Komatsu D 375A-6

SEN05006-09
BULLDOZER
D375A -6
SERIAL NUMBERS
60001
and up
Notice of revision
Notice of revision
9th. revision
The affected pages are indicated by the use of the
following marks. It is requested that necessary actions must be taken to these pages according to the
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2012/02
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Mark
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Colophon
Revision
number
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Page
Revision
number
(07)
(07)
(07)
(07)
(07)
(07)
(07)
(07)
(09)
(04)
(04)
DRAFT
D375A-6
SEN05009-00
Bulldozer
Shop Manual
D375A-6
Machine model
D375A-6
Serial number
60001 and up
00 Index and Foreword
D375A-6
00-1
Shop Manual
Table of contents
Table of contents
Notice of revision.............................................................................................................................................
00 Index and Foreword

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

Engine and cooling system .............................................................................................................................
Cooling system ............................................................................................................................................
Cooling fan pump.........................................................................................................................................
Cooling fan motor.........................................................................................................................................
Power train ......................................................................................................................................................
Power train...................................................................................................................................................
Overall drawing of power train unit ..............................................................................................................
Power train hydraulic equipment arrangement drawing...............................................................................
Damper and universal joint ..........................................................................................................................
Torque converter and PTO ..........................................................................................................................
Torque converter control valve ....................................................................................................................
Main relief valve and torque converter relief valve.......................................................................................
Lockup clutch ECMV and stator clutch ECMV.............................................................................................
Scavenging pump ........................................................................................................................................
Transmission control....................................................................................................................................
PCCS lever ..................................................................................................................................................
Transmission................................................................................................................................................
Transmission ECMV ....................................................................................................................................
Transmission lubricating oil relief valve .......................................................................................................
Steering and brake control...........................................................................................................................
Transfer unit, bevel gear shaft and steering ................................................................................................
Steering control valve ..................................................................................................................................
Steering clutch ECMV and Steering brake ECMV .......................................................................................
Parking brake valve .....................................................................................................................................
Sudden stop prevention valve......................................................................................................................
Final drive ....................................................................................................................................................
Undercarriage and frame ................................................................................................................................
Track frame..................................................................................................................................................
Idler cushion.................................................................................................................................................
Track roller bogie .........................................................................................................................................
Main frame ...................................................................................................................................................
Suspension ..................................................................................................................................................
Hydraulic system .............................................................................................................................................
Work equipment hydraulic piping diagram...................................................................................................
PPC control piping diagram .........................................................................................................................
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D375A-6
(04)
Shop Manual
Table of contents
Work equipment control ...............................................................................................................................

Hydraulic tank ..............................................................................................................................................
Accumulator .................................................................................................................................................
PPC lock valve.............................................................................................................................................
PPC valve ....................................................................................................................................................
Piston valve..................................................................................................................................................
Quick drop valve ..........................................................................................................................................
Pin puller switch ...........................................................................................................................................
Pin puller solenoid valve ..............................................................................................................................
Blade control lever (only for the machine with dual tilt specification)...........................................................
Work equipment pump.................................................................................................................................
Control valve ................................................................................................................................................
Self-pressure reducing valve .......................................................................................................................
Work equipment ..............................................................................................................................................
Cylinder stay ................................................................................................................................................
Cab..................................................................................................................................................................
Cab mount ...................................................................................................................................................
Cab ..............................................................................................................................................................
Electrical system .............................................................................................................................................
Engine control ..............................................................................................................................................
Engine control system..................................................................................................................................
CRI engine control system...........................................................................................................................
Monitor system.............................................................................................................................................
Machine monitor ..........................................................................................................................................
Lamp system................................................................................................................................................
Engine preheat (electrical intake air heater) control ....................................................................................
Palm command control system....................................................................................................................
Sensor..........................................................................................................................................................
Vehicle health monitoring system (VHMS) ..................................................................................................
ORBCOMM system .....................................................................................................................................
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20 Standard value table

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

Tools for testing, adjusting, and troubleshooting.............................................................................................
Diagnosis equipment list ..............................................................................................................................
Testing engine speed...................................................................................................................................
Testing intake air pressure (boost pressure) ...............................................................................................
Testing exhaust temperature .......................................................................................................................
Testing exhaust gas color ............................................................................................................................
Adjusting valve clearance ............................................................................................................................
Measuring compression pressure................................................................................................................
Testing blow-by pressure.............................................................................................................................
Testing engine oil pressure..........................................................................................................................
Testing EGR valve drive oil pressure...........................................................................................................
Handling of fuel system devices ..................................................................................................................
Releasing residual pressure from fuel system .............................................................................................
Testing fuel pressure ...................................................................................................................................
Handling of reduced cylinder mode operation .............................................................................................
Handling of no injection cranking operation .................................................................................................
Testing leakage from pressure limiter and return rate from injector ............................................................
Bleeding air from fuel circuit.........................................................................................................................
Testing fuel circuit for leakage .....................................................................................................................
Replacing and adjusting alternator and air conditioner compressor belt .....................................................
Measuring fan speed ...................................................................................................................................
Testing fan circuit oil pressure .....................................................................................................................
Bleeding air from fan pump..........................................................................................................................
Adjusting fuel control dial and decelerator pedal .........................................................................................
D375A-6
(07)
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00-3
ShopManual
Table of contents
Power train ......................................................................................................................................................

Testing power train oil pressure...................................................................................................................
Adjusting transmission output speed sensor ...............................................................................................
Simple test procedure for brake performance..............................................................................................
Adjusting brake pedal and parking brake lever............................................................................................
Adjusting position of pccs lever console ......................................................................................................
Emergency escape method when there is failure in power train .................................................................
Inspecting wear of sprocket .........................................................................................................................
Testing and adjusting track shoe tension.....................................................................................................
Measuring and adjusting work equipment oil pressure................................................................................
Testing control circuit main pressure ...........................................................................................................
Testing PPC valve output pressure .............................................................................................................
Adjusting play of PPC valve.........................................................................................................................
Testing output pressure of ripper pin-puller solenoid valve .........................................................................
Checking location of cause of hydraulic drift of blade and ripper.................................................................
Testing leakage inside work equipment cylinder .........................................................................................
Releasing remaining pressure in work equipment cylinders........................................................................
Bleeding air from work equipment cylinders ................................................................................................
Adjusting ripper lever position......................................................................................................................
Work equipment ..............................................................................................................................................
Adjusting work equipment lock lever............................................................................................................
Adjusting blade ............................................................................................................................................
Cab and its attachments..................................................................................................................................
Testing and adjusting operator's cab ...........................................................................................................
Testing and adjusting operator's seat isolator..............................................................................................
Electrial system ...............................................................................................................................................
Special functions of machine monitor (EMMS) ............................................................................................
Handling of voltage circuit of engine controller ............................................................................................
Adjustment method when controller has been replaced ..............................................................................
Preparation work for troubleshooting of electrical system ...........................................................................
Inspection procedure of diode......................................................................................................................
Handling of optional devices ........................................................................................................................
Request for opening ORBCOMM terminal...................................................................................................
Initialization procedures for VHMS controller...............................................................................................
Using method of KOMTRAX functions of ORBCOMM terminal...................................................................
Precautions for replacing VHMS controller ..................................................................................................
Pm Clinic service.............................................................................................................................................
Pm Clinic service .........................................................................................................................................
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40 Troubleshooting
General Information on troubleshooting ..........................................................................................................
Points to remember when troubleshooting ..................................................................................................
Sequence of events in troubleshooting........................................................................................................
Checks before troubleshooting ....................................................................................................................
Classification and procedures for troubleshooting .......................................................................................
Failure codes table.......................................................................................................................................
Phenomena and troubleshooting numbers ..................................................................................................
Information in troubleshooting table.............................................................................................................
Troubleshooting method for disconnecting wiring harness of pressure sensor system...............................
Connectors table and arrangement drawing................................................................................................
Connection table for connector pin numbers ...............................................................................................
T-branch box and T-branch adapter table ...................................................................................................
Fuse locations table .....................................................................................................................................
Troubleshooting by failure code ......................................................................................................................
Failure code [AB00MA] Battery Charge Abnormal ......................................................................................
Failure code [1380MW] Lock up clutch: Slip................................................................................................
Failure code [1500L0] Transmission clutch: Abnormal ................................................................................
Failure code [15E0MW] Transmission clutch: Slip.......................................................................................
Failure code [15SAL1] Forward clutch: Fill high ..........................................................................................
Failure code [15SALH] Forward clutch: Fill Low ..........................................................................................
Failure code [15SBL1] Reverse clutch: Fill high ..........................................................................................
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00-4
D375A-6
(07)
Shop Manual
Table of contents
Failure code [15SBLH] Reverse clutch: Fill Low..........................................................................................

Failure code [15SEL1] Speed 1st clutch: Fill high .......................................................................................
Failure code [15SELH] Speed 1st clutch: Fill Low .......................................................................................
Failure code [15SFL1] Speed 2nd clutch: Fill high ......................................................................................
Failure code [15SFLH] Speed 2nd clutch: Fill Low ......................................................................................
Failure code [15SGL1] Speed 3rd clutch: Fill high.......................................................................................
Failure code [15SGLH] Speed 3rd clutch: Fill Low ......................................................................................
Failure code [15SJL1] L/U: Fill high .............................................................................................................
Failure code [15SJLH] L/U: Fill low..............................................................................................................
Failure code [1800MW] P/T clutch: Slip.......................................................................................................
Failure code [2201L1] Right clutch: Fill high ................................................................................................
Failure code [2201LH] Right clutch: Fill low.................................................................................................
Failure code [2202L1] Left clutch: Fill high ..................................................................................................
Failure code [2202LH] Left clutch: Fill low ...................................................................................................
Failure code [2300NR] Brake Themal Load Abnormality.............................................................................
Failure code [2301L1] Right brake: Fill high ................................................................................................
Failure code [2301LH] Right brake: Fill low .................................................................................................
Failure code [2301NR] Steering Brake RH Themal Load Abnormality ........................................................
Failure code [2302L1] Left brake: Fill high...................................................................................................
Failure code [2302LH] Left brake: Fill low....................................................................................................
Failure code [2302NR] Steering Brake LH Themal Load Abnormality.........................................................
Failure code [7RFAKA] ECM ACC CUT RELAY: Disconnection.................................................................
Failure code [7RFAKB] ECM ACC CUT RELAY: Short circuit ....................................................................
Failure code [AA10NX] Air Cleaner Clogging ..............................................................................................
Failure code [B@BAZG] Eng Oil Press Low................................................................................................
Failure code [B@BAZK] Eng Oil Level Low.................................................................................................
Failure code [B@BCNS] Eng Water Overheat ............................................................................................
Failure code [B@BCZK] Eng Water Level Low ...........................................................................................
Failure code [B@CENS] T/C Oil Overheat ..................................................................................................
Failure code [B@HANS] Hyd Oil Overheat..................................................................................................
Failure code [B@HAZK] Hyd Oil Level Low.................................................................................................
Failure code [CA111] ECM Critical Internal Failure .....................................................................................
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ........................................................................
Failure code [CA122] Chg Air Press Sensor High Error ..............................................................................
Failure code [CA123] Chg Air Press Sensor Low Error ...............................................................................
Failure code [CA131] Throttle Sensor High Error ........................................................................................
Failure code [CA132] Throttle Sensor Low Error .........................................................................................
Failure code [CA135] Eng Oil Press Sensor High Error ..............................................................................
Failure code [CA141] Eng Oil Press Sensor Low Error ...............................................................................
Failure code [CA144] Coolant Temp Sens High Error .................................................................................
Failure code [CA145] Coolant Temp Sens Low Error..................................................................................
Failure code [CA153] Chg Air Temp Sensor High Error ..............................................................................
Failure code [CA154] Chg Air Temp Sensor Low Error ...............................................................................
Failure code [CA187] Sens Supply 2 Volt Low Error ...................................................................................
Failure code [CA212] Eng Oil Temp Sensor High Error ..............................................................................
Failure code [CA213] Eng Oil Temp Sensor Low Error ...............................................................................
Failure code [CA221] Ambient Press Sens High Error ................................................................................
Failure code [CA222] Ambient Press Sens Low Error .................................................................................
Failure code [CA227] Sens Supply 2 Volt High Error ..................................................................................
Failure code [CA234] Eng Overspeed .........................................................................................................
Failure code [CA238] Ne Speed Sens Supply Volt Error.............................................................................
Failure code [CA263] Fuel Temp Sensor High Error ...................................................................................
Failure code [CA265] Fuel Temp Sensor Low Error ....................................................................................
Failure code [CA271] IMV/PCV1 Short Error...............................................................................................
Failure code [CA272] IMV/PCV1 Open Error...............................................................................................
Failure code [CA273] PCV2 Short Error ......................................................................................................
Failure code [CA274] PCV2 Open Error ......................................................................................................
Failure code [CA322] Inj #1 (L#1) Open/Short Error....................................................................................
D375A-6
(07)
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00-4-1
Shop Manual
Table of contents
Failure code [CA342] Calibration Code Incompatibility................................................................................

Failure code [CA351] Injectors Drive Circuit Error .......................................................................................
Failure code [CA352] Sens Supply 1 Volt Low Error ...................................................................................
Failure code [CA386] Sens Supply 1 Volt High Error ..................................................................................
Failure code [CA441] Battery Voltage Low Error .........................................................................................
Failure code [CA442] Battery Voltage High Error ........................................................................................
Failure code [CA449] Rail Press Very High Error ........................................................................................
Failure code [CA451] Rail Press Sensor High Error ....................................................................................
Failure code [CA452] Rail Press Sensor Low Error.....................................................................................
Failure code [CA553] Rail Press High Error ................................................................................................
Failure code [CA554] Rail Press Sensor In Range Error.............................................................................
Failure code [CA559] Rail Press Low Error .................................................................................................
Failure code [CA689] Eng Ne Speed Sensor Error .....................................................................................
Failure code [CA731] Eng Bkup Speed Sens Phase Error..........................................................................
Failure code [CA757] All Continuous Data Lost Error..................................................................................
Failure code [CA778] Eng Bkup Speed Sensor Error..................................................................................
Failure code [CA1228] EGR Valve Servo Error 1 ........................................................................................
Failure code [CA1625] EGR Valve Servo Error 2 ........................................................................................
Failure code [CA1633] KOMNET Datalink Timeout Error............................................................................
Failure code [CA2185] Throt Sens Sup Volt High Error...............................................................................
Failure code [CA2186] Throt Sens Sup Volt Low Error ...............................................................................
Failure code [CA2249] Rail Press Very Low Error.......................................................................................
Failure code [CA2271] EGR Valve Pos Sens High Error.............................................................................
Failure code [CA2272] EGR Valve Pos Sens Low Error .............................................................................
Failure code [CA2351] EGR Valve Sol Current High Error..........................................................................
Failure code [CA2352] EGR Valve Sol Current Low Error...........................................................................
Failure code [D110KB] Battery Relay: Drive Short Circuit ...........................................................................
Failure code [D130KA] Neutral relay: Disconnection...................................................................................
Failure code [D130KB] Neutral relay: Short circuit ......................................................................................
Failure code [D161KA] Back-up alarm releay: Disconnection .....................................................................
Failure code [D161KB] Back-up alarm releay: Short circuit.........................................................................
Failure code [D182KZ] Preheater Relay Abnormality ..................................................................................
Failure code [D190KA] ACC signal relay: Disconnection ............................................................................
Failure code [D190KB] ACC signal relay: Short circuit ................................................................................
Failure code [D1EFKA] Pre lub. motor relay: Disconnection .......................................................................
Failure code [D1EFKB] Pre lub. motor relay: Short circuit...........................................................................
Failure code [DAFRKR] Monitor: Can communication lost (PT) ..................................................................
Failure code [dAFRKR] Monitor: CAN communication lost (WE) ................................................................
Failure code [DAFRMC] CAN Discon (Monitor Detected) ...........................................................................
Failure code [DB2RKR] ENG cont.: Can communication lost (PT)..............................................................
Failure code [dB2RKR] ENG controller: CAN communication lost (WE) .....................................................
Failure code [DB90KT] WE controller: Abnormality in controller .................................................................
Failure code [DB91KK] WE controller: Source voltage reduction ................................................................
Failure code [DB92KK] WE controller: Output voltage reduction.................................................................
Failure code [DB97KK] WE cont.: Sensor voltage 5 V (2) reduction ...........................................................
Failure code [DB99KQ] WE controller: Type select signal...........................................................................
Failure code [DB9RKR] WE controller: Can communication lost (PT).........................................................
Failure code [DBB0KK] VHMS controller:Source voltage reduction ............................................................
Failure code [DBB0KQ] VHMS connector connection abnormality .............................................................
Failure code [DBB3KK] VHMS controller: Source voltage reduction ...........................................................
Failure code [DBB5KP] VHMS: Output sensor1 voltage reduction..............................................................
Failure code [DBB6KP] VHMS:Output sensor2 voltage reduction...............................................................
Failure code [DBB7KP] VHMS:Output sensor3 voltage reduction...............................................................
Failure code [DBBQKR] PT cont.: Can communication lost (VHMS) ..........................................................
Failure code [DBE0KT] PT controller: Abnormality in controller ..................................................................
Failure code [DBE1KK] PT controller: Source voltage reduction.................................................................
Failure code [DBE2KK] PT controller: Output voltage reduction .................................................................
Failure code [DBE5KK] PT cont.: Sensor voltage 5 V (1) reduction ............................................................
Failure code [DBE6KK] PT cont.: Sensor voltage 24 V reduction ...............................................................
Failure code [DBE7KK] PT cont.: Sensor voltage 5 V (2) reduction ............................................................
Failure code [DBE9KQ] PT controller: Type select signal ...........................................................................
Failure code [DBERKR] PT controller: Can communication lost (WE) ........................................................
Failure code [DD12KA] Shift up Sw: Disconnection ....................................................................................
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D375A-6
(07)
Shop Manual
Table of contents
Failure code [DD12KB] Shift up Sw: Short circuit ........................................................................................

Failure code [DD13KA] Shift down Sw: Disconnection................................................................................
Failure code [DD13KB] Shift down Sw: Short circuit ...................................................................................
Failure code [DD14KA] Parking lever Sw: Dissconnection..........................................................................
Failure code [DD14KB] Parking lever Sw: Short circuit ...............................................................................
Failure code [DDB9L4] Reverse SW Signal disagreement..........................................................................
Failure code [DDE2KA] Pre lub. oil press sw: Disconnection ......................................................................
Failure code [DDK3L4] Forward SW Signal disagreement..........................................................................
Failure code [DDK5KA] Shift switch disconnection......................................................................................
Failure code [DDK5KB] Shift switch short circuit .........................................................................................
Failure code [DDN2LD] Blade tilt RH pressure SW abnormality .................................................................
Failure code [DDN3LD] Blade tilt LH pressure SW abnormality ..................................................................
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection ..................................................................
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit......................................................................
Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection.......................................................................
Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit ..........................................................................
Failure code [DDNALD] Blade lift up pressure SW abnormality ..................................................................
Failure code [DDNBLD] Ripper lift up pressure SW abnormality.................................................................
Failure code [DDNCLD] Ripper lift down pressure SW abnormality ............................................................
Failure code [DDNDLD] Ripper tilt in pressure SW abnormality..................................................................
Failure code [DDNELD] Ripper tilt back pressure SW abnormality .............................................................
Failure code [DDNFLD] Blade lift down pressure SW abnormality..............................................................
Failure code [DDNLKA] Weq lock Sw: Disconnection .................................................................................
Failure code [DDNLKB] Weq lock Sw: Short circuit.....................................................................................
Failure code [DDT5KA] Neutral switch disconnection .................................................................................
Failure code [DDT5KB] Neutral switch short circuit .....................................................................................
Failure code [DDT5KQ] Lever SPEC selection signal disagreement ..........................................................
Failure code [DDTSL1] S/C: Fill high ...........................................................................................................
Failure code [DDTSLH] S/C: Fill low............................................................................................................
Failure code [DGE5KX] Ambient temp sensor abnormality .........................................................................
Failure code [DGS1KX] Hyd oil temp: signal abnormal ...............................................................................
Failure code [DGT1KA] T/C oil temp sensor: Abnormal ..............................................................................
Failure code [DGT1KX] T/C oil temp sensor: Abnormal ..............................................................................
Failure code [DGT5KA] F exhaust temp sensor disconnection ...................................................................
Failure code [DGT5KB] F exhaust temp sensor short circuit.......................................................................
Failure code [DGT6KA] R exhaust temp sensor disconnection...................................................................
Failure code [DGT6KB] R exhaust temp sensor short circuit ......................................................................
Failure code [DH21KA] Weq pressure sensor: Disconnection ....................................................................
Failure code [DH21KB] Weq pressure sensor: Short circuit ........................................................................
Failure code [DHE5KB] ENG blow-by pressure sensor disconnection........................................................
Failure code [DHE5KY] ENG blow-by pressure sensor short circuit ...........................................................
Failure code [DHT3KX] T/M oil pressure sensor abnormality......................................................................
Failure code [DHT5KA] T/C in-pressure sensor: Disconnection..................................................................
Failure code [DHT5KB] T/C in-pressure sensor: Short circuit .....................................................................
Failure code [DHT7KA] T/C out-pressure sensor: Disconnection................................................................
Failure code [DHT7KB] T/C out-pressure sensor: Short circuit ...................................................................
Failure code [DK10KA] Fuel control Dial: Disconnection.............................................................................
Failure code [DK10KB] Fuel control Dial: Short circuit ................................................................................
Failure code [DK30KA] ST lever 1: Disconnection ......................................................................................
Failure code [DK30KB] ST lever 1: Short circuit ..........................................................................................
Failure code [DK30KX] ST lever: Out of normal range ................................................................................
Failure code [DK30KZ] ST lever: Disconnection or short circuit ..................................................................
Failure code [DK30L8] ST lever: Signal mismatch ......................................................................................
Failure code [DK31KA] ST lever 2: Disconnection ......................................................................................
Failure code [DK31KB] ST lever 2: Short circuit ..........................................................................................
Failure code [DK40KA] Brake potentiometer: Disconnection ......................................................................
Failure code [DK40KB] Brake potentiometer: Short circuit ..........................................................................
Failure code [DK55KX] FR lever: Out of normal range................................................................................
Failure code [DK55KZ] FR lever: Disconnection or short circuit..................................................................
Failure code [DK55L8] FR lever: Signal mismatch ......................................................................................
Failure code [DK56KA] FR lever 1: Disconnection ......................................................................................
Failure code [DK56KB] FR lever 1: Short circuit..........................................................................................
Failure code [DK57KA] FR lever 2: Disconnection ......................................................................................
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(07)
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40 -378
40 -380
40 -382
40 -384
40 -386
40 -388
40 -390
40 -392
40 -394
40 -396
40 -398
40 -400
40 -402
40 -404
40 -406
40 -408
40 -410
40 -412
40 -414
40 -416
40 -418
40 -420
40 -422
40 -424
40 -426
40 -428
40 -430
40 -432
40 -434
40 -436
40 -438
40 -440
40 -440
40 -441
40 -442
40 -444
40 -446
40 -448
40 -450
40 -450
40 -451
40 -452
40 -454
40 -456
00-4-3
Shop Manual
Table of contents
Failure code [DK57KB] FR lever 2: Short circuit..........................................................................................

Failure code [DK60KA] Acceleration sensor: Disconnection .......................................................................
Failure code [DK60KB] Acceleration sensor: Short circuit...........................................................................
Failure code [DKH1KA] Pitch angle sensor: Disconnection.........................................................................
Failure code [DKH1KB] Pitch angle sensor: Short circuit ............................................................................
Failure code [DLF1KA] T/C out-speed sensor: Disconnection ....................................................................
Failure code [DLM3KA] Fan rev. sensor: Disconnection .............................................................................
Failure code [DLM3MB] Fan control: Decline ..............................................................................................
Failure code [DLT3KA] T/M out-speed sensor: Disconnection ....................................................................
Failure code [DLT3KB] T/M out-speed sensor: Abnormal ...........................................................................
Failure code [DW59KA] Blade dual selector SOL disconnection.................................................................
Failure code [DW59KB] Blade dual selector SOL short circuit ....................................................................
Failure code [DW59KY] Blade dual selector SOL hot short.........................................................................
Failure code [DW5AKA] Blade pitch selector SOL disconnection ...............................................................
Failure code [DW5AKB] Blade pitch selector SOL short circuit ...................................................................
Failure code [DW5AKY] Blade pitch selector SOL Short circuit ..................................................................
Failure code [DW7BKA] Fan rev EPC: Disconnection.................................................................................
Failure code [DW7BKB] Fan rev EPC: Short circuit ....................................................................................
Failure code [DWN3KA] Ssp solenoid: Disconnection.................................................................................
Failure code [DWN3KB] Ssp solenoid: Short circuit ....................................................................................
Failure code [DWN3KY] SSP solenoid: Short circuit ...................................................................................
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection....................................................................
Failure code [DWN5KB] Fan pump solenoid 1: Short circuit .......................................................................
Failure code [DWN5KY] Fan pump solenoid 1: Short circuit .......................................................................
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection ...................................................................
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit.......................................................................
Failure code [DWNCKY] Fan pump solenoid 2: Short circuit.......................................................................
Failure code [DXH1KA] Lock-up ECMV: Disconnection ..............................................................................
Failure code [DXH1KB] Lock-up ECMV: Short circuit..................................................................................
Failure code [DXH1KY] Lock-up ECMV: Short circuit..................................................................................
Failure code [DXH4KA] 1st clutch ECMV: Disconnection............................................................................
Failure code [DXH4KB] 1st clutch ECMV: Short circuit ...............................................................................
Failure code [DXH4KY] 1st clutch ECMV: Short circuit ...............................................................................
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection ..........................................................................
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit ..............................................................................
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit ..............................................................................
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection ...........................................................................
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit...............................................................................
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit...............................................................................
Failure code [DXH7KA] R clutch ECMV: Disconnection..............................................................................
Failure code [DXH7KB] R clutch ECMV: Short circuit .................................................................................
Failure code [DXH7KY] R clutch ECMV: Short circuit .................................................................................
Failure code [DXH8KA] F clutch ECMV: Disconnection ..............................................................................
Failure code [DXH8KB] F clutch ECMV: Short circuit..................................................................................
Failure code [DXH8KY] F clutch ECMV: Short circuit..................................................................................
Failure code [DXH9KA] Right clutch ECMV: Disconnection ........................................................................
Failure code [DXH9KB] Right clutch ECMV: Short circuit............................................................................
Failure code [DXH9KY] Right clutch ECMV: Short circuit............................................................................
Failure code [DXHAKA] Left clutch ECMV: Disconnection ..........................................................................
Failure code [DXHAKB] Left clutch ECMV: Short circuit..............................................................................
Failure code [DXHAKY] Left clutch ECMV: Short circuit..............................................................................
Failure code [DXHBKA] Right brake ECMV: Disconnection ........................................................................
Failure code [DXHBKB] Right brake ECMV: Short circuit............................................................................
Failure code [DXHBKY] Right brake ECMV: Short circuit............................................................................
Failure code [DXHCKA] Left brake ECMV: Disconnection ..........................................................................
Failure code [DXHCKB] Left brake ECMV: Short circuit..............................................................................
Failure code [DXHCKY] Left brake ECMV: Short circuit..............................................................................
Failure code [DXJBKA] S/C ECMV: Disconnection .....................................................................................
Failure code [DXJBKB] S/C ECMV: Short circuit.........................................................................................
Failure code [DXJBKY] S/C ECMV: Short circuit.........................................................................................
Failure code [DY2HKA] Pre lub. motor: Disconnection................................................................................
Failure code [F@BBZL] ENG blow-by pressure high level ..........................................................................
Failure code [F@BYNR] F exhaust temp high level (2) ...............................................................................
00-4-4
40 -458
40 -460
40 -462
40 -464
40 -466
40 -468
40 -469
40 -470
40 -471
40 -472
40 -473
40 -474
40 -475
40 -476
40 -477
40 -478
40 -479
40 -480
40 -481
40 -482
40 -484
40 -486
40 -487
40 -488
40 -490
40 -491
40 -492
40 -494
40 -495
40 -496
40 -498
40 -499
40 -500
40 -502
40 -503
40 -504
40 -506
40 -507
40 -508
40 -510
40 -511
40 -512
40 -514
40 -515
40 -516
40 -518
40 -519
40 -520
40 -522
40 -523
40 -524
40 -526
40 -527
40 -528
40 -530
40 -531
40 -532
40 -534
40 -535
40 -536
40 -538
40 -540
40 -541
D375A-6
(07)
Shop Manual
Table of contents
Failure code [F@BYNS] F exhaust temp high level (1) ...............................................................................

Failure code [F@BZNR] R exhaust temp high level (2)...............................................................................
Failure code [F@BZNS] R exhaust temp high level (1) ...............................................................................
Troubleshooting of electrical system (E-mode) ...............................................................................................
Information contained in troubleshooting table ............................................................................................
E-1 Engine does not start (starting motor does not turn) .............................................................................
E-2 Preheater does not operate...................................................................................................................
E-3 When starting switch is turned ON, machine monitor displays nothing.................................................
E-4 When starting switch is turned ON (before starting engine), basic check item lights up.......................
E-5 Precaution item lights up while engine is running .................................................................................
E-6 Emergency stop item lights up while engine is running.........................................................................
E-7 Engine coolant temperature gauge does not indicate normally ............................................................
E-8 Fuel gauge does not indicate properly ..................................................................................................
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally .......................................
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally .............................................
E-11 Contents of display by machine monitor are different from applicable machine .................................
E-12 Machine monitor does not display some items ...................................................................................
E-13 Function switch does not work ............................................................................................................
E-14 Operation mode does not change .......................................................................................................
E-15 Gearshift mode does not change ........................................................................................................
E-16 Customize function does not operate normally ...................................................................................
E-17 Customize memory function does not operate normally .....................................................................
E-18 Alarm buzzer does not sound or does not stop...................................................................................
E-19 When starting switch is turned OFF, service meter is not displayed...................................................
E-20 Machine monitor cannot be set in service mode .................................................................................
E-21 The ripper pin puller cylinder does not operate ...................................................................................
E-22 Horn does not sound or does not stop ................................................................................................
E-23 Back-up alarm does not sound or does not stop.................................................................................
E-24 Fan does not reverse ..........................................................................................................................
E-25 The head lamp and rear lamp do not light up......................................................................................
E-26 Windshield wiper does not operate .....................................................................................................
E-27 Window washer does not operate .......................................................................................................
E-28 Electric priming pump does not operate or does not stop automatically .............................................
E-29 Orbcomm terminal does not operate normally (Data are not transmitted) ..........................................
E-30 Gear cannot be shifted ........................................................................................................................
Troubleshooting of hydraulic and mechanical system (H-mode) ....................................................................
List of Failure Modes and Causes ...............................................................................................................
H-1 Machine lacks power(or drawbar pull) ..................................................................................................
H-2 Machine cannot travel (at 2nd or 3rd each speed)................................................................................
H-3 Machine cannot travel at any gear speeds ...........................................................................................
H-4 Machine travels only in one direction, forward or reverse.....................................................................
H-5 Large time lag at gear shifting or directional change ............................................................................
H-6 Machine connot turn..............................................................................................................................
H-7 Machine turns only to one side .............................................................................................................
H-8 Machine overruns at turnning................................................................................................................
H-9 Brake does not work .............................................................................................................................
H-10 Torque converter does not lock up......................................................................................................
H-11 Power train oil overheats.....................................................................................................................
H-12 All work equipment operates too slow or lacks power ........................................................................
H-13 All work equipment does not operate..................................................................................................
H-14 Blade lift cylinder speed is too slow or lacks power ............................................................................
H-15 Blade tilt cylinder speed is too slow or lacks power ............................................................................
H-16 Ripper lift cylinder speed is too slow or lacks power...........................................................................
H-17 Ripper tilt cylinder speed is too slow or lacks power...........................................................................
H-18 Excessive hydraulic drift of blade lift cylinder......................................................................................
H-19 Excessive hydraulic drift of blade tilt cylinder......................................................................................
H-20 Excessive hydraulic drift of ripper lift cylinder .....................................................................................
H-21 Ripper pin puller cylinder does not operate (machine with giant ripper) .............................................
H-22 Blade pitch does not work (machine with dual tilt specification) .........................................................
H-23 Abnormal noise from around work equipment pump ..........................................................................
H-24 Abnormal fan rotation (noise and/or vibration are abnormally large or engine overheats) .................
H-25 Operator's seat isolator quakes abnormally or makes shocks (Machine with operator's seat isolator)
D375A-6
(07)
40 -542
40 -543
40 -544
40 -545
40 -545
40 -547
40 -550
40 -554
40 -556
40 -558
40 -560
40 -561
40 -562
40 -564
40 -565
40 -566
40 -566
40 -566
40 -567
40 -567
40 -568
40 -568
40 -569
40 -569
40 -569
40 -570
40 -572
40 -574
40 -576
40 -577
40 -584
40 -590
40 -596
40 -598
40 -600
40 -601
40 -601
40 -602
40 -604
40 -606
40 -607
40 -608
40 -609
40 -610
40 -611
40 -612
40 -612
40 -613
40 -614
40 -615
40 -616
40 -617
40 -617
40 -618
40 -618
40 -619
40 -619
40 -620
40 -620
40 -621
40 -621
40 -622
40 -622
00-4-5
Shop Manual
Table of contents
Troubleshooting of engine (S-mode)...............................................................................................................

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

General information on disassembly and assembly........................................................................................
How to read this manual ..............................................................................................................................
Coating materials list....................................................................................................................................
Special tools list ...........................................................................................................................................
Sketches of special tools .............................................................................................................................
Removal and installation of fuel supply pump assembly .............................................................................
Removal and installation of fuel injector assembly ......................................................................................
Removal and installation of cylinder head assembly ...................................................................................
Removal and installation of radiator guard assembly ..................................................................................
Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler)...................
Removal and installation of radiator.............................................................................................................
Removal and installation of hydraulic oil cooler ...........................................................................................
Removal and installation of aftercooler........................................................................................................
Removal and installation of engine assembly..............................................................................................
Removal and installation of engine hood assembly.....................................................................................
Removal and installation of engine front seal ..............................................................................................
Removal and installation of engine rear seal ...............................................................................................
Removal and installation of fan drive assembly...........................................................................................
Removal and installation of fan motor assembly .........................................................................................
Removal and installation of fuel tank assembly ...........................................................................................
Power train ......................................................................................................................................................
Removal and installation of damper assembly ............................................................................................
Disassembly and assembly of damper assembly ........................................................................................
Removal and installation of power train unit assembly ................................................................................
Disconnection and connection of power train unit assembly .......................................................................
Disassembly and assembly of PTO assembly.............................................................................................
Disassembly and assembly of torque converter assembly ..........................................................................
Disassembly and assembly of TORQFLOW transmission assembly ..........................................................
Disassembly and assembly of steering case assembly...............................................................................
Removal and installation of power train pump and lubrication pump assembly ..........................................
Removal and installation of scavenging pump assembly ............................................................................
Removal and installation of final drive assembly .........................................................................................
Disassembly and assembly of final drive assembly.....................................................................................
Removal and installation of track frame assembly.......................................................................................
Removal and installation of idler assembly..................................................................................................
Disassembly and assembly of idler assembly .............................................................................................
Removal and installation of recoil spring assembly .....................................................................................
Disassembly and assembly of recoil spring assembly.................................................................................
Removal and installation of track roller assembly........................................................................................
50 - 4
50 - 4
50 - 6
50 - 9
50 - 16
50 - 24
50 - 24
50 - 28
50 - 33
50 - 49
50 - 54
50 - 59
50 - 61
50 - 62
50 - 63
50 - 70
50 - 73
50 - 75
50 - 79
50 - 81
50 - 83
50 - 86
50 - 86
50 - 90
50 - 93
50 -100
50 -109
50 -115
50 -125
50 -153
50 -169
50 -170
50 -171
50 -173
50 -186
50 -186
50 -191
50 -192
50 -196
50 -201
50 -203
00-4-6
D375A-6
(07)
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 operators cab assembly.................................................................................. 50 -309
Removal and installation of floor frame assembly ....................................................................................... 50 -313
Removal and installation of air conditioner unit assembly ........................................................................... 50 -318
Removal and installation of operator's seat isolator ....................................................................................50-323-1
Disassembly and assembly of operator's seat isolator ................................................................................50-323-2
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 mount...............................................................................................................................................
Cooling fan pump.........................................................................................................................................
Cooling fan motor.........................................................................................................................................
Power train ......................................................................................................................................................
Power train unit ............................................................................................................................................
Scavenging pump ........................................................................................................................................
Transmission................................................................................................................................................
Power train and lubrication pump ................................................................................................................
Transfer, bevel gear shaft and steering unit ................................................................................................
Steering clutch ECMV and steering brake ECMV........................................................................................
Final drive ....................................................................................................................................................
D375A-6
(07)
6060606060606060606060606060606060606060-
3
3
5
12
14
14
16
19
22
23
24
25
26
30
31
32
38
39
40
41
00-4-7
Shop Manual
Table of contents
Sprocket.......................................................................................................................................................
Track frame..................................................................................................................................................
Idler cushion.................................................................................................................................................
Idler ..............................................................................................................................................................
Track roller ...................................................................................................................................................
Carrier roller .................................................................................................................................................
Track roller bogie .........................................................................................................................................
Track shoe ...................................................................................................................................................
Main frame ...................................................................................................................................................
Suspension ..................................................................................................................................................
PPC valve ....................................................................................................................................................
Hydraulic cylinder.........................................................................................................................................
Quick drop valve ..........................................................................................................................................
Control valve ................................................................................................................................................
Work equipment ..............................................................................................................................................
Cylinder stay ................................................................................................................................................
Blade............................................................................................................................................................
Cutting edge and end bit..............................................................................................................................
Ripper ..........................................................................................................................................................
6060606060606060606060606060606060606060606060-
44
46
46
48
50
52
54
55
56
60
62
67
67
72
75
76
79
85
87
87
88
92
94
80 Appendix
Air Conditioner.................................................................................................................................................
Caution about refrigerant .............................................................................................................................
Air conditioner component ...........................................................................................................................
Configuration and function of refrigeration cycle..........................................................................................
Outline of refrigeration cycle ........................................................................................................................
Air conditioner unit .......................................................................................................................................
Blower unit ...................................................................................................................................................
FRESH/RECIRC air changeover damper ....................................................................................................
Compressor .................................................................................................................................................
Condenser ...................................................................................................................................................
Receiver drier...............................................................................................................................................
Air conditioner control panel ........................................................................................................................
Procedure for testing and troubleshooting ...................................................................................................
Circuit diagram and arrangement of connector pins ....................................................................................
System diagram ...........................................................................................................................................
Part and connector locations .......................................................................................................................
Testing temperature control .........................................................................................................................
Testing FRESH/RECIC air changeover .......................................................................................................
Testing relay ................................................................................................................................................
Troubleshooting chart 1 ...............................................................................................................................
Troubleshooting chart 2 ...............................................................................................................................
Troubleshooting for power supply system (Air conditioner does not operate) .............................................
Troubleshooting for compressor system (Air is not cooled).........................................................................
Troubleshooting for blower motor system (Air does not come out or air flow is abnormal) .........................
Troubleshooting for temperature control......................................................................................................
Troubleshooting for FRESH/RECIRC air changeover .................................................................................
Troubleshooting with gauge pressure..........................................................................................................
Connection of service tool............................................................................................................................
Precautions for disconnecting and connecting ............................................................................................
Handling of compressor oil ..........................................................................................................................
80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 -
3
3
4
6
7
10
14
15
16
17
18
20
22
24
26
28
32
32
34
36
38
40
42
44
48
54
56
58
60
62
64
90 Diagrams and Drawings

Hydraulic diagrams and drawings ...................................................................................................................
Symbols used in hydraulic circuit diagrams .................................................................................................
Power train hydraulic circuit diagram ...........................................................................................................
Hydraulic circuit diagram..............................................................................................................................
90 90 90 90 -
3
3
5
7
00-4-8
D375A-6
(07)
Shop Manual
Table of contents
Electrical diagrams and drawings.................................................................................................................... 90 - 9

Symbols use in electric circuit diagrams ...................................................................................................... 90 - 9
Electrical circuit diagram .............................................................................................................................. 90 - 13
Index................................................................................................................................................................ ........ 1
D375A-6
(07)
00-4-9
DRAFT
Table of contents
00-4-10
00-14
D375A-6
(02)
Forword and general information

Safety notice

Safety notice
0 -3
Important safety notice

Appropriate servicing and repair are extremely important to ensure safe operation of the machine.The
shop manuals describe the effective and safe servicing and repair methods recommended by Komatsu.Some of the servicing and repair methods require use of special tools designed by Komatsu for
special purposes.
The symbol mark "k" is indicated for matters that require special precautions for such work.The
work indicated with the warning mark should be carried out along to the instructions with special attention to the precautions.Should a hazardous situation occur or be anticipated during such work, be
sure to proceed it safe and take every necessary measure.
1. General precautions
k Inappropriate handling creates an extreme danger.Read and understand what
is described in the Operation and Maintenance Manual before operating the machine.Read and understand what is
described in this manual before starting
work.
1) Before carrying out any greasing or repairs,
read all the safety labels stuck to the
machine. For the locations of the safety
labels and detailed explanation of precautions, see the Operation and Maintenance
Manual.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always keep
the tools and parts in their correct places.
Always keep the work area clean and make
sure that there is no dirt, water, or oil on the
floor. Smoke only in the areas provided for
smoking. Never smoke while working.
3) When carrying out any operation, always
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons
missing.
q Always wear the safety glasses when hitting parts with a hammer
q Always wear safety glasses when grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or
more workers, always agree on the operating
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 operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the proper
ones of them. Before starting work, thoroughly check the tools, machine, forklift,
service car, etc.
D375A-6
(09)
7) If welding repairs are needed, always have a

trained and experienced welder carry out the
work. When carrying out welding work,
always wear welding gloves, apron, shielding
goggles, cap and other clothes suited for
welding work.
8) Before starting work, warm up your body
thoroughly to start work under good condition.
9) Avoid continuing work for long hours and
take rests at proper intervals to keep your
body in good condition.
Safety points
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signals
5 Prohibition of operation and handling by unlicensed workers
6 Safety check before starting work
7 Wearing protective goggles(for cleaning or grinding work)
8 Wearing shielding goggles and protectors(for
welding work)
9 Good physical condition and preparation
10 Precautions against work which you are not used
to or you are used to too much
00-5

Safety notice
2. Preparation work
1) Before adding oil or making any repairs, park
the machine on a hard and level ground, and
apply the parking brake and block the wheels
or tracks to prevent the machine from
moving.
2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the
ground. If this is not possible, insert the lock
pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock
all the control levers and hang warning tag on
them.
3) When disassembling or assembling, support
the machine with blocks, jacks, or stands
before starting work.
4) Remove all mud and oil from the steps or
other places used to get on and off the
machine. Always use the handrails, ladders
or steps when getting on or off the machine.
Never jump on or off the machine. If it is
impossible to use the handrails, ladders or
steps, use a stand to provide safe footing.
3. Precautions during work
1) Before disconnecting or removing components of the oil, water, or air circuits, first
release the pressure completely from the
circuit. When removing the oil filler cap, a
drain plug, or an oil pressure pickup
plug,loosen it slowly to prevent the oil from
spurting out.
2) The coolant and oil in the circuits are hot
when the engine is stopped, so be careful not
to get scalded. Wait for the oil and coolant to
cool before carrying out any work on the oil or
water circuits.
3) Before starting work, stop the engine. When
working on or around a rotating part, in particular, stop the engine. When checking the
machine without stopping the engine
(measuring oil pressure, revolving speed,
temperature, etc.), take extreme care not to
get caught in rotating parts or moving parts.
4) For the machine equipped with a battery
disconnct switch, turn the battery disconnect switch to the OFF (O) position and
pull the switch key out, before starting the
work. For machines without a battery
disconnct switch, remove the cable from the
battery , before starting the work. Always
remove the cable from the negative (-)
terminal first.
00-6
5) When raising a heavy component (heavier

than 25 kg), use a hoist or crane. Before
starting work, check that the slings (wire
ropes, chains, and hooks) are free from
damage. Always use slings which have
ample capacity and install them to proper
places. Operate the hoist or crane slowly to
prevent the component from hitting any other
part. Do not work with any part still raised by
the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then
remove the cover.
7) When removing components, be careful not
to break or damage the electrical wiring.
Damaged wiring may cause electrical fires.
8) When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips onto
the floor, wipe it up immediately. Fuel or oil
on the floor can cause you to slip and can
even start fires.
9) As a general rule, do not use gasoline to
wash parts. Do not use it to clean electrical
parts, in particular.
10)Be sure to assemble all parts again in their
original places. Replace any damaged parts
and parts which must not be reused with new
parts. When installing hoses and wires, be
sure that they will not be damaged by contact
with other parts when the machine is operated.
11)When installing high pressure hoses and
tubes, make sure that they are not twisted.
Damaged hoses and tubes are dangerous,
so be extremely careful when installing
hoses and tubes for high pressure circuits. In
addition, check that connections of them are
correct.
D375A-6
(09)

Safety notice
12)When assembling or installing parts, always

tighten them to the specified torques. When
installing protective parts such as guards, or
parts which vibrate violently or rotate at high
speeds, be particularly careful to check that
they are installed correctly.
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
tracks of track-type machines. When
removing the track, the track separates
suddenly, so never let anyone stand at either
end of the track.
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 slinging work and making
signals
1) Only one appointed worker must make
signals and co-workers must communicate
with each other frequently. The appointed
signaler must make specified signals clearly
at a place where he is well seen from the
operator's seat and where he can see the
working condition easily. The signaler must
always stand in front of the load and guide
the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling work.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.)
4) Measure the weight of the load by the eye
and check its center of gravity.
5) Use proper sling according to the weight of
the load and method of slinging. If too thick
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 turning of the load during hoisting, untwisting of the rope, or slipping of the
rope from its original winding position
on the load, which can result in a dangerous accident.
D375A-6
(09)
7) Limit the hanging angle to 60 , as a rule.

Do not sling a heavy load with ropes forming
a wide hanging angle from the hook.
When hoisting a load with 2 or more ropes,
the force subjected to each rope will increase
with the hanging angle. The table below
shows the variation of allowable load in kN
{kg} when hoisting is made with 2 ropes,
each of which is allowed to sling up to 9.8 kN
{1,000 kg} vertically, at various hanging
angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight
can be suspended. This weight is reduced to
9.8 kN {1,000 kg} when the 2 ropes make a
hanging angle of 120 . If the 2 ropes sling a
19.6 kN {2,000 kg } load at a lifting angle of
150 , each of them is subjected to a force as
large as 39.2 kN {4,000 kg}.
8) When installing wire ropes to an angular

load, apply pads to protect the wire ropes. If
the load is slippery, apply proper material to
prevent the wire rope from slipping.
9) Use the specified eyebolts and fix wire ropes,
chains, etc. to them with shackles, etc.
10)Apply wire ropes to the middle portion of the
hook.
q Slinging near the tip of the hook may
cause the rope to slip off the hook during
hoisting. The hook has the maximum
strength at the middle portion.
00-7

Safety notice
11)Do not use twisted or kinked wire ropes.

12)When lifting up a load, observe the following.
q Wind in the crane slowly until wire ropes
are stretched. When settling the wire
ropes with the hand, do not grasp them
but press them from above. If you grasp
them, your fingers may be caught.
q After the wire ropes are stretched, stop
the crane and check the condition of the
slung load, wire ropes, and pads.
q If the load is unstable or the wire rope or
chains are twisted, lower the load and lift
it up again.
q Do not lift up the load at an angle.
13)When lowering a load, observe the following.
q When lowering a load, stop it temporarily
at 30 cm above the floor, and then lower
it slowly.
q Check that the load is stable, and then remove the sling.
q Remove kinks and dirt from the wire
ropes and chains used for the sling work,
and put them in the specified place.
5. Precautions for using mobile crane
a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.
6. Precautions for using overhead traveling
crane
k A hoist crane or similar device must be
used for lifting a heavy load (25 kg or
more).The weight of a part that is 25 kg or
more is indicated with the symbol "4" in
"Disassembly and assembly".
1) Before starting work, inspect the wire ropes,
brake, clutch, controller, rails, over wind stop
device, ground fault circuit interrupter, crane
collision prevention device, and power application warning lamp, and check safety.
2) Observe the signals for sling work.
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.
00-8
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 operation 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 2 mabove the floor. Do not leave the
sling installed to the hook.
7. Selecting wire ropes
1) Select adequate ropes depending on the
weight of parts to be hoisted, referring to the
table below
Wire ropes
(Standard "Z" twist ropes without galvanizing)
(JIS G3525, No. 6, Type 6X37-A)
Nominal diameter
Allowable load
of rope
mm
kN
ton
10
8.8
0.9
12
12.7
1.3
14
17.3
1.7
16
22.6
2.3
18
28.6
2.9
20
35.3
3.6
25
55.3
5.6
30
79.6
8.1
40
141.6
14.4
50
221.6
22.6
60
318.3
32.4
a The allowable load is one-sixth of the

breaking strength of the rope used (Safety coefficient: 6).
D375A-6
(09)

Safety notice
8. Precautions
for
disconnecting
and
connecting hoses and tubes in an air conditioner circuit
1) Disconnection
k Although the refrigerant (refrigerant
gas: R134a) used on the machine's air
conditioner is less destructive to the
ozone layer for environmentally friendliness, it is not allowed to be vented
into the atmosphere as is.Whenever
disconnecting the air conditioner gas
circuit, be sure to recover the refrigerant gas to reuse it.
a Ask a gualified person for collecting and
filling operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to
the atmosphere.
k If the refrigerant gas gets in your eyes
or contacts your skin, you may lose
your sight or your skin may be frozen.Whenever recovering or adding
refrigerant gas, you must put on safety
glasses, safety gloves and long
sleeved clothes.
The refrigerant gas must be recovered
and added by a qualified person.
a For tightening torque, see the precautions for installation in each section of
"Disassembly and assembly".
2) Connection
1] When installing the air conditioner circuit
hoses and tubes, take care to prevent dirt
and water from entering into them.
2] Make sure that before installing the air
conditioner hoses or tubes the 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,
coat the O-ring (1) with the compressor oil
(Denso: ND-OIL8 or Valeo Thermal
Systems Japan Corp.:
ZXL100PG
(PAG46 or the equivalent) for the refrigerant (R134a).
a Example of O-ring (Fitted to every
joint of hoses and tubes)
D375A-6
(09)
00-9
DRAFT
How to read the shop manual

q
q
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.
Materials and specifications are subject to change without notice.
Shop manuals are divided into the "Chassis volume" and "Engine volume". For the engine unit, see the engine volume of the engine model mounted on the machine.
Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For
ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section contains table of contents, and safety and basic information. If any revision of the shop manual is made, the LIST OF REVISED PAGES will be added.
01. Specification
This section explains the specifications of the machine.
10. Structure and function
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting,
and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgment criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided
by failure modes. The "S mode" of the troubleshooting related to the engine may be also explained in the
Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque, and quantity and
weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60.Maintenance standard
This section gives maintenance standard values of each component. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
80.Appendix
The section explains the equipment which can not be included in the other sections. This section explains
the structure, function, testing, adjusting, and troubleshooting 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
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)...)
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
Safety
Caution
Special technical precautions or other precautions for preserving standards are

necessary when performing work.
Weight
Weight of parts of component or parts. Caution necessary when selecting hoisting

wire, or when working posture is important, etc.
Remarks
Special safety precautions are necessary when performing work.
Tightening torque Places that require special attention for tightening torque during assembly.
Coat
Oil, coolant
Drain
Places to be coated with adhesives, etc. during assembly.
Places where oil, etc. must be added, and capacity.
Places where oil, etc. must be drained, and quantity to be drained.
Units
In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
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 machine maintenance work. The following terms are used to explain the criteria.
1. Standard size and tolerance
q To be accurate, the finishing size of parts is a
little different from one to another.
q To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated.
q The above size set temporarily is called the
"standard size" and the range of difference
from the standard size is called the "tolerance".
q The tolerance with the symbols of + or is indicated on the right side of the standard size.
Example:
Standard size
Tolerance
- 0.022
- 0.126
120
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)
Usually, the size of a hole and the size of the
shaft to be fitted to that hole are indicated by
the same standard size and different tolerances of the hole and shaft. The tightness of
fit is decided by the tolerance.
Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Standard size
60
00-12
Tolerance
Shaft
- 0.030
- 0.076
Hole
+ 0.046
0
D375A-6
DRAFT
2. Standard clearance and standard value

q The clearance made when new parts are assembled is called the "standard clearance",
which is indicated by the range from the minimum clearance to the maximum clearance.
q When some parts are repaired, the clearance
is generally adjusted to the standard clearance.
q A value of performance and function of new
products or equivalent is called the "standard
value", which is indicated by a range or a target value.
q When some parts are repaired, the value of
performance/function is set to the standard
value.
3. Standard interference
q When the diameter of a hole of a part shown
in the given standard size and tolerance table
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) between the minimum size of the shaft and the
maximum size of the hole to the difference
(B) between the maximum size of the shaft
and the minimum size of the hole is the "standard interference".
q After repairing or replacing some parts, measure the size of their hole and shaft and
check that the interference is in the standard
range.
5. Clearance limit
q Parts can be used until the clearance between them is increased to a certain limit.
The limit at which those parts cannot be used
is called the "clearance limit".
q If the clearance between the parts exceeds
the clearance limit, they must be replaced or
repaired.
6. Interference limit
q The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the
"interference limit".
q The interference limit shows the repair limit of
the part of smaller tolerance.
q If the interference between the parts exceeds
the interference limit, they must be replaced
or repaired.
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 problem is called the "allowable value" or "allowable dimension".
q If a product is worn to the allowable value, it
must be checked or repaired. Since the permissible value is estimated from various tests
or experiences in most cases, however, it
must be judged after considering the operating 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 before they occur, correct "operation", "maintenance and inspection", "troubleshooting", and "repairs" must be
carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and "Handling hydraulic components" (particularly gear oil and hydraulic oil).
Points to remember when handling electric equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wires connecting
one component to another component, connectors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wires.
Compared with other electrical components
fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness
1) Defective contact of connectors (defective
contact between male and female connectors)
Problems with defective contact are likely to
occur because the male connector is not
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 disconnecting the connector about 10 times.
2) Defective crimping or soldering of connectors
The pins of the male and female connectors
are connected to wires by crimping or
soldering. If excessive force is applied to the
wire, the joint is separated to cause defective
contact or the wire is broken.
00-14
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 connector, 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 compressed 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 installed.
When removing a connector from a

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

After removing any connector, cover it
with a vinyl bag to prevent any dust, dirt,
oil, or water from getting in the connector
portion.
a If the machine is left disassembled for
a long time, it is particularly easy for
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 connector 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 removed, be sure to return it to its original 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)
While pressing both locks (a) and (b), pull out
female connector (2).
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
Disconnection
Connection (Example
of incomplete setting of
(a))
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-pressure water or steam directly on the wiring
harness. If water gets directly on the
connector, do as follows.
1] Disconnect the connector and wipe off
the water with a dry cloth.
a If the connector is blown dry with compressed 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 connector 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 disconnecting or connecting connectors.
2) Before carrying out troubleshooting, check all
the related connectors for half fit.
a Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
a If the power is turned ON with the connectors still disconnected, unnecessary abnormality warning will be issued.
4) When carrying out troubleshooting of circuits
(measuring the voltage, resistance, continuity, or current), wag the related wiring
harnesses and connectors several times and
check that there is no change in the reading
of the tester.
a If there is any change, there is probably
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 performance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by
leaking oil, so never do this. Do not simply drain
oil out onto the ground, but collect it and ask the
customer to dispose of it, or take it back with you
for disposal.
4. Do not let any dirt or dust get in during refilling operations

Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning
device is used, it is possible to filter out the dirt
that has collected during storage, so this is an
even more effective method.
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 contaminants and sludge in it will mix with the new oil
and will shorten the life of the hydraulic oil.
6. Flushing operations
After disassembling and assembling the equipment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary 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
(FRAMATOME-3,FRAMATOME-2)
q
95170,12V140 engines
q Various pressure sensors and NE speed
sensor
Examples)
Intake air pressure sensor in intake manifold:
PIM (125,170,12V140 engines)
Oil pressure sensor: POIL (125,170,12V140
engines)
Oil pressure switch (95,107,114 engines)
Ne speed sensor of flywheel housing:
NE(95-170,12V140 engines)
Ambient
pressure
sensor:
PAMB
(125,170,12V140 engines)
Pull lock type (PACKARD-2)

q 95170,12V140 engines
q Various temperature sensors
Examples)
Intake air temperature sensor in intake manifold: TIM
Fuel temperature sensor: TFUEL
Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR, etc.
Disconnect
Disconnect the connector by pulling lock (B) (on the
wiring harness side) of connector (2) outward.
Disconnect
1) Slide lock L1 to the right.
2) While pressing lock L2, pull out connector (1)
toward you.
a Even if lock L2 is pressed, connector (1)
cannot be pulled out toward you, if part A
does not float. In this case, float part A
with a small screwdriver while press lock
L2 , and then pull out connector (1) toward you.
Connect
Insert the connector straight until it "clicks".
Connect
D375A-6
00-23
DRAFT
Push lock type (1)

q 95, 107, 114 engines
Example) Fuel pressure sensor in common rail
(BOSCH-03)
While pressing up lock (C) of the connector with

flat-head screwdriver [1], pull out connector (3) in
the direction of the arrow.
Disconnect
While pressing lock (C), pull out connector (3) in the
direction of the arrow.
q
114 engine
Connect
107 engine
Push lock type (2)

q 107, 114 engines
Example) Intake air pressure/temperature
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 fingers.
Connect
00-24
D375A-6
DRAFT
Push lock type (3)

q 95, 125 170, 12V140 engines
Disconnect
While pressing lock (E) of the connector, pull out
connector (5) in the direction of the arrow.
Example) Fuel pressure sensor in common rail:
PFUEL etc. (AMP-3)
Turn-housing type (Round green connector)

q 140 engine
Example) Intake air pressure sensor in intake
manifold.
(CANNON-04): PIM etc.
Disconnect
1) Turn housing (H1) in the direction of the
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
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
---
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)
Type
Low-voltage
wire for automobile
Thin-cover
low-voltage wire
for automobile
(type 1)
Thin-cover
low-voltage wire
for automobile
(type 2)
Heat-resistant
low-voltage wire
for automobile
00-26
Symbol
Material
Conductor
Annealed copper for electric

appliance
Insulator
Soft polyvinyl chloride
Conductor

appliance
AV
AVS
Insulator
Conductor

appliance
Insulator
CAVS
Conductor
AEX
Insulator

appliance
Heat-resistant crosslinked
polyethylene
Using temperature
Example of use
General wiring
(nominal No. 5 and above.)
-30 to +60
General wiring
(nominal No. 3 and below.)
For mid- to small-size excavators

(nominal No. 1.25 and below.)
General wiring in extremely cold
district, wiring at high ambient tem-50 to +110
perature place
For wiring in a place of high atmo-
D375A-6
(04)

2. Dimensions
(Table 2)
Nominal No.
Conductor
Co
ver
D
Number of
strands/Diameter of strand
Sectional area
(mm2)
0.75f
(0.85)
1.25f
(1.25)
2f
3f
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
0.51
0.56
0.76
0.88
1.27
1.29
1.96
2.09
3.08
3.30
5.23
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
AV
Standard
4.6
AEX
Standard
2.0
2.2
2.7
3.0
3.1
3.8
4.6
15
20
30
50/0.45
84/0.45
41/0.80
70/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
d (approx.)
3.7
4.8
6.0
8.0
8.6
9.8
10.4
12.0
13.6
AVS
Standard
AV
Standard
5.5
7.0
8.2
10.8
11.4
13.0
13.6
16.0
17.6
AEX
Standard
5.3
7.0
8.2
10.8
11.4
13.0
13.6
16.0
17.6
Conductor
Number of
Sectional area
(mm2)
Nominal No.
Conductor
Co
ver
D
(0.5)
d (approx.)
Nominal No.
Co
ver
D
0.5f
CAVS
40
50
60
85
100
85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
0.5f
0.5
0.75f
0.85
1.25f
1.25
7/Circular compressed
0.56
0.88
1.29
(a)
0.9
1.1
1.4
Standard
1.6
1.8
2.1
Number of
Sectional area
(mm2)
"f" of nominal No. denotes "flexible".
D375A-6
(04)
00-27

3. Color codes table

(Table 3)
Color Code
B
Br
BrB
BrR
BrW
BrY
Ch
Dg
G
GB
GL
Gr
GR
GW
GY
L
LB
Lg
LgB
LgR
Color of wire
Black
Brown
Brown & Black
Brown & Red
Brown & White
Brown & Yellow
Charcoal
Dark green
Green
Green & Black
Green & Blue
Gray
Green & Red
Green & White
Green & Yellow
Blue
Blue & Black
Light green
Light green & Black
Light green & Red
Color Code
LgW
LgY
LR
LW
LY
O
P
R
RB
RG
RL
RW
RY
Sb
Y
YB
YG
YL
YR
YW
Color of wire
Light green & White
Light green & Yellow
Blue & Red
Blue & White
Blue & Yellow
Orange
Pink
Red
Red & Black
Red & Green
Red & Blue
Red & White
Red & Yellow
Sky Blue
Yellow
Yellow & Black
Yellow & Green
Yellow & Blue
Yellow & Red
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
AEX
Charge
WG
Ground
Start
Light
RW
RB
RY
RG
RL
Instrument
YR
YB
YG
YL
YW
Gr
Signal
GW
GR
GY
GB
GL
Br
LW
LR
LY
LB
Br
BrW
BrR
BrY
BrB
Lg
LgR
LgY
LgB
LgW
Gr
Sb
Dg
Ch
Type of circuit
Others
00-28
AVS/AV/CAVS
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 disconnecting 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
number
02
03
04
05
06
Plug (nut end)
Sleeve nut (elbow end)
07376 - 70210
07376-70315
07376 - 70422
07376 - 70522
07376 - 70628
02789 - 00210
02789 - 00315
02789 - 00422
02789 - 00522
02789 - 00628
2) Split flange type hoses and tubes

Nominal
number
04
05
Flange (hose end)
Sleeve head (tube end)
Split flange
07379 - 00400
07379 - 00500
07378 - 10400
07378 - 10500
07371 - 30400
07371 - 30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal
number
06
08
10
12
14
16
18
20
22
24
27
D375A-6
Part No.
07049 - 00608
07049 - 00811
07049 - 01012
07049 - 01215
07049 - 01418
07049 - 01620
07049 - 01822
07049 - 02025
07049 - 02228
07049 - 02430
07049 - 02734
D
6
8
10
12
14
16
18
20
22
24
22.5
Dimensions
d
5
6.5
8.5
10
11.5
13.5
15
17
18.5
20
22.5
L
8
11
12
15
18
20
22
25
28
30
34
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 portion with 2 3 drops of adhesive.
q When coating with liquid gasket, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with liquid gasket.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with molybdenum disulfide lubricant (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
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 leakage.
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
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.
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, prepare an oil container.
2. Connection
1) Hold hose adapter (1) or hose (5) and insert
it in mating adapter (3), aligning them with
each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter
perfectly, pull it back to check its connecting
condition. (Fig. 5)
a When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality, 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) contacts 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
mm
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39
Width across flats

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

mm
6
8
10
12
a Figure A
Width across flats

mm
10
12
14
17
Tightening torque
Nm
5.9 - 9.8
13.7 - 23.5
34.3 - 46.1
74.5 - 90.2
kgm
0.6 - 1.0
1.4 - 2.4
3.5 - 4.7
7.6 - 9.2
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
10
12
16
Width across flats

mm
14
17
22
Tightening torque
Nm
59 - 74
98 - 123
235 - 285
kgm
6.0 - 7.5
10.0 - 12.5
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.
Nominal No.
02
03,04
05,06
10,12
14
Thread diameter
mm
14
20
24
33
42
Width across flats

mm
Varies depending on
type of connector.
Tightening torque Nm {kgm}

Range
Target
35 63 {3.5 6.5}
44 {4.5}
84 132 {8.5 13.5}
103 {10.5}
128 186 {13.0 19.0}
157 {16.0}
363 480 {37.0 49.0}
422 {43.0}
746 1,010 {76.0 103}
883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal No.
08
10
12
14
16
18
20
24
30
33
36
42
52
00-36
Thread diameter
mm
8
10
12
14
16
18
20
24
30
33
36
42
52
Width across flats

mm
14
17
19
22
24
27
30
32
32
36

Range
Target
5.88 8.82 {0.6 0.9}
7.35 {0.75}
9.8 12.74 {1.0 1.3}
11.27 {1.15}
14.7 19.6 {1.5 2.0}
17.64 {1.8}
19.6 24.5 {2.0 2.5}
22.54 {2.3}
24.5 34.3 {2.5 3.5}
29.4 {3.0}
34.3 44.1 {3.5 4.5}
39.2 {4.0}
44.1 53.9 {4.5 5.5}
49.0 {5.0}
58.8 78.4 {6.0 8.0}
68.6 {7.0}
93.1 122.5 { 9.5 12.5}
107.8 {11.0}
107.8 147.0 {11.0 15.0}
127.4 {13.0}
127.4 176.4 {13.0 18.0}
151.9 {15.5}
181.3 240.1 {18.5 24.5}
210.7 {21.5}
274.4 367.5 {28.0 37.5}
323.4 {33.0}
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.
Nominal
No. of
hose
Width
across
flats
02
19
03
04
05
06
(10)
(12)
(14)
22
24
27
32
36
41
46
55
Taper seal
Range
Target
Thread size
(mm)
34 54 {3.5 5.5}
34 63 {3.5 6.5}
54 93 {5.5 9.5}
59 98 {6.0 10.0}
84 132 {8.5 13.5}
128 186 {13.0 19.0}
177 245 {18.0 25.0}
177 245 {18.0 25.0}
197 294 {20.0 30.0}
246 343 {25.0 35.0}
44 {4.5}
44 {4.5}
74 {7.5}
78 {8.0}
103 {10.5}
157 {16.0}
216 {22.0}
216 {22.0}
245 {25.0}
294 {30.0}
14
18
22
24
30
33
36
42
Face seal
Nominal No.
Thread diameNumber of
ter (mm) (Refthreads, type
erence)
of thread
9/16 - 18UNF
14.3
11/16 - 16UN
17.5
13/16 - 16UN
20.6
1 - 14UNS
25.4
1 - 3/16 - 12UN
30.2
-
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
diameter
of pipe
(mm)
8
10
12
15 (16)
22 (20)
Width
across
flats
(mm)
19
22
24 (27)
30 (32)
36

Range
Target
14 16 {1.4 1.6}
24 27 {2.4 2.7}
43 47 {4.4 4.8}
60 68 {6.1 6.8}
90 95 {9.2 9.7}
15 {1.5}
25.5 {2.6}
45 {4.6}
64 {6.5}
92.5 {9.4}
Face seal
Nominal No. Number
Thread diameter (mm)
of threads, type of
(Reference)
thread
9/16 18UN
14.3
11/16 16UN
17.5
13/16 16UN
20.6
1 14UN
25.4
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
Bolts and nuts
Thread size
mm
6
8
10
12
14
D375A-6
Nm
10 2
24 4
43 6
77 12
-
kgm
1.02 0.20
2.45 0.41
4.38 0.61
7.85 1.22
-
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 series to the torque below.
Thread size
mm
6
8
10
12
14
Tightening torque
Nm
82
10 2
12 2
24 4
36 5
kgm
0.81 0.20
1.02 0.20
1.22 0.20
2.45 0.41
3.67 0.51
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below.
Material
Thread size (inch)
1/16
1/8
1/4
3/8
1/2
3/4
00-38
Tightening torque
In cast iron or steel
In aluminum
Nm
kgm
Nm
kgm
15 2
1.53 0.20
51
0.51 0.10
20 2
2.04 0.20
15 2
1.53 0.20
25 3
2.55 0.31
20 2
2.04 0.20
35 4
3.57 0.41
25 3
2.55 0.31
55 6
5.61 0.61
35 4
3.57 0.41
75 8
7.65 0.82
45 5
4.59 0.51
D375A-6
DRAFT
List of Abbreviation
q
This list of abbreviations is taken from the abbreviations used in the text of the shop manual for
parts, components, and functions whose meaning is not immediately clear. The spelling is given
in full with an outline of the meaning.
Abbreviations that are used in general society
may not be included.
q
q
Special abbreviations that appear infrequently

are marked in the text with an *.
This list of abbreviations consists of two
parts.The first part is a list of abbreviations used
in the text of the manual, and the second part is
a list of abbreviations used in circuit diagrams.
text of the manual, and the second part is a list
List of abbreviations used in the shop manual

Abbreviation
Full Spelling
Purpose of use
(major applicable machine(*), or
component/
system)
A.B.S.
Travel and brake

Anti-skid Brake System
(HD, HM)
A.I.S.S.
Automatic Idling Setting

Engine
System
A.J.S.S.
Advanced Joystick
Steering System
Steering
(WA)
A.R.A.C.
Automatic Retarder
Accelerator Control
Travel and brake

(HD, HM)
A.R.S.C.
Automatic Retarder
Speed Control
Travel and brake

(HD, HM)
A.S.R.
ATT.
Automatic Spin Regula- Travel and brake

tor
(HD, HM)
Attachment
Work equipment
B.C.V.
Breake Cooling oil con- Brake

trol Valve
(HD)
C.A.N.
Controller Area Network
Communication and electronic

control
Closed-center Load
Sensing System
Hydraulic
C.R.I.
Common Rail Injection
Engine
E.C.M.
Electronic Control ModElectronic control system

ule
C.L.S.S.
E.C.M.V.
Electronic Control Mod- Transmission

ulation Valve
(WA, D, HD, etc.)
Electronically ConTravel
E.C.S.S. trolled Suspension Sys(WA)
tem
D375A-6
Explanation
With this function, when the tires skid (wheels
stop rotating), the brakes are released, and
when the wheels start to rotate, the brakes
are applied again.
This function automatically sets the idling
speed.
Instead of a steering wheel, a lever is used to
carry out the steering operations as well as to
shift gear and change direction (forward or
reverse).
When the machine is traveling downhill, if the
accelerator pedal is released, this function
automatically applies the retarder with a constant braking force.
When the machine is traveling downhill, if the
accelerator pedal is released, this function
automatically applies the retarder to ensure
that the machine speed does not accelerate
above the speed set by the operator.
When the rear wheels spin on soft ground
surfaces, this function automatically uses the
optimum braking force to drive both wheels.
A device that can be fixed onto a machine in
order to enable it to do different jobs.
When the retarder is not being used, this
valve bypasses part of the brake cooling oil to
reduce the load on the hydraulic pump.
Communications standard standardized as
ISO11898.
System that can simultaneously actuate multiple actuators regardless of the load (provides
better ease of combined operation than
O.L.S.S.).
Uses engine controller to carry out electronic
control of supply pump, common rail, and
injector. Functions to maintain optimum fuel
injection amount and fuel injection timing.
Electronic control device that uses the signals
from the sensors on the machine to indicate
to the actuators the optimum actuation. (same
as ECU)
Proportional electromagnetic valve that gradually increases oil pressure to engage clutch
and reduces transmission shock.
System that ensures smooth high-speed
travel by using hydraulic spring effect of accumulator to absorb vibration of machine during
travel.
00-39
DRAFT
Abbreviation
Full Spelling
Purpose of use
component/
system)
E.C.U.
Electronic Control Unit
E.G.R.
Exhaust Gas RecirculaEngine

tion
E.M.M.S.
Electronic control system
Equipment ManageMachine monitor

ment Monitoring System
E.P.C.
Electromagnetic ProporHydraulic
tional Control
F-N-R
Forward-Neutral-Reverse
G.P.S.
Global Positioning Sys- Communication

tem
(KOMTRAX, VHMS)
H.S.S.
Hydrostatic Steering
System
Steering
(D)
H.S.T.
Hydro Static Transmission
Transmission
(WA, D: Small size)
I.M.A.
Inlet Metering Actruator Engine
I.M.V.
Inlet Metering Valve
Engine
L.C.D.
Liquid Crystal Display
Machine monitor
L.E.D.
Light Emitting Diode
Electronic parts
Load Sensing
Hydraulic
Multimedia Messaging
Service
Communication
N.C.
Normally Closed
Electronic and hydraulic
N.O.
Normally Open
Electronic and hydraulic
O.L.S.S.
Open-center Load
Sensing System
Hydraulic
P.C.
Pressure Control
Hydraulic
L.S.
M.M.S.
00-40
Operation
Explanation
Electronic control device that uses the signals
from the sensors on the machine to indicate
to the actuators the optimum actuation. (same
as ECM)
Functions to recirculate part of exhaust gas to
combustion chamber in order to reduce combustion temperature, controls emission of
Nox.
System that allows data (filter, oil replacement
interval, abnormalities on machine, failure
code, and failure history) from each sensor on
the machine to be checked on monitor.
Control system that moves an actuator in proportion to the amperage of an electric current
passing through the solenoid.
Position of the gear shift lever or switch.
System that is used to determine the current
location on the Earth of a ship, car, machine,
etc. by receiving the radio wave signals transmitted from the navigation satellites.
Steering function that uses a combination of
hydraulic motor and bevel shaft to control difference in travel speed of left and right tracks
to turn machine without using steering clutch.
Hydraulic transmission system that uses a
combination of hydraulic pump and hydraulic
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 discharge amount of supply pump. Same as
IMV.
fuel intake amount in order to control fuel discharge amount of supply pump. Described as
IMV (IMA).
Image display device made up of a large
number of pixels filled with liquid crystal.
Semiconductor element that emits light when
the voltage is applied in forward direction,
positive voltage to anode and negative voltage to cathode.
Function that senses differential pressure of
pump and controls discharge amount according to load.
Service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones.
Device actuated to open electric or hydraulic
circuits that are normally closed if not actuated.
Device actuated to close electric or hydraulic
circuits that are normally open if not actuated.
Hydraulic system that can operate multiple
actuators at the same time, regardless of the
load.
Controlling the oil pressure.
D375A-6
DRAFT
Abbreviation
Full Spelling
Palm Command ConP.C.C.S.

trol System
Steering
(D)
P.C.V.
Pump Control Valve
Engine
P.P.C.
Proportional Pressure
Control
Hydraulic
P.P.M.
Piston Pump and Motor
Hydraulic
(PC, D, etc.)
P.T.O.
Power Take Off
Power train
P.T.P.
Power Tilt and power

Pitch dozer
Work equipment
(D)
S.I.
Le System International
Unit
d' Unites
SOL.
Solenoid
Electronic
T.W.V.
Two Way Valve
Hydraulic and electronic
V.H.M.S.
*:
Purpose of use
component/
system)
Vehicle Health Monitor- Monitoring and communication

ing System
(PC, WA, D, HD: Large size)
Explanation
System in which a controller instantly analyses data from each lever, pedal, and dial, and
carries out optimum electronic control of the
engine and HST.
fuel intake amount in order to control fuel discharge amount of supply pump.
Control system that moves an actuator in proportion to the oil pressure.
Piston pump and motor.
A device to take off power of the engine in
order to drive a hydraulic pump, an air compressor, etc.
Function that carries out hydraulic control of
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 system, and is the world's most widely used system of measurement.
There're seven base units: meter (m), kilogram (kg), second (s), ampere (A), kelvin (K),
candela (cd), and mole (mol).
The derived units include Pascal (Pa), Newton (N), etc.
Solenoid is a loop of wire. However, as a matter of fact in engineering, it refers to an actuator consists of a solenoid and an iron core that
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
flow.
Communications system that transmits
machine data, such as the present position of
the machine, daily or aggregate hours of
operation, fuel consumption, radiator water
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
00-42
SW
Switch
T/C
Torque Converter
T/M
Transmission
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 method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.
1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal
line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to
the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches
(A)
D375A-6
(B)
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.017
2.441
2.835
3.228
3.622
2.087
2.480
2.847
3.268
3.661
2.126
2.520
2.913
3.307
3.701
5
0.197
0.591
0.984
1.378
1.772
(C)
2.165
2.559
2.953
3.346
3.740
6
0.236
0.630
1.024
1.417
1.811
7
0.276
0.669
1.063
1.457
1.850
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
1 mm = 0.03937 in
8
9
0.315
0.354
0.709
0.748
1.102
1.142
1.496
1.536
1.890
1.929
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
00-43
DRAFT
Conversion table
Millimeters to inches
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
5
0.197
0.591
0.984
1.378
1.772
5
0.236
0.630
1.024
1.417
1.811
7
0.276
0.669
1.063
1.457
1.850
1 mm = 0.03937 in
8
9
0.315
0.354
0.709
0.748
1.102
1.142
1.496
1.536
1.890
1.929
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.017
2.441
2.835
3.228
3.622
2.087
2.480
2.847
3.268
3.661
2.126
2.520
2.913
3.307
3.701
2.165
2.559
2.953
3.346
3.740
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
2.283
2.677
3.071
3.465
3.858
0
10
20
30
40
0
0
22.05
44.09
66.14
88.18
1
2.20
24.25
46.30
68.34
90.39
2
4.41
26.46
48.50
70.55
92.59
3
6.61
28.66
50.71
72.75
94.80
4
8.82
30.86
51.91
74.96
97.00
5
11.02
33.07
55.12
77.16
99.21
6
13.23
35.27
57.32
79.37
101.41
7
15.43
37.48
59.53
81.57
103.62
1 kg = 2.2046 lb
8
9
17.64
19.84
39.68
41.89
61.73
63.93
83.78
85.98
105.82
108.03
50
60
70
80
90
110.23
132.28
154.32
176.37
198.42
112.44
134.48
156.53
178.57
200.62
114.64
136.69
158.73
180.78
202.83
116.85
138.89
160.94
182.98
205.03
119.05
141.10
163.14
185.19
207.24
121.25
143.30
165.35
187.39
209.44
123.46
145.51
167.55
189.60
211.64
125.66
147.71
169.76
191.80
213.85
127.87
149.91
171.96
194.01
216.05
0
10
20
30
40
0
0
2.642
5.283
7.925
10.567
1
0.264
2.906
5.548
8.189
10.831
2
0.528
3.170
5.812
8.454
11.095
3
0.793
3.434
6.076
8.718
11.359
4
1.057
3.698
6.340
8.982
11.624
5
1.321
3.963
6.604
9.246
11.888
6
1.585
4.227
6.869
9.510
12.152
7
1.849
4.491
7.133
9.774
12.416
1l= 0.2642 U.S.Gal

8
9
2.113
2.378
4.755
5.019
7.397
7.661
10.039
10.303
12.680
12.944
50
60
70
80
90
13.209
15.850
18.492
21.134
23.775
13.473
16.115
18.756
21.398
24.040
13.737
16.379
19.020
21.662
24.304
14.001
16.643
19.285
21.926
24.568
14.265
16.907
19.549
22.190
24.832
14.529
17.171
19.813
22.455
25.096
14.795
17.435
20.077
22.719
25.361
15.058
17.700
20.341
22.983
25.625
15.322
17.964
20.605
23.247
25.889
2.323
2.717
3.110
3.504
3.898
Kilogram to pound
130.07
152.12
174.17
196.21
218.26
Liters to U.S. Gallons
00-44
15.586
18.228
20.870
23.511
26.153
D375A-6
DRAFT
Conversion table
Liters to U.K. Gallons

1l = 0.21997 U.K.Gal
8
9
1.760
1.980
3.950
4.179
6.159
6.379
8.359
8.579
10.559
10.778
0
10
20
30
40
0
0
2.200
4.399
6.599
8.799
1
0.220
2.420
4.619
6.819
9.019
2
0.440
2.640
4.839
7.039
9.239
3
0.660
2.860
5.059
7.259
9.459
4
0.880
3.080
5.279
7.479
9.679
5
1.100
3.300
5.499
7.699
9.899
6
1.320
3.520
5.719
7.919
10.119
7
1.540
3.740
5.939
8.139
10.339
50
60
70
80
90
10.998
13.198
15.398
17.598
19.797
11.281
13.418
15.618
17.818
20.017
11.438
13.638
15.838
18.037
20.237
11.658
13.858
16.058
18.257
20.457
11.878
14.078
16.278
18.477
20.677
12.098
14.298
16.498
18.697
20.897
12.318
14.518
16.718
18.917
21.117
12.528
14.738
16.938
19.137
21.337
0
10
20
30
40
0
0
72.3
144.7
217.0
289.3
1
7.2
79.6
151.9
224.2
296.6
2
14.5
86.8
159.1
231.5
303.8
3
21.7
94.0
166.4
238.7
311.0
4
28.9
101.3
173.6
245.9
318.3
5
36.2
108.5
180.8
253.2
325.5
6
43.4
115.7
188.1
260.4
332.7
7
50.6
123.0
195.3
267.6
340.0
1 kgm = 7.233 ft.lb

8
9
57.9
65.1
130.2
137.4
202.5
209.8
274.9
282.1
347.2
354.4
50
60
70
80
90
361.7
434.0
506.3
578.6
651.0
368.9
441.2
513.5
585.9
658.2
376.1
448.5
520.8
593.1
665.4
383.4
455.7
528.0
600.3
672.7
390.6
462.9
535.2
607.6
679.9
397.8
470.2
542.5
614.8
687.1
405.1
477.4
549.7
622.0
694.4
412.3
484.6
556.9
629.3
701.6
419.5
491.8
564.2
636.5
708.8
426.8
499.1
571.4
643.7
716.1
100
110
120
130
140
723.3
795.6
868.0
940.3
1012.6
730.5
802.9
875.2
947.5
1019.9
737.8
810.1
882.4
954.8
1027.1
745.0
817.3
889.7
962.0
1034.3
752.2
824.6
896.9
969.2
1041.5
759.5
831.8
904.1
976.5
1048.8
766.7
839.0
911.4
983.7
1056.0
773.9
846.3
918.6
990.9
1063.2
781.2
853.5
925.8
998.2
1070.5
788.4
860.7
933.1
1005.4
1077.7
150
160
170
180
190
1084.9
1157.3
1129.6
1301.9
1374.3
1092.2
1164.5
1236.8
1309.2
1381.5
1099.4
1171.7
1244.1
1316.4
1388.7
1106.6
1179.0
1251.3
1323.6
1396.0
1113.9
1186.2
1258.5
1330.9
1403.2
1121.1
1193.4
1265.8
1338.1
1410.4
1128.3
1200.7
1273.0
1345.3
1417.7
1135.6
1207.9
1280.1
1352.6
1424.9
1142.8
1215.1
1287.5
1359.8
1432.1
1150.0
1222.4
1294.7
1367.0
1439.4
12.758
14.958
17.158
19.357
21.557
12.978
15.178
17.378
19.577
21.777
kgm to ft.lb
D375A-6
00-45
DRAFT
Conversion table
kg/cm2 to lb/in2
0
10
20
30
40
0
0
142.2
284.5
426.7
568.9
1
14.2
156.5
298.7
440.9
583.2
2
28.4
170.7
312.9
455.1
597.4
3
42.7
184.9
327.1
469.4
611.6
4
56.9
199.1
341.4
483.6
625.8
5
71.1
213.4
355.6
497.8
640.1
6
85.3
227.6
369.8
512.0
654.3
1 kg/cm2 = 14.2233 lb/in2

7
8
9
99.6
113.8
128.0
241.8
256.0
270.2
384.0
398.3
412.5
526.3
540.5
554.7
668.5
682.7
696.9
50
60
70
80
90
711.2
853.4
995.6
1,138
1,280
725.4
867.6
1,010
1,152
1,294
739.6
881.8
1,024
1,166
1,309
753.8
896.1
1,038
1,181
1,323
768.1
910.3
1,053
1,195
1,337
782.3
924.5
1,067
1,209
1,351
796.5
938.7
1,081
1,223
1,365
810.7
953.0
1,095
1,237
1,380
825.0
967.2
1,109
1,252
1,394
839.2
981.4
1,124
1,266
1,408
100
110
120
130
140
1,422
1,565
1,707
1,849
1,991
1,437
1,579
1,721
1,863
2,005
1,451
1,593
1,735
1,877
2,020
1,465
1,607
1,749
1,892
2,034
1,479
1,621
1,764
1,906
2,048
1,493
1,636
1,778
1,920
2,062
1,508
1,650
1,792
1,934
2,077
1,522
1,664
1,806
1,949
2,091
1,536
1,678
1,821
1,963
2,105
1,550
1,693
1,835
1,977
2,119
150
160
170
180
190
2,134
2,276
2,418
2,560
2,702
2,148
2,290
2,432
2,574
2,717
2,162
2,304
2,446
2,589
2,731
2,176
2,318
2,460
2,603
2,745
2,190
2,333
2,475
2,617
2,759
2,205
2,347
2,489
2,631
2,773
2,219
2,361
2,503
2,646
2,788
2,233
2,375
2,518
2,660
2,802
2,247
2,389
2,532
2,674
2,816
2,262
2,404
2,546
2,688
2,830
200
210
220
230
240
2,845
2,987
3,129
3,271
3,414
2,859
3,001
3,143
3,286
3,428
2,873
3,015
3,158
3,300
3,442
2,887
3,030
3,172
3,314
3,456
2,901
3,044
3,186
3,328
3,470
2,916
3,058
3,200
3,343
3,485
2,930
3,072
3,214
3,357
3,499
2,944
3,086
3,229
3,371
3,513
2,958
3,101
3,243
3,385
3,527
2,973
3,115
3,257
3,399
3,542
00-46
D375A-6
DRAFT
Conversion table
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit
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.
C
40.4
37.2
34.4
31.7
28.9
F
114.8
116.6
118.4
120.2
122.0
C
27.2
27.8
28.3
28.9
29.4
1C = 33.8F
F
81
177.8
82
179.6
83
181.4
84
183.2
85
185.0
54
55
123.8
125.6
127.4
129.2
131.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
13.3
13.9
14.4
15.0
15.6
56
57
58
59
60
132.8
134.6
136.4
138.2
140.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
78.8
80.6
82.4
84.2
86.0
16.1
16.7
17.2
17.8
18.3
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
35.6
36.1
36.7
37.2
37.8
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
18.9
19.4
20.0
20.6
21.1
66
68
69
69
70
150.8
152.6
154.4
156.2
158.0
40.6
43.3
46.1
48.9
51.7
105
110
115
120
125
221.0
230.0
239.0
248.0
257.0
2.2
2.8
3.3
3.9
4.4
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
54.4
57.2
60.0
62.7
65.6
130
135
140
145
150
266.0
275.0
284.0
293.0
302.0
5.0
5.6
6.1
6.7
7.2
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
68.3
71.1
73.9
76.7
79.4
155
160
165
170
175
311.0
320.0
329.0
338.0
347.0
40
35
30
25
20
F
40.0
31.0
22.0
13.0
4.0
C
11.7
11.1
10.6
10.0
9.4
11
12
13
14
15
F
51.8
53.6
55.4
57.2
59.0
C
7.8
8.3
8.9
9.4
10.0
28.3
27.8
27.2
26.7
26.1
19
18
17
16
15
2.2
0.4
1.4
3.2
5.0
8.9
8.3
7.8
7.2
6.7
16
47
18
19
20
60.8
62.6
64.4
66.2
68.0
10.6
11.1
11.7
12.2
12.8
51
52
25.6
25.0
24.4
23.9
23.3
14
13
12
11
10
6.8
8.6
10.4
12.2
14.0
6.1
5.6
5.0
4.4
3.9
21
22
23
24
25
69.8
71.6
73.4
75.2
77.0
22.8
22.2
21.7
21.1
20.6
9
8
7
6
5
15.8
17.6
19.4
21.2
23.0
3.3
2.8
2.2
1.7
1.1
26
27
28
29
30
20.0
19.4
18.9
18.3
17.8
4
3
2
1
0
24.8
26.6
28.4
30.2
32.0
0.6
0
0.6
1.1
1.7
17.2
16.7
16.1
15.6
15.0
1
2
3
4
5
33.8
35.6
37.4
39.2
41.0
14.4
13.9
13.3
12.8
12.2
6
7
8
9
10
42.8
44.6
46.4
48.2
50.0
D375A-6
46
47
48
49
50
00-47
DRAFT
Conversion table
00-48
D375A-6
DRAFT
D375A-6
SEN05011-00
Bulldozer
Shop Manual
D375A-6
Machine model
D375A-6
Serial number
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 ...................................................................................................................................
Specifications...............................................................................................................................................
Weight table .................................................................................................................................................
Table of fuel, coolant and lubricants ............................................................................................................
01-2
01 3
01 4
01 9
01 - 11
D375A-6
DRAFT
Specification drawing

Item
A
B
C
Overall
length
Overall
height
(with ROPS)
Overall width
D375A-6
Unit
Sem i - U tilt dozer +

Giant ripper
Full - U tilt dozer +

Giant ripper
Semi - U tilt dozer + Full - U tilt dozer +

Multi - shank ripper Multi - shank ripper
mm
10,485
10,845
10,195
10,555
mm
4,265
(4,285)
4,265
(4,285)
4,265
(4,285)
4,265
(4,285)
mm
4,774
5,215
4,774
5,215
01-3
DRAFT
Specifications
Weight
Specifications
Machine model
D375A-6
Serial number
60001 and up
Machine weight
q Bare tractor
q Ditto with semi - U dozer
q Ditto with variable multi - shank ripper
q Ditto with ROPS cab + Air conditioner + Seat
belt + Perforated side cover + SSC
q
q
53,200
64,160
70,960
72,230
kg
65,665
Bare tractor with full - U dozer

Ditto with variable giant ripper
71,865
73,135
m
deg.
deg.
4.2
30
35
Forward
1st
2nd
3rd (low speed)
3rd
km/h
0 3.5
0 6.8
0 8.0
0 11.8
Reverse
1st
2nd
3rd (low speed)
3rd
km/h
0 4.6
0 8.9
0 9.7
0 15.8
Forward
1st
2nd
3rd
km/h
0 3.5
0 6.8
0 11.8
Reverse
Transmission speed ranges (man- Transmission speed ranges (autoual gear shift mode)
matic gear shift mode)
Performance
Ditto with ROPS cab + Air conditioner + Seat

belt + Perforated side cover + SSC
Min. turning radius
Gradeability
Stability (front, rear, left, right)
1st
2nd
3rd
km/h
0 4.6
0 8.7
0 14.7
Ground pressure (610 shoe)
q
q
01-4
q
q
q
q
q
Bare tractor
With semi - U dozer
With full - U dozer
With semi - U dozer and variable
multi-shank ripper
107.87 {1.10}
129.45 {1.32}
132.39 {1.35}
143.18 {1.46}
Ditto with ROPS cab + Air conditioner

+ Seat belt + Perforated side cover +
kPa {kg/cm2}
SSC belt, perforated side cover, and
SSC
With full-U dozer and variable giant
ripper
Ditto with ROPS cab + Air conditioner
+ Seat belt + Perforated side cover +
SSC
146.12 {1.49}
145.14 {1.48}
148.08 {1.51}
D375A-6
Dimensions
Overall height Overall width
Dimensions
Overall length
Specification dimension drawings

Specifications
Machine model
D375A-6
Serial number
60001 and up
Bare tractor
With semi-U dozer
With full-U dozer
With semi-U dozer + variable multi-shank ripper
With full-U dozer + variable multi-shank ripper
mm
5,905
7,780
8,140
10,195
10,845
Bare tractor
With semi-U dozer
With full-U dozer
mm
3,240
4,695
5,140
To tip of exhaust pipe

To top of air intake duct
mm
4,265
3,525
mm
2,500
3,980
610
662
Track gauge
Length of track on ground
Track shoe width
Maximum ground clearance
Model
Type
Performance
Engine
No. of cylinders bore x stroke

Piston displacement
Flywheel horsepower (ISO 9249)
Max. torque
Max. high idle speed
Min. low idle speed
Min. fuel consumption ratio
Starting motor
Alternator
Battery
Radiator core type
Torque converter
Power train
Transmission
Bevel gear shaft

Steering clutch
Steering brake
Final drive
D375A-6
(04)
mm
l {cc}
kW {HP} /rpm
Nm {kgm} / rpm
rpm
rpm
g/kWh
{g/HPh}
SAA6D170E-5
4-cycle, water-cooled, in-line vertical,
direct injection type with turbocharger
and aftercooler
6 - 170 x 170
23.15 {23,150}
455 {609} / 1,800
2,730 {278} / 1,300
1,900
750
208 {155}
24 V, 7.5 kW x 2
24 V, 60 A
12 V, 170 Ah x 2
Rectangle corrugated fin
3 - element, 1 - stage, 1 - phase (with
lockup clutch)
Planetary gear and multiple disc clutch
type, hydraulically actuated forced lubricated, forward 3 - speed, reverse 3 speed
Spiral bevel gear type, splash lubrication
type
Wet, multiple disc clutch type, spring loaded and hydraulically released (lever
operated), interconnected with brake
Wet, multiple disc clutch type, spring actuated, hydraulically released (pedal /
lever operated ), interconnected with
clutch
Single reduction spur gear single reduction , planetary gear , lubricating oil
splash lubrication type
01-5
DRAFT
Undercarriage

Specifications
Machine model
D375A-6
Serial number
60001 and up
Rigid, equalizer bar
2 each side
8 each side
Assembly type, single grouser, 41 each side,
pitch: 280.0 mm , width: 610 mm
Suspension
Carrier roller
Track roller
Track shoe
Power train + Lubricating oil pump (tandem)
Gear type (BAL180 + 112)
Scavenging pump (tandem)
Gear type (BAR63 + 277)
Cooling fan pump
MPa {kg/cm2}
l/min / rpm
Cooling fan motor
MPa {kg/cm2}
Variable swash plate type (LPV90 + 30)

Max. delivery pressure: 18.1 {184}
Theoretical delivery: 231/1,926
Fixed swash plate type (LMF 150)
Max. allowable working pressure: 18.1 {184}
MPa {kg/cm2}
27.5 {280}
l/min
Variable swash plate type (HPV190)

366
Hydraulic
pump
Type
Delivery (engine speed at 1,800rpm)
Control valve
Machines with single tilt blade and

variable ripper
q For ripper tilt cylinder
q For ripper lift cylinder
q For blade tilt cylinder
q For blade lift cylinder
Machines with dual tilt blade and variable ripper
q For ripper tilt cylinder
q For ripper lift cylinder
q For blade tilt L.H cylinder
q For blade tilt R.H cylinder
01-6
1 + 1 + 1 + 2 spool type, hydraulic assisted, PPC

type
+ Ripper tilt (in, back)
+ Ripper tilt (raise, lower)
+ Blade tilt
+ Blade lift 2 (raise, lower)
1 + 1 + 2 + 2 spool type, hydraulic assisted, PPC
type
+ Ripper tilt (in, back)
+ Ripper lift (raise, lower)
+ Blade tilt (single, dual and pitch)
+ Blade tilt (dual and pitch)
+ Blade lift 2 (raise, lower)
Dimensions of blade lift

cylinder
double acting piston
Cylinder bore
Piston rod outside diameter
Piston stroke
Max. between pins distance
Min. between pins distance
Dimensions of blade tilt

cylinder
Type
Hydraulic cylinder
Work equipment hydraulic system
Max. pressure
Cylinder bore
Piston stroke
mm
140
90
1,721
2,495
774
mm
200
110
240
1,703
1,463
D375A-6
Dimensions of ripper tilt cylinder Dimensions of ripper lift cylinder
Hydraulic cylinder
Work equipment hydraulic system
Dimensions of blade dual

tilt cylinder

Specifications
Machine model
D375A-6
Serial number
60001 and up
Cylinder bore
200

(both right and left)
110
Piston stroke (both right and left)
mm
Max. distance between pins

Min. distance between pins
Cylinder bore
Piston stroke
Cylinder bore
Piston stroke
1,675
1,490
mm
200
110
495
1,855
1,360
mm
180
110
550
1,800
1,250
Hydraulic tank
Box type (control valve externally installed)

Hydraulic semi-U tilt dozer
Hydraulic full-U tilt dozer
Type
Single tilt
Left: Brace type
Right: Tilt cylinder type
Dual tilt
Left: Tilt cylinder type (for single tilt/dual tilt pitch)
Right: Tilt cylinder type (for dual tilt pitch)
Performance
Max. lift above ground

Max. drop below ground
Max. adjustment tilt
Hydraulic oil tilt (single)
Blade cutting angle adjustment
Blade capacity
mm
mm
mm
mm
deg.
m3
Dimensions
Semi-U dozer
Work equipment
Blade supporting method
D375A-6
(04)
185
Blade width
Blade height
Blade cutting angle
mm
mm
deg.
1,660
715
990
770
5
24.0 <SAE18.5>
4,774
2,265 (with spill guard: 2,525)
55
01-7
DRAFT
Specifications
Machine model
D375A-6
01-8
Performance

Max.drop below ground
Max. adjustment tilt
Hydraulic oil tilt (single)
Blade cutting angle adjustment
Blade capacity
1,660
715
1,080
840
5
26.3 <SAE22.0>
Dimensions
Blade width
Blade height
Blade cutting angle
mm
mm
deg.
5,215
2,265 (with spill guard: 2,525)
55
Performance
Max. hydraulic oil tilt

Max. pitch angle
Blade cutting angle
mm
deg.
deg.
1,185
Forward 4.7 / Backward 5.2
55
Dimensions
60001 and up
mm
mm
mm
mm
deg.
m3
Max. hydraulic oil tilt

Max. pitch angle
Blade cutting angle
mm
deg.
deg.
1,295
Forward 4.7 / Backward 5.2
55
Max. digging depth

Point digging angle
mm
mm
deg.
1,140
1,135
45 (Stepless adjustment between 31.4 54.7)
mm
No. of holes
2,910
2
mm
mm
deg.
1,485
1,100
45 (Stepless adjustment between 31.6 55.0)
mm
No. of holes
1,600
3
Dimensions Performance Dimensions Performance
Full - U dozer + Pitch Semi - U dozer + Pitch

Giant ripper
Multi - shank ripper
Work equipment
Full - U dozer
Serial number
Max. beam width

