CA452] Rail Press Sensor Low Error...................................................................................... 40 -242
Failure code [CA553] Rail Press High Error ................................................................................................. 40 -244
Failure code [CA554] Rail Press Sensor In Range Error.............................................................................. 40 -245
Failure code [CA559] Rail Press Low Error .................................................................................................. 40 -246
Failure code [CA689] Eng Ne Speed Sensor Error ...................................................................................... 40 -250
Failure code [CA731] Eng Bkup Speed Sens Phase Error........................................................................... 40 -252
Failure code [CA757] All Continuous Data Lost Error................................................................................... 40 -253
Failure code [CA778] Eng Bkup Speed Sensor Error................................................................................... 40 -254
Failure code [CA1228] EGR Valve Servo Error 1 ......................................................................................... 40 -256
Failure code [CA1625] EGR Valve Servo Error 2 ......................................................................................... 40 -257
Failure code [CA1633] KOMNET Datalink Timeout Error............................................................................. 40 -258
Failure code [CA2185] Throt Sens Sup Volt High Error................................................................................ 40 -259
Failure code [CA2186] Throt Sens Sup Volt Low Error ................................................................................ 40 -260
Failure code [CA2249] Rail Press Very Low Error........................................................................................ 40 -261
Failure code [CA2271] EGR Valve Pos Sens High Error.............................................................................. 40 -262
Failure code [CA2272] EGR Valve Pos Sens Low Error .............................................................................. 40 -264
Failure code [CA2351] EGR Valve Sol Current High Error........................................................................... 40 -266
Failure code [CA2352] EGR Valve Sol Current Low Error............................................................................ 40 -268
Failure code [D110KB] Battery Relay: Drive Short Circuit ............................................................................ 40 -270
Failure code [D130KA] Neutral relay: Disconnection.................................................................................... 40 -272
Failure code [D130KB] Neutral relay: Short circuit ....................................................................................... 40 -274
D375A-6 40-3
(01)
DRAFT
Contents
Failure code [D161KA] Back-up alarm releay: Disconnection ...................................................................... 40 -276

Failure code [D161KB] Back-up alarm releay: Short circuit.......................................................................... 40 -278
Failure code [D182KZ] Preheater Relay Abnormality ................................................................................... 40 -280
Failure code [D190KA] ACC signal relay: Disconnection ............................................................................. 40 -282
Failure code [D190KB] ACC signal relay: Short circuit ................................................................................. 40 -284
Failure code [D1EFKA] Pre lub. motor relay: Disconnection ........................................................................ 40 -286
Failure code [D1EFKB] Pre lub. motor relay: Short circuit............................................................................ 40 -288
Failure code [DAFRKR] Monitor: Can communication lost (PT) ................................................................... 40 -290
Failure code [dAFRKR] Monitor: CAN communication lost (WE) ................................................................. 40 -291
Failure code [DAFRMC] CAN Discon (Monitor Detected) ............................................................................ 40 -292
Failure code [DB2RKR] ENG cont.: Can communication lost (PT)............................................................... 40 -297
Failure code [dB2RKR] ENG controller: CAN communication lost (WE) ...................................................... 40 -300
Failure code [DB90KT] WE controller: Abnormality in controller .................................................................. 40 -301
Failure code [DB91KK] WE controller: Source voltage reduction ................................................................. 40 -302
Failure code [DB92KK] WE controller: Output voltage reduction.................................................................. 40 -304
Failure code [DB97KK] WE cont.: Sensor voltage 5 V (2) reduction ............................................................ 40 -306
Failure code [DB99KQ] WE controller: Type select signal............................................................................ 40 -308
Failure code [DB9RKR] WE controller: Can communication lost (PT).......................................................... 40 -309
Failure code [DBB0KK] VHMS controller:Source voltage reduction ............................................................. 40 -312
Failure code [DBB0KQ] VHMS connector connection abnormality .............................................................. 40 -314
Failure code [DBB3KK] VHMS controller: Source voltage reduction ............................................................ 40 -316
Failure code [DBB5KP] VHMS: Output sensor1 voltage reduction............................................................... 40 -318
Failure code [DBB6KP] VHMS:Output sensor2 voltage reduction................................................................ 40 -320
Failure code [DBB7KP] VHMS:Output sensor3 voltage reduction................................................................ 40 -322
Failure code [DBBQKR] PT cont.: Can communication lost (VHMS) ........................................................... 40 -323
Failure code [DBE0KT] PT controller: Abnormality in controller ................................................................... 40 -323
Failure code [DBE1KK] PT controller: Source voltage reduction.................................................................. 40 -324
Failure code [DBE2KK] PT controller: Output voltage reduction .................................................................. 40 -326
Failure code [DBE5KK] PT cont.: Sensor voltage 5 V (1) reduction ............................................................. 40 -328
Failure code [DBE6KK] PT cont.: Sensor voltage 24 V reduction ................................................................ 40 -330
Failure code [DBE7KK] PT cont.: Sensor voltage 5 V (2) reduction ............................................................. 40 -332
Failure code [DBE9KQ] PT controller: Type select signal ............................................................................ 40 -334
Failure code [DBERKR] PT controller: Can communication lost (WE) ......................................................... 40 -335
Failure code [DD12KA] Shift up Sw: Disconnection ..................................................................................... 40 -338
Failure code [DD12KB] Shift up Sw: Short circuit ......................................................................................... 40 -340
Failure code [DD13KA] Shift down Sw: Disconnection................................................................................. 40 -342
Failure code [DD13KB] Shift down Sw: Short circuit .................................................................................... 40 -344
Failure code [DD14KA] Parking lever Sw: Dissconnection........................................................................... 40 -346
Failure code [DD14KB] Parking lever Sw: Short circuit ................................................................................ 40 -348
Failure code [DDB9L4] Reverse SW Signal disagreement........................................................................... 40 -350
Failure code [DDE2KA] Pre lub. oil press sw: Disconnection ....................................................................... 40 -352
Failure code [DDK3L4] Forward SW Signal disagreement........................................................................... 40 -354
Failure code [DDK5KA] Shift switch disconnection....................................................................................... 40 -356
Failure code [DDK5KB] Shift switch short circuit .......................................................................................... 40 -358
Failure code [DDN2LD] Blade tilt RH pressure SW abnormality .................................................................. 40 -360
Failure code [DDN3LD] Blade tilt LH pressure SW abnormality ................................................................... 40 -362
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection ................................................................... 40 -364
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit....................................................................... 40 -366
Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection........................................................................ 40 -368
Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit ........................................................................... 40 -370
Failure code [DDNALD] Blade lift up pressure SW abnormality ................................................................... 40 -372
Failure code [DDNBLD] Ripper lift up pressure SW abnormality.................................................................. 40 -374
Failure code [DDNCLD] Ripper lift down pressure SW abnormality ............................................................. 40 -376
Failure code [DDNDLD] Ripper tilt in pressure SW abnormality ................................................................... 40 -378
Failure code [DDNELD] Ripper tilt back pressure SW abnormality .............................................................. 40 -380
Failure code [DDNFLD] Blade lift down pressure SW abnormality ............................................................... 40 -382
Failure code [DDNLKA] Weq lock Sw: Disconnection .................................................................................. 40 -384
Failure code [DDNLKB] Weq lock Sw: Short circuit...................................................................................... 40 -386
40-4 D375A-6
(01)
DRAFT
Contents
Failure code [DDT5KA] Neutral switch disconnection .................................................................................. 40 -388

Failure code [DDT5KB] Neutral switch short circuit ...................................................................................... 40 -390
Failure code [DDT5KQ] Lever SPEC selection signal disagreement ........................................................... 40 -392
Failure code [DDTSL1] S/C: Fill high ............................................................................................................ 40 -394
Failure code [DDTSLH] S/C: Fill low............................................................................................................. 40 -396
Failure code [DGE5KX] Ambient temp sensor abnormality .......................................................................... 40 -398
Failure code [DGS1KX] Hyd oil temp: signal abnormal ................................................................................ 40 -400
Failure code [DGT1KA] T/C oil temp sensor: Abnormal ............................................................................... 40 -402
Failure code [DGT1KX] T/C oil temp sensor: Abnormal ............................................................................... 40 -404
Failure code [DGT5KA] F exhaust temp sensor disconnection .................................................................... 40 -406
Failure code [DGT5KB] F exhaust temp sensor short circuit........................................................................ 40 -408
Failure code [DGT6KA] R exhaust temp sensor disconnection.................................................................... 40 -410
Failure code [DGT6KB] R exhaust temp sensor short circuit ....................................................................... 40 -412
Failure code [DH21KA] Weq pressure sensor: Disconnection ..................................................................... 40 -414
Failure code [DH21KB] Weq pressure sensor: Short circuit ......................................................................... 40 -416
Failure code [DHE5KB] ENG blow-by pressure sensor disconnection......................................................... 40 -418
Failure code [DHE5KY] ENG blow-by pressure sensor short circuit ............................................................ 40 -420
Failure code [DHT3KX] T/M oil pressure sensor abnormality....................................................................... 40 -422
Failure code [DHT5KA] T/C in-pressure sensor: Disconnection................................................................... 40 -424
Failure code [DHT5KB] T/C in-pressure sensor: Short circuit ...................................................................... 40 -426
Failure code [DHT7KA] T/C out-pressure sensor: Disconnection................................................................. 40 -428
Failure code [DHT7KB] T/C out-pressure sensor: Short circuit .................................................................... 40 -430
Failure code [DK10KA] Fuel control Dial: Disconnection.............................................................................. 40 -432
Failure code [DK10KB] Fuel control Dial: Short circuit ................................................................................. 40 -434
Failure code [DK30KA] ST lever 1: Disconnection ....................................................................................... 40 -436
Failure code [DK30KB] ST lever 1: Short circuit ........................................................................................... 40 -438
Failure code [DK30KX] ST lever: Out of normal range ................................................................................. 40 -440
Failure code [DK30KZ] ST lever: Disconnection or short circuit ................................................................... 40 -440
Failure code [DK30L8] ST lever: Signal mismatch ....................................................................................... 40 -441
Failure code [DK31KA] ST lever 2: Disconnection ....................................................................................... 40 -442
Failure code [DK31KB] ST lever 2: Short circuit ........................................................................................... 40 -444
Failure code [DK40KA] Brake potentiometer: Disconnection ....................................................................... 40 -446
Failure code [DK40KB] Brake potentiometer: Short circuit ........................................................................... 40 -448
Failure code [DK55KX] FR lever: Out of normal range................................................................................. 40 -450
Failure code [DK55KZ] FR lever: Disconnection or short circuit................................................................... 40 -450
Failure code [DK55L8] FR lever: Signal mismatch ....................................................................................... 40 -451
Failure code [DK56KA] FR lever 1: Disconnection ....................................................................................... 40 -452
Failure code [DK56KB] FR lever 1: Short circuit........................................................................................... 40 -454
Failure code [DK57KA] FR lever 2: Disconnection ....................................................................................... 40 -456
Failure code [DK57KB] FR lever 2: Short circuit........................................................................................... 40 -458
Failure code [DK60KA] Acceleration sensor: Disconnection ........................................................................ 40 -460
Failure code [DK60KB] Acceleration sensor: Short circuit............................................................................ 40 -462
Failure code [DKH1KA] Pitch angle sensor: Disconnection.......................................................................... 40 -464
Failure code [DKH1KB] Pitch angle sensor: Short circuit ............................................................................. 40 -466
Failure code [DLF1KA] T/C out-speed sensor: Disconnection ..................................................................... 40 -468
Failure code [DLM3KA] Fan rev. sensor: Disconnection .............................................................................. 40 -469
Failure code [DLM3MB] Fan control: Decline ............................................................................................... 40 -470
Failure code [DLT3KA] T/M out-speed sensor: Disconnection ..................................................................... 40 -471
Failure code [DLT3KB] T/M out-speed sensor: Abnormal ............................................................................ 40 -472
Failure code [DW59KA] Blade dual selector SOL disconnection.................................................................. 40 -473
Failure code [DW59KB] Blade dual selector SOL short circuit ..................................................................... 40 -474
Failure code [DW59KY] Blade dual selector SOL hot short.......................................................................... 40 -475
Failure code [DW5AKA] Blade pitch selector SOL disconnection ................................................................ 40 -476
Failure code [DW5AKB] Blade pitch selector SOL short circuit .................................................................... 40 -477
Failure code [DW5AKY] Blade pitch selector SOL Short circuit ................................................................... 40 -478
Failure code [DW7BKA] Fan rev EPC: Disconnection.................................................................................. 40 -479
Failure code [DW7BKB] Fan rev EPC: Short circuit ..................................................................................... 40 -480
Failure code [DWN3KA] Ssp solenoid: Disconnection.................................................................................. 40 -481
D375A-6 40-5
(01)
DRAFT
Contents
Failure code [DWN3KB] Ssp solenoid: Short circuit ..................................................................................... 40 -482

Failure code [DWN3KY] SSP solenoid: Short circuit .................................................................................... 40 -484
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection..................................................................... 40 -486
Failure code [DWN5KB] Fan pump solenoid 1: Short circuit ........................................................................ 40 -487
Failure code [DWN5KY] Fan pump solenoid 1: Short circuit ........................................................................ 40 -488
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection .................................................................... 40 -490
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit........................................................................ 40 -491
Failure code [DWNCKY] Fan pump solenoid 2: Short circuit........................................................................ 40 -492
Failure code [DXH1KA] Lock-up ECMV: Disconnection ............................................................................... 40 -494
Failure code [DXH1KB] Lock-up ECMV: Short circuit................................................................................... 40 -495
Failure code [DXH1KY] Lock-up ECMV: Short circuit................................................................................... 40 -496
Failure code [DXH4KA] 1st clutch ECMV: Disconnection............................................................................. 40 -498
Failure code [DXH4KB] 1st clutch ECMV: Short circuit ................................................................................ 40 -499
Failure code [DXH4KY] 1st clutch ECMV: Short circuit ................................................................................ 40 -500
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection ........................................................................... 40 -502
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit ............................................................................... 40 -503
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit ............................................................................... 40 -504
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection ............................................................................ 40 -506
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit................................................................................ 40 -507
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit................................................................................ 40 -508
Failure code [DXH7KA] R clutch ECMV: Disconnection............................................................................... 40 -510
Failure code [DXH7KB] R clutch ECMV: Short circuit .................................................................................. 40 -511
Failure code [DXH7KY] R clutch ECMV: Short circuit .................................................................................. 40 -512
Failure code [DXH8KA] F clutch ECMV: Disconnection ............................................................................... 40 -514
Failure code [DXH8KB] F clutch ECMV: Short circuit................................................................................... 40 -515
Failure code [DXH8KY] F clutch ECMV: Short circuit................................................................................... 40 -516
Failure code [DXH9KA] Right clutch ECMV: Disconnection ......................................................................... 40 -518
Failure code [DXH9KB] Right clutch ECMV: Short circuit............................................................................. 40 -519
Failure code [DXH9KY] Right clutch ECMV: Short circuit............................................................................. 40 -520
Failure code [DXHAKA] Left clutch ECMV: Disconnection ........................................................................... 40 -522
Failure code [DXHAKB] Left clutch ECMV: Short circuit............................................................................... 40 -523
Failure code [DXHAKY] Left clutch ECMV: Short circuit............................................................................... 40 -524
Failure code [DXHBKA] Right brake ECMV: Disconnection ......................................................................... 40 -526
Failure code [DXHBKB] Right brake ECMV: Short circuit............................................................................. 40 -527
Failure code [DXHBKY] Right brake ECMV: Short circuit............................................................................. 40 -528
Failure code [DXHCKA] Left brake ECMV: Disconnection ........................................................................... 40 -530
Failure code [DXHCKB] Left brake ECMV: Short circuit............................................................................... 40 -531
Failure code [DXHCKY] Left brake ECMV: Short circuit............................................................................... 40 -532
Failure code [DXJBKA] S/C ECMV: Disconnection ...................................................................................... 40 -534
Failure code [DXJBKB] S/C ECMV: Short circuit.......................................................................................... 40 -535
Failure code [DXJBKY] S/C ECMV: Short circuit.......................................................................................... 40 -536
Failure code [DY2HKA] Pre lub. motor: Disconnection................................................................................. 40 -538
Failure code [F@BBZL] ENG blow-by pressure high level ........................................................................... 40 -540
Failure code [F@BYNR] F exhaust temp high level (2) ................................................................................ 40 -541
Failure code [F@BYNS] F exhaust temp high level (1) ................................................................................ 40 -542
Failure code [F@BZNR] R exhaust temp high level (2)................................................................................ 40 -543
Failure code [F@BZNS] R exhaust temp high level (1) ................................................................................ 40 -544
Troubleshooting of electrical system (E-mode) ................................................................................................ 40 -545
Information contained in troubleshooting table ............................................................................................. 40 -545
E-1 Engine does not start (starting motor does not turn) .............................................................................. 40 -547
E-2 Preheater does not operate.................................................................................................................... 40 -550
E-3 When starting switch is turned ON, machine monitor displays nothing.................................................. 40 -554
E-4 When starting switch is turned ON (before starting engine), basic check item lights up........................ 40 -556
E-5 Precaution item lights up while engine is running .................................................................................. 40 -558
E-6 Emergency stop item lights up while engine is running.......................................................................... 40 -560
E-7 Engine coolant temperature gauge does not indicate normally ............................................................. 40 -561
E-8 Fuel gauge does not indicate properly ................................................................................................... 40 -562
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally ........................................ 40 -564
40-6 D375A-6
(01)
DRAFT
Contents
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally .............................................. 40 -565
E-11 Contents of display by machine monitor are different from applicable machine .................................. 40 -566
E-12 Machine monitor does not display some items .................................................................................... 40 -566
E-13 Function switch does not work ............................................................................................................. 40 -566
E-14 Operation mode does not change ........................................................................................................ 40 -567
E-15 Gearshift mode does not change ......................................................................................................... 40 -567
E-16 Customize function does not operate normally .................................................................................... 40 -568
E-17 Customize memory function does not operate normally ...................................................................... 40 -568
E-18 Alarm buzzer does not sound or does not stop.................................................................................... 40 -569
E-19 When starting switch is turned OFF, service meter is not displayed.................................................... 40 -569
E-20 Machine monitor cannot be set in service mode .................................................................................. 40 -569
E-21 The ripper pin puller cylinder does not operate .................................................................................... 40 -570
E-22 Horn does not sound or does not stop ................................................................................................. 40 -572
E-23 Back-up alarm does not sound or does not stop.................................................................................. 40 -574
E-24 Fan does not reverse ........................................................................................................................... 40 -576
E-25 The head lamp and rear lamp do not light up....................................................................................... 40 -577
E-26 Windshield wiper does not operate ...................................................................................................... 40 -584
E-27 Window washer does not operate ........................................................................................................ 40 -590
E-28 Electric priming pump does not operate or does not stop automatically .............................................. 40 -596
E-29 Orbcomm terminal does not operate normally (Data are not transmitted) ........................................... 40 -598
E-30 Gear cannot be shifted ......................................................................................................................... 40 -600
Troubleshooting of hydraulic and mechanical system (H-mode) ..................................................................... 40 -601
Information in troubleshooting table.............................................................................................................. 40 -601
List of Failure Modes and Causes ................................................................................................................ 40 -602
H-1 Machine lacks power(or drawbar pull) ................................................................................................... 40 -604
H-2 Machine cannot travel (at 2nd or 3rd each speed)................................................................................. 40 -606
H-3 Machine cannot travel at any gear speeds ............................................................................................ 40 -607
H-4 Machine travels only in one direction, forward or reverse...................................................................... 40 -608
H-5 Large time lag at gear shifting or directional change ............................................................................. 40 -609
H-6 Machine connot turn............................................................................................................................... 40 -610
H-7 Machine turns only to one side .............................................................................................................. 40 -611
H-8 Machine overruns at turnning................................................................................................................. 40 -612
H-9 Brake does not work .............................................................................................................................. 40 -612
H-10 Torque converter does not lock up....................................................................................................... 40 -613
H-11 Power train oil overheats...................................................................................................................... 40 -614
H-12 All work equipment operates too slow or lacks power ......................................................................... 40 -615
H-13 All work equipment does not operate................................................................................................... 40 -616
H-14 Blade lift cylinder speed is too slow or lacks power ............................................................................. 40 -617
H-15 Blade tilt cylinder speed is too slow or lacks power ............................................................................. 40 -617
H-16 Ripper lift cylinder speed is too slow or lacks power............................................................................ 40 -618
H-17 Ripper tilt cylinder speed is too slow or lacks power............................................................................ 40 -618
H-18 Excessive hydraulic drift of blade lift cylinder....................................................................................... 40 -619
H-19 Excessive hydraulic drift of blade tilt cylinder....................................................................................... 40 -619
H-20 Excessive hydraulic drift of ripper lift cylinder ...................................................................................... 40 -620
H-21 Ripper pin puller cylinder does not operate (machine with giant ripper) .............................................. 40 -620
H-22 Blade pitch does not work (machine with dual tilt specification) .......................................................... 40 -621
H-23 Abnormal noise from around work equipment pump ........................................................................... 40 -621
H-24 Abnormal fan rotation(noise and/or vibration are abnormally large or engine overheats) ................... 40 -622
Troubleshooting of engine (S-mode)................................................................................................................ 40 -624
Method of using troubleshooting chart.......................................................................................................... 40 -624
S-1 Engine does not start easily ................................................................................................................... 40 -628
S-2 Engine does not start ............................................................................................................................. 40 -630
S-3 Engine does not rev up smoothly (response-up is poor)........................................................................ 40 -634
S-4 Engine stops during operation................................................................................................................ 40 -636
S-5 Engine does not rotate smoothly (hunting)............................................................................................. 40 -637
S-6 Engine lacks power (or output shortage)................................................................................................ 40 -638
S-7 Exhaust smoke is black (Incomplete combustion) ................................................................................. 40 -640
S-8 Oil is consumption is excessive(or exhaust smoke is blue) ................................................................... 40 -642
D375A-6 40-7
(01)
DRAFT
Contents
S-9 Engine oil becomes contaminated quickly ............................................................................................. 40 -643

S-10 Fuel consumption is excessive............................................................................................................. 40 -644
S-11 Oil mixes into coolant(coolant blows back or is reduced)..................................................................... 40 -645
S-12 Engine pressure monitor lights up (drop in engine oil pressure) .......................................................... 40 -646
S-13 Oil level rises (Coolant or fuel mixes into oil) ....................................................................................... 40 -647
S-14 Coolant temperature rises too high (overheating) ................................................................................ 40 -649
S-15 Abnormal noise is heard....................................................................................................................... 40 -650
S-16 Vibration is excessive........................................................................................................................... 40 -651
S-17 Air cannot be bled from fuel circuit (when air bleeding is performed after filter is replaced or fuel is used up
and then air is bled, engine does not start or it starts but stalls)................................................................... 40 -652
40-8 D375A-6
(01)
DRAFT
General Information on troubleshooting
Points to remember when troubleshooting

Points to remember when troubleshooting
k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are se-
curely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k 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.
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 the plug or cap from a location which is under pressure from oil, water, or air, al-
ways 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 pre-
ventreoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
standthe structure and function. However, a short cut to effective troubleshooting is to ask the operatorvarious
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 4) Check maintenance items can be checked
to disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
after any failure occurs: 4. Confirming failure
q Parts that have no connection with the failure Confirm the extent of the failure yourself, and
or other unnecessary parts will be disassem- judge whether to handle it as a real failure or as
bled. a problem with the method of operation, etc.
q It will become impossible to find the cause of a When operating the machine to reenact the
the failure. troubleshooting symptoms, do not carry out
It will also cause a waste of manhours, parts, or any investigation or measurement that may
oil or grease, and at the same time, will also lose make the problem worse.
the confidence of the user or operator.
For this reason, when carrying out trouble- 5. Troubleshooting
shooting, it is necessary to carry out thorough Use the results of the investigation and inspec-
prior investigation and to carry out trouble- tion in Items 2 – 4 to narrow down the causes of
shooting in accordance with the fixed procedure. failure, then use the troubleshooting table or
troubleshooting flowchart to locate the position
2. Points to ask the user or operator of the failure exactly.
1) Have any other problems occurred apart a The basic procedures for troubleshooting is
from the problem that has been reported? as follows.
2) Was there anything strange about the 1] Start from the simple points.
machine 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 informa-
problems with the machine condition before tion.
the failure?
4) Under what conditions did the failure occur? 6. Measures to remove root cause of failure
5) Had any repairs been carried out before the Even if the failure is repaired, if the root cause of
failure? When were these repairs carried the failure is not repaired, the same failure will
out? occur again.To prevent this, always investigate
6) Has the same kind of failure occurred why the problem occurred. Then, remove the
before? root cause.
3. Checks before troubleshooting

1) Is there any sign of irregularities of the
machine?
2) Make checks before starting day's work.
3) Make checks of other items.
D375A-6 40-9
(01)
DRAFT
Sequence of events in troubleshooting
Sequence of events in troubleshooting

(Rev. 2007. 12)
40-10 D375A-6
(01)
DRAFT
Checks before troubleshooting

No. Item Criterion Remedy
1 Check for abnormal sounds and smells ― Repair
2 Check for dirt around engine ― Remove
3 Check for water leakage around engine ― Repair
4 Check for oil leakage around engine ― Repair

a. Engine, lubricating oil and coolant
5 Check for leakage from fuel line ― Repair
6 Check of radiator for clogging ― Remove
7 Check of level and type of fuel ― Refilling with oil
8 Check for foreign matter in fuel ― Clean and drain
9 Check of fuel pre filter ― Replace
10 Check of fuel filter ― Replace
11 Check of level (in oil pan) and type of engine oil Between H – L Refilling with oil
12 Check of coolant level (in sub tank) Between H – L Refilling with coolant
No clogging
13 Check of air cleaner for clogging indication on Clean or replace
monitor
1 Check for abnormal sounds and smells ― Repair
2 Check for oil leakage ― Repair
3 Check of hydraulic oil Between H – L Refilling with oil

b. Hydraulic and mechanical equipment
4 Check of hydraulic oil strainer ― Clean and drain
5 Check of hydraulic oil filter ― Replace
6 Check of power train case oil level Between H – L Refilling with oil
7 Check of power train pump strainer ― Clean and drain
8 Check of transmission oil filter and torque converter oil filter ― Clean and drain
9 Check of damper case oil level Between H – L Refilling with oil
10 Check of final drive case oil level Between H – L Refilling with oil
11 Execution of air bleeding operation ― Air bleeding
D375A-6 40-11
(01)
DRAFT
No. Item Criterion Remedy
1 Check of battery terminals for looseness and corrosion ― Retighten or replace
2 Check of alternator terminals for looseness and corrosion ― Retighten or replace
3 Check of starting motor terminals for looseness and corrosion ― Retighten or replace
4 Testing of battery voltage (with engine stopped) 20–30 V Replace
5 Check of battery electrolyte level Between H – L Add or replace
Check of wiring harness for discoloration, burnt areas and cover peel-
6 ― Repair or replace
ing
Check for removal of wiring harness clamp and sagging of wiring har-
7 ― Repair
c. Electrical equipment
ness
8 Check of grounding ― Repair
9 Check for loose connector and damaged lock ― Repair or replace
10 Check of connector pin for corrosion, bends and deformation ― Repair or replace
11 Check for water and foreign matter in connector ― Dry, clean or replace
12 Check of wiring harness for disconnection and short circuit ― Repair or replace
13 Check of fuse for disconnection and corrosion ― Replace
14 Check of circuit breaker ― Push in reset button

After several
minutes opera-
15 Check of alternator voltage (When engine speed is medium or higher) Replace
tion: 27.5 –
29.5 V
Check of battery relay operation sound (When starting switch is
16 ― Replace
turned to ON or OFF position)
e. Interior parts d. Exterior parts
1 Check of undercarriage ― Repair
2 Check of handrails and steps ― Repair
3 Check of mirrors ― Clean or repair
1 Check of gauges and monitors ― Clean or replace
2 Check of seat belt ― Repair
40-12 D375A-6
(01)
DRAFT
Testing procedure before troubleshooting

Walk-around check
Before starting the engine, look around and under the machine to check for any loose nuts or bolts, leakage
of oil, fuel or coolant, and check the condition of the work equipment and hydraulic system.
Check the connectors for looseness, the wiring harnesses for play, and the hot parts for accumulated dust.
k Accumulated combustibles around hot engine parts such as the engine muffler, turbocharger, etc.
and leaking fuel and oil may cause a machine fire. Check thoroughly and repair any abnormalities
without fail.
a1., b1. Check for abnormal sounds and smells b3. Check of hydraulic equipment, hydraulic
Check for abnormal sounds and smells tank, hoses and joints for oil leakage
Some causes of abnormal sounds and smells Check and repair any oil leaks.
can damage the machine if they are left as they
are. Therefore, stop the machine immediately c1. Check around battery and dirt removal
when you discover the cause. Check and remove any accumulated dirt and
combustibles (dead leaves, twigs, etc.) around
a2. Check around engine and dirt removal the battery.
Check and remove any accumulated dirt around
the engine and any combustibles (dead leaves, d1. Check of undercarriage (track, sprocket,
twigs, etc.) on hot engine parts such as the en- idler and guard) for abnormalities, wear, loose
gine muffler, turbocharger, etc.. bolts and oil leakage from roller
Repair any abnormalities.
a3. Check for water leakage around engine
a4. Check for oil leakage around engine d2. Check of handrails and steps for abnormali-
Check any oil leaks from the engine and any wa- ties and loose bolts
ter leaks from the coolant system. If any of them Repair any abnormalities and retighten any
is abnormal, carry out a repair. loose bolts.
a5. Check for leakage from fuel line d3. Check and cleaning of rear view mirrors
Check any fuel leaks and damaged hoses and Check and repair any abnormalities and break-
tubes. If any of them is abnormal, carry out a re- age of the rear view mirrors.
pair. Clean the mirror surfaces and adjust their angles
so that the operator can see the area behind him
a6. Check of radiator and dirt removal from the operator's seat.
Check and remove any accumulated dirt and
combustibles (dead leaves, twigs, etc.) around e1. Check of gauges and monitors for abnormal-
the radiator. ities
For removal of dirt from the radiator, see the Op- Check the gauges and monitors inside the oper-
eration and maintenance manual, "Cleaning and ator cab. If any of them is abnormal, replace it.
testing of radiator fins, oil cooler fins, aftercooler Clean up the surfaces.
fins, fuel cooler fins and air conditioner condens-
er fins (machine with the air conditioner)". e2. Check of seat belt and fittings
Check any damaged hooks, locks and hook fit-
b2. Check of work equipment, cylinders, linkage tings. If any of them is abnormal, carry out a re-
and hoses for breakage, wear and clearance pair.
Check the work equipment, cylinders, linkage
and hoses for cracks and excessive wear, check
that the clearance between them is within the
normal range, and then repair any abnormalities.
D375A-6 40-13
(01)
DRAFT
Testing according to testing procedure a8. Check for foreign matter in fuel
a. Engine, lubricating oil and coolant 1. Open the cover on the rear side of the machine.
2. Put a container under drain hose (1) to receive
a7. Check of level and type of fuel the drained fuel.
k Fuel is flammable and dangerous. Do not 3. Turn drain valve (2) to the "OPEN" position (O)
bring any open flame near fuel.
k When adding fuel, take care not to let it over-
to discharge the sediment and water in the
bottom together with the fuel.
flow.
k Wipe off any spilt fuel. If fuel has spilt over
4. When only the clean fuel flows out, turn drain
valve (2) to the "CLOSE" position (S).
dirt and sand, remove the dirt and sand, too.
5. Close the cover.
1. Turn the starting switch to the ON position and
check the fuel level with fuel level gauge (G) in
the monitor panel.
After checking, return the switch to the OFF posi-
tion.
a9. Check for fuel pre-filter (water separator)

k Immediately after the engine is stopped, its
parts and oil will still be very hot may burn
your hands on contact. Therefore, wait until
they have cooled down before starting the
2. If the fuel level is low, open oil filler cap (F) of the work.
k High pressure is generated in the engine fuel
fuel tank and add fuel through the oil filler port to
the necessary level. piping system while the engine is running.
q If the filter of breather (1) is clogged, the pres-
Wait for at least 30 seconds after stopping
sure in the tank decreases and fuel may not the engine until the internal pressure de-
be supplied. To prevent this, clean the filter. creases, and then replace the filter.
k Do not bring any open flame near the filter.
a Komatsu genuine fuel prefilter cartridges use a
special filter with a high filtration efficiency.
When replacing, be sure to use a Komatsu gen-
uine cartridges.
a The common rail fuel injection system of this ma-

chine consists of parts that are more precise
compared with the conventional injection pump
and nozzle. If a fuel prefilter cartridge other than
Komatsu genuine one is used, foreign matter
may enter, which can cause a trouble in the in-
jection system. Never use a substitute.
a When testing and servicing the fuel system, be

extremely careful that no foreign matter enters. If
any dirt sticks, remove it completely by using fu-
el.
q Prepare an oil receiving container.
q Prepare the filter wrench.
40-14 D375A-6
(01)
DRAFT
1. Turn supply valve (1) of the fuel tank to the

"CLOSE" (S) position.
2. Open the engine hood.

3. Place the oil receiving container under prefilter
cartridge (2).
4. Remove transparent cup (3) from pre-filter
cartridge, and check it. If damaged, replace it
with a new one.
5. Using the filter wrench, rotate filter cartridge (2)
to the left to remove.
9. Clean the filter bracket and thinly apply oil to the

packing surface of the filter cartridge.
a Do not pour fuel into the filter cartridge.
10. Remove cap (A) at the center of the filter
cartridge and install the cartridge in the filter
bracket.
6. Clean transparent cup (3), and remove seal (4).

7. Coat seal with clean fuel or oil, and mount the
seal.
8. Mount transparent cup (3) in pre-filter cartridge.
3 Tightening torque of transparent cup (3):
10 Nm {1.0 kgm}
a Make sure that drain plug (5) at bottom of
transparent cup (3) is secured.
3 Tightening torque of drain plug (5): 11. Install the filter cartridge.
0.2 – 0.4 Nm {0.02 – 0.046 kgm} a When installing the filter cartridge, tighten it
by 3/4 turns after its O-ring has been securely
placed on the sealing surface of the filter
bracket.
a If the prefilter cartridge has been over tight-
ened, fuel will leak because the O-ring will
have been damaged. If the filter cartridge is
not tightened sufficiently, fuel will also leak
through the clearance of the packing. There-
fore, observe the tightening angle.
12. Then, proceed to "a10. Check of fuel filter".
D375A-6 40-15
(01)
DRAFT
a10. Check of fuel filter

work.
k High pressure is generated in the engine fuel
piping system while the engine is running.
Wait for at least 30 seconds after stopping
the engine until the internal pressure de-
creases, and then replace the filter.
k Do not bring any open flame near the filter.
a Komatsu genuine fuel filter cartridges use a spe-
cial filter with a high filtration efficiency. When re- 4. Place the oil receiving container under filter
placing, be sure to use a Komatsu genuine cartridge (3).
cartridges. 5. Using the filter wrench, rotate filter cartridge (3)
to the left to remove.
a The common rail fuel injection system of this ma-
chine consists of parts that are more precise
compared with the conventional injection pump
and nozzle. If a fuel filter cartridge other than Ko-
matsu genuine one is used, foreign matter may
enter, which can cause a trouble in the injection
system. Never use a substitute.
a When testing and servicing the fuel system, be

extremely careful that no foreign matter enters. If
any dirt sticks, remove it completely by using fu-
el.
q Prepare an oil receiving container.
q Prepare the filter wrench.
6. Clean the filter bracket and thinly apply oil to the
packing surface of the filter cartridge.
1. Turn supply valve (1) of the fuel tank to the a Do not pour fuel into the filter cartridge.
"CLOSE" (S) position. 7. Remove cap (A) at the center of the filter
cartridge and install the cartridge in the filter
bracket.
2. Open the engine hood.

3. Open air bleeding valve (2).
40-16 D375A-6
(01)
DRAFT
8. Install the filter cartridge.

a When installing the filter cartridge, tighten it
by 3/4 turns after its O-ring has been securely
placed on the sealing surface of the filter
bracket.
a If the filter cartridge has been over tightened,
fuel will leak because the O-ring will have
been damaged. If the filter cartridge is not
tightened sufficiently, fuel will also leak
through the clearance of the packing. There-
fore, observe the tightening angle.
9. Turn valve (1) at the fuel tank bottom to the
"OPEN" (O) position.
10. Bleed air. For details, see Testing and adjusting, 6. If the oil level is above H
"Bleeding air from fuel circuit". 1) Remove the cover from the machine bottom
11. Close air bleeding valve (2). and place a waste oil container directly below
it.
a11. Check of level (in oil pan) and type of en-
gine oil
work.
a If the engine has been operated, wait for at least
15 minutes after stopping it, and check the oil
level.
a When checking, set the machine in a horizontal
position.
1. Stop the engine.
2. Open the engine hood. 2) Remove drain plug (1).
3. Remove oil level gauge (G) and wipe gauge oil 3) Loosen drain valve (2) slowly so that the oil
off with a cloth. will not spurt over you, and drain the exces-
sive oil.
4. Insert oil level gauge (G) fully and pull it out.
a Take care not to deform the stopper pin in
drain valve (2) by overloosening it.
Tightening torque of drain plug (1):
68.6 ± 9.81 Nm {7 ± 1 kgm}
Tightening torque of drain valve (2):
63.7 ± 14.7 Nm {6.5 ± 1.5 kgm}
5. Check the oil level on the "ENGINE STOPPED"

stamp side of oil level gauge (G). If it is between
the stamps of H and L, it is at the correct level.
If the oil level is below L, add oil through oil filler
port (F).
4) Check the oil level again.
7. If the oil is at the correct level, tighten the oil filler
cap securely and close the engine hood.
D375A-6 40-17
(01)
DRAFT
a12. Check of coolant level (in sub tank)

k The radiator cap does not need to be opened
for the usual check.. Check the coolant level
on the sub tank side while the engine is cold.
k Immediately after the engine is stopped, the
coolant will be hot and pressure will have ac-
cumulated in the radiator. If the cap is
opened under these conditions, you may be
scalded. When the radiator cap needs to be
removed, wait until the temperature drops
and rotate the cap slowly to release the pres-
sure. Remove it fully, exercising care.
1. Open the door on the left side of the engine and
check that coolant level (5) of reservoir tank (2)
is between FULL and LOW.
2. If the reservoir tank is empty, coolant may be
leaking. After checking, repair any abnormalities
immediately. If there are no abnormalities, check
the coolant level in the radiator and add coolant
through coolant filler port (1) if necessary. At this
time, check that the coolant level is above the
bottom of strainer (4).
3. Add coolant to the reservoir tank up to the FULL
level through coolant filler port (6).
40-18 D375A-6
(01)
DRAFT
a13. Check of air cleaner for clogging Cleaning of outer element

k When using compressed air for cleaning, put a Do not leave or store the element in direct sun-
on personal protective items such as safety light before or after cleaning it.
glasses, cotton gloves, dust mask, etc. to a Replace the outer element after cleaning it 6
protect yourself from dirt that will fly out. times or after using it for 1 year. When replacing
k It is dangerous to use excessive force to pull the outer element, replace the inner element,
out the outer element from the air cleaner too.
body. When working in an elevated or unsta- a If dust indicator (1) enters the red zone just after
ble location, take care that you do not fall due the outer element is cleaned, replace both outer
to the momentum created when you pull out and inner elements, even if the outer element
the outer element. has not been cleaned 6 times.
1. Open the door on the left side of the engine and
Testing unlock 6 hooks (2). Remove cover (3).
If the internal yellow piston enters outer red zone (A)
of dust indicator (1), clean the air cleaner element.
After cleaning, press the reset button to reset.
2. Hold and pull out outer element (4) while

swinging it up, down and laterally and rotating
element to the right and left.
a Never remove inner element (5). If it is re-
moved, dirt will enter and can lead to engine
troubles.
a Do not use a screwdriver or another tool.
a After removing outer element (4), check that
the inner element has not come off or slant-
ed. If the inner element is slanting, push it in
straight with the hand.
3. After removing outer element (4), cover the inner
element (5) with a clean cloth or tape to prevent
dirt from sticking to it.
a Do not clean the element until the yellow piston
of dust indicator (1) enters outer red zone (A).
If the element is cleaned frequently before the
yellow piston of dust indicator (1) enters outer
red zone (A), the true performance of the air
cleaner will not be realized and the cleaning
effect will decrease.
a If the outer element is checked or cleaned while
the engine is running, the dirt sticking to it will fall
into the inner element side more frequently and
enter and damage the engine. Be sure to stop
the engine before cleaning.
D375A-6 40-19
(01)
DRAFT
4. Remove any dirt sticking to the inside of air 6. Next, blow air along the outside pleats, and blow
cleaner body (6) and cover (3) with a clean cloth, again along the inside pleats.
brush, etc.
a When cleaning the element, do not tap it or
bump it against other objects.
a After cleaning, light up the inside of the ele-

ment to check it. If the element has a small
hole or a thin component, replace it.
5. Blow dry compressed air (Max. 210 kPa {2

kg/cm2}) along the inside pleats of the outer 7. Remove the cloth or tape covering inner element
element. (6).
8. Check and remove any dirt, oil, etc. sticking to
the sealing surface of the cleaned or new
element.
a If the element or O-ring used for more than 1
year is cleaned and reused, it can cause a
trouble. Therefore, do not reuse it.
a Do not use the element if its pleats, gasket or
seal is damaged.
40-20 D375A-6
(01)
DRAFT
9. Push the outer element straight into the air

cleaner body while swinging it up, down and
laterally.
a Install the air cleaner elements so that their
bottoms (ends with no holes) (B) and (C) will
be on cover (3) side.
If the air cleaner element is installed in
reverse, it may be broken and the engine
may be damaged seriously.
10. Install cover (3) according to the following proce-

dure.
1) Set cover (3) to the element.
2) Hitch the ends of hooks (2) to the projection

of the air cleaner body to lock.
a Hitch hooks (2) diagonally (top, bottom,
right and left) to lock.
a After installing cover (3), check for clear-
ance between air cleaner body and cover
(3). If there is any clearance, remove and
install cover (3) correctly.
D375A-6 40-21
(01)
DRAFT
Replacement of element 4. Replace O-ring (7) of cover (3) with a new one.
1. Remove outer element (4). For details, see
"Cleaning of outer element".
2. Remove inner element (5) and install new inner
element (5) quickly to air cleaner body (6).
a Do not clean or reuse the inner element.
When replacing the outer element, replace
the inner element, too.
5. Install cover (3). For details, see "Cleaning of

outer element".
6. Replace the seal of cover (3) with a new one.
a Install the air cleaner element so that its bot-

tom (end with no hole) (B) will be on cover (3)
side.
a If the outer element and cover are installed
while the inner element is not installed se-
curely, the outer element may be broken.
Therefore, install the inner element securely.
3. Push the outer element straight into the air

cleaner body while swinging it up, down and
laterally.
a Install the air cleaner element so that its bot-
tom (end with no hole) (C) will be on cover (3)
side.
40-22 D375A-6
(01)
DRAFT
b. Hydraulic and mechanical equipment Since the oil level fluctuates according to the oil
temperature, note the following when checking
b3. Check of hydraulic oil level it.
k Immediately after the engine is stopped, its q Before operation (oil temperature: 10 - 30 °
parts and oil will still be very hot may burn C), the oil level should be at the center be-
your hands on contact. Therefore, wait until tween lines H and L.
they have cooled down before starting the q During operation (oil temperature: 50 - 80 °
work. C), the oil level should be near line H.
k If the oil filler cap is removed quickly, the oil
may spurt out. Therefore rotate the oil filler b4. Check of hydraulic oil strainer
cap slowly to release the internal pressure k Immediately after the engine is stopped, its
and remove it. parts and oil will still be very hot may burn
1. Lower the work equipment to the ground and your hands on contact. Therefore, wait until
stop the engine. Check the oil level and add new they have cooled down before starting the
oil if necessary. work.
2. Turn the starting switch to the ON position within k If the oil filler cap is removed quickly, the oil
15 seconds after stopping the engine and may spurt out. Therefore rotate the oil filler
operate each control lever (work equipment and cap slowly to release the internal pressure
travel) to the stroke end in each direction to and then remove it.
release the internal pressure. 1. Stop the engine and remove oil filler cap (F) of
3. Open the cover on the right side of the machine the hydraulic tank to release the internal pres-
and check sight gauge (G). If the oil level is sure.
between lines H and L, it is at the correct level. 2. Remove bolts (5) to remove cover (6).
a If the oil level is below line L, add oil through When removing the bolts, keep pressing down
oil filter port (F). on cover (6) since it may be flung toward you by
a Do not add oil to above line H. If too much is the internal spring.
added, it may damage the hydraulic circuit 3. Pull out the rod and remove the strainer.
and spurt out. 4. Remove dirt from the strainer and clean using
a If the oil level is above line H, stop the engine cleaning oil. If the strainer is broken, replace it
and wait until the hydraulic oil cools down. with a new one.
Then, loosen drain valve (1) at the hydraulic 5. Insert and set the strainer.
tank bottom to drain excessive oil through 6. While pressing down the spring with the projec-
drain plug (P) into a container. tion at the bottom of cover (1), install the bolts.
7. Tighten the mounting bolts.
D375A-6 40-23
(01)
DRAFT
b5. Check of hydraulic oil filter

work.
k If the oil filler cap is removed quickly, the oil
may spurt out. Therefore rotate the oil filler
cap slowly to release the internal pressure
and then remove it.
1. On a level and firm surface, lower the work
equipment to the ground and stop the engine.
2. Remove oil filler cap (F) of the hydraulic tank to
release the internal pressure. 7. Clean the inside of the case and the removed
parts, and install the new element.
8. Set cover (1) and install it with the mounting bolts
while pressing it with your hand.
9. Tighten the mounting bolts.
10. Install oil filler cap (F).
11. Run the engine at a low idling speed for 10
minutes to bleed air.
12. Stop the engine.
3. Prepare a container to receive the drained oil.

4. Remove drain plug (1) at the tank bottom and
loosen drain valve (2) to drain the oil.
a When loosening drain plug (1), take care that
the oil does not splash over you.
5. After draining the oil, tighten drain plug (1) and

drain valve (2).
6. Remove bolts (3), and then remove cover (4)
and pull out the element out.
a Check and remove dirt on the bottom of the
filter case. At this time, take extreme care
that dirt does not enter the hydraulic tank.
40-24 D375A-6
(01)
DRAFT
b6. Check of power train case oil level 6. If the oil level is above H, open the undercover
k Since the undercover is heavy, do not open and drain the oil according to the following
or close it from beneath. When removing procedure.
bolts (5), stand on the rear side just under the 1) Remove 2 bolts (4) on the front side of the
cover so that you can move away quickly in machine.
case of an emergency. 2) Gradually remove 2 bolts (5) on the rear side
q When checking, set the machine in a hori-
of the machine, while holding cover (3).
zontal position.
3) Since the front of cover (3) is equipped with
q While the engine is stopped, the oil level can-
the hinge pin, lower cover (3) gradually.
not be accurately checked since the oil level
increases. When checking while the engine
is running or after the engine is started, check
with the COLD side of gauge (G) in the idle
state.
1. Start the engine, set the fuel control dial to low
idle (MIN) position, and keep running the engine
at a low idling speed for 3 - 5 minutes.
q Perform the following procedure without
stopping the engine.
2. Remove oil level gauge (G) and wipe gauge oil
off with a cloth.
3. Insert oil level gauge (G) fully into the guide.
4. Pull out oil level gauge (G) and check the oil (F): Front of machine
level. If the oil level is between (H) and (L) on the
"COLD IDLE" stamp side of oil level gauge (G),
it is the correct level.
5. If the oil level is below (L) on the "COLD IDLE"
stamp side of oil level gauge (G), remove oil filter
cap (F) and add oil. When adding oil, remove oil
level gauge (G).
4) Remove hose (1) to change its position as

(A) and loosen drain valve (2) to drain exces-
sive oil.
q When draining the oil, put a container under
hose (1) to drain the oil into.
7. After checking the oil level and adding oil, install

oil level gauge (G) and oil filler cap (F).
D375A-6 40-25
(01)
DRAFT
b7. Check of power train pump strainer

1. Remove cover (1) at the rear of the left side
cover and cover (2) on the left fender.
2. Loosen bolts (3) to remove case (4).
7. Add oil through oil filler port (F) up to the speci-

fied level.
8. After adding oil, check the oil level, referring to
"Check of power train case oil level".
3. Remove strainer (5) and magnet (6).

q If strainer (5) and magnet (6) are broken, re-
place with a new ones.
4. Loosen bolt (7) to separate strainer (5) and
magnet (6).
5. Remove dirt from strainer (5) and clean in
cleaning diesel oil.
q Clean the inside of the case and plug, too.
6. Install strainer (5) again.
3 Tightening torque of bolt (7):
46 – 59 Nm {4.7 – 5.9 kgm}
40-26 D375A-6
(01)
DRAFT
b8. Check of transmission oil filter and torque 2. Remove bolts (1) of transmission oil filter (B) and
converter oil filter torque converter oil filter (C). Pull up cover (2)
k If pressure remains in the filter, oil may spurt and take out element (3).
out. To prevent this, depress the brake pedal 3. Clean the inside of the case and the removed
several times and lock it before opening the parts.
filter case. 4. Install cover (A) on the right fender.
1. Remove cover (A) on the right fender.
(B): Transmission oil filter
(C): Torque converter oil filter
D375A-6 40-27
(01)
DRAFT
b9. Check of damper case oil level b10. Check of final drive case oil level
q Check the oil level while the engine is stopped. k Since the oil may spurt out due to internal
q When checking, set the machine in a horizontal pressure, rotate the plug gradually from its
position. side to release the internal pressure and then
1. Pull out oil level gauge (G) and wipe off the oil remove it carefully.
with a cloth. 1. Park the machine on a level place.
2. Insert oil level gauge (G) again fully into the oil 2. Remove oil level plug (G) and check the oil level.
level gauge pipe and pull it out. If the oil level is near the plug hole bottom, it is at
the correct level.
3. If the oil level is between stamps H and L of oil

level gauge (G), it is at the correct level. If the oil 3. If the oil level is low, add power train oil through
level is below L, add oil through the oil level oil filler plug hole (F).
gauge holder. a Remove all dirt and sand around oil filler plug
(F) and take care that dirt and sand will not
enter the plug hole when adding oil.
4. If the oil level is above H, open the undercover,

referring to step 6. of b.6 "Check of power train
case oil level".
5. Prepare an oil pan, remove the drain plug to b11. Execution of air bleeding operation
drain excessive oil, and check the oil level again. q For the procedure for bleeding air from the fuel
system, see Testing and adjusting, "Bleeding air
from fuel circuit".
q For the procedure for bleeding air from the hy-
draulic equipment, see Testing and adjusting,
"Bleeding air from each part".
40-28 D375A-6
(01)
DRAFT
c. Electrical equipment c3. Check of starting motor terminals for loose-

ness and corrosion
c1. Check of battery terminals for looseness and Open the engine hood and check starting motor
corrosion (ST-L) terminals B and C for disconnection, loose-
Open cover (1) at the left front of the machine and ness and corrosion.
check the terminals of battery (A) for looseness and Check starting motor (ST-U) similarly, too.
corrosion.
c2. Check of alternator terminals for looseness c4. Testing of battery voltage (with engine
and corrosion stopped)
Open the engine hood and check alternator termi- Using the battery tester, test the battery voltage
nals B and R for disconnection, looseness and cor- while the engine is stopped.
rosion.
D375A-6 40-29
(01)
DRAFT
c5. Check of battery electrolyte level

Check before operating the machine.
k Do not use the battery while its electrolyte
level is below LOWER LEVEL. If it is used un-
der that condition, its inside will deteriorate,
its service life will be shortened and it may
lead to an explosion.
k Since the battery produces combustible gas
that can explode, do not bring any open
flame near it.
k Battery electrolyte is dangerous. Take care
that it does not come in contact with your
eyes or skin. If it does, wash it away with wa-
ter and contact your doctor. a If you have added refined water above the
a Do not add battery electrolyte to above the UP- U.L. line, take some of it out using a syringe
PER LEVEL mark. If too much is added, it can or similar tool. Neutralize the liquid that has
damage the painted surface and corrode the been taken out with sodium bicarbonate or
parts. other suitable liquid, and wash it out with a
a As refined water (Example: Commercially avail- large amount of water.
able battery fluid) added to the battery may q When electrolyte level cannot be checked from
freeze, add it before starting work for the day so the side of the battery
that it will not freeze. 1. Remove cap (2) on the top of the battery.
q When checking the electrolyte level from the (Described previously)
side of the battery 2. Look into electrolyte level opening (3) to check
1. Clean around the electrolyte level lines with a the electrolyte level. If the electrolyte level is
cloth dampened with water and check that the below sleeve (4), be sure to add refined water
electrolyte level is between UPPER LEVEL (Example: Commercially available battery fluid)
(U.L.) and LOWER LEVEL (L.L.) up to the sleeve bottom (U.L. line).
a Do not clean the battery with a dry cloth since q (A) Correct level: Since the electrolyte level is
static electricity may cause an explosion. higher than the sleeve bottom, the shape of
the electrode plates will appear distorted due
to the surface tension.
q (B) Low: Since the electrolyte level is below
the sleeve bottom, the shape of the electrode
plates will appear straight.
3. After adding the refined water, tighten cap (2).
2. If the electrolyte level is below the center

between the U.L. and L.L. lines, remove cap (2)
and add refined water (Example: Commercially
available battery fluid) to the U.L. line immedi-
ately.
3. After adding the refined water, tighten the cap
securely. a If you have added refined water above the
U.L. line, take some of it out using a syringe
or similar tool. Neutralize the liquid that has
been taken out with sodium bicarbonate or
other suitable liquid, and wash it out with a
large amount of water.
40-30 D375A-6
(01)
DRAFT
c6. Check of wiring harness for discoloration, c9. Check for loose connectors and damaged
burnt areas and cover peeling locks
q Check the wiring harness and cables for discol- q Pull the male and female parts of the connector
oration and burn. by the hand to check the condition of their con-
a Discoloration and burnt areas indicate the possi- nection.
bility of a short circuit or a circuit ground fault. q If the connecting condition is abnormal, connect
q Check the wiring harnesses and cables for dam- it securely.
age and peeling of the covers.
q If any fault are discovered, repair or replace the
wiring harness or cable.
c7. Check for removal of wiring harness clamps

and sagging of the wiring harness
q Check the wiring harnesses for sagging and play
caused by removal of a clamp.
a In particular, carefully check around the hot and
movable parts.
q If any part is off the clamp, resecure it with
clamp.
q Check the connector to see whether it is un-

locked and check its lock portion and housing for
cracks.
q Check lock screws (L) of controller (CNT) for
looseness.
a Use a 4-mm hexagonal wrench.
c8. Check of grounding

a Check the ground terminal for looseness and
rusting in particular.
q Check the connection of ground strap (1) of en-
gine controller (EC).
q Open the cover at the front of the fuel tank on the

left side of the machine and check the connec-
tion of the floor ground strap.
D375A-6 40-31
(01)
DRAFT
c10. Check of connector pin for corrosion, q Remove foreign matter in the connector using a
bends and deformation cloth or other material, and blow compressed air
q Disconnect the connector and check the pins for against the inside of the connector.
corrosion, bending and retraction. Check that
the female pins have not expanded.
q If any pin is found to be abnormal, repair or re-
place it.
a If the pins are not shiny, apply contact restorer to
them and connect and disconnect several times
to shine them. (If the pins do not become shiny,
connect and disconnect the connector 10 times)
c11. Check for water and foreign matter in the

connector
q Disconnect the connector and check whether
there is water, dirt, sand, etc. in it.
a If there is sand or foreign matter in the connec-

tor, check the seal for damage.
q If the seal is defective, repair or replace it.
q Dry the moisture in the connector using a drier.
40-32 D375A-6
(01)
DRAFT
c12. Check of wiring harness for disconnection Open inspection cover (A), and fuse boxes (1) - (3)
and short circuiting are seen.
q Check the connections (crimped parts) between
each connector pin and wiring harness.
q If any wire is disconnected as illustrated in (A),
repair or replace the wiring harness or connec-
tor.
q Check whether any pins are touching any adja-

cent pins due to peeling of the wire cover, defec-
tive crimping of the pin, etc.
c13. Check of fuse for disconnection and corro-

sion
a When replacing a fuse, be sure to turn off the Fuse box (4) is at the overhead section.
power (turn the starting switch to the OFF posi-
tion).
q The fuse holders are installed to the left front
lower part of operator's seat and to the overhead
section.
q If a fuse is corroded and coated with white pow-
der, or there is any play between the fuse and
fuse holder, replace the fuse.
q Replace each fuse with another of the same ca-
pacity.
D375A-6 40-33
(01)
DRAFT
c14. Check of circuit breaker q Check of circuit breaker of main power supply
k Do not keep pressing the reset button of the 1. Turn the starting switch to the OFF position.
circuit breaker. (Doing so can cause a fire.) 2. Open the inspection cover at the front of the fuel
q The circuit breaker breaks the electrical circuit to tank on the left side of the machine. Check circuit
protect the electrical equipment and wiring when breakers (A) - (E).
an overcurrent flows through it. It can be used re-
peatedly.
q Check of circuit breaker in each circuit

If the circuit breaker is turned ON, reset button
(1) comes out.
q Check all the circuit breakers to see whether any
of reset buttons (1) have come out.
q To return the broken electrical circuit to normal
condition, push in reset button (1) that has come
out.
a If reset button (1) comes out again soon after it
is pushed in and the starting switch is turned to
the ON position, the overcurrent is still flowing. 3. Push reset buttons (A) - (E) of the circuit
Check the electrical circuit in this case. breakers in order.
a If the electrical circuit is broken, the operating ef-
fort of the reset button is heavier compared with
the case when the circuit is operating normal.
a The height of the reset button does not change
when the circuit is broken or normal.
40-34 D375A-6
(01)
DRAFT
c15. Check of alternator voltage (when engine c16. Check of battery relay operation sound
speed is medium or higher) 1. Open the battery cover.
1. Open the engine hood. 2. Check whether the battery relay operation sound
2. Connect the positive (+) line of the tester to alter- is heard when the starting switch is turned to the
nator terminal (B) and connect the negative (-) ON/OFF position.
line to the chassis ground. q If the operation sound is not heard, check the
3. Start and warm up the engine and measure the related circuits, referring to E-1 in the E
voltage while running the engine at a medium or mode.
a higher speed. q If the related circuits are free from abnormal-
q If the voltage is abnormal, repair or replace ities, replace the battery relay.
the alternator.
D375A-6 40-35
(01)
DRAFT
Classification and procedures for troubleshooting
Classification of troubleshooting
Mode Contents
Display of code Troubleshooting by failure code
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine
Procedure for troubleshooting

If a phenomenon which appears a source of a trouble occurs on the machine, select a proper troubleshooting
No. according to the following procedure, and then go to the corresponding troubleshooting section.
1. Procedure for troubleshooting when user code and failure code are displayed on machine
monitor:
If a user code and a failure code are displayed on the machine monitor, perform the troubleshooting for
the corresponding "Display of code".
a If multiple failure codes are displayed simultaneously, all the codes are displayed repeatedly in order.
Note down all the codes.
2. Procedure for troubleshooting when a user code and a failure code are not displayed on machine
monitor:
Check a mechanical system failure code and an electrical system failure code with the abnormality record
function of the machine monitor. (See [*1].)
1) If a failure code is displayed, perform troubleshooting for the corresponding "Display of code"
according to the failure code.
a If an electrical system failure code is dispayed after having noted down all the codes, delete all the
codes and reproduce them, and then see if the trouble is still detected. (See [*2].)
a A failure code of the mechanical system cannot be deleted.
2) If no failure code is found in the abnormality record, a trouble that the machine cannot find out by itself
may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon which is assumed to show a trouble again and select the same
phenomenon from the list on the next page, and then perform troubleshooting corresponding to that
phenomenon in the "E-mode", "H-mode", or "S-mode".
3. Action to take after trouble is eliminated

Referring to the next page, clear all the failure codes in the electrical system abnormality record.
40-36 D375A-6
(01)
DRAFT
[*1], [*2] 4. Press [F6] switch ( ) on the panel switch to

1. While pressing numerical key [4] on the panel confirm and go to "Mechanical system" screen.
switch at the normal screen, press [1], [2] and [3]
in order.
5. Press the [F3] switch (R) on the panel switch to

see if the next failure code is displayed and note
down all the failure codes.
a A mechanical system failure code cannot be
cleared.
6. Press [F5] switch (Return) on the panel switch to
return to the "Abnormality record" screen.
7. Enter the "Electrical system abnormality record"
similarly to steps 2 and 3.
8. Press the [F3] switch (R) on the panel switch to
see if the next failure code is displayed and note
down all of the failure codes.
a "E" on the left of a failure code indicates that
the failure code is "active" (the failure re-
mains or restoration to normal has not been
checked). A failure code having no "E" on its
2. On the service menu screen, press [F3] switch left is a "non-active" one. Since it disappears
(R) on the panel switch once to select "02 at the following clear step, be sure to note it
Abnormality Record". down.
3. Press [F6] switch ( ) on the panel switch to 9. While pressing numerical key [4] on the panel
confirm and go to "Abnormality Record" screen. switch, press [1], [2] and [3] in this order to enter
the "Clear mode". (Same as 1)
10. Press [F2] switch(CLEAR) on the panel switch.
11. Press [F6] switch ( ) on the panel switch to clear
all the failure codes temporarily.
return to the "Electrical system abnormality
record" screen. See if any failure code is still
displayed and note down displayed ones.
D375A-6 40-37
(01)
DRAFT

return to the "Abnormality record" screen.
40-38 D375A-6
(01)
DRAFT
Failure codes table
Failure codes table

Failure Component Reference
Trouble (Displayed on screen) Action code Category of record
code in charge document page
1380MW Lock up clutch:Slip P/T – Electrical system 40-109
1500L0 Transmission clutch:Abnormal P/T E03 Electrical system 40-110
15E0MW Transmission clutch:Slip P/T – Electrical system 40-111
15SAL1 Forward clutch:Fill high P/T E03 Electrical system 40-112
15SALH Forward clutch:Fill Low P/T E03 Electrical system 40-114
15SBL1 Reverse clutch:Fill high P/T E03 Electrical system 40-116
15SBLH Reverse clutch:Fill Low P/T E03 Electrical system 40-118
15SEL1 Speed 1st clutch:Fill high P/T E03 Electrical system 40-120
15SELH Speed 1st clutch:Fill Low P/T E03 Electrical system 40-122
15SFL1 Speed 2nd clutch:Fill high P/T E03 Electrical system 40-124
15SFLH Speed 2nd clutch:Fill Low P/T E03 Electrical system 40-126
15SGL1 Speed 3rd clutch:Fill high P/T E03 Electrical system 40-128
15SGLH Speed 3rd clutch:Fill Low P/T E03 Electrical system 40-130
15SJL1 L/U :Fill high P/T E02 Electrical system 40-132
15SJLH L/U :Fill low P/T E02 Electrical system 40-134
1800MW P/T clutch:Slip P/T E02 Electrical system 40-136
2201L1 Right clutch:Fill high P/T E04 Electrical system 40-138
2201LH Right clutch:Fill low P/T E04 Electrical system 40-140
2202L1 Left clutch:Fill high P/T E04 Electrical system 40-142
2202LH Left clutch:Fill low P/T E04 Electrical system 40-144
2300NR Brake Themal Load Abnormality P/T – Mechanical system 40-146
2301L1 Right brake:Fill high P/T E04 Electrical system 40-148
2301LH Right brake:Fill low P/T E04 Electrical system 40-150
Steering Brake RH Themal Load Abnor-
2301NR P/T – Mechanical system 40-152
mality
2302L1 Left brake:Fill high P/T E04 Electrical system 40-154
2302LH Left brake:Fill low P/T E04 Electrical system 40-156
Steering Brake LH Themal Load Abnor-
2302NR P/T – Mechanical system 40-158
mality
7RFAKA ECM ACC CUT RELAY:Disconnection W/E – Electrical system 40-160
7RFAKB ECM ACC CUT RELAY:Short circuit W/E – Electrical system 40-162
AA10NX Air Cleaner Clogging MON – Mechanical system 40-164
AB00MA Battery Charge Abnormal MON – Mechanical system 40-166
B@BAZG Eng Oil Press Low ENG – Mechanical system 40-166
B@BAZK Eng oil level low MON – Mechanical system 40-167
B@BCNS Eng Water Overheat ENG – Mechanical system 40-168
B@BCZK Eng water level low MON – Mechanical system 40-169
B@CENS T/C Oil Overheat P/T – Mechanical system 40-170
B@HANS Hyd Oil Overheat P/T – Mechanical system 40-171
B@HAZK Hyd Oil Level Low W/E – Mechanical system 40-172
CA111 ECM Critical Internal Failure ENG E03 Electrical system 40-174
CA115 Eng Ne and Bkup Speed Sens Error ENG E03 Electrical system 40-176
CA122 Chg Air Press Sensor High Error ENG E03 Electrical system 40-178
CA123 Chg Air Press Sensor Low Error ENG E03 Electrical system 40-180
CA131 Throttle Sensor High Error ENG E03 Electrical system 40-182
CA132 Throttle Sensor Low Error ENG E03 Electrical system 40-184
CA135 Eng Oil Press Sensor High Error ENG E02 Electrical system 40-186
CA141 Eng Oil Press Sensor Low Error ENG E01 Electrical system 40-188
CA144 Coolant Temp Sens High Error ENG E01 Electrical system 40-190
CA145 Coolant Temp Sens Low Error ENG E01 Electrical system 40-192
CA153 Chg Air Temp Sensor High Error ENG E01 Electrical system 40-194
D375A-6 40-39
(01)
DRAFT
Failure codes table

CA154 Chg Air Temp Sensor Low Error ENG E01 Electrical system 40-196
CA187 Sens Supply 2 Volt Low Error ENG E01 Electrical system 40-198
CA212 Eng Oil Temp Sensor Low Error ENG E01 Electrical system 40-200
CA213 Eng Oil Temp Sensor Low Error ENG E01 Electrical system 40-202
CA221 Ambient Press Sens High Error ENG E01 Electrical system 40-204
CA222 Ambient Press Sens Low Error ENG E01 Electrical system 40-206
CA227 Sens Supply 2 Volt High Error ENG E03 Electrical system 40-208
CA234 Eng Overspeed ENG E02 Electrical system 40-209
CA238 Ne Speed Sens Supply Volt Error ENG E03 Electrical system 40-210
CA263 Fuel Temp Sensor High Error ENG E01 Electrical system 40-212
CA265 Fuel Temp Sensor Low Erro ENG E01 Electrical system 40-214
CA271 IMV/PCV1 Short Error ENG E03 Electrical system 40-216
CA272 IMV/PCV1 Open Error ENG E03 Electrical system 40-217
CA273 PCV2 Short Error ENG E03 Electrical system 40-218
CA274 PCV2 Open Error ENG E03 Electrical system 40-219
CA322 Inj #1(L#1) Open/Short Error ENG E03 Electrical system 40-220
CA342 Calibration Code Incompatibility ENG E03 Electrical system 40-232
CA351 Injectors Drive Circuit Error ENG E03 Electrical system 40-233
CA352 Sens Supply 1 Volt Low Error ENG E03 Electrical system 40-234
CA386 Sens Supply 1 Volt High Error ENG E03 Electrical system 40-236
CA441 Battery Voltage Low Error ENG E03 Electrical system 40-237
CA442 Battery Voltage High Error ENG E03 Electrical system 40-238
CA449 Rail Press Very High Error ENG E03 Electrical system 40-239
CA451 Rail Press Sensor High Error ENG E03 Electrical system 40-240
CA452 Rail Press Sensor Low Error ENG E03 Electrical system 40-242
CA453 Rail Press High Error ENG E03 Electrical system 40-244
CA554 Rail Press Sensor In Range Error ENG E03 Electrical system 40-245
CA559 Rail Press Low Error ENG E03 Electrical system 40-246
CA689 Eng Ne Speed Sensor Error ENG E03 Electrical system 40-250
CA731 Eng Bkup Speed Sens Phase Error ENG E03 Electrical system 40-252
CA757 All Continuous Data Lost Error ENG E04 Electrical system 40-253
CA778 Eng Bkup Speed Sensor Error ENG E03 Electrical system 40-254
CA1228 EGR Valve Servo Error 1 ENG E03 Electrical system 40-256
CA1625 EGR Valve Servo Error 2 ENG E03 Electrical system 40-257
CA1633 KOMNET Datalink Timeout Error ENG E03 Electrical system 40-258
CA2185 Throt Sens Sup Volt High Error ENG E03 Electrical system 40-259
CA2186 Throt Sens Sup Volt Low Error ENG E03 Electrical system 40-260
CA2249 Rail Press Very Low Error ENG E03 Electrical system 40-261
CA2271 EGR Valve Pos Sens High Error ENG E03 Electrical system 40-262
CA2272 EGR Valve Pos Sens Low Error ENG E03 Electrical system 40-264
CA2351 EGR Valve Sol Current High Error ENG E03 Electrical system 40-266
CA2352 EGR Valve Sol Current Low Error ENG E03 Electrical system 40-268
D110KB Battery Relay:Drive Short Circuit W/E – Electrical system 40-270
D130KA Neutral relay:Disconnection P/T E02 Electrical system 40-272
D130KB Neutral relay:Short circuit P/T E02 Electrical system 40-274
D161KA Back-up alarm releay:Disconnection P/T E01 Electrical system 40-276
D161KB Back-up alarm releay:Short circuit P/T E01 Electrical system 40-278
40-40 D375A-6
(01)
DRAFT
Failure codes table

D182KZ Preheater Relay Abnormality P/T E01 Electrical system 40-280
D190KA ACC signal relay:Disconnection W/E – Electrical system 40-282
D190KB ACC signal relay:Short circuit W/E – Electrical system 40-284
D1EFKA Pre lub. motor relay:Disconnection P/T E02 Electrical system 40-286
D1EFKB Pre lub. motor relay:Short circuit P/T E02 Electrical system 40-288
DAFRKR Monitor:Can communication lost(PT) P/T E03 Electrical system 40-290
dAFRKR Monitor:Can communication lost(WE) W/E E03 Electrical system 40-291
DAFRMC CAN Discon (Monitor Detected) MON E03 Electrical system 40-292
DB2RKR ENG cont.:Can communication lost(PT) P/T E03 Electrical system 40-297
ENG controller:Can communication
dB2RKR W/E E03 Electrical system 40-300
lost(WE)
DB90KT WE controller:Abnormality in controller W/E E01 Electrical system 40-301
DB91KK WE controller:Source voltage reduction W/E E04 Electrical system 40-302
DB92KK WE controller:Output voltage reduction W/E E04 Electrical system 40-304
DB97KK WE cont.:Sensor voltage 5V (2) reduction W/E – Electrical system 40-306
DB99KQ WE controller:Type select signal W/E E04 Electrical system 40-308
WE controller:CAN communication error
DB9RKR P/T E03 Electrical system 40-309
(PT)
VHMS controller:Source voltage reduc-
DBB0KK VHMS – Electrical system 40-312
tion
VHMS Connector Connection Abnormal-
DBB0KQ VHMS – Electrical system 40-314
ity
VHMS controller:Source voltage reduc-
DBB3KK VHMS – Electrical system 40-316
tion
DBB5KP VHMS:Output sensor1 voltage reduction VHMS – Electrical system 40-318
PT controller:CAN communication lost
DBBQKR VHMS – Electrical system 40-323
(VHMS)
DBE0KT PT controller:Abnormality in controller P/T E01 Electrical system 40-323
DBE1KK PT controller:Source voltage reduction P/T E04 Electrical system 40-324
DBE2KK PT controller:Output voltage reduction P/T E04 Electrical system 40-326
DBE5KK PT cont.:Sensor voltage5V (1) reduction P/T E03 Electrical system 40-328
DBE6KK PT cont.:Sensor voltage 24V reduction P/T E03 Electrical system 40-330
DBE7KK PT cont.:Sensor voltage 5V (2) reduction P/T E01 Electrical system 40-332
DBE9KQ PT controller:Type select signal P/T E04 Electrical system 40-334
PT controller: CAN communication lost
DBERKR W/E E03 Electrical system 40-335
(WE)
DD12KA Shift up Sw:Disconnection P/T E02 Electrical system 40-338
DD12KB Shift up Sw:Short circuit P/T E02 Electrical system 40-340
DD13KA Shift down Sw:Disconnection P/T E02 Electrical system 40-342
DD13KB Shift down Sw:Short circuit P/T E02 Electrical system 40-344
DD14KA Parking lever Sw:Dissconnection P/T E03 Electrical system 40-346
DD14KB Parking lever Sw:Short circuit P/T E03 Electrical system 40-348
DDB9L4 Reverse SW Signal disagreement P/T E03 Electrical system 40-350
DDE2KA Pre lub. oil press sw:Disconnection P/T E02 Electrical system 40-352
DDK3L4 Forward SW Signal disagreement P/T E03 Electrical system 40-354
DDK5KA Shift switch disconnection P/T E02 Electrical system 40-356
DDK5KB Shift switch short circuit P/T E02 Electrical system 40-358
DDN2LD Blade tilt RH pressure SW abnormality W/E – Electrical system 40-360
DDN3LD Blade tilt LH pressure SW abnormality W/E – Electrical system 40-362
DDN7KA WEQ Knob Sw(down):Disconnection W/E E02 Electrical system 40-364
DDN7KB WEQ Knob Sw(down):Short circuit W/E E02 Electrical system 40-366
DDN9KA WEQ Knob Sw(up):Disconnection W/E E01 Electrical system 40-368
DDN9KB WEQ Knob Sw(up):Short circuit W/E E01 Electrical system 40-370
D375A-6 40-41
(01)
DRAFT
Failure codes table

DDNALD Blade lift up pressure SW abnormality W/E – Electrical system 40-372
DDNBLD Ripper lift up pressure SW abnormality W/E – Electrical system 40-374
DDNCLD Ripper lift down pressure SW abnormality W/E – Electrical system 40-376
DDNDLD Ripper tilt in pressure SW abnormality W/E – Electrical system 40-378
DDNELD Ripper tilt back pressure SW abnormality W/E – Electrical system 40-380
DDNFLD Blade lift down pressure SW abnormality W/E – Electrical system 40-382
DDNLKA Weq lock Sw:Disconnection W/E E03 Electrical system 40-384
DDNLKB Weq lock Sw:Short circuit W/E E03 Electrical system 40-386
DDT5KA Neutral switch disconnection P/T E04 Electrical system 40-388
DDT5KB Neutral switch short circuit P/T E04 Electrical system 40-390
Lever SPEC selection signal disagree-
DDT5KQ P/T E04 Electrical system 40-392
ment
DDTSL1 S/C :Fill high P/T E02 Electrical system 40-394
DDTSLH S/C :Fill low P/T E02 Electrical system 40-396
DGE5KX Ambient temp sensor abnormality VHMS – Electrical system 40-398
DGS1KX Hyd oil temp:signal abnormal P/T E01 Electrical system 40-400
DGT1KA T/C oil temp sensor:Abnormal W/E E01 Electrical system 40-402
DGT1KX T/C oil temp sensor:Abnormal W/E E01 Electrical system 40-404
DGT5KA F exhaust temp sensor disconnection VHMS – Electrical system 40-406
DGT5KB F exhaust temp sensor short circuit VHMS – Electrical system 40-408
DGT6KA R exhaust temp sensor disconnection VHMS – Electrical system 40-410
DGT6KB R exhaust temp sensor short circuit VHMS – Electrical system 40-412
DH21KA Weq pressure sensor:Disconnection W/E E01 Electrical system 40-414
DH21KB Weq pressure sensor:Short circuit W/E E01 Electrical system 40-416
ENG blow-by pressure sensor disconnec-
DHE5KB VHMS – Electrical system 40-418
tion
ENG blow-by pressure sensor short cir-
DHE5KY VHMS – Electrical system 40-420
cuit
DHT3KX T/M oil pressure sensor abnormality VHMS – Electrical system 40-422
DHT5KA T/C in-pressure sensor:Disconnection P/T E02 Electrical system 40-424
DHT5KB T/C in-pressure sensor:Short circuit P/T E02 Electrical system 40-426
DHT7KA T/C out-pressure sensor:Disconnection P/T E02 Electrical system 40-428
DHT7KB T/C out-pressure sensor:Short circuit P/T E02 Electrical system 40-430
DK10KA Fuel control Dial:Disconnection P/T E03 Electrical system 40-432
DK10KB Fuel control Dial:Short circuit P/T E03 Electrical system 40-434
DK30KA ST lever1:Disconnection P/T E03 Electrical system 40-436
DK30KB ST lever1:Short circuit P/T E03 Electrical system 40-438
DK30KX ST lever:Out of normal range P/T E04 Electrical system 40-440
DK30KZ ST lever:Disconnection or short circuit P/T E04 Electrical system 40-440
DK30L8 ST lever:Signal mismatch P/T E03 Electrical system 40-441
DK31KA ST lever2:Disconnection P/T E03 Electrical system 40-442
DK31KB ST lever2:Short circuit P/T E03 Electrical system 40-444
DK40KA Brake potentiometer:Disconnection P/T E03 Electrical system 40-446
DK40KB Brake potentiometer:Short circuit P/T E03 Electrical system 40-448
DK55KX FR lever:Out of normal range P/T E04 Electrical system 40-450
DK55KZ FR lever:Disconnection or short circuit P/T E04 Electrical system 40-450
DK55L8 FR lever:Signal mismatch P/T E03 Electrical system 40-451
DK56KA FR lever1:Disconnection P/T E03 Electrical system 40-452
DK56KB FR lever1:Short circuit P/T E03 Electrical system 40-454
DK57KA FR lever2:Disconnection P/T E03 Electrical system 40-456
DK57KB FR lever2:Short circuit P/T E03 Electrical system 40-458
DK60KA Acceleration sensor:Disconnection P/T E01 Electrical system 40-460
DK60KB Acceleration sensor:Short circuit P/T E01 Electrical system 40-462
40-42 D375A-6
(01)
DRAFT
Failure codes table

DKH1KA Pitch angle sensor:Disconnection P/T E03 Electrical system 40-464
DKH1KB Pitch angle sensor:Short circuit P/T E03 Electrical system 40-466
DLF1KA T/C out-speed sensor:Disconnection P/T – Electrical system 40-468
DLM3KA Fan rev. sensor:Disconnection W/E E02 Electrical system 40-469
DLM3MB Fan control:Decline W/E E02 Electrical system 40-470
DLT3KA T/M out-speed sensor:Disconnection P/T E01 Electrical system 40-471
DLT3KB T/M out-speed sensor:Abnormal P/T E01 Electrical system 40-472
DW59KA Blade dual selector SOL disconnection W/E E01 Electrical system 40-473
DW59KB Blade dual selector SOL short circuit W/E E01 Electrical system 40-474
DW59KY Blade dual selector SOL short circuit W/E E01 Electrical system 40-475
DW5AKA Blade pitch selector SOL disconnection W/E E02 Electrical system 40-476
DW5AKB Blade pitch selector SOL short circuit W/E E02 Electrical system 40-477
DW5AKY Blade pitch selector SOL Short circuit W/E E02 Electrical system 40-478
DW7BKA Fan rev EPC:Disconnection W/E E01 Electrical system 40-479
DW7BKB Fan rev EPC:Short circuit W/E E01 Electrical system 40-480
DWN3KA Ssp solenoid:Disconnection P/T E04 Electrical system 40-481
DWN3KB Ssp solenoid:Short circuit P/T E04 Electrical system 40-482
DWN3KY SSP solenoid:Short circuit P/T E04 Electrical system 40-484
DWN5KA Fan pump solenoid 1:Disconnection W/E E01 Electrical system 40-486
DWN5KB Fan pump solenoid 1:Short circuit W/E E01 Electrical system 40-487
DWN5KY Fan pump solenoid 1:Short circuit W/E E02 Electrical system 40-488
DWNCKA Fan pump solenoid 2:Disconnection W/E E01 Electrical system 40-490
DWNCKB Fan pump solenoid 2:Short circuit W/E E01 Electrical system 40-491
DWNCKY Fan pump solenoid 2:Short circuit W/E E02 Electrical system 40-492
DXH1KA Lock-up ECMV:Disconnection P/T E02 Electrical system 40-494
DXH1KB Lock-up ECMV:Short circuit P/T E02 Electrical system 40-495
DXH1KY Lock-up ECMV:Short circuit P/T E03 Electrical system 40-496
DXH4KA 1st clutch ECMV:Disconnection P/T E03 Electrical system 40-498
DXH4KB 1st clutch ECMV:Short circuit P/T E03 Electrical system 40-499
DXH4KY 1st clutch ECMV:Short circuit P/T E03 Electrical system 40-500
DXH5KA 2nd clutch ECMV:Disconnection P/T E03 Electrical system 40-502
DXH5KB 2nd clutch ECMV:Short circuit P/T E03 Electrical system 40-503
DXH5KY 2nd clutch ECMV:Short circuit P/T E03 Electrical system 40-504
DXH6KA 3rd clutch ECMV:Disconnection P/T E03 Electrical system 40-506
DXH6KB 3rd clutch ECMV:Short circuit P/T E03 Electrical system 40-507
DXH6KY 3rd clutch ECMV:Short circuit P/T E03 Electrical system 40-508
DXH7KA R clutch ECMV:Disconnection P/T E03 Electrical system 40-510
DXH7KB R clutch ECMV:Short circuit P/T E03 Electrical system 40-511
DXH7KY R clutch ECMV:Short circuit P/T E04 Electrical system 40-512
DXH8KA F clutch ECMV:Disconnection P/T E03 Electrical system 40-514
DXH8KB F clutch ECMV:Short circuit P/T E03 Electrical system 40-515
DXH8KY F clutch ECMV:Short circuit P/T E04 Electrical system 40-516
DXH9KA Right clutch ECMV:Disconnection P/T E03 Electrical system 40-518
DXH9KB Right clutch ECMV:Short circuit P/T E03 Electrical system 40-519
DXH9KY Right clutch ECMV:Short circuit P/T E04 Electrical system 40-520
DXHAKA Left clutch ECMV:Disconnection P/T E03 Electrical system 40-522
DXHAKB Left clutch ECMV:Short circuit P/T E03 Electrical system 40-523
DXHAKY Left clutch ECMV:Short circuit P/T E04 Electrical system 40-524
DXHBKA Right brake ECMV:Disconnection P/T E04 Electrical system 40-526
DXHBKB Right brake ECMV:Short circuit P/T E04 Electrical system 40-527
DXHBKY Right brake ECMV:Short circuit P/T E04 Electrical system 40-528
DXHCKA Left brake ECMV:Disconnection P/T E04 Electrical system 40-530
D375A-6 40-43
(01)
DRAFT
Failure codes table

DXHCKB Left brake ECMV:Short circuit P/T E04 Electrical system 40-531
DXHCKY Left brake ECMV:Short circuit P/T E04 Electrical system 40-532
DXJBKA S/C ECMV:Disconnection P/T E02 Electrical system 40-534
DXJBKB S/C ECMV:Short circuit P/T E02 Electrical system 40-535
DXJBKY S/C ECMV:Short circuit P/T E02 Electrical system 40-536
DY2HKA Pre lub. motor:Disconnection P/T E02 Electrical system 40-538
F@BBZL ENG blow-by pressure high level VHMS – Mechanical system 40-540
F@BYNR F exhaust temp high level (2) VHMS – Mechanical system 40-541
F@BYNS F exhaust temp high level (1) VHMS – Mechanical system 40-542
F@BZNR R exhaust temp high level (2) VHMS – Mechanical system 40-543
F@BZNS R exhaust temp high level (1) VHMS – Mechanical system 40-544
a The items in this table are arranged in the order of the failure codes.
a A component in charge is a controller or the machine monitor in charge of the system check.
MON : Monitor panel
ENG : Engine controller
P/T : Power train controller
W/E : Work equipment controller
VHMS : VHMS controller
a The failure codes having no numbers in the action code column are not displayed on the ordinary screen
when abnormality related to them occurs. They are simply recorded in the fault history of the service menu
(Electrical equipment system or mechanical equipment system).
a The history classification column shows in which system each failure is classified, the electrical equipment
system or mechanical equipment system, when it is recorded in the failure history.
Since the failure codes of VHMS are special to the VHMS specification and saved only in the VHMS
controller, however, they are not recorded in the fault history
The 4-letter codes in [ ] among the VHMS codes are the failure codes displayed on the 7-segment LED of
the VHMS controller (They are divided into 2 2-letter codes).
a Blinking and lighting of failure code
q Blinking:The trouble has not been repaired.
q Lighting:The trouble has been repaired.
40-44 D375A-6
(01)
DRAFT
Phenomena and troubleshooting numbers

Phenomena looking like troubles and troubleshooting Nos.
Troubleshooting
No. Phenomena supposed to show troubles Reference document
Index
page
Action code and failure code
The action code and failure code are displayed on the machine moni-
1
tor.
When abnormality record is checked, failure code is shown in
2 Take actions by following the failure code.
mechanical system abnormality record
When abnormality record is checked, failure code is shown in electri-
3
cal system abnormality record
Troubleshooting
Index
page
Phenomena related to engine
4 Starting performance is poor S-1 40-628
40-547, 40-630,
5 Engine does not start E-1, S-2, -17
40-652
6 Engine does not pick up smoothly S-3 40-634
7 Engine stops during operations S-4 40-636
8 Engine does not rotate smoothly (such as hunting) S-5 40-637
9 Engine lack output (or lacks power) S-6 40-638
10 Exhaust smoke is black (incomplete combustion) S-7 40-640
11 Oil consumption is excessive (or exhaust smoke is blue) S-8 40-642
12 Oil contaminates quickly S-9 40-643
13 Fuel consumption is excessive S-10 40-644
14 Oil is in coolant (or coolant spurts back or coolant level goes down) S-11 40-645
15 Oil pressure drops S-12 40-646
16 Oil level rises (Entry of coolant/fuel) S-13 40-648
17 Coolant temperature becomes too high (overheating) S-14 40-649
18 Abnormal noise is heard S-15 40-650
19 Vibration is excessive S-16 40-651
20 The preheater does not operate. E-2 40-550
21 Electric priming pump does not operate or does not stop automatically. E-28 40-596
Phenomena related to power train
22 Power is low (Insufficient drawbar pull) H-1 40-604
23 The machine does not travel (at 2nd or 3rd) H-2 40-606
24 The machine does not start at all gear speeds H-3 40-607
25 The machine can travel in forward or reverse only H-4 40-608
26 Large time lag at gear speed shifting or forward-reverse shifting H-5 40-609
27 Steering does not turn H-6 40-610
28 Steering turns only in one direction (left or right) H-7 40-611
29 The machine oversteered H-8 40-612
30 Brake does not work. H-9 40-612
31 Torque converter lockup is not turned on H-10 40-613
32 The torque converter oil temperature is heated abnormally high H-11 40-614
Phenomena related to work equipment
33 All work equipment operates slowly or lacks power. H-12 40-615
34 All work equipment does not operate. H-13 40-616
35 Blade lift is slow to raise, or lifting force is not enough H-14 40-617
36 Blade tilt is slow to raise, or tilting force is not enough H-15 40-617
37 Ripper lift is slow to raise, or lifting force is not enough H-16 40-618
38 Ripper tilt is slow to raise, or tilting force is not enough H-17 40-618
39 Excessive hydraulic drift of blade lift. H-18 40-619
40 Excessive hydraulic drift of blade tilt. H-19 40-619
41 Excessive hydraulic drift of ripper lift. H-20 40-620
42 The ripper pin puller cylinder does not work. E-21, H-21 40-570, 40-620
43 The blade pitch does not work. H-22 40-621
44 Abnormal noise is heard from around the work equipment pump H-23 40-621
Fan speed is abnormal (such as excessive noise or vibration of fan, or
45 H-24 40-622
overheating)
D375A-6 40-45
(01)
DRAFT
Troubleshooting
Index
page
Phenomena related to machine monitor
46 When starting switch turned ON, machine monitor displays nothing E-3 40-554
When starting switch is turned to ON position (with engine stopped),
47 E-4 40-556
basic check item (radiator coolant level) lamp lights.
48 Precaution lights up while engine is running E-5 40-558
49 Emergency stop item lights up while engine is running E-6 40-560
50 Engine coolant temperature gauge does not indicate normally E-7 40-561
51 Fuel gauge does not operate normally E-8 40-562
Power train oil temperature gauge (multi-gauge) does not indicate nor-
52 E-9 40-564
mally
Hydraulic oil temperature gauge (multi-gauge) does not operate nor-
53 E-10 40-565
mally
Contents of display by machine monitor are different from applicable
54 E-11 40-566
machine
55 Machine monitor does not display some items E-12 40-566
56 Function switch does not work E-13 40-566
57 Operation mode does not change E-14 40-567
58 Gear shift mode does not change E-15 40-567
59 Customize function does not operate normally E-16 40-568
60 Customize memory function does not operate normally E-17 40-568
61 Alarm buzzer cannot be stopped E-18 40-569
62 When starting switch is turned OFF, service meter is not displayed. E-19 40-569
63 Machine monitor cannot be set in service mode E-20 40-569
64 Horn does not sound or stop sounding. E-22 40-572
65 Backup alarm does not sound or does not stop from sounding E-23 40-574
66 Fan does not rotate in reverse. E-24 40-576
67 Headlamp, back-up lamp, and/or ripper point lamp does not light E-25 40-577
68 Windshield wiper does not operate. E-26 40-584
69 Window washer does not operate. E-27 40-590
The ORBCOMM terminal does not operate normally (Data are not
70 E-29 40-598
transmitted).
71 Gear cannot be shifted E-30 40-600
40-46 D375A-6
(01)
DRAFT
Information in troubleshooting table

a Troubleshooting Table and Circuit Diagram Related collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.
User code Failure code
Description of problem that appears on machine monitor as: abnor-
Display on Display on Trouble
mality record
machine monitor machine monitor
Failure descrip-
Description of the failure detected by the machine monitor or controller
tion
Action of con- Action taken by machine monitor or controller to protect system or devices when machine monitor or
troller controller detects failure
Indication of
Problem that appears on machine as result of action taken by machine monitor or controller (shown
problem on
above)
machine
Related informa-
Information related to detected failure or troubleshooting
tion
Cause Procedure, measuring location, standard (value) and remarks
<Information described>
q Procedure
q Measuring location
Probable causes a "Between A - B" means "Measure voltage or resistance and so on between
A and B".
q Standard value in normal condition to evalute assumed cause if it is good con-
dition or not.
q Remarks required to evaluate the cause is correct
<How to use the troubleshooting sheet>
1 - Defective q Perform troubleshoot in following procedure in numerical order.
q If the testing result shows abnormality, the cause described on the left column
conforms.
q If it shows normal, and unless otherwise specified particularly, proceed to the
next step (cause).
Disconnection in wiring har-
q Check that the failure is fixed after a failure was found and repaired.
ness
2 <Phenomenon of defective wiring harness>
(Disconnection or defective
q Disconnection in wiring
contact in connector)
The connector connection is defective or the wiring harness is disconnected.
q Ground fault
A harness not connected to ground (earth) circuit contacts the ground (earth) or
machine.
Ground fault of wiring harness q Hot short circuit
3
(Contact with ground circuit) A harness not connected to the power (24 V) circuit contacts the power (24 V)
circuit.
q Short circuit
An independent wire in the harness abnormally contacts another wire.
(Poor insulation at connector and others)
Hot short <Notes on troubleshooting>
4
(Short circuit with 24 V circuit) (1) How to indicate connector number and handle T-branch
For troubleshooting, insert or connect T-branch adapter as follows unless espe-
cially specified.
q When "male" or "female" is not indicated with a connector number, discon-
nect the connector, and insert T-branch adapter in both male and female.
q When "male" or "female" is indicated with a connector number, disconnect
5 Short circuit in wiring harness
the connector, and connect T-branch adapter only to either male or femae
end.
(2) Description sequence of pin number and handling of tester lead
Connect positive (+) lead and negative (-) lead of tester as explained below for
troubleshooting, unless otherwise specified.
qConnect positive (+) lead to pin No. or wiring harness entered on front side.
6 Defective controller
q Connect the minus (-) lead to a pin or harness indicated in the rear.
D375A-6 40-47
(01)
DRAFT
Related circuit diagram
This drawing is a part of the circuit diagram related to trou-

bleshooting.
q Connector No.: Indicates (Model - Number of pins) and
(Color).
q "Connector No. and pin No." from each branching/merg-
ing point: Shows the ends of branch or source of merging
within the parts of the same wiring harness.
q Arrow (io): Roughly shows the location on the ma-
chine.
q NO: Normally Open
q NC: Normally Closed
40-48 D375A-6
(01)
DRAFT
Troubleshooting method for disconnecting wiring harness of pressure sensor system
Troubleshooting method for disconnecting wiring harness of pressure

sensor system
a Since pressure sensor consists not only of resistors but also electronic circuits such as amplifiers, it may
have the deferences among the registances measured and its own polarities. So troubleshoting must be
performed carefully.
Failure codes applicable to this diagnosis

q CA123: Charge air pressure sensor low error
q CA222: Ambient pressure sensor low error
Procedure
1. Measure and record resistance of pressure sensor unit.
1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor.
2) Measure resistances R1 and R2 between pins.
a If tester probes polarities to apply are reversed, measured values may change. Therefore, when
measuring resistances, apply the same tester probe polarities to the pressure sensor in steps 1 and
2.
a If measured value is infinite, take measurements with tester probes polarities exchanged each oth-
er and record the finite value obtained as a measured value.
a Since measured values may be diferent from each other, take several measurements. Cause of the
diferences appears to be that the sensor may be charged by the tester. Take several measurement
in both steps 1 and 2. Take the fact into consideration this diferences when determining whether
the wiring harness is disconnected in step 3.
2. Measure and record resistance with wiring harness between pressure sensor and engine controller
connected
1) Since 5 V power supply to pressure sensor is supplied to other sensors, disconnect the other sensor
connectors first.(*)
2) Connect the pressure sensor to be measured, disconnect connector (3) on engine controller side, and
connect T-adapter (4) to wiring harness side.
3) Connect T-box (5) to T-adapter (4) and measure respective pins for resistances R1' and R2'.
3. Judging disconnection
If there is an "apparent difference" between resistances R1 and R2 measured in step 1 and resistances
R1' and R2' measured in step 2, "wiring harness is disconnected".
D375A-6 40-49
(01)
DRAFT
a "Apparent difference" means a difference of 10 or more times.
List of pressure sensor measuring locations and reference values

Internal resistance of measured
Sensor pin measuring
Sensor sensor Remarks
location
(Reference value)
Charge pressure R2: Between (1) and (3) Approx. 2.9kΩ Sensor is common to engine mod-
sensor R1: Between (2) and (3) Approx. 4.3kΩ els 125, 170 and 12V140
Sensor is common to engine mod-
R2: Between (1) and (3) Approx. 3.2kΩ
els 95, 125, 170 and 12V140
Ambient pressure R1: Between (2) (+) and
Approx. 4.6kΩ
sensor (1) (-) If polarities are reversed, resis-
R1: Between (1) (+) and tance value changes.
Approx. 2.9kΩ
(2) (-)
*: When measuring R2', disconnect the following connectors.(See circuit diagram related to each code)
q When measuring R2' of charge pressure sensor
(CA123)
Connectors of resistance RES, engine oil pressure sensor, ambient pressure sensor, G sensor, EGR lift
sensor and bypass valve lift sensor
q When measuring R2' of ambient pressure sen-
sor (CA222)
Connectors of charge pressure sensor, resistance RES, engine oil pressure sensor, G sensor, EGR lift
sensor and bypass valve lift sensor
40-50 D375A-6
(01)
DRAFT
Measurement record (For measuring locations, see circuit diagram related to each code)
Sensor + Wiring harness
Sensor unit (Measuring
(Measuring location on
Sensor location on sensor pin Measured value Measured value
wiring harness side of
side)
engine controller)
R1: Between (1) (+) and
R2: Between (1) and (3)
Charge pressure (2) (-)
sensor R1': Between (44) and
(47)
R2': Between (37) and
(38) (*)
Ambient pressure R1: Between (2) (+) and R1': Between (3) (+)
sensor (1) (-) and (38) (-)
R1: Between (1) (+) and R1': Between (38) (+)
(2) (-) and (3) (-)
D375A-6 40-51
(01)
DRAFT
Connection table for connector pin numbers

(Rev. 2009. 04)
a The terms of male and female refer to the pins, while the terms of male housing and female housing refer
to the mating portion of the housing.
40-52 D375A-6
(01)
DRAFT
D375A-6 40-53
(01)
DRAFT
40-54 D375A-6
(01)
DRAFT
D375A-6 40-55
(01)
DRAFT
40-56 D375A-6
(01)
DRAFT
D375A-6 40-57
(01)
DRAFT
40-58 D375A-6
(01)
DRAFT
D375A-6 40-59
(01)
DRAFT
40-60 D375A-6
(01)
DRAFT
D375A-6 40-61
(01)
DRAFT
40-62 D375A-6
(01)
DRAFT
D375A-6 40-63
(01)
DRAFT
40-64 D375A-6
(01)
DRAFT
D375A-6 40-65
(01)
DRAFT
40-66 D375A-6
(01)
DRAFT
D375A-6 40-67
(01)
DRAFT
40-68 D375A-6
(01)
DRAFT
D375A-6 40-69
(01)
DRAFT
40-70 D375A-6
(01)
DRAFT
D375A-6 40-71
(01)
DRAFT
40-72 D375A-6
(01)
DRAFT
D375A-6 40-73
(01)
DRAFT
40-74 D375A-6
(01)
DRAFT
D375A-6 40-75
(01)
DRAFT
40-76 D375A-6
(01)
DRAFT
D375A-6 40-77
(01)
DRAFT
40-78 D375A-6
(01)
DRAFT
D375A-6 40-79
(01)
DRAFT
40-80 D375A-6
(01)
DRAFT
D375A-6 40-81
(01)
DRAFT
40-82 D375A-6
(01)
DRAFT
D375A-6 40-83
(01)
DRAFT
40-84 D375A-6
(01)
DRAFT
D375A-6 40-85
(01)
DRAFT
40-86 D375A-6
(01)
DRAFT
D375A-6 40-87
(01)
DRAFT
Connectors table and arrangement drawing
Connec- Connector Number Connec- Connector Number

Location Address Location Address
tor No. type of pins tor No. type of pins
Intermediate Additional
19 DT 4 F-1 ADH1 Relay 5 power supply W-7
connector
Intermediate 1 relay
20 DTHD 1 X-8 Additional
connector
ADH2 Relay 5 power supply W-7
Intermediate
21 DTHD 1 X-8 2 relay
connector
Intermediate
Intermediate ADHA DT 4 U-4
241 DT 6 B-7 connector
connector Air cleaner
Intermediate AF1 DT 2 clogging C-1
241 DT 6 -
connector switch
Starting switch Alternator B
250 Terminal 1 N-2 AL/B Terminal 1 AG-1
B terminal terminal
Starting switch Alternator R
255 Terminal 1 N-1 AL/R Terminal 1 AG-1
R1 terminal terminal
Starting switch Air suspension
256 Terminal 1 N-1 ASUS DT 2 U-6
R2 terminal seat (optional)
Starting switch
260 Terminal 1 N-1 AT11 - 1 GPS antenna -
BR
Starting switch Circuit breaker
270 Terminal 1 N-2 B105L Terminal 1 L-5
ACC terminal (105A)
Starting Circuit breaker
280 Terminal 1 switchC termi- N-2 B105S Terminal 1 L-4
(105A)
nal Circuit breaker
Power train oil B30L Terminal 1 K-5
(30A)
453 DT 2 temperature AB-3
sensor Circuit breaker
B30S Terminal 1 K-4
Standby elec- (30A)
800 Plug 1 tric power sup- U-8 Circuit breaker
B7L Terminal 1 K-5
ply (30A)
Standby elec- Circuit breaker
810 Plug 1 tric power sup- X-9 B7S Terminal 1 J-4
(30A)
ply Circuit breaker
BH1L Terminal 1 K-5
12S1 YAZAKI 2 12 V socket 1 U-5 (105A)
Circuit breaker
BH2S Terminal 1 K-4
12S2 YAZAKI 2 12 V socket 2 U-5 (105A)
Backup alarm
Intermediate BKA Relay 5 U-7
12VS DT 3 X-9 relay
connector
Air condi- BKAL DT 2 Backup alarm J-8
AC1 MIC 17 N-4
tioner unit Blade lift lower
Air condi- BLD DT 2 oil pressure P-9
AC2 AMP 16 tioner control N-5 switch
panel Blade lift raise
Air condi- BLU DT 2 oil pressure P-9
AC3 AMP 12 tioner control N-5 switch
panel
Diode BP DT 2 Bypass valve AF-2
ACS DT 2 AH-1
(surge-killer)
ACC cutout BRB Terminal 1 Battery relay 1 J-2
ACT Relay 5 V-6
relay
Additional BRB Terminal 1 Battery relay 2 L-3
ADH SWP 6 heater switch O-6
(optional) BRC Terminal 1 Battery relay 1 K-3
40-88 D375A-6
(01)
DRAFT

12 V power
BRC Terminal 1 Battery relay 2 L-3 CN-12V - 3 -
supply
CN-12V 12 V power
BRE Terminal 1 Battery relay 1 J-1 - 3 X-9
S supply
Right wiper
BRE Terminal 1 Battery relay 2 L-1 CN-13 - 6 A-9
switch
Brake potenti- Rear wiper
BRK DT 3 Q-1 CN-14 - 6 A-9
ometer switch
Intermediate Rear lamp
connector CN-15 - 2 switch B-9
BSW DT 3 (one-way type - (optional)
model) Right door
CN-17 - 4 E-9
(optional) wiper motor
Circuit breaker Left door wiper
CB1 - 1 W-6 CN-18 - 4 F-9
(20A) motor
Circuit breaker Washer sys-
CB105 - 1 L-4 CN-19 - 4 F-1
(105A) tem harness
Circuit breaker
CB2 - 1 W-5 CN2 DT 2 Injector #2 AF-4
(20A)
Circuit breaker Rear speaker
CB3 - 1 W-5 CN-2 - 1 C-9
(20A) (right)
Circuit breaker ACC power
CB30 - 1 K-4 CN-20 - 1 X-8
(30A) supply
Circuit breaker Battery power
CB4 - 1 W-5 CN-21 - 1 X-8
(20A) supply
Circuit breaker Cigarette
CB40 - 1 (40A) - CN-22 - 2 lighter power I-9
(optional) port
Circuit breaker Front lamp
CB5 - 1 W-5
(20A) CN-23 - 2 switch B-9
Circuit breaker (optional)
CB6 - 1 W-5
(20A) Rotary lamp (If
CN-25 - 2 B-9
Circuit breaker equipped)
CB7 - 1 J-4 Revolving
(30A)
Circuit breaker warning lamp
CBH1 - 1 K-5 CN-26 - 2 B-9
(105A) switch
(optional)
Machine moni-
CM01 070 18 N-6
tor CN3 DT 2 Injector #3 AG-5
Machine moni-
CM02 070 12 N-5 Rear speaker
tor CN-3 - 1 C-9
(right)
Machine moni-
CM03 070 18 - Heated wire
tor CN-34 - 4 -
glass relay
Machine moni-
CM04 070 12 -
tor CN4 DT 2 Injector #4 AH-5
Machine moni-
CM05 MITSUMI 8 - Rear window
tor CN-4 - 4 C-9
wiper motor
CN1 DT 2 Injector #1 AF-4
CN5 DT 2 Injector #5 AI-5
Additional light
CN-1 - 1 B-9 Rear speaker
(optional) CN-5 - 1 C-8
(left)
CN-10 - 9 Radio G-9
CN6 DT 2 Injector #6 AI-5
Left wiper
CN-11 - 6 A-9 Rear speaker
switch CN-6 - 1 C-8
(left)
Front wiper
CN-12 - 6 A-9
switch
D375A-6 40-89
(01)
DRAFT

Heated wire Intermediate
CN-6_1 - 1 glass relay - E22 DT-A 12 AJ-2
connector
(EU model) Electric prim-
Heated wire EFP DT 2 AI-1
ing pump
CN-6_2 - 1 glass relay -
Intermediate
(EU model) EG1 DTP04-2P 2 AJ-3
connector
CN-81 - 2 Room lamp E-9 Intermediate
EG2 DT-B 12 AJ-3
connector
Front wiper
CN-9 - 6 D-8 Intermediate
motor EG3 DT 4 AJ-3
connector
Headlamp
CN-AL1 - 2 - Intermediate
(left) EG4 DT-A 12 C-7
connector
Headlamp
(right) EG5 DT 4 C-8
connector
Headlamp (left
rear) EG6 DT 6 C-7
connector
Headlamp
CN-AL4 - 2 - DRC26-50S Engine con-
(right rear) EGC2 50 AJ-3
04 troller
Back-up lamp
CN-AL5 - 2 - Engine con-
(left) EGC3 DTP06-4S 4 AJ-2
troller
Back-up lamp
CN-AL6 - 2 -
(right) EGR DT 2 EGR valve AF-3
CN-SM1 - 5 - Engine hold-
EHL Relay 5 W-7
ing relay
CONV DT 6 Converter S-1 Blow-by pres-
ENBP DT 3 AI-1
sure sensor
CAN terminat-
CT2 DT 3 AJ-2 Engine con-
ing resistor ENG DRC-60 60 AJ-2
troller
CAN terminat-
CTV DT 3 W-2
ing resistor EPP DT 6 (Spare) C-1
Deceleration
DEC DT 3 Q-1 Intermediate
potentiometer
ES2 DT 2 connector E-9
Fuel control (male)
DIAL H 3 S-8
dial
Service con-
VHMS down- ESD DT 3 T-2
DL1 BENDIX 5 K-9 nector
load connector Exhaust gas
Download temperature
DLSW Terminal 4 K-8 EXAF DT 3 X-3
switch sensor, front
VHMS down- amp
DLT DT 2 K-9 Exhaust gas
load light
Emergency temperature
EXAR DT 3 V-3
evacuation sensor, rear
DPNL - 2 AC-1 amp
system circuit
(C/B model) Exhaust gas
Intermediate EXHF DT 2 temperature AF-9
DS1 DT-B 12 N-4 sensor (front)
connector
Exhaust gas
Intermediate
DS2 DT-C 12 N-3 EXHR DT 2 temperature AE-8
connector
sensor (rear)
Intermediate Exhaust gas
DS3 DT-A 12 N-4
connector temperature
EXTF DT 2 X-3
Intermediate sensor, front
DS4 DT-D 12 N-3
connector amp
Intermediate Exhaust gas
DS5 DT-B 12 N-3 temperature
connector EXTR DT 2 V-2
Alternator E sensor, rear
E Terminal 1 AG-1 amp
terminal
40-90 D375A-6
(01)
DRAFT

1st clutch Fan reverse
F1T DT 2 ECMV (fill Z-9 FRV DT 2 A-3
sensor
switch) Fuse box
2nd clutch FS11 - 5 V-9
(inlet)
F2T DT 2 ECMV (fill Y-8
Fuse box (out-
switch) FS12 - 5 V-9
3rd clutch let)
F3T DT 2 ECMV (fill Y-8 Fuse box
FS21 - 5 V-9
switch) (inlet)
Intermediate Fuse box (out-
FS22 - 5 V-9
F40 DTHD 1 connector - let)
(optional) Fuse box
Fan pump FS31 - 5 W-9
(inlet)
FA1 DT 2 (LPV90) sole- Y-5
Fuse box (out-
noid valve FS32 - 5 W-9
let)
Fan pump
FA2 DT 2 (LPV30) sole- AA-7 Intermediate
FSB 24-31 31 M-8
noid valve connector
Fan reverse Torque con-
FAR2 DT 2 A-3 verter stator
solenoid valve
FSTC DT 2 clutch left Y-5
Intermediate
FD1 24-31 31 J-5 ECMV (fill
connector
switch)
Intermediate Intermediate
FD1 24-31 31 -
connector FTS - 3 connector R-1
Intermediate (optional)
FD2 DT-A 12 K-7
connector Engine Bkup
Intermediate G DT 3 speed (G) AJ-4
FD5 DT-B 12 T-2 sensor
connector
Air condi- GND - 1 Ground E-1
FEN DT 2 tioner com- AH-1
pressor
GND01 - 1 Ground N-7
Forward clutch
FFT DT 2 ECMV (fill AA-9
switch) GND02 - 1 Ground N-7
Fuel level
FGS DT 2 K-6 GND03 - 1 Ground N-7
gauge
Left steering
Ground
FLB DT 2 brake ECMV AD-5 GND05 Terminal 1 H-2
(fender)
(fill switch)
Left steering GND06 Terminal 1 Ground (floor) S-1
FLC DT 2 clutch ECMV AB-8
(fill switch)
GND07 Terminal 1 Ground A-5
Front lamp
FLSW SWP 6 O-7
switch
GND0A Terminal 1 Ground (lamp) A-6
Torque con-
verter lockup Ground
FLUC DT 2 clutch right Y-4 GND0B Terminal 1 H-2
(fender)
ECMV (fill
switch) GND1 Terminal 1 Ground (cab) B-8
Right steering
FRB DT 2 brake ECMV AD-6 Ground
GND11 Terminal 1 AJ-2
(fill switch) (engine)
Right steering GND2 Terminal 1 Ground (cab) B-8
FRC DT 2 clutch ECMV AB-7
(fill switch) Additional
H01 - 1 R-8
Reverse heater PW1
FRT DT 2 clutch ECMV Z-9 Additional
(fill switch) H02 - 1 R-8
heater PW2
FR lever
FRTS Terminal 6 -
(optional)
D375A-6 40-91
(01)
DRAFT

Hydraulic oil Right head-
HDT DT 2 temperature AA-7 lamp (addi-
sensor tional
LHDR1 DT 2 -
Hydraulic oil headlamp
HHP DT 3 pump pres- D-8 model)
sure sensor (optional)
Intermediate Diode
HLS DT 2 connector E-9 LMD1 DT 2 O-1
(surge-killer)
(female) Diode
Hydraulic oil LMD2 DT 2 O-1
(surge-killer)
HLS DT 2 level sensor C-2
(optional) Left headlamp
LMFL Relay 5 U-8
relay
HNSW DT 2 Horn switch Q-8 Right head-
LMFR Relay 5 V-6
lamp relay
HRN - Horn A-3 Back-up lamp
LMRE Relay 5 W-6
relay
Preheater
HT Terminal 1 C-8 Working lamp
relay LMW Relay 5 X-8
relay
Preheater
HT/A Terminal 1 E-1 Left back-up
relay LREL DT 2 K-6
lamp (70W)
Preheater
HT/B Terminal 1 E-1 Right back-up
relay LRER DT 2 F-9
lamp (70W)
Diode
HTD DT 2 I-3 Ripper point
(surge-killer)
LRP DT 2 lamp (70W) -
Intermediate (optional)
INJ DT 12 AJ-5
connector
Intermediate
Intake temper- LRR DT 3 H-9
INT DT 2 B-2 connector
ature sensor
Left working
Service con- LWKL DT 2 F-1
lamp (70W)
J1939 DT 3 nector AG-5
(engine) Right working
LWKR DT 2 A-6
lamp (70W)
Junction con-
JB1 - 8 AF-4 Air condi-
nector
tioner control-
Junction con- M26 DT 6 P-1
JB2 - 11 AG-5 ler (cab
nector model)
JM01 - Junction box - Intermediate
connector
MMS DT-C 12 W-4
(MMS device
KEY DT 6 Starting switch N-6
(optional))
Communica- FRAMA- Engine Ne
KOM1 DRC-40A 40 P-7 NE 3 AJ-3
tion terminal TONE speed sensor
Neutral safety
KOM2 - 1 GPS antenna Q-8 NSF Relay 5 X-8
relay
Communica- Parking brake
NSW DT 3 T-2
KOM3 - 1 tion terminal Q-8 lever switch
antenna Intermediate
OBC DT-A 12 R-8
Intermediate connector
LHD DT 4 A-3
connector Engine oil
OLV DT 2 level switch AI-1
LHDL DT 2 Left headlamp A-2
(optional)
Left headlamp Option switch
OPSW SWP 6 O-6
(additional (optional)
LHDL1 DT 2 headlamp - Engine com-
model) partment lamp
OPT Relay 5 W-7
(optional) relay
Right head- (optional)
LHDR DT 2 A-5
lamp Intermediate
P03 DT 6 P-7
connector
40-92 D375A-6
(01)
DRAFT

Ambient pres- Pre-lubrica-
PAMB AMP 3 AJ-3 PR1 Terminal 1 tion relay -
sure sensor
Supply pump (optional)
PCV1 SUMITOMO 2 AJ-4 Pre-lubrica-
#1
PR2 Terminal 1 tion relay -
Supply pump
PCV2 SUMITOMO 2 AJ-4 (optional)
#2 Pre-lubrica-
Common rail PR3 Terminal 1 tion relay -
PFUEL AMP 3 pressure sen- AH-5 (optional)
sor Pre-lubrica-
Preheater PR4 Terminal 1 tion relay -
PHR Relay 5 X-7
relay (optional)
Boost pres- Pre-lubrica-
PIM SUMITOMO 3 AJ-4 PRE DT 2 D-8
sure sensor tion connector
Intermediate Intermediate
PL1 24-23 23 AD-6 PRT1 DT-A 12 M-2
connector connector
Emergency Intermediate
evacuation PRT2 DT 4 D-1
PL1F 24-23 23 AD-1 connector
system circuit Intermediate
(C/B model) PRT3 DT 2 M-2
connector
Emergency
evacuation Pitch angle
PL1M 24-23 23 AD-1 PT1 DT 3 D-1
system circuit sensor
(C/B model) Power train
PTCN1 DRC26-24A 24 U-6
Intermediate controller
PL2 24-31 31 AD-7
connector Power train
PTCN2 DRC26-40A 40 U-6
Emergency controller
evacuation Power train
PL2 24-31 31 AD-1 PTCN3 DRC26-40B 40 T-7
system circuit controller
(C/B model) Intermediate
Intermediate PWR DTHD 1 U-3
PL3 24-31 31 A-6 connector
connector Intermediate
Intermediate RB1 DT 6 D-8
connector
connector
PLB DT 2 C-1 Intermediate
(pre-lubrica- RDG DT-B 12 A-5
connector
tion system)
Diode RES DT 2 Resistor AI-1
PLS DT 2 I-3
(surge-killer)
Pin puller Rear lamp
PLSW DT 2 Q-8 RLSW SWP 6 O-7
switch switch
Ripper lower
Pre-lubrica-
PLUB Relay 5 U-7 RPD DT 2 oil pressure O-8
tion relay
switch
Pre-lubrica- Emergency
PM1 Terminal 1 tion motor - evacuation
(optional) RPNL - 2 AD-3
system circuit
Emergency
(C/B model)
evacuation Ripper raise
PNL 24-31 31 AB-3
system circuit RPU DT 2 oil pressure P-8
(C/B model) switch
Engine oil
FRAMA- Diode (BR
POIL 3 pressure sen- AI-1 RSD DT 2 J-4
TONE hold (backup))
sor
Pre-lubrica- Ripper tilt back
tion oil pres- RTB DT 2 oil pressure P-8
POP Terminal 1 - switch
sure switch
Ripper tilt in oil
(optional)
RTI DT 2 pressure P-8
Pin puller
PPL DT 2 I-9 switch
solenoid valve
Intermediate
RTS - 3 connector R-1
(optional)
D375A-6 40-93
(01)
DRAFT

1st clutch Acceleration
S1T DT 2 ECMV (sole- Y-9 sensor (dedi-
SSA DT 4 E-1
noid valve) cate SSC
2nd clutch model option)
S2T DT 2 ECMV (sole- Y-7 Torque con-
noid valve) verter stator
3rd clutch SSTC DT 2 clutch left Y-5
S3T DT 2 ECMV (sole- Y-8 ECMV (sole-
noid valve) noid valve)
Bypass valve Starting motor
SBP DT 4 position sen- AF-2 ST/B1 Terminal 1 AE-6
A
sor Starting motor
EGR valve ST/B2 Terminal 1 AE-5
B
SEGR DT 4 position sen- AF-3
sor Starting motor
ST1 DT 2 AG-5
Forward clutch A (top)
SFT DT 2 ECMV (sole- Z-7 Starting motor
ST2 DT 2 AG-5
noid valve) B (bottom)
Shift down Sudden stop
SFTD - 3 R-1 STB DT 2 prevention AC-8
switch
Shift down solenoid valve
SFTU - 3 R-1 Data writing
switch
STF X 4 connector (S/T T-7
Left steering
controller)
brake ECMV
SLB DT 2 AD-5
(solenoid SW Terminal 1 Battery relay 1 K-1
valve)
Left steering SW Terminal 1 Battery relay 2 L-1
clutch ECMV
SLC DT 2 AB-8
(solenoid Ground
SX-8 Terminal 1 F-1
valve) (fender)
Torque con- Torque con-
verter lockup TC1 DT 2 verter output AC-7
SLUC DT 2 clutch right Y-4 speed sensor
ECMV (sole- Fuel tempera-
noid valve) TFUEL PACKARD 2 AG-1
ture sensor
BG shift switch
Boost temper-
(one-way type TIM PACKARD 2 AI-5
SNC DT 6 S-7 ature sensor
model)
Torque con-
(optional)
verter inlet
Pitching sole- TIP DT 3 Y-6
SOL1 DT 2 D-8 pressure sen-
noid valve
sor
Dual-tilt sys-
Intermediate
SOL2 DT 2 tem solenoid D-8 TL1 24-31 31 M-9,U-5
connector
valve
Right steering Intermediate
TL2 DT-B 8 T-7
brake ECMV connector
SRB DT 2 AD-5 Intermediate
(solenoid TL3 DT 6 T-7
valve) connector
Right steering (one-way type
clutch ECMV TL3 DT 6 model) T-7
SRC DT 2 AB-8
(solenoid (optional)
valve) Blade tilt left
Reverse TLS DT 2 oil pressure P-9
clutch ECMV switch
SRT DT 2 Y-8
(solenoid Transmission
valve) outlet shaft
KOMNET ser- speed sensor
SRV DT-A 12 P-1 TM1 DT 2 AD-7
vice connector (VHMS instal-
lation model
only)
40-94 D375A-6
(01)
DRAFT

Data writing VHMS down-
connector VDW BENDIX 5 S-2
load connector
TMF X 4 (work equip- T-7 Intermediate
ment control- VED DT-C 12 K-6
connector
ler)
Intermediate
Transmission VEG DT-C 12 AJ-3
connector
main oil pres-
sure sensor Intermediate
TMMD DT 3 Z-7 VF1 DT-B 12 V-3
(VHMS instal- connector
lation model Intermediate
VF2 24-31 31 U-4,V-2
only) connector
Intermediate Work equip-
TMV 24-23 23 AA-7
connector WECN1 DRC26-24A 24 ment control- T-7
Engine oil ler
TOIL PACKARD 2 temperature AJ-2 Work equip-
sensor WECN2 DRC26-40A 40 ment control- S-8
Torque con- ler
verter outlet Work equip-
TOP DT 3 AB-3 WECN3 DRC26-40B 40 ment control- S-8
pressure sen-
sor ler
Main power WE lock
TR1L - 1 K-3 WELK DT 3 P-7
terminal switch
Main power Coolant level
TR1S - 1 K-3 WLD DT 2 A-3
terminal sensor
Main power Washer tank
TR2L - 1 - WSFR YAZAKI 2 J-5
terminal 2 (front)
TR2L - 1 K-3 WSLH YAZAKI 2 J-5
terminal (left)
TR2S - 1 - WSRH YAZAKI 2 J-4
terminal 2 (right)
Blade tilt right Washer tank
WSRR YAZAKI 2 J-5
TRS DT 2 oil pressure P-9 (rear)
switch Rear view
Coolant tem- TAJIMI camera -
TWTR PACKARD 2 perature sen- AH-5 (optional)
sor
Intermediate
USB DTHD 1 U-3
connector
VHMS control-
V1 070 20 V-2
ler
VHMS control-
V2A 070 18 W-2
ler
VHMS control-
V2B 070 12 X-2
ler
VHMS control-
V3A 070 18 W-2
ler
VHMS control-
V3B 070 12 W-2
ler
VHMS control-
V4A 070 14 X-2
ler
VHMS control-
V4B 070 10 W-2
ler
Intermediate
VDA DT-D 12 L-9
connector
Intermediate
VDB DT-B 12 K-7
connector
Intermediate
VDC DT-D 12 I-3
connector
D375A-6 40-95
(01)
DRAFT
40-96 D375A-6
(01)
DRAFT
D375A-6 40-97
(01)
DRAFT
40-98 D375A-6
(01)
DRAFT
D375A-6 40-99
(01)
DRAFT
40-100 D375A-6
(01)
DRAFT
D375A-6 40-101
(01)
DRAFT
T-branch box and T-branch adapter table

(Rev. 2009. 03)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal col-
umn indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part number Part name
symbol
799-601-2600 T-box(for ECONO) 21 q q q q q

799-601-3100 T-box(for MS) 37 q
799-601-3200 T-box(for MS) 37 q
799-601-3380 • Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3510 Adapter for BENDIX (MS) 5 MS-5S q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box(for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 - q q
799-601-7090 Adapter for M 2 M2P q q q q
799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for M 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
40-102 D375A-6
(01)
DRAFT
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
symbol
799-601-7160 Adapter for S (Blue) 12 S12P q q q

799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 - q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 - q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box(for ECONO) 24 q q q
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430*
Socket for engine(CRI-T3) PCV
2 P q q
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
D375A-6 40-103
(01)
DRAFT
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
symbol
Socket for engine (HPI-T2)

795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540*
Socket for engine(CRI-T3) TIM
2 A q q
795-799-5460 Cable for engine (HPI-T2) 3 - q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE,CAM 3 FCIN q q
799-601-4140
Atomosphere pressure
3 FCIG q q
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160
Oil pressure switch
2 4160 q q
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190*
Common rail pressure
3 1,2,3L q q
799-601-4230*
Air intake pressure/temperature
4 1,2,3,4C q q
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340*
Pump actuator
2 2,PA q q
Socket for engine (CRI-T3)(95)
799-601-4380*
Air intake pressure/temperature
4 1,2,3,4T q
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 - q
799-601-4280* Box for controller (PUMP) 121 - q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
799-601-9890 Multi-adapter for DT2 – 4 andDTM2 3, - q
4
"*" Shows not T-adapter but socket.
40-104 D375A-6
(01)
DRAFT
Fuse locations table

Connection table of circuit breakers and fuse boxes
a This connection table shows the devices to which each power supply of the circuit breakers and fuse box
supplies power (An accessory power supply is a device which supplies power while the starting switch is
in the ON position and an unswitched power supply is a device which supplies power while the starting
switch is in the OFF and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the circuit breakers
and fuses to see if the power is supplied normally.
Mounting location of circuit breakers (1) - (4)
Mounting location of circuit breakers (5) - (10)
D375A-6 40-105
(01)
DRAFT
Circuit breakers CB1–CB7, CB30, CB105 and CBH1

Power breaker Circuit
Capacity (A) Destination of power
(Power supply type) breaker No.
1 (Main power supply) 105 CB105 Main power supply
2 (Constant power supply) 30 CB30 Constant power supply
3 (Main power supply) 105 CBH1 Preheater relay
Engine controller constant power source
4 (Constant power supply) 30 CB7
Power supply of electric priming pump timer
CB105
5 20 CB1 Power train controller
(Main power supply)
Starting switch
6 20 CB2 Machine monitor (ACC)
(ACC)
7 20 CB3 Work equipment controller
CB105
8 20 CB4 Air conditioner
(Main power supply)
9 20 CB5 Headlamp
CB30
10 20 CB6 Constant power supply of starting switch
(Constant power supply)
a Resetting circuit breakers (1) – (4)
Turn starting switch to OFF position, and press RESET button 5 - 10 minutes after power-off. If electrical
circuit is open, the RESET button is heavy to operate when compared with normal operation. The RESET
button has the same height when electrical circuit is open and when breakers are reset. Therefore, you
can determine the condition by checking the return force.
Do not hold down the RESET button too long.
a Resetting circuit breakers (5) – (10)
Turn starting switch to OFF position, and press protruded RESET button (11). If RESET button is
protruded again, perform troubleshooting and repair defect.
40-106 D375A-6
(01)
DRAFT
Mounting location of fuse boxes FS11 – FS31
Mounting location of fuse box (Cab top end)
D375A-6 40-107
(01)
DRAFT
Fuse box FS11

Power breaker Fuse capacity
Destination of power
(Power supply type) (A)
1 CB105 (Main power supply) 20 VHMS controller power supply
Constant power supply of VHMS, power train, and work equip-
2 20
CB30 (Constant power sup- ment controllers
3 ply) 20 Constant power supply of cab
4 10 12V converter constant power supply
5 CB105 (Main power supply) 20 12V converter power supply
Fuse box FS21
Power breaker Fuse capacity
(Power supply type) (A)
1 5 Backup alarm
2 20 Pin puller, preheater, air suspension seats
3 CB105 (Main power supply) 20 Additional heater
4 20 Working lamp
5 20 Rear lamp
Fuse box FS31
Power breaker Fuse capac-
(Power supply type) ity (A)
1 Starting switch (ACC) 5 ACC for engine controller
2 5 Horn
3 CB105 (Main power supply) 20 Spare power supply (1)
4 20 Spare power supply (2)
5 Starting switch (ACC) 20 Spare ACC signal
Fuse box (Cab top end)
Power breaker Fuse capac-
(Power supply type) ity (A)
1 10 Radio, cigarette lighter, room lamp
2 10 Rear wiper
3 15 Rear wiper
4 10 Front wiper
5 CB105 (Main power supply) 15 Left wiper
6 20 Additional back-up lamp
7 20 Additional headlamp, revolving warning lamp
8 20 Glass with heating wire
9 - Spare
CB30 (Constant power sup-
10 10 Radio memory
ply)
40-108 D375A-6
(01)
DRAFT
Troubleshooting by failure code
Failure code [1380MW] Lock up clutch: Slip

Failure code [1380MW] Lock up clutch: Slip
Action code Failure code Lockup clutch slip
Failure
― 1380MW (Power train controller system)
Detail of fail- q When torque converter is locked up, sensed engine speed does not match with sensed torque con-
ure verter output speed.
Action of con-
q None in particular.
troller
Problem on
machine
q Engine speed and torque converter speed can be checked with monitoring function.
Related infor- (Code 01000: Engine speed)
mation (Code 31200: Transmission input speed (Torque converter output speed))
q Method of reproducing failure code: Start engine, turn lockup clutch ON and drive machine.
Cause Procedure, measuring location, criteria and remarks

Lockup clutch slip(When
1 Check for cause of lockup clutch slip and damage of machine.
system is normal)
Defective engine speed
2 If failure code[CA689] or [CA778] is displayed, carry out troubleshooting for it.
sensor system
Defective torque converter
3 If failure code [DLF1KA] is displayed, carry out troubleshooting for it.
speed sensor
Defective power train con-
4 Since failure is in it, troubleshooting cannot be carried out.
troller
D375A-6 40-109
(01)
DRAFT
Failure code [1500L0] Transmission clutch: Abnormal
Failure code [1500L0] Transmission clutch: Abnormal

Action code Failure code Transmission clutch: Abnormal
Failure
E03 1500L0 (Power train controller system)
q Among failure codes related to transmission clutch, following codes occurred at the same time (Gear
speed limit).
(1) Either of [DXH4KA] and [DXH4KB] and either of [DXH5KA] and [DXH5KB].
q Among failure codes related to transmission clutch, following codes occurred at the same time (Travel
trouble).
(2) Either of [DXH8KA] and [DXH8KB] and either of [DXH7KA] and [DXH7KB].
Detail of fail- (3) Either of [DXH6KA] and [DXH6KB] and either of [DXH5KA] and [DXH5KB] and either of [DXH4KA]
ure and [DXH4KB]
(4)[15SALH] and [15SBLH]
(5) Either of [15SAL1] and [DXH8KY] and either of [15SBL1] and [DXH7KY]
(6)[15SELH] and [15SFLH] and [15SGLH]
(7) Either of [15SEL1] and [DXH4KY], and either of [15SFL1] and [DXH5KY]
(8) Either of [15SEL1] and [DXH4KY], and either of [15SGL1] and [DXH6KY]
(9) Either of [15SFL1] and [DXH5KY], and either of [15SGL1] and [DXH6KY]
Action of con-
q Limits operation of engine and transmission.
troller
Problem that q The auto shift down function does not start.
appears on q Once machine is stopped, engine speed is limited to medium (half).
machine q Once machine is stopped, it can travel only by the minimum gear which can operate.
Related infor-
q Method of reproducing failure code: Engine start + Run
mation

Confirm the failure codes displayed at the same time, then carry out troubleshooting for the codes.
[15SAL1], [15SALH], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1], [15SFLH], [15SGL1], [15SGLH]
[DXH4KA], [DXH4KB], [DXH5KA], [DXH5KB], [DXH6KA], [DXH6KB], [DXH7KA], [DXH7KB], [DXH8KA], [DXH8KB],
[DXH4KY], [DXH5KY], [DXH6KY], [DXH7KY], [DXH8KY]
40-110 D375A-6
(01)
DRAFT
Failure code [15E0MW] Transmission clutch: Slip
Failure code [15E0MW] Transmission clutch: Slip

Action code Failure code Transmission clutch slip
Failure
― 15E0MW (Power train controller system)
Detail of failure q Sensed torque converter output speed does not match with sensed transmission output speed.
Action of con-
troller
Problem on
machine
q Torque converter speed and transmission speed can be checked with monitoring function.
Related infor- (Code 31200: Transmission input speed (Torque converter output speed))
mation (Code 31400: Transmission output speed)
q Method of reproducing failure code: Start engine and drive machine.

Transmission clutch slip
1 Check for cause of transmission clutch slip and damage of machine.
(When system is normal)
Defective torque converter Check if failure code [DLF1KA] is displayed
2
speed sensor Carry out troubleshooting for it.
Defective transmission speed Check if failure code [DLT3KA], [DLT3KB] is displayed
3
sensor Carry out troubleshooting for it.
Defective power train control-
4 Since failure is in it, troubleshooting cannot be carried out.
ler
D375A-6 40-111
(01)
DRAFT
Failure code [15SAL1] Forward clutch: Fill high

Action code Failure code Forward clutch fill dwitch signal is ON.
Failure
E03 15SAL1 (Power train controller system)
q Nevertheless controller does not output command current to transmission F clutch ECMV solenoid
Detail of failure
circuit, fill switch signal is ON.
q Sets transmission to neutral when operator sets it to reverse position (Prevention of double engage-
Action of con-
ment).
troller
q Once machine is stopped, engine speed is limited to medium (half).
Problem on
q Once machine is stopped, travel is limited to F1.
machine
q The automatic gearshift system does not operate.
q State (ON/OFF) of F clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 40906 T/M Fill Sw Input 1)
q Method of reproducing failure code: Start engine and set PCCS lever in neutral position.
Related infor-
q Remove seat (approx. 50 kg) and cover under seat.
mation
q First, check the power train oil filter for clogging etc.
q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train
oil pressure".

1. Turn starting switch to OFF position.
Defective F clutch ECMV fill
1 switch (Internal short cir- 2. Disconnect connector FFT and connect T-adapter to male side.
Between FFT (female) (1) and ground
cuit) Resistance Min. 1 MΩ
(Fill switch OFF)
2. Disconnect connector FFT.
Ground fault of wiring har-
2 ness or defective power 3. Start engine
train controller If failure code [15SAL1] is still displayed, there is ground fault of wiring harness or
power train controller is defective.
(If failure code [15SAL1] is not displayed, F clutch fill switch is defective)
a If cause 2 is not the cause for the trouble, this check is not required.
Ground fault of wiring har- 1. Turn starting switch to OFF position.
ness 2. Disconnect connectors PTCN2 and FFT, and connect T-adapter to female side of
3
(Contact with ground cir- either of them.
cuit) Between PTCN2 (female) (5) or FFT (female) (1) and
Resistance Min. 1 MΩ
ground
If "check result of cause 2 is abnormal" and "check result of cause 3 is normal", power
train controller is defective.
q Reference; the followings are criteria in normal condition.
2. Insert T-adapter into connector PTCN2.
Defective power train con- 3. Start engine
4
troller a Keep PCCS lever in N position.
Between PTCN2 (5) and ground Voltage 7 – 11 V
1 – 3 are same as above.
4. While depressing brake pedal, operate PCCS lever (to select gear speed) and per-
form troubleshooting.
Between PTCN2 (5) and ground F1/F2/F3 Voltage Max.1 V
40-112 D375A-6
(01)
DRAFT
Circuit diagram related to forward clutch ECMV
D375A-6 40-113
(01)
DRAFT
Failure code [15SALH] Forward clutch: Fill Low

Action code Failure code Forward clutch fill switch signal is OFF.
Failure
E03 15SALH (Power train controller system)
q Nevertheless controller outputs command current to transmission F clutch ECMV solenoid circuit, fill
Detail of failure
switch signal is turned OFF.
q Sets transmission to neutral when operator sets it to forward position (Prevention of defective en-
Action of con-
gagement).
troller
Problem on
q Once machine is stopped, travel is limited to R1.
machine
q State (ON/OFF) of F clutch ECMV fill switch signal can be checked with monitoring function.
q Method of reproducing failure code: Start engine and set PCCS lever in forward position.
Related infor-
mation
oil pressure".

2. Disconnect connector FFT and connect T-adapter to male side.
3. Start engine
Defective F clutch ECMV fill a Keep PCCS lever in N position.
1 Between FFT (male) (1) and ground Resistance Min. 1 MΩ
switch (It does not turn ON)
Between FFT (male) (1) and ground F1/F2/F3 Resistance Max. 1 Ω
Disconnection in wiring har- 1. Turn starting switch to OFF position.
ness 2. Disconnect connectors PTCN2 and FFT, and connect T-adapters to female side of
2
(Disconnection or defective them.
contact) Between PTCN2 (female) (5) and FFT (female) (1) Resistance Max. 1 Ω
3. Start engine
Defective power train con- a Keep PCCS lever in N position.
3 Between PTCN2 (5) and ground Voltage 7–11 V
troller
Between PTCN2 (5) and ground F1/F2/F3 Voltage Max. 1 V
40-114 D375A-6
(01)
DRAFT
D375A-6 40-115
(01)
DRAFT
Failure code [15SBL1] Reverse clutch: Fill high

Action code Failure code Reverse clutch fill switch signal is ON.
Failure
E03 15SBL1 (Power train controller system)
q Nevertheless controller does not output command current to transmission R clutch ECMV solenoid
Detail of failure
circuit, fill switch signal is turned ON.
q Sets transmission to neutral when operator sets it to forward position (Prevention of double engage-
Action of con-
ment).
troller
Problem on
q Once machine is stopped, travel is limited to R1.
machine
q State (ON/OFF) of R clutch ECMV fill switch signal can be checked with monitoring function.
Related infor-
mation
oil pressure".

Defective R clutch ECMV fill
1 switch (Internal short cir- 2. Disconnect connector FRT and connect T-adapter to male side.
Between FRT(female) (1) and ground
(Fill switch OFF)
2. Disconnect connector FRT.
train controller If failure code [15SBL1] is still displayed, there is ground fault of wiring harness or
(If failure code [15SBL1] is not displayed, R clutch fill switch is defective)
3 ness 2. Disconnect connectors PTCN2 and FRT and connect T-adapter to female side of
(Contact with ground circuit) either of them.
Between PTCN2 (female) (36) or FRT (female) (1)
and ground
If “check result of cause 2 is abnormal” and “check result of cause 3 is normal”,
4
Between PTCN2 (36) and ground Voltage 7 –11 V
Between PTCN2 (36) and ground R1/R2/R3 Voltage Max. 1 V
40-116 D375A-6
(01)
DRAFT
Circuit diagram related to reverse clutch ECMV
D375A-6 40-117
(01)
DRAFT
Failure code [15SBLH] Reverse clutch: Fill Low

Action code Failure code Reverse clutch fill switch signal is OFF.
Failure
E03 15SBLH (Power train controller system)
q Nevertheless controller outputs command current to transmission R clutch ECMV solenoid circuit,
Detail of failure
fill switch signal is turned OFF.
q Sets transmission to neutral when operator sets it to reverse position (Prevention of defective en-
Action of con-
gagement).
troller
Problem on
q Once machine is stopped, travel is limited to F1.
machine
q State (ON/OFF) of R clutch ECMV fill switch signal can be checked with monitoring function.
q Method of reproducing failure code: Start engine and set PCCS lever in reverse position.
Related infor-
mation
oil pressure".

2. Disconnect connector FRT and connect T-adapter to male side.
3. Start engine
Defective R clutch ECMV fill a Keep PCCS lever in N position.
1
switch (It does not turn ON) Between FRT (male) (1) and ground Resistance Min. 1 MΩ
4. While depressing brake pedal, operate PCCS lever (to select gear speed) and
perform troubleshooting.
Between FRT (male) (1) and ground R1/R2/R3 Resistance Max. 1 Ω
ness 2. Disconnect connectors PTCN2 and FRT, and connect T-adapters to female side
2
(Disconnection or defective of them.
contact) Between PTCN2 (female) (36) and FRT (female) (1) Resistance Max. 1 Ω
3. Start engine
3 Between PTCN2 (36) and ground Voltage 7 – 11 V
troller
Between PTCN2 (36) and ground R1/R2/R3 Voltage Max. 1V
40-118 D375A-6
(01)
DRAFT
D375A-6 40-119
(01)
DRAFT
Failure code [15SEL1] Speed 1st clutch: Fill high

Action code Failure code Speed 1st clutch: fill switch signal is ON.
Failure
E03 15SEL1 (Power train controller system)
q Nevertheless controller does not output command current to transmission 1st clutch ECMV solenoid
Detail of failure
Action of con-
troller
Problem on
q Once machine is stopped, travel is limited to F1 and R1.
machine
q State (ON/OFF) of 1st clutch ECMV fill switch signal can be checked with monitoring function.
Related infor-
mation
oil pressure".

Defective 1st clutch ECMV
1 fill switch (Internal short 2. Disconnect connector F1T and connect T-adapter to male side.
Between F1T (female) (1) and ground
circuit) Resistance Min. 1 MΩ
(Fill switch OFF)
2. Disconnect connector F1T.
train controller If failure code [15SEL1] is still displayed, there is ground fault of wiring harness or
(If failure code [15SEL1] is not displayed, 1st clutch fill switch is defective)
ness 2. Disconnect connectors PTCN2 and F1T and connect T-adapter to female side of
3
cuit) Between PTCN2 (female) (35) or F1T (female) (1) and
ground
4
1. – 3. are same as above.
Between PTCN2 (35) and ground F1/R1 Voltage Max. 1 V
40-120 D375A-6
(01)
DRAFT
Circuit diagram related to 1st clutch ECMV
D375A-6 40-121
(01)
DRAFT
Failure code [15SELH] Speed 1st clutch: Fill Low

Action code Failure code Speed 1st clutch fill switch signal is OFF.
Failure
E03 15SELH (Power train controller system)
q Nevertheless controller outputs command current to transmission 1st clutch ECMV solenoid circuit,
Detail of failure
Action of con-
troller
Problem on
machine
q State (ON/OFF) of 1st clutch ECMV fill switch signal can be checked with monitoring function.
q Method of reproducing failure code: Start engine and set PCCS lever in F1 or R1 position.
Related infor-
mation
oil pressure".

3. Start engine
a Keep PCCS lever in N position.
Defective 1st clutch ECMV fill Between F1T (male) (1) and ground Resistance Min. 1 MΩ
1
switch (It does not turn ON) 1 – 3 are same as above.
Between F1T (male) (1) and
F1/R1 Resistance Max. 1 Ω
ground
ness 2. Disconnect connectors PTCN2 and F1T, and connect T-adapters to female side
2
contact) Between PTCN2 (female) (35) and F1T (female) (1) Resistance Max. 1 Ω
3. Start engine
Defective power train control- a Keep PCCS lever in N position.
ler
Between PTCN2 (35) and ground F1/R1 Voltage Max. 1V
40-122 D375A-6
(01)
DRAFT
D375A-6 40-123
(01)
DRAFT
Failure code [15SFL1] Speed 2nd clutch: Fill high

Action code Failure code Speed 2nd clutch fill switch is ON.
Failure
E03 15SFL1 (Power train controller system)
q Nevertheless controller does not output command current to transmission 2nd clutch ECMV sole-
Detail of failure
noid circuit, fill switch signal is turned ON.
Action of con-
troller
Problem on
machine
q State (ON/OFF) of 2nd clutch ECMV fill switch signal can be checked with monitoring function.
Related infor-
mation
oil pressure".

Defective 2nd clutch ECMV
1 fill switch (Internal short cir- 2. Disconnect connector F2T and connect T-adapter to male side.
(Fill switch OFF)
train controller If failure code [15SFL1] is still displayed, there is ground fault of wiring harness or
(If failure code [15SFL1] is not displayed, 2nd clutch fill switch is defective)
3 ness 2. Disconnect connectors PTCN2 and F2T, and connect T-adapter to female side of
Between PTCN2 (female) (25) or F2T (female) (1)
and ground
4
40-124 D375A-6
(01)
DRAFT
D375A-6 40-125
(01)
DRAFT
Failure code [15SFLH] Speed 2nd clutch: Fill Low

Action code Failure code Speed 2nd clutch fill switch signal is OFF.
Failure
E03 15SFLH (Power train controller system)
q Nevertheless controller outputs command current to transmission 2nd clutch ECMV solenoid circuit,
Detail of failure
Action of con-
troller
Problem on
machine
q State (ON/OFF) of 2nd clutch ECMV fill switch signal can be checked with monitoring function.
q Method of reproducing failure code: Start engine and PCCS lever in F2 or R2 position.
Related infor-
mation
oil pressure".
Procedure, measuring location, criteria and remarks

2. Disconnect connector F2Tand connect T-adapter to male side.
3. Start engine
Defective 2nd clutch ECMV fill Between F2T (male) (1) and ground Resistance Min. 1 MΩ
1
switch (It does not turn ON) 1 – 3 are same as above.
ground
ness 2. Disconnect connectors PTCN2 and F2T and connect T-adapters to female side
2 of them.
Between PTCN2 (female) (25) and F2T (female)
contact) Resistance Max. 1 Ω
(1)
3. Start engine
ler
40-126 D375A-6
(01)
DRAFT
D375A-6 40-127
(01)
DRAFT
Failure code [15SGL1] Speed 3rd clutch: Fill high

Action code Failure code Speed 3rd clutch fill switch signal is ON.
Failure
E03 15SGL1 (Power train controller system)
q Nevertheless controller does not output command current to transmission 3rd clutch ECMV solenoid
Detail of failure
Action of con-
troller
Problem on
machine
q State (ON/OFF) of 3rd clutch ECMV fill switch signal can be checked with monitoring function.
Related infor-
mation
oil pressure".

Defective 3rd clutch ECMV
1 fill switch (Internal short cir- 2. Disconnect connector F3T and connect T-adapter to male side.
(Fill switch OFF)
train controller If failure code[15SGL1] is still displayed, there is ground fault of wiring harness or
(If failure code[15SGL1] is not displayed, 3rd clutch fill switch is defective)
ness 2. Disconnect connectors PTCN2 and F3T, and connect T-adapter to female side of
3
cuit) Between PTCN2 (female) (15) or F3T (female) (1)
and ground
4
40-128 D375A-6
(01)
DRAFT
D375A-6 40-129
(01)
DRAFT
Failure code [15SGLH] Speed 3rd clutch: Fill Low

Action code Failure code Speed 3rd clutch fill switch signal is OFF.
Failure
E03 15SGLH (Power train controller system)
q Nevertheless controller outputs command current to transmission 3rd clutch ECMV solenoid circuit,
Detail of failure
Action of con-
troller
Problem on
machine
q State (ON/OFF) of 3rd clutch ECMV fill switch signal can be checked with monitoring function.
q Method of reproducing failure code: Start engine and PCCS lever in F3 or R3 position.
Related infor-
mation
oil pressure".

2. Disconnect connector F3T and connect T-adapter to male side.
3. Start engine
Defective 3rd clutch ECMV a Keep PCCS lever in N position.
1 fill switch (It does not turn Between F3T (male) (1) and ground Resistance Min. 1 MΩ
ON) 1 – 3 are same as above.
ground
ness 2. Disconnect connectors PTCN2 and F3T and, connect T-adapters to female side
2 of them.
Between PTCN2 (female) (15) and F3T (female)
(1)
3. Start engine
ler
40-130 D375A-6
(01)
DRAFT
D375A-6 40-131
(01)
DRAFT
Failure code [15SJL1] L/U: Fill high

Action code Failure code Lockup clutch fill switch signal is ON.
Failure
E02 15SJL1 (Power train controller system)
q Nevertheless controller does not output command current to torque converter lockup clutch ECMV
Detail of failure
solenoid circuit, fill switch signal is turned ON.
Action of con-
q Prohibits lockup.
troller
Problem on
q Engine may stall during travel.
machine
q State of lockup clutch ECMV fill switch signal can be checked with monitoring function.
q Method of reproducing failure code: Start engine and set PCCS lever in R (reverse) position (in au-
Related infor- tomatic gearshift mode).
mation q Remove seat (approx. 50 kg) and cover under seat.
oil pressure".

Defective lockup clutch
1 ECMV fill switch (Internal 2. Disconnect connector FLUC and connect T-adapter to male side.
Between FLUC (female) (1) and ground
short circuit) Resistance Min. 1 MΩ
(Fill switch OFF)
2. Disconnect connector FLUC.
Ground fault of wiring har- 3. Start engine
2 ness or defective power train a Keep PPC lever in N position.
controller If failure code [15SJL1] is still displayed, there is ground fault of wiring harness or
(If failure code [15SJL1] is not displayed, lockup clutch fill switch is defective)
3 ness 2. Disconnect connectors PTCN2 and FLUC, and connect T-adapter to female side
(Contact with ground circuit) of either of them.
Between PTCN2 (female) (38) or FLUC (female) (1)
and ground
If "check result of cause 2 is abnormal" and "check result of cause 3 is normal",
3. Start engine
troller
4. Raise tracks off the ground.
5. Travel in R1 (Reverse) (Automatic gear shift mode) and troubleshoot with clutch
locked up.
a See Testing and adjusting, "Testing power train oil pressure", "4) Testing torque
converter lockup clutch pressure".
Between PTCN2 (38) and ground R1 Voltage Max. 1 V
40-132 D375A-6
(01)
DRAFT
Circuit diagram related to lockup clutch ECMV
D375A-6 40-133
(01)
DRAFT
Failure code [15SJLH] L/U: Fill low

Action code Failure code Lockup clutch fill switch is OFF.
Failure
E02 15SJLH (Power train controller system)
q Nevertheless controller outputs command current to torque converter lockup clutch ECMV solenoid
Detail of failure
circuit, fill switch signal is turned OFF.
Action of con-
q Prohibits lockup.
troller
Problem on
q It is impossible to lockup.
machine
q State of lockup clutch ECMV fill switch signal can be checked with monitoring function.
q Method of reproducing failure code: Start engine and set PCCS lever in R (reverse) position (in au-
Related infor- tomatic gearshift mode).
oil pressure".
Procedure, measuring location, criteria and remarks

2. Disconnect connector FLUC, and connect T-adapter to male side.
3. Start engine
Defective lockup clutch 4. Raise tracks off the ground.
1 ECMV fill switch (It does not 5. Travel machine in R1 (automatic gearshift mode), and troubleshoot with lockup in
turn ON) operation.
a See Testing and adjusting, “Testing power train oil pressure”, 4) Testing torque
converter lockup clutch pressure”.
Between FLUC (female) (1) and ground
Resistance Max. 1 Ω
(Fill switch ON)
ness 2. Disconnect connectors PTCN2 and FLUC and connect T-adapters to female side
2 of them.
Between PTCN2 (female) (38) and FLUC (female)
(1)
If no abnormality is found by the above checks, power train controller is defective.
3. Start engine
Defective power train con- Between PTCN2 (38) and ground Voltage 7 – 11 V
3
troller 1 – 3 are same as above.
4. Raise tracks off the ground.
5. Travel machine in R1 (automatic gearshift mode), and troubleshoot with lockup in
operation.
a See Testing and adjusting, "Testing power train oil pressure", "4) Testing torque
converter lockup clutch pressure".
Between PTCN2 (38) and ground R1 Voltage Max. 1 V
40-134 D375A-6
(01)
DRAFT
Circuit diagram related to lockup clutch ECMV
D375A-6 40-135
(01)
DRAFT
Failure code [1800MW] P/T clutch: Slip

Action code Failure code Power train clutch slip
Failure
E02 1800MW (Power train controller system)
Detail of failure q When torque converter is locked up, engine speed does not match sensed transmission output.
Action of con-
troller
Problem on
machine
q Engine state (speed) and torque converter state (speed) can be checked with monitoring funtion.
Related infor-
(Code 01002: Engine speed, Code 31200: Transmission input speed (Torque converter speed))
mation
q Method of reproducing failure code: Engine start + Turn lockup clutch ON + Drive machine.

Power train clutch slip
a Clutch slip was detected; check the cause and machine damage state, then repair the
1 (When the system is nor-
machine.
mal)
Defective engine rotation Check whether failure codes [CA689] and [CA778] are displayed. If they are displayed,
2
sensor carry out the troubleshooting.
Defective transmission Check whether failure codes [DLT3KA] or [DLT3KB] is displayed. If it is displayed, carry
3
speed sensor out the troubleshooting.
Defective power train
4 Internally trouble; troubleshooting is impossible.
controller
40-136 D375A-6
(01)
DRAFT
D375A-6 40-137
(01)
DRAFT
Failure code [2201L1] Right clutch: Fill high

Action code Failure code Right clutch fill switch signal is ON.
Failure
E04 2201L1 (power train controller system)
q Nevertheless controller does not output command current to right steering clutch ECMV solenoid
Detail of failure
Action of con-
q Limits operation of engine, transmission, and brake.
troller
Problem on q Once machine is stopped, engine speed is limited to medium (half).
machine q Once machine is stopped, it becomes impossible to travel.
q State (ON/OFF) of right steering clutch ECMV fill switch signal can be checked with monitoring func-
tion.
(Code: 31521 Steering Fill Sw Input )
Related infor- q Method of reproducing failure code: Start engine.
oil pressure".

Defective right steering clutch
1 ECMV fill switch (Internal short 2. Disconnect connector FRC and connect T-adapter to male side.
Between FRC (female) (1) and ground
(Fill switch OFF)
2. Disconnect connector FRC.
Ground fault of wiring harness 3. Start engine
2 or defective power train con- If failure code [2201L1] is still displayed, there is ground fault of wiring harness or
troller power train controller is defective.
(If failure code [2201L1] is not displayed, right steering clutch fill switch is defec-
tive)
Ground fault of wiringharness 2. Disconnect connectors PTCN2 and FRC and connect T-adapter to female side
3
Between PTCN2 (female) (16) or FRC (female) (1) Min. 1 MΩ
Resistance
and ground
4 Defective power train controller 3. Start engine
4.While depressing brake pedal, operate PCCS lever (to select steering) and per-
Between PTCN2 (16) and ground Left Max. Voltage Max. 1 V
40-138 D375A-6
(01)
DRAFT
Circuit diagram related to right clutch ECMV
D375A-6 40-139
(01)
DRAFT
Failure code [2201LH] Right clutch: Fill low

Action code Failure code Right steering clutch fill switch signal is OFF.
Failure
E04 2201LH (power train controller system)
q Nevertheless controller outputs command current to right steering clutch ECMV solenoid circuit, fill
Detail of failure
Action of con-
troller
Indication of
problem on
q Once machine is stopped, it becomes impossible to travel.
machine
q State (ON/OFF) of right steering clutch ECMV fill switch signal can be checked with monitoring func-
tion.
(Code: 31521 Steering Fill Sw Input)
q Method of reproducing failure code: Start engine and release parking brake lever and operate PCCS
Related infor-
lever (right steering).
mation
oil pressure".

2. Disconnect connector FRC and connect T-adapter to male side.
3. Start engine
Defective right steering clutch a Keep PCCS lever in N position.
1 ECMV fill switch (It does not Between FRC (male) (1) and ground Resistance Min. 1 MΩ
turn ON) 1 – 3 are same as above.
4.While depressing brake pedal, operate PCCS lever (to select gear speed) and
Between FRC (male) (1) and
Left Max. Resistance Max. 1 Ω
ground
ness 2. Disconnect connectors PTCN2 and FRC, and connect T-adapters to female
2 side of them.
Between PTCN2 (female) (16) and FRC (female)
(1)
3. Start engine
Defective power train control- Between PTCN2 (16) and ground Voltage 7 – 11 V
3
ler 1. – 3. are same as above.
Between PTCN2 (16) and
Left Max. Voltage Max. 1 V
ground
40-140 D375A-6
(01)
DRAFT
Circuit diagram related to right clutch ECMV
D375A-6 40-141
(01)
DRAFT
Failure code [2202L1] Left clutch: Fill high

Action code Failure code Speed Left clutch fill switch signal is ON.
Failure
E04 2202L1 (Power train controller system)
q Nevertheless controller does not output command current to left steering ECMV solenoid circuit, fill
Detail of failure
switch signal is turned ON.
Action of con-
troller
q State (ON/OFF) of left steering ECMV fill switch signal can be checked with monitoring function.
q Method of reproducing failure code: Start engine.
Related infor-
mation
oil pressure".

Defective left steering ECMV
1 fill switch (Internal short cir- 2. Disconnect connector FLC and connect T-adapter to male side.
Between FLC (female) (1) and ground
(Fill switch OFF)
2. Disconnect connector FLC.
Ground fault of wiring harness
2 or defective power train con- 3. Start engine
troller If failure code [2202L1] is still displayed, there is ground fault of wiring harness or
(If failure code [2202L1] is not displayed, left steering fill switch is defective)
Ground fault of wiring harness 2. Disconnect connectors PTCN2 and FLC, and connect T-adapter to female side
3
Between PTCN2 (female) (26) or FLC (female) (1)
and ground
Defective power train control- 3. Start engine
4
ler a Keep PCCS lever in N position.
Between PTCN2 (26) and ground Left Max. Voltage Max. 1 V
40-142 D375A-6
(01)
DRAFT
Circuit diagram related to left clutch ECMV
D375A-6 40-143
(01)
DRAFT
Failure code [2202LH] Left clutch: Fill low

Action code Failure code Left cluth fill switch is OFF.
Failure
E04 2202LH (Power train controller system)
q Nevertheless controller outputs command current to left steering ECMV solenoid circuit, fill switch
Detail of failure
signal is turned OFF.
Action of con-
troller
q State (ON/OFF) of left steering ECMV fill switch signal can be checked with monitoring function.
q Method of reproducing failure code: Engine start and release parking brake lever and operate PCCS
Related infor- lever. (left steering).
oil pressure".

2. Disconnect connector FLC and connect T-adapter to male side.
3. Start engine
Defective left steering ECMV Between FLC (male) (1) and ground Resistance Min. 1 MΩ
1
fill switch (It does not turn ON) 1 – 2 are same as above.
Between FLC (male) (1) and
Left Max. Resistance Max. 1 Ω
ground
ness 2. Disconnect connectors PTCN2 and FLC and connect T-adapters to female side
2 of them.
Between PTCN2 (female) (26) and FLC (female)
(1)
3. Start engine
Defective power train control- Between PTCN2 (26) and ground Voltage 7 – 11 V
3
ler 1. – 3. are same as above.
Between PTCN2 (26) and
Left Max. Voltage Max.1 V
ground
40-144 D375A-6
(01)
DRAFT
Circuit diagram related to left clutch ECMV
D375A-6 40-145
(01)
DRAFT
Failure code [2300NR] Brake Themal Load Abnormality

Action code Failure code Brake thermal load abnormality
Failure
– 2300NR (Power train controller system)
Detail of fail- q The power train controller judged from the angle of inclination, travel speed, continuous operating time
ure of the brake pedal, etc. that the brake was heating abnormally.
Action of con-
troller
Problem on
–
machine
Related infor-
–
mation

1 Improper braking during downhill travel (Machine traveled down a slope with brake pedal pressed)
2 When the operation in cause 1 is not performed
troller
40-146 D375A-6
(01)
DRAFT
D375A-6 40-147
(01)
DRAFT
Failure code [2301L1] Right brake: Fill high

Action code Failure code Speed right brake fill switch signal is ON.
Failure
q Nevertheless controller does not output command current to right steering brake ECMV solenoid cir-
Detail of failure
cuit, fill switch signal is turned ON.
Action of con-
troller
Indication of
problem on
machine
q State (ON/OFF) of right steering brake ECMV fill switch signal can be checked with monitoring func-
tion.
oil pressure".

Defective right steering
1 brake ECMV fill switch (Inter- 2. Disconnect connector FRB and connect T-adapter to male side.
Between FRB(female) (1) and ground
nal short circuit) Resistance Min. 1 MΩ
(Fill switch OFF)
2. Disconnect connector FRB.
2 ness or defective power train 3. Start engine
controller If failure code [2301L1] is still displayed, there is ground fault of wiring harness or
(If failure code [2301L1] is not displayed, right steering brake fill switch is defective)
3 ness 2. Disconnect connectors PTCN2 and FRB, and connect T-adapter to female side of
Between PTCN2(female )(37) or FRB (female) (1)
and ground
4
troller 4. Release the parking brake.
Between PTCN2 (37) and ground Voltage Max. 1 V
5. While depressing the brake and carry out troubleshooting.
40-148 D375A-6
(01)
DRAFT
Circuit diagram related to right brake ECMV
D375A-6 40-149
(01)
DRAFT
Failure code [2301LH] Right brake: Fill low

Action code Failure code Right brake fill switch signal is OFF.
Failure
q Nevertheless controller outputs command current to right steering brake ECMV solenoid circuit, fill
Detail of failure
Action of con-
troller
Indication of
problem on
machine
q State (ON/OFF) of right steering brake ECMV fill switch signal can be checked with monitoring func-
tion.
Related infor- q Method of reproducing failure code:Start engine and release the parking brake.
oil pressure".

2. Disconnect connector FRB and connect T-adapter to male side.
Defective right steering brake Between FRB (male) (1) and ground Resistance Min. 1 MΩ
1 ECMV fill switch (It does not
3. Start engine.
turn ON)
4. Release the parking brake and carry out troubleshooting.
Between FRB (male) (1) and ground Resistance Max. 1 Ω
ness 2. Disconnect connectors PTCN2 and FRB, and connect T-adapters to female side
2
contact) Between PTCN2 (female) (37) and FRB (female) (1) Resistance Max. 1 Ω
3. Start engine
Defective power train control- 4. Release the parking brake.
3 a Keep PCCS lever in N position.
ler
40-150 D375A-6
(01)
DRAFT
D375A-6 40-151
(01)
DRAFT
Failure code [2301NR] Steering Brake RH Themal Load Abnormality

Action code Failure code Right steering brake thermal load abnormality
Failure
Detail of fail- q The power train controller judged from the angle of inclination and continuous operating time of the
ure right steering that the steering brake was heating abnormally.
Action of con-
troller
Problem on
–
machine
Related infor-
–
mation

1 Improper steering during downhill travel (Machine traveled down a slope and was steered to right continuously)
troller
40-152 D375A-6
(01)
DRAFT
D375A-6 40-153
(01)
DRAFT
Failure code [2302L1] Left brake: Fill high

Action code Failure code Left brake fill switch signal is ON.
Failure
q Nevertheless controller does not output command current to left steering brake clutch ECMV solenoid
Detail of failure
Action of con-
troller
q State (ON/OFF) of left steering brake cluth ECMV fill switch signal can be checked with monitoring
function.
oil pressure".

Defective left steering brake
1 clutch ECMV fill switch 2. Disconnect connector FLB and connect T-adapter to male side.
Between FLB(female) (1) and ground
(Internal short circuit)) Resistance Min. 1 MΩ
(Fill switch OFF)
2. Disconnect connector FLB.
Ground fault of wiring har- 3. Start engine
2 ness or defective power If failure code [2302L1] is still displayed, there is ground fault of wiring harness or
train controller power train controller is defective.
(If failure code [2302L1] is not displayed, left steering brake clutch fill switch is defec-
tive)
ness 2. Disconnect connectors PTCN2 and FLB and connect T-adapter to female side of
3
cuit) Between PTCN2(female) (6) or FLB(female) (1) and
ground
If "check result of cause 2 is abnormal" and "check result of cause 3 is normal", power
train controller is defective.
4
troller 4. Release the parking brake.
40-154 D375A-6
(01)
DRAFT
Circuit diagram related to left brake ECMV
D375A-6 40-155
(01)
DRAFT
Failure code [2302LH] Left brake: Fill low

Action code Failure code Left brake fill switch signal is OFF.
Failure
q Nevertheless controller outputs command current to left steering brake clutch ECMV solenoid circuit,
Detail of failure
Action of con-
troller
Indication of
problem on
machine
q State (ON/OFF) of left steering brake cluth ECMV fill switch signal can be checked with monitoring
function.
Related infor- q Method of reproducing failure code: Engine start and release parking bake lever.
oil pressure".

2. Disconnect connector FLB and connect T-adapter to male side.
Defective left steering brake Between FLB(male) (1) and ground Resistance Min. 1 MΩ
1 clutch ECMV fill switch (It
3. Start engine.
does not turn ON)
4. Release the parking brake and carry out troubleshooting.
Between FLB (male) (1) and ground Resistance Max. 1 Ω
ness 2. Disconnect connectors PTCN2 and FLB, and connect T-adapters to female side of
2
contact) Between PTCN2 (female) (6) and FLB(female) (1) Resistance Max. 1 Ω
3. Start engine
Defective power train con- 4. Release the parking brake.
3 a Keep PCCS lever in N position.
troller
40-156 D375A-6
(01)
DRAFT
D375A-6 40-157
(01)
DRAFT
Failure code [2302NR] Steering Brake LH Themal Load Abnormality

Action code Failure code Left steering brake thermal load abnormality
Failure
q Power train controller judged from the angle of inclination, travel speed and continuous operating
Detail of failure
time of the left steering that the steering brake was heating abnormally.
Action of con-
troller
Indication of
problem on –
machine
Related infor-
–
mation

1 Improper steering during downhill travel (Machine traveled down a slope and was steered to left continuously)
ler
40-158 D375A-6
(01)
DRAFT
D375A-6 40-159
(01)
DRAFT
Failure code [7RFAKA] ECM ACC CUT RELAY: Disconnection

Action code Failure code Engine controller ACC cut relay disconnection
Failure
― 7RFAKA (Work equipment controller system)
Detail of failure q No voltage is applied to engine controller ACC cut relay primary (coil side) circuit when no grounding.
Action of con-
q Stops grounding to engine controller ACC cut relay primary (coil side) circuit.
troller
q Engine does not start.
Problem on
q If engine ACC cutoff mechanism is mounted, the engine cannot be stopped by ACC cutoff. (The en-
machine
gine cannot be stopped by engine ACC cutoff mechanism.)
q Output to engine controller ACC cut relay primary (coil side) circuit can be checked with monitoring
function (Code: 40983 W/E controller SW output).
Related infor- q Method of reproducing failure code: Turn the starting switch to ON position
mation q This failure code detects failure on primary side (coil side) of engine controller ACC cut relay, but not
on secondary side (contact side).
q If pin WECN2 (8) has ground fault, engine cannot be started.

Defective engine con- 1. Turn starting switch to OFF position.
troller ACC cut relay 2. Disconnect connector ACT and connect T-adapter to male side.
1
(Internal disconnection
Between ACT (male) (1) and (2) Resistance 200 – 400 Ω
or short circuit)
2. Disconnect connectors WECN2 and KEY, and connect T-adapters to female side of
Disconnection or short them.
2
circuit in wiring harness a If resistance is 1 MΩ or above, wiring harness has disconnection. If resistance is 1 Ω or
below, wiring harness has short circuit.
Between KEY (female) (1) and WECN2 (female) (8) Resistance 200 – 400 Ω
Disconnection in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors WECN2, ACT and KEY, and connect T-adapters to female side
3
(Disconnection or of them.
defective contact) Between WECN2 (female) (8) and ACT (female) (2) Resistance Max. 1 Ω
Between KEY (female) (1) and ACT (female) (1) Resistance Max. 1 Ω
Ground fault of wiring
harness 2. Disconnect connectors WECN2 and ACT, and connect T-adapters to female side of
4 them.
(Contact with ground
Between ACT (female) (2) or WECN2 (female) (8) and
ground
If cause is not found by the above checks, work equipment controller is defective.
q Reference: The following are criteria in normal condition.
Defective work equip- 1. Turn starting switch to OFF position.
5
ment controller 2. Insert T-adapter into connector WECN2.
3. Turn starting switch to ON position.
Between WECN2 (8) and ground Voltage Max. 1 V
40-160 D375A-6
(01)
DRAFT
Circuit diagram related to engine controller shut down
D375A-6 40-161
(01)
DRAFT
Failure code [7RFAKB] ECM ACC CUT RELAY: Short circuit

Action code Failure code Engine controller ACC cut relay disconnection
Failure
― 7RFAKB (Work equipment controller system)
Detail of failure q Abnormal current flows when grounding to engine controller ACC cut relay primary (coil side) circuit .
Action of con-
q Stops grounding to engine controller ACC cut relay primary (coil side) circuit.
troller
Problem on
machine
q Output to engine controller ACC cut relay primary (coil side) circuit can be checked with monitoring
function (Code: 40983 W/E controller SW output).
Related infor-
q Method of reproducing failure code: Turn the starting switch ON.
mation
q This failure code detects failure on primary side (coil side) of engine controller ACC cut relay, but not

Defective engine con- 1. Turn starting switch to OFF position.
troller ACC cut relay 2. Disconnect connector ACT and connect T-adapter to male side.
1
Between ACT (male) (1) and (2) Resistance 200 - 400 Ω
or short circuit)
2. Disconnect connectors WECN2 and KEY and connect T-adapters to female side of
2
circuit in wiring harness a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is below
1 Ω, wiring harness has short circuit.
Between KEY (female) (1) and WECN2 (female) (8) Resistance 200 - 400 Ω
Short circuit with power
2. Disconnect connectors WECN2 and ACT, and connect T-adapter to female side of
supply in wiring harness
3 WECN2.
(Contact with 24 V cir-
cuit) 3. Turn starting switch to ON position.
Between WECN2 (female) (8) and ground Voltage Max. 1 V
q Reference: the followings are criteria in normal condition.
Defective work equip- 1. Turn starting switch to OFF position.
4
Between WECN2 (8) and ground Voltage Max. 1 V
40-162 D375A-6
(01)
DRAFT
Circuit diagram related to engine controller shut down
D375A-6 40-163
(01)
DRAFT
Failure code [AA10NX] Air Cleaner Clogging

Action code Failure code Air cleaner clogging
Failure
– AA10NX (Mechanical system)
q Air cleaner clogging switch signal voltage was not 1 V or less while engine was running, and machine
Detail of failure
monitor detected clogging of air cleaner (open of switch contacts).
Action of con-
q None in particular
troller
Indication of
problem on q If the machine is operated under such a condition, engine may be damaged.
machine
Related infor-
mation

Air cleaner clogging
1 Air cleaner may be clogged. Check it for clogging and then clean or replace if clogged.
2. Disconnect connector AF1 and connect T-adapter to male side.
3. Start engine
Defective air cleaner clog- When air
2 ging switch (Internal dis- cleaner is nor- Resistance Max. 1 Ω
connection) mal *1
Between AF1 (male) (1) and (2)
When air
cleaner is Resistance Min. 1 MΩ
clogged *2
ness 2. Disconnect connectors CM01, CM02 and AF1, and connect T-adapters to female
3 (Disconnection in wiring or side of them.
defective contact in con- Between CM02 (female) (4) and AF1 (female) (1) Resistance Max. 1 Ω
nector) Between CM01 (female) (7) and AF1 (female) (2) Resistance Max. 1 Ω
2. Insert T-adapters into connectors CM01 and CM02.
3. Start engine
Defective power train con- When air
4
troller cleaner is nor- Voltage Max. 1 V
Between CM02 (4) and CM01 (7) mal
Air cleaner is
Voltage 7 – 11 V
clogged
q Air cleaner suction resistance
*1: Max. -3,430 Pa {-350 mmH2O}
*2: -7,470 ± 490 Pa {-762 ± 50 mmH2O}
40-164 D375A-6
(01)
DRAFT
Circuit diagram related to air cleaner
D375A-6 40-165
(01)
DRAFT
Failure code [AB00MA] Battery Charge Abnormal
Failure code [AB00MA] Battery Charge Abnormal

Action code Failure code Battery Charge Abnormal
Trouble
– AB00MA (Machine monitor system)
q While engine was running, voltage from alternator lowered, and machine monitor detected that bat-
Detail of failure
tery charge voltage was low.
Action of con-
q Displays charge level monitor red on machine monitor.
troller
Problem on
q If machine is used as it is, battery may not be charged.
machine
q Battery voltage can be checked with monitoring function.
Related infor-
(Code: 04300 Charge voltage)
mation
Cause Procedure, measuring location,criteria and remarks

Defective charge by alter-
It is suspected that problem causing defective battery charge is occurring at present or
1 nator
occurred in past. Investigate cause and damage condition, and correct it.
Defective charge level If cause 1 is not detected, charge level monitor system may be defective. Perform
2
monitor system “E-5 Caution item lights up while engine is running” in E mode.
Failure code [B@BAZG] Eng Oil Press Low

Action code Failure code Eng Oil Press Low
Failure
– B@BAZG (Engine controller system)
q While engine was running, signal voltage from engine oil pressure sensor dropped, and engine con-
Detail of failure
troller detected engine oil pressure too low.
Action of con-
q Displays engine oil pressure monitor red on machine monitor.
troller
Problem on
q If machine is used as it is, engine may be seized.
machine
q Engine oil pressure sensor signal is input to engine controller and then transmitted to machine mon-
itor through communication system.
Related infor-
q Engine oil pressure can be checked with monitoring function.
mation
(Code: 37200 Engine Oil Pressure)

Lowering of engine oil
1 pressure Engine oil pressure may be low. Check it and remove cause if it is low.
Defective engine oil pres- If cause 1 is not the cause for the trouble, engine oil pressure sensor system may be
2
sure caution lamp circuit defective. Perform troubleshooting for failure codes [CA135] and [CA141].
40-166 D375A-6
(01)
DRAFT
Failure code [B@BAZK] Eng Oil Level Low
Failure code [B@BAZK] Eng Oil Level Low

Action code Failure code Eng oil level low
Failure
– B@BAZK (Machine monitor system)
Detail of fail- q While engine was running, signal voltage from engine oil level switch was not 1 V or less, machine
ure monitor detected that engine oil level was low (oil level switch was open).
Action of con-
q Displays radiator coolant level monitor red on machine monitor.
troller
Problem on
machine
Related infor-
mation

Engine oil level low
1 Check engine oil level. If it is low, remove cause.
Defective engine oil level 2. Disconnect connector OLV.
2
sensor (Internal defect) 3. Turn starting switch to ON position.
Between OLV (male) (1) and ground Resistance Max. 1 Ω
harness 2. Disconnect connector CM02 and connect T-adapter to female side.
3
(Disconnection or defec-
Between CM02 (female) (2) and OLV(female) (1) Resistance Max. 1 Ω
tive contact in connector)
If cause is not found by above checks, machine monitor is defective.
Defective machine moni- 1. Turn starting switch to OFF position.
4
tor 2. Insert T-adapter into connector CM02.
Between CM02 (female) (2) and ground Voltage Max. 1 V
Circuit diagram related to engine oil level
D375A-6 40-167
(01)
DRAFT
Failure code [B@BCNS] Eng Water Overheat
Failure code [B@BCNS] Eng Water Overheat

Action code Failure code Eng Coolant Overheat
Failure
– B@BCNS (Engine controller system)
Detail of fail- q While engine was running, voltage from engine coolant temperature sensor dropped, and engine con-
ure troller detected that engine coolant was overheated.
Action of con-
q Displays engine coolant temperature monitor red on machine monitor.
troller
Problem on
machine
q Engine controller inputs voltage of engine coolant temperature sensor signal and then transmits the
data to machine monitor through CAN communication system.
Related infor-
q Engine coolant temperature can be checked with monitoring function
mation
(Code: 04107 Coolant Temperature)

Overheated engine coolant
1 Check engine coolant for overheating. If it is overheated, remove cause.
(when system is normal)
Defective engine coolant If cause 1 is not detected, engine coolant temperature sensor may be defective. Per-
2
temperature sensor system form troubleshooting for failure codes [CA144] and [CA145].
40-168 D375A-6
(01)
DRAFT
Failure code [B@BCZK] Eng Water Level Low
Failure code [B@BCZK] Eng Water Level Low

Action code Failure code Eng coolant level low
Failure
– B@BCZK (Machine monitor system)
q While starting switch was ON (and engine was stopped) or engine was running, radiator coolant level
Detail of fail-
switch signal was not 1 V or less, machine monitor detected that radiator coolant level was low (sen-
ure
sor contact was open).
Action of con-
q Displays radiator coolant level monitor red on machine monitor.
troller
Problem on
q If machine is used as it is, engine may be overheated.
machine
Related infor-
mation

Coolant level low Check radiator sub tank for lowering of coolant level. If coolant level is low, add cool-
1
(When system is normal) ant.
If cause 1 is not detected, radiator coolant level monitor may be defective. Carry out
Defective radiator cool-
2 "E-4 Caution item lights up while starting switch is ON (and engine is stopped)" in E
ant level monitor system
mode.
D375A-6 40-169
(01)
DRAFT
Failure code [B@CENS] T/C Oil Overheat
Failure code [B@CENS] T/C Oil Overheat

Action code Failure code Torque converter overheating
Failure
― B@CENS (Power train controller system)
Detail of fail- q While engine was running, voltage from torque converter oil temperature sensor dropped, and power
ure train controller detected that power train oil was overheated.
Action of con-
q Displays power train oil temperature monitor red on machine monitor.
troller
Problem on
q If machine is used as it is, power train components may be damaged.
machine
q Work equipment controller inputs the signal voltage of torque converter oil temperature sensor, and
transmits this information to the machine monitor through power train controller on CAN communica-
Related infor- tion system.
mation q Torque converter oil temperature can be checked with monitoring function.
(Code: 30100 T/C Oil Temperature)

Overheating of torque con-
1 verter oil (When system is Torque converter oil may be overheated. If it is overheated, remove cause.
normal)
If cause 1 is not detected, torque converter oil temperature sensor system may be
2 oil temperature sensor sys-
defective. Perform troubleshooting for failure code [DGT1KA] or [DGT1KX] .
tem
40-170 D375A-6
(01)
DRAFT
Failure code [B@HANS] Hyd Oil Overheat
Failure code [B@HANS] Hyd Oil Overheat

Action code Failure code Hydraulic Oil overheating
Failure
― B@HANS (Power train controller system)
Detail fo fail- q While engine was running, hydraulic oil temperature sensor voltage dropped, and power train control-
ure ler detected hydraulic oil overheat by data sent from machine monitor by CAN communication.
Action of con-
q Displays hydraulic oil temperature monitor red on machine monitor.
troller
Problem on
q If machine is operated as it is, work equipment circuit units may be damaged.
machine
q Signal voltage of hydraulic oil temperature sensor is input in machine monitor, and then the data is
transmitted to power train controller through CAN communication system.
Related infor-
q Hydraulic oil temperature can be checked with monitoring function
mation
(Code: 04401 Hyd Oil Temperature)

Hyd Oil Overheat
1 Hydraulic oil may be overheating. Check it and remove cause if it is overheating.
If cause 1 is not the cause for the trouble, hydraulic oil temperature gauge system may
Defective hydraulic oil tem-
2 be defective. Perform troubleshooting for failure code [DGS1KX] or "E-10 Hydraulic oil
perature gauge system
temperature gauge (Multi-gauge) does not display normally" in E-mode.
D375A-6 40-171
(01)
DRAFT
Failure code [B@HAZK] Hyd Oil Level Low

Action code Failure code Low Hydraulic Oil Level
Failure
– B@HAZK (Work equipment controller system)
Detail of fail- q Signal voltage from or hydraulic oil lever switch open oil level switch was not 1 V or less while engine
ure was running, and work equipment controller detected low hydraulic oil level or oil lever switch open..
Action of con-
troller
Problem on
q If machine is operated as it is, work equipment circuit units may be damaged.
machine
q Signal of hydraulic oil level switch is input to work equipment controller and then the data is transmitted
to machine monitor through CAN communication system.
Related infor-
q Hydraulic oil level switch can be checked with monitoring function.
mation
(Code: 40981 W/E controller SW input)

Hydraulic oil level low (dur-
1 ing normal system opera- Hydraulic oil may be low. Check it and add oil if necessary.
tion)
Defective engine oil level 2. Disconnect connector HLS and connect T-adapter to male side.
2
switch (Internal defect) 3. Turn starting switch to ON position.
Between HLS (male) (1) and (2) Resistance Max. 1 Ω
ness 2. Disconnect connectors WECN1 and WECN2, and connect T-adapters to female
3 side of them.
Between WECN2 (female) (28) and WECN1 Resistance Max. 1 Ω
(female) (4)
If cause is not found by above checks, work equipment controller is defective.
Defective work equipment 1. Turn starting switch to OFF position.
4
controller 2. Insert T-adapter into connector CM02.
Between WECN2 (28) and WECN1 (4) Voltage Max. 1 V
Circuit diagram related to hydraulic oil level
40-172 D375A-6
(01)
DRAFT
D375A-6 40-173
(01)
DRAFT
Failure code [CA111] ECM Critical Internal Failure

Action code Failure code Abnormality in engine controller
Failure
E03 CA111 (Engine controller system)
Detail of failure q Trouble occurred in engine controller.
Action of con-
troller
Problem on q Machine continues operation normally but may stop suddenly or may not able to start again once it
machine stops.
q Power supply voltage of engine controller can be checked with moniitoring funtion.
Related infor-
(Code: 03200 Battery Power Supply)
mation
q Method of reproducing failure code: turn engine starting switch to ON position.

Loose or corroded battery
1 Battery terminal is possibly loose or corroded, so inspect it directly.
terminal
Loosened terminal or par- 1. Turn starting switch to OFF position.
2 tial disconnection at termi-
Check terminals of alternator, battery relay, ground (GND11) etc. for looseness.
nal
See the items related to wiring harness and connectors in "c: Electric and electrical
Defective wiring harness
3 equipment" in "Checks before troubleshooting" in "General information on trouble-
connector
shooting" section, and check them directly.
1. Turn starting switch OFF, then carry out troubleshooting.
4 Improper battery voltage 2. Measure voltage with starting switch at OFF position.
Between battery terminal (+) and (-). Voltage 20 – 30V
2. Insert T-adapter between male and female side of connector E22.
5 Defective alternator
3. Start engine (Engine speed: Middle or faster).
Between E22 (3) and ground Voltage 26 – 30.5V
If no abnormality is found by the above checks, the engine controller is defective.
(Since the failure is in it, troubleshooting cannot be performed.)
q Reference: The followings are criteria in normal condition.
1. Turn starting switch to OFF position and disconnect ground cable.
6 Defective engine controller 2. Insert T-adapter between male and female sides of EGC3.
3. Connect ground cable.
4. Measure voltage with starting switch at OFF position and when starting engine.
Between EGC3 (3) and (1) Voltage 20 – 30V
Between EGC3 (4) and (2) Voltage 20 – 30V
40-174 D375A-6
(01)
DRAFT
Circuit diagram related to engine controller power supply
D375A-6 40-175
(01)
DRAFT
Failure code [CA115] Eng Ne and Bkup Speed Sens Error

Action code Failure code Abnormality in engine Ne/Bkup speed sensor
Failure
Detail of failure q Abnormality occurred in the signal of Ne and Bkup speed sensor circuits at the same time.
Action of con-
q Stops the engine.
troller
Problem on q The engine does not start. (if engine has been stopped.)
machine q Engine stops. (if engine has been running.)
Related infor-
mation

1 Defective Ne speed sensor system Carry out troubleshooting for failure code [CA689].
2 Defective Bkup speed sensor system Carry out troubleshooting for failure code [CA778].
If cause is not found by above checks,, engine controller may be
3 Defective engine controller defective. (Since failure is in it, troubleshooting cannot be per-
formed.)
40-176 D375A-6
(01)
DRAFT
D375A-6 40-177
(01)
DRAFT
Failure code [CA122] Chg Air Press Sensor High Error

Action code Failure code Charge pressure sensor too high
Failure
Detail of failure q High voltage occurred in charge pressure sensor (boost pressure sensor) signal circuit.
Action of con- q Sets charge pressure (boost pressure) to fixed value (400kPa {4.1 kg/cm2}), and continues opera-
troller tion.
Problem on
q Engine does not accelerate smoothly.
machine
q The signal (voltage) from the charge pressure sensor (boost pressure sensor) can be checked with
the monitoring function (Code: 36501 (V)).
q Pressure (Boost pressure) sensed by charge pressure sensor (boost pressure sensor) can be
Related infor-
checked with monitoring function (Code: 36500 (kPa)).
mation
q Method of reproducing failure code: Turn the starting switch to ON position.
q If sensor connector is disconnected, code [CA123] "Low Error" is displayed, even in normal condi-
tion.

connector
Defective sensor power If failure code [CA187] or [CA227] is displayed at the same time, carry out trouble-
2
supply system shooting for that first.
2. Disconnect connector PIM.
Defective charge pressure
3 3. Turn starting switch ON position.
(boost pressure) sensor
If failure code changes from [CA122] to [CA123], charge pressure (boost pressure)
sensor is defective.
1. Turn starting switch to OFF position, then carry out troubleshooting.
Short circuit in wiring har- 2. Disconnect connectors ENG and PIM, and connect T-adapter to female side of
4
ness ENG.
Between ENG (female) (37) - (44) Resistance Min. 1 MΩ
Short circuit with power 1. Turn starting switch to OFF position.
supply in wiring harness 2. Disconnect connector PIM, and insert T-adapter into connector ENG.
5
(Short circuit with 24 V cir- 3. Turn starting switch to ON position (with connector PIM disconnected).
cuit) Between ENG (44) and (47) Voltage Max. 1V
6 Defective engine controller
40-178 D375A-6
(01)
DRAFT
Circuit diagram related to charge pressure sensor
D375A-6 40-179
(01)
DRAFT
Failure code [CA123] Chg Air Press Sensor Low Error

Action code Failure code Charge pressure sensor too low
Failure
Detail of failure q Low voltage occurred in charge pressure sensor (boost pressure sensor) signal circuit.
Action of con- q Sets charge pressure (boost pressure) to fixed value (400kPa {4.1 kg/cm2}), and continues opera-
troller tion.
Problem on
q Engine does not accelerate smoothly.
machine
q The signal (voltage) from the charge pressure sensor (boost pressure sensor) can be checked with
the monitoring function (Code: 36501 (V)).
q Pressure (Boost pressure) sensed by charge pressure sensor (boost pressure sensor) can be
Related infor-
checked with monitoring function (Code: 36500 (kPa)).
mation
q Method of reproducing failure code: Turn the starting switch to ON position
q Since T-adapter of sensor connector is "socket", voltage at sensor connector cannot be checked.
q If sensor connector is disconnected, this code is displayed.

Defective wiring harness Directly check wire harness and connectors by referring to "c. Electrical equipment"
1
connector described in "Testing before troubleshooting" of "Related troubleshooting information".
Defective power supply
system of charge pressure
2 If failure code [CA187] or [CA227] is indicated, carry out troubleshooting for it first.
sensor (boost pressure
sensor)
Short circuit in wiring har- 2. Disconnect connectors ENG and PIM.
3
ness 3. Connect T-adapter to female side of ENG.
Between ENG (female) (44) and (47) Resistance Min. 1 MΩ
Ground fault of wiring har- 1. Turn starting switch to OFF position, then carry out troubleshooting.
ness 2. Disconnect connectors ENG and PIM, and connect T-adapter to female side of
4
(Contact with ground cir- ENG.
cuit) Between ENG (female) (44) and ground Resistance Min. 1 MΩ
5 If cause is not found by the above checks, wiring harness may be disconnected. (*)
ness
a If causes 1 - 5 are not the cause for the trouble and check result of cause 6 is ab-
normal, sensor is defective.
Defective charge pressure
(boost pressure) sensor
6 2. Connect T-adapter to connector ENG.
(Improper input voltage of
engine controller) 3. Turn starting switch to ON position.
Between ENG (female) (44)
Sensor output Voltage 0.3–4.7V
and (47)
*: Refer to "Troubleshooting method for disconnected wiring harness of pressure sensor system" of "Related
troubleshooting information".
40-180 D375A-6
(01)
DRAFT
Circuit diagram related to charge pressure sensor
D375A-6 40-181
(01)
DRAFT
Failure code [CA131] Throttle Sensor High Error

Action code Failure code Throttle sensor too high
Failure
Detail of failure q High voltage occurred in decelerator pedal potentiometer signal circuit.
Action of con-
q Operate the decelerator pedal at a fixed value.
troller
Problem on
q The engine does not reach full throttle.
machine
q Signal of decelerator potentiometer voltage can be checked with monitoring function (Code: 31703).
Related infor- q Signal state of decelerator potentiometer (decelerator opening) can be checked with monitoring func-
mation tion (Code: 31701).

Defective wiring harness Directly check wire harness and connectors by referring to "c. Electrical equipment"
1
connector described in "Testing before troubleshooting" of "Related troubleshooting information".
Defective throttle sensor
2 If failure code [CA2185] is displayed, troubleshoot it first.
power supply system
Defective decelerator 2. Disconnect connector DEC and connect T-adapter to male side.
3 Between DEC (female)(B) and (C) Resistance 4.0–6.0 kΩ
pedal (throttle sensor)
Between DEC (female)(A) and (C) Resistance 0.2 - 5.0 kΩ
Between DEC (female)(B) and (A) Resistance 0.2 - 5.0 kΩ
Disconnection or short cir- 2. Disconnect connector EGC2 and connect T-adapter to female side.
4
cuit in wiring harness Between EGC2 (female) (22) and (23) Resistance 4.0–6.0 kΩ
Between EGC2 (female) (9) and (23) Resistance 0.2 - 5.0 kΩ
a If no abnormality is found in checks on cause 4, this check is not required.
Short circuit in wiring har- 2. Disconnect connectors EGC2 and DEC, and connect T-adapter to female side of
5
ness either of them.
Between EGC2 (female) (9) and (22) or between
DEC (female) (A) and (B)
Short circuit with power
2. Disconnect connector DEC and connect T-adapter to female side.
6 supply in wiring harness
(Contact with 24 V circuit) 3. Turn starting switch to ON position.
Between DEC(female)(B) and ground Voltage Max. 1V
(Since the faliure is in it, troubleshooting cannot be performed.)
2. Insert T-adapter between male and female sides of EGC2.
7 Defective engine controller 4. Operate decelerator pedal, and troubleshoot.
EGC2 Between (22) and Power supply
Voltage 4.75–5.25V
(23)
Depress decelerator
Voltage Approx.4.7V
pedal.
EGC2 Between (9) and (23)
Release decelerator
Voltage Approx.0.4V
pedal.
40-182 D375A-6
(01)
DRAFT
Circuit diagram related to decelerator pedal
D375A-6 40-183
(01)
DRAFT
Failure code [CA132] Throttle Sensor Low Error

Action code Failure code Throttle sensor too low
Failure
Detail of failure q Decelerator potentiometer signal circuit of throttle sensor detected abnormally low voltage.
Action of con-
q Operate the decelerator pedal at a fixed value.
troller
Problem on
q The engine does not reach full speed.
machine
q Signal of decelerator potentiometer voltage can be checked with monitoring function (Code:
31703).
Related infor-
q Signal state of decelerator potentiometer (decelerator opening) can be checked with monitoring
mation
function (Code: 31701).

Directly check wire harness and connectors by referring to "c. Electrical equipment"
1 described in "Testing before troubleshooting" of "Related troubleshooting informa-
connector
tion".
Defective throttle sensor
2 If failure code [CA2186] is also indicated, perform troubleshooting for it first.
power supply system
Defective decelerator 2. Disconnect connector DEC and connect T-adapter to male side.
3 Between DEC (female)(B) and (C) Resistance 4.0–6.0 kΩ
pedal (throttle sensor)
Between DEC (female)(A) and (C) Resistance 0.2 - 5.0 kΩ
Between DEC (female)(B) and (A) Resistance 0.2 - 5.0 kΩ
Disconnection or short cir- 2. Disconnect connector EGC2 and connect T-adapter to female side.
4
cuit in wiring harness Between EGC2 (female) (22) and (23) Resistance 4.0–6.0 kΩ
Between EGC2 (female) (9) and (23) Resistance 0.2 - 5.0 kΩ
Disconnection in wiring
harness 2. Disconnect connector EGC2 and DEC and connect T-adapter to each female
5 side.
tive contact in connector) Between EGC2 (female) (22) and DEC (female)(A) Resistance Max. 1 Ω
Between EGC2 (female) (9) and DEC (female)(B) Resistance Max. 1 Ω
Between EGC2 (female) (23) and DEC (female)(C) Resistance Max. 1 Ω
Short circuit in wiring har- 2. Disconnect connectors EGC2 and DEC, and connect T-adapter to female side of
6
Between EGC2 (female) (9) and (23) or between
DEC (female) (B) and (C)
ness 2. Disconnect connectors EGC2 and DEC, and connect T-adapter to female side of
7 either of them.
(Contact with ground cir-
Between EGC2 (female) (9) or DEC (female) (B)
and ground
(Since the failure is it, troubleshooting cannot be performed.)
2. Insert T-adapter between male and female sides of EGC2.
8 Defective engine controller 4. Operate decelerator pedal, and troubleshoot.
EGC2 Between (22) and Power supply
Voltage 4.75–5.25V
(23)
Depress decelerator
Voltage Approx.4.7V
pedal.
EGC2 Between (9) and (23)
Release decelerator
Voltage Approx.0.4V
pedal.
40-184 D375A-6
(01)
DRAFT
D375A-6 40-185
(01)
DRAFT
Failure code [CA135] Eng Oil Press Sensor High Error

Action code Failure code Engine oil pressure sensor signal voltage is too high
Failure
Detail of fail-
q High voltage was detected in engine oil pressure sensor signal circuit.
ure
Action of con-
troller q Sets engine oil pressure to default (250kPa {2.5 kg/cm2}), and allows for operation.
Problem on
machine
q Signal voltage from engine oil pressure sensor can be checked with monitoring function (Code:
37201 (V)).
Related infor-
q Oil pressure sensed by engine oil pressure sensor can be checked with monitoring function (Code:
mation
37200 (kPa)).
q Method of reproducing failure code: Turn starting switch to ON position.
See descriptions of related to wiring harness and connectors in "c: Electrical equip-
1 ment" in "Checks before troubleshooting" of "General information on troubleshooting"
connector
, and check them directly.
2 time of engine oil pressure If failure code [CA187] or [CA227] is displayed, perform troubleshooting for it first.
sensor
Defective engine oil pres- 2. Disconnect connector POIL.
3
sure sensor 3. Turn starting switch to ON position.
If failure code changes from [CA135] to [CA141], sensor is defective.
Short circuit in wiring har- 2. Disconnect connectors ENG and POIL, and connect T-adapter to female side of
4 either one of them.
ness
Between ENG (female)(13) and (37), or between P0IL
(female)(1) and (3)
2. Disconnect connector POIL.
Hot short in wiring harness 3. Connect T-adapter to female side of connector POIL or connect T-adapter to
5 connector ENG.
(Short circuit to 24V circuit)
4. Turn starting switch to ON position (with connector POIL disconnected).
BetweenENG(13) and (47) , or between P0IL (female)
Voltage Max. 1V
(3) and (2)
If no abnormality is found by above checks, the engine controller is defective. (Since
failure is in it, troubleshooting cannot be performed.)
40-186 D375A-6
(01)
DRAFT
Circuit diagram related to engine oil pressure sensor
D375A-6 40-187
(01)
DRAFT
Failure code [CA141] Eng Oil Press Sensor Low Error

Action code Failure code Engine oil pressure sensor signal voltage is too low.
Failure
Detail of failure q Low voltage was detected in engine oil pressure sensor signal circuit.
Action of con- 2
q Sets engine oil pressure to default (250kPa {2.5 kg/cm }), and continues operation.
troller
Problem on
machine
q Signal voltage from the engine oil pressure sensor can be checked with the monitoring function
(Code: 37201 (V)).
Related infor-
q Oil pressure sensed by engine oil pressure sensor can be checked with monitoring function (Code:
mation
37200 (kPa)).

See descriptions wiring harness and connectors in "c: Electrical equipment" in "Checks
1 before troubleshooting" of "General information on troubleshooting" , and check them
connector
directly.
If failure code [CA187] or [CA227] is displayed, perform troubleshooting for it first
2. Disconnect connector POIL and connect T-adapter to each female side of them.
2 system of engine oil pres-
Power supply
Between POIL(female)(1) and (2) Voltage 4.75 – 5.25V
input
2. Disconnect connectors ENG and POIL and connect T-adapter to female side.
a If power input in checks on cause 2 is normal, this
Disconnection in wiring check is not required. Resistance Max. 1 Ω
harness Between ENG (female) (37) and P0IL(female)(1)
3
(Disconnection or defec- a If power input in checks on cause 2 is normal, this
tive contact in connector) check is not required. Resistance Max. 1 Ω
Between ENG (female) (47) and P0IL(female)(2)
Between ENG (female) (3) and P0IL (female)(3) (Sensor
output)
Ground fault of wiring har- 2. Disconnect connectors ENG and POIL, and connect T-adapter to female side of either
4 ness one of them.
(Contact with GND circuit) Between ENG(female)(13) and ground, or between
P0IL(female)(3) and ground
Short circuit in wiring har- 2. Disconnect connectors ENG and POIL, and connect T-adapter to female side of either
5 one of them.
ness
Between ENG (female)(13) and (47), or between P0IL
(female) (2) and (3)
a If causes 1 – 5 are not the cause for failure and check result of cause 6 is abnormal,
Defective engine oil pres- sensor may be defective.
sure sensor (Improper
6 input voltage to engine
2. Insert T-adapter between male and female sides of connector ENG
controller)
Between ENG (13) and (47) Sensor output Voltage 0.3 – 4.7V
Defective engine control- If no abnormality is found by above checks, the engine controller is defective. (Since the-
7
ler failure is in it, troubleshooting cannot be performed.)
40-188 D375A-6
(01)
DRAFT
Circuit diagram related to engine oil pressure sensor
D375A-6 40-189
(01)
DRAFT
Failure code [CA144] Coolant Temp Sens High Error

Action code Failure code Coolant temperature sensor signal valtage is too high.
Failure
Detail of failure q High voltage was detected in engine coolant temperature sensor signal circuit.
Action of con-
q Sets coolant temperature to fised temperature (90 °C) ,and allows for operation.
troller
Problem on q Engine does not start easily at low temperature.
machine q Overheat prevention function does not work.
q Signal voltage from engine coolant temperature sensor can be checked with monitoring function
(Code: 04105 (V)).
q Temperature sensed by engine coolant temperature sensor can be checked with monitoring function
Related infor- (Code: 04104 (°C)).
mation q Method of reproducing failure code: Turn starting switch to ON position.
q If temperature sensor connector is disconnected, this failure code is displayed.
q Since T-adapter for sensor connector is "socket" type , T-adapter cannot be connected to wiring har-
ness.

See descriptions of to wiring harness and connectors in "c: Electrical equipment" in
1 "Checks before troubleshooting" of "General information on troubleshooting", and check
connector
them directly.
2. Disconnect connector TWTR and connect socket to male side of connector.
a If coolant temperature sensor has resistance of 700 Ω - 37 kΩ with coolant tempera-
Defective coolant temper- ture above 0 °C , regard coolant temperature sensor as normal.
2 Between TWTR (male) (A) 0 °C Resistance 30 - 37 kΩ
ature sensor
and (B) 25 °C Resistance 9.3 - 10.7 kΩ
a Coolant temperature 50 °C Resistance 3.2 - 3.8 kΩ
-Resistaure character- 80 °C Resistance 1.0 - 1.3 kΩ
istics 95 °C Resistance 700 - 800 Ω
2. Disconnect connector ENG and connect T-adapter to female side.
Disconnection or short Between ENG (female) (15) and (38) (Coolant tempera-
3 ture: Min. 0 °C)
circuit in wiring harness
a Use” coolant temperature -Resistance Resistance 700 Ω - 37 kΩ
characteristics ” table shown above as resistance cri-
teria.
Defective engine control- If no abnormality is found by the above checks, engine controller is defective. (Since fail-
4
ler ure is in it, troubleshooting cannot be performed.)
40-190 D375A-6
(01)
DRAFT
Circuit diagram related to coolant temperature sensor
D375A-6 40-191
(01)
DRAFT
Failure code [CA145] Coolant Temp Sens Low Error

Action code Failure code Coolant temperature sensor signal valtage is too low
Failure
Detail of failure q Low voltage was detected in engine coolant temperature sensor signal circuit.
Action of con-
q Sets coolant temperature to fixed temperature (90 °C),and allows for operation.
troller
Problem on q Engine does not start easily at low temperature.
machine q Overheat prevention function does not work.
q Signal voltage from engine coolant temperature sensor can be checked with monitoring function
(Code: 04105 (V)).
q Temperature sensed by engine coolant temperature sensor can be checked with monitoring function
Related infor-
(Code: 04104 (°C)).
mation
q If temperature sensor connector is disconnected, this failure code is not displayed but failure code for
High Error is displayed.
See descriptions of wiring harness and connectors in "c: Electrical equipment" in
1 "Checks before troubleshooting" of "General information on troubleshooting" , and
connector
check them directly.
2. Disconnect connector TWTR and connect socket to male side of connector.
a If coolant temperature sensor has resistance of 700 Ω - 37 kΩ with coolant temper-
ature above 0 °C, regard coolant temperature sensor as normal.
Between TWTR (male) (A) 0 °C Resistance 30 - 37 kΩ
Defective coolant tempera- and (B) 25 °C Resistance 9.3 - 10.7 kΩ
2
ture sensor a Coolant temperature 50 °C Resistance 3.2 - 3.8 kΩ
-Resistaure characteris- 80 °C Resistance 1.0 - 1.3 kΩ
tics 95 °C Resistance 700 - 800 Ω
All coolant
Between (B) and ground temperature Resistance Min. 1 MΩ
range
Short circuit in wiring har- Between ENG (female)(15) and (38) (Coolant tempera-
3 ture: Min. 0 °C)
ness
a Use” coolant temperature -Resistance Resistance 700 Ω - 37 kΩ
characteristics ” table shown above as resistance cri-
teria.
4 ness 2. Disconnect connectors ENG and TWTR, and connect T-adapter to female side of
(Contact with GND circuit) ENG.
Between ENG (female) (15) and ground Resistance Min. 1 MΩ
If no abnormality is found by above checks, engine controller is defective. (Since failure
is in it, troubleshooting cannot be performed.)
40-192 D375A-6
(01)
DRAFT
Circuit diagram related to coolant temperature sensor
D375A-6 40-193
(01)
DRAFT
Failure code [CA153] Chg Air Temp Sensor High Error

Action code Failure code Charge (Boost) temperature sensor signal voltage is too high.
Failure
Detail of fail-
q High voltage was detected in charge (boost) temperature sensor signal circuit.
ure
Action of con-
q Sets charge temperature to fixed temperature (70 °C) ,and allows for operation.
troller
Problem on
q Engine does not start easily at low temperature.
machine
q Signal voltage from charge temperature sensor (boost temperature sensor) can be checked with mon-
itoring function (Code: 18501 (V)).
q Temperature sensed by charge temperature sensor (boost temperature sensor) can be checked with
Related infor- monitoring function (Code: 18500 (°C)).
mation q Method of reproducing failure code: Turn the starting switch to ON position.
q Since T-adapter for sensor connector is "socket" type , T-adapter cannot be connected to wiring har-
ness.
q If temperature sensor connector is disconnected, this failure code is displayed.
See descriptions of related to wiring harness and connectors in "c: Electrical equipment"
1 in "Checks before troubleshooting" of "General information on troubleshooting" , and
connector
2. Disconnect connector TIM and connect socket to male side of connector.
a If charge temperature sensor resistance is 280 Ω - 382 kΩ, regard charge tempera-
ture sensor as normal.
Defective charge temper- -40 °C Resistance 291 kΩ – 382 kΩ
2 Between TIM (male) -20 °C Resistance 85 kΩ – 109 kΩ
ature sensor
(A) and (B) 0 °C Resistance 29 kΩ – 36 kΩ
a Charge tempera- 30 °C Resistance 7.3 kΩ – 8.8 kΩ
ture -Resistance 60 °C Resistance 2.3 kΩ –2.7 kΩ
chariacteristic 90 °C Resistance 860 – 970 Ω
130 °C Resistance 280 – 320 Ω
Disconnection or short cir- 2. Disconnect connector ENG and connect T-adapter to female side.
3 Between ENG (female) (23) and (47)
cuit in wiring harness
a Use "charge temperature-Resistance characteris- Resistance 280 Ω - 382 kΩ
tics" table shown above as resistance criteria.
Defective engine control- If no abnormality is found by above checks, engine controller is defective. (Since failure
4
ler is in it, troubleshooting cannot be performed.)
40-194 D375A-6
(01)
DRAFT
Circuit diagram related to charge temperature sensor
D375A-6 40-195
(01)
DRAFT
Failure code [CA154] Chg Air Temp Sensor Low Error

Action code Failure
Charge (Boost) temperature sensor signal volatge too low
code Failure
(Engine controller system)
E01 CA154
Detail of failure q Low voltage was detected in charge (boost) temperature sensor signal circuit.
Action of con-
q Set charge temperature to fixed temperature (70 °C) ,and allow for operation.
troller
Problem on
q Engine does not start easily at low temperature.
machine
q Signal voltage from charge temperature sensor (boost temperature sensor) can be checked with
monitoring function (Code: 18501 (V)).
q Temperature sensed by charge temperature sensor (boost temperature sensor) can be checked
Related infor-
with monitoring function (Code: 18500 (°C)).
mation
q If temperature sensor connector or harness is disconnected,this failure code is not displayed but fail-
ure code for High Error is displayed.
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks
connector
directly.
2. Disconnect connector TIM and connect socket to male side of connector.
a If temperature sensor has resistance of 280 Ω - 382 kΩ, regard charge temperature
sensor as normal.
Defective charge temper- -40 °C Resistance 291 kΩ – 382 kΩ
2 -20 °C Resistance 85 kΩ – 109 kΩ
ature sensor TIM (male) (A) and (B)
0 °C Resistance 29 kΩ – 36 kΩ
a Charge temperature
30 °C Resistance 7.3 kΩ – 8.8 kΩ
-Resistance chari-
60 °C Resistance 2.3 kΩ – 2.7 kΩ
acteristic
Short circuit in wiring har- 2. Disconnect connector ENG and connect T-adapter to female side.
3 Between ENG (female) and (47)
ness
a Use "charge temperature-Resistance characteris- Resistance 280 Ω – 382 kΩ
tics" table shown above as resistance criteria.
Ground fault of wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors ENG and TIM and connect T-adapter to female side of ENG.
4
(Contact with GND cir-
cuit)
Defective engine control- If no abnormality is found by above checks, engine controller is defective. (Since failure is
5
ler in it, troubleshooting cannot be performed.)
40-196 D375A-6
(01)
DRAFT
Circuit diagram related to charge temperature sensor
D375A-6 40-197
(01)
DRAFT
Failure code [CA187] Sens Supply 2 Volt Low Error

Action code Failure code Sensor power source 2 too low
Failure
Detail of failure q Sensor power supply 2 (5 V) circuit voltage is too low.
q Engine controller ignores signals from Bkup speed sensor and controls engine by using Ne speed
sensor signals.
q Engine controller ignores signals from engine oil pressure sensor, sets engine oil pressure to default
value (500 kPa {2.5 kg/cm2}),and allows engine to run.
Action of con- q Engine controller ignores signals from ambient pressure sensor ,sets ambient pressure to default
troller value (52.44 kPa {0.53 kg/cm2}),and allows engine to run.
q Engine controller ignores signals from boost pressure sensor, sets boost pressure to default value
(400 kPa {4.1 kg/cm2}),and allows engine to run.
q Engine controller ignores signals from EGR valve lift sensor , limits engine output and closes EGR
valve.
Problem on
q Engine output drops.
machine
Related infor-
mation

connector
2. Disconnect following connectors one by one and turn starting switch to ON position
each time.
3. After troubleshooting of each connector, turn starting switch to OFF position.
If this failure code is not displayed when a connector is disconnected, that sensor or
engine wiring harness is defective.
Defective sensor or har- a Other failure codes are displayed, too. This is because the connector is disconnect-
2 ed. Ignore failure codes other than [CA187].
ness
Sensor or harness Connector
Bkup speed sensor system G connector
Engine oil pressure sensor POIL connector
Charge (boost) pressure sensor PIM connector
Ambient pressure sensor PAMB connector
EGR valve lift sensor SEGR connector
Engine wiring harness ENG
3 Defective related system If another failure code is displayed, perform troubleshooting for it.
2. Disconnect connector ENG and connect T-adapter to male side.
3. Turn starting switch to ON position with engine wiring harness disconnected.
Between ENG (male) (37) and (47) Voltage 4.75 – 5.25 V
40-198 D375A-6
(01)
DRAFT
Circuit diagram related to sensor power supply 2
D375A-6 40-199
(01)
DRAFT
Failure code [CA212] Eng Oil Temp Sensor High Error

Action code Failure code Engine oil temperature sensor signal voltage is too high.
Failure
Detail of failure q High voltage was detected engine oil temperature sensor signal circuit
Action of con-
q Sets engine oil temperature to fixed value (100 °C), and allows engine to run.
troller
Problem on
machine
q Signal voltage from engine oil temperature sensor can be checked with monitoring function (Code:
42701 (V)).
q Temperature sensed by engine oil temperature sensor can be checked with monitoring function
Related infor-
(Code: 42700 (°C)).
mation
q This failure code is displayed if temperature sensor connector or harness is disconnected.
q Since T-adapter for sensor connector is “socket” type, it cannot be connected to wiring harness.

connector
2. Disconnect connector TOIL and connect socket to male side of connector.
a If coolant temperature sensor resistance is 700 Ω – 37 kΩ with coolant temperature
Defective oil temperature above 0 °C, regard coolant temperature sensor as normal.
2 0 °C Resistance 30 - 37 kΩ
sensor TOIL(male) between (A)
25 °C Resistance 9.3 - 10.7 kΩ
and (B)
a Oil temperature -Resis-
tance characteristic
95 °C Resistance 700 - 800 Ω
2. Disconnect connector ENG and connect T-adapter to female side of connector.
Disconnection or short circuit Between ENG (female) (17) and (47) (with oil tempera-
3
in wiring harness ture above 0 °C)
Resistance 700 Ω - 37 kΩ
a Use”Oil temperature -Resistance charactenis” table
shown above as resistance criteria.
If no abnormality is found by above checks, engine controller is defective. (Since fail-
ure is in it, troubleshooting cannot be performed.)
40-200 D375A-6
(01)
DRAFT
Circuit diagram related to engine oil temperature sensor
D375A-6 40-201
(01)
DRAFT
Failure code [CA213] Eng Oil Temp Sensor Low Error

Action code Failure code Engine oil temperature sensor signal voltage is too low.
Failure
Detail of failure q Low voltage was detected in engine oil temperature sensor signal circuit.
Action of con-
q Sets engine oil temperature to fixed value (100 °C), and allows engine to run.l
troller
Problem on
machine
q Signal voltage from engine oil temperature sensor can be checked with monitoring function (Code:
42701 (V)).
q Temperature sensed by engine oil temperature sensor can be checked with monitoring function
Related infor-
(Code: 42700 (°C)).
mation
q If temperature sensor connector is disconnected, this failure code is not displayed but failure code
for High Error is displayed.

See the descriptions of wiring harness and connectors in "c: Electrical equipment" in
1 "Checks before troubleshooting" of "General information on troubleshooting" sec-
connector
tion, and check them directly.
2. Disconnect connectors TOIL and connect socket to male side of connector.
a If oil temperature sensor resistance is 700 Ω - 37 kΩ with oil temperature is
above0 °C, regard oil temperature sensor as normal.
Between TOIL (male) (A) 0 °C Resistance 30 - 37 kΩ
Defective oil temperature 25 °C Resistance 9.3 - 10.7 kΩ
2 and (B)
sensor 50 °C Resistance 3.2 - 3.8 kΩ
a Oil temperature -Resis-
tance characteristics
95 °C Resistance 700 - 800 Ω
All oil tem-
Between (B) and ground perature Resistance Min. 1 MΩ
range
Short circuit in wiring har- Between ENG (female) (17) and (47) (Oil temperature:
3
ness Min. 0 °C)
Resistance 700 - 37 kΩ
a Use”Oil temperature -Resistance charactenis” ta-
ble shown above as resistance criteria.
4 ness 1. Turn starting switch to OFF position.
(Contact with GND circuit) 2. Disconnect connectors ENG and TOIL, and connect T-adapter to female side of
ENG.
40-202 D375A-6
(01)
DRAFT
Circuit diagram related to engine oil temperature sensor
D375A-6 40-203
(01)
DRAFT
Failure code [CA221] Ambient Press Sens High Error

Action code Failure code Ambient pressure sensor signal voltage is too high.
Trouble
Detail of failure q High voltage was detected in ambient pressure sensor signal circuit .
Action of con- 2
q Sets ambient pressure value to default value (50.99kPa {0.52 kg/cm }),and allow engine to run.
troller
Problem on
machine
q Signal voltage from ambient pressure sensor can be checked with the monitoring function (Code:
37401 (V)).
Related infor-
q Ambient pressure by the ambient pressure sensor can be checked with the monitoring function
mation
(Code: 37400 (kPa)).

Defective wiring har-
1 "Checks before troubleshooting" of "General information on troubleshooting", and check
ness connector
them directly.
2 line of ambient pres- If failure code [CA187] or [CA227] is also displayed, perform troubleshooting for it first.
sure sensor
Defective ambient pres- 2. Disconnect connector PAMB.
3
If failure code changes from [CA221] to [CA222] ,sensor is defective.
Short circuit in wiring
4 2. Disconnect connector ENG and PAMB, and connect T-adapter to female side of ENG.
harness
Hot short in wiring har-
2. Disconnect connector PAMB.
ness
5
(Short circuit to 24 V cir- 3. Insert T-adapter into connector ENG.
cuit) 4. Turn starting switch to ON position (with connector PAMB disconnected).
Between ENG(3) – (38) Voltage Min. 1 V
Defective engine con- If no abnormality is found by the above checks, the engine controller is defective. (Since
6
troller failure is in it, troubleshooting cannot be performed.)
40-204 D375A-6
(01)
DRAFT
Circuit diagram related to atmospheric pressure sensor
D375A-6 40-205
(01)
DRAFT
Failure code [CA222] Ambient Press Sens Low Error

Action code Failure code Ambient pressure sensor value too low.
Failure
Detail of failure q Low voltage was detected ambient pressure sensor signal circuit .
Action of con- 2
q Sets ambient pressure value to default value(52.44 kPa {0.53 kg/cm }),and allows engine to run.
troller
Problem on
machine
q Signal voltage from ambient pressure sensor can be checked with monitoring function (Code: 37401
(V)).
q Ambient pressure sensed by the ambient pressure sensor can be checked with monitoring function
Related infor- (Code: 37400 (kPa)).
mation q Method of reproducing failure code: Turn starting switch to ON position.
q Since T-adapter of sensor connector is "socket" type, voltage at sensor connector cannot be
checked.
q If sensor connector is disconnected, this code is displayed.

See descriptions of wire harness and connectors in "c. Electrical equipment" in "Checks
1 before troubleshooting" of "Gemeral information on troubleshooting ,and check them
connector
directly".
2 line of ambient pressure If failure code [CA187] or [CA227] is also displayed, perform troubleshooting for it first.
sensor
Short circuit in wiring har- 2. Disconnect connectors PAMB and ENG.
3
ness 3. Connect T-adapter to female side of ENG.
harness 2. Disconnect connectors PAMB and ENG and connect T-adapter to female side of
4
cuit) Between ENG(female)(3) and ground Resistance Min. 1 MΩ
5 If cause is not found by the above checks, wiring harness may be disconnected. (*)
harness
a If causes 1 - 5 are not the cause for failure and check result of cause 6 is abnormal,
sensor is defective.
Defective ambient pres-
sure sensor
6 2. Insert T-adapter into connector ENG.
(Improper input voltage
from engine controller) 3. Turn starting switch to ON position.
Sensor Approx. 0.3 - 4.7
ENG Between (3) and (38) Voltage
output V
Defective engine control- If no abnormality is found by above checks, the engine controller is defective. (Since
7
ler failure is in it, troubleshooting cannot be performed.)
*: Refer to "Troubleshooting method for disconnecting wiring harness of pressure sensor system" of "General
information on troubleshooting".
40-206 D375A-6
(01)
DRAFT
Circuit diagram related to ambient pressure sensor
D375A-6 40-207
(01)
DRAFT
Failure code [CA227] Sens Supply 2 Volt High Error

Action code Failure code Sensor power supply circuit valtage is too high
Failure
Detail of failure q High voltage in engine controller sensor power supply 2 (5 V) circuit was detected.
q Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor signals.
q Ignores signals from engine oil pressure sensor,sets engine oil pressure to default value (500 kPa
{2.5 kg/cm2}),and allows engine to run.
Action of con- q Ignores signals from ambient pressure sensor, sets ambient pressure to default value (52.44 kPa
troller {0.53 kg/cm2}),and allows engine to run.
q Ignores signals from boost pressure sensor, sets boost pressure to default value (400 kPa
{4.1 kg/cm2}),and allows engine to run.
q Ignores signals from EGR valve lift sensor, limits engine output and closes EGR valve.
Problem on
machine
Related infor-
q Method of reproducing failure code: Turn the starting switch to ON position .
mation

Perform troubleshooting for failure code [CA187].
40-208 D375A-6
(01)
DRAFT
Failure code [CA234] Eng Overspeed
Failure code [CA234] Eng Overspeed

Action code Failure code Engine overspeed
Failure
Detail of failure q Engine speed exceeded operating range.
Action of con-
q Reduce fuel injection rate until engine speed lowers in operating range.
troller
Problem on
q Engine speed fluctuates.
machine
Related infor- q Engine speed can be checked by monitoring function (Code: 01000 (rpm)).
mation q Method of reproducing failure code: Start engine and keep it running at high idle.

1 Use of improper fuel Improper fuel may be used. Check it directly.
2 Defect in related system If another failure code is displayed, perform troubleshooting for it.
The method of using machine may be improper, so instruct the operator on how to
3 Usage is improper
use machine properly.
If causes 1 and 2 are not cause of failure, engine controller may be defective. (Since
failure is in it , troubleshooting cannot be performed.)
D375A-6 40-209
(01)
DRAFT
Failure code [CA238] Ne Speed Sens Supply Volt Error

Action code Failure code Ne speed sensor power supply voltage error
Failure
Detail of failure q Abmormality was detected rror occurred in Ne speed sensor power supply (5 V) circuit.
Action of con- q Controls engine by using signals from Bkup speed sensor.
troller q Limits engine output and allows engine to run.
Problem on
q Engine stops during operation (when Bkup speed sensor is also defective)
machine
q Engine cannot start during stop (when Bkup speed sensor is also defective)
Related infor-
mation

connector
directly.
each time.
3. After each troubleshooting, turn starting switch to OFF position.
Defective sensor or wir- If this failure code is not displayed when a sensor is disconnected, sensor or engine wiring
2 harness is defective.
ing harness
a Other failure code (s) is (are) also displayed. This is because sensor connector is dis-
connected. Therefore, ignore code(s) other than failure code [CA238].
Sensor or harness Connector
Ne speed sensor NE
Engine harness ENG
Defective engine con- 2. Disconnect connector ENG and connect T-adapter to male side of connector.
3
troller 3. Turn starting switch to ON position with engine wiring harness disconnected.
Between ENG(male)(16) and (48) Voltage 4.75 – 5.25V
Circuit diagram related to Ne speed sensor
40-210 D375A-6
(01)
DRAFT
D375A-6 40-211
(01)
DRAFT
Failure code [CA263] Fuel Temp Sensor High Error

Action code Failure code Fuel temperature sensor signal voltage is too high
Failure
Detail of fail-
q High voltage was detected in fuel temperature sensor signal circuit .
ure
q Uses signals from coolant temperature sensor to perform fuel injection rate correction based on fuel
Action of con-
temperature.
troller
q Sets fuel temperature value to fixed value (95 °C) and allows engine to run.
Problem on
machine
q Signal voltage from the fuel temperature sensor can be checked with the monitoring function (Code:
14201 (V)).
q Temperature sensed by fuel temperature sensor can be checked with the monitoring function (Code:
Related infor- 14200 (°C)).
q This failure code is displayed if temperature sensor connector is disconnected.
q Because that T-adapter for sensor connector is “socket” type, it cannot be connected to wiring har-
ness.

connector
2. Disconnect connector TFUEL and connect socket to male side of connector.
a If coolant temperature sensor resistance is 700 Ω – 37 kΩ with coolant tempera-
ture is above 0 °C, regard coolant temperature sensor as normal.
TFUEL(male) 0 °C Resistance 30 - 37 kΩ
Defective fuel temperature
2 between 25 °C Resistance 9.3 - 10.7 kΩ
sensor
(A) and (B) 50 °C Resistance 3.2 - 3.8 kΩ
a Fuel tempera- 80 °C Resistance 1.0 - 1.3 kΩ
ture -Resis-
t a n c e 95 °C Resistance 700 - 800 Ω
characteristic
Between ENG (female) (30) and (47) (Fuel tem-
Disconnection or short cir-
3 perature : above 0 °C)
a Use “Fuel temperature - Resistance Resistance 700 Ω - 37 kΩ
characteristics” table shown above as resis-
tance critaeria.
40-212 D375A-6
(01)
DRAFT
Circuit diagram related to fuel temperature sensor
D375A-6 40-213
(01)
DRAFT
Failure code [CA265] Fuel Temp Sensor Low Error

Action code Failure code Fuel temperature sensor signal voltage is to low
Failure
Detail of fail-
q Low voltage was detected in fuel temperature sensor signal circuit.
ure
q Uses signals from coolant temperature sensor to perform fuel injection rate correction based on fuel
Action of
temperature.
controller
(Sets to fixed value (95 °C) and ,and allows engine to run)
Problem on
machine
q Signal voltage from fuel temperature sensor can be checked with monitoring function (Code: 14201
(V)).
q Temperature sensed by fuel temperature sensor can be checked with monitoring function (Code:
Related infor-
04204 (°C)).
mation
q This code is not displayed but failure code for “High Error” is displayed, if sensor connector is dis-
connected.

1 "Checks before troubleshooting" of "General information on troubleshooting" section,
connector
and check them directly.
2. Disconnect connector TFUEL and connect socket to male side.
a If coolant temperature sensor resistance is 700 Ω – 37 kΩ with coolant temperature is
above0 °C, regard coolant temperature sensor as normal.
Defective fuel tempera- TFUEL(male) between 0 °C Resistance 30 - 37 kΩ
2 (A) and (B) 25 °C Resistance 9.3 - 10.7 kΩ
ture sensor
a Fuel temperature - 50 °C Resistance 3.2 - 3.8 kΩ
Resistance charac- 80 °C Resistance 1.0 - 1.3 kΩ
teristic 95 °C Resistance 700 - 800 Ω
Between (B) and All fuel tem-
ground perature range
Between ENG (female) (15) and (38) (Fuel tempera-
Short circuit in wiring
3 ture : above 0 °C)
harness
a Use”Fuel temperature - Resistance Resistance 700 Ω - 37 kΩ
characteristics ” table shown above as resistance
criteria.
harness 2. Disconnect connector TFUEL, and connect T-adapter to female side of ENG.
4
(Contact with GND cir-
cuit)
Defective engine control- If no abnormality is found by the above checks, engine controller is defective. (Since fail-
5
ler ure is in it, troubleshooting cannot be performed.)
40-214 D375A-6
(01)
DRAFT
Circuit diagram related to fuel temperature sensor
D375A-6 40-215
(01)
DRAFT
Failure code [CA271] IMV/PCV1 Short Error
Failure code [CA271] IMV/PCV1 Short Error

Failure
Action code IMV/PCV1 short circuit error
code Failure
E03 CA271
Detail of failure q Short circuit was detected in supply pump PCV1 circuit.
Action of con-
troller
Problem on
machine
Related infor- q Pulse voltage of approx. 24V is normally applied to PCV1 (1) while engine is running, but it cannot
mation be measured with circuit tester .

Defective wiring har- Directly check wire harness and connectors by referring to "c. Electrical equipment"
1
ness connector described in "Testing before troubleshooting" of "General information on troubleshooting".
Defective supply pump
2. Disconnect connector PCV1.
2 PCV1 (Internal short
circuit) 3. Turn starting switch to ON position.
If failure code changes from [CA271] to [CA272], supply pump PCV1 is defective.
Short circuit in wiring 2. Disconnect connector ENG and connect T-adapter to female side of connector .
3
harness Between ENG (female) (4) and (5) (PCV1 resistance) Resistance 2.3 – 5.3 Ω
Between ENG(female)(4) and ground Resistance Min. 1 MΩ
harness 2. Disconnect connector ENG and PCV1, and connect Tadapter to female side of ENG.
4
circuit)
ness
(Short circuit to 24 V
circuit) 4. Turn starting switch to ON position (with connector PCV1 disconnected).
ENG Between (4) and (5) Voltage Max. 3 V
Defective engine con- If no abnormality is found by above checks, engine controller is defective. (Since failure is
6
troller in it troubleshooting cannot be performed.)
Circuit diagram related to PCV1
40-216 D375A-6
(01)
DRAFT
Failure code [CA272] IMV/PCV1 Open Error
Failure code [CA272] IMV/PCV1 Open Error

Action code Failure code IMV/PCV1 disconnection
Trouble
Failure descrip-
q Disconnection was detected in supply pump PCV1 circuit.
tion
Action of con-
troller
Indication of
problem on
machine
q While engine is running normally, Pulse voltage of approx. 24 V is normally applied to PCV (1) while
Related infor-
engine is running ,but it cannot be measured with circuit tester since it is pulse voltage.
mation
q Since T-adapter for PCV connector is "socket" type , T-adapter cannot be connected to wiring har-
ness.

See descriptions of wiring harness and connectors in "c: Electrical
1 equipment" in "Checks before troubleshooting" of "General information
connector
on troubleshooting" , and check them directly.
Defective supply pump 1. Turn starting switch to OFF position.
2 PCV1 2. Disconnect connectors PCV1 and connect socket to male side.
(Internal disconnection) Between PCV1 (male) (1) and (2) Resistance 2.3 - 5.3 Ω
3 2. Disconnect connector ENG and connect T-adapter to female side.
Between ENG (female) (4) and (5) (PCV1 resistance) Resistance 2.3 - 5.3 Ω
ness 2. Disconnect connectors ENG and PCV1.
4
(Contact with ground cir- 3. Connect T-adapter to female side of connector ENG.
cuit) Between ENG (4) and (5) Resistance Min. 1 MΩ
D375A-6 40-217
(01)
DRAFT
Failure code [CA273] PCV2 Short Error
Failure code [CA273] PCV2 Short Error

Action code Failure code PCV2 short circuit error
Failure
Detail of failure q Short circuit was detected in supply pump PCV2 circuit.
Action of con-
troller
Problem on
machine
Related infor-
q Pulse voltage of approx. 24 V is normally applied to PCV2 (1) while engine is running , but it cannot
mation
be measured with circuit tester.

Directly check wire harness and connectors by referring to "c. Electrical equipment"
1 described in "Testing before troubleshooting" of "General information troubleshooting
connector
on".
Defective supply pump
2 PCV2
(Internal short) 3. Turn starting switch to ON position.
If failure code changes from [CA273] to [CA274], supply pump PCV2 is defective.
Short circuit in wiring har- 2. Disconnect connector ENG and connect T-adapter to female side.
3
ness Between ENG (female) (9) and (10) (PCV2 resis-
Resistance 2.3 – 5.3 Ω
tance)
ness 2. Disconnect connector ENG and PCV2, and connect Tadapter to female side of
4
cuit) Between ENG(female)(9) and ground Resistance Min. 1 MΩ
Hot short in wiring harness
(Short to 24 V circuit)
4. Turn starting switch to ON position (with connector PCV2 disconnected).
Between ENG(9) and (10) Voltage Max. 3 V
40-218 D375A-6
(01)
DRAFT
Failure code [CA274] PCV2 Open Error
Failure code [CA274] PCV2 Open Error

Action code Failure code PCV2 disconnection
Failure
Detail of failure q Disconnection was detected in supply pump PCV2 circuit.
Action of con-
troller
Problem on
machine
q Method of reproducing failure code: Turn the starting switch ON.
Related infor-
q , Pulse voltage of approx. 24 V is normally applied to PCV2 (1) while engine is running, but it cannot
mation
be measured with circuit tester.

See the descriptions of wiring harness and connectors in "c: Electrical equipment" in
connector
Defective supply pump 1. Turn starting switch to OFF position.
2 PCV2 2. Disconnect connector PCV2 and connect socket to male side.
(Internal disconnection) Between PCV2 (male) (1) and (2) Resistance 2.3 - 5.3 Ω
3 2. Disconnect connector ENG and connect T-adapter to female side.
Between ENG (female) (9) and (10) (PCV2 resist) Resistance 2.3 - 5.3 Ω
2. Disconnect connector ENG and PCV2.
4 ness
(Contact with GND circuit) 3. Connect T-adapter to female side of connector ENG.
If no abnormality is found by above checks, engine controller is defective. (Since the
D375A-6 40-219
(01)
DRAFT
Failure code [CA322] Inj #1 (L#1) Open/Short Error

Action code Failure code Injector #1(L#1) open/short circuit error
Failure
Detail of failure q Disconnection or short circuit was detected in injector #1 circuit.
Action of con-
troller
Problem on q Engine output drops.
machine q Engien speed does not stabilize
Related infor-
q Pulse voltage of about 65 V is applied noromally supplied to injector (+) side while engine is running
mation
but it cannot be measured with circuit tester .

connector
2 Defective injector #1 2. Disconnect connector CN1 and connect T-adapter to male side.
Between CN1 (male) (1) and (2) Resistance 0.4 - 1.1 Ω
Between CN1 (male) (1) – ground Resistance Min. 1 MΩ
Disconnection in, or ground 2. Disconnect connector ENG and connect T-adapter to female side.
3
fault of wiring harness Between ENG (female) (45) – (53) Resistance 0.4 - 1.1 Ω
ness
4 (Disconnection in wiring or 2. Disconnect connectors ENG and CN1, and connect T-adapters to each female
defective contact in connec- side.
tor) Between ENG (female) (45) and CN1 (female) (1) Resistance Max. 1 Ω
Between ENG (female) (53) and CN1 (female) (2) Resistance Max. 1 Ω
5 ness 2. Disconnect connectors ENG and CN1, and connect T-adapter to female side of
(Contact with ground circuit) either one of them.
Between ENG (female) (45) or CN1 (female) (1) and
ground
2. Disconnect connectors ENG and CN1, and connect T-adapter to female side of
ENG.
6
Short circuit in wiring har- a Check with circuit tester in continuity mode.
ness Between ENG (female) (45) and each pin other than No continuity
(45) pin. (No sound is heard)
Between ENG (female) (53) and each pin other than No continuity
Defective other cylinder If the failure codes for other injectors are displayed, perform troubleshooting of them,
7
injectors or wiring harness too.
ure is in it , troubleshooting cannot be performed.)
40-220 D375A-6
(01)
DRAFT
Circuit diagram related to injector #1
D375A-6 40-221
(01)
DRAFT

Action code Failure code Injector #5(L#5) open/short circuit error
Trouble
Action of con-
troller
machine q Engine speed does not stabilize.
Related infor-
q Pulse voltage of about 65V is normally supplied to injector (+) side while engine is running, but it can-
mation
not be measured with circuit tester .

connector
Between CN5 (male) (1) and ground Resistance Min. 1 MΩ
Disconnection in, or
3 ground fault of wiring har- 2. Disconnect connector ENG and connect T-adapter to female side.
ness Between ENG (female) (46) – (60) Resistance 0.4 - 1.1 Ω
Disconnection in wiring a If no abnormality is found in checks on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (Disconnection in wiring or 2. Disconnect connectors ENG and CN5, and connect T-adapters to each female side.
defective contact in con- Between ENG (female) (46) and CN5 (female) (1) Resistance Max. 1 Ω
nector) Between ENG (female) (60) and CN5 (female) (2) Resistance Max. 1 Ω
(Contact with GND circuit) either one of them.
ground
ENG.
6
pin (46) pin. (No sound is heard)
Defective other cylinder
7 If failure codes for other injectors are displayed, perform troubleshooting for them, too.
injectors or wiring harness
Defective engine control- If no abnormality is found by above checks, engine controller is defective. (Since failure
8
ler is in it, troubleshooting cannot be performed.)
40-222 D375A-6
(01)
DRAFT
D375A-6 40-223
(01)
DRAFT

Action code Failure code Injector #3(L#3) open /short circuit error
Failure
Action of con-
troller
Related infor-
q Pulse voltage of approx. 65V is normally supplied to injector (+) side while engine is running, but it
mation
cannot be measured with circuit tester.

connector
3
harness
defective contact in con- side.
ground
ENG.
6
40-224 D375A-6
(01)
DRAFT
D375A-6 40-225
(01)
DRAFT

Action code Failure code Injector #6 (L#6) open / short circuit error
Trouble
Detail of failure q Opening or short circuit was detected in drive circuit of No. 6 injector.
Action of con-
troller
Related infor-
q Pulse voltage of approx. 65 V is normally supplied to injector (+) side while engine is running normally
mation
but it cannot be measured with circuit tester .

connector
Disconnection in, or
3 ground fault of wiring har- 2. Disconnect connector ENG and connect T-adapter to female side.
ness Between ENG (female) (57) – (59) Resistance 0.4 - 1.1 Ω
Disconnection in wiring a If no abnormality is found in checks on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (Disconnection in wiring or 2. Disconnect connectors ENG and CN6, and connect T-adapters to each female side.
defective contact in con- Between ENG (female) (57) and CN6 (female) (1) Resistance Max. 1 Ω
ground
ENG.
6
Defective injector or wiring
If the failure codes for other injectors are displayed, perform troubleshooting for them,
7 harness of another cylin-
too.
der
If no abnormality is found by above checks, engine controller is defective. (Since failure
is in it, troubleshooting cannot be performed.)
40-226 D375A-6
(01)
DRAFT
D375A-6 40-227
(01)
DRAFT

Action code Failure code Injector #2 Open/Short circuit error
Failure
Action of con-
troller
Related infor-
q Pulse voltage of approx. 65V is normally supplied to injector (+) side while engine is running, but it
mation
cannot be measured with circuit tester .

1 "Checks before troubleshooting" of "General information on troubleshooting", and
connector
3
ness
defective contact in connec- side.
tor) Between ENG (female) (54) and CN2 (female) (1) Resistance Max. 1 Ω
ground
2. Disconnect connectors ENG and CN, and connect T-adapter to female side of
ENG.
6
ness Between ENG (female) (54) and each pin other than pin No continuity
Between ENG (female) (51) and each pin other than pin No continuity
Defective other cylinder If failure codes for other injectors are displayed, perform troubleshooting for them,
7
injectors or wiring harness too.
40-228 D375A-6
(01)
DRAFT
D375A-6 40-229
(01)
DRAFT

Action code Failure code Injector #4 (L#4) open / short circuit error
Failure
Action of con-
troller
Related infor-
q Pulse voltage of approx. 65V is normally supplied to injector (+) side while engine is running but it
mation
cannot be measured with circuit tester.

connector
3
ness
defective contact in con- side.
ground
ENG.
6
pin (56) . (No sound is heard)
pin (58) . (No sound is heard)
40-230 D375A-6
(01)
DRAFT
D375A-6 40-231
(01)
DRAFT
Failure code [CA342] Calibration Code Incompatibility
Failure code [CA342] Calibration Code Incompatibility

Failure
Action code Engine controller data inconsistency
code Failure
E03 CA342
Detail of failure q Data inconsistency occurres in engine controller.
Action of con-
troller
Problem on q Engine continues running ordinarily, but it may stop during operation or may not restart once it is
machine stopped.
Related infor-
mation

Preform troubleshooting for failure code [CA111].
40-232 D375A-6
(01)
DRAFT
Failure code [CA351] Injectors Drive Circuit Error
Failure code [CA351] Injectors Drive Circuit Error

Action code Failure code Injectors drive circuit error
Failure
Detail of failure q Abnormality has occurred in injector drive circuit.
Action of con-
q Limits engine output for travel (Limits common rail pressure) and allows engine to run
troller
Problem on
machine
Related infor-
mation
Check whether other failure code (failure code related to injector system ) are displayed
1 Defect in related system
together. If another code is displayed, perform troubleshooting for it.
Perform troubleshooting for failure code [ CA111]
D375A-6 40-233
(01)
DRAFT

Failure
Action code Sensor power supply 1voltage is too low
code Failure
E03 CA352
Detail of failure q Low voltage was detected in sensor power supply 1 (5 V) circuit.
Action of con-
q Limits engine output (limits common rail pressure) and allows engine to run.
troller
Problem on
machine
Related infor-
mation

1 before troubleshooting" of "General information on troubleshooting", and check them
ness connector
directly.
each time.
3. After each troubleshooting, turn starting swith to OFF position.
Defective sensor or wir- If this failure code is not displayed when sensor is disconnected, the sensor or engine wir-
2 ing harness ing harness is defective.
a Other failure code(s) is(are) displayed at the same time. This is because the sensor
connector is disconnected. Therefore, ignore failure codes other than [CA352].
Sensor, harness Connector
Common rail pressure sensor PFUEL
Engine harness ENG
Defect in related sys- If another failure code is displayed, perform troubleshooting for it.
3
tem
Defective engine con- 2. Disconnect connector ENG and connect T-adapter to male side.
4
troller 3. Turn starting switch to ON position with engine wiring harness disconnected.
Between ENG (male) (33) and (47) Voltage 4.75 – 5.25 V
40-234 D375A-6
(01)
DRAFT
Circuit diagram related to sensor power supply 1
D375A-6 40-235
(01)
DRAFT

Failure
Action code Sensor power supply 1 voltage is too high
code Failure
E03 CA386
Detail of failure q High voltage was detected in sensor power supply 1 (5 V) circuit.
Action of con-
q Limits engine output (limits common rail pressure) and allows engine to run
troller
Problem on
machine
Related infor-
mation

Perform troubleshooting for failure code[CA352]
40-236 D375A-6
(01)
DRAFT
Failure code [CA441] Battery Voltage Low Error
Failure code [CA441] Battery Voltage Low Error

Action code Failure code Battery power circuit voltage is to low
Trouble
Contents of
q Low voltage was detected in battery power supply circuit.
trouble
Action of con-
troller
Problem that
q Engine contionues running ordinarily, but it may stop during operation or may not restart once it is
appears on
stopped.
machine
Related infor-
mation

D375A-6 40-237
(01)
DRAFT
Failure code [CA442] Battery Voltage High Error
Failure code [CA442] Battery Voltage High Error

Action code Failure code Battery power supply circuit voltage is too high
Failure
Detail of fail-
q High voltage (36V) was detected in battery power supply circuit.
ure
Action of con-
troller
Problem on q Engine continues running ordinarily, but it may stop during operation or may not restart once it is
machine stoped.
Related infor- q Method of reproducing failure code: Turn the starting switch to ON position.
mation q Power supply voltage of engine controller can be checked with monitoring function (Code: 03200 (V)).

40-238 D375A-6
(01)
DRAFT
Failure code [CA449] Rail Press Very High Error
Failure code [CA449] Rail Press Very High Error

Action code Failure code Common rail pressure is abmormally high
Failure
q Common rail pressure sensor circuit detects abnormally high pressure (pressure exceeding set
Detail of failure
maximum level).
Action of con-
q Limits engine output (limits common rail pressure) ,and allows engine to run.
troller
Problem on
machine
q Signal voltage from common rail pressure sensor can be checked with monitoring function (Code:
36401 (V)).
Related infor-
q Common rail pressure sensed by common rail pressure sensor can be checked with monitoring
mation
function (Code: 36400 (MPa)).

D375A-6 40-239
(01)
DRAFT
Failure code [CA451] Rail Press Sensor High Error

Action code Failure code Common rail pressure sensor signal voltage is too high.
Failure
Detail of failure q High voltage was detected in signal circuit of common rail pressure sensor.
Action of con-
q Limits engine output (limits common rail pressure) and allows engine to run
troller
Problem on
q Engine output is drops.
machine
36401 (V)).
Related infor- q Common rail pressure sensed by common rail pressure sensor can be checked with monitoring
mation function (Code: 36400 (MPa)).
q This code is displayed if common rail pressure sensor connector is disconnected.

See descriptions of wiring harness and connectors in "c: Ellectrical equipment" in
connector
a If failure code [CA352] (Ground fault in sensor power supply line) or [CA386] is dis-
played, perform troubleshooting for it first.
Defective common rail 1. Turn starting switch to OFF position.
2 pressure sensor power 2. Disconnect connector PFUEL and connect T-adapter to female side.
supply line 3. Turn starting switch to ON position.
Power sup-
Between PFUEL(female) (1) and (3) Voltage 4.75 – 5.25V
ply input
2. Disconnect connectors PFUEL and ENG and connect T-adapters to each female
side.
Disconnection in wiring a If power supply input in checks on cause 2 is nor-
harness mal, this check is not required. Resistance Max. 1 Ω
3 (Disconnection in wiring or Between ENG(female) (33) and PFUEL(female) (1)
defective contact in con- a If power supply input in checks on cause 2 is nor-
nector) mal, this check is not required. Resistance Max. 1 Ω
Between ENG (female) (47) and PFUEL (female) (3)
Between ENG (female) (25) and PFUEL (female) (2)
(Sensor output)
Short circuit in wiring har-
2. Disconnect connectors PFUEL and ENG
4 ness
3. Connect T-adapter to female side of ECM.
Hot short in wiring harness 2. Disconnect connectors PFUEL and insert T-adapter into connector ECM.
5 (Short circuit to 24 V cir- 3. Turn starting switch to ON position (with connector PFUEL disconnected).
cuit) a ENG (25) pin is connected to 5V source through resistor in engine controller.
Between ENG (25) and (47) Voltage Approx. 5V
a If causes 1 – 5 are not cause of failure and check result of cause 6 is abnormal, sen-
sor is defective.
Defective common rail
pressure sensor
6 2. Insert T-adapter into connector ENG
(Improper input voltage to
engine controller) 3. Turn starting switch to ON position.
Sensor out-
Between ENG (25) and (47) Voltage 0.2 – 4.6V
put
(Since failure is in it, troubleshooting cannot be performed.)
40-240 D375A-6
(01)
DRAFT
Circuit diagram related to common rail pressure
D375A-6 40-241
(01)
DRAFT
Failure code [CA452] Rail Press Sensor Low Error

Action code Failure code Common rail pressure sensor signal voltage is to low
Failure
Detail of failure q Low voltage was detected in signal circuit of common rail pressure sensor.
Action of con-
q Limits engine output (limits common rail pressure),and allows engine to run.
troller
Problem on
q Engine output is drops.
machine
q Signal voltage from the common rail pressure sensor can be checked with monitoring function
(Code: 36401 (V)).
Related infor-
mation
q This code is not displayed but failure code, position [CA451] for “High Error ” is displayed when
sensor connector is disconnected even if it is normal.

connector
a If failure code [CA352]or [CA386] is displayed, perform troubleshooting for it first.
Defective common rail pres-
2. Disconnect connector PFUEL and connect T-adapter to female side.
2 sure sensor power supply
line 3. Turn starting switch to ON position.
Power sup-
Between PFUEL (female) (1) and (3) Voltage 4.75 – 5.25V
ply input
Defective common rail pres- 2. Disconnect connector PFUEL
3
If failure code changes from [CA452] to [CA451] , sensor is defective.
4 ness 2. Disconnect connectors ENG and PFUEL , and connect T-adapter to female side
(Contact with GND circuit) of ENG
Short circuit in wiring har- 2. Disconnect connectors ENG and PFUEL , and connect T-adapter to female side
5
ness of ENG
Between ENG (25) and (47) Resistance Min. 1 MΩ
40-242 D375A-6
(01)
DRAFT
Circuit diagram related to common rail pressure
D375A-6 40-243
(01)
DRAFT
Failure code [CA553] Rail Press High Error
Failure code [CA553] Rail Press High Error

Action code Failure code Common rail pressure is high
Failure
q Abnormal high pressure (higher than set pressure) was detected more than 10 seconds in the signal
Detail of failure
circuit of common rail pressure sensor.
Action of con-
troller
Problem on
machine
36401 (V)).
Related infor-
q Common rail pressure sensed by common rail pressure sensor can be checked with monitoring func-
mation
tion (Code: 36400 (MPa)).

1 Defect in related system If another failure code is displayed, perform troubleshooting for it.
2 Use of improper fuel Check fuel used directly (for high viscosity).
Defective electrical system
Electrical system of common rail pressure sensor may be defective. Perform trouble-
3 of common rail pressure
shooting for failure codes [CA451] and [CA452].
sensor
Defective mechanical sys-
4 tem of common rail pres- Check mechanical system of common rail pressure sensor directly.
sure sensor
5 Defective overflow valve Check overflow valve directly for broken spring, worn seat, and stuck ball.
6 Clogging of overflow piping Check overflow piping directly for clogging.
7 Defective pressure limiter Check pressure limiter directly for mechanical defect.
40-244 D375A-6
(01)
DRAFT
Failure code [CA554] Rail Press Sensor In Range Error
Failure code [CA554] Rail Press Sensor In Range Error

Action code Failure code Common rail pressure sensor signal voltage is beyond input range
Failure
Detail of failure q Signal voltage of common rail pressure sensor is beyond input range.
Action of con-
q Limits engine output (limits common rail pressure) and allows engine to run.
troller
Problem on
machine
36401 (V)).
Related infor-
q Common rail pressure sensed by common rail pressure sensor can be checked with monitoring func-
mation
tion (Code: 36400 (MPa)).

Perform troubleshooting for failure code [CA451], [CA452]
D375A-6 40-245
(01)
DRAFT
Failure code [CA559] Rail Press Low Error

Action code Failure code Supply pump does not pressure feed fuel
Failure
Detail of failure q Supply pump does not pressure feed fuel (level1).
Action of con-
q Limits common rail pressure.
troller
Problem on
machine
Related infor-
mation

1 Defect in related system If another failure code is displayed, perform troubleshooting for it first.
2 Use of improper fuel Fuel used may be improper. Check it directly.
a For more information on troubleshooting, see Note 1. For check of fuel pressure in
fuel low-pressure circuit, see Testing and adjusting, "Testing fuel pressure".
Defect in low pressure cir-
3 Fuel pressure in low-pressure circuit 0.15 – 0.3 MPa
cuit parts
(At high idle or under load equivalent to rated
output operation) {1.5 – 3.0 kg/cm2}
Clogged fuel filter,or
4 a For more information on troubleshooting, see Note 2.
strainer
Defective electrical sys- Electrical system of supply pump PCV may be defective. Perform troubleshooting for
5
tem of supply pump PCV failure code [CA271], [CA272], [CA273], or [CA274].
Defective common rail
6 Common rail pressure sensor may be defective. Check wiring harness for damage.
pressure sensor
a For check of leakage from pressure limiter, see Testing and adjusting, “Checking
fuel return rate and leakage”.
7 Defective pressure limiter Leakage from pressure limiter
(Rated output operation or equiralent (load at Max. 10 cc/min
stalling))
a For check of limit return rate (spill) from injector, see Testing and adjusting,
“Checking fuel return rate and leakage”.
Engine speed during rated output operation
Injector return
or equivalent
(spill) limit
8 Defective injector (load at stalling)
1,600 rpm 960 cc/min
1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
9 Defective supply pump If causes 1 – 8 are not detected, supply pump may be defective.
<How to use check sheet>
Perform the above troubleshooting and use the attached "Check sheet for no-pressure feed",to note the check
resuets.
40-246 D375A-6
(01)
DRAFT
Note 1: Check the low-pressure circuit parts for the following items.
1) Fuel level
2) Clogging of fuel tank breather
3) Locking and wear of feed pump,clogging of filters
4) Leaking or clogging of fuel low-pressure piping
5) Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
6) Clogged fuel filter
7) Fuel in oil pan (Fuel leakage inside head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2) , and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2) : Spring is seen through hole on nut side.
q Fuel inlet joint(3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the problem is not solved by performing 1) and 2) above, replace the fuel filter.
D375A-6 40-247
(01)
DRAFT
Check sheet for no-pressure feed

Model D375A-6 Work No.
Machine serial No. # Date of check / /
Engine SAA6D170E-5 Service meter reading h
Engine serial No. # Worker's name
A. Visual check Good NG

1 Fuel leakage to outside
2 Clogging of fuel tank breather
B. Inspection with machine monitor (02 = Abnormality record; 01 = Monitoring; 09 = Cylinder cutout mode
Good NG
operation
3 Checking failure code / / / /
Check of monitoring information
Standard
Measured
code Display item Condition for check SI unit value(Refeenc Good NG
value
e value)
Low idle r/min 700 – 800
01000 Engine speed High idle r/min 1,850 – 1,900
At torque converter stalling r/min 1,490 – 1,580
Decelerat or Low idle % 0
31701
opening ratio High idle % 100
Final injection
amount com-
18600 At torque converter stall mg/st - - -
mand
4 (weight)
Final common
36200 rail pressure At torque converter stall Mpa -
command
Common rail
36400 At torque converter stall Mpa -
pressure
Low idle CA - - -
Final injection
36300 High idle CA - - -
timing command
At torque converter stall CA - - -
36500 Boost pressure At torque converter stall kPa - - -
Engine coolant
04104 Low idle °C - - -
temperature
14200 Fuel temperature Low idle °C - - -
Cylinder cut out mode operation (Engine speed)
Standard
Measured
Function Cut out cylinder Condition for check SI unit value(Refer- Good NG
value
ence value)
No. 1 cylinder Low idle r/min - - -
5
Set by No. 3 cylinder Low idle r/min - - -
cylinder No. 4 cylinder Low idle r/min - - -
Standard
Measured
C.Check of fuel circuit pressure Condition for check Unit value(Refer- Good NG
value
ence value)
High idling or under load equiva- Mpa
Fuel low-pressure circuit 0.15 – 0.3
6 lent to rated output operation(stall- 2}
pressure {kg/cm {1.5 – 3.0}
ing)
D.Check of strainers and filters Good NG

7 Visual inspection of strainer
8 Visual inspection of gauze filter
9 Visual check of fuel filter
10 Visual inspection of bypass valve
40-248 D375A-6
(01)
DRAFT
Standard
E.Checking leakage and fuel Measured
Condition for check Unit value(Refer- Good NG
return rate value
ence value)
Leakage from pressure lim- Under load equivalent to rated
11 cc/min Max. 10
iter output operation
Torque converter stall 1,600 rpm cc/min 960 Speed:
Torque converter stall 1,700 rpm cc/min 1,020

12 Return rate from injector Torque converter stall 1,800 rpm cc/min 1,080 Return
rate:
D375A-6 40-249
(01)
DRAFT
Failure code [CA689] Eng Ne Speed Sensor Error

Action code Failure code Engine Ne speed sensor signal is abnormal
Failure
Detail of failure q Abnormal signal appear in engine Ne speed sensor circuit.
Action of con-
q Controls engine by using signals from engine Bkup speed sensor.
troller
Problem on q Engine stops during operation (When engine Bkup speed sensor is also defective).
machine q Engine cannot be started if it is stopped. (When engine Bkup speed sensor is also defective)
q Since inside of speed sensor is not composed of coil but Hall sensor and electronic circuit, speed
Related infor-
sensor cannot be determined to be normal by measuring its resistance with circuit tester.
mation
q Since output of normal speed sensor is 5 V pulse voltage, it cannot be measured with circuit tester.
q Speed sensor calculates engine speed by detecting holes made in the flywheel.

connector
Defective Ne speed sen-
2 If failure code [CA238] is also displayed, perform troubleshooting for it first.
sor power supply line
Breakage or improper
Engine Ne speed sensor may be damaged or improperly installed (loose). Check sen-
3 installation (looseness) of
sor directly.
engine Ne speed sensor
2. Disconnect connector NE and connect T-adapter to female side.
4 Defective Ne speed sensor 3. Turn starting switch to ON position.
power supply input Power supply
Between NE (female) (1) and (2) Voltage 4.75 – 5.25 V
input
2. Disconnect connectors ENG and NE.
Disconnection in wiring If no abnormality is found in checks on cause 4, this
harness check is not required. Resistance Max. 1 Ω
5 Between ENG (female) (16) and NE (female) (1)
tive contact in connector) If no abnormality is found in checks on cause 4, this
check is not required. Resistance Max. 1 Ω
Between ENG (female) (48) and NE (female) (2)
Between ENG (female) (16) and (48), or between NE
2. Disconnect connectors ENG and NE.
Ground fault of wiring har- Between ENG (female) (16) and (27), or between NE
6 Resistance Min. 1 MΩ
ness (female) (1) and (3)
Between ENG (female) (27) and (48), or between NE
ness 2. Disconnect connectors ENG and NE.
7
(Contact with ground cir- Between ENG (female) (27) or NE (female) (3) and
cuit) ground
Hot short in wiring harness 2. Disconnect connector NE.
8
(Short circuit to 24 V circuit) 3. Turn starting switch to ON position.
Between NE (female) (3) and ground Voltage Max. 1V
Defective engine Ne speed If failure is not found by above checks, engine Ne speed sensor may be defective.
9
sensor (Since failure is in it, troubleshooting cannot be performed.)
If failure is not found by above checks, engine controller may be defective. (Since fail-
40-250 D375A-6
(01)
DRAFT
Circuit diagrams related to engine Ne speed sensor
q Ne speed sensor detects part (A) of flywheel (1), where hole (H) is not made to recognize one turn of fly-
wheal, and the engine controller calculates the engine speed and phase.
D375A-6 40-251
(01)
DRAFT
Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error

Action code Failure code Engine Bkup speed sensor phase error
Failure
Detail of fail- q Engine Bkup speed sensor circuit detects phase error.
ure (Bkup speed sensor signal and Ne speed sensor signal are out of phase.)
Action of con-
q Controls the engine by using signals from engine Ne speed sensor.
troller
Problem on q
Engine stops during operation (When engine Ne speed sensor is also defective)
machine q
Engine cannot be started if it is stopped. (When engine Ne speed sensor is also defective).
q
Method of reproducing failure code: Start engine.
Related infor-
a If Bkup speed sensor needs to be replaced, fuel supply pump must be replaced. (See "Disassembly
mation
and assembly", "Removal and installation of fuel supply pump".)

Defective engine Ne speed Engine Ne speed sensor may be defective. Perform troubleshooting for failure code
1
sensor system [CA689]
Defective engine Bkup Engine Bkup speed sensor may be defective. Perform troubleshooting for failure code
2
speed sensor system [CA778]
40-252 D375A-6
(01)
DRAFT
Failure code [CA757] All Continuous Data Lost Error
Failure code [CA757] All Continuous Data Lost Error

Action code Failure code All engine controller data lost error
Failure
Detail of fail-
q All data in engine controller are lost.
ure
Action of
controller
Problem on
q Engine continues running, but it may stop during operations or may not restart once it is in stopped.
machine
Related
q Method of reproducing failure code: Turn starting switch ON.
information

D375A-6 40-253
(01)
DRAFT
Failure code [CA778] Eng Bkup Speed Sensor Error

Action code Failure code Eng Bkup Speed Sensor Error
Failure
q Abnormality has occurred in engine Bkup speed sensor circuit.
Detail of failure
Action of con- q Controls engine by using Ne speed sensor signal.
troller q Limits engine output and allows engine to run.
q Engine stops during operation (when Ne speed sensor is also defective at the same time).
Problem on
q Engine cannot be started once it is stopped (when Ne speed sensor is also defective at the same
machine
time).
a If engine Bkup speed sensor is replaced, fuel supply pump must be replaced.
Related infor- (See "Disassembly and assembly", "Removal and installation of fuel supply pump".)
mation q Since inside of speed sensor is not composed of coil but electronic circuit, speed sensor cannot be
determined to be normal by measuring its resistance with circuit tester.
q Since output of normal speed sensor is 5 V pulse voltage, it cannot be measured with circuit tester.

See descriptions of wiring harness and connectors in "c: Electric and electrical equip-
1 ment" in "Checks before troubleshooting" of "General information on troubleshoot-
connector
ing" , and check them directly.
Defective sensor power
2 If failure code [CA187] or [CA227] is also displayed, troubleshoot it first.
supply line
Damage or improper instal-
Engine Bkup speed (G) sensor may be damaged or improperly installed (loose).
3 lation (loose) of engine
Check sensor directly.
Bkup speed (G) sensor
4 Defective resistor (RES) 2. Disconnect connector RES and connect T-adapter to male side.
Between RES (male) (1) and (2) Resistance 620 Ω
Defective engine Bkup 2. Disconnect connector G and connect T-adapter to female side.
5 speed sensor power supply 3. Turn starting switch to ON position.
input Power sup-
Between G (female) (A) and (B) Voltage 4.75 – 5.25 V
ply
Disconnection or short cir- 1. Turn starting switch to OFF position.
6 cuit in wiring harness 2. Disconnect connectors ENG and G, and connect T-adapter to female side of ENG.
(Resistor RES line) Between ENG (female) (37) and (26) Resistance 620 Ω
2. Disconnect connectors ENG, G and RES, and connect T-adapters to female side
of each one of them.
Disconnection in wiring har- a If power supply voltage in checks on cause 5 is nor-
7
ness mal, this check is not required. Resistance Max. 1 Ω
(Disconnection or defective Between ENG (female) (37) and G (female) (A)
contact in connector) a If power supply voltage in checks on cause 5 is nor-
mal, this check is not required. Resistance Max. 1 Ω
Between ENG (female) (47) and G (female) (B)
Between ENG (female) (26) and G (female) (C) Resistance Max. 1 Ω
2. Disconnect connectors ENG, G and RES, and connect T-adapter to female side of
Short circuit in wiring har- ENG or G.
8 Between ENG (female) (26) and (37), or between G
ness Resistance Min. 1 MΩ
(female) (A) and (C)
Between ENG (female) (26) and (47), or between G
(female) (B) and (C)
Ground fault of wiring har- 2. Disconnect connectors ENG and G and connect T-adapter to female side of either
9 ness(Contact with ground of them.
circuit) Between ENG (female) (26) or G (female) (C) and
ground
Hot short in wiring harness 2. Disconnect connectors G and RES, and connect T-adapter to female side.
10
(Short circuit to 24 V circuit) 3. Turn starting switch to ON position.
Between G (female) (C) and ground Voltage Min. 1 V
40-254 D375A-6
(01)
DRAFT
Defective engine Bkup If engine failure is not found by above checks, engine Bkup speed sensor may be
11
speed sensor defective. (Since failure is in it, troubleshooting cannot be performed.)
If engine failure is not found by above checks, engine controller may be defective.
Circuit diagram related to engine Bkup speed sensor
D375A-6 40-255
(01)
DRAFT
Failure code [CA1228] EGR Valve Servo Error 1

Action code Failure code Abnormal EGR valve servo 1
Failure
q An abnormality has occurred in EGR valve servo (level 1).
Detail of failure
(Response from EGR lift sensor differs for EGR valve opening command value.)
Action of con-
q Stops current to EGR valve (closes EGR valve).
troller
Problem on
machine
q EGR valve position can be checked with monitoring function (Code: 18100 EGR valve position
Related infor-
(mm)).
mation

1 Defect in related system If another failure code is indicated, carry out troubleshooting for it.
a For measurement of EGR valve drive pressure, see Testing and adjusting, “ Mea-
suring EGR valve and bypass valve drive pressure” .
Improper EGR valve drive Engine speed EGR valve drive pressure
2
pressure Low idle Min. 1.18 MPa {12 kg/cm2}
High idle Min. 1.43 MPa {14.6 kg/cm2}
If EGR valve drive pressure is not normal, check items 3 and 4.
a For check of engine oil pressure, see Testing and adjusting, "Testing engine oil
pressure".
Engine Engine oil pressure
Defective engine hydraulic
3 Low idle Min. 0.08 MPa {0.8 kg/cm2}
system (main circuit)
High idle Min. 0.21 MPa {2.1 kg/cm2}
If engine oil pressure is not normal, preform troubleshooting (S mode) for mechanical
system. (S-12 Oil pressure lowers.)
Defective oil pipe for EGR
4 Oil pump relief valve for the EGR valve circuit may be defective, directly check it.
valve
Defective oil pipe for EGR
5 Oil pipe for the EGR valve circuit may be defective, directly check it.
valve
Defective oil return pipe for
6 Oil return pipe for the EGR valve circuit may be defective, directly check it.
EGR valve
7 Defective EGR valve EGR valve may be defective, directly check it.
Defective EGR valve lift
8 Perform troubleshooting for failure code [CA2271].
sensor
If causes 1 – 8 are not cause of faillure, engine controller may be defective. (Since
40-256 D375A-6
(01)
DRAFT

Action code Failure code Abnormal EGR valve servo 2
Failure
q An abnormality has occurred in EGR valve servo (level 2).
Detail of failure
(Response from EGR lift sensor differs for EGR valve opening command value.)
Action of con- q Limits engine output and allows engine to run.
troller q Stops current to EGR valve (closes EGR valve).
Problem on
machine
q EGR valve position can be checked with the monitoring function (Code: 18100 EGR valve position
Related infor-
(mm)).
mation

D375A-6 40-257
(01)
DRAFT
Failure code [CA1633] KOMNET Datalink Timeout Error
Failure code [CA1633] KOMNET Datalink Timeout Error

Action code Failure code CAN (KOMNET) communication disconnection
Failure
Detail of fail- q Engine controller detected communication error in CAN (KOMNET) communication circuit between
ure engine controller and power train controller ,work equipment controller or machine monitor.
Action of con- q Controls engine in default mode, and holds state at the time of abnormally.
troller q If cause of failure disappears, system resets itself.
q Information may not be transmitted normally through CAN (KOMNET) communication and machine
Problem on
may not operate normally.
machine
(Trouble phenomenon depends on failed section.)
Related infor-
mation

Perform troubleshooting for failure code [DB2RKR].
40-258 D375A-6
(01)
DRAFT
Failure code [CA2185] Throt Sens Sup Volt High Error
Failure code [CA2185] Throt Sens Sup Volt High Error

Action code Failure code Throttle sensor power supply voltage is too high
Failure
Detail of failure q High voltage (approx. 5.25 V) was detected in throttle sensor power supply circuit.
Action of con-
q Controls engine with decelerator pedal position at fixed value.
troller
Problem on
q Engine speed cannot be controlled with decelerator pedal.
machine
Related infor-
mation

ness connector
directly.
Defective throttle sen- 2. Disconnect connector DEC and turn starting switch to ON position.
2 If this failure code is not displayed, throttle sensor is defective.
sor (decelerator pedal)
a Other failure codes are displayed, too. This is because the connector is disconnected.
Ignore failure codes other than [CA2185].
2. Disconnect connectors EGC2, EGC3 and DEC, and connect T-adapters to female side
Short circuit in wiring of EGC2 and EGC3.
3
harness Between EGC2 (female) (22) and each pin other than
EGC2 (female) (22) pin
Between EGC2 (female) (22) and EGC3 (female)(3) Resistance Min. 1 MΩ
Hot short in wiring har- 1. Turn starting switch to OFF position.
ness 2. Disconnect connector DEC and connect T-adapter to female side.
4
(Short circuit to 24 V 3. Turn starting switch to ON position.
circuit) Between DEC(female)(A) and ground Voltage 4.75–5.25V
Defective engine con- 2. Disconnect connector EGC2 and connect T-adapter to female side.
5
troller 3. Turn starting switch to ON position.
Between EGC2 (female) (22) and (23) Voltage 4.75–5.25V
D375A-6 40-259
(01)
DRAFT
Failure code [CA2186] Throt Sens Sup Volt Low Error
Failure code [CA2186] Throt Sens Sup Volt Low Error

Action code Failure code Throttle sensor power supply voltage is too low
Failure
Detail of failure q Low voltage was detected in throttle sensor power supply circuit.
Action of con-
q Controls engine with decelerator pedal postion at fixed value.
troller
Problem on
q Engine speed cannot be controlled with decelerator pedal.
machine
Related infor-
mation

ness connector
directly.
Defective throttle 2. Disconnect connector DEC and turn starting switch to ON position.
2 sensor (decelerator If this failure code is not displayed, throttle sensor is defective.
pedal) a Other failure code is displayed together. This is because that the sensor connector is dis-
connected. Ignored except the failure code other than [CA2186].
Short circuit in wir-
ing harness 2. Disconnect connector EGC2 and DEC and connect T-adapter to female side of either one
3 of them.
circuit) Between EGC2 (female) (22) or DEC (female) (A) and
ground
2. Disconnect connector EGC2 and DEC and connect T-adapter to female side of EGC2.
Short circuit in wir-
4 3. Turn starting switch to ON position.
ing harness
Between EGC2 (female) (22) and each pin other than
EGC2 (female) (22) pin
Defective engine 2. Disconnect connector EGC2 and connect T-adapter to male side.
5
controller 3. Turn starting switch to ON position with connecting engine wiring harness disconnected.
Between EGC2 (female) (22) and (23) Voltage 4.75–5.25V
40-260 D375A-6
(01)
DRAFT
Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2249] Rail Press Very Low Error

Failure
Action code Supply pump no-pressure feed error 2
code Failure
E03 CA2249
Detail of failure q No-pressure feed error (level 2) in supply pump was detected.
Action of con-
q Limits common rail pressure.
troller
Problem on
machine
q The signal voltage from the common rail pressure sensor can be checked with the monitoring func-
tion (Code: 36401 (V)).
Related infor-
mation

Perform troubleshooting for failure code [CA559] .
D375A-6 40-261
(01)
DRAFT
Failure code [CA2271] EGR Valve Pos Sens High Error

Action code Failure code EGR valve lift sensor signal voltage is too high.
Failure
Detail of failure q High voltage was detected in EGR valve lift sensor signal circuit.
Action of con- q Limits engine output and continues operation.
troller q Closes the EGR valve.
Problem on
machine
q Signal voltage from EGR valve lift sensor can be checked with monitoring function (Code: 18100
(mm)).
Related infor-
q Position (mm) sensed by EGR valve lift sensor can be checked with monitoring function (Code:
mation
18101 (V)).

connector
2 If failure code [CA187] or [CA227] is also displayed, troubleshoot it first.
supply system
Defective EGR valve lift 2. Disconnect connector SEGR.
3
sensor (internal defect) 3. Turn starting switch to ON position (with connector SEGR disconnected).
If failure code changes from [CA2271] to [CA2272], sensor is defective.
2. Disconnect connectors ENG and SEGR, and connect T-adapter to female side of
Short circuit in wiring har- either of them.
4
ness Between ENG (female) (37) and (19), between SEGR
(female) (1) and (3), or between SEGR (female) (1) and Resistance Min. 1 MΩ
(4)
2. Disconnect connector SEGR and connect T-adapter to female side.
5 ness (contact with 24 V
circuit) 3. Turn starting switch to ON position (with connector SEGR disconnected).
Between SEGR (female) (3) or (4) and (2) Voltage Max. 1 V
If cause is not found by the above checks, engine controller may be defective. (Since
Defective engine control- q Reference; the following is standard value in normal condition.
6
ler 1. Turn starting switch to OFF position.
2. Insert T-adapter into connector ENG.
Between ENG(19) and (47) Voltage 1.0 – 4.0 V
40-262 D375A-6
(01)
DRAFT
Circuit diagram related to EGR valve
D375A-6 40-263
(01)
DRAFT
Failure code [CA2272] EGR Valve Pos Sens Low Error

Action code Failure code EGR valve lift sensor signal voltage is too low.
Failure
Detail of failure q The signal of EGR valve lift sensor circuit is abnormally low.
Problem that
appears on q Engine output drops.
machine
q The signal (voltage) from the EGR valve lift sensor can be checked with the monitoring function
(Code: 18101 (V)).
Related infor-
q Position (mm) sensed by EGR valve lift sensor can be checked with monitoring function (Code:
mation
18100 (mm)).

connector
If failure code [CA187] (Ground fault in sensor power supply line) or [CA227] is dis-
played, perform troubleshooting for it first.
2 2. Disconnect connector SEGR and connect T-adapter to female side.
supply system
Power sup-
Between SEGR (female) (1) and (2) Voltage 4.75 – 5.25 V
ply
2. Disconnect connector SEGR and ENG, and connect T-adapters to each female
side.
Disconnection in wiring har- a If power supply voltage in check on cause 2 is nor-
ness mal, this check is not required. Resistance Max. 1 Ω
3 (Disconnection in wiring or Between ENG (female) (37) and SEGR (female) (1)
a If power supply voltage in check on cause 2 is nor-
defective contact in connec-
mal, this check is not required. Resistance Max. 1 Ω
tor)
Between ENG (female) (47) and SEGR (female) (2)
Between ENG (female) (19) and SEGR (female) (3)
and, between ENG (female) (19) and SEGR (female) Resistance Max. 1 Ω
(4), (Sensor output)
Ground fault of wiring har- 2. Disconnect connectors ENG and SEGR, and connect T-adapter to female side of
4 ness either of them.
(Contact with GND circuit) Between ENG (female) (19) and ground, or between
SEGR (female) (3) and ground
Short circuit in wiring har- 2. Disconnect connectors ENG and SEGR, and connect T-adapter to female side of
5 either of them.
ness
Between ENG (female) (19) and (47), or between
SEGR (female) (2) and (3)
a If cause items 1 - 5 are not the cause for the trouble and check result of cause 6 is
abnormal, sensor is defective.
Defective EGR valve lift
6 2. Insert T-adapter into connector ENG or SEGR.
sensor
Between ENG(19) and (47), or between SEGR (3) and
Voltage 0.5 – 4.5 V
(2)
40-264 D375A-6
(01)
DRAFT
D375A-6 40-265
(01)
DRAFT
Failure code [CA2351] EGR Valve Sol Current High Error

Action code Failure code Short circuit in power supply line to EGR valve solenoid
Failure
Detail of failure q Short circuit was detected in the power supply line to EGR valve solenoid.
Problem on
machine
Related infor- q Method of reproducing failure code: Turn the starting switch to ON position.
mation

Defective wiring harness con-
nector
Defective EGR valve sole- 2. Disconnect connector EGR and connect T-adapter to male side.
2
noid (internal disconnection) Between EGR (male) (1) and (2) Resistance 10 - 21 Ω
Between EGR (male) (1) and ground Resistance Min. 1 MΩ
Disconnection or short circuit 2. Disconnect connector ENG and connect T-adapter to male side.
3
in wiring harness a If resistance is above 1 MΩ, wiring harness is broken. If resistance is below 1 Ω,
wiring harness has short circuit.
Between ENG (male) (22) and (11) Resistance 10 - 21 Ω
2. Disconnect connectors ENG and EGR, and connect T-adapter to female side of
4 Short circuit in wiring harness either of them.
Between ENG (female) (22) and (11), or
between EGR (female) (1) and (2)
Hot short (Short circuit with 24 2. Disconnect connector EGR and connect T-adapter to male side.
5
V circuit) in wiring harness 3. Turn starting switch to ON position (with connector EGR disconnected).
Between EGR (female) (1) and (2) Voltage Max. 1 V
If cause is not found by the above checks, engine controller may be defective.
40-266 D375A-6
(01)
DRAFT
D375A-6 40-267
(01)
DRAFT
Failure code [CA2352] EGR Valve Sol Current Low Error

Action code Failure code Disconnection in power supply line to EGR valve solenoid drive system
Failure
Detail of fail-
q Disconnection error was detected in power supply line to EGR valve solenoid.
ure
Problem on
machine
Related infor-
mation

connector
Defective EGR valve sole- 1. Turn starting switch to OFF position.
2 noid (Internal disconnec- 2. Disconnect connector EGR and connect T-adapter to male side.
tion) Between EGR (male) (1) and (2) Resistance 10 - 21 Ω
Disconnection or short cir- 2. Disconnect connector ENG and connect T-adapter to female side.
3
cuit in wiring harness a If resistance is above 1 MΩ, wiring harness is broken. If resistance is below 1 Ω, wir-
ing harness has short circuit.
Between ENG (female) (22) and (11) Resistance 10 - 21 Ω
Disconnection in wiring har- 2. Disconnect connectors ENG and EGR, and connect T-adapters to female side of
ness (Disconnection or them.
4
defective contact in con- Resis-
nector) Between ENG (female) (22) and EGR (female) (1) Max. 1 Ω
tance
Resis-
Between ENG (female) (11) and EGR (female) (2) Max. 1 Ω
tance
If no abnormality is found by the above checks, engine controller may be defective.
40-268 D375A-6
(01)
DRAFT
D375A-6 40-269
(01)
DRAFT
Failure code [D110KB] Battery Relay: Drive Short Circuit

Action code Failure code Short circuit in battery relay drive circuit
Failure
– D110KB (Work equipment controller system)
Detail of failure q Abnormal current flowed when outputting 24 V to battery relay primary circuit (coil side).
Action of con-
q Stops 24 V output to battery relay primary circuit (coil side).
troller
Problem on
q Problem may occur in data writing to ROM (nonvolatile memory) of each controller.
machine
q Output condition (voltage) to battery relay primary circuit (coil side) can be checked with monitoring
Related infor- function.
mation (Code 60600: Battery relay drive voltage)
q Method of reproducing failure code: Turn starting switch from ON to OFF.

Defective battery relay 1. Turn starting switch to OFF position.
1
(Internal short circuit) Between terminals SW and BRE Continuity
2. Disconnect negative battery cable (in order not to make short circuit).
2 ness
(Contact with GND circuit) 3. Disconnect cable from terminal BRE and disconnect connector WECN3.
Between terminal SW and ground Resistance Min. 1 MΩ
q Reference: the following is standard value in normal condition.
3
controller 2. Insert T-adapter into connector WECN3.
Between WECN3 (4) and ground Voltage 20 – 30 V
40-270 D375A-6
(01)
DRAFT
Circuit diagram related to battery relay
D375A-6 40-271
(01)
DRAFT
Failure code [D130KA] Neutral relay: Disconnection

Action code Failure code Open cricuit in neutral safety relay
Failure
E02 D130KA (Power train controller system)
q No voltage is applied to neutral safety relay primary circuit (coil side) when controller stopped
Detail of failure
grounding.
Action of con-
q Stops grounding to neutral safety relay primary circuit (coil side).
troller
Problem on
machine
q Output to neutral safety relay primary circuit (coil side) can be checked with monitoring function.
(Code: 40909 P/T controller SW output)
q Method of reproducing failure code: Turn starting switch to ON position and operate parking brake
Related infor-
lever to Free position.
mation
q This failure code detects failure on primary side (coil side) of neutral safety relay, but not on second-
ary side (contact side).
q If PTCN2 (8) has ground fault, engine can start even if PCCS lever is not set to Neutral position.

Defective neutral 1. Turn starting switch to OFF position.
safety relay 2. Disconnect connector NSF and connect T-adapter to male side.
1
(Internal disconnec-
Between NSF (male) (1) and (2) Resistance 200 – 400 Ω
tion or short circuit)
Disconnection or short 2. Disconnect connectors PTCN2 and KEY, and connect T-adapters to female side of
2 circuit in wiring har- them.
ness a If resistance is above 1 MΩ, wiring harness is broken. If resistance is below 1 Ω, wiring
harness has short circuit.
Between KEY (female) (1) and PTCN2 (female) (8) Resistance 200 – 400 Ω
Disconnection in wir- 1. Turn starting switch to OFF position.
ing harness 2. Disconnect connectors PTCN2, NSF and KEY, and connect T-adapters to female side
3
defective contact) Between PTCN2 (female) (8) and NSF (female) (2) Resistance Max. 1 Ω
Between KEY (female) (1) and NSF (female) (1) Resistance Max. 1 Ω
harness 2. Disconnect connectors PTCN2 and NSF, and connect T-adapters to female side of
4
(Contact with ground them.
circuit) Between NSF (female) (2) or PTCN2 (female) (8) and ground Resistance Min. 1 MΩ
If cause is not found by the above checks, power train controller is defective.
q Reference: The following are standard values in normal condition.
Defective power train 2. Insert T-adapter into connector PTCN2.
5
controller 3. Turn starting switch to ON position.
4. Operate parking brake lever and troubleshoot.
Lever: FREE Voltage 20 – 30 V
Between PTCN2 (8) and ground
Lever: LOCK Voltage Max. 1 V
40-272 D375A-6
(01)
DRAFT
Circuit diagram related to neutral safety relay
D375A-6 40-273
(01)
DRAFT
Failure code [D130KB] Neutral relay: Short circuit

Action code Failure code Short circuit in neutral safety relay
Failure
E02 D130KB (Power train controller system)
q Abnormal current flowed in neutral safety relay primary circuit (coil side) when controller grounded
Detail of failure
neutral safety relay.
Action of con-
q Stops grounding to neutral safety relay primary circuit (coil side).
troller
Indication of
problem on q Engine does not start.
machine
q Output to neutral safety relay primary circuit (coil side) can be checked with monitoring function.
Related infor- q Method of reproducing failure code: Turn the starting switch to ON position and operate parking
mation brake lever to LOCK position.
q This failure code detects failure on primary side (coil side) of neutral safety relay, but not on second-

Defective neutral safety 1. Turn starting switch to OFF position.
relay 2. Disconnect connector NSF and connect T-adapter to male side.
1
Between NSF (male) (1) and (2) Resistance 200 - 400 Ω
or short circuit)
2. Disconnect connectors PTCN2 and KEY, and connect T-adapters to female side of
2
circuit in wiring harness a If resistance is above 1 MΩ, wiring harness is broken. If resistance is below 1 Ω, wiring
Between KEY (female) (1) and PTCN2 (female) (8) Resistance 200 - 400 Ω
2. Disconnect connectors PTCN2 and NSF, and connect T-adapter to female side of
ness
3 PTCN2.
(Short circuit with 24 V
Between PTCN2 (female) (8) and ground Voltage Max. 1 V
q Reference: the following are standard values in normal condition.
4
4. Operate parking brake lever and troubleshoot.
Lever: FREE Voltage 20 – 30 V
Lever: LOCK Voltage Max. 1 V
40-274 D375A-6
(01)
DRAFT
Circuit diagram related to neutral safety relay
D375A-6 40-275
(01)
DRAFT
Failure code [D161KA] Back-up alarm releay: Disconnection

Action code Failure code Disconnection in Backup alarm relay
Trouble
E01 D161KA (Power train controller system)
Failure q No voltage is applied to backup alarm relay primary circuit (coil side) when controller stopped ground-
description ing.
Action of con-
q Stops grounding to backup alarm relay primary circuit (coil side).
troller
Indication of
problem on q Backup alarm does not sound.
machine
q Output condition to backup alarm relay primary circuit (coil side) can be checked with monitoring func-
tion.
Related infor- q Method of reproducing failure code: Turn starting switch to ON position and operate PCCS lever to
mation neutral.
q This failure code detects failure on primary side (coil side) of backup alarm relay, but not in secondary
side (contact side).
q If pin PTCN2(18) has ground fault, backup alarm keeps sounding.

If fuse FS22-5 is blown out, circuit probably has ground fault. In this case, perform
1 Defective fuse FS22-5
troubleshooting for cause 5 first.
Defective backup alarm 1. Turn starting switch to OFF position.
relay 2. Disconnect connector BKA and connect T-adapter to male side.
2
(Internal disconnection or
short circuit) Between BKA (female)(1) and (2) Resistance 200 – 400 Ω
2. Remove fuse FS22-5.
Disconnection or short cir- 3. Disconnect connector PTCN2 and connect T-adapter to female side.
3
cuit in wiring harness a If resistance is above 1 MΩ, wiring harness is broken. If resistance is below 1 Ω,
wiring harness has short circuit.
Between PTCN2 (female) (18) and FS22-5 Resistance 200 – 400 Ω
ness 2. Disconnect connectors PTCN2 and BKA and connect T-adapters to each female
4
(Disconnection or defective side.
contact) Between PTCN2 (female) (18) and BKA (female) (2) Resistance Max. 1 Ω
Between FS22-5 and BKA (female) (1) Resistance Max. 1 Ω
Ground fault of wiring har- 2. Remove fuse FS22-5.
5 ness 3. Disconnect connector PTCN2 and connect T-adapter to female side.
(Contact with ground circuit) Between BKA(female) (1) and ground Resistance Min. 1 MΩ
Between BKA (female) (2) or PTCN2 (female) (18) and
ground
q Reference: the following is standard value in normal condition.
Defective power train con- 2. Insert T-adapter in connector PTCN2.
6
4. Operate PCCS lever and perform troubleshooting.
Between PTCN2(18) and N Voltage 20 – 30 V
chassis ground R(Reverse) Voltage Max. 1 V
40-276 D375A-6
(01)
DRAFT
Circuit diagram related to back-up alarm relay
D375A-6 40-277
(01)
DRAFT
Failure code [D161KB] Back-up alarm releay: Short circuit

Action code Failure code Short circuit in backup alarm relay
Failure
E01 D161KB (Power train controller system)
Detail of failure q Abnormal current flowed in backup alarm relay circuit when controller grounded backup alarm relay.
Action of con-
q Stops grounding to backup alarm relay primary circuit.
troller
Indication of
problem on q Backup alarm does not sound.
machine
q Output condition to backup alarm relay can be checked by monitoring function.
(Code 40909: P/T control SW output)
Related infor- q Method of reproducing failure code: Turn starting switch to ON position and operate PCCS lever to
mation reverse.
q This failure code detects failure on primary side (coil side) of backup alarm relay, but not on second-

Defective backup alarm 1. Turn starting switch to OFF position.
relay 2. Disconnect connector BKA and connect T-adapter to male side.
1
Between BKA (male) (1) and (2) Resistance 300 - 600 Ω
short circuit)
1.
Turn starting switch to OFF position.
2.
Disconnect fuse FS22-5.
Disconnection or short cir- 3.
Disconnect connector PTCN2 and connect T-adapter to female side.
2
cuit in wiring harness a
If resistance is above1 MΩ, wiring harness is broken. If resistance is below1 Ω, wir-
ing harness has short circuit.
Between PTCN2 (female) (18) and FS22-5 Resistance 300 - 600 Ω
2. Disconnect connectors PTCN2 and BKA and connect T-adapter to female side of
3 PTCN2.
(Contact with 24 V circuit)
q Reference: the following are standard values in normal condition.
Defective transmission 2. Insert T-adapter in connector PTCN2.
4
4. Operate PCCS lever and perform troubleshooting.
N Voltage 20 – 30 V
Between PTCN2(18) and ground
R(Reverse) Voltage Max. 1 V
40-278 D375A-6
(01)
DRAFT
Circuit diagram related to back-up alarm relay
D375A-6 40-279
(01)
DRAFT
Failure code [D182KZ] Preheater Relay Abnormality

Action code Failure code Preheater relay open or short circuit
Failure
E01 D182KZ (Power train controller system)
q Abnormal current flowed when preheater relay primary is grounded circuit (coil side) or no voltage
Detail of failure
is applied when it is not grounded.
Action of con-
q Stops grounding to preheater relay primary circuit (coil side).
troller
Indication of
q Auto preheater does not operate (or continues to preheat).
problem on
q Preheater operates when it is turned ON manually.
machine
q Output to preheater relay primary circuit (coil side) can be checked with monitoring function.
Related infor- q Method of reproducing failure code: Turn starting switch to ON position and operate parking brake
mation lever to free position.
q This failure code detects failure on primary side (coil side) of preheater relay, but not on secondary
side (contact side).

Defective preheater 1. Turn starting switch to OFF position.
relay 2. Disconnect connector PHR and connect T-adapter to male side.
1
Between PHR (male) (1) and (2) Resistance 200 – 400 Ω
ing harness 2. Disconnect connectors PTCN2, PHR and KEY, and connect T-adapters to female side
3
defective contact) Between PTCN2 (female) (19) and PHR (female) (2) Resistance Max. 1 Ω
Between KEY (female) (1) and PHR (female) (1) Resistance Max. 1 Ω
harness 2. Disconnect connectors PTCN2 and PHR, and connect T-adapters to female side of
4 them.
Between PHR (female) (2) or PTCN2 (female) (19) and
ground
2. Disconnect connectors PTCN2 and PHR, and connect T-adapter to PTCN2 female
ness
5 connector.
controller
Auto preheater
Voltage 20 – 30 V
not operated
Auto preheater
Voltage Max. 1 V
operated
40-280 D375A-6
(01)
DRAFT
Circuit diagram related to preheater relay
D375A-6 40-281
(01)
DRAFT
Failure code [D190KA] ACC signal relay: Disconnection

Action code Failure code ACC signal drive relay disconnection
Failure
E00 D190KA (Work equipment controller system)
Detail of failure q No voltage is applied to engine holding relay (EHL) primary circuit (coil side) when no grounding.
Action of con-
q Stops grounding to engine holding relay (EHL) primary circuit (coil side).
troller
Problem on q Turbocharger timer does not function (if the turbocharger timer is installed).
machine q Machine is not affected (if turbocharger timer is not installed).
q Output to engine holding relay (EHL) primary circuit (coil side) can be checked with monitoring func-
tion. (Code: 40983 W/E controller SW output)
Related infor-
q This failure code detects failure on primary side (coil side) of engine holding relay (EHL), but not on
mation
secondary side (contact side).
q If WECN2 (18) has ground fault, engine keeps running even if starting switch is turned to OFF posi-
tion.

Defective engine hold- 1. Turn starting switch to OFF position.
ing relay (Internal dis- 2. Disconnect connector EHL and connect T-adapter to male side.
1
connection or short
Between EHL (male) (1) and (2) Resistance 200 – 400 Ω
circuit)
Disconnection or short 2. Disconnect connectors WECN2 and KEY, and connect T-adapters to female side of
ness a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is below
ing harness 2. Disconnect connectors WECN2, EHL and KEY, and connect T-adapters to female side
3
defective contact) Between WECN2 (female) (8) and EHL (female) (2) Resistance Max. 1 Ω
Between KEY (female) (1) and EHL (female) (1) Resistance Max. 1 Ω
harness 2. Disconnect connectors WECN2 and EHL, and connect T-adapters to female side of
4 them.
Between EHL (female) (2) or WECN2 (female) (18) and
ground
Defective work equip-
5 If cause is not found by the above checks, work equipment controller is defective.
ment controller
40-282 D375A-6
(01)
DRAFT
Circuit diagram related to ACC signal drive relay
D375A-6 40-283
(01)
DRAFT
Failure code [D190KB] ACC signal relay: Short circuit

Action code Failure code ACC signal drive relay short circuit
Failure
E00 D190KB (Work equipment controller system)
Detail of fail- q No current flows when grounding to engine holding relay (EHL) primary circuit (coil side) or no voltage
ure is applied when no grounding.
Action of con-
q Stops grounding to engine holding relay (EHL) primary circuit (coil side).
troller
Problem on q Turbocharger timer does not function (if the turbocharger timer is installed).
machine q Machine is not affected (if turbocharger timer is not installed).
q Output to engine shutoff delay relay (EHL) primary circuit (coil side) can be checked by monitoring
function.
Related infor- (Code: 40983 W/E controller SW output)
mation q Method of reproducing failure code: Turn the starting switch to ON position
q This failure code detects failure on primary side (coil side) of engine shutoff delay relay (EHL), but not

Defective engine hold- 1. Turn starting switch to OFF position.
ing relay (Internal dis- 2. Disconnect connector EHL and connect T-adapter to male side.
1
connection or short
Between EHL (male) (1) and (2) Resistance 200 – 400 Ω
circuit)
2. Disconnect connectors WECN2 and KEY, and connect T-adapters to female side of
2
2. Disconnect connectors WECN2 and EHL, and connect T-adapter to female side of
ness
3 WECN2.
Between WECN2 (female) (18) and ground Voltage Max. 1 V
4 If cause is not found by the above checks, work equipment controller is defective.
ment controller
40-284 D375A-6
(01)
DRAFT
Circuit diagram related to ACC signal drive relay
D375A-6 40-285
(01)
DRAFT
Failure code [D1EFKA] Pre lub. motor relay: Disconnection

Action code Failure code Pre-lubricating motor relay disconnection
Failure
E02 D1EFKA (Power train controller system)
Detail of failure q No voltage is applied to pre-lubricating motor relay primary (coil side) circuit when no grounding.
Action of con-
q Stops grounding to pre-lubricating motor relay primary circuit (coil side).
troller
Problem on q Pre-lubricating motor does not operate.
machine q The engine does not start (engine starts if pre-lubrication is skipped).
q Output to pre-lubricating motor relay primary circuit (coil side) can be checked with monitoring func-
tion. (Code: 40909 P/T controller SW output)
Related infor- q Method of reproducing failure code: Turn the starting switch to ON position
mation q This failure code detects failure on primary side (coil side) of pre-lubricating motor relay, but not on
q If pin PTCN2 (23) has ground fault, pre-lubricating motor keeps running.

Defective pre-lubricat- 1. Turn starting switch to OFF position.
ing motor relay 2. Disconnect connector PLUB and connect T-adapter to male side.
1
Between PLUB (male) (1) and (2) Resistance 200 – 400 Ω
a If cause item 2 is not the cause for the trouble, this check is not required.
ing harness 2. Disconnect connectors PTCN2, PLUB and KEY, and connect T-adapters to female side
3
defective contact) Between PTCN2 (female) (9) and PLUB (female) (2) Resistance Max. 1 Ω
Between KEY (female) (1) and PLUB (female) (1) Resistance Max. 1 Ω
harness 2. Disconnect connectors PTCN2 and PLUB, and connect T-adapter to female side of
4 them.
Between PLUB (female) (2) or PTCN2 (female) (9) and
ground
Defective power train 3. Turn starting switch to ON position.
5
controller When pre-lubrica-
tion has been Voltage 20 – 30 V
Between PTCN2 (9) and ground completed
During pre-lubri-
Voltage Max. 1 V
cation
40-286 D375A-6
(01)
DRAFT
Circuit diagram related to pre-lubricating motor relay
D375A-6 40-287
(01)
DRAFT
Failure code [D1EFKB] Pre lub. motor relay: Short circuit

Action code Failure code Pre-lubricating motor relay disconnection
Failure
E02 D1EFKB (Power train controller system)
Detail of fail- q No current flows when grounding to pre-lubricating motor relay primary (coil side) circuit or no voltage
ure is applied when no grounding.
Action of con-
q Stops grounding to pre-lubricating motor relay primary circuit (coil side).
troller
Problem on q Pre-lubricating motor does not operate.
machine q Engine does not start (engine starts if pre-lubrication is skipped).
q Output to pre-lubricating motor relay primary circuit (coil side) can be checked with monitoring func-
tion. (Code: 40909 P/T controller SW output)
Related infor-
mation
q This failure code detects failure on primary side (coil side) of pre-lubricating motor relay, but not on

Defective pre-lubricat- 1. Turn starting switch to OFF position.
ing motor relay 2. Disconnect connector PLUB and connect T-adapter to male side.
1
Between PLUB (male) (1) and (2) Resistance 200 – 400 Ω
or short circuit)
2. Disconnect connectors PTCN2 and KEY, and connect T-adapters to female side of
2
2. Disconnect connectors PTCN2 and PLUB, and connect T-adapter to female side of
ness
3 PTCN2.
Defective power train 3. Turn starting switch to ON position.
4
controller When pre-lubrica-
tion has been Voltage 20 – 30 V
Between PTCN2 (9) and ground completed
During pre-lubri-
Voltage Max. 1 V
cation
40-288 D375A-6
(01)
DRAFT
Circuit diagram related to pre-lubricating motor relay
D375A-6 40-289
(01)
DRAFT
Failure code [DAFRKR] Monitor: Can communication lost (PT)
Failure code [DAFRKR] Monitor: Can communication lost (PT)

Action code Failure code CAN communication with machine monitor is impossible (detected
Failure by power train controller)
E03 DAFRKR
(Power train controller system)
Detail of failure q Power train controller cannot recognize machine monitor with CAN communication circuit.
Action of con-
troller
q System may not operate properly.
Problem on
q Once machine is stopped, engine speed is limited to half of full speed.
machine
q Start of CAN communication is notified to each controller by ACC signal from starting switch.
q Failure code is displayed on machine monitor by CAN communication. Accordingly, if CAN commu-
Related infor- nication of machine monitor fails, code [DAFRKR] is not displayed on machine monitor and it can be
mation observed only through KOMTRAX system.
q Since each controller and machine monitor receive power from battery directly, they are kept ON
even while starting switch is OFF.
q Since CAN communication signal is pulse voltage, it cannot be measured with multimeter.

1 Perform troubleshooting for E mode, "E-3".
to machine monitor
Defective CAN commu-
2 Perform troubleshooting for failure code [DAFRMC], cause 10 and after.
nication
40-290 D375A-6
(01)
DRAFT
Failure code [dAFRKR] Monitor: CAN communication lost (WE)
Failure code [dAFRKR] Monitor: CAN communication lost (WE)

Action code Failure code CAN communication with machine monitor is impossible (detected
Failure by work equipment controller)
E03 dAFRKR
(Work equipment controller system)
Detail of failure q Work equipment controller cannot recognize machine monitor with CAN communication circuit.
Action of con-
troller
Problem on
machine
q Failure code is displayed on machine monitor by CAN communication. Accordingly, if CAN commu-
Related infor- nication of machine monitor fails, code [dAFRKR] is not displayed on machine monitor and it can be
mation observed only through KOMTRAX system.