Shank positions
Max. digging depth

Point digging angle
Max. beam width

Shank positions
D375A-6

Weight table
Weight table
k
01-9
This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Machine model
D375A-6
Serial number
60001 and up
Engine, damper assembly

q Engine assembly
q Damper assembly
q Engine mounting parts
Radiator assembly
Oil cooler assembly
Fuel tank assembly (when full)
Power train unit
q Torque converter and PTO assembly
q Transmission assembly
q Transmission valve assembly
q Steering clutch and brake assembly
q Steering valve assembly
Final drive assembly
Main frame assembly
Track group assembly (each side)

q Track frame
q Idler assembly
q Track roller assembly (each single flange x each side)
q Track roller assembly (each double flange x each side)
q Carrier roller assembly (each x each side)
q First bogie and track roller assembly
q Each of second fourth bogie and track roller assembly
q Final bogie and track roller assembly
Track shoe assembly (610 mm )

Pivot shaft
Equalizer bar assembly
Hydraulic tank assembly (excluding oil )
Control valve (for single tilt)
Control valve (for dual tilt)
D375A-6
(06)
3,320
3,065
185
70
465
92
580 (1,600)
4,220
795
1,000
13
1,712
13
2,200 2
5,541
7,902
1,896
478
159 2
160 6
71 2
457
742 3
359
4,305 2
210 2
500
236
119
125
01-9

Weight table
Unit: kg
Machine model
D375A-6
Serial number
60001 and up
Semi-U dozer assembly (excluding oil)

q Single tilt
q Dual tilt
Reinforced type semi-U dozer assembly
q Single tilt
q Dual tilt
Reinforced type full-U dozer assembly
q Single tilt
q Dual tilt
Semi-U blade assembly
Reinforced type semi-U blade assembly
Reinforced type full-U blade assembly (with spill guard)
Straight frame
Tilt cylinder (excluding oil)
q Single tilt
q Dual tilt
Variable multi-shank ripper assembly (excluding oil)
q Shank assembly
q Ripper lift cylinder assembly
q Ripper tilt cylinder assembly
Variable giant ripper assembly (excluding oil)
q Shank assembly
q Ripper lift cylinder assembly
q Ripper tilt cylinder assembly
Radiator guard assembly (including cylinder yoke)
q Radiator guard
q Blade lift cylinder assembly
Radiator mask
Engine underguard
Power train underguard (front)
Power train underguard (rear)
Hood and side cover assembly (including air cleaner)
Fender (left)
Fender (right)
ROPS assembly
Floor frame assembly
Cab assembly
Operator seat assembly (with mechanical suspension)
Operator seat assembly (with air suspension)
01-10
10,100
10,180
10,470
18,650
11,500
11,680
6,750
7,220
8,250
1,350 2
275
270 2
6,755
470 3
270 2
240 2
6,155
650 1
270 2
240 2
2,870
1,342
290 2
140
275
220
320
337
331
372
703
591
570
64
58
D375A-6
(06)
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

(both sides)
61
61
Hydraulic oil system

q Single tilt, without ripper
q Single tilt with variable rippers
q Dual tilt with variable rippers
230
275
280
130
Cooling system
120
1,200
Fuel tank
01-12
D375A-6
DRAFT
D375A-6
SEN05013-00
Bulldozer
Shop Manual
D375A-6
Machine model
D375A-6
Serial number
60001 and up
10 Structure and function
D375A-6
10-1
Table of contents
Table of contents
10 Structure, function and maintenance standard
Engine and cooling system .....................................................................................................
Cooling system ....................................................................................................................
Cooling fan pump.................................................................................................................
Cooling fan motor.................................................................................................................
Power train..............................................................................................................................
Power train...........................................................................................................................
Overall drawing of power train unit ......................................................................................
Power train hydraulic equipment arrangement drawing.......................................................
Damper and universal joint ..................................................................................................
Torque converter and PTO ..................................................................................................
Torque converter control valve ............................................................................................
Main relief valve and torque converter relief valve...............................................................
Lockup clutch ECMV and stator clutch ECMV.....................................................................
Scavenging pump ................................................................................................................
Transmission control............................................................................................................
PCCS lever ..........................................................................................................................
Transmission........................................................................................................................
Transmission ECMV ............................................................................................................
Transmission lubricating oil relief valve ...............................................................................
Steering and brake control...................................................................................................
Transfer unit, bevel gear shaft and steering ........................................................................
Steering control valve ..........................................................................................................
Steering clutch ECMV and Steering brake ECMV ...............................................................
Parking brake valve .............................................................................................................
Sudden stop prevention valve..............................................................................................
Final drive ............................................................................................................................
Undercarriage and frame ........................................................................................................
Track frame..........................................................................................................................
Idler cushion.........................................................................................................................
Track roller bogie .................................................................................................................
Main frame ...........................................................................................................................
Suspension ..........................................................................................................................
Hydraulic system.....................................................................................................................
Work equipment hydraulic piping diagram...........................................................................
PPC control piping diagram .................................................................................................
Work equipment control .......................................................................................................
Hydraulic tank ......................................................................................................................
Accumulator .........................................................................................................................
PPC lock valve.....................................................................................................................
PPC valve ............................................................................................................................
Piston valve..........................................................................................................................
Quick drop valve ..................................................................................................................
Pin puller switch ...................................................................................................................
Pin puller solenoid valve ......................................................................................................
Blade control lever (only for the machine with dual tilt specification)...................................
Work equipment pump.........................................................................................................
Control valve ........................................................................................................................
Self-pressure reducing valve ...............................................................................................
Work equipment......................................................................................................................
Cylinder stay ........................................................................................................................
10-2
10-2
10- 4
10- 4
10- 6
10- 26
10- 32
10- 32
10- 34
10- 36
10- 38
10- 40
10- 46
10- 48
10- 50
10- 55
10- 56
10- 58
10- 62
10- 76
10- 81
10- 82
10- 84
10- 90
10- 92
10- 99
10- 101
10- 103
10- 108
10- 108
10- 110
10- 111
10- 112
10- 114
10- 117
10- 117
10- 121
10- 122
10- 124
10- 126
10- 127
10- 129
10- 140
10- 141
10- 142
10- 143
10- 145
10- 146
10- 158
10- 173
10- 180
10- 180
D375A-6
(04)
Table of contents
Cab .........................................................................................................................................
Cab mount ...........................................................................................................................
Cab ......................................................................................................................................
Electrical system .....................................................................................................................
Engine control......................................................................................................................
Engine control system .........................................................................................................
CRI engine control system...................................................................................................
Monitor system ....................................................................................................................
Machine monitor ..................................................................................................................
Lamp system .......................................................................................................................
Engine preheat (electrical intake air heater) control ............................................................
Palm command control system............................................................................................
Sensor .................................................................................................................................
Vehicle health monitoring system (VHMS) ..........................................................................
ORBCOMM system .............................................................................................................
D375A-6
(04)
10- 181
10- 181
10- 182
10- 184
10- 184
10- 185
10- 194
10- 196
10- 198
10- 215
10- 216
10- 217
10- 220
10- 224
10- 230
10-3
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
Core type
Rectangle corrugated
fin
PTO-OL
Fin pitch(mm)
8.0/2
8.0/2
8.0/2
Total heat dissipation surface(m2)
49.09 3
3.77
4.09
27.39 2
88.3 14.7
{0.9 0.15}
0 4.9
{0 0.05}
Cracking pressure of pressure valve

(kPa {kg/cm2})
Cracking pressure of vacuum valve
(kPa {kg/cm2})
D375A-6
Hydraulic oil cooler
Aftercooler
Rectangle corrugated
Rectangle straight fin
fin
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

PA: Pump discharge port
PDI: Drain port
PD2: Drain port (Plug)
PDA: Breather
PEN: Control pressure pickup port (Plug)
PEPC: EPC source pressure input port
PS: Pump suction port
10-8
1. Shaft
2. Cradle
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
D375A-6
DRAFT
Cooling fan pump
Function
q The rotation and torque of the engine are transmitted to the shaft of this pump. Then, this pump
converts the rotation and torque into hydraulic
pressure and discharges pressurized oil according to the load.
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 bearings (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
q
q
The hydraulic balance is maintained properly on

this face.
The oil is sucked into and discharged from each
cylinder in cylinder block (7) through valve plate
(8).
10-9
DRAFT
Cooling fan pump
Operation
Operation of pump
q Cylinder block (7) rotates together with shaft (1)
and shoe (5) slides on plane (A).
q Rocker cam (4) moves along cylindrical face (B).
As a result, angle (a) between center line (X) of
rocker cam (4) and the axis of cylinder block (7)
changes.
q Angle (a) is called the swash plate angle.
q
q
q
q
If center line (X) of rocker cam (4) matches the

axis of cylinder block (7) (the swash plate angle
= 0), the difference between volumes (E) and (F)
in cylinder block (7) is 0.
No oil is sucked or discharged and a pumping
action is not performed. (The swash plate angle
is not set to 0 actually, however.)
The pump delivery is in proportion of swash plate

angle (a).
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).
Piston (6) reciprocates inside cylinder block (7)
and a difference is made between volumes (E)
and (F) of cylinder chamber in cylinder block (7).
Each piston (6) sucks and discharges oil by (F) (E).
If cylinder block (7) rotates and the volume of
chamber (E) is decreased, the oil is discharged
from chamber (E) during this process.
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 difference between volumes (E) and (F) is increased,
or delivery (Q) is increased.
q Swash plate angle (a) is changed with servo piston (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 cylindrical surface of cradle (2) is tilted in the axial direction.
q The pressure receiving area of the top of servo
piston (1) is different from that of the bottom.
Main pump discharge pressure (self-pressure)
(PA) is kept led in the pressure chamber on the
small-diameter piston side (upper side).
q PC valve output pressure (PEN) is led in the
pressure chamber on the large-diameter piston
side (lower side).
q The movement of servo piston (1) is controlled
according to the difference between pressure
(PA) on the small-diameter piston side and pressure (PEN) on the large-diameter piston side
and the ratio of the pressure receiving area of
the small-diameter piston to that of the large-diameter piston.
D375A-6
10-11
DRAFT
Cooling fan pump
PC valve, EPC valve, and servo piston
IM: Control current input connector

PEPC: EPC source pressure input port
Servo piston
1. Servo piston
2. Lever
3. Spring
PC valve
4. Piston
5. Seat
6. Spring
7. Spool
8. Sleeve
9. Plug
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.
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).
Port (f) is connected to port (g) and the pump discharge oil at pressure (PA) flows through port (g)
to port (f). Port (f) is disconnected from the drain
circuit.
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).
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), however, servo piston (1) moves toward the minimum swash plate angle side (upper side).
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.
If spool (7) moves to the right and port (f) is disconnected from port (g), servo piston (1) stops
moving up.
At this time, servo piston (1) stops at a place
higher (nearer to the minimum swash plate angle) than when the EPC discharge pressure is
low.
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 circuit.
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 pressure 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

P1: Pump discharge port
PAEPC: EPC output pressure pickup port
PE: Servo piston control pressure input port
PEPC: EPC valve source pressure input port
PH: Pump discharge pressure output port
TO: Drain port
10-18
1.
2.
3.
4.
piston pump
Servo valve
Bleeder
EPC value
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 rotation and torque of the engine are transmitted to the shaft of this pump. Then, this pump
converts the rotation and torque into hydraulic
energy and discharges hydraulic oil according to
the load.
The discharge of this pump can be changed by
changing the swash plate angle in it.
The oil is sucked into and discharged from each

cylinder chamber of cylinder block (7) through
valve plate (8).
Structure
q
q
q
q
q
q
q
q
q
Cylinder block (7) is connected to shaft (1)

through splines (B).
Shaft (1) is supported by the front and rear bearings (12).
The tip of piston (6) has a spherical hollow in
which shoe (5) is being held by crimping.
Piston (6) and shoe (5) form a spherical bearing.
Shoe (5) is kept pressed against plane (A) of
rocket cam (4) and slids circularly.
Rocker cam (4) pivot on ball (11).
Piston (6) in each cylinder of cylinder block (7)
reciprocates in the axial direction.
Cylinder block (7) rotates relatively against valve
plate (8) sealing the hydraulic oil.
The hydraulic balance on the valve plate is maintained properly.
10-20
D375A-6
DRAFT
Cooling fan pump
Operation
Operation of pump
q Cylinder block (7) rotates together with shaft (1)
and shoe (5) slides on plane (A).
q Rocker cam (4) pivots on ball (11). As a result,
angle (a) between center line (X) of rocker cam
(4) and the axis of cylinder block (7) changes.
q Angle (a) is called the swash plate angle.
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) 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).
D375A-6
If center line (X) of rocker cam (4) matches the

axis of cylinder block (7) (the swash plate angle
is 0), there is no difference between volumes (E)
and (F) in cylinder block (7). The hydraulic oil is
not sucked or discharged.
(The swash plate angle is not set to 0 actually,
however.)
The pump delivery is in proportion to swash plate

angle (a) .
10-21
DRAFT
Cooling fan pump
Control of discharge
q If swash plate angle (a) is increased, the difference between volumes (E) and (F) is increased,
or delivery (Q) is increased.
q Swash plate angle (a) is changed with servo piston (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) pivots on ball (11).
10-22
D375A-6
DRAFT
Cooling fan pump
Servo valve
P: EPC valve source pressure input port

PE: Servo piston control pressure output port
PH: Pump discharge pressure input port
T: Drain port
D375A-6
1.
2.
3.
4.
5.
6.
7.
Plug
Lever
Retainer
Seat
Spool
Piston
Sleeve
10-23
DRAFT
Cooling fan pump
A: Drain side
B: Pump discharge pressure input side
C: EPC output pressure receiving pressure
10-24
D: EPC output pressure side

P: EPC source pressure input side
D375A-6
DRAFT
Cooling fan pump
Function
q The servo valve controls the servo piston so that
the delivery (swash plate angle) is related to the
current input to the EPC valve as shown in the
figure below.
The relationship between the EPC valve input

current (i) and EPC valve output pressure (F) is
as shown in the figure below.
D375A-6
Operation
q The output oil of the EPC valve flows in the piston chamber (C) to push piston (6). Piston (6)
moves spool (5) to a position where the thrust is
balanced with the force of the spring.
q Then, port (PE) of the servo piston pressure passage is connected to the pump discharge passage by the notch of spool (5) and the oil at
pump discharge pressure is led to the servo piston.
q The servo piston raises the rocker cam. The position feedback is applied and the lever moves to
compress the spring.
q If spool (5) is pushed back, the pump discharge
pressure passage is disconnected from the servo piston circuit. The pressure in the servo piston
chamber lowers and the rocker cam returns toward the position for the maximum swash plate
angle.
q These processes are repeated until the swash
plate stabilizes at an angle where the EPC output pressure is balanced with the force exerted
by the spring force.
q Accordingly, as the EPC output pressure increases, the swash plate angle decreases. As
the EPC output pressure lowers, the swash plate
angle increases.
10-25

Cooling fan motor
Cooling fan motor
10-26
Type: LMF180 (150)

Appearance
P: From fan pump

T: To tank through cooler
TC: To tank
10-26
10-26
10-26
Type: LMF150
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}
Specifications
D375A-6
(04)
DRAFT
Cooling fan motor
Sectional view
1.
2.
3.
4.
5.
6.
Output shaft
Case
Thrust plate
Shoe
Piston
Cylinder block
D375A-6
7. Valve plate
8. End cover
9. Center spring
10. Suction safety valve
11. ON/OFF pilot valve
12. Reversible valve spool
13. Speed sensor
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 connecting the top dead center and bottom dead center
of the stroke of piston (4)
q The oil sent to one side of cylinder block (5)
presses 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 ) degrees 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)] rotates cylinder block (5) through the piston.
q Since this cylinder block (5) is splined to the output shaft, the output shaft rotates to transmit the
torque.
10-28
D375A-6
DRAFT
Cooling fan motor
Suction safety valve

Function of suction valve
q If the fan pump stops, the hydraulic oil does not
flow into the motor. Since the motor continues
revolution because of the force of inertia, however, the pressure on the outlet side of the motor
rises.
q When the oil stops flowing in from inlet port (P),
suction safety valve (1) sucks in the oil on the
outlet side and supplies it to port (MA), compensating for the lack of oil on that side to prevent
cavitation.
When the pump is stopped

q If the engine is stopped and the shaft speed of
the fan pump lowers to 0rpm, the pressurized oil
from the pump is not supplied to port (P) any
more. As the pressurized oil is not supplied to
the (MA) side of the motor, the motor speed lowers gradually to stop.
q If the motor shaft is revolved by the force of inertia while the oil flow in the port (P) is reducing,
the oil in port (T) on the outlet side is sent by suction safety valve (1) to the (MA) side to prevent
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
If the pressure in port (P) rises above the cracking 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.
q
10-30
D375A-6
DRAFT
Cooling fan motor
Operation of reversible valve

When the ON/OFF solenoid is de-energized
q If ON/OFF solenoid (1) is "de-energized", the
pressurized oil from the pump is blocked by
ON/OFF selector valve (2), and port (C) connects to the tank circuit.
q Spool (3) is pushed to the right by spring (4).
q Motor port (MA) connects to port (P) and pressurized oil flows in to revolve the motor in normal
direction (clockwise).
D375A-6
When the ON/OFF solenoid is energized

q If ON/OFF solenoid (1) is "energized", ON/OFF
selector valve (2) switches to allow the pressurized oil from the pump to flow through port (C) to
spool chamber (D).
q The pressurized oil in chamber (D) pushes valve
spool (3) to the left against spring (4) .
q Motor port (MB) connects to port (P) and pressurized oil flows in to revolve the motor in reverse (counterclockwise).
10-31
DRAFT
Power train
Power train
Power train
Power train
Outline
q The power generated by engine (1) is transmitted through universal joint (3) to torque converter
(8) while (2) reduces torsional vibration. The
torque converter (8) that uses oil as a medium
for power transmission transmits the power from
the engine to the input shaft (turbine shaft) of
transmission (9) in accordance with the change
in load.
The torque converter is equipped with a lockup
clutch, and when the speed of the output shaft of
the transmission that receives the power from
the torque converter becomes higher, the lockup
clutch is automatically engaged. When this
happens, the drive case and turbine are
combined as a unit to transmit the power from
the engine directly to the transmission input
shaft.
Transmission (9) uses a combination of planetary gear mechanisms and hydraulic clutches to
give three forward speeds and three reverse
speeds. When a gear speed is selected with the
PCCS (gearshift) lever according to the change
in load, two clutches are engaged to transmit the
power from the torque converter to transfer (15)
through its output shaft.
10-32
Transfer (15) reduces the speed of the power

transmitted, and then the combination of the
bevel pinion and bevel gear of the bevel gear
shaft unit reduces the speed further and divides
the power at right angles to the left and right to
send to the respective steering clutches (10).
Steering clutch (10) stops transmission of the
power from the bevel gear shaft unit to the final
drive to steer the machine. Moving the PCCS
(steering) lever in the direction to which the
machine turns disengages the steering clutch on
the side and the machine turns to the direction.
The turning angle is adjusted by controlling
steering brake (11) installed to the outside of the
steering clutch.
Steering brake (11) is the same disc type as that
for the steering clutch. The power output from
the steering clutch goes to final drive (12) ,
where the speed is reduced to drive sprocket
(13).
Double-reduction type final drive (12) consists of
single-reduction
spur
gear
train
and
single-reduction planetary gear train. The
sprocket drives track shoe (14) to make the
machine travel.
D375A-6
DRAFT
Power train
Power train
1. Engine (SAA6D170E-5)
2. Damper
3. Universal joint
4. Cooling fan pump (LPV90 + 30)
5. Power train pump (BAL180+112)
6. PTO
7. Work equipment pump (HPV190)
8. Torque converter
9. Transmission
D375A-6
10. Steering clutch

11. Steering brake
12. Final drive
13. Sprocket
14. Track shoe
15. Transfer
16. Scavenging pump (BAR63+277)
17. Cooling fan motor (LMF150)
18. Bevel gear and pinion gear
10-33
Power train
Overall drawing of power train unit
10-34
10-34
D375A-6
(04)
Power train
A: Torque converter inlet oil pressure pickup port

(IN)
B: Torque converter outlet pressure pickup port
(OUT)
C: Lockup clutch pressure pickup port (LU)
D: Stator clutch oil pressure pickup port (SC)
E: Left steering clutch pressure pickup port (LC)
F: Left steering brake pressure pickup port (LB)
G: Transmission 2nd clutch pressure pickup port
(2ND)
H: Transmission R clutch pressure pickup port
(REV)
J: Power train lubricating oil pressure pickup port
(LUB)
K: Transmission 3rd clutch pressure pickup port
(3RD)
L: Transmission F clutch pressure pickup port
(FWD)
M: Right steering brake pressure pickup port (RB)
Specification
q
N: Right steering clutch pressure pickup port (RC)

P: Transmission 1st clutch pressure pickup port
(1ST)
R: Main relief pressure pickup port (TM)
1. Centralized pressure pickup port
2. Oil level gauge
3. Oil filler pipe
4. Power train and lubrication pump
5. PTO
6. Torque converter
7. Torque converter control valve
8. Transmission control valve
9. Transmission
10. Steering clutch and brake
11. Steering control valve
12. Transmission lubricating oil filter
13. Power train oil filter
14. Power train oil strainer
15. Scavenging pump
10-35
The power train unit consists of torque converter, transmission unit, and steering unit by rough
classification.
Accordingly, after removing power train unit, it
can be divided into torque converter, transmission unit, and steering unit.
The steering unit consists of transfer, bevel gear
shaft, steering clutch, and steering brake.
D375A-6
(04)
10-35
Power train
Power train hydraulic equipment arrangement drawing
1. Oil cooler
2. Power train oil filter
3. Transmission lubricating oil filter
4. Centralized pressure pickup port
5. Torque converter valve
6. Transmission control valve (ECMV)
7. Steering control valve (ECMV)
8. Power train oil tank
9. Power train oil strainer
10. Power train pump (BAL180+112)
11. Scavenging pump (BAR63+277)
12. Cooling fan pump (LPV90+30)
10-36
10-36
A: Torque converter lock-up pressure pickup port

B: Torque converter stator clutch pressure pickup
port
C: Left steering clutch pressure pickup port
D: Left steering brake pressure pickup port
E: Transmission 2nd clutch pressure pickup port
F: Transmission R clutch pressure pickup port
G: Transmission 3rd clutch pressure pickup port
H: Transmission F clutch pressure pickup port
J: Right steering brake pressure pickup port
K: Right steering clutch pressure pickup port
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
R: Main relief pressure pickup port
D375A-6
(06)
DRAFT
Power train
D375A-6
10-37
DRAFT
Power train
Damper and universal joint
10-38
D375A-6
DRAFT
Power train
1. Outer body
2. Engine flywheel
3. Output shaft
4. Coupling
5. Universal joint
6. Flange
7. Rubber coupling
8. Cover
9. Breather (for damper bearing case)
10. Oil fitter pipe
11. Breather (for fly wheel housing)
D375A-6
Outline
q The damper protects the power train (such as
the torque converter and transmission) by buffering torsional vibrations resulting from fluctuations in engine torque or impact torque resulting
from sudden acceleration or heavy duty operation.
The rubber couplings on the damper effciently
absorbs vibrations by rubber material's internal
damping effects and deformation as well as frictional 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).
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

B: To transmission lubrication circuit
C: To transmission oil pan
D: From steering case
E: To power train oil filter
F: To transmission lubricating oil filter
G: To transmission oil pan
H: To scavenging pump
J: To scavenging pump
K: To power train oil filter
L: To transmission lubricating oil filter
M: To transmission control valve
N: To transmission lubrication circuit
P: Torque converter outlet oil pressure pickup
port (OUT)
R: To power train oil cooler
10-42
1. Cooling fan pump mounting location

2. Torque converter outlet oil pressure sensor
mounting location
3. Work equipment pump mounting location
4.Power train and lubricating oil pump mounting
location
5.Scavenging pump mounting location
6.Torque converter control valve
7. Torque converter outlet oil temperature
sensor mounting port
8.Coupling
9. Retainer
10. Input shaft (number of teeth: 61)
11. Front housing
12. PTO idler gear (number of teeth: 77)
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
D375A-6
Power train
10-43
The torque converter is a 3-element, 1-stage
and 1-phase type, and is integral with the transmission.The torque converter is equipped with a
wet double-disc clutch type lockup unit and a
stator clutch unit in order to reduce fuel consumption, to increase the operability, and to reduce captive consumption of the engine
horsepower.
For higher efficiency of continuous light dozing
and leveling operation, the torque converter is
locked up to transmit the engine power directly to
the transmission input shaft. Even when the
torque converter is locked up (the pump is united
with the turbine), the oil is still supplied from the
torque converter relief valve.
The oil sent from the pump to the turbine returns
to the stator. The flow of oil is obstructed by the
stator blades and becomes turbulent (it is
agitated), producing resistance against the rotation of the pump and turbine.
To reduce the resistance against the rotation of
the pump and turbine, the stator clutch is disengaged simultaneously with lockup of the torque
converter, allowing the stator to rotate freely. As
the stator turns along with the pump and turbine,
the oil returns from the turbine to the pump
smoothly with less resistance.
10-43
Pump (19) is united with coupling (8), input shaft
(10), lockup clutch housing (14), and drive case
(15), and is rotated by the engine power.
Turbine (16) is united with the turbine boss (31)
and transmission input shaft (turbine shaft) (24)
and is rotated by the oil from the pump.
Stator (18) is united with the stator shaft (20) and
stator boss (25) and is fixed to rear housing (17)
through the stator clutch unit.
The lock-up clutch unit consists of clutch plate
(28) meshed with drive case (15), clutch discs
(33) meshed with the turbine boss (31) and
clutch piston (30) that slides inside housing (14)
united with the drive case.
The stator clutch unit consists of clutch discs
(29) meshed with boss (25) splined to stator
shaft (20), clutch plate (28) supported on clutch
housing (26) and rear housing (17) with the pins,
and clutch piston (30) that slides inside the rear
housing.
The PTO unit consists of input shaft (10), idler
gear (12), scavenging pump drive gear (35),
cooling fan pump and work equipment pump
drive gear (41) and power train pump drive gear
(38).
Outline
Structure
Conditions for lockup mode and torque converter

mode
Gear speed
Forward 1st
Torque converter output shaft speed:

(rpm)
Lockup mode
Torque converter
mode
Min. 1,320
Max. 1,830
Min. 1,256
Max. 1,830
Forward 2nd
Min. 1,584
Max. 1,555
Forward 3rd
Min. 1,350
Max. 1,320
Reverse 1st
Reverse 2nd
Reverse 3rd
Min. 1,255
Min. 1,359
Min. 1,373
Max. 1,226
Max. 1,330
Max. 1,343
a While the transmission is shifting gears, the

torque converter comes into the torque converter drive mode.
D375A-6
(04)
10-43
DRAFT
Power train
Power transmitting route

When lockup clutch is "disengaged" and stator
clutch is "engaged"
When lockup clutch is "engaged" and stator

clutch is "disengaged"
As drive case (4) and turbine (6) are disconnected from

each other, the torque converter works as an ordinary
torque converter.
Rear housing (9) and stator shaft (10) are connected to
each other to lock stator (11).
Drive case (4) is connected to turbine (6) and torque

converter is locked up.
Rear housing (9) and stator shaft (10) are connected to
each other to fix stator (11).
Engine power
O
Coupling (1)
O
Input shaft (2), clutch housing (3), drive case (4) and
pump (5) rotate together
O
Oil is used as medium
O
Turbine (6) and boss (7)
O
Transmission input shaft (8)
10-44
Engine power
O
Coupling (1)
O
Input shaft (2), clutch housing (3), drive case (4) and
pump (5) rotate together
O
Lockup clutch (9)
O
Turbine (6) and boss (7)
O
Transmission input shaft (8)
D375A-6
DRAFT
Power train
Oil flow
The oil flows through the main relief valve and its
pressure is regulated to the set pressure or below by the torque converter relief valve. It then
flows in inlet port (A), goes through the oil passages of rear housing (1) and pump shaft (2),
and flows into pump (3) .
The oil is given centrifugal force by pump (3) and
flows in turbine (4) to transfer its energy to turbine (4).
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.
Stamp of the nameplates
(A)
Identification
Pressure control
color
valve
(B)
A*******
Yellow
Without slit
E*******
Pink
With slit
Main relief valve

The main relief valve maintains each hydraulic
circuit pressure of the transmission, steering
clutch, steering brake and the lockup clutch and
stator clutch of torque converter constantly at the
set pressure.
Set pressure : 2.63 2.92 MPa {26.8
29.8 kg/cm2 } (At rated engine speed)
Fill switch
(Operation pressure:
MPa{kg/cm2})
Equipped
(0.26 {2.7})
Equipped
(0.26 {2.7})
Operated
clutches
Stator
Lockup
Lockup clutch ECMV

The lockup clutch modulating valve maintains
the clutch pressure at the set pressure or below
to protect the lockup clutch circuit from abnormally high pressure, as well as increasing the
clutch pressure gradually to the set pressure.
Set pressure: 1.3 MPa {13 kg/cm2}
Torque converter relief valve

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 pressure.)
Set pressure: 1.00 MPa {10.2 kg/cm2} (cracking
pressure)
Stator clutch ECMV

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
The oil from the hydraulic pump flows through

the filter, port (A) of the torque converter valve,
and orifice (a) of torque converter relief valve (1)
to chambe (B).
Operation of torque converter relief valve
The oil from the main relief valve flows through

port (C) to the torque converter, and at the same
time, also flows through orifice (b) of torque converter relief valve (3) to chamber (D) .
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.
When the oil pressure in the circuit exceeds the

set pressure, the oil in chamber (B) pushes piston (2), the reaction force of which moves spool
(1) to the left to open port (A) and port (C).
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 pressure.
It forms a modulation wave pattern, so the stator
clutch is engaged smoothly to reduce the shock
when shifting gear. In addition, it prevents generation of peak torque in the power train. As a
result, it provides a comfortable ride for the operator 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)
D375A-6
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).
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
When traveling in lockup drive mode, current

flows in proportional solenoid (1), the oil pressure force balanced with the solenoid force is applied to chamber (B) and pushes pressure
control valve (3) to the left. As a result, pump port
(P) and clutch port (A) open. When the clutch is
filled with oil, oil pressure pickup port (4) actuates and fill switch (5) is turned "ON".
10-52
If current flows in proportional solenoid (1), the

solenoid generates thrust in proportion to the
current. This thrust of the solenoid is balanced
with the sum of the thrust generated by the oil
pressure in clutch port and the reaction force of
pressure control valve spring (2), and then the
pressure is regulated.
While shifting gears, the lockup clutch oil pressure 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.
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 pressure.
It forms a modulation wave pattern, so the stator
clutch is engaged smoothly to reduce the shock
when shifting gear. In addition, it prevents generation of peak torque in the power train. As a
result, it provides a comfortable ride for the operator and greatly increases the durability of the
power train.
Lockup drive mode travel to torque converter
drive mode travel
D375A-6
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".
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
When traveling in torque converter drive mode

current flows in proportional solenoid (1), the oil
pressure force balanced with the solenoid force
is applied to chamber (B) and pushes pressure
control valve (3) to the left.As a result, pump port
(P) and clutch port (A) open. When the clutch is
filled with oil, oil pressure pickup port (4) actuates and fill switch (5) is turned "ON".
10-54
If current flows in proportional solenoid (1), the

solenoid generates thrust in proportion to the
current. This thrust of the solenoid is balanced
with the sum of the thrust generated by the oil
pressure in clutch port and the reaction force of
pressure control valve spring (2), and then the
pressure is regulated.
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
2. Lock lever
3. PCCS lever (Steering, forward-reverse, gearshift)
3A. Upshift switch (Gear upshifts each time this
switch is pressed)
3B. Downshift switch (Gear downshifts each
time this switch is pressed)
4. Transmission neutral switch
5. Cable
7. Power train controller
10-56
Lever position
[1]: Neutral
[2]: Forward
[3]: Reverse
[4]: OFF
[5]: Upshift
[6]: Downshift
[7]: Free
[8]: Lock
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 activates 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.
2.
3.
4.
Boot
Bracket
Plate
Bolt
10-58
5. Screw
6. Lever
7. Connector
D375A-6
(04)
Power train
PCCS lever
Function
Operating effort characteristics
Operation for forward and reverse travel
The control lever is held at 3 positions: "FORWARD" , "NEUTRAL" and "REVERSE".
D375A-6
(04)
Operation for left and right steering
10-59
10-59
Free return
10-59
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 controller.
q A potentiometer is installed to detect each of longitudinal displacement and lateral displacement.
Each potentiometer outputs two signal voltages
which are opposite in phase as shown in the figure on the right.
10-60
D375A-6
Power train
PCCS lever
10-61
Since gear shift during travel is possible, there is no
need to stop the machine to shift gears.
Gear shift of the machine
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 REVERSE 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.
Gear shift operation
D375A-6
(04)
10-61
DRAFT
Power train
Transmission
Transmission
10-62
D375A-6
DRAFT
Power train
Transmission
A:
B:
C:
D:
E:
1st clutch oil pressure pickup port

3rd clutch oil pressure pickup port
R clutch oil pressure pickup port
2nd clutch oil pressure pickup port
F clutch oil pressure pickup port
1.
2.
3.
4.
Transmission control valve

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

6. Front cover
7. Sun gear for reverse clutch (34 teeth)
8. Ring gear for reverse (hub) (91 teeth)
9. Planetary pinion for reverse clutch (25 teeth)
10. Ring gear for reverse clutch (84 teeth)
11. Sun gear for forward clutch (41 teeth)
12. Planetary pinion for forward clutch (25 teeth)
13. Ring gear for forward clutch ( 91 teeth)
14. Ring gear for 3rd clutch (91 teeth)
15. Planetary pinion for 3rd clutch (25 teeth)
16. Sun gear for 3rd clutch (41 teeth)
17. Ring gear for 2nd clutch (93 teeth)
18. Planetary pinion for 2nd clutch (23 teeth)
19. 2nd sun gear(47 teeth )
20. 1st clutch gear
21. 1st clutch piston
22. 1st clutch piston housing
23. Output shaft
24. Spacer
25. Collar
26. 1st clutch spring
27. 2nd carrier
28. Plate
29. Carrier for forward and 3rd clutches
30. Piston housing for forward and 3rd speed gear
31. Carrier for reverse clutch
32. Carrier for reverse clutch
33. Clutch piston
34. Clutch spring
35. Clutch plate
36. Clutch disc
37. Washer spring
38. Pin
39. Tie bolt
D375A-6
Outline
q The transmission is a "forward 3-speed and reverse 3-speed" transmission which consists of
the planetary gear trains and the disc clutches.
q Transmission selects and locks two clutches out
of the five sets of planetary gear trains and disc
clutches hydraulically by using the control valve
to select one travel direction and one gear
speed.
q The transmission transfers the power received
by the transmission input shaft to the output
shaft by changing the gear speed (forward
1st-3rd or reverse 1st-3rd) with any combination
of the forword or reverse clutch, and one of three
speed clutches.
No. of plates and discs used
Clutch No.
R clutch
F clutch
3rd clutch
2nd clutch
1st clutch
Number of plates Number of discs

6
6
5
6
4
4
3
3
5
6
Combinations of clutches at respective gear speeds

and reduction ratio
Gear speed
Forward 1st
Forward 2nd
Forward 3rd
Neutral
Reverse 1st
Reverse 2nd
Reverse 3rd
Clutches
engaged
F 1st
F 2nd
F 3rd
(*1)
R 1st
R 2nd
R 3rd
Reduction ratio
3.220
1.745
1.000
2.471
1.339
0.769
*1: The 1st or 2nd clutch is filled with low-pressure

oil.
10-65
DRAFT
Power train
Transmission
Disc clutch
Structure
q
q
The disc clutch consists of piston (2), plates (3),

discs (4), pin (5), return spring (6), and washer
spring (7) to fix ring gear (1).
Inside teeth of disc (4) are engaged with outside
teeth of ring gear (1).
Plate (3) and clutch housing (8) are assembled
with pin (5).
Operation
When clutch is "engaged" (locked)
The oil from ECMV is routed to the back of piston

(2) through oil passage of clutch housing (8) and
pushes piston (2) leftward.
q Piston (2) presses plate (3) closely against disc
(4) to stop rotation of disc (4) by using friction
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
q
q
10-66
When the supply of oil from ECMV is shut off,

piston (2) is returned rightward by the force of return spring (6).
This relieves the frictional force between plates
(3) and discs (4), making the ring gear (1) free.
Washer spring (7) installed at pin portions between 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.
D375A-6
DRAFT
Power train
Transmission
Oil passage in speed clutch
q
q
When the PCCS lever is in the "Neutral" position

, the 1st or 2nd gear speed is kept selected.
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.
When the PCCS lever is shifted from the "Neutral" position to the "Forward" or "Reverse" position, the pump is required to supply oil enough to
fill the piston chamber of the forward or reverse
clutch.
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.
The time lag at shifting gears is reduced by controlling 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
3rd clutch sun gear (18)
2nd clutch sun gear (17)
O
O
Output shaft (19)i
i
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
Output shaft (19)i
i
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
q The ECMV consists of a pressure control valve
and a fill switch.
q Pressure control valve
A proportional solenoid in this valve receives the
current sent from the controller and this valve
converts it to oil pressure.
q Fill switch
This switch detects that the clutch is filled with oil
and has the following functions.
1. Outputs a signal (a fill signal) to the controller to
notify that filling is completed when the clutch is
filled with oil.
2. Keeps outputting signals (fill signals) to the
controller while oil pressure is applied to the
clutch to notify whether oil pressure is applied or
not .
ECMV and proportional solenoid

q For each ECMV, a proportional solenoid is installed.
The proportional solenoid generates thrust
shown below according to the command current
from the controller.
The thrust generated by the proportional solenoid is applied to the pressure control valve
spool to generate oil pressure as shown in the
figure below. Accordingly, controlling the
command current that changes the thrust to
operate the pressure control valve allows for
controlling the oil flow and pressure to the clutch.
Current - thrust characteristics of proportional
solenoid
Thrust - Oil pressure characteristics of proportional solenoid
Phase A: Before shifting gear (oil is drained)

Phase B: Filling phase
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).
10-78
ECMV and fill switch

For each ECMV, a fill switch is installed.
When the clutch is filled with oil, the fill switch is
turned "ON" by the pressure of the clutch. The oil
pressure starts to build up according to this
signal.
D375A-6
DRAFT
Power train
Transmission ECMV
Operation of ECMV
q ECMV is controlled with the command current
sent from the controller to the proportional solenoid 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.
Before shifting gear (oil is drained) (Phase A in

chart)
Phase A: Before shifting gear (oil is drained)

Phase B: Filling phase
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
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).
10-79
DRAFT
Power train
Transmission ECMV
Filling phase (Phase B in chart)
When current is supplied to proportional solenoid (1) with no oil in the clutch, the force exerted
by the oil pressure, that is equal to the thrust of
the solenoid, develops in chamber (B) and pushes pressure control valve (3) to the right. As a result, pump port (P) and clutch port (A) are
opened and oil starts filling the clutch. When the
clutch is filled with oil, pressure detection value
(4) actuates to turn "ON" fill switch (5).
10-80
Pressure adjustment (Range C in chart)
When current flows through proportional solenoid (1), the solenoid generates thrust in proportion to the current. The clutch circuit pressure
builds up until the thrust of the solenoid is balanced with the sum of the force exerted by the oil
pressure in clutch port and the force of pressure
control valve spring (2), and then the pressure is
settled.
D375A-6
DRAFT
Power train
Transmission lubricating oil relief valve
1. Lubricating oil pressure measurement plug

2. Lubricating oil relief value spool
3. Valve body
Outline
q The lubricating oil relief valve is installed to the
right side face of the transmission, and acts to
prevent any abnormal pressure in the transmission 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
2. Lock lever
3. PCCS lever(steering, forward-reverse, gear shift)
5. Limit switch
6. Steering ECMV
7. Brake valve
8. Parking brake lever (from lock lever)
9. Cable
10. Rod (from brake pedal)
11. Potentiometer
Outline
q PCCS lever (3) sends electric signals to power
train controller (4). After receiving the signals,
power train controller (4) sends a proportional
current to the steering ECMV (6) to operate the
steering clutch and brake.
q Brake pedal (1) sends electric signals to power
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 slightly tilt PCCS lever (3) leftward, the left steering
clutch is partially disengaged, causing the machine to make a gradual left turn.
D375A-6
Positions of levers and pedals

[1]: Neutral
[2]: Forward straight-travel
[3]: Reverse straight-travel
[4]: Left clutch OFF
[5]: Left clutch OFF, Left brake ON
[6]: Right clutch OFF
[7]: Right clutch OFF, Right brake ON
[8]: Brake "released"
[9]: Brake ON
[10]: Free
[11]: Lock
If you completely tilt PCCS lever (3) leftward, the

left steering clutch is "disengaged" completely
and the left steering brake is "applied" , causing
the machine to make a sharp left turn.
The lock lever (2) is connected to parking brake
lever (8) and serves as a parking brake lever.
10-83
DRAFT
Power train
Transfer unit, bevel gear shaft and steering

Machines without VHMS controller
1. Transmission
2. Input shaft
3. Steering unit
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
10. L.H. steering clutch ECMV

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

11. R.H. steering clutch ECMV
10-85
DRAFT
Power train
Transfer unit and bevel pinion

1. Input shaft
2. Drive gear (35 teeth)
4. Rear cover
5. Bearing cage
6. Driven gear (33 teeth)
7. Bevel pinion (23 teeth)
8. Bevel gear (40 teeth)
10-86
Outline
q The transfer unit and bevel pinion are installed at
the rear part inside the steering case, and input
shaft (1) receives the power from the transmission output shaft.
q The transfer unit consists of drive gear (2) and
driven gear (6) to reduce the power speed from
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 controller.
D375A-6
DRAFT
Power train
1. Input shaft
2. Drive gear (35 teeth)
4. Rear cover
5. Torque converter output speed sensor
6. Bearing cage
7. Driven gear (33 teeth)
8. Bevel pinion (23 teeth)
D375A-6
Outline
q The transfer unit and bevel pinion are installed at
the rear part inside the steering case, and input
shaft (1) receives the power from the transmission output shaft.
q The transfer unit consists of drive gear (2) and
the driven gear (7) to reduce the power speed
from the input shaft (1), transferring it to bevel
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 controller.
10-87
DRAFT
Power train
Bevel gear shaft, steering clutch and brake
10-88
D375A-6
DRAFT
Power train
1. Output shaf
2. Sleeve
3. Brake cage
4. Brake spring
5. Brake case
6. Brake piston
7. Torque pin
8. Blake plate (each side: 9 plates)
9. Spacer
10. Brake disc (each side: 9 discs)
11. Brake hub
12. Brake stopper
13. Pipe
14. Bearing cage
15. Bevel gear shaft
16. Bevel gear shaft
18. Bearing cage
19. Clutch hub
20. Clutch stopper
21. Spacer
22. Clutch plate (each side: 9 plates)
23. Clutch disc (each side: 9 discs)
24. Torque pin
25. Clutch piston
26. Clutch spring
27. Clutch housing
28. Clutch cage
D375A-6
Outline
q The steering clutch is wet-type, multiple-disc,
spring-applied type. If you operate the PCCS lever, the controller outputs a proportional solenoid current to hydraulically operate the steering
clutch ECMV. The steering clutch works in conjunction with the steering brake.
q The steering brake is wet type multiple-disc,
spring-applied type. If you operate the brake
pedal and PCCS lever, the controller outputs a
proportional solenoid current to hydraulically operate the steering brake ECMV. The steering
brake works in conjunction with the steering
clutch.
q When the engine is stopped, the steering brake
is "applied" since the pressure acting on the
back of the brake piston lowers, even if you do
not depress the brake pedal. Since the brake is
released as the oil pressure in the circuit goes up
when the engine restarts, the parking brake lever must be set to "LOCK" position.
q The lubrication method is forced lubrication type,
which makes oil from the power train oil cooler
flow through the passage in the steering case to
the housing and cage, and up to the discs and
plates.
10-89
DRAFT
Power train
Steering control valve
10-90
D375A-6
DRAFT
Power train
A: Left clutch pressure pickup port

B: Right clutch pressure pickup port
C: Left brake pressure pickup port
D: Right brake pressure pickup port
E: To left clutch
F: To left lubrication circuit
G: To left brake
H: To right clutch
J: To right lubrication circuit
K: To right brake
L: Bevel gear shaft lubricating oil inlet port
M: To pin puller solenoid valve
N: From pin puller solenoid valve
P: From pump
1. Left steering clutch ECMV
2. Right steering clutch ECMV
5. Left steering brake ECMV
6. Right steering brake ECMV
7. Filter
8. Valve seat
D375A-6
Outline
q
Four ECMV's are installed on the valve seat of
the steering control valve to control the steering
clutch and steering brake.
q The steering control valve is located in the circuit
between the power train pump and the pistons of
the steering clutch and steering brake. It consists of two sets of the steering clutch ECMV
(L.H. and R.H.) and two sets of the steering
brake ECMV (L.H. and R.H.).
q The steering control valve sends the oil from the
power train pump to the both left and right sides
of steering clutches and steering brakes to control respective disc clutches and disc brakes.
q When the PCCS lever is leaned to the right or
left, the steering clutch is disengaged. The steering brake will operate by leaning further the
PCCS lever.
q The controller sends signals to each ECMV according to the right or left travel of the PCCS lever and controls the clutch and brake for the
gradual or sharp turns.
q When the brake pedal is depressed, the controller sends the command current to the steering
brake ECMV according to the pedal travel to apply the L.H. and R.H. brakes to stop the machine.
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. steering brake ECMV and the brake piston to apply
the brake. The parking brake valve is connected
to the brake pedal by the linkage.
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
P: From pump
T: Drain
Dr: Drain
P1: Clutch or brake oil pressure pickup port
*1:
1. Fill switch connector

2. Proportional solenoid connector
3. Pressure detection valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate (*1)
Outline
q Each ECMV keeps the steering clutch pressure
and steering brake pressure to the set pressure
and switches the circuit to the piston chamber of
the steering clutch and steering brake.
10-92
Clutch to use ECMV
Stamp of the name

plate
Steering clutch, Steering

brake
R*******
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
Each ECMV is equipped with a proportional solenoid.
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

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
ECMV is controlled by the command current
sent from the controller to the proportional solenoid 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
q
When the PCCS lever is in "neutral" position and

the brake pedal is "released", proportional solenoid (1) of the clutch ECMV is de-energized and
the sealing part by ball (2) is opened.
The oil from the power train pump flows through
port (Pc) of the clutch ECMV to orifice (a), then it
is drained through the sealing part by ball (2).
Valve (3) is moved to the right by the force of
spring (4) to disconnect port (Pc) from port (C),
and connect port (C) to port (Dr). At this time, the
oil from the port behind the clutch piston is
drained through port (C) and the clutch is "engaged" by the force of the clutch spring.
The oil pressure in the brake circuit, etc. is maintained by orifice (a).
Proportional solenoid (5) of the brake ECMV is
energized and pushes ball (6) to the left to close
the sealing part.
10-94
The oil in port (Pb) of the brake ECMV flows in

port (E) and pushes valve (7) to the left to connect port (Pb) to port (B) and disconnect port (B)
from port (Dr). At this time, the oil flows in the
port behind the brake piston. As the oil pressure
rises, the brake piston is pushed to the left to
compress the brake spring, then the brake is
released.
When the parking brake lever is in "free" position, as the parking brake valve is closed, the oil
in the brake circuit is not drained.
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".)
When the PCCS lever is "operated halfway to

left" and the brake pedal is "released", proportional solenoid (1) of the L.H. clutch ECMV is energized and the sealing part by ball (2) is closed.
port (Pc) of the clutch EMCV and orifice (a) to
port (F) and pushes valve (3) to the left to connect port (Pc) to port (C) and disconnect port (C)
from port (Dr). At this time, the oil flows in the
port behind the clutch piston. As the oil pressure
rises, the clutch piston is pushed to the left to
compress the clutch spring, then the clutch is
"disengaged".
Proportional solenoid (5) of the brake ECMV is
energized and pushes ball (6) to the left to close
the sealing part.
D375A-6
The oil in port (Pb) of the brake ECMV flows in

port (E) and pushes valve (7) to the left. The circuit pressure after port (B) depends on the command current output from the controller to
proportional solenoid (5) according to the travel
of the PCCS lever.
Proportional solenoid (5) generates the thrust in
proportion to the command current. When this
thrust is balanced with the sum of the force generated by the pressure in the port behind the
brake piston and the force of spring (8), the
brake pressure that determines braking force is
set up.
Accordingly, if the travel of the PCCS lever is
short, the cricuit pressure after port (B) is set
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".
10-95
DRAFT
Power train
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".)
When the PCCS lever is moved from "halfway to

left" to "fully to left" position, proportional solenoid (5) of the L.H. brake ECMV is de-energized
and the sealing part by ball (6) is fully opened.
Since the oil in port (E) is drained through the
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 "applied" by the force of the brake spring.
port (Pb) of the brake ECMV and orifice (b), then
it is drained through sealing part by ball (6).
D375A-6
q
q
The oil pressure in the clutch circuit, etc. is maintained by orifice (b).
10-97
DRAFT
Power train
When PCCS lever is in "neutral", brake pedal is "depressed", and parking brake lever is in "free" position: Stop
(L.H. and R.H. clutches are "engaged", L.H. and R.H. brakes are "applied", and parking brake is "released".)
When the brake pedal is depressed fully, proportional solenoids (5) of L.H. and R.H. brake ECMVs are de-energized to open the sealing part by
ball (6).
The controller outputs the command current to
proportional solenoids (5)according to the brake
pedal travel.
Proportional solenoid (5) generates the thrust in
proportion to the command current. When this
thrust is balanced with the sum of the thrust exerted 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.
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".
When the brake pedal is depressed, the parking
brake valve connected to the pedal by the linkage 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
2. Valve body
D375A-6
Outline
q The parking brake valve is installed to the steering control valve, and spool (1) operates with the
parking brake lever.
q When the parking brake lever is in lock" position, the brake is applied by draining the pressurized oil for the L.H. and R.H. steering brakes.
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
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) .
The oil in the port behind the brake piston is
drained from port (C) through ports (A) and (B) .
The oil pressure in the port behind the brake piston continues to decrease, then the brake is fully
"applied" and kept "applied" .
When the engine is started again, as ports (A)
and (B) are still connected to port (C) , the brake
is kept "applied" .
When the parking brake lever is moved to "free"
position, spool (1) moves to the right to disconnect 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 avoided when coil (2) of brake ECMV is de-energized.
q If an abnormality takes place in the electric system, 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 portion 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
The power from the bevel gear shaft and steering clutch is transmitted to No. 1 pinion (15). It
then passes through No. 1 gear (13), which is
meshed with the No. 1 pinion, and is transmitted
to sun gear (2) to rotate it.
The rotation of sun gear (2) is transmitted to
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 transmitted 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
2. Recoil spring assembly
3. Idler cushion
4. Track frame
5. Sprocket
6. Sprocket cover
7. Track roller bogie
8. Track roller
9. Cap
10. Idler yoke
11. Cylinder
12. Guide
Outline
q The track rollers are mounted on the K-shaped
bogies, thereby increasing the actual contact
area between ground and the track even on an
uneven ground to increase drawbar pull.
q Because a rubber pad is mounted on a
K-shaped bogie, the shock from a road surface
is absorbed.
Track roller arrangement
Track roller flange type
1st
2nd
3rd
4th
5th
6th
7th
8th
S: Single flange type

D: Double flange type
10-108
D375A-6
DRAFT
Track frame
D375A-6
10-109

Idler cushion
Idler cushion
1. Yoke
2. Nut
3. Retainer
4. Recoil spring
5. Rod
6. Spring cylinder
7. Retainer
8. Holder
9. Piston
10. Lubricator (for pumping in and discharging
grease)
11. Grease chamber cylinder
10-110
10-1 0
10-1 0
Outline
Pumping in or discharging grease from lubricator
(10) moves rod (5) forward or backward to adjust
track tension. The recoil spring (4) acts to dampen
any sudden shock brought to bear on the idler.
D375A-6
(04)

Track roller bogie
Track roller bogie
1. Guide
2. Cap
3. Track roller assembly (double flange type)
4. Major bogie
5. Rubber mount
6. Miner bogie
7. Track roller assembly
8. Cover
D375A-6
(04)
10-1 1
10-1 1
Outline
q The track roller is mounted on the miner bogie
(6) so that the track roller and track shoe can be
touched constantly.
q The vibration from a road surface is absorbed by
the rubber mount (5).
10-111
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
2. Pivot shaft assembly
3. Cover
4. Thrust plate
5. Thrust plate
6. Pivot shaft
7. Seal cage cover
8. Cover
9. Seal
10. Bushing
D375A-6
11. Side pin

12. Center pin
13. Bushing
Outline
q The track frame allows its front part to move up
and down on the pivot shaft (6) at the tail connected to its rear part.
The equalizer (1) can rock on the center pin (12)
and is connected to the left and right track
frames with side pins (11).
10-115
DRAFT
Suspension
*1
*2
. Indicates the left suspension of single tilt specification machines.

. 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
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
6. L.H. blade lift cylinder
D375A-6
(04)
10-117
DRAFT
Hydraulic system
Full U - Dozer with dual tilt function
1. Blade tilt cylinder

2. R.H. blade lift cylinder
3. Control valve
4. Hydraulic tank
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
(04)
10-119
Hydraulic system
Variable giant ripper (Figure shows a dual tilt specification machine)
1. Control valve
3. Ripper tilt cylinder
4. Ripper lift cylinder
5. Pin puller cylinder (from power train hydraulic circuit)
6. Solenoid valve (for pin-puller)
10-120
D375A-6
(04)
Hydraulic system
PPC control piping diagram
10-121
Blade and ripper control

(Figure shows a dual tilt specification machine)
10-121
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
(04)
10-121
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 system 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" position, 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

2. Hydraulic oil filter element
3. Spring
4. Suction valve
5. Cover
6. Cover
7. Hydraulic tank
8. Strainer (suction)
9. Sight gauge
10. Pressure valve and Breather
11. Drain valve
12. Drain plug
13. Strainer (over flow)
Specified value
Tank capacity (l)
Hydraulic tank Level inside
tank
210
Hi (l)
144
Center (l)
130
Low (l)
112
Cracking pressure of pressure valve

(kPa {kg/cm2})
Breather
Operating pressure of vacuum valve
(kPa {kg/cm2})
17 2.5
{0.17 0.025}
2 0.3
{0.02 0.003}
Specified value
Cracking pressure
(kPa{kg/cm2})
150 30
{1.5 0.3}
Mesh size (mm)
30/8
Filtering area (cm2)
17600
Filtering oil flow (l/min)
720
Strainer
(over flow)
Mesh size (mm)
40
Strainer
(suction)
Mesh size
(mm)
Filtration area
(cm2)
Hydraulic
oil filter
D375A-6
105
3,600
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
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 actuate 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 pressure 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 actuates the main control valve.
q
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
2. Metering spring
3. Centering spring
4. Piston
5. Disc
6. Nut (for lever connection)
7. Joint
10-130
8. Plate
9. Retainer
10. Valve body
11. Filter
D375A-6
DRAFT
Hydraulic system
PPC valve
Operation
When in Neutral
Blade lift valve
q Ports (A) and (B) of the blade lift valve of the control valve and ports (P1) and (P2) of the PPC
valve are connected through fine control hole (f)
of spool (1) to drain chamber (D).
D375A-6
Blade tilt valve

q Ports (C) and (D) of the blade tilt valve of the
control valve and ports (P3) and (P4) of the PPC
valve are connected through fine control hole (f)
of spool (1) to drain chamber (D).
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 metering 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 proportion to the travel of the control lever, the pressure 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 returned)
q When disc (5) begins to return, spool (1) is
pushed up by the force of centering spring (3)
and the force exerted by the pressure at port
(P1) .
q Because of this, fine control hole (f) is connected
to drain chamber (D), and the pressurized oil at
port (P1) is released.
q When the pressure in port (P1) lowers too much,
spool (1) is pushed down by metering spring (2)
and fine control hole (f) is disconnected from
drain chamber (D) and connected to pump pressure 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 supply oil.
D375A-6
When blade control lever is operated to stroke

end
q When disc (5) pushes down piston (4) and retainer (9) pushes down spool (1), fine control
hole (f) is disconnected from drain chamber (D)
and connected to pump pressure chamber (PP).
q Accordingly, the pilot oil flows through fine control hole (f) and port (P1) into port (B) and pushes
the control valve spool.
q The oil returning from port (A) flows through port
(P2) and fine control (f') into drain chamber (D).
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) touches 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 connected 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 chamber (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 exerted 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 chamber. 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
Hydraulic system
PPC valve
10-138
Operation
When ripper control lever is in Neutral
10-138
Ports (A) and (B) of the control valve and ports (P1)
and (P2) of the PPC valve are connected to drain
chamber (D) through fine control hole (f) of spool (1)
.
As a result, spool (1) moves up and down so that

the force of metering spring (2) is balanced with
the force exerted by pressure in port (P1).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).
Since metering spring (2) is compressed in proportion to the travel of the control lever, the pressure in port (P1) rises in proportion to the travel
of the control lever.
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 lever.
When ripper control lever is in fine control range10-138

(Neutal o Fine control range)
10-138
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) to port
(A) through fine control hole (f).
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
(06)
DRAFT
Hydraulic system
PPC valve
When ripper control lever is in fine control range

(When ripper control lever is returned)
q When disc (5) begins to return, spool (1) is
pushed up by the force of centering spring (3)
and the force exerted by the pressure at port
(P1).
q Because of this, fine control hole (f) is connected
to drain chamber (D), and the pressurized oil at
port (P1) is released.
q When the pressure at port (P1) goes down too
far, spool (1) is pushed down by metering spring
(2). Fine control hole (f) is shut off from drain
chamber (D), and almost simultaneously, it is
connected to pump pressure chamber (PP). The
oil at pump pressure is supplied until the pressure at port (P1) recovers to a pressure equivalent 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 control hole (f') in the valve on the side that is not operated. The oil passes through port (P2) and
enters port (B) to replenish the port with pressurized oil.
D375A-6
When ripper control lever is operated to stroke

end
q When disc (5) pushes down piston (4) and retainer (9) pushes down spool (1), fine control
hole (f) is disconnected from drain chamber (D)
and connected to pump pressure chamber (PP).
q Accordingly, the pilot oil flows through fine control hole (f) and port (P1) into port (A) and pushes
the control valve spool.
q The oil returning from port (B) flows through port
(P2) and fine control hole (f') into drain chamber
(D).
10-139
DRAFT
Hydraulic system
Piston valve
Piston valve
For blade lift cylinder
Outline
q The piston valve is installed on the piston in the
blade lift cylinder. When the piston reaches its
stroke end, the valve releases the oil from the
work equipment pump to reduce the oil pressure
being exerted on the piston.
In addition the piston valve relieves the shock
which occurs when the piston comes into
contact with the cylinder head or the bottom and
serves to reduce the subsequent surge pressure
in the cylinder by letting the oil escape from the
cylinder before the piston reaches its stroke end.
2. Piston valve OPEN

Just before piston rod (1) reaches the end of its
stroke, the tip of valve (6) contacts the cylinder bottom, so valve (6) and piston valve (3) stop at that position and do not move further. Only piston (2)
moves further.
When this happens, the oil at the cylinder head,
which has been sealed in by piston valve (3), escapes through piston valve seats (4) and (5), and
the pressure inside the cylinder stops rising.
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 contacts the tapered part of piston valve seat (4) to seal
in the oil. As a result, the pressure in the cylinder rises 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 occurrence 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 generally 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 pressure 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 accordance 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
turning the pin puller switch ON/OFF. This
switches the oil circuit to the pin puller cylinder
and sets the shank mounting pin to the PUSH IN
or PULL OUT position.
10-142
1. Connector
2. Wire
3. Switch
4. Knob
D375A-6
DRAFT
Hydraulic system
Pin puller solenoid valve
1. Plug
2. Spring
3. Spring retainer
4. Valve body
5. Spool
6. Spring retainer
7. Spring
8. Push pin
9. Solenoid assembly
D375A-6
A: To pin puller cylinder bottom end

B: To pin puller cylinder head end
P: From power train pump
T: To steering case
10-143
DRAFT
Hydraulic system
Operation
1. Pin puller switch at PUSH IN position
When the pin puller switch is set to the PUSH IN position, no electric current flows to solenoid (9) and it
is de-energized. For spool (5), ports (P) and (B) connect to ports (A) and (T) respectively, and the oil
from the power train pump flows from port (P) to port
(A), and enters the bottom end of pin puller cylinder
(10). The oil in the bottom end of the cylinder extends the cylinder to push shank mounting pin (11)
into shank (12) when the circuit pressure builds up
sufficiently.
10-144
2. Pin puller switch at PULL OUT position

When the pin puller switch is set to the PULL OUT
position, current flows to solenoid (9) and it is energized. Then, the solenoid pushes out push pin (8)
and spool (5) moves to the left. At this point, ports
(P) and (B) disconnect from ports (A) and (T) respectively, and ports (P) and (A) connect to ports (B)
and (T) respectively, so the oil from the power train
pump flows from port (P) to port (B) and enters the
head end of pin puller cylinder (10). The oil in the
cylinder head end retracts the cylinder to pull shank
mounting pin (11) out of shank (12) when the circuit
pressure builds up sufficiently.
D375A-6
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)

2. Switch (pitch)
3. Cover
Outline
q The blade is raised, lowered, and tilted to the
right or left respectively by moving the blade control lever forward and backward or to the right or
left.Dual tilt operation can be performed by moving the lever to the right and left with switch (1)
set to the "DUAL" position.Pitch operation can
also be performed by moving the lever to the
right and left with switch (2) being pressed.
q When the lever is operated with switch (2) being
pressed, the blade pitches.When the lever is
moved to the left, the blade pitches backward,
and when moved to the right, the blade pitches
forward.
D375A-6
(06)
10-145
4. Connector (male)
5. Connector (female)
10-145
When the switch (1) is set to the "DUAL" position
and the lever is operated, the blade is dual tilted.When the lever is moved to the left, the blade
is dual tilted to the left. When the lever is moved
to the right, the blade is dual tilted to the right.
Even when switch (1) is set to either "DUAL" or
"SINGLE" position, if the lever is moved to the
right or left with the switch (2) kept pressed, the
blade pitches.
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.
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
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 The pump converts the engine rotation transmitted to its shaft to oil pressure and oil flow, corresponding to the load.
q It is possible to change the discharge amount by
changing the swash plate angle.
Structure
Cylinder block (7) is supported by shaft (1) on
splined area (12).
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 sliding in a circular pattern.
q Rocker cam (4) conducts high pressure oil to cylinder surface (2) with cradle (B), which is secured to the case, and forms a static pressure
bearing when it slides.
D375A-6
q
q
Piston (6) carries out relative movement in the

axial direction inside each cylinder chamber of
cylinder block (7).
Cylinder block (7) seals the pressurized oil to
valve plate (8) and carries out relative rotation.
This surface is designed so that the oil pressure
balance is maintained at a suitable level.
The oil inside the respective cylinder chambers
of cylinder block (7) is sucked and discharged
through valve plate (8).
10-149
DRAFT
Hydraulic system
Work equipment pump
Operation of pump
q Cylinder block (1) rotates together with shaft (7),
and shoe (5) slides on flat surface (A).
q Rocker cam (4) moves along cylindrical surface
(B), so angle (4) between center line (X) of rocker cam (7) and the axial direction of cylinder
block (a) changes.
q (a) is called the swash plate angle.
q
q
As center line (X) of rocker cam (4) matches the

axial direction of cylinder block (7) (swash plate
angle (a) = 0), the difference between volumes
(E) and (F) inside cylinder block (7) becomes 0.
Suction and discharge of pressurized oil is not
carried out in this state. Namely pumping action
is not performed. (Actually, however, the swash
plate angle is not set to 0)
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).
Piston (6) slides on the inside of cylinder block
(7), so a difference between volumes (E) and
((F) is created inside cylinder block (7).
A single piston (6) sucks and discharges the oil
by the amount (F) - (E).
As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
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) becomes 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 diameter 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

PDP: Drain port
PLP:LS control pressure output port
PLS: LS pressure input port
PP: Pump port
PPL: Drain port
PSIG: Drain port
1. Sleeve
2. Piston
3. Spool
4. Spring
5. Sheet
6. Sleeve
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) according to differential pressure (dPLS) [= (PP) (PLS)], called the LS differential pressure [the
difference between main pump discharge pressure (PP) and control valve outlet port pressure
(PLS)].
q Main pump discharge pressure (PP), pressure
(PLS) [called LS pressure] coming from the control valve output enter this valve.
q The relationship between LS differential pressure (dPLS) [= (PP) - (PLS)], which is a diffential
pressure between main pump discharge pressure (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
q
q
q
q
The LS valve is a three-way selector valve, with

pressure (PLS) (LS pressure) from the inlet port
of the control valve brought to spring chamber
(B), and pump discharge pressure (PP) brought
to port (H) of sleeve (8)
Magnitude of the force resulting from this LS
pressure (PLS), force of spring (4) and the pump
discharge pressure (self pressure) (PP) determine the position of spool (6).
Before the engine is started, servo piston (10) is
pushed to the right. (See right drawing)
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)
Spool (6) is pushed to the right, and port (C) and
port (D) will be connected.
Pump pressure (PP) is conducted to the larger
diameter end from the port (K).
The same pump pressure (PP) is conducted to
the smaller diameter end from the port (J).
D375A-6
According to the difference in the areas on servo

piston (10), the servo piston is moved in the direction which makes the swash plate angle minimum.
10-153
DRAFT
Hydraulic system
Work equipment pump
Mechanism to make the pump delivery maximum
q
q
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).
When spool (6) moves, port (D) and port (E) are
interconnected and connected to the PC valve.
The pressure across circuits (D) and (K) becomes drain pressure (PT).
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
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.
The movement of spool (6) transmits pump discharge pressure (PP) to the large diameter end
of the piston through port (C) , port (D) and port
(K).
Pump pressure (PP) is also conducted to port (J)
of the small diameter end of the piston, but because of the difference in area between the large
diameter end and the small diameter end on servo piston (10), it is pushed to the right. As the result, 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
The symbols (A1), (A0) and (PEN) represent the

area receiving the pressure at the large diameter
end of the piston, the area receiving the pressure
at the small diameter end and the pressure conducted to the large diameter end of the piston,
respectively.
When the force generated by main pump pressure (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.
The swash plate of the pump is held at the intermediate position. [Spool (6) is stopped at a position where the opening area from port (D) to port
(E) and the distance from port (C) to port (D) is
almost the same.]
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
Force of spring (4) is adjusted in such that the

position of the balanced stop of this spool (6) is
determined when (PP) - (PLS) = 1.96 MPa
{20 kg/cm2} at the median of the specified value.
D375A-6
DRAFT
Hydraulic system
Work equipment pump
D375A-6
10-157
Hydraulic system
Control valve
Control valve
6-spool valve for dual tilt
General view
10-158
10-158
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)

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

General view
10-164
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
(04)
10-164-1
Hydraulic system
Control valve
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
(04)
10-164-3
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

2. Check valve (built-in to spool)
3. Suction valve
4. Suction valve
D375A-6
(04)
10-164-5
Hydraulic system
Control valve
Operation of control valve
10-164-6
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 circuit from rising.
Operation
10-164-6
Function
When set to "HOLD" position (operation of unload

valve)
10-164-6
q
q
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.
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) receiving the pressure.
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.
Therefore, spool (1) is balanced at a position that
matches the supply of oil from the pump.
Actually, the amount of oil supplied from the
pump is small, so the pressure in the circuit is almost 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)
When the spool is set to the "HOLD" position, the

pump pressure is sent from chamber (A) to pressure compensation valve spool (3) through its
notch, and then conducted through chamber (B)
to chamber (C).
The oil in chamber (G) is drained through chamber (H) to chamber (F).
D375A-6
(04)
10-165
When this happens, the pump pressure is acting

on the left end of spool (3) of the pressure compensation valve, so it pushes against the force of
spring (4) and moves rightward to the maximum
stroke position.
At this condition, the area of the opening for
spool (1) of the blade tilt valve is at its minimum.
10-165
Hydraulic system
Control valve
When set to "HOLD" position (blade tilt cylinder circuit on single tilt specification machine)
q
q
10-16
When the spool is se to "HOLD" position, the

pump pressure is sent from chamber (A) through
chamber (B) to chamber (C).
Pressure in chamber (H) is drained to chamber
(F).
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)
When the tilt lever is operated to right tilt position, pilot pressure (PB1) acts on the right end of
spool (1) through the PPC valve.
when the pressure becomes greater than the set
force of spring (2), the spool (1) begins to move
leftward. It is balanced at a position corresponding to PPC output pressure (PB1.
D375A-6
(04)
q
q
10-16 -1
dPLS = differential pressure between ports

(L) and (K) = 1.96 {20 kg/cm2}
dPLS' = differential pressure between ports
(J) and (D)
dPLS C dPLS'
10-166-1
Hydraulic system
Control valve
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).
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).
The condition of the pressure of spool (3) is
chamber (B) pressure C chamber (C) pressure,
and chamber (G) pressure C chamber (D) pressure, 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).
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.
On the other hand, if the oil flow is too small,
spool (3) moves in the direction to increase the
oil flow.
Pump servo valve (7) is controlled so that the differential pressure [LS differentical pressure:
(dPLS)] between pump pressure (P) and LS
pressure (LS) remains constant.
A suitable amount of oil flows to ensure that the
loss of pressure at the control valve (dPLS') is
equal to (dPLS).
The loss of pressure in the control valve is determined by the area of the opening of the main
spool, so the oil flow matches the area of the
opening of the spool.
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)
When the tilt lever is operated to right tilt position, pilot pressure (PB3) acts on the right end of
spool (1) through the PPC valve.
when the pressure becomes greater than the set
force of spring (2), the spool (1) begins to move
leftward. It is balanced at a position corresponding to PPC output pressure (PB3.
D375A-6
(04)
q
q
10-167
dPLS = differential pressure between ports

(K) and (J) = 1.96 {20 kg/cm2}
dPLS' = differential pressure between ports
(H) and (D)
dPLS C dPLS'
10-167
Hydraulic system
Control valve
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).
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).
LS valve (5) is controlled in such that the differential pressure [LS differential pressure: (dPLS)]
between pump pressure (P) and LS pressure
(LS) becomes constant.
A suitable amount of oil flows to ensure that the
loss of pressure at the control valve (dPLS') is
equal to (dPLS).
The loss of pressure in the control valve is determined by the area of the opening of the main
spool, so the oil flow matches the area of the
opening of the spool.
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)
a The diagram shows the condition when work equipment LS valve (5) is relieved at blade tilt stroke end.
q
q
q
dP1 = dP3 + dP4 = Differential pressure between ports (M) and (P)
dP2 = Differential pressure between ports (P)
and (N)
dP3 = Differential pressure between ports (M)
and (B)
D375A-6
(04)
q
q
10-169
dP4 = Differential pressure between ports (B)

and (P)
dLS = dP1 + dP2 = Differential pressure between ports (M) and (N) = 1.96 {20 kg/cm2}
10-169
Hydraulic system
Control valve
If blade tilt valve (1) is moved, and the pressure

of tilt cylinder (8) becomes higher, work equipment LS relief valve (5) will open and oil will be
drained from LS circuit (O).
(Ports (P), (F), (G), (J) and (K))
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.
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.
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).
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.
The swash plate is balanced at a position where
the LS differential pressure is 1.96 {20 kg/cm2}.
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.
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 balance the circuit.
10-170
D375A-6
(04)
Hydraulic system
Control valve
Pitch system on dual tilt specification machine
a A dual tilt specification machine is configured with the dual tilt and pitch system circuits.
When single tilt operation is carried out
In the single tilt mode, solenoid selector valve (1)

is in the neutral position and connected to (PA4)
and (PB4) of the control valve as shown in the
figure.
PPC circuits (2) and (3) are separated from output circuits (4) and (5) of the PPC valve.
D375A-6
(04)
10-171
10-171
As a result, the right tilt cylinder does not move

and only the left tilt cylinder moves to carry out
the single tilt operation.
10-171
Hydraulic system
Control valve
When dual tilt operation is carried out
10-172
In the dual tilt mode, the position of solenoid selector valve (1) is changed as shown in the figure.
At this time, PPC circuit (2) connected to (PB3)
of the control valve is connected to output circuit
(4) of the PPC valve.
10-172
PPC circuit (3) connected to (PA3) of the control

valve is connected to output circuit (5) of the
PPC valve.
Accordingly, both tilt cylinders move in the opposite directions each other to carry out the dual tilt
operation.
D375A-6
(04)
Hydraulic system
Control valve
When pitch operation is carried out
q
q
10-172-1
In the pitch mode, the position of solenoid selector valve (1) is changed as shown in the figure.
At this time, PPC circuit (2) connected to (PB3)
of the control valve is connected to output circuit
(5) of the PPC valve.
D375A-6
(04)
PPC circuit (3) connected to (PA3) of the control

valve is connected to output circuit (4) of the
PPC valve.
Accordingly, both tilt cylinders move in the same
direction to carry out the pitch operation.
10-172-1
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)

2. Spring
3. Valve (pressure reducing valve)
4. Spring (pressure reducing valve main)
5. Filter
10-174
6. Screw
7. Poppet
8. Spring (for pressure reducing valve pilot)
9. Spring (safety valve)
10. Ball
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
q
q
Spring (6) pushes the poppet (5) the seat, and

port (PR) is disconnected from port (T).
Spring (7) pushes the valve (8) to the left, and
port (P1) is connected to port (PR).
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
The force of spring (3) and the force of exerted

by the (PR) pressure [0MPa {0 kg/cm2} at the
time of engine stop] push valve (2) in the direction to block the passage between the ports (P1)
and (P2). When the hydraulic oil enters (P1) port,
the value balances at a position where the expression [Force exerted by pressure (P1) C
Force of spring (3) + Force (area (d) Pressure
(PR) ] holds, and the area of the opening between ports (P1) and (P2) is adjusted so that
pressure (P1) is maintained higher than pressure (PR) .
When the (PR) pressure rises above set pressure, 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
Therefore, differential pressure is developed

across hole (a) in spool (8) to move spool (8) in
the direction to block the opening between ports
(P1) and (PR) . Thus this valve uses the area of
the opening to regulate pressure (P1) to a certain level (set pressure) and supplies it as pressure (PR).
10-177
DRAFT
Hydraulic system
When load pressure (P2) is high
When load pressure (P2) rises due to digging or

other operations, pump delivery increases and
pressure (P1) rises. When the expression {Force
exerted by pressure (P1) > Force of spring (3) +
Force [area (d) pressure (PR)]} holds, and
valve (2) moves downward to its stroke end. As
a result, the opening between the ports (P1) and
(P2) increases, the passage resistance becomes smaller to reduce engine horsepower
loss.
When pressure (PR) rises above the set pressure, 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
Therefore, differential pressure is developed

across hole (a) in spool (8) to move spool (8) to
block the opening between ports (P1) and(PR) .
Thus this valve uses the area of the opening to
regulate pressure (P1) to a certain level (set
pressure) and supplies it as pressure (PR).
D375A-6
DRAFT
Hydraulic system
When abnormally high pressure is generated
When the (PR) pressure of the self-pressure reducing 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
2. Damper mount (front)
3. Damper mount (rear)
D375A-6
Outline
q The cab mounts are installed at two places in the
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 vibration.
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
2. Deceleration potentiometer
3. Starting switch
4. Work equipment controller
6. Fuel control dial
7. Battery
8. Circuit breaker
9. Battery relay
10. Starting motor
11. Engine controller
12. Alternator
10-184
Outline
q The throttle signal of the fuel control dial is input
to the power train controller and processed together with the other information, then the result
is sent as the throttle command to the engine
controller. The engine controller controls the fuel
supply pump according to the command.
D375A-6
DRAFT
Electrical system
Engine control system
Outline
q The engine throttle controller receives the fuel
control dial signal of the 1st throttle, decelerator
pedal signal of the 2nd throttle, and 3rd throttle
signal which is the control signal from the power
train controller, and then controls the fuel supply
pump according to the command signal having
the lowest engine speed.
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 engine throttle controller.
D375A-6
The information of the engine controller is possessed jointly by the other controllers through
the network and used for the optimum control of
the engine and power train.
The automatic deceleration is a function of lowering the engine speed temporarily when the
travel direction is changed from F3, R3, F2 or R2
(for protection of the transmission clutch).
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 engine controller, engine controller cooler is installed to cool the engine controller by fuel.
q Rubber vibration isolator reduces vibration.
Common engine controller
q The common engine controller CM850 is adopted which is co-developed by Komatsu and Cummins.
10-186
D375A-6
DRAFT
Electrical system
Meanings of signal classes in the terminal table

shown below are as follows.
A: Power supply
B: Input
C: Ground/Shield/Return
D: Output
E: Communication
Signal name
NC (*)
Pin No.
Signal name
Input/output
37
Sensor power source (5 V)
38
GND
39
NC (*)
40
NC (*)
41
NC (*)
Input/output
42
NC (*)
43
NC (*)
Boost pressure sensor
CN-CE01
Pin No.
CN-CE01
NC (*)
44
Ambient pressure sensor
45
Injector #1 (+)
Supply pump #1 (+)
46
Injector #5 (+)
Supply pump #1 ()
47
Sensor GND
CAN (-)
48
Ne sensor ()
NC (*)
49
NC (*)
CAN(+)
50
NC (*)
Supply pump #2 (+)
51
Injector #2 ()
10
Supply pump #2 ()
52
Injector #3 ()
11
EGR valve ()
53
Injector #1 ()
12
NC (*)
54
Injector #2 (+)
Injector #3 (+)
13
Engine oil pressure sensor
55
14
NC (*)
56
Injector #4 (+)
15
Coolant temperature sensor
57
Injector #6 (+)
16
58
Injector #4 ()
17
Engine oil temperature sensor
59
Injector #6 ()
18
NC (*)
60
Injector #5 ()
19
EGR valve position sensor
20
NC (*)
21
NC (*)
22
EGR valve (+)
23
Boost temperature sensor
24
NC (*)
25
Common rail pressure sensor
26
BKup sensor (+)
27
NE sensor (+)
28
NC (*)
29
Bypass valve position sensor
30
Fuel temperature sensor
31
Bypass valve (+)
32
NC (*)
33
34
NC (*)
35
NC (*)
36
NC (*)
D375A-6
*: Never connect to NC, or malfunctions or failures

will occur.
10-187
DRAFT
Electrical system
CN-CE02
CN-CE02
Pin No.
Signal name
Input/output
Pin No.
Signal name
Input/output
NC (*)
43
NC (*)
NC (*)
44
NC (*)
NC (*)
45
NC (*)
NC (*)
46
CAN(+)
NC (*)
47
CAN (-)
NC (*)
48
NC (*)
NC (*)
49
NC (*)
NC (*)
50
NC (*)
Decelerator signal
10
NC (*)
11
NC (*)
12
NC (*)
13
NC (*)
14
NC (*)
GND
15
NC (*)
Power source (+24 V constant)
16
NC (*)
Power source (+24 V constant)
17
NC (*)
18
NC (*)
19
NC (*)
20
NC (*)
21
NC (*)
22
23
GND
24
NC (*)
25
NC (*)
26
NC (*)
27
NC (*)
28
NC (*)
29
NC (*)
30
NC (*)
31
NC (*)
32
NC (*)
33
GND
34
NC (*)
35
NC (*)
36
NC (*)
37
CAN shield
38
NC (*)
39
Key switch (ACC)

Electrical intake air heater relay
(+)
NC (*)
Electrical intake air heater relay
return
40
41
42
10-188

will occure.
CN-CE03
Pin No.
1
GND
Signal name
Input/output
C

will occur.
D
C
D375A-6
DRAFT
Electrical system
Sensors
Fuel temperature sensor
q The fuel temperature sensor senses the fuel
temperature and sends it to the engine controller. 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 computer and the resistance of the thermistor.
D375A-6
10-189
Electrical system
EGR valve position sensor

This sensor senses the opening and closing positions of the EGR valve.
10-20
1. EGR valve position sensor

The following graph shows the output characteristics of the position sensor.
10-190
D375A-6
(06)
DRAFT
Electrical system
NE speed sensor (Crank angle sensor)

q If the signal hole made on the flywheel passes
the sensor, the magnetic line of force changes.
q If the magnetic line of force changes, the output
of the Hall element sensor changes linearly and
it is converted into pulse of 0 5 by the wave
form shaping circuit in the sensor, and then output.
Bkup speed sensor (G sensor)

(Cylinder No. sensor)
q Similarly to the NE speed sensor, this sensor utilizes the pulses of 0 5 generated by the change
of the magnetic line crossing the sensor unit.
q The disc gear installed to the central part of the
camshaft of the high-pressure pump has teeth
(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 recognized by the combination of the NE speed
sensor pulse and Bkup speed sensor pulse.

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

q The boost temperature sensor senses the intake
air temperature (boost temperature) and sends it
to the engine controller.
q The sensor unit is a thermistor the resistance of
which changes according to the temperature.
The engine controller applies voltage to the
10-192

q The coolant temperature sensor senses the
coolant temperature and sends it to the engine
controller.
q The sensor unit is a thermistor the resistance of
which changes according to the temperature.
The engine controller applies voltage to the
D375A-6
DRAFT
Electrical system
Deceleration potentiometer
1. Connector
2. Lever
3. Body
4. Potentiometer
5. Coupling
6. Shaft
7. Stopper
D375A-6
Outline
q The deceleration potentiometer is installed to the
front lower part of the operator's cab and connected to the decelerator pedal by linkage.
q
When the decelerator pedal is depressed, the

throttle potentiometer shaft is rotated by the linkage 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 decelerator pedal.
10-193
DRAFT
Electrical system
CRI engine control system

a "CRI" is an abbreviation for Common Rail Injection.
System diagram
10-194
D375A-6
Electrical system
1. NE speed sensor
2. Engine throttle controller
3. Injector assembly
3A. Orifice
3B. Control chamber
3C. Hydraulic piston
3D. Injector
3E. Nozzle
4. Orifice (for air bleeding)
5. Fuel tank
6. Pre fuel filter
7. Main fuel filter
8. Overflow valve
9. Fuel supply pump
9A. PCV
9B. High pressure pump
9C. Priming pump
9D. Feed pump
9E. Bkup speed sensor (G sensor)
10. Common rail
11. High pressure injection pipe
12. Flow damper
13. Pressure limiter
14. Electric priming pump
15. Engine throttle controller cooler
10-205
Outline
q The signals detected by various sensors are input to the engine controller.
q The engine controller processes input signals
and output command signals to each actuator to
control the fuel injection rate and fuel injection
timing.
D375A-6
(06)
10-205
System configuration
q The CRI system consists of fuel supply pump
(9), common rail (10), injectors (3), engine throttle controller (2) to control them, and sensors.
q The fuel supply pump generates fuel pressure in
the common rail. The fuel pressure is controlled
by the fuel delivery from the supply pump. The
discharge rate is controlled by turning on and off
PCV (discharge control valve) (9A) of the fuel
supply pump according to the electric signals
from the engine throttle controller.
The common rail receives the pressurized fuel
from the fuel supply pump and distributes it to
the cylinders.
The fuel pressure is sensed by the common rail
fuel pressure sensor installed to the common rail
and controlled by the feedback method so that
the actual fuel pressure corresponds to the
command pressure set according to the engine
speed and the load on the engine.
The fuel pressure in the common rail is applied
to the nozzle (3E) and control chamber (3B) of
the injector through the high-pressure fuel pipe
of each cylinder.
q The injector controls the fuel injection rate and
fuel injection timing by energizing and de-energizing the TWV (2-way solenoid valve). If the
TWV is energized, the fuel circuit is so changed
that the high-pressure fuel in the control chamber flows out through orifice (3A). As the result,
the force exerted by the pressure of the
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 changed that
the pressure of the fuel applies to the control
chamber through the orifice. As a result, the needle valve lowers and finishes fuel injection. Accordingly, the fuel injection timing and fuel
injection rate are controlled respectively by the
timing to energize the TWV and the duration of
energizing the TWV.
10-195
DRAFT
Electrical system
Monitor system
Monitor system
The monitor system monitors the machine condition with the sensors installed to various parts
of the machine and processes and displays the
obtained information on the monitor panel quickly 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,
The CPU (Central Processing Unit) in the monitor panel displays and outputs various information 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)

Display of machine monitoer
Contents and conditions of processing
1. Display of travel direction and gear speed.
q F1, R3, etc. are notified by CAN according to information of power train
controller.
2. Display of gauges of fuel level, engine coolant temperature, etc.
q Controller converts the sensor signals into gauge numbers and sends
them to the machine monitor by CAN.
3. Display of problem
q When the machine has a trouble, the corresponding failure code is notified to the machine monitor through CAN signal.
q The command to sound the buzzer or to light up the caution lamp is notified, too.
1) In standard screen
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.
q The item Nos. and device conditions are notified to the machine monitor
by CAN.
q The machine monitor displays the items and each value.
2. Each items is selected by using the cursor switches and confirmation
switch.
10-197
Method
Flow of signals
CAN
CAN
Each sensor, solenoid
O
Controller
O
Machine monitor
CAN
Method
CAN
CAN
Flow of signals
Each sensor
O
Controller
O
Machine monitor
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
Method
Flow of signals
a Since this item is included in the service menu, it is not usually displayed.For details of the operating method, see "Special functions of monitor panel (EMMS)" section of Testing and adjusting.
D375A-6
(04)
10-197
DRAFT
Electrical system
Machine monitor
Machine monitor
Outline
q The machine monitor has the display function,
mode selection function and switch function for
electrical parts.
q The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output
the information.
q The monitor display employs an LCD (Liquid
Crystal Display). The switches are flat sheet
switches.
10-198
Precautions on the machine monitor display

q The liquid crystal display panel may have black
spots (which do not light up) or bright spots
(which stay on). Products having 10 or less black
or bright spots conform the product specification;
such the condition is quite normal.
q When the engine is started, the battery voltage
may suddenly drop depending on the temperature and the battery condition. If this happens,
the display on the machine monitor may momentarily go out, but this does not indicate any abnormality.
q Continuous operation of the machine monitor
may display blue bright spots on the screen having 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).
D375A-6
DRAFT
Electrical system
Machine monitor
Input and output signals

CN-CM01
Pin No.
CN-CM03
Signal name
1
2
3
4
Battery power (+24 V constant)

Battery power (+24 V constant)
Battery power GND
Battery power GND
Wake-up
6
7
8
9
10
11
12
13
14
15
16
17
18
Relay output
Chassis signal GND
Hydraulic oil pressure
Fuel level
NC (*)
Battery charge
Chassis analog signal GND
Light switch
Key switch (ACC)
Key switch (C)
Preheating
NC (*)
NC (*)
Input/out
put
Input
Input
Input/out
put
Output
Input
Input
Input
Input
Input
Input
-

will occur.
CN-CM02
Pin No.
Signal name
1
2
3
4
5
6
7
8
NC (*)
NC (*)
Coolant level sensor
NC (*)
NC (*)
NC (*)
Chassis signal GND
CAN terminating resistance
COMM_CAN_H_0
10
COMM_CAN_L_0
11
12
NC (*)
NC (*)
Input/out
put
Input
Input/out
put
Input/out
put
-

will occur.
Pin No.
Signal name
1
2
3
RS232C CD for communication terminal

RS232C RXD for communication terminal
RS232C SG for communication terminal
GND for communication terminal control signal
Communication terminal selection signal
RS232C RTS for communication terminal
RS232C TXD for communication terminal
RS232C DTR for communication terminal
RS232C DSR for communication terminal
RS232C CTS for communication terminal
RS232C RI for communication terminal
GND for communication terminal power
Input CH1 for communication terminal status
Output for communication terminal power
control
Output CH1 for communication terminal control
Output CH2 for communication terminal control
Input CH2 for communication terminal status
Power supply for communication terminal
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Input/out
put
Input
Input
Input
Output
Output
Output
Input
Input
Input
Input
Output
Output
Output
Input
Output
CN-CM04
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
Signal name
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
Input/out
put
-

will occur.
CN-CM05
Pin No.
1
2
3
4
5
6
7
8
D375A-6
Signal name
Power supply for camera
Camera NTSC signal input 1
Electric power supply GND for camera
Camera signal GND1
Camera signal GND2
Camera signal GND3
Input/out
put
Output
Input
Input
Input
-
10-199
DRAFT
Electrical system
Machine monitor
Monitor control portion
1. Gearshift mode selector switch

2. Buzzer cancel switch
3. Operation mode switch
4. Engine coolant temperature gauge
5. Multi gauge
6. Pilot display
7. Service meter/clock
8. Mode display
10-200
9. Fuel level gauge

10. Gearshift mode and preset gearshift pattern
11. Guidance icon
12. Function switch
13. Customization switch
14. Customization memory switch
D375A-6
Electrical system
Machine monitor
Machine monitor display

Display
category
Symbol
10-201
Display item
Contents
Radiator coolant level Below "low" line
Check
Oil pressure
D375A-6
(04)
Description
Displays when engine is stopped and
starting switch is set to ON position
Display when normal: OFF
Display when abnormal: ON
When sensor is abnormal or

when wiring harness is disDisplay when abnormal: ON
connected
Battery charge condiWhen charge is defective

tion
Engine oil level (if

equipped)
Lights up at low level or

below
Hydraulic oil level (if

equipped)
Lights up when oil level is

below suction limit
Displays when starting switch is set to

ON position and engine is running
Display when abnormal: ON CAUTION lamp flashes
Displays when starting switch is
turned to ON position with engine
stopped.
Display when abnormal: OFF Display
when normal: ON
Displays when starting switch is
turned to ON position with engine
stopped.
Display when normal: ON Display
when abnormal: OFF
10-201
Electrical system
Machine monitor
Display
category
Symbol
Display item
Oil pressure
Contents
Description
Lights when it becomes 49.0

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

Battery charge condiand below while engine is
tion
running
Radiator coolant level
Cautions
Engine coolant temperature
Torque converter oil

temperature
Lights when it becomes

below "low" line

When highest gauge segment is;
Above 102 C: Symbol ON
Above 105 C: Symbol ON +
buzzer sounds
Torque converter oil temperature
When highest gauge segment is;
Above 130 C: Symbol ON +
buzzer sounds
Displays when starting switch is set to

ON position and engine is running
Display when abnormal: ON
Alarm buzzer sounds
Pilot

Hydraulic oil temperaAbove 110 C: Symbol ON +
ture
buzzer sounds
10-202
Maintenance
Lights up for 30 seconds

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

Pa {-762 50 mmH2O} is
reached.
Hydraulic oil level (if

equipped)
Lights up when oil level is

below suction limit
Preheating
When preheating
Lights according to required time

determined by engine controller.
It also lights up at the time of manual
preheat by setting the starting switch
at the preheat position (turning the
switch counterclockwise).
D375A-6
(04)
Electrical system
Machine monitor
Display
category
Symbol
Display item
Contents
Description
Reads the temperature
Gauge
Torque converter oil

temperature
Hydraulic oil temperature
D375A-6
(04)
Fuel level
Reads the level
Service meter (Hours

From 0 to 99999
meter)
Progresses when the engine is running
10-203
Electrical system
Machine monitor
10-204
Gauge
The gauge pointer disappears when information on coolant temperature or hydraulic oil temperature cannot
be obtained due to disconnection of CAN.
Gauge
(C)
Power train oil temperature

(C)

(C)
Fuel level
(l)
10-204
Range
A1
A2
A3
A4
A5
A6
B1
B2
B3
B4
B5
B6
C1
C2
C3
C4
C5
C6
D1
D2
D3
D4
D5
D6
Temperature or volume
105
102
100
85
60
30
130
120
118
90
50
0
110
100
98
70
20
0
1000
755
550
395
275
145
Indicator
Red
Red
Off
Off
Off
White
Red
Red
Off
Off
Off
White
Red
Red
Off
Off
Off
White
Off
Off
Off
Off
Off
Red
Buzzer sounds.
D375A-6
(04)
Electrical system
Machine monitor
10-205
Machine speed
1. 0 km/h
2. 5 km/h
3. 10 km/h
4. 15 km/h
1. 0 MPa
2. 10 MPa
3. 20 MPa
10-205
D375A-6
(04)
4. 0.4 MPa
5. 0.5 MPa
6. 0.7 MPa
4. 25 V
5. 30 V
6. 31 V
10-205
Engine speed
1. 500 rpm
2. 1000 rpm
3. 1500 rpm
4. 30 MPa
5. 40 MPa
6. 50 MPa
Engine oil pressure
1. 0 MPa
2. 0.2 MPa
3. 0.3 MPa
1. 0 V
2. 17 V
3. 20 V
10-205
Hydraulic pump oil pressure
10-205
Battery voltage
4. 2000 rpm
5. 2500 rpm
6. 3000 rpm
10-205
Drawbar pull
1. 0 W
2. 0.2 W
3. 0.4 W
4. 0.6 W
5. 0.8 W
6. 1.0 W
10-205
Electrical system
Machine monitor
10-206
Guidance icon and function switch
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.
Symbol
10-206
Switch
power
Item
Function
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.
F5
Selection of maintenance
screen
Switches to Maintenance List screen.
F6
Select user mode screen
Switches to Use Menu screen.
F3
Select item
Selects item on left side (Selects right end item after left end
item).
F4
Select item
Selects item on right side (Selects left end item after right end
item).
F3
Select item
Selects item on lower side (Selects top item after bottom

item)/Resets holding of monitoring.
F4
Select item
Selects item on upper side (Selects bottom item after top

item)/Holds monitoring.
F1
Select item
Displays next page for selection (Selects top page after last
page).
F2
Select item
Displays previous page for selection (Selects last page after

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

adjustment.)
F1
Start
Starts operation. (Used to start measurement of split fuel consumption on fuel consumption display screen.)
F1
Stop
Stops operation. (Used to stop measurement of split fuel consumption 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
D375A-6
(04)
Electrical system
Machine monitor
Service meter and clock switching function10-207

Pressing F4 on the standard screen when the service meter is displayed in the top center of the
screen switches the display to the clock, and doing
so when the clock is displayed switches the display
to the service meter.
Maintenance reminder function
10-207
Pressing F5 on the standard screen switches to the
Maintenance List screen.
F1: Displays the next page.

Displays the top page when the last page is displayed.
F2: Displays the previous page.
Displays the last page when the top page is displayed.
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 Maintenance Time Reset screen.
No operation at least 30 sec.: Returns to the standard screen.
q On the Maintenance List screen, if the time remaining 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 remaining time for the selected item can be reset
and returned to the default.
D375A-6
(04)
10-207
Electrical system
Machine monitor
F5: Cancels the reset to return to the Maintenance

List screen.
F6: Resets the remaining time and returns to the
standard screen.
q
The defailt password is 000000.

Enabling the password lock on an attachmentequipped machine locks the attachment setting
screen at the same time.
a For information on changing the maintenance
password, see "Function of changing maintenance password" of "Testing and adjusting".
q
q
The table below shows the maintenance items

and replacement intervals.
The time remaining to maintenance is reduced
as the machine is operated.
No.
01
02
03
41
04
07
08
10
19
20
Item
Engine oil
Engine oil filter
Fuel main filter
Fuel pre-filter
Hydraulic oil filter
Damper case oil
Finaldrive case oil
Hydraulic oil
P/L oil
P/L oil filter
Replacement interval
(Hours)
500
500
500
500
2000
2000
2000
2000
1000
500
P/L: Power train

q
The display of the maintenance monitor differs

according to the remaining time. The relationship 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.
There is one or more items with
Warning display
(white symbol on red less than 0-hour remaining time
for maintenance.
background)
q
To prevent careless reset of the maintenance interval, the screen is password protected.
10-208
D375A-6
(04)
Electrical system
Machine monitor
User mode
q
q
10-209
Pressing F6 on the standard screen enters the
user mode, switching to the User Menu screen.
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 camera is set)
Fan reverse mode
Skipping pre-lubrication
Normal
q
10-209
The standard screen is displayed.

10-209
The horizontal axis indicates the time and the
vertical axis indicates the drawbar pull. The machine should be operated with the drawbar pull
kept in the green range.
The graph on the screen is updated and scrolled
to the left at intervals of several seconds.
Load display
q
10-209
The horizontal axis indicates the time and the
vertical axis indicates the pitch angle of the body.
The graph on the screen is updated and scrolled
to the left at intervals of several seconds.
Body pitch display

q
q

F5: Returns to the normal screen.
F6: Switches to the setting screen for the selected
item.
(In user mode, no switch operation at least 30 sec.
returns to the previous screen.)
10-209
If Utility Screen Select is selected with switch F6,
(1) Standard Display, (2) Load Display, or (3)
Body Pitch Display can be selected.
Select the desired item with switch F3 or F4 and
enter that item with switch F6.

q
D375A-6
(04)
10-209
On this screen, the display item assigned to the
gauge at the center can be selected.
Multi gauge select

q
10-209
Electrical system
Machine monitor
Select desired item with switch F3 or F4 and enter that item with switch F6.
The following items can be selected.
Sellectable item for multi gauge

No.
Selected item
Remarks
1 PL oil temperature
With caution
Hydraulic oil tempera2
With caution
ture
3 Vehicle speed
Hydraulic pump pres4
sure
5 Engine oil pressure
With caution
6 Battery voltage
7 Engine speed
8 Traction force
9 Clock
Engine coolant temper10
For Utility Screen Select
ature
11 Fuel level
For Utility Screen Select
10-210
Selecting the Screen Adjustment on the User
Menu screen and pressing F6 switches to the
Screen Adjustment screen.
From this menu, you can adjust the brightness,
contrast, and luminance of the machine monitor
screen.
When the light switch is set to "Night mode ON",
the night mode screen is adjustable.
When the light switch is set to "Daytime mode
ON" or OFF, the daytime mode screen is adjustable.
Screen adjustment
q
q
q
F2: Returns all adjusted values to the defaults.

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 camera 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.

F6: Moves to the setup screen of the selected (highlighted) item.
q The adjustment methods for the camera screen
and standard screen are the same.
q The background when adjusting the camera
screen is the No.1 camera image.

F6: Enter the changes and moves to the next item.
10-210
D375A-6
(04)
Electrical system
Machine monitor
10-21
Select the Clock Adjustment on the User Menu
screen and press F6 to switch to the Clock Adjustment screen.
On this screen, you can change the setting of the
time displayed on the standard screen.
F5: Cancels change you made before

entering them with F6 and returns to the User
Menu screen.
F6: Enters the changes and moves to the
Time setting.
Clock adjustment
q
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.
10-21
Select the Language on the User Menu screen
and press F6 to switch to the Language setting
screen.
From this menu, you can change the language to
be displayed on the monitor. Available languages are as follows.
English, Japanese, Chinese, French, Spanish,
Portuguese, Italian, German, Russian, and
Turkish
Language setting
q
1) Time setting
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
entering it with F6 and returns to the User
Menu screen.
F6: Enters the change and moves to the
12/24 Mode setting.

F5: Cancels the change and returns to the User
Menu screen.
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 highlight 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
(04)
10-211
Electrical system
Machine monitor
Setting of camera for reverse-interlock enabled mode

(applied to machines equipped with rear view camera)
10-212
When reversing the machine, the image of rear

view camera can be displayed on the multi monitor.
q Turn "ON" the starting switch, select "Pre-lubrication 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, travel/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
10-213
In this mode, the fan can be set to drive in reverse to clean the radiator core.
While the starting switch is set to OFF, select the
menu with switch F3 or F4 and enter it with
switch F6.
While screen (A) is displayed, press switch F6,
and the fan is ready to run in reverse.
While screen (B) is displayed, start the engine.
Fan reverse mode

q
q
q
q
10-213
The rotation direction of the fan cannnot be
changed while the engine is running.
When running the fan in reverse, set the lock lever to the LOCK position.
While the fan is running in reverse, the machine
cannot travel.
When canceling the reverse mode, set the starting switch to OFF position to stop the engine.
When using this mode, warm up the engine sufficiently. If the engine is not warmed up, the fan
may not supply sufficient air.
Precautions for using fan reverse mode

q
q
q
q
q
D375A-6
(04)
10-213
Electrical system
Machine monitor
Pre-lubrication skip mode (applied to machines

equipped with pre-lubrication)
q
q
10-214
This mode is used for starting engine without activating pre-lubrication.
Turn "ON" the starting switch, select The item on
the screen (A) with F3 or F4 key while engine is
not started, then fix it with F6 key.
Press F6 on screen (B) to complete pre-lubrication skip.
After setting the mode, the display returns to
user menu automatically.
Setting the starting switch to "START" position
initiates the starter rotation and starts up the engine without turning on the pre-lubrication operation.
Function of checking service meter

q
10-214
If you continuously pressing working mode selector switch (1) and buzzer cancel switch (2) at
the same time when setting the starting switch to
the OFF position, the service meter will appear
on the screen in 3 to 5 seconds.
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

q
10-214-1
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.
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.
Pressing any function switch returns to the previous screen.
D375A-6
(04)
10-214-1
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
5. Engine speed sensor
D375A-6
10-217
DRAFT
Electrical system
Gearshift mode function

Outline
There are the auto gearshift mode and manual gearshift mode in the gearshift mode. These modes are
changed to each other each time gearshift mode
switch (1) is pressed.
1. Auto gearshift mode (Heavy duty dozing mode)
q If a load is applied, the gear is shifted down
automatically. When the load is removed,
the gear is shifted up to the set maximum usable gear speed automatically.
q The torque converter lockup operates according to loads and the maximum usable
gear speed is selected automatically. In this
mode, less fuel is consumed and more production is obtained.
2. Manual gearshift mode (General dozing mode,
ripping mode)
however, the gear is not shifted up automatically.
3. Shoe slip control mode (if equipped)
however, the gear is not shifted up automatically.
q Automatic deceleration of the engine during
the ripping operation reduces operator's fatigue and prevents grousers from useless
wearing caused by shoe slippage.
6. Preset gearshift pattern(gear speed at start)

7. Mark of "Dozing 2" (which indicates manual
gearshift mode)
C:Shoe slip control mode (if equipped)
8. Gear speed used currently
9. Preset gearshift pattern (gear speed at start)
10. Mark of "Ripping "(which indicates shoe slip
control mode)
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
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
10-218
D375A-6
DRAFT
Electrical system
Setting preset gearshift pattern by using gearshift switches with travel control lever in neutral
q Set the preset gearshift pattern (gear speed at
start) or the maximum usable gear speed (for
only the auto gearshift mode) by using the gearshift switches with travel control lever in neutral.
Setting preset gearshift pattern (gear speed at
start) or maximum usable gear speed

start)
C:Shoe slip control mode (if equipped)

start)
D375A-6
a When the starting switch is set to ON position,

the auto gearshift mode ([F1 R1]) is set. When
the gearshift mode is changed, [F1 R1] is selected initially.
Changing gear speed by using gearshift switches during travel
q The maximum usable gear speed (in the auto
gearshift mode) or the current gear speed (in the
manual gearshift mode) can be changed with the
gearshift switches while the machine is traveling.
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
During forward travel: The current gear speed
can be set to F1 - F2.
During reverse travel: The current gear speed
can be set to R1 - R2.
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
can be set to R1 - R2.
the current gear speed is shifted up to the next
range.
pressed, the current gear speed is shifted down
to the next range.
10-219
Electrical system
Sensor
Sensor
10-2 0
Sensor name
Type of sensor
When normal
When abnormal
Torque converter oil temperature

sensor
Resistive
Hydraulic oil temperature sensor
Resistive
Coolant level sensor
Contact
ON (Closed)
OFF (Open)
Fuel level sensor
Resistive
Transmission output shaft R speed

sensor
Resistive
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

Hydraulic oil temperature sensor
1. Thermistor
2. Body
3. Tube
10-220
10-2 0
10-2 0
4. Tube
5. Wire
6. Connector
D375A-6
(04)
DRAFT
Electrical system
Sensor
Radiator coolant level sensor
1. Float
2. Sensor
3. Tube
4. Wire
5. Connector
Fuel level sensor
1. Connector
2. Float
3. Arm
4. Body
5. Spring
6. Contact
7. Spacer
D375A-6
Function
q The fuel level sensor is installed to the side face
of the fuel tank. The float moves up and down
according to the fuel level. This movement of the
float is transmitted by the arm to the variable resistor to change its resistance. This sends a signal to the monitor panel to indicate the remaining
fuel level. When the display on the monitor panel
reaches a certain level, a warning lamp flashes.
10-221
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 changes 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 sensor 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
10-2 3-1
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.
Since the clearance between the sensor and
spline is controlled to the specified dimension,
adjustment at installation is not necessary.
Function
q
10-223-1
D375A-6
(04)
Electrical system
Sensor
Engine oil level sensor
1. Connector
2. Bracket
10-2 3-2
3. Float
4. Switch
Air cleaner clogging sensor
1. Spring
2. Switch
3. Hose
10-2 3-2
4. Sensor
5. O-ring
6. Connector
Hydraulic oil level sensor
1. Float
2. Sensor
3. Tube
D375A-6
(04)
4. Wire
5. Connector
10-223-2
DRAFT
Electrical system
Vehicle health monitoring system (VHMS)

Outline
q The VHMS consists of the VHMS controller and
various sensors (some of which are used by other systems, too) and records the operating condition of the machine. It collects and records the
position information and operation information of
the machine, data from measuring instruments,
etc. for later maintenance and service. The data
to be checked are downloaded to a personal
computer.
If the "ORBCOMM terminal system" is installed

to the machine, it can transmit the data recorded
in the VHMS by satellite communication to the
administrator or the service department,
allowing for remote machine management.
For the use of the VHMS, see "30 Testing and
adjusting" of this manual.
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]
Pin No.
Signal name
CN2 [CN2 A, B]
Input/output
Pin No.
Signal name
Input/output
CN2-A1
NC
CN1-1
NC
CN1-2
Sensor power supply (24 V)
Output
CN2-A2
NC
CN1-3
Output
CN2-A3
NC
CN1-4
Output
CN2-A4
NC
CN1-5
Output
CN2-A5
Exhaust temperature (Rear)
Input
CN2-A6
NC
Input
CN2-A7
Exhaust temperature (Front)
CN1-6
CN1-7
Power supply (Constant power

supply) (24 V)
Power supply (Constant power
supply) (24 V)
Input
Input
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
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)
CN2-B7
NC
CN2-B8
NC
CN2-B9
GND
CN2-B10
NC
CN2-B11
NC
CN2-B12
CONNECTOR SEL1 (GND)
D375A-6
Input
-
Input
Input
10-225
DRAFT
Electrical system
CN3 [CN3 A, B]
Pin No.
CN4 [CN4 A, B]
Signal name
Input/output
Pin No.
CN4-A1
NC
Input
CN4-A2
NC
Signal name
Input/output
CN3-A1
NC
CN3-A2
CAB out D/L Sw
CN3-A3
NC
CN4-A3
NC
CN3-A4
NC
CN4-A4
CAN (1) H (KOM-NET/c)
CN3-A5
Model selection (See ORB connection)
Input
CN4-A5
CAN (0) shield (MMS)
CN3-A6
NC
CN4-A6
CAN (0) H (MMS)
CN3-A7
NC
CN4-A7
NC
CN3-A8
NC
CN4-A8
NC
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)
CN3-A15
NC
CN4-B1
NC
CN3-A16
NC
CN4-B2
NC
CN3-A17
NC
CN4-B3
GNG (Orbcomm)
CN3-A18
NC
CN4-B4
RS232C TX1 (Orbcomm)
CN3-B1
NC
CN4-B5
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)
CN3-B6
NC
CN3-B7
NC
Pin No.
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)
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)
CN5-12
GND (LAN)
10-226
Input
Input/output
Input/output
Input/output
Output
Input
CN5
Signal name
Input/output
Output
-
D375A-6
DRAFT
Electrical system
Sensors
Exhaust temperature sensor/amplifier
Engine oil temperature sensor

Specification
Type of sensor: Thermistor
Measurement range : 40 130 C
80 130 C
(Assured accuracy: 2 C)
Max. power consumption:0.5 mW
Pressure capacity: 4.9 MPa {50 kg/cm2}
Operating temperature: -30 C +140 C
Performance table
Specification
Rated voltage: 24V DC
Delectable temperature range: 100 1,000 C
300 800 C
(Assured accuracy: 10 C)
Output voltage characteristics
(Ambient temperature: 20 C)
Reference values
Tem-pe Resis-ta Tem-pe Resis-ta Tem-pe Resis-ta

ra-ture
nce
ra-ture
nce
ra-ture
nce
(C)
(k)
(C)
(k)
(C)
(k)
30
35.27
80
6.571
110
2.887
40
24.28
85
5.682
115
2.544
50
17.05
90
4.931
120
2.248
60
12.20
95
4.293
125
1.992
70
8.884
100
3.750
130
1.769
a. Heat sensing part of sensor

Outside diameter of mounting part: R1/4
Sensed tempera50
100
400
700
800
ture (C)
Output voltage
1.191 1.397 2.626 3.899 4.316
(V)
Operating temperature range: - 40 +110 C

Current consumption: Max. 30 mA
Outside diameter of mounting part: R1/8
b. Amplifier
c. Connector (power supply side)
d. Connector (sensor side)
Function
The exhaust temperature sensor/amplifier is a thermocouple-type temperature sensor, which is installed 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 temperature 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
temperature (C)
Resistance
(k)
-20
-10
10
20
50
30.32 18.58 11.74 7.623 5.077 1.712

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
2. Connector
3. Ambient pressure intake tube
A: GND (Black)
B: Power supply (Red)
C: Output (White)
Specifications and function

Pressure range: 0 20 kPa
{0 2,040 mmH2O}
Allowable pressure: -20 100 kPa
{-2,040 10,200 mmH2O}
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 difference 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 communication system to use the satellite communication
service of ORBCOMM Co., Ltd. (USA). If this
system is installed to the machine, the data recorded in the VHMS controller and various information obtained through the network in the
machine can be transmitted by the satellite communication.
q It is required to sign up for the ORBCOMM terminal 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

2. DRC connector connection (40 poles)
Outline
q The ORBCOMM terminal obtains various kinds
of machine information from the network signals
and input signal in the machine and transmits
them via the wireless communication antenna. It
contains a CPU (Central Processing Unit) and
has wireless communication function.
q This terminal has a LED lamp unit and a 7-segment display lamp unit used for inspection and
troubleshooting.
Input/Output signal
q DRC conector
18
NC
19
NC
20
NC
21
NC
22
NC
23
NC
24
NC
25
NC
26
NC
NC
27
NC
NC
28
NC
NC
29
DOUT (GND)
COMM 232C RXD
30
NC
COMM 232C TXD
31
NC
NC
32
NC
NC
33
NC
NC
34
NC
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
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 communications satellites.
10-232
D375A-6
DRAFT
D375A-6
SEN05175-00
BULLDOZER
D375A-6
Shop Manual
Machine model
D375A-6
Serial number
60001 and up

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

Standard value table for engine
20-3
20-3
Machine model
D375A-6
Engine
Item
Measurement conditions
Engine speed
High idle
Low idle
Rated speed
Boost pressure
At rated horsepower
Exhaust temperature
Exhaust gas color
Valve clearance
(Normal temperature)
EGR valve drive oil
pressure
(Oil temperature: 40
60 C)
Compression pressure
(SAE15W-40 or SAE30
oil)
Blow-by pressure
(SAE15W-40 or SAE30
oil)
Oil pressure
(Oil temperature: 90
110 C)
Oil temperature
Alternator belt tension
Air conditioner compressor belt tension
D375A-6
(06)
Whole speed range (Ambient temperature: 20 C)

At sudden acceleration
At high idle
Intake valve
Exhaust valve
At low speed
At high idle
Engine oil temperature: 40 60 C
(Engine speed)
At rated horsepower
(Coolant temperature: Within operating range)
EOS0W30
At high idle
EOS5W40
EO10W30-DH
EO15W40-DH
At low speed
EO30-DH
Whole speed range (inside oil pan)
Deflection when pressed with finger
force of approximately 58.8 N {6 kg}
Deflection when pressed with finger
force of approximately 98 N {10 kg}
SAA6D170E-5
kPa
{mmHg}
Standard value for

new machine
1,900 (0/-50)
750 50
1,800
Min. 155
{Min. 1,160}
Permissible
value
1,900 (0/-50)
750 50
1,800
Max. 141
{Max. 1,060}
Max. 700
Min. 730
Min. 3.5
Min. 2.0
MPa
{kg/cm2}
(rpm)
Max. 2.5
Max. 1.0
0.32
0.62
Min. 1.18
{Min. 12}
Min. 1.43
{Min. 14.6}
Min. 2.94
{Min. 30}
(210 250)
Max. 2.1
{Max. 21}
kPa
{mmH2O}
Max. 3.43
{Max. 350}
Min. 9.41
{Min. 960}
Min. 392.27
{Min. 4.0}
Max. 235.36
{Max. 2.4}
Min. 117.68
{Min. 1.2}
Max. 78.45
{Max. 0.8}
90 110
Min. 120
mm
(Auto-tension)
mm
(Auto-tension)
Unit
rpm
Bosch index
mm
MPa
{kg/cm2}
kPa
{kg/cm2}
20-3
DRAFT
Standard value table for machine

Machine model
Category
Item
Engine speed
Decelerator pedal
low speed
Measuring condition
q
q
q
q
Torque converter
stall speed
q
q
q
Torque converter
stall + Work equipment relief speed
q
q
Control lever/pedal stroke
PCCS Lever
Forward and
reverse
Engine stopped
Center of lever knob
q
q
q
Brake pedal
Engine stopped
Center of pedal
Engine low idle
Center of pedal
q
q
mm
mm
Full stroke
Until oil pressure becomes
zero
rpm
Neutral o Forward
Neutral o
Reverse
All stroke
(Neutral
Right/Left)
Until clutch is
fully disengaged
Blade control lever
Unit
Working mode: P-mode

Gear shift mode: Manual
Engine coolant temperature: Within operating
range
Torque converter oil temperature: Within operating range
Hydraulic oil temperature: 45 55 C
Decelerator pedal low speed:
Pedal pressed
Torque converter stall speed: F3
Torque converter + Work equipment speed:
F3 + Ripper RAISE
Measure with adjustment ID: 0530 (Stall mode)
Steering
Decelerator pedal
D375A-6
Engine low idle

Hydraulic oil temperature: 45 Neutral Raise
55 C
Neutral Float
Ripper control lever

q
20-4
Engine low idle

Neutral
Hydraulic oil temperature: 45 Raise/Lower
55 C
Neutral Tilt
forward/back
Permissible
value
900 50
900 50
1,530 50
1,450
1,500 50
1,400
30 5
Max. 8.0
30 5
30 5
40 5
40 5
(Play: Max.
(Play: Max. 3)
3)
95
95
45 15
45 15
75 5
75 5
54 5
54 5
60 10
60 10
85 10
85 10
53 10
53 10
78 10
78 10
81 10
81 10
mm
mm
Neutral
Left/Right tilt
q
Standard
value for new
machine
mm
D375A-6
(03)

Machine model
Cate
gory
Item
Left
Engine stopped
Right
PCCS lever
Control lever/pedal operating effort

Control lever/pedal operating effort
Steering
Brake pedal
q
q
q
q
q
Blade control
lever
q
q
Ripper control
lever
Min. speed
Fan
Permissible
value
Neutral o Forward
56.9 6.9
{5.8 0.7}
56.9 6.9
{5.8 0.7}
Neutral o
Reverse
56.9 6.9
{5.8 0.7}
56.9 6.9
{5.8 0.7}
12.8 3.9
{1.3 0.4}
12.8 3.9
{1.3 0.4}
16.7 4.9
{1.7 0.5}
16.7 4.9
{1.7 0.5}
Until clutch is
fully disengaged
13.7 3.9
{1.4 0.4}
13.7 3.9
{1.4 0.4}
At stroke end
19.6 4.9
{2 0.5}
19.6 4.9
{2 0.5}
Until clutch is
fully disengaged
At stroke end
Decelerator pedal
Max. speed
Circuit oil pressure
D375A-6
(06)
Standard
value for new
machine
Measuring condition
q
Forward and
reverse
D375A-6
q
q
Unit
N
{kg}
Engine stopped
Center of pedal
N
{kg}
49.0 9.8
{5.0 1.0}
49.0 9.8
{5.0 1.0}
Engine at low idle

Center of pedal
N
{kg}
460.6 49.0
{47.0 5.0}
460.6 49.0
{47.0 5.0}
39.2 5.9
{4.0 0.6}
39.2 5.9
{4.0 0.6}
82.3 9.8
{8.4 1.0}
82.3 9.8
{8.4 1.0}
Neutral
Left/Right tilt
28.4 4.9
{2.90.5}
28.4 4.9
{2.90.5}
Engine at low idle

Neutral
Hydraulic oil temperature: 45 Raise/Lower
55 C
Neutral Tilt
forward/back
21.6 4.9
{2.20.5}
21.6 4.9
{2.20.5}
20.6 4.9
{2.10.5}
20.6 4.9
{2.10.5}
350 100
1,210 25
Max. 1,110
15.7 2.5
{16025}
15.7 2.5
{16025}
Engine at low idle

Hydraulic oil temperature: 45 Neutral o Raise
55 C
Neutral o Float
Fan 100 % mode

Engine at low
Hydraulic oil temperature: Min. idle
40 C
Engine at high
idle
Engine at high
idle
N
{kg}
N
{kg}
rpm
MPa
{kg/cm2}
20-5

Machine model
Cate
gory
Item
Standard
value for new
machine
Permissible
value
Engine at low
idle
0.03 0.25
{0.3 2.5}
0.03 0.25
{0.3 2.5}
Engine at high
idle
0.69 1.05
{7.0 10.7}
0.69 1.05
{7.0 10.7}
Engine at low
idle
0.03 0.20
{0.3 2.0}
0.03 0.20
{0.3 2.0}
0.44 0.70
{4.5 7.0}
0.44 0.70
{4.5 7.0}
Engine at high
idle
1.29 1.54
{13.2 15.7}
1.29 1.54
{13.2 15.7}
Engine at low
idle
2.25 2.87
{23.0 29.3}
2.25 2.87
{23.0 29.3}
Engine at high
idle
2.55 2.87
{26.0 29.3}
2.55 2.87
{26.0 29.3}
Engine at low
idle
2.48 2.87
{25.3 29.3}
2.38 3.07
{24.3 31.3}
Engine at high
idle
2.68 2.87
{27.3 29.3}
2.58 3.07
{26.3 31.3}
Adjustment ID: 5535 Engine at low

Measure in (both
idle
steering clutch disenEngine at high
gage modes)
idle
2.25 2.84
{23.0 29.0}
2.06 3.13
{21.0 31.9}
2.55 2.87
{26.0 29.3}
2.35 3.16
{23.9 32.2}
2.25 2.84
{23.0 29.0}
2.06 3.13
{21.0 31.9}
Engine at high
idle
2.55 2.87
{26.0 29.3}
2.35 3.16
{23.9 32.2}
Engine at low
idle
2.06 2.35
{21.0 24.0}
1.86 2.55
{18.9 26.0}
Engine at high
idle
2.06 2.35
{21.0 24.0}
1.86 2.55
{18.9 26.0}
Measuring condition
q
Torque converter
inlet pressure
Power train oil temperature:

Within operating range
Torque converter
outlet pressure
Engine at high
idle
Engine at low
idle
Power train oil pressure
Torque converter
lockup clutch
pressure
Torque converter
stator clutch
pressure
q
Transmission
main relief pressure

Transmission F
clutch pressure
Transmission R
clutch pressure
Transmission 1st
clutch pressure
20-6
D375A-6
Engine at low
idle
Unit
MPa
{kg/cm2}
MPa
{kg/cm2}
D375A-6
(06)
DRAFT
Machine model
Category
Item
D375A-6
Measuring condition
q
Transmission 2nd
clutch pressure
Adjustment ID: 5535

Measure in (both
steering clutch disengage modes)
Unit
Power train oil pressure
Transmission lubricating oil pressure
2.25 2.84
2.06 3.13
{23.0 29.0} {21.0 31.9}
Engine high
idle
2.55 2.87
2.30 3.16
{26.0 29.3} {23.4 32.2}
Engine high
idle
2.55 2.87
2.30 3.16
{26.0 29.3} {23.4 32.2}

Engine high
idle
0.08 0.25
{0.8 2.5}

Engine low idle
2.25 2.84
2.2 3.04
{23.0 29.0} {22.4 31.0}
Engine high
idle
2.55 2.87
2.4 3.07
{26.0 29.3} {24.4 31.3}
Engine low idle
2.25 2.84
2.2 3.04
{23.0 29.0} {22.4 31.0}
Engine high
idle
2.55 2.87
2.4 3.07
{26.0 29.3} {24.4 31.3}
Steering left brake

pressure
Engine low idle

Steering right clutch
pressure
Steering right brake

pressure
Flat ground
range
Power train oil temperature: Within operating
range
Engine high idle
Run up distance: 10 - 30
m
Measurement distance:
20 m
Power train performance
q
q
D375A-6
(03)
MPa
{kg/cm2}
0.08 0.25
{0.8 2.5}
2.25 2.84
2.2 3.04
{23.0 29.0} {22.4 31.0}
Engine high
idle
2.55 2.87
2.4 3.07
{26.0 29.3} {24.4 31.3}
Engine low idle
2.25 2.84
2.2 3.04
{23.0 29.0} {22.4 31.0}
Engine high
idle
2.55 2.87
2.4 3.07
{26.0 29.3} {24.4 31.3}
Engine high
idle
Automatic gear shift mode
Travel speed
MPa
2.25 2.84
2.06 3.13
{kg/cm2} {23.0 29.0} {21.0 31.9}
Steering left clutch

pressure
Pin puller operating

pressure
Permissible
value
Engine low idle
Engine low idle

Transmission 3rd
clutch pressure
Standard
value for new
machine
MPa
{kg/cm2}
2.55 0.10
{26.0 1.0}
Min. 2.2
{Min. 22}
F1
20.6 1.0
{3.5 0.2}
20.6 1.0
{3.5 0.2}
F2
10.6 0.6
{6.8 0.3}
10.6 0.6
{6.8 0.3}
F3L
9.0 0.4
{8.0 0.4}
9.0 0.4
{8.0 0.4}
F3
6.1 0.3
{11.8 0.6}
6.1 0.3
{11.8 0.6}
R1
15.7 0.8
{4.6 0.2}
15.7 0.8
{4.6 0.2}
R2
8.1 0.4
{8.9 0.4}
8.1 0.4
{8.9 0.4}
R3L
7.4 0.3
{9.7 0.5}
7.4 0.3
{9.7 0.5}
R3
4.9 0.3
{15.8 0.7}
4.9 0.3
{15.8 0.7}
sec
{km/h}
20-7
DRAFT
Machine model
Item
q
Power train performance
Travel speed
q
q
q
Unload pressure
Work equipment oil pressure
Blade tilt relief pressure
Ripper tilt relief

pressure
LS pressure
(Load sensing pressure)
20-8
Permissible
value
Flat ground
range
Power train oil temperature: Within operating
range
Engine high idle
Run up distance: 10 - 30
m
Measurement distance:
20 m
F1
20.6 1.0
{3.5 0.2}
20.6 1.0
{3.5 0.2}
F2
10.6 0.6
{6.8 0.3}
10.6 0.6
{6.8 0.3}
6.1 0.3
{11.8 0.6}
6.1 0.3
{11.8 0.6}
15.7 0.7
{4.6 0.3}
15.7 0.7
{4.6 0.3}
R2
8.2 0.4
{8.7 0.4}
8.2 0.4
{8.7 0.4}
R3
4.9 0.3
{14.7 0.7}
4.9 0.3
{14.7 0.7}
Unit
F3
R1
q
q
q
q
sec
{km/h}
Hydraulic oil temperature: 45

Engine low idle
55 C
Cylinder stroke end
Engine high
idle
2.45 (+1.37/0)
{25 (+14/0)}
2.45
(+1.37/0)
{25 (+14/0)}
26.4 29.4
{270 300}
Engine low idle
26.4 28.4
{270 290}
Engine high
idle
27.4 29.4
27.4 29.4
{280 300} {280 300}
Engine low idle
Ripper lift relief

pressure
Control circuit oil

pressure
PPC valve output
pressure
Standard
value for new
machine
Measuring condition
Manual gear shift mode
Category
D375A-6
MPa
{kg/cm2}
26.4 28.4
{270 290}
26.4 29.4
{270 300}
Engine high
idle
27.4 29.4
27.4 29.4
{280 300} {280 300}
Engine low idle
26.4 28.4
{270 290}
Engine high
idle
27.4 29.4
27.4 29.4
{280 300} {280 300}
Engine low idle
25.48 1.27
{260 13}
25.48 1.27
{260 13}
25.48 1.27
{260 13}
3.43 4.12
{35 42}
3.43 4.12
{35 42}
25.48 1.27
{260 13}
3.43 4.12
{35 42}
Min. 3.33
{Min. 34}
Engine high
idle
Engine high idle
Circuit oil pressure: Lever in neutral
Output pressure: Lever at stroke end
MPa
{kg/cm2}
26.4 29.4
{270 300}
D375A-6
(03)
DRAFT
Machine model
Category
Item
D375A-6
Standard
value for new
machine
Permissible
value
7 13
20
3.7 4.7
Engine low idle
1.3 1.7
1.3 1.8
Engine high
idle
1.3 1.7
1.3 1.8
24
2.5 3.5
24
2.5 3.5
46
2.5 3.5
46
2.5 3.5
24
2.5 3.5
24
2.5 3.5
Measuring condition
Unit
Raise
Engine low idle

Engine high
idle
Blade lift
q
q
L.H. tilt

Apply no load to blade.
Between ground level
and rising end of blade
Lower
sec
Engine low idle

Engine high
idle
sec
L.H. tilt
q
Single tilt specification

Between left tilt end and
right tilt end
L.H. tilt
Engine low idle

Engine high
idle
Engine high
idle
Engine low idle

Engine high
idle
sec
q
q
q
D375A-6
(03)
Engine high
idle
sec
Blade
dual tilt
Engine low idle
Engine low idle

R.H. tilt
Dual tilt specification

right tilt end

right tilt end
R.H. tilt
Work equipment speed
Work equipment
R.H. tilt
Blade tilt
Engine low idle

Engine high
idle
20-9
DRAFT
Machine model
Category
Measuring condition
Dump
Item
D375A-6
Blade pitch
q
q
Tilt in
Work equipment

Apply no load to ripper.
Between ground level
and rising end of ripper
q
q
q
q
q
Time lag
Blade

Between forward tilt end
and backward tilt end
Engine high
idle
Engine high
idle
Engine low idle

Engine high
idle
sec
2.5 3.5
35
2.5 3.5
*G
46
*M
46
*G
23
7
5
*M 2.5 3.5
Engine low idle
1.5 2.5
1.5 2.5
Engine high
idle
1.5 2.5
1.5 2.5
Engine low idle
10 16
20
Engine high
idle
4.5 5.5
6 10
15
2.8 3.8
Max. 8
12
Max. 1.8
2.0
Engine low idle

Engine high
idle

55 C
Engine low idle
Lever full stroke
Start lowering operation at blade
max. raising position and mea- Engine high
sure time from when blade idle
reaches ground until idler rises.
sec
55 C
Engine low idle
q Lever full stroke
q Start lowering operation at ripper
Ripper
max. raising position and measure time from when ripper Engine high
reaches ground until sprocket idle
rises.
* G: Variable giant ripper specification, M: Variable multi-shank ripper specification
20-10
46
Engine low idle
sec
Tilt back
Ripper tilt
Permissible
value
sec
RAISE
Ripper lift
Standard
value for new
machine
Engine low idle
LOWER

Between dump end and
back end
Back
Unit
*G Max. 1.0 *G
1.5
*M Max. 1.5 *M
D375A-6
(03)

Machine model
Cate
gory
Item
Measuring condition
Hydraulic
drift of lifted
blade
q
q
q
Hydraulic drift
Work equipment
q
q
q
q
q
q
D375A-6
(06)
Permissible
value
mm
Max. 65 mm
130 mm
mm
Max. 50 mm
100 mm
mm
Max. 50 mm
80 mm
mm
Max. 25 mm
50 mm

Engine stopped
Measuring reduction of track shoe bottom height
"h" (for 5 minutes).
Hydraulic
drift of lifted
ripper
q
Standard
value for new
machine

Engine stopped
Measure reduction of idler center height "h" (for
5 minutes).
Hydraulic
drift of
machine
tilted by
blade
q
Unit

Engine stopped
Measuring reduction of blade bottom height "h"
(for 5 minutes).
Hydraulic
drift of lifted
blade
q
D375A-6

Engine stopped
Measuring reduction of height of bottom end of
shank "h" (for 5 minutes).
20-11
DRAFT
Machine model
20-12
Hydraulic drift
Item
Measurement condition
Hydraulic drift
of machine
lifted by ripper
q
q
q
Cylinder internal leakage
Work equipment
Category
Blade tilt cylinder

Ripper lift cylinder
Ripper tilt cylinder
q
q
q

Engine stopped
Measure reduction of sprocket center height
"h" (for 5 minutes).
Engine running at low idle
Relieve cylinder and measure leakage for 1
minute.
D375A-6
Unit
Standard
value for new
machine
Permissible
vable
mm
Max. 30 mm
per 5 minutes
60 mm per 5
minutes
Max. 3.0
12
Max. 3.6
12
Max. 3.2
12
cc/min
D375A-6
(01)
DRAFT
D375A-6
SEN05176-00
BULLDOZER
D375A-6
Shop Manual
Machine model
D375A-6
Serial number
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
(01)
30-1
Contents
Contents
Tools for testing, adjusting and troubleshooting .....................................................................
Diagnosis equipment list ......................................................................................................
Engine and cooling system .....................................................................................................
Testing engine speed...........................................................................................................
Testing intake air pressure (boost pressure) .......................................................................
Testing exhaust temperature ...............................................................................................
Testing exhaust gas color ....................................................................................................
Adjusting valve clearance ....................................................................................................
Measuring compression pressure........................................................................................
Testing blow-by pressure.....................................................................................................
Testing engine oil pressure..................................................................................................
Testing EGR valve drive oil pressure...................................................................................
Handling of fuel system devices ..........................................................................................
Releasing residual pressure from fuel system .....................................................................
Testing fuel pressure ...........................................................................................................
Handling of reduced cylinder mode operation .....................................................................
Handling of no injection cranking operation .........................................................................
Testing leakage from pressure limiter and return rate from injector ....................................
Bleeding air from fuel circuit.................................................................................................
Testing fuel circuit for leakage .............................................................................................
Replacing and adjusting alternator and air conditioner compressor belt .............................
Measuring fan speed ...........................................................................................................
Testing fan circuit oil pressure .............................................................................................
Bleeding air from fan pump..................................................................................................
Adjusting fuel control dial and decelerator pedal .................................................................
Power train..............................................................................................................................
Testing power train oil pressure...........................................................................................
Adjusting transmission output speed sensor .......................................................................
Simple test procedure for brake performance......................................................................
Adjusting brake pedal and parking brake lever....................................................................
Adjusting position of pccs lever console ..............................................................................
Emergency escape method when there is failure in power train .........................................
Undercarriage and frame ........................................................................................................
Inspecting wear of sprocket .................................................................................................
Testing and adjusting track shoe tension.............................................................................
Hydraulic system.....................................................................................................................
Measuring and adjusting work equipment oil pressure........................................................
Testing control circuit main pressure ...................................................................................
Testing PPC valve output pressure .....................................................................................
Adjusting play of PPC valve.................................................................................................
Testing output pressure of ripper pin-puller solenoid valve .................................................
Checking location of cause of hydraulic drift of blade and ripper.........................................
Testing leakage inside work equipment cylinder .................................................................
Releasing remaining pressure in work equipment cylinders................................................
Bleeding air from work equipment cylinders ........................................................................
Adjusting ripper lever position..............................................................................................
Work equipment......................................................................................................................
Adjusting work equipment lock lever....................................................................................
Adjusting blade ....................................................................................................................
Cab and its attachments .........................................................................................................
30-2
30-2
3030303030303030303030303030303030303030303030303030303030303030303030303030303030303030303030303030-
4
4
6
6
8
10
12
14
16
19
21
22
24
25
26
27
27
28
31
33
34
35
36
37
38
40
40
52
53
54
57
58
60
60
61
62
62
65
66
68
69
70
71
72
72
73
74
74
75
77
D375A-6
(07)
Contents
Testing and adjusting operator's cab ...................................................................................

Testing and adjusting operator's seat isolator .....................................................................
Electrical system .....................................................................................................................
Special functions of machine monitor (EMMS)....................................................................
Handling of voltage circuit of engine controller ....................................................................
Adjustment method when controller has been replaced......................................................
Preparation work for troubleshooting of electrical system ...................................................
Inspection procedure of diode .............................................................................................
Handling of optional devices................................................................................................
Request for opening ORBCOMM terminal ..........................................................................
Initialization procedures for VHMS controller.......................................................................
Using method of KOMTRAX functions of ORBCOMM terminal ..........................................
Precautions for replacing VHMS controller..........................................................................
Pm Clinic service ....................................................................................................................
Pm Clinic service .................................................................................................................
D375A-6
(07)
30- 77
30- 81-1
30- 82
30- 82
30- 139
30- 140
30- 144
30- 148
30- 149
30- 150
30- 152
30- 172
30- 175
30- 181
30- 181
30-3
Tools for testing, adjusting and troubleshooting

Diagnosis equipment list
30-4
30-4
Testing/Adjusting item
Symbol
Measuring intake air

pressure (boost pressure)
Measuring exhaust gas
temperature
Checking exhaust gas
color
Remarks
-101 200 kPa {-760 1,500 mmHg}
B
-
799-101-1502
799-201-1150
799-201-9001
Commerciallyavailable
795-502-1590
795-611-1220
6261-71-6150
795-799-5410
795-799-5420
799- 201-1504
Digital thermometer
Adapter connector
Handy smoke checker
1
1
1
-99.9 1,299C
For Pm clinic specification
Smoke meter
Clearance gauge
Compression gauge
Adapter
Gasket
Adapter
Remover
Blow-by checker
1
1
1
1
1
1
1
2
D
E 2
3
Testing blow-by pressure
Q'ty
799-201-2202 Boost gauge kit
1
Testing compression
pressure
Part Name
Adjustment of valve
clearance
Part No.
799-101-5002 Hydraulic tester
790-261-1204 Digital hydraulic tester
799-401-2320
799-101-5230
6215-81-9720
795T-690-1110
01435-00835
07000-E2012
1
1
1
1
2
3
1
Testing engine oil pressure
G 2
3
Testing drive pressure of

EGR valve
Gauge
Nipple
O-ring
Block
Bolt
O-ring
H 2
3
1
2
3
Testing fuel return rate

and leakage
4
5
6
Testing power train oil

pressure
1
2
Emergency retrieval
method when power train L
has trouble
2
Measuring and adjusting
1
work equipment oil presM
sure, Testing control cir2
cuit main pressure
Testing PPC valve output pressure
30-4
Intake side: 0.32 mm, Exhaust side:

0.62 mm
0 7 MPa {0 70 kg/cm2}
Pressure gauge: 2.5, 6, 40, 60 MPa

{25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa {600
kg/cm2}
Pressure gauge: 1.0 MPa {10 kg/cm2}
799-401-2320
799-101-5160
795-471-1450
07005-00812
6167-11-6640
6206-71-1770
799-101-5002
790-261-1204
799-401-2320
19M-06-32820
7824-66-6430
195-06-71220
790-190-1601
799-101-5002
790-261-1204
799-101-5220
07002-11023
Gauge
Nipple
Adapter
Gasket
Spacer
Joint
1
1
1
1
1
1
*As common as G2
R 1/8
M8 1.25
Hose
f 5 mm (Inside diameter) x 2 3 m
Hose
f 16 mm (Inside diameter) x 2 3 m
Measuring cylinder
Stopwatch
Hydraulic tester
Digital hydraulic tester
Gauge
Switch assembly
Resistor
Wiring harness
Pump assembly
Hydraulic tester
Nipple
O-ring
1
1
1
1
1
1
1
1
1
2
2
1
Testing fuel pressure
Bosch index: 0 to 9
*As common as G1
N 1
Inside diameter: 10 mm
Joint diameter: 10 mm
*As common as G1
*As common as G2
*As common as G1
M10 1.25
*As common as G1
D375A-6
(06)

Testing/Adjusting item
Testing ripper pin puller
solenoid valve output
pressure
Symbol
Part Name
Q'ty
799-401-3200 Adapter
CommerciallyMeasuring cylinder
available
Testing for leakage inside

work equipment cylinder
Part No.
*As common as G1
Testing operating effort

and depressing force
Testing stroke and
hydraulic drift
Testing work equipment
speed
Testing voltage and resistance
Initialization of VHMS
controller
2
3
4
T
U
V
Diagnosis sensor and

harness
D375A-6
(06)
*As common as G1
790-301-1330
07372-21055
07000-13035
79A-264-0021
79A-264-0091
q Flange
Bolt
O-ring
Push-pull scale
Push-pull scale
1
4
1
1
1
Ruler
Stopwatch
Multimeter
799-608-3211 Discket
799-608-3220 Wiring harness
Size 03
1
Testing fan circuit oil
pressure
Remarks
799-601-7400
799-601-7500
799-601-9000
799-601-9300
799-601-7360
799-601-3450
799-601-4100
795-799-5530
795-799-5540
799-601-4130
799-601-4150
799-601-4211
799-601-4220
799-601-4240
799-601-4250
799-601-4260
799-601-9020
799-601-9040
799-601-9420
799-601-9430
799-601-9030
Lap top type personal

computer
T-adapter assembly
T-adapter assembly
T-adapter assembly
T-adapter assembly
Adapter
Adapter
T-adapter assembly
q T-adapter
q T-adapter
q T-adapter
q T-adapter
q T-adapter
q T-adapter
q Socket
q Socket
q T-adapter
q T-adapter
q T-adapter
q T-adapter
q T-adapter
T-adapter
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Size: 10
0 294 N {0 30 kg}
0 490 N {0 50 kg}
OS: Windoes98/2000/Me/XP/VISTA
[With RS232C terminal]
AMP040 Connector
AMP040 Connector
DT, HD30 connector
DRC26-24, 40-pin
Relay (5 pins)
VHMS download harness
Connected with engine
Engine coolant, oil, fuel temperature
Boost air temperature sensor
Ne sensor
Oil pressure sensor
Controller (50 poles)
EGR EGR valve, injector
EGR valve potentiometer sensor
Supply pump PCV
G sensor
30-5
DRAFT
Testing engine speed

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 Measure the engine speed under the following
conditions.
q Coolant temperature:
q Power train oil temperature:
q Hydraulic oil temperature: 45 55C
q Working mode: P-mode
q Gear shift mode: Manual
1. Preparation work
Measure the engine speed with the Adjustment
function in the service mode of the machine
monitor.
a For the operating method, see "Special functions of machine monitor (EMMS)".
q Adjustment ID: 0530 (Stall mode)
a When stalling the torque converter for a purpose other than measuring the engine
speed, be sure to use this adjustment code,
too.
2. Measuring low idle speed

1) Start the engine and set the fuel control dial
in the low idle (MIN) position.
2) Set the PCCS lever, blade control lever, and
ripper control lever in neutral and measure
the engine speed.
a The parking brake lever and work equipment lock lever may be kept in the LOCK
position.
30-6
3. Measuring high idle speed

in the high idle (MAX) position.
ripper control lever in neutral and measure
the engine speed.
position.
4. Measuring decelerator pedal speed
in the high idle (MAX) position.
ripper control lever in neutral, press the
decelerator pedal to the stroke end, and
measure the engine speed.
position.
5. Measuring torque converter stall speed
2) Operate the shiftup (UP) switch of the PCCS
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 function 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.
5) Return the decelerator pedal slowly to stall
the torque converter with the engine at high
idle.
k Keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the
work is finished.
6) Right after the power train oil temperature
gauge (T/C TEMPERATURE) indicates 118
C, return the PCCS lever to the neutral
position.
D375A-6
(03)
DRAFT
a The top of the green range of the power

train oil temperature gauge indicates
about 118 120 C.
7) Repeat above steps 3) 6) 3 times.
8) Perform steps 3) - 5) again and measure the
engine speed when the power train oil
temperature gauge (T/C TEMPERATURE)
indicates 118 C.
a Immediately after finishing measuring, return the PCCS lever to the neutral position and lower the power train oil
temperature with the engine at high idle.
6. Measuring torque converter stall speed
(Inspection on Pm clinic screen)
2) 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)".

to [F2-R2].
forward position.
5) Shift to 3rd gear by operating the shift-up
(UP) switch of PCCS lever.
6) Repeat the measuring process in a similar
way by following Step 4) and later of "5.
Measuring torque converter stall speed".
7. Measuring torque converter stall + work equipment relief speed (Full stall speed)

D375A-6
(03)

to [F3-R3].
3) Set the work equipment lock lever in the free
position and operate the ripper control lever
to set the ripper lift cylinder to the raise stroke
end.
forward position.
6) Return the decelerator pedal slowly to stall
the torque converter with the engine at high
idle.
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.
8) Repeat above steps 4) 7) 3 times.
9) Perform steps 4) - 6) again, operate the
ripper control lever to relieve the ripper raise
system, and measure the engine speed
when the power train oil temperature gauge
(T/C TEMPERATURE) indicates 118 C.
a Immediately after finishing measuring, return the PCCS lever to the neutral position and lower the power train oil
temperature with the engine at high idle.
8. Measuring torque converter stall + Work
equipment relief speed (Full stall speed)
(Inspection on Pm clinic screen)
2) Switch the machine monitor to the "Pm clinic"
function display of the service mode.
30-7
DRAFT
3) Operate the shift up (UP) switch of the PCCS

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
(03)
30-7-2
DRAFT
Testing intake air pressure (boost pressure)
Testing intake air pressure (boost

pressure)
a Testing instruments of intake air pressure (boost
pressure)
Symbol
A
Part No.
799-201-2202
Part name
Boost gauge kit

k When installing and removing the testing instrument, 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 pressure) under the following condition.
q Coolant temperature:
a Normally, the intake air pressure (boost pressure) should be tested while the engine is running at the rated output. In the field, however, an
approximate value can be obtained by stalling
the torque converter.
2) Test the boost pressure when the torque

converter is stalled at high idle speed.
a For the torque converter stall procedure,
see Step 3) and later in "6. Measuring
torque converter stall speed (Inspection
on Pm clinic screen)" of "Testing engine
speed".
2. Testing with boost gauge kit
1) Open the engine left cover.
2) Remove boost pressure pickup plug (1) at
the rear of the air intake manifold.
3) Install nipple [1] of boost gauge kit A and

connect gauge [2].
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 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
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 "Adjustment" 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 installing.
2 Plug: LT-2 or LG-5
3 Plug: 9.8 19.6 Nm {1.0 2.0 kgm}
D375A-6
(03)
30-9
30-11
DRAFT
Testing exhaust temperature

a Checking tools for exhaust gas temperature
Symbol
B
Part No.
799-101-1502
Part name
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.
Symbol
B
Part No.
799-101-1502
799-201-1150
Part name
Digital thermometer
Adapter connector

k Remove and install the testing tools after the
exhaust manifold temperature has lowered.
a Test the exhaust temperature under the following conditions.
q Engine coolant temperature: Within operating range
q Hydraulic oil temperature: 45 55 C
1. Measuring with the digital temperature
gauge
1) Open the engine right side cover, and
remove the heat insulation cover.
2) Remove the exhaust
inspection plug.
gas
temperature
3) Install sensors [1] of digital temperature

gauge B and connect them to meter [2].
a Clamp the wiring harness of the digital
thermometer not to come into contact
with any hot parts during measuring.
30-12
30-10
4) Procedure for measuring at maximum

temperature while troubleshooting
Check the maximum exhaust gas temperature during actual operations.
a Use the digital temperature gauge in the
PEAK mode.
a The exhaust gas temperature largely depends on the ambient air temperature (intake air temperature of engine).
Accordingly, if any abnormal value is obtained, correct it using the following calculation.
q Corrected value [C] = Measured
value + 2 x (20 - Ambient temperature)
2. Periodic measurement procedure using the
preventive maintenance service (Pm clinic)
a If the torque converter alone has stalled, the
torque converter oil will overheat before the
exhaust gas temperature stabilizes. Therefore, check the exhaust gas temperature according to the following procedure.
and switch the machine monitor to the
"Adjustment" function display of the service
mode.
functions of machine monitor (EMMS)"
section.
D375A-6
(03)
DRAFT
k
2) Run the engine to warm it up.

a The standard warm-up operation is as follows.
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)
position.
to [F3-R3].
5) Set the work equipment lock lever in the free
position and operate the ripper control lever
to set the ripper lift cylinder to the raise stroke
end.
forward position.
8) Slowly release the decelerator pedal and
stall the torque converter at engine high idle
speed. Relieve the ripper raise system, and
measure the maximum exhaust gas temperature when the power train oil temperature
(T/C TEMPERATURE) shows 118 C.
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
(03)
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.
11)After finishing measuring, remove all test

it was.
3. Testing for VHMS specifications
2) Run the engine to warm it up.

a The standard warm-up operation is as follows.
q Low idle: 3 minutes
q Run at a medium speed: 1 minute
q High idle: 1 minute
30-11
30-13
DRAFT
3) Set the fuel control dial to the low idle (MIN)

position.
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. Periodic measurement procedure using the
preventive maintenance service (Pm clinic)".
30-14
30-11-1
D375A-6
(03)
DRAFT
D375A-6
(03)
30-11-2
30-15
DRAFT
Testing exhaust gas color

a Checking tools for exhaust gas color
Symbol
1
Part No.
799-201-9001
Commercially
available
Part name
Handy smoke checker
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
exhaust pipe using a clip.
Smoke meter

k Be careful not to touch any hot part when removing 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.
a Check the exhaust gas color under the following
condition.
1. Checking with a handy smoke checker C1
1) Stick a sheet of filter paper to smoke checker
C1.
2) Insert the exhaust gas intake pipe into the
exhaust pipe.
3) Start the engine.
4) Accelerate the engine suddenly or run it at
high idle and operate the handle of smoke
checker C1 so that the filter paper will absorb
the exhaust gas.
2) Connect the probe hose, receptacle of the

accelerator switch, and air hose to the smoke
meter C2.
a Limit the supplied air pressure to 1.5 MPa
{15 kg/cm2}.
3) Connect the power cable to an AC receptacle.
a Before connecting the cable, check that
the power switch of the smoke meter is
turned OFF.
4) Loosen the cap nut of the suction pump and
fit the filter paper.
a Fit the filter paper securely so that the exhaust gas will not leak.
5) Turn on the power switch of smoke meter C2.
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
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
(01)
30-13
DRAFT
Adjusting valve clearance

a Adjusting tool for valve clearance
Symbol
Part No.
Commercially
available
Part name
Feeler gauge

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, "Removal and installation of cylinder head assembly".
3. Remove inspection hole plug (5) from the front

side of the timing gear case and rotate the crankshaft forward to set notch (a) of the supply pump
drive gear to the center of the inspection hole.
a Rotate the engine with the cranking device
(6) on the rear left of engine.
a On the right of figure upper, the compres-sion top dead center of No. 1 cylinder is
shown and on the right, the top dead cen-ter
of No. 6 cylinder is shown.
a When the No. 1 cylinder is at the compres-sion top dead center, the rocker arm
can be moved by the valve clearance with the
hand.
30-14
4. When the No. 1 cylinder is at the compression

top dead center, adjust the valve clearance indicated 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.
a Valve clearance
q Air intake valve: 0.32 mm
q Exhaust valve: 0.62 mm
5. While fixing adjustment screw (7), tighten
lock-nut (8).
3 Locknut:
57.8 77.4 Nm {5.9 7.9 kgm}
a After tightening the lock nut, check the valve
clearance again.
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 removedparts.

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
(01)
30-15
DRAFT
Measuring compression pressure

a Testing tools for compression pressure
Symbol
1
E
2
4
Part No.
795-502 1590
795-611-1220
6261-71-6150
795-799-5410
795-799-5420
Part name
Compression gauge
Adapter
Gasket
Adapter
Remover
a Remove the terminal on the injector side and

the mounting bolt on the rocker housing side,
and remove the injector wiring harness from
the injector.
a Loosen the 2 terminal nuts alternately.
5. Remove injector holder (7), and remove injector
(8).

k When testing the compression pres-sure,
take care not to burn yourself on the exhaust
manifold, muffler, etc. or get caught in a rotating part.
a Measuring the compression pressure under the
following condition.
(Engine oil temperature:40 60C)
1. Remove the engine hood.
2. Remove cylinder head cover.
a Remove covers (1) and (2), bracket (3) and
cylinder head cover (4) to test the compression pressure. For details, see Disassembly
and assembly volume, "Removal and installation of cylinder head assembly".
a Insert the pin (indicated by the arrow) at the

end of the tool E3 into hole (a) of adaptor (9),
and pull out the injector by moving the weight
of tool E3 up and down.
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

injector and the compression gauge E1.
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 connecting parts of the adapter and gauge so
that air will not leak easily.
7. Turn the starting switch to the ON position and

switch the machine monitor to "Cylinder Cut-Out
Operation" function display of the service mode.
a For the operating method, see Special functions of machine monitor (EMMS).
k Be sure to set all the injectors in the no-injection state so that the engine will not
start.
8. Rotate the engine with the starting motor and

test the compression pressure.
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
(03)
2) Fit adaptor (9) to injector (8), and press it in

as a unit to the cylinder head by hand.
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).
3 Bolt:
58.8 73.5 Nm {6 7.5 kgm}
6) Fully tighten sleeve nut (5).
3 Sleeve nut :
39.2 - 44.1 Nm {4 - 4.5 kgm}
a Install the injector wiring harness according

to the following procedure
1) Assemble injector wiring harness (6) from the
inside of rocker arm housing and fix the
connector side with plate (15).
30-17
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
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

a Measuring tools for engine oil pressure
Symbol
1
G
3
4
Part No.
799-101-5002
790-261-1204
799-401-2320
799-101-5230
6215-81-9720
2. Measuring with oil pressure gauge

1) Open the engine left cover.
2) Remove oil pressure test plug (1).
Part name
Hydraulic tester
Gauge
Nipple
O-ring

a A nipple (quick coupler) is installed into the hydraulic oil inspection port of the engine for the
Pm clinic specification machine.
a Measure the engine oil pressure under the following condition.
q Engine oil temperature: Min. 70 C
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.
2) Run the engine and measure the engine oil

pressure at low idle and also at high idle.
D375A-6
(03)
3) Install nipple G3 and connect it to gauge G2.
4) Run the engine and measure the engine oil

pressure at low idle and also at high idle.

it was.
30-21
30-25
DRAFT

a Measuring tools for blow-by pressure
Symbol
F
k
Part No.
799-201-1504
Part name
Blow-by checker


and switch the machine monitor to the
"Adjustment" function display of the service
mode.
a Measure the blow-by pressure under the following condition.

1. Testing with blowby kit
1) Open the engine left side cover and pull out
blow-by hose (1).
2) Install nozzle [1] and hose [2] of blowby
checker F to blowby hose (1) and connect
them to gauge [3].
D375A-6
(03)
4) Run the engine at high idle and test the

blow-by pressure when the torque converter
stalls.
a Blow-by varies greatly according to the
condition of the engine. Therefore, if the
blow-by value is considered abnormal,
check for problems connected with defective blow-by, such as excessive oil consumption, defective exhaust gas color,
and prematurely dirty or deteriorated oil.
it was.
30-19
30-23

Testing EGR valve drive oil pressure
30-25
a Measuring instruments for EGR valve drive

pressure
Symbol
Part No.
799-101-5002
790-261-1204
795T-690-1110
G
4 01435-00835
07000-E2012
1
Part name
Hydraulic tester
Block
Bolt
O-ring
Park the machine on a level ground and lower the work equipment and set firmly on the
ground, then set the parking brake lever and
work equipment lock lever to the LOCK position.
a Drive oil pressure for EGR valve will be checked

under the following condition.
q Engine oil temperature: 40 60 C
5. Install the nipple (component part of G1) into

measurement hole (a) (size: PT 1/8) of tool G4
and connect gauge [1] of hydraulic tester G1.
Reference: The oil pressure to be measured will
be a maximum of approximately 3 MPa
{30 kg/cm2}.
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}
30-22
D375A-6
(06)
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
(01)
30-23
DRAFT
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 conventional 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 automatically 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 observe the following.
k Before testing the fuel system or removing
its parts, wait at least 30 seconds after stopping 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
(01)
30-25
DRAFT
3. Install nipple H3 and connect it to gauge H2.
a Measuring tools for fuel pressure

Symbol
1
H
Part No.
Part name

799-401-2320 Gauge
799-101-5160 Nipple (R 1/8)
795-471-1450 Adapter (M8 x 1.25)

07005-00812 Gasket

a Test only the fuel pressure in the low-pressure

circuit from the feed pump through the engine
controller cooler and fuel filter to the supply
pump.
k Since the pressure in the high-pressure circuit from the supply pump through the common rail to the injector is very high, it cannot
be measured.
a Test the fuel pressure under the following conditions.
4. Start the engine and inspect the fuel pressure

with the engine running at high idle or at the
equivalent of rated output speed (stall load).
a If the fuel pressure is in the following range, it
is normal.
Engine speed
At high idle or at the
equivalent of rated output speed
Fuel pressure
0.15 0.3 MPa
{1.5 3 kg/cm2}
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

mode operation
Handling of no injection cranking

operation
a Reduced cylinder mode operation means to run

the engine with the fuel injectors of 1 or more cylinders disabled electrically to reduce the number
of effective cylinders. The purposes and effects
of this operation are as follows.
a No-injection cranking means to crank the engine

with the starting motor while all the injections are
stopped electrically. The purpose and effect of
this operation are as follows.
q When a machine or engine has been stored for
a long time, implementing the no-injection cranking before starting the engine lubricates the engine parts and thus prevents its seizure.
a Do not use the no injection cranking function for
any purpose other than that mentioned above.
a For the no injection cranking procedure, see
"Special functions of machine monitor
(EMMS)"section.
1. This operation is used to find out a cylinder

which does not output power normally (or,
combustion in it is abnormal).
2. When a cylinder is selected for the reduced
cylinder mode operation, if the engine speed and
output do not change from the normal operation
(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 liner
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 electronically, 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 operation, see "Special functions of monitor panel
(EMMS)".
a Use the reduced cylinder mode for only the
purpose of troubleshooting.
D375A-6
(03)
30-27
30-31
DRAFT
Testing leakage from pressure limiter and return rate from injector
a Testing instruments for fuel return rate and leakage

Symbol
1
2
3
J
4
5
6
Part No.
6167-11-6640
6206-71-1770
Commercially
available
Commercially
available
Commercially
available
Commercially
available
Part name
Spacer
Joint
a Test the fuel return rate and leakage under the

following conditions.
Hose
Hose
Measuring cylinder
Stopwatch
a Prepare an oil pan of about 20 l to receive the oil

that will flow out during the testing process..
k

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.
3) Insert joint J2 to common rail (1) side and

tighten the currently removed joint bolt again.
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 limiter.
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 "Adjustment" function display of the service mode.
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
(rpm)
Equivalent to rated operation
D375A-6
(03)
Leakage
(spill) (cc/min)
Max. 10
30-29
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, during the test.
a If the return rate (spill) from the injector is
in the following range, it is normal.
4) After finishing testing, stop the engine.

3. Testing return rate from injector
1) Remove the hose (4) at spill outlet and
connect inspection hose J4 in stead. Then
insert the hose end to the oil pan (saucer).

and switch the machine monitor to "Adjustment" function display of the service mode.
Engine speed
(Equivalent to rated output
operation load)
(rpm)
1,600
1,700
1,800
1,900
2,000
Return (Spill) limit

(spill) (cc/min)
960
1,020
1,080
1,140
1,200
4) After finishing testing, stop the engine.

4. Work after finishing testing
After finishing all testing, remove the testing
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

k

a Bleed air from the fuel circuit in the following cases 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 replaced
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 operation, pressure is applied to the fuel circuit. Do
not loosen the air bleeding plug at this time,
since the fuel may spout out.
1. Set the starting switch to OFF position.
3. Open the engine left cover.

4. Open air bleeding valve (2).
5. Set electric priming pump switch (3) inside the

engine compartment to the "ON" 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
(01)
30-31
DRAFT
a The built-in timer of this switch automatically

starts or stops operation of the electric priming pump. (See the figure below)
a Operation of the electric priming pump is
stopped as long as flashing of the lamp is
continued. It is not an error.
a Shifting the switch to OFF while the lamp
is flashing turns off the lamp and stops the
electric priming pump, too.
2) While the electric priming pump is operating,

crank the engine with the starting motor.
a If the engine does not start, wait for about
2 minutes and then repeat steps 1) and
2).
a Do not rotate the starting motor for more
than 20 seconds continuously.
3) If the engine starts, run it at low idle for 5
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 electric 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 automatically 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 according 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

k
Very high pressure is generated in the

high-pressure circuit of the fuel system. If
fuel leaks while the engine is running, it is
dangerous since it can catch fire.
After checking the fuel system or removing its
parts, check it for fuel leakage according to the
following procedure.
a Clean and degrease the engine and the parts
around it in advance so that you can check it
easily for fuel leakage.
1. Spray color checker (developer) over the fuel
supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
8. Run the engine at high idle and load it.

a Relieve by tilting the blade or raising the ripper.
9. Check the fuel piping and devices for fuel
leakage.
a Check mainly around the high-pressure circuit parts coated with the color checker for
fuel leakage.
a If fuel leakage is recognized, repeat the procedure from step 1 after repairing the leakage.
a If no fuel leakage is detected, check is completed.
2. Start the engine, keep its speed below 1,000

rpm, and stop it when its speed stabilizes.
leakage.
fuel leakage.
4. Run the engine at low idle.
leakage.
fuel leakage.
6. Run the engine at high idle.
leakage.
fuel leakage.
D375A-6
(01)
30-33
DRAFT
Replacing and adjusting alternator and air conditioner compressor belt
Replacing and adjusting alternator and air conditioner compressor belt

k

a The auto-tensioner is provided for the alternator

and air conditioner compressor belt. Thus, testing and adjustment of the belt is usually not necessary.
a Following describes the auto-tensioner adjustment procedure to be employed for the belt replacement.
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

k

a Measure the fan motor speed under the following 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 position, the fan 100% mode is reset.
D375A-6
(01)
30-35
DRAFT
Testing fan circuit oil pressure

a Testing instruments for fan circuit oil pressure
Symbol
1
S
2
4
6
Part No.
799-101-5002
790-261-1204
790-301-1330
07372-21055
07000-13035
Part name
Hydraulic tester
q Flange
Bolt
O-ring
4. Install nipple [2] of hydraulic tester S1 and

connect it to oil pressure gauge [1].
a For an analog oil pressure gauge, the pressure must be 40 MPa {400 kg/cm2}.

a Test the fan circuit oil pressure under the following condition.
1. Open the radiator mask.
2. Remove bolt (1) and disconnect tube (2).
5. Start the engine and switch the machine monitor

to "Adjustment" function display 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.
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

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
(01)
30-37
DRAFT
Adjusting fuel control dial and decelerator pedal
1. Outline of fuel control system

q The following signals are inputted as rotation
command signals to the engine controller.
q Decelerator pedal potentiometer signal
q 3rd throttle signal
The engine controller controls the fuel control
system of the engine (CRI system) according
to the lowest engine speed signal among
those input signals.
q Adjust the deceleration slow speed by adjusting the decelerator pedal linkage.
30-42
30-38
[1] Fuel control dial (2nd throttle signal)

[2] Engine controller
[3] Power train controller
[4] Decelerator pedal (1st throttle signal)
[5] Decelerator potentiometer
[6] Engine (CRI system)
[7] Machine control signal (3rd throttle signal)
[8] Rod
2. Preparation work
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.
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
(03)
30-39
30-43
Power train
Testing power train oil pressure
Power train
30-4
30-4
a Testing tools for power train oil pressure

Symbol
K
1
3
Part No.
Part name
799-401-2320 Gauge

a Test the power train oil pressure under the following condition.
q Power train oil temperature: Within operating
range
q Working mode: P mode
a The power train oil pressure pickup ports (centralized oil pressure pickup ports) are located inside the inspection window cover on the left
outside of the operator's cab.
No. Mark
14
RB
15
LUB
Oil pressure to check

Right steering brake pressure
Output pressure of sudden
stop prevention valve
Transmission lubricating
oil pressure
Gauge
(MPa {kg/cm2})
6 {60}
1.0 {10}
a Table of pressure pick-up port positions and

gauges to use
No. Mark
1
IN
OUT
LU
SC
T/M
FWD
REV
1ST
2ND
10
3RD
11
LC
12
LB
13
RC
30-40
Oil pressure to check

Torque converter inlet
pressure
Torque converter outlet
pressure
Torque converter lock-up
clutch pressure
Torque converter stator
clutch pressure
Transmission main relief
pressure
Transmission F clutch
pressure
Transmission R clutch
pressure
Transmission 1st clutch
pressure
Transmission 2nd clutch
pressure
Transmission 3rd clutch
pressure
Left steering clutch pressure
Left steering brake pressure
Output pressure of sudden
stop prevention valve
Right steering clutch pressure
Gauge
(MPa {kg/cm2})
2.5 {25}
1.0 {10}
2.5 {25}
6 {60}
6 {60}
6 {60}
6 {60}
6 {60}
6 {60}
6 {60}
6 {60}
6 {60}
6 {60}
D375A-6
(06)
Power train
1. Testring torque converter inlet pressure (IN)

(Testing with oil pressure gauge)
1) Connect oil pressure gauge [1] of hydraulic
tester K1 to oil pressure test nipple (1).
a When using an analogue oil pressure
gauge, use one of 2.5 MPa {25 kg/cm2}.
2. Testing torque converter outlet pressure

(OUT)
(Testing with oil pressure gauge)
1) Connect gauge K2 to oil pressure test nipple
(2).
2) Start the engine and set the PCCS lever in

the fully neutral position.
3) Measure the torque converter inlet port pressure with the engine at low idle and high idle.

3) Measure the torque converter outlet port
pressure with the engine at low idle and high
idle.
4) After finishing testing, remove all test tools in

4) After finishing testing, remove all test tools in

D375A-6
(06)
30-41
DRAFT
Power train
3. Measuring torque converter inlet pressure

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

a The test may be performed with the parking 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
(03)
30-41-2
30-47
DRAFT
Power train
4. Testing torque converter lock-up clutch

pressure (LU)
a For an analog oil pressure gauge, the
pressure must be 2.5 MPa {25 kg/cm2}.
3) Set the gearshift mode and preset range as

follows with the gearshift mode selector
switch and shiftup or shiftdown switch.
q Gear shift mode: Automatic gear shift
q Preset range: F2-R2
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 pressure (SC)

a When using an analog oil pressure
gauge, use one of 6 MPa {60 kg/cm2}.

3) Test the torque converter stator clutch pressure with the engine at low idle and high idle.

it was.
D375A-6
(03)
6. Testing transmission main relief pressure

(T/M)
[Testing using oil pressure gauge]

3) Test the transmission main relief pressure
with the engine at low idle and high idle.

it was.
30-43
30-49
DRAFT
Power train
[Checking with machine monitor (for VHMS

specification)]

3) Test the transmission main relief pressure
with the engine at low idle and high idle.
30-50
30-43-1
D375A-6
(03)
DRAFT
Power train
D375A-6
(03)
30-43-2
30-51
DRAFT
Power train
7. Testing transmission F clutch pressure

(FWD)
tester K1 to oil pressure pickup plug (6).

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

lever in the FREE position.
3) Switch the machine monitor to the "Adjustment" function display of the service mode
and disengage both steering clutches.
q Adjustment ID:
5535 (Disengage mode for both steering
clutches)

q Gear shift mode: Manual gear shift
5) While pressing the brake pedal, set the direction 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

(REV)
tester K1 to nipple (7) for checking oil pressure.
6) Check the R clutch pressure with the engine

at low and high idle.

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
(03)
30-45
30-53
DRAFT
Power train
9. Testing transmission 1st clutch pressure

(1st)
6) Check the 1st clutch pressure with the

engine at low and high idle.

it was.

q Adjustment ID:
clutches)

5) While pressing the brake pedal, set the direction of PCCS lever in the forward position.
30-54
30-46
D375A-6
(03)
DRAFT
Power train
10. Testing transmission 2nd clutch pressure

(2nd)
6) Check the 2nd clutch pressure with the


it was.

q Adjustment ID:
clutches)

5) While pressing the brake pedal, set the direction of PCCS lever in the forward position and
shift the gear to 2nd using the shiftup switch.
D375A-6
(03)
30-47
30-55
DRAFT
Power train
11. Testing transmission 3rd clutch pressure

(3rd)
6) Check the 3rd clutch pressure with the


it was.

q Adjustment ID:
clutches)

5) While pressing the brake pedal, set the direction 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)


3) Operate the PCCS lever steering fully to the
left.
a Set the direction to the neutral position.
4) Test the left steering clutch pressure with the
engine at low idle and high idle.
a Check that the oil pressure becomes 0
when the PCCS lever steering is returned
to neutral.

3) Test the left steering brake pressure with the
engine at low idle and high idle.
when the PCCS lever steering is operated fully to the left.
when the brake pedal is depressed fully
or the parking brake lever is operated to
the LOCK position.

it was.
D375A-6
(03)

it was.
30-49
30-57
DRAFT
Power train
14. Testing right steering clutch pressure (RC)

15. Testing right steering brake pressure (RB)


3) Operate the PCCS lever steering fully to the
right.
a Set the direction to the neutral position.
4) Test the right steering clutch pressure with
the engine at low idle and high idle.
when the PCCS lever steering is returned
to neutral.

3) Test the right steering brake pressure with
the engine at low idle and high idle.
when the PCCS lever steering is operated fully to the right.
when the brake pedal is depressed fully
or the parking brake lever is operated to
the LOCK position.

it was.
30-58
30-50

it was.
D375A-6
(03)
DRAFT
Power train
16. Testing transmission lubrication pressure

1) Connect gauge K2 to oil pressure test nipple
(15).
17. Testing of output pressure of sudden stop

prevention valve (Sudden stop prevention
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.
(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 prevention valve operation mode)
section.
D375A-6
(03)
30-51
30-59
DRAFT
Power train
3) Set the parking brake lever in the FREE position 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.
2
q 1.13 1.57 MPa {11.5 16.0 kg/cm }

it was.
30-60
30-51-1
D375A-6
(03)
DRAFT
Power train
D375A-6
(03)
30-51-2
30-61
DRAFT
Power train
Adjusting transmission output speed sensor

k

6. Hold sensor (2) and tighten locknut (4).

a Take care that the speed sensor is not
dragged.
3 Nut: 49.0 68.6 Nm {5 7 kgm}
1. Remove cover (1) under the fuel tank.
7. After finishing adjustment, return the removed

parts.
2. Remove transmission output speed sensor (2).
a Before adjusting, remove the sensor, and
check that the tip of the sensor is not
scratched and that there are no iron particles
sticking to it.
8. Start the engine, set the machine monitor to

"Adjusting" function of the service mode, and
disengage both steering clutches.
q Adjustment ID:
clutches)
9. Operate the PCCS lever in the direction of
forward or reverse position, and check the transmission 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

performance
k
Since the torque converter is stalled, keep

pressing the brake pedal securely and
keep your right foot on the decelerator
pedal for safety until the work is finished.

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 position, the brake will be overloaded. Accordingly, 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
(03)
30-53
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).
3) Adjust installed dimensions c and d of brake
rod (3) with turnbuckle (5) so that the spool of
brake valve (4) is at the OFF position.
a The locknut of the turnbuckle has a
left-handed thread (reverse thread) at the
brake pedal end.
q Stopper bolt installation dimension c: 32
mm
q Stopper bolt installation dimension d: 14
mm
3 Locknut:
34.3 58.8 Nm {3.5 6.0 kgm}
4) Check that clearance x between yoke (12)
and pin (13) is approximately 1 mm.
5. Checking brake oil pressure

monitor to the "Adjustment" function display
of the service mode.
q Adjustment ID: 9995 (Control brake release mode)
a The function of this mode is used to cancel electrical control of brake oil pressure
and makes it possible to check the brake
oil pressure mechanically.
a Set the working mode to P mode and set
the gear shift mode to Manual.
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
mode.
q Adjustment ID: 0005
(Brake pedal potentiometer initial correction)
D375A-6
(03)
2) With the parking brake lever in the FREE

position, depress the brake pedal fully and
check that the brake oil pressure on both
sides of left and right becomes 0.98 MPa {10
kg/cm2} or less.
a For details of the method of testing the
brake oil pressure, see "Testing power
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.
30-55
30-65
DRAFT
Power train
a If the linkage is adjusted normally, the

brake pedal potentiometer may be adjusted wrongly or broken. (Adjust the potentiometer only when necessary.)
a Set the working mode to P mode and set

the gear shift mode to Manual.
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 lever.
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
cable
1) Connect parking brake cable (9) to the lever
and valve, then adjust installed dimensions f
f and g.
q Cable installation dimension (f): 112.8
mm
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.
2) Check that the limit switch signal is input

normally when parking brake lever (10) is set
in the FREE position and LOCK position.
q FREE position:
Travel lock NC OFF, Travel lock NO ON
q LOCK position:
Travel lock NC ON, Travel lock NO OFF
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 position: Specified pressure
4. Checking limit switch
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)
Power train
Adjusting position of pccs lever console
Adjusting position of pccs lever console
30-6
1. Set operators seat (1) facing the front (dozing

position).
2. In this condition, check that console (2) is
parallel to operators seat (1).
a If it is not parallel, adjust installed dimension
(a) of rod (3).
q Standard installed dimension (a): 179 mm
(Machine with operator's seat isolator: 178.5 mm)
a The locknut at the rear of the turnbuckle has
a left-handed thread (reverse thread)
D375A-6
(07)
30-57
Power train
Emergency escape method when there is failure in power train
Emergency escape method when

there is failure in power train
30-67
a Tools for emergency escape
Symbol
L
Part No.
19M-06-32820
1 7824-66-6430
195-06-71220
2 790-190-1601
Part name
Switch assembly
Resistor
Wiring harness
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 range,
steering), retreive the situation according to
the following procedure.
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
release device".
1) Connect switch assembly [1] and resistor [2]
to wiring harness [3] of emergency escape
device L1.
k Resistor [2] controls the drive voltage
of the solenoid, so connect it before
connecting the wiring harness to the
machine.
k In order to prevent mistaken actuation,
set all the gear speed switches of
switch assembly [1] to the OFF position and the directional switch to the P
position.
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
30-58
PL2 connector (2): Connect to male end

a The female end of connector PL2 remains disconnected, so cover it with vinyl.
a Insert switch assembly [1] inside the cab
through the cab window.
3) Disconnect the neutral safety relay (NSF)

inside the fuse room, then connect pin [3] and
pin [5] of the connector at the wiring harness
end directly.
k With this method, if the engine starts,
the neutral safety relay function will
not work, so before starting the engine, set the parking brake lever to the
LOCK position and all the PCCS lever
functions to the neutral position.
k With this method, start the engine only
when carrying out the emergency escape. In all other cases when the engine does not start, always carry out
troubleshooting and repair the cause.

D375A-6
(06)
Power train
Emergency escape method when there is failure in power train
5) Operate switch assembly [1] and move the

machine to a safe place.
a The gear 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. steering directions are opposite when reverse.
2. Emergency escape method with brake

releasing device (Use L2)
a If the engine cannot be started and the parking brake cannot be released, carry out the
emergency escape according to the following
procedure.
1) Assemble pump assembly L2.
2) Install volume pump [4] of pump assembly L2

to the outside of the operators cab.
D375A-6
(06)
3) Remove the fuel tank undercover and

disconnect supply hose (3) of the pin puller
solenoid valve.
4) Connect end hose of pump assembly L2 to

the supply hose. (Use the nipple of face seal
type.)
a Block the solenoid valve side with plug.
Plug: 02789-00315
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
the brake is applied again approximately
one minute after. Therefore, work quickly.
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.
30-59
DRAFT
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 drawing 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
1. Drive the machine forward and stop on a horizontal surface.
a Stop the machine without using the brake.
2. Put straight steel rod (1) on top of the track
between the idler and front carrier roller, and test
clearance (a) from the bottom of the steel rod to
the track shoe grouser.
q Standard clearance (a): 20 30 mm
2. If tension is too high:

Loosen plug (3) and release some of the grease.
k There is danger that the plug may fly out
under the high internal pressure of the
grease, so never loosen the plug more
than 1 turn.
3 Plug: 59 88 Nm {6 9 kgm}
3. If tension is too low:
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 according to the following procedure.
1. Remove cover (2).
D375A-6
(01)
30-61
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
Symbol
1
M
2
Part No.
799-101-5002
790-261-1204
799-101-5220
07002-11023
Part name
Hydraulic tester
Nipple (10 1.25 mm)
O-ring

a Open the cover of the main control valve (both
sides).
Testing
a Measure the work equipment oil pressure under
the following condition.
a The unload pressure, work equipment oil pressure can be checked with the monitoring function of the service mode of the machine monitor
(See 3).
3) Run the engine at high idle and set the blade

control lever and ripper control lever in
neutral and measure the unload pressure.
a The work equipment lock lever may be
set in the LOCK position.
k Do not operate the work equipment
when analog oil pressure gauge (6
MPa {60 kg/cm2}) is mounted. (This is
required to protect the gauge from being damaged.)
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 pressure 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 pressure gauge [1] of hydraulic tester M1.
a When using analog oil pressure gauges,
use ones of 40 MPa {400 kg/cm2}.

it was.
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),
but work equipment LS relief oil pressure
is displayed at LS stamp side (plug-2
side).
D375A-6
(03)
2) Start the engine and measure each oil pressure.

a The measuring condition of each oil pressure 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) cannot be measured.
30-63
30-73
DRAFT
Hydraulic system
Adjustment
1. Adjusting unload pressure
a The unload pressure cannot be adjusted.
4) After finishing measurement, check the work

equipment oil pressure according to the
above measuring method.
2. Adjusting work equipment oil pressure

a If the work equipment oil pressure is abnormal, adjust it with work equipment LS relief
valve (3) according to the following procedure.
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 lowered.
a Quantity of adjustment per turn of adjustment 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

Tools for testing control circuit main pressure
Symbol
M
Part No.
Part name
799 - 101 - 5002 Hydraulic tester
1
790 - 261 - 1204 Digital hydraulic tester

measuring tools and return the removed parts.
Adjusting
a The self pressure reducing valve cannot be adjusted.
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

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
(01)
30-65
DRAFT
Hydraulic system

a Tools for testing PPC valve output pressure
Symbol
N
k
Part No.
Part name
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 Check that the control circuit oil pressure is correct before testing the PPC valve output pressure.
a Test the PPC valve output pressure under the
4. Start the engine and set the work equipment lock

lever in the Free position.
5. Run the engine at high idle, operate the control
lever of the circuit to be tested, and test the oil
pressure.
a Operate the control lever fully when testing.
a For blade LOWER, operate to the FLOAT position.
measuring tools and return the removed parts.
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
B. Blade TILT (Right)
C. Blade LOWER
D. Blade TILT (Left)
D375A-6
(01)
E. Ripper TILT (In)

F. Ripper RAISE
G. Ripper TILT (Back)
H. Ripper LOWER
30-67
DRAFT
Hydraulic system
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
Symbol
1
P
2
Part No.
Part name
799 - 101 - 5002 Hydraulic tester
790 - 261 - 1204 Digital type hydraulic tester
Oil pressure pickup adapter
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
pressure when the ripper pin-puller switch is
actuated.
1. Disconnect pin-puller cylinder hoses (1) and (2).
2. Fit adapter P2, then connect the hoses again.
5. After completing the test remove the testing

equipment and set to the original condition.
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
(01)
30-69
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 cylinder 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
the end of the stroke.
2) Blade tilt cylinder

Extend the tilt cylinder rod fully, then push the
blade against the ground to raise the right
side of the chassis.
3) Ripper lift cylinder

Push the ripper against the ground to raise
the rear of the chassis.
30-80
30-70
2. Operate the control lever in the direction to

extend the cylinder rod, and check the movement of the cylinder.
q If the downward movement becomes faster,
the packing is defective.
q If there is no change, the control valve is defective.
a If there is no more pressure in the accumulator, 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 movement in the above operation will become faster
for the following reasons.
1) When the work equipment is set to the
posture given above, (holding pressure
applied to the bottom end), oil will leak from
the bottom end to the head end. However,
the volume at the head end is smaller than at
the bottom end (by an amount proportional to
the volume of the rod), so if the oil flows in
from the bottom end, the internal pressure at
the head end will rise.
2) If the internal pressure at the head end rises,
a balance will be made in proportion to this at
a certain pressure (this differs according to
the amount of leakage). When the pressure
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
head end flows to the drain circuit. As a
result, the balance is lost and the speed of
downward movement increases.)
D375A-6
(03)
DRAFT
Hydraulic system
Testing leakage inside work equipment cylinder

a Tools for testing leakage from work equipment
cylinder
Symbol
L
Part No.
Commercially
available
Part name
Measuring cylinder
a Test the oil leakage inside the hydraulic cylinder

under the following conditions.
a The blade lift cylinder has a built-in piston valve,
so the internal leakage cannot be tested.
3. Run the engine at high idle and apply the relief

pressure to the bottom end of the cylinder.
q Blade tilt cylinder: Extract the cylinder to be
tested
q Ripper lift cylinder: Lower ripper
q Ripper tilt cylinder: Tilt ripper to front
4. Wait for 30 seconds, then test the amount of
leakage over the next 1 minute.
5. After finishing measurement, return the removed
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 cylinder.
k Take care not to disconnect the hose on
the bottom side.
D375A-6
(01)
30-71
DRAFT
Hydraulic system
Releasing remaining pressure in work equipment cylinders
Releasing remaining pressure

in work equipment cylinders
Bleeding air from work equipment

cylinders
a When disconnecting the piping between the control valve and work equipment cylinder, release
the residual pressure in the circuit according to
a If the work equipment cylinder was removed and

installed or its piping was disconnected and connected, bleed air from its circuit according to the
1. Start the engine, and lower the blade and ripper

to the ground.
1. Run the engine at low idle for about five minutes.
2. Stop the engine.

3. Loosen the hydraulic tank cap gradually to
release the residual pressure in the tank.
4. Set the work equipment lock lever in the FREE
position, and move the work equipment control
lever (for blade and ripper) front, back, left and
right.
a After the levers are operated 2 3 times, the
residual pressure in the accumulator is fully
released.
2. Running the engine at low idle, extend and

retract the cylinder to be bled 4 5 times.
a Stop the piston rod about 100 mm before the
end of the stroke. Never operate it to the relief position.
3. Running the engine at high idle and carry out the
operation in 2.
4. Running the engine at low idle, move the
cylinder to the stroke end to relieve the oil.
5. Fully close the oil filler cap of hydraulic tank.
30-82
30-72
D375A-6
(03)
DRAFT
Hydraulic system
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 position.
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 position.
5) Loosen nut (3).
6) Turn knob (4) 180 .
7) Tighten nut (3) to hold knob (4) in position.
D375A-6
(03)
30-73
30-83
DRAFT
Work equipment
Adjusting work equipment lock lever
Work equipment

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.
q Stroke of limit switch: 2.5 3 mm
4. Turn the starting switch ON and set the machine
monitor to Monitoring function of the service
mode.
a Monitoring code:
70300 (Blade Sw Input)
30-84
30-74
5. Check that the limit switch signal is input

normally when work equipment lock lever (1) is
set in the FREE position and LOCK position.
q FREE position:
Work equipment lock NC OFF, Work equipment lock NO ON
q LOCK position:
Work equipment lock NC ON, Work equipment lock NO OFF
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 assembling
1) Use shims to adjust the clearance at center
portion (1) and (2).
Adjustment
location
1
2
Adjusted
clearance
Standard
clearance
Standard
shim thickness
a
b
See Note
4.5 mm
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
(01)
30-75
DRAFT
Work equipment
Adjusting blade
2) Use shims to adjust the clearance at trunnion

portion (3).
AdjustAdjusted
ment locacleartion
ance
3
Standard clearance
Standard
shim thickness
1.56 0.65 mm
Total clearance
12 mm
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 following conditions.
q Engine speed: High idle
q Blower speed: High (Hi)
q Fresh/Recirculation switch: Fresh air position
monitor to "Adjustment" function display of
the service mode.
q Adjustment code: 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.
a Secure the end of hose [1] to the operator's seat with tape.
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
(01)
30-77
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 pressure)
q Criteria
Measuring value (c) X 8 mm {0.08 kPa {8
mmH2O})
a If the tested value is lower than the standard value, check the following.
q Plug of control box
q Clogging of air filters (recirculation
and fresh air filters) in the air conditioner
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

Close the door and check the relationship
between the operator's cab and door. If there is
any fault, repair it.
1) Check the installed height of damper rubber
(4).
(Check both sides, 4 pieces on each)
q Stick adhesive tape [1] to the contact face
of damper rubber (4), open and close the
door 2 3 times. Then, check the contact
face of adhesive tape [1] against the operator'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
(03)
2) Check the relationship between the door

latch and striker (on both sides).
q Close door (5) and check the engaging
condition of latch (6) and striker (7).
q Normal:
Deviation (a) is 0.5 mm or less.
a Check deviation (a) between latch center
(y) and striker center (x) from (A) direction.
30-79
30-89
DRAFT
3) Adjusting height of damper rubber

q Loosen the mounting bolt of damper rubber (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 rubber (4) to properly adjust the height of
damper rubber (4).
a Open the door and check the engaging 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 adjustment 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
1] Check the relationship between open lock
latch (9) and striker (10) from the direction
of (B).
30-90
30-80
2] Check the installed height of the stopper

rubbers.
(Check both sides, 2 pieces on each.)
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 unlock lever is not heavy.
D375A-6
(03)
DRAFT
2) Adjusting
1] Adjusting latch and striker
q Loosen the adjustment nut of striker
(10) and adjust striker (10) so that it
will not interfere with or ride over open
latch (9), then tighten the nut.
q If interference cannot be eliminated by
adjusting striker (10), loosen the
mounting bolt of open latch (9) and
adjust open latch (9).
q Push the door. If it moves until clearance (b) between striker (10) and
open latch (9) is reduced to "0", loosen
mounting nut (12) of stopper rubber
(11) and extend stopper rubber (11) in
the pushing direction to adjust.
D375A-6
(01)
2] Adjusting installed height of stopper

rubber
1] Loosen locknut (12) of stopper rubber
(11).
2] If there is any play, adjust stopper
rubber (11) until dimension (c) is as
follows.
a If the door is not locked easily or the
unlock lever is heavy, return stopper
rubber (11) in the range that the door
does not have any play.
q Dimension (c) of stopper rubber
above cab:
35 0.5 mm
q Dimension (c) of stopper rubber under
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).
30-81

Testing and adjusting operator's seat isolator

a Machine with operator's seat isolator
30-87
3) Stand backrest (4) of the operator's seat

upright.
1. Breakage of rubber
q Criterion: When the operator's seat is
pressed with the hand, it must not touch the
stopper of operator's seat isolator.
a When the criterion is not satisfied.
q Remove and disassemble the operator's seat
isolator and check the rubber for breakage.
q If the rubber is broken, replace the operator's
seat isolator assembly.
1) Pull slide (1) and move the operator's seat to
the forward end.
2) Pull turning lever (2) and rotate turntable (3)

by 13 degrees.
4) Open window (5) on the left side of the operator's cab.
30-81-1
D375A-6
(07)

5) Press the seat surface through the window.
2. Oil leakage from damper

q Criterion: No oil leakage from damper.
q Replace the operator's seat isolator assembly.
D375A-6
(07)
1) Remove bolts (7) of front cover (6) of the

operator's seat and remove the front cover.
2) Check damper (8) for oil leakage.
30-81-2

3. Breakage of stopper rubber

q Criterion: The stopper must not come off.
q Replace the operator's seat isolator assembly.
1) Put your feet on foot rest (9) and brace your
legs.
2) Check that stopper (10) touches stopper

rubber (11) and does not the steel portion.
30-81-3
D375A-6
(07)

D375A-6
(07)
30-81-4
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 symbols 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 displayed, 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 graphic mark and the function of inputting a numeral.
a The machine monitor automatically judges
which function of each switch is currently effective, according to the display condition of
multi-display (a).
D375A-6
(01)
30-83
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 others 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.
Display of KOMATSU logo
Page
30-85
30-85
Display of check before starting
30-85
Display of warning after check before starting
30-86
A
A
A
A
B
Display of ending of maintenance interval

Display of check of preset
Display of ordinary screen
Display of end screen
Selection of operation mode
30-86
30-86
30-87
30-87
30-87
Selection of gearshift mode
30-87
B
B
B
Customizing operation
Operation of customize memory
Operation to cancel alarm buzzer
Selection of dual tilt
(Dual tilt specification)
30-88
30-88
30-88
B
B
B
B
B
C
C
D
D
D
Operation to display camera mode (if camera is installed)

Operation to display clock and service
Check of maintenance information
Setting and display of user mode
Display of caution monitor
Display function of action code and failure
code
O (Special operation)
Function of checking display of LCD (Liquid
Crystal Display)
Function of changing maintenance password
page
30-94
30-95
Service mode
01 Monitoring
02 Abnormality
Record
Mechanical system "Abnormality Record"
30-100
Electrical system "Abnormal30-101

ity Record"
03 Maintenance Record
04 Maintenance Mode Change
05 Phone Number Entry
Key-on Mode
Unit
Setting of maintenance pass06 Default
word
Setting of camera
Setting of ECO display
07 Adjustment
30-103
30-104
30-105
30-107
30-108
08 PM clinic
30-131
30-88
09 Cylinder Cut-Out
30-133
30-89
30-89
30-89
30-90
10 No Injection
11 Fuel Consumption
12 Display of saved load
13 Setting of VHMS
30-134
30-136
30-137
30-138
30-90
14 Snap shot (Machine equipped with VHMS)
30-138
30-88
OSpecial operations
Operator mode (Outline)
30-109
30-110
30-111
30-112
30-92
30-92
30-93
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)
Electrical system
t Operator mode (Outline)

30-95
a Only outline of the operator mode is described in
this section.
For details of contents/operation of each function/display, see "the Structure, function and
maintenance standard, or Operation and Maintenance Manual".
a The following are the displays or functions of the
operator mode explained in this section (including some items which need special operations).
30-95
When starting switch is turned ON, KOMATSU logo
is displayed for 2 seconds.
After the KOMATSU logo is displayed for two seconds, the screen changes to "Password input (if
password is set)" screen , or "Check before starting"
screen.
Display pattern
a b c d
1 1 1 1
2 2 2 2

Display of warning after check
3
before starting
Display of ending of maintenance
3
interval
3 3 4 4
4 4 5 5
Selection of dual tilt (Dual tilt specification)
Operation to display camera mode (if camera is
installed)
Operation to display clock and service meter
Action code and failure code display function
O (Special operation)
Function of checking display of LCD (Liquid Crystal
Display)
When the screen changes to the check-before-starting screen, the check before starting is carried out
for 2 seconds.
a If any abnormality is detected by the check before starting, the screen changes to "Display of
warning after check before starting" or "Display
of ending of maintenance interval".
a If no abnormality is detected by the check before
starting, the screen changes to "Display of check
of preset".
a The monitors (3 pieces) displayed on the screen
are the items under the check before starting.
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
(06)
30-85
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

starting, the warning monitor is displayed on the
screen.
a The following figure shows that the radiator coolant level monitor (a) is warning of low radiator
coolant level.
When the check before starting is carried out, if a

maintenance item is near or after the end of the set
interval, the maintenance monitor is displayed for 30
seconds to urge the operator to maintenance.
a This screen is displayed only when the maintenance function is effective. The color of the
maintenance monitor (yellow or red) indicates
the length of the time after the maintenance interval.
a Set or change the maintenance function in the
service mode.
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
If the machine monitor starts normally, the ordinary

screen is displayed.
a Service meter (a) or a clock is displayed at the
center upper section of the screen (The service
meter or clock is selected with [F4]).
a Power train oil temperature gauge (b) is displayed 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 service mode).
While the ordinary screen is displayed, press the operation mode selector switch, and the operation
mode monitor (a) changes.
a Each time the switch is pressed, the operation
mode changes between [P (Power)] and [E
(Economy)].
When the starting switch is turned OFF, the end

screen is displayed for 5 seconds.
D375A-6
(03)
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
mode changes among [Automatic gearshift],
[Manual gearshift] and [Shoe slip control] (Optional) in order.
a If the automatic gearshift mode is selected, "AUTO" symbol (b) is displayed in the gear speed
display section. If the manual gearshift mode or
shoe slip control mode is selected, "MAN" symbol is displayed.
30-87
30-97
DRAFT
Electrial system
Selection of dual tilt (Dual tilt specification)

customize switch, and you can change the setting of
the machine.
a If the customize memory switch is operated
while the above screen is displayed, up to 5 settings can be saved.
Select the blade dual tilt mode by changing the

blade control lever knob switch while the ordinary
a If the dual tilt mode is turned ON, dual tilt mode
monitor (a) is displayed. If the former is turned
OFF, the latter is put out.
Operation to display camera mode (if camera is installed)

customize memory switch, and you can select the
recorded setting of customization.

While the alarm buzzer is sounding, if the buzzer
cancel switch is pressed, the alarm buzzer stops.
a Even if the buzzer cancel switch is pressed, the
screen does not change.
30-88
When a camera is installed, if [F3] is pressed, the

multi-display changes to the camera image.
a Set the connection of the camera in the service
mode.
a Up to 3 cameras can be connected. If the camera mode is selected, however, only the image of
camera 1 is always displayed.
D375A-6
(01)
DRAFT
Electrial system
a If a caution is generated in the camera mode, the

caution monitor is displayed at the left upper of
the screen.
a When an error that there is a user code occurs in
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 displayed on the right side. The image of camera 3
is displayed only singly.
a If the images of 2 cameras are displayed simultaneously, images are displayed at intervals of 1
second on the right and left screen.
Operation to display clock and service meter
While the ordinary screen is displayed, press [F4],

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
While the maintenance monitor or ordinary screen is

displayed, press [F5], and the maintenance table
a To reset the time left after finishing maintenance,

more operations are necessary.
(See "Maintenance history" section in service
mode)
While the ordinary screen is displayed, press [F6],

and the user menu screen is displayed.
a Display of clock
D375A-6
(03)
30-89
30-99
DRAFT
Electrial system
a There are following items in the user menu.

Multi gauge select
Screen adjustment
Time adjustment
Language setting
Reverse interlock selection mode
Fan reverse mode
Prelub skip
Display of action code and failure code
If an abnormality which displays an action code and

a failure code occurs on the ordinary screen or camera mode screen, all the information of the abnormality is displayed.
(a): Action code (3 digits)
(b): Failure code (5 or 6 digits)
(c): Telephone mark
(d): Telephone No.
a This screen is displayed only when an abnormality (failure code) for which a user code is set occurs.
a The telephone mark and telephone No. are displayed 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.
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 monitor 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
code
Method of indicating trouble
Examples of trouble
Remedy given to operator to take

q
E01
Action code and failure

code are displayed.
q
q
Backup alarm does not sound.

Fan speed is always at maximum.
q
q
q
q
E02
q

code are displayed.
Alarm buzzer sounds.
q
q
q
q
E03
q
q

code are displayed.
Telephone No. is displayed (if set).
q
q
q
q
q
E04
q
q
D375A-6
(03)

code are displayed.
Telephone No. is displayed (if set).
q
q
q
Gear is not shifted up or down.

Engine boost pressure is abnormal.
Exhaust gas color is bad when
temperature is low.
sensor is abnormal.
Usable gear speeds are limited.
Engine speed does not rise fully.
Gear shift shock is large.
Steering performance lowers.
Braking shock is increased.
Engine cannot be controlled.
Machine cannot travel.
Machine stops.
q
q
q
q
Although all or a part of automatic

function stops, machine can be operated.
Ask your Komatsu distributor for repair.
If operator stops and restarts engine, machine can be operated without any functions being limited.
However, operator has to pay attention.
Move machine to safe place.

Stop machine immediately.