1 Perform troubleshooting for E mode, "E-3".
to machine monitor
Defective CAN commu-
2 Perform troubleshooting for failure code [DAFRMC], cause 10 and after.
nication
D375A-6 40-291
(01)
DRAFT
Failure code [DAFRMC] CAN Discon (Monitor Detected)

Action code Failure code CAN communication is impossible (Machine monitor Detected)
Failure
E03 DAFRMC (Machine monitor system)
q Machine monitor cannot recognize power train controller, work equipment controller or VHMS con-
Detail of failure
troller in CAN communication.
Action of con- q Limits operation of engine and transmission.
troller q When the problem is eliminated, machine monitor returns to normal status.
Problem on
machine
q Failure code is sent to machine monitor by CAN communication. Accordingly, if other CAN-related
failure code such as [DB2RKR] is displayed on machine monitor, wiring harness (CAN communi-
cation line) is free from ground fault, short circuit and hot short.
Related infor-
q If failurecode [DB2RKR] is also displayed, problem with engine controller, cause items 1 to 6, will
mation
be the most probable cause of the failure.
q Since CAN communication line signal in operation is pulse voltage, it cannot be measured with mul-
timeter.
Procedure, measuring location, criteria in normal condition and remarks on trouble-

Cause
shooting
Defective engine control-
1 If circuit breaker has tripped, controller probably has short circuit in it.
ler circuit breaker (CB7)
a If circuit breaker has not tripped, this check is not required.
Defective engine control- 2. Disconnect connectors EGC3 and connect T-adapter to male side.
2
ler (Internal short circuit) a Measured value: approx. 9 – 20 kΩ
a If measured value is below 10 Ω, engine controller is defective (internal short circuit).
Between EGC3 (male) (3) and (1) Resistance Max. 10 Ω
2. Disconnect connectors EGC3 and connect T-adapter to female side.
Defective power supply to 3. If circuit breaker as tripped, reset it.
3
engine controller a If result is abnormal, perform troubleshooting for [CA111].
Between EGC3 (female) (3) and (1) or ground Voltage 20 – 30 V
Broken engine controller 2. Remove fuse in fuse box FS32-5.
4
ACC fuse If fuse has blown out, the circuit probably has ground fault. In this case, perform trouble-
shooting for cause 14 first.
Defective ACC cutout
If failure code [7RFAKA] or [7RFAKB] is also displayed, perform troubleshooting for it
5 relay drive (for engine
first.
controller)
Defective ACC cutout
2. Replace ACC cutout relay (connector ACT) with another relay (backup alarm relay;
relay (for engine control-
6 connector BKA, etc.)
ler) (Internal disconnection
or short circuit) 3. Turn starting switch to ON position.
If this failure code goes off, original ACC cutout relay (for engine controller) is defective.
Defective power supply to If failure code [DBERKR] or [DBBQKR] is also displayed, perform troubleshooting for
7
power train controller failure code [DBE1KK] or [DBE2KK] first.
Defective power supply to If failure code [DB9RKR] is also displayed, perform troubleshooting for failure code
8
work equipment controller [DB91KK] and [DB92KK] first.
Defective power supply to
9 Perform troubleshooting for failure codes [DBB0KK] and [DBB3KK].
VHMS controller
Defective CAN terminal
resistor 2. Disconnect connectors CT2 and CM02, and connect T-adapters to male side of
10 them.
short circuit) Between CT2 (male) (A) and (B) Resistance 120 ± 12
Between CM02 (male) (8) and (10) Resistance 120 ± 12
40-292 D375A-6
(01)
DRAFT
q CAN communication line

a There is 120 Ω CAN terminating resistor inside machine monitor, too. Since 120 Ω
resistor is connected in parallel, if resistance measured at connector of controller oth-
er than machine monitor is 60 Ω which is combined resistance, writing harness is not
open-cricuited.
1. Turn starting switch to OFF position and disconnect ground strap.
2. Disconnect one of connectors EGC2, PTCN2, WECN2, V4A, CT2 and CM02, and
Disconnection or short cir- connect T-adapter to female side of that connector.
11 a If connector has short circuit (resistance between terminals is 1 Ω or less), discon-
nect all of EGC2, PTCN2, WECN2, V4A and CM02, and check again to see if there
is short circuit between wiring harnesses or in controller.
Between EGC2 (female) (46) and (47) Resistance About 60 Ω
Between PTCN2 (female) (32) and (22) Resistance About 60 Ω
Between WECN2 (female) (32) and (22) Resistance About 60 Ω
Between V4A (female) (12) and (4) Resistance About 60 Ω
Between CT2 (female) (A) and (B) Resistance About 120 Ω
Between CM02 (female) (9) and (10) Resistance About 120 Ω
a If check result of cause item 11 is normal, this check is not required.
2. Disconnect connectors EGC2, PTCN2, WECN2, V4A, CT2 and CM02, and connect
T-adapters to female side of them.
Between PTCN2 (female) (32) and CM02 (female)
(9), and between PTCN2 (female) (22) and CM02 Resistance Max. 1 Ω
(female) (8)
Disconnection in wiring (10)
harness Between PTCN2 (female) (32) and EGC2 (female)
12 Resistance Max. 1 Ω
(Disconnection or defec- (46)
tive contact in connector) Between PTCN2 (female) (22) and EGC2 (female) Resistance Max. 1 Ω
(47)
Between PTCN2 (female) (32) and WECN2 (female)
(32)
(22)
Between PTCN2 (female) (32) and V4A (female) (4) Resistance Max. 1 Ω
Between EGC2 (female) (46) and CT2 (female) (A) Resistance Max. 1 Ω
Between EGC2 (female) (47) and CT2 (female) (B) Resistance Max. 1 Ω
q ACC signal from starting switch
2. Insert T-adapters into connectors PTCN3, WECN3, V1, CM01, ACT and EGC2.
Disconnection in wiring 3. Connect ground strap and turn starting switch to ON position.
harness Between PTCN3 (14) or (24) and (31) Voltage 20 – 30 V
13 Between WECN3 (14) or (24) and (31) Voltage 20 – 30 V
tive contact in connector) Between V1 (17) and (19) Voltage 20 – 30 V
Between CM01 (14) and (3) Voltage 20 – 30 V
Between ACT (1) and ground, and between ACT (3)
Voltage 20 – 30 V
and ground
Between EGC2 (39) and ground Voltage 20 – 30 V
D375A-6 40-293
(01)
DRAFT

a If another failure code related to CAN communication [DB2RKR] is displayed on ma-
chine monitor, this check is not required.
a If check result of cause item 11 is normal (there is open cricuit), measure at only 1
place.
2. Disconnect connectors PTCN2, WECN2, V4A, CM02 and EGC2, and connect
T-adapter to female side of one of them.
Between PTCN2 (female) (32), WECN2 (female)
(32), V4A (female) (4), CM02 (female) (8), (9) or Resistance Min. 1 MΩ
Ground fault of wiring har- EGC2 (female) (46) and ground
14 ness (Contact with ground Between PTCN2 (female) (22) , WECN2 (female)
circuit) (22), V4A (female) (12), CM02 (female) (10) or EGC2 Resistance Min. 1 MΩ
(female) (47) and ground
2. Disconnect connectors PTCN3, WECN3, V1, CM01 and ACT, and connect
T-adapter to female side of one of them.
3. Disconnect connector EGC2 and connect T-adapter to female side.
Between PTCN3 (female) (14), (24), WECN3
(female) (14), (24), V1 (female) (17) or CM01 (female) Resistance Min. 1 MΩ
(14) and ground
Between EGC2 (female) (39) and ground Resistance Min. 1 MΩ
a If another failure code related to CAN communication such as [DB2RKR] is displayed
on machine monitor, this check is not required.
a If check result of cause item 11 is normal (there is no disconnection), measure at only
1 place each.
2. Insert T-adapter into connector PTCN2, WECN2, V4A, CM02 or EGC2.
Short circuit or hot short 3. Connect ground strap.
15
a Since voltages of CAN H and CAN L are 2.5 ± 1 V even while communication is con-
tinued, they are judged to be normal if they are 1 - 4 V.
Between PTCN2 (32), WECN2 (32), V4A (4), CM02
Voltage 1–4V
(8), (9) or EGC2(46) and ground
Between PTCN2 (22), WECN2 (22), V4A(12), CM02(
Voltage 1–4V
10), or EGC2 (47) and ground
40-294 D375A-6
(01)
DRAFT
If cause is not found by above checks and another failure code related to CAN commu-
nication such as [DB2RKR] is not displayed, identify which controller is defective
according to following procedure.
q Step 1
2. Disconnect engine controller (connector EGC2).
3. Connect ground strap and turn starting switch to ON position.
Defective power
NO
train controller
Is failure code [DB2RKR] displayed?
Defective engine
YES
controller
Defective work
Defective engine control- NO
equipment controller
ler, power train controller, Is failure code [dB2RKR] displayed?
16 Defective engine
work equipment controller YES
controller
or VHSM controller
q Step 2
2. Disconnect power train controller (connector PTCN2).
Defective work
NO
equipment controller
Is failure code [DBERKR] displayed?
Defective power
YES
train controller
Defective VHMS
NO
controller
Is failure code [DBBQKR] displayed?
Defective power
YES
train controller
Defective machine moni- If Failure is not found by above checks, machine monitor is defective.
17
tor (Since trouble is in it, troubleshooting cannot be performed.)
D375A-6 40-295
(01)
DRAFT
Circuit diagram related to CAN
40-296 D375A-6
(01)
DRAFT
Failure code [DB2RKR] ENG cont.: Can communication lost (PT)

Action code Failure code CAN communication with engine controller is impossible.
Failure (detected by power train controller)
E03 DB2RKR
Detail of failure q Power train controller cannot recognize engine controller in CAN communication.
Action of con-
troller
Problem on
q Once machine stops, engine speed is limited to half of full speed.
machine
q Once machine stops, travel is limited to F1 and R1.
q Failure code is sent to machine monitor by CAN communication. Accordingly, if failure code
[DB2RKR] is displayed on the machine monitor, CAN communication between power train controller
and machine monitor is normal.
Related infor-
That is, there cannot be short circuit, ground fault or hot short in CAN communication line.
mation
q If failure code [DAFRMC] is also displayed, cause of this failure is probably engine controller problem
in cause1 and 2.
q Since each controller and machine monitor receive power from battery directly, they have power
q Since CAN communication line signal is pulse voltage, it cannot be measured with multimeter.
Procedure, measuring location, criteria in normal condition and remarks on trouble-

Cause
shooting
Defective engine controller cir-
1 If circuit breaker is turned OFF, controller probably has short circuit in it.
cuit breaker (CB7)
a If circuit breaker has tripped, this check is not required.
Defective engine controller 2. Disconnect connectors EGC3 and connect T-adapter to male side.
2
(Internal short circuit) a Measured value: approx. 9 – 20 kΩ
a If measured value is below 10 Ω, engine controller is defective (internal short cir-
cuit).
Between EGC3 (male) (3) and (1) Resistance Max. 10 Ω
2. Disconnect connectors EGC3 and connect T-adapter to female side.
Defective power supply to 3. If circuit breaker has tripped, reset it.
3
engine controller a If result is abnormal, perform troubleshooting for [CA111].
Broken engine controller ACC 2. Remove fuse in fuse box FS32-5.
4
fuse If fuse has blown out, the circuit probably has ground fault. In this case, perform
troubleshooting for cause item 11 first.
Defective ACC cutout relay (for If failure code [7RFAKA] or [7RFAKB] is also displayed, perform troubleshooting for
5
engine controller) drive it first.
Defective ACC cutout relay (for 2. Replace ACC cutout relay (connector ACT) with another relay (backup alarm
engine controller) relay; connector BKA, etc.)
6
(Internal disconnection or short 3. Turn starting switch to ON position .
circuit) If this failure code goes off, original ACC cutout relay (for engine controller) is defec-
tive.
Defective CAN terminal resis- 2. Disconnect connectors CT2and CM02 and connect T-adapter to male side of
7 tance (Internal disconnection them.
or short circuit) Between CT2 (male) (A) and (B) Resistance 120 ± 12
D375A-6 40-297
(01)
DRAFT

a There is 120 Ω CAN terminal resistor inside machine monitor, too. Since120 Ω
resistor is connected in parallel, if resistance measured at connector of controller
other than machine monitor is 60 Ω which is combined resistance, wiring harness
is not open-circuited.
2. Disconnect one of following connectors EGC2, PTCN2, WECN2, V4A, CT2 and
Disconnection or short circuit in CM02, and connect T-adapter to female side of that connector.
8 a If connector has short circuit (Resistance between terminals is1 Ω or less), dis-
wiring harness
connect all of EGC2, PTCN2, WECN2, V4A and CM02 and check again to see if
there is short circuit between wiring harnesses or in controller.
Between EGC2 (female) (46) and (47) Resistance Approx. 60 Ω
Between PTCN2 (female) (32) and (22) Resistance Approx. 60 Ω
Between WECN2 (female) (32) and (22) Resistance Approx. 60 Ω
Between V4A (female) (12) and (4) Resistance Approx. 60 Ω
Between CT2 (female) (A) and (B) Resistance Approx. 120 Ω
Between CM02 (female) (9) and (10) Resistance Approx. 120 Ω
a If check result of cause item 8 is normal, this check is not required.
2. Disconnect connectors EGC2, PTCN2, WECN2, V4A, CT2 and CM02, and
connect T-adapter to female side of them.
(9) and between PTCN2 (female) (32) and CH02 Resistance Max. 1 Ω
(female) (8)
(10)
Disconnection in wiring har- Between PTCN2 (female) (32) and EGC2 (female)
9 ness (Disconnection or defec- Resistance Max. 1 Ω
(46)
tive contact in connector) Between PTCN2 (female) (22) and EGC2 (female)
(47)
(32)
(22)
PTCN2 (female) (22) and V4A (female) (12) Resistance Max. 1 Ω
2. Insert T-adapter into connector PTCN3, WECN3, V1, CM01, ACT and EGC2.
Disconnection in wiring har- 3. Connect ground strap and turn starting switch to ON position.
ness Between PTCN3 (14) or (24) and (31) Voltage 20 – 30 V
10 Between WECN3 (14) or (24) and (31) Voltage 20 – 30 V
contact in connector) Between V1 (17) and (19) Voltage 20 – 30 V
Between ACT(1) and ground, and between ACT (3)
Voltage 20 – 30 V
and ground
Ground fault of wiring harness T-adapter to female side of one of them.
11 3. Disconnect EGC2 and connect T-adapter to female side.
(Contact with ground circuit)
Between ground and any one of PTCN3 (female)
(14), (24), WECN3 (female) (14), (24), V1(female) Resistance Min. 1 MΩ
(17) or CM01 (female) (14)
If cause is not found by above checks and failure code [DAFRMC] is displayed,
12 Engine controller is defective engine controller is defective.
Power train controller is defec- If cause is not found by above checks, power train controller is defective.
13
tive (Since failure is in it, troubleshooting cannot be performed.)
40-298 D375A-6
(01)
DRAFT
D375A-6 40-299
(01)
DRAFT
Failure code [dB2RKR] ENG controller: CAN communication lost (WE)
Failure code [dB2RKR] ENG controller: CAN communication lost (WE)

Action code Failure code CAN communication with engine controller is impossible (detected by work
Failure equipment controller)
E03 dB2RKR
Detail of failure q Work equipment controller cannot recognize engine controller in CAN communication circuit.
Action of con-
q Limits operation of engine, transmission, and fan.
troller
Problem on
machine
[dB2RKR] is displayed on machine monitor, CAN communication between work equipment control-
ler and machine monitor is normal.
Related infor-
That is, there cannot be short circuit, ground fault or hot short in CAN communication line.
mation
q If failure code [DAFRMC] is also displayed, cause of this failure is probably engine controller prob-
lem.

Perform troubleshooting for failure code [DB2RKR].
40-300 D375A-6
(01)
DRAFT
Failure code [DB90KT] WE controller: Abnormality in controller
Failure code [DB90KT] WE controller: Abnormality in controller

Action code Failure code Data recorded in work equipment controller are abnormal
Failure
E01 DB90KT (Work equipment controller system)
Detail of failure q Information in ROM (non-volatile memory) in work equipment controller is abnormal.
Action of con-
q Reset internal adjustment values to default values.
troller
Appears on q Operating feel of work equipment may become bad.
machine q Adjusting function by machine monitor may not operate properly.
Related infor-
mation

Use Adjustment function in service mode, and perform operation of reproducing trouble.
Defective adjustment of
1 If "E" of failure code disappears at this time, system is normal.
work equipment controller
q Adjustment code: 0031 (Initialization of work equipment controller)
Defective work equipment Troubleshooting cannot be carried out since defect is in work equipment controller. (If
2
controller there is no visible trouble in machine, controller may be used as it is.)
D375A-6 40-301
(01)
DRAFT
Failure code [DB91KK] WE controller: Source voltage reduction

Action code Failure code Battery direct voltage drop of work equipment controller
Failure
E04 DB91KK (Work equipment controller system)
Detail of failure q The battery direct power supply voltage for work equipment controller is below 17 V.
Action of con-
q Limits operation of engine, transmission, brake and work equipment.
troller
q Machine monitor may not display properly.
Problem on q Relay and solenoid may not be actuated and therefore, system may not operate properly.
machine q Once machine is stopped, engine speed is limited to half of full speed.
q Main power source voltage for work equipment controller can be checked in adjusting function.
Related infor-
(Code 2022: Work equipment controller voltage check mode)
mation

Trip of circuit breakerIf circuit breaker has tripped, circuit probably has ground fault. In this case, perform trou-
1
(CB30) bleshooting for cause 7 first.
If fuse FS12-4 is blown out, circuit probably has ground fault. In this case, perform trouble-
Loose terminal or dis- 1. Turn starting switch to OFF position.
3
connection at terminal Check terminals of battery, battery relay, etc.
Improper battery volt- 1. Perform troubleshooting with starting switch at OFF and when starting engine.
4
age Between battery (+) and (-) Voltage 20 – 30 V
2. Disconnect ground strap.
Disconnection in, or 3. Disconnect connector WECN3 and connect T-adapter to female side.
5 ground fault of wiring 4. Connect ground strap.
harness a If voltage is 0 V, wiring harness has open cricuit or ground fault.
Between WECN3 (female) (1) and (21)/(31) Voltage 20 – 30 V
Between WECN3 (female) (11) and (32)/(33) Voltage 20 – 30 V
Disconnection in wir- 3. If fuse has blown out, replace it.
ing harness 4. If circuit breaker has tripped, reset it.
6
(Disconnection or 5. Disconnect connector WECN3 and connect T-adapter to female side.
defective contact) Between WECN3 (female) (21), (31), (32) or (33) and
ground Resistance Max. 1 Ω
a Check terminal GND01 for looseness and rust.
Between WECN3 (female) (1) or (11) and battery (+) Resistance Max. 1 Ω
Ground fault of wiring 2. Disconnect ground strap.
harness 3. If fuse has blown out, replace it.
7
(Contact with ground 4. If circuit breaker has tripped, reset it.
circuit) 5. Disconnect connector WECN3 and connect T-adapter to female side.
Between WECN3 (female) (1) and (21)/(31) Resistance Min. 1 MΩ
Between WECN3 (female) (11) and (32)/(33) Resistance Min. 1 MΩ
If cause is not found by above checks, work equipment controller is defective.
q Reference: the followings are standard values in normal condition.
Defective work equip- 2. Disconnect ground strap.
8
4. Connect ground strap.
Between WECN3 (1) and (21)/(31) Voltage 20 – 30 V
Between WECN3 (11) and (32)/(33) Voltage 20 – 30 V
40-302 D375A-6
(01)
DRAFT
Circuit diagram related to power supply for work equipment controller
D375A-6 40-303
(01)
DRAFT
Failure code [DB92KK] WE controller: Output voltage reduction

Action code Failure code Voltage drop in power supply for work equipment controller-related
Failure actuators
E04 DB92KK
q Power supply (battery relay output) voltage for the actuators related to work equipment controller (re-
Detail of failure
lay, solenoid or others) is below 17 V.
Action of con-
q Limits operation of engine, transmission, brake and work equipment.
troller
Indication of q Relay and solenoid may not be actuated and therefore, system may not operate properly.
problem on q Once machine is stopped, engine speed is limited to medium (half).
q Power source voltage of work equipment controller can be checked in adjusting function.
Related infor-
(Code 2022: Work equipment controller voltage check mode)
mation

Trip of circuit breaker If CB3 or CB105 circuit breaker has tripped, circuit probably has ground fault. In this case,
1
CB3 or CB105 perform troubleshooting for cause 6 first.
Loose terminal or dis- 1. Turn starting switch to OFF position.
2
connection at terminal Check terminals of battery, battery relay, etc.
3
Defective wiring har- 3. Insert T-adapter into connector WECN3.
4 ness or power train 4. Connect ground strap.
Between WECN3 (2) and (21) Voltage 20 – 30 V
Disconnection in wir- 2. Disconnect ground strap (in order not to make short circuit).
ing harness 3. Disconnect connector WECN3 and connect T-adapter to female side.
5 Between ground and WECN3 (female) (21)/(31)/(32)/
(Disconnection or
defective contact) (33) respectively Resistance Max. 1 Ω
Between terminal BRC and WECN3 (female)
(2)/(12)/(22) respectively
harness 2. Disconnect ground strap (in orde not to make short circuit).
6
(Contact with GND cir- 3. If circuit breaker has tripped, reset it.
cuit) 4. Disconnect connector WECN3.
Between terminal BRC and ground Resistance Min. 1 MΩ
7 If cause is not found by above checks, work equipment controller is defective.
ment controller
40-304 D375A-6
(01)
DRAFT
Circuit diagram related to power supply for work equipment controller
D375A-6 40-305
(01)
DRAFT
Failure code [DB97KK] WE cont.: Sensor voltage 5 V (2) reduction

Action code Failure code Work equipment sensor 5 V power supply abnormality
Failure
― DB97KK (Work equipment controller system)
q Voltage of 5 V power supply circuit for work equipment controller sensor is below 4.5 V or above 5.5
Detail of failure V.
q Abnormal current flowed in 5 V power supply circuit for work equipment controller sensor.
Action of con-
q Stops output to 5 V power supply circuit if abnormal voltage flows.
troller
Problem on q Hydraulic pressure of work equipment pump cannot be monitored correctly (but machine operations
machine are not affected).
Related infor-
mation

2. Disconnect connector HHP.
Defective hydraulic pump 3. Turn starting switch to ON position.
1 pressure sensor (Internal q If this code is not displayed when hydraulic pump pressure sensor is disconnected,
defect) that sensor is defective.
a Other failure codes are displayed, too. This is because the connector is disconnect-
ed. Ignore failure codes other than [DB97KK].
ness 2. Disconnect connectors WECN3 and HHP, and connect T-adapter to female side of
Between WECN3 (female) (34) or HHP (female) (B) and Resis-
cuit) Min. 1 MΩ
ground tance
Short circuit in wiring har- 2. Disconnect connector HHP and connect T-adapter to female side.
3
ness 3. Turn starting switch to ON position.
Between HHP (female) (B) and (A) Voltage 4.5 – 5.5 V
Defective work equipment 2. Insert T-adapters into connectors WECN1 and WECN3.
4
a Since 24 V power is supplied to connector WECN3, 5 V output cannot be checked
with connector WECN3 disconnected.
Between WECN3(34) and WECN1(21) Voltage 4.5 – 5.5 V
40-306 D375A-6
(01)
DRAFT
Circuit diagram related to work equipment controller sensors 5 V power supply
D375A-6 40-307
(01)
DRAFT
Failure code [DB99KQ] WE controller: Type select signal
Failure code [DB99KQ] WE controller: Type select signal

Action code Failure code Machine model selection error on work equipment
Failure
E04 DB99KQ (Work equipment controller system)
q Specification setting in work equipment controller does not match specification setting memory (Initial
Detail of failure
setting of work equipment controller has not yet been performed).
Action of con- q Turns all outputs from work equipment controller OFF.
troller q Limits operation of engine, transmission, brake and work equipment.
q Machine does not move at all.
Problem on
machine
q Once machine stops, it cannot travel at all.
Related infor-
mation
Causes Procedure, measuring location, criteria and remarks

Use adjustment function in service mode, and perform operation of reproducing trou-
1 ble. If “E” of failure code disappears at this time, system function is proper.
work equipment controller
q Adjustment code: 0031 (Initial setting of work equipment controller)
40-308 D375A-6
(01)
DRAFT
Failure code [DB9RKR] WE controller: Can communication lost (PT)

Action code Failure code CAN communication with work equipment controller (detected
Failure power train controller)
E03 DB9RKR
Detail of failure q Power train controller cannot recognize work equipment controller in CAN communication circuit.
Action of con-
troller
Problem on
machine
[DB9RKR] is displayed on the machine monitor, CAN communication between power train controller
Related infor-
and machine monitor is normal. That is, there cannot be short circuit, ground fault or hot short in CAN
mation
communication line.

Defective power supply to If failure code [DAFRMC] is also displayed, perform troubleshooting for failure code
1
work equipment controller [DB91KK] and [DB92KK] first.
Defective CAN terminating
resistor 2. Disconnect connectors CT2 and CM02 and connect T-adapters to male side of
2 them.
a There is 120 Ω CAN terminating resistor inside machine monitor, too. Since 120 Ω
resistor is connected in parallel, if resistance measured at connector of controller
other than machine monitor is 60 Ω which is combined resistance, wiring harness is
not open cricuited.
Disconnection or short cir- CM02 and connect T-adapter to female side of that connector.
3 a If connector has short circuit (Resistance between terminals is1 Ω or less), discon-
nect all of EGC2, PTCN2, WECN2, V4A and CM02 and check again to see if there
is short circuit between wiring harnesses or in controller.
Between CT2 (female) (A) and (B) Resistance Approx. 120 Ω
Between CM02 (female ) (9) and (10) Resistance Approx. 120 Ω
D375A-6 40-309
(01)
DRAFT
a If check result of cause 3 is normal, this check is not required.

2. Disconnect connectors EGC2, PTCN2, WECN2, V4A, CT2 and CM02 and connect
T-adapters to female side of them.
(9)/(8)
(10)
ness (46)
4 Between PTCN2 (female) (22) and EGC2 (female)
(Disconnection or defective Resistance Max. 1 Ω
contact in connector) (47)
(32)
(22)
Between PTCN2 (female) (22) and V4A (female)
(12)
2. Insert T-adapter into connector PTCN3, WECN3, V1, CM01, ACT and EGC2.
Disconnection in wiring har- 3. Connect ground strap and turn starting switch to ON position.
ness Between PTCN3 (14) or (24) and (31) Voltage 20 – 30 V
5
(Disconnection or defective Between WECN3 (14) or (24) and (31) Voltage 20 – 30 V
contact in connector) Between V1 (17) and (19) Voltage 20 – 30 V
Between ACT(1), (3) and ground Voltage 20 – 30 V
Between EGC2(39) and ground Voltage 20 – 30 V
Ground fault in wiring har- T-adapter to female side of one of them.
6 ness 3. Disconnect connectors EGC2 and connect T-adapter to female side.
(Contact with ground circuit) Between ground and any one of PTCN3 (female)
(14), (24), WECN3 (female) (14), (24), V1(female) Resistance Min. 1 MΩ
(17) or CM01 (female) (14)
If cause is not found by above checks and failure code [DAFRMC] is displayed, work
Work equipment controller
7 equipment controller is defective.
is defective
Power train controller is If cause is not found by above checks, power train controller is defective.
8
defective (Since failure is in it, troubleshooting cannot be performed.)
40-310 D375A-6
(01)
DRAFT
D375A-6 40-311
(01)
DRAFT
Failure code [DBB0KK] VHMS controller:Source voltage reduction

Action code Failure code Voltage drop in power supply to VHMS controller
Failure
― DBB0KK ( VHMS contron system)
q When engine was running, the switch power voltage from battery relay to VHMS controller dropped
Detail of failure
below 19.5 V.
Action of con-
troller
Problem on
machine
Related infor-
q VHMS controller LED displays "n9" o "C01".
mation

Trip of circuit breaker If circuit breaker has tripped, circuit probably has ground fault. In this case, perform
1
(CB105) troubleshooting for cause 6 first.
If fuse FS12-5 is blown out, circuit probably has ground fault. In this case, perform
Loose terminal or discon- 1. Turn starting switch to OFF position.
3
nection at terminal Check terminals of battery, battery relay, TR1S, TR2L, etc.
4 Improper battery voltage 2. Perform troubleshooting when engine is cranked.
Between battery (+) and (-) Voltage 20 – 30 V
3. Disconnect connector V1 and connect T-adapter to female side.
4. If fuse has blown out, replace it.
Disconnection in, or ground 5. If circuit breaker has tripped, reset it.
5
fault of wiring harness 6. Connect ground strap.
a If voltage is 0 V, wiring harness is open-cricuited or ground fault.
Between Vl (female) (8) and (11)/(12) Voltage 20 – 30 V
Between Vl (female) (9) and (19)/(20) Voltage 20 – 30 V
Disconnection in wiring 3. If fuse has blown out, replace it.
harness 4. If circuit breaker has tripped, reset it.
6
(Disconnection or defec- 5. Disconnect connector V1 and connect T-adapter to female side.
tive contact) Between V1 (female) (11)/(12)/(19)/(20) and ground Resis-
Max. 1 Ω
a Check terminal GND01 for looseness and rusting. tance
Resis-
Between V1 (female) (8)/(9) and battery relay BRC terminal Max. 1 Ω
tance
Ground fault of wiring har- 3. If fuse is blown out, replace it.
ness 4. If circuit breaker has tripped, reset it.
7
(Contact with ground cir- 5. Disconnect connector V1 and connect T-adapter to female side.
cuit) Resis-
Between V1 (female) (8) and (11)/(20) Min. 1 MΩ
tance
Resis-
Between V1(female)(9) and ground Min. 1 MΩ
tance
8 Defective VHMS controller 3. Insert T-adapter in connector V1.
Between V1(8) and (11)/(12) Voltage 20 – 30 V
40-312 D375A-6
(01)
DRAFT
Circuit diagram related to power supply for VHMS controller
D375A-6 40-313
(01)
DRAFT
Failure code [DBB0KQ] VHMS connector connection abnormality

Action code Failure code VHMS connector connection abnormality
Failure
― DBB0KQ (VHMS controller system)
Detail of failure q Incorrect connection of connector V2A, V2B, V3A or V3B of VHMS controller
Action of con-
troller
Problem on
q Sensor signal value may not be indicated properly.
machine
Related infor-
q VHMS controller LED displays "n9" o "05".
mation

Wrong connector connec- Check if connectors "V2A" and "V3A" as well as connectors "V2B" and "V3B" of VHMS
1
tion controller are connected incorrectly.
40-314 D375A-6
(01)
DRAFT
D375A-6 40-315
(01)
DRAFT
Failure code [DBB3KK] VHMS controller: Source voltage reduction

Action code Failure code Voltage drop in unswithed power supply to VHMS controller
Failure
– DBB3KK (VHMS controller system)
Detail of failure q 24 V power supply voltage from battery to VHMS controller is below 12.5 V.
Action of con-
troller
Problem on
q VHMS does not operate.
machine
Related infor-
mation

Trip of circuit breaker If circuit breaker has tripped, circuit probably has ground fault. In this case, perform
1
(CB30) troubleshooting for cause 6 first.
If fuse FS12-4 is blown out, circuit probably has ground fault. In this case, perform trou-
bleshooting for cause 6 first.
Loose terminal 1. Turn starting switch to OFF position.
3 or disconnection at termi-
nal Check terminals of battery, battery relay, etc.
1. Turn starting switch OFF, then carry out troubleshooting.
2. When starting engine.
4 Improper battery voltage
Between battery (+) and (-) Voltage 20 – 30 V
4. If fuse has blown out, replace it.
Disconnection in, or ground
5 5. If circuit breaker has tripped, reset it.
fault of wiring harness
a If voltage is 0 V, wiring harness is open-cricuited or ground fault.
Between V1 (female) (6) and (11)/(12) Voltage 20 – 30 V
Between V1 (female) (7) and (19)/(20) Voltage 20 – 30 V
Disconnection in wiring 3. If fuse is blown out, replace it.
harness
6 4. If circuit breaker has tripped, reset it.
tive contact)
Between V1 (female) (11)/(12)/(19)/(20) and ground
a Check terminal GND0I for looseness and rust.
Between V1 (female) (6), (7) and battery (+) Resistance Max. 1 Ω
Ground fault of wiring har- 2. Disconnect ground strap.
ness 3. If fuse is broken, replace it.
7
(Contact with ground cir- 4. If circuit breaker is turned OFF, reset it.
cuit) 5. Disconnect connector V1 and connect T-adapter to female side.
Between V1 (female) (6) and (11)/(20) Voltage Min. 1 MΩ
Between V1(female)(7) and ground Voltage Min. 1 MΩ
q Reference; the followings are standard values in normal condition.
8 Defective VHMS controller
3. Insert T-adapter in connector V1.
40-316 D375A-6
(01)
DRAFT
Circuit diagram related to power supply for VHMS controller
D375A-6 40-317
(01)
DRAFT
Failure code [DBB5KP] VHMS: Output sensor1 voltage reduction

Action code Failure code VHMS sensor 5 V power supply abnormality
Failure
E00 DBB5KP ( VHMS contron system)
q Voltage of 5 V power supply circuit from VHMS controller to sensors is below 4.5 V or above 5.5 V.
Detail of failure
q Abnormal current flowed in 5 V power supply circuit for VHMS controller sensor.
Action of con-
troller
Problem on
q A part of VHMS does not operate.
machine
Related infor-
q VHMS controller LED displays "N9" o "04".
mation

2. Disconnect connector ENBP.
Defective blowby pressure 3. Turn starting switch to ON position.
1
sensor (Internal defect) q If this code is not displayed, blowby pressure sensor is defective.
ed. Ignore failure codes other than [DBB5KP].

2. Disconnect connectors V1 and ENBP, and connect T-adapter to female side of
ness
Resis-
cuit) Between V1 (female) (4) or ENBP (female) (B) and ground Min. 1 MΩ
tance
2. Disconnect connector ENBP and connect T-adapter to female side.
3
Between ENBP (female) (B) and (A) Voltage 4.5 – 5.5 V
If cause is not found by the above checks, VHMS controller is defective.
2. Insert T-adapter in connector V1 and V2A.
a Since 24 V power is supplied to connector V1, 5 V output cannot be checked with
4 Defective VHMS controller connector V1 disconnected.
Between V1(4) and V2A(12) Voltage 4.5 – 5.5 V
Between V1(4) and V2A(12) Voltage 4.5 – 5.5 V
40-318 D375A-6
(01)
DRAFT
Circuit diagram related to power supply for VHMS controller sensors 5V
D375A-6 40-319
(01)
DRAFT
Failure code [DBB6KP] VHMS:Output sensor2 voltage reduction

Failure
― DBB6KP (VHMS controller system)
q 24 V power supply circuit voltage from VHMS controller to sensors is above normal range (20 V - 30
Detail of failure V).
q Abnormal current flowed in 24 V sensor power supply circuit to VHMS controller.
Action of con-
troller
Problem on
q Sensor input value to controller may not be obtained correctly.
machine
Related infor-
mation

Defective transmis-
sion main oil pressure 2. Disconnect following connectors one by one and turn starting switch to ON position each
sensor, front (cylinder time.
Nos. 1 - 3) exhaust 3. After troubleshooting, return to 1.
temperature sensor, q If this code is not displayed when a sensor or a device is disconnected, that sensor or
rear (cylinder Nos. 4 - device is defective.
1 6) exhaust tempera- a Other failure codes are displayed, too. This is because the connector is disconnected.
ture sensor, front Ignore failure codes other than [DBB6KP].
exhaust temperature Device or sensor Connector
sensor amplifier or rear Transmission main oil pressure sensor TMMD
exhaust temperature Front (cylinder Nos. 1 - 3) exhaust temperature sensor EXHF
sensor amplifier (Inter- Rear (cylinder No. 4 - 6) exhaust temperature sensor EXHR
Front exhaust temperature sensor amplifier EXAF
nal defect)
Rear exhaust temperature sensor amplifier EXAR
2. Disconnect connectors EXHF, EXHR, EXTF, EXTR, EXAF, EXAR, TMMD, V1 and V2A,
and connect T-adapter to female side of them or to male side of EXTF.
Between EXHF (female) (1) or EXTF (male) (1) and
Ground fault of wiring ground
harness Between EXHF (female) (1) and (2), or between EXTF
2 Resistance Min. 1 MΩ
(Contact with ground (male) (1) and (2)
circuit) Between EXHR (female) (1) or EXTR (male) (1) and
ground
Between EXHR (female) (1) and (2), or between EXTR
(male) (1) and (2)
Between V1 (female) (2) and ground Resistance Min. 1 MΩ
Between V1 (female) (2) and V2A (female) (12)/(13) Resistance Min. 1 MΩ
q Reference; The following are standard values in normal condition.
Defective VHMS con- 2. Insert T-adapter into connectors V1 and V2A.
3
a Since 24 V power is supplied to connector V1, 24 V output cannot be checked with con-
nector V1 disconnected.
Between V1 (2) and V2A (12)/(13) Voltage 20 – 30 V
40-320 D375A-6
(01)
DRAFT
Circuit diagram related to VHMS controller sensor 24V power supply
D375A-6 40-321
(01)
DRAFT

Failure
― DBB7KP ( VHMS contron system)
q Voltage of 12 V power supply circuit from VHMS controller to sensors is below 11.5 V or above 12.5
Detail of failure V.
q Abnormal current flowed in 12 V sensor power supply circuit to VHMS controller.
Action of con-
troller
Problem on
q When downloading from VHMS controller, LED (Download light) does not light up.
machine
Related infor-
q VHMS controller LED displays "N9" o "03".
mation

2. Disconnect connector DLT.
Defective download LED 3. Turn starting switch to ON position.
1
(Internal defect) q If this code is not displayed, download LED is defective.
ed. Ignore failure codes other than [DBB7KP].

2. Disconnect connectors V1 and DLT, and connect T-adapter to female side of either
ness
2 one of them.
Resis-
cuit) Between V1 (female) (3) or DLT (female) (1) and ground Min. 1 MΩ
tance
2. Disconnect connector DLT and connect T-adapter to female side.
3
Between DLT (female) (1) and (2) Voltage 11.5 – 12.5 V
2. Insert T-adapter in connector V1.
4 Defective VHMS controller 3. Turn starting switch to ON position.
a Since 24 V power is supplied to connector V1, 12 V output cannot be checked with
connector V1 disconnected.
V1 Between (3) and (12) Voltage 11.5 – 12.5 V
Circuit diagram related to VHMS controller sensor 24 V power supply
40-322 D375A-6
(01)
DRAFT
Failure code [DBBQKR] PT cont.: Can communication lost (VHMS)
Failure code [DBBQKR] PT cont.: Can communication lost (VHMS)

Action code Failure code CAN communication with power train controller is impossible
Failure (detected by VHMS controller)
E00 DBBQKR
(VHMS controller system)
q VHMS controller cannot recognize engine controller, power train controller, work equipment control-
Detail of failure
ler, and machine monitor in CAN communication.
Action of con-
troller
Problem on
q VHMS function to collect information from other controllers does not work.
machine
Related infor-
q VHMS controller LED panel displays "n8" o "02".
mation

Perform troubleshooting for failure code [DBERKR].
Failure code [DBE0KT] PT controller: Abnormality in controller

Action code Failure code Data recorded in power train controller are abnormal
Failure
E01 DBE0KT (Power train controller system)
Detail of failure q Information in ROM (non-volatile memory) in power train controller is abnormal.
Action of con-
q Resets internal adjustment values to default values.
troller
Problem on q Transmission gear shift feel may become bad.
machine q Adjusting function by power train controller may not operate properly.
Related infor-
mation

Use adjustment function in service mode, and perform operation of reproducing trouble.
1 If "E" of failure code disappears at this time, system function is proper.
power train controller
q Adjustment code: 0002 (initial setting of power train controller)
Defective power train con- Troubleshooting cannot be performed since defect is in power train controller. (If there is
2
troller no any visible trouble in machine, controller may be used as it is.)
D375A-6 40-323
(01)
DRAFT
Failure code [DBE1KK] PT controller: Source voltage reduction

Action code Failure code Battery direct power supply voltage drop for power train controller
Failure
E04 DBE1KK (Power train controller system)
Detail of failure q The voltage of battery direct power supply to power train controller is below 17 V.
Action of con-
troller
q Machine monitor may not display correctly.
Problem on q Relay and solenoid may not be actuated and therefore, system may not operate properly.
machine q Once machine is stopped, engine speed is limited to half of full speed.
q Power source voltage of power train controller can be checked by adjusting function.
Related infor-
(Code 2021: Power train controller voltage check mode)
mation

Trip of circuit breaker If circuit breaker has tripped, circuit probably has ground fault. In this case, perform trou-
1
(CB30) bleshooting for cause 7 first.
If fuse FS12-4 is blown out, circuit probably has ground fault. In this case, perform trouble-
Loose terminal, 1. Turn starting switch to OFF position.
3 or disconnection at ter-
Check terminals of battery, battery relay, etc.
minal
4
Disconnection in, or 3. Disconnect connector PTCN3 and connect T-adapter to female side.
5 ground fault of wiring 4. Connect ground strap.
harness a If voltage is 0 V, wiring harness is open-cricuited or ground fault.
Between PTCN3 (female) (1) and (21), (31) Voltage 20 – 30 V
Between PTCN3 (female) (11) and (32), (33) Voltage 20 – 30 V
Disconnection in wir- 3. If fuse has blown out, replace it.
ing harness 4. If circuit breaker has tripped, reset it.
6
(Disconnection or 5. Disconnect connector PTCN3 and connect T-adapter to female side.
defective contact) Between PTCN3 (female) (21)/(31)/(32)/(33) and
ground Resistance Max. 1 Ω
Between PTCN3 (female) (1)/(11) and battery (+) Resistance Max. 1 Ω
Ground fault of wiring 2. Disconnect ground strap.
harness 3. If fuse is blown out, replace it.
7
circuit) 5. Disconnect connector PTCN3 and connect T-adapter to female side.
Between PTCN3 (female) (1) and (21)/(31) Resistance Min. 1 MΩ
Between PTCN3 (female) (11) and (32)/(33) Resistance Min. 1 MΩ
Defective power train 2. Disconnect ground strap.
8
controller 3. Insert T-adapter into connector PTCN3.
Between PTCN3 (1) and (21)/(31) Voltage 20 – 30 V
Between PTCN3 (11) and (32)/(33) Voltage 20 – 30 V
40-324 D375A-6
(01)
DRAFT
Circuit diagram related to power train controller power supply
D375A-6 40-325
(01)
DRAFT
Failure code [DBE2KK] PT controller: Output voltage reduction

Action code Failure code Voltage drop in power supply for power train controller-related actu-
Failure ators
E04 DBE2KK
q Power supply (battery relay output) voltage for the actuators related to power train controller (relay,
Detail of failure
solenoid or others) is below 17 V.
Action of con-
q Limits operation of engine, transmission and brake.
troller
q Relay and solenoid may not drive be actuated and therefore, system may not operate properly.
Problem on
machine
q Main power source voltage of power train controller can be checked by adjusting function.
Related infor- (Code 2021: Power train controller voltage check mode)
mation q If battery relay is not turned ON, see E-mode, E-1.

Trip of circuit breaker If CB1 or CB105 circuit breaker has tripped circuit probably has ground fault. In this case,
1
CB1 or CB105 perform troubleshooting for cause 6 first.
Loose terminal, 1. Turn starting switch to OFF position.
2 or disconnection at ter-
Check terminals of battery, battery relay, etc.
minal
3
Defective wiring har- 3. Insert T-adapter into connector PTCN3.
4 ness or power train 4. Connect ground strap.
Between PTCN3 (2) and (21) Voltage 20 – 30 V
Disconnection in wiring 2. Disconnect ground strap (in order not to make short circuit).
harness 3. Disconnect connector PTCN3 and connect T-adapter to female side.
5
(Disconnection or Between PTCN3 (female) (21)/(31)/(32)/(33) and
defective contact) ground Resistance Max. 1 Ω
Between PTCN3 (female) (2), (12) or (22) and BRC Resistance Max. 1 Ω
harness 2. Disconnect ground strap (in order not to make short circuit).
6
circuit) 4. Disconnect connector PTCN3.
Between terminal BRC and ground Resistance Min. 1 MΩ
7 If cause is not found by the above checks, power train controller is defective.
controller
40-326 D375A-6
(01)
DRAFT
Circuit diagram related to power train controller power supply
D375A-6 40-327
(01)
DRAFT
Failure code [DBE5KK] PT cont.: Sensor voltage 5 V (1) reduction

Action code Failure code Power train controller 5 V power supply (1) abnormality
Failure
q Voltage of 5 V power supply (1) circuit from power train controller to sensors is below 4.5 V or above
Detail of failure 5.5 V.
q Abnormal current flowed in 5 V power supply (1) circuit for power train controller sensors.
Action of con- q Stops output to 5 V power supply (1) circuit, if abnormal current flows.
troller q Limits operation of engine and transmission.
Problem on
machine
Related infor-
mation

each time.
3. After troubleshooting, return to 1.
Defective fuel control dial, q If this code is not displayed when a sensor is disconnected, that sensor is defec-
1 brake pedal or PCCS lever tive.
(Internal defect) a Other failure codes are displayed at the same time. This is because the connector
is disconnected. Ignore failure codes other than [DBE5KK].
Device Connector
Fuel control dial DIAL
PCCS lever TL2
Brake pedal BRK
2. Disconnect connector PTCN1 and connect T-adapter to female side.
Defective transmission
controller
Between ground and any one of PTCN1 (female) (22)
and (21)
Ground fault of wiring har- 2. Disconnect connectors PTCN1, DIAL and TL2, and connect T-adapter to female
3 ness side of any one of them.
(Contact with GND circuit) Between ground and any one of PTCN1 (female) (22), Resis-
Min. 1 MΩ
TL2 (female) (4)/(5), BRK (C) or DIAL (female) (1) tance
2. Disconnect connectors DIAL, TL2 and BRK, and connect T-adapter to female side
of any one of them.
4 3. Turn starting switch ON.
Between TL2 (female) (4) and (1), or between TL2
(female) (5) and (8), between BRK (C) and (A), or Voltage 4.5 – 5.5 V
between DIAL (female) (1) and (3)
40-328 D375A-6
(01)
DRAFT
Circuit diagram related to power train controller sensors 5 V (1) power supply
D375A-6 40-329
(01)
DRAFT
Failure code [DBE6KK] PT cont.: Sensor voltage 24 V reduction

Action code Failure code Power train controller sensor 24 V power supply abnormality
Failure
q Voltage of 24 V power supply circuit from power train controller to sensors is below 17 V or above
Detail of failure 30 V.
q Abnormal current flowed in 24 V power supply circuit for power train controller sensors.
Action of con- q Stops output to 24 V power source circuit if abnormal voltage flows.
Problem on
machine
Related infor-
mation

Defective inclination angle each time.
sensor, torque converter 3. After troubleshooting, return to 1).
inlet pressure sensor or q If this code is not displayed when a sensor is disconnected, that sensor is defective.
1 a Other failure codes are displayed, too. This is because the connector is disconnect-
torque converter outlet
pressure sensor (Internal ed. Ignore failure codes other than [DBE6KK].
defect) Sensor Connector
Inclination angle sensor PT1
Torque converter inlet pressure sensor TIP
Torque converter outlet pressure sensor TOP
Defective power train con- 2. Disconnect connector PTCN1 and connect T-adapter to female side.
2
Between PTCN1 (female) (16) and (21) Voltage 20 – 30V
ness 2. Disconnect connectors PTCN1, PT1, TIP and TOP, and connect T-adapter to
3 female side of any one of them.
Between ground and any one of PTCN1 (female) (16),
TIP(B), TOP(B) or PT1 (female) (C)
2. Disconnect connectors PT1, TIP and TOP, and connect T-adapter to female side
Short circuit in wiring har- of any one of them.
4
ness 3. Turn starting switch to ON position.
Between TIP(B) and (A), between TOP(B) and (A), or
Voltage 20 – 30V
between PT1 (female) (C) and (A)
40-330 D375A-6
(01)
DRAFT
Circuit diagram related to power train controller sensor 24 V power supply
D375A-6 40-331
(01)
DRAFT

Action code Failure code Power train controller sensor 5 V power supply (2) abnormality
Failure
q Voltage of 5 V power supply (2) circuit from power train controller to sensors is below 4.5 V or above
Detail of failure 5.5 V.
q Abnormal current flowed in 5 V power supply (2) circuit for power train controller sensors.
Action of con-
q Stops output to 5 V power supply (2) circuit, if abnormal current flows.
troller
Problem on
q Shoe slip control function may not operate properly (only for machine with shoe slip control).
machine
Related infor-
mation

2. Disconnect connector SSA.
Defective acceleration sen-
1 sor 3. Turn starting switch to ON position.
q If this code is not displayed, acceleration sensor is defective.
(Internal defect)
ed. Ignore failure codes other than [DBE7KK].
ness 2. Disconnect connectors PTCN3 and SSA, and connect T-adapter to female side of
Between PTCN3 (female) (34) or SSA (female) (1) and Resis-
cuit) Min. 1 MΩ
ground tance
Hot short in wiring harness 2. Disconnect connector SSA and connect T-adapter to female side.
3
Between SSA (female) (1) and (3) Voltage 4.5 – 5.5 V
Defective power train con- 2. Insert T-adapter in connector PTCN3.
4
a Since 24 V power is supplied to connector PTCN3, 5 V output cannot be checked
with connector PTCN3 disconnected.
Between PTCN3(34) and ground Voltage 4.5 – 5.5 V
40-332 D375A-6
(01)
DRAFT
Circuit diagram related to power train controller sensor 5 V (2) power supply
D375A-6 40-333
(01)
DRAFT
Failure code [DBE9KQ] PT controller: Type select signal
Failure code [DBE9KQ] PT controller: Type select signal

Action code Failure code Power train controller: Type select signal
Failure
E04 DBE9KQ (Power train controller system)
q Specification setting in power train controller does not match specification setting memory (Initializa-
Detail of failure
tion of power train controller is not performed).
Action of con- q Turns all outputs of power train controller to OFF position.
q Machine does not move at all.
Problem on
machine
q Once machine stops, it cannot travel at all.
Related infor-
mation

Display adjustment function in service mode and perform operation of reproducing
1 trouble. If “E” of failure code disappears at this time, system is normal.
power train controller
q Adjustment code: 0002 (Initialization of power train controller)
40-334 D375A-6
(01)
DRAFT
Failure code [DBERKR] PT controller: Can communication lost (WE)

Action code Failure code CAN communication with power train controller is impossible.
Failure (detected by work equipment controller )
E03 DBERKR
Detail of failure q Work equipment controller cannot recognize power train controller in CAN communication.
Action of con-
troller
q System may not operate normally.
Problem on
machine
q Start of CAN communication is notified to each controller by ACC signal of starting switch.
q Failure code is sent to machine monitor by CAN communication. Accordingly, if failure code [DBER-
KR] is displayed on the machine monitor, CAN communication between work equipment controller
Related infor- and machine monitor is normal. That is, there cannot be short circuit, ground fault or hot short in CAN
mation communication line.
q Since CAN communication line signal in operation is pulse voltage, it cannot be measured with mul-
timeter.

Defective power supply to If failure code [DBBQKR] is also displayed, perform troubleshooting for failure code
1
power train controller [DBE1KK] and [DBE2KK] first.
Defective CAN terminal
resistor 2. Disconnect connectors CT2 and CM02 and connect T-adapters to male side of
2 them.
a There is 120 Ω CAN terminal resistor inside machine monitor, too. Since 120 Ω re-
sistor is connected in parallel, if resistance measured at connector of controller
other than machine monitor is 60 Ω which is combined resistance, there is not
open circuit in wiring harness.
CM02 and connect T-adapter to female side of that connector.
Disconnection or short cir- a If connector has short circuit (Resistance between terminals is 1 Ω or less), dis-
3 connect all of EGC2, PTCN2, WECN2, V4A and CM02 and check again to see if
there is short circuit between wiring harnesses or in controller.
Between CT2 (female) (A) and (B) Approx.
Resistance
120 Ω
Between CM02 (female) (9) and (10) Approx.
Resistance
120 Ω
D375A-6 40-335
(01)
DRAFT
a If check result of cause 3 is normal, this check is not required.

2. Disconnect connectors EGC2, PTCN2, WECN2, V4A, CT2 and CM02 and
connect T-adapters to female side of them.
Between PTCN2 (female) (32) and CM02 (female) (9),
(8)
(10)
ness Resistance Max. 1 Ω
4 (46)
(Disconnection or defective Between PTCN2 (female) (22) and EGC2 (female)
contact in connector) Resistance Max. 1 Ω
(47)
(32)
Between PTCN2 (female) (22) and WECN (female)
(22)
q Signal ACC of starting switch
2. Insert T-adapters into connectors PTCN3, WECN3, V1, CM01, ACT and EGC2.
Disconnection in wiring har- Between PTCN3 (14) and (31), or between PTCN3
ness Voltage 20 – 30 V
5 (24) and (31)
(Disconnection or defective Between WECN3 (14) and (31), or between WECN
contact in connector) Voltage 20 – 30 V
(24) and (31)
Between V1 (17) and (19) Voltage 20 – 30 V
Between ACT (1), (3) and ground Voltage 20 – 30 V
q Signal ACC of starting switch
Ground fault of wiring har- T-adapter to female side of one of them.
6 ness 3. Disconnect EGC2 and connect T-adapter to female side.
(Contact with ground circuit) Between PTCN3 (female) (14), (24), WECN3 (female)
(14), (24), V1 (female) (17) or CM01 (female) (14) and Resistance Min. 1 MΩ
ground
If cause is not found by above checks and failure code [DAFRMC] is displayed,
7 power train controller is defective.
ler
(Since trouble is in it, troubleshooting cannot be performed.)
Defective work equipment If cause is not found by above checks, work equipment controller is defective.
8
controller (Since failure is in it, troubleshooting cannot be performed.)
40-336 D375A-6
(01)
DRAFT
D375A-6 40-337
(01)
DRAFT
Failure code [DD12KA] Shift up Sw: Disconnection

Action code Failure code Shift up switch: Disconnection
Failure
E02 DD12KA (Power train controller system)
Detail of failure q Both lines of NO* and NC* for shift up switch circuit are OPEN (switch: OFF) at the same time.
Action of con-
q Recognizes that the shift up switch is not pressed.
troller
Problem on
q Transmission gear cannot be shifted up.
machine
q "NO*" line is used for sensing operation and "NC*" line is used for detecting error.
q Condition of shift up switch signal can be checked with monitoring function.
Related infor-
(Code: 40905 Power train control switch Input 3)
mation
q Method of reproducing failure code: Turning on the starting switch and operating the shift up switch
q Connector SFTU has no T-adapters, don't carry out troubleshooting in female side.

2. Disconnect connector SFTU.
3. Turn shift up switch to ON or OFF position and troubleshoot.
1
Defective shift up switch a "Switch OFF": Release, "Switch ON": Press
(Internal disconnection) Between SFTU (male) (3) and Switch: OFF Resistance Max. 1 Ω
(2) Switch: ON Resistance Min. 1 MΩ
Between SFTU (male) (1) and Switch: OFF Resistance Min. 1 MΩ
(2) Switch: ON Resistance Max. 1 Ω
3. Insert T-adapter into connector TL3.
4. Turn starting switch ON position.
Disconnection or hot short a If voltage is 0 V, it shows disconnection in wiring harness, and if voltage is 24 V, it
2
in wiring harness shows hot short in wiring harness.
a Voltage of approx. 9 V is applied to signal lines of "NO" and "NC" through resistor
in power train controller.
Between TL3(1) and (2) Voltage 7 – 11V
2. Disconnect connectors PTCN1 and PTCN3 and connect T-adapters to each female
Disconnection in wiring side.
harness 3. Turn shift up switch to ON or OFF position and troubleshoot.
3
(Disconnection or defec- Between PTCN3 (female) (29) and PTCN1
tive contact) Switch: OFF Resistance Max. 1 Ω
(female) (10).
Between PTCN3 (female) (39) and PTCN1
Switch: ON Resistance Max. 1 Ω
(female) (10).
2. Insert T-adapter into connector PTCN1 and PTCN3.
Defective transmission 4. Turn shift up switch to ON or OFF position and troubleshoot.
4
controller a Voltage of apporx. 9 V is applied to PTCN3 pin (29) and PTCN3 pin (39) through
resistor in power train controller.
Between PTCN3(29) and Switch: OFF Voltage Max. 1V
PTCN1(10) Switch: ON Voltage 7 – 11V
Between PTCN3(39) and Switch: OFF Voltage 7 – 11V
PTCN1(10) Switch: ON Voltage Max. 1V
*NO: Normally Open
*NC: Normally Closed
40-338 D375A-6
(01)
DRAFT
Circuit diagram related to shift up switch
D375A-6 40-339
(01)
DRAFT
Failure code [DD12KB] Shift up Sw: Short circuit

Action code Failure code Shift up switch: Short circuit
Failure
E02 DD12KB (Power train controller system)
Detail of failure q Both lines of NO* and NC* for shift up switch circuit are 0 V (switch: ON) at the same time.
Action of con-
troller
Problem on
q Transmission gear cannot be shifted up.
machine
Related infor-
(Code: 40905 Power train controller input 3)
mation
q Method of reproducing failure code: Turn starting switch to ON position (and operate shift up switch).
q Connector SFTU has no T-adapters, don't carry out troubleshooting in female side.

3. Turn shift switch to ON or OFF position and troubleshoot.
1
Defective shift up switch a "Switch OFF": Release, "Switch ON": Press
(Internal disconnection) Between SFTU (male) (3) and Switch: OFF Resistance Max. 1 Ω
Between SFTU (male) (1) and Switch: OFF Resistance Min. 1 MΩ
ness 2. Disconnect connectors PTCN3 and SFTU, and connect T-adapter to female side of
2 PTCN3.
cuit) Between PTCN3 (female) (39) and ground Resistance Min. 1 MΩ
Between PTCN3 (female) (29) and ground Resistance Min. 1 MΩ
2. Disconnect connectors PTCN3 and SFTU, and connect T-adapter to female side of
PTCN3.
Short circuit in wiring har- a Check with multimeter in continuity mode.
3
ness No continuity
Between PTCN3 (female) (29) and each pin other than (29)
(No sound is heard)
No continuity
(No sound is heard)
Defective power train con- 4. Turn shift switch to ON or OFF position and troubleshoot.
4
troller a Voltage of apporx.9 V is applied to PTCN3 pin (29) and PTCN3 pin (39) through
Between PTCN3(29) and Switch: OFF Voltage Max. 1 V
PTCN1(10) Switch: ON Voltage 7 – 11 V
Between PTCN3(39) and Switch: OFF Voltage 7 – 11 V
PTCN1(10) Switch: ON Voltage Max. 1 V
*NO: Normally Open
40-340 D375A-6
(01)
DRAFT
D375A-6 40-341
(01)
DRAFT
Failure code [DD13KA] Shift down Sw: Disconnection

Action code Failure code Shift-down switch Disconnection
Failure
Detail of failure q Both linens of NO* and NC* for shift down switch circuit are OPEN (switch: OFF) at the same time.
Action of con-
troller
Problem on
q Shift down is not possible.
machine
q “NO*” line is used for sensing operation and “NC*” line is used for detecting error.
q Condition of shift up switch signal can be checked with moniitoring function.
Related infor-
(Code: 40905 Power train control Input 3)
mation
q Method of reproducing failure code: Turn starting switch ON (and operate shift up switch)
q ConnectorSFTD has no T-adapters, don't carry out troubleshooting in female side.

2. Disconnect connector SFTD.
Disconnection or hot short a If voltage is 0 V, it shows open circuit in wiring harness, and if voltage is 24 V, it
1
a Voltage of about 9 V is applied to signal lines of “NO” and “NC” through resistor
Disconnection in wiring 2. Disconnect connectors PTCN1, PTCN3 and SFTD, and connect T-adapter to each
harness female side
2
(Disconnection or defec- Between PTCN3 (female) (19) and SFTD (male) (1) Resistance Max. 1 Ω
tive contact) Between PTCN1 (female) (10) and SFTD (male) (2) Resistance Max. 1 Ω
Between PTCN3 (female) (9) and SFTD (male) (3) Resistance Max. 1 Ω
2. Disconnect connector TL3 and connect T-adapter to male side.
Defective shift down switch a “Switch OFF”: Release, “Switch ON”: Press
3
(Internal disconnection) Switch: OFF Resistance Max. 1 Ω
Between TL3 (male) (5) and (6)
Switch: ON. Resistance Min. 1 MΩ
Switch: OFF Resistance Min. 1 MΩ
Switch:ON Resistance Max. 1 Ω
Defective transmission 4. Turn shift down switch to ON or OFF position and troubleshoot.
4
controller a Voltage of apporx.9 V is applied to PTCN3 pin (19) and pin (9) through resistor in
power train controller.
Between PTCN3 (19) and Switch: OFF Voltage 7 – 11 V
PTCN1 (10) Switch: ON Voltage Max. 1 V
Between PTCN3 (9) and Switch: OFF Voltage Max. 1 V
PTCN1 (10) Switch: ON Voltage 7 – 11 V
*NO: Normally Open
40-342 D375A-6
(01)
DRAFT
D375A-6 40-343
(01)
DRAFT
Failure code [DD13KB] Shift down Sw: Short circuit

Action code Failure code Shiftdown switch: short circuit
Failure
Detail of failure q Both lines of NO* and NC* for shift down switch circuit are 0 V (switch: ON) at the same time.
Action of con-
troller
Problem on
q Shift down is not possible.
machine
q “NO*” line is used for sensing operation and “NC*” line is used for detecting error.
q Condition of shift up switch signal can be checked with moniitoring function.
Related infor-
mation
q Method of reproducing failure code: Turn starting switch ON (and operate shift down switch).
q Connector SFTD has no T-adapters, don't carry out troubleshooting in female side.
Cause Procedure, measuring location, cirteria and remarks

Ground fault of wiring har- 2. Disconnect connectors PTCN3 and SFTD and connect T-adapter to female side of
1 ness PTCN3.
(Contact with GND circuit) Between PTCN3 (female) (9) and ground Resistance Min. 1 MΩ
2. Disconnect connectors PTCN3 and SFTD and connect T-adapter to female side of
PTCN3.
2
ness No continuity
(No sound is heard)
No continuity
(No sound is heard)
3. Turn shift down switch to ON or OFF position and troubleshoot.
Defective shift down switch a “Switch OFF”: Release, “Switch ON”: Press
3
Switch: ON Resistance Min. 1 MΩ
q Reference; the followings are cirteria in normal condition.
Defective transmission 4. Turn shift down switch to ONor OFF position and troubleshoot.
4
controller a Voltage of apporx.9 V is applied to PTCN3 pin (19) and pin (9) through resistor in
Between PTCN3 (19) and Switch: OFF Voltage 7 – 11 V
PTCN1 (10) Switch: ON Voltage Max. 1 V
Between PTCN3 (9) and Switch: OFF Voltage Max. 1 V
PTCN1 (10) Switch: ON Voltage 7 – 11 V
*NO: Normally Open
40-344 D375A-6
(01)
DRAFT
Circuit diagram related to shift down switch
D375A-6 40-345
(01)
DRAFT
Failure code [DD14KA] Parking lever Sw: Dissconnection

Action code Failure code Parking lever switch: Disconnection
Failure
q Both lines of NO* and NC* for parking brake lever switch circuit are OPEN (switch: OFF) at the same
Detail of failure
time.
Action of con- q Recognizes parking brake lever is in Free position.
q Once machine stops, engine speed is limited to medium (half).
Problem on
machine
q Engine cannot start.
q NC* line is used for sensing operation and NO* line is used for detecting error.
q Condition of parking brake lever switch signal can be checked with monitoring function.
Related infor- (Code: 40905 Power train control Input 3)
mation q Method of reproducing failure code: Turn starting switch to ON position and operate parking brake
lever.
q When parking brake lever is in free position, parking brake lever switch is turned to ON position.

2. Disconnect connector NSW and connect T-adapter to male side.
Defective parking brake 3. Operate parking brake lever and troubleshoot.
1 lever switch (Internal dis- Between NSW (male) (A) Lever: LOCK Resistance Min. 1 MΩ
connection) and (B) Lever: FREE Resistance Max. 1 Ω
Between NSW (male) (A) Lever: LOCK Resistance Max. 1 Ω
and (C) Lever: FREE Resistance Min. 1 MΩ
2. Disconnect connector NSW and connect T-adapter to female side.
Disconnection or hot short a If voltage is 0 V, it shows short circuit in wiring harness, and if voltage is 24 V, it
2 shows hot short in wiring harness.
in wiring harness
Between NSW (female) (B) and (A) Voltage 7 – 11 V
Between NSW (female) (C) and (A) Voltage 7 – 11 V
harness 2. Disconnect connectors PTCN1 and NSW and connect T-adapters to each female
3 side.
(Open circuit or defective
contact) Between PTCN1 (female) (12) and NSW (female) (C) Resistance Max. 1 Ω
Between PTCN1 (female) (18) and NSW (female) (B) Resistance Max. 1 Ω
Between NSW(female)(A) and ground Resistance Max. 1 Ω
Defective power train con- 4. Operate parking brake lever and troubleshoot.
4
troller a Voltage of about 9 V is applied to PTCN1 pin (12) and pin (18) through resistor in
Between PTCN1(18) and Lever: LOCK Voltage 7 – 11 V
ground Lever: FREE Voltage Max. 1 V
Between PTCN1(12) and Lever: LOCK Voltage Max. 1 V
ground Lever: FREE Voltage 7 – 11 V
*NO: Normally Open
40-346 D375A-6
(01)
DRAFT
Circuit diagram related to parking brake lever switch
D375A-6 40-347
(01)
DRAFT
Failure code [DD14KB] Parking lever Sw: Short circuit

Action code Failure code Parking lever switch: Short circuit
Failure
q Both lines of NO* and NC* for parking brake lever switch circuit are 0 V (switch: ON) at the same
Detail of failure
time.
Action of con- q Recognizes parking brake lever is in FREE position.
Problem on
machine
q Engine cannot start.
q “NC*” line is used for sensing opration and “NO*” line is used for detecting error.
q Condition of parking brake lever switch signal can be checked with monitoring function.
Related infor- (Code: 40905 Power train control Input 3)
lever.
q When parking brake lever is FREE, parking brake lever switch becomes “ON”.

2. Disconnect connector NSW and connect T-adapter to male side.
Defective parking brake 3. Operate parking brake lever and troubleshoot.
1 lever switch (Internal dis- Between NSW (male) (A) Lever: LOCK Resistance Min. 1 MΩ
connection) and (B) Lever: FREE Resistance Max. 1 Ω
Between NSW (male) (A) Lever: LOCK Resistance Max. 1 Ω
and (C) Lever: FREE Resistance Min. 1 MΩ
2. Disconnect connectors PTCN1 and NSW, and connect T-adapter to female side of
Ground fault of wiring har- one of them.
2 ness Between NSW (female) (B) and ground or between Min. 1 MΩ
(Contact with GND circuit) PTCN1 (female) (18) and ground Resistance
Between NSW (female) (C) and ground or between Min. 1 MΩ
Resistance
PTCN1 (female) (12) and ground
2. Disconnect connectorsPTCN1, NSW and connect T-adapter to female side of
PTCN1.
Short circuit in wiring har- a Check with multimeter continuity mode.
3
ness Between PTCN1 (female) (12) and each pin other than No continuity
(12) (No sound is heard)
Between PTCN1 (female) (18) and each pin other than No continuity
Defective power train con- 4. Operate shiftup switch and troubleshoot.
4
Between PTCN1(18) and Lever: LOCK Voltage 7 – 11V
chassis ground Lever: FREE Voltage Max. 1V
Between PTCN1(12) and Lever: LOCK Voltage Max. 1V
chassis ground Lever: FREE Voltage 7 – 11V
*NO: Normally Open
40-348 D375A-6
(01)
DRAFT
Circuit diagram related to parking brake lever switch
D375A-6 40-349
(01)
DRAFT
Failure code [DDB9L4] Reverse SW Signal disagreement

Action code Failure code Inconsistent reverse switch signal
Failure
E03 DDB9L4 (Power train controller system)
Detail of failure q There is inconsistency in line 2 of NO* for reverse switch circuit.
Action of con-
q Recognizes that reverser switch is not pressed.
troller
machine q Once machine is stopped, travel is limited to F1.
q Condition of reverse switch signal can be checked with monitoring function.
Related infor- (Code: 40905 Power train control input 3)
mation q Method of reproducing failure code: Turn starting switch to ON position (and operate reverse switch).
q Since T-adapter is not prepared for connector RTS, female side check is not required.

Wrong selection of travel
1 If failure code [DDT5KQ] is displayed, carry out troubleshooting for it.
lever type
2. Disconnect connector RTS.
2
Between TL3(4) and (2) Voltage 7 – 11 V
Disconnection in wiring 2. Disconnect connectors PTCN1, PTCN3, TL3 and RTS, and connect T-adapters to
harness female side of PTCN1, PTCN3 and PL3.
3
(Disconnection or defec- Between PTCN3 (female) (19) and RTS (male) (1) Resistance Max. 1 Ω
tive contact) Between PTCN1 (female) (10) and TL3 (female) (2) Resistance Max. 1 Ω
Between PTCN1 (female) (10) and RTS (male) (2) Resistance Max. 1 Ω
ness 2. Disconnect connectors PTCN3 and RTS, and connect T-adapter to female side of
4 PTCN3.
2. Disconnect connectors PTCN3 and RTS, and connect T-adapter to female side of
PTCN3.
5
ness No continuity
(No sound is heard)
No continuity
(No sound is heard)
3. Disconnect connector FTS.
Defective reverse switch 4. Turn reverse switch to ON or OFF position and troubleshoot.
6 a "Switch OFF": Release, "Switch ON": Press
(Internal disconnection)
Between TL3 (male) (4) and Switch: OFF Resistance Min. 1 MΩ
FTS (female) (2) Switch: ON Resistance Max. 1 Ω
40-350 D375A-6
(01)
DRAFT
Defective power train con- 4. Turn reverse switch ON/OFF, and troubleshoot.
7
*NO: Normally Open
Circuit diagram related to reverse switch
a Exclusive for single-direction lever
D375A-6 40-351
(01)
DRAFT
Failure code [DDE2KA] Pre lub. oil press sw: Disconnection

Action code Failure code Pre-lubricating oil pressure switch disconnection
Failure
E02 DDE2KA (Power train controller)
q Power train controller has started pre-lubrication, pre-lubricating motor is operating, and voltage is
Detail of failure detected at pre-lubricating motor. However, pre-lubricating oil pressure switch is not turned to OFF
position.
Action of con-
troller
Problem on
q Engine does not run (It runs in skip mode, however).
machine
q Pre-lubricating oil pressure switch is turned to ON position when oil pressure is not applied.
q Whether pre-lubricating oil pressure switch is turned to ON position can be checked with monitoring
mation (Code: 40910 PT controller SW input 2)
q Whether pre-lubricating motor is in operation can be checked with monitoring function.

2. Disconnect terminal POP.
Defective pre-lubricating oil 3. Turn starting switch to ON position.
1
pressure switch a During pre-lubrication
Between terminal POP (on pre-lubricating oil pressure Not conductive
switch side) and ground
harness 2. Disconnect connector PTCN2 and connect T-adapter to female side.
2
Between PTCN2 (female) (13) and ground Resistance Max. 1 Ω
tive contact)tive contact)
ness 2. Disconnect connector PTCN2 and connect T-adapter to female side.
3
(Contact with ground cir- 3. Disconnect terminal POP.
If cause is not found by above checks, power train controller is defective.
q Reference: Following shows criteria in normal condition.
4 2. Insert T-adapter into connector PTCN2.
troller
a During pre-lubrication
Voltage 7 – 11 V
Between PTCN2 (13) and (29)
Circuit diagram related to pre-lubricating oil pressure switch
40-352 D375A-6
(01)
DRAFT
D375A-6 40-353
(01)
DRAFT
Failure code [DDK3L4] Forward SW Signal disagreement

Action code Failure code Inconsistent forward switch signal
Failure
E03 DDK3L4 (Power train controller system)
Detail of failure q There is inconsistency in line 2 of NO* for forward switch circuit.
Action of con-
q Recognizes that forward switch is not pressed.
troller
machine q Once machine is stopped, travel is limited to R1.
q Condition of forward switch signal can be checked with monitoring function.
Related infor-
(Code: 40905 Power train control input 3)
mation
q Method of reproducing failure code: Turn starting switch to ON position (and operate forward switch).

lever type
3. Disconnect connectors TL3 and connect T-adapters to female side.
Defective forward switch 4. Turn shift up switch to ON or OFF position and troubleshoot.
2 a "Switch OFF": Release, "Switch ON": Press
Between FTS (male) (3) and Switch: OFF Resistance Min. 1 MΩ
TL3 (male) (5) Switch: ON Resistance Max. 1 Ω
Between FTS (male) (1) and (2)
3
Disconnection in wiring 2. Disconnect connectors PTCN1, PTCN3 and TL3, and connect T-adapters to female
harness side of them.
4 3. Disconnect connector RTS.
tive contact) Between PTCN3 (female) (39) and TL3 (female) (1) Resistance Max. 1 Ω
Between PTCN1 (female) (10) and TL3 (female) (2) Resistance Max. 1 Ω
ness 2. Disconnect connectors PTCN3 and FTS, and connect T-adapter to female side of
5 PTCN3.
2. Disconnect connectors PTCN3 and FTS, and connect T-adapter to female side of
PTCN3.
6
ness No continuity
(No sound is heard)
NO continuity
(No sound is heard)
40-354 D375A-6
(01)
DRAFT
Defective power train con- 4. Turn shift up switch to ON or OFF position and troubleshoot.
7
*NO: Normally Open
Circuit diagram related to forward switch
D375A-6 40-355
(01)
DRAFT
Failure code [DDK5KA] Shift switch disconnection

Action code Failure code Shift switch disconnection
Failure
E02 DDK5KA (Transmission controller system)
q Both lines of NO: Normally Open and NC: Normally Closed for shift up switch circuit are OPEN
Detail of failure
(switch: OFF) at the same time.
Action of con-
q Recognizes that switch is not pressed.
troller
Problem on
q Gear cannot be shifted up and down (1st io 2nd).
machine
q NO: Normally Open line is used for sensing operation and NC: Normally Closed line is used for de-
tecting error.
Related infor-
mation
q Method of reproducing failure code: Turn starting switch to ON position and operate shift up switch.

lever type
2. Disconnect connector SNC and connect T-adapter to male side.
3. Turn shift switch to ON or OFF position and troubleshoot.
Defective shift switch a "Switch OFF": Release, "Switch ON": Press
2
Between SNC (male) (1) and (3)
2. Disconnect connector SNC and connect T-adapter to female side.
in wiring harness
Between SNC (female) (2) and (1) Voltage 7–11 V
ness 2. Disconnect connectors PTCN1, PTCN2 and SNC, and connect T-adapter to
4 female side of them.
contact) Between PTCN1 (female) (10) and SNC (female) (1) Resistance Max. 1 Ω
Between PTCN2 (female) (7) and SNC (female) (2) Resistance Max. 1 Ω
Between PTCN1 (female) (6) and SNC (female) (3) Resistance Max. 1 Ω
2. Insert T-connector into connectors PTCN1 and PTCN2.
Defective power train con- 4. Turn shift switch to ON or OFF position and troubleshoot.
5
troller a Voltage of about 9 V is applied to PTCN1 pin (6) and PTCN2 pin (7) through resistor
Switch: OFF Voltage 7–11 V
Between PTCN2 (7) and PTCN1 (10)
Switch: ON Voltage Max. 1 V
Switch: OFF Voltage Max. 1 V
Between PTCN1 (6) and PTCN1 (10)
Switch: ON Voltage 7–11 V
40-356 D375A-6
(01)
DRAFT
Circuit diagram related to shift switch
D375A-6 40-357
(01)
DRAFT
Failure code [DDK5KB] Shift switch short circuit

Action code Failure code Shift switch short circuit
Failure
E02 DDK5KB (Power train controller system)
q Both lines of NO: Normally Open and NC: Normally Closed for shift up switch circuit are 0 V (switch:
Detail of failure
ON) at the same time.
Action of con-
q Recognizes that switch is not pressed.
troller
Problem on
q Gear cannot be shifted up and down (1stio2nd).
machine
tecting error.
Related infor- q Condition of shift up switch signal can be checked with monitoring function.
mation (Code: 40905 Power train control Input 3)
q Method of reproducing failure code: Turn the starting switch to ON position and operate the shift up
switch

lever type
Defective shift up switch a “Switch OFF”: Release, “Switch ON”: Press
2
Switch:OFF Resistance Min. 1 MΩ
2. Disconnect connectors STC1, STC3 and SNC and connect T-adapter to female
Ground fault of wiring har- side of one of them.
3 ness 3. Turn starting switch to ON position.
(Contact with rround circuit) Between SNC (female) (2) and ground , or between Resistance Min. 1 MΩ
PTCN2(female) (7) and ground
Between SNC (female) (3) and ground , or between Resistance Min. 1 MΩ
PTCN1 (female) (6) and ground
2. Disconnect connectors PTCN1, PTCN2 and SNC and connect T-adapters to
female side of PTCN1 and PTCN2.
4
ness Between PTCN1 (female) (6) and each pin other than No continuity (No sound is
(6) heard)
Between PTCN2 (female) (7) and each pin other than No continuity (No sound is
(7) heard)
2. Insert T-adapters into connectors PTCN1 and PTCN2.
Defective power train con- 4. Turn shift up switch to ON or OFF position and troubleshoot.
5
troller a Voltage of about 9 V is applied to PTCN1 pin (6) and PTCN2 pin (7) through resis-
tor in power train controller.
Switch: OFF Voltage 7–11 V
Between PTCN2 (7) and PTCN1(10)
Switch: ON Voltage Max. 1 V
Switch: OFF Voltage Max. 1 V
Between PTCN1 (6) and PTCN1(10)
Switch: ON Voltage 7–11 V
40-358 D375A-6
(01)
DRAFT
Circuit diagram related to shift switch
D375A-6 40-359
(01)
DRAFT
Failure code [DDN2LD] Blade tilt RH pressure SW abnormality

Action code Failure code Blade tilt right hand oil pressure switch is pressed for long time
Failure
― DDN2LD (Work equipment controller system)
Detail of failure q The signal of the blade tilt left oil pressure switch circuit is kept turned O V (ON) for 60 seconds.
Action of con-
q Recognizes that the oil pressure switch is turned to OFF position.
troller
Problem on
q Data communication of VHMS may be abnormal
machine
q The input state (ON/OFF) from the blade tilt right hand oil pressure switch can be checked moniitor-
ing funtion. (Code 90802: Blade oil pressure switch input state)
q Method of reproducing failure code: Turn the starting switch to ON position (Error is reproduced after
Related infor-
60 seconds).
mation
q Next, check that hydraulic pressure of work equipment is normal by referring to Testing and adjust-
ing, "Testing work equipment hydraulic pressure".

Wrong operation of lever
If failure code (reset indication) is displayed even after reset operation, incorrect shift
1 (When electrical system is
lever operation might be made.
normal)
Defective blade tilt right
2 hand oil pressure switch 2. Disconnect connector TRS and connect T-adapter to male side.
Between TRS (female)(1) and (2) Resis-
(Internal short circuit) Min. 1 MΩ
(Oil pressure switch is OFF position.) tance
2. Disconnect connector TRS.
Ground fault of wiring har- 3. Turn starting switch to ON position (and wait for longer than 60 sec.).
3 ness or defective work If failure code [DDN2LD] is still displayed, there is ground fault of wiring harness or
equipment controller work equipment controller is defective.
(If failure code [DDN2LD] is not displayed, blade tilt right oil pressure switch is defec-
tive.)
ness 2. Disconnect connectors WECN2 and TRS, and connect T-adapter to female side of
4
(Contact with ground cir- either one of them.
cuit) Between WECN2 (female) (7) and ground, or betweenTRS Resis-
Min. 1 MΩ
(female) (1) and ground. tance
2. Insert T-adapter into connector WECN1 and WECN2.
Defective work equipment 3. Start engine.
5
controller a Keep PCCS lever in N position.
Between WECN2(7) and WECN1(4) Voltage 7 – 11 V
4. While depressing brake pedal, operate blade lever and perform troubleshooting.
Between WECN2(7) and
R.H. tilt Voltage Max. 1 V
WECN1(4)
40-360 D375A-6
(01)
DRAFT
Circuit diagram related to Blade tilt right hand oil pressure switch
D375A-6 40-361
(01)
DRAFT
Failure code [DDN3LD] Blade tilt LH pressure SW abnormality

Action code Failure code Blade tilt left hand oil pressure switch is pressing for long time
Failure
― DDN3LD (Work equipment controller system)
Detail of failure q The signal of the blade tilt left oil pressure switch circuit is kept turned ON for 60 seconds.
Action of con-
q Recognizes that the oil pressure switch is turned to OFF position.
troller
Problem s on
q Data communication of VHMS may be abnormal.
machine
q The input state (ON/OFF) from the blade tilt left hand oil pressure switch can be checked moniitoring
funtion. (Code 90802: Blade oil pressure switch input state)
Related infor-
60 seconds).
mation

If the error code lamp still lights up (resetting is still urged) after the resetting operation
is performed, it is suspected that the lever was operated to cause an error.
normal)
Defective blade tilt left
2 hand oil pressure switch 2. Disconnect connector TLS and connect T-adapter to male side.
Between TLS (female)(1) and (2) Resis-
(Internal short circuit) Min. 1 MΩ
(Oil pressure switch is OFF position) tance
2. Disconnect connector TLS.
Ground fault of wiring har- 3. Turn starting switch to ON position (and wait for longer than 60 sec.)
3 ness or defective work If failure code [DDN3LD] is still displayed, there is ground fault of wiring harness or
(If failure code [DDN3LD] is not displayed, blade tilt left oil pressure switch is defec-
tive.)
ness 2. Disconnect connectors WECN2 and TLS, and connect T-adapter to female side of
4
cuit) Between WECN2 (female) (17) and ground, or between TLS Resis- Min. 1 MΩ
5
controller a Keep PCCS lever in N position.
4.While depressing brake pedal, operate blade lever and perform troubleshooting.
Between WECN2(17) and Max. 1 V
L.H. tilt Voltage
WECN1(4)
40-362 D375A-6
(01)
DRAFT
Circuit diagram related to blade tilt left hand oil pressure switch
D375A-6 40-363
(01)
DRAFT
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection

Action code Failure code Work equipment knob switch (lower): Disconnection
Failure
E02 DDN7KA (Work equipment controller system)
q Both lines of NO: Normally Open and NC: Normally Closed for blade knob lower switch circuit are
Detail of failure
OPEN (switch: OFF) at the same time.
Action of con-
q Recognizes that blade knob switch lower is not pressed.
troller
Problem on
q Blade knob switch lower does not work.
machine
tecting error.
q Condition of blade knob switch lower signal can be checked with monitoring function.
Related infor-
(Code: 70300 Blade Sw Input)
mation
q Method of reproducing failure code: Turn the starting switch ON position and (operate blade pitch
switch).
q Since T-adapter is not prepared for connector WNBL, female side check is not required.

2. Disconnect connector WNBL.
3. Insert T-adapter into connector P03.
Disconnection or hot a If voltage is 0 V, it shows disconnection in wiring harness, and if voltage is 24 V, it
1
short in wiring harness shows hot short in wiring harness.
a Voltage of approx.9 V is applied to signal lines of “NO” and “NC” through resistor
in work equipment controller.
Between P03 (2) and (1) Voltage 7 – 11 V
Between P03 (5) and (1) Voltage 7 – 11 V
harness 2. Disconnect connectors WECN1, WECN2 and WNBL, and connect T-adapter to each
2 female side
tive contact) Between WECN2 (female) (26) and WNBL (female) (1) Resistance Max. 1 Ω
Between WECN1 (female) (4) and WNBL (female) (2) Resistance Max. 1 Ω
Between WECN2 (female) (36) and WNBL (female) (3) Resistance Max. 1 Ω
2. Disconnect connector P03 and connect T-adapter to male side.
Defective blade knob 3. Turn blade knob lower switch to ON or OFF position and troubleshoot.
3 lower switch(Internal dis- a “Switch OFF”: Release, “Switch ON”: Press
connection) Between P03(male) (2) and Switch: OFF Resistance Max. 1 Ω
Between P03(male) (1) and Switch: OFF Resistance Min. 1 MΩ
Defective work equip- 4. Turn blade knob lower switch (lower) to ON or OFF position and troubleshoot.
4
ment controller a Voltage of approx.9 V is applied to WECN2 pin (26) and pin (36) through resistor in
work equipment controller.
Between WECN2(36) and Switch: OFF Voltage Max. 1 V
WECN1(4) Switch: ON Voltage 7 – 11 V
Between WECN2(26) and Switch: OFF Voltage 7 – 11 V
WECN1(4) Switch: ON Voltage Max. 1 V
40-364 D375A-6
(01)
DRAFT
Circuit diagram related to work equipment knob switch
D375A-6 40-365
(01)
DRAFT
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit

Action code Failure code Work equipment knob switch (Lower): Short circuit
Failure
E02 DDN7KB (Work equipment controller system)
q Both lines of NO: Normally Open and NC: Normally Closed for blade knob switch lower circuit are 0
Detail of failure
V (switch: ON) at the same time.
Action of con-
q Recognizes that blade knob lower switch is not pressed.
troller
Problem on
q Blade knob switch (lower) does not work.
machine
tecting error.
q Condition of blade knob switch lower signal can be checked with monitoring function.
Related infor-
mation
q Method of reproducing failure code: Turn the starting switch to ON position and (operate blade pitch
switch).
q Since T-adapter is not prepared for connector WNBL female side check is not required.

2. Disconnect connectors WECN2 and WNBL and connect T-adapter to female side
Ground fault of wiring har- of WECN2.
1 ness Resis-
(Contact with GND circuit) Between WECN2 (female) (26) and ground tance
Min. 1 MΩ
Resis-
Between WECN2 (female) (36) and ground Min. 1 MΩ
tance
2. Disconnect connectors WECN2 and WNBL and connect T-adapters to female side
of WECN2.
Short circuit in wiring har- a Check with tester in continuity mode.
2
ness No continuity
Between WECN2 (female) (26) and each pin other than (26)
(No sound is heard)
No continuity
Between WECN2 (female) (36) and each pin other than (36)
(No sound is heard)
2. Disconnect connector P03 and connect T-adapter to male side.
3. Turn blade knob switch (lower) to ON or OFF position and troubleshoot.
a “Switch OFF”: Release, “Switch ON”: Press
Defective blade knob Resis-
Switch: OFF Max. 1 Ω
3 switch lower (Internal dis- Between P03 (male) (5) and tance
connection) (1) Resis-
Switch: ON Min. 1 MΩ
tance
Resis-
Switch: OFF Min. 1 MΩ
Between P03 (male) (1) and tance
(2) Resis-
Switch: ON Max. 1 Ω
tance
Defective work equipment 4. Turn blade knob lower switch (lower) to ON or OFF position and troubleshoot.
4
controller a Voltage of approx.9 V is applied to WECN2 pin (26) and pin (36) through resistor in
Between WECN (36) and Switch: OFF Voltage Max. 1 V
WECN (4) Switch: ON Voltage 7 – 11 V
Between WECN (26) and Switch: OFF Voltage 7 – 11 V
WECN (4) Switch: ON Voltage Max. 1 V
40-366 D375A-6
(01)
DRAFT
D375A-6 40-367
(01)
DRAFT
Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection

Action code Failure code Work equipment knob switch (raise): Disconnection
Failure
E01 DDN9KA (Work equipment controller system)
q Both lines of NO: Normally Open and NC : Normally Closed for blade knob upper switch circuit are
Detail of failure
OPEN (switch: OFF) at the same time.
Action of con-
q Recognizes that blade knob upper switch is not pressed.
troller
Problem on
q Blade knob switch (raise) does not work.
machine
tecting error.
q Condition of blade knob switch signal can be checked with monitoring function.
Related infor-
mation
q Method of reproducing failure code: Turn starting switch to ON position and operate blade knob
switch (raise).
q Since T-adapter is not prepared for connector WNBU female side check is not required.

2. Disconnect connector WNBU.
3. Turn blade upper knob switch (raise) to ON or OFF position and troubleshoot.
a “Switch OFF”: Release, “Switch ON”: Press
Defective blade knob Resis-
Switch: OFF Max. 1 Ω
1 switch raise (Internal dis- Between WNBU (male) (3) and tance
connection) (2) Resis-
Switch: ON Min. 1 MΩ
tance
Resis-
Switch: OFF Min. 1 MΩ
Between WNBU (male) (1) and tance
(2) Resis-
Switch:ON Max. 1 Ω
tance
2. Disconnect connector WNBU.
3. Insert T-adapter into connector P03.
2
a Voltage of apporx.9 V is applied to signal lines of “NO” and “NC” through resistor
in work equipment controller.
Between P03 (female) (4) and (3) Voltage 7 – 11 V
Between P03 (female) (6) and (3) Voltage 7 – 11 V
2. Disconnect connectors WECN1 and WECN2 and connect T-adapters to each
Disconnection in wiring female side.
harness 3. Turn blade knob switch (raise) to ON or OFF position and troubleshoot.
3
(Disconnection or defec- Between WECN2 (female) (15) and WECN1 Resis-
tive contact) Switch: OFF Max. 1 Ω
(female) (4) tance
Between WECN2 (female) (5) and WECN1 Resis-
Switch: ON Max. 1 Ω
(female) (4) tance
Defective work equipment 4. Turn blade knob switch (raise) to ON or OFF position and troubleshoot.
4
controller a Voltage of apporx.9 V is applied to WECN2 pin (5) and pin (15) through resistor in
Between WECN2 (5) and Switch: OFF Voltage 7 – 11 V
WECN1 (4) Switch: ON Voltage Max. 1 V
Between WECN2 (15) and Switch: OFF Voltage Max. 1 V
WECN1 (4) Switch: ON Voltage 7 – 11 V
40-368 D375A-6
(01)
DRAFT
D375A-6 40-369
(01)
DRAFT
Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit

Action code Failure code Work equipment knob switch (raise): Disconnection
Failure
E01 DDN9KB (Work equipment controller system)
q Both lines of NO: Normally Open and NC : Normally Closed for blade knob switch raise circuit are 0
Detail of failure
V (switch: ON) at the same time.
Action of con-
q Recognizes that blade knob upper switch is not pressed.
troller
Problem on
q Blade knob switch (raise) does not work.
machine
q NO: Normally Open line is used for sensing operation and NC: line is used for detecting error.
q Condition of blade knob switch signal can be checked with monitoring function.
Related infor- (Code: 70300 Blade Sw Input)
mation q Method of reproducing failure code: Turn starting switch to ON position and operate blade knob
switch (raise).
q Since T-adapter is not prepared for connector WNBU female side check is not required.

2. Disconnect connector WNBU and connect T-adapter to male side.
Defective blade knob switch 3. Turn blade knob switch (raise) to ON or OFF position and troubleshoot.
1 raise (Internal disconnec- a “Switch OFF”: Release, “Switch ON”: Press
tion) Between WNBU (male) (3) and Switch: OFF Resistance Max. 1 Ω
Between WNBU (male) (1) and Switch: OFF Resistance Min. 1 MΩ
Ground fault of wiring har- 2. Disconnect connectors WECN1, WECN2 and WNBU and connect T-adapter to
2 ness female side of either one of them.
(Contact with groung circuit) Between WECN1 (female) (5) and ground Resistance Min. 1 MΩ
Between WECN1 (female) (15) and ground Resistance Min. 1 MΩ
2. Disconnect connectors WECN2 and WNBU and connect T-adapter to female side
of WECN2.
3
ness Between WECN2 (female) (5) and each pin other than No continuity
Between WECN2 (female) (15) and each pin other than No continuity
Defective work equipment 4. Turn blade knob switch (raise) to ON or OFF position and troubleshoot.
4
Between WECN2 (5) and Switch: OFF Voltage 7 – 11 V
WECN1 (4) Switch: ON Voltage Max. 1 V
Between WECN2 (15) and Switch: OFF Voltage Max. 1 V
WECN1 (4) Switch: ON Voltage 7 – 11 V
40-370 D375A-6
(01)
DRAFT
D375A-6 40-371
(01)
DRAFT
Failure code [DDNALD] Blade lift up pressure SW abnormality

Action code Failure code Blade lift raise oil pressure switch is pressed for long time
Failure
― DDNALD (Work equipment controller system)
Detail of fail- q The signal of blade lift raise (full stroke) oil pressure switch circuit is kept turned to ON position for 60
ure seconds.
Action of con-
q Recognizes that the oil pressure switch is turned OFF.
troller
Problem on
q Data of the VHMS may become abnormal.
machine
q Input state (ON/OFF) from blade raise (full stroke) oil pressure switch can be checked monitoring
function. (Code 90802: Blade oil pressure switch input)
q Method of reproducing failure code: Turn starting switch to ON position (Error is reproduced after 60
Related infor-
seconds).
mation
q First, check power train oil filter for clogging etc.
Cause Procedure, measuring location, cirteria and remarks

If failure code lamp still lights up (resetting is still urged) after the resetting operation is
performed, it is suspected that lever was operated to cause an error.
normal)
Defective blade raise oil
2 pressure switch (Internal 2. Disconnect connector BLU and connect T-adapter to male side.
Between BLU (female) (1) and (2)
(Oil pressure switch: OFF)
2. Disconnect connector BLU.
3 ness or defective work 3. Turn starting switch to ON position (and wait for longer than 60 sec.).
equipment controller If failure code [DDNALD] is still displayed, there is ground fault of wiring harness or
work equipment controller is defective.
(If failure code [DDNALD] is not displayed, blade raise oil pressure switch is defective.)
4 ness 2. Disconnect connectors WECN2 and BLU, and connect T-adapter to female side of
Between WECN2 (female) (16) and ground or betweenBLU
(female) (1) and ground.
Defective work equip- 3. Start engine.
5
ment controller a Keep blade lever in neutral position.
Between WECN2 (16) and WECN1 (4) Voltage 7 – 11 V
4. Operate blade lever and troubleshoot.
Between WECN2 (16) and
Blade lever: Raise Voltage Max. 1 V
WECN1 (4)
40-372 D375A-6
(01)
DRAFT
Circuit diagram related to blade raise oil pressure switch
D375A-6 40-373
(01)
DRAFT
Failure code [DDNBLD] Ripper lift up pressure SW abnormality

Action code Failure code Ripper lift raise oil pressure switch is pressed for long time
Failure
― DDNBLD (Work equipment controller system)
Detail of failure q The signal of the ripper raise oil pressure switch circuit is kept turned to ON position for 60 seconds.
Action of con-
q Recognizes that oil pressure switch is turned to OFF position.
troller
Problem on q Shoe slip control (SSC) function does not activate normally.
machine q VHMS data may become abnormal.
q Input state (ON/OFF) from the ripper raise oil pressure switch can be checked moniitoring fun-
tion.(Code 40982: Ripper oil pressure switch input )
Related infor-
60 seconds).
mation

performed, it is suspected that the lever was operated to cause an error.
normal)
Defective ripper raise oil
2 pressure switch (Internal 2. Disconnect connector RPU and connect T-adapter to male side.
Between RPU (female) (1) and (2) Resis-
short circuit) Min. 1 MΩ
(Oil pressure switch: OFF) tance
2. Disconnect connector RPU.
equipment controller If failure code [DDNBLD] is still displayed, there is ground fault of wiring harness or
(If failure code [DDNBLD] is not displayed, ripper raise oil pressure switch is defective)
4 ness 2. Disconnect connectors WECN2 and RPU, and connect T-adapter to female side of
Between WECN2 (female) (13) and ground, or betweenRPU Resis-
Min. 1 MΩ
5
controller a Keep ripper lever in neutral position.
4.Operate ripper lever and perform troubleshooting.
Ripper lever: Raise Voltage Max. 1 V
WECN1 (4)
40-374 D375A-6
(01)
DRAFT
Circuit diagram related to ripper raise oil pressure switch
D375A-6 40-375
(01)
DRAFT
Failure code [DDNCLD] Ripper lift down pressure SW abnormality

Action code Failure code Ripper lower oil pressure switch is pressed for long time
Failure
― DDNCLD (Work equipment controller system)
Detail of failure q Signal of ripper lift lower oil pressure switch circuit is kept turned to ON position for 60 seconds.
Action of con-
q Recognizes that oil pressure switch is turned OFF.
troller
q Input state (ON/OFF) from ripper lower oil pressure switch can be checked in the real-time moniitor-
ing mode. (Code 40982: Ripper oil pressure switch input signal)
Related infor-
60 seconds).
mation

performed, it is suspected that the lever was operated to cause an error.
normal)
Defective ripper lower oil
2 pressure switch (Internal 2. Disconnect connector RPD and connect T-adapter to male side.
Between RPD (female) (1) and (2) Resis-
(Oil pressure switch : OFF) tance
2. Disconnect connector RPD.
3 ness or defective work If failure code [DDNCLD] is still displayed, there is ground fault of wiring harness or
(If failure code [DDNCLD] is not displayed, ripper lift lower oil pressure switch is defec-
tive)
4 ness 2. Disconnect connectors WECN2 and RPD, and connect T-adapter to female side of
Between WECN2 (female) (3) and ground or betweenRPD Resis-
Min. 1 MΩ
5
Ripper lever: Lower Voltage Max. 1 V
WECN1 (4)
40-376 D375A-6
(01)
DRAFT
Circuit diagram related to ripper lower oil pressure switch
D375A-6 40-377
(01)
DRAFT
Failure code [DDNDLD] Ripper tilt in pressure SW abnormality

Action code Failure code Ripper tilt in oil pressure switch is pressed for long time
Failure
― DDNDLD (Work equipment controller system)
Detail of failure q Signal of ripper tilt in oil pressure switch circuit is kept turned to ON position for 60 seconds.
Action of con-
troller
Problem on q Shoe slip control (SSC) function does not operate normally.
q Input state (ON/OFF) from ripper tilt in oil pressure switch can be checked with monitoring function.
(Code 40982: Ripper oil pressure switch input state)
Related infor-
60 seconds).
mation

If failure code (reset indication) is displayed even after reset operation, incorrect lever
operation might be made.
normal)
Defective ripper tilt in oil
2 pressure switch (Internal 2. Disconnect connector RTI and connect T-adapter to male side.
Between RTI (female)(1) and (2) Resis-
(Turn oil pressure switch: OFF.) tance
2. Disconnect connector RTI.
equipment controller If failure code [DDNDLD] is still displayed, there is ground fault of wiring harness or
(If failure code [DDNDLD] is not displayed, ripper tilt in oil pressure switch is defective.)
ness 2. Disconnect connectors WECN2 and RTI, and connect T-adapter to female side of
4
cuit) Between WECN2 (female) (2) and ground or between RTI Resis-
Min. 1 MΩ
5
4. Operate ripper lever and troubleshoot.
Ripper lever: Tilt in Voltage Max. 1 V
WECN1(4)
40-378 D375A-6
(01)
DRAFT
Circuit diagram related to ripper tilt in oil pressure switch
D375A-6 40-379
(01)
DRAFT
Failure code [DDNELD] Ripper tilt back pressure SW abnormality

Action code Failure code Ripper tilt back oil pressure switch is pressed for long time
Failure
― DDNELD (Work equipment controller system)
Detail of failure q Signal of the ripper tilt back oil pressure switch circuit is kept turned to ON position for 60 seconds.
Action of con-
q Recognizes that the oil pressure switch is turned OFF.
troller
q Input state (ON/OFF) from the ripper tilt back oil pressure switch can be checked moniitoring funtion.
(Code 40982: Ripper oil pressure switch input )
q Method of reproducing failure code: Turn starting switch to ON position (Error is reproduced after 60
Related infor-
seconds).
mation

performed, it is suspected that lever was operated to cause an error.
normal)
Defective ripper tilt back oil
2 pressure switch (Internal 2. Disconnect connector RTB and connect T-adapter to male side.
Between RTB (female)(1) and (2) Resis-
(Oil pressure switch: OFF) tance
2. Disconnect connector RTB.
3 ness or defective work If failure code [DDNELD] is still displayed, there is ground fault of wiring harness or
(If failure code [DDNELD] is not displayed, ripper tilt back oil pressure switch is defec-
tive)
ness 2. Disconnect connectors WECN2 and RTB, and connect T-adapter to female side of
4
cuit) Between WECN2 (female) (38) and ground or betweenRTB Resis-
Min. 1 MΩ
5
Ripper lever: Tilt back Voltage Max. 1 V
WECN1 (4)
40-380 D375A-6
(01)
DRAFT
Circuit diagram related to ripper tilt back oil pressure switch
D375A-6 40-381
(01)
DRAFT
Failure code [DDNFLD] Blade lift down pressure SW abnormality

Action code Failure code Blade lift lower oil pressure switch is pressed for long time
Failure
― DDNFLD (Work equipment controller system)
q Signal of blade lower (full stroke) oil pressure switch circuit is kept turned to ON position for 60 sec-
Detail of failure
onds.
Action of con-
troller
Indication of
problem on q VHMS data may become abnormal.
machine
q Input state (ON/OFF) from blade lower (full stroke) oil pressure switch can be checked with monitor-
ing function. (Code 90802: Blade oil pressure switch input state)
q Method of reproducing failure code: Turn starting switch to ON position (and wait for longer than 180
Related infor-
sec.).
mation

If failure code (reset indication) is displayed even after reset operation, incorrect lever
operation might be made.
normal)
Defective blade lower oil
2 pressure switch (Internal 2. Disconnect connector BLD and connect T-adapter to male side.
Between BLD (female)(1) and (2) Resis-
(Oil pressure switch: OFF.) tance
2. Disconnect connector BLD.
3 ness or defective work If failure code [DDNFLD] is still displayed, there is ground fault of wiring harness or
(If failure code [DDNFLD] is not displayed, blade lower oil pressure switch is defec-
tive.)
ness 2. Disconnect connectors WECN2 and BLD, and connect T-adapter to female side of
4
cuit) Between WECN2 (female) (6) and ground or betweenBLD Resis-
Min. 1 MΩ
(female) (1) and ground tance
5
controller a Keep blade lever in neutral position.
4. Operate lever and troubleshoot.
Blade lever: Lower Voltage Max. 1 V
WECN1(4)
40-382 D375A-6
(01)
DRAFT
Circuit diagram related to blade lower oil pressure switch
D375A-6 40-383
(01)
DRAFT
Failure code [DDNLKA] Weq lock Sw: Disconnection

Action code Failure code Work equipment lock switch: Disconnection
Failure
E03 DDNLKA (Work equipment controller system)
q Both lines of NO* and NC* for work equipment lock lever switch circuit are OPEN (switch: OFF) at
Detail of failure
the same time.
Action of con- q Recognizes that work equipment lock lever is in LOCk position.
Problem on q Once machine stops, travel is limited to F1 and R1.
machine q Work equipment operation is impossible.
q Engine does not run.
q Condition of work equipment lock lever switch signal can be checked with monitoring function.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position and operate work eqiupment
mation
lock lever.
q When work equipment lock lever is free, work equipment lock lever switch becomes "ON".
(Lever is locked in illustration.)

2. Disconnect connector WELK and connect T-adapter to male side.
Defective work equipment 3. Operate work equipment lock lever and troubleshoot.
1 lock lever switch (Internal Between WELK (male) (A) and Lever: FREE Resistance Min. 1 MΩ
disconnection) (B) Lever: LOCK Resistance Max. 1 Ω
Between WELK (male) (A) and Lever: FREE Resistance Max. 1 Ω
(C) Lever: LOCK Resistance Min. 1 MΩ
2. Disconnect connector WELK and connect T-adapter to female side.
in wiring harness
Between WELK (female) (A) and (B) Voltage 7 – 11 V
Between WELK (female) (A) and (C) Voltage 7 – 11 V
harness 2. Disconnect connectors WECN1, WECN2 and WELK, and connect T-adapters to
3 female side .
tive contact) Between WECN1 (female) (10) and WELK (female) (A) Resistance Max. 1 Ω
Between WECN2 (female) (35) and WELK (female) (B) Resistance Max. 1 Ω
Between WECN2 (female) (25) and WELK (female) (C) Resistance Max. 1 Ω
Defective work equipment 4. Operate work equipment lock lever switch and troubleshoot.
4
Between WECN2(25) and Lever: FREE Voltage 7 – 11 V
WECN1(10) Lever: LOCk Voltage Max. 1 V
Between WECN2(35) and Lever: FREE Voltage Max. 1 V
WECN1(10) Lever: LOCk Voltage 7 – 11 V
*NO: Normally Open
40-384 D375A-6
(01)
DRAFT
Circuit diagram related to equipment lock switch
D375A-6 40-385
(01)
DRAFT
Failure code [DDNLKB] Weq lock Sw: Short circuit

Action code Failure code Work equipment lock switch: Short circuit
Failure
E03 DDNLKB (Power train controller systerm)
q Both lines of NO* and NC* for work equipment lock lever switch circuit are 0 V (switch: ON) at the
Detail of failure
same time.
Action of con- q Recognizes that work equipment lock lever is in Lock position.
Problem on q Once machine stops, travel is limited to F1 and R1.
machine q Work equipment operation is impossible.
q Engine does not run.
q “NO*” line is used for sensing operation and “NC” line is used for detecting error.
q Condition of work equipment lock lever switch signal can be checked with monitoring function.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position and operate work equipment
mation
lock lever.
q When work equipment lock lever is free, work equipment lock lever switch becomes "ON".
(Lever is locked in illustration.)

2. Disconnect connector WELK and connect T-adapter to male side.
Defective work equipment 3. Operate work equipment lock lever and troubleshoot.
1 lock lever switch (Internal Between WELK (male) (A) and Lever: FREE Resistance Min. 1 MΩ
disconnection) (B) Lever: LOCK Resistance Max. 1 Ω
Between WELK (male) (A) and Lever: FREE Resistance Max. 1 Ω
(C) Lever: LOCK Resistance Min. 1 MΩ
2. Disconnect connectors WECN1, WECN2 and WELK and connect T-adapter to
Ground fault of wiring har- female side of one of them.
2 ness Between WELK (female) (B) and ground or between
(Contact with GND circuit) Resistance Min. 1 MΩ
WECN2 (female) (35) and ground.
Between WELK (female) (C) and ground or between
WECN2 (female) (25) and ground.
2. Disconnect connectors WECN2 and WELKand connect T-adapters to female side
of WECN2.
3
ness Between WECN2 (female) (25) and each pin other than No continuity
Between WECN2 (female) (35) and each pin other than No continuity
Defective power train con- 4. Operate work equipment lock lever switch and troubleshoot.
4
troller a Voltage of approx.9 V is applied to WECN2 pin (25) and pin (35) through resistor in
Between WECN2 (25) and Lever: FREE Voltage 7 – 11 V
WECN1 (10) Lever: LOCK Voltage Max. 1 V
Between WECN2 (35) and Lever: FREE Voltage Max. 1 V
WECN1 (10) Lever: LOCK Voltage 7 – 11 V
*NO: Normally Open
40-386 D375A-6
(01)
DRAFT
Circuit diagram related to work equipment lock switch
D375A-6 40-387
(01)
DRAFT
Failure code [DDT5KA] Neutral switch disconnection

Action code Failure code Neutral switch disconnection
Failure
E04 DDT5KA (Power train controller system)
q Both lines of NO: Normally Open and NC: Normally Closed for neutral switch circuit are OPEN
Detail of failure
(switch: OFF) at the same time.
Action of con-
q Recognizes that neutral switch is not pressed.
troller
machine q Once machine is stopped, it cannot travel any more.
q Method of reproducing failure code: Turn starting switch to ON position and operate neutral switch.
Related infor- q First, check the power train oil filter for clogging etc.
mation q Next, check that hydraulic pressure of work equipment is normal by referring to Testing and adjust-

lever type
3. Turn neutral switch to ON or OFF position and troubleshoot.
2
Defective neutral switch a “Switch OFF”: Release, “Switch ON”: Press
(Internal disconnection) Between SNC (male) (4) Switch: OFF Resistance Max. 1 Ω
and (6) Switch: ON Resistance Min. 1 MΩ
Between SNC (male) (4) Switch: OFF Resistance Min. 1 MΩ
and (5) Switch: ON Resistance Max. 1 Ω
2. Disconnect connector SNC and connect T-adapter to female side.
in wiring harness
a Voltage of apporx.9 V is applied to signal lines of “NO” and “NC” through resistor
harness 2. Disconnect connectors PTCN1, PTCN2 and SNC, and connect T-adapter to each
4 female side
tive contact) BetweenPTCN1 (femail)(10) and SNC (femail)(4) Resistance Max. 1 Ω
BetweenPTCN2(femail)(17) andSNC (femail)(5) Resistance Max. 1 Ω
BetweenPTCN2(femail)(27) andSNC (femail)(6) Resistance Max. 1 Ω
Defective power train con- 4. Turn neutral switch to ON or OFF position and troubleshoot.
5
troller a Voltage of apporx.9 V is applied to PTCN2 pin (17) and PTCN2 pin (27) through re-
sistor in power train controller.
Between PTCN2(27) and Switch: OFF Voltage Max. 1 V
PTCN1(10) Switch: ON Voltage 7–11 V
Between PTCN2(17) and Switch: OFF Voltage 7–11 V
40-388 D375A-6
(01)
DRAFT
Circuit diagram related to neutral switch
D375A-6 40-389
(01)
DRAFT
Failure code [DDT5KB] Neutral switch short circuit

Action code Failure code Neutral switch short circuit
Failure
E04 DDT5KB (Power train controller systerm)
Detail of fail- q Both lines of NO: Normally Open and NC : Normally Closed for neutral switch circuit are 0 V(switch:
ure ON) at the same time.
Action of con-
q Recognizes that neutral switch is not pressed.
troller
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position and operate neutral switch.
mation

Wrong selection of travel lever
type
3. Turn neutral switch to ON or OFF position and troubleshoot.
2
Defective neutral switch a “Switch OFF”: Release, “Switch ON”: Press
(Internal disconnection) Between SNC (male) Switch: OFF Resistance Max. 1 Ω
(4) and (6) Switch: ON Resistance Min. 1 MΩ
Between SNC (male) Switch: OFF Resistance Min. 1 MΩ
(4) and (5) Switch: ON Resistance Max. 1 Ω
Ground fault of wiring harness female side of them.
3 Between SNC (female) (5) or PTCN2 (female)
(Contact with ground circuit) Resistance Min. 1 MΩ
(17) and ground
Between SNC (female) (6) and PTCN2 (female)
(27) and groud
female side of PTCN2.
4 Short circuit in wiring harness a Check with tester in continuity mode.
Between PTCN2 (female) (17) and each pin No continuity
other than (17) (No sound is heard)
Between PTCN2 (female) (27) and each pin No continuity
other than (27) (No sound is heard)
2. Insert T-adapters into connectors PTCN1 and PTCN2.
Defective power train control- 4. Turn shift up switch to ON or OFF position and troubleshoot.
5
ler a Voltage of apporx.9 V is applied to PTCN2 pin (27) and PTCN2 pin (17) through
Between PTCN2 (27) Switch: OFF Voltage Max. 1 V
and PTCN1 (10) Switch: ON Voltage 7–11 V
Between PTCN2 (17) Switch: OFF Voltage 7–11 V
and PTCN1 (10) Switch: ON Voltage Max.1 V
40-390 D375A-6
(01)
DRAFT
Circuit diagram related to meutral switch
D375A-6 40-391
(01)
DRAFT
Failure code [DDT5KQ] Lever SPEC selection signal disagreement

Action code Failure code Lever specification selection signal disagreement
Failure
E04 DDT5KQ (Power train controller system)
Detail of fail-
q While optional travel lever is installed, optional travel lever device is not set.
ure
Action of con-
troller
Related infor-
mation

Wrong selection of travel Check type of travel lever in adjust-
1 Select optional travel lever.
lever ment mode: 0004.
2. Disconnect connectors PTCN2 and SNC and connect T-adapters to female side
Ground fault in wiring har- of them.
2 ness Between PTCN2 (female)(17) and ground or
(Contact with ground circuit) between SNC (female) (5) and ground Resistance Min. 1 MΩ
Between PTCN2 (female)(27) and ground or
between SNC (female) (6) and ground
Defective power train control- If causes 1 and 2 are not detected, power train controller may be defective. (Since
3
ler failure is in it, troubleshooting cannot be carried out.)
Circuit diagram related to lever specification selection
40-392 D375A-6
(01)
DRAFT
D375A-6 40-393
(01)
DRAFT
Failure code [DDTSL1] S/C: Fill high

Action code Failure code Stator clutch oil pressure 1
Failure
E02 DDTSL1 (Power train controller system)
q Nevertheless controller does not output to torque converter stator clutch ECMV solenoid circuit, fill
Detail of failure
switch signal is turned to ON position.
Action of con-
troller
Problem on
q Sufficient traveling torque may not be obtained
machine
q ON/OFF of stator clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 31520 T/M fill SW input 2)
Related infor-
q Remove seat (approx. 50 kg) and seat bottom cover.
mation
oil pressure".

Defective stator clutch
1 ECMV fill switch (Internal 2. Disconnect connector FSTC and connect T-adapter to male side.
Between FSTC (female) (1) and ground
(Fill switch: OFF)
2. Disconnect connector FSTC.
Ground fault of wiring har- 3. Start engine.
2 ness or defective power train a Keep PPC lever in N position.
controller If failure code [DDTSL1] is still displayed, there is ground fault of wiring harness or
(If failure code [DDTSL1] is not displayed, stator clutch fill switch is defective.)
3 ness 2. Disconnect connectors PTCN2 and FSTC, and connect T-adapter to female side
Between PTCN2 (female) (2) and ground or between
FSTC (female) (1) and ground
Defective power train con- 2. Insert T-adapter into connector PTCN2.
4
troller Between PTCN2 (2) and ground Voltage 7 – 11 V
3. Start engine.
40-394 D375A-6
(01)
DRAFT
Circuit diagram related to stator clutch oil pressure
D375A-6 40-395
(01)
DRAFT
Failure code [DDTSLH] S/C: Fill low

Action code Failure code Stator clutch oil pressure 2
Failure
E02 DDTSLH (Power train controller system)
q Nevertheless controller does not output to torque converter stator clutch ECMV solenoid circuit, fill
Detail of failure
Action of con-
troller
Problem on
q Sufficient traveling torque may not be obtained
machine
q ON/OFF of stator clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 31520 T/M fill SW input 2)
Related infor-
q Remove seat (approx. 50 kg) and seat bottom cover.
mation
oil pressure".

Defective stator clutch 2. Disconnect connector FSTC and connect T-adapter to male side.
1 ECMV fill switch (Fill switch- 3. Start engine.
dose not turn to ON position) Between FSTC (female) (1) and ground
(Fill switch: ON)
ness 2. Disconnect connectors PTCN2 and FSTC and connect T-adapter to female side
2
(Disconnection or defective of either of them.
contact) Between PTCN2 (female) (2) and FSTC (female) (1) Resistance Max. 1 Ω
If no abnormality is found by the above checks, power train controller is defective.
Defective power train con- 2. Insert T-adapter into connector PTCN2.
troller
1–2 are same as above.
3. Start engine.
40-396 D375A-6
(01)
DRAFT
Circuit diagram related to stator clutch oil pressure
D375A-6 40-397
(01)
DRAFT
Failure code [DGE5KX] Ambient temp sensor abnormality

Action code Failure code Atmospheric temperature sensor:Abnormality
Failure
– DGE5KX (VHMS controller system)
Detail of fail-
q Input signal voltage from the atmospheric temperature sensor reads 4.9 V and above or 0.3 V or less.
ure
Action of con-
troller
Problem on
q Monitoring function fails to monitor the atmospheric temperature.
machine
q The LED of the VHMS controller displays "n4"o"01".
Related infor- q The input state (temperature) from the atmospheric temperature sensor can be checked with the mon-
mation itoring function (Code: 37501 ATR TEMP).
Cause Procedure, measuring location, and remarks

2. Disconnect connector INT and connect T-adapter to male side.
a If ambient temperature sensor resistance is 700 Ω – 37 kΩ, regard ambient tem-
perature sensor as normal.
INT (male) Atmospheric temperature Resistance
Defective atmospheric tem-
1 -20 °C 27 - 34 kΩ
perature sensor
0 °C 10 - 13 kΩ
Between (1) and (2)
25 °C 3.8 - 4.6 kΩ
40 °C 2.2 - 2.6 kΩ
2. Disconnect connector V2A and connect T-adapter to female side.
Disconnection or short circuit Between V2A (female) (10) and (12)
2
in wiring harness a Resistance accords with ambient temperature - re-
Resistance 2.2 - 34 kΩ
sistance characteristics table of ambient tempera-
ture sensor in cause 2.
ness
3 (Disconnection in wiring or 2. Disconnect connectors V2A and INT and connect T-adapters to female side of
defective contact in connec- them.
tor) Between V2A (female) (10) and INT (female) (1) Resistance Max. 1 Ω
Between V2A (female) (12) and INT (female) (2) Resistance Max. 1 Ω
Ground fault of wiring har- 2. Disconnect connectors INT and V2A and connect T-adapter to female side of
(Contact with ground circuit) Between INT (female) (1) and ground or between V2A
(female) ( 10) and ground
Hot short or short circuit in 2. Disconnect connectors INT and connect T-adapter to female side.
5
wiring harness 3. Turn starting switch to ON position.
Between INT (female) (1) and (2) Voltage Approx. 5 V
If cause is not found by above checks, the VHMS controller is defective.
40-398 D375A-6
(01)
DRAFT
Circuit diagram related to ambient temperature sensor
D375A-6 40-399
(01)
DRAFT
Troubleshootingbyfailurecode
Failurecode[DGS1KX] Hydoil temp: signal abnormal
Failure code [DGS1KX] Hyd oil temp: signal abnormal

Action code Failure code Hydraulic oil temperature sensor: Abnormal
Failure
E01 DGS1KX (Mechane monitor power train control system)
Detail of fail-
q Hydraulic oil temperature sensor signal is out of normal range.
ure
Action of con-
troller
Problem on q Hydraulic oil temperature on monitor panel is not displayed normally.
machine q Fan speed is limited to half.
q Hydraulic oil temperature can be checked in monitoring mode.
Related infor-
(Code: 04401 Hydraulic oil temperature)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
Cause Procedure, measuring location, crit and remarks

Defective hydraulic oil temper- 2. Disconnect connector HDT and connect T-adapter to male side.
ature sensor 10 °C Resistance Approx. 90 kΩ
1 Between HDT (male) (1) and (2)
(Internal disconnection or 30 °C Resistance Approx. 35 kΩ
a Temperature characteristics
short circuit) 80 °C Resistance Approx. 6.5 kΩ
of oil temperature sensor
100 °C Resistance Approx. 3.5 kΩ
2. Disconnect connector HDT and connect T-adapter to female side.
Disconnection, short circuit or 3. Turn starting switch ON position.
2 hot short in or ground fault of a If voltage is 0 V, wiring harness has disconnection, ground fault or short circuit,
wiring harness and if voltage is 24 V, wiring harness has hot short.
a Voltage of 5 V is applied to temperature sensor signal lines through resistor in
Between HDT (female) (1) and (2) Voltage Approx. 5 V
2. Disconnect connector CM01 and connect T-adapter to female side.
Disconnection or short circuit a Resistance accords with temperature characteristics table in cause 1.
3
in wiring harness a If resistance is above1 MΩ, wiring harness has disconnection. If resistance is
below 1 Ω, wiring harness has short circuit.
Approx.3.5 –
Between CM01 (female) (8) and (12) Resistance
90 kΩ
a If neither of causes 2 and 3 is the cause for the trouble, this check is not re-
quired.
ness 2. Disconnect connectors CM01 and HDT, and connect T-adapters to female side
4 of them.
Between CM01 (female) (8) and HDT (female) Resistance
contact) Max. 1 Ω
(1)
Between CM01 (female) (12) and HDT (female) Resistance
Max. 1 Ω
(2)
Ground fault of wiring harness 2. Disconnect connectors CM01 and HDT, and connect T-adapter to female side
5
Between CM01 (female) (8) and (3), or between
HDT (female) (1) and ground
2. Disconnect connectors CM01 and HDT, and connect T-adapter to female side
6 Short circuit in wiring harness of CM01.
a Check with multimeter in continuity mode.
Between CM01 (female) (8) and each pin other
No continuity (No sound is heard)
than (8)
7 Defective machine monitor If no failure is detected by the above checks, machine monitor is defective.
40-400 D375A-6
(01)
DRAFT
Failure code [DGS1KX] Hyd oil temp: signal abnormal
Circuit diagram related to hydraulic oil temperature sensor
D375A-6 40-401
(01)
DRAFT
Failure code [DGT1KA] T/C oil temp sensor: Abnormal

Action code Failure code Torque converter oil temperature sensor: Disconnection
Failure
E01 DGT1KA (Work equipment controller system)
Detail of failure q Torque converter oil temperature sensor signal is out of normal range.
Action of con-
troller
q Power train oil temperature gauge may not indicate normally.
Problem on
q Fan speed is limited to half speed.
machine
q Gear shift shock of transmission increases.
q Torque converter oil temperature is considered to be power train oil temperature.
Related infor- q Torque converter oil temperature can be checked with monitoring function.
mation (Code: 30100 T/C Oil Temperature)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Defective torque con- 1. Turn starting switch to OFF position.
verter oil temperature 2. Disconnect connector 453 and connect T-adapter to male side.
1 sensor 25 °C Resistance Approx. 42 kΩ
Between 453 (male) (1) and (2)
(Internal disconnection a Temperature characteristics of oil 30 °C Resistance Approx. 35 kΩ
or short circuit) temperature sensor
2. Disconnect connectors 453 and connect T-adapter to female side.
Disconnection, short cir- 3. Turn starting switch ON position.
2
cuit or hot short in or a If voltage is 0 V, wiring harness has disconnection, ground fault or short circuit, and if
ground fault of wiring voltage is 24 V, wiring harness has hot short.
harness a Voltage of apporx.5 V is applied to temperature sensor signal lines through resistor in
Between 453 (female) (1) and (2) Voltage Approx. 5 V
2. Disconnect connectors WECN1 and connect T-adapter to female side.
Disconnection or short a Resistance accords with temperature characteristics table in cause 1.
3
circuit in wiring harness a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is below
Approx. 3.5 –
Between WECN1 (female) (20) and (21) Resistance
90 kΩ
a If neither of causes 2 and 3 is the cause for the trouble, this check is not required.
harness 2. Disconnect connectors WECN1 and 453, and connect T-adapters to female side of
4
(Disconnection or them.
defective contact) Between (female) (20) and 453 (female) (1) Resistance Max. 1 Ω
Between WECN1 (female) (21) and 453 (female) (2) Resistance Max. 1 Ω
2. Disconnect connectors WECN1 and 453, and connect T-adapter to female side of
Short circuit in wiring WECN1.
5
harness a Check with multimeter in continuity mode.
Between WECN1 (female) (20) and each pin other No continuity (No sound is
than (20) heard.)
6 If cause is not found by above checks, work equipment controller is defective.
ment controller
40-402 D375A-6
(01)
DRAFT
Circuit diagram related to torque converter oil temperature sensor
D375A-6 40-403
(01)
DRAFT
Failure code [DGT1KX] T/C oil temp sensor: Abnormal

Action code Failure code Torque converter oil temperature sensor: Short circuit
Failure
E01 DGT1KX (Work equipment controller system)
Detail of failure q Torque converter oil temperature sensor signal is out of normal range.
Action of con-
q No particular action
troller
q Power train oil temperature gauge may not indicate normally.
Problem on
q Fan speed is limited to half speed.
machine
q Shock at gear shift is hard.
q Torque converter oil temperature is considered to be power train oil temperature.
Related infor- q For temperature characteristics table of oil temperature sensor, see [DGT1KA].
mation q If the sensor connector is disconnected in the normal condition and turn starting switch to ON posi-
tion, failure code [DGT1KA] is displayde.

Defective torque con- 2. Disconnect connector 453.
verter oil temperature 3. Turn starting switch ON position.
1 sensor If failure code[DGT1KX] goes off and disconnection code [DGT1KA] is displayed, torque
(Internal disconnection converter oil temperature sensor is defective.
or short circuit) (If failure code [DGT1KX] is still displayed, it shows that wiring harness or power train
controller is defective.)
harness 2. Disconnect connectors WECN1 and 453, and connect T-adapter to female side of
2 either of them.
Between WECN1 (female) (20) and ground or
between 453 (female) (1) and ground
2. Disconnect connectors WECN1 and 453, and connect T-adapter to female side of
Short circuit in wiring WECN1.
3
harness a Check with multimeter in continuity mode.
Between WECN1 (female) (20) and each pin other
than (20)
4 If no failure is detected by the above checks, work equipment controller is defective.
ment controller
40-404 D375A-6
(01)
DRAFT
Circuit diagram related to torque converter oil temperature sensor
D375A-6 40-405
(01)
DRAFT
Failure code [DGT5KA] F exhaust temp sensor disconnection

Action code Failure code Front exhaust temp sensor disconnection: Disconnection
Failure
― DGT5KA (VHMS controller system)
Detail of failure q Input signal voltage from the exhaust gas temperature sensor on the engine front side is below 0.5 V.
Action of con-
troller
Problem on
q Monitoring function fails to monitor the exhaust gas temperature on the engine front side
machine
q The LED of the VHMS controller displays “n3" o "12".
Related infor- q The input state (temperature) from the front exhaust gas temperature sensor can be checked with
mation the monitoring function (Code: 42610 EXHAUST TEMP FRONT).

If failure code [DBB6KP] is displayed, troubleshoot it first.
2. Disconnect connector EXAF and connect T-adapter to female side.
Defective sensor power sup-
ply system
a If power supply voltage is abnormal, go to cause 4 or after.
Between EXAF (A) and (C) Power supply Voltage 20 – 30 V
a Check that failure code [DGT6KA] is not displayed.
Defective front (cylinder Nos.
2. Replace connector EXHF with EXHR.
2 1 - 3) exhaust temperature
sensor 3. Turn starting switch to ON position.
If failure code [DGT5KA] changes to [DGT6KA], original front (cylinder Nos. 1 - 3)
exhaust temperature sensor is defective.
2. Disconnect connectors EXTF, EXHF, V1 and V2A, and connect T-adapters to
female side of them or male side of EXTF.
Disconnection in wiring har- a If cause 1 is not the cause for the failure, this check
ness is not required. Resistance Max. 1 Ω
3 (Disconnection in wiring or Between V1 (female) (2) and EXAF (female) (A)
defective contact in connec- Between V2A (female) (7) and EXAF (female) (B) Resistance Max. 1 Ω
a If cause 1 is not the cause for the failure, this check
tor)
is not required. Resistance Max. 1 Ω
Between V2A (female) (13) and EXAF (female) (C)
Between EXHF (female) (1) and EXTF (male) (1) Resistance Max. 1 Ω
Between EXHF (female) (2) and EXTF (male) (2) Resistance Max. 1 Ω
2. Disconnect connectors EXHF, EXTF,EXAF, V1 and V2A, and connect
T-adapters to female side of them or male side of EXTF.
Ground fault of wiring har- Between EXHF (female) (1) or EXTF (male) (1) and
4 ness Resistance Min. 1 MΩ
ground
(Contact with ground circuit) Between EXHF (female) (1) and (2) ,or EXTF (male)
(1) and (2)
Between V2A (female) (7) and ground Resistance Min. 1 MΩ
Between V2A (female) (7) and (13) Resistance Min. 1 MΩ
a Check that failure code [DGT6KA] is not displayed.
Defective front (cylinder Nos.
2. Replace connector EXAF with EXAR.
sensor amplifier 3. Turn starting switch to ON position.
If failure code [DGT5KA] changes to [DGT6KA], original front (cylinder Nos. 1 - 3)
exhaust temperature sensor amplifier is defective.
40-406 D375A-6
(01)
DRAFT
If cause is not found by above checks, VHMS controller may be defective. (Since
q Reference: The following shows standard values in the normal condition.
2. Insert T-adapter into connectors V1 and V2A.
6 Defective VHMS controller 100 °C - 200 °C Voltage 1.4 – 1.8 V
200 °C - 300 °C Voltage 1.8 – 2.2 V
Between V2A(7) and (13) 300 °C - 400 °C Voltage 2.2 – 2.6 V
a Exhaust temperature character- 400 °C - 500 °C Voltage 2.6 – 3.0 V
istics 500 °C - 600 °C Voltage 3.0 – 3.4 V
600 °C - 700 °C Voltage 3.4 – 3.9 V
700 °C - 800 °C Voltage 3.9 – 4.3 V
Circuit diagram related to exhaust temperature sensor
D375A-6 40-407
(01)
DRAFT
Failure code [DGT5KB] F exhaust temp sensor short circuit

Action code Failure code Front exhaust temp sensor disconnection:Short circuit
Failure
― DGT5KB (VHMS controller system)
Detail of fail-
q Input signal voltage from the exhaust gas temperature sensor on the engine front side is above 4.9 V.
ure
Action of con-
troller
Problem on
q Monitoring function fails to monitor the exhaust gas temperature on the engine front side
machine
q The machine monitor does not display any failure code (the relevant failure code can be checked by
downloading data stored in the VHMS controller).
Related infor- q The LED of the VHMS controller displays “n3" o "11".
mation q The input state (temperature) from the front exhaust gas temperature sensor can be checked with the
monitoring function (Code: 42610 EXHAUST TEMP FRONT).

1 If failure code [DBB6KP] is displayed, troubleshoot it first.
ply system
a Check that failure code [DGT6KB] is not displayed.
Defective front (cylinder
2 Nos. 1 - 3) exhaust tempera-
ture sensor 3. Turn starting switch to ON position.
If failure code [DGT5KB] changes to [DGT6KB], original front (cylinder Nos. 1 - 3)
Hot short in wiring harness 2. Disconnect all connectors EXAF and connect T-adapter to female side.
3
Between EXAF (female) (B) and (C) Voltage Max. 1 V
Defective front (cylinder
ture sensor amplifier 3. Turn starting switch to ON position.
If failure code [DGT5KB] changes to [DGT6KB], original front (cylinder Nos. 1 - 3)
200 °C - 300 °C Voltage 1.8 – 2.2 V
Between V2A (7) and (13) 300 °C - 400 °C Voltage 2.2 – 2.6 V
a Exhaust temperature characteris- 400 °C - 500 °C Voltage 2.6 – 3.0 V
tics 500 °C - 600 °C Voltage 3.0 – 3.4 V
600 °C - 700 °C Voltage 3.4 – 3.9 V
700 °C - 800 °C Voltage 3.9 – 4.3 V
40-408 D375A-6
(01)
DRAFT
D375A-6 40-409
(01)
DRAFT
Failure code [DGT6KA] R exhaust temp sensor disconnection

Action code Failure code Rear exhaust temp sensor disconnection: Disconnection
Failure
― DGT6KA (VHMS controller system)
Detail of fail-
q Input signal voltage from the exhaust gas temperature sensor on the engine rear side is below 0.5 V.
ure
Action of con-
troller
Problem on
q Monitoring function fails to monitor the exhaust gas temperature on the engine rear side
machine
q The LED of the VHMS controller displays “n3” o ”22”.
Related infor- q The input state (temperature) from the rear exhaust gas temperature sensor can be checked with the
mation monitoring function (Code: 42611 EXHAUST TEMP REAR).

2. Disconnect connector EXAR and connect T-adapter to female side.
ply system
Between EXAR (A) and (C) Power supply Voltage 20 – 30 V
a Check that failure code [DGT5KA ]is not displayed.
Defective rear (cylinder Nos.
If failure code [DGT5KA] changes to [DGT6KA], original rear (cylinder Nos, 4-6)
2. Disconnect connectors EXTR, EXHR, V1 and V2A, and connect T-adapters to
female side of them or male side of EXTR.
a If cause 1 is not the cause for the trouble, this check
Resis-
is not required. Max. 1 Ω
tance
Disconnection in wiring har- Between V1 (female) (2) and EXAR (female) (A)
Resis-
3
ness Between V2A (female) (5) and EXAR (female) (B) Max. 1 Ω
(Disconnection or defective tance
a If cause 1 is not the cause for the trouble, this check
contact in connector) Resis-
is not required. Max. 1 Ω
tance
Between V2A (female) (13) and EXAR (male) (C)
Resis-
Between EXHR (female) (1) and EXTR (male) (1) Max. 1 Ω
tance
Resis-
Between EXHR (female) (2) and EXTR (male) (2) Max. 1 Ω
tance
2. Disconnect connectors EXHR, EXTR, EXAR, V1 and V2A, and connect
T-adapters to female side of them or male side of EXTR.
Between EXHR (female) (1) or EXTR (male) (1) and Resis-
Ground fault of wiring har- Min. 1 MΩ
ground tance
4 ness Between EXHR (female) (1) and (2) or EXTR (male) (1) Resis-
(Contact with ground circuit) Min. 1 MΩ
and (2) tance
Resis-
V2A (female) (5) and ground Min. 1 MΩ
tance
Resis-
V2A (female) (5) and (13) Min. 1 MΩ
tance
a Check that failure code [DGT5KA ]is not displayed.
Defective rear (cylinder
ture sensor amplifier 3. Turn starting switch to ON position.
If failure code [DGT6KA] changes to [DGT5KA], original rear (cylinder Nos. 4 - 6)
40-410 D375A-6
(01)
DRAFT
200 °C - 300 °C Voltage 1.8 – 2.2 V
Between V2A (5) and (13) 300 °C - 400 °C Voltage 2.2 – 2.6 V
tics 500 °C - 600 °C Voltage 3.0 – 3.4 V
600 °C - 700 °C Voltage 3.4 – 3.9 V
700 °C - 800 °C Voltage 3.9 – 4.3 V
D375A-6 40-411
(01)
DRAFT
Failure code [DGT6KB] R exhaust temp sensor short circuit

Action code Failure code Rear exhaust gas temperature sensor (R): Short circuit
Failure
― DGT6KB (VHMS controller system)
Detail of fail-
q Input signal voltage from the exhaust gas temperature sensor on the engine rear side is above 4.9 V.
ure
Action of con-
troller
Problem on
q Monitoring function fails to monitor the exhaust gas temperature on the engine rear side
machine
q The LED of the VHMS controller displays "n3 o "21".
Related infor- q The input state (temperature) from the rear exhaust gas temperature sensor can be checked with the
mation monitoring function (Code: 42611 EXHAUST TEMP REAR).

1 If failure code [DBB6KP] is displayed, troubleshoot it first.
ply system
If failure code [DGT6KB] changes to [DGT5KB], original rear (cylinder Nos. 4 - 6)
Hot short in wiring harness 2. Disconnect connector EXAR and connect T-adapter to female side.
3
Between EXAR (female) (B) and (C) Voltage Max. 1 V
sensor amplifier 3. Turn starting switch to ON position.
If failure code [DGT6KB] changes to [DGT5KB], original rear (cylinder Nos. 4 - 6)
2. Insert T-adapter into connector V1 and V2A.
200 °C - 300 °C Voltage 1.8 – 2.2 V
Between V2A(5) and (13) 300 °C - 400 °C Voltage 2.2 – 2.6 V
tics 500 °C - 600 °C Voltage 3.0 – 3.4 V
600 °C - 700 °C Voltage 3.4 – 3.9 V
700 °C - 800 °C Voltage 3.9 – 4.3 V
40-412 D375A-6
(01)
DRAFT
D375A-6 40-413
(01)
DRAFT
Failure code [DH21KA] Weq pressure sensor: Disconnection

Action code Failure code Work equipment pump oil pressure sensor : Disconnection
Failure
E01 DH21KA (Work equipment controller system)
Detail of failure q Signal voltage of work equipment pump oil pressure sensor is below 0.2 V.
Action of con-
troller
Problem on
q Oil pressure of work equipment pump cannot be monitored.
machine
q Signal voltage of work equipment pump oil pressure sensor can be checked with monitoring function.
Related infor-
(Code: 70701 Hydraulic Pressure Sensor 1)
mation

If failure code [DB97KK] is also displayed, troubleshoot it first.
2. Disconnect connector HHP and connect T-adapter to female side.
Defective sensor 5 V power
suplly system
Power
supply
2. Insert T-adapter into connector HHP.
Defective work equipment a If power supply voltage is normal and sensor output voltage is abnormal (below
pump oil pressure sensor 0.5 V), internal disconnection and ground fault cannot be identified. In this case,
2
(Internal disconnection) or go to cause 4.
ground fault If check result of cause 4 is normal, work equipment pump oil pressure sensor
is defective.
Sensor
Between HHP (female) (C) and (A) Voltage 0.5 – 4.5 V
output
2. Disconnect connectors WECN1, WECN3 and HHP, and connect T-adapters to
female side of them.)
a If power supply voltage in checks 1 is nor-
mal, this check is not required.
Disconnection in wiring har- Resistance Max. 1 Ω
ness Between WECN1 (female) (21) and HHP
3 (female) (A)
a If power supply voltage in checks 1 is nor-
mal, this check is not required.
Between WECN3 (female) (34) and HHP
(female) (B)
Between WECN1 (female) (9) and HHP
(female) (C)
a If cause 2 is not the cause for the failure, this check is not required.
Ground fault of wiring har- 2. Disconnect connectors STC1 and HHP, and connect T-adapter to female side of
(Contact with ground circuit) Between WECN1 (female) (9) and (21), or
between HHP (female) (C) and (A)
Between WECN1 (female) (9) and ground, or
between HHP (female) (C) and ground
5
controller 2. Insert T-adapter into connector WECN1
Between WECN1 (9) and (21) Voltage 0.5 – 4.5 V
40-414 D375A-6
(01)
DRAFT
Circuit diagram related to work equipment pump oil pressure
D375A-6 40-415
(01)
DRAFT
Failure code [DH21KB] Weq pressure sensor: Short circuit

Action code Failure code Work equipment pump oil pressure sensor: Disconnection
Failure
E01 DH21KB (Work equipment controller system)
Detail of failure q Signal voltage of work equipment pump oil pressure sensor is above 4.8 V.
Action of con-
troller
Problem on
q Oil pressure of work equipment pump cannot be monitored.
machine
q Signal voltage of work equipment pump oil pressure sensor can be checked with monitoring function.
(Code: 70701 Hydraulic Pressure Sensor 1)
Related infor-
mation
q If the sensor connector is disconnected in the normal condition and turn starting switch to ON posi-
tion, failure code [DH21KA] is displayed.

If failure code [DB97KK] is also displayed, troubleshoot it first.
2. Disconnect connector HHP and connect T-adapter to female side.
supply system
Power
supply
2. Disconnect connector HHP
Defective work equipment
pump oil pressure sensor 3. Turn starting switch to ON position.
2 If failure code [DH21KB] is not displayed but [DH21KA] of disconnection is dis-
(Internal disconnection) or
ground fault played, work equipment pump oil pressure sensor is defective. (If failure code
[DH21KB] is still displayed, it shows that wiring harness or power train controller is
defective.)
Hot short in wiring harnesss 2. Disconnect connector HHP and connect T-adapter to female side.
3
(Contact with 24 V circuit) 3. Turn starting switch ON position.
Between HHP (female) (C) and(A) or ground Voltage Max. 1 V
2. Disconnect connectors WECN1 and HHP, and connect T-adapter to female side
4 Short circuit in wiring harness of WECN1.
a Check with tester in continuity mode.
Between WECN1 (female) (9) and each pin
other than (9)
5
controller 2. Insert T-adapter into connector WECN1
Between WECN1 (9) and (21) Voltage 0.5 – 4.5 V
40-416 D375A-6
(01)
DRAFT
Circuit diagram related to work equipment pump oil pressure
D375A-6 40-417
(01)
DRAFT
Failure code [DHE5KB] ENG blow-by pressure sensor disconnection

Action code Failure code Engine blow-by pressure sensor: Disconnection
Failure
– DHE5KB (VHMS controller system)
Detail of failure q Input signal voltage from the blow-by pressure sensor is below 0.1 V.
Action of con-
troller
Problem on
q Monitoring function fails to monitor the blow-by pressure
machine
q The LED of the VHMS controller displays "n3"o"32".
Related infor- q The input state (pressure) from the blow-by pressure sensor can be checked with the monitoring func-
mation tion (Code: 42801 BLOWBY PRESSURE).
q Method of reproducing failure code: Start engine and performs troubleshooting

Defective sensor 5 V power supply 2. Disconnect connectors ENBP and connect T-adapter to female side.
1
system 3. Turn starting switch to ON position.
Between ENBP (B) and (A) Power supply Voltage 4.85 –5.15 V
2. Disconnect connectors ENBP, V1 and V2A, and connect T-adapters to
Ground fault of wiring harness female side of one of them.
2 Between ENBP (female) (C) and (A), or
between V2A (female) (18) and (12)
Between ENBP (female) (C) or V2A (female)
(18) and ground
2. Insert T-adapter into connector ENBP.
3. Turn starting switch to ON position, start engine, and then perform trouble-
shooting.
Defective blow-by pressure sensor Between ENBP (C) Sensor output (Normal) Voltage 0.5 – 4.5 V
3
(Internal defect) and (A) Sensor output (High idle) Voltage 0.5 – 0.9 V
2. Disconnect connectors ENBP and connect T-adapter to male side.
Between ENBP (female) (A), (B), (C) and
ground
2. Disconnect connectors ENBP, V1 and V2A and connect T-adapters to
female side of them.
a If power supply voltage in cause 1 is normal,
Disconnection in wiring harness this check is not required.
(Disconnection or defective contact Resistance Max. 1 Ω
4 Between V1 , V2A (female) (12) and ENBP
in connector) (female) (A)
a If power supply voltage in cause 1 is normal,
this check is not required. Resistance Max. 1 Ω
Between V1 (female) (4) and ENBP (female) (B)
Between V2A (female) (18) and ENBP (female)
(C)
If cause is not found by above checks, VHMS controller may be defective.
3. Turn starting switch to ON position, start engine, and then perform trouble-
shooting.
Between V1 (4) and V2A (12) Power supply Voltage 4.85 – 5.15 V
Between V2A (18) Sensor output (Normal) Voltage 0.5 – 4.7 V
and (12) Sensor output (High idle) Voltage 0.5 – 0.9 V
40-418 D375A-6
(01)
DRAFT
Circuit diagram related to engine blow-by pressure sensor
D375A-6 40-419
(01)
DRAFT
Failure code [DHE5KY] ENG blow-by pressure sensor short circuit

Action code Failure code Engine blow-by pressure sensor: Short circuit
Failure
– DHE5KY (VHMS controller system)
Detail of failure q Input signal voltage from the blow-by pressure sensor is above 4.7 V.
Action of con-
troller
Problem on
q Monitoring function fails to monitor the blow-by pressure
machine
q The LED of the VHMS controller displays "n3" o "31".
Related infor- q The input state (pressure) from the blow-by pressure sensor can be checked with the monitoring
mation function (Code: 42801 BLOWBY PRESS).
q Method of reproducing failure code: Start engine and performs troubleshooting

Defective sensor 5 V power supply
1 2. Disconnect connectors ENBP and connect T-adapter to female side.
system
Between ENBP (B) and (A) Power supply Voltage 4.85 – 5.15 V
2. Disconnect connectors ENBP, V1 and V2A and connect T-adapter to
Hot short in wiring harness female side of one of them.
2
(Contact with 24V circuit)
Between ENBP (female) (C) and (A) , or
Voltage Max. 1 V
between V2A (female) (18) and (12)
2. Insert T-adapter into connector ENBP.
3. Turn starting switch to ON position, start engine, and then perform trou-
Defective blow-by pressure sensor bleshooting.
3 Between ENBP (C) Sensor output (Normal) Voltage 0.5 – 4.5 V
(Internal defect)
and (A) Sensor output (High idle) Voltage 0.5 – 0.9 V
2. Disconnect connectors ENBP and connect T-adapter to male side.
Between ENBP (male) (A), (B),( C) and ground Resistance Min. 1 MΩ
If cause is not found by above checks, VHMS controller may be defective.
3. Turn starting switch to ON position, start engine, and then perform trou-
bleshooting.
Between V1 (4) and V2A (12) Power supply Voltage 4.85 – 5.15 V
Between V2A (18) Sensor output (Normal) Voltage 0.5 – 4.7 V
and (12) Sensor output (High idle) Voltage 0.5 – 0.9 V
40-420 D375A-6
(01)
DRAFT
Circuit diagram related to engine blow-by pressure sensor
D375A-6 40-421
(01)
DRAFT
Failure code [DHT3KX] T/M oil pressure sensor abnormality

Action code Failure code
Failure Transmission oil pressure sensor input signal out of range
– DHT3KX
Detail of fail-
q Signal voltage of transmission oil pressure sensor is abnormal (below 0.3 V or above 4.9 V).
ure
Action of con-
troller
Problem on
q System may not operate normally.
machine
Related infor-
q LED displays "n6" o "14".
mation

Defective sensor power supply 2. Disconnect connectors TMMD and connect T-adapter to female side.
1
Between TMMD (B) and (C) Power supply Voltage 20 – 30 V
Defective transmission main oil 2. Disconnect connectors TMMD and connect T-adapter to female side.
2
pressure sensor 3. Turn starting switch to ON position.
Between TMMD (A) and (C) Voltage 1–5V
2. Disconnect connectors TMMD,V1 and V2A and connect T-adapters to female
side of them.
a If cause 1 is not the cause for the failure, this
Disconnection in wiring harness check is not required. Resistance Max. 1 Ω
(Disconnection or defective con- Between V1 (female) (2) and TMMD (female) (B)
3
tact in connector) a If cause 1 is not the cause for the failure, this
check is not required.
Between V2A (female) (12) and TMMD (female)
(C)
Between V2A (female) (15) and TMMD (female)
(A)
2. Disconnect connectors TMMD,V1 and V2A and connect T-adapter to female
Ground fault of wiring harness side of one of them.
4 Between V2A (female) (15) or TMMD (female) (A)
and ground
Between V2A (female) (15) and (12) , or between
TMMD (female) (A) and (C)
Hot short or short circuit in wiring 2. Disconnect connectors TMMD and connect T-adapter to female side.
5
harness 3. Turn starting switch to ON position.
Between TMMD (female) (A) and (C) Voltage Max. 1 V
If cause is not found by above checks, VHMS controller is defective.
q Reference: Following shows standard values in normal condition.
2. Insert T-adapter into connector V2A.
Between V2A (15) and (12) Voltage 1–5V
40-422 D375A-6
(01)
DRAFT
Circuit diagram related to transmission oil pressure sensor
D375A-6 40-423
(01)
DRAFT
Failure code [DHT5KA] T/C in-pressure sensor: Disconnection

Action code Failure code Torque converter inlet pressure sensor: Disconnection
Failure
E02 DHT5KA (Power train controller system)
Detail of failure q Signal voltage of torque converter inlet pressure sensor is below 0.2 V.
Action of con-
troller
Problem on q No hydraulic pressure can be monitored at torque converter inlet.
machine q Gear shift shock of transmission increases.
q Signal voltage of torque converter inlet pressure sensor can be checked with monitoring function.
Related infor-
(Code 32601: Torque converter inlet pressure sensor voltage)
mation

If failure code [DBE6KK] is also displayed, troubleshoot it first.
2. Disconnect connector TIP and connect T-adapter to female side.
Defective power supply sys-
tem
Power sup-
Between TIP (female) (B) and (A) Voltage 20 – 30 V
ply
2. Insert T-adapter into connector TIP.
Defective torque converter a If power supply voltage is normal and sensor output voltage is abnormal (below
2 inlet pressure sensor (internal 0.5 V), internal disconnection and ground fault cannot be identified. In this case,
failure) or ground fault go to cause 4. If check result of cause 4 is normal, torque converter inlet pres-
sure sensor is defective.
Sensor out-
Between TIP (female) (C) and (A) Voltage 0.5 – 6.0 V
put
2. Disconnect connectors PTCN1 and TIP, and connect T-adapters to female side
of them.
a If power supply voltage in checks on cause 1 is
Disconnection in wiring har- normal, this check is not required.
Between PTCN1 (female) (16) and TIP (female)
3 (Disconnection in wiring or (B)
defective contact in connector) a If power supply voltage in checks on cause 1 is
normal, this check is not required.
(A)
(C)
2. Disconnect connectors PTCN1 and TIP, and connect T-adapter to female side
Ground fault of wiring harness of either of them.
4
(Contact with ground circuit) Between PTCN1 (female) (13) and (21), or
between TIP (female) (C) and (A)
Between PTCN1 (female) (13) and ground, or
between TIP (female) (C) and ground
Defective power train control- 1. Turn starting switch to OFF position.
5
ler 2. Insert T-adapter into connector PTCN1
Between PTCN1 (13) and (21) Voltage 0.5 – 6.0 V
40-424 D375A-6
(01)
DRAFT
Circuit diagram related to torque converter inlet pressure sensor
D375A-6 40-425
(01)
DRAFT
Failure code [DHT5KB] T/C in-pressure sensor: Short circuit

Action code Failure code Torque converter inlet pressure sensor: short circuit
Failure
E02 DHT5KB (Power train controller system)
Detail of fail-
q Signal voltage of torque converter inlet pressure sensor is above 4.7 V.
ure
Action of con-
troller
Problem on q No hydraulic pressure can be monitored at torque converter inlet.
q Signal voltage of torque converter inlet pressure sensor can be checked with monitoring function.
(Code 32601: Torque converter inlet pressure sensor voltage)
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position..
mation
q If the sensor connector is disconnected in the normal condition and turn starting switch to ON position,
failure code [DHT5KA] is displayed.

Defective sensor power sup- 2. Disconnect connector TIP and connect T-adapter to female side.
1
ply system 3. Turn starting switch to ON position.
Between TIP (female) (B) and (A) Power supply Voltage 20 – 30 V
2. Disconnect connector TIP.
2 inlet pressure sensor (internal 3. Turn starting switch to ON position.
failure) or ground fault If failure code [DHT5KB] is not displayed, torque converter inlet pressure sensor is
defective. (If failure code [DHT5KB] is still displayed, it shows that wiring harness
or power train controller is defective.)
2. Disconnect connector TIP and connect T-adapter to female side.
3 (Contact with 24 V circuit)
Between TIP (female) (C) and (A) or ground Voltage Max. 1 V
2. Disconnect connectors PTCN1 and TIP, and connect T-adapter to female side
4 Short circuit in wiring harness of PTCN1.
Between PTCN1 (female ) (13) and each pin No continuity (No sound is
other than (13) heard)
5
40-426 D375A-6
(01)
DRAFT
Circuit diagram related to torque converter inlet pressure sensor
D375A-6 40-427
(01)
DRAFT
Failure code [DHT7KA] T/C out-pressure sensor: Disconnection

Action code Failure code Torque converter outlet pressure sensor: Disconnection
Failure
E02 DHT7KA (Power train controller system)
Detail of failure q Signal voltage of torque converter outlet pressure sensor is below 0.2 V.
Action of con-
troller
Problem on q No hydraulic pressure can be monitored at torque converter outlet.
q Signal voltage of torque converter outlet pressure sensor can be checked with monitoring function.
Related infor-
(Code 32604: Torque converter outlet pressure sensor voltage)
mation

Defective power supply sys- 2. Disconnect connector TOP and connect T-adapter to female side.
1
tem 3. Turn starting switch ON position.
Between TOP (female) (B) and (A) Power supply Voltage 20 – 30 V
2. Insert T-adapter into connector TOP.
Defective torque converter out- 3. Turn starting switch ON position.
2 let pressure sensor (internal a If power supply voltage is normal and sensor output voltage is abnormal (below
failure) or ground fault 0.5 V), internal disconnection and ground fault cannot be identified. In this case,
go to cause 4. If check result of cause 4 is normal, torque converter outlet pres-
sure sensor is defective.
Between TOP (female) (C) and (A) Sensor output Voltage 0.5 – 4.5 V
2. Disconnect connectors PTCN1 and TOP, and connect T-adapters to female
side of them.
a If power supply voltage in checks on cause 1 is
Disconnection in wiring har- normal, this check is not required.
Between PTCN1 (female) (16) and TOP (female)
3 (Disconnection in wiring or (B)
defective contact in connector) a If power supply voltage in checks on cause 1 is
normal, this check is not required.
(A)
(C)
2. Disconnect connectors PTCN1 and TOP, and connect T-adapter to female side
Ground fault of wiring harness of either of them.
4
(Contact with ground circuit) Between PTCN1 (female) (7) and (21), or between
TOP (female) (C) and (A)
between TOP (female) (C) and ground
5
40-428 D375A-6
(01)
DRAFT
Circuit diagram related to torque converter outlet pressure sensor
D375A-6 40-429
(01)
DRAFT
Failure code [DHT7KB] T/C out-pressure sensor: Short circuit

Action code Failure code Torque converter outlet pressure sensor: short circuit
Failure
E02 DHT7KB (Power train controller system)
Detail of fail-
q Signal voltage of torque converter outlet pressure sensor is above 4.7 V.
ure
Action of con-
troller
Problem on q No hydraulic pressure can be monitored at torque converter outlet.
q Signal voltage of torque converter outlet pressure sensor can be checked with monitoring function.
(Code 32604: Torque converter outlet pressure sensor voltage)
Related infor-
mation
tion,failure code [DHT7KA ] is displayed.

Defective sensor power sup- 2. Disconnect connector TOP and connect T-adapter to female side.
1
ply system 3. Turn starting switch to ON position.
Between TOP (female) (B) and (A) Power supply Voltage 20 – 30 V
2. Disconnect connector TOP.
2 outlet pressure sensor (inter- 3. Turn starting switch to ON position.
nal failure) or ground fault If failure code [DHT7KB] is not displayed, torque converter outlet pressure sensor
is defective.(If failure code [DHT7KB] is still displayed, it shows that wiring harness
or power train controller is defective.)
2. Disconnect connector TOP and connect T-adapter to female side.
3 (Contact with 24 V circuit)
Between TOP (female) (C) and (A) or ground Voltage Max. 1 V
2. Disconnect connectors PTCN1 and TOP, and connect T-adapter to female side
4 Short circuit in wiring harness of PTCN1.
Between PTCN 1 (female) (7) and each pin other No continuity (No sound is
than (7) heard)
5
40-430 D375A-6
(01)
DRAFT
Circuit diagram related to torque converter outlet pressure sensor
D375A-6 40-431
(01)
DRAFT
Failure code [DK10KA] Fuel control Dial: Disconnection

Action code Failure code Fuel control Dial: Disconnection
Failure
E03 DK10KA (Power train controller system)
Detail of failure q Signal voltage of fuel control dial is below 0.5 V.
Action of con- q Continues control with signal of decelerator pedal potentiometer.
Problem on q Once machine stops, engine speed is limited to medium (half).
machine q Once machine stops, travel is limited to F1 and R1.
q Signal voltage of fuel control dial signal can be checked with monitoring function.
Related infor-
(Code: 03000 Fuel Dial Sensor)
mation

2. Disconnect connector DIAL and connect T-adapter to female side.
supply system
Between DIAL (female) (1) and
Power supply Voltage 4.5 – 5.5 V
(3)
2. Disconnect connector DIAL and connect T-adapter to male side.
Defective fuel dial 3. Turn starting switch to ON position.
2 (Internal disconnection or 4. Rotate fuel control dial and troubleshoot.
ground fault) Between DIAL (male) (1) and (3) Resistance Approx. 5 Ω
Between DIAL (male) (2) and (3) Resistance 0.5 - 4.5 kΩ
Between DIAL(male) (2) and ground Resistance Min. 1 MΩ
2. Disconnect connectors PTCN1, TL1 and BRK, and connect T-adapter to female
side of PTCN1
Disconnection or short cir- a Resistance is same as table in cause 2.
3
cuit in wiring harness a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is be-
low 1 Ω, wiring harness has short circuit.
Between PTCN1 (female) (8) and (21) Resistance 0.5 - 4.5 kΩ
2. Disconnect connectors PTCN1 and DIAL, and connect T-adapters to female side
of them.
a If power supply voltage in cause 1 or check re-
sult of cause 3 is normal, this check is not re-
quired. Resistance Max. 1 Ω
Disconnection in wiring har- Between PTCN1 (female) (22) and DIAL(female)
ness (1)
4 a If power supply voltage in cause 1 or check re-
tive contact in connector) sult of cause 3 is normal, this check is not re-
Between PTCN1 (female) (21) and DIAL (female)
(3)
a If check result of cause 3 is normal, this check
is not required.
Between PTCN1 (female) (8) and DIAL (female)
(2)
Ground fault of wiring har- 2. Disconnect connectors PTCN1 and DIAL, and connect T-adapter to female side of
5
(Contact with ground cir- PTCN1 (female) (8) and (21), or between DIAL
PTCN1 (female) (8) and ground , or between
DIAL (female) (2) and ground
40-432 D375A-6
(01)
DRAFT
troller
4. Rotate fuel control dial and troubleshoot.
PTCN1 (8) and (21) Voltage 0.5 – 4.5 V
Circuit diagram related to fuel control dial
D375A-6 40-433
(01)
DRAFT
Failure code [DK10KB] Fuel control Dial: Short circuit

Action code Failure code Fuel control Dial: Short circuit
Failure
E03 DK10KB (Power train controller system)
Detail of failure q Signal voltage of fuel control dial is above 4.5 V.
Action of con- q Continues control with signal of decelerator pedal potentiometer..
q Signal voltage of fuel control dial signal can be checked with monitoring function.
Related infor-
(Code: 03000 Fuel Dial Sensor)
mation

Defective sensor 5 V power 2. Disconnect connector DIAL and connect T-adapter to female side.
1
supply system 3. Turn starting switch to ON position.
Between DIAL (female) (1) and (3) Power supply Voltage 4.5 – 5.5 V
Defective fuel dial 3. Turn starting switch to ON position.
2 (Internal disconnection or 4. Rotate fuel control dial and troubleshoot.
short circuit) Between DIAL (male) (1) and (3) Resistance Approx. 5 Ω
Hot short circuit in wiring
3 harness (Contact with 24 V
Between DIAL (female) (2) and (3) or ground Voltage Max. 1 V
2. Disconnect connectors PTCN1 and DIAL, and connect T-adapter to female side of
Short circuit in wiring har- PTCN1.
4
ness a Check with tester in continuity mode.
Between PTCN1 (female) (8) and each pin other No continuity (No sound is
than (8) heard)
troller
4. Rotate fuel control dial and troubleshoot.
PTCN1 (8) and (21) Voltage 0.5 – 4.5 V
40-434 D375A-6
(01)
DRAFT
Circuit diagram related to fuel control dial
D375A-6 40-435
(01)
DRAFT
Failure code [DK30KA] ST lever 1: Disconnection

Action code Failure code Steering potentiometer 1: Disconnection
Failure
Detail of failure q Signal voltage of PCCS lever steering potentiometer 1 (ST lever POT ) is below 0.5 V.
Action of con- q Continues control with signal of PCCS lever steering potentiometer 2 (ST lever POT 2).
q Signal voltage of PCCS lever steering potentiometer 1 can be checked with monitoring function.
Related infor- (Code: 50300 S/T Lever 1 Potentio)
mation q Method of reproducing failure code: Turn starting switch to ON position and Operate PCCS lever (in
steering direction))

2. Disconnect connector TL2 and connect T-adapter to female side.
supply system
Between TL2 (female) (5) and (8) Power sup-
ply
Defective PCCS lever 4. Operate PCCS lever (steering) and troubleshoot.
steering potentiometer 1 a If power supply voltage is normal and sensor output voltage is abnormal (0.5 V or
2 below), internal disconnection and ground fault cannot be identified. In this case,
ground fault go to cause 4.
If check result of cause 4 is normal, PCCS lever steering potentiometer 1 is defec-
tive.
Sensor out-
Between TL2 (female) (7) and (8) Voltage 0.96 – 4.04 V
put
2. Disconnect connectors PTCN1 and TL2, and connect T-adapters to female side of
them.
Disconnection in wiring har- a If power supply voltage in cause 1 is normal, this
3
ness check is not required. Resistance Max. 1 Ω
(Disconnection or defec- Between PTCN1 (female) (22) and TL2 (female) (5)
tive contact in connector) a If power supply voltage in cause 1 is normal, this
Between PTCN1 (female) (21) and TL2 (female) (8)
Ground fault of wiring har- 2. Disconnect connectors PTCN1 and TL2, and connect T-adapter to female side of
4
(Contact with ground cir- Between PTCN1 (female) (2) and (21), or between
TL2 (female) (7) ground (8)
between TL2 (female) (7) and ground
troller
4. Operate PCCS lever (steering) and troubleshoot.
40-436 D375A-6
(01)
DRAFT
Circuit diagram related to steering potentiometer
D375A-6 40-437
(01)
DRAFT
Failure code [DK30KB] ST lever 1: Short circuit

Action code Failure code Steering potentiometer 1: Short circuit
Failure
Detail of failure q Signal voltage of PCCS lever steering potentiometer 1 (ST lever POT) is above 4.5 V.
Action of con- q Continues control with signal of PCCS lever steering potentiometer 2 (ST lever POT 2).
problem on q Once machine stops, engine speed is limited to medium (half).
mation q Method of reproducing failure code: Turn starting switch to ON position and operate PCCS lever (in
steering direction).

1 If failure code [DBE5KK] is also displayed, troubleshoot it first.
supply system
2. Disconnect connector TL2.
Defective PCCS lever 3. Turn starting switch to ON position.
steering potentiometer 1 4. Operate PCCS lever (steering) and troubleshoot.
2 (Internal disconnection) or If failure code [DK30KB] is not displayed, PCCS lever steering potentiometer is defec-
ground fault tive. (If failure code [DK30KB] is still displayed, wiring harness or power train controller
is defective.)
a Since connector TL2is disconnected, many failure codes are displayed. Ignore all
displayed failure codes other than [DK30KB].
Hot short in wiring harness 2. Disconnect connector TL2 and connect T-adapter to female side.
3
Between TL2 (female) (7) and (8) or ground Voltage Max. 1 V
2. Disconnect connectors PTCN1 and TL2, and connect T-adapter to female side of
4
Between PTCN1 (female) (2) and each pin other
than (2)
troller
40-438 D375A-6
(01)
DRAFT
D375A-6 40-439
(01)
DRAFT
Failure code [DK30KX] ST lever: Out of normal range
Failure code [DK30KX] ST lever: Out of normal range

Action code Failure code Steering potentiometers 1 and 2: Out of normal range
Failure
E04 DK30KX (Power train controller system)
q In PCCS lever steering potentiometer 1 (ST lever POT) and 2 (ST lever POT 2), either of failure codes
Detail of fail-
[DK30KA] and [DK30KB] and either of failure codes [DK31KA] and [DK31KB] occurred at the same
ure
time.
Action of con-
troller
machine q Once machine stops, it cannot travel at all.
q Signal voltage of PCCS lever steering potentiometer 1 and 2 can be checked with monitoring func-
tion.
mation (Code: 50301 S/T Lever 2 Potentio)
q Method of reproducing failure code: Turn starting switch to ON position and operate PCCS lever (in

Perform troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA] and [DK31KB].
Failure code [DK30KZ] ST lever: Disconnection or short circuit

Action code Failure code Steering potentiometer: Abnormal at key ON
Failure
E04 DK30KZ (Power train controller system)
q In PCCS lever steering potentiometer 1 (ST lever POT) and 2 (ST lever POT 2), when starting switch
Detail of failure is turned ON, only either side is abnormal and then either of failure codes[DK30KA] and [DK30KB]
and either of failure codes [DK31KA] and [DK31KB] occurred at the same time.
Action of con-
troller
machine q Once machine is stopped, it cannot travel at all.
q Signal voltage of PCCS lever steering potentiometer 1 and 2 can be checked with monitoring func-
tion.
mation (Code: 50301 S/T Lever 2 Potentio)

Perform troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA]and [DK31KB].
40-440 D375A-6
(01)
DRAFT
Failure code [DK30L8] ST lever: Signal mismatch
Failure code [DK30L8] ST lever: Signal mismatch

Action code Failure code Steering potentiometer: Signal mismatch
Failure
E03 DK30L8 (Power train controller system)
q In PCCS lever steering potentiometer 1 (ST lever POT)and 2 (ST lever POT 2), total of both signal
Detail of failure
voltages is below 4.41 V or above 5.59 V.
q Continues control with signal of normal one of PCCS lever steering potentiometer 1 (ST lever POT)or
Action of con-
2 (ST lever POT 2).
troller
q Signal voltage of PCCS lever steering potentiometer can be checked with monitoring function.
(Code: 50300 S/T Lever 1 Potentio)
Related infor-
(Code: 50301 S/T Lever 2 Potentio)
mation

D375A-6 40-441
(01)
DRAFT

Action code Failure code Steering potentiometer 2: Disconnection
Failure
Detail of failure q Signal voltage of PCCS lever steering potentiometer 2 (ST lever POT 2) is below 0.5 V.
Action of con- q Continues control with signal of PCCS lever steering potentiometer 1 (ST lever POT).

2. Disconnect connector TL2 and connect T-adapter to female side.
supply system
Power sup-
ply
Defective PCCS lever 4. Operate PCCS lever (steering) and troubleshoot.
steering potentiometer 2 a If power supply voltage is normal and sensor output voltage is abnormal (below 0.5
2 V), internal disconnection and ground fault cannot be identified. In this case, go to
ground fault cause 4.
If check result of cause 4 is normal, PCCS lever steering potentiometer 2 is defec-
tive.
Sensor out-
put
them.
Disconnection in wiring har- a If power supply voltage in cause 1 is normal, this check
3
ness is not required. Resistance Max. 1 Ω
tive contact in connector) a If power supply voltage in cause 1 is normal, this check
is not required. Resistance Max. 1 Ω
Between PTCN1 (female) (21) and TL2 (female)(8)
Ground fault of wiring har- 2. Disconnect connectors PTCN1 andTL2, and connect T-adapter to female side of
4
(Contact with ground cir- Between PTCN1 (female) (19) and (21) , or between TL2
Between PTCN1 (female) (19) and ground , or between
TL2 (female) (6) and ground
5 2. Insert T-adapter into connector PTCN1
troller
Between PTCN1(19) and (21) Voltage 0.96 – 4.04 V
40-442 D375A-6
(01)
DRAFT
D375A-6 40-443
(01)
DRAFT

Action code Failure code Steering potentiometer 2: Short circuit
Failure
Detail of failure q Signal voltage of PCCS lever steering potentiometer 2 (ST lever POT 2) is above 4.5 V.
Action of con- q Continues control with signal of PCCS lever steering potentiometer 1 (ST lever POT).

supply system
Defective PCCS lever 3. Turn starting switch to ON position.
steering potentiometer 2 4. Operate PCCS lever (steering) and troubleshoot.
2
(Internal disconnection) or If failure code [DK31KB] is not displayed, PCCS lever steering potentiometer is defec-
ground fault tive.( If failure code [DK31KB] is still displayed, wiring harness or power train controller
is defective.)
a Since connector TL2 is disconnected, many failure codes are displayed.Ignore all
displayed failure codes other than [DK31KB]
Hot short of wiring harness 2. Disconnect connectors TL2 and connect T-adapter to female side.
3
4
Between PTCN1 (female) (19) and each pin other No continuity (No sound is heard)
than (19)
troller
40-444 D375A-6
(01)
DRAFT
D375A-6 40-445
(01)
DRAFT
Failure code [DK40KA] Brake potentiometer: Disconnection

Action code Failure code Brake potentiometer: Disconnection
Failure
Detail of failure q Signal voltage of brake pedal potentiometer is below 0.5 V.
Action of con-
troller
Problem on q travel is limited to F1 and R1.
machine q Once machine stops, engine speed is limited to medium (half).
q Signal voltage of brake pedal potentiometer can be checked with monitoring function.
Related infor-
(Code: 50400 Brake Pedal Potentio)
mation
q Method of reproducing failure code: Turn starting switch to ON position and operate brake pedal.

If failure code [DBE5KK]is also displayed, troubleshoot it first.
2. Disconnect connector BRK and connect T-adapter to female side.
Defective sensor 5 V
power supply system
Power
Between BRK (female) (C) and (A) Voltage 4.5 – 5.5 V
supply
2. Disconnect connector BRK and connect T-adapter to male side.
Defective brake pedal 3. Turn starting switch to ON position.
potentiometer 4. Depress brake pedal and troubleshoot.
2
(Internal disconnection or Between BRK (male) (C) and (A) Resistance Approx. 5 kΩ
ground fault) Between BRK (male) (A) and (B) Resistance 0.25 - 7.0 kΩ
Between BRK (male) (B) and (C) Resistance 0.25 - 7.0 kΩ
Between BRK (male) B)and ground Resistance Min. 1 MΩ
2. Disconnect connectors PCTN1 and TL1, and connect T-adapters to female side of
them PTCN1.
Disconnection or short cir- a Resistance is same as table in cause 2.
3
Between PTCN1 (female) (22) and (21) Resistance Approx. 2 kΩ
Between PTCN1 (female) (3) and (21) Resistance 0.2 - 1.8 kΩ
2. Disconnect connectors PTCN1 and BRK, and connect T-adapters to female side of
them.
a If power supply voltage in cause 1 or check re-
sult of cause 3 is normal, this check is not re-
Disconnection in wiring Between PTCN1 (female) (21) and BRK (female)
harness (A)
4
(Disconnection or defec- a If power supply voltage in cause 1 or check re-
tive contact in connector) sult of cause 3 is normal, this check is not re-
Between PTCN1 (female) (22) and BRK (female)
(C)
a If check result of cause 3 is normal, this check is
not required. Resistance Max. 1 Ω
Between PTCN1 (female) (3) and BRK (female) (B)
40-446 D375A-6
(01)
DRAFT
Circuit diagram related to brake potentiometer
D375A-6 40-447
(01)
DRAFT
Failure code [DK40KB] Brake potentiometer: Short circuit

Action code Failure code Brake potentiometer: Short circuit
Failure
Detail of fail-
q Signal voltage of brake pedal potentiometer is above 4.8 V.
ure
Action of con-
troller
Problem on q travel is limited to F1 and R1.
machine q Once machine stops, engine speed is limited to medium (half).
q Signal voltage of brake pedal potentiometer can be checked with monitoring function.
Related infor-
(Code: 50400 Brake Pedal Potentio)
mation
q Method of reproducing failure code: Turn starting switch to ON position and operate brake pedal.

If failure code [DBE5KK]is also displayed, troubleshoot it first.
2. Disconnect connector BRK and connect T-adapter to female side.
supply system
Between BRK (female) (C) and
Power supply Voltage 4.5 – 5.5 V
(A)
2. Disconnect connector BRK and connect T-adapter to male side.
Defective brake pedal
potentiometer 3. Turn starting switch to ON position.
2
(Internal disconnection or 4. Depress brake pedal and troubleshoot.
short circuit) Between BRK (female) (C) and (A) Resistance Approx. 5 kΩ
Between BRK (female) (A) and (B) Resistance 0.25 - 7.0 kΩ
Between BRK (female) (B) and (C) Resistance 0.25 - 7.0 kΩ
Hot short in wiring harness 2. Disconnect connector BRK and connect T-adapter to male side.
3
Between BRK (female) (B) and (A) or ground Voltage Max. 1 V
2. Disconnect connector PTCN1 and BRK , and connect T-adapter to female side of
4
than (3)
troller
4. Depress brake pedal and troubleshoot.
Between PTCN1(3) and (21) Voltage 0.5 – 4.5 V
40-448 D375A-6
(01)
DRAFT
Circuit diagram related to brake potentiometer
D375A-6 40-449
(01)
DRAFT
Failure code [DK55KX] FR lever: Out of normal range
Failure code [DK55KX] FR lever: Out of normal range

Action code Failure code Front/Rear potentiometers 1 and 2: Out of normal range
Failure
E04 DK55KX (Power train controller system)
q In PCCS lever F-R potentiometer 1 (F/R lever 3) and 2 (F/R lever 4), either of failure codes [DK56KA]
Detail of failure
and [DK56KB] and either of failure codes [DK57KA] and [DK57KB]occurred at the same time.
Action of con-
troller
q Signal voltage of PCCS lever F-R potentiometer can be checked with monitoring function.
(Code: 50200 T/M Lever 1 Potentio)
Related infor-
mation
F-R direction)

Failure code [DK55KZ] FR lever: Disconnection or short circuit

Action code Failure code Front/Rear potentiometer: Abnormal at key ON
Failure
E04 DK55KZ (Power train controller system)
q In PCCS lever F-R potentiometer 1 (F/R lever 3) and 2 (F/R lever 4), when starting switch is turned
Detail of fail-
to ON position, only either side is abnormal and then either of failure codes [DK56KA] and
ure
[DK56KB]and either of failure codes [DK57KA] and [DK57KB] occurred at the same time.
Action of con-
troller
machine q Once machine stops, it cannot travel at all.
Related infor-
mation
F-R direction)

40-450 D375A-6
(01)
DRAFT
Failure code [DK55L8] FR lever: Signal mismatch
Failure code [DK55L8] FR lever: Signal mismatch

Action code Failure code Front/Rear potentiometer: Signal mismatch
Failure
E03 DK55L8 (Power train controller system)
q In PCCS lever F-R potentiometer 1 (F/R lever 3) and 2 (F/R lever 4), total of both signal voltages is
Detail of failure
below 4.41 V or above 5.59 V.
Action of con- q Continues control with signal of normal one of PCCS lever F-R potentiometer 1 or 2.
Related infor-
mation
F-R direction)

Perform troubleshooting for failure codes [DK56KA], [DK56KB],[DK57KA] and [DK57KB].
D375A-6 40-451
(01)
DRAFT
Failure code [DK56KA] FR lever 1: Disconnection

Action code Failure code Front/Rear potentiometer 1: Disconnection
Failure
Detail of fail-
q Signal voltage of PCCS lever F-R potentiometer 1 (F/R lever 3) is below 0.5 V
ure
Action of con- q Continues control with signal of PCCS lever F-R potentiometer 2 (F/R lever 4).
q Signal voltage of PCCS lever F-R potentiometer 1 can be checked with monitoring function.
Related infor- (Code: 50200 T/M Lever 1 Potentio)
F-R direction).

Defective sensor 5 V power 2. Disconnect connector TL2 and connect T-adapter to female side.
1
Between TL2 (female) (4) and (1) Power supply Voltage 4.5 – 5.5 V
Defective PCCS lever F-R 3. Turn starting switch ON position.
potentiometer 1 (Internal 4. Operate PCCS lever (F-R) and troubleshoot.
2 disconnection) or ground a If power supply voltage is normal and sensor output voltage is abnormal (below 0.5
fault V), internal disconnection and ground fault cannot be identified. In this case, go to
cause 4.
If check result of cause 4 is normal, PCCS lever F-R potentiometer 1 is defective.
Between TL2 (3) and (1) Sensor output Voltage 1.39 – 3.61 V
them.
3
tive contact in connector) a If power supply voltage in cause 1 is normal, this
Between PTCN1 (female) (21) and TL2 (female) (1)
4
TL2(female)(3) and (1)
Between PTCN1 (female) (20) and ground, or between
TL2 (female) (3) and ground
If cause is not found by the above checks, power train controller is defective
troller
4. Operate PCCS lever (F-R) and troubleshoot.
40-452 D375A-6
(01)
DRAFT
Circuit diagram related to Front/Rear potentiometer
D375A-6 40-453
(01)
DRAFT
Failure code [DK56KB] FR lever 1: Short circuit

Action code Failure code Front/Rear potentiometer 1: Short circuit
Failure
Detail of failure q Signal voltage of PCCS lever F-R potentiometer 1 (F/R lever 3) is above 4.5 V.
mation q Method of reproducing failure code: Turn the starting switch to ON position and operate the PCCS
lever (in F-R direction)

supply system
2. Disconnect connectors TL2.
Defective PCCS lever F-R 3. Turn starting switch to ON position.
potentiometer 1 4. Operate PCCS lever (F-R) and troubleshoot.
2
(Internal disconnection) or If failure code [DK56KB] is not displayed, PCCS lever steering potentiometer is defec-
ground fault tive. (This failure code is still displayed, wiring harness or power train controller is
defective.)
a Since connector TL2 is disconnected, many failure codes are displayed. Ignore all
Hot short of wiring harness 2. Disconnect connectors TL2, and connect T-adapter to female side.
3
4
than (20) heard)
troller
40-454 D375A-6
(01)
DRAFT
D375A-6 40-455
(01)
DRAFT

Action code Failure code Front/Rear potentiometer 2: Disconnection
Failure
Detail of failure q Signal voltage of PCCS lever F-R potentiometer 2 (F/R lever 4) is below 0.5 V.
F-R direction).

Defective sensor 5 V power 2. Disconnect connector TL2 and connect T-adapter to female side.
1
Between TL2 (female) (4) and (1) Power supply Voltage 4.5 – 5.5 V
Defective PCCS lever F-R 3. Turn starting switch ON position.
2 disconnection) or ground a If power supply voltage is normal and sensor output voltage is abnormal (below 0.5
fault V), internal disconnection and ground fault cannot be identified. In this case, go to
cause 4.
If check result of cause 4 is normal, PCCS lever F-R potentiometer 2 is defective.
Between TL2 (2) and (1) Sensor output Voltage 1.39 – 3.61 V
them.
3
tive contact in connector) a If power supply voltage on cause 1 is normal, this
Between PTCN1(female) (21) and TL2 (female) (1)
Between PTCN1(female) (14) and TL2 (female) (2) Resistance Max. 1 Ω
4
TL2 (female) (2) and (1)
Between (female) (14) and ground , or between TL2
(female) (2) and ground
troller
40-456 D375A-6
(01)
DRAFT
D375A-6 40-457
(01)
DRAFT

Action code Failure code Front/Rear potentiometer 2: Short circuit
Failure
Detail of failure q Signal voltage of PCCS lever F-R potentiometer 2 (F/R lever 4) is above 4.5 V.
F-R direction).

supply system
Defective PCCS lever F-R 3. Turn starting switch to ON position.
2 disconnection) or ground If failure code [DK57KB]is not displayed, PCCS lever F-R potentiometer is defective.
fault (If failure code [DK57KB] is still displayed, wiring harness or power train controller is
defective.)
a Since connector TL2 is disconnected, many failure codes are displayed. Ignore all
Hot short of wiring harness 2. Disconnect connector TL2 and connect T-adapter to female side.
3
4
than (14) heard)
troller
40-458 D375A-6
(01)
DRAFT
D375A-6 40-459
(01)
DRAFT
Failure code [DK60KA] Acceleration sensor: Disconnection

Action code Failure code Acceleration sensor: Disconnection
Failure
Detail of failure q Signal voltage of acceleration sensor is below 0.5 V.
Action of con-
q Turns shoe slip control(SSC) function OFF.
troller
Problem on
q Even if shoe slips, engine speed does not change.
machine
q Input (voltage) from acceleration sensor can be checked in moniitoring function.
Related infor-
(Code 60200 : Voltage of acceleration sensor)
mation

If failure code [DBB7KP] is also displayed, troubleshoot it first.
2. Disconnect connector SSA and connect T-adapter to female side.
Defective 5 V power supply
system
Power sup-
Between SSA(female)(1) and (3) Voltage 4.5 – 5.5 V
ply
2. Insert T-adapter into connectorSSA.
Defective acceleration sen- a If power supply voltage is normal and sensor output voltage is abnormal (below
2 sor sensor (Internal discon- 0.5 V), internal disconnection and ground fault cannot be identified. In this case,
nection) or ground fault go to cause 4. If check result of cause 4 is normal, acceleration sensor sensor is
defective.
Sensor out-
put
2. Disconnect connector PTCN1, PTCN3 and SSA, and connect T-adapters to
3
(Disconnection or defective Between PTCN3 (female) (34) and SSA (female) (1)
contact in connector) a If power supply voltage in cause 1 is normal, this
Between PTCN 1(female) (21) and SSA (female) (3)
Between PTCN1 (female) (1) and SSA (female) (2) Resistance Max. 1 Ω
Ground fault of wiring har- 2. Disconnect connector PTCN1, SSA, and connect T-adapter to female side of
(Contact with ground circuit) Between PTCN1 (female) (1) and (21), or between Resistance Max. 1 MΩ
SSA (female) (2) and (3)
Resistance Max. 1 MΩ
between SSA (female) (2) and ground
5
ler 2. Insert T-adapter into connector PTCN1.
40-460 D375A-6
(01)
DRAFT
Circuit diagram related to acceleration sensor
D375A-6 40-461
(01)
DRAFT
Failure code [DK60KB] Acceleration sensor: Short circuit

Action code Failure code Acceleration sensor: Short circuit
Failure
Detail of failure q Signal voltage of acceleration sensor is above 4.5 V.
Action of con-
q Turns shoe slip control(SSC) function OFF.
troller
Problem on
q Even if shoe slips, engine speed does not change.
machine
q Input (voltage) from acceleration sensor can be checked in moniitoring function.
Related infor-
(Code 60200 : Voltage of acceleration sensor)
mation

If failure code [DBB7KP] is also displayed, troubleshoot it first.
2. Disconnect connector SSA and connect T-adapter to female side.
supply system
Power sup-
ply
2. Disconnect connector SSA.
Defective acceleration sen-
2 sor sensor (Internal discon- 3. Turn starting switch to ON position.
nection) or ground fault If failure code [DK60KB] is not displayed , acceleration sensor is defective. (If failure
code [DK60KB] is still displayed, it shows that wiring harness or power train control-
ler is defective.)
Hot short in wiring harness 2. Disconnect connector SSA and connect T-adapter to female side.
3
Between SSA (female) (2) and (3) or ground Voltage Max. 1 V
2. Disconnect connector PTCN1 and SSA, and connect T-adapter to female side of
4 Short circuit in wiring harness PTCN1.
Between PTCN1 (female) (1) and (1) and each pin No continuity(No sound is
other than heard)
5
40-462 D375A-6
(01)
DRAFT
Circuit diagram related to acceleration sensor
D375A-6 40-463
(01)
DRAFT
Failure code [DKH1KA] Pitch angle sensor: Disconnection

Action code Failure code Pitch angle sensor: Disconnection
Failure
E03 DKH1KA (Power train controller system)
Detail of failure q Signal voltage of pitch angle sensor is below 0.15 V.
Action of con- q Cannot sense pitch angle of machine.
q Gearshift shock is made on slope or steering shock is made on level ground.
Problem on
machine
q State of pitch angle sensor signal can be checked with monitoring function.
Related infor- (Code: 60100 Pitch Angle Sensor)
q If sensor connector is disconnected in normal condition, this code is displayed.

Defective 24 V power supply 2. Disconnect connector PT1 and connect T-adapter to female side.
1
Between PT1 (female) (C) and (A) Power supply Voltage 20 – 30 V
2. Insert T-adapter into connector PT1.
Defective pitch angle sensor 3. Turn starting switch to ON position.
2 (Internal defect) or ground a If power supply voltage is normal and sensor output voltage is abnormal (below
fault 0.5 V), internal disconnection and ground fault cannot be identified. In this case,
go to cause 4.
If check result of cause 4 is normal, pitch angle sensor is defective.
Between PT1 (female) (B) and (A) Sensor output Voltage 0.24 – 4.76 V
2. Disconnect connectors PTCN1 and PT1, and connect T-adapters to female side
Disconnection in wiring har- of them.
ness a If power supply voltage in cause 1 is normal, this
3 (Disconnection in wiring or check is not required. Resistance Max. 1 Ω
defective contact in connec- Between PTCN3 (female) (16) and PT1 (female) (C)
a If power supply voltage in cause 1 is normal, this
tor)
Between PTCN1(female) (21) and PT1 (female) (A)
Between PTCN1 (female) (9) and PT1 (female) (B) Resistance Max. 1 Ω
Ground fault of wiring har- 2. Disconnect connectors PTCN1 and PT1, and connect T-adapters to female side
4 ness of either of them.
(Contact with ground circuit) Between PTCN1 (female) (9) and (21), or between
PT1 (female) (B) and (A)
Between PTCN1 (female) (9) and ground, or between
PT1 (female) (B) and ground
5
40-464 D375A-6
(01)
DRAFT
Circuit diagram related to pitch angle sensor
D375A-6 40-465
(01)
DRAFT
Failure code [DKH1KB] Pitch angle sensor: Short circuit

Action code Failure code Pitch angle sensor: Short circuit
Failure
E03 DKH1KB (Power train controller system)
Detail of failure q Signal voltage of pitch angle sensor is above 4.85 V.
Action of con- q Cannot sense pitch angle of machine.
q Gearshift shock is made on slope or steering shock is made on level ground.
Problem on
machine
q State of pitch angle sensor signal can be checked with monitoring function.
(Code: 60100 Pitch Angle Sensor)
Related infor-
mation
tion, failure code [DHT5KA] is displayed.

2. Disconnect connector PT1 and connect T-adapter to female side.
supply system
Power sup-
Between PT1 (female) (C) and (A) Voltage 20 – 30 V
ply
2. Disconnect connector PT1.
Defective pitch angle sensor 3. Turn starting switch to ON position.
2 If failure code [DKH1KB] is not displayed but [DKH1KA] of disconnection is dis-
(Internal defect)
played, pitch angle sensor is defective.
(If failure code [DKH1KB] is still displayed, it shows that wiring harness or power
train controller is defective.)
Hot short in wiring harness 2. Disconnect connector PT1 and connect T-adapter to female side.
3
Between PT1 (female) (B) and (A) or ground Voltage Max. 1 V
2. Disconnect connector PTCN1 and PT1, and connect T-adapter to female side of
Between PTCN1 (female ) (9) and each pin other No continuity (No sound is
than (9) heard)
5
40-466 D375A-6
(01)
DRAFT
Circuit diagram related to pitch angle sensor
D375A-6 40-467
(01)
DRAFT
Failure code [DLF1KA] T/C out-speed sensor: Disconnection
Failure code [DLF1KA] T/C out-speed sensor: Disconnection

Action code Failure code Torque converter oil temperature sensor disconnection
Failure
– DLF1KA (Power train controller system)
Detail of fail-
q No signal is input from torque converter output speed sensor.
ure
Action of con-
q Recognizes that torque converter output speed is 0 rpm .
troller
Problem on
q Torque converter output speed cannot be monitored
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position and travel (travel machine or
mation run tracks in the air with machine body put on the stands).

Defective torque converter 1. Turn starting switch to OFF position.
output speed sensor (Inter- 2. Disconnect connector C1 and connect T-adapter to male side.
1
nal disconnection or short Between TC1 (male) (1) and (2) Resistance Approx. 560 Ω
circuit) Between TC1 (male) (1) and ground Resistance Min. 1 MΩ
Disconnection or short circuit 2. Disconnect connector PTCN2 and connect T-adapter to female side.
2
in wiring harness a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is be-
ness 2. Disconnect connectors PTCN2 and TC1, and connect T-adapters to female side of
3
contact in connector) Between PTCN2 (female) (29) and TC1 (female) (2) Resistance Max. 1 Ω
Between PTCN2 (female) (20) and TC1 (female) (1) Resistance Max. 1 Ω
Hot short in wiring harness 2. Disconnect connector TC1 and connect T-adapter to female side.
4
Between TC1 (female) (1) and (2) Voltage 3–4V
Defective power train con- If cause is not found by above checks, power train controller may be defective. (Since
5
Circuit diagram related to torque converter output speed sensor
40-468 D375A-6
(01)
DRAFT
Failure code [DLM3KA] Fan rev. sensor: Disconnection
Failure code [DLM3KA] Fan rev. sensor: Disconnection

Action code Failure code Fan speed sensor: Disconnection
Failure
E02 DLM3KA (Work equipment controller system)
Detail of fail-
q No signal is input from fan speed sensor.
ure
Action of con-
q Recognizes that fan speed is 0 rpm.
troller
Problem on q Fan speed cannot be monitored.
machine q Fan PID control cannot be started.
q Fan speed can be checked with monitoring function.
Related infor-
(Code: 10007 Fan speed)
mation

Defective fan speed sensor
1 (Internal disconnection or 2. Disconnect connector FRV and connect T-adapter to male side.
short circuit) Between FRV (male) (1) and (2) Resistance Approx. 2 kΩ
Between FRV (male) (1) and ground Resistance Min. 1 MΩ
Disconnection or short circuit 2. Disconnect connector WECN2 and connect T-adapter to female side.
2
Between WECN2 (female) (40) and (39) Resistance Approx. 2 kΩ
ness 2. Disconnect connectors WECN2 and FRV, and connect T-adapters to female side
3
contact in connector) Between WECN2 (female) (39) and FRV (female) (2) Resistance Max. 1 Ω
Between WECN2 (female) (40) and FRV (female) (1) Resistance Max. 1 Ω
Hot short in wiring harness 2. Disconnect connector FRV and connect T-adapter to female side.
4
Between FRV (female) (1) and (2) Voltage 3–4V
Defective work equipment If cause is not found by above checks, work equipment controller may be defective.
5
Circuit diagram related to fan speed sensor
D375A-6 40-469
(01)
DRAFT
Failure code [DLM3MB] Fan control: Decline
Failure code [DLM3MB] Fan control: Decline

Action code Failure code Fan speed control function low
Failure
E02 DLM3MB (Work equipment controller system)
Detail of fail- q Difference between fan speed set value with work equipment controller and actual speed sensed by
ure fan speed sensor exceeds 100 rpm.
Action of con-
q Work equipment controller does not perform PID control on fan.
troller
Problem on
machine
q Fan speed set value with work equipment controller can be checked with monitoring function.
(Code: 10000 Fan speed command)
Related infor- q Fan speed sensed by fan speed sensor can be checked with monitoring function.
mation (Code: 10007 Fan speed)
q This code is conditioned that fan solenoid is normal and fan speed sensor is also normal (it means
normal electrically).

1 Defective hydraulic system Perform Testing and adjusting, "Testing fan hydraulic circuit".
40-470 D375A-6
(01)
DRAFT
Failure code [DLT3KA] T/M out-speed sensor: Disconnection
Failure code [DLT3KA] T/M out-speed sensor: Disconnection

Action code Failure code Transmission output speed sensor: Disconnection
Trouble
E01 DLT3KA (Power train controller system)
Detail of fail-
q No signal is input from transmission output speed sensor.
ure
Action of con-
q Recognizes that transmission output speed is 0 rpm.
troller
q Transmission output speed cannot be monitored.
Problem on q Traction force cannot be calculated.
machine q Automatic shift down function does not operate.
q Once machine stops, gear shift mode is limited to manual gear shift mode.
q Transmission output speed can be checked with monitoring function.
Related infor- (Code: 31400 T/M Out Speed)
mation q Method of reproducing failure code: Turn starting switch to ON position and travel (travel machine or
run tracks in the air with machine body put on the stands).

Defective transmission bevel 1. Turn starting switch to OFF position.
gear (output) speed sensor 2. Disconnect connector TM1 and connect T-adapter to male side.
1
(Internal disconnection or Between TM1 (male) (1) and (2) Resistance About 560 Ω
short circuit) Between TM1 (male) (1) and ground Resistance Min. 1 MΩ
2
Between PTCN2 (female) (39) and (30) Resistance About 560 Ω
ness 2. Disconnect connector PTCN2 and TM1, and connect T-adapters to female side of
3
contact in connector) Between PTCN2 (female) (39) and TM1 (female) (2) Resistance Max. 1 Ω
Between PTCN2 (female) (30) and TM1(female) (1) Resistance Max. 1 Ω
Hot short in wiring harness 2. Disconnect connector TM1 and connect T-adapter to female side.
4
Between TM1 (female) (1) and (2) Voltage 3–4V
6
Circuit diagram related to transmission output speed sensor
D375A-6 40-471
(01)
DRAFT
Failure code [DLT3KB] T/M out-speed sensor: Abnormal
Failure code [DLT3KB] T/M out-speed sensor: Abnormal

Action code Failure code Transmission output speed sensor: Disconnection
Failure
E01 DLT3KB (Power train controller system)
Detail of fail-
q No signal is input from transmission output speed sensor
ure
Action of con-
q Recognizes that transmission output speed is 0 rpm.
troller
q Transmission output speed cannot be monitored
Problem on q Traction force cannot be calculated.
machine q Automatic shift down function may not operate correctly.
q Once machine stops, gear shift mode is limited to manual gear shift mode.
q Transmission output speed sensor can be checked with moniitoring function.
Related infor- (Code: 31400 T/M Out Speed)
mation q Method of reproducing failure code: Turn starting switch to ON position and travel (travel machine or
run tracks in the air with machine body put on the stands).

Defective transmission bevel 1. Turn starting switch to OFF position.
gear (output) speed sensor 2. Disconnect connector TM1 and connect T-adapter to male side.
1
(Internal disconnection or Between TM1 (male) (1) and (2) Resistance Approx. 560 Ω
short circuit) Between TM1 (male)(1) and ground Resistance Min. 1 MΩ
2
Ground fault of wiring har- 2. Disconnect connector PTCN2 and TM1, and connect T-adapter to female side of
(Contact with ground circuit) Between PTCN2 (female) (30) or TM1 (female) (1)
and ground
Defective power train con- If cause is not found by the above checks, power train controller may be defective.
4
troller (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to transmission output speed sensor
40-472 D375A-6
(01)
DRAFT
Failure code [DW59KA] Blade dual selector SOL disconnection
Failure code [DW59KA] Blade dual selector SOL disconnection

Action code Failure code Dual tilt selector solenoid: Disconnection
Failure
E01 DW59KA (Work equipment controller system)
Detail of fail-
q Any current does not flow when power is output to the dual tilt selector solenoid circuit.
ure
Action of con-
q Stops output to dual tilt selector solenoid circuit.
troller
Problem on
q Dual tilt cannot be selector.
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position and operate dual tilt selector
mation switch.

Defective dual tilt selector 1. Turn starting switch to OFF position.
1 solenoid (Internal disconnec- 2. Disconnect connector SOL2 and connect T-adapter to male side.
tion) SOL2 (male) (1) and (2) Resistance 10 – 40 Ω
2
Between WECN3 (female) (7) and (23) Resistance 10 – 40 Ω
ness 2. Disconnect connector WECN3 and SOL2, and connect T-adapters to female side
3 (Disconnection in wiring or of them.
defective contact in connec- Between WECN3 (female) (7) and SOL2 (female) (1) Resistance Max. 1 Ω
tor) Between WECN3 (female) (23) and SOL2 (female)
(2)
Defective work equipment If cause is not found by the above checks, work equipmet controller may be defec-
4
controller tive. (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to dual tilt selector solenoid
D375A-6 40-473
(01)
DRAFT
Failure code [DW59KB] Blade dual selector SOL short circuit
Failure code [DW59KB] Blade dual selector SOL short circuit

Action code Failure code Dual tilt selector solenoid: Short circuit
Failure
E01 DW59KB (Work equipment controller system)
Detail of fail-
q Abnormal current flowed when power is output to dual tilt selector solenoid circuit.
ure
Action of con-
troller
Problem on
q Dual tilt cannot be selector.
machine
mation switch.

Defective dual tilt selector
1 solenoid (Internal short cir- 2. Disconnect connector OL2 and connect T-adapter to male side.
cuit) Between SOL2 (male) (1) and (2) Resistance 10 – 40 Ω
Between SOL2 (female) (1) and ground Resistance Min. 1 MΩ
Ground fault of wiring har- 2. Disconnect connector WECN3 and SOL2, and connect T-adapters to female side
2 ness of them.
(Contact with ground circuit) Between WECN3 (female) (7) or SOL2 (female) (1)
and ground
Short circuit in wiring har- 2. Disconnect connector WECN3 and SOL2, and connect T-adapters to female side
3 of either of them.
ness
Between WECN3 (female) (7) and (23) or between
SOL2 (female) (1) and (2)
Defective work equipment If cause is not found by the above checks, work equipment controller may be defec-
4
40-474 D375A-6
(01)
DRAFT
Failure code [DW59KY] Blade dual selector SOL hot short
Failure code [DW59KY] Blade dual selector SOL hot short

Action code Failure code Dual tilt selector solenoid: Short circuit
Failure
E01 DW59KY (Work equipment controller system)
Detail of fail-
q Current flows constantly to dual tilt selector solenoid circuit.
ure
Action of con-
troller
Problem on q Only tilt can be operated and dual tilt cannot be operated.
machine q Blade single tilt does not operate .
mation switch.

Defective dual tilt selector
1 solenoid (Internal short cir- 2. Disconnect connector SOL2 and connect T-adapter to male side.
cuit) Between SOL2 (male) (1) and (2) Resistance 10 – 40 Ω
Hot short in wiring harness 2. Disconnect connector SOL2 and connect T-adapter to female side.
2
Between SOL2 (female) (1) and ground Voltage Max. 1 V
2. Disconnect connectors WECN3 and SOL2, and connect T-adapter to female side
of WECN3.
than (7) heard.)
Short circuit in wiring har- 1. Turn starting switch to OFF position.
3
ness 2. Disconnect connectors WECN3, RB1 and SOL2, and connect T-adapter to female
side and male side of RB1 in 2 times.
No continuity (No sound is
Between RB1 (female) (3) and each pin other than (3)
heard.)
Between RB1 (male) (3) and each pin other than (3)
heard.)
4
D375A-6 40-475
(01)
DRAFT
Failure code [DW5AKA] Blade pitch selector SOL disconnection
Failure code [DW5AKA] Blade pitch selector SOL disconnection

Action code Failure code Work equipment pitch select solenoid: Disconnection
Failure
E02 DW5AKA (Work equipment controller system)
Detail of fail-
q No current flows when power is output to the work equipment pitch select solenoid circuit.
ure
Action of con-
q Stops output to pitch select solenoid circuit.
troller
Problem on
q Blade pitch cannot be changed.
machine
q Output condition (ON/OFF) to work equipment pitch select solenoid can be checked with monitoring
mode.
Related infor-
(Code 90803: Blade ON/OFF output 1 pitch selector sol.)
mation
q Method of reproducing failure code: Turn starting switch to ON position and operate pitch select
switch.

1 pitch select solenoid (Internal 2. Disconnect connector SOL1 and connect T-adapter to male side.
disconnection) Between SOL1 (male) (1) and (2) Resistance 10 – 40 Ω
Disconnection or short cir- 2. Disconnect connector WECN3 and connect T-adapter to female side.
2
ness 2. Disconnect connector WECN3 and SOL1, and connect T-adapters to female side
3 (Disconnection in wiring or of them.
Between WECN3 (female) (17) and SOL1 (female)
defective contact in connec- Resistance Max. 1 Ω
tor) (1)
Between WECN3 (female) (23) and SOL1 (female)
(2)
4
Circuit diagram related to work equipment pitch select solenoid
40-476 D375A-6
(01)
DRAFT
Failure code [DW5AKB] Blade pitch selector SOL short circuit
Failure code [DW5AKB] Blade pitch selector SOL short circuit

Action code Failure code Work equipment pitch select solenoid: Short circuit
Failure
E02 DW5AKB (Work equipment controller system)
Detail of fail-
q Abnormal current flowed when power was output to work equipment pitch select solenoid circuit.
ure
Action of con-
troller
Problem on
q Blade pitch cannot be changed.
machine
q Output condition (ON/OFF) to work equipment pitch select solenoid can be checked with monitoring
mode.
Related infor-
mation
switch.

short circuit) Between SOL1 (male) (1) and (2) Resistance 10 – 40 Ω
Between SOL1 (male) (1) and ground Resistance Min. 1 MΩ
Ground fault of wiring har- 2. Disconnect connector WECN3 and SOL1, and connect T-adapter to female side
(Contact with ground circuit) WECN3 (female) (17) or SOL1 (female) (1) and
ground
2. Disconnect connector WECN3 and SOL1, and connect T-adapter to female side
3 Short circuit in wiring harness of either of them.
SOL1 (female) (1) and (2)
4
D375A-6 40-477
(01)
DRAFT
Failure code [DW5AKY] Blade pitch selector SOL Short circuit
Failure code [DW5AKY] Blade pitch selector SOL Short circuit

Action code Failure code Work equipment pitch select solenoid: Short circuit
Failure
E02 DW5AKY (Work equipment controller system)
Detail of fail-
q Current flows constantly to work equipment pitch select solenoid circuit.
ure
Action of con-
troller
Problem on
q Only pitch operation can be changed and tilt operation cannot be changed.
machine
q Output condition (ON/OFF) to work equipment pitch select solenoid can be checked in monitoring
mode.
Related infor-
mation
switch.

short circuit) Between SOL1 (male) (1) and (2) Resistance 10 – 40 Ω
Hot short in wiring harness 2. Disconnect connector SOL1 and connect T-adapter to female side.
2
Between SOL1 (female) (1) and ground Voltage Max. 1 V
2. Disconnect connector WECN3 and SOL1 and connect T-adapter to female side
of WECN3.
Between WECN3 (female) (17) and each pin other No continuity(No sound is
than (17) heard)
3 Short circuit in wiring harness 1. Turn starting switch to OFF position.
2. Disconnect connectors WECN3, RB1 and SOL1, and connect T-adapter to
female side and male side of RB1 separately in 2 times
No continuity(No sound is
Between RB1 (female) (1) and each pin other than (1)
heard)
No continuity(No sound is
Between RB1 (male) (1) and each pin of (1)
heard)
4
40-478 D375A-6
(01)
DRAFT
Failure code [DW7BKA] Fan rev EPC: Disconnection
Failure code [DW7BKA] Fan rev EPC: Disconnection

Action code Failure code Fan reverse solenoid: Disconnection
Failure
E01 DW7BKA (Work equipment controller system)
Detail of failure q When power is output to fan reverse solenoid circuit, no current flows.
Action of con-
q Stops output to fan reverse solenoid circuit.
troller
Problem on
q Fan reverse function cannot be used.
machine
q Output condition to fan reverse solenoid can be checked with monitoring function.
Related infor-
(Code: 40983 W/E control SW output)
mation
q Method of reproducing failure code: Turn starting switch to ON position and select fan reverse mode.

Defective fan reverse sole- 1. Turn starting switch to OFF position.
1 noid 2. Disconnect connector FAR2 and connect T-adapter to male side.
(Internal disconnection) Between FAR2 (male) (1) and (2) Resistance 34 – 44 Ω
2
Between WECN3 (female) (18) amd (13) Resistance 34 – 44 Ω
Disconnection in wiring har- 2. Disconnect connector WECN3 and FAR2, and connect T-adapters to their female
ness sides.
3
(Disconnection or defective Between WECN3 (female) (18) and FAR2 (female)
contact in connector) Resistance Max. 1 Ω
(1)
Between WECN3 (female) (13) and FAR2 (female)
(2)
Hot short in wiring harness 2. Disconnect connector FAR2 and connect T-adapter to female side.
4
Between FAR2 (female) (1) and ground Voltage Max. 1 V
5
Circuit diagram related to fan reverse EPC
D375A-6 40-479
(01)
DRAFT
Failure code [DW7BKB] Fan rev EPC: Short circuit
Failure code [DW7BKB] Fan rev EPC: Short circuit

Action code Failure code Fan reverse solenoid: Short circuit
Failure
E01 DW7BKB (Work equipment controller system)
Detail of fail-
q When power was output to fan reverse solenoid circuit, abnormal current flowed.
ure
Action of con-
q Stops output to fan reverse solenoid circuit.
troller
Problem on
q Fan reverse function cannot be used.
machine
q Output condition of fan reverse solenoid can be checked with monitoring function.
Related infor-
(Code: 40983 W/E control SW output)
mation
q Method of reproducing failure code: Turn starting switch to ON position and select fan reverse mode.

Defective fan reverse sole- 2. Disconnect connector FAR2 and connect T-adapter to male side.
1
noid (Internal short circuit) Between FAR2 (male) (1) and (2) Resistance 34 – 44 Ω
Between FAR2 (female) (1) and ground Resistance Min. 1 MΩ
Ground fault of wiring har- 2. Disconnect connector WECN3 and FAR2, and connect T-adapter to female side
(Contact with GND circuit) Between WECN3 (female) (18) or FAR2 (female) (1)
or ground
Short circuit in wiring har- 2. Disconnect connector WECN3 and FAR2, and connect T-adapter to female side
ness
Between WECN3 (female) (18) and (13) or betwen
FAR2 (female) (1) and (2)
4
Circuit diagram related to fan reverse EPC
40-480 D375A-6
(01)
DRAFT
Failure code [DWN3KA] Ssp solenoid: Disconnection
Failure code [DWN3KA] Ssp solenoid: Disconnection

Action code Failure code Sudden stop prevention solenoid disconnection
Failure
E04 DWN3KA (Power train controller system)
Detail of failure q When power is output to sudden stop prevention solenoid circuit, no current flows.
Action of con- q Stops output to sudden stop prevention solenoid circuit.
troller q Restricts operations of engine, transmission, and brake.
Problem on q Once machine is stopped, engine speed is restricted to medium (half).
q Output condition to sudden stop prevention solenoid can be checked with monitoring function.
Related infor-
(Code: 31628 Sudden stop prevention valve current (F/B))
mation

Defective sudden stop pre- 1. Turn starting switch to OFF position.
1 vention solenoid 2. Disconnect connector STB and connect T-adapter to male side.
(Internal disconnection) Between STB (male) (1) and (2) Resistance 5 – 15 Ω
2
Between PTCN3 (female) (7) and (13) Resistance 5 – 15 Ω
ness
3 (Disconnection in wiring or 2. Disconnect connectors PTCN3 and STB, and connect T-adapters to their female
defective contact in connec- sides.
tor) Between PTCN3 (female) (7) and STB (female) (1) Resistance Max. 1 Ω
Between PTCN3 (female) (13) and STB (female) (2) Resistance Max. 1 Ω
Defective power train control- If cause is not found by above checks, power train controller may be defective.
4
ler (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to sudden stop prevention solenoid
D375A-6 40-481
(01)
DRAFT
Failure code [DWN3KB] Ssp solenoid: Short circuit

Action code Failure code Sudden stop prevention solenoid short circuit
Failure
E04 DWN3KB (Power train controller system)
Detail of fail-
q When power is output to sudden stop prevention solenoid circuit, abnormal current flowed.
ure
Problem on q Once machine stops, engine speed is restricted to medium (half).
q Output condition to sudden stop prevention solenoid can be checked with monitoring function.
Related infor-
mation
q Method of reproducing failure code: Turn starting switch tp ON position.

Defective sudden stop pre-
(Internal short circuit) Between STB (male) (1) and (2) Resistance 5 – 15 Ω
Between STB (female) (1) and ground Resistance Min. 1 MΩ
Ground fault of wiring har- 2. Disconnect connector PTCN3 and STB, and connect T-adapter to female side of
(Contact with ground circuit) Between PTCN3 (female) (7) or STB (female) (1) and
ground
2. Disconnect connector PTCN3 and STB, and connect T-adapter to female side of
Between PTCN3 (female) (7) and (13) ro between
STB (female) (1) and (2)
Defective power train control- If cause is not found by the above checks, work equipment controller may be defec-
4
ler tive. (Since failure is in it, troubleshooting cannot be performed.)
40-482 D375A-6
(01)
DRAFT
D375A-6 40-483
(01)
DRAFT
Failure code [DWN3KY] SSP solenoid: Short circuit

Action code Failure code Sudden stop prevention solenoid short circuit
Failure
E04 DWN3KY (Power train controller system)
Detail of fail-
q When power is output to sudden stop prevention solenoid circuit, current flows.
ure
q Emergency sudden stop prevention function does not work.
Problem on
q Once machine stops, engine speed is restricted to medium (half).
machine
q Once machine stops, machine does not travel.
q Output to sudden stop prevention solenoid can be checked with monitoring function
Related infor-
mation

Defective sudden stop pre-
(Internal defect) Between STB (male) (1) and (2) Resistance 5 – 15 Ω
Between STB (female) (1) and ground Resistance Min. 1 MΩ
Hot short in wiring harness 2. Disconnect connector STB and connect T-adapter to female side.
2
Between STB (female) (1) and ground Voltage Max. 1 V
2. Disconnect connector PTCN3 and STB, and connect T-adapter to female side of
PTCN3.
(7) heard)
2. Disconnect connectors PTCN3, STB, PL2 and PL2, and connect T-adapter to
female side and male side of RB1 separately in 2 times
Between PL2 (female) (23) and each pin other than No continuity (No sound is
(23) heard)
Between PL2 (male) (23) and each pin other than No continuity (No sound is
(23) heard)
Defective power train control- If cause is not found by the above checks, power train controller may be defective.
4
40-484 D375A-6
(01)
DRAFT
D375A-6 40-485
(01)
DRAFT
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection

Action code Failure code Fan pump solenoid 1: Disconnection
Failure
E01 DWN5KA (Work equipment controller system)
Detail of fail-
q When power is output to fan pump EPC solenoid 1 circuit (LPV90), no current flows.
ure
Action of con-
q Stops output to fan pump EPC solenoid 1 circuit(LPV90).
troller
Problem on
q The output of fan pump(LPV90) is always at maximum speed.
machine
q Output to fan pump EPC solenoid 1 can be checked with monitoring function.
Related infor-
(Code: 31624 Fan pump Solenoid (F/B))
mation

Defective fan pump solenoid 1. Turn starting switch to OFF position.
1 1 2. Disconnect connector FA1 and connect T-adapter to male side.
(Internal disconnection) Between FA1 (male) (1) and (2) Resistance 2 – 12 Ω
2
ness 2. Disconnect connector WECN3 and FA1, and connect T-adapters to their female
3
(Disconnection or defective sides.
contact in connector) Between WECN3 (female) (36) and FA1 (female) (1) Resistance Max. 1 Ω
Between WECN3 (female) (23) and FA1 (female) (2) Resistance Max. 1 Ω
4
Circuit diagram related to fan pump solenoid 1
40-486 D375A-6
(01)
DRAFT
Failure code [DWN5KB] Fan pump solenoid 1: Short circuit
Failure code [DWN5KB] Fan pump solenoid 1: Short circuit

Action code Failure code Fan pump solenoid 1: Short circuit
Failure
E01 DWN5KB (Work equipment controller system)
Detail of fail-
q When power was output to fan pump control solenoid 1 (LPV90)circuit, abnormal current flowed.
ure
Action of con-
q Stops output to fan pump control solenoid 1 (LPV90) circuit.
troller
Problem on
q Output of fan pump solenoid 1 (LPV90) is always at maximum speed.
machine
q Output condition to fan pump control solenoid 1 can be checked with monitoring function.
Related infor-
mation

Defective fan pump control
1 solenoid 1 2. Disconnect connector FA1 and connect T-adapter to male side.
Between FA1 (female) (1) and ground Resistance Min. 1 MΩ
Ground fault of wiring har- 2. Disconnect connector WECN3 and FA1, and connect T-adapter to female side of
(Contact with ground circuit) Between WECN3 (female) (36) or FA1 (female) (1)
and ground
2. Disconnect connector WECN3 and FA1, and connect T-adapter to female side of
FA1 (female) (1) and (2)
4
D375A-6 40-487
(01)
DRAFT
Failure code [DWN5KY] Fan pump solenoid 1: Short circuit

Action code Failure code Fan pump control solenoid 1: Short circuit
Failure
E02 DWN5KY (Work equipment controller system)
Detail of fail-
q Current flows constantly to fan pump EPC solenoid 1 (LPV90)circuit.
ure
Action of con-
q Stops output to fan pump EPC solenoid 1 circuit.
troller
Problem on q The output of fan pump (LPV90) is always at minimum speed.
machine q Machine may be overheat.
q Output condition to fan pump EPC solenoid 1 can be checked with monitoring function.
Related infor-
mation

Defective fan pump control
(Internal short circuit) Between FA1 (male) (1 and (2) Resistance 2–12 Ω
Hot short in wiring harness 2. Disconnect connector FA1 and connect T-adapter to female side.
2
Between FA1 (female) (1) and ground Voltage Max. 1 V
WECN3.
than (36) heard)
2. Disconnect connectors WECN3, FA1 and PL3, and connect T-adapter to female
side and male side of PL3 separately in 2 times
(21) heard)
(21) heard)
4
40-488 D375A-6
(01)
DRAFT
D375A-6 40-489
(01)
DRAFT
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection

Action code Failure code Fan pump solenoid 2: Disconnection
Failure
E01 DWNCKA (Work equipment controller system)
Detail of fail-
q When power is output to fan pump EPC solenoid 2 (LPV30) circuit, no current flows.
ure
Action of con-
troller
Problem on
q Fan pump solenoid 2 (LPV30) is always at maximum speed.
machine
Related infor-
(Code: 31634 Fan pump Solenoid 2 (F/B))
mation

Defective fan pump EPC 1. Turn starting switch to OFF position.
2
ness 2. Disconnect connector WECN3 and FA2, and connect T-adapters to their female
3
contact in connector) Between WECN3 (female) (26) and FA2 (female) (1) Resistance Max. 1 Ω
Between WECN3 (female) (23) and FA2 (female) (2) Resistance Max. 1 Ω
4
40-490 D375A-6
(01)
DRAFT
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit

Failure
E01 DWNCKB (Work equipment controller system)
Detail of fail-
q When power is output to fan pump EPC solenoid 2 (LPV30) circuit, abnormal current flows.
ure
Action of con-
troller
Problem on
q Outputto fan pump solenoid 2 (LPV30) is kept at maximum.
machine
Related infor-
mation

Defective fan pump EPC
Ground fault of wiring har- 2. Disconnect connector WECN3 and FA2, and connect T-adapter to female side of
(Contact with GND circuit) Between WECN3 (female) (26) or FA2 (female) (1)
and ground
FA2 (female) (1) and (2)
4
D375A-6 40-491
(01)
DRAFT
Failure code [DWNCKY] Fan pump solenoid 2: Short circuit

Failure
E02 DWNCKY (Work equipment controller system)
Detail of fail-
q Current flows always in fan pump EPC solenoid 2 (LPV30) circuit, no current flows.
ure
Action of con-
troller
Problem on q Fan pump (LPV30) output is always at minimum speed.
machine q Fan speed does not increase.
Related infor-
mation

Defective fan pump EPC
(Internal short circuit) Between FA2 (male) (1) and (2) Resistance 2 – 12 Ω
Hot short in wiring harness 2. Disconnect connector FA2 and connect T-adapter to female side.
2
Between FA2 (female) (1) and ground Voltage Max. 1 V
2. Disconnect connectors WECN3 and FA2, and connect T-adapter to female side
of WECN3.
than (26) heard.)
2. Disconnect connectors WECN3, PL3 and FA2, and connect T-adapter to female
side and male side of PL3 separately in 2 times.
(24) heard.)
(24) heard.)
4
40-492 D375A-6
(01)
DRAFT
D375A-6 40-493
(01)
DRAFT
Failure code [DXH1KA] Lock-up ECMV: Disconnection
Failure code [DXH1KA] Lock-up ECMV: Disconnection

Action code Failure code Lock-up solenoid: Disconnection
Failure
E02 DXH1KA (Power train controller system)
Detail of fail-
q When power is output to torque converter lockup clutch ECMV solenoid circuit, no current flows.
ure
Action of con-
q Stops output to torque converter lockup clutch ECMV solenoid circuit.
troller
Problem on
q Torque converter lockup function does not operate.
machine
q Output condition to torque converter lockup clutch ECMV solenoid can be checked with monitoring
mation (Code: 31642 L/U ECMV (F/B))
q Method of reproducing failure code: Start engine and travel reverse (in auto gearshift mode).

Defective lockup clutch 1. Turn starting switch to OFF position.
1 ECMV solenoid (Internal dis- 2. Disconnect connector SLUC and connect T-adapter to male side.
connection) Between SLUC (male) (1) and (2) Resistance 3 – 13 Ω
2
Between PTCN3 (female) (16) and (23) Resistance 3 – 13 Ω
ness
3 (Disconnection in wiring or 2. Disconnect connector PTCN3 and SLUC, and connect T-adapters to their female
tor) Between PTCN3 (female) (16) and SLUC (female) (1) Resistance Max. 1 Ω
Between PTCN3 (female) (23) and SLUC (female) (2) Resistance Max. 1 Ω
Defective power train control- If cause is not found by the above checks, power train controller may be defective.
4
Circuit diagram related to lock-up ECMV
40-494 D375A-6
(01)
DRAFT
Failure code [DXH1KB] Lock-up ECMV: Short circuit
Failure code [DXH1KB] Lock-up ECMV: Short circuit

Action code Failure code Lock-up solenoid: Short circuit
Failure
E02 DXH1KB (Power train controller system)
Detail of fail- q When power is output to torque converter lockup clutch ECMV solenoid circuit, abnormal current
ure flows.
Action of con-
q Stops output to torque converter lockup clutch ECMV solenoid circuit.
troller
Problem on
q Torque converter lockup function does not operate.
machine
q Output condition to torque converter lockup clutch ECMV solenoid can be checked with monitoring
mation (Code: 31642 L/U ECMV (F/B))
q Method of reproducing failure code: Start engine and travel reverse (in auto gearshift mode).

Between SLUC (female) (1) and ground Resistance Min. 1 MΩ
Ground fault of wiring har- 2. Disconnect connector PTCN3 and SLUC, and connect T-adapter to female side
(Contact with ground circuit) Between PTCN3 (female) (16) or SLUC (female) (1)
and ground
2. Disconnect connector PTCN3 and SLUC, and connect T-adapter to female side
3 Short circuit in wiring harness of either of them.
Between PTCN3 (female) (16) and (23)or between
SLUC (female) (1) and (2)
Defective power train control- If cause is not found by the above checks, work equipment controller may be defec-
4
ler tive. (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to lock-up solenoid
D375A-6 40-495
(01)
DRAFT
Failure code [DXH1KY] Lock-up ECMV: Short circuit

Action code Failure code Lock-up solenoid: Short circuit
Failure
E03 DXH1KY (Power train controller system)
Detail of fail-
q Current flows constantly to torque converter lockup clutch ECMV solenoid circuit.
ure
Action of con- q Stops output to torque converter lockup clutch ECMV solenoid circuit.
q Torque converter lockup function operates constantly.
Problem on q Engine may stall during travel.
machine q Once machine stops, engine speed is restricted to medium (half).
q Once machine stops, travel is restricted to F1 and R1.
q Output condition to lockup clutch ECMV solenoid can be checked with monitoring function.
Related infor- (Code: 31642 L/U ECMV (F/B))
mation q Method of reproducing failure code: Start engine and travel in auto gearshift mode (while lockup is in
operation).

Between SLUC (female) (1) and ground Resistance Min. 1 MΩ
Hot short in wiring harness 2. Disconnect connector SLUC and connect T-adapter to female side.
2
Between SLUC (female) (1) and ground Voltage Max. 1 V
2. Disconnect connector PTCN3 and SLUC, and connect T-adapter to female side of
PTCN3.
than (16) heard)
3
ness 2. Disconnect connector PTCN1 to 3 and SLUC, and connect T-adapter to female
side of PTCN1 to 3.
Between PTCN3 (female) (16) and each pin of No continuity (No sound is
PTCN1 (female) heard)
Defective power train con- If cause is not found by the above checks, work equipment controller may be defec-
4
troller tive. (Since failure is in it, troubleshooting cannot be performed.)
40-496 D375A-6
(01)
DRAFT
Circuit diagram related to lock-up solenoid
D375A-6 40-497
(01)
DRAFT
Failure code [DXH4KA] 1st clutch ECMV: Disconnection
Failure code [DXH4KA] 1st clutch ECMV: Disconnection

Action code Failure code 1st clutch ECMV: Disconnection
Failure
Detail of failure q When power is output to transmission 1st clutch ECMV solenoid circuit, no current flows.
Action of con- q Stops output to transmission 1st clutch ECMV solenoid circuit.
troller q Restricts operation of engine and transmission.
q Automatic gear shifting function does not operate.
Problem on
machine
q Output condition to 1st clutch ECMV solenoid can be checked with monitoring function.
Related infor-
(Code: 31612 T/M Clutch 1st ECMV (F/B))
mation
q Method of reproducing failure code: Start engine and set gear to F1 or R1.

Defective 1st clutch ECMV 1. Turn starting switch to OFF position.
1 solenoid (Internal discon- 2. Disconnect connector S1T and connect T-adapter to male side.
nection) Between S1T (male) (1) and (2) Resistance 3 - 13 Ω
2
cuit in wiring harness a If resistance is above 1 MΩ, wiring harness has disconnection.If resistance is be-
Between PTCN3 (female) (37) and (23) Resistance 3 - 13 Ω
ness 2. Disconnect connectors PTCN3 and S1T, and connect T-adapters to their female
3
contact in connector) Between PTCN3 (female) (37) and S1T (female) (1) Resistance Max. 1 Ω
Between PTCN3 (female) (23) and S1T (female) (2) Resistance Max. 1 Ω
4
40-498 D375A-6
(01)
DRAFT
Failure code [DXH4KB] 1st clutch ECMV: Short circuit
Failure code [DXH4KB] 1st clutch ECMV: Short circuit

Action code Failure code 1st clutch ECMV: Short circuit
Failure
Detail of failure q When power was output to transmission 1st clutch ECMV solenoid circuit, abnormal current flowed.
Problem on
machine
Related infor-
mation

1 solenoid (Internal short cir- 2. Disconnect connector S1T and connect T-adapter to male side.
cuit) Between S1T (male) (1) and (2) Resistance 3 – 13 Ω
Between S1T (female) (1) and ground Resistance Min. 1 MΩ
Ground fault of wiring har- 2. Disconnect connectors PTCN3 and S1T and connect T-adapter to female side of
(Contact with ground circuit) Between PTCN3 (female) (37) or S1T (female) (1)
and ground
Short circuit in wiring har- 2. Disconnect connectors PTCN3 and S1T and connect T-adapter to female side of
3 either of them.
ness
Between PTCN3 (female) (37) and (23), or between
S1T (female) (1) and (2)
4
D375A-6 40-499
(01)
DRAFT
Failure code [DXH4KY] 1st clutch ECMV: Short circuit

Action code Failure code 1st clutch ECMV: Short circuit
Failure
Detail of failure q Current flows constantly to transmission 1st clutch ECMV solenoid circuit.
Problem on
machine
Related infor-
mation

cuit) Between S1T (male) (1) and (2) Resistance 3 - 13 Ω
Hot short in wiring harness 2. Disconnect connector S1T and connect T-adapter to female side.
2
Between S1T (female) (1) and ground Voltage Max. 1 V
2. Disconnect connectors PTCN3 and S1T and connect T-adapter to female side of
PTCN3.
(37) heard)
3
ness 2. Disconnect connectors PTCN1 to PTCN3 and S1T, and connect T-adapters to
female sides of PTCN1 to PTCN3.
Between PTCN3 (female) (6) and each pin of PTCN1 No continuity (No sound is
(female) heard)
(female) heard)
4
40-500 D375A-6
(01)
DRAFT
D375A-6 40-501
(01)
DRAFT
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection

Action code Failure code 2nd clutch ECMV: Disconnection
Failure
Detail of failure q When power is output to transmission 2nd clutch ECMV solenoid circuit, no current flows.
Action of con- q Stops output to transmission 2nd clutch ECMV solenoid circuit.
Problem on
machine
q Output condition to 2nd clutch ECMV solenoid can be checked with monitoring function.
Related infor-
(Code: 31613 T/M Clutch 2nd ECMV (F/B))
mation

Defective 2nd clutch ECMV 1. Turn starting switch to OFF position.
nection)) Between S2T (male) (1) and (2) Resistance 3 - 13 Ω
2
3
4
Circuit diagram related to 2nd clutch ECMV
40-502 D375A-6
(01)
DRAFT
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit

Action code Failure code 2nd clutch ECMV: Short circuit
Failure
Detail of failure q When power was output to transmission 2nd clutch ECMV solenoid circuit, abnormal current flowed.
q Automatic gearshift system function does not operate.
Problem on
machine
Related infor-
(Code: 31613 T/M Clutch 2nd ECMV (F/B))
mation

Ground fault of wiring har- 2. Disconnect connectors PTCN3 and S2T and connect T-adapter to female side of
and ground
3 either of them.
ness
4
D375A-6 40-503
(01)
DRAFT
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit

Action code Failure code 2nd clutch ECMV: Short circuit
Failure
Detail of failure q Current flows constantly to transmission 2nd clutch ECMV solenoid circuit.
q Automatic gearshift system function does not operate.
Problem on
machine
q Once machine is stopped, travel is restricted to F2 and R2.
Related infor-
mation

Hot short in wiring harness 2. Disconnect connector S2T and connect T-adapter to female side.
2
Between S2T (female) (1) and ground Voltage Max. 1V
PTCN3.
than (28) heard)
3
female side of PTCN1 to PTCN3.
4
40-504 D375A-6
(01)
DRAFT
D375A-6 40-505
(01)
DRAFT
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection

Action code Failure code 3rd clutch ECMV: Disconnection
Failure
Detail of failure q When power is output to transmission 3rd clutch ECMV solenoid circuit, no current flows.
Action of con- q Stops output to transmission 3rd clutch ECMV solenoid circuit.
machine q Once machine stops, travel is restricted to F1 and R1.
q Output condition to 3rd clutch ECMV solenoid can be checked with monitoring function.
Related infor-
(Code: 31614 T/M Clutch 3rd ECMV (F/B))
mation

Defective 3rd clutch ECMV 1. Turn starting switch to OFF position.
nection) Between S3T (male) (1) and (2) Resistance 3 - 13 Ω
2
cuit in wiring harness a If resistance is above1 MΩ, wiring harness has disconnection. If resistance is
below1 Ω, wiring harness has short circuit.
3
4
Circuit diagram related to 3rd clutch ECMV
40-506 D375A-6
(01)
DRAFT
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit

Action code Failure code 3rd clutch ECMV: Short circuit
Failure
Detail of failure q When power was output to transmission 3rd clutch ECMV solenoid circuit, abnormal current flowed.
machine q Once machine stops, travel is restricted to F1 and R1.
Related infor-
mation

Defective 3rd clutch ECMV
Ground fault of wiring har- 2. Disconnect connectors PTCN3 and S3T, and connect T-adapter to female side of
and ground
3 either of them.
ness
4
D375A-6 40-507
(01)
DRAFT
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit

Action code Failure code 3rd clutch ECMV: Short circuit
Failure
Detail of fail-
q Current flows constantly to transmission 3rd clutch ECMV solenoid circuit.
ure
machine q Once machine is stopped, travel is restricted to F3 and R3.
Related infor-
mation

Defective 3rd clutch
1 ECMV solenoid (Internal 2. Disconnect connector S3T and connect T-adapter to male side.
short circuit) Between S3T (male) (1) and (2) Resistance 3 - 13 Ω
2. Disconnect connector S3T and connect T-adapter to female side.
2 ness
Between S3T (female) (1) and ground Voltage Max. 1 V
PTCN3.
than (38)
3
Between PTCN3 (female) (38) and each pin of
PTCN1 (female)
PTCN2 (female)
Defective power train If cause is not found by the above checks, power train controller may be defective.
4
40-508 D375A-6
(01)
DRAFT
D375A-6 40-509
(01)
DRAFT
Failure code [DXH7KA] R clutch ECMV: Disconnection
Failure code [DXH7KA] R clutch ECMV: Disconnection

Action code Failure code Reverse clutch ECMV: Disconnection
Failure
Detail of failure q When power is output to transmission R clutch ECMV solenoid circuit, no current flows.
Action of con- q Stops output to transmission R clutch ECMV solenoid circuit.
machine q Once machine stops, travel is restricted to F1.
q Output condition to R clutch ECMV solenoid can be checked with monitoring function.
Related infor-
(Code: 31616 T/M Clutch R ECMV (F/B))
mation
q Method of reproducing failure code: Start engine and set gear to R (Reverse).

Defective R clutch ECMV 1. Turn starting switch to OFF position.
1 solenoid (Internal discon- 2. Disconnect connector SRT and connect T-adapter to male side.
nection) Between SRT (male) (1) and (2) Resistance 3 - 13 Ω
2
ness 2. Disconnect connectors PTCN3 and SRT, and connect T-adapters to their female
3
contact in connector) Between PTCN3 (female) (27) and SRT (female) (1) Resistance Max. 1 Ω
Between PTCN3 (female) (3) and SRT (female) (2) Resistance Max. 1 Ω
4
40-510 D375A-6
(01)
DRAFT
Failure code [DXH7KB] R clutch ECMV: Short circuit
Failure code [DXH7KB] R clutch ECMV: Short circuit

Action code Failure code Reverse clutch ECMV: Short circuit
Failure
Detail of failure q When power was output to transmission R clutch ECMV solenoid circuit, abnormal current flowed.
machine q Once machine is stopped, travel is restricted to F1.
Related infor-
mation

Defective R clutch ECMV
1 solenoid (Internal short cir- 2. Disconnect connector SRT and connect T-adapter to male side.
cuit) Between SRT (male) (1) and (2) Resistance 3 - 13 Ω
Between SRT (female) (1) and ground Resistance Min. 1 MΩ
Ground fault of wiring har- 2. Disconnect connectors PTCN3 and SRT, and connect T-adapter to female side of
(Contact with ground circuit) Between PTCN3 (female) (27) or SRT (female) (1)
and ground
Short circuit in wiring har- 2. Disconnect connectors PTCN3 and SRT and connect T-adapter to female side of
3 either of them.
ness
SRT (female) (1) and (2)
4
D375A-6 40-511
(01)
DRAFT
Failure code [DXH7KY] R clutch ECMV: Short circuit

Action code Failure code Reverse clutch ECMV: Short circuit
Failure
Detail of failure q Current flows constantly to transmission R clutch ECMV solenoid circuit.
machine q Once machine stops, machine does not travel at all.
Related infor-
mation

Defective R clutch ECMV
1 solenoid (Internal short cir- 2. Disconnect connector SRT and connect T-adapter to male side.
cuit) Between SRT (male) (1) and (2) Resistance 3 - 13 Ω
Between SRT (female) (1) and ground Resistance Min. 1 MΩ
Hot short in wiring harness 2. Disconnect connector SRT and connect T-adapter to female side.
2
Between SRT (female) (1) and ground Voltage Max. 1 V
2. Disconnect connectors PTCN3 and SRT and connect T-adapter to female side of
PTCN3.
than (27) heard)
3
ness 2. Disconnect connectors PTCN1 to PTCN3 and SRT, and connect T-adapters to
4
40-512 D375A-6
(01)
DRAFT
D375A-6 40-513
(01)
DRAFT
Failure code [DXH8KA] F clutch ECMV: Disconnection
Failure code [DXH8KA] F clutch ECMV: Disconnection

Action code Failure code Forward clutch ECMV: Disconnection
Failure
Detail of failure q When power is output to transmission F clutch ECMV solenoid circuit, no current flows.
Action of con- q Stops output to transmission F clutch ECMV solenoid circuit.
machine q Once machine stops, travel is restricted to R1.
q Output condition to F clutch ECMV solenoid can be checked with monitoring function.
Related infor-
(Code: 31622 T/M Clutch F ECMV (F/B))
mation
q Method of reproducing failure code: Start engine and set gear to F (Forward).

Defective F clutch ECMV 1. Turn starting switch to OFF position.
1 solenoid (Internal discon- 2. Disconnect connector SFT and connect T-adapter to male side.
nection) Between SFT (male) (1) and (2) Resistance 3 - 13 Ω
2
ness 2. Disconnect connectors PTCN3 and SFT, and connect T-adapters to their female
3
contact in connector) Between PTCN3 (female) (17) and SFT (female) (1) Resistance Max. 1 Ω
Between PTCN3 (female) (13) and SFT (female) (2) Resistance Max. 1 Ω
4
40-514 D375A-6
(01)
DRAFT
Failure code [DXH8KB] F clutch ECMV: Short circuit
Failure code [DXH8KB] F clutch ECMV: Short circuit

Action code Failure code Forward clutch ECMV: Short circuit
Failure
Detail of failure q When power was output to transmission F clutch ECMV solenoid circuit, abnormal current flowed.
machine q Once machine is stopped, travel is restricted to R1.
Related infor-
mation

Defective F clutch ECMV
1 solenoid (Internal short cir- 2. Disconnect connector SFT and connect T-adapter to male side.
cuit) Between SFT (male) (1) and (2) Resistance 3 - 13 Ω
Between SFT (female) (1) and ground Resistance Min. 1 MΩ
Ground fault of wiring har- 2. Disconnect connectors PTCN3 and SFT and connect T-adapter to female side of
(Contact with ground circuit) Between PTCN3 (female) (17) or SFT (female) (1) and
ground
Short circuit in wiring har- 2. Disconnect connectors PTCN3 and F SET and connect T-adapter to female side
ness
SFT (female) (1) and (2)
4
D375A-6 40-515
(01)
DRAFT
Failure code [DXH8KY] F clutch ECMV: Short circuit

Action code Failure code Forward clutch ECMV: Short circuit
Failure
Detail of failure q Current flows constantly to transmission F clutch ECMV solenoid circuit.
machine q Once machine stops, machine does not travel at all.
Related infor-
mation

Defective F clutch ECMV
1 solenoid (Internal short cir- 2. Disconnect connector SFT and connect T-adapter to male side.
cuit) Between SFT (male) (1) and (2) Resistance 3 - 13 Ω
Between SFT (female) (1) and ground Resistance Min. 1 MΩ
Hot short in wiring harnesss 2. Disconnect connector SFT and connect T-adapter to female side.
2
Between SFT (female) (1) and ground Voltage Max. 1 V
2. Disconnect connectors PTCN3 and SFT and connect T-adapter to female side of
PTCN3.
than (17)
3
ness 2. Disconnect connectors PTCN1 to PTCN3 and SFT, and connect T-adapters to
PTCN1 (female)
PTCN2 (female)
4
40-516 D375A-6
(01)
DRAFT
D375A-6 40-517
(01)
DRAFT
Failure code [DXH9KA] Right clutch ECMV: Disconnection
Failure code [DXH9KA] Right clutch ECMV: Disconnection

Action code Failure code Right steering clutch ECMV disconnection
Failure
Detail of failure q When power is output to right steering clutch ECMV solenoid circuit, current does not flow.
Action of con- q Stops outputting to right steering clutch ECMV solenoid circuit.
q Machine cannot be steered to right.
Problem on
q Once machine is stopped, engine speed is restricted to medium (half).
machine
q Output condition (current) to right steering clutch ECMV solenoid can be checked with moniitoring
Related infor- funtion. (Code: 90601 Right steering clutch ECMV output current(F/B))
mation q Method of reproducing failure code: Turn starting switch to ON position, release parking brake lever
and operate PCCS lever (to steer to right).

Defective right steering 1. Turn starting switch to OFF position.
1 clutch ECMV solenoid (Inter- 2. Disconnect connector SRC and connect T-adapter to male side.
nal short circuit) Between SRC (male) (1) and (2) Resistance 3 - 13 Ω
2
Between SRC (female) (35) and (23) Resistance 3 - 13 Ω
ness
3 (Disconnection in wiring or 2. Disconnect connectors PTCN3 and SRC , and connect T-adapters to their female
tor) Between PTCN3 (female) (35) and SRC (female) (1) Resistance Max. 1 Ω
Between PTCN3 (female) (23) and SRC (female) (2) Resistance Max. 1 Ω
4
Circuit diagram related to right steering clutch ECMV
40-518 D375A-6
(01)
DRAFT
Failure code [DXH9KB] Right clutch ECMV: Short circuit
Failure code [DXH9KB] Right clutch ECMV: Short circuit

Action code Failure code Right steering clutch ECMV short circuit
Failure
Detail of failure q When power was output to right steering clutch solenoid circuit, abnormal current flowed.
Action of con- q Stops output to right steering clutch solenoid circuit.
q Machine cannot be steered to right.
Problem on
machine
q Output condition (current) to right steering clutch solenoid can be checked with moniitoring funtion.
Related infor- (Code: 90601 Right steering clutch ECMV output current (F/B))
and operate PCCS lever (to steer to right).

Defective rihht steering
nal short circuit) Between SRC (male) (1) and (2) Resistance 3 - 13 Ω
Between SRC (male) (1) and ground Resistance Min. 1 MΩ
Ground fault in wiring har- 2. Disconnect connectors PTCN3 and SRC and connect T-adapter to female side of
(Contact with ground circuit) Between PTCN3 (female) (35) or SRC (female) (1) and Resistance Min. 1 MΩ
ground
Short circuit in wiring har- 2. Disconnect connectors PTCN3 and SRC and connect T-adapter to female side of
3 either of them.
ness
SRC (female) (1) and (2)
4
D375A-6 40-519
(01)
DRAFT
Failure code [DXH9KY] Right clutch ECMV: Short circuit

Action code Failure code Right steering clutch ECMV short circuit
Failure
Detail of failure q Current flows constantly to right steering clutch ECMV solenoid circuit.
Action of con- q Stops outputting to right steering clutch solenoid circuit.
q Right clutch cannot be engaged (machine cannot travel straight).
Problem on
machine
q Once machine is stopped, it cannot travel at all.
q Output (current) condition to right steering clutch ECMV solenoid can be checked with monitoring
Related infor- function. (Code: 90601 Right steering clutch ECMV output current (F/B))
mation q Method of reproducing failure code: Turn starting switch to ON position and release parking brake
lever.

nal short circuit) Between SRC (male) (1) and (2) Resistance 3–13 Ω
Between SRC (male) (1) and ground Resistance Min. 1 MΩ
Hot short in wiring harness 2. Disconnect connector SRC and connect T-adapter to female side.
2
Between SRC (female) (1) and ground Voltage Max. 1V
2. Disconnect connectors PTCN3 and SRC, and connect T-adapter to female side of
PTCN3.
(35) heard.)
3
ness 2. Disconnect connectors PTCN1 to 3 and SRC, and connect T-adapter to female
sides of PTCN1 to 3.
(female) heard.)
(female) heard.)
4
40-520 D375A-6
(01)
DRAFT
D375A-6 40-521
(01)
DRAFT
Failure code [DXHAKA] Left clutch ECMV: Disconnection
Failure code [DXHAKA] Left clutch ECMV: Disconnection

Action code Failure code Left steering clutch ECMV disconnection
Failure
E03 DXHAKA (Power train controller system)
Detail of failure q When power is output to left steering clutch solenoid circuit, current does not flow.
Action of con- q Stops output to left steering clutch solenoid circuit.
q Machine cannot be steered to left.
Problem on
machine
q Output condition (current) to left steering clutch ECMV solenoid can be checked with moniitoring fun-
Related infor- tion. (Code: 90600 Left steering clutch ECMV output current (F/B))
and operate PCCS lever (to steer to left).

Defective left steering clutch 1. Turn starting switch to OFF position.
1 ECMV solenoid (Internal dis- 2. Disconnect connector SLC and connect T-adapter to male side.
connection) Between SLC (male) (1) and (2) Resistance 3 - 13 Ω
2
ness 2. Disconnect connectors PTCN3 and SLC, and connect T-adapters to their female
3
contact in connector) Between PTCN3 (female) (25) and SLC (female) (1) Resistance Max. 1 Ω
Between PTCN3 (female) (23) and SLC (female) (2) Resistance Max. 1 Ω
4
Circuit diagram related to left steering clutch ECMV
40-522 D375A-6
(01)
DRAFT
Failure code [DXHAKB] Left clutch ECMV: Short circuit
Failure code [DXHAKB] Left clutch ECMV: Short circuit

Action code Failure code Left steering clutch ECMV short circuit
Failure
E03 DXHAKB (Power train controller system)
Detail of failure q When signal was output to left steering clutch ECMV solenoid circuit, abnormal current flowed.
Action of con- q Stops outputting to left steering clutch ECMV solenoid circuit.
q Machine cannot be steered to left.
Problem on
machine
q Output condition (current) to left steering clutch ECMV solenoid can be checked with moniitoring fun-
Related infor- tion. (Code: 90600 Left steering clutch ECMV output current (F/B))
and operate PCCS lever (to steer to left).

Defective left steering clutch
1 ECMV solenoid (Internal 2. Disconnect connector SLC and connect T-adapter to male side.
short circuit) Between SLC (male) (1) and (2) Resistance 3 - 13 Ω
Between SLC (male) (1) and ground Resistance Min. 1 MΩ
Ground fault in wiring har- 2. Disconnect connectors PTCN3 and SLC, and connect T-adapter to female side of
(Contact with ground circuit) Between PTCN3 (female) (25) or SLC (female) (1) and
ground
Short circuit in wiring har- 2. Disconnect connectors PTCN3 and SLC and connect T-adapter to female side of
3 either of them.
ness
SLC (female) (1) and (2)
4
D375A-6 40-523
(01)
DRAFT
Failure code [DXHAKY] Left clutch ECMV: Short circuit

Action code Failure code Left steering clutch ECMV circuit short
Failure
E04 DXHAKY (Power train controller system)
Detail of failure q Current flows constantly to left steering clutch ECMV solenoid circuit.
Action of con- q Stops outputting to left steering clutch ECMV solenoid circuit.
q Left clutch cannot be engaged (machine cannot travel straight).
Problem on
machine
q Output condition (current) to left steering clutch solenoid can be checked with moniitoring funtion.
Related infor- (Code: 90600 Left steering clutch ECMV output current (F/B))
lever.

Defective left steering clutch
1 ECMV solenoid (Internal 2. Disconnect connector SRC and connect T-adapter to male side.
short circuit) Between SLC (male) (1) and (2) Resistance 3 – 13 Ω
Between SLC (female) (1) and ground Resistance Min. 1 MΩ
Hot short in wiring harness 2. Disconnect connector SRC and connect T-adapter to female side.
2
Between SLC (female) (1) and ground Voltage Max. 1V
2. Disconnect connectors PTCN3 and SLC and connect T-adapter to female side of
PTCN3.
(25) heard.)
3
ness 2. Disconnect connectors PTCN1 to PTCN3 and SLC, and connect T-adapters to
(female) heard.)
(female) heard.)
4
40-524 D375A-6
(01)
DRAFT
D375A-6 40-525
(01)
DRAFT
Failure code [DXHBKA] Right brake ECMV: Disconnection
Failure code [DXHBKA] Right brake ECMV: Disconnection

Action code Failure code Right brake ECMV disconnection
Failure
E04 DXHBKA (Power train controller system)
Detail of failure q When signal is output to right steering brake solenoid circuit, no current flows.
q Stops outputting to right steering brake ECMV solenoid circuit.
Action of con-
q Restricts operation of engine, transmission and brake.
troller
q Operates sudden stop prevention valve.
q Right brake keeps applied.
Problem on
machine
q Output condition (current) to right steering brake solenoid can be checked with moniitoring funtion.
Related infor- (Code: 31618 output current (F/B) of right steering brake ECMV)
lever.

Defective right steering 1. Turn starting switch to OFF position.
1 brake ECMV solenoid (Inter- 2. Disconnect connector SRB and connect T-adapter to male side.
nal disconnection) Between SRB (male) (1) and (2) Resistance 3 - 13 Ω
2
ness 2. Disconnect connectors PTCN3 and SRB, and connect T-adapters to their female
3
contact in connector) Between PTCN3 (female) (15) and SRB (female) (1) Resistance Max. 1 Ω
Between PTCN3 (female) (13) and SRB (female) (2) Resistance Max. 1 Ω
4
40-526 D375A-6
(01)
DRAFT
Failure code [DXHBKB] Right brake ECMV: Short circuit
Failure code [DXHBKB] Right brake ECMV: Short circuit

Action code Failure code Right brake ECMV short circuit
Failure
E04 DXHBKB (Power train controller system)
Detail of failure q When power was output to right steering brake ECMV solenoid circuit, abnormal current flowed.
Action of con-
q Restricts operation of engine, transmission, and brake.
troller
q Right brake keeps applied.
Problem on
machine
q Output condition (current) to right steering brake ECMV solenoid can be checked with moniitoring
Related infor- funtion. (Code: 31618 output current (F/B) of right steering brake ECMV)

1 brake ECMV solenoid (Inter- 2. Disconnect connector SRB and connect T-adapter to male side.
nal short circuit) Between SRB (male) (1) and (2) Resistance 3 - 13 Ω
Between SRB (male) (1) and ground Resistance Min. 1 MΩ
Ground fault in wiring har- 2. Disconnect connectors PTCN3 and SRB, and connect T-adapter to female side of
(Contact with ground circuit) Between PTCN3 (female) (15) or SRB (female) (1) and
ground
Short circuit in wiring har- 2. Disconnect connectors PTCN3 and SRB, and connect T-adapter to female side of
3 either of them.
ness
SRB (female) (1) and (2)
4
D375A-6 40-527
(01)
DRAFT
Failure code [DXHBKY] Right brake ECMV: Short circuit

Action code Failure code Right brake ECMV hot short
Failure
E04 DXHBKY (Power train controller system)
Detail of failure q When power is output to right steering brake ECMV solenoid circuit, no current flows.
Action of con-
troller
Problem that q Right brake does not operate.
appears on q Once machine is stopped, engine speed is restricted to medium (half).
q Output condition (current) to right steering brake ECMV solenoid can be checked with moniitoring
Related infor- funtion. (Code: 31618 output current (F/B) of right steering brake ECMV)
lever (Lock).

1 brake clutch ECMV solenoid 2. Disconnect connector SRB and connect T-adapter to male side.
(Internal short circuit) Between SRB (male) (1) and (2) Resistance 3 - 13 Ω
Between SRB (male) (1) and ground Resistance Min. 1 MΩ
Hot short in wiring harness 2. Disconnect connector SRB and connect T-adapter to female side.
2
Between SRB (female) (1) and ground Voltage Max. 1 V
2. Disconnect connectors PTCN3 and SRB and connect T-adapter to female side of
PTCN3.
than (15) heard)
3
ness 2. Disconnect connectors PTCN1 to PTCN3 and SRB, and connect T-adapters to
4
troller (Since falure is in it, troubleshooting cannot be performed.)
40-528 D375A-6
(01)
DRAFT
D375A-6 40-529
(01)
DRAFT
Failure code [DXHCKA] Left brake ECMV: Disconnection
Failure code [DXHCKA] Left brake ECMV: Disconnection

Action code Failure code Left brake ECMV disconnection
Failure
E04 DXHCKA (Power train controller system)
Detail of failure q When signal is output to left steering brake solenoid circuit, any current does not flow.
q Stops outputting to left steering brake ECMV solenoid circuit.
Action of con-
troller
Problem that q Left brake keeps applied.
appears on q Once machine is stopped, engine speed is restricted to medium (half).
q Output condition (current) to left steering brake ECMV solenoid can be checked with moniitoring fun-
Related infor- tion. (Code: 31619 output current (F/B)of left steering brake ECMV)

Defective left steering brake 1. Turn starting switch to OFF position.
1 ECMV solenoid (Internal dis- 2. Disconnect connector SLB and connect T-adapter to male side.
connection) Between SLB (male) (1) and (2) Resistance 3 - 13 Ω
2
ness 2. Disconnect connectors PTCN3 and SLB, and connect T-adapters to their female
3
contact in connector) Between PTCN3 (female) (5) and SLB (female) (1) Resistance Max. 1 Ω
Between PTCN3 (female) (13) and SLB (female) (2) Resistance Max. 1 Ω
4
40-530 D375A-6
(01)
DRAFT
Failure code [DXHCKB] Left brake ECMV: Short circuit
Failure code [DXHCKB] Left brake ECMV: Short circuit

Action code Failure code Left brake ECMV short circuit
Failure
E04 DXHCKB (Power train controller system)
Detail of failure q When power was output to left steering brake ECMV solenoid circuit, abnormal current flowed.
q Stops output to left steering brake solenoid circuit.
Action of con-
q Restricts operation of engine, transmission, and brake.
troller
q Left brake keeps applied.
Problem on
machine
q Output condition (current) to left steering brake solenoid can be checked with moniitoring funtion.
Related infor- (Code: 31619 output current (F/B) of left steering brake ECMV)
lever.

1 ECMV solenoid (Internal 2. Disconnect connector SLB and connect T-adapter to male side.
short circuit) Between SLB (male) (1) and (2) Resistance 3 - 13 Ω
Between SLB (male) (1) and ground Resistance Min. 1 MΩ
Ground fault in wiring har- 2. Disconnect connectors PTCN3 and SLB, and connect T-adapter to female side of
(Contact with ground circuit) Between PTCN3 (female) (5) or SLB (female) (1) and
ground
Short circuit in wiring har- 2. Disconnect connectors PTCN3 and SLB and connect T-adapter to female side of
3 either of them.
ness
Between PTCN3 (female) (5) and (13), or between SLB
4
D375A-6 40-531
(01)
DRAFT
Failure code [DXHCKY] Left brake ECMV: Short circuit

Action code Failure code Left brake ECMV hot short
Failure
E04 DXHCKY (Power train controller system)
Detail of failure q When power is output left steering brake solenoid circuit,current flows.
q Stops output to left steering brake ECMV solenoid circuit.
Action of con-
troller
q Left brake does not operate.
Problem on
machine
q Output condition (current) to left steering brake ECMV solenoid can be checked with moniitoring fun-
Related infor- tion. (Code: 31619 Left brake ECMV output current(F/B))
lever (Lock).

1 ECMV solenoid (Internal dis- 2. Disconnect connector SLB and connect T-adapter to male side.
connection) Between SLB (male) (1) and (2) Resistance 3 - 13 Ω
Between SLB (male) (1) and ground Resistance Min. 1 MΩ
Hot short in wiring harness 2. Disconnect connector SLB and connect T-adapter to female side.
2
Between SLB (female) (1) and ground Voltage Max. 1 V
2. Disconnect connectors PTCN3 and SLB, and connect T-adapter to female side of
PTCN3.
than (5) heard)
3
ness 2. Disconnect connectors PTCN1 to PTCN3 and SLB, and connect T-adapters to
4
40-532 D375A-6
(01)
DRAFT
D375A-6 40-533
(01)
DRAFT
Failure code [DXJBKA] S/C ECMV: Disconnection
Failure code [DXJBKA] S/C ECMV: Disconnection

Action code Failure code Stator clutch ECMV: Disconnection
Failure
E02 DXJBKA (Power train controller system)
Detail of failure q When power is output to transmission stator clutch ECMV solenoid circuit, no current flows.
Action of con- q Stops output to transmission stator clutch ECMV solenoid circuit.
troller q Restritcs operation of engine and transmission.
Problem on
q Engine speed may not be transmitted normally.
machine
q Output condition to stator clutch ECMV solenoid can be checked with monitoring function.
Related infor-
(Code: 90700 S/C ECMV output current (F/B))
mation
q Method of reproducing failure code: Start engine and travel.

Defective stator clutch 1. Turn starting switch to OFF position.
1 ECMV solenoid (Internal dis- 2. Disconnect connector SSTC and connect T-adapter to male side.
connection) Between SSTC (male) (1) and (2) Resistance 3 - 13 Ω
2
ness
3 (Disconnection in wiring or 2. Disconnect connectors PTCN3 and SSTC, and connect T-adapters to their female
tor) Between PTCN3 (female) (6) and SSTC (female) (1) Resistance Max. 1 Ω
Between PTCN3 (female) (3) and SSTC (female) (2) Resistance Max. 1 Ω
Defective transmission con- If cause is not found by above checks, power train controller may be defective. (Since
4
troller fialure is in it, troubleshooting cannot be performed.)
Circuit diagram related to stator clutch ECMV
40-534 D375A-6
(01)
DRAFT
Failure code [DXJBKB] S/C ECMV: Short circuit
Failure code [DXJBKB] S/C ECMV: Short circuit

Action code Failure code Stator clutch ECMV: Short circuit
Failure
E02 DXJBKB (Power train controller system)
Detail of failure q When power is output to stator clutch ECMV solenoid circuit, abnormal current flow.
Action of con- q Stops output to transmission stator clutch ECMV solenoid circuit.
Problem on
machine
Related infor-
mation
q Method of reproducing failure code: Start engine and travel.

1 ECMV solenoid (Internal 2. Disconnect connector SSTC and connect T-adapter to male side.
short circuit) Between SSTC (male) (1) and (2) Resistance 3 – 13 Ω
Between SSTC (female) (1) and ground Resistance Min. 1 MΩ
Ground fault of wiring har- 2. Disconnect connector PTCN3 and SSTC , and connect T-adapter to female side
(Contact with GND circuit) Between PTCN3 (female) (6) or SSTC (female) (1)
and ground
Short circuit in wiring har- 2. Disconnect connector PTCN3 and SSTC , and connect T-adapter to female side
ness
Between PTCN 3(female) (6) and (3) or between
SSTC (female) (1) and (2)
4
D375A-6 40-535
(01)
DRAFT
Failure code [DXJBKY] S/C ECMV: Short circuit

Action code Failure code Stator clutch ECMV: Short circuit
Failure
E02 DXJBKY (Power train controller system)
Detail of failure q When power is output to transmission 1st clutch ECMV solenoid circuit, current flows constantly.
Problem on
machine
Related infor-
mation

1 ECMV solenoid (Internal 2. Disconnect connector SSTC and connect T-adapter to male side.
short circuit) Between SSTC (male) (1) and (2) Resistance 3 – 13 Ω
Between SSTC (female) (1) and ground Resistance Min. 1 MΩ
Hot short in wiring harness 2. Disconnect connector SSTC and connect T-adapter to female side.
2
Between SSTC (female) (1) and ground Voltage Max. 1 V
2. Disconnect connector PTCN3 and SSTC , and connect T-adapter to female side
of PTCN3.
heard)
3
ness 2. Disconnect connector PTCN1 to 3 and SSTC , and connect T-adapters to female
sides of PTCN1 to 3.
(female) heard)
(female) heard)
4
40-536 D375A-6
(01)
DRAFT
D375A-6 40-537
(01)
DRAFT
Failure code [DY2HKA] Pre lub. motor: Disconnection

Action code Failure code Pre-lubricating motor disconnection
Failure
E02 DY2HKA (Power train controller system)
Detail of fail-
q After power train controller starts pre-lubrication, power is not supplied to pre-lubricating motor.
ure
Action of con-
q No particular action
troller
Problem on
q Engine does not operate (It operates in skip mode, however).
machine
q Whether pre-lubricating motor is operating can be checked with monitoring function.
Related infor-
(Code: 40910 PT controller SW input 2)
mation
q Primary side of pre-lubricating relay is checked with failure codes [D1EFKA] and [D1EFKB].

Defective circuit breaker If circuit breaker is operating, the circuit probably has ground fault. In this case, per-
1
(CBH1) form troubleshooting for cause 6 first.
Loose terminal or disconnec-
2 Check terminals of battery relay, preheater relay, pre-lubricating relay, pre-lubricating
tion at terminal
motor, etc.
2. Replace relay (PLUB) with another relay (e.g. backup alarm relay BKA).
3 Defective relay (PLUB)
If pre-lubrication is completed, original relay (PLUB) is defective.
2. Disconnect connector PLS.
4 Defective diode (PLS)
If pre-lubrication is completed, diode (PLS) is defective.
Defective pre-lubricating 2. Disconnect terminal PM1.
5
motor Between terminal PM1 (on pre-lubricating motor side)
Continuity
and ground
2. Insert T-adapter into connector PLUB.
3. If circuit breaker is turned OFF, reset it.
a If voltage is 0 V, wiring harness has disconnection or ground fault (If voltage is ab-
Disconnection in, or ground normal and check result of cause 8 is normal, wiring harness has disconnection).
6
fault in wiring harness Between PLUB (3) and ground Voltage 20 – 30 V
Between PLUB (5) and ground Voltage 20 – 30 V
Between PR1 and ground Voltage 20 – 30 V
Between PM1 and ground Voltage 20 – 30 V
Defective pre-lubricating If voltages at terminals PR1 and PR3 are normal and voltage at terminal PR2 is
7
relay abnormal as check result of cause 6, pre-lubricating relay is defective.
Ground fault in wiring har- 3. Disconnect terminal PR3.
8 ness 4. If circuit breaker is turned OFF, reset it.
(Contact with ground circuit) Between PTCN1 (female) (23) and ground Resistance Min. 1 MΩ
Between terminal PR1 and ground Resistance Min. 1 MΩ
Between terminal PR3 (on wiring harness side) and
ground
q Reference: Following shows standard values in normal condition.
Defective power train con- 1. Turn starting switch to OFF position.
9
troller 2. Insert T-adapter into connector PTCN1.
40-538 D375A-6
(01)
DRAFT
Circuit diagram related to pre-lubricating motor
D375A-6 40-539
(01)
DRAFT
Failure code [F@BBZL] ENG blow-by pressure high level
Failure code [F@BBZL] ENG blow-by pressure high level

Action code Failure code
Failure Engine blow-by pressure abnormally high level
– F@BBZL
Detail of failure q Engine blow-by pressure is higher than threshold value of 900 mmH2O {8.83 kPa}.
Action of con-
troller
Problem on
q If machine is used as it is, engine may be broken.
machine
Related infor- q Blow-by pressure can be checked with monitoring code 42801(kPa).
mation q The LED of the VHMS controller displays "n3" and "38" alternately and repeatedly.

q Check engine and then repair if necessary.
Abnormal increase of engine
1 q Check breather hose outlet for clogging with dirt, bend and fold, and then repair if
blow-by pressure
necessary.
Defective engine blow-by
2
pressure sensor Troubleshooting for failure codes [DHE5KB] and [DHE5KY].
40-540 D375A-6
(01)
DRAFT
Failure code [F@BYNR] F exhaust temp high level (2)
Failure code [F@BYNR] F exhaust temp high level (2)

Action code Failure code Front exhaust temperature abnormal increase (2)
Failure
– F@BYNR (VHMS controller system)
q Signal voltage of exhaust temperature sensor for No. 1, 2 and 3 cylinders (front side) increased and
VHMS controller detected temperature higher than exhaust temperature sensor limit line 2 for more
Detail of failure than 10 seconds.
(Exhaust gas temperature limit line 2: Straight line between 750 °C at rated output speed at minimum
and 800 °C at max. torque speed)
Action of con-
troller
Problem on
machine
Related infor- q Front exhaust temperature can be checked with monitoring code: 42610 (°C).

Abnormal increase of
front exhaust tempera-
1 Check the engine for abnormality. Correct, if any.
ture (When system is
normal)
Front exhaust tempera-
2 ture sensor system
defective Troubleshooting for failure codes "DGT5KA" and "DGT5KB".
Defective VHMS control-
3
ler
D375A-6 40-541
(01)
DRAFT
Failure code [F@BYNS] F exhaust temp high level (1)
Failure code [F@BYNS] F exhaust temp high level (1)

Action code Failure code Front exhaust temperature abnormal increase (1)
Failure
– F@BYNS (VHMS controller system)
q Signal voltage of exhaust temperature sensor for No. 1, 2 and 3 cylinders (front side)increased and
Detail of fail-
than 20 seconds.
ure
(Exhaust temperature limit line 1: Straight line between 700 °C at rated output speed and 750 °C at
maximum torque speed)
Action of con-
q Flashes warning lamp and turns on caution buzzer. (Function of monitor panel)
troller
Problem on
machine
Related infor- q Front exhaust temperature can be checked with monitoring code: 42610 (°C).
mation q VHMS controller LED indicates "n3" and "61" alternately and repeatedly.

Abnormal increase of front
1 exhaust temperature Check the engine for abnormality, Correct, if any.
Front exhaust tempera-
2 ture sensor system defec-
tive Troubleshooting for failure codes "DGT5KA" and "DGT5KB".
3
ler
40-542 D375A-6
(01)
DRAFT
Failure code [F@BZNR] R exhaust temp high level (2)
Failure code [F@BZNR] R exhaust temp high level (2)

Action code Failure code Rear exhaust temperature abnormal increase (2)
Failure
– F@BZNR (VHMS controller system)
q Signal voltage of exhaust temperature sensor for No. 4, 5 and 6 cylinders (rear side) increased and
Detail of fialure than 10 seconds.
Action of con-
troller
Problem on
machine
Related infor- q Rear exhaust temperature can be checked with monitoring code: 42611 (°C).

Abnormal increase of
1 rear exhaust temperature Check the engine for abnormality. Correct, if any.
Rear exhaust tempera-
2 ture sensor system
defective Troubleshooting for failure codess "DGT6KA" and "DGT6KB".
3
ler
D375A-6 40-543
(01)
DRAFT
Failure code [F@BZNS] R exhaust temp high level (1)
Failure code [F@BZNS] R exhaust temp high level (1)

Action code Failure code Rear exhaust temperature abnormal increase (1)
Failure
– F@BZNS (VHMS controller system)
q Signal voltage of exhaust temperature sensor for No. 4, 5 and 6 cylinders (rear side) increased and
Detail of fail-
than 20 seconds.
ure
Action of con-
troller
Problem on
machine
Related infor- q Rear exhaust temperature can be checked with monitoring code: 42611 (°C).

Abnormal increase of rear
1 exhaust temperature Check the engine for abnormality. Correct, if any.
Rear exhaust temperature
2
sensor system defective
Troubleshooting for failure codes "DGT6KA" and "DGT6KB".
3
ler
40-544 D375A-6
(01)
DRAFT
Troubleshooting of electrical system (E-mode)
Information contained in troubleshooting table

a Troubleshooting Table and Circuit Diagram Related collectively include the following information. Perform
troubleshooting work after fully grasping their contents.
Trouble Trouble which occurred in the machine
Related infor-
Information related to detected trouble or troubleshooting
mation
<Contents of description>
q Procedure
Possible causes a "Between A and B" means the measurement of voltage, resistance or others
between terminals A and B.
q Standard value in normal state to judge possible causes
q Remarks on judgment
<Troubles in wiring harness>
q Perform troubleshoot in following procedure in numerical order.
1 - defective q If the testing result shows abnormality, the cause described on the left column con-
forms.
q If it shows normal, and unless otherwise specified particularly, proceed to the next
step (cause).
q After correction of a single failure, check to see that this problem has been solved.
Then, start the next troubleshooting.
ness
2 <Troubles in wiring harness>
q Disconnection
Connector is connected imperfectly or wiring harness is broken.
q Ground fault
Wiring harness which is not connected to chassis ground circuit is in contact with
Ground fault of wiring har- chassis ground circuit.
3 ness q Hot short
(Contact with ground circuit) Wiring harness which is not connected to power source (24 V) circuit is in contact
with power source (24 V) circuit.
q Short circuit
Independent wiring harnesses are in contact with each other abnormally.
Hot short (Poor insulation of connector or others)
4 (Short circuit with 24 V cir- <Precautions for troubleshooting>
cuit) (1) Method of indicating connector No. and handling of Tadapter
Insert or connect T-adapter as explained below for troubleshooting, unless other-
wise specified.
q If connector No. has no marks of “male” and “female”, disconnect connector
and insert T-adapters in both male side and female side.
Short circuit in wiring har- q If connector No. has marks of “male” and “female”, disconnect connector
5
ness and connect T-adapter to only male side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (-) lead of tester as explained below for
troubleshooting, unless otherwise specified.
qConnect positive (+) lead to pin No. or wiring harness entered on front side.
qConnect negative (-) lead to pin No. or harness entered on rear side.
6 Defective controller
D375A-6 40-545
(01)
DRAFT

This is the excerpted circuit diagram related to trouble-
shooting
q The circuit diagram includes connector numbers and pin
numbers related to the trouble.
q Indication of "Connector No. & Pin No." from branched
or jointed position: The destination branching position or
source jointed position in the same wiring harness is
shown.
q Arrow (io): Roughly shows the location on the ma-
chine.
q NO: Normally Open
q NC: Normally Closed
40-546 D375A-6
(01)
DRAFT
E-1 Engine does not start (starting motor does not turn)
Trouble q The starting motor does not turn and accordingly the engine does not start.
q Since the engine start circuit has the neutral safety function, the engine does not start unless the
work equipment lock lever and parking brake lever are in the lock position and the travel lever is in
the neutral position.
q Before carrying out troubleshooting, check that no related failure code is displayed.
Related informa- (If the failure code
tion [D110KB][D130KA][D130KB][D190KA][D190KB][D1EFKA][D1EFKB][DD14KA][DD14KB]
[7RFAKA][7RFAKB][DDE2KA][DY2HKA] is displayed, troubleshoot them first.)
q In the case of "the battery relay does not make operating sound" when turning the starting switch
ON, perform E-1 also.
q If engine does not stop, replace engine holding relay.

Defective circuit breaker CB30 If CB30 or CB6 circuit breaker is turned ON, circuit probably has ground fault. In
1
or CB6 this case, perform troubleshooting for cause 16 first.
If fuse FS31-5 is broken, circuit probably has ground fault. In this case, trouble-
shoot cause 16 first.
Loose terminal or disconnec-
3 Check terminals of battery relay, alternator, starting motor, ground, ground 01,
tion at terminal
ground 11 etc.
Battery voltage Min. 24V
4 Insufficient battery capacity
Electrolyte specific gravity Min. 1.26
Defective parking lever switch
5 (internal defect or defective 2. Operate parking brake lever and troubleshoot.
Display of "P" on Free position Other than “P” is displayed.
adjustment)
monitor panel Lock position “P” is displayed.
Defective work equipment lock 2. Operate work equipment lock lever switch and troubleshoot.
lever switch Display of "Lock
6 Free position Symbol OFF
(internal defect or defective work equipment"
adjustment) symbol on monitor Lock position Symbol ON
panel
3. Disconnect connector KEY.
4. Turn starting switch to ON, OFF and START positions and troubleshoot.
Defective starting switch OFF Resistance Min. 1 MΩ
7 Between terminals 250 and 260
(Internal disconnection) ON Resistance Max. 1 Ω
OFF Resistance Min. 1 MΩ
Between terminals 250 and 270
ON Resistance Max. 1 Ω
START Resistance Max. 1 Ω
2. Replace neutral safety relay (NSF) with another relay (such as BKA).
8 Defective neutral safety relay
3. Start engine
If engine starts, original neutral safety relay (NSF) is defective.
Defective engine ACC cutout 2. Replace engine ACC cutout relay (ACT) with another relay (such as BKA).
9
relay 3. Start engine
If engine starts, original engine ACC cutout relay (ACT) is defective.
a If the engine does not stop
10 Defective engine holding relay
3. Replace engine holding relay (EHL) with another relay (such as BKA).
If engine stops, original engine holding relay (EHL) is defective.
Defective diode RSD 2. Remove connector RSD and connect T-adapter to diode.
11 (Internal disconnection or a Measure in diode range of tester.
short circuit) Between RSD (male) (1) (+) and (2) (-) No continuity
Between RSD (male) (2) (+) and (1) (-) Continuity
D375A-6 40-547
(01)
DRAFT

Defective alternator
12 Between terminal AL/R and
(Internal defect) Voltage Max. 12 V
ground
2. Start the engine for troubleshooting.
Between power supply terminal B
Voltage 20 – 30 V
and ground
Detective starting motor (inter- Between charge terminal R and
13 Voltage Max. 12 V
nal defect) ground
Between starting motor terminal C
Voltage 20 – 30 V
and ground
When the voltages of electric power supply, for charging and starting are normal
but the starting motor does not rotate, the starting motor is defective.
q Battery relay
Between terminal BRE and ground Resistance Max. 1 Ω
q Battery relay
2. Turn starting switch to START position.
a Check to where 24 V is supplied to identify disconnected place.
Between terminal 260 and ground Voltage 20 – 30 V
Between terminal SW and ground Voltage 20 – 30 V
Between terminal BRB and ground Voltage 20 – 30 V
Between terminal BRC and ground Voltage 20 – 30 V
q Alternator and starting motor
14
ness 2. Disconnect ground strap.
3. Insert T-adapters into connectors NSF, ST1 and ST2.
5. Turn starting switch to START position and troubleshoot.
a Check to where 24 V is supplied to identify disconnected place.
Between terminal 280 and ground Voltage 20 – 30 V
Between NSF (1) and ground Voltage 20 – 30 V
Between ST1 (1) and ground Voltage 20 – 30 V
Between ST2 (1) and ground Voltage 20 – 30 V
Between terminal AL/B and ground Voltage 20 – 30 V
Between terminal ST/B and ground Voltage 20 – 30 V
Defective battery relay If only terminal BRC voltage is abnormal during battery relay check for cause 14,
15
(Does not turn ON) battery relay is defective.
Ground fault of wiring harness 2. Disconnect ground strap.
16 3. Disconnect connectors NSF, PTCN1, WECN1, CM01 and ST.
(Contact with GND circuit)
Between terminal 250 and ground Resistance Min. 1 MΩ
Between terminal 280 or NSF (3) and ground Resistance Min. 1 MΩ
Between NSF (5), ST2 (1) or ST1 (1) and ground Resistance Min. 1 MΩ
Short circuit with power source 2. Disconnect terminal AL/R.
17 in wiring harness 3. Turn starting switch ON position.
(Short circuit with 24 V circuit) Between terminal AL/R (Wiring harness side)
Voltage Max. 1 V
and ground
40-548 D375A-6
(01)
DRAFT
Circuit diagram related to starting of engine
D375A-6 40-549
(01)
DRAFT
E-2 Preheater does not operate

Trouble 1)Manual preheater does not operate.
a This troubleshooting describes the procedures to be followed when the automatic and manual pre-
heating does not function to heat the electrical intake air heater mounting section.
q For preheating, both the “Automatic preheating function” and “Manual preheating function” are
available. When either function is performed, the preheating lamp lights up.
(When only the preheating does not light up, troubleshoot "3) While the preheater is operating, the
Related informa- preheating monitor does not light up")
tion q If "the machine monitor does not light up" or "the battery relay does not make operating sound"
when turning the starting switch ON, the main electric power supply system is supposed to be de-
fective. So, troubleshoot E-3 and E-1.
(If the failure code [CA153], [CA154], [D110KB] or [D182KZ] is displayed, firstly perform these trou-
bleshooting.)

Defective circuit breaker If CBH1 circuit breaker is turned ON, circuit probably has ground fault. In this case,
1
CBH1 perform troubleshooting for cause 7 first.
Loose terminal or disconnec- 1. Turn starting switch to OFF position.
2
tion at terminal Check terminals of heater relay, battery relay, etc.
Defective diode HTD 2. Remove connector HTD and connect T-adapter to diode.
short circuit) Between HTD (male) (1) (+) and (2) (-) No continuity
Between HTD (male) (2) (+) and (1) (-) Continuity
Defective electrical intake air 1. Turn starting switch to OFF position.
4 heater 2. Disconnect terminal HT/B.
(Internal disconnection) Between terminal HT/B and ground There is continuity
5 Defective starting switch 3. Disconnect connector KEY and connect T-adapter to male side.
4. Turn starting switch to OFF/HEAT position and troubleshoot.
HEAT Resistance Max. 1 Ω
2. Disconnect connector CM01.
Between terminal 255 and ground There is continuity
Disconnection in, or ground Between terminal HT/A and ground Voltage 20 – 30 V
6
fault of wiring harness 1. Turn starting switch to OFF position.
2. Disconnect terminal HT/B.
3. Turn starting switch to HEAT position (Connect R1).
a Disconnect so that current will not flow in heater when starting switch is turned to
HEAT position.
Between terminal HT and ground Voltage 20 – 30 V
7 ness 2. Disconnect connectors KEY and CM01 and terminals HT and BRC.
(Contact with GND circuit) Between terminal HT/A and ground Resistance Min. 1 MΩ
Between terminal HT (on wiring harness side) and
ground
Defective preheater relay
If cause 6 is not the cause for the trouble and preheater relay operation sound is not
8 (Does not turn ON) (Terminal
heard, preheater relay is defective.
HT/B)
40-550 D375A-6
(01)
DRAFT
Circuit diagram related to preheating of engine
D375A-6 40-551
(01)
DRAFT
Trouble 2) Automatic preheater does not operate.

q Automatic preheater operates when engine coolant temperature is below -5 °C.
Related informa- (Monitoring code Engine coolant temperature: 04107)
tion q If automatic preheater does not operate, check if manual preheater operates.
q Engine controller troubleshoots primary (coil) side of preheater relay by failure code [D182KZ].

If fuse FS22-4 is broken, circuit probably has ground fault. In this case, perform trou-
bleshooting for cause 5 first.
2. Replace preheater relay (connector: PHR) with backup alarm relay (connector:
Defective preheater relay
BKA).
2 (Internal disconnection or
short circuit) 3. Turn starting switch ON position.
If automatic preheater operates when engine coolant temperature is below -5 °C,
original preheater relay is defective.
Disconnection in, or ground a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance is be-
3
fault of wiring harness low 1 Ω, wiring harness has short circuit.
a Preheater relay coil resistance
Between PTCN2 (female) (19) and ground Resistance 200 – 400 Ω
Disconnection in wiring har- 2. Disconnect connectors PHR and CM01, and connect T-adapter to female side of
ness PHR.
4
(Disconnection or defective 3. Remove fuse FS22-4.
contact) Between PHR (female) (3) and ground Continuity
Between PHR (female) (5) and FS22-4 Resistance Max. 1 Ω
If fuse is not broken, this check is not required.
2. Disconnect connectors PHR, FSB and ASUS, and connect T-adapter to female
5 ness
side of PHR.
Between PHR (female) (5) and ground Resistance Min. 1 MΩ
Trouble 3) While preheater is operating, the preheating monitor does not light up.
Related informa- q There are "Automatic preheater" and "Manual preheater" installed. When either function is oper-
tion ated, the preheating lamp lights up.

ness 2. Disconnect connectors PHR and CM01, and connect T-adapters to female side
1 of them.
contact) Between PHR (female) (3) and CM01 (female) (16) Resistance Max. 1 Ω
Between terminal 255 and CM01 (female) (16) Resistance Max. 1 Ω
2 ness 2. Disconnect connectors PHR, CM01 and terminal HT, and connect T-adapter to
(Contact with GND circuit) female side of CM01.
Between CM01 (female) (16) and ground Resistance Min. 1 MΩ
q Reference (the followings are standard values in normal condition)
2. Insert T-adapter into connector CM01.
3 Defective machine monitor 3. Disconnect terminal HT.
a Disconnect so that current will not flow in heater when starting switch is turned to
HEAT position.
4. Turn starting switch to HEAT position.
Between CM01 (16) and (3) Resistance 20 – 30 V
40-552 D375A-6
(01)
DRAFT
Circuit diagram related to preheating of engine
D375A-6 40-553
(01)
DRAFT
E-3 When starting switch is turned ON, machine monitor displays nothing
E-3 When starting switch is turned ON, machine monitor displays

nothing
Trouble q When starting switch turned ON, machine monitor displays nothing
q When starting switch is turned ON, machine monitor displays KOMATSU logo, screen to input
password (if set), screen of check before starting, screen to check setting of preset, and ordinary
screen in order.
q When the engine is started, the battery voltage may lower suddenly, depending on the ambient
Related information temperature and the condition of the battery.
In this case, the machine monitor goes off for a moment. This phenomenon is not a failure,
however.
q In the case of "the battery relay does not make operating sound" when turning the starting switch
ON, perform E-1.
Cause Standard value in normal state/Remarks on troubleshooting

Defective circuit breaker CB30 or If CB30 or CB6 circuit breaker is turned ON, circuit probably has ground fault. In
1
CB6 this case, perform troubleshooting for cause 8 first.
Loose terminal or disconnection at 1. Turn starting switch to OFF position.
2
terminal Check terminals of battery, battery relay, etc.
3 Insufficient battery capacity Battery voltage (2pieces) Min. 24V
Electrolyte specific gravity Min. 1.26
a If machine monitor has not been replaced, this check is not required.
Misalignment of wiring harness 1. Turn starting switch to OFF position.
4 (Numbers of pins of CM01 and 2. Remove machine monitor.
CM03 are same) Check that connectors CM01 (white) and CM03 (green) are matched to con-
nector colors of machine monitor unit.
Disconnection in or ground fault of 4. Connect ground strap.
5 wiring harness or defective start- a If voltage is 0 V, wiring harness has disconnection or ground fault.
ing switch Between CM01 (female) (1) and (3) Voltage 20 – 30 V
Between CM01 (female) (2) and (4) Voltage 20 – 30 V
1 - 4 are same as above.
5. Turn starting switch to ON position (Connect ACC).
Between CM01 (female) (14) and (4) Voltage 20 – 30 V
3. Disconnect connector KEY.
4. Turn starting switch to ON/OFF position and troubleshoot.
6 Defective starting switch When the
travel steer-
Between terminals 250 and 270 ing signal is
OFF
3. If circuit breaker is turned ON, reset it.
Disconnection in wiring harness 4. Disconnect connector CM01 and connect T-adapter to female side.
7 (Disconnection or defective con- Between CM01 (female) (3), (4) and ground Resistance Max. 1 Ω
tact) a Check terminal GND01 for looseness and rust.
Between CM01 (female) (1), (2) and battery (+) Resistance Max. 1 Ω
1 - 4 are same as above.
5. Turn starting switch to ON position (Connect ACC with ground strap discon-
nected).
Between CM01 (female) (14) and battery (+) Resistance Max. 1 Ω
40-554 D375A-6
(01)
DRAFT
E-3 When starting switch is turned ON, machine monitor displays nothing
Ground fault of wiring harness 3. If circuit breaker is turned ON, reset it.
8
(Contact with GND circuit) 4. Disconnect connector CM01 and connect T-adapter to female side.
a Check that condition is normal when starting switch is turned to ON position
(Connect ACC with ground strap disconnected).
9 Defective machine monitor If cause is not found by above checks, machine monitor is defective.
Circuit diagram related to machine monitor
D375A-6 40-555
(01)
DRAFT
E-4 When starting switch is turned ON (before starting engine), basic check item lights up
E-4 When starting switch is turned ON (before starting engine), basic

check item lights up
1) When starting switch is turned to ON position (with engine stopped), engine oil pressure monitor
Trouble
lights up.
q Engine oil pressure sensed by engine oil pressure sensor can be checked with monitoring func-
Related informa-
tion.
tion
(Code: 37200 Engine Oil Pressure)

Defective engine oil pressure
1 caution lamp circuit Perform troubleshooting for failure codes [CA135], [CA141].
(Engine controller circuit)
If cause 1 is not detected, machine monitor may be defective.
2 Defective machine monitor
(Since trouble is in system, troubleshooting cannot be carried out.)
2) When starting switch is turned to ON position (with engine stopped), engine oil level monitor lights
Trouble
up.
Related informa-
q Engine oil level monitor (oil level switch) is optional.
tion

Defective engine oil level
1 switch system (machine mon- Perform troubleshooting for failure code [B@BAZK].
itor system)
Trouble 3) Radiator coolant level monitor lights.
Related infor-
mation

Radiator coolant level
The coolant level monitor may be insufficient. Check coolant level and add coolant if
1 decrease
necessary.
Defective coolant level sensor 2. Disconnect connector WLD and connect T-adapter to male side.
2
(Internal defect) Between FULL and LOW Resistance Max. 1 Ω
Between WLD (male) (1)
Value when coolant level
and (2) Resistance Min. 1 MΩ
is low
ness 2. Disconnect connector CM02 and connect T-adapter to female side.
3
(Disconnection or defective a Add coolant.
contact) Between CM02 (female) (3) and WLD (female) (1) Resistance Max. 1 Ω
4 Defective machine monitor 2. Insert T-adapter into connector CM02.
Between FULL and LOW Voltage Max. 1V
Between CM02 (female) (3)
Value when coolant level
and ground Voltage Min. 7V
is low
40-556 D375A-6
(01)
DRAFT
E-4 When starting switch is turned ON (before starting engine), basic check item lights up
Circuit diagram related to radiator coolant level
D375A-6 40-557
(01)
DRAFT
E-5 Precaution item lights up while engine is running

Trouble q Precaution item lights up while engine is running.
q Check item is charge level monitor.
Related infor-
q State of generation signal of alternator can be checked with monitoring function.
mation
(Code 04300: Battery Charge Volt.)

Loose terminal or discon- 1. Turn starting switch to OFF position.
1
nection at terminal Check terminals of alternator etc.
Defective alternator 1. Turn starting switch to OFF position.
2 (insufficient power genera- 2. Start engine and troubleshoot while running engine at medium speed or higher.
tion) Between terminal AL/R and ground Voltage 20 – 30V
Defective diode RSD 2. Remove connector RSD and connect T-adapter to diode.
short circuit) Between RSD (male) (1) (+) and (2) (-) No continuity
Between RSD (male) (2) (+) and (1) (-) Continuity
Disconnection in wiring 2. Disconnect ground strap.
harness 3. Disconnect connectors CM01 and RSD, and connect T-adapter to female side of
4 (Disconnection in wiring or CM01.
defective contact in con- 4. Disconnect terminal AL/R.
nector) Between CM01 (female) (11) and AL/R Resistance Max. 1 Ω
Between alternator terminal E and ground Resistance Max. 1 Ω
5 ness 3. Disconnect connectors CM01, RSD, PTCN1, WECN1, ST1 and ST2, and connect
(Contact with GND circuit) T-adapter to female side of CM01.
4. Disconnect terminal AL/R.
Defective machine moni- 2. Disconnect ground strap.
6
tor panel 3. Insert T-adapter into connector CM01.
5. Start engine and troubleshoot while running engine at medium speed or higher.
Between CM01 (11) and (3) Voltage 20 – 30V
40-558 D375A-6
(01)
DRAFT
Circuit diagram related to charge level
D375A-6 40-559
(01)
DRAFT
E-6 Emergency stop item lights up while engine is running

Trouble 1)Engine coolant temperature monitor lights up.
q Signal voltage of engine coolant temperature sensor is input to engine controller and then the
Related informa- data is transmitted to machine monitor through CAN communication system.
tion q Engine coolant temperature can be checked with monitoring function

Overheating of engine cool-
1 Engine coolant may be overheated. If it is overheated, remove cause.
ant (when system is normal)
Defective coolant tempera- If cause 1 is not detected, engine coolant temperature sensor system may be
2
ture sensor system defective. Perform troubleshooting for failure codes [CA144] and [CA145].
If causes 1 – 2 are not detected, machine monitor may be defective
Trouble 2) Engine oil pressure monitor lights up.
q Signal of engine oil pressure sensor is input to engine controller and then the data is transmitted
Related informa- to machine monitor through CAN communication system.
tion q Engine oil pressure can be checked with monitoring function.
q (Code: 37200 Engine Oil Pressure)

Reduction of engine oil pres-
Check the engine oil pressure as the drop of engine oil pressure is detected.
1 sure
q Perform troubleshooting "S-12 (Oil pressure drop)".
Defective engine oil pressure If cause 1 is not the cause for the trouble, engine oil pressure switch system may be
2
system defective. Perform troubleshooting for failure codes [CA135] and [CA141].
Trouble 3) Torque converter oil temperature monitor lights up.
q Signal voltage of torque converter oil temperature sensor is input to power train controller and
Related informa- then the data is transmitted to machine monitor through CAN communication system.
tion q Torque converter oil temperature can be checked with monitoring function.
q (Code: 30100 T/C oil temperature)

Overheating of torque con-
1 verter oil (When system is nor- Torque converter oil may be overheated. If it is overheated, remove cause.
mal)
If cause 1 is not the cause for the trouble, torque converter oil temperature sensor
Defective torque converter oil
2 system may be defective. Perform troubleshooting for failure codes [DGT1KA] and
temperature sensor system
[DGT1KX].
Trouble 4) Hydraulic oil temperature monitor lights up.
Related informa- q Hydraulic oil temperature can be checked with monitoring function
tion q (Code: 04401 Hyd Oil Temperature)

Overheating of hydraulic oil
1 Hydraulic oil may be overheating. Check it and remove cause if it is overheating.
Defective hydraulic oil temper- If cause 1 is not the cause for the trouble, hydraulic oil temperature sensor system
2 ature gauge system or or machine monitor may be defective. Perform troubleshooting for failure code
machine monitor [DGS1KX].
40-560 D375A-6
(01)
DRAFT
E-7 Engine coolant temperature gauge does not indicate normally
E-7 Engine coolant temperature gauge does not indicate normally

1) While engine coolant temperature is rising normally, temperature gauge does not rise from white
Trouble range (C).
2) While engine coolant temperature is stabilized normally, temperature gauge rises to red range (H).
q Signal voltage of engine coolant temperature sensor is input to engine controller and then the data
Related informa- is transmitted to machine monitor through CAN communication system.

Defective coolant tempera- Engine coolant temperature sensor system may be defective. Perform troubleshooting
1
ture sensor system for failure codes [CA144] and [CA145].
3) Display of coolant temperature gauge is different from actual engine coolant temperature.
Trouble 4) Display of engine coolant temperature gauge is different from display of engine coolant tempera-
ture monitor.
q Signal voltage of engine coolant temperature sensor is input to engine controller and then the data
Related informa- is transmitted to machine monitor through CAN communication system.

a Turn starting switch ON or start engine and troubleshoot.
Engine coolant tempera- Coolant temperature
Color of monitor light (a)
ture gauge level
105 °C 5
Red
1 Defective machine monitor 102 °C 6
100 °C 4
85 °C 3
Blue
60 °C 2
30 °C 1
Engine coolant temperature gauge and coolant

temperature monitor
D375A-6 40-561
(01)
DRAFT
E-8 Fuel gauge does not indicate properly

Trouble 1) Fuel gauge does not indicate properly.
q The input state (voltage signal) from the fuel level sensor can be checked in monitoring mode.
Related information
(Code: 04200 Fuel level sensor voltage)

Defective fuel level sensor 2. Disconnect connector FGS and connect T-adapter to male side.
1 (Internal disconnection or short Between FGS (male) (1) and (2) FULL Resistance Approx. 4 Ω
circuit) a Fuel level sensor characteristics EMPTY Resistance Approx. 85 Ω
Between FGS (male) (2) and ground Resistance Max. 1 Ω
2. Disconnect connector FGS and connect T-adapter to female side.
Disconnection, short circuit or hot a If voltage is 0 V, wiring harness has disconnection, ground fault or short cir-
2 short in or ground fault of wiring cuit, and if voltage is 24 V, wiring harness has hot short.
harness a Voltage of approx. 3.3 V is applied to fuel level sensor signal lines through
resistor inside machine monitor.
Approx. 3.3
Between FGS (female) (1) and (2) Voltage
V
3
Disconnection or short circuit in a Resistance accords with fuel level sensor characteristics table in cause 1.
wiring harness a If resistance is above 1 MΩ, wiring harness has disconnection. If resistance
is below 1 Ω, wiring harness has short circuit.
Approx. 4 –
Between CM01 (female) (9) and (12) Resistance
85 Ω
quired.
Disconnection in wiring harness 1. Turn starting switch to OFF position.
4 (Disconnection or defective con- 2. Disconnect connectors CM01 and FGS, and connect T-adapters to female
tact) side of them.
Between CM01 (female) (9) and FGS (female) (1) Resistance Max. 1 Ω
Between CM01 (female) (12) and FGS (female) (2) Resistance Max. 1 Ω
quired.
5 2. Disconnect connectors CM01 and FGS, and connect T-adapter to female
side of either of them.
Between CM01 (female) (9) or FGS (female) (1)
and ground
2. Disconnect connectors CM01 and FGS, and connect T-adapter to female
6 Short circuit in wiring harness side of CM01.
Between CM01 (female) (9) and each pin other No continuity
than (9) (No sound is heard)
7 Defective machine monitor If cause is not found by the above checks, machine monitor is defective.
40-562 D375A-6
(01)
DRAFT
Circuit diagram related to fuel level gauge
2) Display of fuel level gauge is different from actual fuel level.

Trouble
3) Display of fuel level gauge is different from display of fuel level monitor.
Related infor- q Signal voltage of fuel sensor can be checked with monitoring function.
mation (Code: 04200 Fuel level sensor vol)
Reading of fuel level
Quantity of fuel Color of monitor light (a)
gauge
1005 l 6
1 Defective machine monitor 756 l 5
556 l 4 Blue
398 l 3
276 l 2
144 l 1 Red
Fuel level gauge and fuel level monitor
D375A-6 40-563
(01)
DRAFT
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally
E-9 Power train oil temperature gauge (multi-gauge) does not indicate
normally
1) While power train oil temperature is rising normally, temperature gauge does not rise from white
range (C).
Trouble
2) While power train oil temperature is stabilized normally, temperature gauge rises to red range
(H).
q Torque converter oil temperature is considered as power train oil temperature.
q Signal voltage of power train oil temperature sensor is input to power train controller and then
Related information the data is transmitted to machine monitor through CAN communication system.
q Torque converter (power train) oil temperature can be checked with monitoring function.

Defective torque converter oil Power train oil temperature sensor system may be defective. Perform trouble-
1
temperature sensor system shooting for failure codes [DGT1KA] and [DGT1KX].
(Since trouble is in system, troubleshooting cannot be performed.)
3) Display of power train temperature gauge is different from actual power train oil temperature.
Trouble 4) Display of power train oil temperature gauge is different from display of power train oil tempera-
ture monitor.
q Torque converter oil temperature is considered as power train oil temperature.
q Signal voltage of power train oil temperature sensor is input to power train controller and then the
Related informa-
data is transmitted to machine monitor through CAN communication system.
tion
q Torque converter (power train) oil temperature can be checked with monitoring function.
Power train oil tempera- Power train oil tempera-
Color of monitor light (a)
ture ture gauge level
130 °C 6
Red
118 °C 4
90 °C 3
Blue
50 °C 2
0 °C 1
Power train oil temperature gauge and power train

oil temperature monitor
40-564 D375A-6
(01)
DRAFT
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate

normally
1) While hydraulic oil temperature is rising normally, temperature gauge does not rise from white
Trouble range (C).
2) While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range.
q Hydraulic oil temperature can be checked with monitoring function
Related information
(Code: 04401 Hyd Oil Temperature)

1 Perform troubleshooting for failure code [DGS1KX].
3) Display of hydraulic oil temperature gauge is different from actual hydraulic oil temperature.
Trouble 4) Display of hydraulic oil temperature gauge is different from display of hydraulic oil temperature
monitor.
Related informa- q Hydraulic oil temperature can be checked with monitoring function
tion (Code: 04401 Hyd Oil Temperature)
Reading of hydraulic oil
Hydraulic oil temperature Color of monitor light (a)
temperature gauge
105 °C 5
Red
98 °C 4
70 °C 3
Blue
20 °C 2
0 °C 1
Hydraulic oil temperature gauge and hydraulic oil

temperature monitor
D375A-6 40-565
(01)
DRAFT
E-11 Contents of display by machine monitor are different from applicable machine
E-11 Contents of display by machine monitor are different from appli-

cable machine
Trouble q Contents of display by machine monitor are different from applicable machine.
Related information

Machine monitor may be defective.(Since trouble is in system, troubleshooting
cannot be performed.)
E-12 Machine monitor does not display some items

Trouble q Machine monitor does not display some items
q The LCD panel sometimes has black points (points which are not lighted) and bright points
Related information (points which do not go off) for the reason of its characteristics. If the number of the bright points
and black points does not exceed 10, those points are not a failure or a defect.

a Turn starting switch ON and carry out troubleshooting.
Defective machine monitor When following switches are operated, if all LCD panel is lighted up (all surface
1
(LCD panel) becomes white), LCD panel is normal.
q Operation of switches: [4] + [F2] (Press simultaneously)
Defective machine monitor If cause 1 is not detected, machine monitor may be defective.
2
(body) (Since trouble is in system, troubleshooting cannot be performed.)
E-13 Function switch does not work

Trouble q Function switch does not work
Related information

40-566 D375A-6
(01)
DRAFT
E-14 Operation mode does not change
E-14 Operation mode does not change

Trouble 1) When operation mode switch is operated, display of operation mode monitor does not change.
Related informa- q Before carrying out troubleshooting, check that no related failure code is displayed.
tion (If failure codes [DAFRMC] and/or [DB2RKR] are displayed, troubleshoot them first.)

Trouble 2) When operation mode is changed, engine output is not changed.
q Engine output mode recognized by engine controller can be checked with monitoring function.
Related informa- (Code: 17500 Engine Power Mode)
tion q Before carrying out troubleshooting, check that no related failure code is displayed.
(If failure codes [DAFRMC] and/or [DB2RKR] are displayed, troubleshoot them first.)

Machine monitor may be defective. (Since trouble is in system, troubleshooting
Engine controller may be defective. (Since trouble is in system, troubleshooting
E-15 Gearshift mode does not change

Trouble 1) When gearshift mode switch is operated, display of speed mode section does not change.
Related information (If failure codes [DAFRMC], [DK40KA], [DK40KB], [DLT3KA] and/or [DLT3KB] are displayed,
troubleshoot them first.)