30-91
30-101
DRAFT
Electrial system
Function of checking display of LCD (Liquid Crystal

Display)
While the ordinary screen is displayed, if the following numeral input switch and function switch are operated as follows, all the LCD (Liquid Crystal
Display) lights up in white.
q Operation of switches (simultaneous): [4] + [F2]
a When finishing the operation of the switches, release [F2] first.
a If there is a display error in the LCD, only that
part is indicated in black.
a The LCD panel sometimes has black points
(points which are not lighted) and bright points
(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
To check the service meter while the starting switch

is turned OFF, operate the numeral input switches
as follows. At this time, only the service meter section displays.
q Operation of switches (simultaneous): [4] + [1]
a Since there is some time lag in start of the LCD,
hold down the switches until the LCD displays
normally.
a After the machine monitor is used continuously,
blue points (points which do not go off) may be
seen on this screen. This phenomenon does not
indicate a failure or a defect.
D375A-6
(01)
DRAFT
Electrial system
When changing the maintenance password used for

the maintenance setting function, follow these procedures.
q
q
(If it has only 3 or less digits or has 7 or more

digits, it is not accepted).
[F5]: Delete input numeral/Return to ordinary
screen
[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 accepted until 10 minutes pass after the starting
switch is turned on.
2. After the "Password" screen is displayed, input

the current password with the numeral input
switches and confirm it with the function switch.
q [F5]: Delete input numeral/Return to ordinary
screen
q [F6]: Confirm input numeral
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 message to input the password again is displayed.
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
q [F6]: Confirm input numeral
a If a password different from the password input before is input, the message to input
again is displayed.
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
(01)
30-93
DRAFT
Electrial system
t Service mode
To change the operator mode to the service mode,
perform the following operation.
This operation is always required when you use the
service mode.
1. Check of display of screen and operation of
switches
While the ordinary screen is displayed, perform
the following operation with the numeral input
switches.
[4]+[1]o[2]o[3]
a This operation of the switches is accepted
only while the ordinary screen is displayed.
a The items which can be selected in the service menu are as follows.
01 Monitoring
Mechanical system "Abnormality Record"
Electrical system "Abnormality Record"
03 Maintenance Record
04 Maintenance Mode Change
05 Phone Number Entry
Key-on Mode
Setting of unit
Setting of maintenance pass06 Default
word
Setting of camera
Setting of ECO display
07 Adjustment
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)
02 Abnormality
Record
a Items with 2-digit codes are the menus displayed 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 numeral 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.
2. Selecting monitoring items

After the "Monitoring selection menu screen" is
displayed, select items to be monitored with the
function switches or numeral input switches.
q [F1]: Go to next page (screen)
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 selected 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
(01)
3. Deciding monitoring items

After selecting monitoring items, execute monitoring 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
pressed once more at this time, monitoring is
executed.
a If monitoring items are selected up to the limit
number, monitoring is executed automatically.
30-95
DRAFT
Electrial system
4. Executing monitoring
After the "Executing monitoring screen" is
displayed, perform the necessary operation of
the machine and check the monitoring information.
a Monitoring information is indicated by value,
ON/OFF, or special display.
a The unit of display can be set to SI unit, metric unit, or inch unit with the Default function
in the service mode.
6. Changing machine setting mode

To change the setting of the "P/E Mode", "Fan
Rev." mode, or "Working" mode during monitoring, operate the corresponding switch under
the current condition, and the mode setting
While this screen is displayed, if the corresponding switch is operated further, the corresponding mode is changed.
a After finishing changing the setting, press
[F6] to MPareturn to the monitoring information screen.
a If the setting is changed during monitoring,
the new setting is held even after the screen
returns to the ordinary screen after monitoring 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
No.
50300
50301
50400
31619
31618
90600
90601
31628
32900
60100
60600
03001
03000
31521
50200
50201
31622
31616
31612
31613
31614
30100
31400
32601
32602
32603
32604
31642
90700
40001
60000
70200
31624
10000
40905
40906
31520
Monitoring item (displayed on screen)

S/T Lever 1 Potentio
S/T Lever 2 Potentio
Brake Pedal Potentio
Brake LH ECMV(F/B)
Brake RH ECMV(F/B)
S/T Clutch LH ECMV(F/B)
S/T Clutch RH ECMV(F/B)
S.S.P Solenoid
Pitch Angle
Pitch Angle Sensor
BR Hold Relay
Fuel Dial Throttle
Fuel Dial Sensor
S/T Clutch LH Fill Sw
S/T Brake LH Fill Sw
S/T Fill Sw Input
S/T Clutch RH Fill Sw
S/T Brake RH Fill Sw
T/M Lever 1 Potentio
T/M Lever 2 Potentio
T/M Clutch F ECMV(F/B)
T/M Clutch R ECMV(F/B)
T/M Clutch 1st ECMV(F/B)
T/M Clutch 2nd ECMV(F/B)
T/M Clutch 3rd ECMV(F/B)
T/C Oil Temperature
T/M Out Speed
T/C In Pressure
T/C In Pressure Sensor
T/C Out Pressure
T/C Out Pressure Sensor
L/U ECMV(F/B)
S/C ECMV(F/B)
Vehicle speed
Traction
T/M Out Speed Sensor
Fan Pump Solenoid(F/B)
Fan Speed
SUNC
SUNO
SDNC
P/T SW Input 3
SDNO
PNC
PNO
F
R
T/M Fill Sw Input 1 1st
2nd
3rd
L/U
T/M Fill Sw Input 2
S/C
D375A-6
(03)
Unit (Default: SI)

SI
Metric
mV
mV
mV
mA
mA
mA
mA
mA
mV
mV
%
mV
mV
mV
mV
mA
mA
mA
mA
mA
mV
mV
%
mV
ON OFF
ON OFF
ON OFF
ON OFF
mV
mV
mA
mA
mA
mA
mA
C
rpm
mV
mV
mA
mA
mA
mA
mA
C
r/min
MPa
mV
MPa
mV
mA
mA
km/h
W
mV
mA
r/min
kg/cm2
mV
kg/cm2
mV
mA
mA
km/h
W
mV
mA
rpm
ON OFF
ON OFF
ON OFF
ON OFF
ON OFF
ON OFF
ON OFF
ON OFF
ON OFF
ON OFF
ON OFF
ON OFF
ON OFF
Component
Imperial in charge
mV
mV
mV
mA
mA
mA
mA
mA
mV
mV
%
mV
mV
mV
mA
mA
mA
mA
mA
F
rpm
psi
mV
psi
mV
mA
mA
MPH
W
mV
mA
rpm
Remarks
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
30-97
30-107
Electrical system
Code
No.
40909
70700
70701
60200
60300
31200
43001
40910
70300
90802
31634
10007
40982
01501
40981
40983
37501
42610
42611
42612
42613
42801
20300
99003
20227
20402
30-98

Back-up alarm
N-safty
P/T SW Output
Pre-lub Motor
Pre-heater
Hydraulic Pump Pressure 1
Hydraulic Pressure Sensor 1
Acceleration Sensor Voltage
SSC Command Speed
Torque Converter Output Speed
T/M Main Oil Pressure
P/T SW Input 2
W/E Lock Switch (NO)
W/E Lock SW (NC)
W/E Knob Upper SW
(NO)
W/E Knob Upper SW
Blade Sw Input
(NC)
W/E Knob Lower SW
(NO)
W/E Knob Lower SW
(NC)
Blade Lift Raise
Blade Lift Lower
Blade Lever Oil
Press. Switch
Blade Left Tilt
Blade Right Tilt
Fan Pump Solenoid 2 (F/B)
Fan Speed
Ripper Lift Raise
Ripper Lift Lower
Ripper Lever Oil
Press. Switch
Ripper Tilt in
Ripper Tilt Out
LS Solenoid (F/B)
HYD. Oil Level
ENG Low Idle
W/E SW Input
C-sig
R-sig
Acc
ENG Hold
W/E SW Output
Fan Reverse Solenoid
ENG Shut Down
Ambient Temperature
Exhaust Temperature, front
Exhaust Temperature, rear
Exhaust Temp. sensor, front
Exhaust Temp. sensor, rear
Blow-by Pressure
VHMS LED Monitor
Orbcomm Con. Power
Orbcomm CommuSatellite Condition
nication Status
Data Transmission
Monitor Ass'y P/N
Monitor serial No
Unit (Default: SI)

SI
Metric
Imperial
ON OFF
ON OFF
ON OFF
ON OFF
MPa
mV
mV
r/min
r/min
MPa
mA
r/min
kg/cm2
mV
mV
rpm
rpm
kg/cm2
ON OFF
ON OFF
ON OFF
psi
mV
mV
rpm
rpm
psi
W/E
ON OFF
W/E
ON OFF
W/E
ON OFF
W/E
ON OFF
W/E
mA
rpm
mA
rpm
C
C
C
V
V
kPa
mA
W/E
W/E
W/E
mA
W/E
ON OFF
W/E
ON OFF
W/E
C
C
C
V
V
kg/cm2
Remarks
P/T
P/T
P/T
P/T
W/E
W/E
P/T
P/T
P/T
VHMS
P/T
W/E
W/E
ON OFF
ON OFF
mA
Component
in charge
F
F
F
V
V
psi
VHMS
VHMS
VHMS
VHMS
VHMS
VHMS
VHMS
ON OFF
VHMS
MON
MON
D375A-6
(06)
DRAFT
Electrial system
Code
No.
20228
20242
20404
20243
20244
20405
20245
04200
04300
04401
04402
18900
37200
00201
20216
20217
20400
01002
36700
31701
31703
17500
36400
36401
36200
36300
04107
04105
37400
37401

Monitor Prog P/N
P/T Con Ass'y P/N
P/T Con Serial No
P/T Con Prog P/N
W/E Con Ass'y P/N
W/E Con Serial No
W/E Con Prog P/N
Fuel Level Sensor Volt
Battery charge volt
Hyd Oil Temperature
Hyd Temp Sens Volt
ECM Internal Temp
Engine oil pressure
Machine ID
ECM Build Version
ECM Calibration Data Ver
ECM Serial No
Engine Speed
Engine Torque Ratio
Decel Pedal Position
Decel Pedal Pos Sens Volt
Engine Power Mode
Rail Pressure
Rail Pressure Sens Volt
Rail Press Command
Injection Timing Command
Coolant Temperature
Coolant Temp Sens Volt
Ambient Pressure
Ambient Press Sens Volt
Unit (Default: SI)

SI
V
V
C
V
C
Mpa
r/min
%
%
mV
MPa
V
MPa
CA
C
V
Mpa
V
Metric
V
V
C
V
C
kg/cm2
rpm
%
%
mV
kg/cm2
V
kg/cm2
CA
C
V
kg/cm2
V
Imperial
V
V
F
V
F
psi
rpm
%
%
mV
psi
V
psi
CA
F
V
psi
V
Component
in charge
MON
P/T
P/T
P/T
W/E
W/E
W/E
MON
MON
MON
MON
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
36500 Charge Pressure-Abs
Mpa
kg/cm2
psi
ENG
36501
03203
37300
31706
18500
18501
18600
17201
18700
37201
14200
14201
42700
42701
17903
18001
18100
18101
V
V
l/h
%
C
V
mg/st
CA
Nm
V
C
V
C
mV
Mpa
mV
mm
mV
V
V
l/h
%
C
V
mg/st
CA
kgm
V
C
V
C
mV
V
V
gal/h
%
F
V
mg/st
CA
lbft
V
F
V
F
mV
psi
mV
mm
mV
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
Charge Press Sens Volt

Battery Power Supply
Fuel Rate
Final Throttle Position
Charge Temperature
Charge Temp Sens Volt
Inject Fueling Command
PCV Close Timing
Engine Output Torque
Eng Oil Press Sens Volt
Fuel Temperature
Fuel Temp Sens Volt
ENG Oil Temperature
ENG Oil Temp. sensor
EGR Inlet Pressure-A
EGR In Press Sens Volt
EGR Valve Position
EGR Valve Pos Sens Volt
D375A-6
(03)
kg/cm2
mV
mm
mV
Remarks
Indicated in absolute pressure

(including ambient pressure)
30-99
30-109
Electrical system
Code
No.
18200 BPS Valve Position

18201 BPS Valve Pos Sens Volt
Acc
40912 P/T SW Input 1
R-sig
C-sig
Unit (Default: SI)

SI
Metric
Imperial
mm
mV
mm
mV
ON OFF
ON OFF
ON OFF
mm
mV
Component
in charge
ENG
ENG
P/T
P/T
P/T
Remarks
Not applicable for
this machine
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.
30-99-1
D375A-6
(06)
DRAFT
Electrial system
D375A-6
(03)
30-99-2
30-111
DRAFT
Electrial system
"Abnormality Record" (Mechanical system "Abnormality Record")
The machine monitor classifies and records the abnormalities which occurred in the past or which are
occurring at present into the mechanical system abnormality or electrical system abnormality.
To check the mechanical system abnormality record, perform the following procedures.
1. Selecting menu
Select "02 Abnormality Record" on the "Service
Menu" screen.
2. Selecting sub menu

After the "Abnormality Record" screen is
displayed, select "01 Mechanical Systems" with
the function switches or numeral input switches.
q [F5]: Return to service menu screen
a You may enter a 2-digit code with the numeral input switches to select the record of that
3. Information displayed on "Abnormality Record"

screen
On the "Mechanical Systems" screen, the
following information is displayed.
(a): Sequential order from latest occurrence/Total number of records
(b): Failure code
(c): Contents of trouble
(d): Occurrence number
(e): Service meter reading at first occurrence
(f): Service meter reach at last occurrence
q [F1]: Move to next page (screen) (if displayed)
q [F2]: Move to previous page (screen) (if displayed)
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 occurrence), the service meter reading at the
first occurrence and that at the last occurrence 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.
a For all the failure codes that the machine
monitor can record, see Troubleshooting,
"Failure codes table".
4. Deleting "Abnormality Record"

The contents of the mechanical system "Abnormality Record" cannot be deleted.
30-100
D375A-6
(01)
DRAFT
Electrial system
"Abnormality Record" (Electrical system "Abnormality Record")
The machine monitor classifies and records the abnormalities which occurred in the past or which are
occurring at present into the mechanical system abnormality or electrical system abnormality.
To check the electrical system abnormality record,
perform the following procedures.
1. Selecting menu
Select "02 Abnormality Record" on the "Service
Menu" screen.

After the "Abnormality Record" screen is
displayed, select "02 Electrical Systems" with
the function switches or numeral input switches.
3. Information displayed on "Abnormality Record"

screen
On the "Electrical Systems" screen, the following
information is displayed.
(a): Sequential order from latest occurrence/Total number of records
(b): Failure code
(c): Contents of trouble
(d): Occurrence number
(e): Service meter reading at first occurrence
(f): Service meter reach at last occurrence
q [F1]: Move to next page (screen) (if displayed)
q [F2]: Move to previous page (screen) (if displayed)
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 occurrence), the service meter reading at the
first occurrence and that at the last occurrence 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.
a For all the failure codes that the machine
monitor can record, see Troubleshooting,
"Failure codes table".
4. Deleting "Abnormality Record"

1) While the "Electrical Systems" screen is
displayed, perform the following operation
with the numeral input switches.
[4]+[1]o[2]o[3]
a Operate the switches similarly to the procedure for changing the ordinary display
to the service mode.
D375A-6
(01)
30-101
DRAFT
Electrial system
2) Check that the screen is set in the reset

mode, and then reset the items one by one or
together with the function switches.
a If the screen is set in the reset mode,
[CLEAR] graphic mark is indicated at
[F2].
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.
4) If the screen to notify completion of reset is

displayed and then the "Electrical Systems"
(reset mode) screen is displayed, the reset of
the abnormality record is completed.
a After a while, the screen returns to the
"Electrical Sys. Error Reset" screen.
3) After the "Electrical Sys. Error Reset" screen

is displayed, operate the function switches.
q [F5]: Return to "Electrical Sys. Error Reset" 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
The machine monitor records the maintenance information of the filters, oils, etc., which the operator
can display and check by the following operations.
When maintenance is carried out, if the data are reset in the operator mode, the number of the times of
maintenance is recorded in this section.
1. Selecting menu
Select "03 Maintenance Record" on the "Service
Menu" screen.
a The following items can be selected in the

maintenance record.
01 Engine Oil Change
02 Engine Oil Filter Change
03 Fuel Main Filter Change
41 Fuel Pre Filter Change
04 Hyd Oil Filter Change
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
2. Selecting maintenance record item

After the "Maintenance Record" screen is
displayed, select an item to be checked with the
function switches or numeral input switches.
a You may enter a 2-digit code with the numeral input switches to select the item of that
code.
D375A-6
(03)
3. Items displayed on Maintenance Record screen.

The following items are displayed.
(a): Maintenance items
(b): Number of times of change up to now
(c): Service meter reading (SMR) at previous
change
30-103
30-115
DRAFT
Electrial system
Maintenance Mode Change
The operating condition for maintenance function in the operation mode can be set and
changed with this menu.
q Set function effective or ineffective
q Change set replacement interval (by items)
q Initialize all set change intervals
00 Maintenance Mode On/Off

01 Engine Oil Change Int
02 Eng Oil Filter Change Int
03 Fuel Main Filter Change Int
41 Fuel Pre Filter Change Int
1. Selecting menu
Select "04 Maintenance Mode Change" on the
Service menu screen.
04 Hyd Oil Filter Change Int

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

After the "Maintenance Mode Change" screen is
displayed, select an item to change the setting
with the function switches or numeral input
switches.
a The following items can be selected on the

Change of maintenance mode screen.
30-104
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
function switches.
q ON: Functions of all maintenance items are
set effective in operator mode
q OFF: Functions of all maintenance items are
set ineffective in operator mode
q [F5]: Cancel selection and return to Maintenance mode screen
q [F6]: Confirm selection and return to Maintenance mode screen
a Even if ON/OFF of each item has been set, if
the above setting is changed, it is applied.
4. Contents of setting of each maintenance item

After selecting each maintenance item, if the
screen is displayed, set the item with the function
switches.
D375A-6
(01)
DRAFT
Electrial system
Default: Maintenance interval set in machine

monitor (Recommended by manufacturer
and not changeable).
q Set: Maintenance interval which can be set
freely. Maintenance functions in operator
mode operate on basis of this set time (which
is increased or decreased by 25 hours).
q ON: Maintenance function of this item is set
effective in operator mode.
q OFF: Maintenance function of this item is set
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 changes to the Maintenance mode change screen
with [F5], the setting is effective.
q
a If this operation is executed, the set values of

all the maintenance items are set to default
values.
q [F5]: Return to Maintenance Mode Change
screen
q [F6]: Execute default setting
a A while after [F6] is pressed, the initialization
completion screen is displayed. Then, if the
"Maintenance Mode Change" screen is displayed, initialization is completed.
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
(01)
30-105
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. Input nothing in the surplus positions.
a If one of the input digits is wrong, move to
that digit (and its background changes to orange) and overwrite it with the correct digit.
a If [F6] is pressed without inputting a digit,
there is not information of phone No. Accordingly, no phone No. is displayed in the operator mode.
30-106
D375A-6
(01)
DRAFT
Electrial system
Default setting (Key-on Mode)
Check and change various settings related to the

machine monitor and the machine with the "Default".
The function of Key-on Mode is used to set the initial
mode displayed on the machine monitor when the
starting switch is turned ON.
1. Selecting menu
Select "06 Default" on the "Service Menu"
screen.
Default Value (ALL OFF): Default setting of

all mode items (Power: P, other 3 items:
OFF) is displayed when starting switch is
turned ON
q [F5]: Cancel selection and return to the "Default" screen
q [F6]: Confirm selection and return to default
screen
a When the machine is delivered, Mode at Previous key-off.
q

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
(01)
30-107
DRAFT
Electrial system
Default setting (Setting of unit)

The unit selecting function is used to select the unit
of the data displayed for monitoring, etc.
1. Selecting 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.
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)

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 maintenance mode (with [F5]) and then the "Maintenance table" screen is changed to the
"Maintenance interval reset" screen.

Maintenance Password" with the function
switches or numeral input switches.
5. Changing maintenance password

The password can be changed by operating the
switches specially in the operator mode.
a See "Function of changing maintenance
password" in the operator mode.
a Default password: [000000]
a If the password setting is changed from "Enable" to "Disable", the password is reset to
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
screen
D375A-6
(01)
30-109
DRAFT
Electrial system
Default setting (Setting of camera)

The camera setting function is used to set default
setting and removal of a camera.
1. Selecting menu
screen.
a After "Camera" screen is displayed, camera

1 can be always set.
When 2 or more cameras are connected, if
camera 1 is set, the screen changes to
setting of camera 2 automatically.
a After confirming the setting of each line with
[F6], return to the "Default" screen with [F5],
and the setting is effective.
a If a camera is connected but not set normally
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 simultaneously 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 directly, 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)

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
screen
a If ECO display is turned ON, ECO is displayed when the screen changes to the ordinary screen.
D375A-6
(01)
30-111
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.
2. Selecting adjustment items

After the "Adjustment" screen is displayed, input
the 4-digit adjustment ID of the adjustment item
to be used with the numeral input switches.
q [F5]: Cancel adjustment and return to Service 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.
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 adjustment ID must be filled but they are not displayed on the adjustment screen.
a The functions given to function switches [F3]
[F6] depend on the adjustment item.
a For the method of operating each adjustment
item, see the explanation of its adjustment
ID.
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
ID
0002
0004
0005
0007
0009
0010
0031
0036
0041
Adjustment item
Power train controller initialization
Work equipment specification setting
Brake pedal potentiometer initial correction
Engine decelerator cutting
Pitch angle sensor initial correction
Fan 70% mode
Work equipment controller initialization
Shoe slip control specification code setting
Travel lever code setting
0530
Stall mode
1005
1012
1013
1014
1015
1016
2021
2022
5535
5537
5538
6001
6002
6003
7842
7843
7845
7847
Fan 100 % mode

Steering lever neutral position adjustment
Steering lever leftmost position adjustment
Steering lever rightmost position adjustment
Right brake oil pressure offset
Left brake oil pressure offset
Power train controller voltage check mode
Work equipment controller voltage check mode
Both steering clutch disengage mode
Left steering clutch oil pressure offset
Right steering clutch oil pressure offset
R1 reverse slow set speed
Transmission clutch IP and fill time automatic initial correction
Transmission clutch IP manual initial correction
Transmission clutch IP learning display
Transmission clutch fill time manual initial correction
9995
Control brake release mode
9996
9997
9998
Sudden stop prevent valve operation mode

High idle cut mode
Max. gear speed setting mode
D375A-6
(03)
Remarks
Resetting auto-decelerating function
Setting and resetting uni-direction lever

Recommended mode of torque converter stall
Fine adjustment of reverse slow mode

Control brake: Brake ECMV (Right and

left)
30-113
30-125
DRAFT
Electrial system
Adjustment ID: 0002 (Power train controller

initialization)
Adjustment ID: 0004 (Work equipment specification setting)
This adjustment code is used to initialize the

specification code recognized by the power
train controller and the set values of the
memory in the controller.
a After the power train controller is replaced,
be sure to carry out this adjustment once.
Functions of function switches

[F3]: Unused
[F4]: Unused
[F5]: Return to adjustment item selecting
screen (ID inputting screen)
[F6]: Save setting

[F3]: Increase specification value [CODE]
[F4]: Decrease specification value [CODE]
[F6]: Save setting
Operating method:
1] Press [F6] and check that the alarm
buzzer sounds.
2] Check that the displayed specification
code [CODE] has changed from [1x1] to
[111].
a If specification code [111] is not displayed, the controller unit may be defective.
a Even if this adjustment code is turned off,
the setting is effective.
Operating method:
1] Press [F3] or [F4] to select the specification value [CODE] of the work equipment
concerned.
30-114
This adjustment code is used to make the

work equipment controller recognize the type
of the work equipment.
a After the work equipment controller or the
work equipment is replaced, be sure to carry
out this adjustment once.
CODE
Type of work equipment
0
Dual tiltdozer
1
Single tiltdozer

buzzer sounds.
k If the specification of the work equipment
is different from the setting in the controller, the work equipment may move unexpectedly or an error may be made.
Accordingly, be sure to match the controller to the work equipment.
a Even if this adjustment code is turned off, the
setting is effective.
D375A-6
(01)
DRAFT
Electrial system
Adjustment ID: 0005 (Brake pedal potentiometer

initial correction)
Adjustment ID: 0007 (Engine decelerator cutting)
This adjustment code is used to stop the auto-deceleration function of the engine and
check the high idle speed of the engine unit.
a The engine can be operated and tested with
only the auto-decelerator turned off with this
adjustment code.
a Use this adjustment code for testing, adjusting, or troubleshooting when necessary.

power train controller recognize the zero
point of the brake pedal potentiometer.
a After the power train controller or brake pedal
potentiometer is replaced or the brake pedal
linkage is disconnected and connected, be
sure to carry out this adjustment once.

[F3]: Unused
[F4]: Unused
[F6]: Save corrected value

[F3]: Unused
[F4]: Unused
[F6]: Unused
Operating method:
1] Check that the brake pedal is in the
neutral position (it is not pressed at all)
and keep it in that position.
buzzer sounds.
a Even if the adjustment is carried out, the
displayed value does not change.
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.
Operating method:
When this adjustment code is displayed, its
function is effective and the auto-deceleration function is stopped.
a After this adjustment code is turned OFF,
its function is ineffective.
D375A-6
(01)
30-115
DRAFT
Electrial system
Adjustment ID: 0009 (Pitch angle sensor initial

correction)
Adjustment ID: 0010 (Fan 70% mode)
This adjustment code is used to forcibly set

the cooling fan speed to about 70%.

power train controller recognize the zero
point of the pitch angle sensor and to correct
the installation error.
a After the power train controller is replaced or
the pitch angle sensor is removed and installed or replaced, be sure to carry out this
adjustment once.

[F3]: Unused
[F4]: Unused
[F6]: Save corrected value
Operating method:
1] Check that the machine is level.
buzzer sounds.
a If the adjustment is performed, displayed
item [BODY PITCH ANGLE] changes to
[0.0] (No other displayed item changes).
the correction is effective.
30-116

[F3]: Increase adjustment value [FAN 70 %
SPEED MODE]
[F4]: Decrease adjustment value [FAN 70 %
SPEED MODE]
[F6]: Unused
Operating method:
The function is effective at the time when this
adjustment is displayed and the cooling fan
speed is controlled to about 70% of the
maximum speed.
D375A-6
(01)
DRAFT
Electrial system
Adjustment ID: 0031 (Work equipment controller

initialization)
Adjustment ID: 0036 (Shoe slip control specification code setting)
This adjustment code is used to initialize the

specification code recognized by the work
equipment controller and the set values of
the memory in the controller.
a After the work equipment controller is replaced, be sure to carry out this adjustment
once.

[F3]: Unused
[F4]: Unused
[F6]: Save setting
Operating method:
buzzer sounds.
[222].
a If specification code [222] is not displayed, the controller wiring harness or
the controller unit may be defective.
D375A-6
(01)
This adjustment code is used to change the

rocky terrain specification setting when the
shoe slip control is used.
a When the shoe slip control operates, if shoe

slip is not restrained even if the rocky terrain
specification is set to "5", change the set value.
q

[F3]: Return
[F4]: Go
[F6]: Confirm selection
Operating method:
1] Change the setting from [SSC SPEC H]
to [SSC SPEC L] by pressing [F3] or [F4].
2] Press [F6] to define the selection.
a At this time, check that alarm buzzer
sounds.
30-117
DRAFT
Electrial system
Adjustment ID: 0041 (Travel lever code setting)
This adjustment code is used to correct the

set value of the travel lever code recognized
by the power train controller when it is different 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.
q Functions of function switches
[F3]: Unused
[F4]: Unused
[F6]: Save setting
q
Operating method:
1] Perform adjustment ID "0002" (Initialization 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".
buzzer sounds.
[111].
a If specification code [111] is not displayed, the controller unit may be defective.
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
(03)
30-117-2
30-131
DRAFT
Electrial system
Adjustment ID: 0530 (Stall mode)
Adjustment ID: 1005 (Fan 100% mode)
This adjustment code is used to set the fan

speed in the 100% mode automatically and
make it possible to set the preset (gear speed
at start) to [F3-R3] to stall the torque converter.
a The preset (gear speed at start) can be set to
[F3-R3] only while this adjustment code is selected.
[F3]: Unused
[F4]: Unused
[F6]: Unused
Mode setting information within screen

[P-AUTO SFT MODE]: Automatic Gearshift
In P Mode
[E-AUTO SFT MODE]: Automatic Gearshift
In E Mode
[P-MANUAL SFT MODE]: Manual Gearshift
In P Mode
[E-MANUAL SFT MODE]: Manual Gearshift
In E Mode
a When using this adjustment code, be sure to
select "P-MANUAL SFT MODE".
q Operating method:
when this adjustment code is displayed, its
function is effective and the preset (gear
speed at start) is set to [F3-R3].
k This adjustment code does not stall the
torque converter automatically. Accordingly, operate the levers and pedals securely 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 40C, the fan speed fluctuates)
a After this adjustment code is turned OFF, its
function is ineffective.
q
30-132
30-118
This adjustment code is used to set the cooling fan speed to about 100% forcibly.
It is also used to set the adjustment value of
the maximum speed.
a Functions of function switches
[F3]: Increase adjustment value [FAN 100 %
SPEED MODE]
[F4]: Decrease adjustment value [FAN 100 %
SPEED MODE]
[F6]: Save adjustment value
Operating method:
a When this adjustment code is displayed,
its function is effective and the cooling fan
speed is controlled to about 100% of the
maximum speed.
1] increase Or decrease the adjustment
value by pressing [F3] or [F4].
2] when confirming the adjustment value,
press [F6] and check that the alarm
buzzer sounds.
a When using this adjustment code, be
sure to keep the hydraulic oil temperature
above 45C.(If the hydraulic oil temperature drops below 40C, the fan speed
fluctuates)
its function is ineffective but the set adjustment value is effective.
D375A-6
(03)
DRAFT
Electrial system
Adjustment ID: 1012 (Steering lever neutral position adjustment)
Adjustment ID: 1013 (Steering lever leftmost

position adjustment)

power train controller recognize the neutral
position of the steering potentiometer of the
PCCS lever.
a After the power train controller or PCCS lever
is replaced, be sure to carry out this adjustment once.

[F3]: Unused
[F4]: Unused

[F3]: Unused
[F4]: Unused
Operating method:
1] Check that the PCCS lever is in the
neutral position of the steering direction
and keep it in that position.
buzzer sounds.
the adjustment is effective.
controller recognize the neutral position
of the potentiometer. It is not used to adjust the steering force.
Operating method:
1] Operate the PCCS lever in the steering
direction to the left stroke end and keep it
there.
buzzer sounds.
controller recognize the leftmost position
of the potentiometer. It is not used to adjust the steering force.
D375A-6
(01)

power train controller recognize the leftmost
PCCS lever.
30-119
DRAFT
Electrial system
Adjustment ID: 1014 (Steering lever rightmost

position adjustment)
Adjustment ID: 1015 (Right brake oil pressure

offset)

power train controller recognize the rightmost
PCCS lever.

[F3]: Unused
[F4]: Unused
Operating method:
1] Operate the PCCS lever in the steering
direction to the right stroke end and keep
it there.
buzzer sounds.
controller recognize the rightmost position of the potentiometer. It is not used to
adjust the steering force.
30-134
30-120
This adjustment code is used to adjust the

right brake oil pressure manually.
a Use this adjustment code for work when necessary.

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

The offset oil pressure is displayed and the
adjustment value is increased or decreased
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}.
a The adjustment range is -0.294 - 0.294
MPa {-3 - 3 kg/cm2}.
Operating method:
1] Increase or decrease the adjustment
buzzer sounds.
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 adjustment, however, operate the brake and
check that there is not a problem in the
actual brake performance.
D375A-6
(03)
DRAFT
Electrial system
Adjustment ID: 1016 (Left brake oil pressure

offset)
Adjustment ID: 2021 (Power train controller

voltage check mode)

left brake oil pressure manually.

kg/cm2}.
a The adjustment range is -0.294 0.294
MPa {-3 3 kg/cm2}.
Operating method:
buzzer sounds.
a It is not necessary to operate the brake
during adjustment. After finishing adjustment, however, operate the brake and
actual brake performance.
range.
D375A-6
(03)
This adjustment code is used to check the

constant power supply voltage and switch
power supply voltage applied to the power
train controller.

[F3]: Unused
[F4]: Unused
[F6]: Unused

[PT CONTROLLER UNSWITCH POWER]:
Constant power supply voltage
[PT CONTROLLER ACC POWER]: Switch
power supply voltage
Operating method:
function is effective and the constant power
supply voltage and switch power supply
voltage are displayed simultaneously.
30-121
30-135
DRAFT
Electrial system
Adjustment ID: 2022 (Work equipment controller

voltage check mode)
Adjustment ID: 5535 (Both steering clutch disengage mode)
This adjustment code is used to check the

constant power supply voltage and switch
power supply voltage applied to the work
equipment controller.

[F3]: Unused
[F4]: Unused
[F6]: Unused
[WE CONTROLLER UNSWITCH POWER]:
Constant power supply voltage
[WE CONTROLLER ACC POWER]: Switch
power supply voltage
Operating method:
function is effective and the constant power
supply voltage and switch power supply
voltage are displayed simultaneously.
30-122
This adjustment code is used to disengage

both steering clutches with the parking brake
ON.
a Used to check the torque converter lockup

operation, lockup operating pressure and
transmission clutch operating pressure.
q

[F3]: Unused
[F4]: Unused
[F6]: Unused
Operating method:
function is effective and both steering
clutches are disengaged.
D375A-6
(01)
DRAFT
Electrial system
Adjustment ID: 5537 (Left steering clutch oil pressure offset)
a It is not necessary to steer the machine

during adjustment. After finishing adjustment, however, steer the machine and
check that there is no problem in the actual steering performance.
This adjustment code is used to manually adjust the pressure of the left steering clutch.
q If a machine has been operated for a long period 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.
q

[F5]: Return to adjustment item selection

kg/cm2}.
MPa {-3 3 kg/cm2}.
Operating method:
buzzer sounds.
range.
D375A-6
(03)
30-123
30-137
DRAFT
Electrial system
Adjustment ID: 5538 (Right steering clutch oil

pressure offset)
a It is not necessary to steer the machine

during adjustment. After finishing adjustment, however, steer the machine and
check that there is no problem in the actual steering performance.
This adjustment code is used to manually adjust the pressure of the left steering clutch.
q If a machine has been operated for a long period 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.
q

[F5]: Return to adjustment item selection

kg/cm2}.
MPa {-3 3 kg/cm2}.
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)

engine speed applied to travel at gear speed
R1 with the reverse slow mode ON.



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

in 50 rpm units.
rpm.
rpm)
Operating method:
buzzer sounds.
a If the set speed has been adjusted, the
range.
a It is not necessary to drive the machine
during adjustment. After finishing adjustment, however, drive the machine at R1
with the reverse slow mode ON and
actual travel speed.
Operating method:
buzzer sounds.
range.
D375A-6
(01)

30-125
DRAFT
Electrial system
Adjustment ID: 6003 (R3 reverse slow set

speed)
Adjustment ID: 7842 (Transmission clutch IP and

fill time automatic initial correction)


in 50 rpm units.
rpm (Display: 30).
rpm)
Operating method:
buzzer sounds.
range.
30-126

power train controller recognize the mechanical condition of the transmission.
a After the power train controller or transmission is replaced, be sure to carry out this adjustment once.

[F3]: Unused
[F4]: Unused
Conditions for correction work

1] [ENGINE SPEED]: 1,700 1,950 rpm
2] [T/C TEMPERATURE]: 65 85C
3] Parking brake lever: LOCK position
4] PCCS lever: Neutral position
a When using this adjustment code, keep
the above conditions (In particular, increase the power train oil temperature
sufficiently before starting adjustment).
Operating method:
1] Stall the torque converter so that the
torque converter oil temperature will be
stabilized in the range of 65 85C.
2] Fix the engine speed in the range of 1,700
1,900 rpm.
3] Set the PCCS lever in the neutral position
and set the parking brake lever in the lock
position.
4] Input adjustment ID [7842] directly with
the numeral input switches and press
[F6].
5] Press [F6] again.
a IP correction is started automatically.
a Which clutch is being adjusted is displayed in section "a".
D375A-6
(01)
DRAFT
Electrial system
6] If [End of teaching. Press F6] is displayed

in section "a", press [F6] again.
a The buzzer sounds and the adjustment value is saved.
a This work takes 3 - 5 minutes to complete.
Adjustment ID: 7843 (Transmission clutch IP

manual initial correction)
This adjustment code is used to carry out correction 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 correction work, if necessary.
D375A-6
(01)

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

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

Same as the conditions for IP automatic
correction (Adjustment ID: 7842).
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.
30-127
DRAFT
Electrial system
Adjustment ID: 7845 (Transmission clutch IP

learning display)
Adjustment ID: 7847 (Transmission clutch fill

time manual initial correction)
This adjustment code is used to check the information of correction made by the operation of IP automatic correction (Adjustment
ID: 7842) or IP manual correction (Adjustment ID: 7843).
[F3]: Change display
[F4]: Change display
[F6]: Unused
Operating method:
function is effective and the correction information is displayed.
This adjustment code is used to carry out correction manually when the correction is not
carried out normally by the operation of fill
time automatic correction (Adjustment ID:
7842).
a Use this adjustment code after the fill time
correction 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.
a The value displayed when the clutch is selected is correction information set automatically or manually before.
q Conditions for correction work
Same as the conditions for fill time automatic
correction (Adjustment ID: 7842).
q
30-128
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
(01)
DRAFT
Electrial system
Adjustment ID: 9995 (Control brake release

mode)
Adjustment ID: 9996 (Sudden stop prevent valve

operation mode)
This adjustment code is used to release the

control brake (right and left brake ECMV) to
check the operation of the backup brake
(brake pedal solenoid valve).

[F3]: Unused
[F4]: Unused
[F6]: Unused

[F3]: Unused
[F4]: Unused
[F6]: Unused
Operating method:
function is effective and the control brake
(right and left brake ECMV) is kept released.
Operating method:
function is effective and the sudden stop
prevent solenoid valve and right and left
brake ECMV are kept stopped.
D375A-6
(01)
This adjustment code is used to stop the sudden stop prevent solenoid valve and right
and left brake ECMV to check the operation
of the sudden stop prevent valve.
30-129
DRAFT
Electrial system
Adjustment ID: 9997 (High idle cut mode)
This adjustment code is used to limit the high

idle speed.
Adjustment ID: 9998 (Max. gear speed setting

mode)

[F3]: Increase adjustment value [HI IDLE
RPM SET MODE]
[F4]: Decrease adjustment value [HI IDLE
RPM SET MODE]
Operating method:
buzzer sounds.
a To reset the high idle speed limit, set it to
the original high idle speed (1,900 rpm)
that was set at the time the machine was
shipped.
a The adjustment value is increased or decreased in 50 rpm units.
30-130
This adjustment code is used to limit the

maximum transmission gear speed.
q The limited gear speed is applied in both automatic gearshift mode and manual gearshift
mode.
q

[F3]: Increase adjustment value [MAX
SHIFT]
[F4]: Decrease adjustment value [MAX
SHIFT]
Operating method:
buzzer sounds.
a When resetting the limitation of the maximum gear speed, set the adjustment value to the maximum gear speed (3RD)
which is the initial setting at shipment.
a Setting with this adjustment code becomes effective only after the starting
switch is turned to OFF position and then
to ON position again.
D375A-6
(01)
DRAFT
Electrial system
PM clinic
3rd screen
4th screen (The figure shows VHMS installation specification)
5th screen
6th screen (The figure shows VHMS installation specification)
The machine monitor can check the condition of

the machine without connecting testing tools to
assist the Pm Clinic and other periodic inspections.
1) Selecting menu
Select "08 PM CLINIC" on the Service menu
screen.
2) Information displayed on Pm Clinic screen

The Pm Clinic function displays the following
information on 6 pages.
q 1st screen
D375A-6
(01)
2nd screen (The figure shows VHMS installation specification)
30-131
DRAFT
Electrial system
q
q
q
q
q
[F1]: Change screen

[F2]: Change screen
[F3]: Reset holding
[F4]: Hold (displayed data)
[F5]: Return to service menu screen
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.
2) Selecting cylinder to be disabled

After the "Cylinder Cut-Out" screen is
displayed, select a cylinder to be Cut-Out
with the function switches.
q [F1]: Move selection mark (R) to left
q Move selection mark (R) to right
q [F3]: Reset holding
q [F4]: Hold
a This operation may be performed while
a When [F6] is pressed, if background (a) of
the selected cylinder No. becomes white,
the cylinder is disabled.
a If the machine monitor disables a cylinder
but the engine controller cannot disable
that cylinder, the background of the cylinder No. becomes yellow.
a One or more cylinders can be disabled.
D375A-6
(01)
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
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 background of the cylinder No. becomes red.
a The reduced cylinder mode operation is
not automatically reset after the screen
returns to the operator mode. Accordingly, be sure to perform the resetting operation after the reduced cylinder mode
operation is finished.
4) Function of holding displayed information
If [F4] is pressed during the reduced cylinder
mode operation, the displayed information is
newly held (c) (The real-time information is
kept displayed on the left side).
a While the information is held, if [F3] is
pressed, the holding function is reset.
a The holding function is effective, regardless of setting of the reduced cylinder
mode operation.
30-133
DRAFT
Electrial system
[Reference]
q
If a normally operating cylinder is disabled, the following phenomena occur.

1) Lowering of engine speed
2) Increase of final injection rate
command (quantity)
If the engine is running near the high idle,
however, the engine speed may not lower
for the reason of engine control.
In this case, lower the engine speed with
the fuel control dial and judge by increase
of the injection rate command.
Display of No Injection
If the engine is operated after long storage of the

machine, it may be worn or damaged because of
insufficient lubrication with oil. To prevent this,
the function to lubricate the engine before
starting it by cranking it without injecting fuel is
installed.
Set the no-injection cranking while the engine is
stopped.
1) Selecting menu
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 automatically.
a If no injection cranking cannot be performed because the engine is running or
the communication is abnormal, the
screen does not change from the following 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

The confirmation screen for no injection
cranking is displayed. Select with the function switch.
q [F5]:
Do not perform (Return to Service menu
screen)
q [F6]: Perform
4) Starting no injection cranking

If no injection cranking (Fuel injection in no
cylinders) becomes effective, that is
displayed on the screen. Under this condition, crank the engine with the starting motor.
a While the screen is changing to the following screen, the screen of "Being prepared" is displayed.
a Limit the cranking time to 20 seconds to
protect the starting motor.
D375A-6
(01)
5) Finishing no injection cranking

After completing the no injection cranking
operation, press [F6], and finish of no injection cranking is displayed and the screen
returns to the "2. Preparation of No Injection
cranking" screen automatically
6) Prohibiting no injection cranking

If the operator tries to perform the no injection
cranking while the engine is running, the
message that the engine is running is
displayed and the no injection cranking is not
set effective.
a Depress [F5] to return to the "Service
Menu" screen, stop the engine, and select no injection cranking again.
30-135
DRAFT
Electrial system
Display of Fuel Consumption
This function calculates the hourly fuel

consumption from the actual fuel consumption in
a measuring period and indicates it.
1) Selecting menu
Select "11 Fuel Consumption" on the
2) Starting measurement
After the screen of "Fuel Consumption" is
displayed, start measurement with the function switches.
q [F1]: START
q [F2]: CLEAR
a When the screen of "Fuel Consumption"
is displayed, if a data is indicated, it is the
data of the previous measurement. This
data is not an obstacle to new measurement and can be deleted by pressing
[F2].
a If [F1] is pressed, the data is displayed on
the starting date and time side and measurement starts.
a The display unit of the fuel changes according to the unit set with the initialization (unit setting) function.
SI and meter: l/h, inch: gal/h
30-136
3) Display and function during measurement

Clock mark (a) flashes during measurement.
a While the fuel consumption is being measured, the operator can work with the operator mode and other functions.
Measurement is not finished until this
screen is displayed again and [F1] is
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).
4) Finishing measurement
Press [F1], and measurement is finished and
the data are displayed on the finishing date
and time side.
5) Displaying fuel consumption
If the measurement is finished, the hourly
fuel consumption calculated from the fuel
consumption calculated by the engine
controller and the elapsed time are
displayed.
D375A-6
(01)
DRAFT
Electrial system
[F1]: Change screen

[F2]: Change screen
2nd screen
1] F1 travel distance
The cumulative travel distance in
(theoretical value) is displayed.
(theoretical value) is displayed
4] R1 travel distance
Display of saved load
This function displays the data accumulated

since the machine started operation.
(It displays the data saved in the controller.)
1) Selecting menu
Select "12 Display of saved load" on the
2) Information displayed on Display of saved

load screen
The following Information is displayed 2
screens of the "Display of saved load"
screen.
q
F1
F2
F3
R1
R2
R3
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
(01)
30-137
DRAFT
Electrial system
Setting of VHMS
This function is used to set installation of VHMS.
If VHMS is installed when shipped, this setting
has been completed.
1) Selecting menu
Select "13 Setting of VHMS" on the "Service
Menu" screen.
Snap shot (VHMS specification)

This function sends a snap shot trigger
command to the VHMS controller to execute the
snap shot.
VHMS specification has a manual snap shot
function and an auto snap shot function.
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 troubleshooting 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 incorrect display and partial disability of the
VHMS function.
q
q
q
q
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 indicated in minute and second, and progress 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.
[F3]: Select "ON"

[F4]: Select "OFF"
[F6]: Confirm selection
q
q
30-152
30-138
[F1]: Start measurement

D375A-6
(03)
DRAFT
Electrial system
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 connector, 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 diagnosis.
a The allowed starting switch position is either
OFF or ON. It must not be set to START position.
D375A-6
(01)
30-139
DRAFT
Electrial system
Adjustment method when controller has been replaced

a After machine is assembled or the power train
controller or the work equipment controller is replaced, adjust the system according to the following procedure.
k If the system is not adjusted, the machine
may not operate normally but may move unexpectedly. 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. Accordingly, 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 process for about 30 seconds after the starting
switch is turned to the OFF position and the battery relay is turned OFF, do not remove the controller immediately.
1. Controller initial setting
1) Connect all the wiring harnesses and controllers.
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 buzzer 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
6) Select "07 Adjustment" in the "Service

menu".
7) Input adjustment ID [0002] directly with the

numeral input switches. (Initial setting of
power train controller)
8) Press [F6].
a The buzzer sounds and the specification
selection is saved.
a Confirm that the displayed specification
code has changed from [1 x 1] to [111].
D375A-6
(01)
DRAFT
Electrial system
9) Press [F5] to return to the adjustment ID input

screen.
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.
again.
a The machine monitor lights up and displays normally.
a The engine can be started now.
3. Shoe slip control setting

a Set this item after the machine monitor was
replaced, too.
1) Input "86" with the numeral input switches
and press [F6] in the "Service menu" screen.
2. VHMS device setting (VHMS specification)

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
(01)
30-141
DRAFT
Electrial system
4. Prelube setting
replaced, too.
1) Input "87" with the numeral input switches
and press [F6] in the "Service menu" screen.
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 troubleshooting then carry out steps 5 and 6 again.
5. Turning power on again
Turn the starting switch to the OFF position and
turn it to the ON position again about 1 minute
after (the battery relay is turned OFF).
6. Checking failure codes
1) Set the machine monitor in the service mode.
2) Select "02 Failure history" on the "Service
menu" screen.
a Precautions after replacing controller:

If any controller is replaced, the service
meter in the oil and filter maintenance
mode is reset to 0.
As a result, the replacement period
displayed on the monitor panel may be
different from the actual operating hours.
To solve this problem, determine the first
replacement periods of the oils and filters
after the replacement of the 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"
screen.
11. IP correction value check (Check of correction

value of electric current)
a For details, see "Adjustment" function of
(EMMS)".
12. Trigger teaching value check
(EMMS)".

numeral input switches and press [F6].
3) Press [F3] or [F4] to select Dual tilt or Single
tilt.
4) Press [F6] to settle the selection.
a The buzzer sounds and the work equipment specification is saved.
13. Steering lever neutral position adjustment

(EMMS)".
14. Steering lever leftmost position adjustment
(EMMS)".
15. Steering lever rightmost position adjustment
(EMMS)".
16. Shoe slip control specification setting
(EMMS)".
8. Brake pedal potentiometer initial correction

(EMMS)".
17. Travel lever code setting

(For machines with non-standard travel lever
only)
(EMMS)".
9. Pitch angle sensor standard setting

(EMMS)".
10. IP automatic correction and trigger automatic initial teaching
(EMMS)".
D375A-6
(03)
30-143
30-157
DRAFT
Electrial system
Preparation work for troubleshooting of electrical system

a When performing troubleshooting for an electrical circuit related to the machine monitor, engine
controller, work equipment controller, power
train controller, VHMS controller, or ORBCOMM
terminal, expose the related connectors according to the following procedure.
3) Insert or connect test T-adapters into or to

connectors CM01 and CM02 on the back
side of the machine monitor.
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, loosen its screw.
a When returning the connector to the previous condition, tighten the screw to the
following torque.
3 Screw: 3 1 Nm {0.3 0.1 kgm}
In order to prevent malfunction and mistaken system error warning, be sure to

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

1) Slide the operator's seat to the front end and
fold the seat back forward.

1) Slide the operator's seat to the front end and
fold the seat back forward.
3) Remove the mounting bolts of work equipment controller (10).
3) Remove the mounting bolts of power train

controller (11).

connectors WECN1, WECN2 and WECN3.
a Since the connectors are secured with
screws, loosen those screws before disconnecting.
following torque.
3 Screw: 3 1 Nm {0.3 0.1 kgm}

connectors PTCN1, PTCN2 and PTCN3.
following torque.
3 Screw: 3 1 Nm {0.3 0.1 kgm}
30-160
30-146
D375A-6
(03)
Electrical system
Preparation work for troubleshooting for electrical equipment system
5. VHMS controller (VHMS specification)

1) Open the cover on the left side of the floor
and remove cover (12).
2) Insert or connect troubleshooting T-adapters
into V1, V2A, V2B, V3A, V3B, V4A and 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.
6. ORBCOMM terminal
1) Remove seat belt buckle (14) and remove
cover (15).
D375A-6
(06)
2) Remove the mounting bolts of ORBCOMM

terminal (16) and pull out the terminal.
3) Insert or connect test T-adapter into or to

connector KOM1.
following torque.
3 Screw:3 1 Nm {0.3 0.1 kgm}
30-147
DRAFT
Electrial system
Inspection procedure of diode

a The direction of continuity of diode is marked on
the surface of the diode.
1. When using digital tester

1) Set the tester in the diode range and read the
indicated value.
a When an ordinary circuit tester is used,
the voltage of the internal battery is indicated.
2) Put the red probe (+) of the test lead to the
anode (P) of and the black probe () to the
cathode (N) of diode, and confirm the indicated 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 (defect)
30-148
2. When using analog tester

1) Set the tester in the resistance range.
2) Apply the leads of the tester as explainedbelow 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
value) varies depending on the type of
tester and testing range.)
q Needle deflects with both connection i)
and ii): Defective (internal short circuit)
q Needle does not deflect with either connection 1] or 2]: Defective (internal disconnection)
D375A-6
(01)
DRAFT
Electrial system
Handling of optional devices

a D375A-6 has connectors to install optional devices in its fuse box. When installing any optional
device, receive the necessary signals and power
through those connectors without modifying the
wiring harness.
a For the locations of the connectors, see Troubleshooting, "Connector list and three-dimensional
layout".
1. Connecting the ACC signal of starting switch
If the ACC signal (ON signal) of the starting
switch is necessary for a optional device such as
the turbocharger timer, connect it through the
following connector pin.
q Pin (B) of CN-ESD (3-pole heavy duty wire
connector)
a A 20A fuse is installed on the upstream side
of this connector pin.
4. Connecting C signal of starting switch

When starting switch signal C (starting signal) is
necessary to an optional device such as prelube
device, take it out of the following connector pin.
q CN-PRS (2-pole heavy duty wire connector)
a Remove the connector installed when the
machine was delivered and connect pin (1) to
the final starting signal output point of the
prelube device and connect pin (2) to the input signal point from the starting switch.
5. Connecting external power source
If an external power source is necessary,
connect it through the following connectors.
q CN-800 (Plug connector):
Used for device in cab
q CN-810 (Plug connector):
Used for device out of cab
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
(01)
30-149
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 "KOMATSU KOMTRAX SUPPORT CENTER" before initializing 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 before the opening notification is received, the ORBCOMM terminal transmits radio waves and
ORBCOMM CO. LTD. sends out the stop signal
automatically. In this case, complicated procedures and some time are required to open the
ORBCOMM terminal service again.
30-150
D375A-6
(01)
DRAFT
Electrial system
D375A-6
(03)
30-151
30-165
DRAFT
Electrial system
Initialization procedures for VHMS controller

a Initialization tools for VHMS controller
SymPart No.
bol
1 799-608-3211
799-608-322
2
0
Z
Commer3
cially available
Part name
Discket
Wiring harness
Notebook type personal computer
:Windows98/2000/Me/XP/VISTA
(*) [With RS232C terminal]
*:VHMS setting tool Ver.3.06.00.03 or later, VHMS

analysis tool Ver.3.05.00.00 or later.
a Before starting full operation after completion of
local assembly or before resuming operation after storage for a long period, initialize the VHMS
controller according to the following procedure.
a Machine data collected with the VHMS controller
are stored and managed in WebCARE database. To process the data smoothly on the WebCARE, 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 initialization.
a For the method of installing the VHMS Initialization Program to the personal computer, refer to
the Operation and Maintenance Manual contained 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 advance.
a The initial setting procedure is described in the
ORBCOM installation specification and the ORBCOM-less specification. When using the ORBCOM 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".
30-152
1. Check of machine information, engine information and controller information

a This step is a work performed on the whole
machine.
Check and record the machine information,
engine information, VHMS controller information and ORBCOMM terminal information.
NO
1
2
3
4
5
6
Information to be checked
Model name
Machine serial No.
Current service meter reading
Engine serial No.
Transmission serial No.
VHMS controller serial No.
ORBCOMM terminal serial No.
7
[Only for machines equipped with ORBCOM]
a VHMS controller (1) is in the control box on

the left side of the floor and ORBCOMM terminal (2) is in the control box on the right side
of the floor.
D375A-6
(01)
DRAFT
Electrial system
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 download 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)
a Connect the personal computer to the
RS232C terminal.
3. Check of operation and satellite capturing condition of VHMS controller

a This step is a work performed in the operator's cab.
a Check of satellite capturing condition is necessary o only [ORBCOMM specification].
[Method of checking with monitoring function](Monitoring code: 99003)
2) Set the machine monitor to display the
service menu.
a Execute initialization of VHMS from the

connector in the cab.
a Use the ground download connector for
only downloading.
D375A-6
(01)
3) Select "01 Monitoring".
30-153
DRAFT
Electrial system
4) Input monitoring code 99003 directly with the

a The communication condition of the ORBCOMM terminal is displayed.
[Method of checking with monitoring function]

(Monitoring code: 20300)
1) Input monitoring code 20300 directly with the
a The procedure up to inputting of the monitoring code is the same as the above section.
2) At least 3 minutes after the starting switch is

turned to the ON position, check the communication condition of the ORBCOMM terminal
by the display condition of the decimal point
(indicated with the arrow) of the machine
monitor.
Decimal
point
Condition
q
OFF
q
q
ON
q
q
q
Blinking
q
q
Power is not supplied to ORBCOMM controller.

Communication line to VHMS controller is
abnormal.
Satellite is not captured.
Power is supplied to ORBCOMM controller.
normal.
Power is supplied to ORBCOMM controller.
normal.
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.
30-154
D375A-6
(01)
DRAFT
Electrial system
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

a This step is a work performed in the operator's cab (on the personal computer).
1) Turn on the personal computer and start the
OS.
2) Click the icon of [VHMS Initialization Tool] on
the personal computer screen to start the
VHMS initialization tool.
Important
a The setting screen varies with the version
No. of the VHMS setting tool.
a When using a tool before Ver. 3.5.2.1
(CD-ROM), set the VHMS in step 5.
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.
5. Initialization of VHMS controller (Tool before

Ver. 3.5.2.1)
a When initializing, do not change the data of
service meter [SMR].
[Machine Information]
1) Open the [Machine information] tab.
a The [Machine information] tab is displayed first in the [Data clear and Set up]
menu.
2) Check all the data.
3) If information in the [Date/Time] box is not

correct, change it according to the following
procedures:
D375A-6
(01)
30-155
DRAFT
Electrial system
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 appear. 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.
30-156
D375A-6
(01)
DRAFT
Electrial system
[Communication Setting] (For

ORBCOMM specification only)
a Execute this setting after requesting for
opening of the ORBCOM terminal and finishing the opening procedure.
6) Open the [Communication Setting] tab.
7) Check all the data.
8) To change the setting in [SHORT FAULT

HISTRY], follow the procedure below:
1] Select [SHORT FAULT HISTRY] on the
screen and press [Edit] button (5) on the
left lower part of the [File Transfer Setting]
block to display the setting screen.
2] Change the setting and then press the
[OK] button.
a At initialization, select [Occurrence] at
[Timing] and set the function to [ON].
D375A-6
(01)
9) To change setting in [SHORT TREND ANALYSIS], follow the procedures below:

1] Select [SHORT TREND ANALYSIS] on
the screen and press [Edit] button on the
left lower part of the [File Transfer Setting]
block to display the setting screen.
2] Change the setting and then press the
[OK] button.
a At initialization, input [20h] to [SMR]
and set the function to [ON].
10)To change the setting of [Satellite Setting],

follow the procedure below.
1] Press the [Edit] button in the [Satellite
Setting] block to display the setting
screen.
2] Set the GCC Code to the applicable area
and then press the [OK] button.
30-157
Electrical system
GCC
Code
1
120
130
Area
N.America (*1)
C.S.Americas
Faroe Islands
Europe (*2)
Middle East
Asia (*3)
Africa
Oceania CIS
Japan
Remarks
*1: Except U.S. Territories in
Micronesia and Midway Island
*2 Except Faroe Islands

*3 Except 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 table, select the GCC code in the table or
input the value through the keyboard.
11)After checking/changing all the data in
[Communication Setting], press [Apply]
button to enter the setting.
a If the [Apply] button is pressed, the
screen for checking the setting appears.
Check the setting again and press the
[OK] button if the setting is correct.
6. Initialization of VHMS controller (Ver. 3.5.2.1

or after)
a When initializing, do not change the data of
service meter [SMR].
1) Select [VHMS Setting] and press the "Next"
button.
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 lower right
portion of the screen to finish [VHMS Initial
setting Tool].
30-158
D375A-6
(06)
DRAFT
Electrial system
3) Check the machine information. If it does not

need to be corrected, press the "Next"
button.
4) Select the time zone.

5) Input the local time.
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 advanced 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
Code
1
120
130
Area
N.America (*1)
C.S.Americas
Faroe Islands
Europe (*2)
Middle East
Asia (*3)
Africa
Oceania
CIS
Japan
Remarks
*1: Except U.S. Territories in
Micronesia and Midway Island
*2: Except Faroe Islands

*3: Except 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 table, select the GCC code in the table or
input the value through the keyboard.
D375A-6
(03)
30-159
30-173
DRAFT
Electrial system
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.
30-160
D375A-6
(01)
DRAFT
Electrial system
7. Downloading of set data

1) Connect personal computer Z3 and download connectors (VDW) in the cab or ground
download connector (DL1) by wiring harness
Z2.
2) When using download connector (VDW) in

the cab, set the starting switch in the ON
position.
3) When using ground download connector
(DL1), turn switch (3) ON.
a The green LED lights up.
4) Operate the icon of [VHMS Technical Analysis 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
operator's seat.
a The ground download connector DL1 is

installed to the side of the backup lamp at
the rear right of the machine.
30-176
30-166
a Input [User Name] and [Password].

a For the operation procedures, refer to the
Operation and Maintenance Manual for
VHMS Technical Analysis Tool.
5) Use the [Download] function to download the

data recorded in the VHMS controller to the
personal computer.
a Make sure that downloading has completed before proceeding to the next step.
D375A-6
(03)
DRAFT
Electrial system
8. Check of downloaded data

1) Check the set data with the [View] function.
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 recorded.
3) If the data was downloaded in the cab,

disconnect wiring harness Z2 from download
connector (VDW).
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.
D375A-6
(03)
30-167
30-177
DRAFT
Electrial system
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 inform Komatsu of the completion of the setting.
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
(03)
DRAFT
Electrial system
[For storage]
VHMS initial setting work check sheet
Setting step
Date of setting:
DB/branch
name:
Data entered by:
Check item
Result
Check of nameplates of chassis and

components
Model name
Serial No.
Engine serial No.
Transmission controller serial No.
Connection of personal computer and

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

(Setting of machine information)
5
Set basic information of machine to
VHMS controller in this step.
Is model name correct?

Is machine serial No. input correctly?
Is engine serial No. input correctly?
Is today's date displayed?
Does clock indicate present time?
Is SMR input correctly?
yes
yes
yes
yes
yes
yes
no
no
no
no
no
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
8 Execution of Quick Pm Clinic
Are service mode "SNAPSHOT" selected and is switch

pressed?
yes
no
9 Saving operation of VHMS
yes
no
10 Downloading
Does LED operate normally?
yes
no
Are all files downloaded?

The time downloaded (Reference wrist watch)
11 Check of downloaded data
12 Saving operation of VHMS
D375A-6
(01)
yes no
Hour, minute:
[Check of data]
Is there MFA0 error in Fault History?
Are SMR and time in Fault History matched to set values?
Are all data of Snap Shot prepared?
yes
yes
yes
no
no
no
yes
no
30-169
DRAFT
Electrial system
[For keeping]
ORBCOMM Station Establishment Check
Sheet
Setting step
Date of setting:
DB/branch name:
Data entered by:
Check item
Check of nameplates of chassis

and components
Model name
Serial No.
Engine serial No.
Transmission serial No.
ORBCOMM controller serial No.
Connection of personal computer

and VHMS controller
Is connection made securely?
Check of operation VHMS control- Is operation normal?

ler
(Counting up must be displayed after rotation.)
4 Starting of VHMS Initialization Tool Is setting tool set in "Set up" mode?
Initial setting of VHMS controller

1. Setting of communication
(Machine information and PLM
5
have been set)
2. Setting of start of communication

6 Saving of set items
7
Enter set value of S.Fault History.

Execution of communication
Number of communication (Default: 8)
Enter set value of S. Trend Analysis.
Interval (Default: 20H)
Enter set value of S. Payload data (If PLM is installed).
Time to start collection
Collection interval (Number of days)
yes
no
yes
no
yes
no
On
hrs
Off
On
hrs
Off
On
Off
day
Is GCC code set? (130 for Japan)
yes
no
Is LED (7-segment) turned OFF after saving operation?
yes
no
yes
no
Check of operation of ORBCOMM How is display of decimal point on VHMS monitor (7-segment)?
controller
(Off, On, long/short flashing)
30-170
Result
D375A-6
(01)
DRAFT
Electrial system
D375A-6
(01)
30-171
Electrical system
Using method of KOMTRAX functions of ORBCOMM terminal

a The ORBCOMM terminal equipped with the
KOMTRAX function can display the machine on
the control screen of the KOMTRAX system.
a Whether the ORBCOMM terminal has the
KOMTRAX functions can be checked by the part
No. of the ORBCOMM terminal.
a When using the KOMTRAX functions, perform
1. Make the request for opening the ORBCOMM
terminal and receive the opening notification.
a See "Request for opening ORBCOMM terminal".
2. Initialize the VHMS controller and set the GCC
code of the machine location.
a See "Initialization procedure for VHMS controller".
3. Perform the sign-up test on the machine side.
a Perform the sign-up test in an open outdoor
place.
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 signals from the ORBCOMM communication
satellite and GPS satellite.
1) Check that the VHMS controller, ORBCOMM
terminal, ORBCOMM antenna and GPS
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.
30-172
30-181
a The ORBCOMM terminal executes the

sign-up test and judges the result by itself. The criterion is as follows.
q The starting switch is in the ON position.
q The VHMS controller can communicate
with the ORBCOMM terminal (They are
connected normally).
q A valid GCC code is set to the VHMS controller.
q The ORBCOMM terminal is receiving the
signals from the ORBCOMM communication satellite. (The ORBCOMM antenna is
connected.)
q Positioning of the machine with the is
completed (The GPS antenna is connected.)
4) Check that LED1 is lighting.
a At this time, the sign-up test is completed.
a Once the sign-up test is completed, the
ORBCOMM terminal cannot be returned
to the original state.
D375A-6
(06)
Electrical system
[LED display]
(1) LED-Green
(2) LED-red
(3) LED Yellow

(4) LED Green
[State]
Waiting for server trigger: ON
Normal operating state: OFF
ORBCOMM satellite capture Satellite not captured: ON
Satellite captured (No transmission data):
Satellite captured (There is transmission
Power OFF: OFF
VHMS start recognition
VHMS start recognized: ON
VHMS stop recognized: OFF
ORBCOMM MODEM power ON: ON
KOMTRAX state
(5) LED Red

(6) LED Red
(7) 7 segment
Unused
Unused
(8) Dot
GPS satellite capture state
OFF: OFF
Kept OFF
Kept OFF
Number of mails waiting to be sent (Max. of
Satellite not captured: OFF
Satellite captured: ON
* Flashing interval
Quick flashing: Cycle of 1 sec (ON for 0.5 sec and OFF for 0.5 sec repeatedly)
Slow flashing: Cycle of 4 sec (ON for 0.5 sec and OFF for 1.5 sec repeatedly)
D375A-6
(06)
30-173
DRAFT
Electrial system
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 machine
q Part No. and serial No. of ORBCOMM terminal
q Reading of service meter when sign-up
test was completed (0.1 h unit)
2) Fill in the "VHMS/WebCARE setting notification form" and enter "Use" in the column of
"Use of KOMTRAX Service".
3) Send the "VHMS/WebCARE setting notification form" to VHMS/WebCARE Support
Center in Komatsu Head Office.
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 Manual (For Key Person)".
30-174
D375A-6
(01)
DRAFT
Electrial system
Precautions for replacing VHMS controller

a Tools for replacing VHMS controller
SymPart No.
Part name
bol
1 799-608-3211 Discket
3 799-608-3220 Wiring harness
Notebook type personal comZ
Commercially puter
4
available
:Windows98/2000/Me/XP/VIST
A (*) [With RS232C terminal]
*:VHMS setting tool Ver.3.06.00.03 or later, VHMS

analysis tool Ver.3.05.00.00 or later.
a When the VHMS controller needs to be replaced, set it before removing it and the installed
new VHMS controller according to the following
procedure.
a Machine data collected with the VHMS controller
are stored and managed in WebCARE database. To process the data smoothly on the WebCARE, 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 initialization.
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
a Using the [Download] function, download the
data currently recorded in the VHMS controller to the personal computer.
a For the operating procedures, see Initialization procedures for VHMS controller, "8.
Downloading of set data".
D375A-6
(01)
2. Check, saving and writing of information set in

VHMS controller (Before Ver. 3.5.2.1)
a Transfer the set data of the VHMS controller
to be replaced to the personal computer and
then write it in the newly installed VHMS controller.
2-1. Check and saving of information set in
VHMS controller to be replaced.
1) Connect the personal computer and start the
VHMS technical analysis tool.
a See "Initialization procedures for VHMS
controller".
2) Select "Save/Load" and press the "OK"
button.
3) Check all the information before replacing

the VHMS controller.
4) Select [Save] from [File] in the menu.
30-175
DRAFT
Electrial system
2-2. Writing of set information in new VHMS

controller
1) Connect the personal computer again and
start the VHMS technical analysis tool.
controller".
2) Select "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.
30-176
D375A-6
(01)
DRAFT
Electrial system
4) The saved information is displayed. Press

the "OK" button.
7) After setting the time, press 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.
D375A-6
(01)
30-177
DRAFT
Electrial system
9) The system asks you if you will save the

previous data. Press the "NO" button.
a Usually, you do not need to save the previous data.
3. Check, saving and writing of information set in

VHMS controller (Ver.3.5.2.1 or later)
a Transfer the set data of the VHMS controller to be replaced to the personal computer 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

3) Select [Save Current Setting before replacement of VHMS controller] and press the
"Next" button.
30-178
D375A-6
(01)
DRAFT
Electrial system
4) Check all the information before replacing

the VHMS controller and press the "Save"
button.
3) Select [Use Previous setting after replacement of VHMS controller] and press the
"Next" button.
5) Select [Exit] from [File] in the menu to finish

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.
4) The saved information is displayed. Press

the "Next" button.
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
(01)
30-179
DRAFT
Electrial system
6) The system asks you if you will save the

previous data. Press the "NO" button.
a Usually, you do not need to save the previous data.
[Work after replacing VHMS controller]

a After replacing the VHMS controller, carry out
initialization according to the "Initialization Procedure for VHMS Controller".
a Change the data to the information recorded before the VHMS controller was replaced. (Input
the date and time when the VHMS controller was
replaced.)
a After completing the setting after the replacement, send the check sheet to VHMS/WebCARE Support Center of Komatsu, Tokyo.
a Send the data downloaded before and after replacing the VHMS controller by Notes (LAN) or
E-mail (WAN).
7) The above completes modification of the

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
D375A6 #60001
Serial No.
Service meter
h
User name
Date of inspection
/
/
Serviceman
Specifications
Blade
Semi U blade
U blade
Blade tilt
Single tilt blade
Dual tilt blade
Attachment
Multishank ripper
Variable giant ripper
Counter weight (
kg)
Others
Shoe width
610 mm
710 mm
810 mm
Others
Operating conditions
Construction
Type of soil (specific gravity)
Construction, civil engineering Rock
Roads
Gravel
Tunnels
Sand
Clay
Quarry, mine
Coal
Gold
Limestone
Type of work
Dozing
Side cutting
Ripping
Travel
%
%
%
%
Existence of abnormalities
Oil, coolant level check
Engine coolant level
Engine oil level
Hydraulic oil level
When necessary
Power train
Final drive
Damper case
(
)
Ambient temperature
Max.
Min.
Height above sea level
m
Operator's opinion
Visual check results
[
Content:
[
Content:
Failure code history

[
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
(03)
30-181
30-191
Pm Clinic
Pm Clinic service
30-191
Pm Clinic measurement item or specification of the D375A6

Measuring methods:
Q: Measurement with machine monitor
E: Measurement by gauge. (sensor or quick copuler)
x: Need installation sensor or quick copuler
Engine
Specifications
STD
Pm clinic
VHMS
Specifications
STD
Pm clinic
VHMS
Engine speed
Engine oil pressure Exhaust temperature
Q
Q
Q
Q
Q
Q

pressure
Q
Q
Q

pressure
Q
Q
Q
Blowby
Boost pressure
x
x
Q
Q
Q
E
Q
Power train oil circuit

L/U
clutch pressure
E
E
E
Steering pressure
Brake pressure
E
E
E
E
E
E
E
E
E
Power train oil circuit

Transmission
Specificamain relief
tions
pressure
STD
E
Pm clinic
E
VHMS
Q
1st
2nd
3rd
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
Work equipment circuit

Specifications
STD
Pm clinic
VHMS
30-182
Transmission
lubricating oil
pressure
E
E
E
Fan circuit
Control source pressure
Pump pressure
Engine speed
E
E
E
E
Q
Q
Q
Q
Q
D375A-6
(06)
Pm Clinic
Pm Clinic service
Testing points for Pm clinic (1/3)
30-192
For the measurement procedures, see the following pages.

*1. Engine speed: "Testing engine speed"
*2. Blowby pressure: "Testing blowby pressure"
*3. Engine oil pressure: "Testing engine oil pressure"
*4. Boost pressure: "Testing intake air pressure (boost pressure)"
*5. Exhaust gas temperature: "Testing exhaust temperature"
D375A-6
(06)
30-183
Pm Clinic
Pm Clinic service
30-193

*6. Measurement related to torque converter: "Testing power train oil pressure"
*7. Measurement related to transmission: "Testing power train oil pressure"
*8. Measurement related to steering brake "Testing power train oil pressure"
30-184
D375A-6
(06)
Pm Clinic
Pm Clinic service
30-194

*9. Hydraulic pressure of work equipment: "Measuring and ajusting work equipment oil pressure"
*10. Source pressure of control circuit: "Testing of control circuit main pressure"
*11. Fan speed: "Check of fan speed"
D375A-6
(06)
30-185
DRAFT
Pm Clinic service
Pm Clinic service
Pm Clinic check sheet

Work order No.
D375A6
Date of inspection
/
/
Item
Service meter
Unit
Low idle
Engine speed
Deceleration pedal
depressed
High idle
rpm
Engine
Torque converter stall (Adjustment ID: 0530)

Torque converter stall + Work equipment relief
(ripper raise) (Adjustment ID: 0530)
Blowby pressure
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
Oil temperature:
Min. 70 C
Low idle
Engine oil pressure
High idle
Boost pressure
At torque converter stall
Exhaust temperature
Torque converter stall +

Work equipment relief
Standard
Service limit Test
value for new
OK NG Remarks
value
results
machine
700 800
850 950
1,850 1,900
1,480 1,580
1,450
1,450 1,550
1,400
Max. 3.43
{Max. 350}
Min. 9.41
{Min. 960}
Min. 117.68
{Min. 1.2}
Max. 78.45
{Max. 0.8}
Min. 392.27
{Min. 4.0}
Max. 235.36
{Max. 2.4}
kPa
{mmHg}
Min. 155
{Min. 1,160}
Max. 141
{Max. 1.060}
Max. 700
Min. 730
kPa
{mmH2O}
Serviceman
h
Test conditions
Decel
Serial No.
kPa
{kg/cm2}
No. 1, 2 , 3 cylinder
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.

Item
Test conditions
Unit
Inlet oil pressure
Torque converter
Outlet oil pressure

Lockup clutch pressure
Stator clutch pressure
Engine low idle
Transmission: Neutral
MPa
{kg/cm2}
Inlet oil pressure

Outlet oil pressure
Stator clutch pressure
Engine high idle
Transmission: F2
(Adjustment ID: 5535)
Engine high idle
Standard
Service limit Test
value for new
OK NG Remarks
value
results
machine
0.03 0.25
{0.3 2.5}
0.03 0.20
{0.3 2.0}
00
{0 0}
2.25 2.87
{23.0 29.3}
0.69 1.05
{7.0 10.7}
0.44 0.70
{4.5 7.0}
00
{0 0}
2.55 2.87
{26.0 29.3}
1.29 1.54
{13.2 15.7}
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
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.
Item
Test conditions
Unit
Engine low idle

Main relief pressure
Transmission
Lubricating oil pressure
F clutch pressure
R clutch pressure
1st clutch pressure
2nd clutch pressure
3rd clutch pressure
30-196
30-186
Engine high idle

Engine high idle
Transmission: F1
Transmission: R1
Transmission: F1
Transmission: F2
Transmission: F3
Engine low idle

Engine low idle
Engine low idle
Engine low idle
Engine low idle
MPa
{kg/cm2}
Standard
Service limit Test
OK NG Remarks
value for new
value
results
2.48 2.87
{25.3 29.3}
2.68 2.87
{27.3 29.3}
0.08 0.25
{0.8 2.5}
2.25 2.84
{23.0 29.0}
2.25 2.84
{23.0 29.0}
2.06 2.35
{21.0 24.0}
2.25 2.84
{23.0 29.0}
2.25 2.84
{23.0 29.0}
2.38 3.07
{24.3 31.3}
2.58 3.07
{26.3 31.3}
i
i
2.06 3.13
{21.0 31.9}
2.06 3.13
{21.0 31.9}
1.86 2.55
{18.9 26.0}
2.06 3.13
{21.0 31.9}
2.06 3.13
{21.0 31.9}
D375A-6
(03)
DRAFT
Pm Clinic service
Pm Clinic service

Work order No.
D375A6
Date of inspection
/
Item
Service meter
Test conditions
Unit
Engine low idle

Steering clutch & brake
Left brake pressure

Left clutch pressure
Engine high idle
Left brake pressure
MPa
{kg/cm2}
Right clutch pressure

Engine low idle
Right brake pressure
Engine high idle
Engine at high idle, F2, brake actuated
Hydraulic system
Item
Test conditions
Work equipment
pump
(Unload pressure)
Control lever in NEUEngine high idle

TRAL position
Work equipment
pump
Ripper lift relief or

blade tilt relief
Control circuit source Control lever in NEUpressure

TRAL position
Item
Min. speed
Fan
Engine low idle
Unit
MPa
{kg/cm2}
Engine high idle
Test conditions
Unit
Engine low idle

Fan 100 % mode
Max. speed
Item
Serviceman
Brake performance
Serial No.
Standard value
Service limit
for new
value
machine
Test
results
OK NG Remarks
Test
results
OK NG Remarks
Test
results
OK NG Remarks
Test
results
OK NG Remarks
2.25 2.84
2.2 3.04
{23.0 29.0}
{22.4 31.0}
2.25 2.84
2.2 3.04
{23.0 29.0}
{22.4 31.0}
2.55 2.87
2.4 3.07
{26.0 29.3}
{24.4 31.3}
2.55 2.87
2.4 3.07
{26.0 29.3}
{24.4 31.3}
2.25 2.84
2.2 3.04
{23.0 29.0}
{22.4 31.0}
2.25 2.84
2.2 3.04
{23.0 29.0}
{22.4 31.0}
2.55 2.87
2.4 3.07
{26.0 29.3}
{24.4 31.3}
2.55 2.87
2.4 3.07
{26.0 29.3}
{24.4 31.3}
Machine must not move
Standard value
Service limit
for new
value
machine
2.45 3.82
{25 39}
2.45 3.82
{25 39}
27.5 29.4
{280 300}
27.5 29.4
{280 300}
3.43 4.12
{35 42}
Min. 26.5
{Min. 270}
Min. 26.5
{Min. 270}
Min. 3.1
{Min. 32}
Standard value
Service limit
for new
value
machine
250 450
1,185 1,235
Max. 1,110
rpm
Engine high idle
Test conditions
Unit
Standard value
Service limit
for new
value
machine
Engine low idle
7 13
20
Engine high idle
3.7 4.7
Engine low idle
24
Engine high idle
2.5 3.5
Engine low idle
46
2.5 3.5
Engine low idle
46
Engine high idle
2.5 3.5
Engine low idle
24
Engine high idle
2.5 3.5
Engine low idle
6 10
15
Engine high idle
2.8 3.8
Blade RAISE
Blade tilt (left and right tilt)

[Single tilt model]

[Dual tilt model, Dual setting]
Engine high idle

sec
Blade dump
[Dual tilt specification]

[Dual tilt model, Single setting]
Ripper tilt (ino out)
D375A-6
(03)
30-187
30-197
Pm Clinic
Pm Clinic service

Work order No.
D375A-6
Date of inspection
/
Hydraulic drift
Item
Blade lift cylinder
Visual inspection of
final drive drain plug
Visual check of final
drive drain plug
Service meter
Serviceman
Test conditions
Unit
Engine stopped
Hydraulic oil temperature:
Standard
value for
new
machine
Service
limit value
Max. 65
Max. 25
Standard
value for
new
machine
Service
limit value
Test
results
OK NG Remarks
Test
results
OK NG Remarks
mm/5min.
45 to 55 C
Item
Serial No.
Test conditions
Unit
Engine speed
Engine stopped
There must be no excessive metal particles
Always fill in the record when repairing, adjusting, or replacing main parts.
Date
30-188
Service meter
Repair record
Date
Service meter
Repair record
D375A-6
(06)
DRAFT
Pm Clinic service
Pm Clinic service
D375A-6
(01)
30-189
DRAFT
Pm Clinic service
Pm Clinic service
30-190
D375A-6
(01)
DRAFT
Pm Clinic service
Pm Clinic service
D375A-6
(01)
30-191
DRAFT
Pm Clinic service
Pm Clinic service
30-192
D375A-6
(01)
DRAFT
D375A-6
SEN01868-02
BULLDOZER
D375A-6
Shop Manual
Machine model
D375A-6
Serial number
60001 and up
40 Troubleshooting
D375A-6
(01)
40-1
DRAFT
Contents
Contents
40 Troubleshooting
General Information on troubleshooting ...........................................................................................................
Points to remember when troubleshooting ...................................................................................................
Sequence of events in troubleshooting.........................................................................................................
Checks before troubleshooting .....................................................................................................................
Classification and procedures for troubleshooting ........................................................................................
Failure codes table........................................................................................................................................
Phenomena and troubleshooting numbers ...................................................................................................
Information in troubleshooting table..............................................................................................................
Troubleshooting method for disconnecting wiring harness of pressure sensor system................................
Connection table for connector pin numbers ................................................................................................
Connectors table and arrangement drawing.................................................................................................
T-branch box and T-branch adapter table ....................................................................................................
Fuse locations table ......................................................................................................................................
Troubleshooting by failure code .......................................................................................................................
Failure code [1380MW] Lock up clutch: Slip.................................................................................................
Failure code [1500L0] Transmission clutch: Abnormal .................................................................................
Failure code [15E0MW] Transmission clutch: Slip........................................................................................
Failure code [15SAL1] Forward clutch: Fill high ...........................................................................................
Failure code [15SALH] Forward clutch: Fill Low ...........................................................................................
Failure code [15SBL1] Reverse clutch: Fill high ...........................................................................................
Failure code [15SBLH] Reverse clutch: Fill Low...........................................................................................
Failure code [15SEL1] Speed 1st clutch: Fill high ........................................................................................
Failure code [15SELH] Speed 1st clutch: Fill Low ........................................................................................
Failure code [15SFL1] Speed 2nd clutch: Fill high .......................................................................................
Failure code [15SFLH] Speed 2nd clutch: Fill Low .......................................................................................
Failure code [15SGL1] Speed 3rd clutch: Fill high........................................................................................
Failure code [15SGLH] Speed 3rd clutch: Fill Low .......................................................................................
Failure code [15SJL1] L/U: Fill high ..............................................................................................................
Failure code [15SJLH] L/U: Fill low...............................................................................................................
Failure code [1800MW] P/T clutch: Slip........................................................................................................
Failure code [2201L1] Right clutch: Fill high .................................................................................................
Failure code [2201LH] Right clutch: Fill low..................................................................................................
Failure code [2202L1] Left clutch: Fill high ...................................................................................................
Failure code [2202LH] Left clutch: Fill low ....................................................................................................
Failure code [2300NR] Brake Themal Load Abnormality..............................................................................
Failure code [2301L1] Right brake: Fill high .................................................................................................
Failure code [2301LH] Right brake: Fill low ..................................................................................................
Failure code [2301NR] Steering Brake RH Themal Load Abnormality .........................................................
Failure code [2302L1] Left brake: Fill high....................................................................................................
Failure code [2302LH] Left brake: Fill low.....................................................................................................
Failure code [2302NR] Steering Brake LH Themal Load Abnormality..........................................................
Failure code [7RFAKA] ECM ACC CUT RELAY: Disconnection..................................................................
Failure code [7RFAKB] ECM ACC CUT RELAY: Short circuit .....................................................................
Failure code [AA10NX] Air Cleaner Clogging ...............................................................................................
Failure code [AB00MA] Battery Charge Abnormal .......................................................................................
Failure code [B@BAZG] Eng Oil Press Low.................................................................................................
Failure code [B@BAZK] Eng Oil Level Low..................................................................................................
Failure code [B@BCNS] Eng Water Overheat .............................................................................................
Failure code [B@BCZK] Eng Water Level Low ............................................................................................
Failure code [B@CENS] T/C Oil Overheat ...................................................................................................
Failure code [B@HANS] Hyd Oil Overheat...................................................................................................
Failure code [B@HAZK] Hyd Oil Level Low..................................................................................................
Failure code [CA111] ECM Critical Internal Failure ......................................................................................
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .........................................................................
Failure code [CA122] Chg Air Press Sensor High Error ...............................................................................
40-2
40 - 9
40 - 9
40 - 10
40 - 11
40 - 36
40 - 39
40 - 45
40 - 47
40 - 49
40 - 52
40 - 88
40 -102
40 -105
40 -109
40 -109
40 -110
40 -111
40 -112
40 -114
40 -116
40 -118
40 -120
40 -122
40 -124
40 -126
40 -128
40 -130
40 -132
40 -134
40 -136
40 -138
40 -140
40 -142
40 -144
40 -146
40 -148
40 -150
40 -152
40 -154
40 -156
40 -158
40 -160
40 -162
40 -164
40 -166
40 -166
40 -167
40 -168
40 -169
40 -170
40 -171
40 -172
40 -174
40 -176
40 -178
D375A-6
(01)
DRAFT
Contents
Failure code [CA123] Chg Air Press Sensor Low Error ................................................................................
Failure code [CA131] Throttle Sensor High Error .........................................................................................
Failure code [CA132] Throttle Sensor Low Error ..........................................................................................
Failure code [CA135] Eng Oil Press Sensor High Error ...............................................................................
Failure code [CA141] Eng Oil Press Sensor Low Error ................................................................................
Failure code [CA144] Coolant Temp Sens High Error ..................................................................................
Failure code [CA145] Coolant Temp Sens Low Error...................................................................................
Failure code [CA153] Chg Air Temp Sensor High Error ...............................................................................
Failure code [CA154] Chg Air Temp Sensor Low Error ................................................................................
Failure code [CA187] Sens Supply 2 Volt Low Error ....................................................................................
Failure code [CA212] Eng Oil Temp Sensor High Error ...............................................................................
Failure code [CA213] Eng Oil Temp Sensor Low Error ................................................................................
Failure code [CA221] Ambient Press Sens High Error .................................................................................
Failure code [CA222] Ambient Press Sens Low Error ..................................................................................
Failure code [CA227] Sens Supply 2 Volt High Error ...................................................................................
Failure code [CA234] Eng Overspeed ..........................................................................................................
Failure code [CA238] Ne Speed Sens Supply Volt Error..............................................................................
Failure code [CA263] Fuel Temp Sensor High Error ....................................................................................
Failure code [CA265] Fuel Temp Sensor Low Error .....................................................................................
Failure code [CA271] IMV/PCV1 Short Error................................................................................................
Failure code [CA272] IMV/PCV1 Open Error................................................................................................
Failure code [CA273] PCV2 Short Error .......................................................................................................
Failure code [CA274] PCV2 Open Error .......................................................................................................
Failure code [CA322] Inj #1 (L#1) Open/Short Error.....................................................................................
Failure code [CA342] Calibration Code Incompatibility.................................................................................
Failure code [CA351] Injectors Drive Circuit Error ........................................................................................
Failure code [CA352] Sens Supply 1 Volt Low Error ....................................................................................
Failure code [CA386] Sens Supply 1 Volt High Error ...................................................................................
Failure code [CA441] Battery Voltage Low Error ..........................................................................................
Failure code [CA442] Battery Voltage High Error .........................................................................................
Failure code [CA449] Rail Press Very High Error .........................................................................................
Failure code [CA451] Rail Press Sensor High Error .....................................................................................
Failure code [CA452] Rail Press Sensor Low Error......................................................................................
Failure code [CA553] Rail Press High Error .................................................................................................
Failure code [CA554] Rail Press Sensor In Range Error..............................................................................
Failure code [CA559] Rail Press Low Error ..................................................................................................
Failure code [CA689] Eng Ne Speed Sensor Error ......................................................................................
Failure code [CA731] Eng Bkup Speed Sens Phase Error...........................................................................
Failure code [CA757] All Continuous Data Lost Error...................................................................................
Failure code [CA778] Eng Bkup Speed Sensor Error...................................................................................
Failure code [CA1228] EGR Valve Servo Error 1 .........................................................................................
Failure code [CA1625] EGR Valve Servo Error 2 .........................................................................................
Failure code [CA1633] KOMNET Datalink Timeout Error.............................................................................
Failure code [CA2185] Throt Sens Sup Volt High Error................................................................................
Failure code [CA2186] Throt Sens Sup Volt Low Error ................................................................................
Failure code [CA2249] Rail Press Very Low Error........................................................................................
Failure code [CA2271] EGR Valve Pos Sens High Error..............................................................................
Failure code [CA2272] EGR Valve Pos Sens Low Error ..............................................................................
Failure code [CA2351] EGR Valve Sol Current High Error...........................................................................
Failure code [CA2352] EGR Valve Sol Current Low Error............................................................................
Failure code [D110KB] Battery Relay: Drive Short Circuit ............................................................................
Failure code [D130KA] Neutral relay: Disconnection....................................................................................
Failure code [D130KB] Neutral relay: Short circuit .......................................................................................
D375A-6
(01)
40 -180
40 -182
40 -184
40 -186
40 -188
40 -190
40 -192
40 -194
40 -196
40 -198
40 -200
40 -202
40 -204
40 -206
40 -208
40 -209
40 -210
40 -212
40 -214
40 -216
40 -217
40 -218
40 -219
40 -220
40 -222
40 -224
40 -226
40 -228
40 -230
40 -232
40 -233
40 -234
40 -236
40 -237
40 -238
40 -239
40 -240
40 -242
40 -244
40 -245
40 -246
40 -250
40 -252
40 -253
40 -254
40 -256
40 -257
40 -258
40 -259
40 -260
40 -261
40 -262
40 -264
40 -266
40 -268
40 -270
40 -272
40 -274
40-3
DRAFT
Contents
Failure code [D161KA] Back-up alarm releay: Disconnection ......................................................................

Failure code [D161KB] Back-up alarm releay: Short circuit..........................................................................
Failure code [D182KZ] Preheater Relay Abnormality ...................................................................................
Failure code [D190KA] ACC signal relay: Disconnection .............................................................................
Failure code [D190KB] ACC signal relay: Short circuit .................................................................................
Failure code [D1EFKA] Pre lub. motor relay: Disconnection ........................................................................
Failure code [D1EFKB] Pre lub. motor relay: Short circuit............................................................................
Failure code [DAFRKR] Monitor: Can communication lost (PT) ...................................................................
Failure code [dAFRKR] Monitor: CAN communication lost (WE) .................................................................
Failure code [DAFRMC] CAN Discon (Monitor Detected) ............................................................................
Failure code [DB2RKR] ENG cont.: Can communication lost (PT)...............................................................
Failure code [dB2RKR] ENG controller: CAN communication lost (WE) ......................................................
Failure code [DB90KT] WE controller: Abnormality in controller ..................................................................
Failure code [DB91KK] WE controller: Source voltage reduction .................................................................
Failure code [DB92KK] WE controller: Output voltage reduction..................................................................
Failure code [DB97KK] WE cont.: Sensor voltage 5 V (2) reduction ............................................................
Failure code [DB99KQ] WE controller: Type select signal............................................................................
Failure code [DB9RKR] WE controller: Can communication lost (PT)..........................................................
Failure code [DBB0KK] VHMS controller:Source voltage reduction .............................................................
Failure code [DBB0KQ] VHMS connector connection abnormality ..............................................................
Failure code [DBB3KK] VHMS controller: Source voltage reduction ............................................................
Failure code [DBB5KP] VHMS: Output sensor1 voltage reduction...............................................................
Failure code [DBB6KP] VHMS:Output sensor2 voltage reduction................................................................
Failure code [DBB7KP] VHMS:Output sensor3 voltage reduction................................................................
Failure code [DBBQKR] PT cont.: Can communication lost (VHMS) ...........................................................
Failure code [DBE0KT] PT controller: Abnormality in controller ...................................................................
Failure code [DBE1KK] PT controller: Source voltage reduction..................................................................
Failure code [DBE2KK] PT controller: Output voltage reduction ..................................................................
Failure code [DBE5KK] PT cont.: Sensor voltage 5 V (1) reduction .............................................................
Failure code [DBE6KK] PT cont.: Sensor voltage 24 V reduction ................................................................
Failure code [DBE7KK] PT cont.: Sensor voltage 5 V (2) reduction .............................................................
Failure code [DBE9KQ] PT controller: Type select signal ............................................................................
Failure code [DBERKR] PT controller: Can communication lost (WE) .........................................................
Failure code [DD12KA] Shift up Sw: Disconnection .....................................................................................
Failure code [DD12KB] Shift up Sw: Short circuit .........................................................................................
Failure code [DD13KA] Shift down Sw: Disconnection.................................................................................
Failure code [DD13KB] Shift down Sw: Short circuit ....................................................................................
Failure code [DD14KA] Parking lever Sw: Dissconnection...........................................................................
Failure code [DD14KB] Parking lever Sw: Short circuit ................................................................................
Failure code [DDB9L4] Reverse SW Signal disagreement...........................................................................
Failure code [DDE2KA] Pre lub. oil press sw: Disconnection .......................................................................
Failure code [DDK3L4] Forward SW Signal disagreement...........................................................................
Failure code [DDK5KA] Shift switch disconnection.......................................................................................
Failure code [DDK5KB] Shift switch short circuit ..........................................................................................
Failure code [DDN2LD] Blade tilt RH pressure SW abnormality ..................................................................
Failure code [DDN3LD] Blade tilt LH pressure SW abnormality ...................................................................
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection ...................................................................
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit.......................................................................
Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection........................................................................
Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit ...........................................................................
Failure code [DDNALD] Blade lift up pressure SW abnormality ...................................................................
Failure code [DDNBLD] Ripper lift up pressure SW abnormality..................................................................
Failure code [DDNCLD] Ripper lift down pressure SW abnormality .............................................................
Failure code [DDNDLD] Ripper tilt in pressure SW abnormality ...................................................................
Failure code [DDNELD] Ripper tilt back pressure SW abnormality ..............................................................
Failure code [DDNFLD] Blade lift down pressure SW abnormality ...............................................................
Failure code [DDNLKA] Weq lock Sw: Disconnection ..................................................................................
Failure code [DDNLKB] Weq lock Sw: Short circuit......................................................................................
40-4
40 -276
40 -278
40 -280
40 -282
40 -284
40 -286
40 -288
40 -290
40 -291
40 -292
40 -297
40 -300
40 -301
40 -302
40 -304
40 -306
40 -308
40 -309
40 -312
40 -314
40 -316
40 -318
40 -320
40 -322
40 -323
40 -323
40 -324
40 -326
40 -328
40 -330
40 -332
40 -334
40 -335
40 -338
40 -340
40 -342
40 -344
40 -346
40 -348
40 -350
40 -352
40 -354
40 -356
40 -358
40 -360
40 -362
40 -364
40 -366
40 -368
40 -370
40 -372
40 -374
40 -376
40 -378
40 -380
40 -382
40 -384
40 -386
D375A-6
(01)
DRAFT
Contents
Failure code [DDT5KA] Neutral switch disconnection ..................................................................................

Failure code [DDT5KB] Neutral switch short circuit ......................................................................................
Failure code [DDT5KQ] Lever SPEC selection signal disagreement ...........................................................
Failure code [DDTSL1] S/C: Fill high ............................................................................................................
Failure code [DDTSLH] S/C: Fill low.............................................................................................................
Failure code [DGE5KX] Ambient temp sensor abnormality ..........................................................................
Failure code [DGS1KX] Hyd oil temp: signal abnormal ................................................................................
Failure code [DGT1KA] T/C oil temp sensor: Abnormal ...............................................................................
Failure code [DGT1KX] T/C oil temp sensor: Abnormal ...............................................................................
Failure code [DGT5KA] F exhaust temp sensor disconnection ....................................................................
Failure code [DGT5KB] F exhaust temp sensor short circuit........................................................................
Failure code [DGT6KA] R exhaust temp sensor disconnection....................................................................
Failure code [DGT6KB] R exhaust temp sensor short circuit .......................................................................
Failure code [DH21KA] Weq pressure sensor: Disconnection .....................................................................
Failure code [DH21KB] Weq pressure sensor: Short circuit .........................................................................
Failure code [DHE5KB] ENG blow-by pressure sensor disconnection.........................................................
Failure code [DHE5KY] ENG blow-by pressure sensor short circuit ............................................................
Failure code [DHT3KX] T/M oil pressure sensor abnormality.......................................................................
Failure code [DHT5KA] T/C in-pressure sensor: Disconnection...................................................................
Failure code [DHT5KB] T/C in-pressure sensor: Short circuit ......................................................................
Failure code [DHT7KA] T/C out-pressure sensor: Disconnection.................................................................
Failure code [DHT7KB] T/C out-pressure sensor: Short circuit ....................................................................
Failure code [DK10KA] Fuel control Dial: Disconnection..............................................................................
Failure code [DK10KB] Fuel control Dial: Short circuit .................................................................................
Failure code [DK30KA] ST lever 1: Disconnection .......................................................................................
Failure code [DK30KB] ST lever 1: Short circuit ...........................................................................................
Failure code [DK30KX] ST lever: Out of normal range .................................................................................
Failure code [DK30KZ] ST lever: Disconnection or short circuit ...................................................................
Failure code [DK30L8] ST lever: Signal mismatch .......................................................................................
Failure code [DK31KA] ST lever 2: Disconnection .......................................................................................
Failure code [DK31KB] ST lever 2: Short circuit ...........................................................................................
Failure code [DK40KA] Brake potentiometer: Disconnection .......................................................................
Failure code [DK40KB] Brake potentiometer: Short circuit ...........................................................................
Failure code [DK55KX] FR lever: Out of normal range.................................................................................
Failure code [DK55KZ] FR lever: Disconnection or short circuit...................................................................
Failure code [DK55L8] FR lever: Signal mismatch .......................................................................................
Failure code [DK56KA] FR lever 1: Disconnection .......................................................................................
Failure code [DK56KB] FR lever 1: Short circuit...........................................................................................
Failure code [DK57KA] FR lever 2: Disconnection .......................................................................................
Failure code [DK57KB] FR lever 2: Short circuit...........................................................................................
Failure code [DK60KA] Acceleration sensor: Disconnection ........................................................................
Failure code [DK60KB] Acceleration sensor: Short circuit............................................................................
Failure code [DKH1KA] Pitch angle sensor: Disconnection..........................................................................
Failure code [DKH1KB] Pitch angle sensor: Short circuit .............................................................................
Failure code [DLF1KA] T/C out-speed sensor: Disconnection .....................................................................
Failure code [DLM3KA] Fan rev. sensor: Disconnection ..............................................................................
Failure code [DLM3MB] Fan control: Decline ...............................................................................................
Failure code [DLT3KA] T/M out-speed sensor: Disconnection .....................................................................
Failure code [DLT3KB] T/M out-speed sensor: Abnormal ............................................................................
Failure code [DW59KA] Blade dual selector SOL disconnection..................................................................
Failure code [DW59KB] Blade dual selector SOL short circuit .....................................................................
Failure code [DW59KY] Blade dual selector SOL hot short..........................................................................
Failure code [DW5AKA] Blade pitch selector SOL disconnection ................................................................
Failure code [DW5AKB] Blade pitch selector SOL short circuit ....................................................................
Failure code [DW5AKY] Blade pitch selector SOL Short circuit ...................................................................
Failure code [DW7BKA] Fan rev EPC: Disconnection..................................................................................
Failure code [DW7BKB] Fan rev EPC: Short circuit .....................................................................................
Failure code [DWN3KA] Ssp solenoid: Disconnection..................................................................................
D375A-6
(01)
40 -388
40 -390
40 -392
40 -394
40 -396
40 -398
40 -400
40 -402
40 -404
40 -406
40 -408
40 -410
40 -412
40 -414
40 -416
40 -418
40 -420
40 -422
40 -424
40 -426
40 -428
40 -430
40 -432
40 -434
40 -436
40 -438
40 -440
40 -440
40 -441
40 -442
40 -444
40 -446
40 -448
40 -450
40 -450
40 -451
40 -452
40 -454
40 -456
40 -458
40 -460
40 -462
40 -464
40 -466
40 -468
40 -469
40 -470
40 -471
40 -472
40 -473
40 -474
40 -475
40 -476
40 -477
40 -478
40 -479
40 -480
40 -481
40-5
DRAFT
Contents
Failure code [DWN3KB] Ssp solenoid: Short circuit .....................................................................................

Failure code [DWN3KY] SSP solenoid: Short circuit ....................................................................................
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection.....................................................................
Failure code [DWN5KB] Fan pump solenoid 1: Short circuit ........................................................................
Failure code [DWN5KY] Fan pump solenoid 1: Short circuit ........................................................................
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection ....................................................................
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit........................................................................
Failure code [DWNCKY] Fan pump solenoid 2: Short circuit........................................................................
Failure code [DXH1KA] Lock-up ECMV: Disconnection ...............................................................................
Failure code [DXH1KB] Lock-up ECMV: Short circuit...................................................................................
Failure code [DXH1KY] Lock-up ECMV: Short circuit...................................................................................
Failure code [DXH4KA] 1st clutch ECMV: Disconnection.............................................................................
Failure code [DXH4KB] 1st clutch ECMV: Short circuit ................................................................................
Failure code [DXH4KY] 1st clutch ECMV: Short circuit ................................................................................
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection ...........................................................................
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit ...............................................................................
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit ...............................................................................
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection ............................................................................
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit................................................................................
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit................................................................................
Failure code [DXH7KA] R clutch ECMV: Disconnection...............................................................................
Failure code [DXH7KB] R clutch ECMV: Short circuit ..................................................................................
Failure code [DXH7KY] R clutch ECMV: Short circuit ..................................................................................
Failure code [DXH8KA] F clutch ECMV: Disconnection ...............................................................................
Failure code [DXH8KB] F clutch ECMV: Short circuit...................................................................................
Failure code [DXH8KY] F clutch ECMV: Short circuit...................................................................................
Failure code [DXH9KA] Right clutch ECMV: Disconnection .........................................................................
Failure code [DXH9KB] Right clutch ECMV: Short circuit.............................................................................
Failure code [DXH9KY] Right clutch ECMV: Short circuit.............................................................................
Failure code [DXHAKA] Left clutch ECMV: Disconnection ...........................................................................
Failure code [DXHAKB] Left clutch ECMV: Short circuit...............................................................................
Failure code [DXHAKY] Left clutch ECMV: Short circuit...............................................................................
Failure code [DXHBKA] Right brake ECMV: Disconnection .........................................................................
Failure code [DXHBKB] Right brake ECMV: Short circuit.............................................................................
Failure code [DXHBKY] Right brake ECMV: Short circuit.............................................................................
Failure code [DXHCKA] Left brake ECMV: Disconnection ...........................................................................
Failure code [DXHCKB] Left brake ECMV: Short circuit...............................................................................
Failure code [DXHCKY] Left brake ECMV: Short circuit...............................................................................
Failure code [DXJBKA] S/C ECMV: Disconnection ......................................................................................
Failure code [DXJBKB] S/C ECMV: Short circuit..........................................................................................
Failure code [DXJBKY] S/C ECMV: Short circuit..........................................................................................
Failure code [DY2HKA] Pre lub. motor: Disconnection.................................................................................
Failure code [F@BBZL] ENG blow-by pressure high level ...........................................................................
Failure code [F@BYNR] F exhaust temp high level (2) ................................................................................
Failure code [F@BYNS] F exhaust temp high level (1) ................................................................................
Failure code [F@BZNR] R exhaust temp high level (2)................................................................................
Failure code [F@BZNS] R exhaust temp high level (1) ................................................................................
Troubleshooting of electrical system (E-mode) ................................................................................................
Information contained in troubleshooting table .............................................................................................
E-1 Engine does not start (starting motor does not turn) ..............................................................................
E-2 Preheater does not operate....................................................................................................................
E-3 When starting switch is turned ON, machine monitor displays nothing..................................................
E-4 When starting switch is turned ON (before starting engine), basic check item lights up........................
E-5 Precaution item lights up while engine is running ..................................................................................
E-6 Emergency stop item lights up while engine is running..........................................................................
E-7 Engine coolant temperature gauge does not indicate normally .............................................................
E-8 Fuel gauge does not indicate properly ...................................................................................................
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally ........................................
40-6
40 -482
40 -484
40 -486
40 -487
40 -488
40 -490
40 -491
40 -492
40 -494
40 -495
40 -496
40 -498
40 -499
40 -500
40 -502
40 -503
40 -504
40 -506
40 -507
40 -508
40 -510
40 -511
40 -512
40 -514
40 -515
40 -516
40 -518
40 -519
40 -520
40 -522
40 -523
40 -524
40 -526
40 -527
40 -528
40 -530
40 -531
40 -532
40 -534
40 -535
40 -536
40 -538
40 -540
40 -541
40 -542
40 -543
40 -544
40 -545
40 -545
40 -547
40 -550
40 -554
40 -556
40 -558
40 -560
40 -561
40 -562
40 -564
D375A-6
(01)
Table of contents
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally.....................