Power train controller may be defective. (Since trouble is in system, trouble-
2 Defective power train controller
shooting cannot be performed.)
Trouble 2) When gearshift mode is changed, gearshift setting of power train is not changed.
Related information (If failure codes [DAFRMC], [DK40KA], [DK40KB], [DLT3KA] and/or [DLT3KB] are displayed,
troubleshoot them first.)

D375A-6 40-567
(01)
DRAFT
E-16 Customize function does not operate normally
E-16 Customize function does not operate normally

Trouble 1) When customize switch is operated, customize screen is not displayed.
Related informa-
tion

Trouble 2) When setting is changed on customize screen, setting of machine is not changed.
Related informa-
tion

Defective engine controller or Engine controller or power train controller may be defective. (Since trouble is in
2
defective power train controller system, troubleshooting cannot be performed.)
E-17 Customize memory function does not operate normally

Trouble 1) When customize memory switch is operated, customize memory screen is not displayed.
Related informa-
tion

Trouble 2) When selection is changed on customize memory screen, setting of machine is not changed.
Related informa-
tion

Defective engine controller or Engine controller or power train controller may be defective. (Since trouble is in
2
defective power train controller system, troubleshooting cannot be performed.)
40-568 D375A-6
(01)
DRAFT
E-18 Alarm buzzer does not sound or does not stop
E-18 Alarm buzzer does not sound or does not stop

Trouble q Alarm buzzer does not sound or does not stop.
Related information

E-19 When starting switch is turned OFF, service meter is not displayed
Trouble q When starting switch is turned OFF, service meter is not displayed.
q While starting switch is at OFF position, if following switches are operated, service meter is dis-
Related information
played at top center of screen. Operation of switches: [4] + [1] (Press simultaneously)

When starting switch is turned ON, if machine monitor displays nothing, backup
Defective backup power supply
1 power supply system may be defective. In this case, perform troubleshooting
system
for "E-3 When starting switch is turned ON, machine monitor displays nothing".
(Since trouble is in system, troubleshooting cannot be performed.)
E-20 Machine monitor cannot be set in service mode

Trouble q Machine monitor cannot be set in service mode
q If following switches are operated, machine monitor is set in service mode.
Related information
Operation of switches: [4]+[1]o[2]o[3] (While pressing [4], press other switches in order)

D375A-6 40-569
(01)
DRAFT
E-21 The ripper pin puller cylinder does not operate

Trouble q The ripper pin puller cylinder does not work.
Related infor-
mation

If fuse FS22-4 is broken, circuit probably has ground fault. In this case, perform
Defective pin puller switch 2. Disconnect connector PLSW and connect T-adapter to male side.
2 3. Operate switch and troubleshoot.
(Internal defect)
Pull Resistance Max. 1 Ω
Between PLSW (male) (1) and (2)
Blow out Resistance Min. 1 MΩ
Defective pin puller solenoid 2. Disconnect connector PPL and connect T-adapter to male side.
3
(Internal defect) Between PPL (male) (1) and (2) Resistance 10–40 Ω
Between PPL (male) (1) and ground Resistance Min. 1 MΩ
2. Disconnect connectors ASUS and PHR.
Disconnection or short circuit in 3. Remove fuse FS22-4.
4
wiring harness 4. Turn pin puller switch to ON position (lead-in).
Between terminal FS22-4 of fuse and ground
Resistance 10–40 Ω
a Pin puller solenoid resistance
6 Disconnection in wiring harness 3. Disconnect connectors PLSW and PPL, and connect T-adapters to female side
of them.
Between PPL (female) (2) and ground Resistance Max. 1 Ω
Between PPL (female) (1) and PLSW (female) (2) Resistance Max. 1 Ω
Between fuse FS22-4 and PLSW (female) (1) Resistance Max. 1 Ω
Ground fault of wiring harness 2. Remove fuse FS22-4.
5 3. Disconnect connectors PLSW and PPL, and connect T-adapters to female side
of PLSW.
Between PPL (female) (1) and PLSW (female) (2) Resistance Min. 1 MΩ
Between PLSW (female) (1) and ground Resistance Min. 1 MΩ
2. Disconnect connectors PPL, and connect T-adapter to female side.
4. Turn pin puller switch to OFF position (pull-out).
Between PPL (female) (1) and (2) Voltage Max.1 V
40-570 D375A-6
(01)
DRAFT
Circuit diagram related to ripper pin puller cylinder
D375A-6 40-571
(01)
DRAFT
E-22 Horn does not sound or does not stop

Trouble q The horn does not sound or does not stop.
q Troubleshoot for causes 1 – 7 and 9, when horn does not sound and for causes 2, 8 and 9 when
Related infor- horn does not stop.
mation q Troubleshooting at connector HRN (female) does not perform but perform at connector RDG be-
cause T-adapter for connector HRN is not prepared.

If fuse FS32-4 is broken, circuit probably has ground fault. In this case, trouble-
shoot cause 7 first.
2. Disconnect horn switch terminals (No polarity).
2 Defective horn switch 3. Turn horn switch ON/OFF and troubleshoot.
Between horn switch terminals
2. Disconnect connector RDG and connect T-adapter to female side.
3 Defective wiring harness 3. Turn starting switch ON position.
4. Turn horn switch ON.
Between RDG (female) (3) and ground Voltage 20–30 V
Disconnection in wiring har- 2. Remove fuse FS32-4.
4
ness or horn 3. Turn horn switch ON.
Between FS32-4 and ground Continuity
5 Disconnection in horn
2. Disconnect connector HRN.
Between HRN(male) and ground Continuity
Disconnection in wiring harness
If check of cause 4 is abnormal and check of cause 5 is normal, wiring harness is
6 (Disconnection or defective
disconnected.
contact)
a If fuse is not broken, this check is not required.
Ground fault of wiring harness 1. Turn starting switch to OFF position.
7
(Contact with GND circuit) 2. Disconnect connector HRN and insert T-adapter into RDG.
Between RDG (female) (2) and ground Resistance Min. 1 MΩ
Hot short in wiring harness 2. Disconnect connector HRN and insert T-adapter into RDG.
8
(Contact with 24 V circuit) 3. Turn horn switch ON.
Between RDG (female) (2) and ground Voltage Max. 1 V
9 Defective horn (Internal defect) If the cause cannot be found by above checks, horn may be defective.
40-572 D375A-6
(01)
DRAFT
Circuit diagram related to horn
D375A-6 40-573
(01)
DRAFT
E-23 Back-up alarm does not sound or does not stop

Trouble 1) Back-up alarm does not sound.
q When a failure occurs on the primary side (coil side) of the back-up alarm relay, relevant failure codes
Related infor-
[D161KA], [D161KB] are displayed, but in case of failure on the secondary side (contact side), no fail-
mation
ure code is displayed.

If fuse FS22-5 is broken, circuit probably has ground fault. In this case, trou-
bleshoot cause 6 first.
Defective backup alarm relay 2. Replace backup alarm relay (connector: BKA) with another relay.
2 (Internal disconnection or short 3. Turn starting switch ON position.
circuit) 4. Perform reverse travel operation.
If backup alarm sounds, original backup alarm relay is defective.
2. Disconnect connector BKAL and connect T-adapter to female side.
3 Defective wiring harness 3. Turn starting switch ON position.
4. Perform reverse travel operation.
Between BKAL (1) and (2) Voltage 20 – 30V
4 2. Disconnect connector BKA and connect T-adapter to female side.
or backup alarm
Between BKA (female) (5) and ground Continuity
a If neither of causes 3 and 4 is the cause for the trouble, this check is not
required.
Disconnection in wiring harness 2. Remove fuse FS22-5.
5 (Disconnection or defective con- 3. Disconnect connectors BKA and BKAL and connect T-adapters to female
tact) side of them.
Between BKA (female) (5) and BKAL (female) (1) Resistance Max. 1 Ω
Between BKAL (female) (2) and ground Resistance Max. 1 Ω
Between BKA (female) (1), (3) and FS22-5 Resistance Max. 1 Ω
a If fuse is not broken, this check is not required.
6 3. Disconnect connectors BKA and BKAL and connect T-adapter to female
side of either of them.
Between BKA (female) (1) or (3) and ground Resistance Min. 1 MΩ
Between BKA (female) (5) and ground Resistance Min. 1 MΩ
Defective backup alarm
7 If cause cannot be found by above checks, back-up alarm may be defective.
(Internal defect)
40-574 D375A-6
(01)
DRAFT
Trouble 2) Back-up alarm does not stop.

Related infor-
mation

Defective backup alarm relay 2. Replace backup alarm relay (connector: BKA) with another relay.
1 (Internal disconnection or short a The above can be checked with backup alarm relay removed only.
circuit) 3. Turn starting switch ON position.
If backup alarm stops, original backup alarm relay is defective.
Hot short in wiring harness 2. Disconnect connector BKAL and connect T-adapter to female side.
Between BKAL (female) (1) and (2) Voltage Max. 1V
Between BKAL (female) (1) and ground Voltage Max. 1V
Defective backup alarm
3 If cause cannot be found by above checks, back-up alarm may be defective.
(Internal defect)
Circuit diagram related to backup alarm
D375A-6 40-575
(01)
DRAFT
E-24 Fan does not reverse
E-24 Fan does not reverse

Trouble Fan does not rotate in reverse.
Related infor- q See "Reverse rotation of hydraulic fan" in Machine monitor sections of Structure and Operation sec-
mation tion.

1 Defective fan reverse solenoid Perform troubleshooting for failure codes [DW7BKA] and [DW7BKB].
Circuit diagram related to fan
40-576 D375A-6
(01)
DRAFT
E-25 The head lamp and rear lamp do not light up

Trouble 1) Head lamp does not light up.
q If section between headlamp relay and headlamps, one headlamp lights up.
Related infor-
q If headlamp switch, diode or wiring harness common to right and left headlamps is defective, right and
mation
left headlamps and working lamp do not light up.

Defective head lamp (Breakage
1 Since the head lamp may be defective, check its bulb for breakage.
of bulb)
Defective circuit breaker (CB105
2 If circuit breaker is turned ON, circuit probably has ground fault etc.
or CB5)
Defective head lamp relay 2. Replace relay (connector: LMFL or LMFR) with backup alarm relay
(LMFR, LMFL) (connector: BKA).
3
(Internal disconnection or short 3. Turn starting switch ON position.
circuit) 4. Turn headlamp switch to ON position.
If headlamp lights up, original headlamp relay is defective.
2. Disconnect connector FLSW and connect T-adapter to male side.
4 Defective head lamp switch 3. Turn headlamp switch to ON/OFF position and troubleshoot.
a ON position is located in both directions.
Between FLSW (male) (5) and (6), or OFF Resistance Min. 1 MΩ
between (4) and (5) ON Resistance Max. 1 Ω
2. Disconnect connectors LMD1 and LMD2, and connect T-adapter to diode.
Defective diode LMD1 or LMD2 a Measure in diode range of tester.
5 (Internal disconnection or short Between LMD1 (male) (1) (+) and (2) (-) No continuity
circuit) Between LMD1 (male) (2) (+) and (1) (-) Continuity
Between LMD2 (male) (1) (+) and (2) (-) No continuity
Between LMD2 (male) (2) (+) and (1) (-) Continuity
a Check location where voltage abnormality occurs and locate defective point
of wiring harness.
2. Disconnect connectors LHDR and LHDL, and connect T-adapters to female
side of them.
4. Turn headlamp switch to ON position.
Between LHDL (female) (1) and (2) Voltage 20 – 30V
Between LHDR (female) (1) and (2) Voltage 20 – 30V
a If no failure is detected by above checks, this check is not required.
Disconnection in, or ground fault 2. Disconnect connectors LMFL and LMFR, and connect T-adapter to female
6
of wiring harness side.
Between LMFL (female) (1) and (2) Voltage 20 – 30V
Between LMFL (female) (3) and (2) Voltage 20 – 30V
Between LMFR (female) (1) and (2) Voltage 20 – 30V
Between LMFR (female) (3) and (2) Voltage 20 – 30V
2. Disconnect connector FLSW and connect T-adapter to female side.
Between FLSW (female) (5) and (2) Voltage 20 – 30V
D375A-6 40-577
(01)
DRAFT
2. Disconnect connectors FLSW, LMD1, LMD2, LMFL, LMFR, LHDR, LHDL
and KEY, and connect T-adapters to female side of them.
Between LHDR (female) (2) and ground Resistance Max. 1 Ω
Between LHDL (female) (2) and ground Resistance Max. 1 Ω
Between LHDR (female) (1) and LMFR (female) (5) Resistance Max. 1 Ω
Between LHDL (female) (1) and LMFL (female) (5) Resistance Max. 1 Ω
Disconnection in wiring harness Between LMFL (female) (1) and LMD1 (female) (1) Resistance Max. 1 Ω
7 (Disconnection or defective con- Between LMD1 (female) (1) and LMD2 (female) (1) Resistance Max. 1 Ω
tact) Between LMFL (female) (2) and ground Resistance Max. 1 Ω
Between LMFL (female) (3) and CB5 (2) Resistance Max. 1 Ω
Between LMFL (female) (1) and LMFR (female) (1) Resistance Max. 1 Ω
Between FLSW (female) (6) and LMD1 (female) (2) Resistance Max. 1 Ω
Between FLSW (female) (4) and LMD2 (female) (2) Resistance Max. 1 Ω
Between FLSW (female) (5) and KEY (female) (1) Resistance Max. 1 Ω
Between FLSW (female) (2) and ground Resistance Max. 1 Ω
Ground fault of wiring harness 2. Disconnect connectors LMD1, LMD2, LMFL, LHDR and LHDL, and connect
8 T-adapter to female side of LMFL.
Between LMFL (female) (1) and ground Resistance Min. 1 MΩ
40-578 D375A-6
(01)
DRAFT
Circuit diagram related to ripper point lamp
D375A-6 40-579
(01)
DRAFT
Trouble 2) Working lamp does not light up.

Related infor- q If headlamps do not light up, see "1) Headlamp does not light up" first.
mation

Defective working lamp (Breakage
1 Since the working lamp may be defective, check its bulb for breakage.
of bulb)
When the fuse is blown, a ground fault may have probably occurred in the
2 Defective fuse (FS22-2)
circuit.
2. Replace relay (connector: LMW) with backup alarm relay (connector:
Defective working lamp relay
BKA).
3 (Internal disconnection or short cir-
cuit) 3. Turn starting switch ON position.
If working lamp lights up, original working lamp relay is defective.
a Check location where voltage abnormality occurs and locate defective
point of wiring harness.
2. Disconnect connectors LWKR and LWKL, and connect T-adapters to
Between LWKL (female) (1) and (2) Voltage 20 – 30V
Between LWKR (female) (1) and (2) Voltage 20 – 30V
Disconnection in, or ground fault of
4 1. Turn starting switch to OFF position.
wiring harness
2. Disconnect connector LMW and connect T-adapter to female side.
Between LMW (female) (1) and (2) Voltage 20 – 30V
Between LMW (female) (3) and (2) Voltage 20 – 30V
2. Disconnect connector FLSW and connect T-adapter to female side.
Between FLSW (female) (5) and (2) Voltage 20 – 30V
3. Disconnect connectors LMW, LWKR and LWKL, and connect T-adapters
to female side of them.
Between LWKR (female) (2) and ground Resistance Max. 1 Ω
Disconnection in wiring harness Between LWKL (female) (2) and ground Resistance Max. 1 Ω
5
(Disconnection or defective contact) Between LWKR (female) (1) and LMW (female) Resistance Max. 1 Ω
(5)
Between LWKL (female) (1) and LMW (female)
(5)
Between LMW (female) (1) and LMFL (female)
(1)
Between LMW (female) (2) and ground Resistance Max. 1 Ω
Between LMW (female) (3) and FS22-2 Resistance Max. 1 Ω
6 3. Disconnect connectors LMW, LWKR and LWKL, and connect T-adapters
to female side of LMW.
Between LMW (female) (3) and ground Resistance Min. 1 MΩ
Between LMW (female) (5) and ground Resistance Min. 1 MΩ
40-580 D375A-6
(01)
DRAFT
Circuit diagram related to ripper point lamp
D375A-6 40-581
(01)
DRAFT
Trouble 3) Back-up lamp and ripper point lamp do not light.

q If fuse, back-up lamp relay, back-up lamp switch or common wiring harness of back-up lamp and rip-
Related infor- per point lamp is defective, neither of back-up lamp and ripper point lamp does not light up (If either
mation of back-up lamp and ripper point lamp lights up, this check is not required).
q For related circuit diagram, see 2).

Defective rear lamp (Breakage of
1 Since the rear lamp may be defective, check its bulb for breakage.
bulb)
Defective ripper point lamp (Bro-
2 Since the ripper point lamp may be defective, check its bulb for breakage.
ken bulb)
3 Defective fuse FS22-1 If fuse FS22-1 is broken, circuit probably has ground fault.
2. Replace relay (connector: LMRE) with backup alarm relay (connector:
Defective back-up lamp relay
BKA).
4 (Internal disconnection or short cir-
cuit) 3. Turn starting switch ON position.
4. Turn back-up lamp switch to ON position.
If back-up lamp lights up, original back-up lamp relay is defective.
2. Disconnect connector RLSW and connect T-adapter to male side.
5 Defective rear lamp switch 3. Turn back-up lamp switch to ON/OFF position and troubleshoot.
Between RLSW (female) (5) and (6)
a Check location where voltage abnormality occurs and locate defective
point of wiring harness.
2. Disconnect connectors LREL, LRER and LRP, and connect T-adapter to
Between LREL (female) (1) and (2) Voltage 20 – 30V
Between LRER (female) (1) and (2) Voltage 20 – 30V
Between LRP (female) (1) and (2) Voltage 20 – 30V
Disconnection in, or ground fault of a If no failure is detected by above checks, this check is not required.
6
wiring harness 1. Turn starting switch to OFF position.
2. Disconnect connector LMRE and connect T-adapter to female side.
Between LMRE (female) (1) and (2) Voltage 20 – 30V
Between LMRE (female) (3) and (2) Voltage 20 – 30V
2. Disconnect connector RLSW and connect T-adapter to female side.
Between RLSW (female) (5) and (2) Voltage 20 – 30V
3. Disconnect connectors FLSW, DIODE, FLP, LHDR, LHDL and KEY, and
connect T-adapters to female side of them.
Between LRER (female) (2) and ground Resistance Max. 1 Ω
Between LREL (female) (2) and ground Resistance Max. 1 Ω
Disconnection in wiring harness Between LRP (female) (2) and ground Resistance Max. 1 Ω
7 (Disconnection or defective con- Between LRER (female) (1) and LMRE (female) (5) Resistance Max. 1 Ω
tact) Between LREL (female) (1) and LMRE (female) (5) Resistance Max. 1 Ω
Between LRP (female) (1) and LMRE (female) (5) Resistance Max. 1 Ω
Between LRP (female) (2) and ground Resistance Max. 1 Ω
Between LMRE (female) (1) and RLSW
(female)(1), (6)
Between LMRE (female) (2) and ground Resistance Max. 1 Ω
Between LMRE (female) (3) and FS22-1 Resistance Max. 1 Ω
Between RLSW (female) (5) and KEY (female) (1) Resistance Max. 1 Ω
Between RLSW (female) (2) and ground Resistance Max. 1 Ω
40-582 D375A-6
(01)
DRAFT
Ground fault of wiring harness 3. Disconnect connectors LRER, LREL, LRP, LMRE and RLSW, and connect
8
(Contact with GND circuit) T-adapter to female side of LMRE.
Between LMRE (female) (1) and ground Resistance Min. 1 MΩ
D375A-6 40-583
(01)
DRAFT
E-26 Windshield wiper does not operate

Trouble 1) None of the wipers operate.
Related infor-
mation

If CB105 circuit breaker is turned ON, the circuit probably has ground fault. In
1 Defective CB105 circuit breaker
this case, perform troubleshooting for cause 4 first.
Disconnection in, or ground fault 1. Turn starting switch to OFF position.
2
of wiring harness Between terminal (B) in cab fuse box and ground Voltage 20–30V
Disconnection in wiring harness a If CB105 circuit breaker is turned ON, reset it first.
3 (Disconnection or defective con- 1. Turn starting switch to OFF position.
tact) Between battery relay BRC terminal and cab fuse
box (B) terminal
a If neither of causes 1 and 2 is the cause for the trouble, this check is not
required.
4
(Contact with ground circuit) 2. Remove terminal (B) from cab fuse box.
Between terminal (B) in cab fuse box (Wiring har-
ness side) and ground
Circuit diagram related to wiper
40-584 D375A-6
(01)
DRAFT
Trouble 2) Front windshield wipers do not operate.

Related infor- q T-adapter is not prepared for each connector. (Perform troubleshooting without using T-adapters.)
mation q For related circuit diagram, see Trouble 1).

If fuse shown at left is broken, circuit probably has ground fault. In this case,
1 Defective fuse 4 in cab fuse box
perform troubleshooting for cause 6 first.
Defective front wiper motor
2 2. Disconnect connector CN-9 and connect T-adapter to male side.
Between CN-9 (male) (2) and (5) Continuity
2. Disconnect connector CN-12.
3. Turn front wiper switch ON and OFF, and troubleshoot.
3 Defective front wiper switch OFF Resistance Min. 1 MΩ
Between CN-12 (male) (3) and (4)
OFF Resistance Max. 1 Ω
ON Resistance Min. 1 MΩ
4 Power supply line a If any abnormality occurs, go to Cause 6 and Trouble 1).
Between terminal (4) in cab fuse box and ground Voltage 20–30V
Disconnection in wiring harness 2. Remove fuse 4 from cab fuse box.
6 (Disconnection or defective con- 3. Turn front wiper switch to ON position.
tact) Between terminal (4) in cab fuse box (Wiring har-
Continuity
5
(Contact with ground circuit) 2. Remove fuse 4 from cab fuse box.
3. Disconnect connectors CN-9 and CN-12.
Between terminal (4) in cab fuse box (Wiring har-
D375A-6 40-585
(01)
DRAFT
Trouble 3) Rear wiper does not operate.


Defective rear wiper motor
3. Turn rear wiper switch ON and OFF, and troubleshoot.
3 Defective rear wiper switch OFF Resistance Min. 1 MΩ
Between terminal (2)in cab fuse box and ground Voltage 20–30V
6 (Disconnection or defective con- 3. Turn rear wiper switch to ON position.
Continuity
Between terminal (2)in cab fuse box and ground Voltage 20–30V
5
40-586 D375A-6
(01)
DRAFT
Trouble 4) Left door wiper does not operate.


Defective left door wiper motor
3. Turn left door wiper switch ON and OFF, and troubleshoot.
3 Defective left door wiper switch OFF Resistance Min. 1 MΩ
6 (Disconnection or defective con- 3. Turn left door wiper switch ON.
Continuity
5
D375A-6 40-587
(01)
DRAFT
Trouble 5) Right door wiper does not operate.

mation

Defective right door wiper motor
3. Turn right door wiper switch ON and OFF, and troubleshoot.
3 Defective right door wiper switch OFF Resistance Min. 1 MΩ
6 (Disconnection or defective con- 3. Turn right door wiper switch ON.
Continuity
5
3. Disconnect the connectors CN-17 and CN-13.
40-588 D375A-6
(01)
DRAFT
Circuit diagram related to wiper
D375A-6 40-589
(01)
DRAFT
E-27 Window washer does not operate

Trouble 1) Front window washer does not operate.
q If wiper also does not operate, see E-26 1) or 2).
Related
q T-adapter is not prepared for window washer motor connector (Perform Troubleshooting without
information
T-adapter).

a Check that rear window washer sprays water normally.
Defective front window washer 2. Replace connector WSFR with WSRR.
1 motor (Internal defect) 3. Turn starting switch to ON position.
(Internal disconnection) 4. Turn front window washer switch to ON position.
If rear window washer sprays water, original front window washer motor is
defective.
2 Defective front wiper switch 3. Disconnect connector CN-12 and connect T-adapter to male side.
4. Turn switch ON and OFF, and troubleshoot.
3 (Disconnection or defective con- 3. Turn front window washer switch to ON position.
Continuity
2. Remove fuse 4 from fuse box.
4 3. Disconnect connectors CN-12 and WSFR.
40-590 D375A-6
(01)
DRAFT
Circuit diagram related to window washer
D375A-6 40-591
(01)
DRAFT
Trouble 2) Rear window washer does not operate.

Related infor-
q T-adapter is not prepared for window washer motor connector (Perform Troubleshooting without
mation
T-adapter).

a Check that front window washer sprays water normally.
Defective rear window washer 2. Replace connector WSFR with WSRR.
1 motor 3. Turn starting switch to ON position.
(Internal disconnection) 4. Turn rear window washer switch to ON position.
If front window washer spouts water, original rear window washer motor is
defective.
2 Defective rear wiper switch 3. Disconnect connector CN-14 and connect T-adapter to male side.
3 (Disconnection or defective con- 3. Turn rear window washer switch to ON position.
Continuity
4 3. Disconnect connectors CN-14 and WSRR.
40-592 D375A-6
(01)
DRAFT
Circuit diagram related to window washer
D375A-6 40-593
(01)
DRAFT
Trouble 3) Right door window washer does not operate.

Related infor- q T-adapter is not prepared for window washer motor connector (Perform Troubleshooting without
mation T-adapter).

a Check that left door window washer sprays water normally.
2. Replace connector WSLH with WSRH.
Defective right door washer motor
4. Turn right door window washer switch to ON position.
If left door window washer sprays water, original right door window washer
motor is defective.
2 Defective right door wiper switch 3. Disconnect connector CN-13 and connect T-adapter to male side.
3 (Disconnection or defective con- 3. Turn right door window washer switch to ON position.
Continuity
4 3. Disconnect connectors CN-13 and WSRH.
40-594 D375A-6
(01)
DRAFT
Trouble 4) Left door window washer does not operate.

Related infor- q T-adapter is not prepared for window washer motor connector (Perform Troubleshooting without
mation T-adapter).

a Check that right door window washer sprays water normally.
2. Replace connector WSLH with WSRH.
Defective left door washer motor
4. Turn left door window washer switch to ON position.
If right door window washer sprays water, original left door window washer
motor is defective.
2 Defective left door wiper switch 3. Disconnect connector CN-11 and connect T-adapter to male side.
3 (Disconnection or defective con- 3. Turn left door window washer switch to ON position.
Continuity
4 3. Disconnect connectors CN-11 and WSLH.
D375A-6 40-595
(01)
DRAFT
E-28 Electric priming pump does not operate or does not stop automatically
E-28 Electric priming pump does not operate or does not stop automati-
cally
Trouble q Electric priming pump does not operate or does not stop automatically.
Related infor-
mation

1 Low battery charge level Battery charge level may be low. Check battery directly.
If circuit breaker CB7 is turned OFF, circuit probably has ground fault. (Check
2 Defective circuit breaker CB7
cause No. 5)
2. Disconnect connectors EPP, and connect T-adapter to female side.
(Drive power supply system) 3. Connect ground strap.
3 Between EPP (1) - (2) Voltage 20 – 30V
(Disconnection in wiring or defec-
tive contact in connector) 1. Disconnect ground strap (to turn constant power supply OFF).
Between EPP (female) (2) and ground Resistance Max. 1 Ω
1. Disconnect ground strap (to turn constant power supply OFF).
Ground fault in wiring harness 2. Disconnect connectors EPP, and connect T-adapter to female side.
4 3. Disconnect connectors USB, EG1 and EFP.
Between EPP (female) (1) and ground Resistance Min. 1 MΩ
Between EPP (female) (3) and ground Resistance Min. 1 MΩ
5 Defective electric priming pump 4. Defective electric priming pump ON
Between EPP (3) and (4) Voltage 20 – 30V
q If lamp flashes but output voltage is defective or if result of troubleshooting
1-4 is normal and lamp does not flash, electric priming pump is defective.
Defective electric priming pump When electric priming pump does not stop automatically, electric priming
6 switch (Malfunction or automatic pump switch may be defective.
stop failure) (Turn toggle switch OFF to stop pump and then replace switch.)
q Lamp blinks but stops in about 5 seconds.
Overload on electric priming
7 * If pump is overloaded, power supply is turned OFF automatically to protect
pump
circuit (Priming switch is reset automatically).
2. Disconnect connectors EPP, and connect T-adapter to male side.
8 Trouble in electric priming pump Between EFP (male) (1) and (2) Resistance 1–3Ω
Between EFP (male) (1) – pump body Resistance Min. 1 MΩ
Between EFP (male) (2) – pump body Resistance Min. 1 MΩ
40-596 D375A-6
(01)
DRAFT
E-28 Electric priming pump does not operate or does not stop automatically
Circuit diagram related to electric priming pump
D375A-6 40-597
(01)
DRAFT
E-29 Orbcomm terminal does not operate normally (Data are not transmitted)
E-29 Orbcomm terminal does not operate normally (Data are not trans-
mitted)
Trouble q The ORBCOMM terminal does not operate normally (Data are not transmitted).
Related infor- q Even if the ORBCOMM terminal is abnormal, it does not cause a trouble in the machine.
mation

After 3 minutes or later from VHMS startup, check the VHMS controller
decimal point (dot LED at right lower position of 7-segment display) (*1) or
check the machine monitor display (*2).
*1 Lamp is Power is not applied to ORBCOMM terminal or the communi-
Terminal power supply is abnormal or OFF cation with VHMS controller is abnormal.
1
satellite is not captured Power is applied to ORBCOMM terminal and the communica-
*1 Lamp is
tion with VHMS controller is normal. But it does not capture
ON
satellite.
Power is applied to ORBCOMM terminal, capturing satellie
*1 Flashing
and the communication with VHMS controller is normal.
3. Disconnect connectors KOM1 and V4B, and connect T-adapters to
Disconnection in wiring harness a Constant power supply is used. When disconnecting connector and
2 (Disconnection or defective contact in carrying out troubleshooting, take care.
connector) Between KOM1 (female) (36), (39) and VF2
(male) (5)
Between KOM1 (female) (37), (38) and ground Resistance Max. 1 Ω
Between V4B (female) (3)–KOM1 (female) (11) Resistance Max. 1 Ω
Between V4B (female) (4)–KOM1 (female) (4) Resistance Max. 1 Ω
Between V4B female) (10)–KOM1 (female) (5) Resistance Max. 1 Ω
Defective ORBCOMM terminal 3. Disconnect connectors KOM1, and connect T-adapter to female side.
3
(When LED is turned OFF) 4. Connect ground strap.
Between KOM1 (female) (36) and (37) Voltage 20 – 30V
Between KOM1 (female) (39) and (38) Voltage 20 – 30V
*1 Location of VHMS controller decimal point (dot LED at right lower position of 7-segment display)
*2 Checking on the machine monitor

1) Turn starting switch to ON position.
2) Switch machine monitor to Service menu.
3) Select Monitoring.
4) Enter "99003".
40-598 D375A-6
(01)
DRAFT
E-29 Orbcomm terminal does not operate normally (Data are not transmitted)
Circuit diagram related to ORBCOMM terminal
D375A-6 40-599
(01)
DRAFT
E-30 Gear cannot be shifted
E-30 Gear cannot be shifted

Trouble q Gear cannot be shifted (Shift switch does not work).
Related infor-
mation

Trouble in shift operation a When failure code related to shift operation switch is not displayed.
switch Press shift operation switch for more than 10 seconds. If any of following failure code
q Shift up switch is displayed at this time, carry out troubleshooting for it.
1
q Shift down switch [DD12KA], [DD12KB], [DD13KA], [DD13KB], [DDK5KA], [DDK5KB]
q Shift switch a When failure code related to shift operation switch is displayed.
(Optional-type lever) Carry out troubleshooting for displayed failure code.
Internal defect of transmis-
2 The inside of the transmission clutch is supposed to be defective, check it directly.
sion clutch
40-600 D375A-6
(01)
DRAFT
Troubleshooting of hydraulic and mechanical system (H-mode)

a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before performing troubleshooting, understand that information fully.
Trouble Trouble in machine

Related infor-
Information related to detected trouble or troubleshooting
mation
Possible 2
Possible causes of trouble
causes and <Contents of description>
(Given numbers are reference
standard value q Standard value to determine possible causes
numbers, which do not indicate
for judgment q Remarks on judgment
priority)
3
D375A-6 40-601
(01)
DRAFT
List of Failure Modes and Causes

Components causing failures Hydraulic components
Main
ECMV
pump
Torque converter operation valve
Transmission main relief valve

Transmission operation valve

Torque converter relief valve
For forward-reverse clutch
Hydraulic tank strainer

For gearshift clutch
For steering clutch
Power train pump
For lockup clutch
For brake clutch

Steering valve
Servo valve
EPC valve
Main body
Failure modes
No force (No drawbar pull). Q Q Q Q Q Q Q
No travel (at 2nd or 3rd speed). Q Q Q Q Q
Q Q Q Q Q Q Q Q Q
Related to power train
No travel at all gear speeds.

Machine travels only in one direction forward or in reverse. Q Q
Large time lag at gear speed shifting or forward-reverse shift-
Q Q Q Q Q
ing.
Steering is not possible. Q Q
Steering is possible only on one side. Q Q Q
Steering overrun occurs. Q Q
Brake does not work. Q Q
Torque converter is not locked-up. Q Q Q
Power train oil overheats.
All work equipment operates slowly or lacks power. Q Q Q Q Q
All work equipment does not operate. Q Q Q Q Q
Blade lift speed is slow or lacks power.
Related to work equipment
Blade tilt speed is slow or lacks power.

Ripper lift speed is slow or lacks power
Ripper tilt speed is slow or lacks power
Excessive hydraulic drift of blade lift.
Excessive hydraulic drift of blade tilt.
Excessive hydraulic drift of ripper lift.
Ripper pin puller cylinder does not work (giant ripper attach-
ment machine).
Blade pitch does not work (dual tilt attachment machine).
Abnormal sound comes out from around work equipment
Q Q Q Q
pump.
Fan speed is abnormal (sound and/or vibration are abnor-
mally large or engine overheats).
40-602 D375A-6
(01)
Q
Q
Q
Q
Q
PPC valve
(01)
Q
PPC lock valve
Valve body
D375A-6
Spool
Q
Q Q
Q Q
Q Q
Q
Q
Q
Q
Unload valve
Main relief valve
LS relief valve
Q Q Q
Q Q Q
Suction valve
Q
Q
Control valve
Pressure compensation valve

LS check valve
Q
Q
Hydraulic cylinder
Hydraulic components
Q QQ
Q
Q
Q
Q
QQ
Ripper pin-puller solenoid valve
QQ
Pitch selection solenoid valve
Q
Fan pump
Fan motor
Q Q
Brake pedal linkage
Q
Q
Q
Q
Q
Parking brake linkage
Q Q
Q
Q Q Q
Q Q Q
Steering clutch (disc, plate, etc.)
Q
Q
Q Q
Q Q
Brake clutch (disc, plate, etc.)
Inside of transmission
Q
Q
Q Q
Q Q Q Q Q Q
Q Q
Q Q
Q
Inside of torque converter
DRAFT
Q
Q
PTO
QEngine
Mechanical system
Cooling system
Loosening of piping clamp, air in hydraulic oil and oil leakage
Q
Q Q Q
Q Q
Q
Diagnosis codes
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-11
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-10
40-603
DRAFT
H-1 Machine lacks power(or drawbar pull)

Trouble q Power is low (Insufficient drawbar pull)
q When Manual transmission or show slip control is selected for the gear shift mode, and when operation
Related
is in the E mode, the contents of this section are not applied.
information
q Make sure that hydraulic oil level of power train is normal, and start troubleshooting.

a Prepare by turning starting switch to OFF position, then trouble-
shoot by rotating engine at high idling speed.
Defective engine or trans- Measuring conditions Engine speed
1
mission F3 stall 1,450 rpm
Stall in F3 + Relief of work equip-
1,400 rpm
ment system (Pitch back)
2 Defective power train pump The power train pump is assumed to be defective; directly check it.
Internal defect of torque con- Torque converter Torque converter
3 PCCS lever
verter inlet pressure outlet pressure
0.69 – 1.08 MPa 0.44 – 0.74 MPa
All neutral position
{7.0 – 11.0 kg/cm2} {4.5 – 7.5 kg/cm2}
Transmission
PCCS lever
main relief pressure
2.53 – 3.12 MPa
Defective set pressure of All neutral position
Possible
4 transmission main relief {25.8 – 31.8 kg/cm2}
causes and a Prepare with starting switch OFF, then carry out troubleshooting
valve and internal defect
standard without turning starting switch ON.
value in nor- Directly check that the spring length and the number of shims are nor-
mal state mal and also that the spool rotates smoothly.
q Free length of spring: 120.3 mm
q Number of shims: 4
shoot by rotating engine at low idling speed.
Transmission clutch Clutch pressure
Operation failure of trans- FWD Min. 2.06 MPa {Min. 21.0 kg/cm2}
5 REV Min. 2.06 MPa {Min. 21.0 kg/cm2}
mission valve (ECMV)
1ST Min. 1.86 MPa {Min. 19.0 kg/cm2}
2ND Min. 2.06 MPa {Min. 21.0 kg/cm2}
3RD Min. 2.06 MPa {Min. 21.0 kg/cm2}
a Move the machine to a flat ground and start the engine for trouble-
shooting.
Defective operation (drag-
6 If machine does not move when engine is low-idling and F2 shift is
ging) of brake
selected, braking is applied (troubleshoot by referring to "H-9 Brake
system does not operate".
If the result of the troubleshooting in cause 6 is abnormal, the parking
Defective parking brake
7 brake lever or brake pedal linkage is not assumed to be adjusted nor-
lever or brake pedal linkage
mally. Directly check it.
40-604 D375A-6
(01)
DRAFT

a After checking that the transmission main relief pressure is normal.
shoot by rotating engine at high idling speed.+
PCCS lever Left stroke end Right stroke end
Min. 2.4 MPa 0 MPa
{Min. 24 kg/cm2} {0 kg/cm2}
Possible 0 MPa Min. 2.4 MPa
causes and 8 Defective steering clutch Right clutch pressure
{0 kg/cm2} {Min. 24 kg/cm2}
standard
0 MPa Min. 2.4 MPa
value in nor- Left brake pressure
mal state {0 kg/cm2} {Min. 24 kg/cm2}
Min. 2.4 MPa 0 MPa
When the oil pressure is abnormal, execute the troubleshooting of
"H-6 Steering is not possible."
Internally defective transmis- The transmission is assumed to be defective internally; directly check
9
sion it.
D375A-6 40-605
(01)
DRAFT
H-2 Machine cannot travel (at 2nd or 3rd each speed)
H-2 Machine cannot travel (at 2nd or 3rd each speed)

Trouble q Machine cannot start (at 2nd or 3rd gear speed)
q Before performing troubleshooting, check that the power train oil level is normal.
q Before performing troubleshooting, check that the transmission main relief pressure is normal. (See
Related infor-
H-1.)
mation
q If any one of failure code of [15SFL1], [15SFLH], [15SGL1] or [15SGLH] is displayed, perform trou-
bleshooting for the failure code first.
Cause Standard value /Remarks on troubleshooting

a Prepare with starting switch to OFF position , then run the engine
at full speed to perform troubleshooting.
Internal defect of torque con- Torque converter Torque converter out-
1 PCCS lever
verter inlet pressure let pressure
0.69 – 1.08 MPa 0.44 – 0.74 MPa
Neutral for all controls
{7.0 – 11.0 kg/cm2} {4.5 – 7.5 kg/cm2}
a Prepare with starting at switch OFF positon , then run the engine
at low speed to perform troubleshooting.
Defective operation of trans- Min. 2.06 MPa
2 2ND
{Min. 21.0 kg/cm2}
Min. 2.06 MPa
3RD
{Min. 21.0 kg/cm2}
Defective operation (drag- The operation at the parking brake may be defective (drags) , Check
3
ging) of parking brake the linkage or valves.
Possible a Move the machine to flat ground and start the engine to perform
causes and troubleshooting.
standard value 4 Run the engine at low speed and set the gear to F2. If the machine
ging) of brake
for judgment move, the brake drags. (Perform the troubleshooting for "H-9 Brake
does not work.")
a Prepare with starting switch at OFF position , then run the engine
at full speed to perform troubleshooting
Min. 2.4 MPa 0 MPa
0 MPa Min. 2.4 MPa
Defective steering clutch, or Right clutch pressure
5 {0 kg/cm2} {Min. 24 kg/cm2}
brake
0 MPa Min. 2.4 MPa
Left brake pressure
Min. 2.4 MPa 0 MPa
When the oil pressure is abnormal, perform the troubleshooting for
"H-6 machine cannot turn."
6 Transmission may have an internal defect. Check it directly.
sion
40-606 D375A-6
(01)
DRAFT
H-3 Machine cannot travel at any gear speeds
H-3 Machine cannot travel at any gear speeds

Trouble q Machine can not travel at any gear speeds
q Performing troubleshooting, check that the power train oil level is normal.
Related infor- q If any one of failure code of [1500L0], [2201L1], [2201LH], [2202L1], [2202LH], [DDT5KA],
mation [DDT5KB], [DK30KX], [DK30KZ], [DK55KX] or [DK55KZ] is displayed, perform troubleshooting for
the failure code first.
1 The power train pump is may be defective. Check it directly.
pump
a Prepare with starting switch at OFF position, then run the engine at
full speed to perform troubleshooting.
Incorrect set pressure of Transmission
2 transmission main relief PCCS lever
main relief pressure
valve 2.53 – 3.12 MPa
{25.8 – 31.8 kg/cm2}
a Prepare with starting switch at OFF position, then perform trouble-
shooting leaving starting switch intact.
Defective operation of
Directly check that the spring length and the number of shims are normal
3 transmission main relief
and also that the spool moves smoothly.
valve
q Free length of spring: 120.3 mm
q Number of shims: 4 sheets
a Prepare with starting at OFF position, then run the engine at low
speed to perform troubleshooting.
4 transmission valve FWD Min. 2.06 MPa {Min. 21.0 kg/cm2}
(ECMV) REV Min. 2.06 MPa {Min. 21.0 kg/cm2}
1ST Min. 1.86 MPa {Min. 19.0 kg/cm2}
2ND Min. 2.06 MPa {Min. 21.0 kg/cm2}
3RD Min. 2.06 MPa {Min. 21.0 kg/cm2}
a Move the machine to level ground, raise parking the brake lever, run
Possible
the engine at full speed to perform troubleshooting.(Before starting
causes and
troubleshooting ,check that transmission main relief pressure is nor-
standard value Defective operation of
5 mal).
for judgment brake Brake pedal Brake oil pressure (right and left)
Release Min. 2.4 MPa {Min. 24 kg/cm2}
0 MPa
Depressed
{0 kg/cm2}
a Prepare with starting at switch OFFposition, raise parking brake lever
to release the brake , run the engine at full speed to perform trouble-
shooting (Before starting troubleshooting ,check that transmission
main relief pressure is normal).
Min. 2.4 MPa 0 MPa
Defective seal of steering Left clutch pressure
6 {Min. 24 kg/cm 2}
{0 kg/cm2}
clutch or brake
0 MPa Min. 2.4 MPa
Right clutch pressure
0 MPa Min. 2.4 MPa
Left brake pressure
Min. 2.4 MPa 0 MPa
Internal defect of steer-
7 The inside of the steering clutch may be defective, check it directly.
ing clutch and brake
Perform troubleshooting for the failure codes [DDQ2KA], [DDQ2KB],
Malfunction of parking [DDQ2L4] and [dDQ2L4].
8
brake lever switch Even if failure code is not displayed, check that switch operates nor-
mally.
Internal defect of trans-
9 The inside of transmission clutch may be defective. Check it directly.
mission clutch
D375A-6 40-607
(01)
DRAFT
H-4 Machine travels only in one direction, forward or reverse
H-4 Machine travels only in one direction, forward or reverse

Trouble q Machine travels only in one direction ,forward or in Reverse.
Related infor- q Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.)
mation q If any one of failure code of [15SAL1], [15SALH], [15SBL1] or [15SBLH] is displayed, perform trou-
bleshooting for the failure code first.

a Prepare with starting switch at OFFposition, then run the engine
at low speed to perform troubleshooting.
q Before troubleshooting, check that the transmission main relief
pressure is normal. (See H-1.)
Min. 2.06 MPa
FWD
{Min. 21.0 kg/cm2}
Defective operation of trans- Min. 2.06 MPa
1 REV
mission valve (ECMV) {Min. 21.0 kg/cm2}
Min. 1.86 MPa
Possible 1ST
causes and {Min. 19.0 kg/cm2}
Min. 2.06 MPa
standard value 2ND
in normal state {Min. 21.0 kg/cm2}
Min. 2.06 MPa
3RD
{Min. 21.0 kg/cm2}
Defectively sealed of trans- If the result of the test for cause 4 shows malfunction of the brake,
2
mission clutch the clutch seal may be defective. Check it directly.
Internal defect of transmis- The inside of the transmission clutch is supposed to be defective.
3
sion clutch Check it directly.
a Move the machine to flat ground and start the engine to perform
troubleshooting.
4 Run the engine at low speed mode and set to gear to F2. If the
ging) of brake
machine does not move, the brake drags. (Perform the troubleshoot-
ing for "H-9 Brake does not work").
40-608 D375A-6
(01)
DRAFT
H-5 Large time lag at gear shifting or directional change
H-5 Large time lag at gear shifting or directional change

Trouble q Large time lag at gear shifting or directional change.
Related
q Before performing troubeshooting ,check that the power train oil level is normal.
information

1 Defective power train pump The power train pump may be defective. Check it directly.
a Prepare by turning starting switch at OFF position, then run the en-
gine at full speed to perform troubleshooting.
Transmission
PCCS lever
Defective operation of trans- main relief pressure
2 2.45 – 2.94 MPa
mission main relief valve
{25.0 – 30.0 kg/cm2}
When the oil pressure is abnormal, clean the valve and then check the
oil pressure again.
a Prepare with starting switch at OFF position , then perform trouble
starting switch intact..
Defective operation of trans- Directly check that the spring free length and the number of shims are
3
mission main relief valve normal and that the spool moves smoothly.
q Free length of spring: 120.3mm
q Number of shims: 4
a Prepare by turning starting switch at OFF position, then run the en-
Possible gine at low speed to perform troubleshooting .
causes and Transmission clutch Clutch pressure
standard Min. 2.06 MPa
value in nor- FWD
{Min. 21.0 kg/cm2}
mal state Min. 2.06 MPa
Operation failure of trans- REV
4 {Min. 21.0 kg/cm2}
Min. 1.86 MPa
1ST
{Min. 19.0 kg/cm2}
Min. 2.06 MPa
2ND
{Min. 21.0 kg/cm2}
Min. 2.06 MPa
3RD
{Min. 21.0 kg/cm2}
Defectivly sealed transmis- When the standard values for the cause 3 are not satisfied, the clutch
5
sion clutch seal may be defective. Check it directly.
6 Inside of transmission clutch may be defective. Check it directly.
sion clutch
a Move the machine to flat ground and start the engine to perform
troubleshooting.
Defective operation of brake
7 If machine does not move when engine is low-idling and F2 shift is
(dragging)
selected, braking is applied (troubleshoot by referring to "H-9 Brake
8 Type of oil used Check if an oil other than the specified oil (T030) is being used.
D375A-6 40-609
(01)
DRAFT
H-6 Machine connot turn
H-6 Machine connot turn

Trouble q Machine connot turn.
Related informa-
tion
H-1.)

a Prepare with engine started , then run the engine at low speed
whild performing troubleshooting.
1 Raise machine by using blade and ripper, run tracks with gear at F3
brake
(or R3), and make steering operation .If track stops running, brake is
defective. (Perform troubleshooting for "H-9 Brake does not work".)
a Prepare with starting switch at OFF positon, then run the engine
at full speed to perform troubleshooting
Min. 2.4MPa 0MPa
Left clutch pressure 2}
Possible causes Defective operation of {Min. 24 kg/cm {0 kg/cm2}
and standard 2 steering clutch valve 0MPa Min. 2.4MPa
Right clutch pressure 2
value for judg- (ECMV) {0 kg/cm } {Min. 24 kg/cm2}
ment 0MPa Min. 2.4MPa
Left brake pressure 2
{0 kg/cm } {Min. 24 kg/cm2}
Min. 2.4MPa 0MPa
Right brake pressure 2
{Min. 24 kg/cm } {0 kg/cm2}
Defectively sealed steering When standard values for the cause 2 are not satisfted, the clutch
3
clutch seal may be sealed diffectively. Check it directly.
Internal defect of steering
4 Steering clutch may be defective, check it directly.
clutch
5 steering potentiometer of Perform troubleshooting related to steering potentiometer.
travel control lever
40-610 D375A-6
(01)
DRAFT
H-7 Machine turns only to one side
H-7 Machine turns only to one side

Trouble q Machine turns only to one side.
Related infor-
mation
H-1.)

a Prepare with engine started, then run the engine at low speed
while performing troubleshooting.
Raise machine by using blade and ripper, drive it in F3 (or R3), and
1 Defective operation of brake
steer it in direction in which machine cannot turn. If track shoe stops
at this time, brake is defective. (Carry out troubleshooting for "H-9
Brake does not work".)
a Prepare with starting switch at OFF position, then run the engine
at full speed to perfrom troubleshooting.
Min. 2.4MPa 0MPa
Possible Left clutch pressure 2}
{Min. 24 kg/cm {0 kg/cm2}
causes and Defective operation of steer- 0MPa Min. 2.4MPa
2 Right clutch pressure
standard value ing clutch valve (ECMV)
for judement
0MPa Min. 2.4MPa
Left brake pressure 2
{0 kg/cm } {Min. 24 kg/cm2}
Min. 2.4MPa 0MPa
Right brake pressure 2
{Min. 24 kg/cm } {0 kg/cm2}
Defectively sealed steering When the standard the cause 2 are not satisfied , the clutch seal may
3
clutch be sealed defectively. Check it directly.
Internal defect of steering
4 Steering clutch may be defective, check it directly.
clutch
Defective operation of steer-
5 ing potentiometer of travel Perform troubleshooting related to steering potentiometer.
control lever
D375A-6 40-611
(01)
DRAFT
H-8 Machine overruns at turnning
H-8 Machine overruns at turnning

Trouble q Machine overruns at turnning.
Related
information
H-1.)

a Prepare with starting switch OFF, then drive the engine in low idle
mode for troubleshooting.
Possible
Raise the machine by using the blade and run the engine with gear at
causes and 1 Defective operation of brake
F3 travel (or R3 travel) and make steering operation. If the shoe stops
standard
running ,the brake is defective. (Perform the troubleshooting for “H-9
value for
Brake does not work.”)
judgment
When track shoe does not stop running in the troubleshooting for the
Defective operation of steer-
2 cause 1, the steering clutch is defective. (Perform the troubleshooting
ing clutch
fro “H-6 Machine cannot turn.”)
H-9 Brake does not work

Trouble q Brake does not work.
Related infor- q Before performing troubleshooting, check that the transmission main relief pressure is normal. (See
mation H-1.)
q If failure code [DK40KA] or [DK40KB] is displayed, perform diagnoses for the failure code first .

a Start the engine to perform troubleshooting.
1 Degradation of brake Depress the brake pedal, shift the gear to F2 and run the engine at
full speed. If the machine moves, the brake performance is degraded.
Defective operation of brake Brake pedal, linkage and the brake valve may not work normally.
2
pedal Check them directly.
at full speed to perfrom troubleshooting.
Possible
Min. 2.4MPa 0MPa
causes and Left clutch pressure
standard value {Min. 24 kg/cm2} {0 kg/cm2}
Defective operation of steer- 0MPa Min. 2.4MPa
for judgment 3 Right clutch pressure
ing brake valve (ECMV)
0MPa Min. 2.4MPa
Left brake pressure
Min. 2.4MPa 0MPa
When standard the cause 3 are not satisfied , the brake seals may be
4 Defective brake seal
defective. Check it directly.
5 Internal defect of brake Brakes may be defective. Check it directly.
40-612 D375A-6
(01)
DRAFT
H-10 Torque converter does not lock up
H-10 Torque converter does not lock up

Trouble q The torque converter does not lock up.
Related infor-
H-1.)
mation
q If any one of failure code of [DDTSL1], [DDTSLH], [DXH1KA], [DXH1KB], [DXJBKA] or [DXJBKB] is
displayed, perform diagnoses for the failure code first.

1 Defective power train pump The power train pump may be defective. Check it directly.
Defective operation of Torque converter Clutch pressure
2 torque converter lock up Stator 2.50 – 2.79 MPa
valve (ECMV) clutch {25.5 – 28.5 kg/cm2}
At lock up
1.24 – 1.54
Possible Lock up clutch
{12.7 – 15.7 kg/cm2}
causes and Defectively sealed of lock When standard value for the case 2 is not satisfied, the lock up clutch
standard value 3
up clutch may sealed defectively. Check it directly.
for judgment Internal defect of lock up
4 Lock up clutch may be defective. Check it directly.
clutch
a Prepare with starting at switch OFF position, then run the engine
Measurement conditions Engine speed
Internal defect of torque
5 F3,torque converter stall 1,450rpm
converter
F3,torque converter stall +
Work equipment relief 1,170rpm
(pitch back)
D375A-6 40-613
(01)
DRAFT
H-11 Power train oil overheats
H-11 Power train oil overheats

Trouble q Overheating of power train oil
q Make sure that hydraulic oil level of power train is normal, and start troubleshooting.
q Make sure that power train oil temperature gauge indication matches actual oil temperature of torque
Related
converter and start troubleshooting. (If no match, follow "E-9 Power train oil temperature gauge
information
(multi-gauge) does not indicate normally".)
q Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.)

Engine cooling system may be defective and engine output may be
1 Defective engine system increased abnormally. Carry out troubleshooting according to Engine
volume, Shop manual.
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
verter inlet pressure outlet pressure
Possible 0.69 – 1.08 MPa 0.44 – 0.74 MPa
causes and {7.0 – 11.0 kg/cm2} {4.5 – 7.5 kg/cm2}
standard Defective operation (slide) of The inside of the transmission clutch is supposed to be defective (the
value in nor- 4
transmission clutch clutch slides). Check it directly.
mal state a Start the engine for troubleshooting.
Defective operation of brake If machine does not move when engine is low-idling and F2 shift is
5
(dragging) selected, braking is applied (troubleshoot by referring to "H-9 Brake
Defective operation (slide) of The inside of the steering clutch is supposed to be defective (the clutch
6
steering clutch slides). Check it directly.
a Start the engine for troubleshooting.
Defective operation of brake
7 If the machine cannot be stopped completely while performing F3 stall,
(Slip)
the brake is slipping.
Defective power train oil
8 Check the filter element for clogging.
cooler
40-614 D375A-6
(01)
DRAFT
H-12 All work equipment operates too slow or lacks power
H-12 All work equipment operates too slow or lacks power

Trouble q All work equipment operates slowly or lacks power.
Related
q Make sure that hydraulic oil level is normal, and start troubleshooting.
information

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 it
2
large pump directly.
Defective work equipment The work equipment small pump is supposed to be defective. Check it
3
small pump directly.
Defective operation of Work equipment control levers Unload pressure
4
unload valve 2.45 (+1.37/0) MPa
{25 (+14/0) kg/cm2}
Improper pressure set to shoot by rotating engine at high idling speed.
5 main relief valve for blade lift Blade lever Main relief pressure
valve Min. 26.5 MPa
Raise
{Min. 270 kg/cm2}
Internal defect of main relief The inside of the main relief valve for blade lift valve is supposed to be
6
Possible valve for blade lift valve defective. Check it directly
causes and a Prepare by turning starting switch to OFF position, then trouble-
standard Improper pressure set to shoot by rotating engine at high idling speed.
value in nor- 7 main relief valve for blade tilt Blade lever Main relief pressure
mal state ripper Lo valve Min. 26.5 MPa
Raise
{Min. 270 kg/cm2}
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
Defective pressure setting or shoot by rotating engine at high idling speed.
9 defective operation of LS Work equipment control levers LS relief pressure
relief valve Min. 24.52 MPa
At stroke end
{Min. 250 kg/cm2}
Malfunction of self pressure shoot by rotating engine at high idling speed.
10 reducing valve (PPC basic Work equipment control levers Control relief pressure
pressure) Min. 3.1 MPa
{Min. 32 kg/cm2}
If cause 8 is detected, oil may be leaking in PPC valve. Check PPC
11 Internal leak of PPC valve
valve directly.
Operation failure of check
12 Directly inspect the check valve for clogging.
valve of PPC control circuit
D375A-6 40-615
(01)
DRAFT
H-13 All work equipment does not operate
H-13 All work equipment does not operate

Trouble q All work equipment does not operate.
Related
q Make sure that hydraulic oil level is normal, and start troubleshooting.
information

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 it
2
large pump directly.
Defective work equipment The work equipment small pump is supposed to be defective. Check it
3
small pump directly.
Prepare by turning starting switch to OFF position, then troubleshoot
by rotating engine at high idling speed.
Defective operation of Work equipment control levers Unload pressure
4
unload valve 2.45(+1.37/0) MPa
{25(+14/0) kg/cm2}
Improper pressure set to shoot by rotating engine at high idling speed.
5 main relief valve for blade lift Blade lever Main relief pressure
valve Min. 26.5 MPa
Raise
{Min. 270 kg/cm2}
Internal defect of main relief The inside of the main relief valve for blade lift valve is supposed to be
6
valve for blade lift valve defective. Check it directly
Possible Improper pressure set to shoot by rotating engine at high idling speed.
causes and 7 main relief valve for blade tilt Blade lever Main relief pressure
standard ripper Lo valve Min. 26.5 MPa
value in nor- Raise
{Min. 270 kg/cm2}
mal state
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
Defective pressure setting or shoot by rotating engine at high idling speed.
9 defective operation of LS Work equipment control levers LS relief pressure
relief valve 27.44 ± 1.37 MPa
At stroke end
{280 ± 14 kg/cm2}
Malfunction of self pressure shoot by rotating engine at high idling speed.
10 reducing valve (PPC basic Work equipment control levers Control relief pressure
pressure) Min. 3.1 MPa
{Min. 32 kg/cm2}
Defective operation of PPC The PPC lock valve is supposed to operate abnormally. Check the
11
lock valve lever linkage or the lock valve directly.
Operation failure of check Work equipment control levers Control relief pressure
12
valve of PPC control circuit Min. 3.1 MPa
{Min. 32 kg/cm2}
40-616 D375A-6
(01)
DRAFT
H-14 Blade lift cylinder speed is too slow or lacks power
H-14 Blade lift cylinder speed is too slow or lacks power

Trouble q Blade lift cylinders speed is too slow or lacks power.
q Before performing troubleshooting, check that hydraulic tank oil level is normal.
q Check whether the blade is remodeled.
Related infor- q When hydraulic drift rate of the blade lift cylinders is also high, perform troubleshooting for “H-18
mation Excessive hydraulic drift of blade Lift cylinders.”
q If either one of failure code of [DDNALD] or [DDNFLD] is displayed, troubleshooting corresponding to
such code are to be reformed.

a Prepare with starting switch OFF, then run the engine of the full
speed position to perform troubleshooting.
Defective operation of PPC Blade control lever PPC valve output pressure
Possible 1
valve Min. 3.1 MPa
causes and
Raise stroke end
standard value {Min. 32 kg/cm2}
for judgement Defective operation of blade Operation of the blade lift valve spool may be defective. Check it
2
lift control valve (spool) directly.
Air entering blade lift cylin- Air blade lift cylinders.Bleed air and check whether the phenomenon
3
ders changes.
H-15 Blade tilt cylinder speed is too slow or lacks power

Trouble q Blade tilt cylinders speed is too slow or lacks power.
q Before performing troubleshooting, check the hydraulic oil level is normal.
q Check whether the blade is remodeled.
Related infor- q When the hydraulic drift rate of the blade tilt cylinders is also high, perform troubleshooting for “H-19
mation Excessive hydraulic drift of blade tilt cylinders.”
q If either one of failure code of [DDNZLD] or [DDN3LD] is displayed, troubleshooting corresponding to
such code are to be performed.

a Prepare with starting switch OFF, then run the engine at the full
speed position to performe troubleshooting.
Defective operation of PPC Blade control lever PPC valve output pressure
Possible 1
valve Min. 3.1 MPa
causes and
Raise stroke end
standard value {Min. 32 kg/cm2}
for judgement Defective operation of blade Operation of the blade tilt valve spool may be defective.Check it
2
tilt control valve (spool) directly.
Air entering blade tilt cylin- Air may enter the blade tilt cylinders.Bleed air and check wether the
3
ders phenomenon changes.
D375A-6 40-617
(01)
DRAFT
H-16 Ripper lift cylinder speed is too slow or lacks power
H-16 Ripper lift cylinder speed is too slow or lacks power

Trouble q Ripper lift cylinders speed is too slow or lacks power.
q Before performing troubleshooting, check the hydraulic tank oil level is normal.
q Check whether the ripper is remodeled.
Related q When the hydraulic drift rate of the ripper lift cylinders is also high, perform troubleshooting for “H-20
information Excessive hydraulic drift of ripper Lift cylinders.”
q If either one of failure code of [DDNBLD] or [DDNCLD] is displayed, troubleshooting corresponding to
such code are to be performed.

speed position to perform troubleshooting
Defective operation of PPC Ripper control lever PPC valve output pressure
1
valve Min. 3.1 MPa
Possible Raise stroke end
causes and {Min. 32 kg/cm2}
Defective operation of ripper Operation of the ripper lift control valve may be defective.Check it
standard 2
lift control valve (Spool) directly.
value for
The operation of the suction valve for the ripper lift control valve may be
judgement Defective operation of ripper
3 lift control valve (suction
a Judgment may be made by checking a change of phenomenon after
valve)
exchanging suction valves on the head side and on the bottom side.
Air entering ripper lift cylin- Air may enter The ripper lift cylinders.Bleed air and check whether the
4
der phenomenon changes.
H-17 Ripper tilt cylinder speed is too slow or lacks power

Trouble q Ripper tilt cylinders speed is too slow or lacks power.
q Before performing troubleshooting, check that the hydraulic oil level tank is normal.
Related q Check whether the ripper is remodeled.
information q If either one of [DDNDLD] or [DDNELD] is displayed, troubleshooting corresponding to such code are
to be performed first.

a Prepare with starting switch OFF, then run the engine at full speed po-
sition to perform troubleshooting
Defective operation of Ripper lever PPC valve output pressure
1
PPC valve Min.3.1 MPa
Possible Tilt stroke end
causes and {Min. 32 kg/cm2}
Defective operation of rip- Operation of the ripper tilt control valve spool may be defective. Check it
standard 2
per tilt control valve(spool) directly.
value for
Operation of the suction valve for the ripper tilt control valve may be
judgement Defective operation of rip-
3 per tilt operation
a Judgement may be made by checking a change of phenomenon after
valve(suction valve)
exchanging suction valves on the head side and on the bottom side.
Air entering ripper tilt cylin- Air may enter ripper tilt cylinders. Bleed air and check whether the phe-
4
ders nomenon changes.
40-618 D375A-6
(01)
DRAFT
H-18 Excessive hydraulic drift of blade lift cylinder
H-18 Excessive hydraulic drift of blade lift cylinder

Trouble q Excessive hydraulic drift of blade lift cylinders.
Related q Check whether the blade is remodeled.
information q Before performing troubleshooting, check that no oil leaks in the work equipment circuit.

a Prepare with the engine started, then stop the engine to perform
troubleshooting.
Follow the procedure below for troubleshooting. If the hydraulic drift
speed becomes higher,sealing of the blade lift control valve spool may
Defectively sealed blade lift be sealed defectively.
1
control valve (spool) 1. Use the blade lift cylinders to thrust the blade againment the ground,
and raise the front of the machine.
2. Stop the engine, and release the work equipment lock lever.
3. Set the blade control lever to LOWER side, and check whether the
speed changes.
Defectively sealed of blade
2 The blade lift cylinders may be sealed defectively. Check it directly.
Possible lift cylinder
causes and Raise blade about 1,000 mm above the ground and check hydraulic
Defective fitting of quick drop
standard 3 drift of its cutting edge.
valve
value for q 400 mm /15 min
judgement a Prepare by starting the engine, and troubleshoot by rotating engine
at high idling speed.
Troubleshoot using the following procedure and if the work equipment
pump pressure is below the limit, cylinder piston valve is defective.
1. Raise the blade about 1,000 mm and hook the end bit on a rock or
other object. (Do not move the blade.)
Operation failure of piston 2. Raise blade in the above conditions, and measure the pump pres-
4
valve
sure.
3. If pump pressure is within the limit, cylinder piston valve is defective.
4. Disassemble the cylinder, and check piston valve.
Blade lever Blade Pump pressure
24.5 MPa
Raising stroke end Cannot move
{250 kg/cm2}
H-19 Excessive hydraulic drift of blade tilt cylinder

Trouble q Excessive hydraulic drift of tilting blade tilt cylinder.
Related q Check whether the blade is remodeled.
information q Before performing troubleshooting, check that no oil leaks in the work equipment circuit.

a Prepare with the engine started, then stop the engine to performing
troubleshooting.
speed becomes higher, the sealing of the blade tilt control valve spool
Possible Defectively sealed blade tilt may be defective.
1
causes and control valve (spool) 1. Use the blade tilt cylinder to thrust the blade against the ground, and
standard raise the right of the machine.
value for 2. Stop the engine, and release the work equipment lock lever.
judgement 3. Set the blade contorl lever to the right tilt side, and check whether
the speed changes.
Defectively sealed blade tilt speed position to perform troubleshooting
2
cylinder Blade tilt cylinder Oil leak from cylinder
Right tilt stroke end 12 cc/min
D375A-6 40-619
(01)
DRAFT
H-20 Excessive hydraulic drift of ripper lift cylinder
H-20 Excessive hydraulic drift of ripper lift cylinder

Trouble q Excessive hydraulic drift of ripper lift cylinders.
q Check whether the ripper is remodeled.
Related
q Before performing troubleshooting, check that no oil leaks the circuits in the work equipment before
information
troubleshooting.

a Prepare with the engine started, then stop the engine for trouble-
shooting.
speed becomes higher, sealing of the ripper lift control valve (Hi) may
Possible Defectively sealed of ripper be defective.
1
causes and lift control valve (spool) 1. Use the ripper lift cylinders to thrust the ripper against the ground,
standard and raise the rear of the machine.
value for 2. Stop the engine, and release the work equipment lock lever.
judgement 3. Set the ripper control lever to the LOWER side, and check whether
the speed changes.
a Prepare with starting switch OFF, then run the engine at full speed
Defectively sealed of ripper position to perform troubleshooting
2
lift cylinder Ripper lift cylinder Oil leak from cylinder
LOWER stroke end 12 cc/min
H-21 Ripper pin puller cylinder does not operate (machine with giant
ripper)
Trouble q The ripper pin puller cylinder does not operate.
Related
q Check that the transmission main relief pressure is normal before troubleshooting.
information

a Prepare with starting switch at OFF position, then run the engine at
high speed to perform troubleshooting
Defective operation of pin Pin puller working
Possible 1 Pin puller switch Measuring position
puller solenoid pressure
causes and Push-in Cylinder bottom side Min. 2.2 MPa
standard
Pull-in Cylinder head side {Min. 22 kg/cm2}
value for
Internal defect of pin puller
judgment 2 Pin puller cylinder may be defective internally. Check it directly
cylinder
Check fuse for breakage. If it is broken, short circuit has probably
Defective fuse FS2-2(20A)
3 occurred.
for pin puller
Check wiring harness of related circuit.
40-620 D375A-6
(01)
DRAFT
H-22 Blade pitch does not work (machine with dual tilt specification)
H-22 Blade pitch does not work (machine with dual tilt specification)
Trouble q The blade pitch does not work.
Related infor- q If either one failure code of [DW5AKA] or [DW5AKB] is displayed, failure diagnoses corresponding
mation to such code are to be performed first.

Defective operation of blade Operation of the blade pitch selector valve may be defective. Check it
1
pitch selector solenoid valve directly .
Possible Defective function of blade Operation of the blade pitch cylinder may be defective. Check it
2
causes and pitch control valve (Spool) directly.
standard value Defective operation of blade Operation of the blade pitch cylinder may be defective. Check it
3
for judgment pitch cylinder directly.
Perform troubleshooting related to blade pitch switch.
Defective function of blade
4 Even if failure code is not displayed, check that switch operates nor-
pitch switch
mally.
H-23 Abnormal noise from around work equipment pump

Trouble q Abnormal noise from around work equipment pump.
Related
q Befor performing troubleshooting , check hydraulic oil lever is normal.
information

1 Inappropriate oil The oil may be inappropriate. Check it directly.
Possible
Clogged hydraulic tank
causes and 2 The strainer of the hydraulic tank may be clogged. Check it directly.
strainer
standard
Air may be inhaled in the suction circuit of the work machine pump.
value for 3 Air inhaled in suction circuit
Check the circuit directly.
judgment
Internal defect of work equip-
4 The work equipment pump may be defective. Check it directly.
ment pump
D375A-6 40-621
(01)
DRAFT
H-24 Abnormal fan rotation(noise and/or vibration are abnormally large or engine overheats)
H-24 Abnormal fan rotation(noise and/or vibration are abnormally large

or engine overheats)
Trouble q Abnormal fan rotation (noise and/on vibration are abnormally large or engine overheats)
Related
q Before performing troubleshooting, check that oil level in hydraulic tank is normal.
information

a Start engine to performing troubleshooting.
Measuring conditions Engine speed
Engine at low idling 750 ± 50 rpm
1 Defective engine speed
Engine at high idling 1,900 (0/-50) rpm
If engine speed is not increased to specification, perform troubleshoot-
ing for "S-5 Engine dose not rotate smoothly(hunting)".
Defective PTO (fan pump
2 Fan pump drive of PTO may be defective. Check it directly.
drive)
a Prepare with starting switch at OFF position, then run engine at high
idle to perform troubleshooting.
Fan pump EPC circuit source pres-
Measurement conditions
Possible sure
causes and Min. 3.1 MPa
―
standard {Min. 32 kg/cm2}
value for a Prepare with starting switch at OFF position, then run engine at high
Defect in fan pump or fan
judgment 3 idle to perform troubleshooting.
motor
Measurement conditions Fan drive circuit pressure
15.7 ± 15.7 MPa
Fan 100 % mode
{160 ± 25 kg/cm2}
a Prepare with starting switch at OFF position, then run engine at high
idle to perform troubleshooting.
Measurement conditions Fan speed
Fan 100 % mode Max. 1,110 rpm
4 Defective fan Fan may be broken or may be installed defectively. Check it directly.
Defective sensor for engine
water temperature, power
5 Any of these sensors may be defective. Check them directly.
train oil temperature, or
hydraulic oil temperature
40-622 D375A-6
(01)
DRAFT
H-24 Abnormal fan rotation(noise and/or vibration are abnormally large or engine overheats)
D375A-6 40-623
(01)
DRAFT
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart

This troubleshooting chart is divided into four sections: Questions, Check items, Causes and Troubleshooting.
First, use the Questions and Check items to select highly probable causes among the Causes. The Questions
and Check items allows for the selection based on the failure symptoms or simple inspection results without
using troubleshooting tools.
Next, use troubleshooting tools or perform direct inspection to check the selected causes in the order of prob-
ability to determine the real cause.
Questions:
Questions placed in the sections A and B in the table on the next page are those to be answered by the user
or operator.
Questions in section A are for basic information about the failure. Depth and accuracy of their answers to the
questions in section B may depend on their skill level.
Check items:
Check items placed in the section C in the table on the right are to be simply checked by the technician to
select highly probable causes.
Causes:
The technician selects highly probable causes from among the Causes based on the answers to the Ques-
tions in sections A and B and the check results of Check items in section C.
Troubleshooting:
The Troubleshooting indicates the items to be checked by the serviceman in order to ultimately check that the
selected causes are truly the defect factors by using troubleshooting tools or making direct checking starting
with probable causes of higher order.
This troubleshooting chart marks the content of the questions and check items with E, Q or w according to
their closer relationship with the causes.
E: A cause that can be referred to in relation to the question or check item.
Q: A cause that relates to the question or check item.
w: A cause particularly probable among those marked with Q above.
a Count the priority level of each marking as w > Q when determining the cause.
Don’t count E when determining the cause. The item with this marking may be counted, however, if no
difference is present than this and the cause cannot be determined.
40-624 D375A-6
(01)
DRAFT
D375A-6 40-625
(01)
DRAFT
<Example of troubleshooting> Exhaust smoke is black (Incomplete combustion)

Let us assume that a problem of "Exhaust smoke is black" occurred and we checked the [Questions] and
[Check items] and found the following 3 items to be the causal symptoms; "Exhaust smoke gradually became
black", "Power was lost gradually", and "Dust indicator piston indicates red zone".
40-626 D375A-6
(01)
DRAFT
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in
the [Causes] section.
The method of pinpointing the [Causes] from the causal relationship and approaching the [troubleshooting] is
explained according to Step 1 - Step 3 shown below.
D375A-6 40-627
(01)
DRAFT
S-1 Engine does not start easily

General causes that engine does not start easily Cause
Leakage or clogging of fuel piping or air in the fuel piping

q Electrical system is defective.
Cracked EGR cooler (coolant mixing in the exhaust)

q Fuel level is low.
q Air intake is in short supply.
Defective contact between valve and valve seat

q Wrong fuel selection.
q Coolant leaks into exhaust pipe.
Clogged breather hole in fuel tank cap

a Common rail fuel injection system (CRI) controls the fuel
Stuck or seized supply pump plunger

injection timing electrically. Therefore, there are cases
Defective intake air heater system
Defective or deteriorated battery

where the engine does not start before the crankshaft
Clogged feed pump gauze filter
Defective alternator (generator)

Defective alternator (regulator)
Wear of piston ring or cylinder
makes two revolutions maximum after starting operation.
Clogged air cleaner element

This is not an abnormal state, however.
Clogged fuel filter element
Defective injector
Check recent repair history
Degree of use Operated for long period EE EE E
Ease of start- Gradually became worse QQww QQ
Starts when warm w w
Questions
ing
Non-specified fuel is being used QQ Q Q
Replacement of filters is not performed according to Operation & Mainte-
w ww Q Q
nance Manual.
Engine oil must be added more frequently. w
Preheat monitor does not light up during preheating or at low temperature. w
Charge monitor indicates abnormal charging during operation. ww
Dust indicator lamp piston indicates red zone. w
Clogged breather hole in fuel tank cap w
Leaking from fuel piping w Q
No response or heavy resistance is felt when operating priming pump. wQQ
Starting motor rotates engine slowly. Q w
When engine and air bleeding plug is removed from fuel filter, fuel does
ww
is rotated with not flow out.
Check items
starting motor, and spill hose is separated from injector, spill flow is small. w
When exhaust manifold, are touched immediately after starting engine,
w
temperature of manifold for some cylinders is low.
Engine does not rey smoothly , and combustion is irregular. QQ w
Engine hunts (rotation is irregular). QwQQ
Blowby gas is excessive. w
Inspect air cleaner directly. q
Removing EGR cooler inlet gas pipe causes coolant containing antifreeze
q
to flow out (*1).
When compression pressure is measured, the pressure is low. qq
q
Troubleshooting
Air is discharged when bleeding from fuel system.

Inspect fuel filter and strainer directly. q
Inspect feed pump gauze filter directly. q
Perform troubleshoot for "Rail Press Very Low Error" (*2) q
Engine speed does not change even when running engine with some cyl-
q
inder cut out.
Intake air heater mount does not warm up during preheating operation. q
Does voltage B – E appear between alternator terminals 25 Yes q
and 30V with engine running at low idle? None q
Specific gravity of electrolyte and voltage of battery are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
For *1 and *2, see the next page
40-628 D375A-6
(01)
DRAFT
*1: EGR cooler inlet gas pipe

Loosen 4 mounting bolts (1) of gas pipe connected to the EGR cooler inlet and check for the outflow of
coolant.
Condensed water from cooled exhaust gas may come out in small quantity but it is no problem if colorless
and transparent.
*2:Troubleshooting by failure code (Display of code), Code[CA559] , and Code [CA2249]
D375A-6 40-629
(01)
DRAFT
S-2 Engine does not start

a) Engine does not crank Cause
Cracked EGR cooler (coolant mixing in the exhaust)

General causes that engine does not rotate
q Seized inside engine
Defective starting motor (safety relay section)

See the troubleshooting for "S-4 Engine stops during operations".
q Coolant leaking inside cylinder causes water hammer.
Defective starting motor (motor section)

q Electrical system is defective.
Defective battery terminal connection
Defective wiring of starting circuit

Demaged flywheel ring gear
Defective starting switch

Defective battery relay
Questions
Degree of use of
Operated for long period E EE
machine
When starting Horn does not sound. Q Q w
switch is set to
Horn volume is slow. w
ON position.
Battery electrolyte is low. w
Cable is loosely connected to battery terminal. w
No operating sound from battery relay when starting switch is set to ON position. Q w
When starting switch is set to START position, pinion does not come out. Q Q w
When starting Speed of rotation is low. Q w
Check items
switch is set to Grating noise is heard. w w

START position, Soon pinion again. w
the starting pin-
ion comes out, Ratting noise is heard and engine does not turn. w Q Q w
but
Removing EGR cooler outlet gas pipe causes coolant containing antifreeze to flow
Perform troubleshooting for E-mode
q
out (*1).
Inspect flywheel ring gear directly q
Specific gravity of electrolyte and voltage of battery are low. q
Troubleshooting
There is no voltage (B – E) between battery relay terminals 20

Set starting q
and 30V.
switch to OFF When terminals B and C of starting switch are connected, engine
position, connect starts. q
the cord, then set When safety relay outlet terminals B and C are connected, engine
starting switch to starts. q
ON position to
perform trouble- When safety relay outlet terminals B and C are connected, engine
q
shooting does not start.
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
-
For *1, see the next page
40-630 D375A-6
(01)
DRAFT

Loosen 4 mount bolts (1) of gas pipe connected to the EGR cooler inlet and check for the outflow of cool-
ant.
and transparent.
D375A-6 40-631
(01)
DRAFT
b) Engine rotates but no exhaust smoke comes out (Fuel Cause

is not injected)
Leakage or clogging of air in fuel piping, or air in fuel piping
Defective operation of overflow valve (does not close)

General causes that engine rotates but no exhaust smoke
comes out
q Fuel is not being supplied.
q Supply of fuel is extremely small.
q Improper selection of fuel (particularly in winter)
Seizure or abnormally wear of feed pump
Wrong connection of supply pump PCV

Defective operation of flow damper

Broken supply pump shaft or key
Defective supply pump PCV

Clogged fuel filter element
Insufficient fuel in tank
Defective fuel injector

Improper fuel used
Degree of use of
Questions
Operated for long period EEE

machine
Exhaust smoke suddenly stopped coming out (when starting again). wQ w w w EE
w w E Q
nance Manual.
Fuel tank is found to be empty. w
Clogged breather hole in fuel tank cap. Q w
Rust and water are dectected when fuel tank is drained. Q QQ Q Q
When fuel filter is removed, no fuel is inside the fuel filter. w w
Check items
Leakage from fuel piping w

and air bleeding plug is removed from fuel filter, fuel
When engine is Q Q wQ
does not flow out.
rotated with start-
and spill hose is separated from injector, spill flow is
ing motor, Q w w w w Q
small.
Air is discharged when bleeding air from the fuel system. q
Inspect the fuel filter directly. q
Troubleshooting
Inspect the fuel feed pump gauze filter directly. q

Inspect feed pump directly. q
Perform troubleshoot for "Rail Press Very Low Error" (*1) q q q q
Perform troubleshoot for "PCV1 Error (*2) or PCV2 Error" (*3) q
Inspect overflow valve directly. q
Engine can start when operated in cylinder cut out mode. qq
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Remedy
Add
*1: Troubleshooting by failure code (Display of code), Code [CA559] and Code [CA2249]
40-632 D375A-6
(01)
DRAFT
c) Exhaust smoke comes out but engine does not Cause

start (Fuel is injected)
Defective coolant temperature sensor or defective wiring harness

General causes that exhaust smoke comes out but
engine does not start
q Starting motor lacks in rotating force due to defec-
Leakage or clogging of fuel piping, or air in fuel piping

tive electrical system.
q Supply of fuel is small.
Wear of valve system (valve, rocker lever, etc.)

q Small air intake
q Improper selection of fuel
Clogged injection nozzle or defective spray

Defective intake air heater system

Worn piston ring or cylinder liner

Clogged fuel filter, strainer

Improper fuel
Degree of machine
Operated for long period E EE E
operation
Questions
Engine suddenly failed to start. w w Q

Non-specified fuel is being used. Q Q
w ww
nance Manual
Engine oil must be added more frequently. w
Preheat monitor does not light up during preheating or at low temperature. w
Dust indicator piston indicates red zone. w
Clogged breather hole in fuel tank cap. w
Rust and water are detected when fuel tank is drained. ww
When fuel filter is removed, no fuel is inside the fuel filter. w
Starting motor rotates engine slowly. w
When engine is rotated, abnormal sound is generated around cylinder head. w
and air bleeding plug of the fuel filter is removed, fuel
Check items
When engine is Q ww
does not flow out.
rotated with starting
and spill hose is separated from injector, spill flow is
motor w
small.
When exhaust manifolds are touched immediately after starting engine,
w
temperature of manifold for some cylinders is low.
Inspect air cleaner directly. q
Inspect valve system directly q
When compression pressure is measured, pressure is low q
Troubleshooting
Air is discharged when bleeding air from the fuel system. q

Inspect the fuel filter, strainer directly. q
Inspect the fuel feed pump gauze filter directly. q
Perform troubleshoot or "Rail Press Very Low Error" (*1). q
Testing a single unit injector indicates defective spraying. q
Specific gravity of electrolyte and voltage of battery are low. q
Coolant temperature gauge indication is not normal (if equipped the gauge). q
Intake air heater mounting portion does not warm up during preheating. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Remedy
*1: Troubleshooting by failure code (Display of code) , Code [CA559], and Code [CA2249]
D375A-6 40-633
(01)
DRAFT
S-3 Engine does not rev up smoothly (response-up is poor)

General causes why engine does not pick up smoothly Cause
Defective operation of flow damper (excessive injector leakage)

q Insufficient intake of air
q Insufficient supply of fuel
q Fuel injection condition not normal
q Controller in derate control mode
(Controlling injection capacity (output) due to an error in
the electrical system)
q EGR valve is stuck in open state
Clogged air breather hole in fuel tank cap
Clogged injection nozzle, defective spray

Defective contact of valve and valve seat
Seizure and interference of turbocharger

(Shortage of air intake due to excessive EGR gas)
Defective EGR valve or bypass valve

Leakage, clogging, air in fuel piping

Worn piston ring, cylinder liner

Improper valve clearance
Confirm recent repair history
Questions tem-
Degree of use of machine Operated for long period EEE E EE

perature
Engine pick-up suddenly became poor Q w Q Q Q

Non-specified fuel is being used w w w w
Replacement of filters has not been carried out according to Opera- w w w
Engine oil must be added more frequently w
Dust indicator is red w
Clogged air breather hole in fuel tank cap w
Rust and water are observed when fuel tank is drained w w
No response or heavy resistance felt when operating priming pump w Q Q
When exhaust manifold is touched immediately after starting engine,
Q w
temperature of some cylinders is low
Blue under light load w
Color of exhaust gas
Check items
Black w Q w w
When engine is cranked, abnormal noise is heard from around cylin- w
When engine is cranked, abnormal noise is heard from around turbo- w
High idle speed under no load is normal, but speed suddenly drops
Q w w
when load is applied
There is hunting from engine (rotation is irregular) Q Q w Q
Blow-by gas is excessive w w
Inspect air cleaner directly q
Carry out troubleshooting for "EGR valve abnormality (*1)" or
q
"Bypass valve abnormality (*1)".
Troubleshooting
When compression pressure is measured, the oil pressure is low. q q

Inspect valve clearance directly q
When turbocharger is rotated by hand, it is found to be heavy q
Air is discharged when the air is bled from the fuel system q
Inspect the fuel filter, strainer directly q
Inspect the fuel feed pump gauze filter directly q
Carry out troubleshoot by "Rail Press Very Low Error (*2)" q
Speed of some cylinders does not change when operated in reduced q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
40-634 D375A-6
(01)
DRAFT
*1: Troubleshooting by failure code (Display of code), Codes [CA1228] and [CA1625] or Codes [CA1628] and
[CA1629]
*2: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
D375A-6 40-635
(01)
DRAFT
S-4 Engine stops during operation
S-4 Engine stops during operation

General causes why engine stops during oper- Cause
ations
Defective engine controller power supply

Broken auxiliary equipment (pump, com-
Breakage of valve system (valve, rocker
Broken, seized piston or connecting rod

q Seized parts inside engine
Broken, seized crankshaft metal
Leakage, clogging in fuel piping

q Overheating
Broken supply pump shaft, key

q Trouble in power train
Broken, seized feed pump

Broken, seized gear train
Defective starting switch

Trouble power train

pressor, etc.)
lever, etc.)
Degree of use
Operated for long period EE
of machine
Abnormal noise was heard and engine
w w w w Q w Q w w
stopped suddenly
Questions
Condition when
Engine overheated and stopped w Q Q
engine stopped
Engine stopped slowly w Q Q Q Q
There was hunting and engine stopped w Q Q Q Q Q Q
Non-specified fuel is being used Q Q Q Q
Replacement of filters not carried out according to Opera-
w w
tion & Maintenance Manual
Fuel level monitor indicates low fuel level w
Fuel tank is found to be empty w
Rust and water are detected when fuel tank is drained w w
Metal particles are found when oid pan is drained w w w
Check items
Does not turn at all w w

When engine is
Turns in opposite direction w
cranked manu-
Moves by the amount of gear backlash w w
ally
Supply pump shaft does not turn w
Engine rotates, but stops when load is applied to machine w
Inspect valve system directly q
Carry out troubleshooting in H-mode
Check piston and connecting rod directly q

Check crankshaft bearing directly q
Inspect gear train directly q
Inspect fuel filter, strainer directly q
Troubleshooting
Inspect feed pump gauze filter directly q

Inspect feed pump directly q
Carry out troubleshoot by "Rail Press Very Low Error (*1)" q q
Engine rotates when auxiliary equipment (pump, com-

q
pressor) is removed
Inspect controller power supply wiring q

Check starting switch wiring q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Clean
Add
Remedy
-
40-636 D375A-6
(01)
DRAFT
S-5 Engine does not rotate smoothly (hunting)
S-5 Engine does not rotate smoothly (hunting)

General causes why engine does not rotate smoothly Cause
Defective operation of flow damper (excessive injector leakage)

q Air in fuel system
q Defective speed sensor (Error at degree that it is not indicat-
ed)
Clogged injector and/or defective spray (dirt in injector)
Defective Bkup speed sensor, defective wiring harness

q Defective EGR valve
Defective Ne speed sensor, defective wiring harness

q Defective bypass valve

Defective operation of bypass valve
Leakage, clogging, air in fuel piping

Low setting of low idle speed

Malfunction of EGR valve

Degree of use of machine Operated for long period EE EE
Q Q Q Q Q
Questions
Occurs at a certain speed range

Occurs at low idle w Q Q Q Q Q Q Q
Condition of hunting
Occurs even when speed is raised Q Q Q Q Q
Occurs on slopes w Q Q
Replacement of filters not carried out according to Operation & Mainte-
w w
nance Manual
Fuel tank is found to be empty w
Check tems
Rust and water are found when fuel tank is drained Q Q

Leakage from fuel pipe w
Carry out troubleshoot by "EGR Valve Servo Error (*1)" q

Carry out troubleshoot by "Bypass Valve Servo Error (*2)" q
Air is discharged when the air is bled from the fuel system q
Troubleshooting

Inspect fuel filter, strainer directly q
Speed of some cylinders does not change when operated in reduced cylin-
q q
der mode
Carry out troubleshooting according to “Abnormality in engine Ne speed
q
sensor (*3)”
Carry out troubleshooting according to “Abnormality in engine Bkup
q
speed sensor (*4)”
Correct or replace
Correct or replace
Replace, Clean
Replace
Replace
Replace
Replace
Repair
Repair
Clean
Clean
Add
Remedy
*3: Troubleshooting by failure code (Display of code), Code [CA689]
*4: Troubleshooting by failure code (Display of code), Code [CA778]
D375A-6 40-637
(01)
DRAFT
S-6 Engine lacks power (or output shortage)

General causes why engine lacks output Cause
Defective charge pressure sensor or defective wiring harness

Defective fuel temperature sensor and/or wiring harness

Defective mounting of charge pressure sensor (air leak)

Clogged injector and/or defective spray (dirt in injector)
q Defective condition of fuel injection
Seized turbocharger, interference of turbocharger

q There is overheating
o See the troubleshooting for "S-14 Coolant
Defective drive of injector (signal, solenoid)

Clogged air breather hole of fuel tank cap
Temperature too High (Overheat)"
Defective contact of valve, valve seat

q Controller is controlling in derate mode
(limiting injection rate (output) because of an error
Air leakage from air intake piping

in electrical system)

Clogged, leaking fuel piping

Degree of use Operated for long period E E E EE
Questions
Power was lost

Suddenly Q Q Q Q
Gradually Q Q Q Q Q Q Q
Non-specified fuel is being used Q Q
Replacement of filters has not been carried out according to Operation w
Oil must be added more frequently Q Q Q
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w
Output becomes insufficient after short stop of operation w
Black w w w
When exhaust manifold is touched immediately after starting engine,
w
Check items
temperature of some cylinders is low

When engine is cranked, interference sound is generated around turbo- w
When engine is cranked, abnormal sound is generated around cylinder w
High idle speed is too low Q
High idle speed under no load is normal, but speed suddenly drops
when load is applied
w w Q
Engine does not pick up smoothly and combustion is irregular w Q Q w
There is hunting from engine (rotation is irregular) Q Q Q Q
Inspect air intake piping directly q
When charge (boost) pressure is measured, the oil pressure is low q q q
q q
Troubleshooting
When compression pressure is measured, it is found to be low

Inspect fuel filter and strainer directly q
Carry out troubleshooting according to “No-pressure feed by supply q
When a cylinder is cut out for reduced cylinder mode operation, engine q q
Check the mount of charge (boost) pressure sensor directly q
Carry out troubleshoot by "Chg Air Press Sensor Error (*2)" q
Carry out troubleshooting according to “Abnormality in fuel tempera- q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Adjust
Clean
Clean
Clean
Remedy
For *1, *2 and *3, see the next page
40-638 D375A-6
(01)
DRAFT
D375A-6 40-639
(01)
DRAFT
S-7 Exhaust smoke is black (Incomplete combustion)

General causes why exhaust smoke is black Cause
Seized turbocharger, interference of turbocharger
Clogged fuel spill piping (on cylinder head side)

Leakage of air between turbocharger and cylin-
Defective coolant temperature sensor or defec-

q Excessive injection of fuel
q Defective condition of fuel injection
Defective EGR valve or bypass valve

Defective contact of valve, valve seat
q There is overheating
Stuck, seized supply pump plunger

o See the troubleshooting for "S-14 Coolant Temperature
Defective fuel injection pressure

too High (Overheat)"
Improper fuel injection timing

q Controller is controlling in derate mode
Crushed, clogged muffler

(limiting injection rate (output) because of an error in elec-
Clogged, seized injector

trical system)
q EGR valve is stuck in open state
tive wiring harness

Worn fuel injector
(There is much EGR gas and intake of air is insufficient.)
q EGR gas pressure piping is clogged
(Exhaust gas is mixed in intake air during acceleration and
der head
deceleration)

Degree of use Operated for long period E EE E E
Suddenly became black w Q Q Q
Questions
Color of exhaust gas Gradually became black w Q Q Q

Oil must be added more frequently w
Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Leakage of air between turbocharger and cylinder head,
w
loose clamp
Operates in low-temperature mode even at normal tempera- Q Q Q
When exhaust manifold is touched immediately after starting
w
engine, temperature of some cylinders is low
When engine is cranked, interference sound is generated w
Check items
When engine is cranked, abnormal sound is generated w

Torque converter stall speed or pump relief speed is high
Q Q
(Fuel is injected excessively)
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly , and combustion is irregu- Q Q Q Q Q Q w
When hose from injector to spill collection portion is discon-
w
nected, spill flow is found to be abnormally high
When turbocharger is rotated by hand, it is found to be heavy q
Carry out troubleshooting for "EGR valve abnormality (*1)" or
q
Troubleshooting
"Bypass valve abnormality (*1)"

When compression pressure is measured, it is found to be q q
When muffler is removed, exhaust color returns to normal q
Carry out troubleshoot by "Rail Press Very Low Error (*2)" q q
Engine speed does not change when operation of certain cyl-
q
inders is stopped in reduced cylinder mode
Inspect fuel spill piping (on cylinder head side) directly q
Carry out troubleshooting according to “Abnormality in cool- q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Adjust
Clean
Remedy
For *1, *2 and *3, see the next page
40-640 D375A-6
(01)
DRAFT
*1: Troubleshooting by failure code (Display of code), Codes [CA1228] and [CA1625] or Codes [CA1628] and
[CA1629]
D375A-6 40-641
(01)
DRAFT
S-8 Oil is consumption is excessive(or exhaust smoke is blue)
S-8 Oil is consumption is excessive(or exhaust smoke is blue)

General causes why oil consumption is excessive Cause
q Abnormal oil combustion

q Extended operation for long hours in low or high idle (continuous
no load operation for 20 minutes and longer inhibited)
Worn or damaged valve (stem, guide, and seal)

q Oil leakage to outside
q Wear of lubricating system
Turbocharger
Leakage from oil pan, cylinder head, etc.

Oil leakage from EGR valve system
Clogged breather or breather hose
Dust sucked in from intake system
Worn, damaged rear seal surface

Leakage from oil drain plug

Worn seal at turbine end
Worn seal at blower end
Leakage from oil cooler
Leakage from oil piping

Leakage from oil filter
Broken piston ring
Broken oil cooler

Questions
Degree of use of machine Operated for long period E EE E E

Oil consumption suddenly increased w Q
Engine oil must be added more frequently Q w Q
Engine oil becomes contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w w
Pipe clamps for intake system are loose w
Inside of turbocharger air intake outlet pipe is contaminated with oil w
Inside of turbocharger exhaust outlet pipe is contaminated with oil Q w
Check items
There is oil in coolant w

Oil level in clutch or damper chambers on applicable machine side
w
increasing
Color of exhaust gas blue under light load Q w w
Excessive Q QQ w w
Amount of blow-by gas
None w
When intake manifold is removed, dust is found inside q
When intake manifold is removed, inside is contaminated abnor- q
mally
Troubleshooting
Excessive play of turbocharger shaft qq

When EGR valve is removed, exhaust port is contaminated with oil q
Inspect breather, breather hose directly q
When compression pressure is measured, the oil pressure is low q q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
40-642 D375A-6
(01)
DRAFT
S-9 Engine oil becomes contaminated quickly
S-9 Engine oil becomes contaminated quickly

General causes why oil becomes contaminated quickly Cause
q Entry of exhaust gas into oil due to internal wear
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
q Clogging of lubrication passage
q Use of improper fuel
q Use of improper oil
q Operation under excessive load
Clogged breather, breather hose

Defective oil filter safety valve

Worn valve, valve guide
Worn EGR valve guide
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Degree of use Operated for long period EEEE
Questions
Non-specified fuel is being used Q

Oil must be added more frequently Q w
Even when engine oil temperature rises, oil filter clogging monitor indicates clog-
w Q
ging
Metal particles are found when oil filter is drained Q Q w
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Check items

Black w
Excessive Q Q w
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q
When EGR valve is removed, exhaust port is found to be smeared with oil. q
Troubleshooting
When compression pressure is measured, it is found to be low q q
(See S-7)
Check breather and breather hose directly q
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
-
D375A-6 40-643
(01)
DRAFT
S-10 Fuel consumption is excessive
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive Cause
Defective coolant temperature sensor or defective wiring harness

q Leakage of fuel
q Fuel injection condition (fuel pressure and injection timing) not normal
q Excessive fuel injection
Fuel leakage from fuel filter, piping, etc
Defective common rail fuel pressure

Leakage of fuel inside head cover
Defective supply pump plunger

Defective feed pump oil seal
Defective injector operation

Defective injector spray
Questions
Degree of use of machine Operated for long period E E E

More than for other machines of same model Q Q Q
Condition of fuel consumption Gradually increased Q Q
Suddenly increased Q Q
Fuel leakage to outside w
There is irregular combustion w
Oil increasing, smelling of diesel oil w w
When exhaust manifold is touched immediately after starting engine, temperature of
w w
Check items
some cylinders is low

Low idle speed is high Q
Torque converter stall or hydraulic pump relief speed is high Q
Black Q Q Q
White Q
Remove head cover and inspect directly q
Troubleshooting
Inspect feed pump oil seal directly q

Carry out troubleshoot by "Rail Press Very Low Error (*1)" q
Speed of some cylinders does not change when operated in reduced cylinder mode q q
Spill flow is excessive when spill hose is separated from injector q
Carry out troubleshoot by "Coolant Temp Sensor Error (*2)" q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Remedy
40-644 D375A-6
(01)
DRAFT
S-11 Oil mixes into coolant(coolant blows back or is reduced)
S-11 Oil mixes into coolant(coolant blows back or is reduced)

General causes why oil is in coolant Cause
q Internal leakage in lubrication system
Damaged cylinder liner O-ring or holes caused by pitting

q Internal leakage in cooling system
q Internal leakage in hydraulic oil cooler or power train oil cooler
Broken hydraulic oil cooler, power train oil cooler

Insufficient protrusion of cylinder liner
Broken cylinder head, head gasket
Broken oil cooler core or O-ring

Cracks inside cylinder block
Questions
Degree of use Operated for long period E E

Sudden overheated Q Q Q
Oil level
Gradually occurred Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
There are excessive air bubbles in radiator, coolant spurts back w w
Check items
Power train oil is milky w
When power train oil is drained, water is found w
Pressure-tightness test of cylinder head shows there is leakage q
shooting in H-mode
q q
Carry out trouble-

Inspect cylinder block and liner directly
Troubleshooting
Check cylinder liner directly q
Pressure-tightness test of oil cooler shows there is leakage q

Replace
Replace
Replace
Replace
Replace
Remedy
-
D375A-6 40-645
(01)
DRAFT
S-12 Engine pressure monitor lights up (drop in engine oil pressure)
S-12 Engine pressure monitor lights up (drop in engine oil pressure)

General causes that oil pressure drops Cause
Defective oil pressure sensor and/or defective wiring harness

q Leakage, clogging or wear of lubricating system
q Defective hydralic control
q Wrong oil selection (viscosity not appropriate)
q Oil deteriorated by overheating
Leaking, crushed or clogging of hydraulic pipe

Clogged or brakage of pipe inside oil pan
Leakage from EGR oil pressure piping

Clogged strainer inside oil pan
Defective oil pump relief valve
Defective EGR oil pump

Wear of metal journal
Lack of oil in oil pan
Defective oil pump

Water or fuel in oil
Clogged oil filter

Degree of use of machine Operated for long period E E E E
Questions
Engine oil pressure monitor lights up. Q w

Non-specified oil is used. Q Q
Replacement of filters is not perform according to Operation & Mainte-
w
nance. Manual
Lights up with engine at low dile. w Q Q
Lights up with engine at low and idle. Q w w w Q Q Q
Engine oil pressure monitor
Lights up with machine on a slope. w
Lights up occasionally. w Q
Oil level monitor indicates low amount of oil (when monitor is installed) w
Oil level in oil pan is low w
Leakage or crushing of external hydraulic pipe. w w
Check items
Oil is cloudy white or smells of diesel oil. w

Metal particles are found when oil is drained from oil pan. w
Metal particles are found when oil is drained from oil filter. w Q Q
Metal particles are found in oil filter. q
Inspect oil pan strainer and pipe directly. q q
Troubleshooting
Oil pump rotation is heavy or it has play. q

See S - 13
Oil pump relief valve or spring is failed or damaged. q

Inspect oil filter directly. q
Relief valve of EGR oil pump is damaged or has oil leak. q
Inspect EGR hydraulic piping visually. q
Perform troubleshooting for "Eng Oil Press. Sensor Error"(*1) q
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Clean
Clean
Add
Remedy
-
*1: Troubleshooting by failure code, Codes [CA135] and [CA141]
40-646 D375A-6
(01)
DRAFT
S-13 Oil level rises (Coolant or fuel mixes into oil)

General causes that oil level rises Cause
Damagee O-ring for cylinder liner or pitted cylinder liner due to pitting corrosion.
q Coolant mixing into oil (oil becomes clouded)
q Fuel mixing into oil (smells diluted diesel fuel)
a If oil mixes into the coolant, perform troubleshooting for "S-11Oil mixes into
coolant"
Clogged water pump drain hole (breather hole) or defective seal
Defective seals for auxiliarise (pump or compressor)

Cracked EGR cooler (Entry of coolant)
Broken cylinder head or head gasket
Worn or damaged rear seal surface

Leakage of fuel inside head cover
Broken oil cooler core or O-ring

Internal cracks in cylinder block
Defect inside supply pump

Check recent repair history.
Questions
Degree of use of machine Operated for long period E E E E

Fuel consumption is increased. w w
Coolant must be added more frequently. Q Q
Oil in coolant. Q Q Q w
Engine oil smells of diesel fuel. w w
Oil become clouded. Q Q Q
After starting engine, drops of water come out of muffler. Q Q
When engine is run at idle with radistor cap open a large number of air bub-
w Q
bles appear or coolant blows back.
Check items
Exhaust smoke is white. Q

Clogged water pump drain hole (weep hole). w
Coolant comes out when water pump drain hole (weep hole) is cleaned. w
Oil level in clutch or damper chambers of machine lower w
Oil level in hydraulic tank of machine decreases. w
Removing EGR cooler inlet gas piping causes coolant containing antifreeze to
q
flow out (*1)
When compression pressure is measured, pressure is low. q
Troubleshooting
Remove head cover and check directly. q

Inspect cylinder block and liner directly. q q
Inspect rear oil seal directly. q
Pressure test of cylinder head shows it leaks. q
Remove water pump and inspect directly. q
Remove supply pump and inspect directly. q
Inspect seals for auxiliaries directly. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
For *1, see the next page.
D375A-6 40-647
(01)
DRAFT

Loosen 4 mounting bolts (1) of gas pipe connected to the EGR cooler inlet and check for the outflow of
coolant.
and transparent.
40-648 D375A-6
(01)
DRAFT
S-14 Coolant temperature rises too high (overheating)
S-14 Coolant temperature rises too high (overheating)

General causes that coolant temperature becomes too high Cause
q Lack of cooling air (deformed or damaged fan)
Hole drilled by damages or pitching of cylinder liner O-ring

q Drop in heat dissipation efficiency
q Defective coolant circulation system
q Rise of power train oil temperature
q Defective fan drive pump or fan motor
Defective radiator cap (pressure valve)
Defective fan drive pump or fan motor

Defective coolant temperature gauge
Broken cylinder head, head gasket
Rise of power train oil temperature

Defective operation of thermostat
Clogged or crushed radiator fins
Water leakage from EGR cooler
Clogged or broken oil cooler
Clogged radiator core

Broken water pump
Wear of fan pulley

Lack of coolant
Degree of use of machine Operated for long period EEE EE
Questions
Condition of overheating Engine overheat suddenly Q Qw Q

Engine tends to overheat. Qww Q
Coolant temperature rises quickly. Q w
Coolant temperature gauge Coolant temperature does not go down below
w
red range
Radiator coolant level monitor indicates low level Q w
Engine oil level has risen, oil is cloudy white wQ
Cloudy white oil is floating on coolant w
Coolant in radiator has excessive air bubbles and blows backs. w
Check items
When light bulb is held behind radiator, no light passes. w

Radiator shroud and inside of under cover are clogged with dirt or mud. w w
Coolant leaks from cracks in the radiator hose or clamps are loosened. w
Coolant flows out from radiator overflow hose. w
Power train oil temperature gauge enters red range faster than engine cool-
w
ant temperature gauge
Inspect EGR cooler directly for coolant leakage. q
Carry out troubleshooting in
Carry out troubleshooting in
Inspect cylinder liner directly. q
Inspect oil cooler directly. q
q
Troubleshooting
Temperature difference between top and bottom radiator tanks is excessive.

When function test is preformed on thermostat, it does not open even at
q
cracking temperature.
Temperature difference between top and bottom radiator tanks is slight. q
Inspect radiator core directly. q
When function test is preformed on the radiator cap, cracking pressure is
q
low.
Inspect fan pulley directly. q
When coolant temperature is measured, it is found to be normal. q
Measured fan speed is low. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Add
Remedy
-
-
D375A-6 40-649
(01)
DRAFT
S-15 Abnormal noise is heard
S-15 Abnormal noise is heard

General causes that abnormal noise is heard Cause
Defective fuel injection timing (defective coolant temperature sensor)

q Noise from defective parts
Seizave or interfevance of valve system (valve, rocker lever, etc.)

Air leakage from piping between turbocharger and cylinder head
q Abnormal combustion
q Air sucked in from intake system
a Detemine whether the noise from inside or outside before proceeding with
troubleshooting.
a When engine is not fully warmed up, engine noise rises slightly because it
Defec inside muffler (dividing board out of position)

runs in the low temperature mode. This is not abnormal, however.
a When the engine is accelerated, it runs in the acceleration mode, where en-
Crack of or gas leakage from EGR gas piping
Excessive wear of piston ring or cylinder liner

gine noise remains slightly higher for about 5 seconds maximum, This is not
abnormal, however.
Missing or seizure of gear train bushing

Improper gear train backlash
Clogged or seized injector

Brakage of turbocharger
Dirt caught in injector

Deformed fan
Degree of use of machine Operated for long period E
Questions
Gradually occurred. QQ Q
Abnormal noise
Sudden overheated. QQQ Q
Non-specified fuel is used Q
Engien oil must be added more frequently. w
Metal particles are found when oil is drained from oil filter. Q w w
Leakage of air between turbocharger and cylinder head w
When engine is rotated, abnormal noise is heard from around turbocharger. w
When engine is rotated, abnormal noise comes out around EGR gas piping. w
When engine is rotated, abnormal noise is heard from around cylinder head. w w
When engine is rotated, abnormal noise is heard from around muffler. w
Check items
When exhaust manifolds are touched immediately after starting engine, tem-
wQ
perature of manifold for some cylinders is low.
Blue during light load operation w
Color of exhaust smoke
Black. Qw Q
Engine rev-up is poor and combustion is abnormal. w
Abnormal noise is loud when engine is accelerated. Q Q Q Q
Blowby gas is excessive w
When turbocharger is rotated by hand, it is found to be heavy. q
Inspect EGR gas piping directly. q
Inspect dynamic valve system directly q
q
Troubleshooting
When muffler is removed, abnormal noise disappears.

Inspect valve clearance directly. q
Inspect gear train directly. qq
Inspect fan directly. q
Engine speed does not change when running engine with some cylinder cut
qq
out.
Abnormal noise is heard only when engine is started. q
Use real-time monitoring mode to check. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Adjust
Remedy
40-650 D375A-6
(01)
DRAFT
S-16 Vibration is excessive
S-16 Vibration is excessive

General causes that vibration is excessive Cause
Loose engine mounting bolts or broken cushions

q Defective parts (abnormal wear, breakage,etc)
Worn main bearing or connecting rod bearing

Stuck valve system (valve, rocker lever, etc.)
q Misalignment of engine and chassis
q Abnormal combustion
a If there is abnormal noise together with the vibration, perform troubleshooting also for
Misalignment of engine and chassis

“S-15 Abnormal noise is heard”.
Wear of front support spigot joint

Improper gear train backlash
Worn camshaft bushing
Broken parts in damper

Questions
Degree of use Operated for long period E EE E

Suddenly increased. Q Q
Vibration
Gradually increased. Q Q Q Q
Metal particles are found when oil is drained from oil filter. w w
Metal particles are found when oil is drained from oil pan. w w
Oil pressure is when running engine low at low idle. Q Q
Check items
Vibration occurs when running engine at mid-range speed. Q Q

Vibration follows engine speed. Q Q Q Q Q
Exhaust smoke is black. w
Inspect valve system directly. q
Inspect main bearing and connecting rod metal directly. q
Troubleshooting
Inspect gear train directly. q

Inspect camshaft bushing directly. q
Inspect engine mounting bolts and cushions directly. q
When face runout and radial runout are inspected, they are found to be incorrect. q
Inspect front support portion directly. q
Inspect inside of damper directly. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Remedy
D375A-6 40-651
(01)
DRAFT
S-17 Air cannot be bled from fuel circuit (when air bleeding is performed after filter is replaced or fuel is used up and then
S-17 Air cannot be bled from fuel circuit (when air bleeding is performed
after filter is replaced or fuel is used up and then air is bled, engine does
not start or it starts but stalls)
General causes why that cannot be bled Cause
Defective wiring harness of electric priming pump

q Electric priming pump does not operate.
Improper setting of air bleeding valve (closed)

q Fuel is not supplied or is supplied very little.
Malfunction of electric priming pump switch

Leaking or clogging of fuel piping or air in it
q Fuel valve or air bleeding valve is not set properly.
q Air bleeding piping is clogged.
Improper setting of fuel valve (closed)
Malfunction of electric priming pump

q Fuel return piping is clogged.
Clogged water separator screen

Clogged fuel tank breather hole
Clogged air bleeding pipe
Low battery charge level

Clogged fuel filter
Lack of fuel
Questions
Degree of use of macine Operated for long period EE

Fuel tank is empty w
Fuel tank breather cap is clogged w
Fuel leaks from fuel piping w
Check items
Switch lamp does not blink w w Q

Lamp blinks but pump operation sound is not
When electric priming w w
heard.
pump switch is operated
Pump operation sound is heard but fuel does
Q Q Q Q w w w Q Q
not flow out of hose return soon.
Air bleeding valve is closed q
Fuel valve (supply side) is closed q
Fuel valve (return side) is closed q
Water drain valve and air intake plug of water separator are loosened q
Troubleshooting
Water drain valve of fuel pre-filter is loosened q

There is flaw or dirt on sealing face of fuel pre-filter or main filter q
Check air bleeding pipe and orifice directly (see Note 1) q
Check fuel piping (supply side and return side) directly (for clogging and
q
breakage)
Check electric priming pump directly q
Check electric priming system directly (see E-28 in E-mode) q q
Check water separator screen directly q
Check fuel filter for clogging (see failure code CA559, Note 2) q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Charge
Clean
Add
Remedy
40-652 D375A-6
(01)
DRAFT
Note 1: Check of air bleeding pipe for clogging

q Remove joint bolt (1) and blow clean compressed air into hole a of the orifice to check for clogging.
q Remove air bleeding pipes (2) and (3) and blow compressed air against its both ends to check for clogging.
D375A-6 40-653
(03)
DRAFT
40-654 D375A-6
(01)
DRAFT
D375A-6
SEN001879-00
Bulldozer
Shop Manual
D375A-6

D375A-6 60001 and up
D375A-6 50-1
(02)
DRAFT
Contents
Contents
General information on disassembly and assembly ..................................................................... 50 - 4
How to read this manual ............................................................................................................ 50 - 4
Coating materials list.................................................................................................................. 50 - 6
Special tools list ......................................................................................................................... 50 - 9
Sketches of special tools ........................................................................................................... 50 - 16
Engine and cooling system ........................................................................................................... 50 - 24
Removal and installation of fuel supply pump assembly ........................................................... 50 - 24
Removal and installation of fuel injector assembly .................................................................... 50 - 28
Removal and installation of cylinder head assembly ................................................................. 50 - 33
Removal and installation of radiator guard assembly ................................................................ 50 - 49
Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler). 50 - 54
Removal and installation of radiator........................................................................................... 50 - 59
Removal and installation of hydraulic oil cooler ......................................................................... 50 - 61
Removal and installation of aftercooler...................................................................................... 50 - 62
Removal and installation of engine assembly............................................................................ 50 - 63
Removal and installation of engine hood assembly................................................................... 50 - 70
Removal and installation of engine front seal ............................................................................ 50 - 73
Removal and installation of engine rear seal ............................................................................. 50 - 75
Removal and installation of fan drive assembly......................................................................... 50 - 79
Removal and installation of fan motor assembly ....................................................................... 50 - 81
Removal and installation of fuel tank assembly ......................................................................... 50 - 83
Power train.................................................................................................................................... 50 - 86
Removal and installation of damper assembly .......................................................................... 50 - 86
Disassembly and assembly of damper assembly ...................................................................... 50 - 90
Removal and installation of power train unit assembly .............................................................. 50 - 93
Disconnection and connection of power train unit assembly ..................................................... 50 - 100
Disassembly and assembly of PTO assembly........................................................................... 50 - 109
Disassembly and assembly of torque converter assembly ........................................................ 50 - 115
Disassembly and assembly of TORQFLOW transmission assembly ........................................ 50 - 125
Disassembly and assembly of steering case assembly............................................................. 50 - 153
Removal and installation of power train pump and lubrication pump assembly ........................ 50 - 169
Removal and installation of scavenging pump assembly .......................................................... 50 - 170
Removal and installation of final drive assembly ....................................................................... 50 - 171
Disassembly and assembly of final drive assembly................................................................... 50 - 173
Undercarriage and frame .............................................................................................................. 50 - 186
Removal and installation of track frame assembly..................................................................... 50 - 186
Removal and installation of idler assembly................................................................................ 50 - 191
Disassembly and assembly of idler assembly ........................................................................... 50 - 192
Removal and installation of recoil spring assembly ................................................................... 50 - 196
Disassembly and assembly of recoil spring assembly............................................................... 50 - 201
Removal and installation of track roller assembly...................................................................... 50 - 203
Disassembly and assembly of track roller assembly ................................................................. 50 - 206
Removal and installation of carrier roller assembly ................................................................... 50 - 209
Disassembly and assembly of carrier roller assembly ............................................................... 50 - 210
Removal and installation of bogie assembly.............................................................................. 50 - 214
Disassembly and assembly of bogie assembly ......................................................................... 50 - 219
Removal and installation of first bogie assembly ....................................................................... 50 - 221
Separation and connection of track shoe assembly .................................................................. 50 - 226
Overall disassembly and assembly of track shoe ...................................................................... 50 - 230
Link press press-fitting jig dimensions ....................................................................................... 50 - 247
Disassembly and assembly of one link assembly in the field .................................................... 50 - 248
50-2 D375A-6
(02)
DRAFT
Contents
Disassembly and assembly of master link................................................................................. 50 - 253

Removal and installation of pivot shaft assembly ...................................................................... 50 - 257
Removal and installation of equalizer bar.................................................................................. 50 - 258
Disassembly and assembly of equalizer bar bushing................................................................ 50 - 262
Removal and installation of segment tooth................................................................................ 50 - 264
Hydraulic system .......................................................................................................................... 50 - 266
Removal and installation of hydraulic tank assembly ................................................................ 50 - 266
Removal and installation of work equipment pump assembly ................................................... 50 - 269
Removal and installation of fan pump assembly ....................................................................... 50 - 273
Removal and installation of control valve assembly .................................................................. 50 - 275
Disassembly and assembly of control valve assembly.............................................................. 50 - 277
Disassembly and assembly of blade PPC valve assembly ....................................................... 50 - 282
Disassembly and assembly of ripper PPC valve assembly ....................................................... 50 - 285
Disassembly and assembly of hydraulic cylinder assembly ...................................................... 50 - 287
Disassembly and assembly of ripper pin puller cylinder assembly ............................................ 50 - 295
Work equipment............................................................................................................................ 50 - 298
Removal and installation of blade assembly.............................................................................. 50 - 298
Disassembly and assembly of blade assembly ......................................................................... 50 - 300
Disassembly and assembly of giant ripper assembly ................................................................ 50 - 304
Cab and its attachments ............................................................................................................... 50 - 308
Removal and installation of ROPS guard .................................................................................. 50 - 308
Removal and installation of operator’s cab assembly................................................................ 50 - 309
Removal and installation of floor frame assembly ..................................................................... 50 - 313
Removal and installation of air conditioner unit assembly ......................................................... 50 - 318
Electrical system ........................................................................................................................... 50 - 324
Removal and installation of transmission controller assembly and steering controller assembly50 - 324
Removal and installation of engine controller assembly............................................................ 50 - 325
Removal and installation of VHMS controller assembly ............................................................ 50 - 327
Removal and installation of machine monitor assembly............................................................ 50 - 328
D375A-6 50-3
(02)
DRAFT
General information on disassembly and assembly
How to read this manual

(Rev. 2009.01)
1. Removal and installation of assemblies
Special tools Installation
q Special tools which are necessary for removal or q Unless otherwise instructed, installation of parts
installation of parts are described as A1, ... X1 is to be done in the reverse order to removal.
etc. and their part numbers, part names and q Instructions and precautions for parts installion
quantities are described in the special tool list. is shown with the mark ([*1], [*2]...which corre-
q Also the following information is described in the sponds to the mark in “Removal” section).
special tool list. q Common tools that are necessary for installation
1) Necessity are described as [1], [2]•••etc. and their part
t : Special tools that cannot be substituted numbers, part names and quantities are not de-
and should always be used. scribed.
q : Special tools that will be useful if avail- q Marks shown in the “Installation” section stand
able and are substitutable with tools avail- for the following.
able on the market. k : Precautions related to work safety.
2) Distinction of new and existing special tools a : Guidance or precautions for the work
N : Tools newly developed for this model. 2 : Type of coating material
They have a new part number respectively. 3 : Tightening torque
R : Tools made available by redesigning the 5 : Amount of oil or coolant to be replenished.
existing tools which were developed for other

models. Each of them has a new part number Sketch of special tool
assigned by setting forward the part number q Various special tools are illustrated for the local
of the existing tool. manufacture.
Blank: Tools already available for other
models. They can be used without any modi-
fication.
3) Circle mark Q in sketch column:
q The sketch of the special tool is present-
ed in the section of "Sketches of special
tools".
q Part No. of special tools starting with
79*T-***-****: means that they are not
available from Komatsu Ltd. (i.e. tools to
be made locally).
Removal
q In “Removal” section, the work procedures, pre-
cautions and know-how to do the work and the
amount of oil and coolant to be drained are dis-
cribed.
q Common tools that are necessary for removal
are described as [1], [2]•••etc. and their part
numbers, part names and quantities are not de-
scribed.
q Various symbols used in the “Removal” section
are explained and listed below.
k : Precautions related to work safety.
a : Guidance or precautions for the work
[*1]: This mark shows that instructions or precau-
tions for parts installation work are given in
“Installation” section.
6 : This mark shows the amount of oil or cool-
ant to be drained.
4 : Weight of part or component
50-4 D375A-6
(02)
DRAFT
2. Disassembly and assembly of assemblies

Special tools Assembly
q Special tools which are necessary for disassem- q In “Assembly” section, the work procedures,
bly and assembly of parts are described as A1, precautions and know-how to do the work, and
••• X1 etc. and their part numbers, part names amount of the oil and coolant to be replenished
and quantities are described in the special tool are described.
list. q Common tools that are necessary for the disas-
q Also the following information is described in the sembly work are indicated as [1],[2]•••etc. and
special tool list. their part numbers, part names, and quantities
1) Necessity are not described.
t : Special tools that cannot be substituted q The meanings of the symbols used in
and should always be used. “Assembly” section are as follows.
q : Special tools that will be useful if avail- k : Precautions related to work safety
able and are substitutable with tools avail- a : Guidance or precautions for the work
able on the market. 2 : Type of coating material
2) Distinction of new existing special tools 3 : Tightening torque
N : Tools newly developed for this model. 5 : Amount of oil or coolant to be replenished
They have a new part number respectively.

R : Tools made available by redesigning the Sketch of special tool
existing tools which were developed for other q Various special tools are illustrated for the local
models. Each of them has a new part number manufacture.
assigned by setting forward the part number
of the existing tool.
Blank:Tools already available for other
models. They can be used without any modi-
fication.
3) Circle mark Q in sketch column:
q The sketch of the special tool is present-
ed in the section of "Sketches of special
tools".
q Part No. of special tools starting with
79*T-***-****:
means that they are not available from
Komatsu Ltd. (i.e. tools to be made
locally).
Disassembly
q In “Disassembly” section, the work procedures,
precautions and know-how to do the work, and
amount of the oil and coolant drained are de-
scribed.
q Common tools that are necessary for the disas-
sembly work are indicated as [1], [2]•••etc. and
their part numbers, part names, and quantities
are not described.
q The meanings of the symbols used in
“Disassembly” section are as follows.
k : Precautions related to work safety
a : Guidance or precautions for the work
6 : Amount of oil or coolant drained.
D375A-6 50-5
(02)
DRAFT
Coating materials list

(Rev. 2009. 08)
a The recommended coating materials such as adhesives, liquid gaskets, and greases used for disassem-
bly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part No. Capacity Container Main features and applications
gory code
q Use to prevent rubber gaskets, rubber cushions,

LT-1A 790-129-9030 150 g Tube
and cork plugs from coming out.
q Use for plastic (except polyethylene, polypropyl-
20 g Polyethylene ene, tetrafluoroethylene and vinyl chloride), rub-
LT-1B 790-129-9050
(2 pcs.) container ber, metal, and non-metal parts which require
immediate and strong adhesion.
Polyethylene q Features: Resistance to heat and chemicals.
LT-2 790-129-9040 50 g
container q Use to fix and seal bolts and plugs.
790-129-9060 Adhesive:
(Set of adhe- 1 kg
LT-3 Can q Use to bond and seal metal, glass and plastics.
sive and hard- Hardener:
ener) 500 g
Adhesive
Polyethylene
LT-4 790-129-9040 250 g q Use to seal plugs for blank holes
container
Holtz
790-129-9120 75 g Tube q Heat-resistant seal used to repair engines.
MH 705
q Instanetaneous adhesive.
ThreeBond Polyethylene q Curing time: From 5 sec. to 3 min.
790-129-9140 50 g
1735 container q Use mainly to bond metals, rubbers, plastics, and
woods.
q Instanetaneous adhesive.
Aron-alpha Polyethylene q Quick-curing type (max. strength is obtained after
790-129-9130 2g
201 container 30 minutes)
q Use mainly to bond rubbers, plastics, and metals.
q Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc q Use for fitted portions subjected to high tempera-
648-50 container
ture.
q Use to seal various threaded portions, pipejoints,
Polyethylene and flanges.
LG-5 790-129-9080 1 kg
container q Use to seal taper plugs, elbows, and nipples for
hydraulic piping.
q Features: Silicon-based heat and cold-resistant
sealant.
LG-6 790-129-9160 200 g Tube q Use to seal flange surfaces and threaded por-
tions.
Liquid gasket
q Use to seal oil pan, final drive case, etc.

q Features: Silicon-based quick-curing sealant.
LG-7 790-129-9170 1 kg Tube q Use to seal flywheel housing, intake manifold,
thermostat old, oil pan, thermostat housing, etc.
LG-8 q Features: Silicon-based, heat and cold-resistant,
ThreeBond 419-15-18131 100 g Tube vibration-resistant, impact-resistant sealant.
1207B q Use to seal transfer case, etc.
q Use for rough surfaces such as the circle gear top
LG-9
seal which is not clamped by bolts, gaps in the
ThreeBond 790-129-9310 200 g Tube
weld which must be caulked, etc.
1206D
q Can be coated with paint.
50-6 D375A-6
(02)
DRAFT
Cate- Komatsu
gory code
LG-10 q Use as lubricant/sealant when installing the radia-
ThreeBond 790-129-9320 200 g Tube tor hoses to the water tubes.
Liquid gasket
1206E q Can be coated with paint.

LG-11 q Feature: Can be used together with solid gaskets.
ThreeBond 790-129-9330 200 g Tube q Use for covers of the transmission case and steer-
1121 ing case etc.
ThreeBond
790-129-9090 100 g Tube q Liquid gasket used to repair engine.
1211
q Use to prevent galling and seizure of press-fitted
Molybdenum disulfide
portions, shrinkage-fitted portions, and threaded

LM-P 09940-00040 200 g Tube
portions.
lubricant
q Use to lubricate linkages, bearings, etc.

q Spray type
q Thin molybdenum disulphide films are made on
― 09995-00250 190 g Can metal surfaces to prevent the metals from galling.
q Use for the drive shaft splines, needle bearings,
various link pins, bolts, etc.
prevention compound
q Feature: Seizure and galling prevention com-

Seizure
LC-G pound with metallic super-fine-grain, etc.

NEVER-SE ― ― Can q Use for the mounting bolt in the high temperature
EZ area of the exhaust manifold and the turbocharg-
er, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI (*) q Feature: Lithium grease with extreme pressure lu-
SYGA-160CNLI Various Various
*: For cold brication performance, general purpose type.
SYG0-400LI-A
district
(*)
SYG0-160CNLI
(*)
q Use for parts under heavy load.
Molybde- Caution:
Bellows-type
num disul- SYG2-400M 400 g × 10 q Do not use this grease for rolling bearings like
container
fide grease SYG2-400M-A 400 g × 20 swing circle bearings, etc. and spline.
LM-G SYGA-16CNM 16 kg q Use this grease for work equipment pins only
Can
(G2-M) when installing them, but do not use it after-
ward.
SYG2-400T-A
Grease
Hyper White
SYG0-400T-A q Seizure resistance, heat resistance and water re-
G2-T, Bellows-type
(*) 400 g sistance higher than molybdenum disulfide
G0-T (*) container
SYG2-16CNT 16 kg grease.
*: For cold Can
SYG0-16CNT q Not conspicuous on machine since color is white.
district
(*)
Biogrease
G2-B SYG2-400B
G2-BT (*) SYG2-400BT
Bellows-type q Since this grease is biodegradable in short period,
*: For use at (*) 400 g
container it has less impact on microorganisms, animals,
high temper- SYGA-16CNB 16 kg
Can and plants.
ature and SYGA-16CNBT
under high (*)
load
q Feature: Silicone grease with wide usable temper-
G2-S ature range, high resistance to thermal-oxidative
ThreeBond ― 200 g Tube degradation and performance to prevent deterio-
1855 ration of rubber and plastic parts.
q Use for oil seals of the transmission, etc.
D375A-6 50-7
(02)
DRAFT
Cate- Komatsu
gory code
q Feature: Urea (organic system) grease with heat
resistance and long life, can be packed into the
Grease
G2-U-S
427-12-11871 2 kg Can confined space and left intact until next overhaul.
ENS grease
q Use for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
q Use as primer for painted cab sheet metal
SUNSTAR
Glass con- surface.
PAINT 20 ml
tainer (Effective period: four months after date of
PRIMER580
manufacture)
SUPER 417-926-3910
SUNSTAR
q Use as primer for glass.
GLASS Glass con-
For adhered window glass

20 ml (Effective period: four months after date of
PRIMER tainer
manufacture)
580 SUPER
SUNSTAR q Use as primer for painted cab sheet metal
Primer
PAINT Glass con- surface.

22M-54-27230 20 ml
PRIMER tainer (Effective period: four months after date of
435-95 manufacture)
q Use as primer for black ceramic-coated
SUNSTAR
glass surface and for hard polycarbon-
GLASS
22M-54-27240 150 ml Can ate-coated surface.
PRIMER
(Effective period: four months after date of
435-41
manufacture)
SUNSTAR q Use as primer for sash (anodized aluminum
SASH Glass con- surface).
22M-54-27250 20 ml
PRIMER tainer (Effective period: four months after date of
GP-402 manufacture)
SUNSTAR q Use “S" in high-temperature season and
PENGUINE “W" in low-temperature season as adhesive
Polyethylene
SEAL580 417-926-3910 320 ml for glass.
container
SUPER “ (Effective period: four months after date of
Adhesive
S" or “ W" manufacture)

Sika Japan, q Use as adhesive for glass.
Polyethylene
Sikaflex 20Y-54-39850 310 ml (Effective period: six months after date of
container
For adhered window glass
256HV manufacture)
SUNSTAR q Use as adhesive for glass.
Ecocart (Spe-
PENGUINE 22M-54-27210 320 ml (Effective period: six months after date of
cial container)
SUPER 560 manufacture)
SUNSTAR
q Use to seal glass-to-glass joints.
PENGUINE Polyethylene
417-926-3920 320 ml (Effective period: four months after date of
SEAL No. container
manufacture)
Caulking material
2505
SEKISUI q Use to seal front window.
Polyethylene
SILICONE 20Y-54-55130 333 ml (Effective period: six months after date of
container
SEALANT manufacture)
GE
q Use to seal glass-to-glass joint. Translu-
TOSHIBA
cent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Effective period: 12 months after date of
TOSSEAL3
manufacture)
81
50-8 D375A-6
(02)
DRAFT
Special tools list
Special tools list

a Tools with part number 79 QT-QQQ-QQQQ means that they are not available from Komatsu Ltd. (i.e.
tools to be made locally).
a Necessity:
t . . . . . . Special tools that cannot be substituted and should always be used
q . . . . . . Special tools that will be useful if available and are substitutable with tools available on the
market
a Distinction of new and existing special tools.
N: . . . . . . Tools newly developed for this model. They have a new part number respectively.
R: . . . . . . Tools made available by redesigning the existing tools which were developed for other models.
Each of them has a new part number assigned by setting forward the part number of the existing tool.
Blank: . . . Tools already available for other models. They can be used without any modification.
a Tools marked with Q in the sketch column are presented in the sketches of the special tools. (See "Sketch-
es of special tools")
Necessity
Sketch
Q'ty
N/R
Device Symbol Part No. Part name Work item and remarks
795-799-5410 Adapter t 1
1 Removal and installation of
795-799-5420 Remover t 1
fuel injector assembly
2 795T-675-1110 Socket q 1 NQ
Removal and installation of
3 795-931-1100 Seal puller assembly t 1 engine front seal and rear
seal
Push tool
795T-621-1180 t 1 Q
(For oil seal)
Push tool Removal and installation of
4 795T-621-1171 t 1 Q
(For dust seal) engine front seal
795-902-1460 Bolt t 3
Engine assem- 01582-02218 Nut t 3
A
bly Push tool
795T-621-1161 (For standard seal and sleeved t 1 Q
seal)
5 Push tool
795T-621-1190 t 1 Q engine rear seal
(For sleeved seal)
01050-32235 Bolt t 5
01050-32245 Bolt t 5
Tightening of cylinder head
6 790-331-1120 Wrench (angle) q 1
bolt
791-451-1000 Remover t 1
7 790-101-2102 Puller (294 kN {30 ton}) t 1
radiator guard assembly
790-101-1102 Pump t 1
Torque con- 790-413-1010 Bracket t 1
Disassembly and assembly of
verter valve C
790-501-5000 Repair stand(100 V) t 1 torque converter assembly
assembly
790-415-1011 Bracket t 1 Disassembly and assembly of
1 TORQFLOW transmission
750-501-5000 Repair stand(100 V) t 1
assembly
2 791-615-1130 Push tool t 1
snap ring
791-615-1200 Ring assembly t 1
791-615-1210 q Ring 1
TORQFLOW
3 135-A90-1150 q Bolt 1 Installation of No.3 ring gear
transmission D
01580-01008 q Nut 1
assembly
01641-51032 q Washer 2
791-615-1111 q Ring 1
4 135-A90-1150 q Bolt 1 Installation of No.1 ring gear
01580-01008 q Nut 1
01641-51032 q Washer 2
5 799-301-1600 Oil leak checker t 1 Checking actuation of piston
D375A-6 50-9
(02)
DRAFT
Special tools list
Necessity
Sketch
Q'ty
N/R

1 790-337-1001 Lifting tool t 1
final drive assembly
791-580-3200 Remover t 1
Separation of sprocket hub
2 790-101-2102 Puller (294 kN {30 ton}) t 1
assembly and bearing
790-101-1102 Pump t 1
791-580-3300 Installer t 1
Press-fitting of bearing
3 790-101-2102 Puller (294 kN {30 ton}) t 1
(sprocket hub assembly)
790-101-1102 Pump t 1
4 790-431-1071 Installer t 1 N Installation of floating seal
Final drive
J 791-580-3400 Remover t 1
assembly Disassembly of hub shaft
5 790-101-2102 Puller (294 kN {30 ton}) t 1
assembly
790-101-1102 Pump t 1
791-580-3500 Installer t 1
Press-fitting of bearing (hub
6 790-101-2102 Puller (294 kN {30 ton}) t 1
shaft assembly)
790-101-1102 Pump t 1
790-431-1230 Remover and installer t 1
7 790-101-2102 Puller (294 kN {30 ton}) t 1
planetary gear shaft
790-101-1102 Pump t 1
8 790-431-1250 Guide t 1 Installation of gear assembly
791T-630-2210 Plate t 1 Q
792-530-1630 Stud t 2
790-101-2510 Block t 1
790-101-2570 Washer t 2
1 Press fitting of bushing
01580-01613 Nut t 2
Idler assembly L 01643-31645 Washer t 2
790-101-2102 Puller (294 kN {30 ton}) t 1
790-101-1102 Pump t 1
2 791-515-1520 Installer t 1 Installation of floating seal
3 791-685-8310 Push tool t 1 Press fitting of seal guide
4 791-601-1000 Oil pump t 1 Adding oil
791-730-1110 Bolt t 4
01580-12722 Nut t 4
1 01643-32780 Washer t 1 Removal of pin
790-101-2102 Puller (294 kN {30 ton}) t 1
Recoil spring
M 790-101-1102 Pump t 1
assembly
791-685-8501 Compressor t 1
790-101-1600 Cylinder (686 kN {70 ton}) t 1 Disassembly and assembly of
2
790-101-1102 Pump t 1 recoil spring assembly
791-635-3160 Extension t 1
195-30-68610 Plate t 6 N
01010-62450 Bolt t 6
01010-62455 Bolt t 6
22
19M-54-11770 Washer t 6 N
01643-32460 Washer t 6
198-30-66190 Collar t 6 N Locking bogie assembly
Track frame
L 195-30-69540 Plate t 2 N
assembly
01011-82410 Bolt t 2
23 01011-82420 Bolt t 2
19M-54-11770 Washer t 4 N
195-30-69550 Collar t 2 N
24 791-685-1320 Lifting tool t 1
track frame assembly
50-10 D375A-6
(02)
DRAFT
Special tools list
Necessity
Sketch
Q'ty
N/R
8 791T-630-2220 Plate t 1 Q Press fitting of bushing

10 791T-630-2230 Push tool t 1 Q Press fitting of seal guide
11 791-601-1000 Oil pump t 1 Supplying oil
790-401-1700 Lifting tool t 1
790-401-1761 Adapter t 1
12 Lifting of rack roller assembly
790-401-1540 Shackle t 2
790-401-1770 T-bolt t 2
Track roller 195-30-68610 Plate t 6 N
L 01010-62450 Bolt t 6
assembly
01010-62455 Bolt t 6
22
19M-54-11770 Washer t 6 N
01643-32460 Washer t 6
198-30-66190 Collar t 6 N Locking bogie assembly
195-30-69540 Plate t 2 N
01011-82410 Bolt t 2
23 01011-82420 Bolt t 2
19M-54-11770 Washer t 4 N
195-30-69550 Collar t 2 N
4 791-601-1000 Oil pump t 1
Carrier roller 5 791-515-1520 Installer t 1 Disassembly and assembly of
L
assembly 6 791-830-1770 Push tool t 1 carrier roller assembly
7 791-630-1270 Wrench t 1
1 791-630-2260 Plate t 1
2 790-201-2730 Spacer t 1
3 791-630-2270 Screw t 3
14 4 01580-12419 Nut t 3
5 01643-32460 Washer t 3
6 790-101-4000 Puller (490 kN {50 ton}) t 1
7 790-101-1102 Pump t 1
1 791-630-2280 Adapter t 1 Pulling out shaft and ring
2 790-201-2770 Spacer t 1
3 791-630-2250 Plate t 1
4 790-434-1070 Screw t 1
15
5 01580-13629 Nut t 2
Bogie assembly L 6 01643-33690 Washer t 2
7 790-101-4000 Puller (490 kN {50 ton}) t 1
8 790-101-1102 Pump t 1
1 791-630-2260 Plate t 1
2 791-630-2270 Screw t 3
3 01580-12419 Nut t 3
16 Press fitting of pin assembly
4 01643-32460 Washer t 3
5 790-101-4000 Puller (490 kN {50 ton}) t 1
6 790-101-1102 Pump t 1
Alignment of track frame and
17 791T-630-2290 Guide t 2 Q
bogie pin holes
195-30-68610 Plate t 6 N
01010-62450 Bolt t 6
01010-62455 Bolt t 6
22
19M-54-11770 Washer t 6 N
01643-32460 Washer t 6
Bogie assembly L 198-30-66190 Collar t 6 N Fixing of bogie assembly
195-30-69540 Plate t 2 N
01011-82410 Bolt t 2
23 0101-82420 Bolt t 2
19M-54-11770 Washer t 4 N
195-30-69550 Collar t 2 N
D375A-6 50-11
(02)
DRAFT
Special tools list
Necessity
Sketch
Q'ty
N/R
1 791-630-2260 Plate t 1
2 790-201-2730 Spacer t 1
3 791-630-2270 Screw t 3
14 4 01580-12419 Nut t 3
5 01643-32460 Washer t 3
6 790-101-4000 Puller (490kN {50ton}) t 1
7 790-101-1102 Pump t 1
1 791-630-2280 Adapter t 1 Pulling out shaft and ring
2 790-201-2770 Spacer t 1
3 791-630-2250 Plate t 1
4 790-434-1070 Screw t 1
15
5 01580-13629 Nut t 2
6 01643-33690 Washer t 2
7 790-101-4000 Puller (490 kN {50 ton}) t 1
8 790-101-1102 Pump t 1
1 791-630-2260 Plate t 1
2 791-630-2270 Screw t 3
3 01580-12419 Nut t 3
No. 1 bogie 16 Press fitting of pin assembly
L 4 01643-32460 Washer t 3
assembly 5 790-101-4000 Puller (490 kN {50 ton}) t 1
6 790-101-1102 Pump t 1
Alignment of track frame and
17 791T-630-2290 Guide t 2 Q
bogie pin holes
1 791-630-1860 Bracket (L. H) t 1 N
2 791-630-1870 Bracket (R.H) t 1 N Setting bogie to installed posi-
20
3 01010-62760 Bolt t 2 tion
4 01643-32780 Washer t 2
791T-630-1900 Lifting tool q 1 Q
791T-630-1910 q Tube 1 Q
791T-630-1920 q Plate 1 Q
07283-38973 q Grip 1 Installation of track roller
21
04530-11628 q Eyebolt 1 assembly
01643-31645 q Washer 1
01643-31232 q Washer 2
01582-01210 q Nut 2
1 791-646-7351 Push tool t 1 Removal of pin small plug
2 791-660-7460 Pin brush t 1 Cleaning of pin hole
Push tool
3 791-646-7900 t 1 Drive-in of large plug
(For large plug)
791-701-3000
Seal checker
4 or t 2 Filling with oil
Oil pump
791-601-1000
Push tool
5 791-932-1110 t 1 Drive-in of small plug
(For small plug)
Track shoe 6 791-632-1021 Installer t 1 Installation of seal assembly
R 1 791-632-1300 Push tool assembly t 1 N
assembly
2 791-632-1260 q Push tool 1
3 791-632-1270 q Adapter 1
4 791-632-1220 q Adapter (small) 1
5 791-632-1230 q Ring 1
8 6 791-632-1240 q Plate 1 Assembly of link
7 791-685-5730 q Bar 1
8 791-632-1250 q Ring 1
9 791-632-1280 q Spring 1
10 01252-30605 q Bolt 1
11 01580-01210 q Nut 1
50-12 D375A-6
(02)
DRAFT
Special tools list
Necessity
Sketch
Q'ty
N/R
1 791-632-1200 Push tool assembly t 1 N

2 791-632-1260 q Push tool 1
3 791-632-1270 q Adapter 1
4 791-631-1210 q Adapter (large) 1
5 791-632-1230 q Ring 1
9 6 791-632-1240 q Plate 1
7 791-685-5730 q Bar 1
Assembly of link
8 791-632-1250 q Ring 1
9 791-632-1280 q Spring 1
10 01252-30650 q Bolt 1
11 01580-01210 q Nut 1
10 2 791-685-5730 Bar 1
3 01580-01210 Nut 1
1 791-646-7351 Push tool t 1
2 791-660-7460 Pin brush t 1
3 791-646-7900 Push tool (for large plug) t 1
791-701-3000
Seal checker
4 or t 2
Oil pump
791-601-1000
5 791-932-1110 Push tool (for small plug) t 1
6 791-632-1021 Installer t 1
1 791-632-1100 Remover & installer assembly t 1
2 791-632-1130 q Adapter 1
Track shoe 3 790-434-1610 q Guide 1
R
assembly 4 01010-51440 q Bolt 2
5 791-685-9510 q Frame 1
6 791-685-9520 q Rod 1
7 791-685-9520 q Frame 1
8 791-685-9550 q Nut 3
9 04530-12030 q Eyebolt 1
10 791-685-9560 q Bolt 4 Disassembly and assembly of
11 791-126-0150 q Adapter 1 one link assembly in field
12 791-685-9540 q Rod 1
13 791-632-1140 q Adapter 1
14 791-680-5520 q Guide 1
7
15 01010-51030 q Bolt 1
16 791-632-1150 q Pusher 1
17 791-685-9620 q Extension 1
18 791-632-1180 q Adapter 1
19 791-680-5543 q Adapter 1
20 791-632-1170 q Guide 1
21 791-680-5551 q Guide 1
22 791-680-9630 q Adapter 1
23 791-632-1160 q Guide 1
24 195-32-61210 Bolt 1
25 790-101-4300 Cylinder (1,470 kN {150 ton}) t 1
26 790-101-1102 Pump t 1
27 790-101-4200 Cylinder (294 kN {30 ton}) t 1
28 791-680-1630 Spacer t 1 N
D375A-6 50-13
(02)
DRAFT
Special tools list
Necessity
Sketch
Q'ty
N/R
1 791-646-7351 Push tool t 1

2 791-660-7460 Pin brush t 1
3 791-646-7900 Push tool (for large plug) t 1
791-701-3000 Seal checker
4 or t 2
791-601-1000 Oil pump
5 791-932-1110 Push tool (for small plug) t 1
6 791-632-1021 Installer t 1
1 791-632-1100 Remover & installer assembly t 1
2 791-632-1130 q Adapter 1
3 790-434-1610 q Guide 1
4 01010-51440 q Bolt 2
5 791-685-9510 q Frame 1
6 791-685-9530 q Rod 1
7 791-685-9520 q Frame 1
8 791-685-9550 q Nut 3
9 04530-12030 q Eyebolt 1
10 791-685-9560 q Bolt 4
11 791-126-0150 q Adapter 1
12 791-685-9540 q Rod 1
13 791-632-1140 q Adapter 1
14 791-680-5520 q Guide 1
7
15 01010-51030 q Bolt 1
Track shoe Disassembly and assembly of
R 16 791-632-1150 q Pusher 1
assembly master link
17 791-685-9620 q Extension 1
18 791-632-1180 q Adapter 1
19 791-630-5543 q Adapter 1
20 791-632-1160 q Guide 1
21 791-680-5551 q Guide 1
22 791-680-9630 q Adapter 1
23 791-632-1160 q Guide 1
24 195-32-61210 Bolt 2
25 790-101-4300 Cylinder (1,470 kN {150 ton}) t 1
26 790-101-1102 Pump t 1
27 790-101-4200 Cylinder (294 kN {30 ton}) t 1
28 791-680-1630 Spacer t 1
2 791-632-1260 q Push tool 1
3 791-632-1270 q Adapter 1
4 791-632-1220 q Pin (small) 1
5 791-632-1230 q Ring 1
8 6 791-632-1240 q Plate 1
7 791-685-5730 q Bar 1
8 791-632-1250 q Ring 1
9 791-632-1280 q Spring 1
10 01252-30605 q Bolt 1
11 01580-01210 q Nut 1
2 791-632-1260 q Push tool 1
3 791-632-1270 q Adapter 1
4 791-632-1210 q Pin (large) 1
5 791-632-1230 q Ring 1
9 6 791-632-1240 q Plate 1
Track shoe 7 791-685-5730 q Bar 1 Disassembly and assembly of
R
assembly 8 791-632-1250 q Ring 1 master link
9 791-632-1280 q Spring 1
10 01252-30650 q Bolt 1
11 01580-01210 q Nut 1
10 2 791-632-1260 Bar 1
3 01580-01210 Nut 1
50-14 D375A-6
(02)
DRAFT
Special tools list
Necessity
Sketch
Q'ty
N/R
1 791T-650-2330 Sleeve t 1 N Q
2 791T-650-2340 Plate t 1 N Q
3 790-201-3310 Bolt t 2
Pivot shaft 4 790-101-2510 Block t 1 Removal and installation of
assembly
P 5 790-101-2570 Washer t 2 pivot shaft assembly
6 01580-01613 Nut t 2
7 01643-31645 Washer t 2
8 790-105-2300 Jack assembly t 1
9 790-101-1102 Pump t 1
791-650-1300 Remover q 1
791-735-1123 q Sleeve 1
790-434-1050 q Screw 1
Equalizer bar N 1 01580-02419 q Nut 1
q Washer
equalizer bar assembly
01643-32460 1
790-101-2102 Puller (294 kN {30 ton}) q 1
790-101-1102 Pump q 1
1 791T-650-2410 Bracket t 1 N Q
2 791T-650-2420 Bracket t 1 N Q
Equalizer bar 3 790-438-1110 Screw t 1 Disassembly and assembly of
bushing
N 2 4 791-112-1180 Nut t 2 equalizer bar bushing
5 790-101-2540 Washer t 2
6 790-101-2102 Puller (294 kN {30 ton}) t 1
7 791-101-1102 Pump t 1
Cylinder Disassembly and assembly of
1 790-502-1003 q 1
Repair stand hydraulic cylinder assembly
790-201-1702 Push tool kit t 1
790-201-1841 q Push tool 1
2 790-201-1861 q Push tool 1 Press fitting of bushing
Hydraulic cylin- 790-101-5021 q Grip 1
U
der assembly 01010-50816 q Bolt 1
790-201-1650 q Plate 1
3 790-201-1670 q Plate 1 Press fitting of seal
790-101-5021 q Grip 1
01010-50816 q Bolt 1
4 790-720-1000 Expander t 1
796-720-1680 Ring t 1
07281-01589 Clamp t 1
796-720-1720 Ring t 1 Installation of bearing
5
Hydraulic cylin- 07281-02429 Clamp t 1
U
der assembly 796-720-1690 Ring t 1
07281-02169 Clamp t 1
790-102-4300 Wrench t 1 Disassembly and assembly of
6 ripper cylinder piston assem-
790-102-4310 Pin t 2
bly
Assembly and disassembly of
Cylinder
1 790-502-1003 q 1 ripper pin puller cylinder
Repair stand
assembly
790-201-1721 q Push tool 1
2 Press fitting of bushing
790-101-5021 q Grip 1
Ripper pin 01010-50816 q Bolt 1
puller cylinder U 790-201-1500 Push tool kit t 1
assembly 790-201-1530 q Plate 1
3 Press fitting of dust seal
790-101-5021 q Grip 1
01010-50816 q Bolt 1
4 790-720-1000 Expander t 1
796-720-1630 Ring t 1 Press fitting of dust seal
5
07281-00709 Clamp t 1
7 790-102-2302 Wrench t 1 Tightening cylinder head
D375A-6 50-15
(02)
DRAFT
Sketches of special tools

Caution: Komatsu will not accept any responsibility for any special tools manufactured according to these
sketches.
A2 Socket
A4 Push tool (for oil seal)
50-16 D375A-6
(02)
DRAFT
A4 Push tool (for dust seal)
A5 Push tool (for standard seal and sleeved seal)
D375A-6 50-17
(02)
DRAFT
A5 Push tool (for sleeved seal)
L1 Plate
50-18 D375A-6
(02)
DRAFT
L8 Plate
L10 Push tool
D375A-6 50-19
(02)
DRAFT
L17 Guide
L21 Lifting tool
50-20 D375A-6
(02)
DRAFT
L21 Tube
L21 Plate
D375A-6 50-21
(02)
DRAFT
P1 Sleeve
P2 Plate
50-22 D375A-6
(02)
DRAFT
N2-1 Bracket
N2-2 Bracket
D375A-6 50-23
(02)
DRAFT
Removal and installation of fuel supply pump assembly

Removal 5. Remove common rail cover (5).
k Park the machine on a level surface and low- a Pull up the cover at an angle toward the front
er the work equipment to the ground. side to remove.
k Set the parking brake lever and work equip-
ment lock lever in the lock position. 6. Disconnect wiring connectors (6).
k Stop the engine and disconnect the cable a Wiring connectors: PCV1, PCV2
from the negative (-) terminal of the battery.
a Remove the wiring clamp and move the wiring
aside.
1. Close the fuel valve under the fuel tank.
2. Open the left side cover and remove lower side

cover (1).
7. Loosen clamps (8), (9), and (10) of high-pres-

sure pipes (7) between the supply pump and the
common rail, and remove the high-pressure
pipes (7).
3. Remove covers (2) and (3).
4. Disconnect common rail wiring (4).
50-24 D375A-6
(02)
DRAFT
8. Remove the fuel pre-filter. 11. Remove the mounting bolts of brackets (16) and
a The fuel pre-filter may be removed first. (17) and remove the fuel supply pump assembly
(18).
9. Remove tubes (11), (12), (13), and (14).
[*1]
12. Remove the following parts from fuel supply

pump assembly (18).
1) Oil tube (19)
2) Plate (20)
3) Overflow valve (21)
10. Disconnect G sensor connector (15) on the

opposite side of the supply pump.
D375A-6 50-25
(02)
DRAFT
Installation
1. Install the following parts to fuel supply pump
assembly (18).
1) Plate (20)
2) Oil tube (19)
a Replace gaskets (GA) and (G10) with
new ones.
q GA : Accessory to supply pump
q G10: Part No. (07005-01012)
3) Overflow valve (21)
3 Plate (20) mounting bolt:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
3 Oil tube (19) joint bolt:
3. Install fuel supply pump assembly (18).
3 Fuel supply pump mounting bolt:
Upper side: 7.9 – 12.7 Nm {0.8 – 1.3
kgm}
59 – 74 Nm {6 – 7.5 kgm}
Lower side: 9.8 – 12.7 Nm {1.0 – 1.3
kgm}
3 Overflow valve (21):
59 – 74 Nm {6.0 – 7.5 kgm}
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
4. Install oil tube (22).
a Replace 4 gaskets (G) with new ones.
(Part number: 07005 -01012.)
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
2. Place the fuel supply pump assembly to the drive

case according to the following procedure.
a Match part (A) of the fuel supply pump drive
gear where there is one tooth missing with
part (AA) of the coupling where there is one
spline missing to place the fuel supply pump
assembly.
50-26 D375A-6
(02)
DRAFT
High-pressure pipe
k When handling the high-pressure pipe
and clamp, observe the following.
q Never bend the high-pressure pipe to in-
stall or use it in other locations.
q Install the specified clamp to the specified
position securely and tighten it to the
specified torque.
q Do not apply lubricant to the high-pres-
sure pipe sleeve nuts and the threads of
the mating part.
a Axial force in the tightening can be exces-
sive, potentially damaging the high-pres-
sure pipe. q Carry out the subsequent installation in the re-
k Before installing the high-pressure pipe, verse order to removal.
check it for the following defects. If it has
any defect, replace it with new one since [*1]
fuel may leak. 3 Tube (11)
q Check the taper seal of the connecting Joint bolt:24.5 – 34.3 Nm {2.5 – 3.5 kgm}
part (Part (a): Part of 2 mm from the end) 3 Tube (12)
for visible lengthwise slit (b) and dent (c). Joint bolt (Supply pump side):
q Check part (d) (End of the taper seal: Part 14.8 – 19.6 Nm {1.51 – 1.99 kgm}
at 2 mm from the end) for stepped-type Sleeve nut:43 – 47 Nm {4.4 – 4.8 kgm}
wear (fatigue) which your nail can feel. 3 Tube (13)
Joint bolt (Overflow valve):
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
Joint bolt (Supply pump side):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
Sleeve nut (Fuel block side):
24 – 27 Nm {2.4 – 2.7 kgm}
3 Tube (14)
Joint bolt (Supply pump side):
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
Sleeve nut: 43 – 47 Nm {4.4 – 4.8 kgm}
k Make sure that a clearance of 10 mm mini-

5. Connect G sensor connector (15). mum is provided between the high-pressure
pipe and adjacent wiring harness. If not, se-
6. Tighten high-pressure pipes (7) and (11) cure the clearance by repositioning the wir-
partially. ing harness.
q Air bleeding
7. Tighten clamps (8) to (10) partially. Bleed air from the fuel circuit. For details, see
Testing and adjusting, "Bleeding air from fuel
circuit".
8. Tighten high-pressure pipes (7) and (11) to the
specified torque.
3 High-pressure pipe sleeve nut:
39.2 – 44.1 Nm {4.0 – 4.5 kgm}
9. Tighten clamps (8) to (10) to the specified

torque.
3 Clamp bolt: 9.8 ± 1.0 Nm {1 ± 0.1 kgm}
D375A-6 50-27
(02)
DRAFT
Removal and installation of fuel injector assembly

35. Disconnect high-pressure pipe clamps (7) and
Special tools (8).
a A clamp is provided on the fuel supply pump
New/remodel
Necessity
side.
Sketch
Sym-
Q'ty
Part No. Part name
bol
795-799-5410 Adapter t 1
1
A 795-799-5420 Remover t 1
2 795T-675-1110 Socket q 1 N Q
Removal
k Park the machine on a level surface and low-
er the work equipment to the ground.
ment lock lever in the lock position.
k Stop the engine and disconnect the cable
36. Remove clamp (9).
1. Perform steps 1 to 31 of “Removal and installa-
tion of cylimder head assembly”. (See "Removal 37. Remove covers (10).
and installation of cylinder head assembly")
32. Disconnect high-pressure pipe clamps (1) - (3).
33. Remove tubes (4) and (5). [*1]
34. Remove bracket (6).
50-28 D375A-6
(02)
DRAFT
38. Disconnect sleeves (11) and (12) at 6 places 41. Remove terminal mounting nuts (15).
each. a Loosen the nuts alternately.
39. Remove high-pressure pipes (13). 42. Remove wiring harness assembly mounting
bolts (16) and spacer (17).
40. Remove cylinder head cover (14).
43. Remove fuel injector holder (21).
44. Using tool A1, remove fuel injector assembly

(22).
a Hook the end of tool A1 onto hole (H) of the fuel
injector to pull out.
a Never grip the solenoid valve on the top of the
fuel injector with pliers, etc. to pull out.
a The figure shows the fuel injector after the rocker
arm and shaft assembly is removed.
a If tool A2 is not available, disconnect sleeve (12)

from above.
q Tool A2
D375A-6 50-29
(02)
DRAFT
Installation 2) Install terminal mounting nuts (15) and wiring

1. Fuel injector harness fixing bolts (16).
a Check that the injector mounting bore is free a Tighten the terminal mounting nuts alter-
from dirt. nately
2 O-ring: Engine oil (EO30) 3 Terminal mounting nut:
2 ± 0.2 Nm {0.2 ± 0.02 kgm}
1) Install gasket (22) and O-rings (24) and (25)
to fuel injector (26).
a Take care not to fit O-ring (25) to center
groove (A).
2) Install fuel injector (22) to adapter (27) and

injector holder (21).
3) Attach spherical washer (29) to bolt (30) and

then tighten the bolt to fasten injector holder
(31) partially.
2 Spherical washer: Engine oil (EO30)
a The bolt of injector holder (21) is to be
tightened to the specified torque after
3. High-pressure pipe
tightening the high-pressure pipe pantial-
ly.
specified torque.
the mating part.
a If lubricant is applied, the axial force
becomes too high and can break the
high-pressure pipe.
2. Injector wiring harness

1) Install spacer (17).
a Install the spacer with its slit (B) up.
50-30 D375A-6
(02)
DRAFT
k Before installing the high-pressure pipe, 5) Tighten high-pressure pipe sleeve nuts (11)
check it for the following defects. If it has and (12) to the specified torque by using the
any defect, replace it with new one since spanner type torque wrench.
fuel may leak. 3 Sleeve nut:
q Check the taper seal of the connecting 39.2 – 44.1 Nm {4 – 4.5 kgm}
part (Part (a): Part of 2 mm from the end) a After finishing the work, check that
for visible lengthwise slit (b) and dent (c). O-ring (32) is not projected from the
q Check part (d) (End of the taper seal: Part end of the sleeve nut (12).
at 2 mm from the end) for stepped-type
wear (fatigue) which your nail can feel. 6) Install cylinder head cover (14).
a A different tightening torque is employed
for No. 2 cylinder head cover mounting
bolt alone.
3 Cylinder head cover mounting bolt:
No. 1, 3, 4, 5, and 6 cylinders:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
No.2 cylinder:59 – 74 Nm {6 – 7.5
kgm}
1) Install O-ring (32) to sleeve (31) of high-pres-

sure pipe (13).
2 O-ring: Engine oil (EO30)
2) Tighten sleeve nut (12) partially aligning it

with connector (28) of the injector.
a When it is difficult to engage sleeve nut
(12) with the threaded portion, turn sleeve
nut (12) with the spanner while pushing
sleeve nut (12) toward the injector by use
of a short bar or the like.
3) Tighten the common rail side sleeve nut (11)

partially, too.
4) Tighten injector holder (21) to the specified

torque.
3 Injector holder mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
D375A-6 50-31
(02)
DRAFT
4. High-pressure pipe clamp k Make sure that a clearance of 10 mm mini-

1) Install the clamps on the high-pressure pipes mum is provided between the high-pressure
according to the following procedure. pipe and adjacent wiring harness. If not, se-
1] Finger-tighten 17 high-pressure pipe cure the clearance by repositioning the wir-
clamps (33) in the position indicated in ing harness.
the figure.
q Bleeding air
2] Finger-tighten common rail side clamp
Bleed air from the fuel circuit. For details, see
bracket (34) and clamp (9) and then
Testing and adjusting, "Bleeding air from fuel
tighten clamp (9).
3 Common rail side clamp bolt:
circuit".
9.8 ± 1.0 Nm {1 ± 0.1 kgm}
3] Tighten common rail side clamp bracket
(34) to the specified torque.
4] Tighten high-pressure pipe clamps (33).
3 High-pressure pipe clamp bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
5] Install covers (10) on the common rail
side sleeve nuts.
a When installing it, direct the slit down-
ward.
q Carry out the subsequent installation in the re-

verse order to removal.
[*1]
3 Tube (4) joint bolt:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
3 Tube (5) sleeve nut:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
a Refer to the precautions in "Installation of cylin-

der head" for the installation.
50-32 D375A-6
(02)
DRAFT
Removal and installation of cylinder head assembly

4. Loosen the clamp and disconnect exhaust tube
Special tools (2).
New/remodel
Necessity
Symbol
5. Disconnect exhaust temperature sensor wiring
Sketch
Q'ty
Part No. Part name (3).
795-799-5410 Adapter t 1
6. Remove front heat insulation cover (4), center
1 heat insulation cover (5), and rear heat insula-
795-799-5420 Remover t 1
A
2 795T-675-1110 Socket q 1 N Q tion cover (6).
6 790-331-1120 Wrench (angle) q 1
7. Disconnect the muffler drain tube.
Removal
8. Lift off muffler (7).
4 Muffler assembly: 75 kg
ment lock lever in the lock position. 9. Remove muffler mounting bracket (8).
k If the coolant temperature is high, wait until it
decreases to avoid scalding yourself with the
hot coolant, and then disconnect the heater
hose and drain the coolant.
1. Drain the coolant.