E-11 Contents of display by machine monitor are different from applicable machine .........
E-12 Machine monitor does not display some items ...........................................................
E-13 Function switch does not work ....................................................................................
E-14 Operation mode does not change...............................................................................
E-15 Gearshift mode does not change ................................................................................
E-16 Customize function does not operate normally ...........................................................
E-17 Customize memory function does not operate normally .............................................
E-18 Alarm buzzer does not sound or does not stop...........................................................
E-19 When starting switch is turned OFF, service meter is not displayed...........................
E-20 Machine monitor cannot be set in service mode.........................................................
E-21 The ripper pin puller cylinder does not operate...........................................................
E-22 Horn does not sound or does not stop ........................................................................
E-23 Back-up alarm does not sound or does not stop.........................................................
E-24 Fan does not reverse ..................................................................................................
E-25 The head lamp and rear lamp do not light up .............................................................
E-26 Windshield wiper does not operate .............................................................................
E-27 Window washer does not operate...............................................................................
E-28 Electric priming pump does not operate or does not stop automatically.....................
E-29 Orbcomm terminal does not operate normally (Data are not transmitted) ..................
E-30 Gear cannot be shifted................................................................................................
Troubleshooting of hydraulic and mechanical system (H-mode) ............................................
Information in troubleshooting table.....................................................................................
List of Failure Modes and Causes .......................................................................................
H-1 Machine lacks power(or drawbar pull) ..........................................................................
H-2 Machine cannot travel (at 2nd or 3rd each speed) .......................................................
H-3 Machine cannot travel at any gear speeds ...................................................................
H-4 Machine travels only in one direction, forward or reverse.............................................
H-5 Large time lag at gear shifting or directional change ....................................................
H-6 Machine connot turn .....................................................................................................
H-7 Machine turns only to one side .....................................................................................
H-8 Machine overruns at turnning .......................................................................................
H-9 Brake does not work .....................................................................................................
H-10 Torque converter does not lock up .............................................................................
H-11 Power train oil overheats ............................................................................................
H-12 All work equipment operates too slow or lacks power ................................................
H-13 All work equipment does not operate..........................................................................
H-14 Blade lift cylinder speed is too slow or lacks power ....................................................
H-15 Blade tilt cylinder speed is too slow or lacks power ....................................................
H-16 Ripper lift cylinder speed is too slow or lacks power...................................................
H-17 Ripper tilt cylinder speed is too slow or lacks power...................................................
H-18 Excessive hydraulic drift of blade lift cylinder..............................................................
H-19 Excessive hydraulic drift of blade tilt cylinder..............................................................
H-20 Excessive hydraulic drift of ripper lift cylinder .............................................................
H-21 Ripper pin puller cylinder does not operate (machine with giant ripper) .....................
H-22 Blade pitch does not work (machine with dual tilt specification) .................................
H-23 Abnormal noise from around work equipment pump ..................................................
H-24 Abnormal fan rotation (noise and/or vibration are abnormally large or engine overheats)
H-25 Operator's seat isolator quakes abnormally or makes shocks
(Machine with operator's seat isolator) .......................................................................
Troubleshooting of engine (S-mode) ......................................................................................
Method of using troubleshooting chart.................................................................................
S-1 Engine does not start easily ..........................................................................................
S-2 Engine does not start ....................................................................................................
S-3 Engine does not rev up smoothly (response-up is poor)...............................................
S-4 Engine stops during operation ......................................................................................
S-5 Engine does not rotate smoothly (hunting) ...................................................................
S-6 Engine lacks power (or output shortage) ......................................................................
D375A-6
(07)
40- 565
40- 566
40- 566
40- 566
40- 567
40- 567
40- 568
40- 568
40- 569
40- 569
40- 569
40- 570
40- 572
40- 574
40- 576
40- 577
40- 584
40- 590
40- 596
40- 598
40- 600
40- 601
40- 601
40- 602
40- 604
40- 606
40- 607
40- 608
40- 609
40- 610
40- 611
40- 612
40- 612
40- 613
40- 614
40- 615
40- 616
40- 617
40- 617
40- 618
40- 618
40- 619
40- 619
40- 620
40- 620
40- 621
40- 621
40- 622
40- 622
40- 624
40- 624
40- 628
40- 630
40- 634
40- 636
40- 637
40- 638
40-7
Table of contents
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
40-8
D375A-6
(07)
DRAFT
General Information on troubleshooting
Points to remember when troubleshooting

k
k
k
k
k
k
Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative () terminal of the battery first.
When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect
it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to preventreoccurrence of the failure. When carrying out troubleshooting, an important point is of course to understandthe 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
to disassemble the components.
If components are disassembled immediately
after any failure occurs:
q Parts that have no connection with the failure
or other unnecessary parts will be disassembled.
q It will become impossible to find the cause of
the failure.
It will also cause a waste of manhours, parts, or
oil or grease, and at the same time, will also lose
the confidence of the user or operator.
For this reason, when carrying out troubleshooting, it is necessary to carry out thorough
prior investigation and to carry out troubleshooting in accordance with the fixed procedure.
2. Points to ask the user or operator
1) Have any other problems occurred apart
from the problem that has been reported?
2) Was there anything strange about the
machine before the failure occurred?
3) Did the failure occur suddenly, or were there
problems with the machine condition before
the failure?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the
failure? When were these repairs carried
out?
6) Has the same kind of failure occurred
before?
4) Check maintenance items can be checked

externally, so check any item that is considered to be necessary.
4. Confirming failure
Confirm the extent of the failure yourself, and
judge whether to handle it as a real failure or as
a problem with the method of operation, etc.
a When operating the machine to reenact the
troubleshooting symptoms, do not carry out
any investigation or measurement that may
make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in Items 2 4 to narrow down the causes of
failure, then use the troubleshooting table or
troubleshooting flowchart to locate the position
of the failure exactly.
a The basic procedures for troubleshooting is
as follows.
1] Start from the simple points.
2] Start from the most likely points.
3] Investigate other related parts or information.
6. Measures to remove root cause of failure
Even if the failure is repaired, if the root cause of
the failure is not repaired, the same failure will
occur again.To prevent this, always investigate
why the problem occurred. Then, remove the
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
(01)
40-9
DRAFT
Sequence of events in troubleshooting

(Rev. 2007. 12)
40-10
D375A-6
(01)
DRAFT
Checks before troubleshooting
a. Engine, lubricating oil and coolant
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
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
indication on
monitor
Clean or replace
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
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
Air bleeding
b. Hydraulic and mechanical equipment
13 Check of air cleaner for clogging
11 Execution of air bleeding operation
D375A-6
(01)
40-11
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
3 Check of starting motor terminals for looseness and corrosion
2030 V
Replace
Between H L
Add or replace
Repair or replace
Repair
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
4 Testing of battery voltage (with engine stopped)

5 Check of battery electrolyte level
Check of wiring harness for discoloration, burnt areas and cover peeling
Check for removal of wiring harness clamp and sagging of wiring har7
ness
c. Electrical equipment
e. Interior parts d. Exterior parts
After several
minutes opera15 Check of alternator voltage (When engine speed is medium or higher)
tion: 27.5
29.5 V
Check of battery relay operation sound (When starting switch is
16
turned to ON or OFF position)
40-12
Replace
Replace
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
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

Check for abnormal sounds and smells
Some causes of abnormal sounds and smells
can damage the machine if they are left as they
are. Therefore, stop the machine immediately
when you discover the cause.
a2. Check around engine and dirt removal
Check and remove any accumulated dirt around
the engine and any combustibles (dead leaves,
twigs, etc.) on hot engine parts such as the engine muffler, turbocharger, etc..
a3. Check for water leakage around engine
a4. Check for oil leakage around engine
Check any oil leaks from the engine and any water leaks from the coolant system. If any of them
is abnormal, carry out a repair.
a5. Check for leakage from fuel line
Check any fuel leaks and damaged hoses and
tubes. If any of them is abnormal, carry out a repair.
a6. Check of radiator and dirt removal
Check and remove any accumulated dirt and
combustibles (dead leaves, twigs, etc.) around
the radiator.
For removal of dirt from the radiator, see the Operation and maintenance manual, "Cleaning and
testing of radiator fins, oil cooler fins, aftercooler
fins, fuel cooler fins and air conditioner condenser fins (machine with the air conditioner)".
b2. Check of work equipment, cylinders, linkage
and hoses for breakage, wear and clearance
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
(01)
b3. Check of hydraulic equipment, hydraulic

tank, hoses and joints for oil leakage
Check and repair any oil leaks.
c1. Check around battery and dirt removal
Check and remove any accumulated dirt and
combustibles (dead leaves, twigs, etc.) around
the battery.
d1. Check of undercarriage (track, sprocket,
idler and guard) for abnormalities, wear, loose
bolts and oil leakage from roller
Repair any abnormalities.
d2. Check of handrails and steps for abnormalities and loose bolts
Repair any abnormalities and retighten any
loose bolts.
d3. Check and cleaning of rear view mirrors
Check and repair any abnormalities and breakage of the rear view mirrors.
Clean the mirror surfaces and adjust their angles
so that the operator can see the area behind him
from the operator's seat.
e1. Check of gauges and monitors for abnormalities
Check the gauges and monitors inside the operator cab. If any of them is abnormal, replace it.
Clean up the surfaces.
e2. Check of seat belt and fittings
Check any damaged hooks, locks and hook fittings. If any of them is abnormal, carry out a repair.
40-13
DRAFT
Testing according to testing procedure

a. Engine, lubricating oil and coolant
a7. Check of level and type of fuel
Fuel is flammable and dangerous. Do not
bring any open flame near fuel.
k When adding fuel, take care not to let it overflow.
k Wipe off any spilt fuel. If fuel has spilt over
dirt and sand, remove the dirt and sand, too.
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 position.
k
2. If the fuel level is low, open oil filler cap (F) of the
fuel tank and add fuel through the oil filler port to
the necessary level.
q If the filter of breather (1) is clogged, the pressure in the tank decreases and fuel may not
be supplied. To prevent this, clean the filter.
a8. Check for foreign matter in fuel

1. Open the cover on the rear side of the machine.
2. Put a container under drain hose (1) to receive
the drained fuel.
3. Turn drain valve (2) to the "OPEN" position (O)
to discharge the sediment and water in the
bottom together with the fuel.
4. When only the clean fuel flows out, turn drain
valve (2) to the "CLOSE" position (S).
5. Close the cover.
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
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 decreases, 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 genuine cartridges.
a The common rail fuel injection system of this machine 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 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 fuel.
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):
0.2 0.4 Nm {0.02 0.046 kgm}
D375A-6
(01)
11. 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 prefilter 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. Therefore, observe the tightening angle.
12. Then, proceed to "a10. Check of fuel filter".
40-15
DRAFT
a10. Check of fuel filter

Immediately after the engine is stopped, its
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 decreases, and then replace the filter.
k Do not bring any open flame near the filter.
a Komatsu genuine fuel filter cartridges use a special filter with a high filtration efficiency. When replacing, be sure to use a Komatsu genuine
cartridges.
k
a The common rail fuel injection system of this machine consists of parts that are more precise
compared with the conventional injection pump
and nozzle. If a fuel filter cartridge other than Komatsu 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 fuel.
q Prepare an oil receiving container.
q Prepare the filter wrench.
1. Turn supply valve (1) of the fuel tank to the
"CLOSE" (S) position.
4. Place the oil receiving container under filter

cartridge (3).
5. Using the filter wrench, rotate filter cartridge (3)
to the left to remove.
6. 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.
7. Remove cap (A) at the center of the filter
cartridge and install the cartridge in the filter
bracket.

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. Therefore, 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,
"Bleeding air from fuel circuit".
11. Close air bleeding valve (2).
a11. Check of level (in oil pan) and type of engine 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.
3. Remove oil level gauge (G) and wipe gauge oil
off with a cloth.
4. Insert oil level gauge (G) fully and pull it out.
6. If the oil level is above H

1) Remove the cover from the machine bottom
and place a waste oil container directly below
it.
2) Remove drain plug (1).

3) Loosen drain valve (2) slowly so that the oil
will not spurt over you, and drain the excessive oil.
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
(01)
40-17
DRAFT
a12. Check of coolant level (in sub tank)

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 accumulated 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 pressure. 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).
k
40-18
D375A-6
(01)
DRAFT
a13. Check of air cleaner for clogging

k When using compressed air for cleaning, put
on personal protective items such as safety
glasses, cotton gloves, dust mask, etc. to
protect yourself from dirt that will fly out.
k It is dangerous to use excessive force to pull
out the outer element from the air cleaner
body. When working in an elevated or unstable location, take care that you do not fall due
to the momentum created when you pull out
the outer element.
Testing
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.
Cleaning of outer element

a Do not leave or store the element in direct sunlight before or after cleaning it.
a Replace the outer element after cleaning it 6
times or after using it for 1 year. When replacing
the outer element, replace the inner element,
too.
a If dust indicator (1) enters the red zone just after
the outer element is cleaned, replace both outer
and inner elements, even if the outer element
has not been cleaned 6 times.
1. Open the door on the left side of the engine and
unlock 6 hooks (2). Remove cover (3).
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 removed, 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 slanted. 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
(01)
40-19
DRAFT
4. Remove any dirt sticking to the inside of air

cleaner body (6) and cover (3) with a clean cloth,
brush, etc.
a When cleaning the element, do not tap it or
bump it against other objects.
6. Next, blow air along the outside pleats, and blow

again along the inside pleats.
a After cleaning, light up the inside of the element 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
element.
40-20
7. Remove the cloth or tape covering inner 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.
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 procedure.

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 clearance between air cleaner body and cover
(3). If there is any clearance, remove and
install cover (3) correctly.
D375A-6
(01)
40-21
DRAFT
Replacement of element
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.
4. Replace O-ring (7) of cover (3) with a new one.
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 bottom (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 securely, 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 bottom (end with no hole) (C) will be on cover (3)
side.
40-22
D375A-6
(01)
DRAFT
b. Hydraulic and mechanical equipment

b3. Check of hydraulic oil level
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 remove it.
1. Lower the work equipment to the ground and
stop the engine. Check the oil level and add new
oil if necessary.
2. Turn the starting switch to the ON position within
15 seconds after stopping the engine and
operate each control lever (work equipment and
travel) to the stroke end in each direction to
release the internal pressure.
3. Open the cover on the right side of the machine
and check sight gauge (G). If the oil level is
between lines H and L, it is at the correct level.
a If the oil level is below line L, add oil through
oil filter port (F).
a Do not add oil to above line H. If too much is
added, it may damage the hydraulic circuit
and spurt out.
a If the oil level is above line H, stop the engine
and wait until the hydraulic oil cools down.
Then, loosen drain valve (1) at the hydraulic
tank bottom to drain excessive oil through
drain plug (P) into a container.
D375A-6
(01)
Since the oil level fluctuates according to the oil

temperature, note the following when checking
it.
q Before operation (oil temperature: 10 - 30
C), the oil level should be at the center between lines H and L.
q During operation (oil temperature: 50 - 80
C), the oil level should be near line H.
b4. Check of hydraulic oil strainer
work.
and then remove it.
1. Stop the engine and remove oil filler cap (F) of
the hydraulic tank to release the internal pressure.
2. Remove bolts (5) to remove cover (6).
When removing the bolts, keep pressing down
on cover (6) since it may be flung toward you by
the internal spring.
3. Pull out the rod and remove the strainer.
4. Remove dirt from the strainer and clean using
cleaning oil. If the strainer is broken, replace it
with a new one.
5. Insert and set the strainer.
6. While pressing down the spring with the projection at the bottom of cover (1), install the bolts.
7. Tighten the mounting bolts.
k
40-23
DRAFT
b5. Check of hydraulic oil filter

work.
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.
k
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

k Since the undercover is heavy, do not open
or close it from beneath. When removing
bolts (5), stand on the rear side just under the
cover so that you can move away quickly in
case of an emergency.
q When checking, set the machine in a horizontal position.
q While the engine is stopped, the oil level cannot 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
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).
6. If the oil level is above H, open the undercover

and drain the oil according to the following
procedure.
1) Remove 2 bolts (4) on the front side of the
machine.
2) Gradually remove 2 bolts (5) on the rear side
of the machine, while holding cover (3).
3) Since the front of cover (3) is equipped with
the hinge pin, lower cover (3) gradually.
(F): Front of machine
4) Remove hose (1) to change its position as

(A) and loosen drain valve (2) to drain excessive 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
(01)
40-25
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 specified 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, replace 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

converter oil filter
k If pressure remains in the filter, oil may spurt
out. To prevent this, depress the brake pedal
several times and lock it before opening the
filter case.
1. Remove cover (A) on the right fender.
(B): Transmission oil filter
(C): Torque converter oil filter
D375A-6
(01)
2. Remove bolts (1) of transmission oil filter (B) and

torque converter oil filter (C). Pull up cover (2)
and take out element (3).
3. Clean the inside of the case and the removed
parts.
4. Install cover (A) on the right fender.
40-27
DRAFT
b9. Check of damper case oil level

Check the oil level while the engine is stopped.
q When checking, set the machine in a horizontal
position.
1. Pull out oil level gauge (G) and wipe off the oil
with a cloth.
2. Insert oil level gauge (G) again fully into the oil
level gauge pipe and pull it out.
q
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
level is below L, add oil through the oil level
gauge holder.
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
drain excessive oil, and check the oil level again.
40-28
b10. Check of final drive case oil level

k Since the oil may spurt out due to internal
pressure, rotate the plug gradually from its
side to release the internal pressure and then
remove it carefully.
1. Park the machine on a level place.
2. Remove oil level plug (G) and check the oil level.
If the oil level is near the plug hole bottom, it is at
the correct level.
3. If the oil level is low, add power train oil through

oil filler plug hole (F).
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.
b11. Execution of air bleeding operation

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 hydraulic equipment, see Testing and adjusting,
"Bleeding air from each part".
q
D375A-6
(01)
DRAFT
c. Electrical equipment
c1. Check of battery terminals for looseness and
corrosion
Open cover (1) at the left front of the machine and
check the terminals of battery (A) for looseness and
corrosion.
c2. Check of alternator terminals for looseness

and corrosion
Open the engine hood and check alternator terminals B and R for disconnection, looseness and corrosion.
D375A-6
(01)
c3. Check of starting motor terminals for looseness and corrosion

Open the engine hood and check starting motor
(ST-L) terminals B and C for disconnection, looseness and corrosion.
Check starting motor (ST-U) similarly, too.
c4. Testing of battery voltage (with engine

stopped)
Using the battery tester, test the battery voltage
while the engine is stopped.
40-29
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 under 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 water and contact your doctor.
a Do not add battery electrolyte to above the UPPER LEVEL mark. If too much is added, it can
damage the painted surface and corrode the
parts.
a As refined water (Example: Commercially available battery fluid) added to the battery may
freeze, add it before starting work for the day so
that it will not freeze.
q When checking the electrolyte level from the
side of the battery
1. Clean around the electrolyte level lines with a
cloth dampened with water and check that the
electrolyte level is between UPPER LEVEL
(U.L.) and LOWER LEVEL (L.L.)
a Do not clean the battery with a dry cloth since
static electricity may cause an explosion.
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 immediately.
3. After adding the refined water, tighten the cap
securely.
40-30
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.
q When electrolyte level cannot be checked from
the side of the battery
1. Remove cap (2) on the top of the battery.
(Described previously)
2. Look into electrolyte level opening (3) to check
the electrolyte level. If the electrolyte level is
below sleeve (4), be sure to add refined water
(Example: Commercially available battery fluid)
up to the sleeve bottom (U.L. line).
q (A) Correct level: Since the electrolyte level is
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).
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.
D375A-6
(01)
DRAFT
c6. Check of wiring harness for discoloration,

burnt areas and cover peeling
q Check the wiring harness and cables for discoloration and burn.
a Discoloration and burnt areas indicate the possibility of a short circuit or a circuit ground fault.
q Check the wiring harnesses and cables for damage and peeling of the covers.
q If any fault are discovered, repair or replace the
wiring harness or cable.
c9. Check for loose connectors and damaged

locks
q Pull the male and female parts of the connector
by the hand to check the condition of their connection.
q If the connecting condition is abnormal, connect
it securely.
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.
Check the connector to see whether it is unlocked and check its lock portion and housing for
cracks.
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 engine controller (EC).
Open the cover at the front of the fuel tank on the

left side of the machine and check the connection of the floor ground strap.
D375A-6
(01)
40-31
DRAFT
c10. Check of connector pin for corrosion,

bends and deformation
q Disconnect the connector and check the pins for
corrosion, bending and retraction. Check that
the female pins have not expanded.
q If any pin is found to be abnormal, repair or replace 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)
Remove foreign matter in the connector using a

cloth or other material, and blow compressed air
against the inside of the connector.
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 connector, 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

and short circuiting
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 connector.
Open inspection cover (A), and fuse boxes (1) - (3)

are seen.
Check whether any pins are touching any adjacent pins due to peeling of the wire cover, defective crimping of the pin, etc.
c13. Check of fuse for disconnection and corrosion

a When replacing a fuse, be sure to turn off the
power (turn the starting switch to the OFF position).
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 powder, or there is any play between the fuse and
fuse holder, replace the fuse.
q Replace each fuse with another of the same capacity.
D375A-6
(01)
Fuse box (4) is at the overhead section.
40-33
DRAFT
c14. Check of circuit breaker

Do not keep pressing the reset button of the
circuit breaker. (Doing so can cause a fire.)
q The circuit breaker breaks the electrical circuit to
protect the electrical equipment and wiring when
an overcurrent flows through it. It can be used repeatedly.
k
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.
Check the electrical circuit in this case.
Check of circuit breaker of main power supply

1. Turn the starting switch to the OFF position.
2. Open the inspection cover at the front of the fuel
tank on the left side of the machine. Check circuit
breakers (A) - (E).
40-34
3. Push reset buttons (A) - (E) of the circuit

breakers in order.
a If the electrical circuit is broken, the operating effort 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.
D375A-6
(01)
DRAFT
c15. Check of alternator voltage (when engine

speed is medium or higher)
2. Connect the positive (+) line of the tester to alternator terminal (B) and connect the negative (-)
line to the chassis ground.
3. Start and warm up the engine and measure the
voltage while running the engine at a medium or
a higher speed.
q If the voltage is abnormal, repair or replace
the alternator.
D375A-6
(01)
c16. Check of battery relay operation sound

1. Open the battery cover.
2. Check whether the battery relay operation sound
is heard when the starting switch is turned to the
ON/OFF position.
q If the operation sound is not heard, check the
related circuits, referring to E-1 in the E
mode.
q If the related circuits are free from abnormalities, replace the battery relay.
40-35
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]
1. While pressing numerical key [4] on the panel
switch at the normal screen, press [1], [2] and [3]
in order.
2. On the service menu screen, press [F3] switch

(R) on the panel switch once to select "02
Abnormality Record".
3. Press [F6] switch ( ) on the panel switch to
confirm and go to "Abnormality Record" screen.
D375A-6
(01)
4. Press [F6] switch ( ) on the panel switch to

confirm and go to "Mechanical system" screen.
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 remains or restoration to normal has not been
checked). A failure code having no "E" on its
left is a "non-active" one. Since it disappears
at the following clear step, be sure to note it
down.
9. While pressing numerical key [4] on the panel
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.
40-37
DRAFT

return to the "Abnormality record" screen.
40-38
D375A-6
(01)
DRAFT
Failure codes table
Failure codes table

Failure
code
1380MW
1500L0
15E0MW
15SAL1
15SALH
15SBL1
15SBLH
15SEL1
15SELH
15SFL1
15SFLH
15SGL1
15SGLH
15SJL1
15SJLH
1800MW
2201L1
2201LH
2202L1
2202LH
2300NR
2301L1
2301LH
2301NR
2302L1
2302LH
2302NR
7RFAKA
7RFAKB
AA10NX
AB00MA
B@BAZG
B@BAZK
B@BCNS
B@BCZK
B@CENS
B@HANS
B@HAZK
CA111
CA115
CA122
CA123
CA131
CA132
CA135
CA141
CA144
CA145
CA153
D375A-6
(01)
Trouble (Displayed on screen)

Lock up clutch:Slip
Transmission clutch:Abnormal
Transmission clutch:Slip
Forward clutch:Fill high
Forward clutch:Fill Low
Reverse clutch:Fill high
Reverse clutch:Fill Low
Speed 1st clutch:Fill high
Speed 1st clutch:Fill Low
Speed 2nd clutch:Fill high
Speed 2nd clutch:Fill Low
Speed 3rd clutch:Fill high
Speed 3rd clutch:Fill Low
L/U :Fill high
L/U :Fill low
P/T clutch:Slip
Right clutch:Fill high
Right clutch:Fill low
Left clutch:Fill high
Left clutch:Fill low
Brake Themal Load Abnormality
Right brake:Fill high
Right brake:Fill low
Steering Brake RH Themal Load Abnormality
Left brake:Fill high
Left brake:Fill low
Steering Brake LH Themal Load Abnormality
ECM ACC CUT RELAY:Disconnection
ECM ACC CUT RELAY:Short circuit
Air Cleaner Clogging
Battery Charge Abnormal
Eng Oil Press Low
Eng oil level low
Eng Water Overheat
Eng water level low
T/C Oil Overheat
Hyd Oil Overheat
Hyd Oil Level Low
ECM Critical Internal Failure
Eng Ne and Bkup Speed Sens Error
Chg Air Press Sensor High Error
Chg Air Press Sensor Low Error
Throttle Sensor High Error
Throttle Sensor Low Error
Eng Oil Press Sensor High Error
Eng Oil Press Sensor Low Error
Coolant Temp Sens High Error
Coolant Temp Sens Low Error
Chg Air Temp Sensor High Error
Component
Reference
Action code Category of record
in charge
document page
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
E03
E03
E03
E03
E03
E03
E03
E03
E03
E03
E03
E02
E02
E02
E04
E04
E04
E04
E04
E04
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Mechanical system
Electrical system
Electrical system
40-109
40-110
40-111
40-112
40-114
40-116
40-118
40-120
40-122
40-124
40-126
40-128
40-130
40-132
40-134
40-136
40-138
40-140
40-142
40-144
40-146
40-148
40-150
P/T
Mechanical system
40-152
P/T
P/T
E04
E04
Electrical system
Electrical system
40-154
40-156
P/T
Mechanical system
40-158
W/E
W/E
MON
MON
ENG
MON
ENG
MON
P/T
P/T
W/E
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
E03
E03
E03
E03
E03
E03
E02
E01
E01
E01
E01
Electrical system
Electrical system
Mechanical system
Mechanical system
Mechanical system
Mechanical system
Mechanical system
Mechanical system
Mechanical system
Mechanical system
Mechanical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
40-160
40-162
40-164
40-166
40-166
40-167
40-168
40-169
40-170
40-171
40-172
40-174
40-176
40-178
40-180
40-182
40-184
40-186
40-188
40-190
40-192
40-194
40-39
DRAFT
Failure codes table
Failure
code
CA154
CA187
CA212
CA213
CA221
CA222
CA227
CA234
CA238
CA263
CA265
CA271
CA272
CA273
CA274
CA322
CA323
CA324
CA325
CA331
CA332
CA342
CA351
CA352
CA386
CA441
CA442
CA449
CA451
CA452
CA453
CA554
CA559
CA689
CA731
CA757
CA778
CA1228
CA1625
CA1633
CA2185
CA2186
CA2249
CA2271
CA2272
CA2351
CA2352
D110KB
D130KA
D130KB
D161KA
D161KB
40-40

Chg Air Temp Sensor Low Error
Sens Supply 2 Volt Low Error
Eng Oil Temp Sensor Low Error
Eng Oil Temp Sensor Low Error
Ambient Press Sens High Error
Ambient Press Sens Low Error
Sens Supply 2 Volt High Error
Eng Overspeed
Ne Speed Sens Supply Volt Error
Fuel Temp Sensor High Error
Fuel Temp Sensor Low Erro
IMV/PCV1 Short Error
IMV/PCV1 Open Error
PCV2 Short Error
PCV2 Open Error
Inj #1(L#1) Open/Short Error
Calibration Code Incompatibility
Injectors Drive Circuit Error
Sens Supply 1 Volt Low Error
Sens Supply 1 Volt High Error
Battery Voltage Low Error
Battery Voltage High Error
Rail Press Very High Error
Rail Press Sensor High Error
Rail Press Sensor Low Error
Rail Press High Error
Rail Press Sensor In Range Error
Rail Press Low Error
Eng Ne Speed Sensor Error
Eng Bkup Speed Sens Phase Error
All Continuous Data Lost Error
Eng Bkup Speed Sensor Error
EGR Valve Servo Error 1
EGR Valve Servo Error 2
KOMNET Datalink Timeout Error
Throt Sens Sup Volt High Error
Throt Sens Sup Volt Low Error
Rail Press Very Low Error
EGR Valve Pos Sens High Error
EGR Valve Pos Sens Low Error
EGR Valve Sol Current High Error
EGR Valve Sol Current Low Error
Battery Relay:Drive Short Circuit
Neutral relay:Disconnection
Neutral relay:Short circuit
Back-up alarm releay:Disconnection
Back-up alarm releay:Short circuit
Component
Reference
in charge
document page
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
W/E
P/T
P/T
P/T
P/T
E01
E01
E01
E01
E01
E01
E03
E02
E03
E01
E01
E03
E03
E03
E03
E03
E03
E03
E03
E03
E03
E03
E03
E03
E03
E03
E03
E03
E03
E03
E03
E03
E03
E03
E03
E04
E03
E03
E03
E03
E03
E03
E03
E03
E03
E03
E03
E02
E02
E01
E01
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
40-196
40-198
40-200
40-202
40-204
40-206
40-208
40-209
40-210
40-212
40-214
40-216
40-217
40-218
40-219
40-220
40-222
40-224
40-226
40-228
40-230
40-232
40-233
40-234
40-236
40-237
40-238
40-239
40-240
40-242
40-244
40-245
40-246
40-250
40-252
40-253
40-254
40-256
40-257
40-258
40-259
40-260
40-261
40-262
40-264
40-266
40-268
40-270
40-272
40-274
40-276
40-278
D375A-6
(01)
DRAFT
Failure codes table
Failure
code
D182KZ
D190KA
D190KB
D1EFKA
D1EFKB
DAFRKR
dAFRKR
DAFRMC
DB2RKR
dB2RKR
DB90KT
DB91KK
DB92KK
DB97KK
DB99KQ
DB9RKR
DBB0KK
DBB0KQ
DBB3KK
DBB5KP
DBB6KP
DBB7KP
DBBQKR
DBE0KT
DBE1KK
DBE2KK
DBE5KK
DBE6KK
DBE7KK
DBE9KQ
DBERKR
DD12KA
DD12KB
DD13KA
DD13KB
DD14KA
DD14KB
DDB9L4
DDE2KA
DDK3L4
DDK5KA
DDK5KB
DDN2LD
DDN3LD
DDN7KA
DDN7KB
DDN9KA
DDN9KB
D375A-6
(01)

Preheater Relay Abnormality
ACC signal relay:Disconnection
ACC signal relay:Short circuit
Pre lub. motor relay:Disconnection
Pre lub. motor relay:Short circuit
Monitor:Can communication lost(PT)
Monitor:Can communication lost(WE)
CAN Discon (Monitor Detected)
ENG cont.:Can communication lost(PT)
ENG controller:Can communication
lost(WE)
WE controller:Abnormality in controller
WE controller:Source voltage reduction
WE controller:Output voltage reduction
WE cont.:Sensor voltage 5V (2) reduction
WE controller:Type select signal
WE controller:CAN communication error
(PT)
VHMS controller:Source voltage reduction
VHMS Connector Connection Abnormality
VHMS controller:Source voltage reduction
VHMS:Output sensor1 voltage reduction
PT controller:CAN communication lost
(VHMS)
PT controller:Abnormality in controller
PT controller:Source voltage reduction
PT controller:Output voltage reduction
PT cont.:Sensor voltage5V (1) reduction
PT cont.:Sensor voltage 24V reduction
PT cont.:Sensor voltage 5V (2) reduction
PT controller:Type select signal
PT controller: CAN communication lost
(WE)
Shift up Sw:Disconnection
Shift up Sw:Short circuit
Shift down Sw:Disconnection
Shift down Sw:Short circuit
Parking lever Sw:Dissconnection
Parking lever Sw:Short circuit
Reverse SW Signal disagreement
Pre lub. oil press sw:Disconnection
Forward SW Signal disagreement
Shift switch disconnection
Shift switch short circuit
Blade tilt RH pressure SW abnormality
Blade tilt LH pressure SW abnormality
WEQ Knob Sw(down):Disconnection
WEQ Knob Sw(down):Short circuit
WEQ Knob Sw(up):Disconnection
WEQ Knob Sw(up):Short circuit
Component
Reference
in charge
document page
P/T
W/E
W/E
P/T
P/T
P/T
W/E
MON
P/T
E01
E02
E02
E03
E03
E03
E03
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
40-280
40-282
40-284
40-286
40-288
40-290
40-291
40-292
40-297
W/E
E03
Electrical system
40-300
W/E
W/E
W/E
W/E
W/E
E01
E04
E04
E04
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
40-301
40-302
40-304
40-306
40-308
P/T
E03
Electrical system
40-309
VHMS
Electrical system
40-312
VHMS
Electrical system
40-314
VHMS
Electrical system
40-316
VHMS
VHMS
VHMS
Electrical system
Electrical system
Electrical system
40-318
40-320
40-322
VHMS
Electrical system
40-323
P/T
P/T
P/T
P/T
P/T
P/T
P/T
E01
E04
E04
E03
E03
E01
E04
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
40-323
40-324
40-326
40-328
40-330
40-332
40-334
W/E
E03
Electrical system
40-335
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
W/E
W/E
W/E
W/E
W/E
W/E
E02
E02
E02
E02
E03
E03
E03
E02
E03
E02
E02
E02
E02
E01
E01
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
40-338
40-340
40-342
40-344
40-346
40-348
40-350
40-352
40-354
40-356
40-358
40-360
40-362
40-364
40-366
40-368
40-370
40-41
DRAFT
Failure codes table
Failure
code
DDNALD
DDNBLD
DDNCLD
DDNDLD
DDNELD
DDNFLD
DDNLKA
DDNLKB
DDT5KA
DDT5KB
DDT5KQ
DDTSL1
DDTSLH
DGE5KX
DGS1KX
DGT1KA
DGT1KX
DGT5KA
DGT5KB
DGT6KA
DGT6KB
DH21KA
DH21KB
DHE5KB
DHE5KY
DHT3KX
DHT5KA
DHT5KB
DHT7KA
DHT7KB
DK10KA
DK10KB
DK30KA
DK30KB
DK30KX
DK30KZ
DK30L8
DK31KA
DK31KB
DK40KA
DK40KB
DK55KX
DK55KZ
DK55L8
DK56KA
DK56KB
DK57KA
DK57KB
DK60KA
DK60KB
40-42

Blade lift up pressure SW abnormality
Ripper lift up pressure SW abnormality
Ripper lift down pressure SW abnormality
Ripper tilt in pressure SW abnormality
Ripper tilt back pressure SW abnormality
Blade lift down pressure SW abnormality
Weq lock Sw:Disconnection
Weq lock Sw:Short circuit
Neutral switch disconnection
Neutral switch short circuit
Lever SPEC selection signal disagreement
S/C :Fill high
S/C :Fill low
Ambient temp sensor abnormality
Hyd oil temp:signal abnormal
T/C oil temp sensor:Abnormal
T/C oil temp sensor:Abnormal
F exhaust temp sensor disconnection
F exhaust temp sensor short circuit
R exhaust temp sensor disconnection
R exhaust temp sensor short circuit
Weq pressure sensor:Disconnection
Weq pressure sensor:Short circuit
ENG blow-by pressure sensor disconnection
ENG blow-by pressure sensor short circuit
T/M oil pressure sensor abnormality
T/C in-pressure sensor:Disconnection
T/C in-pressure sensor:Short circuit
T/C out-pressure sensor:Disconnection
T/C out-pressure sensor:Short circuit
Fuel control Dial:Disconnection
Fuel control Dial:Short circuit
ST lever1:Disconnection
ST lever1:Short circuit
ST lever:Out of normal range
ST lever:Disconnection or short circuit
ST lever:Signal mismatch
ST lever2:Disconnection
ST lever2:Short circuit
Brake potentiometer:Disconnection
Brake potentiometer:Short circuit
FR lever:Out of normal range
FR lever:Disconnection or short circuit
FR lever:Signal mismatch
FR lever1:Disconnection
FR lever1:Short circuit
FR lever2:Disconnection
FR lever2:Short circuit
Acceleration sensor:Disconnection
Acceleration sensor:Short circuit
Component
Reference
in charge
document page
W/E
W/E
W/E
W/E
W/E
W/E
W/E
W/E
P/T
P/T
E03
E03
E04
E04
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
40-372
40-374
40-376
40-378
40-380
40-382
40-384
40-386
40-388
40-390
P/T
E04
Electrical system
40-392
P/T
P/T
VHMS
P/T
W/E
W/E
VHMS
VHMS
VHMS
VHMS
W/E
W/E
E02
E02
E01
E01
E01
E01
E01
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
40-394
40-396
40-398
40-400
40-402
40-404
40-406
40-408
40-410
40-412
40-414
40-416
VHMS
Electrical system
40-418
VHMS
Electrical system
40-420
VHMS
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
E02
E02
E02
E02
E03
E03
E03
E03
E04
E04
E03
E03
E03
E03
E03
E04
E04
E03
E03
E03
E03
E03
E01
E01
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
40-422
40-424
40-426
40-428
40-430
40-432
40-434
40-436
40-438
40-440
40-440
40-441
40-442
40-444
40-446
40-448
40-450
40-450
40-451
40-452
40-454
40-456
40-458
40-460
40-462
D375A-6
(01)
DRAFT
Failure codes table
Failure
code
DKH1KA
DKH1KB
DLF1KA
DLM3KA
DLM3MB
DLT3KA
DLT3KB
DW59KA
DW59KB
DW59KY
DW5AKA
DW5AKB
DW5AKY
DW7BKA
DW7BKB
DWN3KA
DWN3KB
DWN3KY
DWN5KA
DWN5KB
DWN5KY
DWNCKA
DWNCKB
DWNCKY
DXH1KA
DXH1KB
DXH1KY
DXH4KA
DXH4KB
DXH4KY
DXH5KA
DXH5KB
DXH5KY
DXH6KA
DXH6KB
DXH6KY
DXH7KA
DXH7KB
DXH7KY
DXH8KA
DXH8KB
DXH8KY
DXH9KA
DXH9KB
DXH9KY
DXHAKA
DXHAKB
DXHAKY
DXHBKA
DXHBKB
DXHBKY
DXHCKA
D375A-6
(01)

Pitch angle sensor:Disconnection
Pitch angle sensor:Short circuit
T/C out-speed sensor:Disconnection
Fan rev. sensor:Disconnection
Fan control:Decline
T/M out-speed sensor:Disconnection
T/M out-speed sensor:Abnormal
Blade dual selector SOL disconnection
Blade dual selector SOL short circuit
Blade dual selector SOL short circuit
Blade pitch selector SOL disconnection
Blade pitch selector SOL short circuit
Blade pitch selector SOL Short circuit
Fan rev EPC:Disconnection
Fan rev EPC:Short circuit
Ssp solenoid:Disconnection
Ssp solenoid:Short circuit
SSP solenoid:Short circuit
Fan pump solenoid 1:Disconnection
Fan pump solenoid 1:Short circuit
Fan pump solenoid 2:Disconnection
Lock-up ECMV:Disconnection
Lock-up ECMV:Short circuit
Lock-up ECMV:Short circuit
1st clutch ECMV:Disconnection
1st clutch ECMV:Short circuit
1st clutch ECMV:Short circuit
2nd clutch ECMV:Disconnection
2nd clutch ECMV:Short circuit
2nd clutch ECMV:Short circuit
3rd clutch ECMV:Disconnection
3rd clutch ECMV:Short circuit
3rd clutch ECMV:Short circuit
R clutch ECMV:Disconnection
R clutch ECMV:Short circuit
R clutch ECMV:Short circuit
F clutch ECMV:Disconnection
F clutch ECMV:Short circuit
F clutch ECMV:Short circuit
Right clutch ECMV:Disconnection
Right clutch ECMV:Short circuit
Right clutch ECMV:Short circuit
Left clutch ECMV:Disconnection
Left clutch ECMV:Short circuit
Left clutch ECMV:Short circuit
Right brake ECMV:Disconnection
Right brake ECMV:Short circuit
Right brake ECMV:Short circuit
Left brake ECMV:Disconnection
Component
Reference
in charge
document page
P/T
P/T
P/T
W/E
W/E
P/T
P/T
W/E
W/E
W/E
W/E
W/E
W/E
W/E
W/E
P/T
P/T
P/T
W/E
W/E
W/E
W/E
W/E
W/E
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
E03
E03
E02
E02
E01
E01
E01
E01
E01
E02
E02
E02
E01
E01
E04
E04
E04
E01
E01
E02
E01
E01
E02
E02
E02
E03
E03
E03
E03
E03
E03
E03
E03
E03
E03
E03
E03
E04
E03
E03
E04
E03
E03
E04
E03
E03
E04
E04
E04
E04
E04
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
40-464
40-466
40-468
40-469
40-470
40-471
40-472
40-473
40-474
40-475
40-476
40-477
40-478
40-479
40-480
40-481
40-482
40-484
40-486
40-487
40-488
40-490
40-491
40-492
40-494
40-495
40-496
40-498
40-499
40-500
40-502
40-503
40-504
40-506
40-507
40-508
40-510
40-511
40-512
40-514
40-515
40-516
40-518
40-519
40-520
40-522
40-523
40-524
40-526
40-527
40-528
40-530
40-43
DRAFT
Failure codes table
Failure
code
DXHCKB
DXHCKY
DXJBKA
DXJBKB
DXJBKY
DY2HKA
F@BBZL
F@BYNR
F@BYNS
F@BZNR
F@BZNS

Left brake ECMV:Short circuit
Left brake ECMV:Short circuit
S/C ECMV:Disconnection
S/C ECMV:Short circuit
S/C ECMV:Short circuit
Pre lub. motor:Disconnection
ENG blow-by pressure high level
F exhaust temp high level (2)
F exhaust temp high level (1)
R exhaust temp high level (2)
R exhaust temp high level (1)
Component
Reference
in charge
document page
P/T
P/T
P/T
P/T
P/T
P/T
VHMS
VHMS
VHMS
VHMS
VHMS
E04
E04
E02
E02
E02
E02
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Electrical system
Mechanical system
Mechanical system
Mechanical system
Mechanical system
Mechanical system
40-531
40-532
40-534
40-535
40-536
40-538
40-540
40-541
40-542
40-543
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
page
Index
Action code and failure code

The action code and failure code are displayed on the machine moni1
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 electri3
cal system abnormality record
Troubleshooting
No.

Index
Reference document
page
Phenomena related to engine

4 Starting performance is poor
5 Engine does not start
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
S-1
E-1, S-2, -17
Engine does not pick up smoothly

S-3
Engine stops during operations
S-4
Engine does not rotate smoothly (such as hunting)
S-5
Engine lack output (or lacks power)
S-6
Exhaust smoke is black (incomplete combustion)
S-7
Oil consumption is excessive (or exhaust smoke is blue)
S-8
Oil contaminates quickly
S-9
Fuel consumption is excessive
S-10
Oil is in coolant (or coolant spurts back or coolant level goes down)
S-11
Oil pressure drops
S-12
Oil level rises (Entry of coolant/fuel)
S-13
Coolant temperature becomes too high (overheating)
S-14
Abnormal noise is heard
S-15
Vibration is excessive
S-16
The preheater does not operate.
E-2
Electric priming pump does not operate or does not stop automatically.
E-28
Phenomena related to power train
Power is low (Insufficient drawbar pull)
H-1
The machine does not travel (at 2nd or 3rd)
H-2
The machine does not start at all gear speeds
H-3
The machine can travel in forward or reverse only
H-4
Large time lag at gear speed shifting or forward-reverse shifting
H-5
Steering does not turn
H-6
Steering turns only in one direction (left or right)
H-7
The machine oversteered
H-8
Brake does not work.
H-9
Torque converter lockup is not turned on
H-10
The torque converter oil temperature is heated abnormally high
H-11
Phenomena related to work equipment
All work equipment operates slowly or lacks power.
H-12
All work equipment does not operate.
H-13
Blade lift is slow to raise, or lifting force is not enough
H-14
Blade tilt is slow to raise, or tilting force is not enough
H-15
Ripper lift is slow to raise, or lifting force is not enough
H-16
Ripper tilt is slow to raise, or tilting force is not enough
H-17
Excessive hydraulic drift of blade lift.
H-18
Excessive hydraulic drift of blade tilt.
H-19
Excessive hydraulic drift of ripper lift.
H-20
The ripper pin puller cylinder does not work.
E-21, H-21
The blade pitch does not work.
H-22
Abnormal noise is heard from around the work equipment pump
H-23
Fan speed is abnormal (such as excessive noise or vibration of fan, or
H-24
overheating)
D375A-6
(01)
40-628
40-547, 40-630,
40-652
40-634
40-636
40-637
40-638
40-640
40-642
40-643
40-644
40-645
40-646
40-648
40-649
40-650
40-651
40-550
40-596
40-604
40-606
40-607
40-608
40-609
40-610
40-611
40-612
40-612
40-613
40-614
40-615
40-616
40-617
40-617
40-618
40-618
40-619
40-619
40-620
40-570, 40-620
40-621
40-621
40-622
40-45
DRAFT
Troubleshooting
No.
Phenomena related to machine monitor

46 When starting switch turned ON, machine monitor displays nothing
When starting switch is turned to ON position (with engine stopped),
47
basic check item (radiator coolant level) lamp lights.
48 Precaution lights up while engine is running
49 Emergency stop item lights up while engine is running
50 Engine coolant temperature gauge does not indicate normally
51 Fuel gauge does not operate normally
Power train oil temperature gauge (multi-gauge) does not indicate nor52
mally
Hydraulic oil temperature gauge (multi-gauge) does not operate nor53
mally
Contents of display by machine monitor are different from applicable
54
machine
55 Machine monitor does not display some items
56 Function switch does not work
57 Operation mode does not change
58 Gear shift mode does not change
59 Customize function does not operate normally
60 Customize memory function does not operate normally
61 Alarm buzzer cannot be stopped
62 When starting switch is turned OFF, service meter is not displayed.
63 Machine monitor cannot be set in service mode
64 Horn does not sound or stop sounding.
65 Backup alarm does not sound or does not stop from sounding
66 Fan does not rotate in reverse.
67 Headlamp, back-up lamp, and/or ripper point lamp does not light
68 Windshield wiper does not operate.
69 Window washer does not operate.
The ORBCOMM terminal does not operate normally (Data are not
70
transmitted).
71 Gear cannot be shifted
40-46
Index
Reference document
page
E-3
40-554
E-4
40-556
E-5
E-6
E-7
E-8
40-558
40-560
40-561
40-562
E-9
40-564
E-10
40-565
E-11
40-566
E-12
E-13
E-14
E-15
E-16
E-17
E-18
E-19
E-20
E-22
E-23
E-24
E-25
E-26
E-27
40-566
40-566
40-567
40-567
40-568
40-568
40-569
40-569
40-569
40-572
40-574
40-576
40-577
40-584
40-590
E-29
40-598
E-30
40-600
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
Display on
machine monitor
Failure description
Action of controller
Indication of
problem on
machine
Related information
Failure code
Display on
machine monitor
Trouble
Description of problem that appears on machine monitor as: abnormality record
Description of the failure detected by the machine monitor or controller

Action taken by machine monitor or controller to protect system or devices when machine monitor or
controller detects failure
Problem that appears on machine as result of action taken by machine monitor or controller (shown
above)
Information related to detected failure or troubleshooting
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 condition 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 harq 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 especially specified.
q When "male" or "female" is not indicated with a connector number, disconnect 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
(01)
40-47
DRAFT
Related circuit diagram
This drawing is a part of the circuit diagram related to troubleshooting.

q Connector No.: Indicates (Model - Number of pins) and
(Color).
q "Connector No. and pin No." from each branching/merging 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 machine.
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 other 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
(01)
40-49
DRAFT
a "Apparent difference" means a difference of 10 or more times.
List of pressure sensor measuring locations and reference values

Sensor
Charge pressure
sensor
Ambient pressure
sensor
R2: Between (1) and (3)

Internal resistance of measured

sensor
(Reference value)
Approx. 2.9k
Approx. 4.3k
Approx. 3.2k
Sensor pin measuring

location
R1: Between (2) (+) and

(1) (-)
(2) (-)
Approx. 4.6k
Approx. 2.9k
Remarks
Sensor is common to engine models 125, 170 and 12V140
Sensor is common to engine models 95, 125, 170 and 12V140
If polarities are reversed, resistance value changes.
*: When measuring R2', disconnect the following connectors.(See circuit diagram related to each code)
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 sensor (CA222)
Connectors of charge pressure sensor, resistance RES, engine oil pressure sensor, G sensor, EGR lift
sensor and bypass valve lift sensor
q
40-50
D375A-6
(01)
DRAFT
Measurement record (For measuring locations, see circuit diagram related to each code)
Sensor
Charge pressure
sensor
Sensor unit (Measuring

location on sensor pin
side)
Ambient pressure
sensor
D375A-6
(01)

(1) (-)
(2) (-)
Measured value
Sensor + Wiring harness

(Measuring location on
wiring harness side of
engine controller)
(2) (-)
R1': Between (44) and
(47)
R2': Between (37) and
(38) (*)
R1': Between (3) (+)
and (38) (-)
R1': Between (38) (+)
and (3) (-)
Measured value
40-51
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
(01)
40-53
DRAFT
40-54
D375A-6
(01)
DRAFT
D375A-6
(01)
40-55
DRAFT
40-56
D375A-6
(01)
DRAFT
D375A-6
(01)
40-57
DRAFT
40-58
D375A-6
(01)
DRAFT
D375A-6
(01)
40-59
DRAFT
40-60
D375A-6
(01)
DRAFT
D375A-6
(01)
40-61
DRAFT
40-62
D375A-6
(01)
DRAFT
D375A-6
(01)
40-63
DRAFT
40-64
D375A-6
(01)
DRAFT
D375A-6
(01)
40-65
DRAFT
40-66
D375A-6
(01)
DRAFT
D375A-6
(01)
40-67
DRAFT
40-68
D375A-6
(01)
DRAFT
D375A-6
(01)
40-69
DRAFT
40-70
D375A-6
(01)
DRAFT
D375A-6
(01)
40-71
DRAFT
40-72
D375A-6
(01)
DRAFT
D375A-6
(01)
40-73
DRAFT
40-74
D375A-6
(01)
DRAFT
D375A-6
(01)
40-75
DRAFT
40-76
D375A-6
(01)
DRAFT
D375A-6
(01)
40-77
DRAFT
40-78
D375A-6
(01)
DRAFT
D375A-6
(01)
40-79
DRAFT
40-80
D375A-6
(01)
DRAFT
D375A-6
(01)
40-81
DRAFT
40-82
D375A-6
(01)
DRAFT
D375A-6
(01)
40-83
DRAFT
40-84
D375A-6
(01)
DRAFT
D375A-6
(01)
40-85
DRAFT
40-86
D375A-6
(01)
DRAFT
D375A-6
(01)
40-87
DRAFT
Connectors table and arrangement drawing

Connec- Connector Number
tor No.
type
of pins
19
DT
20
DTHD
21
DTHD
241
DT
241
DT
250
Terminal
255
Terminal
256
Terminal
260
Terminal
270
Terminal
280
Terminal
453
DT
Location
Intermediate
connector
Intermediate
connector
Intermediate
connector
Intermediate
connector
Intermediate
connector
Starting switch
B terminal
Starting switch
R1 terminal
Starting switch
R2 terminal
Starting switch
BR
Starting switch
ACC terminal
Starting
switchC terminal
Power train oil
temperature
sensor
Standby electric power supply
Standby electric power supply
Address
F-1
ADH2
Relay
ADHA
DT
AF1
DT
N-2
AL/B
Terminal
N-1
AL/R
Terminal
N-1
ASUS
DT
N-1
AT11
N-2
B105L
Terminal
N-2
B105S
Terminal
B30L
Terminal
B30S
Terminal
U-8
B7L
Terminal
X-9
B7S
Terminal
BH1L
Terminal
BH2S
Terminal
BKA
Relay
BKAL
DT
BLD
DT
BLU
DT
BP
DT
Bypass valve
AF-2
BRB
Terminal
Battery relay 1
J-2
BRB
Terminal
Battery relay 2
L-3
BRC
Terminal
Battery relay 1
K-3
X-8
X-8
B-7
AB-3
810
Plug
12S1
YAZAKI
12 V socket 1
U-5
12S2
YAZAKI
12 V socket 2
U-5
12VS
DT
AC1
MIC
17
16
AC3
AMP
12
ACS
DT
ACT
Relay
ADH
40-88
SWP
Additional
power supply
1 relay
Additional
power supply
2 relay
Intermediate
connector
Air cleaner
clogging
switch
Alternator B
terminal
Alternator R
terminal
Air suspension
seat (optional)
AMP
Address
Relay
Plug
AC2
Location
ADH1
800
Intermediate
connector
Air conditioner unit
Air conditioner control
panel
Air conditioner control
panel
Diode
(surge-killer)
ACC cutout
relay
Additional
heater switch
(optional)

tor No.
type
of pins
X-9
N-4
N-5
N-5
AH-1
V-6
W-7
W-7
U-4
C-1
AG-1
AG-1
U-6
GPS antenna
Circuit breaker
(105A)
Circuit breaker
(105A)
Circuit breaker
(30A)
Circuit breaker
(30A)
Circuit breaker
(30A)
Circuit breaker
(30A)
Circuit breaker
(105A)
Circuit breaker
(105A)
Backup alarm
relay
L-5
L-4
K-5
K-4
K-5
J-4
K-5
K-4
U-7
Backup alarm
J-8
Blade lift lower

oil pressure
switch
Blade lift raise
oil pressure
switch
P-9
P-9
O-6
D375A-6
(01)
DRAFT

tor No.
type
of pins
Location
Address

tor No.
type
of pins
Location
12 V power
supply
12 V power
supply
Right wiper
switch
Rear wiper
switch
Rear lamp
switch
(optional)
Right door
wiper motor
Left door wiper
motor
Washer system harness
Address
BRC
Terminal
Battery relay 2
L-3
CN-12V
BRE
Terminal
Battery relay 1
J-1
CN-12V
S
BRE
Terminal
Battery relay 2
L-1
CN-13
BRK
DT
Q-1
CN-14
CN-15
BSW
DT
CN-17
W-6
CN-18
L-4
CN-19
W-5
CN2
DT
W-5
CN-2
K-4
CN-20
W-5
CN-21
CN-22
CN-23
CN-25
CN-26
CN3
DT
CN-3
CN-34
CN4
DT
Injector #4
CN-4
Rear window
wiper motor
C-9
CN5
DT
Injector #5
AI-5
CN-5
Rear speaker
(left)
C-8
CN6
DT
Injector #6
AI-5
CN-6
Rear speaker
(left)
C-8
Brake potentiometer
Intermediate
connector
(one-way type
model)
(optional)
Circuit breaker
(20A)
Circuit breaker
(105A)
Circuit breaker
(20A)
Circuit breaker
(20A)
Circuit breaker
(30A)
Circuit breaker
(20A)
Circuit breaker
(40A)
(optional)
Circuit breaker
(20A)
Circuit breaker
(20A)
Circuit breaker
(30A)
Circuit breaker
(105A)
Machine monitor
Machine monitor
Machine monitor
Machine monitor
Machine monitor
CB1
CB105
CB2
CB3
CB30
CB4
CB40
CB5
CB6
CB7
CBH1
CM01
070
18
CM02
070
12
CM03
070
18
CM04
070
12
CM05
MITSUMI
CN1
DT
Injector #1
B-9
G-9
CN-1
Additional light
(optional)
CN-10
Radio
CN-11
CN-12
D375A-6
(01)
Left wiper
switch
Front wiper
switch
W-5
W-5
J-4
K-5
N-6
N-5
AF-4
A-9
Injector #2
Rear speaker
(right)
ACC power
supply
Battery power
supply
Cigarette
lighter power
port
Front lamp
switch
(optional)
Rotary lamp (If
equipped)
Revolving
warning lamp
switch
(optional)
Injector #3
Rear speaker
(right)
Heated wire
glass relay
X-9
A-9
A-9
B-9
E-9
F-9
F-1
AF-4
C-9
X-8
X-8
I-9
B-9
B-9
B-9
AG-5
C-9
AH-5
A-9
40-89
DRAFT

of pins
type
tor No.
CN-6_1
CN-6_2
CN-81
CN-9
CN-AL1
CN-AL2
CN-AL3
CN-AL4
CN-AL5
CN-AL6
CN-SM1
CONV
DT
CT2
DT
CTV
DT
DEC
DT
DIAL
DL1
BENDIX
DLSW
Terminal
DLT
DT
DPNL
DS1
DT-B
12
DS2
DT-C
12
DS3
DT-A
12
DS4
DT-D
12
DS5
DT-B
12
40-90
Terminal
Location
Heated wire
glass relay
(EU model)
Heated wire
glass relay
(EU model)
Room lamp
Front wiper
motor
Headlamp
(left)
Headlamp
(right)
Headlamp (left
rear)
Headlamp
(right rear)
Back-up lamp
(left)
Back-up lamp
(right)
Address
-
CAN terminating resistor

CAN terminating resistor
Deceleration
potentiometer
Fuel control
dial
VHMS download connector
Download
switch
VHMS download light
Emergency
evacuation
system circuit
(C/B model)
Intermediate
connector
Intermediate
connector
Intermediate
connector
Intermediate
connector
Intermediate
connector
Alternator E
terminal
E22
DT-A
12
EFP
DT
EG1
DTP04-2P
EG2
DT-B
12
EG3
DT
EG4
DT-A
12
EG5
DT
EG6
DT
EGC2
DRC26-50S
04
50
EGC3
DTP06-4S
EGR
DT
EHL
Relay
ENBP
DT
ENG
DRC-60
60
EPP
DT
ES2
DT
ESD
DT
EXAF
DT
EXAR
DT
EXHF
DT
EXHR
DT
EXTF
DT
EXTR
DT
E-9
D-8
-
Converter

of pins
tor No.
type
S-1
AJ-2
W-2
Q-1
S-8
K-9
K-8
K-9
AC-1
N-4
N-3
N-4
N-3
N-3
AG-1
Location
Intermediate
connector
Electric priming pump
Intermediate
connector
Intermediate
connector
Intermediate
connector
Intermediate
connector
Intermediate
connector
Intermediate
connector
Engine controller
Engine controller
EGR valve
Engine holding relay
Blow-by pressure sensor
Engine controller
(Spare)
Intermediate
connector
(male)
Service connector
Exhaust gas
temperature
sensor, front
amp
Exhaust gas
temperature
sensor, rear
amp
Exhaust gas
temperature
sensor (front)
Exhaust gas
temperature
sensor (rear)
Exhaust gas
temperature
sensor, front
amp
Exhaust gas
temperature
sensor, rear
amp
Address
AJ-2
AI-1
AJ-3
AJ-3
AJ-3
C-7
C-8
C-7
AJ-3
AJ-2
AF-3
W-7
AI-1
AJ-2
C-1
E-9
T-2
X-3
V-3
AF-9
AE-8
X-3
V-2
D375A-6
(01)
DRAFT

of pins
tor No.
type
F1T
DT
F2T
DT
F3T
DT
F40
DTHD
FA1
DT
FA2
DT
FAR2
DT
FD1
24-31
31
FD1
24-31
31
FD2
DT-A
12
FD5
DT-B
12
FEN
DT
FFT
DT
FGS
DT
FLB
DT
FLC
DT
FLSW
SWP
FLUC
DT
FRB
DT
FRC
DT
FRT
FRTS
D375A-6
(01)
DT
Terminal
2
6
Location
1st clutch
ECMV (fill
switch)
2nd clutch
ECMV (fill
switch)
3rd clutch
ECMV (fill
switch)
Intermediate
connector
(optional)
Fan pump
(LPV90) solenoid valve
Fan pump
(LPV30) solenoid valve
Fan reverse
solenoid valve
Intermediate
connector
Intermediate
connector
Intermediate
connector
Intermediate
connector
Air conditioner compressor
Forward clutch
ECMV (fill
switch)
Fuel level
gauge
Left steering
brake ECMV
(fill switch)
Left steering
clutch ECMV
(fill switch)
Front lamp
switch
Torque converter lockup
clutch right
ECMV (fill
switch)
Right steering
brake ECMV
(fill switch)
Right steering
clutch ECMV
(fill switch)
Reverse
clutch ECMV
(fill switch)
FR lever
(optional)
Address

tor No.
type
of pins
Location
Fan reverse
sensor
Fuse box
(inlet)
Fuse box (outlet)
Fuse box
(inlet)
Fuse box (outlet)
Fuse box
(inlet)
Fuse box (outlet)
Intermediate
connector
clutch left
ECMV (fill
switch)
Intermediate
connector
(optional)
Engine Bkup
speed (G)
sensor
Address
FRV
DT
FS11
FS12
FS21
FS22
FS31
FS32
FSB
24-31
31
FSTC
DT
FTS
DT
GND
Ground
E-1
GND01
Ground
N-7
GND02
Ground
N-7
K-6
GND03
Ground
N-7
AD-5
GND05
Terminal
Ground
(fender)
H-2
GND06
Terminal
Ground (floor)
S-1
GND07
Terminal
Ground
A-5
GND0A
Terminal
Ground (lamp)
A-6
GND0B
Terminal
Ground
(fender)
H-2
GND1
Terminal
Ground (cab)
B-8
GND11
Terminal
Ground
(engine)
AJ-2
GND2
Terminal
Ground (cab)
B-8
H01
H02
Z-9
Y-8
Y-8
Y-5
AA-7
A-3
J-5
K-7
T-2
AH-1
A-3
V-9
V-9
V-9
V-9
W-9
W-9
M-8
Y-5
R-1
AJ-4
AA-9
AB-8
O-7
Y-4
AD-6
AB-7
Z-9
Additional
heater PW1
Additional
heater PW2
R-8
R-8
40-91
DRAFT

tor No.
type
of pins
HDT
DT
HHP
DT
HLS
DT
HLS
DT
HNSW
DT
HRN
HT
Terminal
HT/A
Terminal
HT/B
Terminal
HTD
DT
INJ
DT
12
INT
DT
J1939
DT
Location
Hydraulic oil
temperature
sensor
Hydraulic oil
pump pressure sensor
Intermediate
connector
(female)
Hydraulic oil
level sensor
(optional)
Address
AA-7
LHDR1
DT
LMD1
DT
LMD2
DT
LMFL
Relay
LMFR
Relay
LMRE
Relay
LMW
Relay
LREL
DT
LRER
DT
LRP
DT
LRR
DT
LWKL
DT
LWKR
DT
M26
DT
MMS
DT-C
12
D-8
E-9
C-2
Horn switch
Q-8
Horn
A-3
Preheater
relay
Preheater
relay
Preheater
relay
Diode
(surge-killer)
Intermediate
connector
Intake temperature sensor
Service connector
(engine)
Junction connector
Junction connector

tor No.
type
of pins
C-8
E-1
E-1
I-3
AJ-5
B-2
AG-5
JB1
JB2
11
JM01
KEY
DT
Starting switch
N-6
KOM1
DRC-40A
40
Communication terminal
P-7
NE
FRAMATONE
KOM2
GPS antenna
Q-8
NSF
Relay
KOM3
NSW
DT
OBC
DT-A
12
LHD
DT
LHDL
DT
OLV
DT
OPSW
SWP
OPT
Relay
P03
DT
LHDL1
LHDR
40-92
DT
DT
Junction box
Communication terminal
antenna
Intermediate
connector
Left headlamp
Left headlamp
(additional
headlamp
model)
(optional)
Right headlamp
AF-4
AG-5
-
Q-8
A-3
A-2
A-5
Location
Right headlamp (additional
headlamp
model)
(optional)
Diode
(surge-killer)
Diode
(surge-killer)
Left headlamp
relay
Right headlamp relay
Back-up lamp
relay
Working lamp
relay
Left back-up
lamp (70W)
Right back-up
lamp (70W)
Ripper point
lamp (70W)
(optional)
Intermediate
connector
Left working
lamp (70W)
Right working
lamp (70W)
Air conditioner controller (cab
model)
Intermediate
connector
(MMS device
(optional))
Engine Ne
speed sensor
Neutral safety
relay
Parking brake
lever switch
Intermediate
connector
Engine oil
level switch
(optional)
Option switch
(optional)
Engine compartment lamp
relay
(optional)
Intermediate
connector
Address
O-1
O-1
U-8
V-6
W-6
X-8
K-6
F-9
H-9
F-1
A-6
P-1
W-4
AJ-3
X-8
T-2
R-8
AI-1
O-6
W-7
P-7
D375A-6
(01)
DRAFT

tor No.
type
of pins
PAMB
AMP
PCV1
SUMITOMO
PCV2
SUMITOMO
PFUEL
AMP
PHR
Relay
PIM
SUMITOMO
PL1
24-23
23
PL1F
24-23
23
PL1M
24-23
23
PL2
24-31
31
PL2
24-31
31
PL3
24-31
31
PLB
DT
PLS
DT
PLSW
DT
PLUB
Relay
PM1
Terminal
PNL
24-31
31
POIL
FRAMATONE
POP
Terminal
PPL
DT
D375A-6
(01)
Location
Supply pump
#1
Supply pump
#2
Common rail
pressure sensor
Preheater
relay
Intermediate
connector
Emergency
evacuation
system circuit
(C/B model)
Emergency
evacuation
system circuit
(C/B model)
Intermediate
connector
Emergency
evacuation
system circuit
(C/B model)
Intermediate
connector
Intermediate
connector
(pre-lubrication system)
Diode
(surge-killer)
Pin puller
switch
Pre-lubrication relay
Pre-lubrication motor
(optional)
Emergency
evacuation
system circuit
(C/B model)
Engine oil
pressure sensor
Pre-lubrication oil pressure switch
(optional)
Pin puller
solenoid valve
Address
AJ-3

of pins
type
tor No.
PR1
Terminal
PR2
Terminal
PR3
Terminal
X-7
PR4
Terminal
AJ-4
PRE
DT
AD-6
PRT1
DT-A
12
PRT2
DT
PRT3
DT
PT1
DT
AJ-4
AJ-4
AH-5
AD-1
AD-1
PTCN1 DRC26-24A
24
PTCN2 DRC26-40A
40
PTCN3 DRC26-40B
40
AD-7
AD-1
PWR
DTHD
RB1
DT
RDG
DT-B
12
I-3
RES
DT
Q-8
RLSW
SWP
U-7
RPD
DT
RPNL
RPU
DT
RSD
DT
RTB
DT
RTI
DT
RTS
A-6
C-1
AB-3
AI-1
I-9
Location
(optional)
(optional)
(optional)
(optional)
Pre-lubrication connector
Intermediate
connector
Intermediate
connector
Intermediate
connector
Pitch angle
sensor
Power train
controller
Power train
controller
Power train
controller
Intermediate
connector
Intermediate
connector
Intermediate
connector
Resistor
Rear lamp
switch
Ripper lower
oil pressure
switch
Emergency
evacuation
system circuit
(C/B model)
Ripper raise
oil pressure
switch
Diode (BR
hold (backup))
Ripper tilt back
oil pressure
switch
Ripper tilt in oil
pressure
switch
Intermediate
connector
(optional)
Address
-
D-8
M-2
D-1
M-2
D-1
U-6
U-6
T-7
U-3
D-8
A-5
AI-1
O-7
O-8
AD-3
P-8
J-4
P-8
P-8
R-1
40-93
DRAFT

tor No.
type
of pins
S1T
DT
S2T
DT
S3T
DT
SBP
DT
SEGR
DT
SFT
DT
SFTD
SFTU
SLB
DT
SLC
DT
SLUC
DT
SNC
DT
SOL1
DT
SOL2
DT
SRB
SRC
DT
DT
SRT
DT
SRV
DT-A
12
40-94
Location
1st clutch
ECMV (solenoid valve)
2nd clutch
3rd clutch
Bypass valve
position sensor
EGR valve
position sensor
Forward clutch
Shift down
switch
Shift down
switch
Left steering
brake ECMV
(solenoid
valve)
Left steering
clutch ECMV
(solenoid
valve)
Torque converter lockup
clutch right
BG shift switch
(one-way type
model)
(optional)
Pitching solenoid valve
Dual-tilt system solenoid
valve
Right steering
brake ECMV
(solenoid
valve)
Right steering
clutch ECMV
(solenoid
valve)
Reverse
clutch ECMV
(solenoid
valve)
KOMNET service connector
Address
Y-9

tor No.
type
of pins
Location
Address
Acceleration
sensor (dedicate SSC
model option)
clutch left
Starting motor
A
Starting motor
B
Starting motor
A (top)
Starting motor
B (bottom)
Sudden stop
prevention
solenoid valve
Data writing
connector (S/T
controller)
SSA
DT
SSTC
DT
ST/B1
Terminal
ST/B2
Terminal
ST1
DT
Z-7
ST2
DT
R-1
STB
DT
STF
SW
Terminal
Battery relay 1
K-1
SW
Terminal
Battery relay 2
L-1
SX-8
Terminal
TC1
DT
TFUEL
PACKARD
TIM
PACKARD
TIP
DT
TL1
24-31
31
TL2
DT-B
TL3
DT
TL3
DT
TLS
DT
TM1
DT
Y-7
Y-8
AF-2
AF-3
R-1
AD-5
AB-8
Y-4
S-7
D-8
D-8
AD-5
AB-8
Y-8
P-1
E-1
Y-5
AE-6
AE-5
AG-5
AG-5
AC-8
T-7
Ground
F-1
(fender)
Torque converter output
AC-7
speed sensor
Fuel temperaAG-1
ture sensor
Boost temperAI-5
ature sensor
Y-6
pressure sensor
Intermediate
M-9,U-5
connector
Intermediate
T-7
connector
Intermediate
T-7
connector
(one-way type
model)
T-7
(optional)
Blade tilt left
oil pressure
P-9
switch
Transmission
outlet shaft
speed sensor
AD-7
(VHMS installation model
only)
D375A-6
(01)
DRAFT

of pins
type
tor No.
TMF
TMMD
DT
TMV
24-23
23
TOIL
PACKARD
TOP
DT
TR1L
TR1S
TR2L
TR2L
TR2S
TRS
DT
TWTR
PACKARD
USB
DTHD
V1
070
20
V2A
070
18
V2B
070
12
V3A
070
18
V3B
070
12
V4A
070
14
V4B
070
10
VDA
DT-D
12
VDB
DT-B
12
VDC
DT-D
12
D375A-6
(01)
Location
Data writing
connector
(work equipment controller)
Transmission
main oil pressure sensor
(VHMS installation model
only)
Intermediate
connector
Engine oil
temperature
sensor
pressure sensor
Main power
terminal
Main power
terminal
Main power
terminal 2
Main power
terminal
Main power
terminal 2
Blade tilt right
oil pressure
switch
Intermediate
connector
VHMS controller
VHMS controller
VHMS controller
VHMS controller
VHMS controller
VHMS controller
VHMS controller
Intermediate
connector
Intermediate
connector
Intermediate
connector
Address

tor No.
type
of pins
VDW
BENDIX
VED
DT-C
12
VEG
DT-C
12
VF1
DT-B
12
VF2
24-31
31
T-7
Z-7
AA-7
WECN1 DRC26-24A
24
WECN2 DRC26-40A
40
WECN3 DRC26-40B
40
AJ-2
AB-3
K-3
WELK
DT
K-3
WLD
DT
WSFR
YAZAKI
K-3
WSLH
YAZAKI
WSRH
YAZAKI
WSRR
YAZAKI
P-9
TAJIMI
AH-5
Location
Address
VHMS downS-2
load connector
Intermediate
K-6
connector
Intermediate
AJ-3
connector
Intermediate
V-3
connector
Intermediate
U-4,V-2
connector
Work equipment controlT-7
ler
Work equipment controlS-8
ler
Work equipment controlS-8
ler
WE lock
P-7
switch
Coolant level
A-3
sensor
Washer tank
J-5
(front)
Washer tank
J-5
(left)
Washer tank
J-4
(right)
Washer tank
J-5
(rear)
Rear view
camera
(optional)
U-3
V-2
W-2
X-2
W-2
W-2
X-2
W-2
L-9
K-7
I-3
40-95
DRAFT
40-96
D375A-6
(01)
DRAFT
D375A-6
(01)
40-97
DRAFT
40-98
D375A-6
(01)
DRAFT
D375A-6
(01)
40-99
DRAFT
40-100
D375A-6
(01)
DRAFT
D375A-6
(01)
40-101
DRAFT
T-branch box and T-branch adapter table
799-601-2600
799-601-3100
799-601-3200
799-601-3380
799-601-3410
799-601-3420
799-601-3430
799-601-3440
799-601-3450
799-601-3460
799-601-3510
799-601-3520
799-601-3530
799-601-2910
799-601-3470
799-601-2710
799-601-2720
799-601-2730
799-601-2740
799-601-2950
799-601-2750
799-601-2760
799-601-2770
799-601-2780
799-601-2790
799-601-2810
799-601-2820
799-601-2830
799-601-2840
799-601-2850
799-601-4350
799-601-4360
799-601-7010
799-601-7020
799-601-7030
799-601-7040
799-601-7050
799-601-7060
799-601-7310
799-601-7070
799-601-7320
799-601-7080
799-601-7090
799-601-7110
799-601-7120
799-601-7130
799-601-7340
799-601-7140
799-601-7150
40-102
T-box(for ECONO)
T-box(for MS)
T-box(for MS)
Plate for MS (14-pin)
Adapter for BENDIX (MS)
Case
Adapter for MIC
Adapter for MIC
Adapter for MIC
Adapter for MIC
Adapter for MIC
Adapter for ECONO
Adapter for ECONO
Adapter for ECONO
Adapter for ECONO
Adapter for ECONO
Adapter for DLI
Adapter for DLI
Adapter for DLI
Extension cable (ECONO type)
Case
T-box(for DRC 60, ECONO)
Case
Adapter for X (T-adapter)
Adapter for X
Adapter for X
Adapter for X
Adapter for SWP
Adapter for SWP
Adapter for SWP
Adapter for SWP
Adapter for SWP
Adapter for M (T-adapter)
Adapter for M
Adapter for M
Adapter for M
Adapter for M
Adapter for M
Adapter for M
Adapter for S (White)
24
24
17
17
5
10
5
17
19
14
q
q
q
q
q
q
q q
q q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q q
q q
q q q
Out of kit
q
q
q
60
X2P
X3P
X4P
SW6P
SW8P
SW12P
SW14P
SW16P
M2P
M3P
M4P
M6P
M8P
S8P
S10P
799-601-4201
799-601-9300
799-601-9200
799-601-4101
q
q
q
q
q
q
q
q
q
q
q
q
q
q
MS-24P
MS-24P
MS-17P
MS-17P
MS-5P
MS-10P
MS-5S
MS-17P
MS-19P
MS-14P
5
MIC-5P
13
MIC-13P
17
MIC-17P
21
MIC-21P
9
MIC-9P
2
ECONO2P
3
ECONO3P
4
ECONO4P
8
ECONO8P
12 ECONO12P
8
DLI-8P
12
DLI-12P
16
DLI-16P
12 ECONO12P
1
2
3
4
6
8
12
14
16
1
2
3
4
6
8
8
10
799-601-9100
799-601-9000
799-601-8000
q q
799-601-7500
799-601-7400
799-601-7100
799-601-7000
21
37
37
799-601-2800
Identification
symbol
799-601-2700
Part name
T-adapter kit
799-601-2500
Part number
Number of pins
(Rev. 2009. 03)

a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal column indicates a part number of harness checker assembly.
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q q q
q q q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
D375A-6
(01)
DRAFT
799-601-7160
799-601-7170
799-601-7330
799-601-7350
799-601-7180
799-601-7190
799-601-7210
799-601-7220
799-601-7230
799-601-7240
799-601-7270
799-601-7510
799-601-7520
799-601-7530
799-601-7540
799-601-7550
799-601-7360
799-601-7370
799-601-7380
799-601-9010
799-601-9020
799-601-9030
799-601-9040
799-601-9050
799-601-9060
799-601-9070
799-601-9080
799-601-9090
799-601-9110
799-601-9120
799-601-9130
799-601-9140
799-601-9210
799-601-9220
799-601-9230
799-601-9240
799-601-9250
799-601-9260
799-601-9270
799-601-9280
799-601-9290
799-601-9310
799-601-9320
799-601-9330
799-601-9340
799-601-9350
799-601-9360
799-601-9410*
Adapter for S (Blue)

Adapter for S (Blue)
Adapter for AMP040
Adapter for AMP040
Adapter for AMP040
Adapter for AMP040
Short connector for X
Case
Case
Adapter for 070
Adapter for 070
Adapter for 070
Adapter for 070
Adapter for 070
Adapter for relay
Adapter for relay
Adapter for JFC
Adapter for DTM
Adapter for DT
Adapter for DT
Adapter for DT
Adapter for DT
Adapter for DT (Gray)
Adapter for DT (Black)
Adapter for DT (Green)
Adapter for DT (Brown)
Adapter for DT (Gray)
Adapter for DT (Black)
Adapter for DT (Green)
Adapter for DT (Brown)
Adapter for HD30-18
Adapter for HD30-18
Adapter for HD30-18
Adapter for HD30-18
Adapter for HD30-24
Adapter for HD30-24
Adapter for HD30-24
Adapter for HD30-24
Adapter for HD30-24
Plate for HD30 (24-pin)
T-box(for ECONO)
Case
Case
Adapter for DRC
Adapter for DRC
Socket for engine (CRI-T2)
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL
Oil pressure sensor
799-601-9430*
Socket for engine(CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2)
795-799-5520* Socket for engine (HPI-T2)
D375A-6
(01)
24
q
q
q q q
q q q
q q q
q q
q
q
q
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
q q q
q q q
799-601-7500
799-601-7400
07-10
07-12
07-14
07-18
07-20
REL-5P
REL-6P
DTM2
DT2
DT3
DT4
DT6
DT8GR
DT8B
DT8G
DT8BR
DT12GR
DT12B
DT12G
DT12BR
D18-8
D18-14
D18-20
D18-21
D24-9
D24-16
D24-21
D24-23
D24-31
799-601-7100
10
12
14
18
20
5
6
2
2
2
3
4
6
8
8
8
8
12
12
12
12
8
14
20
21
9
16
21
23
31
799-601-7000
S12P
S16P
S16PW
S12PW
A8P
A12P
A16P
A20P
-
799-601-2800
12
16
16
12
8
12
16
20
2
799-601-2700
Identification
symbol
799-601-2500
Part name
Number of pins
Part number
T-adapter kit
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q q
q q
q
q
q
q
40
24
2
DRC-40
DRC-24
G
A3
q q
q q
3
2
1,2,3
S
q
q
40-103
DRAFT
Socket for engine (HPI-T2)

795-799-5530* Socket for engine (CRI-T3)
2
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540*
2
Socket for engine(CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2)
3
3
3
799-601-4110 Adapter for engine (140-T3) PIM
4
799-601-4130 Adapter for engine (CRI-T3) NE,CAM 3
799-601-4140
3
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL
3
799-601-4160
2
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA
3
799-601-4190*
3
Common rail pressure
799-601-4230*
4
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB
3
799-601-4250* Socket for engine (CRI-T3) PIM
3
799-601-4330* Socket for engine (CRI-T3) G
3
799-601-4340*
2
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380*
4
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG)
4
50
60
799-601-4390* Socket for controller (95 ENG)
60
799-601-4280* Box for controller (PUMP)
121
799-601-9720 Adapter for controller (HST)
16
16
26
2,
799-601-9890 Multi-adapter for DT2 4 andDTM2
3,
4
q q
q q
ITT3N
FCIN
q q
q q
FCIG
q q
FCIB
q q
4160
q q
4180
q q
1,2,3L
q q
1,2,3,4C
q q
1,2,3A
1,2,3B
1,2,3,G
q q
q q
q q
2,PA
q q
q
q
q
1,2,3,4T
DTP4
DRC50
DRC60
HST16A
HST16B
HST26A
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
Identification
symbol
799-601-2700
Part name
T-adapter kit
799-601-2500
Part number
Number of pins

q q
q
q
q
q
q
q
q
q
"*" 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
(01)
40-105
DRAFT
Circuit breakers CB1CB7, CB30, CB105 and CBH1
1
2
3
Power breaker
(Power supply type)
(Main power supply)
(Constant power supply)
(Main power supply)
5
6
CB105
(Main power supply)
Starting switch
(ACC)
Capacity (A)
105
30
105
30
Circuit
Destination of power
breaker No.
CB105
Main power supply
CB30
Constant power supply
CBH1
Preheater relay
Engine controller constant power source
CB7
Power supply of electric priming pump timer
20
CB1
Power train controller
20
CB2
Machine monitor (ACC)
7
8
9
CB105
(Main power supply)
20
20
20
CB3
CB4
CB5
Work equipment controller

Air conditioner
Headlamp
10
CB30
20
CB6
Constant power supply of starting switch
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
(01)
40-107
DRAFT
Fuse box FS11
1
2
3
4
5
Power breaker
Fuse capacity
(Power supply type)
(A)
CB105 (Main power supply)
20
VHMS controller power supply
Constant power supply of VHMS, power train, and work equip20
CB30 (Constant power supment controllers
ply)
20
Constant power supply of cab
10
12V converter constant power supply
20
12V converter power supply
Fuse box FS21

Power breaker
(Power supply type)
1
2
3
4
5
Fuse capacity
(A)
5
20
20
20
20
Backup alarm
Pin puller, preheater, air suspension seats
Additional heater
Working lamp
Rear lamp
Fuse box FS31
1
2
3
4
5
Power breaker
(Power supply type)
Starting switch (ACC)
Fuse capacity (A)

5
5
20
20
Starting switch (ACC)
20
ACC for engine controller
Horn
Spare power supply (1)
Spare power supply (2)
Spare ACC signal
Fuse box (Cab top end)

Power breaker
(Power supply type)
1
2
3
4
5
6
7
8
9
10
40-108
Fuse capacity (A)

10
10
15
10
15
20
20
20
CB30 (Constant power sup10
ply)
Radio, cigarette lighter, room lamp
Rear wiper
Rear wiper
Front wiper
Left wiper
Additional back-up lamp
Additional headlamp, revolving warning lamp
Glass with heating wire
Spare
Radio memory
D375A-6
(01)
Troubleshooting by failurecode
Failure code [1380MW] Lock up clutch: Slip
40-109
Failure code [1380MW] Lock up clutch: Slip
40-109
Action code
Failure code
Failure
1380MW
Detail of failure
Problem on
machine
When torque converter is locked up, sensed engine speed does not match with sensed torque converter output speed.
None in particular.
None in particular.
Engine speed and torque converter speed can be checked with monitoring function.
(Code 01002: Engine speed)
(Code 31200: Transmission input speed (Torque converter output speed))
Method of reproducing failure code: Start engine, turn lockup clutch ON and drive machine.
Related information
q
Cause
Lockup clutch slip(When
system is normal)
Defective engine speed sen2
sor system
Defective torque converter
3
speed sensor
Defective power train con4
troller
1
D375A-6
(06)
Lockup clutch slip

(Power train controller system)
Procedure, measuring location, criteria and remarks

Check for cause of lockup clutch slip and damage of machine.
If failure code[CA689] or [CA778] is displayed, carry out troubleshooting for it.
If failure code [DLF1KA] is displayed, carry out troubleshooting for it.
Since failure is in it, troubleshooting cannot be carried out.
40-109
DRAFT
Troubleshooting by failure code
Failure code [1500L0] Transmission clutch: Abnormal
Failure code [1500L0] Transmission clutch: Abnormal

Action code
E03
Failure code
Transmission clutch: Abnormal
Failure
1500L0
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].
(3) Either of [DXH6KA] and [DXH6KB] and either of [DXH5KA] and [DXH5KB] and either of [DXH4KA]
Detail of failand [DXH4KB]
ure
(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 conq 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 inforq Method of reproducing failure code: Engine start + Run
mation
Cause
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
Detail of failure
Problem on
machine
q
q
None in particular.
None in particular.
Torque converter speed and transmission speed can be checked with monitoring function.
(Code 31200: Transmission input speed (Torque converter output speed))
(Code 31400: Transmission output speed)
Method of reproducing failure code: Start engine and drive machine.
Related information
q
1
2
3
4
Failure code
Transmission clutch slip
Failure
15E0MW
Sensed torque converter output speed does not match with sensed transmission output speed.
Cause
Transmission clutch slip
(When system is normal)
speed sensor
Defective transmission speed
sensor
Defective power train controller
D375A-6
(01)

Check for cause of transmission clutch slip and damage of machine.
Check if failure code [DLF1KA] is displayed
Carry out troubleshooting for it.
Check if failure code [DLT3KA], [DLT3KB] is displayed
Carry out troubleshooting for it.
Since failure is in it, troubleshooting cannot be carried out.
40-111
DRAFT
Failure code [15SAL1] Forward clutch: Fill high

Action code
E03
Failure code
Forward clutch fill dwitch signal is ON.
Failure
15SAL1
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 engageAction of conment).
troller
q Limits operation of engine and transmission.
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 inforq 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".
Cause

1. Turn starting switch to OFF position.
Defective F clutch ECMV fill
2. Disconnect connector FFT and connect T-adapter to male side.
1 switch (Internal short cirBetween FFT (female) (1) and ground
cuit)
Resistance
Min. 1 M
(Fill switch OFF)
2. Disconnect connector FFT.
Ground fault of wiring har3. Start engine
2 ness or defective power
If failure code [15SAL1] is still displayed, there is ground fault of wiring harness or
train controller
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 cireither of them.
cuit)
Between PTCN2 (female) (5) or FFT (female) (1) and
Resistance
Min. 1 M
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 perform troubleshooting.
F1/F2/F3
Voltage
Max.1 V
40-112
D375A-6
(01)
DRAFT
Circuit diagram related to forward clutch ECMV
D375A-6
(01)
40-113
DRAFT
Failure code [15SALH] Forward clutch: Fill Low

Action code
E03
Detail of failure
Problem on
machine
Related information
q
q
q
q
q
q
q
q
q
q
q
Failure code
Forward clutch fill switch signal is OFF.
Failure
15SALH
Nevertheless controller outputs command current to transmission F clutch ECMV solenoid circuit, fill
switch signal is turned OFF.
Sets transmission to neutral when operator sets it to forward position (Prevention of defective engagement).
Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, travel is limited to R1.
The automatic gearshift system does not operate.
State (ON/OFF) of F clutch ECMV fill switch signal can be checked with monitoring function.
Method of reproducing failure code: Start engine and set PCCS lever in forward position.
Remove seat (approx. 50 kg) and cover under seat.
First, check the power train oil filter for clogging etc.
Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train
oil pressure".
Cause
Defective F clutch ECMV fill

switch (It does not turn ON)
Disconnection in wiring harness

contact)
40-114

2. Disconnect connector FFT and connect T-adapter to male side.
3. Start engine
Between FFT (male) (1) and ground
Resistance
Min. 1 M
Between FFT (male) (1) and ground
F1/F2/F3
Resistance
Max. 1
2. Disconnect connectors PTCN2 and FFT, and connect T-adapters to female side of
them.
Between PTCN2 (female) (5) and FFT (female) (1)
Resistance
Max. 1
3. Start engine
Voltage
711 V
F1/F2/F3
Voltage
Max. 1 V
D375A-6
(01)
DRAFT
D375A-6
(01)
40-115
DRAFT
Failure code [15SBL1] Reverse clutch: Fill high

Action code
E03
Failure code
Reverse clutch fill switch signal is ON.
Failure
15SBL1
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 engageAction of conment).
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.
mation
oil pressure".
Cause

Defective R clutch ECMV fill
2. Disconnect connector FRT and connect T-adapter to male side.
1 switch (Internal short cirBetween FRT(female) (1) and ground
cuit)
Resistance
Min. 1 M
(Fill switch OFF)
2. Disconnect connector FRT.
If failure code [15SBL1] is still displayed, there is ground fault of wiring harness or
train controller
(If failure code [15SBL1] is not displayed, R clutch fill switch is defective)
Ground fault of wiring har2. Disconnect connectors PTCN2 and FRT and connect T-adapter to female side of
3 ness
either of them.
Between PTCN2 (female) (36) or FRT (female) (1)
Resistance
Min. 1 M
and ground
If check result of cause 2 is abnormal and check result of cause 3 is normal,
4
troller
Voltage
7 11 V
R1/R2/R3
Voltage
Max. 1 V
40-116
D375A-6
(01)
DRAFT
Circuit diagram related to reverse clutch ECMV
D375A-6
(01)
40-117
DRAFT
Failure code [15SBLH] Reverse clutch: Fill Low

Action code
E03
Detail of failure
Problem on
machine
Related information
q
q
q
q
q
q
q
q
q
q
q
Failure code
Reverse clutch fill switch signal is OFF.
Failure
15SBLH
Nevertheless controller outputs command current to transmission R clutch ECMV solenoid circuit,
fill switch signal is turned OFF.
Sets transmission to neutral when operator sets it to reverse position (Prevention of defective engagement).
Once machine is stopped, travel is limited to F1.
State (ON/OFF) of R clutch ECMV fill switch signal can be checked with monitoring function.
Method of reproducing failure code: Start engine and set PCCS lever in reverse position.
oil pressure".
Cause

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
Resistance
Min. 1 M
switch (It does not turn ON) Between FRT (male) (1) and ground
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
Disconnection in wiring har- 1. Turn starting switch to OFF position.
ness
2. Disconnect connectors PTCN2 and FRT, and connect T-adapters to female side
2
of them.
contact)
Between PTCN2 (female) (36) and FRT (female) (1) Resistance
Max. 1
3. Start engine
Voltage
7 11 V
troller
R1/R2/R3
Voltage
Max. 1V
40-118
D375A-6
(01)
DRAFT
D375A-6
(01)
40-119
DRAFT
Failure code [15SEL1] Speed 1st clutch: Fill high

Action code
E03
Failure code
Speed 1st clutch: fill switch signal is ON.
Failure
15SEL1
q Nevertheless controller does not output command current to transmission 1st clutch ECMV solenoid
Detail of failure
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.
mation
oil pressure".
Cause
Defective 1st clutch ECMV
1 fill switch (Internal short
circuit)
Ground fault of wiring har2 ness or defective power

train controller
Ground fault of wiring harness

3
40-120

2. Disconnect connector F1T and connect T-adapter to male side.
Between F1T (female) (1) and ground
Resistance
Min. 1 M
(Fill switch OFF)
2. Disconnect connector F1T.
3. Start engine
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)
2. Disconnect connectors PTCN2 and F1T and connect T-adapter to female side of
either of them.
Between PTCN2 (female) (35) or F1T (female) (1) and
Resistance
Min. 1 M
ground
3. Start engine
Voltage
7 11 V
1. 3. are same as above.
F1/R1
Voltage
Max. 1 V
D375A-6
(01)
DRAFT
Circuit diagram related to 1st clutch ECMV
D375A-6
(01)
40-121
DRAFT
Failure code [15SELH] Speed 1st clutch: Fill Low

Action code
E03
Detail of failure
Problem on
machine

Once machine is stopped, travel is limited to F2 and R2.
State (ON/OFF) of 1st clutch ECMV fill switch signal can be checked with monitoring function.
Method of reproducing failure code: Start engine and set PCCS lever in F1 or R1 position.
oil pressure".
q
q
q
Related information
Failure code
Speed 1st clutch fill switch signal is OFF.
Failure
15SELH
Nevertheless controller outputs command current to transmission 1st clutch ECMV solenoid circuit,
q
q
q
q
Cause

3. Start engine
Defective 1st clutch ECMV fill Between F1T (male) (1) and ground
Resistance
Min. 1 M
1
switch (It does not turn ON) 1 3 are same as above.
Between F1T (male) (1) and
F1/R1
Resistance
Max. 1
ground
ness
2. Disconnect connectors PTCN2 and F1T, and connect T-adapters to female side
2
of them.
contact)
Between PTCN2 (female) (35) and F1T (female) (1) Resistance
Max. 1
3. Start engine
Defective power train control- a Keep PCCS lever in N position.
3
Voltage
7 11 V
ler
F1/R1
Voltage
Max. 1V
40-122
D375A-6
(01)
DRAFT
D375A-6
(01)
40-123
DRAFT
Failure code [15SFL1] Speed 2nd clutch: Fill high

Action code
E03
Failure code
Speed 2nd clutch fill switch is ON.
Failure
15SFL1
q Nevertheless controller does not output command current to transmission 2nd clutch ECMV soleDetail of failure
noid circuit, fill switch signal is turned ON.
troller
Problem on
machine
q State (ON/OFF) of 2nd clutch ECMV fill switch signal can be checked with monitoring function.
mation
oil pressure".
Cause

Defective 2nd clutch ECMV
fill switch (Internal short cir- 2. Disconnect connector F2T and connect T-adapter to male side.
cuit)
Resistance
Min. 1 M
(Fill switch OFF)
ness or defective power
If failure code [15SFL1] is still displayed, there is ground fault of wiring harness or
train controller
(If failure code [15SFL1] is not displayed, 2nd clutch fill switch is defective)
Ground fault of wiring har2. Disconnect connectors PTCN2 and F2T, and connect T-adapter to female side of
ness
either of them.
Between PTCN2 (female) (25) or F2T (female) (1)
Resistance
Min. 1 M
and ground
troller
Voltage
7 11 V
F2/R2
Voltage
Max. 1 V
40-124
D375A-6
(01)
DRAFT
D375A-6
(01)
40-125
Failure code [15SFLH] Speed 2nd clutch: Fill Low

Action code
Failure code
Failure
E03
15SFLH
Detail of failure
Problem on
machine
2nd clutch oil pressure 2

Nevertheless controller outputs command current to transmission 2nd clutch ECMV solenoid circuit, fill switch signal is turned OFF.
Once machine is stopped, engine speed is limited to medium (half) speed.

The condition (ON/OFF) of the 2nd clutch ECMV fill switch signal can be checked with the monitoring function.
Method of reproducing failure code: Start engine and PCCS lever in F2 or R2 position.
First, check power train oil filter for clogging etc.
Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power
q
q
q
Related information
40-126
q
q
q
q
Cause

1.
2.
3.
a
Turn starting switch to OFF position.

Disconnect connector F2Tand connect T-adapter to male side.
Start engine.
Keep PCCS lever in N position.

Between F2T (male) (1) and ground
Resistance
Min. 1 Mz
1 fill switch (It does not turn
Descriptions for 1 to 3 are the same as above.
ON)
F2/R2
Resistance
Max. 1 z
ground
Open circuit in wiring har2. Disconnect connectors PTCN2 and F2T and connect T-adapters to each female
ness
2
side.
(Open circuit in wiring or
defective contact)
Between PTCN2 (female) (25) and F2T (female) (1)

1.
2.
3.
a
Max. 1 z
Voltage
7 11 V

40-126
Resistance

Insert T-adapter into connector PTCN2.
Start engine.
Keep PCCS lever in N position.
F2/R2
Voltage
Max. 1 V
D375A-6
(06)
DRAFT
D375A-6
(01)
40-127
DRAFT
Failure code [15SGL1] Speed 3rd clutch: Fill high

Action code
E03
Failure code
Speed 3rd clutch fill switch signal is ON.
Failure
15SGL1
q Nevertheless controller does not output command current to transmission 3rd clutch ECMV solenoid
Detail of failure
troller
Problem on
machine
q State (ON/OFF) of 3rd clutch ECMV fill switch signal can be checked with monitoring function.
mation
oil pressure".
Cause

Defective 3rd clutch ECMV
fill switch (Internal short cir- 2. Disconnect connector F3T and connect T-adapter to male side.
cuit)
Resistance
Min. 1 M
(Fill switch OFF)
ness or defective power
If failure code[15SGL1] is still displayed, there is ground fault of wiring harness or
train controller
(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
cuit)
Between PTCN2 (female) (15) or F3T (female) (1)
Resistance
Min. 1 M
and ground
troller
Voltage
7 11 V
F3/R3
Voltage
Max. 1 V
40-128
D375A-6
(01)
DRAFT
D375A-6
(01)
40-129
DRAFT
Failure code [15SGLH] Speed 3rd clutch: Fill Low

Action code
E03
Detail of failure
Problem on
machine
Failure code
Speed 3rd clutch fill switch signal is OFF.
Failure
15SGLH
Nevertheless controller outputs command current to transmission 3rd clutch ECMV solenoid circuit,

State (ON/OFF) of 3rd clutch ECMV fill switch signal can be checked with monitoring function.
Method of reproducing failure code: Start engine and PCCS lever in F3 or R3 position.
oil pressure".
q
q
q
Related information
q
q
q
q
Cause

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.
Between F3T (male) (1) and ground
Resistance
Min. 1 M
1 fill switch (It does not turn
1
3
are
same
as
above.
ON)
F3/R3
Resistance
Max. 1
ground
Disconnection in wiring har2. Disconnect connectors PTCN2 and F3T and, connect T-adapters to female side
ness
2
of them.
Between PTCN2 (female) (15) and F3T (female)
contact)
Resistance
Max. 1
(1)
3. Start engine
Defective power train control- a Keep PCCS lever in N position.
3
Voltage
7 11 V
ler
F3/R3
Voltage
Max. 1 V
40-130
D375A-6
(01)
DRAFT
D375A-6
(01)
40-131
Failure code [15SJL1] L/U: Fill high

Action code
Failure code
Failure
E02
15SJL1
Detail of failure
Problem on
machine
Lockup clutch fill switch signal is ON.

Nevertheless controller does not output command current to torque converter lockup clutch ECMV
solenoid circuit, fill switch signal is turned ON.
Prohibits lockup.
Engine may stall during travel.
State of lockup clutch ECMV fill switch signal can be checked with monitoring function.
Method of reproducing failure code: Start engine and set PCCS lever in R (reverse) position (in automatic gearshift mode).
Related information
40-132
q
q
q
Cause

2. Disconnect connector FLUC and connect T-adapter to male side.
Between FLUC (female) (1) and ground
Resistance
Min. 1 Mz
(Fill switch OFF)
2. Disconnect connector FLUC.
Ground fault in wiring har- 3. Start engine.
If failure code [15SJL1] is still displayed, there is ground fault in wiring harness or
train controller
(If failure code [15SJL1] is not displayed, lockup clutch fill switch is defective)
Ground fault in wiring har2. Disconnect connectors PTCN2 and FLUC, and connect T-adapters to either
3 ness
female side.
Between PTCN2 (female) (38) or FLUC (female) (1) and
Resistance
Min. 1 Mz
ground
If "check result of cause 2 is abnormal" and "check result of cause 3 is normal",
q Reference; the followings are standard values in normal condition.
3. Start engine.
Defective power train con- Between PTCN2 (38) and ground
Voltage
7 11 V
4
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 (LU)".
Defective lockup clutch
1 ECMV fill switch (Internal
short circuit)
40-132
R1
Voltage
Max. 1 V
D375A-6
(06)
DRAFT
Circuit diagram related to lockup clutch ECMV
D375A-6
(01)
40-133
Failure code [15SJLH] L/U: Fill low

Action code
Failure code
Failure
E02
Detail of failure
Problem on
machine
15SJLH
Lockup clutch fill switch is OFF.

Nevertheless controller outputs command current to torque converter lockup clutch ECMV solenoid
circuit, fill switch signal is turned OFF.
Prohibits lockup.
It is impossible to lockup.
State of lockup clutch ECMV fill switch signal can be checked with monitoring function.
Method of reproducing failure code: Start engine and set PCCS lever in R (reverse) position (in automatic gearshift mode).
Related information
40-134
q
q
q

1.
2.
3.
4.
5.

Disconnect connector FLUC, and connect T-adapter to male side.
Start engine.
Raise tracks off the ground.
Travel machine in R1 (automatic gearshift mode), and troubleshoot with lockup in
1 ECMV fill switch (It does not
operation.
turn ON)
a See Testing and adjusting, Testing power train oil pressure, 4) Testing torque
converter lockup clutch pressure (LU).
Between FLUC (female) (1) and ground
Resistance
Max. 1 z
(Fill switch ON)
Open circuit in wiring har2. Disconnect connectors PTCN2 and FLUC and connect T-adapters to each female
ness
2
side.
Between PTCN2 (female) (38) and FLUC (female) (1)
Resistance
Max. 1 z
defective contact)
If no abnormality is found by the above checks, power train controller is defective.
Reference; the followings are criteria in normal condition.
3. Start engine.
q
7 11 V

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 (LU)".
40-134
Voltage
R1
Voltage
Max. 1 V
D375A-6
(06)
DRAFT
Circuit diagram related to lockup clutch ECMV
D375A-6
(01)
40-135
DRAFT
Failure code [1800MW] P/T clutch: Slip

Action code
Failure code
Power train clutch slip
Failure
E02
1800MW
Detail of failure q When torque converter is locked up, engine speed does not match sensed transmission output.
Action of conq None in particular.
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.
1
2
3
4
Cause
Power train clutch slip
(When the system is normal)
Defective engine rotation
sensor
Defective transmission
speed sensor
Defective power train
controller
40-136

a Clutch slip was detected; check the cause and machine damage state, then repair the
machine.
Check whether failure codes [CA689] and [CA778] are displayed. If they are displayed,
carry out the troubleshooting.
Check whether failure codes [DLT3KA] or [DLT3KB] is displayed. If it is displayed, carry
out the troubleshooting.
Internally trouble; troubleshooting is impossible.
D375A-6
(01)
DRAFT
D375A-6
(01)
40-137
DRAFT
Failure code [2201L1] Right clutch: Fill high

Action code
E04
Detail of failure
Problem on
machine
Related information
Failure code
Right clutch fill switch signal is ON.
Failure
2201L1
(power train controller system)
Nevertheless controller does not output command current to right steering clutch ECMV solenoid
Limits operation of engine, transmission, and brake.

Once machine is stopped, it becomes impossible to travel.
State (ON/OFF) of right steering clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 31521 Steering Fill Sw Input )
Method of reproducing failure code: Start engine.
oil pressure".
q
q
q
q
q
q
Cause

Defective right steering clutch
ECMV fill switch (Internal short 2. Disconnect connector FRC and connect T-adapter to male side.
Between FRC (female) (1) and ground
circuit)
Resistance
Min. 1 M
(Fill switch OFF)
2. Disconnect connector FRC.
Ground fault of wiring harness 3. Start engine
or defective power train conIf failure code [2201L1] is still displayed, there is ground fault of wiring harness or
troller
(If failure code [2201L1] is not displayed, right steering clutch fill switch is defective)
Ground fault of wiringharness 2. Disconnect connectors PTCN2 and FRC and connect T-adapter to female side
of either of them.
Between PTCN2 (female) (16) or FRC (female) (1)
Min. 1 M
Resistance
and ground
Defective power train controller 3. Start engine
Voltage
7 11 V
4.While depressing brake pedal, operate PCCS lever (to select steering) and perform troubleshooting.
Left Max.
Voltage
Max. 1 V
40-138
D375A-6
(01)
DRAFT
Circuit diagram related to right clutch ECMV
D375A-6
(01)
40-139
DRAFT
Failure code [2201LH] Right clutch: Fill low

Action code
E04
Detail of failure
Indication of
problem on
machine

q
q
Related information
Failure code
Right steering clutch fill switch signal is OFF.
Failure
2201LH
Nevertheless controller outputs command current to right steering clutch ECMV solenoid circuit, fill
q
q
q
q
State (ON/OFF) of right steering clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 31521 Steering Fill Sw Input)
Method of reproducing failure code: Start engine and release parking brake lever and operate PCCS
lever (right steering).
oil pressure".
Cause

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.
Resistance
Min. 1 M
ECMV fill switch (It does not Between FRC (male) (1) and ground
1
3
are
same
as
above.
turn ON)
4.While depressing brake pedal, operate PCCS lever (to select gear speed) and
Between FRC (male) (1) and
Left Max.
Resistance
Max. 1
ground
Disconnection in wiring har2. Disconnect connectors PTCN2 and FRC, and connect T-adapters to female
ness
side of them.
Between PTCN2 (female) (16) and FRC (female)
contact)
Resistance
Max. 1
(1)
3. Start engine
Defective power train control- Between PTCN2 (16) and ground
Voltage
7 11 V
ler
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
(01)
40-141
DRAFT
Failure code [2202L1] Left clutch: Fill high

Action code
E04
Detail of failure
Problem on
machine
Related information
Failure code
Speed Left clutch fill switch signal is ON.
Failure
2202L1
Nevertheless controller does not output command current to left steering ECMV solenoid circuit, fill
switch signal is turned ON.

State (ON/OFF) of left steering ECMV fill switch signal can be checked with monitoring function.
oil pressure".
q
q
q
q
q
q
Cause

Defective left steering ECMV
2. Disconnect connector FLC and connect T-adapter to male side.
fill switch (Internal short cirBetween FLC (female) (1) and ground
cuit)
Resistance
Min. 1 M
(Fill switch OFF)
2. Disconnect connector FLC.
or defective power train con- 3. Start engine
If failure code [2202L1] is still displayed, there is ground fault of wiring harness or
troller
(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
of either of them.
Between PTCN2 (female) (26) or FLC (female) (1)
Resistance
Min. 1 M
and ground
Defective power train control- 3. Start engine
ler
Voltage
7 11 V
Left Max.
Voltage
Max. 1 V
40-142
D375A-6
(01)
DRAFT
Circuit diagram related to left clutch ECMV
D375A-6
(01)
40-143
DRAFT
Failure code [2202LH] Left clutch: Fill low

Action code
E04
Detail of failure
Problem on
machine

State (ON/OFF) of left steering ECMV fill switch signal can be checked with monitoring function.
Method of reproducing failure code: Engine start and release parking brake lever and operate PCCS
lever. (left steering).
oil pressure".
q
q
q
Related information
Failure code
Left cluth fill switch is OFF.
Failure
2202LH
Nevertheless controller outputs command current to left steering ECMV solenoid circuit, fill switch
signal is turned OFF.
q
q
q
Cause

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 M
1
fill switch (It does not turn ON) 1 2 are same as above.
Between FLC (male) (1) and
Left Max.
Resistance
Max. 1
ground
Disconnection in wiring har2. Disconnect connectors PTCN2 and FLC and connect T-adapters to female side
ness
2
of them.
Between PTCN2 (female) (26) and FLC (female)
contact)
Resistance
Max. 1
(1)
3. Start engine
Defective power train control- Between PTCN2 (26) and ground
Voltage
7 11 V
3
ler
Left Max.
Voltage
Max.1 V
ground
40-144
D375A-6
(01)
DRAFT
Circuit diagram related to left clutch ECMV
D375A-6
(01)
40-145
DRAFT
Failure code [2300NR] Brake Themal Load Abnormality

Action code
Detail of failure
Problem on
machine
Related information
Failure code
Brake thermal load abnormality
Failure
2300NR
q The power train controller judged from the angle of inclination, travel speed, continuous operating time
of the brake pedal, etc. that the brake was heating abnormally.
q
None in particular.
Cause
1 Improper braking during downhill travel (Machine traveled down a slope with brake pedal pressed)
When the operation in cause 1 is not performed
troller
40-146
D375A-6
(01)
DRAFT
D375A-6
(01)
40-147
DRAFT
Failure code [2301L1] Right brake: Fill high

Action code
E04
Detail of failure
Indication of
problem on
machine
Failure code
Speed right brake fill switch signal is ON.
Failure
2301L1
Nevertheless controller does not output command current to right steering brake ECMV solenoid circuit, fill switch signal is turned ON.

q
q
Related information
q
q
q
q
State (ON/OFF) of right steering brake ECMV fill switch signal can be checked with monitoring function.
oil pressure".
Cause

Defective right steering
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 M
(Fill switch OFF)
2. Disconnect connector FRB.
Ground fault of wiring harness or defective power train 3. Start engine
controller
(If failure code [2301L1] is not displayed, right steering brake fill switch is defective)
Ground fault of wiring har2. Disconnect connectors PTCN2 and FRB, and connect T-adapter to female side of
ness
either of them.
Between PTCN2(female )(37) or FRB (female) (1)
Resistance
Min. 1 M
and ground
Defective power train con3. Start engine
troller
4. Release the parking brake.
Voltage
Max. 1 V
5. While depressing the brake and carry out troubleshooting.
Voltage
7 11 V
40-148
D375A-6
(01)
DRAFT
Circuit diagram related to right brake ECMV
D375A-6
(01)
40-149
DRAFT
Failure code [2301LH] Right brake: Fill low

Action code
E04
Detail of failure
Indication of
problem on
machine
Failure code
Right brake fill switch signal is OFF.
Failure
2301LH
Nevertheless controller outputs command current to right steering brake ECMV solenoid circuit, fill

q
q
Related information
q
q
q
q
State (ON/OFF) of right steering brake ECMV fill switch signal can be checked with monitoring function.
Method of reproducing failure code:Start engine and release the parking brake.
oil pressure".
Cause
Defective right steering brake

1 ECMV fill switch (It does not
turn ON)

2
contact)
40-150

2. Disconnect connector FRB and connect T-adapter to male side.
Between FRB (male) (1) and ground
Resistance
Min. 1 M
3. Start engine.
4. Release the parking brake and carry out troubleshooting.
Between FRB (male) (1) and ground
Resistance
Max. 1
2. Disconnect connectors PTCN2 and FRB, and connect T-adapters to female side
of them.
Between PTCN2 (female) (37) and FRB (female) (1) Resistance
Max. 1
3. Start engine
Voltage
Max. 1 V
Voltage
7 11 V
D375A-6
(01)
DRAFT
D375A-6
(01)
40-151
DRAFT
Failure code [2301NR] Steering Brake RH Themal Load Abnormality

Action code
Detail of failure
Problem on
machine
Related information
Failure code
Right steering brake thermal load abnormality
Failure
2301NR
The power train controller judged from the angle of inclination and continuous operating time of the
right steering that the steering brake was heating abnormally.
None in particular.
Cause
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
(01)
40-153
DRAFT
Failure code [2302L1] Left brake: Fill high

Action code
E04
Failure code
Left brake fill switch signal is ON.
Failure
2302L1
q Nevertheless controller does not output command current to left steering brake clutch ECMV solenoid
Detail of failure
Action of conq 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 left steering brake cluth ECMV fill switch signal can be checked with monitoring
function.
Related infor- q Method of reproducing failure code: Start engine.
q Remove seat (approx. 50 kg) and cover under seat.
mation
oil pressure".
Cause

Defective left steering brake
2. Disconnect connector FLB and connect T-adapter to male side.
1 clutch ECMV fill switch
Between FLB(female) (1) and ground
(Internal short circuit))
Resistance
Min. 1 M
(Fill switch OFF)
2. Disconnect connector FLB.
Ground fault of wiring har- 3. Start engine
train controller
(If failure code [2302L1] is not displayed, left steering brake clutch fill switch is defective)
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
Resistance
Min. 1 M
ground
If "check result of cause 2 is abnormal" and "check result of cause 3 is normal", power
train controller is defective.
4
troller
Voltage
Max. 1 V
Voltage
7 11 V
40-154
D375A-6
(01)
DRAFT
Circuit diagram related to left brake ECMV
D375A-6
(01)
40-155
DRAFT
Failure code [2302LH] Left brake: Fill low

Action code
E04
Failure code
Left brake fill switch signal is OFF.
Failure
2302LH
q Nevertheless controller outputs command current to left steering brake clutch ECMV solenoid circuit,
Detail of failure
Action of conq Limits operation of engine, transmission, and brake.
troller
Indication of
problem on
q Once machine is stopped, it becomes impossible to travel.
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.
mation
q Remove seat (approx. 50 kg) and cover under seat.
oil pressure".
Cause

2. Disconnect connector FLB and connect T-adapter to male side.
Resistance
Min. 1 M
Defective left steering brake Between FLB(male) (1) and ground
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
ness
2. Disconnect connectors PTCN2 and FLB, and connect T-adapters to female side of
2
them.
contact)
Between PTCN2 (female) (6) and FLB(female) (1)
Resistance
Max. 1
3. Start engine
Defective power train con- 4. Release the parking brake.
3
troller
Voltage
Max. 1 V
Voltage
7 11 V
40-156
D375A-6
(01)
DRAFT
D375A-6
(01)
40-157
DRAFT
Failure code [2302NR] Steering Brake LH Themal Load Abnormality

Action code
Detail of failure
Indication of
problem on
machine
Related information
Failure code
Left steering brake thermal load abnormality
Failure
2302NR
Power train controller judged from the angle of inclination, travel speed and continuous operating
time of the left steering that the steering brake was heating abnormally.
None in particular.
Cause
1 Improper steering during downhill travel (Machine traveled down a slope and was steered to left continuously)
Defective power train control2
ler
40-158
D375A-6
(01)
DRAFT
D375A-6
(01)
40-159
DRAFT
Failure code [7RFAKA] ECM ACC CUT RELAY: Disconnection

Action code
Detail of failure
Problem on
machine
Failure code
Engine controller ACC cut relay disconnection
Failure
7RFAKA
(Work equipment controller system)
No voltage is applied to engine controller ACC cut relay primary (coil side) circuit when no grounding.
Stops grounding to engine controller ACC cut relay primary (coil side) circuit.
Engine does not start.

If engine ACC cutoff mechanism is mounted, the engine cannot be stopped by ACC cutoff. (The engine cannot be stopped by engine ACC cutoff mechanism.)
Output to engine controller ACC cut relay primary (coil side) circuit can be checked with monitoring
function (Code: 40983 W/E controller SW output).
Method of reproducing failure code: Turn the starting switch to ON position
This failure code detects failure on primary side (coil side) of engine controller ACC cut relay, but not
on secondary side (contact side).
If pin WECN2 (8) has ground fault, engine cannot be started.
q
q
Related information
q
q
q
Cause
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
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 M or above, wiring harness has disconnection. If resistance is 1 or
below, wiring harness has short circuit.
Between KEY (female) (1) and WECN2 (female) (8)
Resistance
200 400
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
Between KEY (female) (1) and ACT (female) (1)
Resistance
Max. 1
Ground fault of wiring
2. Disconnect connectors WECN2 and ACT, and connect T-adapters to female side of
harness
4
them.
(Contact with ground
Between ACT (female) (2) or WECN2 (female) (8) and
circuit)
Resistance
Min. 1 M
ground
If cause is not found by the above checks, work equipment controller is defective.
q Reference: The following are criteria in normal condition.
1.
Defective work equip5
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
(01)
40-161
DRAFT
Failure code [7RFAKB] ECM ACC CUT RELAY: Short circuit

Action code
Detail of failure
Problem on
machine
Related information
Failure code
Engine controller ACC cut relay disconnection
Failure
7RFAKB
Abnormal current flows when grounding to engine controller ACC cut relay primary (coil side) circuit .
Stops grounding to engine controller ACC cut relay primary (coil side) circuit.
Output to engine controller ACC cut relay primary (coil side) circuit can be checked with monitoring
function (Code: 40983 W/E controller SW output).
Method of reproducing failure code: Turn the starting switch ON.
This failure code detects failure on primary side (coil side) of engine controller ACC cut relay, but not
q
q
Cause
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
or short circuit)
2. Disconnect connectors WECN2 and KEY and connect T-adapters to female side of
them.
2
circuit in wiring harness a If resistance is above 1 M, wiring harness has disconnection. If resistance is below
1 , wiring harness has short circuit.
Resistance
200 - 400
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 cir3.
Turn
starting switch to ON position.
cuit)
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
ment controller
Voltage
Max. 1 V
40-162
D375A-6
(01)
DRAFT
Circuit diagram related to engine controller shut down
D375A-6
(01)
40-163
Failure code [AA10NX] Air Cleaner Clogging

Action code
Failure code
Failure
AA10NX
Detail of failure
Problem on
machine
Related information
40-164

(Machine monitor system)
Air cleaner clogging switch signal voltage was not 1 V or less while engine was running, and machine monitor detected clogging of air cleaner (open of switch contacts).
None in particular
If the machine is operated under such a condition, engine may be damaged.
Cause
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.
Defective air cleaner clog- 3. Start engine.
2 ging switch (Internal disconWhen air cleaner is
Resistance
Max. 1 z
nection)
normal *1
Between AF1 (male) (1) and (2)
When air cleaner is
Resistance
Min. 1 Mz
clogged *2
Open circuit in wiring har2. Disconnect connectors CM01, CM02 and AF1, and connect T-adapters to each
ness
female side.
3 (Open circuit in wiring or
Between
CM02 (female) (4) and AF1 (female) (1)
Resistance
Max. 1 z
defective contact in connector)
Between CM01 (female) (7) and AF1 (female) (2)
Resistance
Max. 1 z
1


2. Insert T-adapters into connectors CM01 and CM02.
3. Start engine.
When air cleaner is
normal
Between CM02 (4) and CM01 (7)
Air cleaner is
clogged
Voltage
Max. 1 V
Voltage
7 11 V
Air cleaner suction resistance

*1: Max. -3,430 Pa {-350 mmH2O}
*2: -7,470 490 Pa {-762 50 mmH2O}
q
40-164
D375A-6
(06)
DRAFT
Circuit diagram related to air cleaner
D375A-6
(01)
40-165
DRAFT
Failure code [AB00MA] Battery Charge Abnormal
Failure code [AB00MA] Battery Charge Abnormal

Action code
Failure code
Battery Charge Abnormal
Trouble
AB00MA
q While engine was running, voltage from alternator lowered, and machine monitor detected that batDetail of failure
tery charge voltage was low.
Action of conq 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
q Method of reproducing failure code: Start engine.
Cause
Defective charge by alter1 nator
Defective charge level
2
monitor system
Procedure, measuring location,criteria and remarks

It is suspected that problem causing defective battery charge is occurring at present or
occurred in past. Investigate cause and damage condition, and correct it.
If cause 1 is not detected, charge level monitor system may be defective. Perform
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 conDetail of failure
troller detected engine oil pressure too low.
Action of conq 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 monitor through communication system.
Related inforq Engine oil pressure can be checked with monitoring function.
mation
(Code: 37200 Engine Oil Pressure)
Cause
Lowering of engine oil
1 pressure
2

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
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
Detail of failure
Problem on
machine
Related information
Failure code
Eng oil level low
Failure
B@BAZK
q While engine was running, signal voltage from engine oil level switch was not 1 V or less, machine
monitor detected that engine oil level was low (oil level switch was open).
q
Displays radiator coolant level monitor red on machine monitor.
If machine is used as it is, engine may be seized.
Cause
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)
Between OLV (male) (1) and ground
Resistance
Disconnection in wiring
harness
2. Disconnect connector CM02 and connect T-adapter to female side.
3
(Disconnection or defecBetween CM02 (female) (2) and OLV(female) (1)
Resistance
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
Max. 1
Max. 1 V
Circuit diagram related to engine oil level
D375A-6
(01)
40-167
DRAFT
Failure code [B@BCNS] Eng Water Overheat
Failure code [B@BCNS] Eng Water Overheat

Action code
Detail of failure
Problem on
machine
Related information
Failure code
Eng Coolant Overheat
Failure
B@BCNS
While engine was running, voltage from engine coolant temperature sensor dropped, and engine controller detected that engine coolant was overheated.
Displays engine coolant temperature monitor red on machine monitor.
If machine is used as it is, engine may be seized.
Engine controller inputs voltage of engine coolant temperature sensor signal and then transmits the
data to machine monitor through CAN communication system.
Engine coolant temperature can be checked with monitoring function
(Code: 04107 Coolant Temperature)
q
q
Cause
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. Per2
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
q While starting switch was ON (and engine was stopped) or engine was running, radiator coolant level
Detail of failswitch signal was not 1 V or less, machine monitor detected that radiator coolant level was low (senure
sor contact was open).
Action of conq 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 inforq Method of reproducing failure code: Start engine.
mation
1
2
Cause
Coolant level low
Check radiator sub tank for lowering of coolant level. If coolant level is low, add cool(When system is normal) ant.
If cause 1 is not detected, radiator coolant level monitor may be defective. Carry out
Defective radiator cool"E-4 Caution item lights up while starting switch is ON (and engine is stopped)" in E
ant level monitor system
mode.
D375A-6
(01)
40-169
DRAFT
Failure code [B@CENS] T/C Oil Overheat
Failure code [B@CENS] T/C Oil Overheat

Action code
Detail of failure
Problem on
machine
Related information
Failure code
Torque converter overheating
Failure
B@CENS
q While engine was running, voltage from torque converter oil temperature sensor dropped, and power
train controller detected that power train oil was overheated.
q
Displays power train oil temperature monitor red on machine monitor.
If machine is used as it is, power train components may be damaged.
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 communication system.
Torque converter oil temperature can be checked with monitoring function.
(Code: 30100 T/C Oil Temperature)
q
q
Cause
Overheating of torque con1 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 sysdefective. 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
Detail fo failure
Problem on
machine
Related information
Failure code
Hydraulic Oil overheating
Failure
B@HANS
While engine was running, hydraulic oil temperature sensor voltage dropped, and power train controller detected hydraulic oil overheat by data sent from machine monitor by CAN communication.
Displays hydraulic oil temperature monitor red on machine monitor.
If machine is operated as it is, work equipment circuit units may be damaged.
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.
Hydraulic oil temperature can be checked with monitoring function
(Code: 04401 Hyd Oil Temperature)
q
q
Cause
Hyd Oil Overheat
1
2

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 tembe 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
(01)
40-171
Failure code [B@HAZK] Hyd Oil Level Low

Action code
Failure code
Failure
B@HAZK
Related information
Low Hydraulic Oil Level

Signal voltage from or hydraulic oil lever switch open oil level switch was not 1 V or less while engine was running, and work equipment controller detected low hydraulic oil level or oil lever switch
open..
None in particular.
If machine is operated as it is, work equipment circuit units may be damaged.
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.
Hydraulic oil level switch can be checked with monitoring function.
(Code: 40981 W/E controller SW input)
Detail of failure
Problem on
machine
40-173
q
q
Cause
Hydraulic oil level low (dur1 ing normal system operation)

Hydraulic oil may be low. Check it and add oil if necessary.

Defective hydraulic oil level 2. Disconnect connector HLS and connect T-adapter to male side.
2
switch (Internal defect)
Between HLS (male) (1) and (2)
Resistance
Max. 1 z

Open circuit in wiring har2. Disconnect connectors WECN1 and WECN2, and connect T-adapters to each
ness
3
female side.
(wire breakage or defective
Between WECN2 (female) (28) and WECN1 (female)
Resistance
Max. 1 z
contact of connector)
(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
2. Insert T-adapter into connectors WECN1 and WECN2.
controller
Between WECN2 (28) and WECN1 (4)
Circuit diagram related to hydraulic oil level
40-172
Voltage
Max. 1 V
40-173
D375A-6
(06)
DRAFT
D375A-6
(01)
40-173
Failure code [CA111] ECM Critical Internal Failure

Action code
Failure code
Failure
E03
CA111
Detail of failure
Problem on
machine
Related information
40-174
Abnormality in engine controller

Trouble occurred in engine controller.
None in particular
Machine continues operation normally but may stop suddenly or may not able to start again once
it stops.
Power supply voltage of engine controller can be checked with moniitoring funtion.
(Code: 03203 Power supply voltage)
Method of reproducing failure code: turn engine starting switch to ON position.
q
q
Cause
Looseness or corrosion of
battery terminal
Loosened terminal or partial 1. Turn starting switch to OFF position.

disconnection at terminal
Check terminals of alternator, battery relay, ground (GND11) etc. for looseness.
Defective wiring harness

connector
4 Improper battery voltage
5 Defective alternator
6 Defective engine controller
40-174
The battery terminal may be loose or corroded. Inspect the terminal itself.
See descriptions of wiring harness and connectors in "c: Electrical equipment" in

"Checks before troubleshooting" of "General information on troubleshooting", and
check them directly.
1. Turn starting switch to OFF position, then carry out troubleshooting.
2. Perform troubleshooting when engine is cranked.
Between battery terminal
Voltage
20 30V
(+) and (-).
2. Insert T-adapter between male and female side of connector E22.
3. Start engine (Engine speed: Middle or faster).
Between E22 (3) and
Voltage
26 30.5V
ground
If no abnormality is found by the above checks, the engine controller is defective.
(Since this is an internal failure, troubleshooting cannot be performed.)
q Reference: The followings are standard values in normal condition.
1. Turn starting switch to OFF position and disconnect ground strap.
2. Insert T-adapter between male and female sides of EGC3.
3. Connect the 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
D375A-6
(06)
DRAFT
Circuit diagram related to engine controller power supply
D375A-6
(01)
40-175
DRAFT
Failure code [CA115] Eng Ne and Bkup Speed Sens Error

Action code
E03
Detail of failure
Problem on
machine
Related information
Failure code
Abnormality in engine Ne/Bkup speed sensor
Failure
CA115
Abnormality occurred in the signal of Ne and Bkup speed sensor circuits at the same time.
Stops the engine.
q
q
The engine does not start. (if engine has been stopped.)
Engine stops. (if engine has been running.)
1
2
Cause
Defective Ne speed sensor system
Defective Bkup speed sensor system
Defective engine controller
40-176

Carry out troubleshooting for failure code [CA689].
Carry out troubleshooting for failure code [CA778].
If cause is not found by above checks,, engine controller may be
defective. (Since failure is in it, troubleshooting cannot be performed.)
D375A-6
(01)
DRAFT
D375A-6
(01)
40-177
DRAFT
Failure code [CA122] Chg Air Press Sensor High Error

Action code
E03
Detail of failure
Problem on
machine
Related information
q
q
Failure code
Charge pressure sensor too high
Failure
CA122
High voltage occurred in charge pressure sensor (boost pressure sensor) signal circuit.
Sets charge pressure (boost pressure) to fixed value (400kPa {4.1 kg/cm2}), and continues operation.
Engine does not accelerate smoothly.
The signal (voltage) from the charge pressure sensor (boost pressure sensor) can be checked with
the monitoring function (Code: 36501 (V)).
Pressure (Boost pressure) sensed by charge pressure sensor (boost pressure sensor) can be
checked with monitoring function (Code: 36500 (kPa)).
Method of reproducing failure code: Turn the starting switch to ON position.
If sensor connector is disconnected, code [CA123] "Low Error" is displayed, even in normal condition.
q
q
q
Cause
1
2

See the items related to wiring harness and connectors in "c: Electric and electrical
equipment" in "Checks before troubleshooting" in "General information on troubleconnector
shooting" section, and check them directly.
Defective sensor power
If failure code [CA187] or [CA227] is displayed at the same time, carry out troublesupply system
shooting for that first.
2. Disconnect connector PIM.
Defective charge pressure
3. Turn starting switch ON position.
(boost pressure) sensor
If failure code changes from [CA122] to [CA123], charge pressure (boost pressure)
sensor is defective.
Short circuit in wiring har- 2. Disconnect connectors ENG and PIM, and connect T-adapter to female side of
ness
ENG.
Between ENG (female) (37) - (44)
Resistance
Min. 1 M
Short circuit with power
supply in wiring harness
2. Disconnect connector PIM, and insert T-adapter into connector ENG.
(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
(Since the failure is in it, troubleshooting cannot be performed.)
40-178
D375A-6
(01)
DRAFT
Circuit diagram related to charge pressure sensor
D375A-6
(01)
40-179
Failure code [CA123] Chg Air Press Sensor Low Error

Action code
Failure code
Failure
E03
CA123
40-180
Charge pressure sensor too low

Detail of failure
Low voltage occurred in charge pressure sensor (boost pressure sensor) signal circuit.
Problem on
machine
Sets charge pressure (boost pressure) to fixed value (400kPa {4.1 kg/cm2}), and continues operation.
Engine does not accelerate smoothly.
The signal (voltage) from the charge pressure sensor (boost pressure sensor) can be checked with
the monitoring function (Code: 36501 (V)).
Pressure (Boost pressure) sensed by charge pressure sensor (boost pressure sensor) can be
checked with monitoring function (Code: 36500 (kPa)).
Method of reproducing failure code: Turn starting switch to ON position.
Since T-adapter of sensor connector is "socket", voltage at sensor connector cannot be checked.
If sensor connector is disconnected, this code is displayed.
Related information
q
q
q
q
Cause
1

connector

Defective power supply sys2 tem of charge pressure sen- If failure code [CA187] or [CA227] is indicated, carry out troubleshooting for it first.
sor (boost pressure sensor)
2. Disconnect connectors ENG and PIM.
Short circuit in wiring har3
3. Connect T-adapter to female side of ENG.
ness
Between ENG (female)
Resistance
Min. 1 Mz
(44) and (47)
Ground fault in wiring har- 2. Disconnect connectors ENG and PIM, and connect T-adapter to female side of
4 ness
ENG.
(Contact with ground circuit) Between ENG (female)
Resistance
Min. 1 Mz
(44) and ground
Open circuit in wiring harIf cause is not found by the above checks, there may be open circuit in wiring har5
ness
ness. (*)
a If causes 1 - 5 are not the cause for the trouble and check result of cause 6 is abnormal, sensor is defective.
Defective charge pressure 2. Connect T-adapter to connector ENG.
(boost pressure) sensor
6
Between
(Improper input voltage of
ENG
engine controller)
Sensor out(female)
Voltage
0.34.7V
put
(44) and
(47)
Defective
7 engine
controller
*: See "Troubleshooting method for disconnected wiring harness of pressure sensor system" of "Related troubleshooting information".
40-180
D375A-6
(06)
DRAFT
Circuit diagram related to charge pressure sensor
D375A-6
(01)
40-181
Failure code [CA131] Throttle Sensor High Error

Action code
Failure code
Failure
E03
CA131
Detail of failure
Problem on
machine
Related information
40-182
Throttle sensor too high

High voltage occurred in decelerator pedal potentiometer signal circuit.
Operate the decelerator pedal at a fixed value.
The engine does not reach full throttle.
Signal of decelerator potentiometer voltage can be checked with monitoring function (Code:
31703).
Signal state of decelerator potentiometer (decelerator opening) can be checked with monitoring
function (Code: 31701).
q
q
Cause

connector

Defective throttle sensor

power supply system
If failure code [CA2185] is displayed, troubleshoot it first.

2. Disconnect connector DEC and connect T-adapter to male side.
Defective decelerator pedal Between DEC (male) (B) and (C)

(throttle sensor)
Between DEC (male) (A) and (C)
Resistance
4.06.0 kz
Resistance
0.25.0 kz
Between DEC (male) (B) and (A)
Resistance
0.25.0 kz

2. Disconnect connector EGC2 and connect T-adapter to female side.
Open or short circuit in wirBetween EGC2 (female) (22) and (23)

ing harness
Between EGC2 (female) (9) and (23)
Short circuit in wiring harness
Hot short circuit in wiring

6 harness
(Contact with 24 V circuit)
40-182
Resistance
4.06.0 kz
Resistance
0.25.0 kz
a If no abnormality is found in checks on cause 4, this check is not required.

2. Disconnect connectors EGC2 and DEC, and connect T-adapters to either female
side.
Between EGC2 (female) (9) and (22), or between DEC
Resistance
Min. 1 Mz
(female) (A) and (B)
2. Disconnect connector DEC and connect T-adapter to female side.
Between DEC (female) (B) and ground
Voltage
Max. 1 V

4. Operate decelerator pedal, and troubleshoot.
Between
EGC2 (22)
Power supply
Voltage
4.75 5.25 V
and (23)
Approx. 4.7
Between
Depress decelerator pedal.
Voltage
V
EGC2 (9)
Approx. 0.4
Release decelerator pedal.
Voltage
and (23)
V
D375A-6
(06)
DRAFT
Circuit diagram related to decelerator pedal
D375A-6
(01)
40-183
DRAFT
Failure code [CA132] Throttle Sensor Low Error

Action code
E03
Detail of failure
Problem on
machine
Related information
Failure code
Throttle sensor too low
Failure
CA132
q Decelerator potentiometer signal circuit of throttle sensor detected abnormally low voltage.
q
Operate the decelerator pedal at a fixed value.
The engine does not reach full speed.
Signal of decelerator potentiometer voltage can be checked with monitoring function (Code:
31703).
Signal state of decelerator potentiometer (decelerator opening) can be checked with monitoring
function (Code: 31701).
q
q
Cause
1

connector
Defective throttle sensor

power supply system

Directly check wire harness and connectors by referring to "c. Electrical equipment"
described in "Testing before troubleshooting" of "Related troubleshooting information".
If failure code [CA2186] is also indicated, perform troubleshooting for it first.

2. Disconnect connector DEC and connect T-adapter to male side.
Defective decelerator
Between DEC (female)(B) and (C)
Resistance
4.06.0 k
pedal (throttle sensor)
Between DEC (female)(A) and (C)
Resistance
0.2 - 5.0 k
Between DEC (female)(B) and (A)
Resistance
0.2 - 5.0 k
Disconnection or short cir- 2. Disconnect connector EGC2 and connect T-adapter to female side.
cuit in wiring harness
Resistance
4.06.0 k
Resistance
0.2 - 5.0 k
2. Disconnect connector EGC2 and DEC and connect T-adapter to each female
harness
side.
(Disconnection or defecBetween
EGC2 (female) (22) and DEC (female)(A)
Resistance
Max. 1
Between EGC2 (female) (9) and DEC (female)(B)
Resistance
Max. 1
Between EGC2 (female) (23) and DEC (female)(C)
Resistance
Max. 1
Short circuit in wiring har- 2. Disconnect connectors EGC2 and DEC, and connect T-adapter to female side of
ness
either of them.
Between EGC2 (female) (9) and (23) or between
Resistance
Min. 1 M
DEC (female) (B) and (C)
Ground fault of wiring har2. Disconnect connectors EGC2 and DEC, and connect T-adapter to female side of
ness
either of them.
(Contact with ground cirBetween EGC2 (female) (9) or DEC (female) (B)
cuit)
Resistance
Min. 1 M
and ground
(Since the failure is it, troubleshooting cannot be performed.)
q Reference: The following are criteria in normal condition.
Defective engine controller 4. Operate decelerator pedal, and troubleshoot.
EGC2 Between (22) and
Power supply
Voltage
4.755.25V
(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
(01)
40-185
Failure code [CA135] Eng Oil Press Sensor High Error

Action code
Failure code
Failure
E03
CA135
Detail of failure
Problem on
machine
Related information
Engine oil pressure sensor signal voltage is too high

High voltage was detected in engine oil pressure sensor signal circuit.
Sets engine oil pressure to default (250kPa {2.5 kg/cm2}), and allows for operation.
Signal voltage from engine oil pressure sensor can be checked with monitoring function (Code:
37201 (V)).
Oil pressure sensed by engine oil pressure sensor can be checked with monitoring function (Code:
37200 (kPa)).
q
q
40-186
Cause

connector
described in "Check before troubleshooting" of "General information on troubleshooting".
Defective power supply time

2 of engine oil pressure sen- If failure code [CA187] or [CA227] is displayed, perform troubleshooting for it first.
sor
2. Disconnect connector POIL.
Defective engine oil pres3
sure sensor
If failure code changes from [CA135] to [CA141], sensor is defective.

5 harness
40-186

2. Disconnect connectors ENG and POIL, and connect T-adapters to either female
side.
Between ENG (female)(13) and (37), or between POIL
Resistance
Min. 1 Mz
(female)(1) and (3)
2. Disconnect connector POIL.
3. Connect T-adapter to female side of connector POIL or connect T-adapter to
connector ENG.
4. Turn starting switch to ON position (with connector POIL disconnected).
BetweenENG(13) and (47) , or between POIL (female)
Voltage
Max. 1V
(3) and (2)
If no abnormality is found by above checks, the engine controller is defective. (Since
this is an internal failure, troubleshooting cannot be performed.)
D375A-6
(06)
DRAFT
Circuit diagram related to engine oil pressure sensor
D375A-6
(01)
40-187
Failure code [CA141] Eng Oil Press Sensor Low Error

Action code
Failure code
Failure
E01
CA141
Detail of failure
Problem on
machine
Related information
Engine oil pressure sensor signal voltage is too low.

Low voltage was detected in engine oil pressure sensor signal circuit.
Sets engine oil pressure to default (250kPa {2.5 kg/cm2}), and continues operation.
Signal voltage from the engine oil pressure sensor can be checked with the monitoring function
(Code: 37201 (V)).
Oil pressure sensed by engine oil pressure sensor can be checked with monitoring function (Code:
37200 (kPa)).
q
q
40-18
Cause

connector
If failure code [CA187] or [CA227] is displayed, perform troubleshooting for it first
Defective power supply sys- 1. Turn starting switch to OFF position.

2 tem of engine oil pressure 2. Disconnect connector POIL and connect T-adapter to each female side of them.
sensor
Between POIL(female)(1) and (2)
Open circuit in wiring harness

3
Ground fault in wiring har4 ness

Defective engine oil pressure sensor (Improper input

6
voltage to engine controller)

40-188
Power supply input
Voltage
4.75 5.25V

2. Disconnect connectors ENG and POIL and connect T-adapters to each female
side.
a If power input in checks on cause 2 is normal, this
check is not required.
Resistance
Max. 1 z
Between ENG (female) (37) and POIL(female)(1)
a If power input in checks on cause 2 is normal, this
Resistance
Max. 1 z
Between ENG (female) (47) and POIL(female)(2)
Between ENG (female) (3) and POIL (female)(3) (SenResistance
Max. 1 z
sor output)
side.
Between ENG(female)(13) and ground, or between
Resistance
Min. 1 Mz
POIL(female)(3) and ground
side.
Between ENG (female)(13) and (47), or between POIL
Resistance
Min. 1 Mz
(female) (2) and (3)
a If causes 1 5 are not the cause for failure and check result of cause 6 is abnormal, sensor may be defective.
2. Insert T-adapter between male and female sides of connector ENG
Sensor output
Voltage
0.3 4.7 V
If no abnormality is found by above checks, the engine controller is defective. (Since

D375A-6
(06)
DRAFT
Circuit diagram related to engine oil pressure sensor
D375A-6
(01)
40-189
Failure code [CA144] Coolant Temp Sens High Error

Action code
Failure code
Failure
E01
CA144
Detail of failure
Problem on
machine
Coolant temperature sensor signal valtage is too high.

High voltage was detected in engine coolant temperature sensor signal circuit.
Sets coolant temperature to fised temperature (90 C) ,and allows for operation.
Engine does not start easily at low temperature.

Overheat prevention function does not work.
Signal voltage from engine coolant temperature sensor can be checked with monitoring function
(Code: 04105 (V)).
Temperature sensed by engine coolant temperature sensor can be checked with monitoring function (Code: 04107 (C)).
If temperature sensor connector is disconnected, this failure code is displayed.
Since T-adapter for sensor connector is "socket" type , T-adapter cannot be connected to wiring
harness.
q
q
q
Related information
40-190
q
q
q
Cause
2. Disconnect connector TWTR and connect socket to male side of connector.
a If coolant temperature sensor has resistance of 700 z - 37 kz with coolant temperature above 0 C , regard coolant temperature sensor as normal.
Between
0 C
Resistance
30 - 37 kz
TWTR
25 C
Resistance
9.3 - 10.7 kz
(male) (A)
Defective coolant temperaand (B)
2
50 C
Resistance
3.2 - 3.8 kz
ture sensor
a Coolant
80 C
Resistance
1.0 - 1.3 kz
temperature
-Resistaure
95 C
Resistance
700 - 800 z
characteristics
2. Disconnect connector ENG and connect T-adapter to female side.
Open or short circuit in wir- Between ENG (female) (15) and (38) (Coolant tempera3
ture: Min. 0 C)
700 z ing harness
Resistance
a Use coolant temperature -Resistance characteris37 kz
tics table shown above as resistance criteria.
If no abnormality is found by the above checks, engine controller is defective. (Since
1

connector
40-190
D375A-6
(06)
DRAFT
Circuit diagram related to coolant temperature sensor
D375A-6
(01)
40-191
Failure code [CA145] Coolant Temp Sens Low Error

Action code
Failure code
Failure
E01
CA145
Detail of failure
Problem on
machine
Low voltage was detected in engine coolant temperature sensor signal circuit.
Sets coolant temperature to fixed temperature (90 C),and allows for operation.

Overheat prevention function does not work.
Signal voltage from engine coolant temperature sensor can be checked with monitoring function
(Code: 04105 (V)).
Temperature sensed by engine coolant temperature sensor can be checked with monitoring function (Code: 04107 (C)).
If temperature sensor connector is disconnected, this failure code is not displayed but failure code
for High Error is displayed.
q
q
q
Cause
1
Coolant temperature sensor signal valtage is too low

Related information
40-192

connector
Defective coolant temperature sensor

2. Disconnect connector TWTR and connect socket to male side of connector.
a If coolant temperature sensor has resistance of 700 z - 37 kz with coolant temperature above 0 C, regard coolant temperature sensor as normal.
Between TWTR (male) (A)

and (B)
a Coolant temperature-Resistaure characteristics
0 C
Resistance
30 - 37 kz
25 C
Resistance
9.3 - 10.7 kz
50 C
Resistance
3.2 - 3.8 kz
80 C
Resistance
1.0 - 1.3 kz
95 C
Resistance
700 - 800 z
All coolant
temperature
Resistance
Min. 1 Mz
range
Between ENG (female)(15) and (38) (Coolant temperature:
Min. 0 C)
700 z Resistance
a Use coolant temperature -Resistance characteristics
37 kz
table shown above as resistance criteria.
2. Disconnect connectors ENG and TWTR, and connect T-adapter to female side of
ENG.
Between (B) and ground

40-192
Between ENG (female) (15) and ground
Resistance Min. 1 Mz
If no abnormality is found by above checks, engine controller is defective. (Since this

is an internal failure, troubleshooting cannot be performed.)
D375A-6
(06)
DRAFT
Circuit diagram related to coolant temperature sensor
D375A-6
(01)
40-193
DRAFT
Failure code [CA153] Chg Air Temp Sensor High Error

Action code
E01
Detail of failure
Problem on
machine
Failure code
CA153
Charge (Boost) temperature sensor signal voltage is too high.

High voltage was detected in charge (boost) temperature sensor signal circuit.
Sets charge temperature to fixed temperature (70 C) ,and allows for operation.
Signal voltage from charge temperature sensor (boost temperature sensor) can be checked with monitoring function (Code: 18501 (V)).
Temperature sensed by charge temperature sensor (boost temperature sensor) can be checked with
monitoring function (Code: 18500 (C)).
Since T-adapter for sensor connector is "socket" type , T-adapter cannot be connected to wiring harness.
If temperature sensor connector is disconnected, this failure code is displayed.
Related information
Failure
q
q
q
Cause

See descriptions of related to wiring harness and connectors in "c: Electrical equipment"
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 - 382 k, regard charge temperature sensor as normal.
-40 C
Resistance
291 k 382 k
Defective charge temperBetween TIM (male)
-20 C
Resistance
85 k 109 k
ature sensor
(A) and (B)
0 C
Resistance
29 k 36 k
a Charge tempera30 C
Resistance
7.3 k 8.8 k
60 C
Resistance
2.3 k 2.7 k
ture
-Resistance
90 C
Resistance
860 970
chariacteristic
130 C
Resistance
280 320
Disconnection or short cir- 2. Disconnect connector ENG and connect T-adapter to female side.
Between ENG (female) (23) and (47)
a Use "charge temperature-Resistance characteris- Resistance
280 - 382 k
tics" table shown above as resistance criteria.
Defective engine control- If no abnormality is found by above checks, engine controller is defective. (Since failure
ler
is in it, troubleshooting cannot be performed.)
40-194
D375A-6
(01)
Circuit diagram related to charge temperature sensor
D375A-6
(06)
40-195
40-195
DRAFT
Failure code [CA154] Chg Air Temp Sensor Low Error

Action code
E01
Detail of failure
Problem on
machine
Related information
Failure
Charge (Boost) temperature sensor signal volatge too low
Failure
code
CA154
Low voltage was detected in charge (boost) temperature sensor signal circuit.
Set charge temperature to fixed temperature (70 C) ,and allow for operation.
Signal voltage from charge temperature sensor (boost temperature sensor) can be checked with
monitoring function (Code: 18501 (V)).
Temperature sensed by charge temperature sensor (boost temperature sensor) can be checked
with monitoring function (Code: 18500 (C)).
If temperature sensor connector or harness is disconnected,this failure code is not displayed but failure code for High Error is displayed.
q
q
q
Cause

See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks
before troubleshooting" of "General information on troubleshooting" , and check them
connector
directly.
2. Disconnect connector TIM and connect socket to male side of connector.
a If temperature sensor has resistance of 280 - 382 k, regard charge temperature
sensor as normal.
-40 C
Resistance
291 k 382 k
Defective charge temper-20
C
Resistance
85 k 109 k
ature sensor
TIM (male) (A) and (B)
0 C
Resistance
29 k 36 k
a Charge temperature
30 C
Resistance
7.3 k 8.8 k
-Resistance
chari60 C
Resistance
2.3 k 2.7 k
acteristic
90 C
Resistance
860 970
130 C
Resistance
280 382
Short circuit in wiring har- 2. Disconnect connector ENG and connect T-adapter to female side.
Between ENG (female) and (47)
ness
a Use "charge temperature-Resistance characteris- Resistance
280 382 k
tics" table shown above as resistance criteria.
harness
2. Disconnect connectors ENG and TIM and connect T-adapter to female side of ENG.
(Contact with GND cirBetween ENG (female) (23) and ground
Resistance
Min. 1 M
cuit)
Defective engine control- If no abnormality is found by above checks, engine controller is defective. (Since failure is
ler
in it, troubleshooting cannot be performed.)
40-196
D375A-6
(01)
Circuit diagram related to charge temperature sensor
D375A-6
(06)
40-197
40-197
Failure code [CA187] Sens Supply 2 Volt Low Error

Action code
Failure code
Failure
E03
CA187
Detail of failure
Sensor power supply 2 (5 V) circuit voltage is too low.
Engine controller ignores signals from Bkup speed sensor and controls engine by using Ne speed
sensor signals.
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.
Engine controller ignores signals from ambient pressure sensor ,sets ambient pressure to default
value (52.44 kPa {0.53 kg/cm2}),and allows engine to run.
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.
Engine controller ignores signals from EGR valve lift sensor , limits engine output and closes EGR
valve.
q
q
q
Problem on
machine
Related information
Engine output drops.
Cause
1
Sensor power source 2 too low

40-198

connector
2 Defective sensor or harness

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.
a Other failure codes are displayed, too. This is because the connector is disconnected. Ignore failure codes other than [CA187].
Sensor or harness
Connector
Bkup speed sensor system
G connector
Engine oil pressure sensor
POIL connector
Charge (boost) pressure sensor
PIM connector
PAMB connector
EGR valve lift sensor
SEGR connector
Engine wiring harness
ENG connector
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)
40-198
Voltage
4.75 5.25 V
D375A-6
(06)
Circuit diagram related to sensor power supply 2
D375A-6
(06)
40-19
40-199
DRAFT
Failure code [CA212] Eng Oil Temp Sensor High Error

Action code
E01
Detail of failure
Problem on
machine
Related information
Failure code
Engine oil temperature sensor signal voltage is too high.
Failure
CA212
High voltage was detected engine oil temperature sensor signal circuit
Sets engine oil temperature to fixed value (100 C), and allows engine to run.
Signal voltage from engine oil temperature sensor can be checked with monitoring function (Code:
42701 (V)).
Temperature sensed by engine oil temperature sensor can be checked with monitoring function
(Code: 42700 (C)).
This failure code is displayed if temperature sensor connector or harness is disconnected.
Since T-adapter for sensor connector is socket type, it cannot be connected to wiring harness.
q
q
q
q
Cause

"Checks before troubleshooting" of "General information on troubleshooting" , and
connector
2. Disconnect connector TOIL and connect socket to male side of connector.
a If coolant temperature sensor resistance is 700 37 k with coolant temperature
above 0 C, regard coolant temperature sensor as normal.
Defective oil temperature
0 C
Resistance
30 - 37 k
sensor
TOIL(male) between (A)
25 C
Resistance
9.3 - 10.7 k
and (B)
50 C
Resistance
3.2 - 3.8 k
a Oil temperature -Resis80 C
Resistance
1.0 - 1.3 k
tance characteristic
95 C
Resistance
700 - 800
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 temperain wiring harness
ture above 0 C)
Resistance 700 - 37 k
a UseOil temperature -Resistance charactenis table
shown above as resistance criteria.
If no abnormality is found by above checks, engine controller is defective. (Since failDefective engine controller
ure is in it, troubleshooting cannot be performed.)
40-200
D375A-6
(01)
DRAFT
Circuit diagram related to engine oil temperature sensor
D375A-6
(01)
40-201
DRAFT
Failure code [CA213] Eng Oil Temp Sensor Low Error

Action code
E01
Detail of failure
Problem on
machine
Related information
Failure code
Engine oil temperature sensor signal voltage is too low.
Failure
CA213
Low voltage was detected in engine oil temperature sensor signal circuit.
Sets engine oil temperature to fixed value (100 C), and allows engine to run.l
Signal voltage from engine oil temperature sensor can be checked with monitoring function (Code:
42701 (V)).
Temperature sensed by engine oil temperature sensor can be checked with monitoring function
(Code: 42700 (C)).
If temperature sensor connector is disconnected, this failure code is not displayed but failure code
for High Error is displayed.
q
q
q
Cause
1

connector
Defective oil temperature

sensor
Ground fault of wiring har4 ness

(Contact with GND circuit)
40-202

See the descriptions of wiring harness and connectors in "c: Electrical equipment" in
"Checks before troubleshooting" of "General information on troubleshooting" section, and check them directly.
2. Disconnect connectors TOIL and connect socket to male side of connector.
a If oil temperature sensor resistance is 700 - 37 k with oil temperature is
above0 C, regard oil temperature sensor as normal.
0 C
Resistance
30 - 37 k
Between TOIL (male) (A)
25 C
Resistance
9.3 - 10.7 k
and (B)
50 C
Resistance
3.2 - 3.8 k
a Oil temperature -Resis80 C
Resistance
1.0 - 1.3 k
tance characteristics
95 C
Resistance
700 - 800
All oil temBetween (B) and ground
perature
Resistance
Min. 1 M
range
Between ENG (female) (17) and (47) (Oil temperature:
Min. 0 C)
Resistance 700 - 37 k
a UseOil temperature -Resistance charactenis table shown above as resistance criteria.
2. Disconnect connectors ENG and TOIL, and connect T-adapter to female side of
ENG.
Resistance
Min. 1 M
If no abnormality is found by above checks, engine controller is defective. (Since failure is in it, troubleshooting cannot be performed.)
D375A-6
(01)
DRAFT
Circuit diagram related to engine oil temperature sensor
D375A-6
(01)
40-203
DRAFT
Failure code [CA221] Ambient Press Sens High Error

Action code Failure code
Ambient pressure sensor signal voltage is too high.
Trouble
E01
CA221
Detail of failure q High voltage was detected in ambient pressure sensor signal circuit .
Action of con2
q Sets ambient pressure value to default value (50.99kPa {0.52 kg/cm }),and allow engine to run.
troller
Problem on
q Engine output drops.
machine
q Signal voltage from ambient pressure sensor can be checked with the monitoring function (Code:
37401 (V)).
Related inforq Ambient pressure by the ambient pressure sensor can be checked with the monitoring function
mation
(Code: 37400 (kPa)).
q Method of reproducing failure code: Turn the starting switch to ON position.
Cause
1
Defective wiring harness connector

"Checks before troubleshooting" of "General information on troubleshooting", and check
them directly.
Defective power supply

2 line of ambient presIf failure code [CA187] or [CA227] is also displayed, perform troubleshooting for it first.
sure sensor
Defective ambient pres- 2. Disconnect connector PAMB.
3
sure sensor
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
Resistance
Min. 1 M
Hot short in wiring har2. Disconnect connector PAMB.
ness
5
(Short circuit to 24 V cir- 3. Insert T-adapter into connector ENG.
4. Turn starting switch to ON position (with connector PAMB disconnected).
cuit)
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
(01)
40-205
DRAFT
Failure code [CA222] Ambient Press Sens Low Error

Ambient pressure sensor value too low.
Failure
E01
CA222
Detail of failure q Low voltage was detected ambient pressure sensor signal circuit .
Action of con2
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
(Code: 37400 (kPa)).
Related inforq Method of reproducing failure code: Turn starting switch to ON position.
mation
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.
Cause

See descriptions of wire harness and connectors in "c. Electrical equipment" in "Checks
before troubleshooting" of "Gemeral information on troubleshooting ,and check them
connector
directly".
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.
ness
3. Connect T-adapter to female side of ENG.
Resistance
Min. 1 M
harness
2. Disconnect connectors PAMB and ENG and connect T-adapter to female side of
(Contact with ground cirENG.
cuit)
Between ENG(female)(3) and ground
Resistance
Min. 1 M
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,
Defective ambient pres1. Turn starting switch to OFF position.
sure sensor
2. Insert T-adapter into connector ENG.
(Improper input voltage
from engine controller)
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
ler
*: 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
(01)
40-207
Failure code [CA227] Sens Supply 2 Volt High Error

Action code
Failure code
Failure
E03
CA227
Detail of failure
High voltage in engine controller sensor power supply 2 (5 V) circuit was detected.
Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor signals.
Ignores signals from engine oil pressure sensor,sets engine oil pressure to default value (250 kPa
{2.5 kg/cm2}),and allows engine to run.
Ignores signals from ambient pressure sensor, sets ambient pressure to default value (52.44 kPa
Ignores signals from boost pressure sensor, sets boost pressure to default value (400 kPa
Ignores signals from EGR valve lift sensor, limits engine output and closes EGR valve.
Method of reproducing failure code: Turn the starting switch to ON position .
q
q
Problem on
machine
Related information
Sensor power supply circuit valtage is too high

q
q
40-208
Cause

Perform troubleshooting for failure code [CA187].
40-208
D375A-6
(06)
Failure code [CA234] Eng Overspeed
Failure code [CA234] Eng Overspeed

Action code
Failure code
Failure
E02
CA234
Detail of failure
Problem on
machine
Related information
Engine overspeed
(Engine controller defective)
Engine speed exceeded operating range.
Reduce fuel injection rate until engine speed lowers in operating range.
Engine speed fluctuates.
Engine speed can be checked by monitoring function (Code: 01002 (rpm)).

Method of reproducing failure code: Start engine and keep it running at high idle.
Cause
1 Use of improper fuel
Improper fuel may be used. Check it directly.
2 Defect in related system
3 Usage is improper
D375A-6
(06)
40-209
The method of using machine may be improper, so instruct the operator on how to
use machine properly.
If causes 1 and 2 are not cause of failure, engine controller may be defective. (Since
40-209
DRAFT
Failure code [CA238] Ne Speed Sens Supply Volt Error

Ne speed sensor power supply voltage error
Failure
E03
CA238
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.
q Limits engine output and allows engine to run.
troller
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)
mation
Cause

1
connector
directly.
2. Disconnect following connectors one by one and turn starting switch to ON position
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 disconnected. Therefore, ignore code(s) other than failure code [CA238].
Sensor or harness
Connector
Ne speed sensor
NE
Engine harness
ENG
Defective engine con2. Disconnect connector ENG and connect T-adapter to male side of connector.
3
troller
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
(01)
40-211
DRAFT
Failure code [CA263] Fuel Temp Sensor High Error

Action code
E01
Detail of failure
Failure code
CA263
Failure
Fuel temperature sensor signal voltage is too high

High voltage was detected in fuel temperature sensor signal circuit .
Uses signals from coolant temperature sensor to perform fuel injection rate correction based on fuel
temperature.
Sets fuel temperature value to fixed value (95 C) and allows engine to run.
Problem on
machine
q
q
Related information
q
q
q
Signal voltage from the fuel temperature sensor can be checked with the monitoring function (Code:
14201 (V)).
Temperature sensed by fuel temperature sensor can be checked with the monitoring function (Code:
14200 (C)).
This failure code is displayed if temperature sensor connector is disconnected.
Because that T-adapter for sensor connector is socket type, it cannot be connected to wiring harness.
Cause
1

connector
Defective fuel temperature

sensor
Disconnection or short circuit in wiring harness
40-212

2. Disconnect connector TFUEL and connect socket to male side of connector.
a If coolant temperature sensor resistance is 700 37 k with coolant temperature is above 0 C, regard coolant temperature sensor as normal.
TFUEL(male)
0 C
Resistance
30 - 37 k
25 C
Resistance
9.3 - 10.7 k
between
50 C
Resistance
3.2 - 3.8 k
(A) and (B)
80 C
Resistance
1.0 - 1.3 k
a Fuel temperature
-Resis95 C
Resistance
700 - 800
t a n c e
characteristic
Between ENG (female) (30) and (47) (Fuel temperature : above 0 C)
a Use Fuel temperature - Resistance
Resistance
700 - 37 k
characteristics table shown above as resistance critaeria.
If no abnormality is found by above checks, engine controller is defective. (Since failure is in it, troubleshooting cannot be performed.)
D375A-6
(01)
DRAFT
Circuit diagram related to fuel temperature sensor
D375A-6
(01)
40-213
DRAFT
Failure code [CA265] Fuel Temp Sensor Low Error

Action code
E01
Detail of failure
Action of
controller
Failure code
CA265
Failure
Fuel temperature sensor signal voltage is to low

Low voltage was detected in fuel temperature sensor signal circuit.
Uses signals from coolant temperature sensor to perform fuel injection rate correction based on fuel
temperature.
(Sets to fixed value (95 C) and ,and allows engine to run)
Signal voltage from fuel temperature sensor can be checked with monitoring function (Code: 14201
(V)).
Temperature sensed by fuel temperature sensor can be checked with monitoring function (Code:
04204 (C)).
This code is not displayed but failure code for High Error is displayed, if sensor connector is disconnected.
Problem on
machine
Related information
q
q
q
Cause

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 37 k with coolant temperature is
above0 C, regard coolant temperature sensor as normal.
0 C
Resistance
30 - 37 k
Defective fuel tempera- TFUEL(male) between
2
25 C
Resistance
9.3 - 10.7 k
(A)
and
(B)
ture sensor
50 C
Resistance
3.2 - 3.8 k
a Fuel temperature 80 C
Resistance
1.0 - 1.3 k
Resistance charac95 C
Resistance
700 - 800
teristic
Between (B) and
All fuel temResistance
Min. 1 M
ground
perature range
Between ENG (female) (15) and (38) (Fuel temperaShort circuit in wiring
3
ture : above 0 C)
harness
a UseFuel
temperature
Resistance Resistance
700 - 37 k
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 cirBetween ENG (female) (30) and ground
Resistance
Min. 1 M
cuit)
Defective engine control- If no abnormality is found by the above checks, engine controller is defective. (Since fail5
ler
40-214
D375A-6
(01)
DRAFT
Circuit diagram related to fuel temperature sensor
D375A-6
(01)
40-215
Failure code [CA271] IMV/PCV1 Short Error
Failure code [CA271] IMV/PCV1 Short Error

Action code
Failure code
E03
CA271
Detail of failure
Problem on
machine
Related information
40-216
Fail- IMV/PCV1 short circuit error

ure (Engine controller system)
Short circuit was detected in supply pump PCV1 circuit.
Pulse voltage of approx. 24V is normally applied to PCV1 (1) while engine is running, but it cannot
be measured with circuit tester .
Cause

1
connector
2. Disconnect connector PCV1.
Defective supply pump
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.

Hot short in wiring harness


2. Disconnect connector ENG and connect T-adapter to female side of connector .
Between ENG (female) (4) and (5) (PCV1 resistance)
Resistance
2.3 5.3 z
Resistance
Min. 1 Mz

2. Disconnect connector ENG and PCV1, and connect Tadapter to female side of
ENG.
1.
2.
3.
4.
Voltage
Max. 3 V

Circuit diagram related to PCV1
40-216
Min. 1 Mz

Disconnect connector PCV1.
Insert T-adapter into connector ENG.
Turn starting switch to ON position (with connector PCV1 disconnected).
ENG Between (4) and (5)

Resistance
40-216
D375A-6
(06)
Failure code [CA272] IMV/PCV1 Open Error
Failure code [CA272] IMV/PCV1 Open Error

Action code
Failure code
E03
Failure description
Problem on
machine
CA272
Related information
Failure
IMV/PCV1 disconnection
Disconnection was detected in supply pump PCV1 circuit.

While engine is running normally, Pulse voltage of approx. 24 V is normally applied to PCV (1) while
engine is running ,but it cannot be measured with circuit tester since it is pulse voltage.
Since T-adapter for PCV connector is "socket" type , T-adapter cannot be connected to wiring harness.
q
q
Cause
1
40-217

connector

2. Disconnect connectors PCV1 and connect socket to male side.

PCV1
2
(Internal open circuit in wirBetween PCV1 (male) (1) and (2)
Resistance
ing)
Open or short circuit in wir- 2. Disconnect connector ENG and connect T-adapter to female side.
3
ing harness
Resistance
2.3 - 5.3 z

2. Disconnect connectors ENG and PCV1.
3. Connect T-adapter to female side of connector ENG.
Resistance
Min. 1 Mz

D375A-6
(06)
2.3 - 5.3 z
40-217
40-217
Failure code [CA273] PCV2 Short Error
Failure code [CA273] PCV2 Short Error

Action code
Failure code
E03
CA273
Detail of failure
Problem on
machine
Related information
Fail- PCV2 short circuit error

ure (Engine controller system)
Short circuit was detected in supply pump PCV2 circuit.

While engine is running normally, approximately 24 V of pulse voltage is applied to PCV2 (1). But
it is pulse voltage and cannot be measured by using multimeter.
Cause
1

connector

2 PCV2
(Internal short)


5 harness

2. Disconnect connector PCV2.
If failure code changes from [CA273] to [CA274], supply pump PCV2 is defective.
Resistance
2.3 5.3 z

2. Disconnect connector ENG and PCV2, and connect Tadapter to female side of
ENG.
1.
2.
3.
4.
Resistance
Min. 1 Mz

Disconnect connector PCV2.
Insert T-adapter into connector ENG.
Turn starting switch to ON position (with connector PCV2 disconnected).
Voltage
Max. 3 V

40-218
40-218
40-218
D375A-6
(06)
DRAFT
Failure code [CA274] PCV2 Open Error
Failure code [CA274] PCV2 Open Error

Action code
E03
Detail of failure
Problem on
machine
Related information
Failure code
PCV2 disconnection
Failure
CA274
q Disconnection was detected in supply pump PCV2 circuit.
q
q
Method of reproducing failure code: Turn the starting switch ON.

, Pulse voltage of approx. 24 V is normally applied to PCV2 (1) while engine is running, but it cannot
be measured with circuit tester.
Cause

See the descriptions of wiring harness and connectors in "c: Electrical equipment" in
connector
PCV2
2. Disconnect connector PCV2 and connect socket to male side.
(Internal disconnection)
Between PCV2 (male) (1) and (2)
Resistance
2.3 - 5.3
Disconnection or short cir2. Disconnect connector ENG and connect T-adapter to female side.
Between ENG (female) (9) and (10) (PCV2 resist)
Resistance
2.3 - 5.3
Ground fault of wiring har2. Disconnect connector ENG and PCV2.
ness
(Contact with GND circuit) 3. Connect T-adapter to female side of connector ENG.
Resistance
Min. 1 M
If no abnormality is found by above checks, engine controller is defective. (Since the
D375A-6
(01)
40-219
DRAFT
Failure code [CA322] Inj #1 (L#1) Open/Short Error

Action code
E03
Detail of failure
Problem on
machine
Related information
Failure code
Injector #1(L#1) open/short circuit error
Failure
CA322
q Disconnection or short circuit was detected in injector #1 circuit.
q
q
q
q

Engien speed does not stabilize
Pulse voltage of about 65 V is applied noromally supplied to injector (+) side while engine is running
but it cannot be measured with circuit tester .
Cause
1

connector
2 Defective injector #1
Disconnection in, or ground

fault of wiring harness

4 (Disconnection in wiring or

Defective other cylinder

injectors or wiring harness
40-220

2. Disconnect connector CN1 and connect T-adapter to male side.
Between CN1 (male) (1) and (2)
Resistance
0.4 - 1.1
Between CN1 (male) (1) ground
Resistance
Min. 1 M
Between ENG (female) (45) (53)
Resistance
0.4 - 1.1
Resistance
Min. 1 M
2. Disconnect connectors ENG and CN1, and connect T-adapters to each female
side.
Between ENG (female) (45) and CN1 (female) (1)
Resistance
Max. 1
Resistance
Max. 1
2. Disconnect connectors ENG and CN1, and connect T-adapter to female side of
either one of them.
Between ENG (female) (45) or CN1 (female) (1) and
Resistance
Min. 1 M
ground
ENG.
a Check with circuit tester in continuity mode.
Between ENG (female) (45) and each pin other than
No continuity
(45) pin.
(No sound is heard)
No continuity
(53) pin.
(No sound is heard)
If the failure codes for other injectors are displayed, perform troubleshooting of them,
too.
If no abnormality is found by above checks, engine controller is defective. (Since failure is in it , troubleshooting cannot be performed.)
D375A-6
(01)
DRAFT
Circuit diagram related to injector #1
D375A-6
(01)
40-221
DRAFT

Action code
E03
Detail of failure
Problem on
machine
Related information
Failure code
Injector #5(L#5) open/short circuit error
Trouble
CA323
q
q
q
q

Engine speed does not stabilize.
Pulse voltage of about 65V is normally supplied to injector (+) side while engine is running, but it cannot be measured with circuit tester .
Cause
1

connector
Disconnection in, or
3 ground fault of wiring harness
harness

Resistance
0.4 - 1.1
Between CN5 (male) (1) and ground
Resistance
Min. 1 M
Resistance
0.4 - 1.1
Resistance
Min. 1 M
2. Disconnect connectors ENG and CN5, and connect T-adapters to each female side.
Resistance
Max. 1
Resistance
Max. 1
either one of them.
Resistance
Min. 1 M
ground
ENG.
No continuity
pin (46) pin.
(No sound is heard)
No continuity
pin (60) pin.
(No sound is heard)

If failure codes for other injectors are displayed, perform troubleshooting for them, too.
Defective engine control- If no abnormality is found by above checks, engine controller is defective. (Since failure
8
ler
7
40-222
D375A-6
(01)
DRAFT
D375A-6
(01)
40-223
DRAFT

Action code
E03
Detail of failure
Problem on
machine
Related information
Failure code
Injector #3(L#3) open /short circuit error
Failure
CA324
q
q
q
q

Pulse voltage of approx. 65V is normally supplied to injector (+) side while engine is running, but it
cannot be measured with circuit tester.
Cause
1

connector

harness


Resistance
0.4 - 1.1
Resistance
Min. 1 M
Resistance
0.4 - 1.1
Resistance
Min. 1 M
side.
Resistance
Max. 1
Resistance
Max. 1
either one of them.
Resistance
Min. 1 M
ground
ENG.
No continuity
pin (55) pin.
(No sound is heard)
No continuity
pin (52) pin.
(No sound is heard)

If no abnormality is found by above checks, engine controller is defective. (Since fail8 Defective engine controller
7
40-224
D375A-6
(01)
DRAFT
D375A-6
(01)
40-225
DRAFT

Action code
E03
Detail of failure
Problem on
machine
Related information
Failure code
Injector #6 (L#6) open / short circuit error
Trouble
CA325
q Opening or short circuit was detected in drive circuit of No. 6 injector.
q
q
q
q

Pulse voltage of approx. 65 V is normally supplied to injector (+) side while engine is running normally
but it cannot be measured with circuit tester .
Cause
1

connector
3 ground fault of wiring harness
harness

Resistance
0.4 - 1.1
Resistance
Min. 1 M
Resistance
0.4 - 1.1
Resistance
Min. 1 M
2. Disconnect connectors ENG and CN6, and connect T-adapters to each female side.
Resistance
Max. 1
Resistance
Max. 1
either one of them.
Resistance
Min. 1 M
ground
ENG.
No continuity
pin (57) pin.
(No sound is heard)
No continuity
pin (59) pin.
(No sound is heard)
Defective injector or wiring

If the failure codes for other injectors are displayed, perform troubleshooting for them,
7 harness of another cylintoo.
der
If no abnormality is found by above checks, engine controller is defective. (Since failure
40-226
D375A-6
(01)
DRAFT
D375A-6
(01)
40-227
DRAFT

Action code
E03
Detail of failure
Problem on
machine
Related information
Failure code
Injector #2 Open/Short circuit error
Failure
CA331
Disconnection or short circuit was detected in injector #2 circuit.
q
q
q
q

Pulse voltage of approx. 65V is normally supplied to injector (+) side while engine is running, but it
cannot be measured with circuit tester .
Cause
7
8

connector
Defective injector #2
Resistance
0.4 - 1.1
Resistance
Min. 1 M
Disconnection in, or ground 2. Disconnect connector ENG and connect T-adapter to female side.
Resistance
0.4 - 1.1
Resistance
Min. 1 M
Disconnection in wiring har1. Turn starting switch to OFF position.
ness
(Disconnection in wiring or 2. Disconnect connectors ENG and CN2, and connect T-adapters to each female
side.
defective contact in connecBetween ENG (female) (54) and CN2 (female) (1)
Resistance
Max. 1
tor)
Resistance
Max. 1
Ground fault of wiring har2. Disconnect connectors ENG and CN2, and connect T-adapter to female side of
ness
either one of them.
Resistance
Min. 1 M
ground
2. Disconnect connectors ENG and CN, and connect T-adapter to female side of
ENG.
Short circuit in wiring hara Check with circuit tester in continuity mode.
ness
Between ENG (female) (54) and each pin other than pin
No continuity
(54) pin.
(No sound is heard)
Between ENG (female) (51) and each pin other than pin
No continuity
(51) pin.
(No sound is heard)
If failure codes for other injectors are displayed, perform troubleshooting for them,
injectors or wiring harness too.
If no abnormality is found by above checks, engine controller is defective. (Since failDefective engine controller
40-228
D375A-6
(01)
DRAFT
D375A-6
(01)
40-229
DRAFT

Action code
E03
Detail of failure
Problem on
machine
Related information
Failure code
Injector #4 (L#4) open / short circuit error
Failure
CA332
q
q
q
q

Pulse voltage of approx. 65V is normally supplied to injector (+) side while engine is running but it
cannot be measured with circuit tester.
Cause
1

connector




Resistance
0.4 - 1.1
Resistance
Min. 1 M
Resistance
0.4 - 1.1
Resistance
Min. 1 M
side.
Resistance
Max. 1
Resistance
Max. 1
either one of them.
Resistance
Min. 1 M
ground
ENG.
No continuity
pin (56) .
(No sound is heard)
No continuity
pin (58) .
(No sound is heard)

If no abnormality is found by above checks, engine controller is defective. (Since fail8 Defective engine controller
7
40-230
D375A-6
(01)
DRAFT
D375A-6
(01)
40-231
DRAFT
Failure code [CA342] Calibration Code Incompatibility
Failure code [CA342] Calibration Code Incompatibility

Action code
E03
Detail of failure
Problem on
machine
Related information
Engine continues running ordinarily, but it may stop during operation or may not restart once it is
stopped.
Cause
40-232
Failure
Engine controller data inconsistency
Failure
code
CA342
Data inconsistency occurres in engine controller.

Preform troubleshooting for failure code [CA111].
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
E03
CA351
Detail of failure q Abnormality has occurred in injector drive circuit.
Action of conq Limits engine output for travel (Limits common rail pressure) and allows engine to run
troller
Problem on
machine
mation
Cause
D375A-6
(01)

Check whether other failure code (failure code related to injector system ) are displayed
together. If another code is displayed, perform troubleshooting for it.
Perform troubleshooting for failure code [ CA111]
40-233
DRAFT

Action code
E03
Detail of failure
Problem on
machine
Related information
Failure
Sensor power supply 1voltage is too low
Failure
code
CA352
Low voltage was detected in sensor power supply 1 (5 V) circuit.
Limits engine output (limits common rail pressure) and allows engine to run.
Cause

Defective wiring harbefore 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 wiring 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
PFUEL
Engine harness
ENG
Defect in related sysIf another failure code is displayed, perform troubleshooting for it.
tem
Defective engine con- 2. Disconnect connector ENG and connect T-adapter to male side.
troller
Voltage
4.75 5.25 V
40-234
D375A-6
(01)
DRAFT
Circuit diagram related to sensor power supply 1
D375A-6
(01)
40-235
DRAFT

Action code
E03
Detail of failure
Problem on
machine
Related information
q
q
Limits engine output (limits common rail pressure) and allows engine to run
Cause
40-236
Failure
Sensor power supply 1 voltage is too high
Failure
code
CA386
High voltage was detected in sensor power supply 1 (5 V) circuit.

Perform troubleshooting for failure code[CA352]
D375A-6
(01)
DRAFT
Failure code [CA441] Battery Voltage Low Error
Failure code [CA441] Battery Voltage Low Error

Battery power circuit voltage is to low
Trouble
E04
CA441
Contents of
q Low voltage was detected in battery power supply circuit.
trouble
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 inforq Method of reproducing failure code: Turn the starting switch to ON position.
mation
Cause
D375A-6
(01)

40-237
Failure code [CA442] Battery Voltage High Error
Failure code [CA442] Battery Voltage High Error

Action code
Failure code
Failure
E03
CA442
Detail of failure
Problem on
machine
Related information
40-238
Battery power supply circuit voltage is too high

High voltage (36V) was detected in battery power supply circuit.
Engine continues running ordinarily, but it may stop during operation or may not restart once it is
stoped.
Power supply voltage of engine controller can be checked with monitoring function (Code: 03203
(V)).
q
q
Cause

40-238
D375A-6
(06)
DRAFT
Failure code [CA449] Rail Press Very High Error
Failure code [CA449] Rail Press Very High Error

Action code
E03
Failure code
Common rail pressure is abmormally high
Failure
CA449
q Common rail pressure sensor circuit detects abnormally high pressure (pressure exceeding set
Detail of failure
maximum level).
Action of conq 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 inforq Common rail pressure sensed by common rail pressure sensor can be checked with monitoring
mation
function (Code: 36400 (MPa)).
Cause
D375A-6
(01)

40-239
Failure code [CA451] Rail Press Sensor High Error

Action code
Failure code
Failure
E03
CA451
Detail of failure
Problem on
machine
Related information
40-240
Common rail pressure sensor signal voltage is too high.

High voltage was detected in signal circuit of common rail pressure sensor.
Limits engine output (limits common rail pressure) and allows engine to run
Engine output is drops.
Signal voltage from common rail pressure sensor can be checked with monitoring function (Code:
36401 (V)).
Common rail pressure sensed by common rail pressure sensor can be checked with monitoring
This failure code is displayed if common rail pressure sensor connector is disconnected.
q
q
q
Cause
1
described in "Check before troubleshooting" of "General information on troubleshootconnector
ing".
a If failure code [CA352] (Ground fault in sensor power supply line) or [CA386] is displayed, perform troubleshooting for it first.
Defective common rail pres- 1. Turn starting switch to OFF position.
2 sure sensor power supply
2. Disconnect connector PFUEL and connect T-adapter to female side.
line
Power supply
Between PFUEL (female) (1) and (3)
Voltage
4.75 5.25V
input
2. Disconnect connectors PFUEL and ENG and connect T-adapters to each female
side.
a If power supply input in checks on cause 2 is normal,
Open circuit in wiring harthis check is not required.
Resistance
Max. 1 z
ness
3
Between ENG(female) (33) and PFUEL(female) (1)
a If power supply input in checks on cause 2 is normal,
this check is not required.
Resistance
Max. 1 z
Between ENG (female) (47) and PFUEL (female) (3)
Between ENG (female) (25) and PFUEL (female) (2)
Resistance
Max. 1 z
(Sensor output)
2. Disconnect connectors PFUEL and ENG
3. Connect T-adapter to female side of ECM.
ness
Resistance
Min. 1 Mz

1.
2.
3.
a

Disconnect connectors PFUEL and insert T-adapter into connector ECM.
Turn starting switch to ON position (with connector PFUEL disconnected).
ENG (25) pin is connected to 5V source through resistor in engine controller.
Voltage
Approx. 5V
a If causes 1 5 are not cause of failure and check result of cause 6 is abnormal,
Defective common rail pres1.
Turn
starting switch to OFF position.
sure sensor
6
2. Insert T-adapter into connector ENG
(Improper input voltage to
engine controller)
40-240
Sensor output
Voltage
0.2 4.6V

D375A-6
(06)
DRAFT
Circuit diagram related to common rail pressure
D375A-6
(01)
40-241
Failure code [CA452] Rail Press Sensor Low Error

Action code
Failure code
Failure
E03
CA452
Detail of failure
Problem on
machine
Related information
Common rail pressure sensor signal voltage is to low

Low voltage was detected in signal circuit of common rail pressure sensor.
Limits engine output (limits common rail pressure),and allows engine to run.
Engine output is drops.
Signal voltage from the common rail pressure sensor can be checked with monitoring function
(Code: 36401 (V)).
This failure code is not displayed but failure code, position [CA451] for High Error is displayed
when sensor connector is disconnected even if it is normal.
q
q
q
40-242
Cause

connector
a If failure code [CA352]or [CA386] is displayed, perform troubleshooting for it first.
Defective common rail pres- 1. Turn starting switch to OFF position.

2. Disconnect connector PFUEL and connect T-adapter to female side.
2 sure sensor power supply
line
Power supply
Between PFUEL (female) (1) and (3)
Voltage
4.75 5.25V
input
Defective common rail pres- 2. Disconnect connector PFUEL
3
sure sensor
If failure code changes from [CA452] to [CA451] , sensor is defective.
Ground fault in wiring har- 2. Disconnect connectors ENG and PFUEL , and connect T-adapter to female side
4 ness
of ENG
Resistance
Min. 1 Mz

2. Disconnect connectors ENG and PFUEL , and connect T-adapter to female side
of ENG
40-242
Resistance
Min. 1 Mz

D375A-6
(06)
DRAFT
Circuit diagram related to common rail pressure
D375A-6
(01)
40-243
DRAFT
Failure code [CA553] Rail Press High Error
Failure code [CA553] Rail Press High Error

Action code
E03
Failure code
Common rail pressure is high
Failure
CA553
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.
Problem on
machine
36401 (V)).
Related inforq Common rail pressure sensed by common rail pressure sensor can be checked with monitoring funcmation
tion (Code: 36400 (MPa)).
Cause
Defective electrical system
3 of common rail pressure
sensor
Defective mechanical sys4 tem of common rail pressure sensor
5 Defective overflow valve
6 Clogging of overflow piping
7 Defective pressure limiter
40-244

Check fuel used directly (for high viscosity).
Electrical system of common rail pressure sensor may be defective. Perform troubleshooting for failure codes [CA451] and [CA452].
Check mechanical system of common rail pressure sensor directly.
Check overflow valve directly for broken spring, worn seat, and stuck ball.
Check overflow piping directly for clogging.
Check pressure limiter directly for mechanical defect.
D375A-6
(01)
DRAFT
Failure code [CA554] Rail Press Sensor In Range Error
Failure code [CA554] Rail Press Sensor In Range Error

Common rail pressure sensor signal voltage is beyond input range
Failure
E03
CA554
Detail of failure q Signal voltage of common rail pressure sensor is beyond input range.
Action of conq Limits engine output (limits common rail pressure) and allows engine to run.
troller
Problem on
machine
36401 (V)).
Related inforq Common rail pressure sensed by common rail pressure sensor can be checked with monitoring funcmation
tion (Code: 36400 (MPa)).
q Method of reproducing failure code: Turn starting switch to ON position.
Cause
D375A-6
(01)

Perform troubleshooting for failure code [CA451], [CA452]
40-245
DRAFT
Failure code [CA559] Rail Press Low Error

Action code
E03
Detail of failure
Problem on
machine
Related information
Failure code
Supply pump does not pressure feed fuel
Failure
CA559
q Supply pump does not pressure feed fuel (level1).
q
Limits common rail pressure.
Cause
4
5
6
Procedure, measuring location,criteria and remarks

If another failure code is displayed, perform troubleshooting for it first.
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 cirFuel pressure in low-pressure circuit
0.15 0.3 MPa
cuit parts
(At high idle or under load equivalent to rated
{1.5
3.0 kg/cm2}
output operation)
Clogged fuel filter,or
a For more information on troubleshooting, see Note 2.
strainer
Defective electrical sysElectrical system of supply pump PCV may be defective. Perform troubleshooting for
tem of supply pump PCV failure code [CA271], [CA272], [CA273], or [CA274].
Defective common rail
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.
Leakage from pressure limiter
Defective 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
(load at stalling)
Defective injector
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
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
(01)
40-247
Model
Machine serial No.
Engine
Engine serial No.
#
#
Check sheet for no-pressure feed

D375A-6
Work No.
Date of check
SAA6D170E-5
Service meter reading
Worker's name
A. Visual check
1 Fuel leakage to outside
2 Clogging of fuel tank breather
Good NG
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
unit
value(Refeenc
Good NG
value
e value)
Low idle
r/min
700 800
01003 Engine speed
High idle
r/min
1,850 1,900
At torque converter stalling
r/min
1,490 1,580
Low
idle
%
0
Decelerator
31701
Pedal Position
High idle
%
100
Inject Fueling
18600
mg/st
Command
4
Rail Press Com36200
MPa
mand
Common rail
36400
MPa
pressure
Low idle
CA
Injection timing
36300
High idle
CA
command
CA
Charge Pres36500
kPa
sure-ABS
Coolant Temper04107
Low idle
C
ature
14200 Fuel Temperature Low idle
C
Cylinder cut out mode operation (Engine speed)
Standard
Measured
Good NG
Function Cut out cylinder
Condition for check
unit
value(Refervalue
ence value)
No. 1 cylinder
Low idle
r/min
5
No. 2 cylinder
Low idle
r/min
Low idle
r/min
Set by No. 3 cylinder
cylinder No. 4 cylinder
Low idle
r/min
No. 5 cylinder
Low idle
r/min
No. 6 cylinder
Low idle
r/min
-
C.Check of fuel circuit pressure
Fuel low-pressure circuit

pressure
Condition for check
High idling or under load equivaMPa

lent to rated output operation(stall{kg/cm2}
ing)
D.Check of strainers and filters

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
Unit
Standard
value(Reference value)
Measured
Good NG
value
0.15 0.3
{1.5 3.0}
Good NG
D375A-6
(06)
E.Checking leakage and fuel

return rate
11
Unit
Standard
value(Reference value)
cc/min
Max. 10
Torque converter stall 1,600 rpm
cc/min
960
cc/min
1,020
cc/min
1,080
cc/min
1,140
cc/min
1,200
Condition for check
Leakage from pressure lim- Under load equivalent to rated

iter
output operation (stalling)
12 Return rate from injector
D375A-6
(06)
Measured
Good NG
value
Speed:
Return
rate:
40-249
Failure code [CA689] Eng Ne Speed Sensor Error

Action code
Failure code
Failure
E03
CA689
Detail of failure
Problem on
machine
Engine Ne speed sensor signal is abnormal

Abnormal signal appear in engine Ne speed sensor circuit.
Controls engine by using signals from engine Bkup speed sensor.
Engine stops during operation (When engine Bkup speed sensor is also defective).
Engine cannot be started if it is stopped. (When engine Bkup speed sensor is also defective)
Since inside of speed sensor is not composed of coil but Hall sensor and electronic circuit, speed
sensor cannot be determined to be normal by measuring its resistance with circuit tester.
Since output of normal speed sensor is 5 V pulse voltage, it cannot be measured with circuit tester.
Speed sensor calculates engine speed by detecting holes made in the flywheel.
q
q
Related information
40-250
q
q
q
Cause

connector
Defective Ne speed sensor

If failure code [CA238] is also displayed, perform troubleshooting for it first.
power supply line
Breakage or improper instalEngine Ne speed sensor may be damaged or improperly installed (loose). Check
3 lation (looseness) of engine
sensor directly.
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.
If no abnormality is found in checks on cause 4, this
Open circuit in wiring harcheck is not required.
Resistance
Max. 1 z
ness
5
(wire breakage or defective Between ENG (female) (16) and NE (female) (1)
If no abnormality is found in checks on cause 4, this
Resistance
Max. 1 z
Between ENG (female) (48) and NE (female) (2)
Between ENG (female) (27) and NE (female) (3)
2. Disconnect connectors ENG and NE.
Short circuit in wiring harBetween ENG (female) (16) and (27), or between NE
6
ness
Between ENG (female) (27) and (48), or between NE
Ground fault in wiring har2. Disconnect connectors ENG and NE.
7 ness
Between ENG (female) (27) or NE (female) (3) and
ground
Hot short in wiring harness 2. Disconnect connector NE.
8
Between NE (female) (3) and ground
Resistance
Max. 1 z
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Voltage
Max. 1V
Defective engine Ne speed If failure is not found by above checks, engine Ne speed sensor may be defective.
sensor
(Since failure is in it, troubleshooting cannot be performed.)
If failure is not found by above checks, engine controller may be defective. (Since
9
40-250
D375A-6
(06)
Circuit diagrams related to engine Ne speed sensor
40-251
Ne speed sensor detects part (A) of flywheel (1), where hole (H) is not made to recognize one turn of flywheal, and the engine controller calculates the engine speed and phase.
D375A-6
(06)
40-251
Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error

Action code
Failure code
Failure
E03
CA731
Detail of failure
Problem on
machine
40-252
Engine Bkup speed sensor phase error

Engine Bkup speed sensor circuit detects phase error.

(Bkup speed sensor signal and Ne speed sensor signal are out of phase.)
Controls the engine by using signals from engine Ne speed sensor.
Engine stops during operation (When engine Ne speed sensor is also defective)
Engine cannot be started if it is stopped. (When engine Ne speed sensor is also defective).
Related infora 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 assembly".)
q
Cause
Defective engine Ne speed

1
sensor system
Defective engine Bkup
2
speed sensor system
Engine Ne speed sensor may be defective. Perform troubleshooting for failure code
[CA689]
Engine Bkup speed sensor may be defective. Perform troubleshooting for failure
code [CA778]
40-252
D375A-6
(06)
DRAFT
Failure code [CA757] All Continuous Data Lost Error
Failure code [CA757] All Continuous Data Lost Error

All engine controller data lost error
Failure
E04
CA757
Detail of failq 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
Cause
D375A-6
(01)

40-253
Failure code [CA778] Eng Bkup Speed Sensor Error

Action code
Failure code
Failure
E03
CA778
40-254
Eng Bkup Speed Sensor Error

Detail of failure
Abnormality has occurred in engine Bkup speed sensor circuit.
Controls engine by using Ne speed sensor signal.

Limits engine output and allows engine to run.
Engine stops during operation (when Ne speed sensor is also defective at the same time).
Engine cannot be started once it is stopped (when Ne speed sensor is also defective at the same
time).
a If engine Bkup speed sensor is replaced, fuel supply pump must be replaced.
(See "Disassembly and assembly", "Removal and installation of fuel supply pump assembly".)
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.
Since output of normal speed sensor is 5 V pulse voltage, it cannot be measured with circuit tester.
Problem on
machine
q
q
q
q
Related information
q
q
Cause

connector
Defective sensor power supIf failure code [CA187] or [CA227] is also displayed, troubleshoot it first.
ply line
Damage or improper instalEngine Bkup speed (G) sensor may be damaged or improperly installed (loose).
3 lation (loose) of engine Bkup
Check sensor directly.
speed (G) sensor
2. Disconnect connector RES and connect T-adapter to male side.
4 Defective resistor (RES)
Between RES (male) (1) and (2)
Resistance
620 z

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.
Power supply
input
Between G (female) (A) and (B)
Voltage
4.75 5.25 V
input
Open or short circuit in wir- 1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and G, and connect T-adapter to female side of ENG.
6 ing harness
Resistance
620 z
(Resistor RES line)
2. Disconnect connectors ENG, G and RES, and connect T-adapters to each female
side.
a If power supply voltage in checks on cause 5 is norOpen circuit in wiring harmal, this check is not required.
Resistance
Max. 1 z
ness
7
(wire breakage or defective Between ENG (female) (37) and G (female) (A)
a If power supply voltage in checks on cause 5 is norcontact of connector)
mal, this check is not required.
Resistance
Max. 1 z
Between ENG (female) (47) and G (female) (B)
Between ENG (female) (26) and G (female) (C)
40-254
Resistance
Max. 1 z
D375A-6
(06)
Cause

2. Disconnect connectors ENG, G and RES, and connect T-adapter to female side
of ENG or G.
Between ENG (female) (26) and (37), or between G
Resistance
Min. 1 Mz
(female) (A) and (C)
Between ENG (female) (26) and (47), or between G
(female) (B) and (C)
Ground fault in wiring har9 ness (contact with ground

circuit)
Resistance
Min. 1 Mz

2. Disconnect connectors ENG and G and connect T-adapters to either female side.
Between ENG (female) (26) or G (female) (C) and
ground
Resistance
Min. 1 Mz

2. Disconnect connectors G and RES, and connect T-adapter to female side.
10 harness (Contact with 24 V 3. Turn starting switch to ON position.
circuit)
Between G (female) (C) and ground
Voltage
Max. 1 V
11
Defective engine Ne speed If engine failure is not found by above checks, engine Bkup speed sensor may be
sensor
defective. (Since this is an internal failure, troubleshooting cannot be performed.)
If failure is not found by above checks, engine controller may be defective. (Since
Circuit diagram related to engine Bkup speed sensor
D375A-6
(06)
40-25
40-255
DRAFT
Failure code [CA1228] EGR Valve Servo Error 1

Action code
E03
Failure code
Abnormal EGR valve servo 1
Failure
CA1228
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 conq 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
4
5
6
7
8
9
Cause
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, Measuring EGR valve and bypass valve drive pressure .
Engine speed
EGR valve drive pressure
Improper EGR valve drive
Low idle
Min. 1.18 MPa {12 kg/cm2}
pressure
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
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
Oil pump relief valve for the EGR valve circuit may be defective, directly check it.
valve
Defective oil pipe for EGR
Oil pipe for the EGR valve circuit may be defective, directly check it.
valve
Defective oil return pipe for
Oil return pipe for the EGR valve circuit may be defective, directly check it.
EGR valve
Defective EGR valve
EGR valve may be defective, directly check it.
Defective EGR valve lift
sensor
If causes 1 8 are not cause of faillure, engine controller may be defective. (Since
40-256
D375A-6
(01)
DRAFT

Action code
E03
Failure code
Abnormal EGR valve servo 2
Failure
CA1625
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
Cause
D375A-6
(01)

40-257
DRAFT
Failure code [CA1633] KOMNET Datalink Timeout Error
Failure code [CA1633] KOMNET Datalink Timeout Error

CAN (KOMNET) communication disconnection
Failure
E03
CA1633
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.)
mation
Cause
40-258

Perform troubleshooting for failure code [DB2RKR].
D375A-6
(01)
DRAFT
Failure code [CA2185] Throt Sens Sup Volt High Error
Failure code [CA2185] Throt Sens Sup Volt High Error

Action code
E03
Detail of failure
Problem on
machine
Related information
Failure code
Throttle sensor power supply voltage is too high
Failure
CA2185
High voltage (approx. 5.25 V) was detected in throttle sensor power supply circuit.
Controls engine with decelerator pedal position at fixed value.
Engine speed cannot be controlled with decelerator pedal.
Cause
1
Defective throttle sensor (decelerator pedal)

harness

4
(Short circuit to 24 V
circuit)
5

directly.
2. Disconnect connector DEC and turn starting switch to ON position.
If this failure code is not displayed, throttle sensor is defective.
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
of EGC2 and EGC3.
Between EGC2 (female) (22) and each pin other than
Resistance
Min. 1 M
EGC2 (female) (22) pin
Between EGC2 (female) (22) and EGC3 (female)(3)
Resistance
Min. 1 M
2. Disconnect connector DEC and connect T-adapter to female side.
Between DEC(female)(A) and ground
Voltage
4.755.25V
2. Disconnect connector EGC2 and connect T-adapter to female side.
Voltage
4.755.25V
D375A-6
(01)
40-259
Failure code [CA2186] Throt Sens Sup Volt Low Error
Failure code [CA2186] Throt Sens Sup Volt Low Error

Action code
Failure code
Failure
E03
Detail of failure
Problem on
machine
Related information
CA2186
Throttle sensor power supply voltage is too low

Low voltage was detected in throttle sensor power supply circuit.
Controls engine with decelerator pedal postion at fixed value.
Engine speed cannot be controlled with decelerator pedal.
Cause
40-260
Defective wiring
1
harness connector
Directly check wire harness and connectors by referring to "c. Electrical equipment" described
in "Check before troubleshooting" of "General information on troubleshooting".
Defective throttle
2. Disconnect connector DEC and turn starting switch to ON position.
sensor (decelerator If this failure code is not displayed, throttle sensor is defective.
a Other failure code is displayed together. This is because that the sensor connector is dispedal)
connected. Ignored except the failure code other than [CA2186].
Ground fault of wir- 1. Turn starting switch to OFF position.
ing harness
2. Disconnect connectors EGC2 and DEC and connect T-adapters to either female side.
(Contact with
Between EGC2 (female) (22) or DEC (female) (A) and ground
Resistance
Min. 1 Mz
ground circuit)
2. Disconnect connector EGC2 and DEC and connect T-adapter to female side of EGC2.
Short circuit in wir3. Turn starting switch to ON position.
ing harness
Between EGC2 (female) (22) and each pin other than EGC2
Resistance
Min. 1 Mz
(female) (22) pin
2. Disconnect connector EGC2 and connect T-adapter to male side.
Defective engine
3. Turn starting switch to ON position with connecting engine wiring harness disconnected.
controller
40-260
Voltage
4.755.25V
40-260
D375A-6
(06)
DRAFT
Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2249] Rail Press Very Low Error

Failure
Supply pump no-pressure feed error 2
Failure
code
E03
CA2249
Detail of failure q No-pressure feed error (level 2) in supply pump was detected.
Action of conq Limits common rail pressure.
troller
Problem on
machine
q The signal voltage from the common rail pressure sensor can be checked with the monitoring function (Code: 36401 (V)).
Related inforq Common rail pressure sensed by common rail pressure sensor can be checked with monitoring
mation
Action code
Cause
D375A-6
(01)

Perform troubleshooting for failure code [CA559] .
40-261
Failure code [CA2271] EGR Valve Pos Sens High Error

Action code
Failure code
Failure
E03
CA2271
40-262
EGR valve lift sensor signal voltage is too high.

Detail of failure
High voltage was detected in EGR valve lift sensor signal circuit.
Problem on
machine
q
q
Limits engine output and continues operation.