6 Coolant: 120 l
2. Remove the engine hood assembly. For details,

see "Removal and installation of hood
assembly".
10. Disconnect fuel hoses (9) and (11). [*1]
3. Remove left and right lower side covers (1).
4 Left lower side cover: 40 kg
11. Disconnect tube (10). [*2]
Right lower side cover: 50 kg
12. Remove fuel pre-filter assembly (12).
D375A-6 50-33
(02)
DRAFT
13. Remove fuel tube clamps (17). 18. Lift off engine oil filter assembly (23).
14. Remove fuel tubes (18), (18-1), and (19).

[*3]
15. Disconnect connector TOIL (20).
a Drive lock (L) upward to pull out the connec-
tor.
16. Disconnect connector POIL (21) according to

the following procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connector
POIL (21).
17. Remove tube assembly (22).

19. Disconnect wiring harnesses (24)
20. Disconnect water tube (25).
21. Remove EGR valve and cooler assembly (26)

and exhaust tube (27).
50-34 D375A-6
(02)
DRAFT
22. Remove each tube of the turbocharger. [*4] 24. Lift off turbocharger and exhaust manifold
q Lubricating oil tube (28) assembly (32). [*5]
q Lubricating oil drain tube (29) 4 Turbocharger and exhaust mainfold as-
q Coolant tube (30) sembly:120 kg
q Coolant drain tube (31).
25. Remove breather and tube assembly (33).
26. Remove wiring harness covers (34) and (35).
23. Disconnect connectors V30 (31-1) and V29

(31-2).
27. Disconnect connector PFUEL(36).
28. Remove common rail cover (37).
D375A-6 50-35
(02)
DRAFT
29. Disconnect 6 injector connectors (38). 37. Remove clamp (52).
30. Disconnect connector CN6 (39). 38. Remove covers (53) and (54).
31. Remove wiring harness bracket (40). 39. Loosen clamps (55) and (56).
40. Remove high-pressure tube assembly (57).
41. Disconnect connector (58).
42. Disconnect fuel hose (120).
43. Disconnect connector PIM (121).
32. Disconnect high-pressure pipe clamps (41) to

(43).
33. Remove tubes (44) to (46). [*6]
34. Remove brackets (47) and (48).
35. Disconnect high-pressure pipe clamps (49) and

(50).
36. Remove fuel tube (51). [*7]
50-36 D375A-6
(02)
DRAFT
44. Disconnect wiring harness clamp (59) from rear 50. Disconnect sleeves (69).
side of the fuel supply pump.
51. Remove high-pressure pipes (70).
45. Disconnect the connector from the bottom of
clamp (59).
46. Disconnect connectors PCV1 (60) and PCV2 53. Remove 4 mounting bolts (73) of air intake mani-
(61). fold assembly (72) from the radiator side.
47. Disconnect harness clamps (62).
48. Remove tubes (63) to (65). [*8]
49. Remove fuel supply pump assembly (66).

a Do not loosen overflow valve (ofv).
a Do not remove oil tube (t) and plate (p).
D375A-6 50-37
(02)
DRAFT
54. Disconnect high-pressure pipe sleeve nut (75)

on the injector side.
a If tool A2 is available, you can work from the
side, not from above.
60. Remove air intake connector (76).

a Since the tube convexly bites into the inside
of the air intake connector (part A), take care
a Tool A2 not to damage the tube when removing the
air intake connector.
55. Remove high-pressure pipes (74).

61. Lift off air intake manifold assembly (72).
4 Air intake manifold assembly:110 kg
56. Sling air intake manifold assembly (72).
a Install eyebolt [1] to the mounting hole of
bracket (71) (described above) and sling air
intake manifold assembly (72) by using lifting
tool [2].
57. Remove the mounting bolts of air intake mani-

fold assembly (72), leaving some of them tight-
ened.
58. Install guide bolts [3].

a Use the filter mounting bolt as the guide bolt.
a The tube convexly bites into the inside of the
connector. Thus, take care not to demage .
the tube when removing the air intake con-
nector by using the guide bolts. (See the fol-
lowing section)
59. Remove the remaining mounting bolts of air

intake manifold assembly (72).
50-38 D375A-6
(02)
DRAFT
62. Remove brackets (77).
63. Remove turbocharger lubrication tube (78) and

coolant tube (79).
64. Remove air vent tube (80).
68. Remove terminal mounting nuts (82).

a Loosen the nuts alternately.
69. Remove wiring harness assembly mounting
bolts (83) and spacer (84).
70. Loosen locknut (85) and then loosen adjustment
screw (86).
65. Remove pin (A) and then push in bolt (B).
71. Remove rocker arm assembly (87)
66. Rotate the crankshaft by using bolt (B) as a
barring location to set the No. 1 or No. 6 cylinder
to the compression top dead center.
a Remove plug (BB) to check the result visual-
ly.
a For above operation, see Testing and adjust-
ing, "Testing and adjusting valve clearance".
72. Remove push rods (88).
73. Remove crosshead assemblies (89).
74. Remove rocker arm housing (90).
75. Remove fuel injector holder (91).

67. Remove cylinder head cover (81).
a Check that you can move the rocker arm of
the No. 1 or No. 6 cylinder with fingers by the
distance of the valve clearance.
76. Using tool A1, remove fuel injector assembly

(92).
D375A-6 50-39
(02)
DRAFT
a Remove the assembly by hooking the end of

tool A1 onto hole (H) of the fuel injector.
a Never grip the solenoid valve on the top of
the fuel injector with pliers, etc to pull out.
77. Lift off cylinder head assembly (93).

4 Cylinder head assembly:50 kg
78. Remove the cylinder head gasket.
50-40 D375A-6
(02)
DRAFT
Installation
1. Cylinder head assembly
1) Install the cylinder head gasket.
2) Sling and install cylinder head assembly (93).

4 Cylinder head assembly:50 kg
a If there are 5 punch marks on the head of
a bolt, do not reuse that bolt but replace it.
a Tighten the mounting bolts in the order
shown in the figure.
2 Cylinder head assembly mounting
bolt:
Molybdenum disulfide lubricant
(LM-P)
3 Cylinder head assembly mounting
bolts (1 – 7):
1st time: 245 ± 9.8 Nm {25 ± 1 kgm}
2nd time: 382.5 ± 9.8 Nm {39 ± 1
kgm}
3rd time: 90 – 120 ° retightening
a Use tool A6 (See the tool table) to retight-
en. When not using tool A6, make marks
on the cylinder head and bolt using paint,
etc., and then retighten the bolt to 90 -
120 ° (target: 120 °).
3 cylinder head assembly mounting bolt
(8 and 9): a After tightening the bolt, make punch
93.2 – 103 Nm {9.5 – 10.5 kgm} mark "(a)" on the main bolt head (Do not
make it when new bolt is used, however).
D375A-6 50-41
(02)
DRAFT
2. Fuel injector a Do not forget to install O-ring (OR).

a Check that the fuel injector mounting bore is 3 Rocker arm housing mounting bolt:
free from dirt or other particles. 78.4 – 93.2 Nm {8.0 – 9.5 kgm}
1) Install gasket (94) and O-rings (95) and (96)

to fuel injector (92).
a Take care not to fit O-ring (95) to center
groove (A).
2) Insert fuel injector (92) to adapter (97) and

injector holder (91).
3) Attach spherical washer (100) to bolt (99)

and then tighten injector holder (91) partially.
2 Spherical washer: Engine oil (EO30)
6) Install crossheads (89).
a Injector holder (91) is to be tightened to

the specified torque after installing the in-
7) Adjust the crossheads according to the
take manifold and tightening the
following procedure.
high-pressure pipe partially.
1] Loosen locknut (102) and then loosen
adjustment screw (103) to a position
4) Install push rods (88).
where it will not touch valve stem (104).
a Check that the push rod end is securely
placed in the cam follower socket. 2] Hold the rocket arm contact face on the
crosshead with the finger to keep the
crosshead in contact with valve stem
5) Apply liquid gasket and then install rocker
(105) on the push rod side.
arm housing (90).
2 Rocker arm housing: Liquid gasket
3] Slowly tighten adjustment screw (103)
(LG-7) and check the position at which adjust-
a Apply the liquid gasket 2 to 3 mm in bead ment screw (103) touches valve stem
diameter along the housing groove as (104).
shown in the figure. 4] Screw in adjustment screw (103) further
by 20 ° – 30 ° from the contacting position
against valve stem (104).
50-42 D375A-6
(02)
DRAFT
5] While holding adjustment screw (103) to

prevent it from moving, tighten locknut
(102).
3 Locknut:
53.0 – 64.7 Nm {5.4 – 6.6 kgm}
4. Injector wiring harness

a Install the spacer with its slit (B) up.
3. Rocker arm assembly

1) Install rocker arm assembly (87).
a Install each rocker arm assembly with the
riveted side of its shaft facing the front
side of the engine.
a When installing, direct the wider seat of
the shaft to the rocker arm housing.
a Make sure that the ball of adjustment
screw (86) is securely placed in the push
rod socket.
a When tightening the mounting bolt, check
that adjustment screw (86) does not
press the push rod. 2) Install terminal mounting nuts (82) and wiring
2 Theaded portion and seat surface of harness fixing bolts (83).
rocker arm assembly mounting bolt: a Tighten the terminal mounting nuts alter-
Engine oil (EO30) nately
3 Rocker arm assembly mounting bolt : 3 Terminal mounting nut:
235.2 – 254.8 Nm {24 – 26 kgm} 2 ± 0.2 Nm {0.2 ± 0.02 kgm}

a Adjust the valve clearance. For details,
see Testing and adjusting, "Testing and
adjusting valve clearance".
3 Locknut (85):
57.8 – 77.4 Nm {5.9 – 7.9 kgm}
a After tightening the locknut, check the
valve clearance again.
D375A-6 50-43
(02)
DRAFT
5. Air intake manifold assembly: k Before installing the high-pressure pipe,

1) Place connector (76) on air lifted intake mani- check it for the following defects. If it has
fold assembly (72) being lifted. any defect, replace it with new one since
a Since the tube convexly bites into the in- fuel may leak.
side of the air intake connector (part A), q Check the taper seal of the connecting
take care not to damage the tube when in- part (Part (a): Part of 2 mm from the end)
stalling the air intake connector. for visible lengthwise slit (b) and dent (c).
4 Air intake manifold and connector as- q Check part (d) (End of the taper seal: Part
sembly: 135 kg at 2 mm from the end) for stepped-type

wear (fatigue) which your nail can feel.
2) Install air intake manifold assembly (72).

a Tighten the mounting bolts in the order 1) Install O-ring (106) to high-pressure pipe
shown in the figure. sleeve (101).
2) Tighten sleeve nut (75) partially aligning it

with connector (98) of the injector.
a If sleeve nut (75) does not catch the
threads, press the end of sleeve nut (75)
with a small rod, etc. toward the injector
and turn the spanner.
3) Tighten the common rail side sleeve nuts

(69) partially, too.
4) Tighten injector holder (91) to the specified
torque.
3 Injector holder mounting bolt:
58.9 – 73.5 Nm {6.0 – 7.5 kgm}
specified torque.
the mating part.
a If lubricant is applied, the axial force
becomes too high and can break the
high-pressure pipe.
50-44 D375A-6
(02)
DRAFT
5) Tighten high-pressure pipe sleeve nuts (69) 9) Install brackets (77).

and (75) to the specified torque by using the
spanner type torque wrench.
3 Sleeve nut :
39.2 – 44.1 Nm {4 – 4.5 kgm}
a After finishing the work, check that
O-ring (106) is not projected from the
end of the sleeve nut (75).
7. High-pressure pipe clamp

1) Install the high-pressure pipe clamps
1] Finger-tighten 17 high-pressure pipe
clamps (107) in the position indicated in
the figure.
2] Finger-tighten common rail side clamp
bracket (108) and clamp (52) and then
tighten clamp (52).
3 Common rail side clamp bolt:
9.8 ± 1.0 Nm {1 ± 0.1 kgm}
3] Tighten common rail side clamp bracket
4] Tighten high-pressure pipe clamps (107).
3 High-pressure pipe side clamp
bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
5] Install covers (53) on the common rail
side sleeve nuts.
6) Install cylinder head cover (81). a When installing it, direct the slit down-
a A different tightening torque is employed ward.
only for No. 2 cylinder mounting bolt.
No. 1, 3, 4, 5, and 6 cylinders:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
No. 2 cylinder:
59 – 74 Nm {6 – 7.5 kgm}
7) Install air vent tube (80).
3 Air bleeding tube joint bolt (cylinder
head side):
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
8) Install turbocharger coolant tube (79) and
lubricating oil tube (78).
D375A-6 50-45
(02)
DRAFT
8. Fuel supply pump 3 Fuel supply pump (66) mounting bolt:

a If overflow valve (ofv) is loosened or oil tube 59 – 74 Nm {6 – 7.5 kgm}
(t) and plate (p) are removed, install them, re- 3 Lower bracket (111) mounting bolt:
ferring to "Removal and installation of fuel 59 – 74 Nm {6.0 – 7.5 kgm}
supply pump assembly".
1) Place the fuel supply pump assembly to the k Handle the high-pressure pipe and clamp
drive case according to the following proce- in the same way as the pipe between the
dure. fuel injector and common rail (noted in
a Match part (A) of the fuel supply pump the foregoing) is handled.
drive gear where there is one tooth miss- 1) Tighten high-pressure pipes (57) partially.
ing with part (AA) of the coupling where
there is one spline missing to place the 2) Tighten clamps (55), (56) and (109) partially.
fuel supply pump assembly.
3) Tighten bracket (110) partially.
4) Tighten high-pressure pipes (57) to the spec-

ified torque.
3 High-pressure pipe sleeve nut:
39.2 – 44.1 Nm {4.0 – 4.5 kgm}
5) Tighten clamps (55), (56) and (109) to the

specified torque.
3 Clamp bolt :
9.8 ± 1.0 Nm {1 ± 0.1 kgm}
6) Tighten bracket (110) to the specified torque.
7) Install covers (54).
50-46 D375A-6
(02)
DRAFT
q Carry out the subsequent installation in the re- a Tighten the mounting bolts in the order
verse order to removal. shown in the figure.
2 Exhaust manifold mounting bolt:
[*1] Seizure prevention compound (LC-G)
3 Fuel hose (9):90 – 95 Nm {9.2 – 9.7 kgm} (NEVER-SEEZ (BOSTIK) or equivalent)
3 Sleeve nut of fuel hose (11): 3 Exhaust manifold mounting bolt:
43 – 47 Nm {4.4 – 4.8 kgm} 1st time:39.2 – 58.8 Nm {4.0 – 6.0 kgm}
2nd time:98.1 – 122.6 Nm {10 – 12.5
[*2] kgm}
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
[*3]
3 Tube (18-1) joint bolt (filter side):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3 Tube (18-1) joint bolt (supply pump side):
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
3 Tube (18-2) joint bolt:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
[*4]
3 Coolant tube (30)
Joint bolt:24.5 – 34.3 Nm {2.5 – 3.5 kgm}
Sleeve:24.5 – 59 Nm {2.5 – 6.0 kgm}
3 Lubricating oil tube (28), coolant tube joint
bolt (31):24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*5]
Exhaust manifold assembly
1. If the exhaust manifold assembly was divided,
apply adhesive (heat-resistant sealant) to joints
(A) (2 places) when assembling.
2 Exhaust manifold joint:
Adhesive (HOLTS MH705)
D375A-6 50-47
(02)
DRAFT
Reference k Make sure that a clearance of 10 mm mini-

Installation of turbocharger assembly mum is provided between the high-pressure
1. Lift and install turbocharger assembly (112). pipe and adjacent wiring harness. 10 mm not,
4 Turbocharger:55 kg secure the clearance by repositioning the
2 Turbocharger mounting bolt and nut: wiring harness.
Seizure prevention compound (LC-G)
(NEVER-SEEZ (BOSTIK) or equivalent) q Bleeding air
3 Turbocharger mounting bolt and nut: Bleed air from the fuel circuit. For detail, see
78.5 – 88.3 Nm {8.0 – 9.0 kgm} Testing and adjusting, "Bleeding air from fuel
circuit".
[*6]
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
3 Tubes (45) and (46) and sleeve nut:
54 – 93 Nm {5.5 – 9.5 kgm}
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*7]
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
[*8]
3 Oil tube (63) joint bolt (supply pump side):
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3 Oil tube (63) joint bolt (block side):
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3 Tube (65)
Joint bolt (supply pump side):
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
Sleeve nut:43 – 47 Nm {4.4 – 4.8 kgm}
3 Tube (64):19.6 – 29.4 Nm {2.0 – 3.0 kgm}
50-48 D375A-6
(02)
DRAFT
Removal and installation of radiator guard assembly
Special tools
Necessity
Sketch
Sym-
Q'ty
N/R
Part No. Part name
bol
791-451-1000 Remover t 1
Puller
A 7 790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
Removal
a Move the machine forward and backward to set
the master link of the track shoe away from the
radiator guard. 5. Drain the hydraulic oil and coolant.
k Park the machine on a level surface and low- 6 Hydraulic:130 l
er the work equipment to the ground. 6 Coolant: 120 l
ment lock lever in the lock position. 6. Remove the engine hood assembly. For details,
k Stop the engine and disconnect the cable see "Removal and installation of engine hood
from the negative (-) terminal of the battery. assembly".
k If the radiator coolant temperature is high,
wait until the temperature decreases to avoid 7. Disconnect radiator inlet hose (4). [*1]
getting scalded, and then drain the coolant or a Disconnect the hose from the radiator and re-
disconnect the radiator hoses/tubes. position the hose on the engine side.
1. Sling the blade lift cylinders. 8. Disconnect air vent hose (5). [*2]
a Disconnect the hose from the radiator, re-
2. Remove the lock plate and remove connecting move the 2 clamps, and reposition the hose
pin (1) on the piston rod side of the blade lift on the engine side.
cylinder.
3. Start the engine and retract the piston rod fully

and bind it with a wire so that it does not come
off.
4. Lift up blade lift cylinder (2) and fix bracket (2-1)

to cylinder fixing portion (A) of the radiator guard.
D375A-6 50-49
(02)
DRAFT
10. Remove air conditioner condenser (21) without

disconnecting the air conditioner hoses.
a Place air conditioner condenser on the track
shoes.
k When disconnecting the air conditioner
hoses, collect the refrigerant, referring to
"Removal and installation of floor frame
assembly".
15. Loosen U-bolt (9) of the aftercooler outlet tube.
16. Disconnect aftercooler outlet tube (8). [*3]

a Do not loosen hose clamp (MC).
17. Disconnect blade pipes (10) and (11).
11. Disconnect oil cooler hose (22).
12. Open the undercover. For details, see "Removal

and installation of engine assembly".
13. Disconnect two fan motor hoses (6).
14. Disconnect radiator outlet tube (7).
50-50 D375A-6
(02)
DRAFT
18. Sling the radiator guard assembly, remove the 20. Lift off radiator guard and blade lift cylinder
pin lock bolt, and push rear pin (12) toward the assembly (14).
inside of the radiator guard to take it out using a When removing, take extreme care not to
tool A7. damage the wiring, pipes, etc.
a Remove the shoe plates to secure a working 4 Radiator guard and blade lift cylinder as-
space. sembly:3,300 kg
(Radiator guard assembly only: 2,750 kg)
19. Remove the lock plate and pull front pin (13)
toward the outside of the radiator to remove it
using tool A7.
Installation
q Carry out installation in the reverse order to re-
moval.
[*1]
3 Radiator inlet hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*2]
3 Air vent hose clamp:
3.3 ± 0.5 Nm {0.34 ± 0.05 kgm}
D375A-6 50-51
(02)
DRAFT
[*3] q When using a new hose

MIKALOR clamps (MC10), (MC20), (MC23) a Tighten the clamp so that dimension BDG
a Use a new MIKALOR clamp. is as follows.
1) Set each hose to the original position. MC10: 7 - 10 mm
(Hose insertion depth: 80 mm) MC20: 17 - 20 mm
2) Set bridge (BR) under the clamp bolt and MC23: 20 - 23 mm
secure at least 5 mm of overlap (b) between
the bridge and band (BD).
3) Tighten the clamp.
a Do not use an impact wrench for tighten-
ing.
2 Clamp bolt (BC):
Lubricating oil (THREEBOND
PANDO 18B)
q When reusing the hose
a Install the clamp aligning it with the clamp
mark made on the hose.
3 Clamp bolt (BC):
Min. 6 Nm {0.6 kgm}
Constant torque clamp (CTC)
3 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
(TC): Turbocharger
50-52 D375A-6
(02)
DRAFT
q Refilling of coolant
Supply coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
5 Coolant: 120 l
q Refilling of oil (Hydraulic tank)

Supply oil through the oil filler to the specified
level. Run the engine to circulate the oil through
the system. Then, check the oil level again.
5 Hydraulic tank: 130 l
D375A-6 50-53
(02)
DRAFT
Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler)
Removal and installation of cooling assembly (radiator, after cooler, and

hydraulic oil cooler)
a Place air conditioner condenser on the track
Removal shoes.
k Park the machine on a level surface and low- k When disconnecting the air conditioner
er the work equipment to the ground. hoses, collect the refrigerant, referring to
k Set the parking brake lever and work equip- "Removal and installation of floor frame
ment lock lever in the lock position. assembly".
wait until the temperature decreases to avoid
getting scalded, and then drain the coolant or
disconnect the radiator hoses.

6 Coolant: 120 l
2. Drain the hydraulic oil.

6 Hydraulic: 130 l

10. Open the undercover. For details, see "Removal
see "Removal and installation of engine hood
and installation of engine assembly".
assembly".
11. Disconnect hydraulic oil cooler upper hose (7)
4. Disconnect radiator inlet hose (3). [*1]
and lower hose (7-1).
5. Disconnect air vent hose (4). [*2]
6. Remove the mounting bolts and disconnect

aftercooler duct (5). [*3]
a Do not loosen clamp (MC).
7. Disconnect four wiring clamps (6) and discon-
nect each wiring connector.
q Headlamp intermediate: CN-LHD
q Radiator guard intermediate: CN-RDG
q Fan motor: FAR2
q Horn: CN-HRN
q Radiator coolant level sensor: CN-WLD
9. Remove air conditioner condenser (21) without

disconnecting the air conditioner hoses.
50-54 D375A-6
(02)
DRAFT
12. Disconnect radiator outlet tube (8). 16. Remove two upper mounting bolts (12) on both
the left and right sides.
a Do not loosen clamp (MC). 17. Remove lower mounting bolts (12-1) on both the
left and right sides.
a Remove the bolts through the fan.
14. Remove radiator mask (10) and remove left and

right fan nets (11).
18. Lift off cooling assembly (13).
4 Cooling assembly:480 kg
15. Remove shroud (22).
D375A-6 50-55
(02)
DRAFT
Installation
moval.
a When installing the cooling assembly, adjust the
direction of windbreaker rubbers (R) so that they
do not get caught.
[*1]
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*2]
3 Air vent hose clamp:
3.3 ± 0.5 Nm {0.34 ± 0.05 kgm}
50-56 D375A-6
(02)
DRAFT
[*3][*4] q When using a new hose

MIKALOR clamps (MC10), (MC20), (MC23) a Tighten the clamp so that dimension BDG
a Use a new MIKALOR clamp. is as follows.
1) Set each hose to the original position. MC10: 7 - 10 mm
(Hose insertion depth: 80 mm) MC20: 17 - 20 mm
2) Set bridge (BR) under the clamp bolt and MC23: 20 - 23 mm
secure at least 5 mm of overlap (b) between
the bridge and band (BD).
3) Tighten the clamp.
a Do not use an impact wrench for tighten-
ing.
2 Clamp bolt (BC):
PANDO 18B)
3 Clamp bolt (BC):
Min. 6 Nm {0.6 kgm}
3 10.5 ± 0.5Nm {1.07 ± 0.05 kgm}
(TC): Turbocharger
D375A-6 50-57
(02)
DRAFT
5 Coolant: 120 l

50-58 D375A-6
(02)
DRAFT
Removal and installation of radiator

7. Remove cushions (7) and plates (8).
Removal

6 Coolant: 120 l
2. Remove the radiator upper cover. For details,

assembly".
3. Remove stay (1).
8. Lift off radiator (9).

4 Radiator:25 kg
4. Disconnect upper hose (2).
5. Remove front bolts (3) of bracket (6) and remove

mounting bolts (4).
6. Remove collar (5) and bracket (6).
D375A-6 50-59
(02)
DRAFT
Installation 2) Install collar (5) upside down (with 13 mm

1. Install the radiator unit. side up) and tighten mounting bolt (4).
a Replace O-rings (10) with new ones. a This compresses cushion (7). (L1oL2)
a Apply detergent (undiluted) to the O-rings. 3) Tighten mounting bolts (3) of bracket (6).
a Remove the fan net and check that the con- 4) Remove mounting bolt (4).
vex part of the radiator is matched with the
concave part of the lower tank, and then in-
stall the radiator securely.
5) Install collar (5) again in the normal direction

(with 6 mm side up).
6) Tighten mounting bolt (4).
2. Install radiator mounting brackets (6) and cush- 7) Check clearance (L3).
ions (7) according to the following procedure. q Clearance (L3): Approx. 7 mm
1) Set plate (8), cushion (7) and bracket (6) on
the mounting boss of radiator (9).
a At this time, fit bracket (6) tightly to the
mounting seat of upper tank (11).
(You may tighten bracket mounting bolts
(3) partially)
3. Carry out the subsequent installation in the

reverse order to removal.
5 Coolant: 120 l
50-60 D375A-6
(02)
DRAFT
Removal and installation of hydraulic oil cooler
Removal and installation of hydraulic oil cooler
Removal

6 Hydraulic:130 l

cover (1).
4 Lower side cover: 40 kg Installation
moval.

the supply. Then, check the oil level again.
3. Disconnect upper hydraulic oil cooler hose (2).
4. Open the undercover.
5. Disconnect lower hydraulic oil cooler hose (3).
6. Remove the upper and lower mounting bolts and

remove hydraulic oil cooler assembly (4).
4 Hydraulic oil cooler assembly: 105 kg
D375A-6 50-61
(02)
DRAFT
Removal and installation of aftercooler
Removal and installation of aftercooler

5. Open the undercover.
Removal
k Park the machine on a level surface and low- 6. Remove lower mounting bolts (4) of the after-
er the work equipment to the ground. cooler.
1. Remove the radiator upper cover. For details,

assembly".
2. Remove right stay (1).
3. Remove upper mounting bolts (2) of the after-

cooler.
7. Lift off aftercooler (5).

4 Aftercooler: 40 kg
4. Open the right side cover and disconnect after-
cooler inlet duct (3).
a Loosen the mounting bolts of the aftercooler
that is not being removed, too.
Installation
moval.
50-62 D375A-6
(02)
DRAFT
Removal and installation of engine assembly

Removal

6 Coolant: 120 l
5. Disconnect starting motor wiring (2) and wiring
2. Using sling [1], gradually open the undercover of clamp (3).
the engine and power train.
6. Close heater valve (4) and disconnect heater
pipes (5a) and (5b).
7. Disconnect four heater pipe clamps (6).
8. Disconnect nine wiring connectors (7a) to (7g).
9. Disconnect two wiring clamps (8).
10. Remove wiring connector bracket (9).

assembly".
4. Remove left and right lower side covers (1).

4 Left lower side cover: 40 kg
Right lower side cover: 50 kg
D375A-6 50-63
(02)
DRAFT
11. Disconnect radiator outlet hose (10) from the 15. Disconnect fuel supply hose (15). [*2]
engine.
16. Disconnect fuel return hoses (16a) and (16b).
a Disconnect the hose clamps.
12. Loosen locknut (11) and fully tighten belt tension

adjustment bolt (12). [*1]
17. Disconnect wiring connectors (17).
13. Remove belt (13).
14. Disconnect air conditioner compressor (14).

a Do not disconnect the air conditioner hoses
from the air conditioner compressor.
a Remove all clamps from the air conditioner
hoses.
a Place air conditioner compressor (14) on the
track shoes.
k When disconnecting the air conditioner
hoses, collect the refrigerant, referring to
"Removal and installation of floor frame
assembly".
18. Disconnect radiator inlet hose (18). [*3]
19. Disconnect air vent hose (19). [*4]
20. Disconnect aftercooler ducts (20) and air hose

(21). [*5]
50-64 D375A-6
(02)
DRAFT

a Loosen clamp (23) and disconnect the tube
at the hose clamping point.
22. Disconnect oil cooler pipes (24) and (25).
6) Disconnect air conditioner hose clamps (38).

(This task is not necessary if the air condi-
tioner hoses are disconnected.)
23. Remove the bulkhead bracket according to the

1) Remove relay protection cover (26) at the
rear of the bulkhead bracket.
7) Sling bulkhead bracket (39) and remove

mounting bolts (40).
2) Disconnect electrical intake air heater relay

wiring (27) to (29).
3) Disconnect wiring connectors PRT2 (30),
SS8A (31) and PRT1 (32).
4) Disconnect wiring clamps (33), (34) and (35).
5) Remove electrical intake air heater relay
bracket assembly (36) and sensor bracket
assembly (37).
D375A-6 50-65
(02)
DRAFT
8) While slinging bulkhead bracket (39), discon- 25. Remove dashboard front duct (44).
nect starting motor cable clamps (41) from
bulkhead bracket (39).
26. Sling universal joint (45), remove the mounting

9) Remove bulkhead bracket (39) and sub tank bolts, and remove the universal joint. [*7]
(42) as a unit. 4 Universal joint assembly: 40 kg
4 Bulkhead bracket assembly: 250 kg
27. Remove front mounting bolts (46) and rear
mounting bolts (47). [*8]
24. Remove damper case oil level gauge (43) and

the bracket as a unit.
50-66 D375A-6
(02)
DRAFT
28. Remove the engine assembly according to the Installation

following procedure. q Carry out installation in the reverse order to re-
1) Install the lifting tools to parts [A] and [B]. moval.
[*1]
a Install the belt. For details, see Testing and ad-
justing (Part 1), "Replacement and adjusting of
alternator and air conditioner compressor belts".
[*2]
3 Fuel supply hose:90 – 95 Nm {9.2 – 9.7
kgm}
[*3]
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*4]
3
2) Lift up engine assembly (48).
4 Engine assembly:3,320 kg
Air vent hose clamp:
3.3 ± 0.5 Nm {0.34 ± 0.05 kgm}
3) While moving engine assembly (48) toward [*5] [*6]
the front of the machine, operate the chain MIKALOR clamps (MC10), (MC20), (MC23)
block to raise the front of the engine to slant a Use a new MIKALOR clamp.
the engine assembly. 1) Set each hose to the original position.
4) After the front and rear portions of the engine (Hose insertion depth: 80 mm)
assembly (48) clear the machine body parts 2) Adjust the position of bridge (BR) so that the
(the aftercooler assembly), turn the engine bridge is under the band.
assembly toward the right of the machine by a Secure at least 5 mm of overlap (b) be-
90 degrees to allow it to clear the blade lift tween the bridge and band (BD).
cylinder and cab, and then remove it. 3) Tighten clamp bolt (BC).
a When removing, take care not to damage a Do not use an impact wrench for tighten-
the wiring and hoses. ing.
2 Clamp bolt (BC):
PANDO 18B)
3 Clamp bolt (BC):
Min. 6 Nm {0.6 kgm}
q When using a new hose
a Tighten the clamp so that dimension BDG
is as follows.
MC10:7 – 10 mm
MC20:17 – 20 mm
MC23: 20 – 23 mm
D375A-6 50-67
(02)
DRAFT

3 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
(TC): Turbocharger
50-68 D375A-6
(02)
DRAFT
[*7]
3 Universal joint mounting bolt:
156.9 – 196.1 Nm {16 – 20 kgm}
[*8]
3 Engine mounting bolt:
823 – 1,029 Nm {84 – 105 kgm}
5 Coolant: 120 l
D375A-6 50-69
(02)
DRAFT
Removal and installation of engine hood assembly

5. Remove right cover (3-1) and left cover (3-2).
Removal
k Park the machine on a level surface and low- 6. Remove cover (3).
7. Remove precleaner cover (4).
1. Remove radiator upper inspection cover (1).
2. Disconnect headlamp connector LHD (1-1).
3. Disconnect reservoir tank hose (1-2).
4. Lift off radiator upper cover (2).

4 Radiator upper cover:80 kg
8. Disconnect connectors EG5(5-1) and EG4(5-2)

at the right rear of the hood.
9. Disconnect clamp (5-3) at the right rear of the

hood.
50-70 D375A-6
(02)
DRAFT
10. Disconnect connector RDG (6) at the front of the 16. Remove rear mounting bolts (11).
hood. a Take care not to drop plate NP.
11. Loosen the clamp and remove air cleaner hose

(7). [*1]
a Securely cover the air cleaner outlet and the
air intake port on the impeller side of the tur-
bocharger to prevent foreign matter from en-
tering.
17. Remove front mounting bolts (12a). [*2]
12. Remove the bolts and remove KOMACLONE

hose and tube assembly (8) from the muffler.
13. Disconnect reservoir tank hose (9) from the

reservoir tank.
14. Disconnect reservoir tank hose clamp (9a).
15. Disconnect duct (10).
D375A-6 50-71
(02)
DRAFT
18. Lift up engine hood assembly (12).

4 Engine hood assembly: 350 kg
Installation
moval.
[*1]
3 Air cleaner hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*2]
q Install the front mounting bolts according to the
1) Install resin plates (14) so that hood (13) is
sandwitched between them.
2) Install washer (15).
3) Install bolt (16).
50-72 D375A-6
(02)
DRAFT
Removal and installation of engine front seal

4. Remove dust seal (7).
Special tools
New/remodel
5. Remove front seal (8) according to the following
Necessity
procedure.
Sketch
Sym-
Q'ty
Part No. Part name
bol
Seal puller
3 795-931-1100 t 1
assembly
Push tool (for oil
795T-621-1180 t 1 Q
seal)
A
Push tool (for
4 795T-621-1171 t 1 Q
dust seal)
795-902-1460 Bolt t 3
01582-02218 Nut t 3
Removal
1) Change the end of tool A3 to the hook type
ment lock lever in the lock position. one.
k Stop the engine and disconnect the cable 2) Hitch the hook to the metal ring of front seal
from the negative (-) terminal of the battery. (8).
3) Remove the front seal with impact of slide
1. Remove the radiator guard assembly. For hammer (SH).
details, see "Removal and installation of radiator
guard assembly". q Tool A3
2. Sling crankshaft pulley and damper assembly

(1).
3. Lift off crankshaft pulley and damper assembly

(1).
[*1]
4 Crankshaft pulley and damper assembly
(1): 40 kg
a CS : Crankshaft
D375A-6 50-73
(02)
DRAFT
Installation
1. Clean, degrease and then dry the front cover
contact surface on the front seal.
2. Using a clean cloth, remove foreign matter

deposited on the crankshaft flange.
a Clean, degrease, and dry the seal lip sliding
surface (peripheral surface of the crank-
shaft).
a Check that the crankshaft end face corners,
seal lip sliding surface and housing are free
from dents, burrs, rust, oil, grease or water.
3. Install front oil seal (8) according to the following

3) Using tool A4 (for dust seal), press fit dust
procedure.
seal (7) to the front cover to dimension (b)
a Before installing the seal, check that crank-
shaft end face corners, seal lip sliding surfac-
a Dust seal press fitting dimension (b): 2
es and housing are free from flaws, burr, fins,
mm (Projection from the front cover end
rust, etc.
face)
a When installing the seal, do not apply oil or
grease to the crankshaft and seal lip. Wipe
off oil from the crankshaft thoroughly.
1) Install the oil seal directing its side stamped
with "IN" toward the inside of the engine.
a The "OUT" stamped side is directed to-
ward the outside of the engine.
q Carry out the subsequent installation in the re-

verse order to removal.
[*1]
3 Crankshaft pulley mounting bolt:
1st time: 53.9 – 93.1 Nm {5.5 – 9.5 kgm}
2nd time: 225.4 – 264.6 Nm {23 – 27 kgm}
a Take care not to install the wrong end. 3rd time: 617.4 – 656.6 Nm {63 – 67 kgm}
2) Using tool A4 (for oil seal), press fit oil seal
(8) to the front case to dimension (a) shown
in the figure.
a Oil seal press fitting dimension (a): 18.5
mm (when measured from the front cover
end face)
50-74 D375A-6
(02)
DRAFT
Removal and installation of engine rear seal
Removal and installation of engine 5. Remove rear seal (2).

rear seal a Take care not to damage the seal installation
position on the flywheel housing and the seal
contact surface on the crankshaft.
Special tools a Before removing, slightly tap the front seal
New/remodel
once to unstick it.
Necessity
a When rear seal (2) is fixed too hard to the fly-
Sketch
Sym-
Q'ty
Part No. Part name wheel housing (FWH), perform the following
bol
procedure.
a The left one in the following figure shows
Seal puller assem-
3 795-931-1100 t 1 the standard seal and the right one shows
bly
Push tool the sleeved seal.
795T-621-1161 (for standard seal t 1 Q 1] Change the end of tool A3 to the drill type
A and sleeved seal) one.
5 Push tool
795T-621-1190 t 1 Q 2] Drill several holes about 3 mm in diameter
(for sleeved seal) in rear seal (2).
01050-32235 Bolt t 5
01050-32245 Bolt t 5 3] Set tool A3 to the drilled hole.
4] Remove the rear seal with impact of slide
hammer (SH).
Removal
a For the sleeved seal, cut sleeve (5) using a
chisel and hammer to remove it.
a Take care not to damage crankshaft (4).
a Remove all the broken pieces of the rear
seal.
1. Remove the damper assembly. For details, see

"Removal and installation of damper assembly".
2. Remove one of the mounting bolts of flywheel (1)
and install guide bolt [1].
3. Using eyebolt [2], sling flywheel (1) and remove
the remaining mounting bolts. [*1]
4. Move flywheel (1) toward this side and lift it off.
k Since the socket portion of the flywheel is
shallow, the flywheel may fall suddenly.
Take care not to get your finger caught.
4 Flywheel: 85 kg
q Tool A3
D375A-6 50-75
(02)
DRAFT
Installation
a Check the wear of the crankshaft and select the
type of the Teflon seal (laydown lip seal) to in-
stall, "standard seal" or "sleeved seal", depend-
ing on the wear of the crankshaft.
a If the crankshaft is worn to a degree of luster
(you can feel the wear with the pad of your finger
and the wear depth is a maximum of 10 mm) and
there are no scratches, install standard seal (A).
In other cases, install sleeved seal (B).
a (3): Shows the plastic inside cylinder doubling as
the Installation guide.
a (5): Shows the sleeve.
a Don't remove Installation guide (3) from rear seal
(2) before Installation. q Installation procedure for standard seal
a Handle rear seal (2) and sleeve (5) as a unit. a Do not apply grease, oil, etc. to the seal lip slid-
Don't try to separate them. ing surface.
1) Set the large inside diameter side "(2)" of
plastic inside cylinder (3) of rear seal (b) to
the end of crankshaft (4).
a Take care not to install the wrong end of
the plastic inside cylinder.
a Clean, degrease and then dry the flywheel hous-

ing contact surface on the rear seal.
a Clean, degrease, and dry the seal lip sliding sur-
face (peripheral surface of the crankshaft).
a Check that the crankshaft end face corners, seal
lip sliding surface and housing are free from 2) Hold the metal ring of rear seal (2) with both
burrs, dents, rust, etc. hands and push it in firmly.
3) After pushing in rear seal (2), remove plastic
inside cylinder (3).
a When removing the inside cylinder, take
care not to damage the seal lip.
50-76 D375A-6
(02)
DRAFT
4) Tighten the bolts evenly to press fit rear seal 3) Remove tool A5 (for press fitting the sleeved
(2) until the end face of tool A5 touches the seal) and install tool A5 (for press fitting the
end face of crankshaft (4). standard seal).
a Oil seal press fitting dimension (when 4) Tighten the five bolts evenly to press fit
measured from the crankshaft end face) sleeve and rear seal assembly (6) until the
(a):20 mm end face of tool A5 (for press fitting the stan-
a After press fitting the rear seal, remove the dard seal) touches the end face of crankshaft
red sealant layer from its periphery. (4).
a Use the bolts (stem length: 45 mm) to
tighten tool A5 (for press fitting the stan-
dard seal) first, and then tighten tool A5
(for press fitting standard seal) with the
bolts (stem length 35 mm).
a Driving depth of rear seal (a) (from crank-
shaft end face): 20 mm
a After press fitting the rear seal, remove
the red sealant layer from its periphery.
q Installation procedure for sleeved seal

a When installing the rear seal, do not apply oil,
grease, etc. to the crankshaft, the inside cy-
lindrical surface (C) of the sleeve, or the seal
lip surface.
1) Set sleeve and rear seal assembly (6) to tool
A5 (for press fitting the sleeved seal).
3 Sleeve inside cylindrical surface (C):
Liquid gasket (LG-7)
2) Place sleeve (5) of the rear seal to the end q Carry out the subsequent installation in the re-
face of crankshaft (4) and tighten the five verse order to removal.
bolts evenly to press fit sleeve and rear seal
assembly (6) until the end face of tool A5 [*1]
touches the end face of the crankshaft (4). Flywheel assembly
a If there are 5 punch marks on the head of a bolt,
do not reuse that bolt but replace it.
a Fix the flywheel by using the bolt holes in the fly-
wheel and flywheel housing so that the flywheel
does not turn.
a Tighten the mounting bolts in the order shown in
the figure.
2 Flywheel assembly mounting bolt:
Engine oil
D375A-6 50-77
(02)
DRAFT
3 Flywheel assembly mounting bolt: q Measure radial runout and facial runout of the
1st time: 196.1 ± 19.6 Nm {20 ± 2 kgm} flywheel using dial gauge [1].
2nd time: 460.9 ± 19.6 Nm {47±2kgm} a Standard radial and facial runout:
3rd time: 90 – 120 ° Retightening Measurement
Tolerance (mm)
a After tightening the bolt, make a punch mark (a) items
on its head. (When a new bolt is used, do not Radial runout Approx. 0.13
make a punch mark on its head.) 0.0005 × Diameter of
Facial runout
measuring point
a When the measured value is out of the standard,

determine the cause by disassembling the fly-
wheel.
50-78 D375A-6
(02)
DRAFT
Removal and installation of fan drive assembly
Removal 5. Remove fan nets (4), (5), and (6).

er the work equipment to the ground. 6. Remove wiring harness clamp (7) and discon-
k Set the parking brake lever and work equip- nect the connector.
6 Hydraulic oil: 130 l
2. Remove radiator mask (1).
7. Disconnect fan motor pipes (8), (9), and (10).
3. Remove mark plate (2).

a Disconnect the horn connector and then re-
move it.
D375A-6 50-79
(02)
DRAFT
8. Lift off fan drive assembly (11). [*1] Installation

4 Fan drive assembly: 200 kg q Carry out installation in the reverse order to re-
a Install the wire to the left and right of the fan moval.
drive, lift it at a point, and pull out it evenly to [*1]
remove. a Ensure that position (m) of the reflector tape for
measuring the fan speed is of the specified di-
mension.
Distance (m) from fan blade end: Max. 5 mm
a After installing the fan, check clearance (l) be-

tween the fan blade and the shroud. If the clear-
ance is larger or smaller than the specified
dimension, adjust it.
Clearance (l): 6 + 3/ - 1 mm

50-80 D375A-6
(02)
DRAFT
Removal and installation of fan motor assembly
Removal
1. Remove the fan drive assembly. For details, see
"Removal and installation of fan drive
assembly".
2. Remove the mounting bolt and lock plate (1).

[*1]
3. Remove nut (2). [*2]
4. Using puller [1], remove fan (3).

[*3]
5. Remove the four mounting bolts and fan motor

assembly (4).
4 Fan motor assembly: 60 kg
D375A-6 50-81
(02)
DRAFT
Installation
moval.
[*1]
Be sure to adjust the hole of lock plate (1) by turning
nut (2) in the tightening direction.
[*2]
3 Mounting (2):
1,079 – 1,275 Nm {110 – 130 kgm}
a After tightening the nut, measure dimension (d)
shown in the following figure.
q Min: 1.2 mm
q Max: 3.0 mm
[* 3]
a Wipe off dirt from fitting parts (P) of the fan motor
and fan boss and degrease those parts.
50-82 D375A-6
(02)
DRAFT
Removal and installation of fuel tank assembly

Removal
1. Remove (1) and (2).
8. Disconnect fuel return hoses (13).
2. Open fuel drain valve (3) to drain fuel.

6 Fuel: 1,200 l (at full)
3. Close fuel stop valve (4), and disconnect fuel
drain hose (5).
4. Remove mounting bolts (7) of filter assembly (6),
and remove filter assembly (6) together with the
fuel hose. 9. Disconnect wiring connector FGS (14) of the fuel
5. Close fuel drain valve (3), and disconnect hose level sensor.
clamps (8).
6. Remove mounting bolt (10) of bracket (9), and
disconnect fuel drain hose (11).
D375A-6 50-83
(02)
DRAFT
10. Remove three mounting bolts (15) from each Installation

side of the fuel tank.
moval.
(Refilling)
Fill fuel through the fuel filler port.
5 Fuel tank: 1,200 l (at full)
11. Lift off fuel tank assembly (16).

4 Fuel tank assembly: 600 kg (tank only)
a Reference: 1,500 kg (when tank is full)
50-84 D375A-6
(02)
DRAFT
D375A-6 50-85
(02)
DRAFT
Power train
Removal and installation of damper assembly
Power train
Removal

1. Open left and right engine side covers (1) and

lock them.
a Check that they are securely locked.
5. Open undercover (7) slowly using lifting tools [1].

4. Remove covers (4), (5) and (6).
50-86 D375A-6
(02)
DRAFT
Power train
6. Remove universal joint assembly (8). [*1] 9. Remove divider board (11).
a Sling the universal joint assembly and lower
it to remove.
4 Universal joint assembly: 40 kg
10. Remove bolt (12) and remove holder (13). [*2]

11. Remove coupling (14).
7. Loosen drain plug (9) to drain damper case oil.

6 Damper case: 2.1 l
8. Remove oil level gauge (10) and bracket as a

unit.
D375A-6 50-87
(02)
DRAFT
Power train
12. Remove the damper cover according to the a Tighten forcing screws [3] evenly.
following procedure. [*3] 4 Damper assembly: 70 kg
1) Using eyebolt [1] attached to the damper,
sling damper cover (15).
2) Remove two damper cover mounting bolts
(16) marked with a in the drawing, and
install guide bolts [2].
k Be sure to use guide bolts to prevent
the damper cover from coming off
abruptly. (M12 x 1.75 x 200 mm)
3) Remove the remaining damper cover
mounting bolts (16) marked with *, and lift off
damper cover (15).
a If it is difficult to remove the damper cov-
er, use forcing screws [3] (M12 x 1.75).
a Install forcing screws [3] at 3 places, and
tighten them evenly. 14. If bearing (19) is damaged, remove bearing (19).
4 Damper cover: 75 kg
13. Remove the damper according to the following

procedure. [*4]
1) Using eyebolt [4], sling damper (17).
2) Install guide bolts [5].
k Be sure to use guide bolts to prevent
the damper from coming off abruptly.
(M16 x 2 x 200 mm)
3) Remove mounting bolts (18), and lift off
damper (17).
a If it is difficult to remove the damper, use
forcing screws [3].
50-88 D375A-6
(02)
DRAFT
Power train
Installation [*5]
Fill gap (a) at the hatched area in the illustration with
q Carry out installation in the reverse order to re- grease (G2-LI) by approx. 50% (11 g).
moval.
[*1]
156.8 - 196 Nm {16 - 20 kgm}
[*2]
245 - 309 Nm {25 - 31.5 kgm}
[*3]
a Install the damper cover according to the follow-
ing procedure.
1) Using guide bolts [2] (M12 x 1.75 x 200 mm),
position the damper cover. (Refilling)
2) Finger-tighten twelve mounting bolts (16) Fill the damper case with oil.
(indicated by * mark). 5 Damper case: 2.1 l (engine oil EO-DH)
3) Remove guide bolts [2] and finger-tighten the
remaining two bolts.
4) While tightening fourteen mounting bolts
gradually and evenly, press fit bearing (19)
and damper shaft (3) to install.
[*4]
a Using guide bolts [5] (M12 x 2 x 200 mm), posi-
tion the damper.
D375A-6 50-89
(02)
DRAFT
Power train
Disassembly and assembly of damper assembly

6. Remove seal (7) from each of flanges (2) and
Disassembly of damper assembly (5).
1. Place the damper assembly on block [1].
2. Remove mounting nuts (1) and remove flange

(2) using forcing screws [2].
Disassembly of damper cover assembly

1. Remove bearing (8) and oil seal (9) from cover
(10).
3. Remove shaft (3). 2. Remove oil seal (11) from retainer (12).
4. Remove rubbers (4).
5. Using forcing screws [2], remove flange (5) from

body (6).
50-90 D375A-6
(02)
DRAFT
Power train
Assembly of damper assembly

1. Install seal (7) to each of flanges (2) and (5).
a Install the seal with the lip facing the inside as
5. Install flange (2).

2 Mating face of flange: Liquid gasket
(LG-6)
a Check that the mating faces are free from
2. Install flange (5) to body (6), while matching their dents, rust, oil, grease and water, and apply
bolt holes with each other. the liquid gasket to the surfaces of both the
2 Mating face of flange: Liquid gasket flange and the body.
(LG-4)
a Check that the mating faces are free from 6. Set the bolts and tighten mounting nuts (1).
dents, rust, oil, grease and water, and apply
the liquid gasket to the surfaces of both the
flange and the body.
3. Place the flange and body assembly on the block

and set shaft (3).
4. Install the rubbers.

a Check the installed positions of large rubber
(4a) and small rubber (4b).
(Install the large rubber to large diameter
side (R) of body (BD) and install the small
rubber to small diameter side (r).)
a When installing the rubbers, apply grease
(G2-LI)) to all surfaces of the rubbers, the
outside of the shaft, and the inside of the
body (BD).
a After installing the rubbers, supply grease
(G2-LI) of approx. 30 % (190 g) to gaps (CL)
(16 places) between the shaft and body.
D375A-6 50-91
(02)
DRAFT
Power train
Assembly of damper cover assembly

1. Using push tool [3], press fit oil seal (11) to
retainer (12).
2 Oil seal press fitting surface on retainer:
a Apply a thin film of the liquid gasket to the in-
side of the retainer and wipe off any liquid
gasket that is squeezed out.
2 Oil seal lip: Grease (G2-LI)
2. Using push tool [4], press fit bearing (8) to cover

(10).
3. Using push tool [5], press fit oil seal (9) to cover
(10).
2 Oil seal press fitting surface on cover:
a Apply a thin film of the liquid gasket to the in-
side of the cover and wipe off any liquid gas-
ket that is squeezed out.
2 Oil seal lip portion: Grease (G2-LI)
50-92 D375A-6
(02)
DRAFT
Power train
Removal and installation of power train unit assembly
Removal
k Park the machine on a level place and lower
the work equipment to the ground complete-
ly.
k Release the residual pressure in the hydrau-
lic tank and piping. For details, see Testing
and adjusting, "Releasing residual pressure
in work equipment cylinders".
1. Drain the oil from the hydraulic tank.

2. Remove the fuel tank assembly. For details, see

"Removal and installation of fuel tank assembly".
3. Remove the ROPS guard. For details, see

"Removal and installation of ROPS guard".
4. Remove the operator cab assembly. For details,

see "Removal and installation of operator cab
assembly".
5. Remove the floor frame assembly. For details, 7. Sling universal joint assembly (2) and lower it to
see "Removal and installation of floor frame remove. [*1]
4 Universal joint assembly: 40 kg
assembly".
6. Using sling [1], open undercover (1) gradually.
D375A-6 50-93
(02)
DRAFT
Power train
8. Disconnect wiring connectors (3) from bracket 12. Disconnect wiring connectors VDA (9), LRR
(3a). (10), FD2 (11), and VDB (12).
9. Disconnect wiring clamps (4) and (5). 13. Disconnect wiring clamps (13) and (14).
10. Disconnect wiring (6) and (7).
15. Disconnect ripper lift hoses (16) and ripper tilt

hoses (17).
11. Disconnect wiring connector 241 (8).
16. Disconnect ripper pin puller hoses (18).
50-94 D375A-6
(02)
DRAFT
Power train
17. Disconnect hose (19) and clamps (20).
21. Disconnect work equipment hose (29) from the

18. Disconnect return hoses (21) to (24) running to work equipment valve.
the hydraulic tank.
22. Disconnect hose clamps (30) to (33).

19. Disconnect work equipment valve hose (25).
20. Disconnect suction tube (26) from coupling (27)

and flange (28).
D375A-6 50-95
(02)
DRAFT
Power train
23. Disconnect oil cooler hose (34) on the left side of

the torque converter from the torque converter.
24. Disconnect oil cooler hose (35) at the left bottom

of the power train.
25. Remove damper oil level gauge (36).
50-96 D375A-6
(02)
DRAFT
Power train
27. Pull out left and right drive shafts (39) according
to the following procedure. [*3]
2) Install eyebolt [2] to drive shaft (39).
3) Pull out drive shaft (39).
a If the drive shaft cannot be pulled out, push
up the shoe grouser by using jack [3] from the
ground to rotate the sprocket clockwise or
counterclockwise, and set it to a position
where the shaft can be pulled out easily.
a Pull out the shaft until it touches the sprocket.
D375A-6 50-97
(02)
DRAFT
Power train
28. Remove left and right rear mount caps (40). 32. Remove four power train mounting bolts (44)
each on the left and right sides. [*4]
29. Loosen left and right rear coupling clamps (41).

[*2] 33. Lift off power train assembly (45).
a Reposition the clamp toward the main frame, a Install sling to parts [A] and [B] and lift up the
and open the coupling to reposition the seal power train assembly while balancing it hori-
toward the main frame. zontally.
30. Remove oil filler tube clamp (42) of the power

train case.
50-98 D375A-6
(02)
DRAFT
Power train
Installation q Bleeding air

Bleed air from the piping. For details, see
q Carry out installation in the reverse order to re- Testing and adjusting, "Bleeding air from work
moval. equipment cylinders".
a When installing the power train unit assembly,

focus your attention on the mating face of the
coupling in order not to damage the seal of the
coupling.
[*1]
156.8 – 196 Nm {16 – 20 kgm}
[*2]
3 Mounting nut of rear coupling clamp:
4.9 – 8.82 Nm {0.5 – 0.9 kgm}
[* 3]
a If the drive shaft cannot be inserted, push up the
shoe grouser by using a jack from the ground to
rotate the sprocket clockwise or counterclock-
wise, and set it to a position where the shaft can
be inserted easily.
[*4]
a Install left front mount (46a) and right front mount
(46b) of the power train unit with the tap holes (t)
on their side facing the front of the machine.
Refilling of oil (Hydraulic tank)

a Supply oil through the oil filler to the specified
the system. Then check the oil level again.
5 Hydraulic tank:130 l (Power train oil)
Refilling of oil (Power train case)

a Supply oil through the oil filler to the specified
Reference
Power train case:150 l (Power train oil)
D375A-6 50-99
(02)
DRAFT
Power train
Disconnection and connection of power train unit assembly

2) FA2 (7), intermediate connector (8)
Disconnection
a Before disconnecting the wires and hoses, fit

them with tags to show their connecting loca-
tions.
1. Lift power train unit assembly (1) and place it on

blocks [1] to [4].
a Use blocks of sufficient height so that the oil
can be easily drained.
2. Drain the oil from the power train case.

6 Power train case:150 l
3) SLB (9), FLB (10), SRB (11), FRB (12), FRC

(13), SRC (14), FLC (15), SLC (16)
3. Disconnect the following wiring connectors and

remove the wiring.
a Disconnect all the related wiring clamps. 4) STB (17), TM1 (18), TC1 (19)
1) SSTC (2), FSTC (3), SLUC (4), FLUC (5),
FA1 (6)
50-100 D375A-6
(02)
DRAFT
Power train
5) TOP (20), 453 (21)
4. Remove hydraulic hoses (22) to (36).

a Remove hoses (24) and (28) as a unit.
D375A-6 50-101
(02)
DRAFT
Power train
5. Disconnect the fifteen pressure pickup hoses 4) Disconnect transmission gear shift clutch
and remove them together with the central pres- pressure pickup hoses (44) to (48).
sure pickup bracket according to the following (Hose band color)
procedure. 1st (44): Red
1) Remove suction tube (37). 3rd (45): Yellow/Black
2) Remove covers (38) and (39). Reverse (46): Red/Blue
2nd (47): White/Yellow
Forward (48): White/Blue
3) Disconnect steering clutch pressure pickup

hoses (40) and (42) and brake pressure
pickup hoses (41) and (43). 5) Disconnect torque converter output pressure
(Hose band color) pickup hose (49).
Left clutch pressure (40): Black (Hose band color): White/Red
Left brake pressure (41): White
Right clutch pressure (42): White/Black
Right brake pressure (43): Yellow
50-102 D375A-6
(02)
DRAFT
Power train
6) Disconnect pressure pickup hoses (50) to 7. Remove the following parts.

(53) connected to the ECMV valves. 1) Oil level gauge (57)
(Hose band color) 2) Oil filler pipe (58)
Transmission main relief pressure (50): - 3) Oil filter assembly (59)
4 Oil filter assembly: 120 kg
Torque converter inlet pressure (51): Blue
Lockup clutch pressure (52): Yellow/Red
4) Strainer assembly (60)
4 Strainer assembly: 50 kg
Stator clatch pressure (53): Yellow/Blue
5) Work equipment pump assembly (61)
4 Work equipment pump assembly: 110
7) Disconnect power train lubrication pressure
pickup hose (54).
kg
8) Remove pressure pickup hose (55) and pres-
6) Power train pump and lubrication pump
sure pickup block (56) as a unit.
assembly (62)
4 Power train pump and lubrication
6. Remove hydraulic tube (88) between the torque pump assembly: 40 kg
converter and transmission.
7) Scavenging pump assembly (63)
4 Scavenging pump assembly: 25 kg
8) Fan pump assembly (64)
4 Fan pump assembly: 80 kg
D375A-6 50-103
(02)
DRAFT
Power train
8. Disconnect the steering case assembly

1) Remove case mounting bolts (65).
2) Remove case (66) and bearing cage
assembly (67) and torque converter speed
sensor (67a) as a unit.
3) Remove shaft (68). [*1]
9. Disconnect the PTO unit assembly according to

1) Remove coupling (71).
2) Remove front mount (71a).
4 Front mount: 150 kg
4) Sling steering case assembly (69).

5) Remove two mounting bolts (70) and install
two guide bolts [5].
6) Remove remaining mounting bolts (70).
7) Lift off steering case assembly (69). [*2]
4 Steering case assembly: 1,800 kg
a Lift the steering case assembly by 3-point
lifting and disconnect it along the guide
bolts.
a After disconnecting the steering case as-
sembly, remove the guide bolts.
50-104 D375A-6
(02)
DRAFT
Power train
3) Remove bracket (72). 2] Shorten sling [7] to slant “PTO, torque

converter and transmission” assembly
(74).
4) Remove eye plates (73), reverse them, and

install them in the same positions at the left
and right. 3] Disconnect sling [6] from the transmission
and use lifting tool [8] to connect sling [6]
to the PTO unit.
4] Shorten sling [6] to set “PTO, torque
converter and transmission” assembly
(74) upright.
5) Place “PTO, torque converter and

transmission” assembly (74) on blocks with
the PTO unit up according to the following
procedure.
1] Install slings [6] and [7].
a Install sling [7] so that its length is ad-
justable.
D375A-6 50-105
(02)
DRAFT
Power train
6) Sling oil pan case (75) and remove two 9) Remove retainer (80). [*4]
mounting bolts (76), eight mounting bolts a Note the thickness and quantity of the
(77) and four mounting bolts (78). shims.
7) Lift off oil pan case (75). [*3] 10)Remove snap ring (81) and spacer (82).
4 Oil pan case: 110 kg
11)Remove the PTO assembly mounting bolts.

12)Lift off the PTO assembly.
4 PTO assembly: 300 kg
10. Sling torque converter assembly (89) and

remove the nineteen mounting bolts. [*5]
a The upper three mounting bolts are installed
from the transmission side.
11. Lift off torque converter assembly (89).
4 Torque converter assembly: 550 kg
8) Sling PTO assembly (79).
50-106 D375A-6
(02)
DRAFT
Power train
Connection 3 Steering case mounting bolt:

245 – 309 Nm {25 – 31.5 kgm}
q Carry out connection in the reverse order to dis-
connection.
[*1]
a Check that shaft (68) is inserted in boss (83) at
the end of the transmission input shaft.
[*3]
q When installing the gasket, carefully observe the
following.
a Use a new gasket.
a Check that the mating faces of the case and
. cover are free from dents, rust, oil, grease
and water.
a Apply liquid gasket to both the mating faces
of the case and cover.
2 Mating faces of case and cover:
a Apply liquid gasket continuously around the
tap holes and bolt holes as shown in the fig-
ure.
(Positions to apply liquid gasket)
(L1): Intermediate position between inside
face of oil pan case and tap holes or bolt
holes
(L2): Center of inside and outside faces of oil
pan case
(Quantity of liquid gasket to apply)
a When installing case (66) and bearing cage as-
B x H = 2 to 5 cc
sembly (67), check that shaft (68) is inserted in
drum (84) of the bearing cage assembly secure-
(OUT): Outside face of oil pan case
ly and then install the case mounting bolts.
(IN): Inside face of oil pan case
(TP): Tap hole
(HL): Bolt hole
[*2]
a When installing steering case (69), install guide
bolts [5] and install the steering case along them.
D375A-6 50-107
(02)
DRAFT
Power train
[*4] a Set shims (87) as shown in the figure so

q Adjust the retainer shim according to the follow- that they do not block forcing screw tap
ing procedure. holes (H) of retainer (80).
1) Install retainer (80) without inserting any
shim and tighten the mounting bolts to the
following torque.
2 Oil seal: Grease (G2-LI)
3 Retainer mounting bolt: 9.8 Nm {1
kgm}
2) Using thickness gauges, measure clearance
(a) between retainer (80) and PTO housing
(86).
a Measure clearance (a) at 4 places (A, B,
C, and D) on the periphery and calculate
the average.
[*5]
3 Torque converter assembly mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
Refilling of oil (power train case)

a Supply oil through oil filler to the specified level.
a After installing the power train unit assembly on
the machine, start the engine to circulate the oil
through the system. Then, check the oil level
again.
5 Power train case:150 l (Power train oil)
3) Determine the total thickness of the shim

pack and select shims to tbe installed in
clearance (a).
a Total shim thickness: (a) + 0 - 0.05 mm
a Available shims: 0.15 mm, 0.2 mm, 0.5
mm
4) Install the shims of the calculated thickness
and tighten the mounting bolts of retainer
3 Retainer mounting bolt :
58.8 – 73.5 Nm {6 – 7.5 kgm}
a Determine the quantity and thickness of
the shims so that the thickness is the
same on both the left and right sides.
50-108 D375A-6
(02)
DRAFT
Power train
Disassembly and assembly of PTO assembly

3) Using puller [2], remove bearings (5) and (6)
Disassembly from gear (7).
1. PTO lubrication tube
Sling PTO assembly and remove lubrication

tube (1).
a Remove the three lubrication tubes installed
on the opposite side, then lower the assem-
ble on blocks with its face to be jointed to the
torque conventer up.
3. Power train pump gear assembly

1) Using forcing screws [1], pull out cover
assembly (8) and lift it off.
2) Using the puller, remove gear assembly (10)
from cover (9).
2. Work equipment and PPC pump gear assembly

1) Using forcing screws [1], pull out cover
assembly (2) and lift it off.
2) Using puller [2], remove gear assembly (3)
from cover (4).
3) Using puller [2], remove bearings (11) and

(12) from gear (13).
D375A-6 50-109
(02)
DRAFT
Power train
4) Reverse the PTO case and remove cover

(14).
4. Scavenging pump gear

1) Remove snap ring (15) from under the PTO
case, then remove gear (16).
4) Remove bearing outer races (21) and (22)

from gear (23).
5. Idler gear assembly

1) Remove plate (17).
6. PTO case
1) Remove race assembly (24) and bearing
outer race (25) as a unit.
2) Reverse the PTO case and remove shaft

assembly (18) by using forcing screws [1].
a Since the bearing outer race and gear as-
sembly come off the bottom of the PTO
case, place wooden blocks under them to
protect them from being damaged.
3) Remove plugs (19) and push out bearing
inner race (20) by using forcing screws.
a After removing the bearing, install the
plugs.
50-110 D375A-6
(02)
DRAFT
Power train
2) Remove bearing inner races (26) and (27) Assembly

from race (28). a Clean all parts, and check them for dirt and dam-
age before installing.
a Check that the snap ring is fitted securely in the
groove.
1. Bearing
1) Using the push tool, press fit bearing (32) to
the case.
a Drop approx. 6 cc of power train oil
(TO-10 or TO-30) on the bearing and ro-
tate the bearing approximately 10 turns.
2) Install snap ring (31).
3) Remove bearing outer race (29).

4) Remove sleeve (30).
2. PTO case
1) Install sleeve (30) to the case.
a Install the sleeve with the chamfered in-
side edge facing down.
a Expand-fit the sleeve.
7. Bearing 2) Using the push tool, press fit bearing outer
Remove snap ring (31) and bearing (32). race (29).
D375A-6 50-111
(02)
DRAFT
Power train
3) Using the push tool, press fit bearing inner 2) Using push tool [4], press fit bearing inner
races (27) and (26) to race (28). race (20) to the shaft.
3) Fit the O-ring and install shaft assembly (18).
4) Install race assembly (24).

2 Inside surface of race:
4) Turn over the PTO case and install gear
Molybdenum disulfide lubricant assembly (33).
(LM-P)
5) Press fit bearing spacer (34) and bearing
5) Using the push tool, press fit bearing outer inner race (35).
race (25). a Drop approx. 6 cc of power train oil
a Drop approx. 6 cc of power train oil (TO-10 or TO-30) on the bearing and ro-
(TO-10 or TO-30) on the bearing and rotate the bearing approximately 10 turns.
tate the bearing approximately 10 turns.
3. Idler gear
1) Using push tool [3], press fit bearing outer
races (22) and (21) to gear (23).
50-112 D375A-6
(02)
DRAFT
Power train
6) Install plate (17). 2) Using push tool [5], press fit bearings (11)
2 Mounting bolt: Adhesive (LT-2) and (12) to gear (13).
3 Mounting bolt:
110.35 ± 12.25 Nm {11.25 ± 1.25
kgm}
4. Scavenging pump gear

1) Install gear (16).
2 Spline: Grease (G2-LI)
3) Using push tool [6], press fit gear assembly

(10) to cover (9).
2 Gear spline: Grease (G2-LI)
4) Fit the O-ring, then hoist cover assembly (8)
to install to the case.
a If the cover assembly does not fit in the
case, tap its periphery evenly with a plas-
2) Install snap ring (15) from under the PTO tic hammer to install.
case. a Drop approx. 6 cc of power train oil
(TO-10 or TO-30) on the bearing and ro-
5. Power train pump gear assembly tate the bearing approximately 10 turns.
1) Fit the O-ring and install cover (14).
D375A-6 50-113
(02)
DRAFT
Power train
6. Work equipment pump and PPC pump gear 7. Lubrication tube

assembly Sling the PTO assembly and install lubrication
1) Using push tool [5], press fit bearings (5) and tube (1).
(6) to gear (7). a Install three lubrication tubes also on the op-
posite side.
2) Using push tool [6], press fit gear assembly

(3) to cover (4).
a Set the assembly with the side where the
bearing end face is flush with the gear
end face facing the cover.
2 Gear spline:
Molybdenum disulphide grease
(LM-G)
3) Fit the O-ring, then hoist cover assembly (2)
and install to the case.
a If the cover assembly does not fit in the
case, tap its periphery evenly with a plas-
tic hammer to install.
a Drop approx. 6 cc power train oil (TO-10
or TO-30) on the bearing and rotate the
bearing approximately 10 turns.
50-114 D375A-6
(02)
DRAFT
Power train
Disassembly and assembly of torque converter assembly
Special tools
New/remodel
Necessity
Sym-
Quantity
Part No. Part name
Sketch
bol
790-413-1010 Bracket t 1
C Repair stand
790-501-5000 t 1
(100 V)
Disassembly
q Preparatory work
Set torque converter assembly (56) to tool C. 2) Using eyebolt [1] , remove lockup clutch and
drive case assembly (4).
3) Disassemble the lockup clutch and drive
case assembly according to the following
procedure.
1] Remove two seal rings (5).
2] Using forcing screws [2], remove input
shaft (6).
1. Torque converter valve assembly

Remove torque converter valve assembly (1).
2. Draining of oil
Remove two drain plugs (2) to drain the oil in the
pump case.
a After draining the oil, tighten the plugs.
3] Remove snap ring (7) and plate (8).
3. Lockup clutch and drive case assembly 4] Set the assembly with the clutch housing
1) Leaving two mounting bolts (3) in position, side down, and using forcing screws [3],
remove other mounting bolts, then place the remove turbine (9).
assembly with the input shaft side up and
remove the remaining two mounting bolts.
D375A-6 50-115
(02)
DRAFT
Power train
5] Set the assembly with the clutch housing 10] Remove two discs (16) and one plate (17)
side up and remove the housing and from drive case (18).
piston assembly (10) by using eyebolts a Keep the disc and plate on a flat sur-
[4]. face so that they do not warp.
a When the assembly is removed, the
piston may fall out, so support it by
hand when removing
6] Remove piston (11) from housing (12).
4. Stator assembly
1) Remove snap ring (19), then remove stator
assembly (20).
2) Disassemble the stator assembly as follows.
7] Remove seal ring (13) from the piston. 1] Remove snap ring (21), then remove race
8] Remove seal ring (14) from the housing. (22) from stator (23).
9] Using push tool [5], remove bearing (15) 2] Remove snap ring (24) from stator (23).
from the housing.
5. Pump assembly
1) Remove snap ring (25).
2) Remove pump assembly (26).
50-116 D375A-6
(02)
DRAFT
Power train
3) Disassemble the pump assembly as follows. 7. Spring

1] Remove retainer (27). Remove springs (33).
2] Remove bearing and guide assembly
(28) from pump (29). 8. Spring, disc, and plate
Remove springs (34), two discs (35), and one
plate (36).
a Keep the disc and plate on a flat place so that
they do not warp.
9. Pin
Remove pins (37).
3] Remove bearing outer race (30) from

guide (31).
6. Stator clutch housing

Set the assembly with the stator clutch housing
up and remove stator clutch housing (32).
10. Inner gear

Remove snap ring (38), then remove inner gear
(39).
11. Piston
Remove piston (40) from case (41).
D375A-6 50-117
(02)
DRAFT
Power train
1) Remove seal ring (42) from the piston. 2] Remove snap ring (47) and remove
2) Remove seal ring (43) from the case. bearing inner race (48), bushing (49), and
seal ring (50) from the shaft.
3] Remove seal ring (51) and remove plate
(54)
4] Remove snap ring (53) and plate (54).
12. Stator shaft assembly

1) Tap stator shaft assembly (44) with a plastic
hammer to remove it from case (45).
2) Disassemble the stator shaft assembly as
follows. 5] Using push tool [7], remve bearing (55).
1] Using push tool [6], remove shaft
assembly (45) from the stator shaft
assembly.
50-118 D375A-6
(02)
DRAFT
Power train
Assembly 4] Install seal ring (50) to the shaft.

a Clean all parts, and check them for dirt and dam- a After installing the seal ring, apply
age before installing. grease (G2-LI) to securely fix the seal
a Check that the snap ring is fitted securely into ring to the shaft.
the groove. 5] Using push tool [9], press fit bushing (49).
a When press fitting the bushing, take
q Preparatory work care not to deform it.
Set case (41) to tool C..
6] Using push tool [10], press fit bearing

1. Stator shaft assembly inner race (48).
1) Assemble the stator shaft assembly 7] Install snap ring (47) to fix the bearing
according to the following procedure. inner race.
1] Using the push tool, press fit bearing (55)
to stator shaft (52).
2] Install plate (54), and secure it with snap
ring (53).
3] Install the seal ring (51).
a After installing the seal ring, apply
grease (G2-LI) to securely fix the seal
ring to the shaft.
D375A-6 50-119
(02)
DRAFT
Power train
2) Tap stator shaft (52) with a plastic hammer to a Install the seal ring as shown in the figure
press fit the bearing portion to the case. since it has directional properties.
3) Set shaft (46) to the stator shaft and press fit (P: Direction of pressure)
the bearing by using the push tool.
4) Turn over the case and tighten mounting
bolts of the shaft from the case end.
2 Periphery of seal ring: Grease (G2-LI)
3 Mounting bolt:
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
3) Install piston (40) to case (41).

2 Seal ring contact surface:
Grease (G2-LI)
3. Inner gear
Install inner gear (39) and secure it with snap
2. Piston ring (38).
1) Install seal ring (43) to the case.
a Install the seal ring as shown in the figure
since it has directional properties.
2) Install seal ring (42) to the piston.
50-120 D375A-6
(02)
DRAFT
Power train
4. Pin 2] Set bearing and guide assembly (28) to

Install pins (37). pump (29), then tap the assembly with a
plastic hammer to press fit the bearing
5. Plate, disc, and spring portion.
Install one plate (36), two discs (35), and springs 3] Install retainer (27).
(34). 2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
6. Spring 66.15 ± 7.35 Nm {6.75 ± 0.75
Install springs (33). kgm}
2) Install pump assembly (26),
a When installing the pump, take care not
to damage the seal ring fitted to the shaft.
3) Install snap ring (25).
7. Stator clutch housing

Install stator clutch housing (32).
a Check that the springs are fitted securely in
the holes in the housing and piston.
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
110.35 ± 12.25 Nm {11.25 ± 1.25
kgm}
8. Pump assembly
1) Assemble the pump assembly as follows.
1] Using the push tool, press fit bearing
outer race (30) to guide (31).
a Drop approx. 6cc of power train oil
(TO-10 or TO-30) on the bearing and
rotate the bearing approximately 10
turns.
D375A-6 50-121
(02)
DRAFT
Power train
9. Stator assembly
1) Assemble the stator assembly as follows.
1] Install snap ring (24) to stator (23).
2] Install two discs (16) and one plate (17).
2] Install race (22) to stator (23) and fix it

with snap ring (21).
2) Install stator assembly (20) to the stator
shaft, and secure it with snap ring (19).
3] Install seal ring (14) to the housing.

2 Periphery of seal ring:
Grease (G2-LI)
4] Install seal ring (13) to the piston.
2 Periphery of seal ring:
Grease (G2-LI)
10. Lockup clutch and drive case assembly

1) Assemble the lockup clutch and drive case
assembly as follows.
1] Set turbine (9) to block [11], and set drive
case (18) to the turbine.
50-122 D375A-6
(02)
DRAFT
Power train
5] Install piston (11) to housing (12). 2) Using eyebolt [1], install lockup clutch and
2 Seal ring contact surface: drive case assembly (4).
Grease (G2-LI) a When installing, match oil groove (a) of
a When installing, take care not to dam- the turbine with drain plugs (2).
age the seal ring.
6] Using eyebolts [4], install housing and
piston assembly (10).
3 Mounting bolt:
110.35 ± 12.25 Nm {11.25 ±
1.25 kgm}
3) Tighten mounting bolts (3).

a Check that drain plugs (2) are tightened.
3 Mounting bolt:
53.9 ± 4.9 Nm {5.5 ± 0.5 kgm}
3 Drain plug :
11.25 ± 1.45 Nm {1.15 ± 0.15
kgm}
7] Press fit bearing (15) by using the push
tool.
8] Install plate (8), and secure it with snap
ring (7).
9] Install input shaft (6).
2 Mounting bolt: Adhesive LT-2
3 Mounting bolt:
277.0 ± 31.9 Nm {28.5 ± 3.25
kgm}
10] Install two seal rings (5).
D375A-6 50-123
(02)
DRAFT
Power train
11. Torque converter valve assembly

Install torque converter valve assembly (56).
a Tighten the mounting bolts uniformly in turn
and be careful not to tighten them unevenly.
3 Mounting bolt:
49.0 ± 4.9 Nm {5.0 ± 0.5 kgm}
12. Remove the torque converter assembly from

tool C.
50-124 D375A-6
(02)
DRAFT
Power train
Disassembly and assembly of TORQFLOW transmission assembly

2. Control valve assembly
Special tools 1) Remove nut (2-1) from connector (P).
New/remodel
a Note that cover (2) is wired.
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
790-415-1011 Bracket t 1
1 Repair stand (100
750-501-5000 t 1
V)
2 791-615-1130 Push tool t 1
791-615-1210 q Ring 1
3 135-A90-1150 q Bolt 1
D 01580-01008 q Nut 1
01641-51032 q Washer 2
791-615-1111 q Ring 1
4 135-A90-1150 q Bolt 1
01580-01008 q Nut 1
01641-51032 q Washer 2
5 799-301-1600 Oil leak tester t 1 3) Remove sleeves (3).
4) Remove control valve assembly (4).
Disassembly (G): Gasket
1. Preparatory work
Set transmission assembly (1) to tool D1.
3. Lubrication valve assembly

Remove lubrication valve assembly (5).
D375A-6 50-125
(02)
DRAFT
Power train
4. Front case 3) Using eyebolt [2], lift off input shaft and No. 1
1) Set the transmission assembly with the input carrier assembly (8).
shaft up. 4) Reverse the input shaft and No. 1 carrier
2) Using eyebolts, remove front case (6). assembly and remove seal ring (9).
5. Input shaft and No. 1 carrier assembly 5) Disassemble the input shaft and No. 1 carrier
1) Remove seventeen tie bolts (7). assembly according to the following proce-
2) Using forcing screws [1], disconnect input dure.
shaft and No. 1 carrier assembly (8). 1] Remove snap ring (10) and remove No. 2
a Tighten the forcing screws evenly and sun gear (11).
take care not to twist the input shaft and 2] Remove spacer and bearing assembly
No. 1 carrier assembly. (12).
3] Using the push tool, remove ball bearings

(13) and (14) from spacer (15).
50-126 D375A-6
(02)
DRAFT
Power train
Disassemblyandassemblyof TORQFLOWtransmissionassembly
4] Remove No. 1 sun gear (16).

5] Remove spacer (17).
10] Remove snap ring (24) from housing and

No. 1 carrier assembly (20).
11] Set the housing and No. 1 carrier
6] Using eyebolt [3], sling housing and No. 1
assembly on the blocks and remove
carrier assembly (18) and set it on the
housing (25) from No. 1 carrier assembly
blocks.
(26) by using push tool [4].
a Lower the input shaft end to the
ground and make a clearance of ap-
prox. 20 mm between the "housing
and No. 1 carrier assembly" and the
blocks.
7] Remove snap ring (19).
12] Remove snap ring (27) from housing (25).

13] Reverse the housing and set it on the
blocks and remove seal ring (146).
8] Tap the housing with a plastic hammer to

drop housing and No. 1 carrier assembly
(20) onto the blocks and remove input
shaft assembly (21).
9] Using the press, remove ball bearing (22)
from input shaft (23).
D375A-6 50-127
(02)
DRAFT
Power train
14] Using push tool [5], remove ball bearing

(28) from the housing.
15] Remove spacer (29) from No. 1 carrier
assembly (26).
6. No. 1 disc, plates, and springs

1) Remove twelve springs (37).
2) Remove six discs (38), six springs (40), and
five plates (39) in turn to remove the guide
16] Reverse the No. 1 carrier assembly, plate.
remove snap ring (30), and remove collar a Keep the disc and plate on a flat place so
(31). that they do not warp.
17] Reverse the No. 1 carrier assembly, pull
out shafts (33) halfway from carrier (32),
remove balls (34), and remove shafts
(33).
a Take care not to lose the balls and
store them carefully.
7. No. 1 clutch ring gear

Remove No. 1 clutch ring gear (41).
18] Remove gears (34) and thrust washers

(35) from the carrier.
19] Remove needle bearings (36) from gears
(34).
50-128 D375A-6
(02)
DRAFT
Power train
8. No. 1 housing 9. No. 2 disc, plate, and spring

1) Using eyebolt [5], remove No. 1 housing 1) Remove twelve springs (47).
assembly (42). 2) Remove six discs (48), five plates (49), and
six springs (50) in turn.
a Keep the disc and plate on a flat place so
that they do not warp.
2) Disassemble the No. 1 housing assembly

1] Remove piston (43) from housing (44).
3) Remove seventeen sleeves (51).
2] Remove seal ring (45) from piston (43).

3] Remove seal ring (46) from housing (44). 4) Remove seal ring (52) from the No. 2 and No.
3 carrier assembly.
5) Remove six torque pins (53).
6) Remove twelve guide pins (54).
D375A-6 50-129
(02)
DRAFT
Power train
10. No. 1 ring gear and No. 2 and No. 3 carrier 3] Pull out shafts (61) halfway from carrier
assembly (60), remove balls (62), and remove
1) Using eyebolts [6], lift off "No. 1 ring gear, No. shafts (61).
2 and No. 3 carrier" assembly (55). a Take care not to lose the balls and
2) Disassemble the "No. 1 ring gear, No. 2 and

No. 3 carrier" assembly according to the 4] Remove gears (63) and thrust washers
following procedure. (64) from the carrier.
1] Remove seal rings (57) and (58). 5] Remove needle bearings (65) from gears
(63).
2] Remove ring (59).
a Since No. 2 and No. 3 carrier assem-
bly (60) is embedded in No. 1 ring
gear (66), they cannot be disassem-
bled.
50-130 D375A-6
(02)
DRAFT
Power train
11. No. 2 ring gear 2] Remove seal ring (72) from piston (69).
Remove No. 2 ring gear (67). 3] Remove seal ring (73) from piston (70).
12. No. 2 and No. 3 housing assembly 4] Remove seal rings (74) and (75) from
1) Using eyebolts [7], remove No. 2 and No. 3 housing (71).
housing assembly (68) together with the
upper and lower pistons.
a Bind the lower piston with a wire to pre-
vent it from coming off.
13. No. 3 disc, plate, and spring

1) Remove the guide plate and remove twelve
springs (76).
2) Remove four discs (77), four springs (79),
2) Disassemble the No. 2 and No. 3 housing and three plates (78) in turn.
assembly according to the following proce- a Keep the disc and plate on a flat surface
dure. so that they do not warp.
1] Remove pistons (69) and (70) from
housing (71).
D375A-6 50-131
(02)
DRAFT
Power train
14. No. 3 and No. 4 clutch plate 16. No. 4 housing assembly
Using eyebolts [8], remove plate (80). 1) Using eyebolts [9], remove housing
assembly (85) and the piston as a unit.

1) Remove three discs (81), three springs (83), 2) Disassemble the No. 4 housing assembly
and two plates (82) in turn and remove guide according to the following procedure.
plate (147). 1] Remove piston (86) from housing (87).
a Keep the disc and plate on a flat place so
that they do not warp.
2) Remove six torque pins (84).
2] Remove seal ring (88) from piston (86).

3] Remove seal ring (89) from housing (87).
50-132 D375A-6
(02)
DRAFT
Power train
17. "No. 3 ring gear, No. 4 carrier and No. 5 clutch" 7) Disassemble the "No. 3 ring gear, No. 4
assembly carrier and No. 5 clutch" assembly according
1) Operate tool D1 to turn the transmission to the following procedure.
assembly sideways. 1] Remove two seal rings (56) from the
2) Remove plate (90). housing.
3) Remove snap ring (91) and plate (92). 2] Remove seal ring (118) from the input
shaft.
4) Remove snap ring (93) and spacer (94).

3] Remove snap ring (96) and remove No. 3
sun gear (97).
4] Remove collar and bearing assembly
(98).
5) Set the transmission assembly with the No. 4

carrier up.
6) Using eyebolts [10], sling "No. 3 ring gear,
No. 4 carrier and No. 5 clutch" assembly (95)
and hit the bottom of the output shaft with a
copper hammer to remove.
D375A-6 50-133
(02)
DRAFT
Power train
5] Using the push too, remove ball bearing 10] Remove snap ring (106) and remove
(99) from collar (100). collar (107) from No. 3 ring gear and No.
4 carrier assembly (101).
11] Remove seal ring (108) from collar (107).
6] Using eyebolts [11], remove No. 3 ring

gear and No. 4 carrier assembly (101)
together with the No. 4 sun gear. 12] Pull out shaft (110) halfway from carrier
7] Remove No. 4 sun gear (102) from No. 3 (109), remove balls (111), and remove
ring gear and No. 4 carrier assembly shafts (110).
(101). a Take care not to lose the balls and
13] Remove gears (112) and thrust washers
(113) from the carrier.
14] Remove needle bearings (114) from
gears (112).
8] Reverse the No. 3 ring gear and No. 4

carrier assembly and remove hub (103).
9] Remove seal rings (104) and (105) from
hub (103).
50-134 D375A-6
(02)
DRAFT
Power train
15] Reverse carrier (109) and remove snap 19] Remove six discs (119), six springs (121),
ring (115). and five plates (120) from housing (122)
16] Reverse the carrier and remove ball in turn.
bearing (116) by using the push tool. a Keep the disc and plate on a flat sur-
a Since No. 4 carrier (109) is embedded face so that they do not warp.
in No. 3 ring gear (117), they cannot
be disassembled.
20] Set the output shaft and housing

assembly to the press and remove
17] Set output shaft and housing assembly housing assembly (123) from output shaft
(118) on the blocks with the output side of assembly (124) by using push tool [13].
the output shaft up. a Set blocks [14] under the housing as-
18] Using the forcing screws, disconnect sembly to prevent the housing assem-
input shaft and housing assembly (118) bly from falling out.
and remove it by using eyebolts [12].
a Tighten the forcing screws evenly to
disconnect the output shaft and hous-
ing assembly.
D375A-6 50-135
(02)
DRAFT
Power train
21] Set housing assembly (123) to the press 24] Remove seal ring (131) from housing
and compress the spring to remove snap (128).
ring (125) by using tool D2. 25] Remove snap ring (132) from the
a Operate the press slowly to push up housing.
the spring evenly. 26] Using the push tool, remove ball bearing
22] Remove retainer (126) and spring (127) (133) from the housing.
from housing (128).
27] Remove snap ring (134) and remove

23] Remove piston (129) from the housing. needle bearing (135) from input shaft
Remove seal ring (130) from piston (129). (124).
28] Reverse the output shaft, remove snap
ring (136), and remove the roll bearing
(137) from the output shaft.
50-136 D375A-6
(02)
DRAFT
Power train
18. Rear case assembly Assembly

1) Remove collar (138) from rear case (139). a Clean all the parts thoroughly (oil holes etc. in
particular), check them for dirt and dents, and
apply engine oil to the sliding parts before install-
ing.
a Apply grease (G2-LI) to each spline.
1. Preparatory work
Set rear case (139) to tool D1.
2) Remove seal ring (140) from collar (138).
2. Rear case assembly

1) Install seal ring (149) to collar (138).
a Direct the seal ring as shown in the figure
below.
2 Seal ring: Grease (G2-LI)
3) Reverse the rear case, remove snap ring

(141), and remove ball bearing (142).
D375A-6 50-137
(02)
DRAFT
Power train
2) Reverse rear case (139) and install collar

(138).
a Take care not to get the seal ring caught.
6) Reverse rear case (139), set output shaft

assembly (124) to the case, and press fit the
bearing portion by using the push tool.
3. Output shaft assembly 7) Install snap ring (141).
1) Using the push tool, press fit needle bearing
(135) to output shaft (124) and fix it with snap
ring (134).
2) Using the push tool, press fit ball bearing
(142) to the output shaft.
8) Install plate (92), and fit it with snap ring (91).
3) Install spacer (94) and fix it with snap ring

(93).
2 Inside surface of spacer:
Molybdenum disulphide lubricant
(LM-P)
4) Install plate (90).
3 Mounting bolt:
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
5) Install seal ring (118).
50-138 D375A-6
(02)
DRAFT
Power train
4. "No. 3 ring gear, No. 4 carrier and No. 5 clutch" 2] Reverse the carrier.
assembly 3] Install needle bearings (114) to gears
1) Assemble the "No. 3 ring gear, No. 4 carrier (112), fit thrust washers (113) to both
and No. 5 clutch" assembly according to the sides of the gears, and set them to the
following procedure. carrier.
q When No. 3 ring gear and No. 4 carrier 4] Fit balls (111) and install shafts (110) to
are supplied individually: the carrier.
Using tool D3, compress ring (143), set a Check that each gear rotates smooth-
No. 3 ring gear (117) on No. 4 carrier ly.
(109), and tap No. 3 ring gear (117) with
a plastic hammer to install.
a Check that the ring is fitted securely
into the groove.
5] Install seal ring (108) to collar (107).

2 Seal ring : Grease (G2-LI)
6] Install collar (107) to No. 3 ring gear and
No. 4 carrier assembly (101), alining its
1] Using the push tool, press fit ball bearing dowel hole with the dowel pin, and fix it
(116) to carrier (109) and fix it with snap with snap ring (106).
ring (115). a Tap the dowel pin fitting portion with a
plastic hammer until the clearance be-
tween the mating faces is eliminated.
D375A-6 50-139
(02)
DRAFT
Power train
7] Install seal rings (105) and (104) to hub 10] Install six discs (119), six springs (121),
(103). and five plates (120) in turn.
8] Install hub (103) to No. 3 ring gear and
No. 4 carrier assembly (101).
a Take care not to get the seal ring
caught.
11] Using the push tool, press fit ball bearing

(133) to housing (128) and fix it with snap
ring (132).
9] Using eyebolts [15], install housing (122)

to No. 3 ring gear and No. 4 carrier
assembly.
12] Install seal ring (131) to the housing.

a Install the seal ring as shown in the fig-
ure below.
50-140 D375A-6
(02)
DRAFT
Power train
13] Install seal ring (130) to piston (129). 17] Using bolt [16], install housing assembly
a Install the seal ring as shown in the fig- (123).
ure below. 2 Mounting bolt: Adhesive (LT-2)
2 Seal ring: Grease (G2-LI) 3 Mounting bolt:
14] Install piston (129) to housing (128). 176.4 ± 19.6 Nm {18 ± 2 kgm}
a Take care not to get the spring caught. 18] Install two seal rings (56) to the housing.
15] Set springs (127) and retainer (126) to the

housing. 2) Reverse rear case (139) and "No. 3 ring
a Set the three springs as shown in the gear, No. 4 carrier and No. 5 clutch"
following figure. assembly (95).
16] Set housing assembly (123) to the press
and compress the springs to install snap 3) Using eyebolts [10], set "No. 3 ring gear, No.
ring (125) by using tool D2. 4 carrier and No. 5 clutch" assembly (95) to
a Installed load of spring: the rear case and output shaft.
2,175 N {222 kg} a Take care not to get the seal ring caught.
D375A-6 50-141
(02)
DRAFT
Power train
4) Using push tool [17], press fit the bearing 2) Install collar and bearing assembly (98).
portion of "No. 3 ring gear, No. 4 carrier and a Install the assembly with collar flange
No. 5 clutch" assembly (95) to the output side up.
shaft. 3) Install No. 3 sun gear (97) and fix it with snap
ring (96).
2 Spline:
(LM-P)
5. No. 4 sun gear

Install No. 4 sun gear (102).
2 Spline:
(LM-P) 7. No. 4 housing assembly
1) Install seal ring (89) to housing(87).
below.
2) Install seal ring (88) to piston (86).
below.
6. No. 3 sun gear

1) Using the push tool, press fit ball bearing (99)
to collar (100).
2 Spline:
(LM-P)
50-142 D375A-6
(02)
DRAFT
Power train
3) Install piston (86) to housing (87). 9. No. 3 and No. 4 clutch plate
a Take care not to get the seal ring caught. Using eyebolts [8], install plate (80) aligning the
dowel holes with the dowel pins.
a Tap the dowel pin fitting portions with a plas-
tic hammer until the clearance between the
mating faces is eliminated.
4) Using eyebolts [9], install No. 4 housing

assembly (85) aligning the dowel holes with
the dowel pins.
a Tap the dowel pin fitting portions with a
plastic hammer until the clearance be- 10. No. 3 disc, plate, and spring
tween the mating faces is eliminated. 1) Install four discs (77), four springs (79), and
three plates (78) alternately.
2) Install twelve guide pins (54).
a Guide pin length: 360 mm
3) Install twelve springs (76) and install the
guide plate.
a Spring free length: 97 mm

1) Install six torque pins (84).
a Torque pin length: 162 mm
2) Install guide plate (147), and install three
discs (81), three springs (83) and two plates
(82) in turn.
D375A-6 50-143
(02)
DRAFT
Power train
11. No. 1 ring gear and No. 3 housing assembly 4) Install pistons (70) and (69) to housing (71).
1) Install seal rings (74) and (75) to housing a Take care not to get the seal ring caught.
(71). a Bind piston (70) with a fine wire to prevent
a Install the seal ring as shown in the figure. it from falling when the housing is lifted
2 Seal ring: Grease (G2-LI) up.
2) Install seal ring (73) to piston (70). 5) Install housing assembly (68) aligning the
a Direct the seal ring as shown in the figure. dowel holes with the dowel pins.
a Tap the dowel pin fitting portions with a
a Direct the seal ring as shown in the figure.
50-144 D375A-6
(02)
DRAFT
Power train
12. No. 2 ring gear 1] Install needle bearings (65) to gears (63),
Install ring gear (67). fit thrust washers (64) to both sides of the
gears, and set them to carrier (60).
13. "No. 1 ring gear and No. 2 and No. 3 carrier"

assembly 2] Fit balls (62) and install shafts (61) to the
1) Assemble the "No. 1 ring gear and No. 2 and carrier.
No. 3 carrier" assembly according to the a Check that each gear rotates smooth-
following procedure. ly.
q When No. 1 ring gear, No. 2 and No. 3
carrier are supplied individually:
Using tool D4, compress ring (144), set
No. 1 ring gear (66) on No. 2 and No. 3
carrier (60), and tap the No. 1 ring gear
(66) with a plastic hammer to install.
a Check that the ring is fitted securely into
the groove.
D375A-6 50-145
(02)
DRAFT
Power train
3] Install ring (59) to the carrier. 14. No. 2 disc, plate, and spring
a Check that the ring is fitted securely 1) Install six torque pins (53).
into the groove. a Torque pin length: 199 mm
4] Install seal rings (58) and (57) to the 2) Install seal ring (52) to the No. 2 and No. 3
carrier. carrier.
2 Seal ring: Grease (G2-LI) 2 Seal ring: Grease (G2-LI)
a Align seal ring (58) with the carrier and
fix it with grease (G2-LI).
3) Install seventeen sleeves (51).
2) Using eyebolts [6], install "No. 1 ring gear

and No. 2 and No. 3 carrier" assembly (55).
a Take care no to get the seal ring caught.
3) Using push tool [18], press fit the bearing

portion of "No. 1 ring gear and No. 2 and No.
3 carrier assembly" (55).
50-146 D375A-6
(02)
DRAFT
Power train
a Install sleeve (51) into the bolt hole

marked with *, with the slit (part S) down. 3) Install piston (43) to housing (44).
4) Install twelve springs (47).

a Spring free length: 70 mm 4) Using eyebolts [5], install housing (42)
5) Install six discs (48), four springs (50), and aligning the dowel holes with the dowel pins.
five plates (49) in turn. a Check that the springs are fitted securely
a Align the notches of the oil grooves on the into the grooves of the housing.
periphery of the discs. a Tap the dowel pin fitting portions with a
15. No. 1 housing assembly

1) Install seal ring (46) to housing (44).
a Install the seal ring as shown in the figure.
a Direct the seal ring as shown in the figure.
D375A-6 50-147
(02)
DRAFT
Power train
16. No. 1 clutch ring gear

Install No. 1 clutch ring gear (41). 2] Fit balls (34) and install shafts (33) to the
carrier.
3] Install collar (31) to the carrier and fix it
with snap ring (30).

1) Install the guide plate and install twelve
springs (37).
a Spring free length: 66 mm 4] Using push tool [19], press fit ball bearing
2) Install six discs (38), six springs (40), and five (28) to plate (25) and fix it with snap ring
plates (39) in turn. (27).
18. Input shaft and No. 1 carrier assembly

1) Assemble the input shaft and No. 1 carrier
assembly according to the following proce-
dure.
1] Install needle bearings (36) to gears (34),
fit thrust washers (35) to both sides of the
gears, and set them to carrier (32).
50-148 D375A-6
(02)
DRAFT
Power train
5] Reverse the plate and install seal ring

(146).
a Align seal ring with the plate and fix it
with grease (G2-LI).
6] Install spacer (29) to No. 1 carrier
assembly (26).
11] Install snap ring (19).
7] Set plate (25) to No. 1 carrier (26), press

fit the bearing portion with push tool [20]
and fix it with snap ring (24).
12] Turn the input shaft and No. 1 carrier

assembly sideways and install spacer
(17).
13] Install No. 1 sun gear (16).
2 Spline:
Molybdenum disulphide lubri-
cant (LM-P)
8] Using the press, install ball bearing (22)

to input shaft assembly (23).
9] Set housing and No. 1 carrier assembly
(20) to the blocks.
10] Using eyebolt [3], install input shaft
assembly (18) to the housing and No. 1
carrier assembly.
D375A-6 50-149
(02)
DRAFT
Power train
14] Using the push tool, press fit ball bearings

(13) and (14) to spacer (15).
3) Evenly tighten four tie bolts (12) on the diag-

onal line.
15] Install spacer and bearing assembly (12). 4) Tighten remaining tie bolts (12).
3 Tie bolt:
a Install the assembly with the small-di-
ameter bearing toward the No. 1 sun 259.7 ± 14.7 Nm {26.5 ± 1.5 kgm}
gear.
2 Spline:
cant (LM-P)
16] Install No. 2 sun gear (11) and fix it with
snap ring (10).
2 Spline:
cant (LM-P)
17] Install seal ring (9) to the No. 1 carrier.

a Align seal ring with the carrier and fix
it with grease (G2-LI).
2) Reverse input shaft and No. 1 carrier
assembly (8) and set it to the No. 1 housing
by using eyebolt [2].
a Lower the input shaft slowly while check-
ing that its end does not interfere with the
output shaft bearing.
50-150 D375A-6
(02)
DRAFT
Power train
19. Checking piston stroke 21. Output shaft bearing

Using tool D5, check the stroke of each clutch 1) Set the transmission assembly with the
piston. output shaft side up.
a Air pressure: 490 – 588 kPa {5 – 6 kg/cm2} 2) Using the push tool, press fit roller bearing
a Standard stroke of piston (137) to the output shaft and fix it with snap
Piston No. 1 No. 2 No. 3 No. 4 No. 5 ring (136).
Stroke (mm) 6.7 7.0 5.6 4.7 7.0 a Take care not to hit or scratch the cage or
rollers of the bearing.
Use a push tool of a size which pushes
only the outer race.
20. Front case

Fit the O-ring and install front case (6) by using
the eyebolts. 22. Lubrication valve assembly
a Lower the front case gradually while check- Install lubrication valve assembly (5).
ing that it does not interfere with other parts.
D375A-6 50-151
(02)
DRAFT
Power train
23. Control valve assembly (OUT): Outside face of cover

1) Install gasket (G) to the control valve. (IN): Inside face of cover
3 Mounting bolt: (HL): Bolt holes
49.0 ± 4.9 Nm {5.0 ± 0.5 kgm}
2) Install the O-rings to sleeves (3).
2 All O-rings: Grease (G2-LI)
3) Install nut (2-1) to connector cover (2).

2 Nut: 39.6 – 42.4 Nm {4.0 – 4.3 kgm}
4) Install cover (2).
a Check that the mating faces of the case
and cover (2) are free from dents, rust, oil,
grease and water.
2 Both mating faces of case and cover
(2):
a Apply liquid gasket continuously around
the bolt holes as shown in the figure.
(Positions to apply liquid gasket)
(L1): Intermediate position between bolt
holes and inside face of cover
(L2): Center of inside and outside faces of
cover
(Quantity of liquid gasket to apply)
B x H = 2 - 5 cc
50-152 D375A-6
(02)
DRAFT
Power train
Disassembly and assembly of steering case assembly
Disassembly
1. Clutch and brake assembly
1) Using the eyebolts, sling the clutch and brake
assembly. Remove the mounting bolts to
remove clutch and brake assembly (3).
a Remove the clutch and brake assembly
from the opposite side in the same way.
a When removing the clutch and brake as-
sembly, take care not to scratch or dam-
age discs and plates.
5] Reverse the clutch and brake assembly.

Using eyebolts [3], separate clutch
assembly (9) from brake assembly (10).
2) Remove the clutch and brake assembly as

follows:
1] Remove plate (4), then remove collar (5).
2] Remove plate (6).
3) Disassemble the clutch assembly as follows:

1] Remove stopper (11).
2] Remove disc (12), springs (13), and
plates (14) in turn.
a Keep the disc and plate on a flat sur-
face so that they do not warp.
3] Using forcing screws [1], remove sleeve

(7).
4] Using puller [2], pull out bearing inner
race (8) from the sleeve.
D375A-6 50-153
(02)
DRAFT
Power train
3] Remove torque pins (15).

4] Using eyebolts, remove clutch hub (16).
5] Remove plate (17), using forcing screws
[4].
10] Remove clutch cage (27) by using

eyebolts.
11] Remove seal ring (28) from the clutch
cage.
6] Remove outer race (18) from the plate. 12] Remove piston (29).
7] Remove bearing and cage assembly 13] Remove seal ring (30) from the piston.
(19).
14] Remove bearing outer race (31) from the

8] Remove plate (21) and nut (22) from cage clutch cage.
(20). 15] Remove Belleville springs (32).
9] Remove bearing and inner race (23),
spacers (24) and (25), and bearing outer
race (26).
50-154 D375A-6
(02)
DRAFT
Power train
16] Using eyebolts [6], remove brake hub 7] Remove seal ring (44) from the piston.
(33).
17] Remove bearing (34) from the brake hub.
8] Remove Belleville springs (45).
4) Disassemble the brake assembly as follows:

1] Remove stopper (35).
2] Remove discs (36), springs (37), and
plates (38) in turn.
a Keep the disc and plate on a flat sur-
face so that they do not warp.
2. Shaft
Remove left and right shafts (46).
3] Using eyebolts [7], remove brake cage

(39).
4] Remove bearing outer race (40) and seal
ring (41) from the brake cage.
3. Lubrication tube
Remove lubrication tubes (47), (47-1), and
(47-2).
5] Remove torque pins (42).

6] Remove piston (43).
D375A-6 50-155
(02)
DRAFT
Power train
2) Disassemble transfer and gear housing

assembly (50) as follows:
1] Place the transfer and gear assembly
onto blocks.
2] Remove lubrication tube (51).
2-1] Remove the cage and bearing
assembly.
4. Pipe
1) Remove left and right pipes (48).
2) Remove pipe (49).
3] Using the push tool, remove bearing (53)

from cage (52a).
4] Remove drive gear (54).
5. Steering control valve and seat assembly

Remove steering control valve and seat
assembly (2).
4 Steering control valve and seat assembly:
75 kg
a Check that lubrication tubes are already re-
moved.
5] Using puller [10], remove both sides of
bearing inner races (55) on both sides of
the gear.
6] Remove lubrication tube (56).
6. Transfer and gear housing assembly

1) Install guide bolts [8] on housing assembly
(50). Lift off the housing assembly using the
eyebolts [9].
50-156 D375A-6
(02)
DRAFT
Power train
7] Using eyebolts [11], remove pinion

housing assembly (57).
a Note the quantity and thickness of the
shims for installation purpose.
8] Using forcing screws, remove cover (58).
9] Remove holder (59).
15] Remove bearing (70) from the case.

16] Remove bearing (71) from the case.
10] Pull out pinion gear (60) by pressing the

pinion shaft using the press.
11] Remove the holder, and remove bearing
inner race (61) from pinion gear (60) by
using puller [12].
12] Remove cage and bearing assembly
(62).
7. Right cage
1) Turn the steering case to put the right cage
up.
2) Remove cage and bearing assembly (72).
a Note the quantity and thickness of the
shims for installation purpose.
3) Remove the bearing outer race from the
cage bearing assembly.
4) Using eyebolts [14], remove cage (73).
13] Remove collar (63) from gear (64).

14] Using push tool [13], remove bearing
outer races (65) and (69), bearing inner
races (66) and (67), and collar (68).
D375A-6 50-157
(02)
DRAFT
Power train
8. Bevel gear and shaft assembly

1) Remove bevel gear and shaft assembly (74)
using eyebolts.
2) Disassemble bevel gear and shaft assembly
(74) as follows:
1] Remove the reamer bolts, and remove
bevel gear (75) from shaft (76).
2] Using puller [15], remove bearing inner

races (77) and (78) from the shaft.
9. Left cage
1) Turn the steering case to put the left side of
the case up, and remove cage and bearing
assembly (79).
a Note the quantity and thickness of shims
for installation purpose.
2) Remove bearing outer race (80) from the

cage and bearing assembly.
50-158 D375A-6
(02)
DRAFT
Power train
Assembly 2. Bevel gear and shaft assembly

a Clean all parts, and check them for dirt and dam- 1) Assemble the bevel gear and shaft assembly
age before installing. as follows:
a Apply engine oil to the rotating part of the bear- 1] Using push tool [16], press fit bearing
ing, and rotate it several times. inner races (78) and (77).
a Also, apply engine oil to the sliding parts before
2] Set bevel gear (75) to shaft (76), and
installing.
secure them by tightening the reamer
a Check that the snap ring securely fit into the
bolts.
3 Reamer bolt :
groove.
274.4 ± 29.4 Nm {28 ± 3 kgm}
1. Left cage
2) Install bevel gear and shaft assembly (74)
1) Using the push tool, press fit bearing outer using the eyebolts.
race (80) to the cage.
2) Install the shims and install cage and bearing
assembly (79).
a Standard thickness of shim: 2 mm
3 Cage and bearing assembly mounting
bolts:
176.4 ± 19.6 Nm {18 ± 2 kgm}
3. Right cage
1) Using eyebolts [14], install cage (73) in posi-
tion.
D375A-6 50-159
(02)
DRAFT
Power train
2) Install the shims and install cage and bearing 3] Press fit bearing outer race (69) into the
assembly (72). cage using the push tool.
a Standard thickness of shims: 2 mm 4] Install bearing inner races (67), (66) and
3 Cage and bearing assembly mounting collar (68).
bolts: 5] Using the push tool, press fit bearing
176.4 ± 19.6 Nm {28 ± 2 kgm} outer race (65).
4. Preload adjustment 6] Using push tool [18], press fit inner race
Adjust the rotating force of the bevel gear shaft (61) to pinion gear (60).
by adjusting the thickness of shims on the cage. 7] Install the holder.
a Rotate the bevel gear two or three times, and
place the push-pull scale onto the tip of the 276.85 ± 31.85 Nm {28.25 ±
gear teeth to measure the force. 3.25 kgm}
a Rotating force (when bevel gear is not en-
8] Install gear (64) and collar (63) to the
gaged):
pinion gear.
2 Spline of gears:
4.9 – 5.88 N {0.5 – 0.6 kg}
(Rotating torque: 23.52 – 28.42 Nm {2.4 –
2.9 kgm})
cant (LM-P)
5. Transfer and gear housing assembly

1) Assemble the transfer and gear housing
assembly according to the following proce-
dure.
1] Press fit transfer gear bearing (71) into
the case using push tool [16].
2] Using push tool [17], press fit pinion
bearing (70) into the case.
50-160 D375A-6
(02)
DRAFT
Power train
9] Using push tool [19], press fit cage and 12] Check clearance (A) between the cover
bearing assembly (62). and cage, and check that it is as follows.
10] Install holder (59). a Clearance (A) : 0.48 ± 0.27 mm
3 Holder mounting bolt : a Make sure that the variation of entire
276.85 ± 31.85 Nm {28.25 ± periphery is 0.05 mm maximum, bear-
3.25 kgm} ings have been press fitted completely
and are not at an angle.
11] Tighten the mounting bolts of cover (58)

in the order shown in the following figure 13] Tighten the mounting bolts of cover (58)
and to the torque shown below, to install to the specified toque in the following
the cover temporarily. order.
3 Mounting bolts: 49 Nm {5 kgm} 3 Mounting bolt:
66.15 ± 7.35 Nm {6.75 ± 0.75
kgm}
D375A-6 50-161
(02)
DRAFT
Power train
14] Installing the shims to pinion housing 18] Using push tool [21], press fit bearing
assembly (57), and install the housing (53).
using eyebolts [11]. 19] Install bearing assembly (52) to the case.
a Standard thickness of shims: 2 mm 20] Install lubrication tube (51) together with
15] Install lubrication tube (56). the block.
16] Using push tool [20], press fit bearing 2) Install guide bolt [8] to the steering case.
inner races (55) to both sides of the drive Using eyebolts [9], install transfer and gear
gear. housing assembly (50) in position.
17] Set drive gear (54) to the case. 3 Mounting bolt:
2 Spline of gear: 276.85 ± 31.85 Nm {28.25 ± 3.25
Molybdenum disulphide lubri- kgm}
cant (LM-P)
50-162 D375A-6
(02)
DRAFT
Power train
6. Adjusting backlash and tooth contact 2] When backlash is too large

1) Adjusting backlash Adjust the thickness of the shim pack for
Testing the bevel pinion to move it in direction (C).
Apply the probe of dial gauge [22] to the tooth Or, adjust the thickness of the shim packs
surface at the top of the bevel gear at right for the bearing cages of the bevel gear
angle to the surface. Holding the bevel pinion shaft to move the bevel gear in direction
stationary, wiggle the bevel gear forward and (D).
and backward, and read the gauge at this a When adjusting the thickness of the shim
time. packs for the bearing cages of the bevel
a Standard backlash: 0.3 – 0.4 mm gear shaft, if the thickness of the shim
a Measure the backlash at diagonal three pack on one side is decreased, increase
points or more. the thickness on the other side by the
same quantity and vice versa, in order not
to change the preload of the bearings.
Adjusting
If the measured backlash is out of the stan-
dard range, adjust it according to the 2) Adjusting tooth contact
following procedure: Testing
1] When backlash is too small 1] Apply red lead thinly to the tooth surfaces
Adjust the thickness of the shim pack for of the bevel pinion and turn the bevel gear
the bevel pinion to move it in direction (A). in the forward and reverse directions,
Or, adjust the thickness of the shim packs then check the tooth contact pattern left
for the bearing cages of the bevel gear on tooth surfaces of the bevel gear.
shaft to move the bevel gear in direction (Be): Big end
(B). (Se): Small end
(Rt): Root of tooth
(Tt): Top of tooth
D375A-6 50-163
(02)
DRAFT
Power train
2] The standard values for the tooth contact

are as follows:
(From the small end of the bevel gear)
a) Width of tooth contact: 30 – 75%
b) Center of tooth contact: 25 – 50%
c) Position of tooth contact: 25 – 50%
a The standard values for the tooth contact
must be satisfied under the following con-
ditions; the taper roller bearings support-
ing the bevel gear are given with the
preload, the bevel gear is meshed only
with the bevel pinion, and no load is ap-
plied.
a Check that the center of tooth contact is at
the center of the tooth height and there is 2] If the bevel pinion is too close to the
not a strong contact at the dedendum. center line of the bevel gear, the contacts
The contact pattern must be made in are at the convex faces close to the big
almost the same position when the bevel end and concave faces close to the small
gear is rotated in forward and reverse end of the bevel gear.
directions. [Adjustment]
(Be): Big end The adjustment is the same as that
(Se): Small end described in step 1] except for reversed
direction (A) of the bevel pinion and for
reversed direction (B) of the bevel gear.
a When changing the position of the bevel
gear, if the thickness of the shim pack on
one side is decreased, increase the thick-
ness on the other side by the same quan-
tity and vice versa, in order not to change
the preload of the bearings.
Adjusting
If the tooth contact pattern is not proper,
adjust the tooth contact according to the
1] If the bevel pinion is too far from the
center line of the bevel gear, the contacts
are at the convex faces colse to the samll
end and at the concave faces close to the
big end of the bevel gear.
[Adjustment]
Adjust the thickness of the shim pack for
the bevel pinion to move the bevel pinion
in direction (A) .
Also move the bevek gear in direction (B)
by adjusting the thickness of the shim
packs for bearing cages of the bevel gear
shaft, then check the tooth contact
pattern and backlash again.
50-164 D375A-6
(02)
DRAFT
Power train
7. Steering control valve and seat assembly 10. Lubrication tube

1) Install steering control valve and seat Install lubrication tubes (47), (47-1), and (47-2).
assembly (2) in position.
2) As for the mounting bolts, tighten them after
installing pipes (48) described in the next
step.
q Mounting bolt:
49.0 ± 4.9 Nm {5.0 ± 0.5 kgm}
11. Clutch and brake assembly

1) Assemble the clutch and brake assembly as
follows:
1] Install Belleville springs (45).
a Set the belleville springs back to back
to install.
8. Pipes 2] Install seal ring (44) to piston (43).
1) Install pipe (49).
2) Install left and right pipes (48).
3] Install piston (43).

4] Install torque pins (42).
9. Shaft 5] Install seal ring (41) and bearing outer
Install left and right shafts (46). race (40) to the brake cage using the
push tool.
D375A-6 50-165
(02)
DRAFT
Power train
6] Using eyebolts [7], install brake cage (39) 2] Install brake hub (33) to the clutch
in position. housing, using eyebolts [6].
3 Mounting bolt: 3] Install Belleville springs (32).
110.25 ± 12.25 Nm {11.25 ± a Set the Belleville springs back to back
1.25 kgm} to install.
7] Install plates (38), springs (37), and discs
(36) in position.
a Check that a mating face between the
disc and plate is free from scratches
and foreign materials. Then, apply a
thin film of engine oil to the surface
and install.
4] Install outer race (31) to the clutch cage.

5] Install seal ring (30) to the piston.
6] Install piston (29).
8] Install stopper (35).

3 Mounting bolt:
276.85 ± 31.85 Nm {28.25 ±
3.25 kgm}
2) Assemble the clutch assembly as follows:

1] Using the push tool, install bearing (34) to
the brake hub.
7] Install seal ring (28) to the clutch cage.

8] Using eyebolts, install clutch cage (27) to
the housing.
9] Install bearing inner race (26), spacers

(25) and (24), and bearing inner race (23)
to cage (20).
50-166 D375A-6
(02)
DRAFT
Power train
10] Tighten nut (22) and install plate (21). 13] Install plate (17).
a Using the push tool, hold the cage 3 Mounting bolt:
with the press, and use a hook wrench 110.25 ± 12.25 Nm {11.25 ±
to tighten the nut. 1.25 kgm}
14] Set the guide bolts to the housing.
15] Using eyebolts, install clutch hub (16) in
position.
a Check that the rotating force of the
housing is 29.4 N {3 kg} or less and
that the housing rotates smoothly.
16] Install torque pins (15).
17] Install plates (14), springs (13), and discs

(12) in turn.
a Check that a mating face between the
disc and plate is free from scratches
and foreign materials. Then, apply a
thin film of engine oil to the surfaces
before installing.
11] Install bearing and cage assembly (19) in 18] Install stopper (11).
position. 3 Mounting bolt:
12] Using the push tool, install outer race (18) 276.85 ± 31.85 Nm {28.25 ±
to the plate. 3.25 kgm}
D375A-6 50-167
(02)
DRAFT
Power train
3) Connect the clutch assembly to the brake 4] Install plate (6).

assembly as follows: 3 Mounting bolt:
1] Using eyebolts [13], install brake 110.25 ± 12.25 Nm {11.25 ±
assembly (10) to clutch assembly (9). 1.25 kgm}
2] Using push tool [14], press fit bearing 5] Fit collar (5) and install plate (4).
inner race (8) to the sleeve. 4) Install the clutch brake assembly using
eyebolts.
3 Mounting bolt:
276.85 ± 31.85 Nm {28.25 ± 3.25
kgm}
3] Set sleeve (7) to the clutch and brake

assembly.
12. Final drive shaft

Install left and right final drive shafts (83) in posi-
tion.
a If the bevel gear is locked and it is hard to in-
sert the final drive shaft, release the steering
brake and insert the shaft.
Remove plugs (81) and bolts (82). Then,
screw in the bolts in the plug holes to
compress the clutch spring in order to
release the brake.
50-168 D375A-6
(02)
DRAFT
Power train
Removal and installation of power train pump and lubrication pump assembly
Removal and installation of power train pump and lubrication pump

assembly
Removal Installation
k Park the machine on a level surface and low- q Carry out installation in the reverse order to re-
er the work equipment to the ground. moval.
k Stop the engine, and disconnect the cable
from the negative terminal of the battery.
1. Remove the power train underguard (front).

4 Power train underguard (front): 280 kg
3. Disconnect tube (2).
4. Lift off power train pump and lubrication pump

assembly (3).
4 Power train pump and lubrication pump
assembly: 50 kg
D375A-6 50-169
(02)
DRAFT
Power train
Removal and installation of scavenging pump assembly
Removal and installation of scavenging pump assembly
Removal Installation
k Park the machine on a level surface and low- q Carry out installation in the reverse order to re-
er the work equipment to the ground. moval.
ment lock lever in the lock position. q Refilling (Power train case)
k Stop the engine, and disconnect the cable Supply oil through the oil filler to the specified
from the negative terminal of the battery. level. Run the engine to circulate the oil through
the system. Then check the oil level again.
1. Remove the power train underguard (front).
4 Power train underguard (front): 280 kg
2. Disconnect inlet tube (1).

a The oil in the piping will leak out, so prepare
a container to catch the oil.
3. Disconnect outlet tube (2).
4. Remove scavenging pump assembly (3).
50-170 D375A-6
(02)
DRAFT
Power train
Removal and installation of final drive assembly
Special tools
New/remodel
Necessity
Sketch
Sym-
Q'ty
Part No. Part name
bol
J 1 790-337-1001 Lifting tool t 1
Removal
k Stop the engine, and disconnect the cable
1. Separate the track shoe assembly. For details,

see "Separation of track shoe assembly".
2. Raise the machine off the ground by using jacks

or ripper, and set stand [1] under the frame.
5. Remove three bolts from the final drive, and

install tool J1 instead.
6. Sling final drive assembly (5), remove the

mounting bolts, and remove the final drive. [*2]
4 Final drive assembly: 2,300 kg
4. Pull out drive shaft (4) as follows: [*1]

2) Install eyebolts [2] to the drive shaft.
3) Pull out drive shaft (4).
a If it is difficult to pull out the shaft, push up the
shoe grouser by using jack [3] or other device
set on the ground to move the sprocket back-
ward and forward, and set the sprocket to a
position where the shaft can be pulled out
easily.
a Pull the shaft to a point where it touches the
sprocket.
D375A-6 50-171
(02)
DRAFT
Power train
Installation
moval.
[*1]
a If it is difficult to insert the shaft into position,
push up the shoe grouser by using a jack or oth-
er device set on the ground to move the sprocket
backward and forward, and set the sprocket to a
position where the shaft can be inserted easily.
[*2]
2 Final drive assembly mounting bolt :
Adhesive (LT-2)
3 Final drive assembly mounting bolt :
1,720 ± 190 Nm {175 ± 20 kgm}
q Refilling (Final drive case)

Supply the oil through the oil filler port to the
specified level.
5 Final drive case: Approx. 61 l (TO 30)
50-172 D375A-6
(02)
DRAFT
Power train
Disassembly and assembly of final drive assembly

Disassembly
Special tools
1. Draining oil
Remove the drain plug and drain the oil from the
New/remodel
Necessity
final drive case.
Sketch
6 Final drive case: Approx. 61 l
Sym-
Q'ty
Part No. Part name
bol
2. Sprocket
791-580-3200 Remover t 1
Puller 1) Place the final drive assembly on blocks
2 790-101-2102 t 1 (approx. 50 mm high).
(294 kN {30 ton})
790-101-1102 Pump t 1 2) Remove sprocket (1).
791-580-3300 Installer t 1
Puller
3 790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
4 790-431-1071 Installer t 1 N
791-580-3400 Remover t 1
Puller
5 790-101-2102 t 1
J (294 kN {30 ton})
790-101-1102 Pump t 1
791-580-3500 Installer t 1
Puller
6 790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
Remover and
790-431-1230 t 1
installer
7 Puller
790-101-2102 t 1
(294 kN {30 ton})
3. Cover
790-101-1102 Pump t 1
8 790-431-1250 Guide t 1 Using eyebolts [1], remove cover (2).
D375A-6 50-173
(02)
DRAFT
Power train
4. Hub
2) Using eyebolts [2], lift off hub (4).
4) Remove bearing inner race (8) from the

sprocket hub assembly.
5. Sprocket hub assembly

1) Remove holder (5).
5) Turn over the sprocket hub assembly, then

remove floating seal cover (9) and bearing
outer races (10) and (11).
2) Using tool J2, disconnect sprocket hub 6) Remove floating seal (12) from the floating
assembly (6) at the press-fitting portion of seal cover.
bearing (7). a Take care not to damage the floating
seal, and keep it in a safe place.
3) Using eyebolts [3], remove sprocket hub
assembly (6).
50-174 D375A-6
(02)
DRAFT
Power train
6. Wear guard
Lift off wear guard (13).
7. Cover assembly
1) Using eyebolts [4], remove cover assembly
(14).
4] Remove the plate, then remove ring gear

(19).
8. Carrier assembly
1) Remove carrier assembly (20) by using
eyebolts [5].
2) Disassemble the cover assembly as follows.
1] Remove floating seal cover (15).
2] Remove floating seal (16) from the
floating seal cover.
a Take care not to damage the floating
seal, and keep it in a safe place.
2) Disassemble the carrier assembly as follows.

1] Place the carrier assembly on the block
(approx. 100 mm high).
2] Remove spacer (26) and bearing (26-1).
3] Remove spacer (17) and bearing inner

race (18).
D375A-6 50-175
(02)
DRAFT
Power train
3] Remove holders (21). 9. Sun gear and shaft assembly

4] Using tool J7, remove planetary gear 1) Remove sun gear and shaft (25).
shafts (22). 2) Remove plate (25-1) and bearing inner race
(26-2).
3) Remove plate (25-2) and sun gear (27).
5] Remove planetary gears (23), bearing

inner races (24A) and (24B), and spacers
(24C). 10. Hub and shaft assembly
6] Pull out bearing outer races (24D).

2) Using tool J5, pull out hub assembly (29) and
bearing inner race (30) from shaft assembly
(31).
50-176 D375A-6
(02)
DRAFT
Power train
3) Disassemble the hub assembly according to 11. Cage assembly

the following procedure. 1) Using eyebolts [7], remove cage assembly
1] Remove gear (32) from hub (33). (39).
2] Remove hub (33) from boss (34). 2) Remove shims (40).
3] Using the puller, remove bearing outer a Note the quantity and thickness of shims
races (35) from boss (34). for installation purpose.
4) Using eyebolts [6], pull out shaft assembly 3) Disassemble the cage assembly as follows:
(31) from the case. 1] Using puller [8], remove bearing outer
5) Disassemble the shaft assembly as follows. race (41).
1] Remove collar (36). 2] Remove oil seal (42).
2] Remove bearing inner race (37) and
collar (38).
D375A-6 50-177
(02)
DRAFT
Power train
12. Gear assembly Assembly

1) Remove gear assembly (44). a Clean all parts, and check them for dint and
2) Using puller [9], remove bearing inner races dents. Apply engine oil to the sliding surface be-
(45) and (46) from the gear. fore installing.
1. Oil seal and bearing outer race

1) Using push tools [11], install oil seals (49).
a Install the lower oil seal with its pressure
receiving side down and the top oil seal
with its pressure receiving side up.
2 Oil seal lip:
Grease (G2-LI)
2 Oil seal press-fitting surface:
a Apply a thin film of liquid gasket on the in-
side surface of the case and wipe off any
liquid gasket that is squeezed out.
13. Outer race and oil seal

1) Using puller [10], remove bearing outer race
(48).
2) Remove oil seal (49) from the case.
2) Press fit bearing outer race (48) with push

tool [13].
50-178 D375A-6
(02)
DRAFT
Power train
2. Gear assembly 2] Press fit bearing outer race (41) with push
1) Using push tool [14], press fit bearing inner tool [15].
races (46) and (45) to the gear.
2) Set tool J8 to the case to install gear
assembly (44) in position.
a Do not remove tool J8 until the cage is in-
stalled.
2) Using eyebolts [7], set case assembly (39) to

the case, and equally tighten the cage
mounting bolts (C) and (D).
3 Mounting bolt: 14.7 Nm {1.5 kgm}
3. Cage assembly
1) Assemble the cage assembly as follows.
1] Using push tool [11], install oil seals (42).
a Install the lower oil seal with its pres-
sure receiving side down and the top
oil seal with its pressure receiving side
up.
2 Oil seal lip (OL):
Grease (G2-LI)
2 Oil seal press-fitting surface (OP):
a Apply a thin film of liquid gasket on the
inner surface of the case and wipe off
any liquid gasket that is squeezed out.
D375A-6 50-179
(02)
DRAFT
Power train
3) Using feeler gauge [16] as shown in the 4. Hub and shaft assembly
figure below, measure the clearances (a) and 1) Assemble the shaft assembly as follows.
(b) between cage (A) and case (B), at the two 1] Install collar (38).
points "m" distance away from bolts (C) and 2] Press fit bearing inner race (37) by using
(D), respectively. push tool [17].
4) Determine total thickness (c) of the shim 3] Install collar (36).
pack and select shims to use according the
table below.
5) Insert the shims selected in Step 4 in posi-
tion, and tighten four cage mounting bolts.
3 Mounting bolt:
227.3 ± 80.85 Nm {23.25 ± 8.25
kgm}
a Equally tighten the bolts while rotating the
gear by hand, and then remove tool J8.
2) Using eyebolts [6], install shaft assembly (31)

to the case.
3) Assemble the hub assembly as follows.
1] Using the push tool, press fit bearing
outer race (35) to boss (34).
Number of shims to be
(a) + (b) [mm]
used Total thick-
ness of
Larger t=
Below t = 0.5 t = 1.0 shims
than 0.1
(c) [mm]
1.6 1.8 1 1.0
1.8 2.0 1 1 1.1
2.0 2.2 2 1 1.2
2.2 2.4 3 1 1.3
2.4 2.6 4 1 1.4
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 2.2
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
50-180 D375A-6
(02)
DRAFT
Power train
2] Set boss (34) to hub (33).

4) Set shaft assembly (31) to hub assembly
(29). Using tool J6, press fit bearing (30)
portion.
6. Carrier assembly
1) Assemble the carrier assembly as follows.
a As each bearing of the planetary gear is a
selective combination part, match the ID
5) Tighten mounting bolts of hub assembly (29). marks on the inner race, outer race and
3 Mounting bolt:
spacer when assembling.
276.85 ± 31.85 Nm {28.25 ± 3.25 *1. Bearing ID mark
kgm} *2. Spacer ID mark
(ID mark "MZ-12B" is an example in this
figure.)
3 Mounting bolt:
548.8 ± 58.8 Nm {56 ± 6 kgm}
7) Install gear (32).
3 Mounting bolt:
539 ± 49 Nm {55 ± 5 kgm}
1] Install the rings and spacer to the plane-

tary gear. Using push tool [18], press fit
upper and lower bearing outer races
(24D) into position.
5. Sun gear
1) Install inner race (26-2) to the shaft of plate
(25-1).
2) Install sun gear (27) to the shaft of plate
(25-2).
3) Install shaft (25).
D375A-6 50-181
(02)
DRAFT
Power train
2] Install spacer (24C) and bearing inner 2) Install bearing (26-1) and spacer (26) to
races (24B) and (24A) to each planetary carrier assembly (20).
gear (23), and set it to the carrier.
3) Using eyebolts [5] , install carrier assembly

3] Using tool J7, press fit planetary gear (20).
shaft (22) in position.
a Press fit the shaft gradually matching 7. Cover assembly
the holes of the bearing and spacer. 1) Assemble the cover assembly as follows.
4] Install holder (21). 1] Fit ring gear (19) and install the plate.
3 Mounting bolt: a Install the plate with its chamfered sur-
548.8 ± 58.8 Nm {56 ± 6 kgm} face up.
a After tightening the bolts, check that
each gear rotates smoothly.
50-182 D375A-6
(02)
DRAFT
Power train
2] Using tool J3, press fit bearing inner race

(18).
3] Install spacer (17).
a Install the floating seal cover with its

cut-out portion facing down as shown
in the diagram below.
4] Using tool J4, press fit floating seal (16) to
the floating seal cover.
a Thoroughly degrease and dry the
O-ring and O-ring contact surfaces of
the floating seal before installing.
a After installing the floating seal, check
that its leaning is less than 1 mm.
2) Using eyebolts [4], hoist cover assembly (14)

to install.
a Apply the 1216 ThreeBond adhesive to
the mating surfaces.
8. Wear guard
Hoist wear guard (13) to install.
5] Install floating seal cover (15).
a Fit a cork plug in the forcing tap.
D375A-6 50-183
(02)
DRAFT
Power train
9. Sprocket hub assembly 4) Set bearing (8) to the sprocket hub

1) Using tool J4, install floating seal (12) to the assembly.
floating seal cover.
a Thoroughly degrease and dry the O-ring
and O-ring contact surfaces of the floating
seal before installing.
a After installing the floating seal, check
that its leaning is less than 1 mm.
5) Using eyebolts [3], sling sprocket hub

assembly (6) and set it to the cover.
a Check that the sliding surface of floating
seal is free from dirt, and apply a thin film
of engine oil on it.
2) Using the push tool, press fit bearing outer

races (11) and (10).
3) Install floating seal cover (9).
6) Using tool J3, press fit bearing (7) portion.

a Press fit the sprocket hub assembly while
rotating it by hand.
50-184 D375A-6
(02)
DRAFT
Power train
7) Install holder (5). 12. Sprocket

2 Mounting bolt: Adhesive (LT-2) Install sprocket (1).
3 Mounting bolt: 2 Mounting bolt:
276.85 ± 31.85 Nm {28.25 ± 3.25 Molybdenum disulphide lubricant
kgm} (LM-P)
3 Mounting bolt:
1,813 ± 98 Nm {185 ± 10 kgm}
13. Refilling of oil

Tighten the drain plug, and supply engine oil
through the filler port.
5 Final drive case: Approx. 61 liters
a After installing the final drive assembly on the
machine, finally check that the oil is at the
specified level.
10. Hub
1) Lift hub (4) using eyebolts [2], and install the
hub in position.
11. Cover
Using eyebolts [1], install cover (2) in position.
D375A-6 50-185
(02)
DRAFT
Removal and installation of track frame assembly

Special tools
New/remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
195-30-68610 Plate t 6 N
01010-62450 Bolt t 6
01010-62455 Bolt t 6
22
19M-54-11770 Washer t 6 N
01643-32460 Washer t 6
198-30-66190 Collar t 6 N
L
195-30-69540 Plate t 2 N
01011-82410 Bolt t 2
23 01011-82420 Bolt t 2
19M-54-11770 Washer t 4 N 5. Using tools L22 and L23, lcok the bogies.
195-30-69550 Collar t 2 N 6. Remove cover (1).
24 791-685-1320 Lifting tool t 1
Removal
see "Separation and connection of track shoe
assembly".
1-1. Place blocks [3] (at right and left sides)
between the equalizer bar and frame, to lock the
equalizer bar.
2. Raise the machine off the ground by using the

ripper or a crane, place stands [1] under the
frame, and lift the rear of machine off the ground.
k Stand [1] must be able to support the
weight of 25 tons or more .
3. Place hydraulic jack [2] (490 kN {50 ton}) at the

center of the equalizer bar, and lift the front of the
machine off the ground.
4. Sling the track frame assembly.
50-186 D375A-6
(02)
DRAFT
7. Remove cover (2). [*1] 13. Remove the mounting bolts and remove cover
8. Remove grease tube (4). (7) from the track frame.
9. Remove cover (3). [*1]
10. Loosen front and rear bolts (6-1). [*2]
a Bolt: M30; Width across flats: 46 mm
12. Place a pad on the rear of pin (6), and drive out
the pin by hammering. [*3]
a If the equalizer bar hole is not aligned with
the track frame hole, the pin cannot be re-
moved easily. Adjust the lifting height of
the track frame properly.
a Put "UP" mark on the top of the pin for in-
stallation purpose.
15. Disconnect lower hose (9) and upper hose (10)

of the blade tilt cylinder.
a Perform this step for only the right track
frame of the single tilt specification machine,
or both track frames of the dual tilt specifica-
tion machine.
16. Remove the mounting bolts and cover (11).

a Take care not to damage the hose connected
to the inside face of the cover.
D375A-6 50-187
(02)
DRAFT
17. Disconnect hoses (12) and (13) from the inside 19. Remove seal (15) and cover (14) as a unit. [*6]
face of cover (11), and remove cover (11). [*4] a Perform this step for only the right track
a Perform this step for only the right track frame of the single tilt specification machine,
frame of the single tilt specification machine, or both track frames of the dual tilt specifica-
or both track frames of the dual tilt specifications machine.
tions machine.
a Note the color of hose band for installation 20. Remove washer (16) and spacer (17).
purpose.
(Single tilt)
(12a) (13a)
Right track frame: Red -
(Dual tilt)
(12a) (13a)
Right track frame: Red -
(12a) (13a)
Left track frame: Blue -
RH: Both dual tilt and single tilt specifications
LH: Dual tilt specification

21. Using tool L24, lift off track frame assembly (18).
4 Track frame: 7,940 kg (each)

a Three mounting bolts are used on the track
frame, and six bolts are used on the pivot
frame.
a Take care not to damage O-rings.
a As the oil drains from the pivot shaft case,
place an oil container to receive it.
6 Pivot shaft case:18 l
50-188 D375A-6
(02)
DRAFT
Installation q Carry out the subsequent installation in the re-

a Take care not to install seal (19) twisted to the verse order to removal.
track frame.
a When replacing seal (19), see "Removal and in- [*1]
stallation of pivot shaft assembly". a Install covers (2) and (3), and tighten bolts (6-1).
3 Covers (2) and (3):
245 – 309 Nm {25 – 31.5 kgm}
[*2]
3 Bolt (6-1):
1,960 – 2,450 Nm {200 – 250 kgm}
[*3]
2 Inside surface of bushing: Grease (G2-LI)
a Install pin (6) with the "UP" mark on it up, a mark
put upon removal.
a Align the notch of pin (6) with the left and right of
machine.
2 Apply G2-LI grease on (GR) portions before

installing equalizer bar (EB), bushing (7) and
pin (6).
a Before installing pin (6), adjust the lifting height
of the track frame so that the hole of equalizer
bar (EB) matches the center of track frame hole.
a When aligning the pin holes, never insert your
fingers in them.
2 Bushing contact surface on pivot shaft:
Molybdenum disulphide lubricant (LM-P)
a When replacing the pivot shaft bushing of track
frame assembly, install a new bushing with its
abutment joint up. .
D375A-6 50-189
(02)
DRAFT
[*4] [*5]
q Install the hoses taking care not to install hoses a Install cover (14) using three bolts (indicated by
with wrong band colors. arrows).
a Hose band colors
(Single tilt specification) [*6]
(12a) (13a) a Completely degrease the contact surface (15) of
Right track frame: Red - seal when mounting it.
(Dual tilt specification) 2 Contact surface of seal (15): Liquid gasket
(12a) (13a) (LG-6)
Right track frame: Red - a Be careful not to twist the seal when installing it.
(12a) (13a)
Left track frame: Blue -
q Refilling (Pivot shaft case)

level.
5 Pivot shaft case: 18 l (EO30)
50-190 D375A-6
(02)
DRAFT
Removal and installation of idler assembly
Removal and installation of idler assembly

Installation
Removal q Carry out installation in the reverse order to re-
1. Separate the track shoe assembly. For details, moval.
see "Separation and connection of track shoe
assembly". a For both the right and left idler assemblies,
install the assembly with the oil filler plug fac-
2. Remove scraper (1). ing the left side of machine.
a Remove the inside scraper, too. a Tighten idler cap mounting bolts in the follow-
ing order.
3. Remove cover (2). Tightening order:
a Remove the inside cover, too. 1] Two bolts at side (a)
2] Two bolts at side (b)
3] Two bolts at side (a)
4] Tighten all bolts to the specified torque.
3 Mounting bolt:
1,470 - 1,813 Nm {150 - 185 kgm}
a After tightening the idler cap mounting bolts,
check that clearance (c) between the bottom
of idler cap and the yoke is zero.
4. Sling the idler assembly, and remove idler cap

(3).
a For both the left and right idler assemblies, a
ball is installed to the left idler cap. Take care
not to lose the ball.
5. Lift off idler assembly (4).