Closes the EGR valve.
Signal voltage from EGR valve lift sensor can be checked with monitoring function (Code: 18101
(V)).
Position (mm) sensed by EGR valve lift sensor can be checked with monitoring function (Code:
18100 (mm).
Related information
q
q
Cause
Defective wiring
1
harness connector
Directly check wire harness and connectors by referring to "c. Electrical equipment" described
in "Check before troubleshooting" of "General information on troubleshooting".
Defective sensor
2 power supply system
If failure code [CA187] or [CA227] is also displayed, troubleshoot it first.
Defective EGR
3 valve lift sensor
(internal defect)
Short circuit in wir4
ing harness
Hot short in wiring
5 harness (contact
with 24 V circuit)

2. Disconnect connector SEGR.
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-adapters to either female side.
Between ENG (female) (37) and (19), between SEGR (female)
Resistance
Min. 1 Mz
(1) and (3), or between SEGR (female) (1) and (4)
2. Disconnect connector SEGR and connect T-adapter to female side.
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 this is
an internal failure, troubleshooting cannot be performed.)
6
Defective engine
controller
q Reference; the following is standard value in normal condition.

2. Insert T-adapter into connector ENG.
Between ENG(19) and (47)
40-262
Voltage
1.0 4.0 V
D375A-6
(06)
DRAFT
Circuit diagram related to EGR valve
D375A-6
(01)
40-263
DRAFT
Failure code [CA2272] EGR Valve Pos Sens Low Error

Action code
E03
Detail of failure
Problem that
appears on
machine
Related information
Failure code
EGR valve lift sensor signal voltage is too low.
Failure
CA2272
The signal of EGR valve lift sensor circuit is abnormally low.
The signal (voltage) from the EGR valve lift sensor can be checked with the monitoring function
(Code: 18101 (V)).
Position (mm) sensed by EGR valve lift sensor can be checked with monitoring function (Code:
18100 (mm)).
q
q
q
q
Cause

equipment" in "Checks before troubleshooting" in "General information on troubleconnector
shooting" section, and check them directly.
If failure code [CA187] (Ground fault in sensor power supply line) or [CA227] is displayed, perform troubleshooting for it first.
Defective sensor power
2. Disconnect connector SEGR and connect T-adapter to female side.
supply system
Power supBetween 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.
a
If power supply voltage in check on cause 2 is norDisconnection in wiring harmal, this check is not required.
Resistance
Max. 1
ness
Between ENG (female) (37) and SEGR (female) (1)
(Disconnection in wiring or
a If power supply voltage in check on cause 2 is nordefective contact in connecmal, this check is not required.
Resistance
Max. 1
tor)
and, between ENG (female) (19) and SEGR (female)
Resistance
Max. 1
(4), (Sensor output)
Ground fault of wiring har- 2. Disconnect connectors ENG and SEGR, and connect T-adapter to female side of
ness
either of them.
(Contact with GND circuit) Between ENG (female) (19) and ground, or between
Resistance
Min. 1 M
SEGR (female) (3) and ground
Short circuit in wiring har- 2. Disconnect connectors ENG and SEGR, and connect T-adapter to female side of
either of them.
ness
Between ENG (female) (19) and (47), or between
Resistance
Min. 1 M
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
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)
(Since the failure is in it, troubleshooting cannot be performed.)
40-264
D375A-6
(01)
DRAFT
D375A-6
(01)
40-265
DRAFT
Failure code [CA2351] EGR Valve Sol Current High Error

Action code
E03
Detail of failure
Problem on
machine
Related information
q
q
q
Failure code
Short circuit in power supply line to EGR valve solenoid
Failure
CA2351
Short circuit was detected in the power supply line to EGR valve solenoid.
Cause
1
Defective EGR valve solenoid (internal disconnection)
Disconnection or short circuit

in wiring harness
Hot short (Short circuit with 24

V circuit) in wiring harness
40-266

equipment" in "Checks before troubleshooting" in "General information on troubleshooting" section, and check them directly.
2. Disconnect connector EGR and connect T-adapter to male side.
Between EGR (male) (1) and (2)
Resistance
10 - 21
Between EGR (male) (1) and ground
Resistance
Min. 1 M
2. Disconnect connector ENG and connect T-adapter to male side.
a If resistance is above 1 M, wiring harness is broken. If resistance is below 1 ,
wiring harness has short circuit.
Resistance
10 - 21
2. Disconnect connectors ENG and EGR, and connect T-adapter to female side of
either of them.
Between ENG (female) (22) and (11), or
Resistance
Min. 1 M
between EGR (female) (1) and (2)
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.
D375A-6
(01)
DRAFT
D375A-6
(01)
40-267
DRAFT
Failure code [CA2352] EGR Valve Sol Current Low Error

Action code
E03
Detail of failure
Problem on
machine
Related information
Failure code
CA2352
Disconnection error was detected in power supply line to EGR valve solenoid.
q
q


connector
Defective EGR valve sole2 noid (Internal disconnection)
Disconnection in wiring harness (Disconnection or

4
40-268
Disconnection in power supply line to EGR valve solenoid drive system

Cause
1
Failure

equipment" in "Checks before troubleshooting" in "General information on troubleshooting" section, and check them directly.
Between EGR (male) (1) and (2)
Resistance
10 - 21
a If resistance is above 1 M, wiring harness is broken. If resistance is below 1 , wiring harness has short circuit.
Resistance
10 - 21
2. Disconnect connectors ENG and EGR, and connect T-adapters to female side of
them.
ResisBetween ENG (female) (22) and EGR (female) (1)
Max. 1
tance
ResisBetween ENG (female) (11) and EGR (female) (2)
Max. 1
tance
If no abnormality is found by the above checks, engine controller may be defective.
D375A-6
(01)
DRAFT
D375A-6
(01)
40-269
DRAFT
Failure code [D110KB] Battery Relay: Drive Short Circuit

Action code
Detail of failure
Problem on
machine
Failure code
Short circuit in battery relay drive circuit
Failure
D110KB
Abnormal current flowed when outputting 24 V to battery relay primary circuit (coil side).
Stops 24 V output to battery relay primary circuit (coil side).
Problem may occur in data writing to ROM (nonvolatile memory) of each controller.
Output condition (voltage) to battery relay primary circuit (coil side) can be checked with monitoring
function.
(Code 60600: Battery relay drive voltage)
Method of reproducing failure code: Turn starting switch from ON to OFF.
Related information
q
Cause
Defective battery relay
1
(Internal short circuit)
Defective work equipment

controller
40-270

Between terminals SW and BRE
Continuity
2. Disconnect negative battery cable (in order not to make short circuit).
3. Disconnect cable from terminal BRE and disconnect connector WECN3.
Between terminal SW and ground
Resistance
Min. 1 M
q Reference: the following is standard value in normal condition.
Voltage
20 30 V
D375A-6
(01)
DRAFT
Circuit diagram related to battery relay
D375A-6
(01)
40-271
DRAFT
Failure code [D130KA] Neutral relay: Disconnection

Action code
E02
Detail of failure
Problem on
machine
Related information
Failure code
Open cricuit in neutral safety relay
Failure
D130KA
No voltage is applied to neutral safety relay primary circuit (coil side) when controller stopped
grounding.
Stops grounding to neutral safety relay primary circuit (coil side).
Output to neutral safety relay primary circuit (coil side) can be checked with monitoring function.
(Code: 40909 P/T controller SW output)
Method of reproducing failure code: Turn starting switch to ON position and operate parking brake
lever to Free position.
This failure code detects failure on primary side (coil side) of neutral safety relay, but not on secondary side (contact side).
If PTCN2 (8) has ground fault, engine can start even if PCCS lever is not set to Neutral position.
q
q
q
Cause
Defective neutral
safety relay
1
(Internal disconnection or short circuit)

2. Disconnect connector NSF and connect T-adapter to male side.
Between NSF (male) (1) and (2)
Resistance
200 400

Disconnection or short 2. Disconnect connectors PTCN2 and KEY, and connect T-adapters to female side of
them.
circuit in wiring hara
If resistance is above 1 M, wiring harness is broken. If resistance is below 1 , wiring
ness
harness has short circuit.
Between KEY (female) (1) and PTCN2 (female) (8)
Resistance 200 400
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
(Disconnection or
of them.
defective contact)
Between PTCN2 (female) (8) and NSF (female) (2)
Resistance
Max. 1
Between KEY (female) (1) and NSF (female) (1)
Resistance
Max. 1
Ground fault of wiring 1. Turn starting switch to OFF position.
harness
2. Disconnect connectors PTCN2 and NSF, and connect T-adapters to female side of
them.
circuit)
Between NSF (female) (2) or PTCN2 (female) (8) and ground Resistance
Min. 1 M
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.
controller
4. Operate parking brake lever and troubleshoot.
Lever: FREE
Voltage
20 30 V
Lever: LOCK
Voltage
Max. 1 V
40-272
D375A-6
(01)
DRAFT
Circuit diagram related to neutral safety relay
D375A-6
(01)
40-273
DRAFT
Failure code [D130KB] Neutral relay: Short circuit

Action code
E02
Detail of failure
Indication of
problem on
machine
Related information
Failure code
Short circuit in neutral safety relay
Failure
D130KB
Abnormal current flowed in neutral safety relay primary circuit (coil side) when controller grounded
neutral safety relay.
Stops grounding to neutral safety relay primary circuit (coil side).
Output to neutral safety relay primary circuit (coil side) can be checked with monitoring function.
Method of reproducing failure code: Turn the starting switch to ON position and operate parking
brake lever to LOCK position.
This failure code detects failure on primary side (coil side) of neutral safety relay, but not on secondary side (contact side).
q
q
Cause
Defective neutral safety
relay
1
or short circuit)
circuit in wiring harness

3
(Short circuit with 24 V
circuit)

controller
40-274

2. Disconnect connector NSF and connect T-adapter to male side.
Between NSF (male) (1) and (2)
Resistance
200 - 400

2. Disconnect connectors PTCN2 and KEY, and connect T-adapters to female side of
them.
a If resistance is above 1 M, wiring harness is broken. If resistance is below 1 , wiring
Resistance
200 - 400
2. Disconnect connectors PTCN2 and NSF, and connect T-adapter to female side of
PTCN2.
Between PTCN2 (female) (8) and ground
Voltage
Max. 1 V
q Reference: the following are standard values in normal condition.
Lever: FREE
Voltage
20 30 V
Lever: LOCK
Voltage
Max. 1 V
D375A-6
(01)
DRAFT
Circuit diagram related to neutral safety relay
D375A-6
(01)
40-275
DRAFT
Failure code [D161KA] Back-up alarm releay: Disconnection

Action code
E01
Failure
description
Indication of
problem on
machine
Related information
Failure code
Disconnection in Backup alarm relay
Trouble
D161KA
No voltage is applied to backup alarm relay primary circuit (coil side) when controller stopped grounding.
Stops grounding to backup alarm relay primary circuit (coil side).
Output condition to backup alarm relay primary circuit (coil side) can be checked with monitoring function.
Method of reproducing failure code: Turn starting switch to ON position and operate PCCS lever to
neutral.
This failure code detects failure on primary side (coil side) of backup alarm relay, but not in secondary
side (contact side).
If pin PTCN2(18) has ground fault, backup alarm keeps sounding.
q
q
q
Cause
1 Defective fuse FS22-5
Defective backup alarm
relay
2
(Internal disconnection or
short circuit)

If fuse FS22-5 is blown out, circuit probably has ground fault. In this case, perform
troubleshooting for cause 5 first.
2. Disconnect connector BKA and connect T-adapter to male side.
Between BKA (female)(1) and (2)
Resistance
200 400

Remove fuse FS22-5.
Disconnection or short cirDisconnect connector PTCN2 and connect T-adapter to female side.
If resistance is above 1 M, wiring harness is broken. If resistance is below 1 ,
wiring harness has short circuit.
Between PTCN2 (female) (18) and FS22-5
Resistance 200 400
ness
2. Disconnect connectors PTCN2 and BKA and connect T-adapters to each female
side.
contact)
Between PTCN2 (female) (18) and BKA (female) (2)
Resistance
Max. 1
Between FS22-5 and BKA (female) (1)
Resistance
Max. 1
Ground fault of wiring har- 2. Remove fuse FS22-5.
3. Disconnect connector PTCN2 and connect T-adapter to female side.
ness
Resistance
Min. 1 M
(Contact with ground circuit) Between BKA(female) (1) and ground
Between BKA (female) (2) or PTCN2 (female) (18) and
Resistance
Min. 1 M
ground
q Reference: the following is standard value in normal condition.
Defective power train con- 2. Insert T-adapter in connector PTCN2.
troller
4. Operate PCCS lever and perform troubleshooting.
Between PTCN2(18) and
N
Voltage
20 30 V
R(Reverse)
Voltage
Max. 1 V
chassis ground
40-276
1.
2.
3.
a
D375A-6
(01)
DRAFT
Circuit diagram related to back-up alarm relay
D375A-6
(01)
40-277
DRAFT
Failure code [D161KB] Back-up alarm releay: Short circuit

Action code
E01
Detail of failure
Indication of
problem on
machine
Related information
Failure code
Short circuit in backup alarm relay
Failure
D161KB
q Abnormal current flowed in backup alarm relay circuit when controller grounded backup alarm relay.
q
Stops grounding to backup alarm relay primary circuit.
Output condition to backup alarm relay can be checked by monitoring function.

(Code 40909: P/T control SW output)
Method of reproducing failure code: Turn starting switch to ON position and operate PCCS lever to
reverse.
This failure code detects failure on primary side (coil side) of backup alarm relay, but not on secondary side (contact side).
q
q
Cause
relay
1
short circuit)

2. Disconnect connector BKA and connect T-adapter to male side.
Between BKA (male) (1) and (2)
Resistance
300 - 600
1.
2.
3.
a

Disconnect fuse FS22-5.
Disconnection or short cirDisconnect
connector PTCN2 and connect T-adapter to female side.
2
If resistance is above1 M, wiring harness is broken. If resistance is below1 , wiring harness has short circuit.
Between PTCN2 (female) (18) and FS22-5
Resistance 300 - 600
2. Disconnect connectors PTCN2 and BKA and connect T-adapter to female side of
3
PTCN2.
Voltage
Max. 1 V
q Reference: the following are standard values in normal condition.
2. Insert T-adapter in connector PTCN2.
4
controller
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
(01)
40-279
DRAFT
Failure code [D182KZ] Preheater Relay Abnormality

Action code
E01
Detail of failure
Indication of
problem on
machine
Stops grounding to preheater relay primary circuit (coil side).
Auto preheater does not operate (or continues to preheat).

Preheater operates when it is turned ON manually.
q
q
Related information
Failure code
Preheater relay open or short circuit
Failure
D182KZ
Abnormal current flowed when preheater relay primary is grounded circuit (coil side) or no voltage
is applied when it is not grounded.
q
q
Output to preheater relay primary circuit (coil side) can be checked with monitoring function.
lever to free position.
This failure code detects failure on primary side (coil side) of preheater relay, but not on secondary
side (contact side).
Cause
Defective preheater
relay
1
(Internal disconnection or short circuit)

2. Disconnect connector PHR and connect T-adapter to male side.
Between PHR (male) (1) and (2)
Resistance
200 400

Disconnection or short 2. Disconnect connectors PTCN2 and KEY, and connect T-adapters to female side of
them.
circuit in wiring hara
If resistance is above 1 M, wiring harness is broken. If resistance is below 1 , wiring
ness
Resistance 200 400
ing harness
2. Disconnect connectors PTCN2, PHR and KEY, and connect T-adapters to female side
(Disconnection or
of them.
defective contact)
Between PTCN2 (female) (19) and PHR (female) (2)
Resistance
Max. 1
Between KEY (female) (1) and PHR (female) (1)
Resistance
Max. 1
2. Disconnect connectors PTCN2 and PHR, and connect T-adapters to female side of
harness
them.
Between PHR (female) (2) or PTCN2 (female) (19) and
circuit)
Resistance
Min. 1 M
ground
Hot short in wiring har2. Disconnect connectors PTCN2 and PHR, and connect T-adapter to PTCN2 female
ness
connector.
(Contact with 24 V cir3. Turn starting switch to ON position.
cuit)
Voltage
Max. 1 V
Defective power train 2. Insert T-adapter into connector PTCN2.
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
(01)
40-281
DRAFT
Failure code [D190KA] ACC signal relay: Disconnection

Action code
E00
Detail of failure
Problem on
machine
Related information
Failure code
ACC signal drive relay disconnection
Failure
D190KA
No voltage is applied to engine holding relay (EHL) primary circuit (coil side) when no grounding.
Stops grounding to engine holding relay (EHL) primary circuit (coil side).
Turbocharger timer does not function (if the turbocharger timer is installed).
Machine is not affected (if turbocharger timer is not installed).
Output to engine holding relay (EHL) primary circuit (coil side) can be checked with monitoring function. (Code: 40983 W/E controller SW output)
This failure code detects failure on primary side (coil side) of engine holding relay (EHL), but not on
secondary side (contact side).
If WECN2 (18) has ground fault, engine keeps running even if starting switch is turned to OFF position.
q
q
q
q
q
Cause
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
circuit)
Disconnection or short 2. Disconnect connectors WECN2 and KEY, and connect T-adapters to female side of
them.
2 circuit in wiring hara
If resistance is above 1 M, wiring harness has disconnection. If resistance is below
ness
Resistance 200 400
ing harness
2. Disconnect connectors WECN2, EHL and KEY, and connect T-adapters to female side
3
(Disconnection or
of them.
defective contact)
Between WECN2 (female) (8) and EHL (female) (2)
Resistance
Max. 1
Between KEY (female) (1) and EHL (female) (1)
Resistance
Max. 1
2. Disconnect connectors WECN2 and EHL, and connect T-adapters to female side of
harness
4
them.
Between EHL (female) (2) or WECN2 (female) (18) and
circuit)
Resistance
Min. 1 M
ground
ment controller
40-282
D375A-6
(01)
DRAFT
Circuit diagram related to ACC signal drive relay
D375A-6
(01)
40-283
DRAFT
Failure code [D190KB] ACC signal relay: Short circuit

Action code
E00
Detail of failure
Problem on
machine
Related information
Failure code
ACC signal drive relay short circuit
Failure
D190KB
No current flows when grounding to engine holding relay (EHL) primary circuit (coil side) or no voltage
is applied when no grounding.
Stops grounding to engine holding relay (EHL) primary circuit (coil side).
Turbocharger timer does not function (if the turbocharger timer is installed).
Machine is not affected (if turbocharger timer is not installed).
Output to engine shutoff delay relay (EHL) primary circuit (coil side) can be checked by monitoring
function.
(Code: 40983 W/E controller SW output)
This failure code detects failure on primary side (coil side) of engine shutoff delay relay (EHL), but not
q
q
q
q
Cause
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
circuit)
2. Disconnect connectors WECN2 and KEY, and connect T-adapters to female side of
them.
2
circuit in wiring harness a If resistance is above 1 M, wiring harness is broken. If resistance is below 1 , wiring
Resistance
200 400
Hot short in wiring har2. Disconnect connectors WECN2 and EHL, and connect T-adapter to female side of
ness
3
WECN2.
Turn
cuit)
Voltage
Max. 1 V
ment controller
40-284
D375A-6
(01)
DRAFT
Circuit diagram related to ACC signal drive relay
D375A-6
(01)
40-285
Failure code [D1EFKA] Pre lub. motor relay: Disconnection

Action code
Failure code
Failure
E02
Detail of failure
Problem on
machine
D1EFKA
No voltage is applied to pre-lubricating motor relay primary (coil side) circuit when grounding is cut
off.
Stops grounding to pre-lubricating motor relay primary circuit (coil side).
The pre-lubricating motor does not operate.

The engine does not start (engine starts if pre-lubrication is skipped).
Output to pre-lubricating motor relay primary circuit (coil side) can be checked with monitoring function. (Code: 40909 P/T controller SW Output)
This failure code detects failure on primary side (coil side) of pre-lubricating motor relay, but not on
If pin PTCN2 (9) has ground fault, pre-lubricating motor keeps running.
q
q
q
Cause
Pre-lubricating motor relay open circuit

Related information
40-286
Defective pre-lubri- 1. Turn starting switch to OFF position.

cating motor relay 2. Disconnect connector PLUB and connect T-adapter to male side.
1
(internal open cirBetween PLUB (male) (1) and (2)
Resistance 200 400 z
cuit or short circuit)
Open or short cir- 2. Disconnect connectors PTCN2 and KEY, and connect T-adapters to each female side.
a If resistance is above 1 Mz, wiring harness is broken. If resistance is below 1 z, wiring har2 cuit in wiring harness has short circuit.
ness
Resistance
200 400 z
a If cause item 2 is not the cause for the trouble, this check is not required.
Open circuit in wir- 1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN2, PLUB and KEY, and connect T-adapters to each female
ing harness
side.
3 (Wire breakage or
defective contact of Between PTCN2 (female) (9) and PLUB (female) (2)
Resistance
Max. 1 z
connector)
Between KEY (female) (1) and PLUB (female) (1)
Resistance
Max. 1 z
Ground fault in wir- 1. Turn starting switch to OFF position.
ing harness
2. Disconnect connectors PTCN2 and PLUB, and connect T-adapters to each female side.
4
(Contact with
Between PLUB (female) (2) or PTCN2 (female) (9) and ground
Resistance
Min. 1 Mz
ground circuit)
Defective power
5
When pre-lubricatrain controller
tion has been comVoltage
20 30 V
pleted
Pre-lubrication is in
Voltage
Max. 1 V
operation.
40-286
D375A-6
(06)
DRAFT
Circuit diagram related to pre-lubricating motor relay
D375A-6
(01)
40-287
DRAFT
Failure code [D1EFKB] Pre lub. motor relay: Short circuit

Action code
E02
Detail of failure
Problem on
machine
Related information
Failure code
Pre-lubricating motor relay disconnection
Failure
D1EFKB
No current flows when grounding to pre-lubricating motor relay primary (coil side) circuit or no voltage
is applied when no grounding.
Stops grounding to pre-lubricating motor relay primary circuit (coil side).
Pre-lubricating motor does not operate.

Engine does not start (engine starts if pre-lubrication is skipped).
Output to pre-lubricating motor relay primary circuit (coil side) can be checked with monitoring function. (Code: 40909 P/T controller SW output)
This failure code detects failure on primary side (coil side) of pre-lubricating motor relay, but not on
q
q
q
q
Cause
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
or short circuit)
2. Disconnect connectors PTCN2 and KEY, and connect T-adapters to female side of
them.
2
circuit in wiring harness a If resistance is above 1 M, wiring harness is broken. If resistance is below 1 , wiring
Resistance
200 400
Hot short in wiring har2. Disconnect connectors PTCN2 and PLUB, and connect T-adapter to female side of
ness
3
PTCN2.
Turn
cuit)
Voltage
Max. 1 V
Defective power train 3. Turn starting switch to ON position.
4
controller
When pre-lubrication has been
Voltage
20 30 V
completed
During pre-lubriVoltage
Max. 1 V
cation
40-288
D375A-6
(01)
DRAFT
Circuit diagram related to pre-lubricating motor relay
D375A-6
(01)
40-289
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

by power train controller)
DAFRKR
Power train controller cannot recognize machine monitor with CAN communication circuit.
System may not operate properly.

Once machine is stopped, engine speed is limited to half of full speed.
Start of CAN communication is notified to each controller by ACC signal from starting switch.
Failure code is displayed on machine monitor by CAN communication. Accordingly, if CAN communication of machine monitor fails, code [DAFRKR] is not displayed on machine monitor and it can be
observed only through KOMTRAX system.
Since each controller and machine monitor receive power from battery directly, they are kept ON
even while starting switch is OFF.
Since CAN communication signal is pulse voltage, it cannot be measured with multimeter.
Failure
E03
Detail of failure
Problem on
machine
q
q
q
q
q
Related information
q
q
Cause
1
Perform troubleshooting for E mode, "E-3".
to machine monitor
Defective CAN commu2
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

by work equipment controller)
dAFRKR
Work equipment controller cannot recognize machine monitor with CAN communication circuit.

Failure code is displayed on machine monitor by CAN communication. Accordingly, if CAN communication of machine monitor fails, code [dAFRKR] is not displayed on machine monitor and it can be
observed only through KOMTRAX system.
Failure
E03
Detail of failure
Problem on
machine
q
q
q
q
q
Related information
q
q
Cause
1
Perform troubleshooting for E mode, "E-3".
to machine monitor
Defective CAN commu2
Perform troubleshooting for failure code [DAFRMC], cause 10 and after.
nication
D375A-6
(01)
40-291
Failure code [DAFRMC] CAN Discon (Monitor Detected)

Action code
Failure code
Failure
E03
Detail of failure
Problem on
machine
DAFRMC
q
q
q
q
q
q
q
q
q
Related information
q
q
q
40-293
CAN communication is impossible (Machine monitor Detected)

Machine monitor cannot recognize power train controller, work equipment controller or VHMS controller in CAN communication.
If cause of failure disappears, machine monitor returns to normal status.
Once machine is stopped, engine speed is limited to medium (half) speed.
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, there can not be ground fault,
short circuit and hot short circuit in wiring harness (CAN communication line).
If failurecode [DB2RKR] is also displayed, problem with engine controller, cause items 1 to 6, will
be the most probable cause of the failure.
The CAN communication line signal in operation is pulse voltage, so it cannot be measured by using multimeter.
Cause
Defective engine
1 controller circuit
breaker (CB7)
Defective engine
2 controller (Internal
short circuit)

If circuit breaker trips, controller probably has short circuit in it.
a
1.
2.
a
a
If circuit breaker does not trip, this check is not required.

Disconnect connectors EGC3 and connect T-adapter to male side.
Measured value: approx. 9 20 kz
If measured value is below 10 z, engine controller is defective (internal short circuit).
Between EGC3 (male) (3) and (1)
Defective power
3 supply to engine
controller
1.
2.
3.
a
Resistance
Max. 10 z

Disconnect connectors EGC3 and connect T-adapter to female side.
If circuit breaker has tripped, reset it.
If result is abnormal, perform troubleshooting for [CA111].
Between EGC3 (female) (3) and (1) or ground
Voltage
20 30 V
Voltage
20 30 V

Broken engine con- 2. Remove the fuse in fuse box FS32-5.
4
troller ACC fuse
If fuse has blown out, the circuit probably has ground fault. In this case, perform troubleshooting for cause 14 first.
Defective ACC cut5 out relay drive (for If failure code [7RFAKA] or [7RFAKB] is also displayed, perform troubleshooting for it first.
engine controller)
40-292
D375A-6
(06)
Cause
10
Defective ACC cutout relay (for engine

controller) (Internal
disconnection or
short circuit)
Defective power
supply to power
train controller
Defective power
supply to work
equipment controller
Defective power
supply to VHMS
controller
Defective CAN terminating resistor
(Internal open or
short circuit in wiring)

2. Replace ACC cutout relay (connector ACT) with another relay (backup alarm relay;
connector BKA, etc.)
If this failure code goes off, original ACC cutout relay (for engine controller) is defective.
If failure code [DBERKR] or [DBBQKR] is also displayed, perform troubleshooting for failure
code [DBE1KK] or [DBE2KK] first.
If failure code [DB9RKR] is also displayed, perform troubleshooting for failure code
[DB91KK] and [DB92KK] first.
Perform troubleshooting for failure codes [DBB0KK] and [DBB3KK].

2. Disconnect connectors CT2 and CM02 and connect T-adapters to male side of them.
Between CT2 (male) (A) and (B)
Resistance
120 12 z
Between CM02 (male) (8) and (10)
Resistance
120 12 z
1.
2.
a
Open or short cir11 cuit in wiring harness
CAN communication line

There is 120 z CAN terminating resistor inside machine monitor, too. Since120 z resistor
is connected in parallel, if resistance measured at connector of controller other than machine monitor is 60 z which is combined resistance, there is no open circuit in writing harness.
Turn starting switch to OFF position and disconnect ground cable.
Disconnect one of following connectors EGC2, PTCN2, WECN2, V4A, CT2 and CM02 and
connect T-adapter to female side of that connector.
If connector has short circuit (Resistance between terminals is1 z or less), disconnect all
of EGC2, PTCN2, WECN2, V4A and CM02 and check again to see if there is short circuit
between wiring harnesses or in controller.
Resistance Approx. 60 z
Between PTCN2 (female) (32) and (22)
Between WECN2 (female) (32) and (22)
Between V4A (female) (12) and (4)
Between CT2 (female) (A) and (B)
Resistance
Between CM02 (female) (9) and (10)
Resistance
Approx.
120 z
Approx.
120 z
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)/(8)
Resistance
Max. 1 z
Between PTCN2 (female) (22) and CM02 (female) (10)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Between PTCN2 (female) (32) and V4A (female) (4)
Resistance
Max. 1 z
Resistance
Max. 1 z
Between EGC2 (female) (46) and CT2 (female) (A)
Resistance
Max. 1 z
Between EGC2 (female) (47) and CT2 (female) (B)
Resistance
Max. 1 z
Open circuit in wir- Between PTCN2 (female) (32) and EGC2 (female) (46)
ing harness
12 (wire breakage or Between PTCN2 (female) (22) and EGC2 (female) (47)
defective contact of Between PTCN2 (female) (32) and WECN2 (female) (32)
connector)
Between PTCN2 (female) (22) and WECN2 (female) (22)
D375A-6
(06)
40-293
Cause

q ACC signal from starting switch
2. Insert T-adapters into connectors PTCN3, WECN3, V1, CM01, ACT and EGC2.
3. Connect the ground cable and turn the starting switch to ON position.
Open circuit in wir- Between PTCN3 (14) or (24) and (31)

ing harness
13 (wire breakage or Between WECN3 (14) or (24) and (31)
defective contact of Between V1 (17) and (19)
connector)
Between CM01 (14) and (3)
Voltage
20 30 V
Voltage
20 30 V
Voltage
20 30 V
Voltage
20 30 V
Between ACT(1), (3) and ground
Voltage
20 30 V
Between EGC2 (39) and ground
Voltage
20 30 V
q CAN communication line

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 open cricuit), measure at only 1 place.
2. Disconnect connectors PTCN2, WECN2, V4A, CM02 and EGC2, and connect T-adapters
to either female side.
Between PTCN2 (female) (32), WECN2 (female) (32), V4A
(female) (4), CM02 (female) (8), (9) or EGC2 (female) (46) and
Resistance
Min. 1 Mz
ground
Ground fault in wiring harness (Con- Between PTCN2 (female) (22) , WECN2 (female) (22), V4A
14
(female) (12), CM02 (female) (10) or EGC2 (female) (47) and
Resistance
Min. 1 Mz
tact with ground
ground
circuit)
2. Disconnect connectors PTCN3, WECN3, V1, CM01 and ACT, and connect T-adapters to
either female side.
3. Disconnect connectors EGC2 and connect T-adapter to female side.
Short circuit or hot

short circuit in wir15 ing harness
(Contact with 24 V
circuit)
Between PTCN3 (female) (14), (24), WECN3 (female) (14), (24),

V1 (female) (17) or CM01 (female) (14) and ground
Resistance
Min. 1 Mz
Between EGC2 (female) (39) and ground
Resistance
Min. 1 Mz
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.
3. Connect ground strap.
a Since voltages of CAN H and CAN L are 2.5 1 V even while communication is continued,
they are judged to be normal if they are 1 - 4 V.
Between PTCN2 (32), WECN2 (32), V4A (4), CM02 (8), (9) or
Voltage
14V
EGC2(46) and ground
Between PTCN2 (22), WECN2 (22), V4A(12), CM02( 10), or
EGC2 (47) and ground
40-294
Voltage
14V
D375A-6
(06)
Cause
If cause is not found by above checks and another failure code related to CAN communication such as [DB2RKR] is not displayed, identify which controller is defective according to following procedure.
q Step 1
2. Disconnect engine controller (connector EGC2).
Defective
NO
power train
controller
Is failure code [DB2RKR] displayed?
Defective
YES
engine controller
Defective
work equipNO
ment controlDefective engine
Is failure code [dB2RKR] displayed?
ler
controller, power
Defective
train controller, work
YES
engine con16
equipment controltroller
ler or VHMS conq Step 2
troller
2. Disconnect power train controller (connector PTCN2).
Defective
work equipNO
ment controlIs failure code [DBERKR] displayed?
ler
Defective
YES
power train
controller
Defective
NO
VHMS controller
Is failure code [DBBQKR] displayed?
Defective
YES
power train
controller
Defective machine If Failure is not found by above checks, machine monitor is defective.
17
monitor
D375A-6
(06)
40-295
DRAFT
Circuit diagram related to CAN
40-296
D375A-6
(01)
Failure code [DB2RKR] ENG cont.: Can communication lost (PT)

Action code
Failure code
Failure
E03
DB2RKR
40-298
CAN communication with engine controller is impossible.

(detected by power train controller)
Detail of failure
Power train controller cannot recognize engine controller in CAN communication.

Once machine stops, engine speed is limited to half of full speed.
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.
That is, there cannot be short circuit, ground fault or hot short circuit in CAN communication line.
If failure code [DAFRMC] is also displayed, cause of this failure is probably engine controller problem in cause1 and 2.
Since each controller and machine monitor receive power from battery directly, they have power
Since CAN communication line signal is pulse voltage, it cannot be measured with multimeter.
Problem on
machine
q
q
q
q
q
Related information
q
q
q
Cause
1
circuit breaker (CB7)


If circuit breaker is turned OFF, controller probably has short circuit in it.
a
1.
2.
a
a
If circuit breaker has tripped, this check is not required.

Disconnect connectors EGC3 and connect T-adapter to male side.
Measured value: approximately 9-20 kz
If measured value is below 10 z, engine controller is defective (internal short circuit).
Between EGC3 (male) (3) and (1)
Defective power supply to

engine controller
Broken engine controller

ACC fuse
Defective ACC cutout relay

(for engine controller) drive
Defective ACC cutout relay

(for engine controller)
6
(internal open circuit or short
circuit)
Defective CAN terminating

7 resistor (Internal open or
short circuit)
D375A-6
(06)
1.
2.
3.
a
Resistance
Max. 10 z

Disconnect connectors EGC3 and connect T-adapter to female side.
If circuit breaker has tripped, reset it.
If result is abnormal, perform troubleshooting for [CA111].
Voltage
20 30 V
Voltage
20 30 V

2. Remove the fuse in fuse box FS32-5.
If fuse has blown out, the circuit probably has ground fault. In this case, perform troubleshooting for cause item 11 first.
If failure code [7RFAKA] or [7RFAKB] is also displayed, perform troubleshooting for
it first.
2. Replace ACC cutout relay (connector ACT) with another relay (backup alarm
relay; connector BKA, etc.)
3. Turn starting switch to ON position .
If this failure code goes off, original ACC cutout relay (for engine controller) is defective.
2. Disconnect connectors CT2 and CM02 and connect T-adapters to male side of
them.
Resistance
120 12 z
Resistance
120 12 z
40-297
Cause
Open or short cir8 cuit in wiring harness

a There is 120 z CAN terminating resistor inside machine monitor, too. Since 120 z resistor
is connected in parallel, if resistance measured at connector of controller other than machine monitor is 60 z which is combined resistance, there is no open circuit in writing harness.
1. Turn starting switch to OFF position and disconnect ground cable.
2. Disconnect one of following connectors EGC2, PTCN2, WECN2, V4A, CT2 and CM02 and
connect T-adapter to female side of that connector.
a If connector has short circuit (Resistance between terminals is1 z or less), disconnect all
of EGC2, PTCN2, WECN2, V4A and CM02 and check again to see if there is short circuit
between wiring harnesses or in controller.
Resistance
Approx. 60 z
Resistance
Approx. 60 z
Resistance
Approx. 60 z
Resistance
Approx. 120 z

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-adapters to female side of them.
Between PTCN2 (female) (32) and CM02 (female) (9)/(8)
Resistance
Max. 1 z
Identifying open circuit in wiring harness (Wire
9
breakage or defective contact of connector)
Resistance
Max. 1 z
Between PTCN2 (female) (32) and EGC2 (female) (46)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z

Resistance
Max. 1 z
Open circuit in wir- 3. Connect the ground cable and turn the starting switch to ON position.
Between PTCN3 (14) or (24) and (31)
Voltage
20 30 V
ing harness
10 (wire breakage or Between WECN3 (14) or (24) and (31)
defective contact of Between V1 (17) and (19)
connector)
Voltage
20 30 V
Voltage
20 30 V
Voltage
20 30 V
Voltage
20 30 V

Voltage
20 30 V
Ground fault in wir- 2. Disconnect connectors PTCN3, WECN3, V1, CM01 and ACT, and connect T-adapters to
either female side.
ing harness (Con11
3. Disconnect connectors EGC2 and connect T-adapter to female side.
tact with ground
Between PTCN3 (female) (14), (24), WECN3 (female) (14),
circuit)
Resistance
Min. 1 Mz
(24), V1 (female) (17) or CM01 (female) (14) and ground
12
Defective engine
controller
13
Defective power
train controller
40-298
Resistance
Min. 1 Mz
If cause is not found by above checks and failure code [DAFRMC] is displayed, engine controller is defective.
D375A-6
(06)
DRAFT
D375A-6
(01)
40-299
DRAFT
Failure code [dB2RKR] ENG controller: CAN communication lost (WE)
Failure code [dB2RKR] ENG controller: CAN communication lost (WE)

Action code
Failure code
E03
Detail of failure
Problem on
machine
q
q
Limits operation of engine, transmission, and fan.

Method of reproducing failure code: Turn starting switch ON.
[dB2RKR] is displayed on machine monitor, CAN communication between work equipment controller and machine monitor is normal.
That is, there cannot be short circuit, ground fault or hot short in CAN communication line.
If failure code [DAFRMC] is also displayed, cause of this failure is probably engine controller problem.
q
q
q
q
q
Related information
q
q
q
Cause
40-300
CAN communication with engine controller is impossible (detected by work

equipment controller)
dB2RKR
Work equipment controller cannot recognize engine controller in CAN communication circuit.
Failure

Perform troubleshooting for failure code [DB2RKR].
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
Detail of failure q Information in ROM (non-volatile memory) in work equipment controller is abnormal.
Action of conq 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 inforq Method of reproducing failure code: Turn starting switch ON.
mation
Cause

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
(01)
40-301
DRAFT
Failure code [DB91KK] WE controller: Source voltage reduction

Action code
E04
Detail of failure
Problem on
machine
Failure code
Battery direct voltage drop of work equipment controller
Failure
DB91KK
The battery direct power supply voltage for work equipment controller is below 17 V.
Limits operation of engine, transmission, brake and work equipment.
Machine monitor may not display properly.

Relay and solenoid may not be actuated and therefore, system may not operate properly.
Main power source voltage for work equipment controller can be checked in adjusting function.
(Code 2022: Work equipment controller voltage check mode)
q
q
q
Related information
q
q
Cause
Trip of circuit breaker
1
(CB30)

If circuit breaker has tripped, circuit probably has ground fault. In this case, perform troubleshooting for cause 7 first.
If fuse FS12-4 is blown out, circuit probably has ground fault. In this case, perform trouble2 Defective fuse FS12-4
shooting for cause 7 first.
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.
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
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
defective contact)
Between WECN3 (female) (21), (31), (32) or (33) and
Resistance
Max. 1
ground
a Check terminal GND01 for looseness and rust.
Between WECN3 (female) (1) or (11) and battery (+)
Resistance
Max. 1
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)
Resistance
Min. 1 M
Resistance
Min. 1 M
q Reference: the followings are standard values in normal condition.
Defective work equip- 2. Disconnect ground strap.
8
ment controller
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
(01)
40-303
DRAFT
Failure code [DB92KK] WE controller: Output voltage reduction

Action code
Failure code
E04
Detail of failure
Indication of
problem on
machine
Related information
Voltage drop in power supply for work equipment controller-related

actuators
DB92KK
Power supply (battery relay output) voltage for the actuators related to work equipment controller (relay, solenoid or others) is below 17 V.
Failure
Limits operation of engine, transmission, brake and work equipment.
Power source voltage of work equipment controller can be checked in adjusting function.
(Code 2022: Work equipment controller voltage check mode)
q
q
q
q
Cause
1
CB3 or CB105
Loose terminal or dis2
connection at terminal
Improper battery volt3
age

If CB3 or CB105 circuit breaker has tripped, circuit probably has ground fault. In this case,
perform troubleshooting for cause 6 first.
Check terminals of battery, battery relay, etc.
1. Perform troubleshooting with starting switch at OFF and when starting engine.
Voltage
20 30 V
Defective wiring har4. Connect ground strap.
ness or power train
controller
Between WECN3 (2) and (21)
Voltage
20 30 V
Voltage
20 30 V
Voltage
20 30 V
Disconnection in wir- 2. Disconnect ground strap (in order not to make short circuit).
ing harness
Between ground and WECN3 (female) (21)/(31)/(32)/
(Disconnection or
(33) respectively
Resistance
Max. 1
defective contact)
Between terminal BRC and WECN3 (female)
Resistance
Max. 1
(2)/(12)/(22) respectively
harness
2. Disconnect ground strap (in orde not to make short circuit).
(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 M
Defective work equipIf 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
(01)
40-305
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
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 conq 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
are not affected).
machine
Related inforq Method of reproducing failure code: Turn the starting switch to ON position
mation
Cause

2. Disconnect connector HHP.
Defective hydraulic pump 3. Turn starting switch to ON position.
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 disconnected. Ignore failure codes other than [DB97KK].
Ground fault of wiring har2. Disconnect connectors WECN3 and HHP, and connect T-adapter to female side of
ness
either one of them.
(Contact with ground cirBetween WECN3 (female) (34) or HHP (female) (B) and Resiscuit)
Min. 1 M
ground
tance
Short circuit in wiring har- 2. Disconnect connector HHP and connect T-adapter to female side.
ness
Between HHP (female) (B) and (A)
Voltage
4.5 5.5 V
Defective work equipment 2. Insert T-adapters into connectors WECN1 and WECN3.
controller
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
(01)
40-307
DRAFT
Failure code [DB99KQ] WE controller: Type select signal
Failure code [DB99KQ] WE controller: Type select signal

Action code
E04
Failure code
Machine model selection error on work equipment
Failure
DB99KQ
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
q Once machine is stopped, engine speed is limited to half of full speed.
machine
q Once machine stops, it cannot travel at all.
mation
Causes
1
40-308

Use adjustment function in service mode, and perform operation of reproducing trouble. If E of failure code disappears at this time, system function is proper.
q Adjustment code: 0031 (Initial setting of work equipment controller)
D375A-6
(01)
DRAFT
Failure code [DB9RKR] WE controller: Can communication lost (PT)

Action code
Failure code
CAN communication with work equipment controller (detected

power train controller)
DB9RKR
Power train controller cannot recognize work equipment controller in CAN communication circuit.

[DB9RKR] is displayed on the machine monitor, CAN communication between power train controller
and machine monitor is normal. That is, there cannot be short circuit, ground fault or hot short in CAN
communication line.
Failure
E03
Detail of failure
Problem on
machine
q
q
q
q
q
Related information
q
q
Cause
1

If failure code [DAFRMC] is also displayed, perform troubleshooting for failure code
[DB91KK] and [DB92KK] first.
Defective CAN terminating
resistor
2
them.
Resistance
120 12
short circuit)
Resistance
120 12
a There is 120 CAN terminating resistor inside machine monitor, too. Since 120
resistor is connected in parallel, if resistance measured at connector of controller
other than machine monitor is 60 which is combined resistance, wiring harness is
not open cricuited.
2. Disconnect one of following connectors EGC2, PTCN2, WECN2, V4A, CT2 and
CM02 and connect T-adapter to female side of that connector.
Disconnection or short cir3
a
If connector has short circuit (Resistance between terminals is1 or less), disconcuit in wiring harness
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.
Resistance
Approx. 60
Resistance
Approx. 60
Resistance
Approx. 60
Resistance
Approx. 60
Resistance
Approx. 120
Between CM02 (female ) (9) and (10)
Resistance
Approx. 120
D375A-6
(01)
40-309
Cause

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)
Resistance
Max. 1 z
(9)/(8)
Resistance
Max. 1 z

Open circuit in wiring harBetween PTCN2 (female) (22) and EGC2 (female) (47)
ness
4
(wire breakage or defective Between PTCN2 (female) (32) and WECN2 (female)
(32)
Between PTCN2 (female) (22) and WECN2 (female)
(22)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
ACC signal from starting switch

Between WECN3 (14) or (24) and (31)
5
Between V1 (17) and (19)
Voltage
20 30 V
Voltage
20 30 V
Voltage
20 30 V
Voltage
20 30 V
Voltage
20 30 V
Voltage
20 30 V

2. Disconnect connectors PTCN3, WECN3, V1, CM01 and ACT, and connect
T-adapters to either female side.
Ground fault in wiring har3. Disconnect connectors EGC2 and connect T-adapter to female side.
6 ness
(Contact with ground circuit) Between PTCN3 (female) (14), (24), WECN3 (female)
(14), (24), V1 (female) (17) or CM01 (female) (14) and
Resistance
Min. 1 Mz
ground
7

controller
40-310
Resistance
Min. 1 Mz
If cause is not found by above checks and failure code [DAFRMC] is displayed, work
equipment controller is defective.
D375A-6
(06)
DRAFT
D375A-6
(01)
40-311
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.
troller
Problem on
q System may not operate properly.
machine
Related inforq VHMS controller LED displays "n9" o "C01".
mation
Cause
1
(CB105)
2
3
4

If circuit breaker has tripped, circuit probably has ground fault. In this case, perform
If fuse FS12-5 is blown out, circuit probably has ground fault. In this case, perform
Defective fuse FS12-5
Loose terminal or discon- 1. Turn starting switch to OFF position.
nection at terminal
Check terminals of battery, battery relay, TR1S, TR2L, etc.
Improper battery voltage
2. Perform troubleshooting when engine is cranked.
Voltage
20 30 V
3. Disconnect connector V1 and connect T-adapter to female side.
Disconnection in, or ground 5. If circuit breaker has tripped, reset it.
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
harness
(Disconnection or defec5. Disconnect connector V1 and connect T-adapter to female side.
tive contact)
Between V1 (female) (11)/(12)/(19)/(20) and ground
ResisMax. 1
a Check terminal GND01 for looseness and rusting.
tance
ResisBetween V1 (female) (8)/(9) and battery relay BRC terminal
Max. 1
tance
Ground fault of wiring har- 3. If fuse is blown out, replace it.
ness
(Contact with ground cir5. Disconnect connector V1 and connect T-adapter to female side.
cuit)
ResisBetween V1 (female) (8) and (11)/(20)
Min. 1 M
tance
ResisBetween V1(female)(9) and ground
Min. 1 M
tance
Defective VHMS controller 3. Insert T-adapter in connector V1.
Between V1(8) and (11)/(12)
Voltage
20 30 V
Voltage
20 30 V
40-312
D375A-6
(01)
DRAFT
Circuit diagram related to power supply for VHMS controller
D375A-6
(01)
40-313
DRAFT
Failure code [DBB0KQ] VHMS connector connection abnormality

Action code
Detail of failure
Problem on
machine
Related information
Failure code
VHMS connector connection abnormality
Failure
DBB0KQ
(VHMS controller system)
q Incorrect connection of connector V2A, V2B, V3A or V3B of VHMS controller
q
None in particular.
Sensor signal value may not be indicated properly.
VHMS controller LED displays "n9" o "05".
Cause
Wrong connector connec1
tion
40-314

Check if connectors "V2A" and "V3A" as well as connectors "V2B" and "V3B" of VHMS
controller are connected incorrectly.
D375A-6
(01)
DRAFT
D375A-6
(01)
40-315
DRAFT
Failure code [DBB3KK] VHMS controller: Source voltage reduction

Action code
Detail of failure
Problem on
machine
Related information
Failure code
Voltage drop in unswithed power supply to VHMS controller
Failure
DBB3KK
q 24 V power supply voltage from battery to VHMS controller is below 12.5 V.
q
None in particular.
VHMS does not operate.
Cause
1
(CB30)
Loose terminal
3 or disconnection at terminal
4 Improper battery voltage

If circuit breaker has tripped, circuit probably has ground fault. In this case, perform
If fuse FS12-4 is blown out, circuit probably has ground fault. In this case, perform troubleshooting for cause 6 first.
1. Turn starting switch OFF, then carry out troubleshooting.
2. When starting engine.
Voltage
20 30 V

5
Between V1 (female) (6) and (11)/(12)
Voltage
20 30 V

Voltage
20 30 V
3. If fuse is blown out, replace it.
harness
6
(Disconnection or defec5. Disconnect connector V1 and connect T-adapter to female side.
tive contact)
Between V1 (female) (11)/(12)/(19)/(20) and ground
Resistance Max. 1
a Check terminal GND0I for looseness and rust.
Between V1 (female) (6), (7) and battery (+)
Resistance Max. 1
Ground fault of wiring har- 2. Disconnect ground strap.
3. If fuse is broken, replace it.
ness
7
(Contact with ground cir4. If circuit breaker is turned OFF, reset it.
cuit)
Voltage
Min. 1 M
Between V1(female)(7) and ground
Voltage
Min. 1 M
8 Defective VHMS controller
3. Insert T-adapter in connector V1.
Voltage
20 30 V
Voltage
20 30 V
40-316
D375A-6
(01)
DRAFT
Circuit diagram related to power supply for VHMS controller
D375A-6
(01)
40-317
DRAFT
Failure code [DBB5KP] VHMS: Output sensor1 voltage reduction

Action code
E00
Failure code
VHMS sensor 5 V power supply abnormality
Failure
DBB5KP
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.
troller
Problem on
q A part of VHMS does not operate.
machine
Related inforq VHMS controller LED displays "N9" o "04".
mation
Cause

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.
a Other failure codes are displayed, too. This is because the connector is disconnected. Ignore failure codes other than [DBB5KP].
Ground fault of wiring har2. Disconnect connectors V1 and ENBP, and connect T-adapter to female side of
ness
2
either one of them.
(Contact with ground cirResiscuit)
Between V1 (female) (4) or ENBP (female) (B) and ground
Min. 1 M
tance
2. Disconnect connector ENBP and connect T-adapter to female side.
3
(Contact with 24 V circuit) 3. Turn starting switch to ON position.
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.

Reference: The following are standard values in normal condition.
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
connector V1 disconnected.
q
40-318
Between V1(4) and V2A(12)
Voltage
4.5 5.5 V
Between V1(4) and V2A(12)
Voltage
4.5 5.5 V
D375A-6
(01)
DRAFT
Circuit diagram related to power supply for VHMS controller sensors 5V
D375A-6
(01)
40-319
DRAFT
Failure code [DBB6KP] VHMS:Output sensor2 voltage reduction

Action code
Failure code
Failure
DBB6KP
24 V power supply circuit voltage from VHMS controller to sensors is above normal range (20 V - 30
V).
Abnormal current flowed in 24 V sensor power supply circuit to VHMS controller.
None in particular.
Sensor input value to controller may not be obtained correctly.
Detail of failure
Problem on
machine
Related information
Cause

Defective transmission main oil pressure 2. Disconnect following connectors one by one and turn starting switch to ON position each
time.
sensor, front (cylinder
3.
After
troubleshooting, return to 1.
Nos. 1 - 3) exhaust
q If this code is not displayed when a sensor or a device is disconnected, that sensor or
temperature sensor,
device is defective.
rear (cylinder Nos. 4 a Other failure codes are displayed, too. This is because the connector is disconnected.
1 6) exhaust temperaIgnore failure codes other than [DBB6KP].
ture sensor, front
Device or sensor
Connector
exhaust temperature
TMMD
sensor amplifier or rear Transmission main oil pressure sensor
Front
(cylinder
Nos.
1
3)
exhaust
temperature
sensor
EXHF
exhaust temperature
Rear
(cylinder
No.
4
6)
exhaust
temperature
sensor
EXHR
sensor amplifier (InterFront 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
Resistance
Min. 1 M
Ground fault of wiring ground
Between EXHF (female) (1) and (2), or between EXTF
harness
Resistance
Min. 1 M
2
(Contact with ground (male) (1) and (2)
Between EXHR (female) (1) or EXTR (male) (1) and
circuit)
Resistance
Min. 1 M
ground
Between EXHR (female) (1) and (2), or between EXTR
Resistance
Min. 1 M
(male) (1) and (2)
Between V1 (female) (2) and ground
Resistance
Min. 1 M
Between V1 (female) (2) and V2A (female) (12)/(13)
Resistance
Min. 1 M
q Reference; The following are standard values in normal condition.
Defective VHMS con- 2. Insert T-adapter into connectors V1 and V2A.
3
troller
a Since 24 V power is supplied to connector V1, 24 V output cannot be checked with connector 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
(01)
40-321
DRAFT

Action code
Failure code
Failure
DBB7KP
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.
troller
Problem on
q When downloading from VHMS controller, LED (Download light) does not light up.
machine
Related inforq VHMS controller LED displays "N9" o "03".
mation
Cause
Defective download LED

(Internal defect)

2. Disconnect connector DLT.
q If this code is not displayed, download LED is defective.
a Other failure codes are displayed, too. This is because the connector is disconnected. Ignore failure codes other than [DBB7KP].

Ground fault of wiring har2. Disconnect connectors V1 and DLT, and connect T-adapter to female side of either
ness
2
one of them.
(Contact with ground cirResiscuit)
Between V1 (female) (3) or DLT (female) (1) and ground
Min. 1 M
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

(detected by VHMS controller)
DBBQKR
VHMS controller cannot recognize engine controller, power train controller, work equipment controller, and machine monitor in CAN communication.
Failure
E00
Detail of failure
Problem on
machine
Related information
None in particular.
VHMS function to collect information from other controllers does not work.
VHMS controller LED panel displays "n8" o "02".
Cause

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
Detail of failure q Information in ROM (non-volatile memory) in power train controller is abnormal.
Action of conq 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.
mation
Cause

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
(01)
40-323
DRAFT
Failure code [DBE1KK] PT controller: Source voltage reduction

Action code
E04
Detail of failure
Problem on
machine
Failure code
Battery direct power supply voltage drop for power train controller
Failure
DBE1KK
The voltage of battery direct power supply to power train controller is below 17 V.
Machine monitor may not display correctly.

Power source voltage of power train controller can be checked by adjusting function.
(Code 2021: Power train controller voltage check mode)
q
q
q
Related information
q
q
Cause
1
(CB30)
2
3
4

If circuit breaker has tripped, circuit probably has ground fault. In this case, perform troubleshooting for cause 7 first.
If fuse FS12-4 is blown out, circuit probably has ground fault. In this case, perform troubleDefective fuse FS12-4
shooting for cause 7 first.
Loose terminal,
or disconnection at terCheck terminals of battery, battery relay, etc.
minal
Improper battery volt- 1. Perform troubleshooting with starting switch at OFF and when starting engine.
age
Voltage
20 30 V
ground fault of wiring 4. Connect ground strap.
harness
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
(Disconnection or
defective contact)
Between PTCN3 (female) (21)/(31)/(32)/(33) and
ground
Resistance
Max. 1
Between PTCN3 (female) (1)/(11) and battery (+)
Resistance
Max. 1
Ground fault of wiring 2. Disconnect ground strap.
harness
3. If fuse is blown out, replace it.
circuit)
Between PTCN3 (female) (1) and (21)/(31)
Resistance
Min. 1 M
Between PTCN3 (female) (11) and (32)/(33)
Resistance
Min. 1 M
Defective power train 2. Disconnect ground strap.
controller
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
(01)
40-325
DRAFT
Failure code [DBE2KK] PT controller: Output voltage reduction

Action code
Failure code
E04
Detail of failure
Problem on
machine
Related information
Voltage drop in power supply for power train controller-related actuators

DBE2KK
Power supply (battery relay output) voltage for the actuators related to power train controller (relay,
solenoid or others) is below 17 V.
Failure
Limits operation of engine, transmission and brake.
Relay and solenoid may not drive be actuated and therefore, system may not operate properly.
Main power source voltage of power train controller can be checked by adjusting function.
(Code 2021: Power train controller voltage check mode)
If battery relay is not turned ON, see E-mode, E-1.
q
q
q
q
q
Cause
1
CB1 or CB105
Loose terminal,
2 or disconnection at terminal
Improper battery volt3
age

If CB1 or CB105 circuit breaker has tripped circuit probably has ground fault. In this case,
1. Perform troubleshooting with starting switch at OFF and when starting engine.
Voltage
20 30 V
Defective wiring har- 3. Insert T-adapter into connector PTCN3.
4 ness or power train
controller
Between PTCN3 (2) and (21)
Voltage
20 30 V
Voltage
20 30 V
Voltage
20 30 V
Disconnection in wiring 2. Disconnect ground strap (in order not to make short circuit).
harness
5
(Disconnection or
Between PTCN3 (female) (21)/(31)/(32)/(33) and
defective contact)
ground
Resistance
Max. 1
Between PTCN3 (female) (2), (12) or (22) and BRC
Resistance
Max. 1
harness
2. Disconnect ground strap (in order not to make short circuit).
6
circuit)
4. Disconnect connector PTCN3.
Resistance
Min. 1 M
7
controller
40-326
D375A-6
(01)
DRAFT
Circuit diagram related to power train controller power supply
D375A-6
(01)
40-327
DRAFT
Failure code [DBE5KK] PT cont.: Sensor voltage 5 V (1) reduction

Action code
E03
Failure code
Power train controller 5 V power supply (1) abnormality
Failure
DBE5KK
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
Problem on
machine
mation
Causes
Defective fuel control dial,

brake pedal or PCCS lever
(Internal defect)
controller


40-328

each time.
3. After troubleshooting, return to 1.
q If this code is not displayed when a sensor is disconnected, that sensor is defective.
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
Between ground and any one of PTCN1 (female) (22)
Voltage
4.5 5.5 V
and (21)
2. Disconnect connectors PTCN1, DIAL and TL2, and connect T-adapter to female
side of any one of them.
Between ground and any one of PTCN1 (female) (22),
ResisMin. 1 M
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.
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)
D375A-6
(01)
DRAFT
Circuit diagram related to power train controller sensors 5 V (1) power supply
D375A-6
(01)
40-329
DRAFT
Failure code [DBE6KK] PT cont.: Sensor voltage 24 V reduction

Action code
E03
Failure code
Power train controller sensor 24 V power supply abnormality
Failure
DBE6KK
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.
troller
Problem on
machine
q Once machine stops, travel is limited to F1 and R1.
Related inforq Method of reproducing failure code: Turn starting switch ON.
mation
Causes

each time.
Defective inclination angle
3. After troubleshooting, return to 1).
sensor, torque converter
q If this code is not displayed when a sensor is disconnected, that sensor is defective.
inlet pressure sensor or
a Other failure codes are displayed, too. This is because the connector is disconnecttorque converter outlet
ed. Ignore failure codes other than [DBE6KK].
pressure sensor (Internal
Sensor
Connector
defect)
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.
troller
Voltage
20 30V
Ground fault of wiring har2. Disconnect connectors PTCN1, PT1, TIP and TOP, and connect T-adapter to
ness
female side of any one of them.
(Contact with ground cirBetween ground and any one of PTCN1 (female) (16),
cuit)
Resistance
Min. 1 M
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 harof any one of them.
ness
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
(01)
40-331
DRAFT

Action code
E01
Failure code
Power train controller sensor 5 V power supply (2) abnormality
Failure
DBE7KK
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 conq 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 inforq Method of reproducing failure code: Turn the starting switch to ON position
mation
Cause

2. Disconnect connector SSA.
Defective acceleration sen3. Turn starting switch to ON position.
sor
q If this code is not displayed, acceleration sensor is defective.
(Internal defect)
a Other failure codes are displayed, too. This is because the connector is disconnected. Ignore failure codes other than [DBE7KK].
Ground fault of wiring har2. Disconnect connectors PTCN3 and SSA, and connect T-adapter to female side of
ness
either one of them.
(Contact with ground cirResisBetween PTCN3 (female) (34) or SSA (female) (1) and
cuit)
Min. 1 M
ground
tance
Hot short in wiring harness 2. Disconnect connector SSA and connect T-adapter to female side.
Between SSA (female) (1) and (3)
Voltage
4.5 5.5 V
Defective power train con- 2. Insert T-adapter in connector PTCN3.
troller
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
(01)
40-333
DRAFT
Failure code [DBE9KQ] PT controller: Type select signal
Failure code [DBE9KQ] PT controller: Type select signal

Action code
E04
Failure code
Power train controller: Type select signal
Failure
DBE9KQ
q Specification setting in power train controller does not match specification setting memory (InitializaDetail of failure
tion of power train controller is not performed).
Action of con- q Turns all outputs of power train controller to OFF position.
troller
q Machine does not move at all.
Problem on
machine
q Once machine stops, it cannot travel at all.
mation
Causes
1
40-334

Display adjustment function in service mode and perform operation of reproducing
trouble. If E of failure code disappears at this time, system is normal.
q Adjustment code: 0002 (Initialization of power train controller)
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.

(detected by work equipment controller )
DBERKR
Work equipment controller cannot recognize power train controller in CAN communication.
System may not operate normally.

Start of CAN communication is notified to each controller by ACC signal of starting switch.
Failure code is sent to machine monitor by CAN communication. Accordingly, if failure code [DBERKR] is displayed on the machine monitor, CAN communication between work equipment controller
and machine monitor is normal. That is, there cannot be short circuit, ground fault or hot short in CAN
communication line.
Since CAN communication line signal in operation is pulse voltage, it cannot be measured with multimeter.
Failure
E03
Detail of failure
Problem on
machine
q
q
q
q
q
Related information
q
q
Cause
1
Defective CAN terminal
resistor
2
short circuit)
D375A-6
(01)

If failure code [DBBQKR] is also displayed, perform troubleshooting for failure code
[DBE1KK] and [DBE2KK] first.
them.
Resistance
120 12
Resistance
120 12
a There is 120 CAN terminal resistor inside machine monitor, too. Since 120 resistor is connected in parallel, if resistance measured at connector of controller
other than machine monitor is 60 which is combined resistance, there is not
open circuit in wiring harness.
2. Disconnect one of following connectors EGC2, PTCN2, WECN2, V4A, CT2 and
CM02 and connect T-adapter to female side of that connector.
a If connector has short circuit (Resistance between terminals is 1 or less), disconnect all of EGC2, PTCN2, WECN2, V4A and CM02 and check again to see if
there is short circuit between wiring harnesses or in controller.
Resistance Approx. 60
Approx.
Resistance
120
Approx.
Resistance
120
40-335
Cause

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
Between PTCN2 (female) (32) and CM02 (female)
Resistance
Max. 1 z
(9)/(8)
Resistance
Max. 1 z

Open circuit in wiring harBetween PTCN2 (female) (22) and EGC2 (female) (47)
ness
4
(wire breakage or defective Between PTCN2 (female) (32) and WECN2 (female)
(32)
Between PTCN2 (female) (22) and WECN2 (female)
(22)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z

Between WECN3 (14) or (24) and (31)
5
Between V1 (17) and (19)
Voltage
20 30 V
Voltage
20 30 V
Voltage
20 30 V
Voltage
20 30 V
Voltage
20 30 V
Voltage
20 30 V

2. Disconnect connectors PTCN3, WECN3, V1, CM01 and ACT, and connect
T-adapters to either female side.
Ground fault in wiring har3. Disconnect connectors EGC2 and connect T-adapter to female side.
6 ness
(Contact with ground circuit) Between PTCN3 (female) (14), (24), WECN3 (female)
(14), (24), V1 (female) (17) or CM01 (female) (14) and
Resistance
Min. 1 Mz
ground
7

controller
40-336
Resistance
Min. 1 Mz
If cause is not found by above checks and failure code [DAFRMC] is displayed,
D375A-6
(06)
DRAFT
D375A-6
(01)
40-337
DRAFT
Failure code [DD12KA] Shift up Sw: Disconnection

Action code
E02
Detail of failure
Problem on
machine
Related information
Failure code
Shift up switch: Disconnection
Failure
DD12KA
q Both lines of NO* and NC* for shift up switch circuit are OPEN (switch: OFF) at the same time.
q
Recognizes that the shift up switch is not pressed.
Transmission gear cannot be shifted up.
"NO*" line is used for sensing operation and "NC*" line is used for detecting error.
Condition of shift up switch signal can be checked with monitoring function.
(Code: 40905 Power train control switch Input 3)
Method of reproducing failure code: Turning on the starting switch and operating the shift up switch
Connector SFTU has no T-adapters, don't carry out troubleshooting in female side.
q
q
q
Cause

2. Disconnect connector SFTU.
3. Turn shift up switch to ON or OFF position and troubleshoot.
Defective shift up switch
a "Switch OFF": Release, "Switch ON": Press
Between SFTU (male) (3) and
Switch: OFF
Resistance Max. 1
Switch: ON
Resistance Min. 1 M
(2)
Switch: OFF
Resistance Min. 1 M
Switch: ON
Resistance Max. 1
(2)
3. Insert T-adapter into connector TL3.
Disconnection or hot short a If voltage is 0 V, it shows disconnection in wiring harness, and if voltage is 24 V, it
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
Voltage
7 11V
2. Disconnect connectors PTCN1 and PTCN3 and connect T-adapters to each female
side.
harness
(Disconnection or defec- Between PTCN3 (female) (29) and PTCN1
Switch: OFF Resistance Max. 1
tive contact)
(female) (10).
Between PTCN3 (female) (39) and PTCN1
Switch: ON Resistance Max. 1
(female) (10).
2. Insert T-adapter into connector PTCN1 and PTCN3.
controller
a Voltage of apporx. 9 V is applied to PTCN3 pin (29) and PTCN3 pin (39) through
resistor in power train controller.
Switch: OFF
Voltage
Max. 1V
7 11V
Switch: ON
Voltage
PTCN1(10)
Switch: OFF
Voltage
7 11V
Max. 1V
Switch: ON
Voltage
PTCN1(10)
*NO: Normally Open

*NC: Normally Closed
40-338
D375A-6
(01)
DRAFT
Circuit diagram related to shift up switch
D375A-6
(01)
40-339
DRAFT
Failure code [DD12KB] Shift up Sw: Short circuit

Action code
E02
Detail of failure
Problem on
machine
Related information
Failure code
Shift up switch: Short circuit
Failure
DD12KB
q Both lines of NO* and NC* for shift up switch circuit are 0 V (switch: ON) at the same time.
q
Transmission gear cannot be shifted up.
"NO*" line is used for sensing operation and "NC*" line is used for detecting error.
Condition of shift up switch signal can be checked with monitoring function.
(Code: 40905 Power train controller input 3)
Method of reproducing failure code: Turn starting switch to ON position (and operate shift up switch).
Connector SFTU has no T-adapters, don't carry out troubleshooting in female side.
q
q
q
Cause

3. Turn shift switch to ON or OFF position and troubleshoot.
1
Switch: OFF
Resistance Max. 1
Switch: ON
Resistance Min. 1 M
(2)
Switch: OFF
Resistance Min. 1 M
Switch: ON
Resistance Max. 1
(2)
Ground fault of wiring har2. Disconnect connectors PTCN3 and SFTU, and connect T-adapter to female side of
ness
2
PTCN3.
(Contact with ground cirBetween
PTCN3 (female) (39) and ground
Resistance Min. 1 M
cuit)
Resistance Min. 1 M
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
Switch: OFF
Voltage
Max. 1 V
7 11 V
Switch: ON
Voltage
PTCN1(10)
Switch: OFF
Voltage
7 11 V
Max. 1 V
Switch: ON
Voltage
PTCN1(10)
*NO: Normally Open

40-340
D375A-6
(01)
DRAFT
D375A-6
(01)
40-341
DRAFT
Failure code [DD13KA] Shift down Sw: Disconnection

Action code
E02
Detail of failure
Problem on
machine
Related information
Failure code
Shift-down switch Disconnection
Failure
DD13KA
q Both linens of NO* and NC* for shift down switch circuit are OPEN (switch: OFF) at the same time.
q
Shift down is not possible.
NO* line is used for sensing operation and NC* line is used for detecting error.
Condition of shift up switch signal can be checked with moniitoring function.
(Code: 40905 Power train control Input 3)
Method of reproducing failure code: Turn starting switch ON (and operate shift up switch)
ConnectorSFTD has no T-adapters, don't carry out troubleshooting in female side.
q
q
q
Cause

Disconnect connector SFTD.
Insert T-adapter into connector TL3.
Turn starting switch ON position.
If voltage is 0 V, it shows open circuit in wiring harness, and if voltage is 24 V, it
a Voltage of about 9 V is applied to signal lines of NO and NC through resistor
Voltage
7 11V
Voltage
7 11V
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
tive contact)
Between PTCN1 (female) (10) and SFTD (male) (2)
Resistance Max. 1
Between PTCN3 (female) (9) and SFTD (male) (3)
Resistance Max. 1
2. Disconnect connector TL3 and connect T-adapter to male side.
Defective shift down switch a Switch OFF: Release, Switch ON: Press
3
Switch: OFF
Resistance Max. 1
Between TL3 (male) (5) and (6)
Switch: ON.
Resistance Min. 1 M
Switch: OFF
Resistance Min. 1 M
Switch:ON
Resistance Max. 1
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.
Switch: OFF
Voltage
7 11 V
Max. 1 V
Switch: ON
Voltage
PTCN1 (10)
Switch: OFF
Voltage
Max. 1 V
7 11 V
Switch: ON
Voltage
PTCN1 (10)
1.
2.
3.
4.
Disconnection or hot short a
1
in wiring harness
*NO: Normally Open

40-342
D375A-6
(01)
DRAFT
D375A-6
(01)
40-343
DRAFT
Failure code [DD13KB] Shift down Sw: Short circuit

Action code
E02
Detail of failure
Problem on
machine
Related information
Failure code
Shiftdown switch: short circuit
Failure
DD13KB
q Both lines of NO* and NC* for shift down switch circuit are 0 V (switch: ON) at the same time.
q
Shift down is not possible.
NO* line is used for sensing operation and NC* line is used for detecting error.
Condition of shift up switch signal can be checked with moniitoring function.
Method of reproducing failure code: Turn starting switch ON (and operate shift down switch).
Connector SFTD has no T-adapters, don't carry out troubleshooting in female side.
q
q
q
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
ness
PTCN3.
(Contact with GND circuit) Between PTCN3 (female) (9) and ground
Resistance Min. 1 M
Resistance Min. 1 M
2. Disconnect connectors PTCN3 and SFTD and connect T-adapter to female side of
PTCN3.
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
Switch: OFF
Resistance Max. 1
Switch: ON
Resistance Min. 1 M
Switch: OFF
Resistance Min. 1 M
Switch: ON
Resistance Max. 1
q Reference; the followings are cirteria in normal condition.
4. Turn shift down switch to ONor OFF position and troubleshoot.
controller
a Voltage of apporx.9 V is applied to PTCN3 pin (19) and pin (9) through resistor in
Switch: OFF
Voltage
7 11 V
Max. 1 V
Switch: ON
Voltage
PTCN1 (10)
Switch: OFF
Voltage
Max. 1 V
7 11 V
Switch: ON
Voltage
PTCN1 (10)
*NO: Normally Open

40-344
D375A-6
(01)
DRAFT
Circuit diagram related to shift down switch
D375A-6
(01)
40-345
DRAFT
Failure code [DD14KA] Parking lever Sw: Dissconnection

Action code
E03
Failure code
Parking lever switch: Disconnection
Failure
DD14KA
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.
troller
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.
Cause

2. Disconnect connector NSW and connect T-adapter to male side.
Defective parking brake
lever switch (Internal dis- Between NSW (male) (A) Lever: LOCK
Resistance
Min. 1 M
connection)
Lever: FREE
Resistance
Max. 1
and (B)
Between NSW (male) (A) Lever: LOCK
Resistance
Max. 1
Lever: FREE
Resistance
Min. 1 M
and (C)
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
in wiring harness
Between NSW (female) (B) and (A)
Voltage
7 11 V
Between NSW (female) (C) and (A)
Voltage
7 11 V
2. Disconnect connectors PTCN1 and NSW and connect T-adapters to each female
harness
side.
(Open circuit or defective
Between PTCN1 (female) (12) and NSW (female) (C)
Resistance
Max. 1
contact)
Between PTCN1 (female) (18) and NSW (female) (B)
Resistance
Max. 1
Between NSW(female)(A) and ground
Resistance
Max. 1
Defective power train con- 4. Operate parking brake lever and troubleshoot.
troller
a Voltage of about 9 V is applied to PTCN1 pin (12) and pin (18) through resistor in
Lever: LOCK
Voltage
7 11 V
Max. 1 V
Lever: FREE
Voltage
ground
Lever: LOCK
Voltage
Max. 1 V
7 11 V
Lever: FREE
Voltage
ground
*NO: Normally Open

40-346
D375A-6
(01)
DRAFT
Circuit diagram related to parking brake lever switch
D375A-6
(01)
40-347
DRAFT
Failure code [DD14KB] Parking lever Sw: Short circuit

Action code
E03
Failure code
Parking lever switch: Short circuit
Failure
DD14KB
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.
troller
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)
mation
q Method of reproducing failure code: Turn starting switch to ON position and operate parking brake
lever.
q When parking brake lever is FREE, parking brake lever switch becomes ON.
Cause

2. Disconnect connector NSW and connect T-adapter to male side.
lever switch (Internal dis- Between NSW (male) (A) Lever: LOCK
Resistance
Min. 1 M
connection)
Lever: FREE
Resistance
Max. 1
and (B)
Between NSW (male) (A) Lever: LOCK
Resistance
Max. 1
Lever: FREE
Resistance
Min. 1 M
and (C)
2. Disconnect connectors PTCN1 and NSW, and connect T-adapter to female side of
Ground fault of wiring harone of them.
ness
Between NSW (female) (B) and ground or between
Min. 1 M
Resistance
(Contact with GND circuit) PTCN1 (female) (18) and ground
Between NSW (female) (C) and ground or between
Min. 1 M
Resistance
2. Disconnect connectorsPTCN1, NSW and connect T-adapter to female side of
PTCN1.
Short circuit in wiring har- a Check with multimeter continuity mode.
ness
Between PTCN1 (female) (12) and each pin other than
No continuity
(12)
(No sound is heard)
No continuity
(18)
(No sound is heard)
Defective power train con- 4. Operate shiftup switch and troubleshoot.
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 11V
Lever: FREE
Max. 1V
Voltage
chassis ground
Between PTCN1(12) and Lever: LOCK
Voltage
Max. 1V
Lever: FREE
7 11V
Voltage
chassis ground
*NO: Normally Open

40-348
D375A-6
(01)
DRAFT
Circuit diagram related to parking brake lever switch
D375A-6
(01)
40-349
DRAFT
Failure code [DDB9L4] Reverse SW Signal disagreement

Action code
E03
Detail of failure
Problem on
machine
Related information
Failure code
Inconsistent reverse switch signal
Failure
DDB9L4
q There is inconsistency in line 2 of NO* for reverse switch circuit.
q
Recognizes that reverser switch is not pressed.

Once machine is stopped, travel is limited to F1.
Condition of reverse switch signal can be checked with monitoring function.
(Code: 40905 Power train control input 3)
Method of reproducing failure code: Turn starting switch to ON position (and operate reverse switch).
Since T-adapter is not prepared for connector RTS, female side check is not required.
q
q
q
q
Cause
Wrong selection of travel
1
lever type

If failure code [DDT5KQ] is displayed, carry out troubleshooting for it.
1.
2.
3.
4.
Disconnection or hot short a
2
in wiring harness

Disconnect connector RTS.
Insert T-adapter into connector TL3.
Turn starting switch to ON position.
If voltage is 0 V, it shows disconnection in wiring harness, and if voltage is 24 V, it
Voltage
7 11 V
Voltage
7 11 V
2. Disconnect connectors PTCN1, PTCN3, TL3 and RTS, and connect T-adapters to
female side of PTCN1, PTCN3 and PL3.
harness
3
Resistance Max. 1
(Disconnection or defec- Between PTCN3 (female) (19) and RTS (male) (1)
Between
PTCN1
(female)
(10)
and
TL3
(female)
(2)
Resistance Max. 1
tive contact)
Between PTCN1 (female) (10) and RTS (male) (2)
Resistance Max. 1
Resistance Max. 1
Ground fault of wiring har2. Disconnect connectors PTCN3 and RTS, and connect T-adapter to female side of
ness
4
PTCN3.
Resistance Min. 1 M
cuit)
Resistance Min. 1 M
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.
4. Turn reverse switch to ON or OFF position and troubleshoot.
Defective reverse switch
6
Switch: OFF
Resistance Min. 1 M
Switch: ON
Resistance Max. 1
Between TL3 (male) (4) and
Switch: OFF
Resistance Min. 1 M
Switch: ON
Resistance Max. 1
FTS (female) (2)
40-350
D375A-6
(01)
Cause
Defective reverse switch


1.
2.
3.
4.
a

Disconnect connectors TL3 and connect T-adapters to female side.
Disconnect connector FTS.
Turn reverse switch ON/OFF, and troubleshoot.
Switch OFF: Release, Switch ON: Press
Between TL3 (male) (5)

and (6)
Switch: OFF
Resistance
Min. 1 Mz
Switch: ON
Resistance
Max. 1 z
Between TL3 (male) (4)

and FTS (female) (2)
Switch: OFF
Resistance
Min. 1 Mz
Switch: ON
Resistance
Max. 1 z
2. Insert T-adapters into connectors PTCN1 and PTCN3.
4. Turn reverse switch ON/OFF, and troubleshoot.
a Voltage of approximately 9 V is applied to PTCN3 pin (19) and pin (9) through resistor in power train controller.
PTCN1 (10)
Switch: OFF
Voltage
7 11 V
Switch: ON
Voltage
Max. 1 V

PTCN1 (10)
Switch: OFF
Voltage
7 11 V
Switch: ON
Voltage
Max. 1 V
*NO: Normally Open

Circuit diagram related to reverse switch
40-35
a Exclusive for single-direction lever
D375A-6
(06)
40-351
DRAFT
Failure code [DDE2KA] Pre lub. oil press sw: Disconnection

Action code
E02
Failure code
Pre-lubricating oil pressure switch disconnection
Failure
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 conq None in particular
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
Related inforfunction.
mation
(Code: 40910 PT controller SW input 2)
q Whether pre-lubricating motor is in operation can be checked with monitoring function.
Cause

2. Disconnect terminal POP.
Defective pre-lubricating oil 3. Turn starting switch to ON position.
pressure switch
a During pre-lubrication
Between terminal POP (on pre-lubricating oil pressure
Not conductive
switch side) and ground
harness
(Disconnection or defecBetween PTCN2 (female) (13) and ground
Resistance Max. 1
tive contact)tive contact)
ness
(Contact with ground cir3. Disconnect terminal POP.
cuit)
Resistance Min. 1 M
If cause is not found by above checks, power train controller is defective.
q Reference: Following shows criteria in normal condition.
Defective power train con2. Insert T-adapter into connector PTCN2.
troller
a During pre-lubrication
Voltage
7 11 V
Circuit diagram related to pre-lubricating oil pressure switch
40-352
D375A-6
(01)
DRAFT
D375A-6
(01)
40-353
DRAFT
Failure code [DDK3L4] Forward SW Signal disagreement

Action code
E03
Detail of failure
Problem on
machine
Related information
Failure code
Inconsistent forward switch signal
Failure
DDK3L4
q There is inconsistency in line 2 of NO* for forward switch circuit.
q
Recognizes that forward switch is not pressed.

Once machine is stopped, travel is limited to R1.
Condition of forward switch signal can be checked with monitoring function.
(Code: 40905 Power train control input 3)
Method of reproducing failure code: Turn starting switch to ON position (and operate forward switch).
q
q
q
Cause
1
lever type


3. Disconnect connectors TL3 and connect T-adapters to female side.
Defective forward switch
Between FTS (male) (3) and
Switch: OFF
Resistance Min. 1 M
Switch: ON
Resistance Max. 1
TL3 (male) (5)
Switch: OFF
Resistance Min. 1 M
Between FTS (male) (1) and (2)
Switch: ON
Resistance Max. 1
in wiring harness
Voltage
7 11 V
Voltage
7 11 V
2. Disconnect connectors PTCN1, PTCN3 and TL3, and connect T-adapters to female
side of them.
harness
3.
Disconnect
connector RTS.
PTCN3
(female) (39) and TL3 (female) (1)
Resistance Max. 1
tive contact)
Between PTCN1 (female) (10) and TL3 (female) (2)
Resistance Max. 1
Resistance Max. 1
Resistance Max. 1
Ground fault of wiring har2. Disconnect connectors PTCN3 and FTS, and connect T-adapter to female side of
ness
PTCN3.
Resistance Min. 1 M
cuit)
Resistance Min. 1 M
2. Disconnect connectors PTCN3 and FTS, and connect T-adapter to female side of
PTCN3.
ness
No continuity
(No sound is heard)
NO continuity
(No sound is heard)
40-354
D375A-6
(01)
Cause

2. Disconnect connectors PTCN3 and FTS, and connect T-adapter to female side of
PTCN3.
a Check with multimeter in continuity mode.
No continuity
(29)
(No sound is heard)
No continuity
(39)
(No sound is heard)
a The voltage of approximately 9 V is applied to PTCN3 pin (29) and pin (39) through
the resistor in power train controller.
PTCN1 (10)
Switch: OFF
Voltage
7 11 V
Switch: ON
Voltage
Max. 1 V

PTCN1 (10)
Switch: OFF
Voltage
7 11 V
Switch: ON
Voltage
Max. 1 V
*NO: Normally Open

Circuit diagram related to forward switch
40-359
D375A-6
(06)
40-355
DRAFT
Failure code [DDK5KA] Shift switch disconnection

Action code
E02
Failure code
Shift switch disconnection
Failure
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 conq 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 detecting error.
Related inforq Condition of shift up switch signal can be checked with monitoring function.
mation
q Method of reproducing failure code: Turn starting switch to ON position and operate shift up switch.
Cause
1
lever type


Disconnect connector SNC and connect T-adapter to male side.
Turn shift switch to ON or OFF position and troubleshoot.
Defective shift switch
"Switch OFF": Release, "Switch ON": Press
Switch: OFF
Resistance
Max. 1
Between SNC (male) (1) and (3)
Switch: ON
Resistance
Min. 1 M
Switch: OFF
Resistance
Min. 1 M
Switch: ON
Resistance
Max. 1
2. Disconnect connector SNC and connect T-adapter to female side.
in wiring harness
Between SNC (female) (2) and (1)
Voltage
711 V
Voltage
711 V
Disconnection in wiring har2. Disconnect connectors PTCN1, PTCN2 and SNC, and connect T-adapter to
ness
female side of them.
Between
PTCN1 (female) (10) and SNC (female) (1)
Resistance
Max. 1
contact)
Between PTCN2 (female) (7) and SNC (female) (2)
Resistance
Max. 1
Between PTCN1 (female) (6) and SNC (female) (3)
Resistance
Max. 1
2. Insert T-connector into connectors PTCN1 and PTCN2.
Defective power train con- 4. Turn shift switch to ON or OFF position and troubleshoot.
troller
a Voltage of about 9 V is applied to PTCN1 pin (6) and PTCN2 pin (7) through resistor
Switch: OFF
Voltage
711 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
711 V
40-356
1.
2.
3.
a
D375A-6
(01)
DRAFT
Circuit diagram related to shift switch
D375A-6
(01)
40-357
DRAFT
Failure code [DDK5KB] Shift switch short circuit

Action code
E02
Failure code
Shift switch short circuit
Failure
DDK5KB
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 conq Recognizes that switch is not pressed.
troller
Problem on
q Gear cannot be shifted up and down (1stio2nd).
machine
Related infor- q Condition of shift up switch signal can be checked with monitoring function.
mation
q Method of reproducing failure code: Turn the starting switch to ON position and operate the shift up
switch
Cause
1
lever type


Disconnect connector SNC and connect T-adapter to male side.
Turn shift up switch to ON or OFF position and troubleshoot.
Switch: OFF
Resistance
Max. 1
Switch: ON
Resistance
Min. 1 M
Switch:OFF
Resistance
Min. 1 M
Switch: ON
Resistance
Max. 1
2. Disconnect connectors STC1, STC3 and SNC and connect T-adapter to female
side of one of them.
Ground fault of wiring har3.
Turn
ness
Resistance
Min. 1 M
(Contact with rround circuit) Between SNC (female) (2) and ground , or between
PTCN2(female) (7) and ground
Between SNC (female) (3) and ground , or between
Resistance
Min. 1 M
2. Disconnect connectors PTCN1, PTCN2 and SNC and connect T-adapters to
female side of PTCN1 and PTCN2.
Short circuit in wiring hara Check with multimeter in continuity mode.
ness
No continuity (No sound is
(6)
heard)
(7)
heard)
Defective power train con- 4. Turn shift up switch to ON or OFF position and troubleshoot.
troller
a Voltage of about 9 V is applied to PTCN1 pin (6) and PTCN2 pin (7) through resistor in power train controller.
Switch: OFF
Voltage
711 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
711 V
40-358
1.
2.
3.
a
D375A-6
(01)
DRAFT
Circuit diagram related to shift switch
D375A-6
(01)
40-359
DRAFT
Failure code [DDN2LD] Blade tilt RH pressure SW abnormality

Action code
Detail of failure
Problem on
machine
Related information
Failure code
Blade tilt right hand oil pressure switch is pressed for long time
Failure
DDN2LD
q The signal of the blade tilt left oil pressure switch circuit is kept turned O V (ON) for 60 seconds.
q
Recognizes that the oil pressure switch is turned to OFF position.
Data communication of VHMS may be abnormal
The input state (ON/OFF) from the blade tilt right hand oil pressure switch can be checked moniitoring funtion. (Code 90802: Blade oil pressure switch input state)
Method of reproducing failure code: Turn the starting switch to ON position (Error is reproduced after
60 seconds).
Next, check that hydraulic pressure of work equipment is normal by referring to Testing and adjusting, "Testing work equipment hydraulic pressure".
q
q
q
Cause
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. Disconnect connector TRS and connect T-adapter to male side.
2 hand oil pressure switch
Between TRS (female)(1) and (2)
Resis(Internal short circuit)
Min. 1 M
(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
work equipment controller is defective.
(If failure code [DDN2LD] is not displayed, blade tilt right oil pressure switch is defective.)
ness
2. Disconnect connectors WECN2 and TRS, and connect T-adapter to female side of
4
(Contact with ground cireither one of them.
cuit)
Between WECN2 (female) (7) and ground, or betweenTRS
ResisMin. 1 M
(female) (1) and ground.
tance
2. Insert T-adapter into connector WECN1 and WECN2.
Defective work equipment 3. Start engine.
5
controller
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
(01)
40-361
DRAFT
Failure code [DDN3LD] Blade tilt LH pressure SW abnormality

Action code
Detail of failure
Problem s on
machine
Related information
Failure code
Blade tilt left hand oil pressure switch is pressing for long time
Failure
DDN3LD
q The signal of the blade tilt left oil pressure switch circuit is kept turned ON for 60 seconds.
q
Recognizes that the oil pressure switch is turned to OFF position.
Data communication of VHMS may be abnormal.
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)
60 seconds).
q
q
q
Cause
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. Disconnect connector TLS and connect T-adapter to male side.
2 hand oil pressure switch
Between TLS (female)(1) and (2)
Resis(Internal short circuit)
Min. 1 M
(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.)
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 defective.)
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 ResisMin. 1 M
tance
5
controller
Voltage
7 11 V
4.While depressing brake pedal, operate blade lever and perform troubleshooting.
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
(01)
40-363
DRAFT
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection

Action code
E02
Failure code
Work equipment knob switch (lower): Disconnection
Failure
DDN7KA
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 conq Recognizes that blade knob switch lower is not pressed.
troller
Problem on
q Blade knob switch lower does not work.
machine
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.
Cause

Disconnect connector WNBL.
Insert T-adapter into connector P03.
Disconnection or hot
If voltage is 0 V, it shows disconnection in wiring harness, and if voltage is 24 V, it
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
2. Disconnect connectors WECN1, WECN2 and WNBL, and connect T-adapter to each
harness
female side
WECN2 (female) (26) and WNBL (female) (1)
Resistance Max. 1
tive contact)
Between WECN1 (female) (4) and WNBL (female) (2)
Resistance Max. 1
Between WECN2 (female) (36) and WNBL (female) (3)
Resistance Max. 1
2. Disconnect connector P03 and connect T-adapter to male side.
3. Turn blade knob lower switch to ON or OFF position and troubleshoot.
Defective blade knob
lower switch(Internal dis- a Switch OFF: Release, Switch ON: Press
Between P03(male) (2) and
Switch: OFF
Resistance Max. 1
connection)
Switch: ON
Resistance Min. 1 M
(1)
Between P03(male) (1) and
Switch: OFF
Resistance Min. 1 M
Switch: ON
Resistance Max. 1
(2)
Defective work equip4. Turn blade knob lower switch (lower) to ON or OFF position and troubleshoot.
ment controller
a Voltage of approx.9 V is applied to WECN2 pin (26) and pin (36) through resistor in
work equipment controller.
Switch: OFF
Voltage
Max. 1 V
7 11 V
Switch: ON
Voltage
WECN1(4)
Switch: OFF
Voltage
7 11 V
Max. 1 V
Switch: ON
Voltage
WECN1(4)
40-364
1.
2.
3.
4.
a
D375A-6
(01)
DRAFT
Circuit diagram related to work equipment knob switch
D375A-6
(01)
40-365
DRAFT
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit

Action code
E02
Failure code
Work equipment knob switch (Lower): Short circuit
Failure
DDN7KB
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 conq Recognizes that blade knob lower switch is not pressed.
troller
Problem on
q Blade knob switch (lower) does not work.
machine
q Condition of blade knob switch lower signal can be checked with monitoring function.
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.
Cause

2. Disconnect connectors WECN2 and WNBL and connect T-adapter to female side
Ground fault of wiring harof WECN2.
ness
ResisMin. 1 M
(Contact with GND circuit) Between WECN2 (female) (26) and ground
tance
ResisBetween WECN2 (female) (36) and ground
Min. 1 M
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.
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
ResisDefective blade knob
Switch: OFF
Max. 1
Between
P03
(male)
(5)
and
tance
switch lower (Internal disResis(1)
connection)
Switch: ON
Min. 1 M
tance
ResisSwitch: OFF
Min. 1 M
Between P03 (male) (1) and
tance
Resis(2)
Switch: ON
Max. 1
tance
Defective work equipment 4. Turn blade knob lower switch (lower) to ON or OFF position and troubleshoot.
controller
Between WECN (36) and
Switch: OFF
Voltage
Max. 1 V
Switch: ON
7 11 V
Voltage
WECN (4)
Between WECN (26) and
Switch: OFF
Voltage
7 11 V
Switch: ON
Max. 1 V
Voltage
WECN (4)
40-366
D375A-6
(01)
DRAFT
D375A-6
(01)
40-367
DRAFT
Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection

Action code
E01
Failure code
Work equipment knob switch (raise): Disconnection
Failure
DDN9KA
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 conq Recognizes that blade knob upper switch is not pressed.
troller
Problem on
q Blade knob switch (raise) does not work.
machine
q Condition of blade knob switch signal can be checked with monitoring function.
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.
Cause

Disconnect connector WNBU.
Turn blade upper knob switch (raise) to ON or OFF position and troubleshoot.
ResisDefective blade knob
Switch: OFF
Max. 1
tance
switch raise (Internal dis- Between WNBU (male) (3) and
Resis(2)
connection)
Switch: ON
Min. 1 M
tance
ResisSwitch: OFF
Min. 1 M
Between WNBU (male) (1) and
tance
Resis(2)
Switch:ON
Max. 1
tance
2. Disconnect connector WNBU.
3. Insert T-adapter into connector P03.
in wiring harness
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
female side.
harness
3. Turn blade knob switch (raise) to ON or OFF position and troubleshoot.
(Disconnection or defec- Between WECN2 (female) (15) and WECN1
ResisSwitch: OFF
Max. 1
tive contact)
(female) (4)
tance
Between WECN2 (female) (5) and WECN1
ResisSwitch: ON
Max. 1
(female) (4)
tance
Defective work equipment 4. Turn blade knob switch (raise) to ON or OFF position and troubleshoot.
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
Switch: ON
Voltage
Max. 1 V
WECN1 (4)
Switch: OFF
Voltage
Max. 1 V
Switch: ON
Voltage
7 11 V
WECN1 (4)
1.
2.
3.
a
40-368
D375A-6
(01)
DRAFT
D375A-6
(01)
40-369
DRAFT
Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit

Action code
E01
Failure code
Work equipment knob switch (raise): Disconnection
Failure
DDN9KB
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 conq 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.
q Method of reproducing failure code: Turn starting switch to ON position and operate blade knob
mation
switch (raise).
q Since T-adapter is not prepared for connector WNBU female side check is not required.
Cause

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.
raise (Internal disconnecBetween WNBU (male) (3) and Switch: OFF
Resistance
Max. 1
tion)
Switch: ON
Resistance
Min. 1 M
(2)
Between WNBU (male) (1) and Switch: OFF
Resistance
Min. 1 M
Switch: ON
Resistance
Max. 1
(2)
Ground fault of wiring har- 2. Disconnect connectors WECN1, WECN2 and WNBU and connect T-adapter to
ness
female side of either one of them.
(Contact with groung circuit) Between WECN1 (female) (5) and ground
Resistance
Min. 1 M
Resistance
Min. 1 M
2. Disconnect connectors WECN2 and WNBU and connect T-adapter to female side
of WECN2.
Short circuit in wiring hara Check with multimeter in continuity mode.
ness
Between WECN2 (female) (5) and each pin other than
No continuity
(5)
(No sound is heard)
No continuity
(15)
(No sound is heard)
Defective work equipment 4. Turn blade knob switch (raise) to ON or OFF position and troubleshoot.
controller
Switch: OFF
Voltage
7 11 V
Switch: ON
Max. 1 V
Voltage
WECN1 (4)
Switch: OFF
Voltage
Max. 1 V
Switch: ON
7 11 V
Voltage
WECN1 (4)
40-370
D375A-6
(01)
DRAFT
D375A-6
(01)
40-371
DRAFT
Failure code [DDNALD] Blade lift up pressure SW abnormality

Action code
Detail of failure
Problem on
machine
Related information
Failure code
Blade lift raise oil pressure switch is pressed for long time
Failure
DDNALD
q The signal of blade lift raise (full stroke) oil pressure switch circuit is kept turned to ON position for 60
seconds.
q
Recognizes that the oil pressure switch is turned OFF.
Data of the VHMS may become abnormal.
Input state (ON/OFF) from blade raise (full stroke) oil pressure switch can be checked monitoring
function. (Code 90802: Blade oil pressure switch input)
Method of reproducing failure code: Turn starting switch to ON position (Error is reproduced after 60
seconds).
q
q
q
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)
short circuit)
Resistance Min. 1 M
(Oil pressure switch: OFF)
2. Disconnect connector BLU.
Ground fault of wiring har3. Turn starting switch to ON position (and wait for longer than 60 sec.).
If failure code [DDNALD] is still displayed, there is ground fault of wiring harness or
(If failure code [DDNALD] is not displayed, blade raise oil pressure switch is defective.)
Ground fault of wiring har2. Disconnect connectors WECN2 and BLU, and connect T-adapter to female side of
4 ness
either one of them.
Between WECN2 (female) (16) and ground or betweenBLU
Resistance Min. 1 M
Defective work equip3. Start engine.
5
ment controller
a Keep blade lever in neutral position.
Voltage
7 11 V
4. Operate blade lever and troubleshoot.
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
(01)
40-373
DRAFT
Failure code [DDNBLD] Ripper lift up pressure SW abnormality

Action code
Detail of failure
Problem on
machine
Related information
Failure code
Ripper lift raise oil pressure switch is pressed for long time
Failure
DDNBLD
q The signal of the ripper raise oil pressure switch circuit is kept turned to ON position for 60 seconds.
q
Recognizes that oil pressure switch is turned to OFF position.
Shoe slip control (SSC) function does not activate normally.

VHMS data may become abnormal.
Input state (ON/OFF) from the ripper raise oil pressure switch can be checked moniitoring funtion.(Code 40982: Ripper oil pressure switch input )
60 seconds).
q
q
q
q
q
Cause
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)
Resisshort circuit)
Min. 1 M
tance
2. Disconnect connector RPU.
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)
Ground fault of wiring har2. Disconnect connectors WECN2 and RPU, and connect T-adapter to female side of
4 ness
either one of them.
Between WECN2 (female) (13) and ground, or betweenRPU ResisMin. 1 M
tance
5
controller
a Keep ripper lever in neutral position.
Voltage
7 11 V
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
(01)
40-375
DRAFT
Failure code [DDNCLD] Ripper lift down pressure SW abnormality

Action code
Detail of failure
Problem on
machine
Related information
Failure code
Ripper lower oil pressure switch is pressed for long time
Failure
DDNCLD
q Signal of ripper lift lower oil pressure switch circuit is kept turned to ON position for 60 seconds.
q
Recognizes that oil pressure switch is turned OFF.

Input state (ON/OFF) from ripper lower oil pressure switch can be checked in the real-time moniitoring mode. (Code 40982: Ripper oil pressure switch input signal)
60 seconds).
q
q
q
q
q
Cause
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)
Resisshort circuit)
Min. 1 M
(Oil pressure switch : OFF)
tance
2. Disconnect connector RPD.
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 defective)
Ground fault of wiring har2. Disconnect connectors WECN2 and RPD, and connect T-adapter to female side of
4 ness
either one of them.
Between WECN2 (female) (3) and ground or betweenRPD
ResisMin. 1 M
tance
5
controller
Voltage
7 11 V
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
(01)
40-377
DRAFT
Failure code [DDNDLD] Ripper tilt in pressure SW abnormality

Action code
Detail of failure
Problem on
machine
Related information
Failure code
Ripper tilt in oil pressure switch is pressed for long time
Failure
DDNDLD
q Signal of ripper tilt in oil pressure switch circuit is kept turned to ON position for 60 seconds.
q
Recognizes that oil pressure switch is turned to OFF position.
Shoe slip control (SSC) function does not operate normally.