4 Idler assembly: 480 kg
D375A-6 50-191
(02)
DRAFT
Disassembly and assembly of idler assembly

4. Turn over idler assembly (1).
Special tools
Necessity
5. Remove the mounting bolts. Using eyebolts [3],
Quantity
Sketch
Sym-
N/R
Part No. Part Name remove shaft (5) and the retainer as a unit.
bol
791T-630-2210 Plate t 1 Q 6. Using puller [4], remove retainers (3) and (7),
791-530-1630 Rod t 2 and seal guide (6).
790-101-2510 Block t 1
790-101-2570 Washer t 2
1 01580-01613 Nut t 2
L 01643-31645 Washer t 2
Puller
790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
2 791-515-1520 Installer t 1
3 791-685-8310 Push tool t 1
4 791-601-1000 Oil pump 1
Disassembly
1. Remove the oil filler plug to drain oil.
6 Idler: 0.95 – 1.05 l
2. Place idler assembly (1) on blocks [1] (approx. 7. Remove seal guides (2) and (6) from retainers
140 mm high). (3) and (7) respectively.
3. Remove mounting bolts, then using forcing 8. Remove plates (4) and (8) from the respective
screws [2], remove seal guide (2), retainer (3) retainers.
and plate (4) as a unit.
50-192 D375A-6
(02)
DRAFT
9. Remove respective floating seals (9) from seal Assembly

guides (2) and (6). a Clean all parts and check them for dirt and dam-
a Keep the floating seal in a safe place so that age before installing.
it does not get damaged.
1. Place bushings (11) and tool L1 on idler (12),
10. Remove respective floating seals (10) from and press fit bushings (11) in position.
retainers (3) and (7). a First, center the bushing with a plastic ham-
a Keep the floating seal in a safe place so that mer, then press fit with the puller.
it does not get damaged. a Press fit the bushing so that press-fitting di-
mension (a) from the end face of the idler to
the top surface of the bushing is as follows.
q Press-fitting dimension (a): 17 ± 0.5 mm
11. Remove bushings (11) from idler (12).
2. Using tool L2, install respective floating seals

(10) to seal guides (3) and (7).
a Completely degrease and dry the O-ring and
the O-ring contact surfaces (hatched por-
tions) of floating seal.
a Apply oil to the sliding surface of floating seal,
and take care not to allow dirt and foreign
matter to attach on the seal.
a After installing the floating seal, check that its
leaning is less than 1 mm and that the protru-
sion (a) of the seal is between 7 to 11 mm.
D375A-6 50-193
(02)
DRAFT
3. Install retainer (3) with the O-ring and plate (4) to 6. Install retainer (7) with the O-ring and plate (8) to
the idler. the idler.
a Check that the plate can be turned smoothly
with the hand.
7. Using tool L2 install respective floating seals (9)

. to seal guides (2) and (6).
a For installation procedures, refer to Step 2.
4. Using eyebolts [3], install idler (12) to shaft (5).

a Place blocks (approx. 140 mm high) under 8. Set seal guide (2) to the shaft, and press fit seal
the idler. guide (2) by using tool L3.
a Press-fitting force of seal guide: 43 – 71 kN
5. Turn over the idler assembly. {4.4 – 7.2 tons}
a Tie the shaft with wire to prevent it from fall-
ing out.
50-194 D375A-6
(02)
DRAFT
a Press fit the seal guide so that press-fitting di-

mension (b) from the end face of the shaft to
the top surface of the seal guide is as follows.
q Press-fit dimensions (b): 102 ± 0.2 mm
a Turn over the idler assembly and repeat the
same procedure to press fit the seal guide (6)
on the opposite side.
9. Using tool L4, supply oil to the specified level

and tighten the oil filler plug.
6 Idler: 0.95 – 1.05 l (GO140)
3 Oil filler plug: 206 ± 49 Nm {21 ± 5
kgm}
VT: To vacuum tank
OP: To oil pump
D375A-6 50-195
(02)
DRAFT
Removal and installation of recoil spring assembly

5. Lift off trunnion (3).
Special tools 4 Trunnion: 75 kg
New/remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
791-730-1110 Bolt t 6
01580-12722 Nut t 6
01643-32780 Washer t 1
M 1
Puller
790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
Removal
see “Separation and connection of track shoe 6. Remove cover (4).
assembly.” a Remove both the inside and outside covers.
k Set the parking brake lever and work
equipment lock lever in the lock position. 7. Using tool M1, remove pin (5). [*1]
k Stop the engine and disconnect the cable a Remove both the inside and outside pins.
from the negative (-) terminal of the bat-
tery.
2. Drain the oil from the recoil cylinder chamber by
using the oil pump.
6 Recoil cylinder chamber: Approx. 50 l
3. Using eyebolts [1], remove cover (1).

4 Cover:40 kg
50-196 D375A-6
(02)
DRAFT
8. Lift off the idler and idler cushion assembly (6). 2) Loosen idler yoke assembly mounting bolts
[*2] (9) on diagonally opposite sides gradually in
a Keep the assembly horizontal by using lever turn. [*4]
blocks, and take care not to damage the oil k For safety reasons, no one is allowed
seal installed on the track frame during re- to be in front of the idler yoke during
moval. the work.
4 Idler and idler cushion assembly: k The recoil spring mounted in the recoil
2,180 kg cylinder is under the installed load of
approximately 500 kN {approx. 51
tons}. Never loosen the mounting
bolts quickly. Gradually loosen the
bolts until clearance (a) between the
idler yoke and recoil cylinder flange
(FL) becomes 8 to 12 mm.
9. Disconnect idler cushion assembly (7) from idler

yoke assembly (8) according to the following
procedure. [*3]
1) Place idler yoke assembly (8) on the ground,
and sling idler cushion assembly (7).
a Check the welded area of idler cushion
assembly (7) for any defect.
a Protect the chrome plated bushing (CP)
by covering it with cloths.
D375A-6 50-197
(02)
DRAFT
3) Check that the loosening torque of all the 1] Prepare the following parts of tool M1:
bolts suddenly drop. If so, it indicates that the q Bolt [1] (6 bolts): Part No.
installed load of the recoil spring is not 791-730-1110
applied on the mounting bolts. Then, remove q Nut [2] (6 nuts): Part No. 01580-12722
all bolts. q Washer [3] (6 washers): Part No.
a If the torque increases (the installed load 01643-32780 (may be used ones)
of the recoil spring is applied) during the
loosening operation, stop the loosening
operation and disassemble as follows.
k If the torque is not reduced in Steps (2)
or (3) and if the loosening torque is still
large, recoil spring set bolt (10) may be
broken or shaft end nut (11) may fall
out. In such a case, the idler yoke as-
sembly may fly off to the front of the
machine. Disassemble it as follows:
k Do not allow anyone to remain in front
of the idler yoke or at the back of the
recoil cylinder until the idler yoke as-
sembly is separated from the idler
cushion assembly and the recoil
2] Remove six bolts marked with*, then
spring is removed.
install bolts [1], nuts [2], and washers [3].
a Check that dimension (L) is below 30
mm.
a Screw in bolts [1] until they reach the
bottom of yoke threaded holes.
3] Remove remaining twelve bolts (those
not marked).
4] Hold bolts [1] with a wrench to prevent
them from turning, and loosen two nuts
[2] simultaneously on diagonally opposite
sides.
a Take care not to let the load bear on
only one bolt.
50-198 D375A-6
(02)
DRAFT
5] Loosen bolts until the recoil spring is 12. Disassemble piston assembly (15) as follows.
extended completely and the loosening 1) Remove wear rings (16) from the piston.
torque of nuts [2] is reduced. Then, 2) Remove snap ring (17), then remove packing
remove bolts [1]. (18).
a When clearance (b) reaches approx.
230 mm, the spring is extended com-
pletely.
13. Remove recoil spring assembly (19).

4 Recoil spring assembly: 550 kg
10. Remove ring (12).
14. Remove holder (20) from the recoil spring

assembly.
11. Pump in grease through lubricator (13), and
remove cylinder (14) and piston assembly (15).
D375A-6 50-199
(02)
DRAFT
Installation
moval.
3 Cover mounting bolt:
277 ± 32 Nm {28.25 ± 3.25 kgm}
[*1]
a Before installing the pin, align the dowel hole in
the track frame with the dowel pin on the recoil
cylinder by using a pinch bar.
[*2]
a Keep the assembly horizontal by using lever
blocks, and take care not to damage the oil seal
installed on the track frame during installation.
[*3]
a If the recoil spring set bolt is broken or the shaft
end nut falls out, see "Disassembly and assem-
bly of idler cushion assembly".
[*4]
2 Idler yoke assembly mounting bolt :
Adhesive (LT-2)
3 Idler yoke assembly mounting bolt :
1,519 – 1,911 Nm {155 – 195 kgm}
a To prevent a trapped air in the cylinder, pump in

grease as follows:
1) Refill the cylinder with approx. 1.3 liters of
grease.
2) Set the cylinder with the drain hole up, then
loosen the lubricator.
3) Push the piston until it reaches the stopper to
remove any air and excess grease from the
cylinder.
50-200 D375A-6
(02)
DRAFT
Disassembly and assembly of recoil spring assembly

4. Remove rear pilot (5), spacer (6), bolt (7), and
Special tools pilot (8) from spring (4).
Necessity
Quantity
Sketch
Sym-
N/R
Part No. Part Name
bol
791-685-8501 Compressor t 1
Cylinder
790-101-1600 t 1
M 2 (980 kN {100 ton})
790-101-1102 Pump t 1
791-635-3160 Extension t 1
Disassembly
1. Set recoil spring assembly (1) to tool M2.
k As the spring is under high installed load,
so set the assembly correctly to the tool.
a Installed load of spring: Approx. 500 kN {ap-
prox. 51 tons}
2. Apply hydraulic pressure slowly to compress the

spring, then remove lock plate (2) and remove
nut (3).
3. Release hydraulic pressure gradually and

relieve tension of the spring.
D375A-6 50-201
(02)
DRAFT
Assembly 3. Install nut (3), and install lock plate (2) in posi-
1. Install pilot (8), bolt (7), spacer (6), and rear pilot tion.
(5) to spring (4), and set them to tool M2. a To prevent the nut from protruding from the
end of bolt (7), make a clearance of 0 – 1.0
mm between the nut and lock plate.
a Bring lock plate (2) and bolt (7) (CE portion)
into tight contact to secure.
2 Lock plate mounting bolt:
Adhesive (LT-2)
4. Gradually release hydraulic pressure to reduce

the spring tension, and them remove recoil
spring assembly (1) from tool M2.
k As the spring will be under high installed

load, so set them correctly to the tool.
2. Apply hydraulic pressure gradually to compress

the spring until the spring installed length is the
standard length.
a Installed length (a) of spring: 1,329.5 mm
a Installed load of spring: 500 kN {50,994 kg}
50-202 D375A-6
(02)
DRAFT
Removal and installation of track roller assembly
Special tools Removal

1. Decrease the track tension. For details, see
New/remodel
Necessity
"Separation and connection of track shoe
Sketch
Sym-
Q'ty
Part No. Part name assembly".
k Set the parking brake lever and work
bol
equipment lock lever in the lock position.

790-401-1700 Lifting tool t 1
790-401-1761 Adapter t 1
12 from the negative (-) terminal of the bat-
790-401-1540 Shackle t 2
790-401-1770 T-bolt t 2 tery.
195-30-68610 Plate t 6 N
01010-62450 Bolt t 6 2. Install tools L22 or L23 to lock bogie assembly
01010-62455 Bolt t 6 (1) to be removed. [*1]
22
L 19M-54-11770 Washer t 6 N S: Single flange type
01643-32460 Washer t 6
D: Double flange type
198-30-66190 Collar t 6 N
195-30-69540 Plate t 2 N
01011-82410 Bolt t 2
23 01011-82420 Bolt t 2
19M-54-11770 Washer t 4 N
195-30-69550 Collar t 2 N
D375A-6 50-203
(02)
DRAFT
3. Raise the machine until track roller assembly (2) 7. Using the crane and tool L12, pull out track roller
leaves the track by operating the blade and assembly (2) on the steed plate to the outside of
ripper. the machine.
4 Track roller assembly:
4. Place steel plate [1] on the track and operate the 150 kg (single flange)
blade and ripper to lower the machine until the 160 kg(double flange)
track roller assembly comes in contact with the
steel plate.
a Operate the blade and ripper slowly, running
the engine at the low speed.
5. Remove the mounting bolts, and place track

roller assembly (2) on steed plate [1].
6. Raise the machine until track roller assembly (2)

leaves the bogie by operating the blade and
ripper.
50-204 D375A-6
(02)
DRAFT
Installation
moval.
[*1]
a After removing tool L22, replace the mounting
bolt of cover (3) with the normal bolt.
3 Cover mounting bolt :
927 ± 103 Nm { 94.5 ± 10.5 kgm}
a Note that the installation location differs be-

tween single flange and double flange track
roller assemblies. Install them in the correct
locations.
S : Single flange
D: Double flange
a Install the track roller assembly with the oil
filler plug outside.
D375A-6 50-205
(02)
DRAFT
Disassembly and assembly of track roller assembly

6. Using the press, remove seal guide (6), retainer
Special tools (7) and plate (8) as a unit from the shaft.
New/remodel
7. Remove seal guides (2) and (6) from retainers
Necessity
(3) and (7).
Sketch
Sym-
Q’ty
Part No. Part Name
bol
8 791T-630-2220 Plate t 1 Q
9 796-670-1020 Installer t 1
L
10 791T-630-2230 Push tool t 1 Q
11 791-601-1000 Oil pump t 1
Disassembly
1. Remove oil filler plug to drain oil.
6 Track roller: 1.4 – 1.5 l
2. Place track roller assembly (1) on block [1].
3. Remove the mounting bolts, then using forcing 8. Remove respective floating seals (9) from seal
screws [2], remove seal guide (2), retainer (3) guides (2) and (6).
and plate (4) as a unit. a Keep the floating seal in a safe place to pro-
tect it from damage.
4. Turn over the track roller assembly.
9. Remove respective floating seals (10) from
5. Remove the mounting bolts, then using eyebolts retainers (3) and (7).
[3], remove shaft (5) and the retainer as a unit. a Keep the floating seal in a safe place to pro-
tect it from damage.
50-206 D375A-6
(02)
DRAFT
10. Remove bushings (11) from roller (12). 3. Using tool L9, install respective floating seals
(10) to retainers (3) and (7).
4. Install the O-rings, and install retainers (3) and

(7) and plate (8) to the roller.
a Check that the plate can be turned smoothly
with the hand.
Assembly
a Clean all parts, and check them for dirt and dam-
1. Set roller (12) on the press. Using tool L8, press

fit bushings (11) in position.
a First, center the bushing by using a plastic 5. Using tool L9, install respective floating seals (9)
hammer, then press fit it with the press. to seal guides (2) and (6).
a Press fit the bushing so that press-fitting di-
mension (a) from the end face of the roller to 6. Using tool L10, press fit seal guide (2) to the
the top surface of the bushing is as follows . shaft.
q Press-fitting dimensions (a): 17 ± 0.5 mm
a Seal guide press-fitting force:
36 – 63 kNm {3.7 – 6.4 ton}
2. Set shaft (5) to the roller.
D375A-6 50-207
(02)
DRAFT
a Press fit the seal guide so that press-fitting di-

mension (b) from the end face of the shaft to
the top surface of the seal guide is as follows.
q Press-fitting dimensions (b): 77 ± 0.2 mm
a Turn over the track roller assembly and press
fit seal guide (6) on the opposite side accord-
ing to the above procedure.
7. Using tool L11, refill with the specified amount of

oil and tighten the oil filler plug.
6 Track roller: 1.4 ± 1.5 l (GO140)
3 Oil filler plug:206 ± 49 Nm {21 ± 5 kgm}
50-208 D375A-6
(02)
DRAFT
Removal and installation of carrier roller assembly
Removal and installation of carrier roller assembly

Installation
1. Decrease the track tension. For details, see moval.
"Sepatation and connection of track shoe
assembly". [*1]
k Set the parking brake lever and work a Make a clearance (a) of 1.75 mm between the
equipment lock lever in the lock position. carrier roller and support.
k Stop the engine and disconnect the cable 2 Carrier roller assembly mounting bolt :
from the negative (-) terminal of the bat- Adhesive (LT-2)
tery. 3 Carrier roller assembly mounting bolt :
662 – 829 Nm {67.5 – 84.5 kgm}
2. Push up the track by using hydraulic jack [1].
3. Lift off carrier roller assembly (1). [*1]

4 Carrier roller assembly: 75 kg
D375A-6 50-209
(02)
DRAFT
Disassembly and assembly of carrier roller assembly

5. Using tool L7, remove nut (4).
Special tools
Necessity
6. Using puller [2], remove the press-fitted seal
Quantity
Sketch
Sym-
N/R
Part No. Part Name guide, and remove bearing (5) and roller (6) as a
bol
unit using eyebolts.
4 791-601-1000 Oil pump t 1
5 791-515-1520 Installer t 1
L
6 791-830-1770 Push tool t 1
7 791-630-1270 Wrench t 1
Disassembly
1. Remove the oil filler plug to drain oil.
a Drain the oil while rotating the shaft.
6 Carrier roller: 0.7 – 0.8 l
2. Place carrier roller assembly (1) on block [1].
3. Remove the mounting bolts and cover (2).

7. Remove bearing outer race (7) from the roller.
4. Remove snap ring (3).
8. Remove seal guide (8) and bearing inner race
(9) as a unit by using puller [3].
50-210 D375A-6
(02)
DRAFT
9. Remove floating seal (10) from seal guide (8). Assembly

a Clean all parts, and check them for dirt and dam-
1. Press fit bearing inner race (9) with push tool [5].
2. Press fit bearing outer race (7) with push tool [6].
10. Remove seal guide (11) with push tool [4].
11. Remove floating seal (12) from seal guide (11).
3. Set roller (6) and bearing inner race (5) to the

shaft.
4. Using push tool [7], press fit bearing inner race

(5) to the shaft.
a Press fit the bearing inner race, turning the
roller, until the roller becomes a little hard to
turn.
D375A-6 50-211
(02)
DRAFT
5. Using tool L7, tighten nut (4).

3 Nut: 98 Nm {10 kgm}
a After the nut is tightened, If the nut hole is not
aligned with the shaft hole, loosen the nut to
align them.
6. Install snap ring (3).

a Check that the end play (clearance between
bearing and nut) is within 0.01 – 0.22 mm.
7. Install cover (2) with the O-ring.
8. Using tool L5, install floating seal (10) to seal

guide (8).
9. Fit the O-ring to seal guide (8) and install them,

matching the dowel hole to the dowel pin.
a Completely degrease and dry the O-ring and
the O-ring contact surfaces (shaded area) of
the floating seal before installing. Also, take
care not to allow dirt to attach the floating
seal contact surfaces.
a After installing the floating seal, check that its
learning is less than 1 mm and that the pro-
trusion (a) of the seal is between 7 to 11 mm.
50-212 D375A-6
(02)
DRAFT
10. Using tool L5, install floating seal (12) to seal

guide (11).
a For precautions for installing the floating
seal, see a in Step 9.
11. Using tool L6, press fit seal guide (11) in posi-
tion.
a Press fit the seal guide so that dimension (a)
between the shaft end surface and seal
guide top surface is 158.75 ± 0.2 mm.
a After press-fitting of the seal guide, check
that its learning from the shaft is less than 1
mm.
12. Using tool L4, supply the specified amount of oil

and tighten the oil filler plug.
6 Carrier roller: 0.7 – 0.8 l (GO140)
3 Oil filler plug: 157 – 255 Nm {16 – 26 kgm}
D375A-6 50-213
(02)
DRAFT
Removal and installation of bogie assembly
New/remodel
Special tools
Necessity
New/remodel
Sketch
Q'ty
Necessity
Sketch
1 791-630-2260 Plate t 1
Q'ty
2 791-630-2270 Screw t 3
1 791-630-2260 Plate t 1 3 01580-12419 Nut t 3
2 790-201-2730 Spacer t 1 16 4 01643-32460 Washer t 3
3 791-630-2270 Screw t 3 Puller
5 790-101-4000 t 1
4 01580-12419 Nut t 3 (490 kN {50
14
5 01643-32460 Washer t 3 6 790-101-1102 Pump t 1
Puller
6 790-101-4000 t 1 17 791T-630-2290 Guide t 2 Q
(490 kN {50 ton})
18 791-530-1510 Installer t 1
7 790-101-1102 Pump t 1
19 791-601-1000 Oil pump t 1
L 1 791-630-2280 Adapter t 1 L 195-30-68610 Plate t 6 N
2 790-201-2770 Spacer t 1
01010-62450 Bolt t 6
3 791-630-2250 Plate t 1
01010-62455 Bolt t 6
4 790-434-1070 Screw t 1 22
19M-54-11770 Washer t 6 N
15 5 01580-13629 Nut t 2
01643-32460 Washer t 6
6 01643-33690 Washer t 2
198-30-66190 Collar t 6 N
Puller
7 790-101-4000 t 1 195-30-69540 Plate t 2 N
(490kN {50ton}) 01011-82410 Bolt t 2
8 790-101-1102 Pump t 1 23 01011-82420 Bolt t 2
19M-54-11770 Washer t 4 N
195-30-69550 Collar t 2 N
Removal
1. Decrease the track tension. For details, see "Separation and connection of track shoe assembly".
k Set the parking brake lever and work equipment lock lever in the lock position.
k Stop the engine and disconnect the cable from the negative (-) terminal of the battery.
2. Install tool L22 or L23 to lock the bogie assembly to be removed.
50-214 D375A-6
(02)
DRAFT
3. Raise the machine body until the track rollers 8. Removal of shaft and ring
leave the track links, by operating the blade and 1) Set tool L14 in position.
ripper. 2) Push out shaft (3) and ring (4) to the opposite
k Place a block between the track roller and side simultaneously.
the track link so that the machine does a Pressing force: 137.2 – 274.4 kN {14 – 28
not lower. tons}
Pressing force C 1.8 x Average pressure
4. Set block [1] outside of the track shoes, (Set the pressing force by adjusting the
matching it to the height of the track link. relief pressure of the link press.)
5. Place steel plate [2] on the track shoes and block

[1].
6. Operate the blade and ripper to lower the

machine until the track roller of bogie assembly
(1) touches steel plate [2].
a Operate the blade and ripper slowly, running
the engine at low speed.
3) Remove respective floating seals (5) from

the end faces of rings (4) and (7).
a Keep the floating seal in a safe place so
that it does not get damaged.
7. Remove (outside and inside) covers (2).
D375A-6 50-215
(02)
DRAFT
4) Set tool L15 in position.

5) Pull out spacer (6) and rings (7) and (8).
a Pulling force: 205.8 – 382.2 kN {21 – 39
tons}
13. Last bogie

1) Perform Step 1 and Steps 3 to 6 for the last
bogie.
6) Remove spacer (6). 2) Sling bogie assembly (1).

7) Remove spacer (9) and floating seals (10)
between rings (7) and (8). 3) Loosen roller cap bolts (20) for approx. 20
a Keep the floating seal in a safe place so mm. (Loosen both the inside and outside
that it does not get damaged. bolts.)
8) Pull out the shaft and rings on the opposite
side of the bogie according to above steps 1) 4) Hit the end of shaft (21) with a hammer to
to 7). remove track roller assembly (22).
a Take care not to damage the dowel pin in-
stalled to the shaft of the track roller as-
sembly. (Insertion depth of dowel pin: 5 –
6 mm)
5) Remove roller cap bolts (20), and place track

roller assembly (22) on the steel plate, and
pull it out.
4 Track roller assembly: 150 kg
9. Remove tool L22 or L23 that locks the bogie to

be removed.
10. Place bogie assembly (1) on steel plate [2].
11. Operate the blade and ripper to raise the

machine body until the bogie assembly can be
pulled out.
k Place a block between the track roller and
track link so that the machine does not
lower.
7) Perform Steps 9 to 13 to remove bogie
12. Sling bogie assembly (1), slide it on steel plate assembly (1).
[2] to remove. 4 Bogie assembly: 150 kg
4 Bogie assembly: 720 kg
50-216 D375A-6
(02)
DRAFT
Installation 2. Apply lever block [3] between the guard of bogie

1. Assembly of pin assembly. assembly (1) and that of the bogie assembly on
1) Using tool L18, install respective floating the opposite side, slide bogie assembly (1) on
seals (5) to rings (4) and (7). Also, install the steel plate, and place it in the mounting posi-
respective floating seals (10) to the opposite tion.
surface of ring (7) and to ring (8).
a Completely degrease the O-ring and the
O-ring contact surfaces of floating seal
before installing.
a Check that the leaning of the floating seal
is less than 1 mm.
3. Align pin holes of the track frame and bogie with

each other, and set guidance tool L17 in posi-
tion.
2) Press fit shaft (3) to ring (8).

4) Press fit ring (7) to shaft (3).
2 Part (a) of ring (8) and ring (4) (approx.
10 mm):
(LM-P)
4. Press fitting of pin assembly

1) Set tool L16 and cover (2) in position.
D375A-6 50-217
(02)
DRAFT
2) Press fit the pin assembly. 6. Press fit the pin assembly on the opposite side of
a Install the pin assembly with arrow (a) on the bogie according to above steps 3 and 4.
its end face up (when it is mounted on the
machine). 7. Tighten the mounting bolts of pin assembly
a Push in the pin assembly with cover (2). cover (2) (2 covers on inside and outside).
a Push in the pin assembly to machined 3 Cover mounting bolt:
face (b) of the bogie. 927 ± 103 Nm {94.5 ± 10.5 kgm}
2 Periphery of pin:
cant (LM-P)
a Press-fitting force of pin assembly:
245 – 441 kN {25 – 45 tons}
8. Adjust the track tension. For details, see Testing

and adjusting "Inspection and adjustment of
track tension".
5. Refilling
Using tool L19, refill with the specified amount of
oil.
a Oil supply pressure: 0.49 MPa {5 kg/cm2}
5 Pin assembly: 95 –115 cc (GO140)
50-218 D375A-6
(02)
DRAFT
Disassembly and assembly of bogie assembly

3. Remove the pin assembly following the same
Special tools procedure as described in the "Removal of bogie
assembly".
New/remodel
Necessity
(See Step 8.)
Sketch
Q’ty
Symbol Part No. Part Name
4. Disconnection of bogie
Disconnect inner bogies (4) from outer bogie (5).
1 791-630-2260 Plate t 1
2 791-630-2270 Screw t 3
3 01580-12419 Nut t 3
L
16 4 01643-32460 Washer t 3
Puller
5 790-101-4000 t 1
(490 kN {50 ton})
6 790-101-1102 Pump t 1
19 791-601-1000 Oil pump t 1
Disassembly
Reverse bogie assembly (1). Then, lift off two
track roller assemblies (2).
D375A-6 50-219
(02)
DRAFT
Assembly 4. Refilling
1. Assembly of pin assembly Using tool L19, supply the specified amount of
Assembly the pin assembly following the same oil.
procedure as described in the "Installation of a Oil supply pressure: 0.49 MPa {5 kg/cm2}
bogie assembly". 5 Pin assembly: 90 – 115 cc (GO140)
(See Steps 3 to 5.)
2. Set inner bogies (4) to outer bogie (5).
3. Press-fitting of pin assembly

2) Press fit the pin assembly.
a Install the pin assembly with arrow (a) on
machine).
a Push in the pin assembly with cover (3).
a Push in the pin assembly to the machined
surface of the bogie and maintain step (b)
of 5 mm between the bogie and the pin
assembly. 5. Press fit the pin assembly at the opposite side of
2 Periphery of pin: bogie in the same way as shown in Steps 3 and
Molybdenum disulphide lubri- 4.
cant (LM-P) a After press-fitting of pin assembly, rock the
a Total press fitting force of pin assembly : small bogie so that it can move smoothly.
245 – 441 kN {25 – 45 ton}
6. Tighten the mounting bolts of pin assembly
cover (3) (two covers, inside and outside).
3 Cover mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}

Lift and install two track roller assemblies (2) to
bogie assembly (1).
2 Track roller mounting bolt:
Adhesive (LT-2)
3 Track roller mounting bolt:
1,180 – 1,470 Nm {120 – 150 kgm}
50-220 D375A-6
(02)
DRAFT
Removal and installation of first bogie assembly

Removal
Special tools 1. Separate the track shoe assembly. For details,
see “ Separation and connection of track shoe
New/remodel
Necessity
assembly.”
Sketch
Q'ty
2. Raise the machine so that the track rollers of the
second bogie assembly leave the track link, by
1 791-630-2360 Plate t 1
t
operating the blade and ripper.
k Place a block between track roller and
2 790-201-2730 Spacer 1
3 791-630-2270 Screw t 3
4 01580-12419 Nut t 3 track link so that the machine does not
14 5 01643-32460 Washer t 3 lower.
Puller k Set the parking brake lever and work
6 790-101-4000 (490 kN {50 t 1 equipment lock lever in the lock position.
ton}) k Stop the engine and disconnect the cable
7 790-101-1102 Pump t 1
1 791-630-2280 Adapter t 1
2 790-201-2770 Spacer t 1
3 791-630-2250 Plate t 1 3. Install eyebolts to the pad mounting bolts (two
4 790-434-1070 Screw t 1 M12 bolts) at the rear of the first bogie assembly,
5 01580-13629 Nut t 2 and lift the first bogie assembly (1).
15
6 01643-33690 Washer t 2
Puller
7 790-101-4000 (490 kN {50 t 1
ton})
8 790-101-1102 Pump t 1
1 791-630-2260 Plate t 1
2 791-630-2270 Screw t 3
3 01580-12419 Nut t 3
L 4 01643-32460 Washer t 3
16
Puller
5 790-101-4000 (490 kN {50 t 1
ton})
6 790-101-1102 Pump t 1
17 791T-630-2290 Guide t 2 Q
18 790-434-1350 Installer t 1
19 791-601-1000 Oil pump t 1
Bracket
1 791-630-1860 t 1 N
(L, H)
Bracket
20 2 791-630-1870 t 1 N
(R, H)
3 01010-62760 Bolt t 2
4 01643-32780 Washer t 2
791T-630-1900 Lifting tool q 1
791T-630-1910 q Tube 1 Q
791T-630-1920 q Plate 1 Q
q Grip
21 07283-38973 1
04530-11628 q Eyebolt 1
01643-31645 q Washer 1
01643-31232 q Washer 2
01582-01210 q Nut 2
D375A-6 50-221
(02)
DRAFT
4. Place an steel plate between the track shoe and 9. Pulling out shaft and ring
roller, and loosen roller cap bolts (2) for approx. 1) Set tool L14 in position.
20 mm. 2) Push out shaft (7) and ring (8) to the opposite
(both inside and outside) side simultaneously.
a Pressing force: 137.3 – 274.6 kN {14 – 28
5. Hit the end face of shaft (3) with a hammer to tons}
remove track roller assembly (4). a To avoid an interference with the idler
a Take care not to break the dowel pin installed when pressing the ring, pump grease in
on the front side (oil plug side) of the track the track tension adjusting section in ad-
roller assembly. vance to move the idler cushion forward.
(Insertion depth of dowel pin: 5 – 6 mm)
6. Remove roller cap bolts (2), place track roller

assembly (4) on the steel plate, and pull it out
from the machine.
3) Remove respective floating seals (9) from

the end faces of rings (8) and (12).
7. Sling first bogie (5) by using tool L20.
50-222 D375A-6
(02)
DRAFT
4) Set tool L15 in position. Installation

1. Assembly of pin assembly
1) Using tool L18, install respective floating
seals (9) to rings (8) and (12). Also, install
respective floating seals (10) to the opposite
surface of ring (12) and to ring (13).
a Completely degrease the O-ring and the
O-ring contact surfaces of the floating
seal before installing.
a Check that the leaning of the floating seal
is less than 1 mm.
5) Pull out spacer (11) and rings (12) and (13).

a Pulling force: 205.8 – 382.2 kN {21 – 37
tons}
6) Remove spacer (11).
7) Remove spacer (14) and floating seals (10)
between rings (12) and (13).
2) Press fit shaft (7) to ring (13).

2 Part (a) of ring (13) and ring (8) (ap-
prox. 10 mm):
(LM-P)
10. Lower bogie (5) on the steel plate and pull it out.
4 Bogie assembly: 110 kg
D375A-6 50-223
(02)
DRAFT
2. Place bogie (5) on steel plate [1], and slide them 2) Press fit the pin assembly.
beneath the center of the mounting position. a Install the pin assembly with arrow (a) on
3. Using tool L20, set the bogie to the mounting machine).
position. a Push in the pin assembly with cover (6).
a Push in the pin assembly to machined
surface (b) of the bogie and maintain step
of 5 mm between bogie and pin assem-
bly.
2 Periphery of pin:
cant (LM-P)
a Press-fitting force of pin assembly:
245 – 441 kN {25 – 45 ton}
4. Align the pin holes of the track frame and bogie,

and install guidance tool L17 in position.
6. Refilling
Using tool L19, supply the specified amount of
oil.
a Oil supply pressure: 0.49 MPa {5 kg/cm2}
5 Pin assembly: 95 – 115 cc (GO140)
5. Press-fitting of pin assembly

50-224 D375A-6
(02)
DRAFT
7. Press fit the pin assembly at the opposite side of 11. Gradually lower the machine and when the
the bogie following the same procedure in Steps clearance between bogie (5) and shaft (3)
5 and 6. becomes approx. 20 mm, install cap (15) and
tighten bolts (2) partially.
8. Install covers (6) (two covers, inside and
outside). 12. Matching the dowel hole with the dowel pin,
tighten bolts (2) to the specified torque.
9. Install eyebolts to the bolt holes of the pad 2 Cap mounting bolt: Adhesive (LT-2)
mounting bolts (M12 x 2 pieces) of bogie (5) and 3 Cap mounting bolt:
sling the bogie. 1,180 – 1,470 Nm {120 – 150 kgm}
10. Insert tool L21 into the shaft of track roller 13. Adjust the track tension. For details, see Testing
assembly (4), lift and balance the track roller and adjusting, "Inspection and adjustment of
assembly, and place it on the track shoes. track tension".
D375A-6 50-225
(02)
DRAFT
Separation and connection of track shoe assembly

Checking before separation of the track shoe as-
Separation sembly
k In some cases, it may be extremely danger-
1. Remove the blade assembly. For details see ous to separate the track shoe assembly. To
"Removal and installation of blade assembly". prevent danger, perform the following
checks before separation of the track shoe
2. Remove cover (1). assembly.
k Do not loosen the lubricator more than one
turn.
q Loosen lubricator (2) of the adjustment cylin-
der to drain the grease. Move the machine
forward a short distance and check that the
track tension is decreased.
a When the track tension is decreased, fol-
low the procedure in the "Separation of
track shoe assembly (normal)".
a Because the machine needs to move later,

do not disconnect battery cables.
q If the track tension is not decreased and is

still high, a problem may have occurred in-
side the track frame (such as damaged recoil
spring case, broken recoil spring set bolts, or
coming off of shaft end nut).
a If the track tension is not decreased, fol-
low the procedure in the "Separation of
track shoe assembly (when track frame
has internal defect)".
50-226 D375A-6
(02)
DRAFT
Separation of track shoe assembly 4. Sling the front end of master link (3), move the
(When track frame has internal defect) machine backward slowly to spread track shoe
a If any abnormality is detected by "Checking be- assembly (5).
fore separation of track shoe assembly", perform a Length of track: Approx. 12.5 m
k If a problem has occurred inside the track
frame, the track shoe may spring back when
the assembly is separated. Also, the idler
may fly out when the track shoe assembly is
separated. This is potentially very danger-
ous. Be sure to separate the track shoe as-
sembly as follows.
1. Loosen lubricator (2), and move the machine

backward and forward to drain the grease. [*1]
k Do not loosen lubricator (2) more than
one turn.
a Check that all the grease is discharged.
2. Move the machine forward slowly to press the

trach shoes on the idler side against large block
[3] or a wall (or a blade of another machine of
same size). When the recoil spring is
compressed and the track shoe assembly sags,
stop the machine and apply the brake.
Locate master link (3) between the idler and front
carrier roller.
a Apply lever lock [4] between the carrier roller
support and link to assure safety.
3. Remove track shoe (4) and separate master link

(3). [*2]
D375A-6 50-227
(02)
DRAFT
Separation of track shoe assembly (normal) 3. Remove track shoe (4). [*2]
a If no abnormality is detected by "Checking be- a Loosen each of four bolts by one or two turns.
fore separation of track shoe assembly", perform Check that they can be unscrewed smoothly,
the following procedure. and then remove them. Do not remove only
one bolt without loosening the other three.
1. Position the master link properly. a If a bolt does not turn smoothly and it is un-
a Locate master link (3) above the idler (a little screwed forcibly, the threads of the bolt and
backward from the center). master link (3) may be damaged.
a Place blocks [1] between the carrier rollers
and place block [2] under the front track so
that the mating faces of master link do not
open until the master bolts are removed.
4. Sling the front end of the master link, move the

machine backward slowly to spread track shoe
assembly (5).
a Length of track: Approx. 12.5 m
2. Loosen lubricator (2). [* 1] k For purposes of safety, check that no one
k Do not loosen lubricator (2) more than remains in front of the idler.
one turn.
50-228 D375A-6
(02)
DRAFT
Connection
q Perform connection in the reverse to separation.
[*1]
a Adjust the track tension. For details, see Testing
and adjusting, “Testing and adjusting track
tension”.
[*2]
a Finger-tighten the four bolts until the mating fac-
es of the master link are fitted.
a If the bolts are tightened forcibly before the mas-
ter link mating faces are fitted, the threads of
bolts and master link may be damaged.
a Tighten the bolts in the order shown in the figure.
2 Shoe bolt:
Molybdenum disulfide lubricant
(LM-P)
3 Shoe bolt:
(Master link)
Initial torque: 686 ± 69 Nm {70 ± 7
kgm}
Retightening angle: 180° ± 10°
(Regular link)
Initial torque: 1,372 ± 140 Nm {140 ± 14
kgm}
D375A-6 50-229
(02)
DRAFT
Overall disassembly and assembly of track shoe
Special tools Overall disassembly

a For the overall disassembly of the track shoe as-
New/remodel
Necessity
sembly, see Parts judgment guide,
Sketch
Q'ty
Symbol Part No. Part name “Undercarriage, Lubricated track" and Parts
judgment guide, “Undercarriage, Reversing pro-
cedure for pin and bushing.".
1 791-646-7351 Push tool t 1
2 791-660-7460 Pin brush t 1
1. Removal of track shoe
Push tool
3 791-646-7900 t 1 Lift the track shoe assembly and place the
(For large plug)
assembly on the floor with shoes (1) up. Remove
791-701-3000 Seal checker the track shoes by using shoe bolt impact
4 or t 2 wrench [1].
791-601-1000 Oil pump a If shoe bolt (2) is not loosened (if its rotational
Push tool torque is not reduced to zero) even after it is
5 791-932-1110 t 1 loosened by one turn, loosen other bolts so
(For small plug)
6 791-632-1021 Installer t 1
that the bolt can be loosened smoothly.
a Forcibly rotating the bolt the rotational torque
Push tool assem-
1 791-632-1300 t 1 N of which is not reduced to zero may cause
bly
2 791-632-1260 q Push tool 1
adhesive transformation between the bolt
and link, which may require repairs.
3 791-632-1270 q Adapter 1
a When repositioning the track shoe assembly,
q A d a p t e r
4 791-632-1220 1 take care not to damage the master links.
(small)
a If the shoe nut needs to be removed by gas
5 791-632-1230 q Ring 1 cut, keep the temperature in the seal section
7 6 791-632-1240 q Plate 1 below 80 °C to prevent thermal deteriora-
tion of the seals and take measures to pre-
7 791-685-5730 q Bar 1
vent the spatters from entering through the
8 791-632-1250 q Ring 1 clearances between the links.
R 9 791-632-1280 q Spring 1
10 01252-30605 q Bolt 1
11 01580-01210 q Nut 1
Push tool assem-
1 791-632-1200 t 1 N
bly
2 791-632-1260 q Push tool 1
3 791-632-1270 q Adapter 1
q A d a p t e r
4 791-632-1210 1
(large)
5 791-632-1230 q Ring 1
8 6 791-632-1240 q Plate 1
7 791-685-5730 q Bar 1
2. Disassembly of track links
8 791-632-1250 q Ring 1
1) Place the link assembly on the link press and
9 791-632-1280 q Spring 1 hit it with a hammer to fit the bushing to jaw
10 01252-30650 q Bolt 1 [2] firmly.
a If the link tread or outer periphery of the
11 01580-01210 q Nut 1 bushing is worn, adjust the height of jaw
Push tool assem- [2] or guide plate to align the pin or bush-
1 791-632-1290 t 2 N
bly ing with the disassembly jigs so that the
9
2 791-685-5730 Bar 1 pin-bore or bushing-bore in the link is not
3 01580-01210 Nut 1 damaged during disassembly.
50-230 D375A-6
(02)
DRAFT
a If the pin or bushing is not aligned with the 3) Return the left cylinder and operate the right
jig, the bore in the link may be damaged cylinder to pull out the pin and bushing from
or the pin or bushing may be broken dur- the right link simultaneously.
ing disassembly.
a Using tool R5, drive in the small plug of
the pin after disassembly so that the work
place does not become dirty.
4) Return the right cylinder, take out the right

and left links, pins, bushings and spacers,
and feed the next set of the link assembly to
the jaw.
k Because the broken wedge ring has
sharp edges, take care not to cut your
hands with them.
a If the bushing end faces and its sealing
surface are damaged, oil will leak. Ac-
cordingly, handle them carefully.
2) Operate the left cylinder to pull out the pin

and bushing from the left link simultaneously.
a Check the pulling-out force of the pin and
bushing to see if the press-fitting force is
obtained, that is required when they are
reused by being turned 180 degree.
a The wedge ring is broken with a bang.
This sound does not indicate abnormality
D375A-6 50-231
(02)
DRAFT
3. Checking
Check the removed parts for following items,
then determine to reuse them for a lubricated
track or grease-lubricated track, depending on
the check results.
a For judgment of reuse of the parts,
see Parts judgment guide, “Undercarriage,
Lubricated track".
1) Check the parts visually for damage. If a
parts seems to be damaged, check it by dye
penetrant test or magnaflux inspection.
If it has any crack, it cannot be reused.
Discard it.
2) Measure the outside diameter of the
press-fitting portions of the pin and bushing a Precautions for storage
and the inside diameter of the link bores 1) Store the seal without removing it from the
where the pin and bushing are press fitted to link so that the link bore does not rust, and
by using micrometer [5] and cylinder gauge take care not to damage the seal lip.
[6], to see if the allowable interference is 2) Apply rust-preventive oil to the pin and
obtained. Note that the standard interference bushing press-fitting bores, shoe mounting
must be secured between the pin and link surface of the link, and mating face of the
when they are reused for a lubricated track. master link.
a If the allowable interference is not ob-
3) Apply rust-preventive oil to the all surfaces of
tained, replace the parts with new ones.
the pin, bushing, and spacer prior to storage.
a For the dimensional criteria, see "Mainte-
Take extreme care not to damage the
nance standard".
bushing end faces.
50-232 D375A-6
(02)
DRAFT
Overall assembly
a For the overall assembly of the track shoe as-
sembly, see Parts judgment guide,
“Undercarriage, Lubricated track" and Parts
judgment guide, “Undercarriage, Reversing pro-
cedure for pin and bushing.".
Reusing the link assembly for lubricated track

1. Preparatory work
1) Cleaning of seal assembly
Remove the seal assembly from the link,
divide it into seal ring (3) and load ring (4),
and clean them.
a Clean seal ring (3) and load ring (4) quick- 4) If the large plug was removed from the pin,
ly because they are easily deteriorated by drive in large plug (5) by using tool R3.
the cleaning agent (trichloroethylene, At this time, clean the pin hole in advance by
etc.). Wipe off the cleaning agent with a using tool R2.
cloth from them. 1] Insert the plug in the hole of the guide
through the plug inserting window.
2] Press the bar with hand until the plug
stops.
3] Press the plug with the bar until the guide
touches the pin.
4] Hit the bar with a hammer to drive in the
plug.
a Driving distance (a) from pin end face:
11 ± 2 mm
a If chamfered face of the pin hole is lost
due to wear, chamfer it by using a
small-sized grinder (grindstone end
angle: 45 ° – 60 °) so that the plug
2) When reusing the pin, chamfer the edges of is not damaged.
its end faces with a grinder. Remove the a If the hole face of the pin is chamfered
nodules formed on its press-fitting portions with the grinder, clean the pin hole
with the grinder. again by using tool R2.
a If the edge of its end face is worn and a Apply oil (GO90) on the outside pe-
sharpened, the press-fitting portion of the riphery of the plug, and drive it with its
pin may cause galling, resulting in oil smaller diameter end facing pin (6).
leak.
3) Clean the dirty links, pins, bushings, and
spacers. Remove the nodules formed on the
link and bushing with the grinder, too.
a Clean the parts immediately before the
assembly because they easily rust.
a Do not grind the bushing end faces be-
cause doing so may cause oil leak.
D375A-6 50-233
(02)
DRAFT
5) Installation of seal assembly

Clean the bores of the link, and push in the
seal to the bottom by using tool R6.
a Do not apply oil to the link bores and the
seal assembly (portion (d)) because any
adhered oil causes the seal to turn and its
sealing performance is lowered. Accord-
ingly, take care not to allow any oil to ad-
here to the seal when installing the seal to
the link bore.
6) Adjust the installed dimensions of the link

press press-fitting jigs to keep the protrusion
of the pin and bushing constant and to keep
the installed dimensions of the seal within the
standard range.
a If the pin end faces (portion P) or link side
faces (portions Q and R) are worn, add
the wear reduction to the standard in-
stalled dimensions of the press-fitting jigs
so that the right and left protrusions of the
pin and bushing are even.
50-234 D375A-6
(02)
DRAFT
7) Adjust the relief pressure of the link press so 2. Assembly of link

that the pressing force of the press does not 1) Apply oil (GO90) on the mating faces of pin
exceed the standard value. and bushing with a clean brush and
a If the pressing force is excessive, the assemble them, then set them on the
spacer is pressed against the bushing ex- bushing jaw of the link press.
cessively. As a result, the spacer may be a When reusing the bushing (by turning it
broken or abnormal wear may occur be- 180 degree), set it with the worn outside
tween the spacer and bushing end face. surface facing the shoe mounting face of
a Pressing force for pin and bushing: the link (set the bushing on the link press
980 kN {100 ton} with the face up).
Pressing force C 1.8 x Average pressure
(Adjust the relief pressure of the link
press to obtain the pressing force.)
2) Set the right and left master links having

bushing-bore with their shoe mounting faces
up, and press fit them to the bushing.
a At this time, use the master links having
pin-bore as supports.
a Bushing press-fitting force:
196 – 343 kN {20 – 35 ton}
D375A-6 50-235
(02)
DRAFT
3) While checking the distance between the 6) Send out the master link portion, and then set
shoe bolt holes of the right and left master the next pins and bushings.
links by using the shoe bolt pitch gage, press a Install the pin, even it is reused, with its
fit the master links to the bushing until the cross hole (its direction is indicated with
distance is the standard value. mark (e)) facing the link tread as in the
a Remove all steel chips generated by the case of new one.
press-fitting process completely with If it is not installed so, the strength of the
compressed air. assembly may be lowered. Accordingly,
indicate the direction of the cross hole on
the end face to prevent wrong installation.
4) Turn over the master links and check that

they are press fitted in parallel.
5) Measure the right and left protrusions of the 7) Apply liquid gasket (198-32-19890) to all
bushing by using depth gauge [7]. surfaces of pin press-fitting portion (f) and
a Adjust the link press press-fitting jigs so link bore (g).
that the right and left protrusions of the a This prevents the galling of the pin
bushing are even. press-fitting portion that may cause oil to
seep out.
50-236 D375A-6
(02)
DRAFT
8) Set the right link and install the spacer to the 10)Use minor adjustment spacer (8) to press fit
pin. the pin until its end face reaches the bottom
a Check that the seal surfaces and bushing of the receiver jig.
end faces are free from dirt, then apply oil a Adjust the depth of the receiver jig hole so
(GO90) on them using a clean cloth or that the right and left protrusions of the pin
brush. are even.
a Wipe the spacer with a clean cloth before
installing.
11)Set the left link and install the spacer to the

pin.
9) Using the right jig as receiver jig and the left a Apply oil similarly to the right link.
jig as pusher jig, press fit the pin and bushing
simultaneously.
a Press fit them smoothly because bumpy
press-fitting may cause the seal to come
off the link.
When the seal comes off the link, stop the
press-fitting and set the seal to the link
correctly, then restart the press-fitting.
a Press-fitting force for pin and bushing:
392 – 686 kN {40 – 70 ton}
12)By using the left jig as receiver jig, and the

right jig as pusher jig, press fit the left link.
a When press fitting, take care that the right
and left seals and spacers do not come
off.
a Press-fitting force for pin and bushing:
392 – 686 kN {40 – 70 ton}
D375A-6 50-237
(02)
DRAFT
13)Perform the press fitting until the link, 15)Set the ring on jig R8.
spacers, and bushing are mutually fitted.
a Actually, you cannot see from outside if
the above parts are fitted. Accordingly,
control the hydraulic pressure of the link
press. Set the relief pressure to a proper
level and raise the pressure of the link
press to that level while performing the
press fitting.
For the relief pressure settings, see
"Preparatory work."
a Check that adjacent two sets of links pivot
on the pin.
16)Match the jig to the pin-bore of the link and

push the ring in until the ring is fitted in the pin
groove.
a A click is heard when the ring is fitted in
the pin groove.
14)Using the shoe bolt pitch gage, check that the

distance between the shoe bolt holes is
within the standard range.
a If the distance between the shoe bolt
holes is longer than the standard range,
disassemble and check for abnormality,
then assemble them again if no abnor- 17)Using jig R9, install the ring into the pin
mality is found. groove on the other side similarly.
a If the distance between the shoe bolt
holes is less than the standard range and
the track shoe cannot be installed, then
wear of the spacer or bushing end face
may exceeds the allowable limit. In this
case, disassemble it and replace the rele-
vant part.
50-238 D375A-6
(02)
DRAFT
18)Press the ring by using jig R10. a For cold or extremely cold district, supply
a Pressing force: 294 – 372 kN {30 – 38 Komatsu genuine engine oil
ton} (150-09-19270 or 195-32-61990), which
has excellent low-temperature character-
istics, instead of oil (GO90).
a If the charged oil pressure is increased
too much, it has bad effects on the seals.
a Supply oil (d) up to the level (a) where
depth (L) of the hollow of the hole of pin
(c) is in the following range when the pin
is left with the small plug side (b) up (the
link assembly placed on its side) for thirty
minutes.
a Dimension (L): 40 – 70 mm
19)Use tool R4 for each link assembly to remove

air from inside the pin, and check the sealing
performance.
a Keep the degree of vacuum inside the pin
at 86.7 – 93.3 kPa {650 – 700 mmHg} for
5 seconds to check that the pressure
does not change.
If the pressure changes, disassemble the
link assembly to check the seals. If no
abnormality is found, assemble them.
21)After supplying oil, drive in the small plug to

the specified position by using tool R5.
a Apply oil (GO90) on the outside periphery
of the small plug.
a Drive in the plug to the following depth.
Driving depth from end face: 7.5 ± 1 mm
20)Use tool R4 to supply oil (GO90) until the

charged pressure rises to 196.1–294.2 kPa
{2–3 kg/cm2}.
22)Install the master links having pin-bore at

last.
a Check that the right and left master links
are press fitted in parallel.
D375A-6 50-239
(02)
DRAFT
3. Installation of track shoe 2) For the track that has two master link joints
1) Place the link assembly on the bed, and and consists of two track shoe assemblies,
install track shoes (1) by using shoe bolt connect the two track shoe assemblies as
impact wrench [1] and torque wrench. follows. Place the two assemblies on a level
3 Shoe bolt (2) (Regular link) place in a line with the track shoes up. Pull
Initial torque: master links with pin-bore (1) of one
1,372 ± 140 Nm {140 ± 14 kgm} assembly and master links with bushing-bore
Retightening angle: 120° ± 10° (2) together to contact their mating faces
2 Shoe bolt: each other. Place shoe (3) on the master
Molybdenum disulphide lubricant links, and finger-tighten shoe bolts (4) for
(LM-P) master link so that their mating faces are in
close contact. Then tighten the bolts to the
specified torque to complete the connection.
2 Shoe bolt:
(LM-P)
3 Shoe bolt (Master link)
Initial torque: 686 ± 68.6 Nm {70 ± 7
kgm}
a Tighten the bolts in the order of [1] – [4].
50-240 D375A-6
(02)
DRAFT
Reusing the link assembly for grease lubricated 3) Clean any dirty surfaces among the outside
track periphery of the pin, spacer surface, and end
1. Cleaning of seal assembly faces and inside surface of the bushing.
1) Cleaning of seal assembly 4) Drive in the large plug by using tool R3.
q Remove seal assembly from the link, di- 1] Insert the plug in the hole of the guide
vide it into seal ring (3) and load ring (4), through the plug inserting window. (Apply
and clean them. oil to the plug.)
a Clean seal ring (3) and load ring (4) 2] Press the bar with hand until the plug
quickly because they are easily deteri- stops.
orated by the cleaning agent. Wipe off 3] Press the plug with the bar until the guide
the cleaning agent with a cloth from touches the pin.
them.
4] Hit the bar with a hammer to drive in the
plug.
a Driving distance (a) from pin end face:
Large plug: 11 ± 2 mm
a If the plug was not removed from the
pin when disassembling the track
shoe assembly, reuse as it is.
2) When reusing the pin, chamfer the edges of

its end faces with a grinder to allow for
smooth press fitting.
D375A-6 50-241
(02)
DRAFT
5) Apply grease on the outside periphery of the 2. Assembly of link

pin and surfaces of the spacer. 1) Apply lithium grease (G2-LI) on the mating
6) Installation of seal assembly faces of the pin and bushing and assemble
q Clean the bores of the link, and push in them, then set them on the bushing jaw of the
the seal to the bottom by using tool R6. link press.
a Do not apply grease to the link bores a When reusing the bushing (by turning it
and the seal assembly because any 180 degree), set it with the worn outside
adhered grease causes the seal to surface facing the shoe mounting face of
turn and its sealing performance is the link (set the bushing on the link press
lowered. with the face up).
7) Adjust the installed dimensions of the link 2) Set the right and left master links having
press press-fitting jigs to keep the protrusion bushing-bore with their shoe mounting faces
of the pin and bushing constant and to keep up, and press fit them to the bushing.
the installed dimensions of the seal within the a At this time, use the master links having
standard range. pin-bore as supports.
a For the standard dimensions of the link a Bushing press-fitting force:
press press-fitting jigs, see "Link press 196 – 343 kN {20 – 35 ton}
press-fitting jig dimensions."
a If the pin end faces (portion P) or link side
faces (portions Q and R) are worn, add
the wear reduction to the standard in-
stalled dimensions of the press-fitting jigs
so that the right and left protrusions of the
pin and bushing are even.
50-242 D375A-6
(02)
DRAFT
3) While checking the distance between the 6) Send out the master link portion, and then set
shoe bolt holes of the right and left master the next pins and bushings.
links by using the shoe bolt pitch gage, press a Install the pin, even it is reused, with its
fit the master links to the bushing until the cross hole (its direction is indicated with
distance is the standard value. mark (e)) facing the link tread as in the
a Remove all steel chips generated by the case of new one.
press-fitting process completely with If it is not installed so, the strength of the
compressed air. assembly may be lowered. Accordingly,
4) Turn over the master links and check that indicate the direction of the cross hole on
they are press fitted in parallel. the end face to prevent wrong installation.
a If a pin has worn outside periphery, it is to

5) Measure the right and left protrusions of the be installed with its un-worn periphery to-
bushing by using depth gauge [7]. ward the traction side. Even in this case,
a Adjust the link press press-fitting jigs so the pin must be installed with its cross
that the right and left protrusions of the hole facing the link tread.
bushing are even.
D375A-6 50-243
(02)
DRAFT
7) Set the left and right links, and operate the 9) Set the ring on jig R8.
left and right press-fittng jigs to press fit the
pin and bushing simultaneously.
a Press fit them smoothly because bumpy
press-fitting may cause the seal to come
off the link. When the seal comes off the
link, stop the press-fitting and set the seal
to the link correctly, then restart the
press-fitting.
a Pressing force for pin and bushing:
980 kN {100 ton}
Pressing forceC1.8 x Average pressure
(Adjust the relief pressure of the link
press to obtain the pressing force.)
10)Match the jig to the pin-bore of the link and

push the ring in until the ring is fitted in the pin
groove.
Using jig R9, install the ring into the pin
groove on the other side similarly.
a A click is heard when the ring is fitted in
the pin groove.
8) Check the distance between the shoe bolt

holes by using the shoe bolt pitch gage, and
when it reaches the standard range, stop the
press-fitting.
11)Press the ring by using jig R10.

a Pressing force:
294 – 372 kN {30 – 38 ton}
50-244 D375A-6
(02)
DRAFT
12)Pump in grease. 3. Installation of track shoe (to regular links)

a Pump in grease (d) up to the level (a) Place the link assembly on the bed, and install
where depth (L) of the hollow of the hole track shoes (1) by using shoe bolt impact wrench
of pin (c) is in the following range when [1] and torque wrench.
the pin is left with the small plug side (b) 2 Shoe bolt (2):
up (the link assembly placed on its side). Molybdenum disulphide lubricant
a Dimension (L): 40 – 70 mm (LM-P)
3 Shoe bolt (2) (Regular link)
Initial torque:
1,372 ± 140 Nm {140 ± 14 kgm}
13)After pumping in grease, drive in the small

plug to the specified position by using tool
R5.
a Drive in the plug to the following depth.
Driving depth from end face: 7.5 ± 1 mm
14)Install the master links having pin-bore at

last.
a Check that the right and left master links
are press fitted in parallel.
D375A-6 50-245
(02)
DRAFT
4. Connection of track consisting of two track shoe

assemblies
Place the two assemblies on a level place in a
line with the track shoes up. Pull master links
with pin-bore (1) of one assembly and master
links with bushing-bore (2) together to contact
their mating faces each other. Place shoe (3) on
the master links, and finger-tighten shoe bolts
(4) for master link so that their mating faces are
in close contact. Then tighten the bolts to the
specified torque to complete the connection.
2 Shoe bolt:
(LM-P)
3 Shoe bolt (Master link)
Initial torque:
686 ± 68.6 Nm {70 ± 7 kgm}
a Tighten the bolts in the order of [1] – [4].
50-246 D375A-6
(02)
DRAFT
Link press press-fitting jig dimensions
Link press press-fitting jig dimensions
Unit: mm
Jig dimensions
(a) 4.2
(b) 2.0
(c) 52.1
Precaution
The link receiving face of jaw(1) must be vertical.
Replaceable wear plate (2) shown below is desir-
able.
D375A-6 50-247
(02)
DRAFT
Disassembly and assembly of one link assembly in the field
Special tools
New/remodel
New/remodel
Necessity
Necessity
Sketch
Sketch
Q'ty
Q'ty
Symbol Part No. Part name Symbol Part No. Part name
1 791-646-7351 Push tool t 1 21 791-680-5551 q Guide 1

2 791-660-7460 Pin brush t 1 22 791-680-9630 q Adapter 1
Push tool (for 23 791-632-1160 q Guide 1
3 791-646-7900 t 1
large plugs) 24 195-32-61210 Bolt 2
791-701-3000 Cylinder
Seal checker oil
4 or t 2 R 7 25 790-101-4300 (1,470 kN {150 t 1
pump
791-601-1000 ton})
Push tool (for 26 790-101-1102 Pump t 1
5 791-932-1110 t 1 Cylinder
small plug) 27 790-101-4200 t 1
6 791-632-1021 Installer t 1 (294 kN {30 ton})
Remover & 28 791-680-1630 Spacer t 1 N Q
1 791-632-1100 t 1
installer assembly
2 791-632-1130 q Adapter 1
3 790-434-1610 q Guide 1 Disassembly
4 01010-51440 q Bolt 2 q Separate the track shoe assembly. For details,
R 5 791-685-9510 q Frame 1 see “Separation and connection of track shoe
6 791-685-9530 q Rod 1 assembly.”
7 791-685-9520 q Frame 1 a Move the machine forward or backward to
8 791-685-9550 q Nut 3
bring the link assembly to be disassembled
9 04530-12030 q Eyebolt 1
7 10 791-685-9560 q Bolt 4 to a position where tool 7 can be easily in-
11 791-126-0150 q Adapter 1 stalled on the link when the track shoe as-
12 791-685-9540 q Rod 1 sembly is separated.
13 791-632-1140 q Adapter 1 k Set the parking brake lever and work equip-
14 791-680-5520 q Guide 1 ment lock lever in the lock position.
15 01010-51030 q Bolt 1 k Stop the engine and disconnect the cable
16 791-632-1150 q Pusher 1
17 791-685-9620 q Extension 1
18 791-632-1180 q Adapter 1 1. Install tool R7-2 on link (1) with R7-24, and install
19 791-680-5543 q Adapter 1 tool R7-3 to the link with R7-4.
20 791-632-1170 q Guide 1 a Use the shoe bolts for installing R7-24.
50-248 D375A-6
(02)
DRAFT
2. Assemble tools R7-25 and R7-5 to R7-11, then 4. Set tools R7-13 to R7-16, connect tool R7-26,
sling them to place on the shoe. and then apply oil pressure to pull out the pin (2).
3. Insert tool R7-12 from the cylinder side, and a If cylinder reaches its stroke end, connect
install it by using two R7-8. tool R7-17 and repeat the work.
D375A-6 50-249
(02)
DRAFT
5. Set tools R7-27 and R7-28 in the middle of the 7. Repeat step 5 to remove links (4).
links to be disassembled on their tread side,
connect tool R7-26, then apply oil pressure to
open the links by 5 – 6 mm to disconnect them.
Assembly
1. Assemble the link sub-assembly according to
1) Set tool R7-18 to the bushing-bore end of link
6. Repeat steps 1 to 4 to pull out another pin (3) on (5), and press fit bushing (6).
the other side. a Bushing press-fitting force:
196 – 294 kN {20 – 35 ton}
2) Set tool R7-19 to the pin-bore end of the link,

and press fit pin (7).
a Install the pin with the cross hole (a) fac-
ing link tread (b).
a Press-fitting force for pin:
206 – 323 kN {21 – 33 ton}
50-250 D375A-6
(02)
DRAFT
2. Set link sub-assembly (8) to the link to be 4. Similarly to the disassembly procedure, set tools
connected. R7-25, R7-5 to R7-12,R7-17 to the links.
5. Use tools R7-19 and R7-21 to press fit the

pin-bore end and use tools R7-22, R7-1, and
R7-21 to press fit the bushing-bore end of the
link. Press fit them alternately.
a First press fit the pin-bore end of the link.
When the bushing is partially inserted into
the link bore, remove tool R7-20 that is in-
stalled in step 3, then press fit the bush-
ing-bore end of the link.
206 – 323 kN {21 – 33 ton}
a Press-fitting force for bushing:
196 – 294 kN {20 – 30 ton}
3. Set counterpart link (9) and support it with tool
R7-20.
6. Similarly to the disassembly procedure, use

tools R7-27 and R7-28 to push open links (10) to
be connected.
D375A-6 50-251
(02)
DRAFT
7. Set link (11) to be connected to link (10), fix them

by using tool R7-23, and then remove tools
R7-27 and R7-28.
8. Similarly to the disassembly procedure, set tools

R7-2 to R7-12 and press fit pin (12) to the links.
2 Pin press-fitting hole in link:
Liquid gasket (198-32-19890)
a Set the pin with its side hole facing the link
tread.
412 – 646 kN {42 – 66 ton}
a If the cylinder reaches its stroke end, add tool
R7-17, and R7-14 to R7-16, then repeat the
work.
50-252 D375A-6
(02)
DRAFT
Disassembly and assembly of master link

N
N
Special tools e S
e
Q w/ k
New/remodel
c
Necessity
Symbol Part No. Part name 't re et
Sketch
e
Q'ty
Symbol Part No. Part name y m c
ss
od h
ity
el
1 791-646-7351 Push tool t 1 26 790-101-1102 Pump t 1
t 1 Cylinder
2 791-660-7460 Pin brush 7 27 790-101-4200 t 1
Push tool (for (294 kN {30 ton})
3 791-646-7900 t 1 28 791-680-1630 Spacer t 1
large plug)
Push tool assem-
791-701-3000
Seal checker oil 1 791-632-1300 t 1 N
4 or t 2 bly
pump 2 791-632-1260 q Push tool 1
791-601-1000
Push tool (for 3 791-632-1270 q Adapter 1
5 791-932-1110 t 1 4 791-632-1220 q Pin (small) 1
small plug)
5 791-632-1230 q Ring 1
6 791-632-1021 Installer t 1 8
Remover & 6 791-632-1240 q Plate 1
7 791-685-5730 q Bar 1
1 791-632-1100 installer assem- t 1
8 791-632-1250 q Ring 1
bly
9 791-632-1280 q Spring 1
2 791-632-1130 q Adapter 1
10 01252-30605 q Bolt 1
3 790-434-1610 q Guide 1
11 01580-01210 q Nut 1
4 01010-51440 q Bolt 2 R
Push tool assem-
5 791-685-9510 q Frame 1 1 791-632-1200 t 1 N
bly
6 791-685-9530 q Rod 1
2 791-632-1260 q Push tool 1
7 791-685-9520 q Frame 1
R 3 791-632-1270 q Adapter 1
8 791-685-9550 q Nut 3
4 791-632-1210 q Pin (large) 1
9 04530-12030 q Eyebolt 1
5 791-632-1230 q Ring 1
10 791-685-9560 q Bolt 4 9
6 791-632-1240 q Plate 1
11 791-126-0150 q Adapter 1
7 791-685-5730 q Bar 1
12 791-685-9540 q Rod 1
8 791-632-1250 q Ring 1
7 13 791-632-1140 q Adapter 1
9 791-632-1280 q Spring 1
14 791-680-5520 q Guide 1
10 01252-30650 q Bolt 1
15 01010-51030 q Bolt 1
11 01580-01210 q Nut 1
16 791-632-1150 q Pusher 1
Push tool assem-
17 791-685-9620 q Extension 1 1 791-632-1290 t 2 N
18 791-632-1180 q Adapter 1 bly
10
2 791-685-5730 Bar 1
19 791-680-5543 q Adapter 1
3 01580-01210 Nut 1
20 791-632-1160 q Guide 1
21 791-680-5551 q Guide 1
22 791-680-9630 q Adapter 1
23 791-632-1160 Guide 1
24 195-32-61210 Bolt 2
Cylinder
25 790-101-4300 (1,470 kN {150 t 1
ton})
D375A-6 50-253
(02)
DRAFT
Disassembly q For master link type

a For the method of using tool R7, see "Disassem- 1) Gas cut and removal of master link with
bly of one link assembly in the field." bushing-bore.
1. Removal of track shoe assembly Gas cut the pin and bushing along the wavy
Remove the track shoe assembly from the track lines and remove the hatched parts. Move
frame. For details, see “Separation of track shoe master links (4) vertically as shown by the
assembly”. arrow to remove them, and then pull out
remaining pins (5a) and (5b) press fitted in
2. Disassembly of track shoe assembly respective regular links (2) by moving them
Disconnect the all master link joints to divide the vertically as shown by the arrow using the
track into two track shoe assemblies. press.
q Necessary special tools:
3. Removal of master link 1. Gas cutting machine

q For master pin type 2. Tool R7
1) Gas cutting of regular link
Gas cut the links along the wavy lines, and
remove the hatched parts.
q Necessary special tool: Gas cutting ma-
chine
2) Removal of master link with pin-bore

Gas cut the master links along the wavy lines
and remove the hatched parts. Press pin (6)
downward as shown by the arrow by using
the press to pull it out from link (2a), then pull
2) Removal of regular link out pin (6) and link (2b) as a unit from bush
Press pin (1) downward as shown by the (3).
q Special tools:
arrow by using the press to pull it out from link
(2), and then pull out the pin (1) and the other 1. Gas cutting machine
link (2) as a unit from bushing (3). 2. Tool R7
50-254 D375A-6
(02)
DRAFT
Assembly
a For the method of using tool R7, see "Disassem- 2) Set spacers (6) and seal assemblies (7) to
bly of one link assembly in the field." the bores of links (2a) to be connected.
(3): Bushing
1. Assembly of master links with bushing-bore
1) Press fit master links with bushing-bore (4) to
bushing (3) using the press.
a When press fitting the left and right mas-
ter links, take care so that the links are fit
in parallel.
a Do not damage the mating face of the
master link and the end faces of the
bushing.
Unit: mm
L1 184 ± 0.7
L2 253.4±0.7
3) Match the pin bores of the links and the bores
D1 33 Drill for bushing (3) of the master links, and fix
them with guide pin [1].
D2 30 × 2.0
4) Press fit pin (5) by using tool R7 to install

master links with bushing bore (4).
2 Pin press-fitting bore in link:
2. Installation of master link with bushing-bore
Liquid gasket (198-32-19890)
1) Increase the space between the links at the a Install the pin with its cross hole facing the
centers of their treads by using tool R7 as link tread.
5) Install the rings by using tool R7 and tools
a: 5 mm
R8, R9, and R10.
(Increase by 10 mm between the ends of the
links.)
D375A-6 50-255
(02)
DRAFT
6) Install the track shoe to the links of the 2) Pass pin (5) through bushing (3), set right
connecting part. and left master links with pin-bore (4), and
7) Drive in large plug (8) by using tool R3, pump press fit them from both sides by using tool
in oil by using tool R4, and then drive in small R7.
plug (9) by using tool R5. 3) Install the rings by using tool R7 and tools
R8, R9, and R10.
4) Drive in large plug (8) by using tool R3, pump
in oil by using tool R4, and then drive in small
plug (9) by using tool R5.
a When press fitting the right and left mas-

ter links, take care so that the links are in
parallel (both for master links with bush-
ing bore and pin-bore).
a Do not damage the mating face of the 4. Connection of master links
master link and the end faces of the Place the two track shoe assemblies on a level
bushing. place in a line with the track shoes up. Pull
a Adjust the end play of the connecting part master links with pin-bore (4a) of one assembly
(the thrust end play between the links and master links with bushing-bore (4b) together
connected with the pin) to 0 - 0.13 mm. to contact their mating faces each other. Place
a Take care not to allow dirt, sand, or dust the track shoe on the master links, and
to attach the seal, spacer, end face of the finger-tighten the shoe bolts for master link so
bushing, and the master link mating face that their mating faces are in close contact. Then
with tap holes. tighten the bolts to the specified torque to
complete the connection.
3. Assembly of master link with pin-bore 3 Shoe bolt (Master link)
1) Set spacers (6) and seal assemblies (7) to Initial torque: 686 ± 68.6 Nm {70 ± 7
the bores of master links (4a). kgm}
(3): Bushing Retightening angle: 180° ± 10°
50-256 D375A-6
(02)
DRAFT
Removal and installation of pivot shaft assembly
Removal and installation of pivot shaft assembly

3. Remove seal (2), then remove cover (3). [*2]
Special tools
New/remodel
Necessity
Sketch
Sym
Q'ty
Part No. Part name
-bol
1 791T-650-2330 Sleeve t 1 N Q
2 791T-650-2340 Plate t 1 N Q
3 790-201-3310 Bolt t 2
4 790-101-2510 Block t 1
P 5 790-101-2570 Washer t 2
6 01580-01613 Nut t 2
7 01643-31645 Washer t 2
8 790-105-2300 Jack assembly t 1
9 790-101-1102 Pump t 1
Installation
1. Remove the track frame assembly. moval.
For details, see "Removal of track frame
assembly". [*1]
2 Pivot shaft press-fitting surface:
2. Sling pivot shaft assembly (1), remove the Molybdenum disulphide lubricant (LM-P)
mounting bolts, and pull out the pivot shaft
assembly using forcing screws [1]. [*1] [*2]
4 Pivot shaft assembly: 390 kg a Press fit the seal (2) to the pivot shaft using tool
P.
2 Seal press-fitting surface: Liquid gasket
(LG-6)
a Check that press-fitting dimension (a) of the seal
from the end face of the shaft is the specified di-
mension.
q Press-fitting dimension (a) : 665 ± 1.0 mm
D375A-6 50-257
(02)
DRAFT
Removal and installation of equalizer bar

4. Remove washer (4), then remove spacer (5).
Special tools a Oil will flow out from the pivot case, so use a
container to receive the oil.
New/remodel
6 Pivot case: 18 l
Necessity
Sketch
Sym-
Q'ty
Part No. Part name
bol
791-650-1300 Remover t 1
791-735-1123 Sleeve 1
790-434-1050 Screw 1
01580-02419 Nut 1
N 1
01643-32460 Washer
Puller
790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
Removal
5. Place hydraulic jack [1] (490 kN {50 ton }) under
ment lock lever in the lock position. the radiator guard.
1. Remove the engine underguard and the power

train underguard (front).
4 Engine underguard: 290 kg
Power train underguard (front): 280 kg
2. Remove pivot shaft cover (1).

a For the right track frame, disconnect four
blade tilt cylinder hoses from the cover.
a Because the machine will be raised up using
the blade, install blind plugs to the tilt cylinder
hoses.
3. Remove seal (2) and washer (3) as a unit.

a Perform this procedure for only right track
frame. [*1] 6. Remove cover (6). [*2]
7. Remove grease tube (7-1).
9. Loosen clamping bolts (9-1) and (9) of the equal-

izer bar side pin. [*3]
a Bolt: M30, Width accross flats: 46 mm
50-258 D375A-6
(02)
DRAFT
10. Remove cover (8). 12. Repeat steps 6 - 11 to remove the side pin on the
other side.
13. Operate hydraulic jack [1] slowly, and lower the

machine to the position where the left and right
equalizer bar touches both track frames.
14. Disconnect lubrication tube (12).
15. Remove two lockplates (13). [*5]
16. Remove center pin (14) using tool N1. [*6]

the main frame hole, the pin cannot removed
easily. Adjust the height of the main frame by
operating hydraulic jack [1].
11. Remove side pin (10). [*4]
k Support the track frame on the opposite
side with a block as it lowers when the pin
is removed.
the track frame hole, the pin cannot be re-
moved easily. Adjust the height of the equal-
izer by operating hydraulic jack [1].
a Put an "UP" mark at the top of the pin.
D375A-6 50-259
(02)
DRAFT
17. Raise the front of the machine by operating the Installation

blade, and place stand [3] under the radiator q Carry out installation in the reverse order to re-
guard. moval.
[*1]
a Degrease the press-fitting surface of the seal.
2 Seal press-fitting surface: Liquid gasket
(LG-6)
a Be careful not to install the seal twisted.
[*2]
a Install covers (6) and (7), then tighten bolts (9)
and (9-1).
3 Covers (6) and (7):
245 – 309 Nm {25 – 31.5 kgm}
[*3]
3 Bolts (9) and (9-1):
18. Sling equalizer bar (15) and remove it clearing 1,960 – 2,450 Nm {200 – 250 kgm}
the main frame and the track frames.
k Do not lower the machine after removing
[*4]
2 Inside surface of bushing: Grease (G2-LI)
the equalizer bar.
4 Equalizer bar assembly: 500 kg
a Before installing the pin, adjust the height of the
main frame by operating hydraulic jack [1] to
align the equalizer bar hole with that of track
frame hole.
a Install pin (10) with the "UP" mark up, a mark put
upon removal.
50-260 D375A-6
(02)
DRAFT
[*5]
3 Lock plate mounting bolt :
549 ± 59 Nm {56 ± 6 kgm}
[*6]
2 Equalizer bar bushing and
main frame bushing: Grease (G2-LI)
a Before installing the pin, operate the crane to
align the main frame hole with the equalizer bar
hole.
q Refilling
level.
5 Pivot case: 18 l (SAE30)
D375A-6 50-261
(02)
DRAFT
Disassembly and assembly of equalizer bar bushing

3) Set tool N2 to remove side bushing (4) from
Special tools equalizer bar (5).
New/remodel
Necessity
Sketch
Sym-
Q'ty
Part No. Part name
bol
1 791T-650-2410
Bracket t 1 N Q
2 791T-650-2420
Bracket t 1 N Q
3 790-438-1110
Screw t 1
N 2 4 791-112-1180
Nut t 2
5 790-101-2540
Washer t 2
Puller
6 790-101-2102 t 1
(294kN {30ton})
7 790-101-1102 Pump t 1
Disassembly
1. Center bushing
1) Remove center bushings (1).
2. Guide bushing
1) Remove seals (2).
2) Remove snap ring (3).
50-262 D375A-6
(02)
DRAFT
Assembly 2) Install snap ring (3).

1. Side bushing a After installing the snap ring, fill parts (c)
1) Set side bushing (4) and tool N2 to press fit before and after the side bushing with
side bushing (4) to equalizer bar (5). grease (G2-LI).
2 Outside surface of side bushing: 2 Grease to be supplied to side bushing:
Molybdenum disulphide lubricant 0.3 l
(LM-P) 3) Press fit seals (2) by using the press.
a Install the side bushing in the direction a Press-fitting force for seal:
shown in the following figure. 9.8 – 29.4 kN {1 – 3 ton}
a Press fit the seal so that its metal ring
does not protrude from the end face of the
equalizer bar.
2 Seal lip: Grease (G2-LI)
1] Install the outer bushing with split

faces (a) (jointed face) level.
2] Set the greasing holes (b) of the inner
and outer bushings at an angle.
a Press-fitting force for side bushing: 2. Center bushing
34.3 – 73.5 kN {3.5 – 7.5 ton} Press fit bushings (1) by using the press.
2 Outside surface of center bushing:
(LM-P)
a Press-fitting force for center bushing:
4.9 – 186.2 kN {5 – 19 ton}
D375A-6 50-263
(02)
DRAFT
Removal and installation of segment tooth

Installation
1. Set the segment tooth to be removed to a posi- moval.
tion where it can be removed easily (between the
track and track frame). 2 Seat of segment tooth mounting nut:
k Park the machine on a level surface and Molybdenum disulphide lubricant
lower the work equipment to the ground. (LM-P)
k Set the parking brake lever and work 3 Segment tooth mounting nut:
equipment lock lever in the lock position. 1,813 ± 98 Nm {185 ± 10 kgm}
from the negative (-) terminal of the bat-
tery.
3. Remove the mounting bolts and remove the

segment tooth (3).
a Before removing all mounting bolts, insert the
bar [1] into the upper mounting bolt hole, then
slide the segment tooth outward to remove it.
4 Segment tooth: 35 kg
50-264 D375A-6
(02)
DRAFT
D375A-6 50-265
(02)
DRAFT
Hydraulic system
Removal and installation of hydraulic tank assembly
Hydraulic system
Removal

k Release the internal pressure of the hydrau-
lic tank and residual pressure inside the pip-
ing. For details, see Testing and adjusting
"Releasing residual pressure of hydraulic
circuit".
3. Loosen drain valve (2) to drain oil in the suction
1. Drain the hydraulic tank.
hose.
a Prepare a container to catch the oil, and take
care not to allow the drained oil to splash any.
2. Sling undercover (1) and lower it by using lifting
tool [1].
a Because one side of the undercover is
hinged, remove bolts on the other side to
sling the undercover.
50-266 D375A-6
(02)
DRAFT
Hydraulic system
5. Disconnect main valve return hose (5) and fan 8. Remove four hydraulic tank mounting bolts (16).
motor return hose (6) from the hydraulic tank.
9. Lift off hydraulic tank assembly (17). [*1]

6. Disconnect suction tube (8). 4 Hydraulic tank assembly: 240 kg
7. Disconnect following return hoses (9) to (15).
(9): Self-pressure reducing valve drain hose
(10): Work equipment pump drain hose
(11): Fan motor drain hose
(12): Blade PPC drain hose
(13): Ripper PPC drain hose
(14): Fan pump (LPV90) drain hose
(15): Fan pump (LPV30) drain hose
D375A-6 50-267
(02)
DRAFT
Hydraulic system
Installation
moval.
a Install the tank assembly properly, so that the
tank side is flush with the fender outside surface.
Difference (d): Max. 3 mm
(Refilling)
Supply oil through the oil filler to the specified level.
Run the engine to circulate the oil through the sys-
tem. Then, check the oil level again.
q Air bleeding
Testing and adjusting "Bleeding air from
hydraulic circuit".
50-268 D375A-6
(02)
DRAFT
Hydraulic system
Removal and installation of work equipment pump assembly
Removal
lic tank and residual pressure inside piping.
For details, see Testing and adjusting "Re-
leasing residual pressure of hydraulic cir-
cuit".
1. Drain the hydraulic tank.
3. Loosen drain valve (2) to drain oil in the suction
hose.
2. Sling undercover (1) and lower it by using lifting a Prepare a container to catch the oil, and take
tool [1]. care not to allow the drained oil to splash any.
a Because one side of the undercover is
hinged, remove bolts on the other side to
sling the undercover.
4. Remove the floor plate and brake pedal

assembly according to the following procedure.
1) Remove inspection cover (3).
D375A-6 50-269
(02)
DRAFT
Hydraulic system
2) Disconnect connectors DEC (4) and BRK (5). 5. Remove the cover according to the following
3) Remove the mounting bolts of floor plate (6). procedure.
4) Remove brake rod (7) according to the 1) Remove covers (10), (11) and (12).
following procedure. [*1] 2) Remove headlamp protection cover (13).
1] Raise floor plate (6) and support it with a 3) Remove the mounting bolts of battery case
block. (14) and reposition battery case (14)
2] Remove cotter pin (8), and then remove outward.
nut (9) under floor plate (6). 4) Remove covers (15) and (16).
3] Disconnect brake rod (7).
a Note the installed dimensions of the
rod for installation purpose.
5) Remove floor plate and brake pedal
assembly (6).
6. Remove damper case oil level gauge (17) and

bracket (18) as a unit from the damper case.
50-270 D375A-6
(02)
DRAFT
Hydraulic system
7. Disconnect hose (19). k Never operate the crane while imple-

a Also disconnect two hose clamps. menting steps 2) and 3). This is very
dangerous.
8. Disconnect mounting bracket (20) of the wiring

clamp from filter assembly (21). 4) Pull out filter assembly (21) toward frame
9. Disconnect wiring clamps (22), (23), and (24) (29) keeping the assembly level.
from filter assembly (21).
10. Remove twelve mounting bolts (25) and (25a) of
the filter assembly.
5) Lift off filter assembly (21) at an angle gradu-

ally.
11. Remove filter assembly (21) according to the

following procedure. [*2]
1) Lift filter assembly (21) to the position very
close to frame (26).
2) Disconnect tube (27).
3) Disconnect connector (28).
D375A-6 50-271
(02)
DRAFT
Hydraulic system
12. Remove hose (30). q Carry out installation in the reverse order to re-
13. Disconnect suction tube clamp (31). [*3] moval.
[*1]
a Install the brake rod according to the installed di-
mensions noted when it is removed.
a Be sure to bend the split pin installed on the cot-
ter pin.
a Adjust the brake rod. For details, see Testing
and adjusting "Adjusting brake pedal and park-
ing brake lever".
[*2]
a Install the filter assembly aligning it with the
block so that the O-ring does not come off.
[*3]
3
14. Disconnect hose (32). Clamp mounting bolt:
15. Disconnect tube (33) from work equipment 24.5 – 29.4 Nm {2.5 – 3.0 kgm}
pump assembly (34).
q Refilling (hydraulic tank)
q Air bleeding
Testing and adjusting "Bleeding air from the
work equipment cylinder".
16. Remove four mounting bolts (35) of the work

equipment pump.
17. Sling work equipment pump assembly (34), then
lower it to remove.
4 Work equipment pump assembly:110 kg
50-272 D375A-6
(02)
DRAFT
Hydraulic system
Removal and installation of fan pump assembly

. 9. Loosen suction tube clamp (8) and disconnect
Removal suction tube (9).
k Loosen the oil filler cap of the hydraulic oil
tank gradually to release the internal pres-
sure of the hydraulic tank.
1. Drain the oil from the hydraulic tank.


"Removal and installation of fuel tank assembly."
3. Remove the ROPS guard. For details, see 10. Remove two mounting bolts (10) and lift off fan
"Removal and installation of ROPS guard pump assembly (11).
assembly." 4 Fan pump assembly: 80 kg
a Steps 2 to 5 are not required when removing
4. Remove the operator cab assembly. For details, the pump unit only.
see "Removal and installation of operator cab
assembly."
5. Remove the floor frame assembly. For details,

see "Removal and installation of floor frame
assembly."
6. Disconnect pilot valve sensor connector FA2 (2).
7. Disconnect four hose clamps (3).
8. Disconnect hoses (4) to (7).
D375A-6 50-273
(02)
DRAFT
Hydraulic system
Installation

moval.
(Refilling)
q Air bleeding
a Bleed air from the piping. For details, see
Testing and adjusting "Bleeding air from fan
pump".
50-274 D375A-6
(02)
DRAFT
Hydraulic system
Removal and installation of control valve assembly

. 3. Disconnect three hose clamps (9).
Removal
.
lic tank and residual pressure inside piping.
For details, see Testing and adjusting "Re-
leasing residual pressure of hydraulic cir-
cuit".
a Note the connection points of each disconnected
hose.
4. Disconnect wiring connector (10).
2. Disconnect PPC hoses (3) to (8).

(hose band color)
(3): White
(4): Green
(5): Black/Blue
(6): Brown
(7): Black
(8): Yellow
D375A-6 50-275
(02)
DRAFT
Hydraulic system
5. Disconnect hoses (11) to (24). 6. Remove four control valve mounting bolts (25).
(11): Ripper tilt BACK 7. Lift off control valve assembly (26).
(12): Ripper tilt IN 4 Control valve assembly: 130 kg
(13): Ripper lift RAISE
(14): Ripper lift LOWER
(15): Blade left tilt BACK (Only for dual tilt speci-
fication machine)
(16): Blade left tilt DUMP (Only for dual tilt spec-
ification machine)
(17): Blade right tilt BACK
(18): Blade right tilt DUMP
(19): Blade lift RAISE
(20): Blade lift LOWER
(21): Blade lift RAISE
(22): Blade lift LOWER
(23): From work equipment pump
(24): To work equipment pump Ls port
Installation
moval.
(Refilling)
q Air bleeding
Testing and adjusting "Bleeding air from the
work equipment cylinder".
50-276 D375A-6
(02)
DRAFT
Hydraulic system
Disassembly and assembly of control valve assembly
a This section provides only the precautions when 3. Assembly of suction valve assembly
assembling the control valve assembly. Check that O-ring (38) is fitted to suction valve
assembly (37), and install suction valve
Assembly assembly (37) to valve body (1).
a Clean all parts, check them for dirt and damage, 3 Suction valve assembly (37):
and apply oil to the sliding surfaces before in- 176.6 – 196.1 Nm {18 – 20 kgm}
stalling.
4. Assembly of check valve assembly
1. Assembly of main relief valve assembly 1) Install valve (39) and spring (40) to valve
Check that O-ring (3) is fitted to main relief valve body (1).
assembly (2), and install main relief valve 2) Fit backup ring (42) and O-ring (41) to plug
assembly (2) to valve body (1).
3 Main relief valve assembly (2):
(43), and install plug (43) to valve body (1).
3 Plug (43):
176.6 – 196.1 Nm {18 – 20 kgm} 176.6 – 196.1 Nm {18 – 20 kgm}
2. Assembly of LS relief valve assembly 5. Assembly of check valve assembly

a Install backup ring (15), O-rings (16) and (17) Check that O-ring (45) is fitted in check valve
to LS relief valve assembly (14), and install assembly (44), and install check valve assembly
LS relief valve assembly (14) to valve body (41) to valve body (1).
3 Check valve assembly (44):
(1).
3 LS relief valve assembly (14):
58.8 – 78.5 Nm {6 – 8 kgm}
137 – 157 Nm {14 – 16 kgm}
D375A-6 50-277
(02)
DRAFT
Hydraulic system
6. Installation of plug (54), (55):

1) Installation of plug (46) 107.8 – 140.7 Nm {11.0 – 15.0
1] Install retainer (50) to valve body (1). kgm}
(56): 29.4 – 39.2 Nm {3 – 4.8 kgm}
2] Install O-ring (47) and backup ring (42) to
(57):
plug (46).
3 Plug (46):
107.7 – 161.8 Nm {12 – 16.5 kgm}
274.6 – 367.7 Nm {28 – 37.5 kgm}
3) Installation of plugs (58) and (59)
2) Installation of plugs (51) to (60) 1] If plugs (58) (2 places) are removed, wrap
a Check that O-ring or backup ring is fitted sealing tape around the thread portion
when installation.
3 Plug (58):
to each plug, and then install the plug to
valve body (1).
3 Plug:
58.9 ± 6.9 Nm {6 ± 0.7 kgm}
(51) (2 places): 2] If plugs (59) (11 places) have been
176.6 – 196.1 Nm {18 – 20 kgm} removed, replace with new ones.
(52) (2 places), (53) and (58) (2 a The plug is a dry-seal type with spe-
places): cial nylon coated on its threads.
19.6 – 27.5 Nm {2 – 2.8 kgm} 3 Plug (59):
7.8 – 13.7 Nm {0.8 – 1.4 kgm}
(Blade tilt valve) 8. Assembly of suction safety valve assembly

7. Assembly of suction valve assembly Fit O-ring (31a) to suction safety valve assembly
1) Install spool (19a) to valve body (1a). (30a), and install suction safety valve assembly
2) Fit spring (20a), O-ring (23a), backup ring (30a) to valve body (1a).
(22a) and O-ring (21a) to plug (24a), and 3 Suction safety valve assembly (30a):
install plug (24a) to valve body (1a). 176.6 – 196.1 Nm {18 – 20 kgm}
3 Plug (24a):
372.7 – 465.8 Nm {38 – 47.5 kgm}
50-278 D375A-6
(02)
DRAFT
Hydraulic system
9. Assembly of check valve assembly 11. Installation of plug

1) Install valve (25a) and spring (24a) to valve 1) Fit O-ring (35a), O-ring (36a), backup ring
body (1). (37a) to plug (34a), and install plug (34a) to
2) Fit backup ring (28a) and O-ring (27a) to plug valve body (1).
(29a), and install plug (29a) to valve body (1). 3 Check valve assembly (32a):
3 Plug (29a): 58.8 – 78.5 Nm {6 – 8 kgm}
176.6 – 196.1 Nm {18 – 20 kgm} 2) If plugs (38a) (2 places) are removed,
10. Assembly of check valve assembly replace with new ones.
Fit O-ring (33a) to check valve assembly (32a), a The plug is a dry-seal type with special
and install check valve assembly (32a) to valve nylon coated on its threads.
body (1). 3 Plug (38a):
3 Check valve assembly (32a): 7.8 – 13.7 Nm {0.8 – 1.4 kgm}
58.8 – 78.5 Nm {6 – 8 kgm}
(Ripper lift valve) 14. Assembly of check valve assembly

12. Assembly of check valve assembly Fit O-ring (20b) to check valve assembly (19b),
1) Install valve (14b) and spring (15b) to valve and install check valve assembly (19b) to valve
body (1b). body (1b).
2) Fit spring (15b), backup ring (17b) and O-ring 3 Check valve assembly (19b):
(16b) to plug (18b), and install plug (18b) to 58.8 – 78.5 Nm {6 – 8 kgm}
valve body (1b).
3 Plug (18b):
176.6 – 196.1 Nm {18 – 20 kgm}
13. Assembly of suction valve assembly

Fit O-ring (22b) to suction valve assembly (21b),
and install suction valve assembly (21b) to valve
body (1b).
3 Suction valve assembly (21b):
176.6 – 196.1 Nm {18 – 20 kgm}
D375A-6 50-279
(02)
DRAFT
Hydraulic system
15. Installation of plug 3 Plug (27b):

1) Installation of plug (27b) 176.6 – 196.1 Nm {18 – 20 kgm}
1] Install plug (23b) to valve body (1b). 2) If plug (28b) is removed, replace with new
2] Fit O-ring (24b), backup ring (25b) and one.
O-ring (26b) to plug (27b), and install plug a The plug is a dry-seal type. Special nylon
is coated on its threads.
3 Plug (28b):
(27b) to valve body (1b).
7.8 – 13.7 Nm {0.8 – 1.4 kgm}
(Ripper tilt valve) 19. Installation of plug

16. Assembly of check valve assembly 1) Installation of plug (27c)
1) Install valve (14c) and spring (15c) to valve 1] Install plug (23c) to valve body (1c).
body (1c). 2] Fit O-ring (24c), backup ring (25c) and
2) Fit spring (15c), backup ring (17c) and O-ring O-ring (26c) to plug (27c), and install plug
(16c) to plug (18c), and install plug (18c) to (27c) to valve body (1c).
valve body (1c). 3 Plug (27c):
3 Plug (18c): 176.6 – 196.1 Nm {18 – 20 kgm}
176.6 – 196.1 Nm {18 – 20 kgm} 2) Installation of plug (28c)
17. Assembly of suction valve assembly Fit O-ring (29c), backup ring (30c) and O-ring
Fit O-ring (22c) to suction valve assembly (21c), (31c) to plug (28c), and install plug (28c) to
and install suction valve assembly (21c) to valve valve body (1c).
body (1c). 3 Plug (28c):
3 Suction valve assembly (21c): 176.6 – 196.1 Nm {18 – 20 kgm}
176.6 – 196.1 Nm {18 – 20 kgm}
18. Assembly of check valve assembly 3) If plugs (32c) and (33c) are removed, replace
Fit O-ring (20c) to check valve assembly (19c), with new ones.
and install check valve assembly (19c) to valve a The plug is a dry-seal type with special
body (1c). nylon coated on its threads.
3 Check valve assembly (19c): 3 Plug:
58.8 – 78.5 Nm {6 – 8 kgm} (32c)(4 places):
16.7 ± 2.9 Nm {1.7 ± 0.3 kgm}
50-280 D375A-6
(02)
DRAFT
Hydraulic system
(33c)(3 places):
7.8 – 13.7 Nm {0.8 – 1.4 kgm}
D375A-6 50-281
(02)
DRAFT
Hydraulic system
Disassembly and assembly of blade PPC valve assembly

.
a This section provides only the precautions when

assembling the blade PPC valve assembly.
a As the parts look alike, note the locations to
which they are installed during disassembly.
a Spare part cannot be supplied individually for the
following parts. If any of them needs to be re-
placed, replace the blade PPC valve assembly
with new one.
(2),(3),(4),(5),(6),(7),(8),(9),
(11),(12),(13),(14),(15),(16),(17),
(18),(19),(20),(21),(22),(23),(24),
(39),(40),(41),(42),(43),(44)
a Do not remove nipples (39) to (41) unless it is
necessary.
50-282 D375A-6
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DRAFT
Hydraulic system
Assembly 8. Install plates (31) and (32).

1. Install the blade RAISE valve. 3 Mounting bolt:
1) Install valve (2) to valve body (1). 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
2) Install shims (3) and spring (4) to valve (2).
a Install spring (4) with its small diameter 9. Install joint (33).
(inside diameter) end facing shims (3). a When installing joint (33) to body (29), apply
3) Install spring (5), retainer (6), piston (7), Loctite in the following manner.
spring (8), shim (3), piston (9) and seat (10). 1] When installing the joint, apply a drop
a When installing piston (7), apply grease (approx. 0.02 g) of Loctite (No. 648) to
(G2-LI) to the periphery of the piston and each female thread portion (A) (2 places)
inner surface of the body bore. of the valve body. Before installing the
a When installing piston (9), apply grease joint, degrease its male threads and
(G2-LI) to the inner surface of the body female threads of the valve body with
bore. Drysol and dry them.
2] Drop LOCTITE to the following positions.
2. Install the blade LOWER valve. (L): 5 – 7 mm from end surface
1) Install valve (11) to valve body (1). 2 Body female threads (A):
Adhesive (Loctite No. 648)
3 Joint (33):
2) Install shims (3) and spring (12) to valve (11).
a Install spring (12) with its small diameter
(inside diameter) end facing shims (3). 39 – 49 Nm {4 – 5 kgm}
3) Install spring (13), retainer (14), piston (7),
shims (42), retainer (15), balls (16), collar
(17), spring (18), spacers (19) and piston
(44).
a When installing piston (7), apply grease
(G2-LI) to the periphery of the piston and
inner surface of the body bore.
(G2-LI) to the inner surface of the body
bore.
3. Install the blade tilt valve.

1) Install valve (2) to valve body (1).
2) Install shims (3) and spring (20) to valve (2). a Apply gear oil grease (G2-LI) to the sliding
a Install spring (20) with its small diameter portion of the joint.
(inside diameter) end facing shims (3). (J portion): Apply grease (G2-LI) 7 – 10 ml to
entire circumference.
3) Install spring (21), retainer (22), piston (23),
(P portion): Apply gear oil 0.2 – 0.4 ml to the
shim (43) and piston (24).
sliding portions (4 places) between joint and
pin.
(G2-LI) to the periphery of the piston and
inner surface of the body bore.
(G2-LI) to the inner surface of the body
bore.
4. Install orifice (25).

3 Orifice: 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
5. Fit O-rings (26) and (27), and install plate (28).
6. Fit O-rings (26) and (27), and install valve body

(29).
7. Install seal (30) to valve body (29).
D375A-6 50-283
(02)
DRAFT
Hydraulic system
10. Install boot (37) and disc (35), and tighten nut
(36).
1) Install disc (35), so that each bolt (38) is posi-
tioned at the center of each side of disc (35)
to prevent the disc from interfering with any
bolt (38) during compound operation.
2) When installing disc (35), adjust the play at
lever end (400 mm from the fulcrum of the
lever) to 1 - 6 mm.
3) Holding disc (35) with tool [1], tighten nut
(36).
a At this time, allow valve body (29) or plate
(31) to have play (a) and (b), and lock with
tool [2].
3 Nut (36):
93.1 – 112.7 Nm {9.5 – 11.5 kgm}
a After installing the disc, adjust the disc

height. For details, see Testing and adjust-
ing, "Adjusting PPC valve".
50-284 D375A-6
(02)
DRAFT
Hydraulic system
Disassembly and assembly of ripper PPC valve assembly

a Install spring (4) with its small diameter end
a This section provides only the precautions when (inside diameter) facing shims (3).
assembling the ripper PPC valve assembly.
a Spare part is not available for nipples (18) and 3. Install springs (5) and (6), retainer (7) and piston
(19). Do not remove them unless necessary. (8).
a Springs (5) and (6) having different number
Assembly of turns are used for the oil pressure ports
shown below. Take care not to install wrong
springs.
Port Total number of turns

P1, P2 11
P3, P4 9
a Each port is stamped on the bottom of the
valve body.
a When installing piston (8), coat the outside
surface of the piston and the inside surface of
the bore in the valve body with grease.
2 Piston: Grease (G2-LI)
4. Install seat (9) and seal (10) to valve body (1).
5. Install plates (11) and (12).

3 Mounting bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kg}
6. Install joint (13).

a When installing joint (13) to valve body (1),
apply Loctite in the following manner.
1] When installing the joint, apply a drop
(approx. 0.02 g) of Loctite (No. 648) to
each female thread portion (A) (2 places)
of the valve body.
Before installing the joint, degrease its
male threads and the female threads of
the valve body with Drysol and dry them.
2] Drop LOCTITE to the following positions.
(L): 5 – 7 mm from end face
2 Body female threads (A): Adhe-
sive (Loctite No. 648)
3 Jonit (13): 39 – 49 Nm {4 – 5 kgm}
1. Install valve (2) to valve body (1).
2. Install shims (3) and spring (4) to valve (2).
D375A-6 50-285
(02)
DRAFT
Hydraulic system
a Apply gear oil and grease (G2-LI) to the slid-

ing portions of the joint.
(J portion): Apply grease (G2-LI) 7 – 10 ml to
entire circumference.
(P portion): Apply gear oil 0.2 – 0.4 ml to the
sliding portions (4 places) between the joint
and pin.
7. Install disc (14) and boot (15), and tighten with

nut (16).
3 Nut: 69 – 88 Nm {7 – 9 kgm}
a After installing the disc, adjust the disc
height. For details, see Testing and adjust-
ing, "Adjusting PPC valve".
50-286 D375A-6
(02)
DRAFT
Hydraulic system
Disassembly and assembly of hydraulic cylinder assembly

Disassembly
Special tools
1. Cylinder tube
New/remodel
Necessity
Remove the cylinder tube.
Sketch
Sym-
Q'ty
Part No. Part name
bol
2. Quick drop valve assembly
a Perform this procedure for only the blade lift
1 790-502-1003 Stand t 1
cylinder.
790-201-1841 q Push tool 1 1) Remove quick drop valve assembly (1).
2 790-201-1861 q Push tool 1
790-101-5021 q Grip 1
01010-50816 q Bolt 1
790-201-1650 q Plate 1
3 790-201-1670 q Plate 1
U 790-101-5021 q Grip 1
01010-50816 q Bolt 1
4 790-720-1000 Expander t 1
796-720-1680 Ring t 1
07281-01589 Clamp t 1
796-720-1720 Ring t 1
5
07281-02429 Clamp t 1
796-720-1690 Ring t 1
07281-02169 Clamp t 1
790-102-4300 Wrench t 1
6
790-102-4310 Pin t 2
2) Disassemble the quick drop valve assembly
1] Remove elbow (2).
2] Remove spring (3), washer (4), and
valves (5) and (6), and pull out collar (7).
D375A-6 50-287
(02)
DRAFT
Hydraulic system
3. Piston rod assembly 2) Remove bolt (11).

1) Set cylinder assembly (8) to tool U1. 3) Remove spacer (12).
2) Remove head assembly (9). 4) Remove valve (13) from spacer (12). (Only
3) Pull out piston rod assembly (10). for lift cylinder)
a Put an oil container under the cylinder to 5) Remove piston assembly (14).
receive the oil. 6) Remove backup rings (15) and O-ring (16).
7) Remove retainer (17). (Only for lift cylinder)
4. Piston assembly .
q Blade lift cylinder, and blade tilt cylinder 8) Disassemble the piston assembly according
1) Set piston rod assembly (10) to tool U1. to the following procedure.
1] Remove wear ring (18).
2] Remove piston rings (19).
a Do not reuse valve (V) and seat (S).
BL: Blade lift cylinder
BT: Blade tilt cylinder
50-288 D375A-6
(02)
DRAFT
Hydraulic system
q Ripper lift cylinder and ripper tilt cylinder a If screw (31) cannot be removed because
1) Set piston rod assembly (10) to tool D1. it is punched too tight, screw in it deeply
into the hole once, tap the hole by using
tap [1], then remove the screw.
2) Remove lock screw (31) of piston assembly

(30).
q Screw size: M12 × pitch 1.75 3) Using tool U6, remove piston assembly (30)
from piston rod (32).
4) Disassembly of the piston assembly

1] Remove the backup ring and O-ring (33).
2] Remove wear ring (34).
3] Remove piston ring (35).
D375A-6 50-289
(02)
DRAFT
Hydraulic system
5. Cylinder head assembly Assembly

1) Remove cylinder head assembly (20) from a Apply engine oil to the sliding surfaces of each
the piston rod. part and install the packings, dust seals, and
O-rings, taking care not to damage them.

1) Assemble the cylinder head assembly
1] Using tool U2, press fit bushing (28) to the
cylinder head
3] Install buffer ring (26) and rod packing
(25).
4] Using tool U3, press fit seal (24).
2) Disassemble the cylinder head assembly

1] Remove O-ring (21) and backup ring (22).
2] Remove snap ring (23), then remove dust

seal (24).
3] Remove rod packing (25) and buffer ring
(26).
4] Remove snap ring (27), then pull out
bushing (28).
50-290 D375A-6
(02)
DRAFT
Hydraulic system
6] Install backup ring (22) and O-ring (21).
a Replace valve (V) and seat (S)with

2) Install cylinder head assembly (20) to the new ones.
piston rod.
2. Piston assembly
q Blade lift cylinder and blade tilt cylinder
1) Assemble the piston assembly according to
1] Using tool U4 expand piston ring (19).
a 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 (19) from tool U4, and
install it to the piston.
3] Set tool U5, to compress piston ring (19).
4] Install wear ring (18) to the piston.
D375A-6 50-291
(02)
DRAFT
Hydraulic system
2) Install retainer (17). (Only for lift cylinder) 5] Install backup rings and O-ring (33).
3) Install O-ring (16) and backup rings (15). a Install the backup rings after warming
a Apply grease to the O-ring and backup it in hot water at about 50 – 60°C.
rings so that the backup rings do not sep- a Apply grease to the O-ring and back-
arate from each other. up rings, so that the backup rings do
4) Install piston assembly (14). not separate from each other.
5) Install valve (13) to the spacer. (Only for lift
cylinder)
6) Install spacer (12) and tighten the mounting
bolts (11).
a After tightening the mounting bolts, leave
the piston and piston rod assembly for 30
minutes.
3 Mounting bolt:
Lift cylinder
98–122.6 Nm {10–12.5 kgm}
Tilt cylinder
157 – 196 Nm {16 – 20 kgm}
2) Install the piston assembly to piston rod (10),

and set the piston rod to tool U1.
q Ripper lift cylinder and ripper tilt cylinder

1) Assembly of the piston assembly
1] Using tool U4, expand piston ring (35).
a Set the piston ring to tool U4, and turn
the handle 8 – 10 turns to expand the
piston ring.
2] Remove piston ring (35) from tool U4 and
intall it to piston.
3] Using tool U5, compress piston ring (35).
4] Install wear ring (34).
50-292 D375A-6
(02)
DRAFT
Hydraulic system
3) When reusing piston rod (32) and piston 4) When using new parts for either or both of
assembly (30), take the following steps for piston rod (10) and piston assembly (30),
installation. take the following steps for installation.
a Remove any flash or burr on the threaded 1] Using tool U6, tighten piston assembly
portion by using a file or other tool. (30).
a Clean the parts thoroughly and remove 3 Piston assembly:
metal chips and dust. 294 ± 29.4 Nm {30 ± 3.0 kgm}
1] Screw piston assembly (30) into piston 2] Make a hole to install the screw.
rod (32) by using tool U6, and tighten the a Apply the drill tip to the groove where
piston assembly until the tapped holes the piston and piston rod are en-
are aligned. gaged, and make a horizontal hole.
q Dimensions of a screw hole (mm):
Tap hole diameter: 10.3
Tap hole depth: 27
Tap used: 12 x 1.75
Tap depth: 20
3] Remove steel chips and dust and clean
the assembly completely.
2] Install screw (31) to piston (30).

a Install the screw after degreasing and
drying its threads adequately.
a After installing the screw, punch it at
four points on it periphery.
2 Threads of screw:
Adhesive(Loctite No.262)
3 Screw:
58.9 – 73.6 Nm {6.0 – 7.5 kgm}
D375A-6 50-293
(02)
DRAFT
Hydraulic system
4] Install screw (31). 4. Quick drop valve assembly

a Install the screw after degreasing and a Perform this procedure for only the blade lift
drying the threads completely. cylinder.
a After tightening the screw, punch it at 1) Install the quick drop valve assembly as
four points on its periphery. follows.
2 Threads of screw: 1] Install collar (7), and install valves (6) and
Adhesive (Loctite No.262) (5), washer (4), and spring (3).
3 Screw:
58.9 – 73.6 Nm {6.0 – 7.5 kgm}
2) Install quick drop valve assembly (1).
3. Piston rod assembly 5. Cylinder tube

1) Set cylinder (8) to tool U1. Install the cylinder tube.
2) Install piston rod (10) to cylinder (8).
a Apply grease to the sealing part of the pis-
ton.
a Push in the piston rod fully
3) Push in head assembly (9) to the cylinder
and tighten the mounting bolts.
a Apply grease to the backup ring.
50-294 D375A-6
(02)
DRAFT
Hydraulic system
Disassembly and assembly of ripper pin puller cylinder assembly

Disassembly
Special tools 1. Cylinder assembly
1) Set pin puller cylinder assembly (1) to tool
New/remodel
U1.
Necessity
Sketch
Sym- 2) Using tool U7, remove cylinder head
Q'ty
Part No. Part name assembly (2) and piston rod (3) as a unit.
bol
a Put an oil container under the cylinder to
receive the oil.
1 790-502-1003 Cylinder repair stand t 1
790-201-1721 q Push tool 1
2
790-101-5021 q Grip 1
01010-50816 q Bolt 1
U 790-201-1530 q Plate 1
3
790-101-5021 q Grip 1
01010-50816 q Bolt 1
4 790-720-1000 Expander t 1
796-720-1630 Ring t 1
5
07281-00709 Clamp t 1
7 790-102-2302 Wrench t 1

1) Remove cylinder head assembly (2) from
piston rod (3).
D375A-6 50-295
(02)
DRAFT
Hydraulic system
2) Remove O-ring (5) and backup ring (6). Assembly

3) Remove O-ring (7). a Apply engine oil to the sliding surfaces of each
4) Remove snap ring (8), then remove dust seal part and install the packings, dust seals, and
(9). O-rings, taking care not to damage them.
5) Remove rod packing (10), and remove
bushing (11). 1. Piston rod assembly
1) Using tool U4, expand piston ring (12).
a Set the piston ring to the tool and turn the
handle 8 – 10 turns to expand the ring.
2) Remove piston ring (12) from the tool, then
install it to piston rod (3).
3) Using tool U5, compress piston ring (12).
3. Piston rod assembly

Remove piston ring (12) from piston rod (3).
50-296 D375A-6
(02)
DRAFT
Hydraulic system
2. Cylinder head assembly 6) Install cylinder head assembly (2) to piston

1) Using tool U2, press fit bushing (11) to rod (3).
cylinder head (4).
3. Cylinder assembly
2) Using tool U3, press fit dust seal (9) to 1) Set the cylinder to tool U1 and support the
cylinder head (4). cylinder with block [1].
2) Install piston rod (3) and cylinder head
assembly (2) as a unit.
a Apply grease to the sealing part of the pis-
ton.
a Apply grease to the backup ring.
a Push in the piston fully.
3) Using tool U7, tighten cylinder head
assembly (2).
3 Cylinder head assembly:
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).
D375A-6 50-297
(02)
DRAFT
Work equipment
Removal and installation of blade assembly
Work equipment
Removal
k Park the machine on a level place and lower

the work equipment to the ground complete-
ly.
1. Set blocks [1] securely under left and right

straight frames (9).
k Release the residual pressure from the

piping. For details, see "Releasing residu-
al pressure of work equipment cylinder"
in Testing and adjusting.
6. Remove right and left covers (5).
7. Disconnect hose (6).

a Plug the hose to prevent dust etc. from enter-
2. Sling lift cylinder assembly (2). ing the piping.
3. Remove lock plate (1), and remove connecting 8. Remove left and right trunnion caps (7).
pin (1a) on the piston rod side of the blade lift
cylinder. 9. Remove blade assembly (8). [*1]
a Start the engine and move the machine slow-
4. Start the engine and retract piston rod (3) fully. ly in reverse to separate the blade assembly
from the trunnions.
5. Lift cylinder (2) and bracket (4) as a unit, and
secure it to the radiator guard at position (A).
a Bind with wire to prevent the piston rod from
pulling out.
a Use the same procedure to separate the cyl-
inder on the opposite side from the blade.
50-298 D375A-6
(02)
DRAFT
Work equipment
Installation
moval.
[*1]
a Adjust height (b) of the right and left straight
frames and distance (c) between the frames by
using blocks [1] so that the dimensions are as
follows.
q Height at trunnion (b) : Apporx. 863 mm
q Distance (c) between frames: Apporx. 3,484
mm
q Refilling (hydraulic tank)

D375A-6 50-299
(02)
DRAFT
Work equipment
Disassembly and assembly of blade assembly

3. Sling tilt cylinder assembly (4), remove the lock
Disassembly plate, and remove pin (5).
k Place blocks [1] and [2] under the right and 4. Remove the lock plate, remove pin (6), and
left straight frames and blade to support the remove tilt cylinder assembly (4).
blade securely. 4 Tilt cylinder assembly: 380 kg
1. Remove right frame covers (1) and (2). 5. Set block [3] under right center brace (7), and
remove the mounting bolt of cap (8) on the right
2. Disconnect tilt cylinder hoses (3). straight frame side.
a Shims are fitted in the cap. Note the quantity
and thickness of the shims for installation
purpose.
50-300 D375A-6
(02)
DRAFT
Work equipment
6. Sling right straight frame (9) and disconnect right 11. Sling center brace (15), remove the mounting
center brace (7). bolts to remove cap (16). Then remove right and
left center braces (15) and (7).
7. Remove the lock plate, remove pin (10), and a Shims are fitted in the cap. Note the quantity
remove right straight frame (9). and thickness of the shims for installation
4 Straight frame: 1,150 kg purpose.
4 Center brace: 220 kg
8. Sling tilt brace (11), remove the lock plate, and

remove pin (12) from the blade. 12. Sling blade (17), and lay down the blade.
4 Blade: 4,900 kg
9. Remove the lock plate, remove pin (13), and lift

off tilt brace (11).
4 Tilt brace: 200 kg
10. Disconnect the left center brace using the same

procedure as steps 5 to 7, and remove left
straight frame (14).
D375A-6 50-301
(02)
DRAFT
Work equipment
Assembly 3. Sling right straight frame (9), install pin (10), and
a Check the quantity and thickness of the removed secure with the lock plate.
shims, and fit shims of the same quantity and 4 Straight frame: 220 kg
same thickness to the original locations.
a To adjust the shims, see Testing and adjusting, 4. Sling right straight frame (9) and set the ball of
"Adjusting blade". right center brace (7) to right straight frame (9).
1. Sling blade (17), place blocks or stands under

the blade to support the blade.
4 Blade: 4,900 kg
5. Install the shims to cap (8) of right center brace

(7), and tighten the mounting bolt.
a Standard thickness of shims: 4.5 mm
2. Sling center brace (15), install shim(s), and

tighten the mounting bolt of cap (16).
a Set a block under the center brace to align its
height with the height of the straight frame.
a Standard thickness of shims: 4.5 mm
4 Center brace: 220 kg
a Install center brace (7) of the opposite side in
the same manner.
50-302 D375A-6
(02)
DRAFT
Work equipment
6. Sling tilt cylinder assembly (4), install pin (6), and 10. Install left straight frame (14) using the same
secure with the lock plate. procedure as steps 3 to 5, and connect the left
4 Tilt cylinder assembly: 380 kg center brace.
7. Install pin (5), and secure with the lock plate. 11. Sling tilt brace (11), install pin (13), and secure
with the lock plate.
4 Tilt brace: 200 kg
12. Install pin (12), and secure with the lock plate.
8. Connect tilt cylinder hoses (3).
9. Install right frame covers (2) and (1).
13. Greasing
After assembly, apply sufficient amount of
grease to the points indicated by arrows in the
figure.
2 Greasing points of work equipment:
Grease (G2-LI)
D375A-6 50-303
(02)
DRAFT
Work equipment
Disassembly and assembly of giant ripper assembly

a Start the engine, retract the piston rod fully,
Disassembly and lower the tilt cylinder assemble on top of
the lift cylinder.
1. Stop the machine with its track riding on blocks k After stopping the engine, release the re-
[1], and lower the blade to the ground. sidual pressure from the piping. For de-
k Set the parking brake to the lock position. tails, see Testing and adjusting
"Releasing residual pressure of work
2. Sling the shank, then operate the pin-puller equipment cylinder".
switch to pull out the shank pin.
7. Disconnect four lift cylinder hoses (4), four tilt
3. Raise the ripper fully, and lower the shank to cylinder hoses (5), and two pin puller cylinder
remove. hoses (6).
4 Shank: 470 kg
4. Set stand [2] under the arm and beam.
8. Sling tilt cylinder assembly (7), remove pin (8),

and remove tilt cylinder assembly (7).
4 Tilt cylinder assembly : 270 kg
5. Sling the lift cylinder assembly and remove pin

(2).
a Start the engine, retract the piston rod fully,
and lower the lift cylinder assembly on top of
the arm.
6. Sling the tilt cylinder assembly and remove pin

(3).
50-304 D375A-6
(02)
DRAFT
Work equipment
9. Sling lift cylinder assembly (9), remove pin (10),

and remove lift cylinder assembly (9).
4 Lift cylinder assembly : 350 kg
10. Sling beam (11), remove right and left pins (12),
and remove beam (11).
4 Beam: 2,000 kg
11. Sling arm (13), remove right and left pins (14),
and remove arm (13).
4 Arm: 1,000 kg
D375A-6 50-305
(02)
DRAFT
Work equipment
Assembly 4. Sling tilt cylinder assembly (7) and set it to the

1. Sling arm (13) and set it to the mounting position, mounting position. Install pin (8), and secure it
install right and left pins (14), and secure them with the lock plate.
with the lock plates. 4 Tilt cylinder assembly: 270 kg
4 Arm: 1,000 kg
a Set a stand under the arm.
5. Connect two pin puller cylinder hoses (6), four tilt

cylinder hoses (5), and four lift cylinder hoses
2. Sling beam (11) and set it to the mounting posi- (4).
tion, install right and left pins (12), and secure
them with the lock plates.
4 Beam: 2,000 kg
a Set a stand under the beam.
6. Sling the tilt cylinder assembly, start the engine

to extend the piston rod to align the pin holes.
Install pin (3), and secure it with the lock plate.
3. Sling lift cylinder assembly (9) and set it to the 7. Sling the lift cylinder assembly, start the engine
mounting position. Install pin (10), and secure it to extend the piston rod to align the pin holes.
with the lock plate. Install pin (2), and secure it with the lock plate.
4 Lift cylinder assembly : 350 kg
50-306 D375A-6
(02)
DRAFT
Work equipment
8. Make both tracks of the machine ride blocks [1],

stop the machine and lower the blade to the
ground.
k Set the parking brake in the lock position.
9. Operate the ripper to raise the machine slightly

to remove stand [2].
10. Raise the ripper fully, pass wire through the

shank holder, then raise the shank slowly, align
the pin holes, and operate the pin puller switch to
insert the shank pin.
11. Raise the blade, and run the machine off blocks
[1].
12. Bleed air from the cylinders. For details, see

Testing and adjusting "Bleeding air from
hydraulic cylinder".
D375A-6 50-307
(02)
DRAFT
Removal and installation of ROPS guard

Removal and installation of ROPS guard
Installation
k Park the machine on a level surface and low- moval.
k Set the parking brake lever and work equip- [*1]
ment lock lever in the lock position. 3 ROPS guard mounting bolt :
k Stop the engine and disconnect the cable 1,519–1,911 Nm {155–195 kgm}
[*2]
1. Remove antenna (1). q Installed direction of ROPS guard
2. Sling ROPS guard (2), and remove the twelve

mounting bolts. [*1]
3. Lift off ROPS guard (2). [*2]

4 ROPS guard: 700 kg
50-308 D375A-6
(02)
DRAFT
Removal and installation of operator’s cab assembly

Removal
k Park the machine on a leve surface surface
and lower the work equipment to the ground.

"Removal and installation of ROPS guard."
2. Remove cover (1) on the left side of the

operator’s cab.
5. Remove three mounting bolts (8) of lower angle
(7).
3. Disconnect wiring connectors CN19 (2),

CN12VS (3), CN21 (4) and CN20 (5).
6. Remove back side cover (9) of the monitor
4. Disconnect four window washer hoses (6). [*1] panel.
a Pull the wires and window washer hoses into
the operator’s cab.
D375A-6 50-309
(02)
DRAFT
7. Remove angle (10). 10. Remove covers (13), (14) and (15).
8. Remove the operator’s cab mounting bolt 11. Remove twenty-one mounting bolts (indicated
according to the following procedure. by * mark) and lift off operator’s cab assembly
1) Remove right and left covers (11). (16).
4 operator’s cab assembly: 500 kg
50-310 D375A-6
(02)
DRAFT
Installation 2) Sling operators cab assembly (16), and bond

a Before installing the operator’s cab, loosen the seal (19) to the mating face.
mounting bolts of angle (7) and those of angle
(10) inside the operator’s cab.
1. Seal
1) Fit seal (17) to guide plate (18) of the air
conditioner box.
2 Part (A) on outside of seal (sealing
face agaist cab):
Grease (G2-LI)
D375A-6 50-311
(02)
DRAFT
2. Operator’s cab assembly

1) Lower the operator’s cab assembly slowly to
the floor frame.
a Take care not to shift or damage the seal.
a Check that the air conditioner duct seal
on the cab mates tightly with the air con-
ditioner duct of the dashboard.
a Lower the operator’s cab assembly car-
fully, as the clearance between the air
conditioner duct on the cab and the mon-
itor is small.
2) Tighten twenty-one mounting bolts (indicated
by * mark) partially.
a Note that the mounting bolts to be used at
the door portions differ in bolt length and 3) Tighten the mounting bolts to the specified
washer size from other mountinh bolts. torque, that are tightened partially in step 2.
a Check that air conditioner bracket (20) is 4) Tighten the mounting bolts of angle (7) and
fitted securely to the seal installed to the those of angle (10) inside the cab to the spec-
cab (21). ified torque.
a Check joint (B) between the seal and floor
frame for gap. a Perform the subsequent installation in the re-
If a clearance is found, remove the cab, verse order to removal from step 7.
and reinstall it correctly. If the clearance is
small, seal it with sealant. [*1]
a When connecting the window washer hoses,
match their band colors.
50-312 D375A-6
(02)
DRAFT
Removal and installation of floor frame assembly
Removal
k Park the machine on a leve surface surface
and lower the work equipment to the ground.
k If you drain the coolant or disconnect the
heater hose when the coolant or disconnect
the high, you may be scalded. In this case,
wait until the coolant temperature lowers and
then drain the coolant of disconnect the heat-
er hose.
a Note the installed positions of the hoses and wir-
ings for installation purpose.
a Plug the disconnected hoses to prevent oil from
flowing out.
1. Collect the air conditioner refrigerant (R134a)

from the air conditioner circuit in advance.
a Ask a qualified distributor for collection and
charge of the refrigerant (R134a).
a Never discharge the refrigerant (R134a) into
the atmosphere.
k If refrigerant gas (R134a) gets in your
eyes, you may lose your sight. Therefore,
put on safety glasses, safety gloves and
working suits with long sleeves when col-
lecting or charging the refrigerant.
q Quantity of refrigerant: 1,100 ± 100 g

6 Hydraulic tank: 130 l (refill capacity)

6 Radiator: 120 l

"Removal and installation of ROPS guard."

"Removal and installation of fuel tank assembly."
6. Remove the operator’s cab assembly. For

details, see "Removal and installation of
operator’s cab assembly."
7. Remove the cover’s according to the following

procedure.
D375A-6 50-313
(02)
DRAFT
8. Remove cover (5). 17. Disconnect two clamps (23).

9. Disconnect clamp (6).
18. Disconnect clamps (24) and (25).
11. Disconnect two air conditioner hoses (8). [*1]

a Plug the hoses to prevent entry of dirt and
water.
12. Disconnect heater hose clamp (9).
13. Disconnect two heater hoses (10).
a Close the heater valve on the engine side.
14. Remove clamp (11) and disconnect air hose
(12). [*2]
15. Disconnect ground wire (13).

16. Disconnect following wiring connectors (14) to
(22).
(From left top)
VED (14), PWR (15), USL (16)
(From right top)
VED (17), VDB (18), PL2 (19), PL1 (20), PL1
(21), PL1 (22)
50-314 D375A-6
(02)
DRAFT
19. Disconnect PPC hose (26) (band color: green). a Take care not to loosen the turnbuckle in
20. Disconnect hydraulic hose (27). wrong direction since it has left-hand
21. Disconnect clamp (28). threads.
22. Disconnect ripper PPC hose (29).
26. Disconnect right levers (38) and PPC valve as a

unit from the console according to the following
procedure.
1) Remove armrest (39).
2) Remove the mounting bolts of console cover
(40).
3) Remove each lever cover (41) from the
console cover and pull the console cover
away from levers (38).
a Lift up the console cover carefully since
the wiring connectors are installed to its
back side.
4) Disconnect wiring connectors PLSW (42)
and HNSW (43) from the back side of the
23. Remove wiring connectors RT1 (30), RPU (31), console cover.
RTB (32), and BLD (33). 5) Remove console cover (38).
6) Roll up lever cover (41) and remove four
mounting bolts (44) of each lever.
7) Lower the levers and PPC valve as a unit
below the console.
24. Remove pin (34) to disconnect parking brake

cable (35) from lever (36). [*3]
a Note the installed dimensions of the cable
before disconnecting it. (Nut position: N)
25. Remove pin (37) to disconnect brake rod (38)

from lever (39). [*4]
a Note the installed dimension of the brake rod
before disconnecting it.
D375A-6 50-315
(02)
DRAFT
27. Remove left console cover (45). 28. Remove four mounting bolts (47) each at the
right rear and left rear of the floor frame. [*5]
29. Remove four mounting bolts (48) at the left front

of the floor frame. [*6]
30. Remove mounting bolt (49) at the right front of

the floor frame. [*7]
31. Lift off floor frame assembly (50).

a Lift the assembly while checking all the hos-
es and wirings are disconnected.
a After removing the floor frame assembly, re-
move the spacer on the right front mount.
4 Floor frame assembly: 600 kg
50-316 D375A-6
(02)
DRAFT
Installation [*4]
q Carry out installation in the reverse order to re- a Install the brake rod to the turnbuckle, set it to
moval. the installed dimension noted when it was re-
moved.
[*1] a Be sure to bend the cotterpin securely.
a Install the hose without twisting it. a Adjust the brake rod. For details, see testing and
a When installing the air conditioner circuit hose, adjusting,”Adjusting brake pedal and parking
take care not to allow dint, dust and water to en- brake parking brake lever.”
ter it.
a Check that the O-ring is fitted to the air condition- [*5][*6]
er hose adapter before tightening the adapter 3 Mounting bolts at the right rear, left rear and
a When connecting the refrigerant hose, apply left front sides:
compressor oil for new refrigerant (R134a) (Den- 338.1 ± 39.2 Nm {34.5 ± 4 kgm}
so: ND-OIL8 or Zexcel: ZXL100PG (equivalent
to PAG 46)) to the O-ring. [*7]
3 Mounting bolt at right front:
1,370 - 1,666 Nm {140 - 170 kgm}
5 Coolant:120 l
q Charging air conditioner with refrigerant

Charge the air conditioner circuit with refrigerant
(R134a).
a Quantity of refrigerant: 1,100 ± 100 g
3 Tightening torque for air conditioner gas
piping.
12.23 ± 1.47 Nm {1.35 ± 0.15
16 x 1.5
kgm}
22.05 ± 2.45 Nm {2.25 ± 0.25
22 x 1.5
kgm}
31.85 ± 2.45 Nm {3.25 ± 0.25
24 x 1.5
kgm}
M6 bolt 5.39 ± 1.47 Nm {0.55 ± 0.15
(receiver portion) kgm}
M6 bolt
9.8 ± 1.96 Nm {1.0 ± 0.2 kgm}
(compressor portion)
[*2]
3 Air hose clamp:
6.8 ± 0.49 Nm {0.69 ± 0.05 kgm}
[*3]
a Install the cable to the bracket setting it to the di-
mension noted when the cable was removed.
a Be sure to bend the cotter pin securely.
a Adjust the parking brake. For details, see Test-
ing and adjusting, "Adjusting PCCS lever".
D375A-6 50-317
(02)
DRAFT
Removal and installation of air conditioner unit assembly
Removal
k If you drain the coolant or disconnect the
heater hose when the coolant temperature is
high, you may be scalded. In this case, wait
until the coolant temperature lowers and
then drain the coolant or disconnect the
heater hose.
a Note the installed positions of the hoses and wir-
ings for installation purpose.
a Plug the disconnected hoses to prevent oil from
flowing out.
1. Collect the air conditioner refrigerant (R134a)

from the air conditioner circuit in advance.
a Ask a qualified distributor for collection and
charge of the refrigerant (R134a).
a Never discharge the refrigerant (R134a) into
the atmosphere.
k If refrigerant gas (R134a) gets in your
eyes, you may lose your sight. According-
ly, put on safety glasses, safety gloves 4. Disconnect two air conditioner hoses (5). [*1]
and long sleeved work clothes when col- a Plug the hoses to prevent entry of dirt, dust
lecting or charging the refrigerant. and water.
q Quantity of refrigerant: 1,100 ± 100 g 5. Disconnect heater hose clamp (6).
6. Disconnect two heater hoses (7).
2. Drain the coolant. a Close the heater valve on the engine side.
6 Radiator: 120 l 7. Loosen clamp (8) and remove duct (9). [*2]
3. Remove the covers according to the following

procedure.
50-318 D375A-6
(02)
DRAFT
8. Disconnect wiring connectors DS3 (10), DS1 10. Remove monitor cover (16). [*3]
(11), DS2 (12), DS4 (13), and DS5 (14). a Four connectors are installed at the back of
the cover. Disconnect the connectors before
removing the cover.
(From left top) (From right top)
(17): FLSW (19): ADH
(18): RLSW (20): OPSW
9. Open air conditioner filter cover (15).
D375A-6 50-319
(02)
DRAFT
11. Remove covers (21a) and (21b). [*4] 16. Disconnect wiring connector AC1 (26).
12. Remove right and left foot rests (22).
13. Remove right and left ducts (23).
17. Remove four mounting bolts (27) and disconnect

monitor assembly (28) from the dashboard of the
monitor.
a Wires are connected to the back side. Pull
out the monitor assembly toward you careful-
ly.

18. Disconnect wiring connectors CM01 (29) and

CM02 (30).
50-320 D375A-6
(02)
DRAFT
19. Disconnect wiring connectors AC2 (31) and AC3 23. Remove back side cover (36) of the monitor
(32). panel.
20. Disconnect four relay wiring connectors (33). 24. Disconnect dummy connector (37) from clip
21. Disconnect wiring connector (34) of the servo- (38).
motor. 25. Disconnect clamp (40) of wiring (39).
22. Disconnect wiring connector M26 (35).
D375A-6 50-321
(02)
DRAFT
26. Remove two mounting bolts (41a), (41b), and

(41c) of the air conditioner unit assembly each,
and remove air conditioner unit assembly (42).
(41a): 2 places at right and left of lower part on
this side
(41b): 2 places at right and left of lower part on
engine side
(41c): 2 places at upper part on engine side
(a): Installed position of bolts (41a)

(b): Installed position of bolts (41b)
(c): Installed position of bolts (41c)
50-322 D375A-6
(02)
DRAFT
Installation [*3][*4]
q Carry out installation in the reverse order to re- a Adjust the monitor panel plate position according
moval. to the following procedure.
1) Tighten bolts (A) and (B) partially.
[*1] 2) Tighten bolts (A) so that gaps (C) are set
a Install the hose without twisting it. uniform in horizontal and vertical directions to
a When installing the air conditioner circuit hose, prevent interference between the monitor
take care not to allow dint, dust and water to en- panel, SW panel, and cover.
ter it. 3) Tighten bolts (B).
a Check that the O-ring is fitted to the air condition-
er hose adapter before tightening the adapter.
a When connecting the refrigerant hose, apply
compressor oil for new refrigerant (R134a) (Den-
so: ND-OIL8 or Zexcel: ZXL100PG (equivalent
to PAG 46)) to the O-ring.
3 Tightening torque for air conditioner gas plp-

ing.
12.23 ± 1.47 Nm {1.35 ± 0.15
16 x 1.5
kgm}
22.05 ± 2.45 Nm {2.25 ± 0.25
22 x 1.5
kgm}
31.85 ± 2.45 Nm {3.25 ± 0.25
24 x 1.5
kgm} q Charging air conditioner with refrigerant
M6 bolt 5.39 ± 1.47 Nm {0.55 ± 0.15 Charge the air conditioner circuit with refrigerant
(receiver portion) kgm}
(R134a).
M6 bolt
9.8 ± 1.96 Nm {1.0 ± 0.2 kgm}
(compressor portion)
[*2] specified level. Run the engine to circulate the
3 Air hose clamp: coolant through the system. Then, check the
6.8 ± 0.49 Nm {0.69 ± 0.05 kgm} coolant level again.
5 Coolant:120 l
D375A-6 50-323
(02)
DRAFT
Electrical system
Removal and installation of transmission controller assembly and steering controller assembly
Electrical system
Removal and installation of transmission controller assembly and
steering controller assembly
Installation
k Park the machine on a level surface and low- moval.
1. Remove plate (1).
2. Disconnect transmission controller wiring

connector (2) and steering controller wiring
connector (3). Remove the mounting bolts, and
remove transmission controller assembly (4)
and steering controller assembly (5).
50-324 D375A-6
(02)
DRAFT
Electrical system
Removal and installation of engine controller assembly

3. Disconnect wiring connectors EGC3(3),
Removal EGC1(4) and EGC2(5). [*1]
k Park the machine on a level surface and low- a E: Ground cable

cover (1).
4. Remove the mounting bolt and remove engine

controller assembly (6).
2. Remove controller box cover (2).
Installation
moval.
[*1]
3 Screw: 2.82 Nm {0.288 kgm}
.
D375A-6 50-325
(02)
DRAFT
Electrical system
a Reference
q Power supply connector EGC3(5) seal replace-
ment procedure
Seal part No.: 1010-074-0406 [DEUTSCH
JAPAN]
1) Using tweezers [1], pinch the claw to remove
cover (8).
2) Remove seal (9) by using tweezers [1].
50-326 D375A-6
(02)
DRAFT
Electrical system
Removal and installation of VHMS controller assembly
Removal and installation of VHMS controller assembly

5. Remove the mounting bolts and remove
Removal controller case cover (4).
1. Lift off cover (1) on the left side of the operators

cab.
6. Remove the mounting bolts and remove VHMS

controller assembly (5).

3. Disconnect wiring clamp (2a).
4. Disconnect main harness cap (3).
Installation
moval.
D375A-6 50-327
(02)
DRAFT
Electrical system
Removal and installation of machine monitor assembly

2. Remove four mounting bolts (6) and disconnect
Installation machine monitor assembly (7) from the dash-
k Park the machine on a level surface and low- board.
er the work equipment to the ground. a Wrings are connected in the back side. Be
k Set the parking brake lever and work equip- careful of this when pulling it toward you.
ment lock lever to lock position.
1. Remove monitor cover (1). [*1]

a Four connectors are installed at the back of
the cover. Disconnect the connectors before
removing the cover.
(From upper left) (From upper right)
(2): FLSW (4): ADH
(3): RLSW (5): OPSW
3. Disconnect wiring connectors CM01 (8) and

CM02 (9).
4. Remove four mounting bolts (10) and remove
machine monitor assembly (7).
50-328 D375A-6
(02)
DRAFT
Electrical system
Installation
Carry out installation in the reverse order to remov-

al.
[*1]
a Adjust the machine monitor panel plate position
1) Tighten bolts (A) partially.
2) Tighten bolts (A) so that gaps (C) are set
uniform in horizontal and vertical directions to
prevent interference between the momitor
cover and the monitor or the switch panel.
D375A-6 50-329
(02)
DRAFT
Electrical system
50-330 D375A-6
(02)
DRAFT
D375A-6
SEN07777-00
Bulldozer
Shop Manual
D375A-6

D375A-6 60001 and up
D375A-6 60-1
DRAFT
Contents
Contents
Engine mount............................................................................................................................................... 60 - 3
Cooling fan pump......................................................................................................................................... 60 - 5
Cooling fan motor......................................................................................................................................... 60 - 12
Power train
Power train unit ............................................................................................................................................ 60 - 14
Damper and universal joint .......................................................................................................................... 60 - 16
Torque converter and PTO .......................................................................................................................... 60 - 19
Main relief valve and torque converter relief valve....................................................................................... 60 - 22
Lockup clutch ECMV and stator clutch ECMV............................................................................................. 60 - 23
Scavenging pump ........................................................................................................................................ 60 - 24
Transmission control.................................................................................................................................... 60 - 25
Transmission................................................................................................................................................ 60 - 26
Transmission lubricating oil relief valve ....................................................................................................... 60 - 30
Power train and lubrication pump ................................................................................................................ 60 - 31
Transfer, bevel gear shaft and steering unit ................................................................................................ 60 - 32
Steering control valve .................................................................................................................................. 60 - 38
Steering clutch ECMV and steering brake ECMV........................................................................................ 60 - 39
Parking brake valve ..................................................................................................................................... 60 - 40
Final drive .................................................................................................................................................... 60 - 41
Sprocket....................................................................................................................................................... 60 - 44
Track frame.................................................................................................................................................. 60 - 46
Idler cushion................................................................................................................................ 60 - 48
Idler .............................................................................................................................................................. 60 - 50
Track roller ................................................................................................................................................... 60 - 52
Carrier roller ................................................................................................................................................. 60 - 54
Track roller bogie ......................................................................................................................................... 60 - 55
Track shoe ................................................................................................................................................... 60 - 56
Main frame ................................................................................................................................................... 60 - 60
Suspension .................................................................................................................................................. 60 - 62
Hydraulic system
PPC valve .................................................................................................................................................... 60 - 67
Hydraulic cylinder......................................................................................................................................... 60 - 72
Quick drop valve .......................................................................................................................................... 60 - 75
Work equipment pump................................................................................................................................. 60 - 76
Control valve ................................................................................................................................................ 60 - 79
Self-pressure reducing valve ....................................................................................................................... 60 - 85
Work equipment
Cylinder stay ................................................................................................................................................ 60 - 87
Blade............................................................................................................................................................ 60 - 88
Cutting edge and end bit.............................................................................................................................. 60 - 92
Ripper .......................................................................................................................................................... 60 - 94
60-2 D375A-6
DRAFT
Engine mount

Engine mount
Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Clearance

Clearance between bracket and size Shaft Hole clearance limit
1
cushion
+ 0.018 + 0.078 0.014 –
70 0.2
- 0.012 + 0.032 0.090 Replace
Standard size Repair limit

2 Free height of mount rubber
102 100
D375A-6 60-3
DRAFT
Engine mount
60-4 D375A-6
DRAFT
Cooling fan pump
Cooling fan pump

Type: LPV90 + 30
General view
D375A-6 60-5
DRAFT
Cooling fan pump
LPV90 hydraulic pump

General view
60-6 D375A-6
DRAFT
Cooling fan pump
Sectional view
D375A-6 60-7
DRAFT
Cooling fan pump
LPV30 hydraulic pump

General view
60-8 D375A-6
DRAFT
Cooling fan pump
Sectional view
D375A-6 60-9
DRAFT
Cooling fan pump
Servo valve
60-10 D375A-6
DRAFT
Cooling fan pump
D375A-6 60-11
DRAFT
Cooling fan motor
Cooling fan motor

Type: LMF180 (150)
General view
60-12 D375A-6
DRAFT
Cooling fan motor
Sectional view
Unit: mm
No. Check item Criteria Remedy
Free length × Replace spring

Installed length Installed load Free length Installed load
1 Spool return spring outside diameter if damaged or
deformed.
172 N 137 N
83.8 × 19 67.5 -
{17.5} {14}
D375A-6 60-13
Power train
Power train unit
Power train 60-14

Power train unit 60-14
60-14 D375A-6
(04)
Power train
Power train unit
D375A-6 60-15
(04)
DRAFT
Power train
60-16 D375A-6
DRAFT
Power train
Unit: mm
Standard Tolerance Standard clear-

Clearance limit
Clearance between flywheel size Shaft Hole ance
1
housing and cover
- 0.024 + 0.080
647.7 0.024 – 0.185 0.2
- 0.105 0
Clearance between flywheel and - 0.022 + 0.110
2 546.0 0.022 – 0.202 0.25
damper - 0.092 0
Standard size Tolerance Repair limit Replace

Outside diameter of oil seal con-
3 0
tact surface of coupling 110 109.9
- 0.035
Outside diameter of oil seal con- 0

4 110 109.9
tact surface of output shaft - 0.035
Dimension between bearing and

5 53 ± 0.1 52.7
holder
D375A-6 60-17
DRAFT
Power train
60-18 D375A-6
DRAFT
Power train
D375A-6 60-19
DRAFT
Power train
60-20 D375A-6
DRAFT
Power train
Unit:mm
Standard size Tolerance Repair limit

Outside diameter of coupling
1 0
oil seal contact surface 125 124.8
- 0.063 Apply hard
Inner diameter of seal ring + 0.046 chrome plating
2 190 190.5 or replace
contact surface of retainer 0
Inside diameter of seal ring + 0.035
3 110 110.2
contact surface of sleeve 0
Backlash between PTO drive
4 gear and scavenging pump 0.25 – 0.42
gear
Backlash between PTO drive
5 0.204 – 0.516
gear and idler gear
Thickness of lockup clutch
5.4 ± 0.1 4.9
disc
Thickness of lockup clutch
6 5.0 ± 0.1 4.5
plate
Total thickness of lockup
15.8 ± 0.17 14.3
clutch assembly
Replace
Thickness of stator clutch disc 5.4 ± 0.1 4.9
Thickness of stator clutch

7 5.0 ± 0.05 4.5
plate
Total thickness of stator clutch
15.8 ± 0.15 14.7
assembly
Free length Installed length Installation load Free length Installation load
8 Stator clutch return spring
125.5 N 106.9 N
54.1 37.0 50.9
{12.8 kg} {10.9 kg}
D375A-6 60-21
DRAFT
Power train
Unit: mm
Tolerance Standard clear-
Standard size Clearance limit
Clearance between main Shaft Hole ance
1
relief 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 converter relief valve and 40 0.035 – 0.061 0.08
- 0.045 0
valve body Replace
3 Main relief valve spring Free length Installed length Installation load Free length Installation load
1,419 N 1,348 N
120.3 102 116.7
{144.7 kg} {137.5 kg}
Torque converter relief 645.1 N 613 N
4 116.92 86.3 113.4
valve spring {65.83 kg} {62.5 kg}
60-22 D375A-6
DRAFT
Power train

a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
D375A-6 60-23
DRAFT
Power train
Scavenging pump
Scavenging pump
1 Spline shaft rotating torque -
Discharge Standard Acceptable

Rotating
Type pressure delivery delivery
speed (rpm)
MPa {kg/cm2} (l/min) (l/min) -
Delivery
- Oil: TO10
BAR 63 63.3 -
Oil temperature: (45 - 50 °C) 0.15
1,743
{1.5}
BAR 277 276.8 -
60-24 D375A-6
DRAFT
Power train
PCCS Lever
a Don't try disassemble PCCS lever because, adjustments will be required for the characteristics of voltage
output and operating efforts.
D375A-6 60-25
DRAFT
Power train
Transmission
Transmission
60-26 D375A-6
DRAFT
Power train
Transmission
D375A-6 60-27
DRAFT
Power train
Transmission
60-28 D375A-6
DRAFT
Power train
Transmission
Unit: mm
1 R clutch spring (12 pcs) Free length Installed length Installed load Free length Installed load
126 N 107 N
66.0 57.0 62.0
{12.8 kg} {10.9 kg}
219 N 186 N
2 F clutch spring (12 pcs) 70.0 60.3 65.8
{22.3kg} {19.0 kg}
149 N 127 N
3 3rd and 2nd clutch spring (12 pcs) 97.0 82.4 91.2
{15.2 kg} {12.9 kg}
3,420 N 2,910 N
4 1st clutch spring (3 pcs) 7.75 6.75 -
{349 kg} {297 kg}
Total thickness of R clutch consisting of 6 Standard size Tolerance Repair limit
5
discs and 6 plates 54.6 ± 0.35 51.4
Total thickness of F clutch consisting of 6
6 50.3 ± 0.33 47.1
discs and 5 plates
Total thickness of 3rd clutch consisting of 4
7 36.4 ± 0.28 34.3
discs and 4 plates
Total thickness of 2nd clutch consisting of 3
8 27.3 ± 0.24 25.7
discs and 3 plates
Total thickness of 1st clutch consisting of 6
9 50.0 ± 0.33 46.8
discs and 5 plates
R, F,
3rd, 2nd
4.8 ± 0.1 4.3
10 Thickness of clutch disc
1st 5.0 ± 0.1 4.5
R, F,
3rd, 2nd
4.3 ± 0.1 3.9
11 Thickness of clutch plate
1st 4.0 ± 0.1 3.6
- 0.01
Wear of transmission input shaft Width 3.0 2.7
12 - 0.03
seal ring
Thickness 3.5 ± 0.1 3.35
- 0.01
Wear of front cover and R clutch Width 4.0 3.6
13 - 0.04
carrier seal ring
Thickness 4.0 ± 0.15 3.85
- 0.01 Replace
Wear of F clutch and 3rd clutch Width 4.0 3.6
14 - 0.03
carrier seal ring (small)
Thickness 5.0 ± 0.15 4.85
- 0.01
Wear of F clutch and 3rd clutch Width 4.0 3.6
15 - 0.04
carrier seal ring (large)
Thickness 4.0 ± 0.15 3.85
- 0.01
Width 4.0 3.6
16 Wear of 1st clutch collar seal ring - 0.04
Thickness 5.0 ± 0.15 4.85
- 0.01
Width 4.0 3.6
- 0.03
17 Wear of 1st clutch gear seal ring
Thickness 5.1 ± 0.12 4.95
- 0.01
Width 4.5 4.1
18 Wear of 1st clutch gear seal ring - 0.03
Thickness 6.0 ± 0.15 5.85
- 0.01
Wear of transmission output shaft Width 4.5 4.1
19 - 0.03
seal ring
Thickness 5.8 ± 0.15 5.65
- 0.01
Wear of 1st clutch piston housing Width 5.0 4.5
20 - 0.03
seal ring
Thickness 6.0 ± 0.15 5.85
Backlash between R and F clutch sun gear
21 0.13 – 0.40
and planetary pinion
Backlash between R clutch planetary pinion
22 0.13 – 0.40
and ring gear teeth
Backlash between F, 3rd and 2nd clutch
23 0.14 – 0.40
planetary pinion and ring gear teeth
Backlash between 3rd and 2nd clutch plane-
24 0.13 – 0.37
tary pinion and ring gear
D375A-6 60-29
DRAFT
Power train
60-30 D375A-6
DRAFT
Power train
Power train and lubrication pump
Power train and lubrication pump

BAL 180 + 112
Unit: mm
Type Standard clearance Clearance limit
BAL180 0.07 – 0.12 0.15

1 Side clearance
BAL112 0.04 – 0.10 0.13
Clearance between plain bearing BAL180

2 inside diameter and gear shaft out- 0.060 – 0.145 0.20
side diameter BAL112
Type Standard size Tolerance Repair limit
BAL180 Replace
3 Pin driving depth 0
14 -
- 0.5
BAL112
4 Spline shaft rotating torque 5.9 Nm {0.6 kgm} or less
Discharge Standard Acceptable

Rotating speed
Delivery Type pressure delivery delivery
(rpm)
MPa {kg/cm2} (l/min) (l/min)
(Oil: E010-CD
- 2.5 – 2.7
Oil temperature: 45 – 50 °C) BAL180 2,033 334 308
{26 – 28}
(Engine speed at 1900 rpm) 0.26
BAL112 2,033 210 200
{2.7}
D375A-6 60-31
DRAFT
Power train
Transfer, bevel gear shaft and steering unit

60-32 D375A-6
DRAFT
Power train
Unit: mm
Standard clearance Clearance limit

Adjust or
1 Backlash between transfer gears
0.24 - 0.63 0.75 replace

Thickness of collar between
2 Replace
transfer gear and bearing 24 ± 0.1 23.6
Standard shim thickness for bear-

3 2.0 Adjust shim
ing cage mount
D375A-6 60-33
DRAFT
Power train
60-34 D375A-6
DRAFT
Power train
Unit: mm

Adjust or
1 Backlash between transfer gears
0.24 - 0.63 0.75 replace

Thickness of collar between
2 Replace
transfer gear and bearing 24 ± 0.1 23.6
Standard shim thickness for bear-

3 2.0 Adjust shim
ing cage mount
D375A-6 60-35
DRAFT
Power train
Bevel gear shaft, steering clutch, and steering brake
60-36 D375A-6
DRAFT
Power train
Unit: mm

Plate for steer- Replace
Thickness 2.9 ± 0.1 2.6
1 ing brake and
clutch
Repair or
Strain - Max. 0.3 0.4
replace
Disc for steer- Thickness 4.7 ± 0.1 4.2 Replace

2 ing brake and
clutch Repair or
Strain - Max. 0.3 0.4
replace
Total thickness of brake

3 68.4 ± 0.42 65.4
plate and disc assembly
Total thickness of clutch

4 68.4 ± 0.42 65.4
plate and disc assembly Replace
Backlash between brake Standard clearance Repair limit

5 or clutch disc and brake
hub 0.17 - 0.52 1.0
Backlash between bevel Adjust or

6 0.3 - 0.4 0.75
gear and pinion replace
Tolerance Standard
Inside diameter of seal ring Shaft Hole clearance
7
contact surface of cage
- 0.5 + 0.081
290 0.5 - 0.781 –
- 0.7 0
Inside diameter of piston
- 0.100 + 0.072
8 seal ring contact surface of 245 0.100 - 0.244 –
- 0.172 0
piston
Free length Installed length Installed load Free length Installed load Replace
9 Brake spring
38.7 kN 36.8 kN
17.1 11.2 16.6
{3,950 kg} {3,750 kg}
37.9 kN 36.0 kN
10 Clutch spring 17.55 11.6 17.0
{3,860 kg} {3,670 kg}
Tolerance Standard Interference

Standard size
Interference between Shaft Hole interference limit
11
bevel gear and reamer bolt
+ 0.019 + 0.027
16 - 0.026 - 0.019 0.019 or less
+ 0.001 0
Runout of back face of Repair or
12 Repair limit: 0.05 (measure after installing to bevel gear shaft)
bevel gear replace
Preload of bevel gear shaft Standard rotating torque: 4.9 – 5.9 Nm {0.5 – 0.6 kgm}
13 Adjust
taper roller bearing (At tip of bevel gear teeth not meshed with bevel pinion: 23.5 – 28.4 N {2.4 – 2.9 kg})
Standard shim thickness of
14 2.0 Adjust shim
bearing cage
D375A-6 60-37
DRAFT
Power train
60-38 D375A-6
DRAFT
Power train
Steering clutch ECMV and steering brake ECMV
Steering clutch ECMV and steering brake ECMV

a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
D375A-6 60-39
DRAFT
Power train
Parking brake valve
Parking brake valve
Unit: mm
Tolerance Standard Clearance

Standard size
Clearance between parking brake 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
Outside diameter of dust seal and Standard size Tolerance Repair limit Repair hard
2 U-packing contact surface of park- - 0.020 chrome plating
ing brake valve spool 14 13.9 or replace
- 0.030
Free length Installed length Installed load Free length Installed load
3 Parking brake valve spool spring Replace
38.2 N 36.4 N
65 47.7 63.1
{3.9 kg} {3.71 kg}
60-40 D375A-6
DRAFT
Power train
Final drive
Final drive
D375A-6 60-41
DRAFT
Power train
Final drive
60-42 D375A-6
DRAFT
Power train
Final drive
Unit: mm

Backlash between No.1 pinion and
1
No.1 gear 0.25 - 0.99 1.5
Backlash betwee sun gear and

2 0.22 - 0.81 1.5
planetary pinion
Backlash between planetary pinion
3 0.25 - 0.81 1.5
and ring gear

Outside diameter of oil seal contact
4
surface of No.1 pinion 115.0 114.9
Replace
Thickness of thrust collar of inner
5 25.14 24.9
body roller bearing
Thickness of thrust coller of No.1
6 10.0 9.5
gear boss roller bearing
Dimensions from cover mounting
7 24.0 22.5
face to button head

Clearance between pinion shaft and size Shaft Hole clearance limit
8
carrie
- 0.036 - 0.024 - 0.023
85 0.1
- 0.058 - 0.059 - 0.034
Standard shim thickness for No.1
9 2
pinion bearing cage
Dimension of end face of final drive
10 7 (0/-0.2) Adjust
cover and end face of bearing
11 Clearance of floating seal guard 4.1 - 5.3

12 Wear of wear guard Rebuild or replace
47 18
D375A-6 60-43
DRAFT
Power train
Sprocket
Sprocket
Unit: mm

1 Wear of tooth tip
433 417 Replace or rebuild by
build up welding
2 Thickness of tooth root 28.7 22.7
60-44 D375A-6
DRAFT
Power train
Sprocket
Full-scale drawing of sprocket tooth profile
D375A-6 60-45
DRAFT
Track frame

Track frame
60-46 D375A-6
DRAFT
Track frame
Unit: mm
Item Repair limit
Bend 7 (per length 3,000)

Deformation of track frame outer
1
casing
Torsion 3 (per level length 300)
Dents (pipe portion) 12

Repair or replace

Clearance between inner casing size Shaft Hole clearance limit
2
and stopper protruding portion
- 0.15 + 0.3
60 0.15 - 0.65 3.0
- 0.35 0
Clearance between track frame - 0.043 + 0.063 0.043 -
3 161 1.0
and stopper - 0.106 0 0.163
4 Press-fitting force for cartridge pin 245 – 441 kN {25 – 45 ton} -
D375A-6 60-47
DRAFT
Idler cushion
Idler cushion
60-48 D375A-6
DRAFT
Idler cushion
Unit: mm
1 Recoil spring
499.7 kN 458.5 kN
1,461 1,230.5 1,440
{50,994 kg} {46,790 kg}
Standard Tolerance Standard Replace

Clearance between outer diame- Clearance limit
size Outer bushing Outer sleeve clearance
2 ter of outer sleeve bushing and
inner diameter of outer sleeve - 0.058 + 0.317
380 0.118 – 0.545 0.8
- 0.228 + 0.060
Clearance between adjustment - 1.000 + 0.063
3 135 1.000 – 1.363 –
cylinder and bushing - 1.300 0
Press-fitting force for inserting
4 outer sleeve bushing into outer 49.0 – 109.8 kN {5.0 – 11.2 ton}
sleeve
Press-fitting force for installing
Adjust
5 outer sleeve bushing to spring 91.2 – 322.6 kN {9.3 – 32.9 ton}
cylinder
Clearance between recoil spring
6 0 – 1.0
mounting nut and lock plate
Press-fitting force for cartridge
7 245 – 441 kN {25 – 45 ton} –
pin

Clearance between bogie and
8
idler cap 0.266 – 0.940 0.05
Replace
Clearance between bogie and

9 0.42 – 1.4 0.05
roller cap
D375A-6 60-49
DRAFT
Idler
Idler
60-50 D375A-6
DRAFT
Idler
Unit: mm

Outside diameter of protuding
1
portion 927 -
2 Outside diameter of tread 880 855
3 Depth of tread 23.5 36 Rebuild by build-up

welding or replace
4 Thickness of tread 32.5 20
5 Total width 294 -
6 Overall with of tread 79.0 87.5

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

Rebuild by build-up
8 Collar width of shaft
252 - welding or replace

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

10 End play Adjust or replace
0.49 - 0.86 -

11 Outside diameter of shaft - 0.410 Replace
95 - 0.5
- 0.484
D375A-6 60-51
DRAFT
Track roller
Track roller
q 2nd – 7th track roller (double flanged roller)

Unit: mm

Outer diameter of flange (outside
1
flange) 310 -
Outer diameter of flange (inside

2 300 -
flange)
4 Thickness of tread 60 30
Rebuild by build-up
5 Overall width 358 - welding or replace
6 Width of tread 82 -
7 Width of flange (outside flange) 29 14
8 Width of flange (inside flange) 27 12
9 Collar width of shaft 306 -

Standard size
Clearance between shaft and Shaft Hole clearance limit
10 Replace bushing
bushing
- 0.350 + 0.260 0.360 –
140 -
- 0.413 + 0.010 0.673
Standard size
Interference between shaft and Shaft Hole interference limit
11 Replace
seal ring
+ 0.046 - 0.13 0.130 –
75 -
+0 - 0.18 0.226
0.44 - 0.91 -

13 Outside diameter of shaft 0 Replace
74.5 - 0.2
- 0.12
60-52 D375A-6
Track roller
q 1st and 8th track roller (single flanged roller)

Unit: mm

1 Outside diameter of flange
314 –
3 Thickness of tread 65 27.5

Rebuild by build-up
4 Overall width 358 – welding or replace
5 Width of tread 82 –
6 Width of flange 29 14
7 Collar width of shaft 306 –

Clearance between shaft and bush- size Shaft Hole clearance limit
8 Replace bushing
ing -0.350 +0.260 0.350 –
140 –
-0.413 +0.010 0.673
Standard Tolerance Standard Interference
size Shaft Hole interference limit
9 Interference between shaft and ring Replace
+0.046 -0.13 0.130 –
75 –
0 -0.18 0.226
0.44 – 0.91 –
D375A-6 60-53
(04)
DRAFT
Carrier roller
Carrier roller
Unit: mm

1 Outside diameter of flange
242 -

Rebuild by build-up
3 Width of tread 79 - welding or replace
4 Thickness of tread 40 27.5
5 Width of flange 23 12
Standard Tolerance
Standard interference
size Shaft Hole
6 Interference between shaft and ring
+ 0.245 + 0.035
90 0.150 - 245
+ 0.185 0
Standard Tolerance
Standard clearance
Clearance between shaft and sup- size Replace
Shaft Hole
7
port
0 + 0.350
86 0 - 0.550
- 0.2 0

8 Axial play of roller
0 - 0.22 -
60-54 D375A-6
Track roller bogie
Track roller bogie 60-5
Unit: mm
1 Press-fitting force for cartridge pin 245–441 kN {25–45 ton} –
Clearance between bogie and cap Standard clearance Clearance limit

2 (average of front and rear clear- Replace
0.42–1.4 0.05
ances)
D375A-6 60-55
(04)
DRAFT
Track shoe
Track shoe
a Portion P shows the link on the side where the bushing is pressed fitted.
60-56 D375A-6
DRAFT
Track shoe
Unit: mm

1 Link pitch
280.3 283.3
Reverse
Standard size
Turn 180° or replace
Light load Heavy load
2 Outside diameter of bushing
98.5 90 92.5
3 Thickness of bushing 18.8 10.3 12.8

4 Height of link
181 163 Rebuild by build-up
welding or replace
Thickness of link (bushing press-fit-
5 56 38
ting portion)
One side Both side

6 Clearance between links -
1.4 2.8
Tolerance Standard
Standard size
Interference between bushing and interference Adjust or replace
Shaft Hole
7
link
+ 0.622 + 0.087
98 0.435 - 0.622
+ 0.522 0
Interference between regular pin and + 0.426 + 0.127
8 60 0.239 - 0.373
link + 0.366 + 0.053
Tightening torque Retightening angle
(Nm {kgm}) (Degree)
a. Regular link
9 Shoe bolt 1,372 ± 137 {140 ± 14} 120 ± 10 Retighten
b. Master link 686.4 ± 68.6 {70 ± 7} 180 ± 10
D375A-6 60-57
DRAFT
Track shoe
Single grouser shoe
Unit: mm

1 Height of grouser
93 30 Repair by lug weld-
ing or replace
2 Overall height of shoe 116 53
60-58 D375A-6
DRAFT
Track shoe
D375A-6 60-59
DRAFT
Main frame
Main frame
60-60 D375A-6
DRAFT
Main frame
Unit: mm

Interference between steering case size Shaft Hole interference limit
1
and bushing
+ 0.108 + 0.052 0.004 -
275 Min. 0
+ 0.056 0 0.108

Clearance between steering case size Shaft Hole clearance limit
2
and final drive cage
- 0.018 + 0.057 0.018 -
332 0.2
- 0.075 0 0.132
Clearance between bracket and + 0.018 + 0.046 - 0.018 -
3 70 0.1
cushion - 0.012 0 0.058
Clearance between ripper beam - 0.036 + 0.166 0.064 -
4 120 1.5
mounting pin and bushing - 0.090 + 0.028 0.256
Clearance between ripper - 0.036 + 0.287 0.236 -
5 100 1.5 Replace
cylinder mounting pin and bushing - 0.090 + 0.200 0.377
Clearance between radiator guard - 0.030 + 0.371 0.299 -
6 80 1.5
Clearance between radiator guard - 0.036 + 0.369 0.303 -
7 90 1.0
Clearance between equalizer bar - 0.036 + 0.243 0.137 -
8 120 1.0
shaft and bushing - 0.090 + 0.101 0.333

Protrusion of rubber on seal end
9
face 1 0.5
Free height of front cab mount rub-

10 105 103
ber
Free height of rear cab mount rub-
11 58 56
ber
Press-fitting force for ripper beam
12 44.1 – 117.6 kN {4.5 – 12 ton}
mounting bushing
Press-fitting force for ripper cylin-
13 58.8 – 171.6 kN {6 – 17.5 ton}
der mounting bushing
Press-fitting force for radiator guard
14 98.0 – 181.4 kN {10 – 18.5 ton} Adjust
mounting bushing
Press-fitting force for radiator guard
15 58.8 – 137.3 kN {6 – 14 ton}
mounting bushing
Press-fitting force for equalizer bar
16 31.4 – 105.9 kN {3.2 – 10.8 ton}
shaft mounting bushing
D375A-6 60-61
DRAFT
Suspension
Suspension
60-62 D375A-6
DRAFT
Suspension
Unit: mm

Clearance between center pin and size Shaft Hole clearance limit
1
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 -
2 95 1.0 Replace bushing
bushing - 0.078 - 0.015 0.093

Interference between side pin boss size Shaft Hole interference limit
3
and bushing
+ 0.045 - 0.028 0.055 -
160 -
+ 0.027 - 0.068 0.113
Press-fitting force for center pin
4 49.0 – 186.3 kN {5 – 19 ton}
bushing
-
Press-fitting force for side pin bush-
5 34.3 – 73.5 kN {3.5 – 7.5 ton}
ing
D375A-6 60-63
DRAFT
Suspension
*1 . Indicates the left suspension of single tilt specification machine.

*2 . Indicates the right suspension of single tilt specification machine.
Indicates the left and right suspension of dual tilt specification machine.
60-64 D375A-6
DRAFT
Suspension
Unit: mm

Standard size
Interference between thrust Shaft Hole interference limit
6
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 -
7 165 -
washer and seal + 0.100 - 0.124 0.264
Interference between pivot shaft + 0.096 - 0.115 0.165 -
8 213 -
and seal + 0.050 - 0.187 0.283

Standard size
Clearance between pivot shaft Shaft Hole clearance limit
9
and bushing
- 0.145 + 0.097 0.174 - Replace bushing
175 1.0
- 0.208 + 0.029 0.305
Clearance between pivot shaft - 0.170 + 0.072 0.170 -
10 210 1.0
and bushing - 0.242 0 0.314
D375A-6 60-65
DRAFT
Suspension
60-66 D375A-6
DRAFT
Hydraulic system
PPC valve
Hydraulic system
PPC valve
Blade PPC valve
General view
D375A-6 60-67
DRAFT
Hydraulic system
PPC valve
Sectional view
60-68 D375A-6
DRAFT
Hydraulic system
PPC valve
Ripper PPC valve

General view
D375A-6 60-69
DRAFT
Hydraulic system
PPC valve
Sectional view
60-70 D375A-6
DRAFT
Hydraulic system
PPC valve
Unit: mm
Free length x
Centering spring Installed length Installed load Free length Installed load
1 Outside diameter
(for ports P3 and P4)
55.9 N 44.7 N If damaged or
50.35 × 15.5 34 -
{5.7 kg} {4.56 kg} deformed, replace
spring
Centering spring 71.4 N 57.1 N
2 50.05 × 15.5 34 -
(for ports P1 and P2) {7.28 kg} {5.82 kg}
16.7 N 13.3 N
3 Metering spring 26.53 × 8.15 24.9 -
{1.7 kg} {1.36 kg}
D375A-6 60-71
Hydraulic system
Hydraulic cylinder
Hydraulic cylinder 60-72

Blade lift cylinder
Blade tilt cylinder (for single tilt)
Pin puller cylinder
Blade tilt cylinder (for dual tilt)
60-72 D375A-6
(04)
Hydraulic system
Hydraulic cylinder
Unit: mm
NO Item Criteria Remedy
size Shaft Hole clearance limit
- 0.036 + 0.257 0.084 –
Blade lift 90 0.693
- 0.090 + 0.048 0.347
Clearance between pis- Blade tilt - 0.036 + 0.274 0.096 –

1 (Single tilt)
110 –
ton rod and bushing - 0.090 + 0.060 0.364
- 0.065 + 0.133 0.072 –
Pin puller 30 0.55
- 0.117 + 0.007 0.250
Blade tilt - 0.036 + 0.261 0.083 –
(Dual tilt )
110 –
- 0.090 + 0.047 0.351
Clearance between pis-
- 0.3 + 0.5
2 ton rod supporting shaft Blade lift 65 0.5 – 1.0 2
- 0.5 + 0.2
and bushing
Clearance between cyl-
- 0.120 + 0.035 0.120 –
3 inder support shaft Blade lift 105 0.5
- 0.207 0 0.242
bushing and yoke Replace
Blade tilt - 0.200 + 0.200 0.200 –
75 1.0
Clearance between pis- (Single tilt) - 0.300 0 0.500
4 ton rod supporting shaft
and bushing Blade tilt - 0.200 + 0.200 0.200 –
(Dual tilt)
75 1.0
- 0.300 0 0.500
Blade tilt - 0.200 + 0.423 0.542 –

75 1.0
Clearance between cyl- (Single tilt) - 0.300 + 0.342 0.723
5 inder bottom support
shaft and bushing Blade tilt - 0.200 + 0.423 0.542 –
(Dual tilt)
75 1.0
- 0.300 + 0.342 0.723
Clearance between pis-
- 0.100 + 1.300
6 ton rod spherical sur- Pin puller 29 1.3 – 1.5 –
- 0.200 + 1.200
face and cap
Clearance between cyl-
- 1.1
7 inder bottom support Pin puller 26 ± 0.1 1.0 – 1.3 –
- 1.2
shaft and boss
D375A-6 60-73
(04)
DRAFT
Hydraulic system
Hydraulic cylinder
q Ripper lift cylinder
q Ripper tilt cylinder
Unit: mm

size Shaft Hole clearance limit
Clearance between
1 - 0.036 + 0.274 0.096 -
piston rod and bushing Ripper lift 110 0.697
- 0.090 + 0.060 0.364
- 0.036 + 0.274 0.096 -
Ripper tilt 110 0.697
- 0.090 + 0.060 0.364
- 0.036 + 0.207 0.156 - Replace
Clearance between Ripper lift 100 1.0
- 0.090 + 0.120 0.297
2 piston rod support
shaft and bushing - 0.036 + 0.207 0.156 -
Ripper tilt 100 1.0
- 0.090 + 0.120 0.297
- 0.036 + 0.207 0.156 -
Clearance between Ripper lift 100 1.0
- 0.090 + 0.120 0.297
3 cylinder bottom sup-
port shaft and bushing Ripper tilt - 0.036 + 0.207 0.156 -
100 1.0
- 0.090 + 0.120 0.297
60-74 D375A-6
DRAFT
Hydraulic system
Quick drop valve
Quick drop valve
Unit: mm
Tolerance Standard clear-

Clearance between spool Shaft Hole ance
1
and valve body
- 0.011 + 0.010
38.0 0.011 - 0.026 0.03
- 0.016 0
Replace
2 Valve spring
136.3 N 122.6 N
75.2 55.9 67.7
{13.9 kg} {12.5 kg}
D375A-6 60-75
DRAFT
Hydraulic system
Work equipment pump
Work equipment pump

Type: HPV190
General view
60-76 D375A-6
DRAFT
Hydraulic system
Work equipment pump
Sectional view
D375A-6 60-77
DRAFT
Hydraulic system
Work equipment pump
60-78 D375A-6
Hydraulic system
Control valve
Control valve 60-79

6-spool valve for dual tilt 60-79
Appearance 60-79
D375A-6 60-79
(04)
DRAFT
Hydraulic system
Control valve
Sectional view(1/4)
60-80 D375A-6
DRAFT
Hydraulic system
Control valve
Unit:mm

Freelength x
Installed Installation Installation
Steering signal spring Outside Free length
1 length load load
(only for blade lift) diameter
202 N 162 N
73.9 × 30 68.5 -
{20.6 kg} {16.5 kg}
Steering signal spring 279 N 224 N
2 51.12 × 31.3 47.8 -
(for blade tilt) {28.5 kg} {22.8 kg}
140 N 112 N If damaged or
3 Spool return spring (for ripper) 51.7 × 31.3 50 - deformed, replace
{14.3 kg} {11.4 kg}
spring
4 54.7 × 36.5 33.5 -
(only for blade lift) {22.1 kg} {17.7 kg}
12.7 N 10.2 N
5 Load check valve spring 20.8 × 12.2 13.5 -
{1.3 kg} {1.04 kg}
Pressure compensation valve 562 N 449 N
6 108.3 × 29.5 81 -
spring {57.3 kg} {45.8 kg}
193 N 154 N
7 Unload valve spring 86.7 × 30 66 -
{19.63 kg} {15.7 kg}
D375A-6 60-81
DRAFT
Hydraulic system
Control valve
(2/4)
60-82 D375A-6
DRAFT
Hydraulic system
Control valve
(3/4)
Unit:mm

Freelength x
1 Suction valve spring
Outside diam- Free length
length load load If damaged or
eter
deformed, replace
6.37 N 5.10 N spring
64.9 × 12.5 56 -
{0.65 kg} {0.52 kg}
0.49 N 0.39 N
2 Check valve spring 9.4 × 4.6 7.75 -
{0.05 kg} {0.04 kg}
D375A-6 60-83
DRAFT
Hydraulic system
Control valve
(4/4)
Unit:mm

Freelength x
1 Check valve spring
Outside diam- Free length
length load load If damaged or
eter
deformed,
14.7 N 11.8 N replace spring
27.9 × 6.5 22.5 _
{1.5 kg} {1.2 kg}
5.49 N _ 4.41 N
2 Suction valve spring 46.8 × 7.5 40.6
{0.56 kg} {0.45 kg}
60-84 D375A-6
Hydraulic system
Control valve
5-spool valve for single tilt 60-84-1

Appearance 60-84-1
D375A-6 60-84-1
(04)
Hydraulic system
Control valve
Sectional view (1/4) 60-84-2
60-84-2 D375A-6
(04)
Hydraulic system
Control valve
Unit: mm

Free length x Out- Load at Load at
Steering signal spring Installed length Free length
1 side diameter installed length installed length
(only for blade lift)
202 N 162 N
73.9 × 30 68.5 —
{20.6 kg} {16.5 kg}
Steering signal spring 94.1 N 75.3 N
2 51.12 × 31.3 50 —
(for blade tilt) {9.6 kg} {7.7 kg} If damaged or
Spool return spring (for 140 N 112 N deformed, replace
3 51.7 × 31.3 50 —
spring
ripper) {14.3 kg} {11.4 kg}
4 54.7 × 36.5 33.5 —
(only for blade lift) {22.1 kg} {17.7 kg}
Load check valve 12.7 N 10.2 N
5 20.8 × 12.2 13.5 —
spring {1.3 kg} {1.04 kg}
193 N 154 N
6 Unload valve spring 86.7 × 30 66 —
{19.63 kg} {15.7 kg}
D375A-6 60-84-3
(04)
Hydraulic system
Control valve
(2/4) 60-84-
60-84-4 D375A-6
(04)
Hydraulic system
Control valve
(3/4) 60-84-5
Unit: mm

Free length x Load at Load at
1 Suction valve spring Installed length Free length If damaged or
Outside diameter installed length installed length
6.37 N 5.10 N deformed, replace
64.9 × 12.5 56 — spring
{0.65 kg} {0.52 kg}
0.49 N 0.39 N
2 Check valve spring 9.4 × 4.6 7.75 —
{0.05 kg} {0.04 kg}
D375A-6 60-84-5
(04)
Hydraulic system
Control valve
(4/4) 60-84-6
Unit: mm

Free length x Out- Load at installed Load at installed
1 Check valve spring
Installed length Free length If damaged or
side diameter length length
14.7 N 11.8 N deformed,
27.9 × 6.5 22.5 ― replace spring
{1.5 kg} {1.2 kg}
5.49 N 4.41 N
2 Suction valve spring 46.8 × 7.5 40.6 ―
{0.56 kg} {0.45 kg}
60-84-6 D375A-6
(04)
DRAFT
Hydraulic system

General view
D375A-6 60-85
DRAFT
Hydraulic system
Sectional view

Free length x
Installed
Pressure reducing value main Outside Installed load Free length Installed load
1 length
spool spring diameter
250 N 200 N
70.91 × 18 56 - If damaged or
{25.52 kg} {20.4 kg}
deformed, replace
Pressure reducing valve pilot 28.0 N 22.5 N spring
2 17.8 × 7.2 12.7 -
spring {2.86 kg} {2.29 kg}
61.8 N 49.4 N
3 Safety valve spring 16.13 × 7.8 13.4 -
{6.3 kg} {5.04 kg}
19.6 N 15.7 N
4 Spool return spring 19.15 × 7.2 16.05 -
{2.0 kg} {1.6 kg}
60-86 D375A-6
DRAFT
Work equipment
Cylinder stay
Work equipment
Cylinder stay
Unit: mm

Clearance between cylinder yoke size Shaft Hole clearance limit
1
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 -
2 115 0.5
and bushing - 0.126 0 0.180
Clearance between lift cylinder - 0.120 + 0.035 0.120 -
3 105 0.5
support shaft and bushing - 0.207 0 0.242
D375A-6 60-87
Work equipment
Blade
Blade 60-8
Semi-U dozer
(The figure shows a single tilt specification machine. The spill guard is optional.) 60-8
60-88 D375A-6
(04)
DRAFT
Work equipment
Blade
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 spherical sur- - 0.2 + 0.3 Adjust shims or
5 170 0.2 - 0.6 1
faces of center brace and cap - 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 and - 0.3 + 0.3
7 100 0.3 - 0.8 3
joint - 0.5 0
8 100 0.5 - 1.0 2
bracket - 0.5 + 0.2
Clearance between straight frame + 0.063 + 0.174 0.071 -
9 160 1
joint bushings 0 + 0.134 0.174
Clearance between spherical sur- - 0.5 + 0.5
10 200 0.5 - 1.5 8
faces of trunnion and cap - 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 pin - 0.3 + 0.5
14 125 0.5 - 1.0 2
and blade bracket - 0.5 + 0.2
15 125 0.5 - 1.0 2
and center link - 0.5 + 0.2
Clearance between center link and - 0.2 + 0.3
16 280 0.3 - 0.7 2
blade bracket - 0.4 + 0.1
Clearance between center brace - 0.2 + 0.3 Adjust shims or
17 170 0.2 - 0.6 1
spherical surfaceand cap - 0.3 0 replace
Clearance between lift cylinder - 0.3 + 0.5
18 65 0.5 - 1.0 2
head pin and cylinder - 0.5 + 0.2
19 65 0.3 - 0.8 2
head pin and cross joint - 0.5 0
Replace
Clearance between bracket and - 0.3 + 0.3
20 65 0.3 - 0.8 2
side pin - 0.5 0
Clearance between cross joint and - 0.3 + 0.5
21 65 0.5 - 1.0 2
side pin - 0.5 + 0.2
D375A-6 60-89
Work equipment
Blade
Full-U dozer
(The figure shows a dual tilt specification machine) 60-90
60-90 D375A-6
(04)
DRAFT
Work equipment
Blade
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
Clearance between spherical sur- - 0.2 + 0.3 Adjust shims or
5 170 0.2 - 0.6 1
faces of center brace and cap - 0.3 0 replace
6 200 0.3 - 1.0 3
bracket - 0.7 + 0.1
7 100 0.3 - 0.8 3
joint - 0.5 0
8 100 0.5 - 1.0 2
bracket - 0.5 + 0.2
Clearance between straight frame + 0.063 + 0.174 0.071 -
9 160 1
joint bushings 0 + 0.134 0.174
Clearance between spherical sur- - 0.5 + 0.5
10 200 0.5 - 1.5 8
faces of trunnion and cap - 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
and blade bracket - 0.5 + 0.2
15 125 0.5 - 1.0 2
and center link - 0.5 + 0.2
Clearance between center link and - 0.2 + 0.3
16 280 0.3 - 0.7 2
blade bracket - 0.4 + 0.1
Clearance between center brace - 0.2 + 0.3 Adjust shims or
17 170 0.2 - 0.6 1
spherical surface and cap - 0.3 0 replace
18 65 0.5 - 1.0 2
head pin and cylinder - 0.5 + 0.2
19 65 0.3 - 0.8 2
head pin and cross joint - 0.5 0
Replace
Clearance between bracket and - 0.3 + 0.3
20 65 0.3 - 0.8 2
side pin - 0.5 0
Clearance between cross joint and - 0.3 + 0.5
21 65 0.5 - 1.0 2
side pin - 0.5 + 0.2
D375A-6 60-91
DRAFT
Work equipment
Cutting edge and end bit

(Standard)
Unit: mm

1 Height of end bit, outside
495 340
Replace
2 Width of end bit 740 600
3 Height of end bit, inside 395 335
4 Height of cutting edge 406 335 (264 after reversed) Reverse or replace
60-92 D375A-6
DRAFT
Work equipment
(If equipped)
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 reversed) Reverse or replace
D375A-6 60-93
Work equipment
Ripper
Ripper 60-94
Variable multi-shank ripper 60-94
60-94 D375A-6
(04)
Work equipment
Ripper
Giant ripper 60-95
Unit: mm

Clearance between bushing and pin size Shaft Hole clearance limit
1
for bracket and arm connection - 0.036 + 0.208 0.161 –
120 1.5
- 0.090 + 0.125 0.298
Clearance between bushing and pin - 0.036 + 0.208 0.161 –
2 120 1.5
for beam and arm connection - 0.090 + 0.125 0.298
Clearance between cylinder mounting - 0.036 + 0.207 0.156 –
3 100 1.5
pin and bushing - 0.090 + 0.120 0.207
Replace
Clearance between shank and mount-
4
ing pin 82 ± 0.3 –

5 Wear of point
420 255
6 Wear of protector 155 115
D375A-6 60-95
(04)
DRAFT
Work equipment
Ripper
60-96 D375A-6
DRAFT
D375A-6
SEN07777A-00
BULLDOZER
Shop Manual
D375A-6

D375A-6 60001 and up
80 Appendix
Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80 -
2
Caution about refrigerant - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80 -
3
Air conditioner component- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80 -
4
Configuration and function of refrigeration cycle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80 -
6
Outline of refrigeration cycle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80 -
7
Air conditioner unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80 -
10
Blower unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80 -
14
FRESH/RECIRC air changeover damper - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80 -
15
Compressor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80 -
16
Condenser- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80 -
17
Receiver drier - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80 -
18
Air conditioner control panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80 -
20
D375A-6 80-1
(01)
DRAFT
Contents
Contents
80 Appendix
Air Conditioner.................................................................................................................................................. 80 - 3
Caution about refrigerant .............................................................................................................................. 80 - 3
Air conditioner component ............................................................................................................................ 80 - 4
Configuration and function of refrigeration cycle........................................................................................... 80 - 6
Outline of refrigeration cycle ......................................................................................................................... 80 - 7
Air conditioner unit ........................................................................................................................................ 80 - 10
Blower unit .................................................................................................................................................... 80 - 14
FRESH/RECIRC air changeover damper ..................................................................................................... 80 - 15
Compressor .................................................................................................................................................. 80 - 16
Condenser .................................................................................................................................................... 80 - 17
Receiver drier................................................................................................................................................ 80 - 18
Air conditioner control panel ......................................................................................................................... 80 - 20
Procedure for testing and troubleshooting .................................................................................................... 80 - 22
Circuit diagram and arrangement of connector pins ..................................................................................... 80 - 24
System diagram ............................................................................................................................................ 80 - 26
Part and connector locations ........................................................................................................................ 80 - 28
Testing temperature control .......................................................................................................................... 80 - 32
Testing FRESH/RECIC air changeover ........................................................................................................ 80 - 32
Testing relay ................................................................................................................................................. 80 - 34
Troubleshooting chart 1 ................................................................................................................................ 80 - 36
Troubleshooting chart 2 ................................................................................................................................ 80 - 38
Information in troubleshooting table.............................................................................................................. 80 - 40
Troubleshooting for power supply system (Air conditioner does not operate) .............................................. 80 - 42
Troubleshooting for compressor system (Air is not cooled).......................................................................... 80 - 44
Troubleshooting for blower motor system (Air does not come out or air flow is abnormal) .......................... 80 - 48
Troubleshooting for temperature control....................................................................................................... 80 - 54
Troubleshooting for FRESH/RECIRC air changeover .................................................................................. 80 - 56
Troubleshooting with gauge pressure........................................................................................................... 80 - 58
Connection of service tool............................................................................................................................. 80 - 60
Precautions for disconnecting and connecting ............................................................................................. 80 - 62
Handling of compressor oil ........................................................................................................................... 80 - 64
80-2 D375A-6
(01)
DRAFT
Air Conditioner
Caution about refrigerant
Air Conditioner
Caution about refrigerant
k Collect the air conditioner refrigerant (R134a)

from air conditioner circuit before discon-
necting air conditioner hose to replace air
conditioner unit, air conditioner compressor
or receiver drier and so on.
a Ask a qualified shop for collecting, adding and
filling operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the at-
mosphere.
k If refrigerant gas (R134a) gets in your eyes,
you may lose your sight. And if it touches
your skins, you may suffer from frostbite. Ac-
cordingly, put on protective goggles, gloves
and working suits with long sleeves while
you are collecting the refrigerant (R134a) or
filling the air conditioner circuit with the re-
frigerant (R134a). Collecting and filling work
must be conducted by a qualifier person.
D375A-6 80-3
(01)
DRAFT
Air Conditioner
Air conditioner component
80-4 D375A-6
(01)
DRAFT
Air Conditioner
A: Front window glass warm/cool air outlet Specifications

B: Overhead warm/cool air outlet Refrigerant R134a
C: Side warm/cool air outlet Refrigerant refill capacity (g) Approx. 1,100 ± 100
D: Front warm/cool air outlet
E: Recirculation air inlet
F: Fresh air inlet
1. Condenser
2. Air conditioner unit
3. Fresh air filter
4. Blower unit
5. Refrigerant piping
6. Receiver drier
7. Compressor
8. Air intake cap
9. Hot water return pipe
10. Hot water supply pipe
11. FRESH/RECIRC air changeover damper
12. Recirculation air filter
13. Air conditioner control panel
14. Sight glass
D375A-6 80-5
(01)
DRAFT
Air Conditioner
Configuration and function of refrigeration cycle
Configuration and function of refrigeration cycle

Cycle
Compressor Condenser Expansion valve Evaporator
(Component)
In operator’s cab In operator’s cab
Location Engine compartment Front of radiator
(In air conditioner unit) (In air conditioner unit)
Circulates refrigerant
gas and increases its Lowers temperature and Evaporates refrigerant to
Condenses refrigerant
temperature and pres- pressure of refrigerant liq- absorb heat from (or
to discharge heat
sure so that it can be uid and gas for easy evap- cool) air around evapora-
Function absorbed in evaporator.
liquefied easily in con- oration with throttle. tor.
(condensation of refrig-
denser. Controls flow rate, too. (Evaporation of refriger-
erant)
(Compression of (Throttle of refrigerant) ant)
refrigerant)
GasoGas GasoLiquid
State of refriger- LiquidoLiquid and gas Liquid and gas oGas
Adiabatic compres- Constant pressure
ant Adiabatic expansion Cnstant pressure change
sion change
80-6 D375A-6
(01)
DRAFT
Air Conditioner
Outline of refrigeration cycle

The refrigeration cycle is comprised of 4 cycles. The refrigerant is circulated while repeatedly liquefying and
vaporizing.
1. Compression (Compressor)
The compressor sucks in the refrigerant that has (*1) Throttle action
been vaporized in the evaporator and If there is a narrow section in the passage
compresses it into a state where it can be easily through which liquid is flowing at a constant rate,
liquefied at the ambient temperature. a resistance to the flow will be generated.
The gaseous refrigerant sucked into the The liquid expands when it passes through the
compressor cylinder is compressed to a temper- narrow section and rushes into the passage
ature and pressure at which it can be easily where the sectional area is larger,and conse-
liquefied when cooled to the ambient tempera- quently, its pressure and temperature are
ture. reduced.
Heat is not transferred from or to the outside
2. Condensation (Condenser) during the throttle action.
The condenser cools and liquefies the high pres-
sure and high-temperature gaseous refrigerant 4. Evaporation (Evaporator)
sent from the compressor. The evaporator evaporates the liquid refrigerant
The heat released to the outside from the (superheated vapor).
condenser is called condensation heat. The refrigerant evaporates, while absorbing an
The amount of condensation heat is the sum amount of heat necessary for evaporation (evap-
total of the heat absorbed by the evaporator from oration heat) from the air around the cooling fins
the air in the cab and the quantity of the work (air in the cab).
applied (the value converted into a heat quantity) After the heat has been removed, the cooled air
by compression of the compressor. is sent into the cab by the blower fan, reducing
The refrigerant liquefied in the condenser is sent the temperature inside the cab.
to the receiver drier, where moisture is removed. The mist refrigerant that has been sent from the
In the compression cycle, the gaseous refrig- expansion valve coexists with the evaporated
erant and liquid refrigerant coexist. refrigerant in the evaporator
The temperature (condensation temperature) The temperature (evaporation temperature) and
and the pressure (condensation pressure) at the pressure (evaporation pressure) at which the
which the gaseous refrigerant is liquefied are liquid refrigerant is evaporated are proportional
proportional to each other. to each other.
The compressor sucks in the evaporated refrig-
Reference: The pressure varies depending on erant in order to keep the pressure level in the
the condensation temperature of the refrigerant. evaporator as low as possible so that the liquid
3. Expansion (Expansion valve) refrigerant can be evaporated at a much lower
The expansion valve reduces the liquid refrig- temperature.
erant pressure to a level where liquid refrigerant
can be easily evaporated by the throttle action
(*1).
The action of reducing the liquid refrigerant pres-
sure to a level where it can be easily evaporated
before it is sent to the evaporator is called
expansion.
The expansion valve, which reduces the refrig-
erant pressure, also adjusts the refrigerant flow
rate simultaneously.
The quantity of the liquid refrigerant that can be
evaporated in the evaporator depends on the
amount of heat (refrigeration load) to be
removed under the specific evaporation temper-
ature (evaporation pressure).
The expansion valve controls the refrigerant
feed rate so that the optimum quantity of liquid
refrigerant is supplied to the evaporator.
D375A-6 80-7
(01)
DRAFT
Air Conditioner
Relationship between refrigerant and defective

air conditioning
q The refrigerant circulates in the refrigeration cir-
cuit while repeating the refrigeration cycle to ex-
pel the heat from inside the cab.
q If there is an insufficient quantity of refrigerant,
all of it will be evaporated while it is passing
through the evaporator. This causes evaporator
efficiency to deteriorate, which will result in de-
fective air conditioning.
q If there is excessive refrigerant, not all of it will be
evaporated and part of it will be sucked into the
compressor in liquid form, which will cause the
compressor to compress the liquid and may
damage the components.
q If water gets into the refrigeration circuit, it will
freeze at a small hole in the expansion valve,
lower the refrigerant flow, and may result in de-
fective air conditioning.
80-8 D375A-6
(01)
DRAFT
Air Conditioner
D375A-6 80-9
(01)
DRAFT
Air Conditioner
Air conditioner unit
80-10 D375A-6
(01)
DRAFT
Air Conditioner
A: Refrigerant inlet (From condenser) Functions of major components

B: Refrigerant outlet (To compressor) Evaporator
C: Hot water inlet q Evaporator (1) is cooled by the low-pressure,
D: Hot water outlet low-temperature refrigerant gas being sent from
expansion valve (3). Air from the blower fan is
1: Evaporator cooled and dehumidified when passing through
2: Heater core the evaporator fins.
3: Expansion valve
4: Air mix servomotor Heater core
5: Air mix door q Heater core (2) is warmed by the hot water (en-
6: Blower resistor gine coolant ) being sent from the engine. Air
7: Evaporator temperature sensor from the blower fan is warmed as it passes
8: Hot water valve through the heater core fins.
9: Dual pressure switch
10: Compressor clutch relay Air mix servomotor
11: Condenser relay (Not used)
Outline
q The air conditioner unit consists of the evapora-
tor (1) and heater core (2), and is used to cool
down or warm up the air in the cab.
Temperature control
q When the temperature control switch on the air
conditioner control panel is operated, the air
conditioner control panel controls the air mix ser-
vomotor (4) which opens or closes the air mix
door (5) and hot water valve (8) to adjust the
temperature.
q When the switch on the air conditioner control
Overcooling (freeze) prevention
panel is operated, the motor drive power (24 V)
q Evaporator temperature sensor (7) varies its
is supplied to servomotor terminal (3) or (5).
electrical resistance according to temperature.
q The rotation direction of the motor changes ac-
q The air conditioner control panel converts the
cording to the terminal that receives the power.
variation in resistance of the evaporator temper-
q The variable resistor is built into the servomotor,
ature sensor (7) into voltage and uses the volt-
and its resistance changes as the motor rotates.
age for detecting the evaporator (1)
q A voltage of 5V is supplied to the variable resis-
temperature.
tor from the air conditioner control panel, and the
q The air conditioner control panel activates the
air conditioner control panel detects the motor
compressor clutch relay (10) to stop the com-
rotation angle based on the potential difference.
pressor and to prevent the evaporator (1) from
q When the air mix door reaches the position spec-
freezing.
ified by the air conditioner control panel, the air
conditioner control panel stops current output to
Air flow control
the servomotor to stop the air mix door.
q When the air flow control switch on the air condi-
a Do not supply power directly between terminals
tioner control panel is operated, the air condi-
(3) and (5) of the servomotor to drive the servo-
tioner control panel controls the blower motor of
motor for testing purposes.
the blower unit through blower resistor (6) to ad-
just the air flow.
D375A-6 80-11
(01)
DRAFT
Air Conditioner
Expansion valve
A: When evaporator outlet temperature is high Structure

B: When evaporator outlet temperature is low q Box-shape expansion valve (1) consists of nee-
C: From receiver drier (high-pressure refrigerant) dle valve (1a), spring (1b), etc.
D: To compressor (low-pressure refrigerant) q Refrigerant gas (2) is sealed in the diaphragm
chamber (hatched area) outside diaphragm
1. Expansion valve (1a-1) of needle valve (1a).
1a. Needle valve q The opening angle of needle valve (1a) is deter-
1a-1. Diaphragm mined based on the balance between the reac-
1a-2. Thermoprobe tion force exerted by spring (1b) in a rightward
1b. Spring direction, and force (Fg) of refrigerant gas (2)
2. Refrigerant gas pushing needle valve (1a) through diaphragm
3. Evaporator (1a-1) in a leftward direction.
q The refrigerant flow rate flowing from the receiv-
Outline er drier to evaporator (3) is determined based on
q The expansion valve converts high pressure and the opening angle of needle valve (1a).
high-temperature liquid refrigerant from the re-
ceiver drier to low-pressure, low-temperature
misty refrigerant through the throttling action.
q It controls the flow rate of refrigerant by changing
the level of throttling depending on the tempera-
ture in the cab.
q The temperature of the air blown out of the air
vent is adjusted depending on the volume of re-
frigerant circulating in the evaporator (3).
80-12 D375A-6
(01)
DRAFT
Air Conditioner
Operation Dual pressure switch

q Thermoprobe (1a-2) senses the refrigerant tem- q The dual pressure switch turns "OFF" when the
perature after it passes through the evaporator refrigerant circuit pressure becomes abnormally
(3). low or abnormally high.
q After the refrigerant passes through evaporator q Turning the dual pressure switch "OFF" causes
(3), its temperature is transferred to the refriger- the compressor clutch relay to turn "OFF". Then
ant gas (2) in the diaphragm chamber (hatched the magnetic clutch of the compressor is re-
area) through the thermoprobe (1a-2). leased in order to protect air conditioner compo-
q The pressure of the refrigerant gas (2) sealed in nents.
the diaphragm chamber (hatched area) changes
in response to the temperature change of the
thermoprobe (1a-2), which therefore changes
the force (Fg) pushing the needle valve (1a).
q The opening angle of the needle valve (1a) is de-
termined based on the balance between the re-
action force exerted by the spring (1b) in a
rightward direction, and the force (Fg) of the re-
frigerant gas (2) pushing the needle valve (1a)
through the diaphragm (1a-1) in a leftward direc-
tion.
When evaporator (3) outlet temperature is high

[Air in the cab is not cooled: condition (A) in the
figure] a LA or low: Abnormally low pressure
q The refrigerant gas (2) pressure and the volume
a HA or high: Abnormally high pressure
are increased.
q The force (Fg) of the refrigerant gas (2) pushing
LA: 0.20 MPa {2 kg/cm2}
the needle valve (1a) is increased, and the nee- LB: 0.02 MPa {0.2 kg/cm2}
dle valve (1a) moves leftward. HA: 3.14 MPa {32 kg/cm2}
q As a result, the opening angle of the needle
HB: 0.59 MPa {6 kg/cm2}
valve (1a) is increased and the refrigerant flow
rate to the evaporator (3) is increased to improve Evaporator temperature sensor
cooling capacity. q To prevent the evaporator from freezing, the
evaporator temperature sensor varies its electri-
When evaporator (3) outlet temperature is low cal resistance with the evaporator temperature,
[Air in the cab is already cooled: condition (B) in and the temperature is monitored via the air con-
the figure] ditioner control panel.
q The refrigerant gas (2) pressure and the volume
are decreased.
q The force (Fg) of the refrigerant gas (2) pushing
the needle valve (1a) is reduced, and the needle
valve (1a) is moved rightward by the spring force
(1b).
q The opening angle of the needle valve (1a) is re-
duced and the refrigerant flow rate to the evapo-
rator (3) is reduced to lower the cooling capacity.
D375A-6 80-13
(01)
DRAFT
Air Conditioner
Blower unit
Blower unit
1. Blower motor FRESH/RECIRC air changeover servomotor

2. Blower fan
3. FRESH/RECIRC air changeover servomotor
Outline
q The blower unit consists of a blower motor (1), a
blower fan (2) and a FRESH/RECIRC air
changeover servomotor (3). The blower unit
sends air into the cab.
q When the FRESH/RECIRC air changeover
switch on the air conditioner control panel is op-
erated, the air conditioner control panel supplies
a current to the servomotor (3).
Functions of major components

Blower motor
q The FRESH/RECIRC air changeover servomo-
q The blower motor (1) rotates the blower fan (2)
tor (3) receives the drive current from the air con-
to suck air and send it to the evaporator and
ditioner control panel, and opens or closes the
heater core.
FRESH/RECIRC air changeover damper door to
switch between the fresh air and recirculated air
settings.
q When the switch on the air conditioner control
panel is operated, the motor drive power (24 V)
is supplied to servomotor terminal (3) or (5).
q The rotation direction of the motor changes ac-
cording to the terminal that receives the power.
a Do not supply power directly to drive the servo-
motor for testing purposes.
80-14 D375A-6
(01)
DRAFT
Air Conditioner
FRESH/RECIRC air changeover damper
FRESH/RECIRC air changeover damper
1. Door open/close lever

2. FRESH/RECIRC air changeover door
Outline
q The door open/close lever (1) is connected to the
FRESH/RECIRC air changeover servomotor of
the blower unit with the cable and the
FRESH/RECIRC air changeover door (2) is
opened or closed by the operation of the
FRESH/RECIRC air changeover servomotor.
D375A-6 80-15
(01)
DRAFT
Air Conditioner
Compressor
Compressor
A: Refrigerant inlet (From air conditioner unit) Function

B: Refrigerant outlet (To condenser) q The compressor circulates the refrigerant and
compresses the gaseous refrigerant from the
1. Pulley evaporator into a misty refrigerant at high pres-
2. Magnetic clutch sure and high temperature so that it will be easily
3. Relief valve regenerated (liquefied) at the normal tempera-
ture.
q Its built-in magnetic clutch (2) is engaged or dis-
engaged according to the evaporator tempera-
ture and refrigerant pressure.
q If the clutch is engaged, the power of the engine
rotates the compressor shaft to drive the com-
pressor.
Specifications
Number of cylinder – Bore x
Stroke 10 - 32 x 20.8
(mm)
Piston capacity
157.3
(cc/rev)
Allowable maximum speed
6,000
(rpm)
Denso:ND-OIL8 (For
Refrigerant oil used
R134a)
Compressor oil refill capacity
180
(cc)
80-16 D375A-6
(01)
DRAFT
Air Conditioner
Condenser
Condenser
A: Refrigerant inlet (From compressor) Specifications

B: Refrigerant outlet (To receiver drier) Fin pitch (mm) 4.0
Height × width × thickness
350 x 570 x 16
Function (mm)
q The condenser cools and liquefies the high pres- Max. working pressure
3.6 {36}
sure and high temperature misty refrigerant from (MPa{kg/cm2})
the compressor.
a If the fin is crushed or is clogged with dust, heat

exchange efficiency is reduced and complete liq-
uefaction of refrigerant becomes impossible.
If the heat exchange efficiency is reduced, pres-
sure in the refrigerant circulation circuit will be
increased, applying extra load to the engine or
reducing the cooling effect. Take extreme care
not to crush or damage the fins when hangling
and performing daily inspection.
D375A-6 80-17
(01)
DRAFT
Air Conditioner
Receiver drier
Receiver drier
Function
q The receiver drier temporarily stores the high
pressure and high-temperature liquid refrigerant
from the condenser so that it can be supplied to
the evaporator according to the need of cooling.
q It sends the stored refrigerant from its bottom to
the evaporator, allowing the refrigerant to be liq-
uefied completely ever when it contains bubbles
due to the lowerd heat dissipation of the con-
denser.
q The built-in filter and desiccating agent eliminate
foreign substances in the circulation circuit and
water content in the refrigerant.
Specifications
Effective volume (cc) 370
Weight of desiccating agent
290
(g)
A: Refrigerant inlet (From condenser)

B: Refrigerant outlet (To air conditioner unit)
80-18 D375A-6
(01)
DRAFT
Air Conditioner
Receiver drier
D375A-6 80-19
(01)
DRAFT
Air Conditioner
Air conditioner control panel
NO Model Function Operation

Switch to start and stop cooling, drying or heating function
(When the fan switch is turned "ON" and the air conditioner
1 Air conditioner switch OFFioON
switch is pressed, the indicator lamp above the switch lights
up.)
Switch to select RECIRC or FRESH air RECIRC
2 RECIRC/FRESH switch (When the switch is pressed, the indicator lamp above the IO
selected switch lights up.) FRESH
OFF: Off
Switch to adjust fan speed in 4 levels LO: Low
3 Fan switch (When the switch is pressed, the indicator lamp above the t: Medium 1
selected switch lights up.) tt: Medium 2
HI: High
Switch to adjust outlet air temperature in 8 levels Low tempera-
4 Temperature control switch (The rough outlet air temperature is indicated by the tempera- tureioHigh temper-
ture level indicator lamp above the switch.) ature
80-20 D375A-6
(03)
DRAFT
Air Conditioner
Outline
q The air conditioner control panel has a CPU
(Central Processing Unit) that processes the in-
put signals from each sensor and the control sig-
nals from each switch, and displays them on the
panel and controls the servomotors and relays.
Input/Output signal
AMP 172021-2-16P AMP 172245-2-12P
Pin No. Signal name Input/Out- Pin No. Signal name Input/Out-
put signal put signal
1 Power supply Input 17 NC (*) -
2 Blower main relay Output 18 NC (*) -
3 Blower medium 1 relay Output 19 Air mix servomotor (B) Output
4 Blower medium 2 relay Output 20 Air mix servomotor (A) Output
5 Blower high relay Output FRESH/RECIRC air changeover
21 Output
6 Compressor clutch relay Output servomotor (FRESH)
7 NC (*) - FRESH/RECIRC air changeover
22 Output
8 NC (*) - servomotor (RECIRC)
9 Evaporator temperature sensor Input 23 NC (*) -
Air mix servomotor potentiometer 24 NC (*) -
10 Input
signal 25 NC (*) -
11 NC (*) - 26 NC (*) -
12 NC (*) - 27 NC (*) -
13 Sensor GND Input 28 NC (*) -
14 DIS_SEL0 (GND) Output
15 NC (*) -
Air mix servomotor potentiometer
16 Output
power supply
D375A-6 80-21
(01)
DRAFT
Air Conditioner
Procedure for testing and troubleshooting

Reference: The air conditioner does not have a self-diagnosis function.
1. After basic check, find the defective part according to the problem that appears on the air conditioner.
2. Narrow down the probable causes by operating the switches on the control panel.
However, if the air conditioner unit or control panel does not operate at all, check to see whether power is
supplied to the control amplifier normally.
If any part of the air conditioner unit or control panel operates, the power supply should be considered
normal.
3. After narrowing down the probable causes, perform the relevant testing procedure to determine the defec-
tive part to be repaired.
Basic flow of testing and troubleshooting
*1. Self-diagnosis function is not installed.
80-22 D375A-6
(03)
DRAFT
Air Conditioner
*2. Simple check of refrigerant quantity through sight glass.

Start the engine first, and then check the refrigerant level 5 minutes after turning the air conditioner switch
ON.
1) If bubbles are continually seen, the quantity of refrigerant is insufficient.
2) If bubbles in the refrigerant appear intermittently, the quantity of refrigerant is appropriate.
3) When no bubble can be seen (transparent), the refrigerant is excessive or no refrigerant is in the
system. However, there may be exception. In such cases, read the pressure gauge to judge the refrig-
erant level, referring to "Troubleshooting by gauge pressure".
S: View through sight glass
R: Refrigerant level in receiver dryer
LR: Liquid refrigerant
*3. If the refrigerant is leaking, the compressor oil circulating in the air conditioner circuit is also leaking from
the same place.
In this case, retighten the pipe fitting by referring to the tightening torque table in "Precautions for connecting
air conditioner piping".
*4. Start the engine first and turn the air conditioner switch ON to check the noise.
D375A-6
(03) 80-23
DRAFT
Air Conditioner
Circuit diagram and arrangement of connector pins
80-24 D375A-6
(01)
DRAFT
Air Conditioner
Input/output signal of control panel

Connector on control panel: AMP 172241-2 (DLI28PM)
Connector on wiring harness:
AC2: AMP 172021-2(DLI16PF)
AC3: AMP 172245-2(DLI12PF)
AC2
Pin No. Code Signal name Input/output
1 24V 24V power supply Input
2 RL-BM Blower main relay Output
3 RL-ME1 Blower medium 1 relay Output
4 RL-ME2 Blower medium 2 relay Output
5 RL-HI Blower HI relay Output
6 RL-CC Compressor clutch relay Output
7 NC
8 NC
Evaporator temperature sensor
9 TH-F Input
(Thermistor voltage)
A/M servo potentiometer volt-
10 S-AM Input
age
11 NC
12 NC
13 GS Sensor GND Output
14 GND GND Input
15 NC
A/M servo potentiometer 5V
16 AMP-5V Output
power supply
AC3
Pin No. Code Signal name Input/output
17 NC
18 NC
19 M-AMB A/M servo B terminal Output
20 M-AMA A/M servo A terminal Output
Fresh air terminal of
21 M-RFF FRESH/RECIRC air change- Output
over servomotor
Recirculated air terminal of
22 M-RFR FRESH/RECIRC air change- Output
over servomotor
23 NC
24 NC
25 NC
26 NC
27 NC
28 NC
q NC: No connection
q RL-: Relay
q M-: Servomotor
q AM: Air mix
q RF: Recirculation/Fresh (recirculated/fresh air)
D375A-6 80-25
(01)
DRAFT
Air Conditioner
System diagram
System diagram
a This air conditioner has manual temperature control only. (It is not Automatic air conditioner)
80-26 D375A-6
(03)
DRAFT
Air Conditioner
System diagram
Operation of control panel

a The air conditioner does not have a self-diagno-
sis function.
1. The control panel controls the air conditioner
according to each switch inputting.
2. The control panel adjust the temperature (AIR
MIX) by controlling the air mix servomotor
(A/MS).
3. The control panel switches the air between the
recirculated air and fresh air by controlling
FRESH/RECIRC air changeover servomotor
(R/FS).
4. The control panel turns the blower main relay
ON to drive the blower fan.
5. The control panel adjusts the air flow as follows.
1) The control panel turns ON one of the three
relays of blower HI, blower Me1 or blower
Me2. (If none of the three relays is turned
ON, the air flow is set to "LO")
2) The terminal that connects to "ON" relay of
the four blower resistor terminals is
connected to the GND.
3) The current flowing into the blower motor
changes, and consequently the blower fan
speed changes to control the air flow.
a The blower resistor has an overcurrent
protection fuse in it.
6. The control panel senses the evaporator
temperature with the evaporator temperature
sensor.
7. The control panel controls ON/OFF of the
compressor clutch relay to operate the
compressor so that the evaporator does not
freeze.
a If the dual pressure switch detects abnormal
pressure, it is turned OFF, then the compres-
sor clutch relay is turned OFF and the com-
pressor stops.
D375A-6
(03) 80-27
DRAFT
Air Conditioner
Part and connector locations

The air conditioner unit, blower unit and various re- a Condition with cover (4) removed
lays are in the dashboard. q AC2, AC3: Air conditioner control panel
1. Remove cover (1). connectors
a Right figure shows condition with cover (1) q CP: Air conditioner control panel
removed.
q Circuit breaker CB4 (4th from the top) :
For power supply for blower motor, air condi-
tioner compressor and air conditioner unit
(All equipment related to air conditioner)
a If reset button (2) of the circuit breaker comes
out, the circuit is cut off (OFF). In this case,
push reset button (2) in. After setting starting
switch to ON position, if the reset button does
not come out but keeps pushed , it is no prob-
lem. If the reset button comes out soon after
pushing, the electrical circuit may has a
ground fault or another abnormality. (See
"Troubleshooting for power supply system")
4. Remove recirculated air filter cover (5).
2. Pull out four switches (3) forward and disconnect

each connector.
80-28 D375A-6
(01)
DRAFT
Air Conditioner
a Condition with recirculated air filter cover (5) 6. Disconnect connectors AC2 and AC3 and
removed remove air conditioner control panel CP and its
q BM: Blower motor bracket as a unit. (Described above)
q CN-B: Blower motor connector a Condition with air conditioner control panel
q R/FS: FRESH/RECIRC air changeover CP removed
servomotor q AC1: Connector between air conditioner con-
q CN-S: Connector of FRESH/RECIRC air trol panel and air conditioner unit
changeover servomotor
q MAIN: Blower main relay 7. Remove brackets (7) and (8).
q CN-R1: Blower main relay connector
q HI: Blower HI relay
q CN-R2: Blower HI relay connector
q ME1: Blower medium 1 relay
q CN-R3: Blower medium 1 relay connector
q ME2: Blower medium 2 relay
q CN-R4: Blower medium 2 relay connector
q CN-M26: Air conditioner intermediate
connector
(24V power supply, GND, compressor)
D375A-6 80-29
(01)
DRAFT
Air Conditioner
a Condition with brackets (7) and (8) removed

q A/MS: Air mix servomotor
q TH: Evaporator temperature sensor
q [1]: Blower resistor connector
q [2]: Air mix servomotor connector
q [3]: Evaporator temperature sensor connector
q [4]: Dual pressure switch connector
q [5]: Compressor clutch relay connector
80-30 D375A-6
(01)
DRAFT
Air Conditioner
8. Remove the cover between operator cab and

engine hood.
10. Remove duct (10).
q A/C UNIT: Air conditioner unit

q BR: Blower resistor
D375A-6 80-31
(01)
DRAFT
Air Conditioner
Testing temperature control
Testing temperature control Testing FRESH/RECIC air change-

Outline over
The angle of the door (damper) in the air conditioner Outline
unit is changed with air mix servomotor (AM/S) in or- FRESH/RECIRC air changeover servomotor
der to switch the air path between the hot air path to changes the angle of FRESH/RECIRC air change-
the heater and the cold air path to the evaporator. over door (damper) through the lever and cable to
Moreover, for heating, the hot water valve changes switch the air between the recirculated air and fresh
the quantity of the hot water from engine by control- air. Visually check the operation of the lever and
ling the opening angle of valve through the shaft and opening and closing of the door (damper).
controls the outlet air temperature.The shaft and hot
water valve lever can be seen from outside. 1. Remove the recirculated air filter cover from
. lower part of the dashboard.
1. With reference to "Parts and connector loca- 2. Check that cable (1) is not disconnected from the
tions", remove the air conditioner control panel level. (Check its connection to the
and its bracket as a unit. FRESH/RECIRC air changeover door (R/FD),
2. Remove bracket (1). too.)
3. Check that connector (CN-S) is connected
securely.
4. Start the engine and turn the air conditioner ON.
5. Press the FRESH/RECIRC air changeover
switch on the air conditioner control panel and
visually check opening and closing of door
(F/RD).
6. If door (R/FD) does not open or close, check that
lever (2) of FRESH/RECIRC air changeover
servomotor (R/FS) moves to the respective posi-
tions as shown in the figure when the RECIRC
air or FRESH air is selected.
F: FRESH air position
R: RECIRC air position
3. Check that shaft (2) is not disconnected.
4. Check that connector [2] of air mix servomotor
(A/MS) is connected securely. (Check for partial
connection.)
5. Start the engine and turn the air conditioner ON.
Set the temperature setting to the maximum and
minimum with the control panel and check visu-
ally that lever (3) moves smoothly between
COOL MAX and HOT MAX.
a For an electrical trouble, see "Troubleshooting

for FRESH/RECIRC air changeover".
a For an electrical trouble, see "Troubleshoot-

ing for temperature control".
80-32 D375A-6
(03)
DRAFT
Air Conditioner
Testing FRESH/RECIC air changeover
D375A-6 80-33
(01)
DRAFT
Air Conditioner
Testing relay
Testing relay
a If the air conditioner compressor is normal and a If the fan sound is so large that you cannot
the cool air flow rate is adjusted to the four lev- hear the operation sound of the compressor
els, skip this test. clutch relay, set the starting switch to OFF
a Move your ear closer to the relay to check the position and disconnect connector R1 and
operation sound. then perform the check.(*)
7. Operation check of relay responding to air flow
Condenser relay among six relays is not used. switch operation
q Compressor clutch relay CCR, connector [5]: a If the fan sound is so large that you cannot
For ON/OFF of air conditioner compressor hear the operation sound of the compressor
(clutch) relay, set the starting switch to OFF position
q Blower main relay MAIN, connector R1: and disconnect connector R1 and then per-
For ON/OFF of blower motor form the test.(*)
q Blower relays of HI, ME2 and ME1: 1) Set the starting switch to the ON position
For air flow adjustment (with engine stopped) and turn the air condi-
1. Remove the recirculated air filter cover from tioner switch ON.
lower part of the dashboard. 2) Set the air flow to HI, ".." and "." in order to
2. With reference to the parts and connectors turn relays HI, ME2 and ME1 ON respec-
arrangement, remove cover (1). tively. Check their operation sounds (click).
3. Remove bracket (2). a If the air flow is set to LO, ME1 relay turns
OFF.
q X view
4. Check the connection between connectors

CN-R1 and CN-R4, and connector [5].
(Check for partial connection.)
5. Turn the starting switch to the ON position (with
engine stopped) and turn the air conditioner
switch ON. If the blower main relay is normal, it
turns ON and you can hear its operation sound
(click).
6. If the compressor clutch relay (CCR) is normal, it

turns ON and you can hear its operation sound
(click).
a The control panel does not turn the compres-
sor relay ON in the following cases.
q When the evaporator temperature is 3°C or
below (temperature sensed by the evapora-
tor temperature sensor) *: Since the connector R1 is disconnected, the
a Compressor clutch relay (CCR) does not turn blower does not start and the pressure in air
ON in the following cases. compressor hose (high-pressure hose) may rise.
q When the dual pressure switch detects ab-
normal pressure (the dual pressure switch is
OFF)
80-34 D375A-6
(03)
DRAFT
Air Conditioner
Testing relay
q Testing for relay units

a Since no T-adapter is available, it is actually
impossible to check each relay while apply-
ing voltage to its coil.
a Set the starting switch to the OFF position
and remove the relays.
a Common to each relay
1) The coil resistance between terminals (1)
and (2) is 140 – 340 Ω
2) While the voltage (20 - 30 VDC) is not applied
between terminals (1) (+) and (2), terminals
(3) and (4) are disconnected.
3) While the voltage (20 - 30 VDC) is applied
between terminals (1) (+) and (2), terminals
(3) and (4) are connected.
D375A-6 80-35
(01)
DRAFT
Air Conditioner
Troubleshooting chart 1
The numbers in the boxes are the item numbers in the troubleshooting table.
1.Cooling trouble
80-36 D375A-6
(01)
DRAFT
Air Conditioner
2.Heating trouble
D375A-6 80-37
(01)
DRAFT
Air Conditioner
1. Blower fan motor does not revolve or its speed is different from set value.
a See "Troubleshooting of blower motor system (Air does not come out or air flow is abnormal)".
Probable causes Check method Remedy
Defective blower main relay See “Testing relay” Replace
Check connector of blower fan motor for disconnection.
Open circuit or defective con- Repair broken parts and
See "Troubleshooting of blower motor system" and "Parts and
nection of wiring harness connect correctly
connector locations".
Check two lead wires of motor by using circuit tester. If there is
not continuity, motor is defective.
Defective blower fan motor Replace
See "Troubleshooting of blower motor system" and "Parts and
connector locations".
Defective blower resistor, Activate fan switches in order and check fan speed.
blower ME1 relay, blower ME2 See "Troubleshooting of blower motor system" and "Testing Replace
relay, blower HI relay relay".
2. Blower fan motor is normal but air flow is insufficient.

Large airflow resistance Check duct for crushing and clogging and filter for clogging Repair
Check duct joints.
Air leakage through duct joints Repair
Check for defective duct seal and disconnection of duct
Obstruction on suction side of Remove obstruction
Check evaporator for dirt and obstruction
evaporator and clean
Defective evaporator tempera- Check evaporator for freeze.
ture sensor Check sensor clip. Check sensor for dirt.
Defective contact of evapora- Repair or replace
Check for frost on the hose near pressure switch (when freez-
tor temperature sensor or
ing advances furthermore)
defective expansion valve*
* The evaporator temperature sensor and expansion valve are in the air conditioner unit.
3. Low/high pressure
Collect the refrigerant
Excessive or insufficient refrig-
and refill with proper
erant
amount of refrigerant.
Repair leaking part,
Check the normal refrigerant quantity through sight glass.
Insufficient refrigerant then refill with proper
To be exact, check by connecting gauge manifold.
Collect the refrigerant
Excessive refrigerant and refill with proper
Normal refrigerant pressure
Low pressure side: Approx. 0.13-0.2 MPa {1.3–2.0 kg/cm2}
Judgment by pressure at High pressure side: Approx. 1.5-1.7 MPa {15-17 kg/cm2} See Troubleshooting
inlet/outlet of compressor Under following conditions: with gauge pressure
Temperature inside cab: 30 - 35 °C
Engine speed: Approx.1,500 rpm
80-38 D375A-6
(03)
DRAFT
Air Conditioner
4. Compressor does not revolve at all or its speed is low.

a See "Troubleshooting of compressor system (Air is not cooled)".
Troubled part Possible cause Check method Remedy
Compressor
Loosened compressor belt Check for excessive deflection of belt. Adjust tension
belt
Trouble in compressor Check for slipping of belt. Repair or replace
Insufficient compressor oil or
Compressor See "Handling compres-
seizure in the compressor Check for compressor overheat
sor oil"
Low battery voltage Slip of clutch Charge battery
Disconnection or short circuit
Inspect with circuit tester (10 - 20 Ω) Replace
in coil
Magnet clutch
Disconnection of wiring har-
Check ground wire and connections
ness or defective connection Repair
See "Troubleshooting of compressor system".
of ground wire
Defective compressor clutch
Relay See “Testing relay” Replace
relay
Refrigerant Low/high pressure (Operation Troubleshooting with
Troubleshooting with gauge pressure
pressure of pressure switch) gauge pressure
Pressure
Defective pressure switch See "Troubleshooting of compressor system". Replace
switch
Check diode (ACS). See "Troubleshooting of
Diode Defective diode(ACS) Replace
compressor system".
5. Blower fan motor is normal but air flow is insufficient.

Possible causes Check method Remedy
Large airflow resistance Check duct for crushing and clogging, and filter for clogging Repair
Check duct joints for defective duct seal and disconnection of
Air leakage through duct joints Repair
duct
Clogging of heater core fins Check heater core fins for clogging Clean
6. Engine coolant temperature or level is abnormal.

Low engine coolant tempera-
Warm up engine, and then check engine coolant temperature Find out cause
ture
Low engine coolant level Check coolant level in radiator Add coolant
Insufficient circulation of Check engine coolant piping for clogging
Bleed air and repair
engine coolant (Hose, pipe, and core)
Contrary connection of IN and
Check the destination of heater hoses Repair
OUT heater hoses
7. Fan speed is abnormal.

Fan speed is low See "Testing fan motor speed" and "Testing fan pump circuit
(Defective fan motor EPC or pressure" in chapter 30 "Testing and adjusting" of Shop Man- Repair
hydraulic system) ual.
8. Other abnormalities
Possible causes Check method Remarks
Temperature cannot be con- See "Testing temperature control" and "Troubleshooting for
trolled temperature control" Common to cooling and
Fresh air and recirculated air See "Testing Recirc/Fresh air changeover" and "Troubleshoot- heating
cannot change. ing for Recirc/Fresh air changeover"
Excessive compressor oil See "Handling compressor oil"
Cooling only
Water leakage into the cab Clogging of drain hole
D375A-6 80-39
(01)
DRAFT
Air Conditioner

a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before troubleshooting, understand the information fully.
Trouble Problem that appears on machine
Related information Information related to detected trouble or troubleshooting
<Information described>
q Procedure
1 a "Between A – B" means “Measure voltage or resistance and so on between A – B.
Possible causes for
q Standard value in normal condition to evaluate possible cause if it is applicable or not
trouble
q Remarks requiredfor to evaluate the cause is correct
(Perform trouble-
shooting according
<Notes on troubleshooting>
to these numbers,
(1) Pin number description sequence and tester lead handling
however.)
2 For troubleshooting, connect the plus (+) and minus (–) leads as shown below unless other-
wise specified.
q Connect the plus (+) lead to pin or harness indicated in the front.
q Connect the minus (–) lead to a pin or harness indicated in the rear.
(2) Example of troubleshooting by inspection of multiple items
a Normal in 1 but abnormal in 2
At this time“ - defective” shown at left is applied
4 defective
a If a wiring harness is burnt, replace it.

<Phenomenon of defective wiring harness>
q Disconnection in wiring harness
The connector connection is defective or wiring harness is disconnected.
q Ground fault
A harness not to be connected to the ground (earth) circuit comes into contact with the ground (earth)
circuit or chassis accidentally.
q Hot short circuit
A harness not to be connected to the power (24 V) circuit comes into contact with the power (24 V) circuit
accidentally.
q Short circuit
An independent wire in the harness abnormally comes into contact with one of another wire. (Defective
insulation in connector or others)

This is the excerpted circuit diagram related to trouble
q The circuit diagram includes connector numbers and pin numbers related to the trouble.
q See “Circuit diagram and arrangement of connector pins” and “Parts and connector locations” for connector lo-
cation.
q The circuit diagram shows the size and colors of wires.
W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown, Gr: Gray, Sb:
Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown
a When there are 2 colors
Example: WY: Yellow line on white background
a The number before the wire color symbol indicates the wire size.
q N.C.: Normally closed (Normally ON)
q [1], [2],··· are numbers of unlabeled connectors.
q Arrow (↔): Roughly indicates their mounting place on the machine.
80-40 D375A-6
(01)
DRAFT
Air Conditioner
D375A-6 80-41
(01)
DRAFT
Air Conditioner
Troubleshooting for power supply system (Air conditioner does not operate)
Troubleshooting for power supply system (Air conditioner does not

operate)
Failure Air conditioner does not operate due to failure in power supply system
Problem on
q When control panel is operated, related LED does not light up.
machine
q Air conditioner ground is housed in the chassis wiring harness toghether with those of electric equip-
ment installed on the machine and connected to the chassis ground.
q For connectors etc., see "Parts and connector locations".
Related infor- q T-adapter for connector CN-M26: 799-601-7130, T-adapter for connector AC1: 799-601-2730
mation a T-adapter is not prepared for other connectors.
q Turn starting switch to ON position and turn air conditioner switch A/C to ON position. At this time, if
LED above A/C switch lights up for a moment and circuit breaker trips immediately, see "Troubleshoot-
ing for compressor system" and "Troubleshooting for blower motor system".
Probable causes Procedure, measuring location, standard (value) and remarks

Activation of circuit breaker
1 If circuit breaker trips, circuit probably has ground fault etc.
(CB4)
Defective wiring harness 2. Disconnect connector AC2 from control panel.
2
(ground) 3. Insert T-adapter into connector AC1.
Between AC1 (1) and chassis ground Resistance Max. 1 
a If circuit breaker trips, press its reset button in advance.
2. Disconnect connector AC2 from control panel.
3. Insert T-adapter into connector AC1.
Between AC1 (10) and (1) Voltage 20 – 30 V A
a Perform the following when the test result "A" above is abnormal
2. Disconnect connector M26 and connect T-adapter to female side.
a If circuit breaker trips again or the test result "B" or "C" below is abnormal, wiring
harness on machine body side is defective.
Between M26 (2) and (6) Voltage 20 – 30 V B
Between M26 (5) and (6) Voltage 20 – 30 V C
3 Defective wiring harness a Perform the following when circuit breaker trips during test "A" above and the
test results "B" and "C" above are normal.
2. Disconnect connector AC2 from control panel.
4. Disconnect connectors CN-B, R1 - R4 and [5].
Between AC1 (10) and (1) Voltage 20 – 30 V D
a If the test result "D" above is abnormal, air conditioner wiring harness is defec-
tive.
a If circuit breaker trips during test "D" above, disconnect male side of connector
AC1 and perform test again to see on which side wiring harness is defective,
control panel side or air conditioner unit side.
a If the test result "A" is abnormal and test result "D" is normal, see "Trouble-
shooting for compressor system" and "Troubleshooting for blower motor sys-
tem".
4 a If circuit breaker does not trip, check with circuit diagram.
(on control panel side)
5 Defective control panel If cause is not found by above checks, control panel may be defective.
80-42 D375A-6
(03)
DRAFT
Air Conditioner
Troubleshooting for power supply system (Air conditioner does not operate)
Related electrical circuit diagram
D375A-6 80-43
(01)
DRAFT
Air Conditioner
Troubleshooting for compressor system (Air is not cooled)

Failure Air is not cooled because of trouble in compressor or refrigerant system
Problem on q
When engine is started and A/C switch is pressed while the blower is turned ON, air is not cooled.
machine q
Air conditioner compressor does not operate.
q If refrigerant pressure is abnormal, air is not cooled because the compressor is not turned ON.
q When evaporator temperature is below 3 °C, control panel does not turn compressor relay ON to
prevent evaporator from freezing (this is normal operation.).
Related infor- q For connectors etc., see "Parts and connector locations".
mation q T-adapter for connector CN-M26: 799-601-7130, T-adapter for connector AC1: 799-601-2730
a T-adapter is not prepared for connectors other than the above and for DT connectors. Accordingly,
perform troubleshooting by using connectors which T-adapter is avilable for.
q Since condenser relay is not used, it may be used as a replacement when replacing other relays.

2. Disconnect connector FEN from air conditioner compressor and connect
Defective air conditioner compres- T-adapter to male side.
1
sor
Between FEN (1) and ground (air conditioner com- Resis-
Approx. 15 
pressor coil resistance) tance
2. Remove diode ACS.
a Measure with circuit tester in diode range.
2 Defective diode Between ACS (male) (1) (+) and (2) (-) No continuity
Max. 1 
Between ACS (male) (2) (+) and (1) (-) Continuity
Disconnection in wiring harness 2. Disconnect connector M26 and connect T-adapter to female side.
3
(on machine side) Between M26 (female) (3) and ground Resis-
Approx. 15 
(air conditioner compressor coil resistance) tance
a If circuit breaker does not trip, this check is not required.
Ground fault of wiring harness 2. Disconnect connector FEN.
4 (Contact with ground circuit) 3. Insert T-adapter into connector M26.
(on machine side) Resis-
Between M26 (female) (3) and ground Min. 1 M
tance
Resis-
Between M26 (female) (3) and (6) Min. 1 M
tance
q Referring to "Testing relay", check operation Click is
A
sound of compressor clutch relay. heard.
a If the test result "A" above is normal, this check is not required.
a Check that air flow can be controlled.
Defective compressor clutch relay 1. Turn starting switch to OFF position.
5
(It does not turn ON) 2. Replace compressor clutch relay with blower Me2 relay (CN-R4).
4. Turn air conditioner switch ON.
If compressor operates (air is cooled), original compressor clutch relay is
defective.
2. Disconnect connector AC1 and insert T-adapter into female side.
Resis-
0°C 4.6 - 5.1 k
Defective evaporator temperature tance
6
sensor Resis-
Between AC1 (female) (15) and (17) 15°C 2.1 - 2.6 k
tance
Resis-
25°C 1.5 k
tance
80-44 D375A-6
(03)
DRAFT
Air Conditioner

2. Disconnect connector AC1 and connect T-adapter to female side.
a The switch may be turned OFF normally. If the following is abnormal (switch
is turned OFF), install pressure gauge to low-pressure side of air condition-
7 Defective pressure switch er compressor and check refrigerant pressure. (See "Troubleshooting with
gauge pressure".)
Between AC1 (10) and (14)
Resistance 240 ± 40 Ω
(compressor relay coil resistance)
k When replacing pressure switch, collect refrigerant in advance.
Check of voltage 2. Insert T-adapter into connector AC1.
8 (Defective wiring harness or defec- 3. Turn starting switch to ON position.
tive control panel) 4. Turn air conditioner switch ON.
Between AC1 (14) and (1) Voltage Max. 1 V
2. Disconnect connectors M26, AC2, R1 - R4 and [5].
9 Short circuit in wiring harness 3. Insert T-adapter into connector AC1.
Between AC1 (10) and each pin other than (10) No continuity
10 Disconnection in wiring harness a Check with circuit diagram.
If check result for cause 8 is abnormal and check results for causes 9 and 10
11 Defective control panel
are normal, control panel is defective.
D375A-6 80-45
(01)
DRAFT
Air Conditioner
80-46 D375A-6
(01)
DRAFT
Air Conditioner
D375A-6 80-47
(01)
DRAFT
Air Conditioner
Troubleshooting for blower motor system (Air does not come out or air flow is abnormal)
Troubleshooting for blower motor system (Air does not come out or air
flow is abnormal)
Air does not come out or air flow is abnormal because of trouble in blower motor system
Trouble
1) Air does not come out in any air flow setting.
Problem that
appears on the q When any fan switch is pressed, air does not come out.
machine
q For connectors, relays, etc., see "Parts and connector locations".
Related infor- q Since condenser relay is not used, it may be used as replacement when replacing other relays.
mation q T-adapter for connector CN-M26: 799-601-7130, T-adapter for connector AC1: 799-601-2730
a T-adapter is not prepared for other connectors.
Causes Procedure, measuring location, standard (value) and remarks

1 Defective blower (fan) motor 2. Disconnect connector CN-B.
Between CN-B (male) (1) and (2) Continuity
q Referring to testing of relay, check turn-on sound of Click is
A
blower main relay. heard.
a If the test result "A" above is normal, this check is not required.
Defective blower main relay 1. Turn starting switch to OFF position.
2
(It does not turn ON) 2. Replace blower main relay with blower Me2 relay (CN-R4).
If air comes out, original blower main relay is defective.
q Primary output to relay from control panel
Check of voltage
3 (Defective wiring harness or
defective control panel) 3. Turn starting switch to ON position.
Between AC1(11) and (1) Voltage Max. 1 V
2. Disconnect connectors M26, AC2, R1 - R4 and [5].
4 Short circuit in wiring harness
If check result for cause 3 is abnormal and check results for causes 4 and 5 are
normal, control panel is defective.
80-48 D375A-6
(01)
DRAFT
Air Conditioner
D375A-6 80-49
(01)
DRAFT
Air Conditioner
Air does not come out or air flow is abnormal because of trouble in blower motor system
Trouble
2) Air does not come out or air flow is abnormal in certain air flow setting.
Problem that
appears on the Air does not come out or air flow is abnormal in certain air flow setting.
machine
q If air flow decreases (air does not come out) after a while in cooling mode, evaporator may have fro-
zen. The possible causes for this trouble are as follows.
1) Compressor clutch relay is defective (kept ON) (See "Troubleshooting for compressor system",
5-A).
2) Evaporator temperature sensor mounting holder is removed (Remove and disassemble air condi-
Related infor- tioner unit).
mation 3) Expansion valve is not adjusted properly (Remove air conditioner unit and replace expansion
valve).
q For connectors, relays, etc., see "Parts and connector locations".
q Since condenser relay is not used, it may be used as replacement when replacing other relays.
q T-adapter for connector CN-M26: 799-601-7130, T-adapter for connector AC1: 799-601-2730

3. Set air flow to each level in order.
Defective blower resistor If air comes out only in air flow HI, blower resistor is defective.
q Reference: Between [1] (male) (1) and (2) Approx.
1 (Breakage of fuse in blower Resistance
resistor) a Fuses 600 Ω
Approx.
q Reference: Between [1] (male) (2) and (3) Resistance
900 Ω
Approx.
q Reference: Between [1] (male) (3) and (4) Resistance
530 Ω
3. Set air flow to each level in order.
q Replace corresponding relay in each of following checks. Following phenomena
show: 1. Relay is kept turned ON, 2. Relay is not turned ON.
1. Air flow is HI in any air flow setting.
2. Air flow is LO when the air flow is set to HI.
Defective blower HI relay, q Replace blower HI relay with condenser relay. If air flow becomes normal, orig-
2 blower Me2 relay or blower Me1 inal blower HI relay is defective.
relay 1. Air flow HI and ".."is normal, but air flow is ".." even if the air flow set to"." or LO.
2. Air flow is LO when air flow is set to "..".
q Replace blower Me2 relay with condenser relay. If air flow becomes normal,
original blower Me2 relay is defective.
1. Air flow HI ,".." and "." is normal, but air flow is "." even if the air flow is set to LO.
2. Air flow is LO when air flow is set to ".".
q Replace blower Me1 relay with condenser relay. If air flow becomes normal,
original blower Me1 relay is defective.
q Primary output to relay from control panel
Check of voltage 5. Press each air flow switch and perform troubleshooting.
3 (Defective wiring harness or Between AC1(13) and (1) HI Voltage Max. 1 V
defective control panel) Other than
Between AC1(13) and (1) Voltage 20 – 30 V
HI
Between AC1(12) and (1) "··" Voltage Max. 1 V
Other than
Between AC1(12) and (1) Voltage 20 – 30 V
".."
Between AC1(7) and (1) "·" Voltage Max. 1 V
Between AC1(7) and (1) Other than Voltage 20 – 30 V
80-50 D375A-6
(01)
DRAFT
Air Conditioner
2. Disconnect connectors M26, AC2, CN-B, R1 - R4 and [5].
D375A-6 80-51
(01)
DRAFT
Air Conditioner
80-52 D375A-6
(01)
DRAFT
Air Conditioner
D375A-6 80-53
(01)
DRAFT
Air Conditioner
Troubleshooting for temperature control

Failure q Temperature cannot be controlled
Problem on
q When temperature control switch is operated, temperature does not change.
machine
q Referring to "Testing temperature control", check connector [2] for defecive contact and mechanical
trouble (desconnection of shaft, interference of lever, etc.)
Related infor- q For connectors etc., see "Parts and connector locations".
mation q T-adapter for connector CN-M26: 799-601-7130, T-adapter for connector AC1: 799-601-2730,
T-adapter for connector [2]: 799-601-2710

2. Disconnect connector [2] and connect T-adapter to male side.
Between connector [2] (male) (4) and (1) Resistance 6 k
a If air mix servomotor does not operate (the test result "C" below is abnormal)
while the test results "A" and "B" below are normal, air mix servomotor is de-
fective.
2. Insert T-adapter in connector [2]
Between connector [2] (4) and (1) Voltage 5V A
2. Insert T-adapter in connector [2]
5. Press left triangle temperature control switch many times to set to minimum
temperature in advance.
1 Defective air mix servomotor 6. Perform troubleshooting while pressing right triangle temperature control
switch.
7. Press right triangle temperature control switch many times to set to maximum
temperature in advance.
8. Perform troubleshooting while pressing left triangle temperature control
switch.
Between connector [2] (3) and (5)
a Voltage appears for only approxi-
mately 1 second (only while hot water
valve is moving) and polarity is re-
versed when right triangle and left tri- Voltage ± 24 V B
angle temperature control switch is
pressed. When right triangle switch
(WARM side) is pressed, polarity of
pin 3 becomes +.
Between connector [2] (2) and (1)
a Voltage changes only while hot water Varies
Voltage C
valve is moving (Voltage settles after below 5 V
the door stops).
2. Disconnect connectors AC1 and [2], and connect T-adapters to female side of
them.
2 Disconnection in wiring harness Between AC1 (2) and [2](4) Resistance Max. 1 
Between AC1 (3) and [2](5) Resistance Max. 1 
80-54 D375A-6
(03)
DRAFT
Air Conditioner
2. Disconnect connectors M26, AC2, AC3 and [2].
3. Insert T-adapter in connector AC1.
4 a Check with circuit diagram.
D375A-6 80-55
(01)
DRAFT
Air Conditioner
Troubleshooting for FRESH/RECIRC air changeover

Trouble q
Fresh air and recirculated air cannot switch between them.
Problem that q
When FRESH/RECIRC air changeover switch on control panel is operated, fresh air or recirculated
appears on air does not switch between them.
the machine (FRESH/RECIRC air changeover door (damper) does not rotate)
q Referring to "Testing FRESH/RECIRC air changeover", operate FRESH/RECIRC air changeover
switch and check FRESH/RECIRC air changeover door (damper) for mechanical trouble (descon-
nection of cable, interference of lever, etc.)
Related infor-
q For connectors etc., see "Parts and connector locations".
mation
q T-adapter for connector CN-M26: 799-601-7130, T-adapter for connector AC1: 799-601-2730,
T-adapter for connector S: 799-601-2710

a If FRESH/RECIRC air changeover servomotor does not operate while following
is normal (See Testing FRESH/RECIRC air changeover), FRESH/RECIRC air
changeover servomotor is defective.
2. Insert T-adapter into connector CN-S.
Defective FRESH/RECIRC air 5. Perform troubleshooting while pressing RECIRC air switch and FRESH air
1 switch.
changeover servomotor
a Voltage appears only for approx. 3 seconds (only while door is moving to
FRESH or RECIRC position).
From fresh
Between CN-S(5) (+) and (3) (-) air to recir- Voltage 24 V
culated air
From recir-
Between CN-S(5) (-) and (3) (+) culated air to Voltage 24 V
fresh air
2 Disconnection in wiring harness 2. Disconnect connectors AC1 and [2] and connect T-adapter to female side of
them.
Between AC1(5) and CN-S(3) Resistance Max. 1 Ω
Between AC1(6) and CN-S(5) Resistance Max. 1 Ω
2. Disconnect connectors M26, AC2, AC3 and [2].
4 a Check with circuit diagram.
If check result for cause 1 is abnormal and check results for causes 2 to 4 are nor-
mal, control panel is defective.
80-56 D375A-6
(01)
DRAFT
Air Conditioner
D375A-6 80-57
(01)
DRAFT
Air Conditioner

Referring to “Connection of service tool”, perform <Measurement condition for pressure>
troubleshooting by reading the gauge pressure of Item Condition value
the high-pressure and low-pressure lines in the re- Ambient temperature 20 – 50 °C
frigeration cycle. Engine speed 1,500 rpm
a The gauge pressure varies largely with the Air conditioner switch ON
Fan switch HI
weather condition and operating condition of the
Set temperature Full cool
machine. Check the gauge pressure under the
pressure measurement conditions. q Dual pressure switch
q High-pressure line pressure is too high: Above a The swiths is normally "ON", and becomes
approx. 2.5 MPa {25 kg/cm2} "OFF" for compressor operation when it detects
q High-pressure line pressure is too low: Below
abnormal pressure.
approx. 1 MPa {10 kg/cm2}
q Low-pressure line pressure is too high: Above
approx. 0.3 MPa {3 kg/cm2}

q Low-pressure line pressure is too low: Below ap-
prox. 0.0 5MPa {0.5 kg/cm2}

a Dual pressure switch turns "OFF" to protect the
air conditioner circuit if the pressure of the
high-pressure or low-perssure line is abnormal.
LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
80-58 D375A-6
(01)
DRAFT
Air Conditioner
Indicated gauge
Cause Check method Remedy
pressure
Air conditioner cycle is normal.
If there is any trouble (cooling trouble), there is another cause.
Pressure is normal -
High-pressure: Approx. 1.5 – 1.7 MPa {15 – 17 kg/cm2}
Low-pressure: Approx. 0.13 – 0.2 MPa {1.3 – 2.0 kg/cm2}
Collect refrigerant, then
Bubble can be seen through sight glass refill with proper amount
Insufficient refrigerant
(*3) of refrigerant again
(*2)
There is a temperature difference between
Replace
Clogging of receiver drier inlet and outlet pipes of receiver drier.
(*2)
Tank is frosty
<Pressure of both Clean or replace
Clogging of expansion valve Expansion valve is frosty
high-pressure and (*2)
low-pressure lines Refrigerant leakage from thermoprobe Replace
Low pressure gauge reads vacuum
are too low> tube of expansion valve (*2)
Repair or replace
Evaporator is frozen
Low-pressure gauge Replace receiver drier
Defective evaporator sensor or defective Flow rate of refrigerant is reduced due to
reads vacuum Collect refrigerant, then
contact of sensor (removal of mounting freezing
refill with proper amount
clip) (After setting to cool max. and HI fan
of refrigerant again
speed, air becomes not to be cooled.)
(*2)
Piping between receiver drier and com-
pressor is clogged or crushed. Clean or replace
Clogged or crushed piping
If clogged completely, low-pressure gauge (*2)
reads vacuum
Collect refrigerant, then
refill with proper amount
Excessive refrigerant Connect gauge manifold
of refrigerant again
(*2)
Clean, repair fins, or
<Pressure of both Dirty condenser, clogging or crushing of repair or replace con-
Defective cooling of condenser
high-pressure and fins, or defective revolution of cooling fan denser
low-pressure lines (*2)
are too high> Defective adjustment of expansion valve Bubble can be seen through sight glass Replace
(Valve is opened too wide) ( *3) (*2)
Vacuum and then refill
Bubble can be seen through sight glass with proper amount of
Air in cycle parts
(*3) refrigerant again
(*2)
<High-pressure line
pressure is too high Clean inside of cycle
Clogged or crushed piping between com- There is a remarkable temperature differ-
and low-pressure parts or replace
pressor and condenser ence across clogged part
line pressure is too (*2)
low>
<High-pressure line
Both high-pressure and low-pressure lines
pressure is too low
Defective compressor (Compression stop while compressor is in operation. Replace
and low-pressure
trouble of compressor) Compressor has seized and is extremely (*2)
line pressure is too
hot.
high>
*1 If refrigerant leaks, compressor oil in the air conditioner circuit always leaks, too. So perform the check
mainly on pipe joints and dirty parts with oil.
*2
k When replacing a cooling cycle part, see “Caution about refrigerant” and collect refrigerant. After
replacing it, fill up the air conditioner system with refrigerant again.
*3 Sight glass is on the receiver drier .
D375A-6 80-59
(01)
DRAFT
Air Conditioner
Connection of service tool

Connect the gauge manifold, hoses and other ser-
Symbol Part No. Part name vice tools according to the following procedure.
X 799-703-1200 Service tool kit 1. Close the high-pressure valve (6) and low-pres-
a Use the service tool kit for R134a. sure valve (7) of gauge manifold (1).
Service tool kit X 2. Connect red charging hose (2) to the (HI) side
(1): Gauge manifold and blue charging hose (3) to the (LO) side of the
(2): High pressure charging hose (red) gauge manifold.
(3): Low pressure charging hose (blue)
(4): Quick joint (Hi) (Large diameter) 3. Connect quick joints (4) and (5) to each hose.
(5): Quick joint (Lo) (Small diameter)
4. Connect the quick joints (4) and (5) to the service
(a): The thread is rough. So be careful not to loosen. valves (8) and (9) of the high and low-pressure
pipings.
80-60 D375A-6
(01)
DRAFT
Air Conditioner
D375A-6 80-61
(01)
DRAFT
Air Conditioner
Precautions for disconnecting and connecting

Precautions for disconnecting Precautions for connecting
k Collect the air conditioner refrigerant (R134a) q When connecting the piping, apply compressor
from air conditioner circuit before discon- oil NDOIL-8 for R134a to the O-rings. (See item
necting air conditioner hose to replace air 4. in “Handling of compressor oil”)
conditioner unit, air conditioner compressor Do not apply oil to the threads of a bolt, nut or
or receiver drier and so on. union, however.
a Ask a qualified shop for collecting, adding and q Once an O-ring is used, it is deformed and dete-
filling operation of refrigerant (R134a). riorated. Accordingly, do not reuse it. When re-
a Never release the refrigerant (R134a) to the at- moving it, use a soft tool (such as a toothpick) so
mosphere. that the piping will not be damaged.
k If refrigerant gas (R134a) gets in your eyes, q Push in each pipe to the stopper and tighten the
you may lose your sight. And if it touches bolt or nut fully with your fingers.
your skins, you may suffer from frostbite. Ac- q Be sure to use two wrenches to tighten each nut
cordingly, put on protective goggles, gloves (Use a torque wrench for tightening). Use one
and working cloth with long sleeves while wrench to fix and tighten the nut with the other
you are collecting the refrigerant (R134a) or wrench to the specified torque.
filling the air conditioner circuit with the re-
frigerant (R134a). Collecting and filling work
must be conducted by a qualified person.
q When loosening the air conditioner hose nuts af-

ter collecting the refrigerant, be sure to use 2
wrenches; use one wrench to fix and use the oth-
er one to loosen the nuts.
80-62 D375A-6
(01)
DRAFT
Air Conditioner
Table of tightening torque for refrigerant pipe joint.

Unit: Nm {kgm}
Screw size Tightening torque
3.9 – 6.9 {0.4 - 0.7} (Receiver drier)
Approx. M6 × 1.0
8 - 12 {0.8 - 1.2} (A/C unit and compressor)
Approx. M16 × 1.5 12 - 15 {1.2 - 1.5}
Approx. M24 × 1.5 30 - 35 {3.1 - 3.6}
1. Engine
2. Compressor
3. Condenser
4. Receiver drier
5. Air conditioner unit
D375A-6 80-63
(01)
DRAFT
Air Conditioner
Handling of compressor oil

1. Control of compressor oil (Denso: ND-OIL8: 2. Adding of compressor oil
For R134a)
k Since refrigerant is dangerous and bad for
Compressor oil does not need to be checked or add- environment, collect the refrigerant before
ed so frequently as engine oil. Insufficiency or ex- disconnecting the air conditioner hose. See
cess of compressor oil can cause the following “Caution about refrigerant”.
troubles. a If oil for CFC-12 (R-12) is used, lubrication trou-
Condition Contents ble will occur and the compressor may be broken
Insufficiency of Lubrication trouble and seizure of com- or seized.
oil pressor Be sure to use the specified oil for R134a
Cooling trouble (Denso: ND-OIL8)
Excess of oil (Excessive oil stick to parts and lower a Oil for R134a absorbs moisture very easily. Ac-
heat exchange performance)
cordingly, fit the cap to the oil container immedi-
ately after using the oil to shield against the
Accordingly, compressor oil must be filled to the atmosphere.
specified level, similarly to refrigerant. Store the oil container in a dry and ventilated
place.
a Precautions for using oil
Oil for R134a may dissolve acrylic resin and
polystyrene (excluding baked polystyrene paint
film). Accordingly, do not stick oil to those plas-
tics.
Check compressor oil in the following cases, and
then add new oil if necessary.
q When much refrigerant is discharged because of
leakage.
q When the compressor is troubled and replaced.
q When a cycle parts such as the air conditioner
unit, condenser, receiver drier, evaporator unit,
etc. is replaced.
q Quantity of oil to be added when cycle part is re-

placed
Quantity to be
Air conditioner par
added (cc)
Air conditioner unit, evaporator Approx. 40
Condenser Approx. 40
Receiver drier Approx. 20
Hose (Compressor – Cab) Approx. 30
Hose (Compressor – Condenser) Approx. 10
Hose(Condenser–
Approx. 10
Receiver driver)
Hose (Cab – Receiver driver) Approx. 20
80-64 D375A-6
(01)
DRAFT
Air Conditioner
3. Compressor replacement 4. Applying compressor oil to O-ring
q In case of compressor seizure or breakage. When connecting a pipe or hose, apply oil (Denso:
Metal chips will circulate through the air condi- ND-OIL8) to its O-ring to prevent refrigerant leak-
tioner circuit and contaminate the compressor oil age.
extremely.
In this case, flush the air conditioner circuit and
replace the compressor and receiver drier.
The compressor oil is removed from the air
conditioner circuit by flushing. Accordingly,
install a new compressor with the oil of the spec-
ified quantity (180 cc) filled in it.
q Other cases
a New compressor has 180 cc compressor oil in it.
So drain excessive compressor oil before install-
ing the new compressor as follows.
1) Prepare an oil container and drain oil from
the old compressor.
2) Measure the quantity of the drained oil with a
measuring cylinder, and note the quantity.
3) Drain below-mentioned quantity of oil from

the new compressor.
180 cc – “the noted quantity”.
EX. If drained oil quantity from removed
compressor is 30cc, drain oil of 180 – 30 cc =
150 cc from new one.
D375A-6 80-65
(01)
DRAFT
Air Conditioner
80-66 D375A-6
(01)
DRAFT
D375A-6
SEN05027-00
Bulldozer
Shop Manual
D375A-6

D375A-6 60001 and up

Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90 -
2
Powertrain hydraulic diagrams and drawings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90 -
5
Hydraulic diagrams and drawings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90 -
7
Electrical diagrams and drawings- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90 -
13
D375A-6 90-1
DRAFT
Contents
Contents
Hydraulic diagrams and drawings
Symbols used in hydrauric cirxuit diagrams................................................................................................. 90 - 3
Powertrain hydraulic diagrams and drawings .............................................................................................. 90 - 5
Hydraulic diagrams and drawings................................................................................................................ 90 - 7
Electrical diagrams and drawings
Symbol use in electric circuit diagram.......................................................................................................... 90 - 9
Electrical diagrams and drawings ................................................................................................................ 90 - 13
90-2 D375A-6
DRAFT
Symbols used in hydrauric cirxuit diagrams

Symbols Substance
Main piping lines
Pilot, drain lines
Flexible pipe (hose, etc.)
Lines intersecting without joining
Lines joining (junction with a round black mark)
Direction of flow of liquid.
Throttle in passage.
Variable
Electricity
Spring
Take-off port
Take-off port and pressure gauge
Check valves
Suction (with strainer)
Tank and return pipe
Filter
Oil cooler
Stop valve
Drive shaft䋨unidirectional䋩
Drive shaft䋨bidirectional䋩
D375A-6 90-3
DRAFT
Symbols Substance
Pump
Note : Black triangle shows outlet port䋩
Variable capacity hydraulic pump
Hydraulic motor (The figure shows bidirectional type.)

Note䋺Two black triangles in the figure show direction of oil entering hydraulic motor
㩷㩷㩷㩷㩷㩷㩷㩷㩷depending on the oil entry port, the direction of rotation is reversed.
Servo piston
PPC valve
Control valve
Single-acting solenoid
Hydraulic pilot valve
Hydraulic two-stage pilot valve
Lock valve
Drain valve
Pressure regulator valve/ Safety valve/ Abnormal pressure prevention valve
Pressure regulator valve/Safety valve/ Abnormal pressure prevention valve

䋨When the figure shows air pressure, being released to atmosphere.䋩
Bypass valve
Accumulator
Cylinder
Component Group
90-4 D375A-6
Power train hydraulic circuit diagram
D375A-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
D375A-6 90-5
Hydraulic circuit diagram(1/2) Hydraulic circuit diagram(1/2)
D375A-6
DUAL TILT SPEC.
D375A-6 90-7
(04)
Hydraulic circuit diagram(2/2) Hydraulic circuit diagram(2/2)
D375A-6
SINGLE TILT SPEC.
D375A-6 90-7-1
(04)
DRAFT
Symbol use in electric circuit diagram

Symbol Substance
Electric wire
Electric wire 䋨Wires intersecting without connecting䋩
Electric wire 䋨Wires intersecting and connecting (junction) with a round

black mark 䋩
Electric wire (Bundled drawing style)
Terminal
Body ground
Ground using terminal
Contact
Switch
Push-button type switch (N.O. type)

*N.O.: Normally Open
Push-button type switch (N.C. type)

*N.C.: Normally Close
Pull-button type switch (N.O. type)

Pull-button type switch (N.C. type)

Variable
Resistance (resistor)
Variable resistance (variable resistor)
D375A-6 90-9
DRAFT
Symbol Substance
Diode
Light emitting diode (LED)
Photo diode
Constant voltage diode (Zener diode)
Transistor (PNP type)
Transistor (NPN type)
Coil
Battery
Fuse
Connector
䋨Note䋩
䊶Convex side of connecting portion (right in figure): male
䊶Concave side of connecting portion (left in figure): female
*Figure shows a line disconnection status.
Plug and receptacle type connector (left: male, right: female)

Note: Figure shows a line connection status.
Solenoid
Motor
90-10 D375A-6
DRAFT
Symbol Substance
Lamp
Pressure switch (N.O. type)

Pressure switch (N.C. type)

Potentiometer
Fuel dial
Temperature sensor
Starting switch
Back up alarm
Horn
Buzzer
Antenna
D375A-6 90-11
DRAFT
90-12 D375A-6
Electrical circuit diagram (1/14) Electrical circuit diagram (1/14)
D375A-6
D375A-6
D375A-6 90-13
D375A-6
D375A-6
D375A-6 90-15
D375A-6
D375A-6
D375A-6 90-17
D375A-6
D375A-6
D375A-6 90-19
D375A-6
D375A-6
D375A-6 90-21
D375A-6
D375A-6
D375A-6 90-23
D375A-6
D375A-6
D375A-6 90-25
D375A-6
D375A-6
D375A-6 90-27
D375A-6
D375A-6
D375A-6 90-29
D375A-6
D375A-6
D375A-6 90-31
D375A-6
D375A-6
D375A-6 90-33
D375A-6
D375A-6
D375A-6 90-35
D375A-6
D375A-6
D375A-6 90-37
D375A-6
D375A-6
D375A-6 90-39
Index
Index
A Disassembly and assembly of control valve assembly
Accumulator 10-126 50-277
Adjusting blade 30-75 Disassembly and assembly of damper assembly 50-90
Adjusting brake pedal and parking brake lever 30-54 Disassembly and assembly of equalizer bar bushing
Adjusting fuel control dial and decelerator pedal 30-38 50-262
Adjusting play of PPC valve 30-68 Disassembly and assembly of final drive assembly
Adjusting position of PCCS lever console 30-57 50-173
Adjusting ripper lever position 30-73 Disassembly and assembly of giant ripper assembly
Adjusting transmission output speed sensor 30-52 50-304
Adjusting valve clearance 30-14 Disassembly and assembly of hydraulic cylinder
Adjusting work equipment lock lever 30-74 assembly 50-287
Adjustment method when controller has been replaced Disassembly and assembly of idler assembly 50-192
30-140 Disassembly and assembly of master link 50-253
Air conditioner component 80-4 Disassembly and assembly of one link assembly in the
Air conditioner control panel 80-20 field 50-248
Air conditioner unit 80-10 Disassembly and assembly of PTO assembly 50-109
50-201
B
Disassembly and assembly of ripper pin puller cylinder
Blade 60-88
assembly 50-295
Blade control lever (only for the machine with dual tilt
specification) 10-145
50-285
Bleeding air from fan pump 30-37
Bleeding air from fuel circuit 30-31
50-153
Bleeding air from work equipment cylinders 30-72
Disassembly and assembly of TORQFLOW transmission
Blower unit 80-14
assembly 50-125
C 50-115
Cab 10-182 Disassembly and assembly of track roller assembly
Cab mount 10-181 50-206
Carrier roller 60-54 Disconnection and connection of power train unit
Caution about refrigerant 80-3 assembly 50-100
Checking location of cause of hydraulic drift of blade and
ripper 30-70
Checks before troubleshooting 40-11 E
Circuit diagram and arrangement of connector pins 80-24
Classification and procedures for troubleshooting 40-36
40-547
Coating materials list 50-6
E-2 Preheater does not operate 40-550
Compressor 80-16
E-3 When starting switch is turned ON, machine monitor
Condenser 80-17
displays nothing 40-554
Configuration and function of refrigerating cycle 80-6
E-4 When starting switch is turned ON (before starting
Connection of service tool 80-60
engine), basic check item lights up 40-556
Connection table for connector pin numbers 40-52
Connectors table and arrangement drawing 40-88
40-558
Control valve 10-158, 60-79
Conversion table 00-43
40-560
Cooling fan motor 10-26, 60-12
E-7 Engine coolant temperature gauge does not indicate
Cooling fan pump 10-6, 60-5
normally 40-561
Cooling system 10-4
E-8 Fuel gauge does not indicate properly 40-562
CRI engine control system 10-194
E-9 Power train oil temperature gauge (multi-gauge) does
Cutting edge and end bit 60-92
not indicate normally 40-564
Cylinder stay 10-180, 60-87
E-10 Hydraulic temperature gauge (multi-gauge) does not
indicate normally 40-565
D E-11 Contents of display by machine monitor are different
Damper and universal joint 10-38, 60-16 from applicable machine 40-566
Disassembly and assembly of blade assembly 50-300 E-12 Machine monitor does not display some items
Disassembly and assembly of blade PPC valve assembly 40-566
50-282 E-13 Function switch does not work 40-566
Disassembly and assembly of bogie assembly 50-219 E-14 Operation mode does not change 40-567
Disassembly and assembly of carrier roller assembly E-15 Gearshift mode does not change 40-567
50-210
D375A-6 1
(04)
Index
E-16 Customize function does not operate normally Failure code (2301LH) Right brake Fill low 40-150
40-568 Failure code (2301NR) Steering Brake RH Themal Load
E-17 Customize memory function does not operate Abnormality 40-152
normally 40-568 Failure code (2302L1) Left brake Fill high 40-154
E-18 Alarm buzzer does not sound or does not stop Failure code (2302LH) Left brake Fill low 40-156
40-569 Failure code (2302NR) Steering Brake LH Themal Load
E-19 When starting switch is turned OFF, service meter is Abnormality 40-158
not displayed 40-569 Failure code (7RFAKA) ECM ACC CUT RELAY
E-20 Machine monitor cannot be set in service mode Disconnection 40-160
40-569 Failure code (7RFAKB) ECM ACC CUT RELAY Short
E-21 The ripper pin puller cylinder does not operate circuit 40-162
40-570 Failure code (AA10NX) Air Cleaner Clogging 40-164
E-22 Horn does not sound or does not stop 40-572 Failure code (AB00MA) Battery Charge Abnormal 40-166
E-23 Back-up alarm does not sound or does not stop Failure code (B@BAZG) Eng Oil Press Low 40-166
40-574 Failure code (B@BAZK) Eng Oil Level Low 40-167
E-24 Fan does not reverse 40-576 Failure code (B@BCNS) Eng Water Overheat 40-168
E-25 The head lamp and rear lamp do not light up Failure code (B@BCZK) Eng Water Level Low 40-169
40-577 Failure code (B@CENS) T/C Oil Overheat 40-170
E-26 Windshield wiper does not operate 40-584 Failure code (B@HANS) Hyd Oil Overheat 40-171
E-27 Window washer does not operate 40-590 Failure code (B@HAZK) Hyd Oil Level Low 40-172
E-28 Electric priming pump does not operate or does not Failure code (CA111) ECM Critical Internal Failure
stop automatically 40-596 40-174
E-29 Orbcomm terminal does not operate normally Failure code (CA115) Eng Ne and Bkup Speed Sens Error
(Data are not transmitted) 40-598 40-176
E-30 Gear cannot be shifted 40-600 Failure code (CA122) Chg Air Press Sensor High Error
Electrical diagrams and drawings 90-13 40-178
Emergency escape method when there is failure in power Failure code (CA1228) EGR Valve Servo Error 1 40-256
train 30-58 Failure code (CA123) Chg Air Press Sensor Low Error
Engine and cooling system 10-4, 30-6 40-180
Engine control 10-184 Failure code (CA131) Throttle Sensor High Error 40-182
Engine control system 10-185 Failure code (CA132) Throttle Sensor Low Error 40-184
Engine mount 60-3 Failure code (CA135) Eng Oil Press Sensor High Error
Engine preheat (electrical intake air heater)control 40-186
10-216 Failure code (CA141) Eng Oil Press Sensor Low Error
Explanation of terms for maintenance standard 00-12 40-188
Failure code (CA144) Coolant Temp Sens High Error
F 40-190
Failure code ([DK60KA) Acceleration sensor: Failure code (CA145) Coolant Temp Sens Low Error
Disconnection 40-460 40-192
Failure code (1380MW) Lock up clutch Slip 40-109 Failure code (CA153) Chg Air Temp Sensor High Error
Failure code (1500L0) Transmission clutch Abnormal 40-194
40-110 Failure code (CA154) Chg Air Temp Sensor Low Error
Failure code (15E0MW) Transmission clutch Slip 40-111 40-196
Failure code (15SAL1) Forward clutch Fill high 40-112 Failure code (CA1625) EGR Valve Servo Error 2 40-257
Failure code (15SALH) Forward clutch Fill Low 40-114 Failure code (CA1633) KOMNET Datalink Timeout Error
Failure code (15SBL1) Reverse clutch Fill high 40-116 40-258
Failure code (15SBLH) Reverse clutch Fill Low 40-118 Failure code (CA187) Sens Supply 2 Volt Low Error
Failure code (15SEL1) Speed 1st clutch Fill high 40-120 40-198
Failure code (15SELH) Speed 1st clutch Fill Low 40-122 Failure code (CA212) Eng Oil Temp Sensor High Error
Failure code (15SFL1) Speed 2nd clutch Fill high 40-124 40-200
Failure code (15SFLH) Speed 2nd clutch Fill Low 40-126 Failure code (CA213) Eng Oil Temp Sensor Low Error
Failure code (15SGL1) Speed 3rd clutch Fill high 40-128 40-202
Failure code (15SGLH) Speed 3rd clutch Fill Low 40-130 Failure code (CA2185) Throt Sens Sup Volt High Error
Failure code (15SJL1) L/U Fill high 40-132 40-259
Failure code (15SJLH) L/U Fill low 40-134 Failure code (CA2186) Throt Sens Sup Volt Low Error
Failure code (1800MW) P/T clutch Slip 40-136 40-260
Failure code (2201L1) Right clutch Fill high 40-138 Failure code (CA221) Ambient Press Sens High Error
Failure code (2201LH) Right clutch Fill low 40-140 40-204
Failure code (2202L1) Left clutch Fill high 40-142 Failure code (CA222) Ambient Press Sens Low Error
Failure code (2202LH) Left clutch Fill low 40-144 40-206
Failure code (2300NR) Brake Themal Load Abnormality Failure code (CA2249) Rail Press Very Low Error 40-261
40-146 Failure code (CA227) Sens Supply 2 Volt High Error
Failure code (2301L1) Right brake Fill high 40-168 40-208
2 D375A-6
(04)
Index
Failure code (CA2271) EGR Valve Pos Sens High Error Failure code (D161KA) Back-up alarm releay
40-262 Disconnection 40-276
Failure code (CA2272) EGR Valve Pos Sens Low Error Failure code (D161KB) Back-up alarm releay Short circuit
40-264 40-278
Failure code (CA234) Eng Overspeed 40-209 Failure code (D182KZ) Preheater Relay Abnormality
Failure code (CA2351) EGR Valve Sol Current High Error 40-280
40-266 Failure code (D190KA) ACC signal relay Disconnection
Failure code (CA2352) EGR Valve Sol Current Low Error 40-282
40-268 Failure code (D190KB) ACC signal relay Short circuit
Failure code (CA238) Ne Speed Sens Supply Volt Error 40-284
40-210 Failure code (D1EFKA) Pre lub. motor relay
Failure code (CA263) Fuel Temp Sensor High Error Disconnection 40-286
40-212 Failure code (D1EFKB) Pre lub. motor relay Short circuit
Failure code (CA265) Fuel Temp Sensor Low Error 40-288
40-214 Failure code (DAFRKR) Monitor Can communication lost
Failure code (CA271) IMV/PCV1 Short Error 40-216 (PT) 40-290
Failure code (CA272) IMV/PCV1 Open Error 40-217 Failure code (dAFRKR) Monitor CAN communication lost
Failure code (CA273) PCV2 Short Error 40-218 (WE) 40-291
Failure code (CA274) PCV2 Open Error 40-219 Failure code (DAFRMC) CAN Discon (Monitor Detected)
Failure code (CA322) Inj #1 (L#1) Open/Short Error 40-292 Failure code (DB2RKR) ENG cont. Can
40-220 communication lost (PT) 40-297
Failure code (CA323) Inj #5 (L#5) Open/Short Error Failure code (dB2RKR) ENG controller CAN
40-222 communication lost (WE) 40-300
Failure code (CA324) Inj #3 (L#3) Open/Short Error Failure code (DB90KT) WE controller Abnormality in
40-224 controller 40-301
Failure code (CA325) Inj #6 (L#6) Open/Short Error Failure code (DB91KK) WE controller Source voltage
40-226 reduction 40-302
Failure code (CA331) Inj #2 (L#2) Open/Short Error Failure code (DB92KK) WE controller Output voltage
40-228 reduction 40-304
Failure code (CA332) Inj #4 (L#4) Open/Short Error Failure code (DB97KK) WE cont. Sensor voltage 5 V (2)
40-226 reduction 40-306
Failure code (CA342) Calibration Code Incompatibility Failure code (DB99KQ) WE controller Type select signal
40-232 40-308
Failure code (CA351) Injectors Drive Circuit Error 40-233 Failure code (DB9RKR) WE controller Can
Failure code (CA352) Sens Supply 1 Volt Low Error communication lost (PT) 40-309
40-234 Failure code (DBB0KK) VHMS controller Source voltage
Failure code (CA386) Sens Supply 1 Volt High Error reduction 40-312
40-236 Failure code (DBB0KQ) VHMS connector connection
Failure code (CA441) Battery Voltage Low Error 40-237 abnormality 40-314
Failure code (CA442) Battery Voltage High Error 40-238 Failure code (DBB3KK) VHMS controller Source voltage
Failure code (CA449) Rail Press Very High Error 40-239 reduction 40-316
Failure code (CA451) Rail Press Sensor High Error Failure code (DBB5KP) VHMS Output sensor1 voltage
40-240 reduction 40-318
Failure code (CA452) Rail Press Sensor Low Error Failure code (DBB6KP) VHMS Output sensor1 voltage
40-242 reduction 40-320
Failure code (CA553) Rail Press High Error 40-244 Failure code (DBB7KP) VHMS Output sensor3 voltage
Failure code (CA554) Rail Press Sensor In Range Error reduction 40-322
40-245 Failure code (DBBQKR) PT cont. Can communication lost
Failure code (CA559) Rail Press Low Error 40-246 (VHMS) 40-323
Failure code (CA689) Eng Ne Speed Sensor Error Failure code (DBE0KT) PT controller Abnormality in
40-250 controller 40-323
Failure code (CA731) Eng Bkup Speed Sens Phase Error Failure code (DBE1KK) PT controller Source voltage
40-252 reduction 40-324
Failure code (CA757) All Continuous Data Lost Error Failure code (DBE2KK) PT controller Output voltage
40-253 reduction 40-326
Failure code (CA778) Eng Bkup Speed Sensor Error Failure code (DBE5KK) PT cont. Sensor voltage 5 V (1)
40-254 reduction 40-328
Failure code (D110KB) Battery Relay Drive Short Circuit Failure code (DBE6KK) PT cont. Sensor voltage 24 V
40-270 reduction 40-330
Failure code (D130KA) Neutral relay Disconnection Failure code (DBE7KK) PT cont. Sensor voltage 5 V
40-272 reduction 40-332
Failure code (D130KB) Neutral relay Short circuit 40-274 Failure code (DBE9KQ) PT controller Type select signal
40-334
D375A-6 3
(04)
Index
Failure code (DBERKR) PT controller Can Failure code (DGT1KA) T/C oil temp sensor Abnormal
communication lost (WE) 40-335 40-402
Failure code (DD12KA) Shift up Sw Disconnection Failure code (DGT1KX) T/C oil temp sensor Abnormal
40-338 40-404
Failure code (DD12KB) Shift up Sw Short circuit 40-340 Failure code (DGT5KA) F exhaust temp sensor
Failure code (DD13KA) Shift down Sw Disconnection disconnection 40-406
40-342 Failure code (DGT5KB) F exhaust temp sensor short
Failure code (DD13KB) Shift down Sw Short circuit circuit 40-408
40-344 Failure code (DGT6KA) R exhaust temp sensor
Failure code (DD14KA) Parking lever Sw Dissconnection disconnection 40-410
40-346 Failure code (DGT6KB) R exhaust temp sensor short
Failure code (DD14KB) Parking lever Sw Short circuit circuit 40-412
40-348 Failure code (DH21KA) Weq pressure sensor
Failure code (DDB9L4) Reverse SW Signal disagreement Disconnection 40-414
40-350 Failure code (DH21KB) Weq pressure sensor Short circuit
Failure code (DDE2KA) Pre lub. oil press sw 40-416
Disconnection 40-352 Failure code (DHE5KB) ENG blow-by pressure sensor
Failure code (DDK3L4) Forward SW Signal disagreement disconnection 40-418
40-354 Failure code (DHE5KY) ENG blow-by pressure sensor
Failure code (DDK5KA) Shift switch disconnection short circuit 40-420
40-356 Failure code (DHT3KX) T/M oil pressure sensor
Failure code (DDK5KB) Shift switch short circuit 40-358 abnormality 40-422
Failure code (DDN2LD) Blade tilt RH pressure SW Failure code (DHT5KA) T/C in-pressure sensor
abnormality 40-360 Disconnection 40-424
Failure code (DDN3LD) Blade tilt LH pressure SW Failure code (DHT5KB) T/C in-pressure sensor Short
abnormality 40-362 circuit 40-426
Failure code (DDN7KA) WEQ Knob Sw (down) Failure code (DHT7KA) T/C out-pressure sensor
Disconnection 40-364 Disconnection 40-428
Failure code (DDN7KB) WEQ Knob Sw (down) Short Failure code (DHT7KB) T/C out-pressure sensor Short
circuit 40-366 circuit 40-430
Failure code (DDN9KA) WEQ Knob Sw (up) Failure code (DK10KA) Fuel control Dial Disconnection
Failure code (DDN9KB) WEQ Knob Sw (up) Short circuit Failure code (DK10KB) Fuel control Dial Short circuit
40-370 40-434
Failure code (DDNALD) Blade lift up pressure SW Failure code (DK30KA) ST lever 1 Disconnection 40-436
abnormality 40-372 Failure code (DK30KB) ST lever 1 Short circuit 40-438
Failure code (DDNBLD) Ripper lift up pressure SW Failure code (DK30KX) ST lever Out of normal range
abnormality 40-374 40-440
Failure code (DDNCLD) Ripper lift down pressure SW Failure code (DK30KZ) ST lever Disconnection or short
abnormality 40-376 circuit 40-440
Failure code (DDNDLD) Ripper tilt in pressure SW Failure code (DK30L8) ST lever Signal mismatch 40-441
abnormality 40-378 Failure code (DK31KA) ST lever 2 Disconnection 40-442
Failure code (DDNELD) Ripper tilt back pressure SW Failure code (DK31KB) ST lever 2 Short circuit 40-444
abnormality 40-380 Failure code (DK40KA) Brake potentiometer
Failure code (DDNFLD) Blade lift down pressure SW Disconnection 40-446
abnormality 40-382 Failure code (DK40KB) Brake potentiometer Short circuit
Failure code (DDNLKA) Weq lock Sw Disconnection 40-448
40-384 Failure code (DK55KX) FR lever Out of normal range
Failure code (DDNLKB) Weq lock Sw Short circuit 40-450
40-386 Failure code (DK55KZ) FR lever Disconnection or short
Failure code (DDT5KA) Neutral switch disconnection circuit 40-450
40-388 Failure code (DK55L8) FR lever Signal mismatch 40-451
Failure code (DDT5KB) Neutral switch short circuit Failure code (DK56KA) FR lever 1 Disconnection 40-452
40-390 Failure code (DK56KB) FR lever 1 Short circuit 40-454
Failure code (DDT5KQ) Lever SPEC selection signal Failure code (DK57KA) FR lever 2 Disconnection 40-456
disagreement 40-392 Failure code (DK57KB) FR lever 2 Short circuit 40-458
Failure code (DDTSL1) S/C Fill high 40-394 Failure code (DK60KB) Acceleration sensor Short circuit
Failure code (DDTSLH) S/C Fill low 40-396 40-462
Failure code (DGE5KX) Ambient temp sensor Failure code (DKH1KA) Pitch angle sensor Disconnection
abnormality 40-398 40-464
Failure code (DGS1KX) Hyd oil temp signal abnormal Failure code (DKH1KB) Pitch angle sensor Short circuit
40-400 40-466
4 D375A-6
(04)
Index
Failure code (DLF1KA) T/C out-speed sensor Failure code (DXH6KB) 3rd clutch ECMV Short circuit
Failure code (DLM3KA) Fan rev. sensor Disconnection Failure code (DXH6KY) 3rd clutch ECMV Short circuit
40-469 40-508
Failure code (DLM3MB) Fan control Decline 40-470 Failure code (DXH7KA) R clutch ECMV Disconnection
Failure code (DLT3KA) T/M out-speed sensor 40-510
Disconnection 40-471 Failure code (DXH7KB) R clutch ECMV Short circuit
Failure code (DLT3KB) T/M out-speed sensor Abnormal 40-511
40-472 Failure code (DXH7KY) R clutch ECMV Short circuit
Failure code (DW59KA) Blade dual selector SOL 40-512
disconnection 40-473 Failure code (DXH8KA) F clutch ECMVDisconnection
Failure code (DW59KB) Blade dual selector SOL short 40-514
circuit 40-474 Failure code (DXH8KB) F clutch ECMV Short circuit
Failure code (DW59KY) Blade dual selector SOL hot 40-515
short 40-475 Failure code (DXH8KY) F clutch ECMV Short circuit
Failure code (DW5AKA) Blade pitch selector SOL 40-516
disconnection 40-476 Failure code (DXH9KA) Right clutch ECMV
Failure code (DW5AKB) Blade pitch selector SOL short Disconnection 40-518
circuit 40-477 Failure code (DXH9KB) Right clutch ECMV Short circuit
Failure code (DW5AKY) Blade pitch selector SOL hot 40-519
short 40-478 Failure code (DXH9KY) Right clutch ECMV Hot Short
Failure code (DW7BKA) Fan rev EPC Disconnection 40-520
40-479 Failure code (DXHAKA) Left clutch ECMV Disconnection
Failure code (DW7BKB) Fan rev EPC Short circuit 40-522
40-480 Failure code (DXHAKB) Left clutch ECMV Short circuit
Failure code (DWN3KA) Ssp solenoid Disconnection 40-523
40-481 Failure code (DXHAKY) Left clutch ECMV Hot Short
Failure code (DWN3KB) Ssp solenoid Short circuit 40-524
40-482 Failure code (DXHBKA) Right brake ECMV
Failure code (DWN3KY) SSP solenoid Short circuit Disconnection 40-526
40-484 Failure code (DXHBKB) Right brake ECMV Short circuit
Failure code (DWN5KA) Fan pump solenoid 1 40-527
Disconnection 40-486 Failure code (DXHBKY) Right brake ECMV Short circuit
Failure code (DWN5KB) Fan pump solenoid 1 Short 40-528
circuit 40-487 Failure code (DXHCKA) Left brake ECMV Disconnection
Failure code (DWN5KY) Fan pump solenoid 1 Hot Short 40-530
40-488 Failure code (DXHCKB) Left brake ECMV Short circuit
Failure code (DWNCKA) Fan pump solenoid 2 40-531
Disconnection 40-490 Failure code (DXHCKY) Left brake ECMV Short circuit
Failure code (DWNCKB) Fan pump solenoid 2 Short 40-532
circuit 40-491 Failure code (DXJBKA) S/C ECMV Disconnection
Failure code (DWNCKY) Fan pump solenoid 2 Hot Short 40-534
40-492 Failure code (DXJBKB) S/C ECMV Short circuit 40-535
Failure code (DXH1KA) Lock-up ECMV Disconnection Failure code (DXJBKY) S/C ECMV Short circuit 40-536
40-494 Failure code (DY2HKA) Pre lub. motor Disconnection
Failure code (DXH1KB) Lock-up ECMV Short circuit 40-538
40-495 Failure code (F@BBZL) ENG blow-by pressure high level
Failure code (DXH1KY) Lock-up ECMV Short circuit 40-540
40-496 Failure code (F@BYNR) F exhaust temp high level (2)
Failure code (DXH4KA) 1st clutch ECMV Disconnection 40-541
40-498 Failure code (F@BYNS) F exhaust temp high level (1)
Failure code (DXH4KB) 1st clutch ECMV Short circuit 40-542
40-499 Failure code (F@BZNR) R exhaust temp high level (2)
Failure code (DXH4KY) 1st clutch ECMV Short circuit 40-543
40-500 Failure code (F@BZNS) R exhaust temp high level (1)
Failure code (DXH5KA) 2nd clutch ECMV Disconnection 40-544
40-502 Failure codes table 40-39
Failure code (DXH5KB) 2nd clutch ECMV Short circuit Final drive 10-103, 60-41
40-503 FRESH/RECIRC air changeover damper 80-15
Failure code (DXH5KY) 2nd clutch ECMV Short circuit Fuse locations table 40-105
40-504
Failure code (DXH6KA) 3rd clutch ECMV Disconnection H
40-506 H-1 No force (no drawbar pull) 40-604
D375A-6 5
(04)
Index
H-2 No travel (at 2nd or 3rd speed) 40-606 M

H-3 No travel at all gear speeds 40-607 Machine monitor 10-198
H-4 Machine travels only in one direction forward or in Main frame 10-112, 60-60
reverse 40-608 Main relief valve and torque converter relief valve
H-5 Large time lag at gear speed shifting or 10-48, 60-22
forward-reverse shifting 40-609 Measuring and adjusting work equipment oil pressure
H-6 Steering is not possible 40-610 30-62
H-7 Steering is possible only on one side 40-611 Measuring compression pressure 30-16
H-8 Steering overrun occurs 40-612 Measuring fan speed 30-35
H-9 Brake does not work 40-612 Method of disassembling and connecting push-pull type
H-10 Torque converter is not lock-up 40-613 coupler 00-32
H-11 Power train oil overheats 40-614 Method of using troubleshooting chart 40-624
H-12 All work equipment operates slowly or lacks power Monitor system 10-196
40-615
H-13 All work equipment does not operate 40-616
N
H-14 Blade lift speed is slow or lacks power 40-617
Notice of revision 1
H-15 Blade tilt speed is slow or lacks power 40-617
H-16 Ripper lift speed is slow or lacks power 40-618
H-17 Ripper tilt speed is slow or lacks power 40-618 O
H-18 Excessive hydraulic drift of blade lift 40-619 ORBCOMM system 10-230
H-19 Excessive hydraulic drift of blade tilt 40-619 Outline of refrigerating cycle 80-7
H-20 Excessive hydraulic drift of ripper lift 40-620 Overall disassembly and assembly of track shoe 50-230
H-21 Ripper pin puller cylinder does not work (giant ripper Overall drawing of power train unit 10-34
attachment machine) 40-620
H-22 Blade pitch does not work (dual tilt attachment P
machine) 40-621 Palm command control system 10-217
H-23 Abnormal sound comes out from around work Parking brake valve 10-99, 60-40
equipment pump 40-621 Part and connector locations 80-28
H-24 Fan speed is abnormal (Sound and/or vibration are PCCS lever 10-58
abnormally large or engine over heats) 40-622 Pin puller solenoid valve 10-143
Handling of compressor oil 80-64 Pin puller switch 10-142
Handling of connectors newly used for engines 00-23 Pm Clinic service 30-181
Handling of electric equipment and hydraulic component Points to remember when troubleshooting 40-9
00-14 Power train 10-32
Handling of fuel system devices 30-24 Power train and lubricating pump 60-31
Handling of no injection cranking operation 30-27 Power train hydraulic circuit diagram 90-5
Handling of optional devices 30-149 Power train hydraulic equipment arrangement drawing
Handling of reduced cylinder mode operation 30-27 10-36
Handling of voltage circuit of engine controller 30-139 Power train unit 60-14
How to read electric wire code 00-26 PPC control piping diagram 10-121
How to read the shop manual 00-10 PPC lock valve 10-127
How to read this manual 50-4 PPC valve 10-129, 60-67
Hydraulic circuit diagram 90-7 Precautions for disconnecting and connecting in air
Hydraulic cylinder 60-72 conditioner piping 80-62
Hydraulic tank 10-124 Precautions for replacing VHMS controller 30-175
Precautions when carrying out work 00-29
I Preparation work for troubleshooting of electrical system
Idler 60-50 30-144
Idler cushion 10-110, 60-48 Procedure for testing and troubleshooting 80-22
Information contained in troubleshooting table 40-545
Information in troubleshooting table 40-47,40-601,80-40 Q
Initialization procedures for VHMS controller 30-152 Quick drop valve 10-141, 60-75
Inspecting wear of sprocket 30-60
Inspection procedure of diode 30-148
R
Receiver drier 80-18
L Releasing remaining pressure in work equipment
Lamp system 10-215 cylinders 30-72
Link press press-fitting jig dimensions 50-247 Releasing residual pressure from fuel system 30-25
List of Abbreviation 00-39 Removal and installation of aftercooler 50-63
List of Failure Modes and Causes 40-602 Removal and installation of air conditioner unit assembly
Lockup clutch ECMV and stator clutch ECMV 50-318
10-50, 60-23 Removal and installation of blade assembly 50-298
6 D375A-6
(04)
Index
Removal and installation of bogie assembly 50-214 S-2 Engine does not start 40-630
Removal and installation of carrier roller assembly50-209 S-3 Engine does not pick up smoothly (follow-up is poor)
Removal and installation of control valve assembly 40-634
50-275 S-4 Engine stops during operation 40-636
Removal and installation of cooling assembly (radiator, S-5 Engine does not rotate smoothly (hunting) 40-637
after cooler, and hydraulic oil cooler) 50-54 S-6 Engine lacks output (or lacks power) 40-638
Removal and installation of cylinder head assembly S-7 Exhaust smoke is black (Incomplete combustion)
50-33 40-640
Removal and installation of damper assembly 50-86 S-8 Oil is consumed much (or exhaust gas color is blue)
Removal and installation of engine assembly 50-63 40-642
Removal and installation of engine controller assembly S-9 Engine oil becomes contaminated quickly 40-643
50-325 S-10 Fuel consumption is excessive 40-644
Removal and installation of engine front seal 50-73 S-11 Coolant contains oil (blows back or reduces)40-645
Removal and installation of engine hood assembly 50-70 S-12 Oil pressure monitor lights up (drop in oil pressure)
Removal and installation of engine rear seal 50-75 40-646
Removal and installation of equalizer bar 50-258 S-13 Oil level rises (Water, fuel in oil) 40-647
Removal and installation of fan drive assembly 50-79 S-14 Coolant temperature rises too high (Overheating)
Removal and installation of fan motor assembly 50-81 40-649
Removal and installation of fan pump assembly 50-273 S-15 Abnormal noise is made 40-650
Removal and installation of final drive assembly 50-171 S-16 Vibration is excessive 40-651
Removal and installation of first bogie assembly 50-221 S-17 Air cannot be bled from fuel circuit (After filter is
Removal and installation of floor frame assembly 50-313 replaced or fuel is used up and then air is bled, engine
Removal and installation of fuel injector assembly 50-28 does not start or it starts but stalls) 40-652
Removal and installation of fuel supply pump assembly Safety notice 00-5
50-24 Scavenging pump 10-55, 60-24
Removal and installation of fuel tank assembly 50-83 Self-pressure reducing valve 10-173, 60-85
Removal and installation of hydraulic oil cooler 50-61 Sensor 10-220
Removal and installation of hydraulic tank assembly Sequence of events in troubleshooting 40-10
50-266 Separation and connection of track shoe assembly
Removal and installation of idler assembly 50-192 50-226
Removal and installation of machine monitor assembly Simple test procedure for brake performance 30-53
50-328 Sketches of special tools 50-16
Removal and installation of operator's cab assembly Special functions of machine monitor (EMMS) 30-82
50-309 Special tool list 50-9
Removal and installation of pivot shaft assembly 50-257 Specification drawing 01-3
Removal and installation of power train pump and Specifications 01-4
lubrication pump assembly 50-169 Sprocket 60-44
Removal and installation of power train unit assembly Standard tightening torque table 00-35
50-93 Standard value table for engine 20-3
Removal and installation of radiator 50-59 Standard value table for machine 20-4
Removal and installation of radiator guard assembly Steering and brake control 10-82
50-49 Steering clutch ECMV and steering brake ECMV
Removal and installation of recoil spring assembly 10-92, 60-39
50-196 Steering control valve 10-90, 60-38
Removal and installation of ROPS guard 50-308 Sudden stop prevention valve 10-101
Removal and installation of scavenging pump assembly Suspensions 10-114, 60-62
50-170 Symbols used in electrical circuit diagrams 90-9
Removal and installation of segment tooth 50-264 Symbols used in hydraulic circuit diagrams 90-3
Removal and installation of track frame assembly 50-186 System diagram 80-26
Removal and installation of track roller assembly 50-203
Removal and installation of transmission controller T
assembly and steering controller assembly 50-324 T-branch box and T-branch adapter table 40-102
Removal and installation of VHMS controller assembly Table of contents 00-2
50-327 Table of fuel, coolant and lubricants 01-11
Removal and installation of work equipment pump Testing and adjusting operator's cab 30-77
assembly 50-269 Testing and adjusting track shoe tension 30-61
Replacing and adjusting alternator and air conditioner Testing blow-by pressure 30-19
compressor belt 30-34 Testing control circuit main pressure 30-65
Request for opening ORBCOMM terminal 30-150 Testing EGR valve and bypass valve drive oil pressure
Ripper 60-94 30-22
Testing engine oil pressure 30-21
S Testing engine speed 30-6
S-1 Engine does not start easily 40-628 Testing exhaust gas color 30-12
D375A-6 7
(04)
Index
Testing exhaust temperature 30-10

Testing fan circuit oil pressure 30-36
Testing FRESH/RECIC changeover 80-32
Testing fuel circuit for leakage 30-33
Testing fuel pressure 30-26
Testing intake air pressure (boost pressure) 30-8
Testing leakage from pressure limiter and return rate from
injector 30-28
Testing leakage inside work equipment cylinder 30-71
30-69
Testing power train oil pressure 30-40
Testing PPC valve output pressure 30-66
Testing relay 80-34
Testing temperature control 80-32
Tools for testing, adjusting, and troubleshooting 30-4
Torque converter and PTO 10-40, 60-19
Torque converter control valve 10-46
Track frame 10-108, 60-46
Track roller 60-52
Track roller bogie 10-111, 60-55
Track shoe 60-56
Transfer unit, bevel gear shaft and steering 10-84
Transfer, bevel gear shaft and steering unit 60-32
Transmission 10-62, 60-26
Transmission control 10-56, 60-25
Transmission ECMV 10-76
Transmission lubricating oil relief valve 10-81, 60-30
Troubleshooting chart 1 80-36
Troubleshooting chart 2 80-38
Troubleshooting for blower motor system (Air does not
come out or air flow is abnormal) 80-48
80-44
80-56
Troubleshooting for power supply system (Air conditioner
does not operate) 80-42
Troubleshooting for temperature control 80-54
Troubleshooting method for disconnecting wiring harness
of pressure sensor system 40-49
Troubleshooting with gauge pressure 80-58
Using method of KOMTRAX functions of ORBCOMM
terminal 30-172
V
Vehicle health monitoring system (VHMS) 10-224
W
Weight table 01-9
Work equipment control 10-122
Work equipment hydraulic piping diagram 10-117
Work equipment pump 10-146, 60-76
8 D375A-6
(04)
D375A-6 BULLDOZER
Form Number: SEN05006-05
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 06-10

D375a-6 SM

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Machine model Serial number

00 Index and Foreword

00 Index and Foreword

10 Structure,function and maintenance standard

Work equipment control ............................................................................................................................... 10- 122

20 Standard value table

30 Testing and adjusting

Power train ...................................................................................................................................................... 30 - 40

Failure code [CA351] Injectors Drive Circuit Error ....................................................................................... 40 -233

Failure code [DD13KA] Shift down Sw: Disconnection................................................................................ 40 -342

Failure code [DK60KA] Acceleration sensor: Disconnection ....................................................................... 40 -460

Failure code [F@BZNR] R exhaust temp high level (2)............................................................................... 40 -543

Troubleshooting of engine (S-mode)............................................................................................................... 40 -624

50 Disassembly and assembly

Disassembly and assembly of track roller assembly ................................................................................... 50 -206

Undercarriage and frame ................................................................................................................................ 60- 46

90 Diagrams and Drawings

Electrical circuit diagram .............................................................................................................................. 90 - 13

Forword and general information

2. Preparation work 5) When raising a heavy component (heavier

16)If the engine is operated for a long time in a

4. Precautions for sling work and making

8. Precautions for disconnecting and

How to read the shop manual

Composition of shop manual

00. Index and foreword

10. Structure and function

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

Revision and distribution

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving standards are

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

Explanation of terms for maintenance standard

1. Standard size and tolerance

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

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value or allowable

Handling of electric equipment and hydraulic components

Points to remember when handling electric equipment

4) High-pressure water entering connector

3. Removing, installing, and drying connectors

q When removing a connector from a

3] Action to take after removing connectors

3) DT connector (DT 8-pole, 12-pole)

4) Drying wiring harness

2] Dry the inside of the connector with a dryer.

3] Carry out a continuity test on the connector.

5. Points to remember when troubleshooting electric circuits

Points to remember when handling hydraulic components