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)
60 seconds).
q
q
q
q
q
Cause
If failure code (reset indication) is displayed even after reset operation, incorrect lever
operation might be made.
normal)
Defective ripper tilt in oil
2. Disconnect connector RTI and connect T-adapter to male side.
2 pressure switch (Internal
Between RTI (female)(1) and (2)
Resisshort circuit)
Min. 1 M
(Turn oil pressure switch: OFF.)
tance
2. Disconnect connector RTI.
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
ResisMin. 1 M
tance
5
controller
Voltage
7 11 V
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
(01)
40-379
DRAFT
Failure code [DDNELD] Ripper tilt back pressure SW abnormality

Action code
Detail of failure
Problem on
machine
Related information
Failure code
Ripper tilt back oil pressure switch is pressed for long time
Failure
DDNELD
q Signal of the ripper tilt back oil pressure switch circuit is kept turned to ON position for 60 seconds.
q
Recognizes that the oil pressure switch is turned OFF.

Input state (ON/OFF) from the ripper tilt back oil pressure switch can be checked moniitoring funtion.
(Code 40982: Ripper oil pressure switch input )
Method of reproducing failure code: Turn starting switch to ON position (Error is reproduced after 60
seconds).
q
q
q
q
q
Cause
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)
Resisshort circuit)
Min. 1 M
tance
2. Disconnect connector RTB.
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 defective)
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
ResisMin. 1 M
tance
5
controller
Voltage
7 11 V
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
(01)
40-381
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
q Signal of blade lower (full stroke) oil pressure switch circuit is kept turned to ON position for 60 secDetail of failure
onds.
Action of conq Recognizes that oil pressure switch is turned to OFF position.
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 monitoring 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 inforsec.).
mation
q First, check power train oil filter for clogging etc.
q Next, check that hydraulic pressure of work equipment is normal by referring to Testing and adjusting, "Testing work equipment hydraulic pressure".
Cause
If failure code (reset indication) is displayed even after reset operation, incorrect lever
operation might be made.
normal)
Defective blade lower oil
2. Disconnect connector BLD and connect T-adapter to male side.
2 pressure switch (Internal
Between BLD (female)(1) and (2)
Resisshort circuit)
Min. 1 M
(Oil pressure switch: OFF.)
tance
2. Disconnect connector BLD.
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 defective.)
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
ResisMin. 1 M
(female) (1) and ground
tance
5
controller
a Keep blade lever in neutral position.
Voltage
7 11 V
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
(01)
40-383
DRAFT
Failure code [DDNLKA] Weq lock Sw: Disconnection

Action code
E03
Failure code
Work equipment lock switch: Disconnection
Failure
DDNLKA
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.
troller
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.
(Code: 70300 Blade Sw Input)
Related inforq 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.)
Cause

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 M
disconnection)
Lever: LOCK
Resistance Max. 1
(B)
Between WELK (male) (A) and Lever: FREE
Resistance Max. 1
Lever: LOCK
Resistance Min. 1 M
(C)
2. Disconnect connector WELK and connect T-adapter to female side.
2
in wiring harness
Between WELK (female) (A) and (B)
Voltage
7 11 V
Between WELK (female) (A) and (C)
Voltage
7 11 V
2. Disconnect connectors WECN1, WECN2 and WELK, and connect T-adapters to
harness
3
female side .
WECN1 (female) (10) and WELK (female) (A)
Resistance Max. 1
tive contact)
Between WECN2 (female) (35) and WELK (female) (B)
Resistance Max. 1
Between WECN2 (female) (25) and WELK (female) (C)
Resistance Max. 1
Defective work equipment 4. Operate work equipment lock lever switch and troubleshoot.
4
controller
Lever: FREE
Voltage
7 11 V
Max. 1 V
Lever: LOCk
Voltage
WECN1(10)
Lever: FREE
Voltage
Max. 1 V
7 11 V
Lever: LOCk
Voltage
WECN1(10)
*NO: Normally Open

40-384
D375A-6
(01)
DRAFT
Circuit diagram related to equipment lock switch
D375A-6
(01)
40-385
DRAFT
Failure code [DDNLKB] Weq lock Sw: Short circuit

Action code
E03
Failure code
Work equipment lock switch: Short circuit
Failure
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.
troller
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.
(Code: 70300 Blade Sw Input)
Related inforq 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.)
Cause

1 lock lever switch (Internal
disconnection)


2. Disconnect connector WELK and connect T-adapter to male side.
3. Operate work equipment lock lever and troubleshoot.
Resistance Min. 1 M
Lever: LOCK
Resistance Max. 1
(B)
Resistance Max. 1
Lever: LOCK
Resistance Min. 1 M
(C)
2. Disconnect connectors WECN1, WECN2 and WELK and connect T-adapter to
female side of one of them.
Between WELK (female) (B) and ground or between
Resistance Min. 1 M
WECN2 (female) (35) and ground.
Between WELK (female) (C) and ground or between
Resistance Min. 1 M
WECN2 (female) (25) and ground.
2. Disconnect connectors WECN2 and WELKand connect T-adapters to female side
of WECN2.
No continuity
(25)
(No sound is heard)
No continuity
(35)
(No sound is heard)
4. Operate work equipment lock lever switch and troubleshoot.
Lever: FREE
Voltage
7 11 V
Max. 1 V
Lever: LOCK
Voltage
WECN1 (10)
Lever: FREE
Voltage
Max. 1 V
7 11 V
Lever: LOCK
Voltage
WECN1 (10)
*NO: Normally Open

40-386
D375A-6
(01)
DRAFT
Circuit diagram related to work equipment lock switch
D375A-6
(01)
40-387
DRAFT
Failure code [DDT5KA] Neutral switch disconnection

Action code
E04
Failure code
Neutral switch disconnection
Failure
DDT5KA
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 conq Recognizes that neutral switch is not pressed.
troller
Problem on q Once machine is stopped, engine speed is limited to medium (half).
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 adjusting, "Testing work equipment hydraulic pressure".
Cause
1
lever type


2. Disconnect connector SNC and connect T-adapter to male side.
3. Turn neutral switch to ON or OFF position and troubleshoot.
Defective neutral switch
Between SNC (male) (4)
Switch: OFF
Resistance
Max. 1
Switch: ON
Resistance
Min. 1 M
and (6)
Between SNC (male) (4)
Switch: OFF
Resistance
Min. 1 M
Switch: ON
Resistance
Max. 1
and (5)
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
Voltage
711 V
Voltage
711 V
2. Disconnect connectors PTCN1, PTCN2 and SNC, and connect T-adapter to each
harness
female side
(Disconnection or defecBetweenPTCN1 (femail)(10) and SNC (femail)(4)
Resistance
Max. 1
tive contact)
BetweenPTCN2(femail)(17) andSNC (femail)(5)
Resistance
Max. 1
BetweenPTCN2(femail)(27) andSNC (femail)(6)
Resistance
Max. 1
Defective power train con- 4. Turn neutral switch to ON or OFF position and troubleshoot.
troller
a Voltage of apporx.9 V is applied to PTCN2 pin (17) and PTCN2 pin (27) through resistor in power train controller.
Switch: OFF
Voltage
Max. 1 V
Switch: ON
Voltage
711 V
PTCN1(10)
Switch: OFF
Voltage
711 V
Switch: ON
Max. 1 V
Voltage
PTCN1(10)
40-388
D375A-6
(01)
DRAFT
Circuit diagram related to neutral switch
D375A-6
(01)
40-389
DRAFT
Failure code [DDT5KB] Neutral switch short circuit

Action code
E04
Detail of failure
Problem on
machine
Related information
Failure code
Neutral switch short circuit
Failure
DDT5KB
Both lines of NO: Normally Open and NC : Normally Closed for neutral switch circuit are 0 V(switch:
ON) at the same time.
Recognizes that neutral switch is not pressed.
q
q

Once machine is stopped, it cannot travel any more.
Method of reproducing failure code: Turn starting switch to ON position and operate neutral switch.
Cause
Wrong selection of travel lever
type
2. Disconnect connector SNC and connect T-adapter to male side.
3. Turn neutral switch to ON or OFF position and troubleshoot.
Defective neutral switch
Between SNC (male) Switch: OFF
Resistance
Max. 1
Resistance
Min. 1 M
Switch: ON
(4) and (6)
Between SNC (male) Switch: OFF
Resistance
Min. 1 M
Resistance
Max. 1
Switch: ON
(4) and (5)
Between
SNC (female) (5) or PTCN2 (female)
Resistance
Min. 1 M
(17) and ground
Between SNC (female) (6) and PTCN2 (female)
Resistance
Min. 1 M
(27) and groud
female side of PTCN2.
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)
Defective power train control- 4. Turn shift up switch to ON or OFF position and troubleshoot.
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
Switch: ON
Voltage
711 V
and PTCN1 (10)
Between PTCN2 (17) Switch: OFF
Voltage
711 V
Switch: ON
Voltage
Max.1 V
and PTCN1 (10)
40-390
D375A-6
(01)
DRAFT
Circuit diagram related to meutral switch
D375A-6
(01)
40-391
Failure code [DDT5KQ] Lever SPEC selection signal disagreement

Action code
Failure code
Failure
E04
DDT5KQ
Detail of failure
Problem on
machine
Related information
Lever specification selection signal disagreement

While optional travel lever is installed, optional travel lever device is not set.
q
q

Once machine is stopped, it cannot travel any more.
Cause
40-396
Check type of travel lever in

Select optional travel lever.
adjustment mode: 0041.
2. Disconnect connectors PTCN2 and SNC and connect T-adapters to each female
Ground fault in wiring harside.
2 ness
Between PTCN2 (female)(17) and ground or between
Resistance
Min. 1 Mz
(Contact with ground circuit) SNC (female) (5) and ground
Between PTCN2 (female)(27) and ground or between
Resistance
Min. 1 Mz
SNC (female) (6) and ground
Defective power train con- If causes 1 and 2 are not detected, power train controller may be defective. (Since
3
troller
this is an internal failure, troubleshooting cannot be performed..)

lever
Circuit diagram related to lever specification selection
40-392
40-396
D375A-6
(06)
DRAFT
D375A-6
(01)
40-393
DRAFT
Failure code [DDTSL1] S/C: Fill high

Action code
E02
Detail of failure
Problem on
machine
Related information
Failure code
Stator clutch oil pressure 1
Failure
DDTSL1
Nevertheless controller does not output to torque converter stator clutch ECMV solenoid circuit, fill
switch signal is turned to ON position.
None in particular
Sufficient traveling torque may not be obtained
ON/OFF of stator clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 31520 T/M fill SW input 2)
Remove seat (approx. 50 kg) and seat bottom cover.
oil pressure".
q
q
q
q
Cause

Defective stator clutch
2. Disconnect connector FSTC and connect T-adapter to male side.
ECMV fill switch (Internal
Between FSTC (female) (1) and ground
short circuit)
Resistance
Min. 1 M
(Fill switch: OFF)
2. Disconnect connector FSTC.
Ground fault of wiring har3. Start engine.
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.)
Ground fault of wiring har2. Disconnect connectors PTCN2 and FSTC, and connect T-adapter to female side
ness
of either of them.
Between PTCN2 (female) (2) and ground or between
Resistance
Min. 1 M
FSTC (female) (1) and ground
troller
Voltage
7 11 V
3. Start engine.
Voltage
Max. 1 V
40-394
D375A-6
(01)
DRAFT
Circuit diagram related to stator clutch oil pressure
D375A-6
(01)
40-395
DRAFT
Failure code [DDTSLH] S/C: Fill low

Action code
E02
Detail of failure
Problem on
machine
Related information
Failure code
Stator clutch oil pressure 2
Failure
DDTSLH
Nevertheless controller does not output to torque converter stator clutch ECMV solenoid circuit, fill
None in particular
Sufficient traveling torque may not be obtained
ON/OFF of stator clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 31520 T/M fill SW input 2)
Remove seat (approx. 50 kg) and seat bottom cover.
oil pressure".
q
q
q
q
Cause
1 ECMV fill switch (Fill switchdose not turn to ON position)
2
contact)
40-396

2. Disconnect connector FSTC and connect T-adapter to male side.
3. Start engine.
Between FSTC (female) (1) and ground
Resistance
Max. 1
(Fill switch: ON)
2. Disconnect connectors PTCN2 and FSTC and connect T-adapter to female side
of either of them.
Between PTCN2 (female) (2) and FSTC (female) (1) Resistance
Max. 1
If no abnormality is found by the above checks, power train controller is defective.
Voltage
7 11 V
12 are same as above.
3. Start engine.
Voltage
Max. 1 V
D375A-6
(01)
DRAFT
Circuit diagram related to stator clutch oil pressure
D375A-6
(01)
40-397
Failure code [DGE5KX] Ambient temp sensor abnormality

Action code
Failure code
Failure
DGE5KX
Detail of failure
Problem on
machine
Related information
40-402
Atmospheric temperature sensor:Abnormality

Input signal voltage from the atmospheric temperature sensor reads 4.9 V and above or 0.3 V or
less.
None in particular
Monitoring function fails to monitor the atmospheric temperature.
The LED of the VHMS controller displays "n4"o"01".

If the machine is normal, the input state (temperature) from the atmospheric temperature sensor
can be checked with the monitoring function (Code: 37501 ATR TEMP).
q
q
Cause

2. Disconnect connector INT and connect T-adapter to male side.
a If ambient temperature sensor resistance is 2.2 34 kz, regard ambient temperature sensor as normal.
Defective atmospheric temperature sensor
INT (male)
Between (1)
and (2)
Atmospheric temperature
Resistance
-20 C
27 - 34 kz
0 C
10 - 13 kz
25 C
3.8 - 4.6 kz
40 C
2.2 - 2.6 kz

2. Disconnect connector V2A and connect T-adapter to female side.
Open or short circuit in wir- Between V2A (female) (10) and (12)
2
a Resistance accords with ambient temperature - reing harness
Resistance 2.2 - 34 kz
sistance characteristics table of ambient temperature
sensor in cause 2.
Open circuit in wiring har2. Disconnect connectors V2A and INT and connect T-adapters to each female side.
ness
3
(wire breakage or defective Between V2A (female) (10) and INT (female) (1)
Resistance
Max. 1 z
Between V2A (female) (12) and INT (female) (2)
Resistance
Max. 1 z
Ground fault in wiring har- 2. Disconnect connectors INT and V2A and connect T-adapters to either female
4 ness
side.
(Contact with ground circuit) Between INT (female) (1) and ground or between V2A
Resistance
Min. 1 Mz
(female) ( 10) and ground
Hot short circuit or short cir- 2. Disconnect connectors INT and connect T-adapter to female side.
5
Between INT (female) (1) and (2)
40-398
Voltage
Approx. 5 V
If cause is not found by above checks, the VHMS controller is defective.

D375A-6
(06)
DRAFT
Circuit diagram related to ambient temperature sensor
D375A-6
(01)
40-399
DRAFT
Troubleshootingbyfailurecode
Failurecode[DGS1KX] Hydoil temp: signal abnormal
Failure code [DGS1KX] Hyd oil temp: signal abnormal

Action code
E01
Detail of failure
Problem on
machine
Related information
Failure code
DGS1KX
Failure
Hydraulic oil temperature sensor: Abnormal

(Mechane monitor power train control system)
Hydraulic oil temperature sensor signal is out of normal range.
None in particular.
Hydraulic oil temperature on monitor panel is not displayed normally.

Fan speed is limited to half.
Hydraulic oil temperature can be checked in monitoring mode.
(Code: 04401 Hydraulic oil temperature)
Method of reproducing failure code: Turn starting switch to ON position or start engine.
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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 k
1
Between HDT (male) (1) and (2)
30 C
Resistance
Approx. 35 k
a Temperature characteristics
short circuit)
80 C
Resistance
Approx. 6.5 k
of oil temperature sensor
100 C
Resistance
Approx. 3.5 k
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,
and if voltage is 24 V, wiring harness has hot short.
wiring harness
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
Disconnection or short circuit a Resistance accords with temperature characteristics table in cause 1.
3
in wiring harness
a If resistance is above1 M, wiring harness has disconnection. If resistance is
below 1 , wiring harness has short circuit.
Approx.3.5
Resistance
90 k
a If neither of causes 2 and 3 is the cause for the trouble, this check is not required.
Disconnection in wiring har2. Disconnect connectors CM01 and HDT, and connect T-adapters to female side
ness
4
of them.
Between
CM01 (female) (8) and HDT (female)
Resistance
contact)
Max. 1
(1)
Between CM01 (female) (12) and HDT (female)
Resistance
Max. 1
(2)
Ground fault of wiring harness 2. Disconnect connectors CM01 and HDT, and connect T-adapter to female side
5
of either of them.
Between CM01 (female) (8) and (3), or between
Resistance
Min. 1 M
HDT (female) (1) and ground
2. Disconnect connectors CM01 and HDT, and connect T-adapter to female side
of CM01.
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
(01)
40-401
DRAFT
Failure code [DGT1KA] T/C oil temp sensor: Abnormal

Action code
E01
Detail of failure
Problem on
machine
Related information
Failure code
Torque converter oil temperature sensor: Disconnection
Failure
DGT1KA
Torque converter oil temperature sensor signal is out of normal range.
None in particular.
Power train oil temperature gauge may not indicate normally.

Fan speed is limited to half speed.
Gear shift shock of transmission increases.
Torque converter oil temperature is considered to be power train oil temperature.
Torque converter oil temperature can be checked with monitoring function.
Method of reproducing failure code: Turn starting switch to ON position or start engine.
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Cause

1.
Turn
starting
switch
to OFF position.
Defective torque con2.
Disconnect
connector
453 and connect T-adapter to male side.
verter oil temperature
25 C
Resistance
Approx. 42 k
1 sensor
Between 453 (male) (1) and (2)
30 C
Resistance
Approx. 35 k
(Internal disconnection a Temperature characteristics of oil
80 C
Resistance
Approx. 6.5 k
or short circuit)
temperature sensor
100 C
Resistance
Approx. 3.5 k
2. Disconnect connectors 453 and connect T-adapter to female side.
Disconnection, short cir- 3. Turn starting switch ON position.
cuit or hot short in or
a If voltage is 0 V, wiring harness has disconnection, ground fault or short circuit, and if
2
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 M, wiring harness has disconnection. If resistance is below
Approx. 3.5
Resistance
90 k
Disconnection in wiring 1. Turn starting switch to OFF position.
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
Between WECN1 (female) (21) and 453 (female) (2)
Resistance
Max. 1
2. Disconnect connectors WECN1 and 453, and connect T-adapter to female side of
WECN1.
5
harness
Between WECN1 (female) (20) and each pin other
than (20)
heard.)
ment controller
40-402
D375A-6
(01)
DRAFT
Circuit diagram related to torque converter oil temperature sensor
D375A-6
(01)
40-403
DRAFT
Failure code [DGT1KX] T/C oil temp sensor: Abnormal

Action code
E01
Detail of failure
Problem on
machine
Related information
Failure code
Torque converter oil temperature sensor: Short circuit
Failure
DGT1KX
Torque converter oil temperature sensor signal is out of normal range.
No particular action
Power train oil temperature gauge may not indicate normally.

Fan speed is limited to half speed.
Shock at gear shift is hard.
Torque converter oil temperature is considered to be power train oil temperature.
For temperature characteristics table of oil temperature sensor, see [DGT1KA].
If the sensor connector is disconnected in the normal condition and turn starting switch to ON position, failure code [DGT1KA] is displayde.
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Cause

Defective torque con2. Disconnect connector 453.
verter oil temperature
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
either of them.
(Contact with ground cirBetween WECN1 (female) (20) and ground or
cuit)
Resistance
Min. 1 M
between 453 (female) (1) and ground
WECN1.
harness
than (20)
Defective work equipIf 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
(01)
40-405
Failure code [DGT5KA] F exhaust temp sensor disconnection

Action code
Failure code
Failure
DGT5KA
Detail of failure
Problem on
machine
Related information
40-410
Front exhaust temp sensor disconnection: Disconnection

Input signal voltage from the exhaust gas temperature sensor on the engine front side is below 0.5
V.
None in particular
Monitoring function fails to monitor the exhaust gas temperature on the engine front side
The LED of the VHMS controller displays n3" o "12".

If the machine is normal, the input state (temperature) from the front exhaust gas temperature sensor can be checked with the monitoring function (Code: 42610 EXHAUST TEMP FRONT).
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Cause

If failure code [DBB6KP] is displayed, troubleshoot it first.

Defective sensor power sup- 2. Disconnect connector EXAF and connect T-adapter to female side.
1
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
2. Replace connector EXHF with EXHR.
2 Nos. 1 - 3) exhaust tempera3. Turn starting switch to ON position.
ture sensor
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
each female side or male side of EXTF.
a If cause 1 is not the cause for the failure, this check
is not required.
Resistance
Max. 1 z
Open circuit in wiring harBetween V1 (female) (2) and EXAF (female) (A)
ness
Between V2A (female) (7) and EXAF (female) (B)
Resistance
Max. 1 z
3
a If cause 1 is not the cause for the failure, this check
is not required.
Resistance
Max. 1 z
Between V2A (female) (13) and EXAF (female) (C)
Between EXHF (female) (1) and EXTF (male) (1)
Resistance
Max. 1 z
Between EXHF (female) (2) and EXTF (male) (2)
Resistance
Max. 1 z

2. Disconnect connectors EXHF, EXTF,EXAF, V1 and V2A, and connect T-adapters
to each female side or male side of EXTF.
Between EXHF (female) (1) or EXTF (male) (1) and
Resistance
Min. 1 Mz
Ground fault in wiring harground
4 ness
Between EXHF (female) (1) and (2) ,or EXTF (male) (1)
Resistance
Min. 1 Mz
and (2)
40-406
Between V2A (female) (7) and ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
D375A-6
(06)
Cause
a Check that failure code [DGT6KA] is not displayed.

2. Replace connector EXAF with EXAR.
5 Nos. 1 - 3) exhaust tempera- 3. Turn starting switch to ON position.
ture sensor amplifier
If failure code [DGT5KA] changes to [DGT6KA], original front (cylinder Nos. 1 - 3)
exhaust temperature sensor amplifier is defective.
If cause is not found by above checks, VHMS controller may be defective. (Since this
q Reference: The following shows standard values in the normal condition.
2. Insert T-adapter into connectors V1 and V2A.
100 C - 200 C
Voltage
1.4 1.8 V
200 C - 300 C
Voltage
1.8 2.2 V
300 C - 400 C
Between V2A(7) and (13)
a Exhaust temperature characteris- 400 C - 500 C
tics
500 C - 600 C
Voltage
2.2 2.6 V
Voltage
2.6 3.0 V
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
(06)
40-41
40-407
Failure code [DGT5KB] F exhaust temp sensor short circuit

Action code
Failure code
Failure
DGT5KB
Detail of failure
Problem on
machine
Related information
40-412
Front exhaust temp sensor disconnection:Short circuit

Input signal voltage from the exhaust gas temperature sensor on the engine front side is above 4.9
V.
None in particular
Monitoring function fails to monitor the exhaust gas temperature on the engine front side
The machine monitor does not display any failure code (the relevant failure code can be checked
by downloading data stored in the VHMS controller).
The LED of the VHMS controller displays n3" o "11".
If the machine is normal, the input state (temperature) from the front exhaust gas temperature sensor can be checked with the monitoring function (Code: 42610 EXHAUST TEMP FRONT).
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Cause
Defective sensor power sup1

ply system
a Check that failure code [DGT6KB] is not displayed.
ture sensor
If failure code [DGT5KB] changes to [DGT6KB], original front (cylinder Nos. 1 - 3)
2. Disconnect all connectors EXAF and connect T-adapter to female side.
3 harness
Between EXAF (female) (B) and (C)
Voltage
Max. 1 V
ture sensor amplifier
If failure code [DGT5KB] changes to [DGT6KB], original front (cylinder Nos. 1 - 3)

Between V2A (7) and (13)
a Exhaust temperature characteristics
40-408
100 C - 200 C
Voltage
1.4 1.8 V
200 C - 300 C
Voltage
1.8 2.2 V
300 C - 400 C
Voltage
2.2 2.6 V
400 C - 500 C
Voltage
2.6 3.0 V
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
(06)
DRAFT
D375A-6
(01)
40-409
Failure code [DGT6KA] R exhaust temp sensor disconnection

Action code
Failure code
Failure
DGT6KA
Detail of failure
Problem on
machine
Related information
40-414
Rear exhaust temp sensor disconnection: Disconnection

Input signal voltage from the exhaust gas temperature sensor on the engine rear side is below 0.5
V.
None in particular
Monitoring function fails to monitor the exhaust gas temperature on the engine rear side
The LED of the VHMS controller displays n3 o 22.

If the machine is normal, the input state (temperature) from the rear exhaust gas temperature sensor can be checked with the monitoring function (Code: 42611 EXHAUST TEMP REAR).
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Cause


Defective sensor power sup- 2. Disconnect connector EXAR and connect T-adapter to female side.
1
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.
2 4 - 6) exhaust temperature
sensor
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
each female side or male side of EXTR.
a If cause 1 is not the cause for the trouble, this check
is not required.
Resistance
Max. 1 z
Open circuit in wiring harBetween V1 (female) (2) and EXAR (female) (A)
ness
Between V2A (female) (5) and EXAR (female) (B)
Resistance
Max. 1 z
3
a If cause 1 is not the cause for the trouble, this check
is not required.
Resistance
Max. 1 z
Between V2A (female) (13) and EXAR (male) (C)
Between EXHR (female) (1) and EXTR (male) (1)
Resistance
Max. 1 z
Between EXHR (female) (2) and EXTR (male) (2)
Resistance
Max. 1 z

2. Disconnect connectors EXHR, EXTR, EXAR, V1 and V2A, and connect
T-adapters to each female side or male side of EXTR.
Between EXHR (female) (1) or EXTR (male) (1) and
Resistance
Min. 1 Mz
Ground fault in wiring harground
4 ness
Between EXHR (female) (1) and (2) or EXTR (male) (1)
Resistance
Min. 1 Mz
and (2)
40-410
V2A (female) (5) and ground
Resistance
Min. 1 Mz
V2A (female) (5) and (13)
Resistance
Min. 1 Mz
D375A-6
(06)
Cause
a Check that failure code [DGT5KA ]is not displayed.

sensor amplifier
If failure code [DGT6KA] changes to [DGT5KA], original rear (cylinder Nos. 4 - 6)

Between V2A(5) and (13)
D375A-6
(06)
100 C 200 C
Voltage
1.4 1.8 V
200 C 300 C
Voltage
1.8 2.2 V
300 C 400 C
Voltage
2.2 2.6 V
400 C 500 C
Voltage
2.6 3.0 V
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
40-415
40-411
Failure code [DGT6KB] R exhaust temp sensor short circuit

Action code
Failure code
Failure
DGT6KB
Detail of failure
Problem on
machine
Related information
40-416
Rear exhaust gas temperature sensor (R): Short circuit

Input signal voltage from the exhaust gas temperature sensor on the engine rear side is above 4.9
V.
None in particular
Monitoring function fails to monitor the exhaust gas temperature on the engine rear side
The LED of the VHMS controller displays "n3 o "21".

If the machine is normal, the input state (temperature) from the rear exhaust gas temperature sensor can be checked with the monitoring function (Code: 42611 EXHAUST TEMP REAR).
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Cause
Defective sensor power supIf failure code [DBB6KP] is displayed, troubleshoot it first.
ply system
sensor
If failure code [DGT6KB] changes to [DGT5KB], original rear (cylinder Nos. 4 - 6)
2. Disconnect connector EXAR and connect T-adapter to female side.
3 harness
Between EXAR (female) (B) and (C)
Voltage
Max. 1 V

sensor amplifier
If failure code [DGT6KB] changes to [DGT5KB], original rear (cylinder Nos. 4 - 6)
2. Insert T-adapter into connector V1 and V2A.

40-412
100 C - 200 C
Voltage
1.4 1.8 V
200 C - 300 C
Voltage
1.8 2.2 V
300 C - 400 C
Voltage
2.2 2.6 V
400 C - 500 C
Voltage
2.6 3.0 V
500 C - 600 C
Voltage
3.0 to 3.4 V
600 C - 700 C
Voltage
3.4 to 3.9 V
700 C - 800 C
Voltage
3.9 to 4.3 V
D375A-6
(06)
DRAFT
D375A-6
(01)
40-413
DRAFT
Failure code [DH21KA] Weq pressure sensor: Disconnection

Action code
E01
Detail of failure
Problem on
machine
Related information
Failure code
Work equipment pump oil pressure sensor : Disconnection
Failure
DH21KA
Signal voltage of work equipment pump oil pressure sensor is below 0.2 V.
None in particular.
Oil pressure of work equipment pump cannot be monitored.
Signal voltage of work equipment pump oil pressure sensor can be checked with monitoring function.
(Code: 70701 Hydraulic Pressure Sensor 1)
Cause
Defective sensor 5 V power

suplly system

pump oil pressure sensor
(Internal disconnection) or
ground fault



controller
40-414

If failure code [DB97KK] is also displayed, troubleshoot it first.
2. Disconnect connector HHP and connect T-adapter to female side.
Power
Voltage
4.5 5.5 V
supply
2. Insert T-adapter into connector HHP.
a If power supply voltage is normal and sensor output voltage is abnormal (below
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, 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 normal, this check is not required.
Resistance
Max. 1
Between WECN1 (female) (21) and HHP
(female) (A)
a If power supply voltage in checks 1 is normal, this check is not required.
Resistance
Max. 1
(female) (B)
Resistance
Max. 1
(female) (C)
a If cause 2 is not the cause for the failure, this check is not required.
2. Disconnect connectors STC1 and HHP, and connect T-adapter to female side of
either of them.
Between WECN1 (female) (9) and (21), or
Resistance
Min. 1 M
between HHP (female) (C) and (A)
Between WECN1 (female) (9) and ground, or
Resistance
Min. 1 M
between HHP (female) (C) and ground
2. Insert T-adapter into connector WECN1
Voltage
0.5 4.5 V
D375A-6
(01)
DRAFT
Circuit diagram related to work equipment pump oil pressure
D375A-6
(01)
40-415
DRAFT
Failure code [DH21KB] Weq pressure sensor: Short circuit

Action code
E01
Detail of failure
Problem on
machine
Related information
Failure code
Work equipment pump oil pressure sensor: Disconnection
Failure
DH21KB
Signal voltage of work equipment pump oil pressure sensor is above 4.8 V.
None in particular.
Oil pressure of work equipment pump cannot be monitored.
Signal voltage of work equipment pump oil pressure sensor can be checked with monitoring function.
(Code: 70701 Hydraulic Pressure Sensor 1)
If the sensor connector is disconnected in the normal condition and turn starting switch to ON position, failure code [DH21KA] is displayed.
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Cause

If failure code [DB97KK] is also displayed, troubleshoot it first.
2. Disconnect connector HHP and connect T-adapter to female side.
supply system
Power
Voltage
4.5 5.5 V
supply
2. Disconnect connector HHP
pump oil pressure sensor
If failure code [DH21KB] is not displayed but [DH21KA] of disconnection is dis(Internal disconnection) or
played, work equipment pump oil pressure sensor is defective. (If failure code
ground fault
[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.
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
of WECN1.
a Check with tester in continuity mode.
Between WECN1 (female) (9) and each pin
other than (9)
controller
2. Insert T-adapter into connector WECN1
Voltage
0.5 4.5 V
40-416
D375A-6
(01)
DRAFT
Circuit diagram related to work equipment pump oil pressure
D375A-6
(01)
40-417
DRAFT
Failure code [DHE5KB] ENG blow-by pressure sensor disconnection

Action code
Detail of failure
Problem on
machine
Related information
Failure code
Engine blow-by pressure sensor: Disconnection
Failure
DHE5KB
Input signal voltage from the blow-by pressure sensor is below 0.1 V.
None in particular.
Monitoring function fails to monitor the blow-by pressure
The LED of the VHMS controller displays "n3"o"32".

The input state (pressure) from the blow-by pressure sensor can be checked with the monitoring function (Code: 42801 BLOWBY PRESSURE).
Method of reproducing failure code: Start engine and performs troubleshooting
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Cause
Defective sensor 5 V power supply

system

Defective blow-by pressure sensor

(Internal defect)

(Disconnection or defective contact
in connector)
Defective VHMS controller
40-418

2. Disconnect connectors ENBP and connect T-adapter to female side.
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
Between ENBP (female) (C) and (A), or
Resistance
Min. 1 M
between V2A (female) (18) and (12)
Between ENBP (female) (C) or V2A (female)
Resistance
Min. 1 M
(18) and ground
2. Insert T-adapter into connector ENBP.
3. Turn starting switch to ON position, start engine, and then perform troubleshooting.
Between ENBP (C)
Sensor output (Normal)
Voltage
0.5 4.5 V
Sensor output (High idle)
Voltage
0.5 0.9 V
and (A)
2. Disconnect connectors ENBP and connect T-adapter to male side.
Between ENBP (female) (A), (B), (C) and
Resistance
Min. 1 M
ground
2. Disconnect connectors ENBP, V1 and V2A and connect T-adapters to
a If power supply voltage in cause 1 is normal,
Resistance
Max. 1
Between V1 , V2A (female) (12) and ENBP
(female) (A)
a If power supply voltage in cause 1 is normal,
Resistance
Max. 1
Between V1 (female) (4) and ENBP (female) (B)
Between V2A (female) (18) and ENBP (female)
Resistance
Max. 1
(C)
If cause is not found by above checks, VHMS controller may be defective.
Between V1 (4) and V2A (12)
Power supply
Voltage
4.85 5.15 V
Between V2A (18)
Voltage
0.5 4.7 V
Voltage
0.5 0.9 V
and (12)
D375A-6
(01)
DRAFT
Circuit diagram related to engine blow-by pressure sensor
D375A-6
(01)
40-419
DRAFT
Failure code [DHE5KY] ENG blow-by pressure sensor short circuit

Action code
Detail of failure
Problem on
machine
Related information
Failure code
Engine blow-by pressure sensor: Short circuit
Failure
DHE5KY
Input signal voltage from the blow-by pressure sensor is above 4.7 V.
None in particular.
Monitoring function fails to monitor the blow-by pressure
The LED of the VHMS controller displays "n3" o "31".

The input state (pressure) from the blow-by pressure sensor can be checked with the monitoring
function (Code: 42801 BLOWBY PRESS).
Method of reproducing failure code: Start engine and performs troubleshooting
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Cause
Defective sensor 5 V power supply

system

(Contact with 24V circuit)
Defective blow-by pressure sensor

(Internal defect)
40-420

2. Disconnect connectors ENBP and connect T-adapter to female side.
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
Between ENBP (female) (C) and (A) , or
Voltage
Max. 1 V
between V2A (female) (18) and (12)
2. Insert T-adapter into connector ENBP.
Between ENBP (C)
Voltage
0.5 4.5 V
Voltage
0.5 0.9 V
and (A)
2. Disconnect connectors ENBP and connect T-adapter to male side.
Between ENBP (male) (A), (B),( C) and ground Resistance Min. 1 M
If cause is not found by above checks, VHMS controller may be defective.
Between V1 (4) and V2A (12)
Power supply
Voltage
4.85 5.15 V
Between V2A (18)
Voltage
0.5 4.7 V
Voltage
0.5 0.9 V
and (12)
D375A-6
(01)
DRAFT
Circuit diagram related to engine blow-by pressure sensor
D375A-6
(01)
40-421
DRAFT
Failure code [DHT3KX] T/M oil pressure sensor abnormality

Action code
Detail of failure
Problem on
machine
Related information
Failure code
DHT3KX
Failure
Transmission oil pressure sensor input signal out of range
Signal voltage of transmission oil pressure sensor is abnormal (below 0.3 V or above 4.9 V).
None in particular.
System may not operate normally.
LED displays "n6" o "14".
Cause

Defective sensor power supply
2. Disconnect connectors TMMD and connect T-adapter to female side.
system
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.
pressure sensor
Between TMMD (A) and (C)
Voltage
15V
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
Resistance
Max. 1
(Disconnection or defective con- Between V1 (female) (2) and TMMD (female) (B)
tact in connector)
a If cause 1 is not the cause for the failure, this
Resistance
Max. 1
Between V2A (female) (12) and TMMD (female)
(C)
Between V2A (female) (15) and TMMD (female)
Resistance
Max. 1
(A)
2. Disconnect connectors TMMD,V1 and V2A and connect T-adapter to female
side of one of them.
Between
V2A (female) (15) or TMMD (female) (A)
Resistance
Min. 1 M
and ground
Between V2A (female) (15) and (12) , or between
Resistance
Min. 1 M
TMMD (female) (A) and (C)
Hot short or short circuit in wiring 2. Disconnect connectors TMMD and connect T-adapter to female side.
harness
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.
Voltage
15V
40-422
D375A-6
(01)
DRAFT
Circuit diagram related to transmission oil pressure sensor
D375A-6
(01)
40-423
Failure code [DHT5KA] T/C in-pressure sensor: Disconnection

Action code
Failure code
Failure
E02
DHT5KA
Detail of failure
Problem on
machine
Related information
40-428
Torque converter inlet pressure sensor: Disconnection

Signal voltage of torque converter inlet pressure sensor is below 0.2 V.
None in particular
No hydraulic pressure can be monitored at torque converter inlet.

Signal voltage of torque converter inlet pressure sensor can be checked with monitoring function.
(Code 32602: Torque converter inlet pressure sensor voltage)
q
q
q
Cause

If failure code [DBE6KK] is also displayed, troubleshoot it first.

Defective 5 V power supply 2. Disconnect connector TIP and connect T-adapter to female side.
1
system
Between TIP (female) (B) and (A)

2 inlet pressure sensor (internal failure) or ground fault
1.
2.
3.
a
Power supply
Voltage
20 30 V

Insert T-adapter into connector TIP.
If power supply voltage is normal and sensor output voltage is abnormal (below
go to cause 4. If check result of cause 4 is normal, torque converter inlet pressure
Between TIP (female) (C) and (A)
Sensor output
Voltage
0.5 6.0 V

2. Disconnect connectors PTCN1 and TIP, and connect T-adapters to each female
side.
Open circuit in wiring hara If power supply voltage in checks on cause 1 is norness
mal, this check is not required.
Resistance
Max. 1 z
3 (wire breakage or defective Between PTCN1 (female) (16) and TIP (female) (B)
a If power supply voltage in checks on cause 1 is normal, this check is not required.
Resistance
Max. 1 z
Between PTCN1 (female) (21) and TIP (female) (A)
Between PTCN1 (female) (13) and TIP (female) (C)
Resistance
Max. 1 z
2. Disconnect connectors PTCN1 and TIP, and connect T-adapters to either female
Ground fault in wiring harside.
4 ness
Between PTCN1 (female) (13) and (21), or between TIP
Resistance
Min. 1 Mz
(female) (C) and (A)
Between PTCN1 (female) (13) and ground, or between
Resistance
Min. 1 Mz
TIP (female) (C) and ground
Defective power train con- 1. Turn starting switch to OFF position.
5
2. Insert T-adapter into connector PTCN1
troller
40-424
Voltage
0.5 6.0 V
D375A-6
(06)
DRAFT
Circuit diagram related to torque converter inlet pressure sensor
D375A-6
(01)
40-425
Failure code [DHT5KB] T/C in-pressure sensor: Short circuit

Action code
Failure code
Failure
E02
DHT5KB
Detail of failure
Problem on
machine
Torque converter inlet pressure sensor: short circuit

Signal voltage of torque converter inlet pressure sensor is above 4.7 V.
None in particular
No hydraulic pressure can be monitored at torque converter inlet.

Signal voltage of torque converter inlet pressure sensor can be checked with monitoring function.
(Code: 32602 Torque converter inlet pressure sensor voltage)
Method of reproducing failure code: Turn starting switch to ON position..
If the sensor connector is disconnected in the normal condition and turn starting switch to ON position, failure code [DHT5KA] is displayed.
q
q
Related information
40-430
q
q
Cause


Defective sensor 5 V power 2. Disconnect connector TIP and connect T-adapter to female side.
1
supply system
Between TIP (female) (B) and (A)
Power supply
Voltage
20 30 V

2. Disconnect connector TIP.
2 inlet pressure sensor (interIf failure code [DHT5KB] is not displayed, torque converter inlet pressure sensor is
nal failure) or ground fault
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.
harness
3
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 of
PTCN1.
Between PTCN1 (female ) (13) and each pin other than No continuity (No sound is
(13)
heard)
40-426
Voltage
0.5 6.0 V
D375A-6
(06)
DRAFT
Circuit diagram related to torque converter inlet pressure sensor
D375A-6
(01)
40-427
DRAFT
Failure code [DHT7KA] T/C out-pressure sensor: Disconnection

Action code
E02
Detail of failure
Problem on
machine
Related information
Failure code
Torque converter outlet pressure sensor: Disconnection
Failure
DHT7KA
Signal voltage of torque converter outlet pressure sensor is below 0.2 V.
None in particular.
No hydraulic pressure can be monitored at torque converter outlet.

Signal voltage of torque converter outlet pressure sensor can be checked with monitoring function.
(Code 32604: Torque converter outlet pressure sensor voltage)
q
q
q
Cause
Defective power supply system
Defective torque converter outlet pressure sensor (internal

failure) or ground fault

(Disconnection in wiring or

40-428

2. Disconnect connector TOP and connect T-adapter to female side.
Between TOP (female) (B) and (A) Power supply
Voltage
20 30 V
2. Insert T-adapter into connector TOP.
go to cause 4. If check result of cause 4 is normal, torque converter outlet pressure 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
normal, this check is not required.
Resistance
Max. 1
Between PTCN1 (female) (16) and TOP (female)
(B)
a If power supply voltage in checks on cause 1 is
normal, this check is not required.
Resistance
Max. 1
(A)
Resistance
Max. 1
(C)
2. Disconnect connectors PTCN1 and TOP, and connect T-adapter to female side
of either of them.
Between PTCN1 (female) (7) and (21), or between
Resistance
Min. 1 M
TOP (female) (C) and (A)
Between PTCN1 (female) (7) and ground, or
Resistance
Min. 1 M
between TOP (female) (C) and ground
Voltage
0.5 6.0 V
D375A-6
(01)
DRAFT
Circuit diagram related to torque converter outlet pressure sensor
D375A-6
(01)
40-429
DRAFT
Failure code [DHT7KB] T/C out-pressure sensor: Short circuit

Action code
E02
Detail of failure
Problem on
machine
Related information
Failure code
DHT7KB
Failure
Torque converter outlet pressure sensor: short circuit

Signal voltage of torque converter outlet pressure sensor is above 4.7 V.
None in particular.
No hydraulic pressure can be monitored at torque converter outlet.

Signal voltage of torque converter outlet pressure sensor can be checked with monitoring function.
(Code 32604: Torque converter outlet pressure sensor voltage)
If the sensor connector is disconnected in the normal condition and turn starting switch to ON position,failure code [DHT7KA ] is displayed.
q
q
q
q
Cause

Defective sensor power sup- 2. Disconnect connector TOP and connect T-adapter to female side.
ply system
Between TOP (female) (B) and (A) Power supply
Voltage
20 30 V
2. Disconnect connector TOP.
outlet pressure sensor (inter- 3. Turn starting switch to ON position.
If failure code [DHT7KB] is not displayed, torque converter outlet pressure sensor
nal failure) or ground fault
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.
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
of PTCN1.
Between PTCN 1 (female) (7) and each pin other
than (7)
heard)
Defective power train control- 1. Turn starting switch to OFF position.
ler
Voltage
0.5 6.0 V
40-430
D375A-6
(01)
DRAFT
Circuit diagram related to torque converter outlet pressure sensor
D375A-6
(01)
40-431
DRAFT
Failure code [DK10KA] Fuel control Dial: Disconnection

Action code
E03
Detail of failure
Problem on
machine
Related information
q
q
q
q
q
q
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Failure code
Fuel control Dial: Disconnection
Failure
DK10KA
Signal voltage of fuel control dial is below 0.5 V.
Continues control with signal of decelerator pedal potentiometer.
Once machine stops, engine speed is limited to medium (half).
Once machine stops, travel is limited to F1 and R1.
Signal voltage of fuel control dial signal can be checked with monitoring function.
(Code: 03000 Fuel Dial Sensor)
Cause

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
(Internal disconnection or 4. Rotate fuel control dial and troubleshoot.
Between DIAL (male) (1) and (3)
Resistance
Approx. 5
ground fault)
Resistance
0.5 - 4.5 k
Resistance
0.5 - 4.5 k
Between DIAL(male) (2) and ground
Resistance
Min. 1 M
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.
a If resistance is above 1 M, wiring harness has disconnection. If resistance is below 1 , wiring harness has short circuit.
Resistance
Approx. 5
Resistance
0.5 - 4.5 k
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 result of cause 3 is normal, this check is not required.
Resistance
Max. 1
Between
PTCN1
(female)
(22)
and
DIAL(female)
Disconnection in wiring har(1)
ness
a If power supply voltage in cause 1 or check re(Disconnection or defecsult of cause 3 is normal, this check is not retive contact in connector)
quired.
Resistance
Max. 1
Between PTCN1 (female) (21) and DIAL (female)
(3)
a If check result of cause 3 is normal, this check
is not required.
Resistance
Max. 1
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
ness
either of them.
(Contact with ground cirPTCN1 (female) (8) and (21), or between DIAL
Resistance
Min. 1 M
cuit)
PTCN1 (female) (8) and ground , or between
Resistance
Min. 1 M
DIAL (female) (2) and ground
40-432
D375A-6
(01)
Cause

4. Rotate fuel control dial and troubleshoot.
PTCN1 (8) and (21)
Circuit diagram related to fuel control dial
D375A-6
(06)
Voltage
0.5 4.5 V
40-437
40-433
DRAFT
Failure code [DK10KB] Fuel control Dial: Short circuit

Action code
E03
Detail of failure
Problem on
machine
Related information
q
q
q
q
q
q
q
Failure code
Fuel control Dial: Short circuit
Failure
DK10KB
Signal voltage of fuel control dial is above 4.5 V.
Continues control with signal of decelerator pedal potentiometer..
Signal voltage of fuel control dial signal can be checked with monitoring function.
(Code: 03000 Fuel Dial Sensor)
Cause

Defective sensor 5 V power 2. Disconnect connector DIAL and connect T-adapter to female side.
supply system
Between DIAL (female) (1) and (3)
Power supply
Voltage
4.5 5.5 V
Defective fuel dial
(Internal disconnection or 4. Rotate fuel control dial and troubleshoot.
short circuit)
Resistance
Approx. 5
Resistance
0.5 - 4.5 k
Resistance
0.5 - 4.5 k
harness (Contact with 24 V
circuit)
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 harPTCN1.
ness
Between PTCN1 (female) (8) and each pin other
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
(01)
40-435
DRAFT
Failure code [DK30KA] ST lever 1: Disconnection

Action code
E03
Detail of failure
Problem on
machine
Related information
q
q
q
q
q
q
q
Failure code
Steering potentiometer 1: Disconnection
Failure
DK30KA
Signal voltage of PCCS lever steering potentiometer 1 (ST lever POT ) is below 0.5 V.
Continues control with signal of PCCS lever steering potentiometer 2 (ST lever POT 2).
Signal voltage of PCCS lever steering potentiometer 1 can be checked with monitoring function.
(Code: 50300 S/T Lever 1 Potentio)
Method of reproducing failure code: Turn starting switch to ON position and Operate PCCS lever (in
steering direction))
Cause

2. Disconnect connector TL2 and connect T-adapter to female side.
supply system
Between TL2 (female) (5) and (8)
Power supVoltage
4.5 5.5 V
ply
4. Operate PCCS lever (steering) and troubleshoot.
Defective PCCS lever
a If power supply voltage is normal and sensor output voltage is abnormal (0.5 V or
steering potentiometer 1
below), internal disconnection and ground fault cannot be identified. In this case,
go to cause 4.
ground fault
If check result of cause 4 is normal, PCCS lever steering potentiometer 1 is defective.
Sensor outBetween 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
ness
Resistance
Max. 1
(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
Resistance
Max. 1
Resistance
Max. 1
Ground fault of wiring har- 2. Disconnect connectors PTCN1 and TL2, and connect T-adapter to female side of
ness
either of them.
(Contact with ground cirBetween PTCN1 (female) (2) and (21), or between
Resistance
Min. 1 M
cuit)
TL2 (female) (7) ground (8)
Resistance
Min. 1 M
between TL2 (female) (7) and ground
troller
Voltage
0.96 4.04 V
40-436
D375A-6
(01)
DRAFT
Circuit diagram related to steering potentiometer
D375A-6
(01)
40-437
DRAFT
Failure code [DK30KB] ST lever 1: Short circuit

Action code
E03
Detail of failure
problem on
machine
Related information
q
q
q
q
q
q
q
Failure code
Steering potentiometer 1: Short circuit
Failure
DK30KB
Signal voltage of PCCS lever steering potentiometer 1 (ST lever POT) is above 4.5 V.
Continues control with signal of PCCS lever steering potentiometer 2 (ST lever POT 2).
Method of reproducing failure code: Turn starting switch to ON position and operate PCCS lever (in
steering direction).
Cause
supply system
2. Disconnect connector TL2.
(Internal disconnection) or If failure code [DK30KB] is not displayed, PCCS lever steering potentiometer is defecground 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.
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
ness
than (2)
troller
Voltage
0.96 4.04 V
40-438
D375A-6
(01)
DRAFT
D375A-6
(01)
40-439
DRAFT
Failure code [DK30KX] ST lever: Out of normal range
Failure code [DK30KX] ST lever: Out of normal range

Action code
E04
Detail of failure
Problem on
machine
Failure code
Steering potentiometers 1 and 2: Out of normal range
Failure
DK30KX
In PCCS lever steering potentiometer 1 (ST lever POT) and 2 (ST lever POT 2), either of failure codes
[DK30KA] and [DK30KB] and either of failure codes [DK31KA] and [DK31KB] occurred at the same
time.

Once machine stops, it cannot travel at all.
Signal voltage of PCCS lever steering potentiometer 1 and 2 can be checked with monitoring function.
q
q
Related information
q
Cause
Perform troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA] and [DK31KB].
Failure code [DK30KZ] ST lever: Disconnection or short circuit

Action code
E04
q
Failure code
Steering potentiometer: Abnormal at key ON
Failure
DK30KZ
In PCCS lever steering potentiometer 1 (ST lever POT) and 2 (ST lever POT 2), when starting switch
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.

Once machine is stopped, it cannot travel at all.
Signal voltage of PCCS lever steering potentiometer 1 and 2 can be checked with monitoring function.
Detail of failure
Problem on
machine
q
q
Related information
q
Cause
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
E03
Detail of failure
Problem on
machine
q
q
q
q
q
q
Related information
Failure code
Steering potentiometer: Signal mismatch
Failure
DK30L8
In PCCS lever steering potentiometer 1 (ST lever POT)and 2 (ST lever POT 2), total of both signal
voltages is below 4.41 V or above 5.59 V.
Continues control with signal of normal one of PCCS lever steering potentiometer 1 (ST lever POT)or
2 (ST lever POT 2).
Signal voltage of PCCS lever steering potentiometer can be checked with monitoring function.
Cause
D375A-6
(01)
40-441
DRAFT

Action code
E03
Detail of failure
Problem on
machine
Related information
q
q
q
q
q
q
q
Failure code
Steering potentiometer 2: Disconnection
Failure
DK31KA
Signal voltage of PCCS lever steering potentiometer 2 (ST lever POT 2) is below 0.5 V.
Continues control with signal of PCCS lever steering potentiometer 1 (ST lever POT).
Cause

supply system
Power supBetween TL2 (female) (5) and (8)
Voltage
4.5 5.5 V
ply
a If power supply voltage is normal and sensor output voltage is abnormal (below 0.5
V), internal disconnection and ground fault cannot be identified. In this case, go to
cause 4.
ground fault
If check result of cause 4 is normal, PCCS lever steering potentiometer 2 is defective.
Sensor outBetween TL2 (female) (6) and (8)
Voltage 0.96 4.04 V
put
them.
Disconnection in wiring har- a If power supply voltage in cause 1 is normal, this check
ness
is not required.
Resistance
Max. 1
(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 check
is not required.
Resistance
Max. 1
Between PTCN1 (female) (21) and TL2 (female)(8)
Resistance
Max. 1
Ground fault of wiring har- 2. Disconnect connectors PTCN1 andTL2, and connect T-adapter to female side of
ness
either of them.
(Contact with ground cirBetween PTCN1 (female) (19) and (21) , or between TL2
Resistance Min. 1 M
cuit)
Between PTCN1 (female) (19) and ground , or between
Resistance Min. 1 M
TL2 (female) (6) and ground
Defective power train con2. 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
(01)
40-443
DRAFT

Action code
E03
Detail of failure
Problem on
machine
Related information
q
q
q
q
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q
q
Failure code
Steering potentiometer 2: Short circuit
Failure
DK31KB
Signal voltage of PCCS lever steering potentiometer 2 (ST lever POT 2) is above 4.5 V.
Continues control with signal of PCCS lever steering potentiometer 1 (ST lever POT).
Cause
supply system
(Internal disconnection) or If failure code [DK31KB] is not displayed, PCCS lever steering potentiometer is defective.( If failure code [DK31KB] is still displayed, wiring harness or power train controller
ground fault
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.
Voltage
Max. 1 V
ness
Between PTCN1 (female) (19) and each pin other No continuity (No sound is heard)
than (19)
Defective power train con2. Insert T-adapter into connector PTCN1
troller
Voltage
0.96 4.04 V
40-444
D375A-6
(01)
DRAFT
D375A-6
(01)
40-445
DRAFT
Failure code [DK40KA] Brake potentiometer: Disconnection

Action code
E03
Detail of failure
Problem on
machine
Related information
Failure code
Brake potentiometer: Disconnection
Failure
DK40KA
Signal voltage of brake pedal potentiometer is below 0.5 V.
travel is limited to F1 and R1.

Signal voltage of brake pedal potentiometer can be checked with monitoring function.
(Code: 50400 Brake Pedal Potentio)
Method of reproducing failure code: Turn starting switch to ON position and operate brake pedal.
q
q
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Cause

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
potentiometer
4. Depress brake pedal and troubleshoot.
(Internal disconnection or Between BRK (male) (C) and (A)
Resistance
Approx. 5 k
ground fault)
Between BRK (male) (A) and (B)
Resistance
0.25 - 7.0 k
Between BRK (male) (B) and (C)
Resistance
0.25 - 7.0 k
Between BRK (male) B)and ground
Resistance
Min. 1 M
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.
a If resistance is above 1 M, wiring harness has disconnection. If resistance is below 1 , wiring harness has short circuit.
Resistance
Approx. 2 k
Resistance
0.2 - 1.8 k
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 result of cause 3 is normal, this check is not required.
Resistance
Max. 1
Between PTCN1 (female) (21) and BRK (female)
harness
(A)
(Disconnection or defec- a If power supply voltage in cause 1 or check retive contact in connector)
sult of cause 3 is normal, this check is not required.
Resistance
Max. 1
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
Between PTCN1 (female) (3) and BRK (female) (B)
40-446
D375A-6
(01)
DRAFT
Circuit diagram related to brake potentiometer
D375A-6
(01)
40-447
DRAFT
Failure code [DK40KB] Brake potentiometer: Short circuit

Action code
E03
Detail of failure
Problem on
machine
Related information
Failure code
DK40KB
Failure
Brake potentiometer: Short circuit

Signal voltage of brake pedal potentiometer is above 4.8 V.
travel is limited to F1 and R1.

Signal voltage of brake pedal potentiometer can be checked with monitoring function.
(Code: 50400 Brake Pedal Potentio)
Method of reproducing failure code: Turn starting switch to ON position and operate brake pedal.
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Cause

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
(Internal disconnection or 4. Depress brake pedal and troubleshoot.
Between BRK (female) (C) and (A)
Resistance
Approx. 5 k
short circuit)
Between BRK (female) (A) and (B)
Resistance
0.25 - 7.0 k
Between BRK (female) (B) and (C)
Resistance
0.25 - 7.0 k
Hot short in wiring harness 2. Disconnect connector BRK and connect T-adapter to male side.
(Contact with 24 V circuit) 3. Turn starting switch ON position.
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
ness
than (3)
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Reference: the followings are standard values in normal condition.
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
(01)
40-449
DRAFT
Failure code [DK55KX] FR lever: Out of normal range
Failure code [DK55KX] FR lever: Out of normal range

Action code
E04
Detail of failure
Problem on
machine
Related information
Failure code
Front/Rear potentiometers 1 and 2: Out of normal range
Failure
DK55KX
In PCCS lever F-R potentiometer 1 (F/R lever 3) and 2 (F/R lever 4), either of failure codes [DK56KA]
and [DK56KB] and either of failure codes [DK57KA] and [DK57KB]occurred at the same time.

Signal voltage of PCCS lever F-R potentiometer can be checked with monitoring function.
(Code: 50200 T/M Lever 1 Potentio)
F-R direction)
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Cause
Failure code [DK55KZ] FR lever: Disconnection or short circuit

Action code
E04
Detail of failure
Problem on
machine
Failure code
Front/Rear potentiometer: Abnormal at key ON
Failure
DK55KZ
In PCCS lever F-R potentiometer 1 (F/R lever 3) and 2 (F/R lever 4), when starting switch is turned
to ON position, only either side is abnormal and then either of failure codes [DK56KA] and
[DK56KB]and either of failure codes [DK57KA] and [DK57KB] occurred at the same time.

Once machine stops, it cannot travel at all.
F-R direction)
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Related information
Cause
40-450
D375A-6
(01)
DRAFT
Failure code [DK55L8] FR lever: Signal mismatch
Failure code [DK55L8] FR lever: Signal mismatch

Action code
E03
Detail of failure
Problem on
machine
Related information
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Failure code
Front/Rear potentiometer: Signal mismatch
Failure
DK55L8
In PCCS lever F-R potentiometer 1 (F/R lever 3) and 2 (F/R lever 4), total of both signal voltages is
below 4.41 V or above 5.59 V.
Continues control with signal of normal one of PCCS lever F-R potentiometer 1 or 2.
F-R direction)
Cause
Perform troubleshooting for failure codes [DK56KA], [DK56KB],[DK57KA] and [DK57KB].
D375A-6
(01)
40-451
Failure code [DK56KA] FR lever 1: Disconnection

Action code
Failure code
Failure
E03
DK56KA
40-460
Front/Rear potentiometer 1: Disconnection

Detail of failure
Signal voltage of PCCS lever F-R potentiometer 1 (F/R lever 3) is below 0.5 V
Problem on
machine
Continues control with signal of PCCS lever F-R potentiometer 2 (F/R lever 4).
Signal voltage of PCCS lever F-R potentiometer 1 can be checked with monitoring function.
Method of reproducing failure code:Turn starting switch to ON position and operate PCCS lever (in
F-R direction).
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Related information
Cause


Defective sensor 5 V power 2. Disconnect connector TL2 and connect T-adapter to female side.
1
supply system
Between TL2 (female) (4) and
Power supply
Voltage
4.5 5.5 V
(1)
Defective PCCS lever F-R 3. Turn starting switch ON position.
4. Operate PCCS lever (F-R) and troubleshoot.
potentiometer 1 (Internal
2 disconnection) or ground
fault
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
1.393.61 V

2. Disconnect connectors PTCN1 and TL2, and connect T-adapters to each female
side.
a
If power supply voltage in cause 1 is normal, this
Disconnection in wiring harcheck is not required.
Resistance
Max. 1 z
ness
3
(open circuit or defective
a If power supply voltage in cause 1 is normal, this
contact)
Resistance
Max. 1 z
Resistance
Max. 1 z
2. Disconnect connectors PTCN1 and TL2, and connect T-adapters to either female
Ground fault of wiring harside.
4 ness
Resistance
Min. 1 Mz
TL2(female)(3) and (1)
Resistance
Min. 1 Mz
between TL2 (female) (3) and ground
Defective power train con- 2. Insert T-adapter into connector PTCN1.
5
troller
40-452
Voltage
1.39 3.61 V
D375A-6
(06)
DRAFT
Circuit diagram related to Front/Rear potentiometer
D375A-6
(01)
40-453
Failure code [DK56KB] FR lever 1: Short circuit

Action code
Failure code
Failure
E03
DK56KB
40-462
Front/Rear potentiometer 1: Short circuit

Detail of failure
Signal voltage of PCCS lever F-R potentiometer 1 (F/R lever 3) is above 4.5 V.
Problem on
machine
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Related information

Method of reproducing failure code:Turn starting switch to ON position and operate PCCS lever (in
F-R direction).
Cause

supply system
2. Disconnect connectors TL2.
Defective PCCS lever F-R
potentiometer 1
If failure code [DK56KB] is not displayed, PCCS lever steering potentiometer is
2
defective. (This failure code is still displayed, wiring harness or power train controller
ground fault
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
40-454
Voltage
Max. 1 V

PTCN1.
Between PTCN1 (female) (20) and each pin other than No continuity (No sound is
(20)
heard)
Voltage
1.39 3.61 V
D375A-6
(06)
DRAFT
D375A-6
(01)
40-455
DRAFT

Action code
E03
Detail of failure
Problem on
machine
Related information
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Failure code
Front/Rear potentiometer 2: Disconnection
Failure
DK57KA
Signal voltage of PCCS lever F-R potentiometer 2 (F/R lever 4) is below 0.5 V.
F-R direction).
Cause

supply system
Defective PCCS lever F-R

potentiometer 2 (Internal
disconnection) or ground
fault

(Disconnection or defective contact in connector)

40-456

Between TL2 (female) (4) and (1)
Power supply
Voltage
4.5 5.5 V
a If power supply voltage is normal and sensor output voltage is abnormal (below 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, PCCS lever F-R potentiometer 2 is defective.
Between TL2 (2) and (1)
Sensor output
Voltage
1.39 3.61 V
them.
Resistance
Max. 1
a If power supply voltage on cause 1 is normal, this
Resistance
Max. 1
Between PTCN1(female) (21) and TL2 (female) (1)
Between PTCN1(female) (14) and TL2 (female) (2)
Resistance
Max. 1
either of them.
Resistance
Min. 1 M
TL2 (female) (2) and (1)
Between (female) (14) and ground , or between TL2
Resistance
Min. 1 M
(female) (2) and ground
Voltage
1.39 3.61 V
D375A-6
(01)
DRAFT
D375A-6
(01)
40-457
DRAFT

Action code
E03
Detail of failure
Problem on
machine
Related information
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Failure code
Front/Rear potentiometer 2: Short circuit
Failure
DK57KB
Signal voltage of PCCS lever F-R potentiometer 2 (F/R lever 4) is above 4.5 V.
F-R direction).
Cause
supply system
Defective PCCS lever F-R 3. Turn starting switch to ON position.
potentiometer 2 (Internal 4. Operate PCCS lever (F-R) and troubleshoot.
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.
Voltage
Max. 1 V
ness
than (14)
heard)
troller
Voltage
1.39 3.61 V
40-458
D375A-6
(01)
DRAFT
D375A-6
(01)
40-459
DRAFT
Failure code [DK60KA] Acceleration sensor: Disconnection

Action code
E01
Detail of failure
Problem on
machine
Related information
Failure code
Acceleration sensor: Disconnection
Failure
DK60KA
Signal voltage of acceleration sensor is below 0.5 V.
Turns shoe slip control(SSC) function OFF.
Even if shoe slips, engine speed does not change.
Input (voltage) from acceleration sensor can be checked in moniitoring function.

(Code 60200 : Voltage of acceleration sensor)
Cause

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 supBetween 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
sor sensor (Internal discon0.5 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 outBetween SSA (female) (2) and (3)
Voltage
0.75 4.25 V
put
2. Disconnect connector PTCN1, PTCN3 and SSA, and connect T-adapters to
Disconnection in wiring har- a If power supply voltage in cause 1 is normal, this
ness
Resistance
Max. 1
(Disconnection or defective Between PTCN3 (female) (34) and SSA (female) (1)
Resistance
Max. 1
Between PTCN 1(female) (21) and SSA (female) (3)
Between PTCN1 (female) (1) and SSA (female) (2)
Resistance
Max. 1
2. Disconnect connector PTCN1, SSA, and connect T-adapter to female side of
Ground fault of wiring hareither of them.
ness
(Contact with ground circuit) Between PTCN1 (female) (1) and (21), or between
Resistance
Max. 1 M
SSA (female) (2) and (3)
Resistance
Max. 1 M
between SSA (female) (2) and ground
ler
Voltage
0.75 4.25 V
40-460
D375A-6
(01)
DRAFT
Circuit diagram related to acceleration sensor
D375A-6
(01)
40-461
DRAFT
Failure code [DK60KB] Acceleration sensor: Short circuit

Action code
E01
Detail of failure
Problem on
machine
Related information
Failure code
Acceleration sensor: Short circuit
Failure
DK60KB
Signal voltage of acceleration sensor is above 4.5 V.
Turns shoe slip control(SSC) function OFF.
Even if shoe slips, engine speed does not change.
Input (voltage) from acceleration sensor can be checked in moniitoring function.

(Code 60200 : Voltage of acceleration sensor)
Cause

If failure code [DBB7KP] is also displayed, troubleshoot it first.
supply system
Power supBetween SSA (female) (1) and (3)
Voltage
4.5 5.5 V
ply
2. Disconnect connector SSA.
Defective acceleration sensor sensor (Internal discon- 3. Turn starting switch to ON position.
If failure code [DK60KB] is not displayed , acceleration sensor is defective. (If failure
nection) or ground fault
code [DK60KB] is still displayed, it shows that wiring harness or power train controller is defective.)
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
PTCN1.
Between PTCN1 (female) (1) and (1) and each pin
No continuity(No sound is
other than
heard)
ler
Voltage
0.75 4.25 V
40-462
D375A-6
(01)
DRAFT
Circuit diagram related to acceleration sensor
D375A-6
(01)
40-463
DRAFT
Failure code [DKH1KA] Pitch angle sensor: Disconnection

Action code
E03
Detail of failure
Problem on
machine
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Related information
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Failure code
Pitch angle sensor: Disconnection
Failure
DKH1KA
Signal voltage of pitch angle sensor is below 0.15 V.
Cannot sense pitch angle of machine.
Gearshift shock is made on slope or steering shock is made on level ground.
State of pitch angle sensor signal can be checked with monitoring function.
(Code: 60100 Pitch Angle Sensor)
If sensor connector is disconnected in normal condition, this code is displayed.
Cause
Defective 24 V power supply

system
Defective pitch angle sensor

2 (Internal defect) or ground
fault


40-464

2. Disconnect connector PT1 and connect T-adapter to female side.
Between PT1 (female) (C) and (A)
Power supply
Voltage
20 30 V
2. Insert T-adapter into connector PT1.
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
of them.
Resistance
Max. 1
Between PTCN3 (female) (16) and PT1 (female) (C)
Resistance
Max. 1
Between PTCN1(female) (21) and PT1 (female) (A)
Between PTCN1 (female) (9) and PT1 (female) (B)
Resistance
Max. 1
2. Disconnect connectors PTCN1 and PT1, and connect T-adapters to female side
of either of them.
Resistance
Max. 1 M
PT1 (female) (B) and (A)
Between PTCN1 (female) (9) and ground, or between
Resistance
Max. 1 M
PT1 (female) (B) and ground
Voltage
0.24 4.76 V
D375A-6
(01)
DRAFT
Circuit diagram related to pitch angle sensor
D375A-6
(01)
40-465
DRAFT
Failure code [DKH1KB] Pitch angle sensor: Short circuit

Action code
E03
Detail of failure
Problem on
machine
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Related information
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Failure code
Pitch angle sensor: Short circuit
Failure
DKH1KB
Signal voltage of pitch angle sensor is above 4.85 V.
Cannot sense pitch angle of machine.
Gearshift shock is made on slope or steering shock is made on level ground.
State of pitch angle sensor signal can be checked with monitoring function.
(Code: 60100 Pitch Angle Sensor)
If the sensor connector is disconnected in the normal condition and turn starting switch to ON position, failure code [DHT5KA] is displayed.
Cause

supply system
Defective pitch angle sensor

(Internal defect)

40-466

Power supBetween PT1 (female) (C) and (A)
Voltage
20 30 V
ply
2. Disconnect connector PT1.
If failure code [DKH1KB] is not displayed but [DKH1KA] of disconnection is displayed, pitch angle sensor is defective.
(If failure code [DKH1KB] is still displayed, it shows that wiring harness or power
train controller is defective.)
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
than (9)
heard)
Voltage
0.24 4.76 V
D375A-6
(01)
DRAFT
Circuit diagram related to pitch angle sensor
D375A-6
(01)
40-467
DRAFT
Failure code [DLF1KA] T/C out-speed sensor: Disconnection
Failure code [DLF1KA] T/C out-speed sensor: Disconnection

Action code
Detail of failure
Problem on
machine
Related information
Failure code
DLF1KA
Failure
Torque converter oil temperature sensor disconnection

No signal is input from torque converter output speed sensor.
Recognizes that torque converter output speed is 0 rpm .
Torque converter output speed cannot be monitored
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).
Cause
output speed sensor (Inter1
nal disconnection or short
circuit)

2. Disconnect connector C1 and connect T-adapter to male side.
Between TC1 (male) (1) and (2)
Between TC1 (male) (1) and ground
Resistance
Min. 1 M
Disconnection or short circuit 2. Disconnect connector PTCN2 and connect T-adapter to female side.
a If resistance is above 1 M, wiring harness has disconnection. If resistance is bein wiring harness
low 1 , wiring harness has short circuit.
ness
2. Disconnect connectors PTCN2 and TC1, and connect T-adapters to female side of
them.
Between PTCN2 (female) (29) and TC1 (female) (2)
Resistance
Max. 1
Between PTCN2 (female) (20) and TC1 (female) (1)
Resistance
Max. 1
Hot short in wiring harness 2. Disconnect connector TC1 and connect T-adapter to female side.
Between TC1 (female) (1) and (2)
Voltage
34V
Defective power train conIf cause is not found by above checks, power train controller may be defective. (Since
troller
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
E02
Detail of failure
Problem on
machine
Related information
Failure code
DLM3KA
Failure
Fan speed sensor: Disconnection

No signal is input from fan speed sensor.
Recognizes that fan speed is 0 rpm.
Fan speed cannot be monitored.

Fan PID control cannot be started.
Fan speed can be checked with monitoring function.
(Code: 10007 Fan speed)
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Cause

Defective fan speed sensor
2. Disconnect connector FRV and connect T-adapter to male side.
Between FRV (male) (1) and (2)
Resistance
Approx. 2 k
short circuit)
Between FRV (male) (1) and ground
Resistance
Min. 1 M
Disconnection or short circuit 2. Disconnect connector WECN2 and connect T-adapter to female side.
Resistance
Approx. 2 k
ness
2. Disconnect connectors WECN2 and FRV, and connect T-adapters to female side
of them.
Between WECN2 (female) (39) and FRV (female) (2) Resistance
Max. 1
Between WECN2 (female) (40) and FRV (female) (1) Resistance
Max. 1
Hot short in wiring harness 2. Disconnect connector FRV and connect T-adapter to female side.
Between FRV (female) (1) and (2)
Voltage
34V
If cause is not found by above checks, work equipment controller may be defective.
controller
Circuit diagram related to fan speed sensor
D375A-6
(01)
40-469
DRAFT
Failure code [DLM3MB] Fan control: Decline
Failure code [DLM3MB] Fan control: Decline

Action code
E02
Detail of failure
Problem on
machine
Related information
Failure code
Fan speed control function low
Failure
DLM3MB
Difference between fan speed set value with work equipment controller and actual speed sensed by
fan speed sensor exceeds 100 rpm.
Work equipment controller does not perform PID control on fan.
Fan speed set value with work equipment controller can be checked with monitoring function.
(Code: 10000 Fan speed command)
Fan speed sensed by fan speed sensor can be checked with monitoring function.
(Code: 10007 Fan speed)
This code is conditioned that fan solenoid is normal and fan speed sensor is also normal (it means
normal electrically).
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Cause
1 Defective hydraulic system
40-470

Perform Testing and adjusting, "Testing fan hydraulic circuit".
D375A-6
(01)
DRAFT
Failure code [DLT3KA] T/M out-speed sensor: Disconnection
Failure code [DLT3KA] T/M out-speed sensor: Disconnection

Action code
E01
Detail of failure
Problem on
machine
Failure code
DLT3KA
Transmission output speed sensor: Disconnection

No signal is input from transmission output speed sensor.
Recognizes that transmission output speed is 0 rpm.
Transmission output speed cannot be monitored.

Traction force cannot be calculated.
Automatic shift down function does not operate.
Once machine stops, gear shift mode is limited to manual gear shift mode.
Transmission output speed can be checked with monitoring function.
(Code: 31400 T/M Out Speed)
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Related information
Trouble
Cause
Defective transmission bevel
gear (output) speed sensor
1
short circuit)

2. Disconnect connector TM1 and connect T-adapter to male side.
Between TM1 (male) (1) and (2)
Resistance
About 560
Between TM1 (male) (1) and ground
Resistance
Min. 1 M
Resistance
About 560
ness
2. Disconnect connector PTCN2 and TM1, and connect T-adapters to female side of
them.
Between PTCN2 (female) (39) and TM1 (female) (2)
Resistance
Max. 1
Between PTCN2 (female) (30) and TM1(female) (1)
Resistance
Max. 1
Hot short in wiring harness 2. Disconnect connector TM1 and connect T-adapter to female side.
Between TM1 (female) (1) and (2)
Voltage
34V
troller
Circuit diagram related to transmission output speed sensor
D375A-6
(01)
40-471
DRAFT
Failure code [DLT3KB] T/M out-speed sensor: Abnormal
Failure code [DLT3KB] T/M out-speed sensor: Abnormal

Action code
E01
Detail of failure
Problem on
machine
Failure code
DLT3KB
Transmission output speed sensor: Disconnection

No signal is input from transmission output speed sensor
Recognizes that transmission output speed is 0 rpm.
Transmission output speed cannot be monitored

Traction force cannot be calculated.
Automatic shift down function may not operate correctly.
Once machine stops, gear shift mode is limited to manual gear shift mode.
Transmission output speed sensor can be checked with moniitoring function.
(Code: 31400 T/M Out Speed)
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Related information
Failure
Cause
Defective transmission bevel
gear (output) speed sensor
1
short circuit)

2. Disconnect connector TM1 and connect T-adapter to male side.
Between TM1 (male) (1) and (2)
Between TM1 (male)(1) and ground
Resistance
Min. 1 M
2
Ground fault of wiring har2. Disconnect connector PTCN2 and TM1, and connect T-adapter to female side of
3 ness
either of them.
(Contact with ground circuit) Between PTCN2 (female) (30) or TM1 (female) (1)
Resistance
Min. 1 M
and ground
Defective power train conIf cause is not found by the above checks, power train controller may be defective.
4
troller
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
E01
Detail of failure
Problem on
machine
Related information
Failure code
DW59KA
Failure
Dual tilt selector solenoid: Disconnection

Any current does not flow when power is output to the dual tilt selector solenoid circuit.
Stops output to dual tilt selector solenoid circuit.
Dual tilt cannot be selector.
Method of reproducing failure code: Turn starting switch to ON position and operate dual tilt selector
switch.
Cause
Defective dual tilt selector
1 solenoid (Internal disconnec- 2. Disconnect connector SOL2 and connect T-adapter to male side.
tion)
SOL2 (male) (1) and (2)
Resistance
10 40
2
Resistance
10 40
ness
2. Disconnect connector WECN3 and SOL2, and connect T-adapters to female side
of them.
defective contact in connec- Between WECN3 (female) (7) and SOL2 (female) (1) Resistance
Max. 1
tor)
Between WECN3 (female) (23) and SOL2 (female)
Resistance
Max. 1
(2)
If cause is not found by the above checks, work equipmet controller may be defec4
controller
tive. (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to dual tilt selector solenoid
D375A-6
(01)
40-473
DRAFT
Failure code [DW59KB] Blade dual selector SOL short circuit
Failure code [DW59KB] Blade dual selector SOL short circuit

Action code
E01
Detail of failure
Problem on
machine
Related information
Failure code
DW59KB
Failure
Dual tilt selector solenoid: Short circuit

Abnormal current flowed when power is output to dual tilt selector solenoid circuit.
Dual tilt cannot be selector.
switch.
Cause

solenoid (Internal short cir- 2. Disconnect connector OL2 and connect T-adapter to male side.
Between SOL2 (male) (1) and (2)
Resistance
10 40
cuit)
Between SOL2 (female) (1) and ground
Resistance
Min. 1 M
Ground fault of wiring har2. Disconnect connector WECN3 and SOL2, and connect T-adapters to female side
ness
of them.
(Contact with ground circuit) Between WECN3 (female) (7) or SOL2 (female) (1)
Resistance
Min. 1 M
and ground
2. Disconnect connector WECN3 and SOL2, and connect T-adapters to female side
Short circuit in wiring harof either of them.
ness
Between WECN3 (female) (7) and (23) or between
Resistance
Min. 1 M
SOL2 (female) (1) and (2)
If cause is not found by the above checks, work equipment controller may be defeccontroller
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
E01
Detail of failure
Problem on
machine
Related information
Failure code
DW59KY
Failure
Dual tilt selector solenoid: Short circuit

Current flows constantly to dual tilt selector solenoid circuit.
Only tilt can be operated and dual tilt cannot be operated.

Blade single tilt does not operate .
switch.
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Cause
1 solenoid (Internal short circuit)


controller

2. Disconnect connector SOL2 and connect T-adapter to male side.
Resistance
10 40
Resistance
Min. 1 M
2. Disconnect connector SOL2 and connect T-adapter to female side.
Voltage
Max. 1 V
2. Disconnect connectors WECN3 and SOL2, and connect T-adapter to female side
of WECN3.
than (7)
heard.)
2. Disconnect connectors WECN3, RB1 and SOL2, and connect T-adapter to female
side and male side of RB1 in 2 times.
Between RB1 (female) (3) and each pin other than (3)
heard.)
Between RB1 (male) (3) and each pin other than (3)
heard.)
D375A-6
(01)
40-475
Failure code [DW5AKA] Blade pitch selector SOL disconnection
Failure code [DW5AKA] Blade pitch selector SOL disconnection

Action code
Failure code
Failure
E02
DW5AKA
Detail of failure
Problem on
machine
Related information
Work equipment pitch select solenoid: Disconnection

No current flows when power is output to the work equipment pitch select solenoid circuit.
Stops output to pitch select solenoid circuit.
Blade pitch cannot be changed.
Method of reproducing failure code: Turn starting switch to ON position and operate pitch select
switch.
Cause
Defective work equipment 1. Turn starting switch to OFF position.

1 pitch select solenoid (Inter- 2. Disconnect connector SOL1 and connect T-adapter to male side.
Resistance
nal disconnection)
40-48
10 40 z

a If resistance is above 1 Mz, wiring harness has disconnection. If resistance is below 1 z, wiring harness has short circuit.
Resistance
10 40 z
Disconnection in wiring har2. Disconnect connectors WECN3 and SOL1, and connect T-adapters to each
ness
female side.
3
Between
WECN3 (female) (17) and SOL1 (female) (1)
Resistance
Max. 1 z
Between WECN3 (female) (23) and SOL1 (female) (2)
4
controller
Circuit diagram related to work equipment pitch select solenoid
40-476
Resistance
Max. 1 z
If cause is not found by the above checks, work equipment controller may be defective. (Since this is an internal failure, troubleshooting cannot be performed.)
40-48
D375A-6
(06)
Failure code [DW5AKB] Blade pitch selector SOL short circuit
Failure code [DW5AKB] Blade pitch selector SOL short circuit

Action code
Failure code
Failure
E02
DW5AKB
Detail of failure
Problem on
machine
Related information
40-489
Work equipment pitch select solenoid: Short circuit

Abnormal current flowed when power was output to work equipment pitch select solenoid circuit.
Blade pitch cannot be changed.
switch.
Cause


1 pitch select solenoid (Inter- Between SOL1 (male) (1) and (2)
nal short circuit)
Between SOL1 (male) (1) and ground
Resistance
10 40 z
Resistance
Min. 1 Mz

Ground fault of wiring har- 2. Disconnect connector WECN3 and SOL1, and connect T-adapter to female side
2 ness
of either of them.
WECN3 (female) (17) or SOL1 (female) (1) and ground Resistance
Min. 1 Mz

controller

2. Disconnect connectors WECN3 and SOL1, and connect T-adapters to either
female side.
Resistance
Min. 1 Mz
SOL1 (female) (1) and (2)
D375A-6
(06)
40-489
40-477
Failure code [DW5AKY] Blade pitch selector SOL Short circuit
Failure code [DW5AKY] Blade pitch selector SOL Short circuit

Action code
Failure code
Failure
E02
DW5AKY
Detail of failure
Problem on
machine
Related information
40-490
Work equipment pitch select solenoid: Short circuit

Current flows constantly to work equipment pitch select solenoid circuit.
Only pitch operation can be changed and tilt operation cannot be changed.
switch.
Cause


1 pitch select solenoid (Inter- Between SOL1 (male) (1) and (2)
nal short circuit)
2

controller
Resistance
Min. 1 Mz
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 than No continuity(No sound is
(17)
heard)
2. Disconnect connectors WECN3, RB1 and SOL1, and connect T-adapter to female
side and male side of RB1 separately in 2 times
Between RB1 (female) (1) and each pin other than (1)
heard)
Between RB1 (male) (1) and each pin of (1)
heard)
40-478
10 40 z

2. Disconnect connector SOL1 and connect T-adapter to female side.
Resistance
40-491
D375A-6
(06)
DRAFT
Failure code [DW7BKA] Fan rev EPC: Disconnection
Failure code [DW7BKA] Fan rev EPC: Disconnection

Action code
E01
Detail of failure
Problem on
machine
Related information
Failure code
Fan reverse solenoid: Disconnection
Failure
DW7BKA
When power is output to fan reverse solenoid circuit, no current flows.
Stops output to fan reverse solenoid circuit.
Fan reverse function cannot be used.
Output condition to fan reverse solenoid can be checked with monitoring function.
(Code: 40983 W/E control SW output)
Method of reproducing failure code: Turn starting switch to ON position and select fan reverse mode.
Cause
Defective fan reverse sole1 noid

2. Disconnect connector FAR2 and connect T-adapter to male side.
Between FAR2 (male) (1) and (2)
Resistance
34 44
Between WECN3 (female) (18) amd (13)
Resistance
34 44
Disconnection in wiring har- 2. Disconnect connector WECN3 and FAR2, and connect T-adapters to their female
ness
sides.
Between WECN3 (female) (18) and FAR2 (female)
Resistance
Max. 1
(1)
Between WECN3 (female) (13) and FAR2 (female)
Resistance
Max. 1
(2)
2. Disconnect connector FAR2 and connect T-adapter to female side.
Between FAR2 (female) (1) and ground
Voltage
Max. 1 V
Circuit diagram related to fan reverse EPC
D375A-6
(01)
40-479
DRAFT
Failure code [DW7BKB] Fan rev EPC: Short circuit
Failure code [DW7BKB] Fan rev EPC: Short circuit

Action code
E01
Detail of failure
Problem on
machine
Related information
Failure code
DW7BKB
Fan reverse solenoid: Short circuit

When power was output to fan reverse solenoid circuit, abnormal current flowed.
Stops output to fan reverse solenoid circuit.
Fan reverse function cannot be used.
Output condition of fan reverse solenoid can be checked with monitoring function.
(Code: 40983 W/E control SW output)
Method of reproducing failure code: Turn starting switch to ON position and select fan reverse mode.
Cause
1
Failure
Defective fan reverse solenoid (Internal short circuit)


controller

2. Disconnect connector FAR2 and connect T-adapter to male side.
Between FAR2 (male) (1) and (2)
Resistance
34 44
Between FAR2 (female) (1) and ground
Resistance
Min. 1 M
2. Disconnect connector WECN3 and FAR2, and connect T-adapter to female side
of either of them.
Between WECN3 (female) (18) or FAR2 (female) (1)
Resistance
Min. 1 M
or ground
2. Disconnect connector WECN3 and FAR2, and connect T-adapter to female side
of either of them.
Between WECN3 (female) (18) and (13) or betwen
Resistance
Min. 1 M
FAR2 (female) (1) and (2)
If cause is not found by the above checks, work equipment controller may be defective. (Since failure is in it, troubleshooting cannot be performed.)
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
E04
Detail of failure
Problem on
machine
Related information
q
q
q
q
q
q
q
Failure code
Sudden stop prevention solenoid disconnection
Failure
DWN3KA
When power is output to sudden stop prevention solenoid circuit, no current flows.
Stops output to sudden stop prevention solenoid circuit.
Restricts operations of engine, transmission, and brake.
Once machine is stopped, engine speed is restricted to medium (half).
Output condition to sudden stop prevention solenoid can be checked with monitoring function.
(Code: 31628 Sudden stop prevention valve current (F/B))
Cause
Defective sudden stop pre1 vention solenoid

2. Disconnect connector STB and connect T-adapter to male side.
Between STB (male) (1) and (2)
Resistance
5 15
2
Resistance
5 15
ness
2. Disconnect connectors PTCN3 and STB, and connect T-adapters to their female
sides.
defective contact in connecBetween PTCN3 (female) (7) and STB (female) (1)
Resistance
Max. 1
tor)
Between PTCN3 (female) (13) and STB (female) (2) Resistance
Max. 1
Defective power train control- If cause is not found by above checks, power train controller may be defective.
4
ler
Circuit diagram related to sudden stop prevention solenoid
D375A-6
(01)
40-481
DRAFT
Failure code [DWN3KB] Ssp solenoid: Short circuit

Action code
E04
Detail of failure
Problem on
machine
Related information
Failure code
DWN3KB
Failure
Sudden stop prevention solenoid short circuit

When power is output to sudden stop prevention solenoid circuit, abnormal current flowed.

Once machine stops, engine speed is restricted to medium (half).
Output condition to sudden stop prevention solenoid can be checked with monitoring function.
Method of reproducing failure code: Turn starting switch tp ON position.
q
q
q
q
q
Cause

Defective sudden stop pre2. Disconnect connector STB and connect T-adapter to male side.
vention solenoid
Resistance
5 15
Between STB (female) (1) and ground
Resistance
Min. 1 M
Ground fault of wiring har2. Disconnect connector PTCN3 and STB, and connect T-adapter to female side of
ness
either of them.
(Contact with ground circuit) Between PTCN3 (female) (7) or STB (female) (1) and
Resistance
Min. 1 M
ground
2. Disconnect connector PTCN3 and STB, and connect T-adapter to female side of
either of them.
Between PTCN3 (female) (7) and (13) ro between
Resistance
Min. 1 M
STB (female) (1) and (2)
Defective power train control- If cause is not found by the above checks, work equipment controller may be defecler
40-482
D375A-6
(01)
DRAFT
D375A-6
(01)
40-483
DRAFT
Failure code [DWN3KY] SSP solenoid: Short circuit

Action code
E04
Detail of failure
Failure code
DWN3KY
When power is output to sudden stop prevention solenoid circuit, current flows.

Emergency sudden stop prevention function does not work.
Once machine stops, machine does not travel.
Output to sudden stop prevention solenoid can be checked with monitoring function
q
q
q
Related information
Sudden stop prevention solenoid short circuit

Problem on
machine
Failure
q
q
Cause

Defective sudden stop pre2. Disconnect connector STB and connect T-adapter to male side.
vention solenoid
Resistance
5 15
(Internal defect)
Resistance
Min. 1 M
2. Disconnect connector STB and connect T-adapter to female side.
Voltage
Max. 1 V
2. Disconnect connector PTCN3 and STB, and connect T-adapter to female side of
PTCN3.
(7)
heard)
1.
Turn
starting
switch
to
OFF
position.
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
(23)
heard)
Between PL2 (male) (23) and each pin other than
(23)
heard)
Defective power train control- If cause is not found by the above checks, power train controller may be defective.
ler
40-484
D375A-6
(01)
DRAFT
D375A-6
(01)
40-485
DRAFT
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection

Action code
E01
Detail of failure
Problem on
machine
Related information
Failure code
DWN5KA
Failure
Fan pump solenoid 1: Disconnection

When power is output to fan pump EPC solenoid 1 circuit (LPV90), no current flows.
Stops output to fan pump EPC solenoid 1 circuit(LPV90).
The output of fan pump(LPV90) is always at maximum speed.
Output to fan pump EPC solenoid 1 can be checked with monitoring function.
(Code: 31624 Fan pump Solenoid (F/B))
Cause
Defective fan pump solenoid 1. Turn starting switch to OFF position.
1 1
2. Disconnect connector FA1 and connect T-adapter to male side.
Between FA1 (male) (1) and (2)
Resistance
2 12
2
Resistance
2 12
ness
2. Disconnect connector WECN3 and FA1, and connect T-adapters to their female
3
sides.
Between WECN3 (female) (36) and FA1 (female) (1) Resistance
Max. 1
Max. 1
If cause is not found by the above checks, work equipment controller may be defec4
controller
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
E01
Detail of failure
Problem on
machine
Related information
Failure code
DWN5KB
Failure
Fan pump solenoid 1: Short circuit

When power was output to fan pump control solenoid 1 (LPV90)circuit, abnormal current flowed.
Stops output to fan pump control solenoid 1 (LPV90) circuit.
Output of fan pump solenoid 1 (LPV90) is always at maximum speed.
Output condition to fan pump control solenoid 1 can be checked with monitoring function.
Cause

Defective fan pump control
solenoid 1
Resistance
2 12
Between FA1 (female) (1) and ground
Resistance
Min. 1 M
Ground fault of wiring har2. Disconnect connector WECN3 and FA1, and connect T-adapter to female side of
ness
either of them.
(Contact with ground circuit) Between WECN3 (female) (36) or FA1 (female) (1)
Resistance
Min. 1 M
and ground
2. Disconnect connector WECN3 and FA1, and connect T-adapter to female side of
either of them.
Resistance
Min. 1 M
FA1 (female) (1) and (2)
D375A-6
(01)
40-487
DRAFT
Failure code [DWN5KY] Fan pump solenoid 1: Short circuit

Action code
E02
Detail of failure
Problem on
machine
Related information
Failure code
DWN5KY
Failure
Fan pump control solenoid 1: Short circuit

Current flows constantly to fan pump EPC solenoid 1 (LPV90)circuit.
Stops output to fan pump EPC solenoid 1 circuit.
The output of fan pump (LPV90) is always at minimum speed.

Machine may be overheat.
Output condition to fan pump EPC solenoid 1 can be checked with monitoring function.
q
q
q
Cause

Defective fan pump control
solenoid 1
Between FA1 (male) (1 and (2)
Resistance
212
Resistance
Min. 1 M
2. Disconnect connector FA1 and connect T-adapter to female side.
Voltage
Max. 1 V
WECN3.
than (36)
heard)
1.
Turn
starting
switch
to
OFF
position.
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)
If cause is not found by the above checks, work equipment controller may be defecDefective work equipment
controller
40-488
D375A-6
(01)
DRAFT
D375A-6
(01)
40-489
DRAFT
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection

Action code
E01
Detail of failure
Problem on
machine
Related information
Failure code
DWNCKA
Failure
Fan pump solenoid 2: Disconnection

When power is output to fan pump EPC solenoid 2 (LPV30) circuit, no current flows.
Fan pump solenoid 2 (LPV30) is always at maximum speed.
(Code: 31634 Fan pump Solenoid 2 (F/B))
Cause
Defective fan pump EPC
1 solenoid 2

Resistance
2 12
2
Resistance
2 12
ness
2. Disconnect connector WECN3 and FA2, and connect T-adapters to their female
3
sides.
Max. 1
Max. 1
If cause is not found by the above checks, work equipment controller may be defec4
controller
40-490
D375A-6
(01)
DRAFT
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit

Action code
E01
Detail of failure
Problem on
machine
Related information
Failure code
DWNCKB
Failure

When power is output to fan pump EPC solenoid 2 (LPV30) circuit, abnormal current flows.
Outputto fan pump solenoid 2 (LPV30) is kept at maximum.
Cause

solenoid 2
Resistance
2 12
Resistance
Min. 1 M
Ground fault of wiring har2. Disconnect connector WECN3 and FA2, and connect T-adapter to female side of
ness
either of them.
Between WECN3 (female) (26) or FA2 (female) (1)
Resistance
Min. 1 M
and ground
either of them.
Resistance
Min. 1 M
FA2 (female) (1) and (2)
D375A-6
(01)
40-491
DRAFT
Failure code [DWNCKY] Fan pump solenoid 2: Short circuit

Action code
E02
Detail of failure
Problem on
machine
Related information
Failure code
DWNCKY
Failure

Current flows always in fan pump EPC solenoid 2 (LPV30) circuit, no current flows.
Fan pump (LPV30) output is always at minimum speed.

Fan speed does not increase.
q
q
q
Cause

solenoid 2
Resistance
2 12
Resistance
Min. 1 M
2. Disconnect connector FA2 and connect T-adapter to female side.
Voltage
Max. 1 V
2. Disconnect connectors WECN3 and FA2, and connect T-adapter to female side
of WECN3.
than (26)
heard.)
1.
Turn
starting
switch
to
OFF
position.
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.)
controller
40-492
D375A-6
(01)
DRAFT
D375A-6
(01)
40-493
DRAFT
Failure code [DXH1KA] Lock-up ECMV: Disconnection
Failure code [DXH1KA] Lock-up ECMV: Disconnection

Action code
E02
Detail of failure
Problem on
machine
Failure code
DXH1KA
Failure
Lock-up solenoid: Disconnection

When power is output to torque converter lockup clutch ECMV solenoid circuit, no current flows.
Stops output to torque converter lockup clutch ECMV solenoid circuit.
Torque converter lockup function does not operate.
Output condition to torque converter lockup clutch ECMV solenoid can be checked with monitoring
function.
(Code: 31642 L/U ECMV (F/B))
Method of reproducing failure code: Start engine and travel reverse (in auto gearshift mode).
Related information
q
Cause
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
2
Resistance
3 13
ness
2. Disconnect connector PTCN3 and SLUC, and connect T-adapters to their female
sides.
defective contact in connecBetween
PTCN3 (female) (16) and SLUC (female) (1) Resistance
Max. 1
tor)
Between PTCN3 (female) (23) and SLUC (female) (2) Resistance
Max. 1
Defective power train control- If cause is not found by the above checks, power train controller may be defective.
4
ler
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
E02
Detail of failure
Problem on
machine
Failure code
Lock-up solenoid: Short circuit
Failure
DXH1KB
When power is output to torque converter lockup clutch ECMV solenoid circuit, abnormal current
flows.
Torque converter lockup function does not operate.
Output condition to torque converter lockup clutch ECMV solenoid can be checked with monitoring
function.
Method of reproducing failure code: Start engine and travel reverse (in auto gearshift mode).
Related information
q
Cause
1 ECMV solenoid (Internal disconnection)

2. Disconnect connector SLUC and connect T-adapter to male side.
Resistance
3 13
Between SLUC (female) (1) and ground
Resistance
Min. 1 M
2. Disconnect connector PTCN3 and SLUC, and connect T-adapter to female side
of either of them.
Between PTCN3 (female) (16) or SLUC (female) (1)
Resistance
Min. 1 M
and ground
2. Disconnect connector PTCN3 and SLUC, and connect T-adapter to female side
of either of them.
Between PTCN3 (female) (16) and (23)or between
Resistance
Min. 1 M
SLUC (female) (1) and (2)
Circuit diagram related to lock-up solenoid
D375A-6
(01)
40-495
DRAFT
Failure code [DXH1KY] Lock-up ECMV: Short circuit

Action code
E03
Detail of failure
Failure code
DXH1KY
Current flows constantly to torque converter lockup clutch ECMV solenoid circuit.

Torque converter lockup function operates constantly.
Engine may stall during travel.
Once machine stops, travel is restricted to F1 and R1.
Output condition to lockup clutch ECMV solenoid can be checked with monitoring function.
Method of reproducing failure code: Start engine and travel in auto gearshift mode (while lockup is in
operation).
q
q
q
q
q
Related information
Lock-up solenoid: Short circuit

Problem on
machine
Failure
Cause

ECMV solenoid (Internal dis- 2. Disconnect connector SLUC and connect T-adapter to male side.
Resistance
3 13
connection)
Resistance
Min. 1 M
Hot short in wiring harness 2. Disconnect connector SLUC and connect T-adapter to female side.
Voltage
Max. 1 V
2. Disconnect connector PTCN3 and SLUC, and connect T-adapter to female side of
PTCN3.
than (16)
heard)
Short circuit in wiring har1. Turn starting switch to OFF position.
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
PTCN1 (female)
heard)
PTCN2 (female)
heard)
Defective power train conIf cause is not found by the above checks, work equipment controller may be defectroller
40-496
D375A-6
(01)
DRAFT
Circuit diagram related to lock-up solenoid
D375A-6
(01)
40-497
DRAFT
Failure code [DXH4KA] 1st clutch ECMV: Disconnection
Failure code [DXH4KA] 1st clutch ECMV: Disconnection

Action code
E03
Detail of failure
Problem on
machine
Related information
q
q
q
q
q
q
q
q
Failure code
1st clutch ECMV: Disconnection
Failure
DXH4KA
When power is output to transmission 1st clutch ECMV solenoid circuit, no current flows.
Stops output to transmission 1st clutch ECMV solenoid circuit.
Restricts operation of engine and transmission.
Automatic gear shifting function does not operate.
Output condition to 1st clutch ECMV solenoid can be checked with monitoring function.
(Code: 31612 T/M Clutch 1st ECMV (F/B))
Method of reproducing failure code: Start engine and set gear to F1 or R1.
Cause
1 solenoid (Internal disconnection)

2. Disconnect connector S1T and connect T-adapter to male side.
Between S1T (male) (1) and (2)
Resistance
3 - 13
Disconnection or short cir- 2. Disconnect connector PTCN3 and connect T-adapter to female side.
2
a If resistance is above 1 M, wiring harness has disconnection.If resistance is becuit in wiring harness
Resistance
3 - 13
ness
2. Disconnect connectors PTCN3 and S1T, and connect T-adapters to their female
3
sides.
Between PTCN3 (female) (37) and S1T (female) (1)
Resistance
Max. 1
Resistance
Max. 1
Defective power train con- If cause is not found by the above checks, power train controller may be defective.
4
troller
40-498
D375A-6
(01)
DRAFT
Failure code [DXH4KB] 1st clutch ECMV: Short circuit
Failure code [DXH4KB] 1st clutch ECMV: Short circuit

Action code
E03
Detail of failure
Problem on
machine
Related information
q
q
q
q
q
q
q
q
Failure code
1st clutch ECMV: Short circuit
Failure
DXH4KB
When power was output to transmission 1st clutch ECMV solenoid circuit, abnormal current flowed.
Cause

solenoid (Internal short cir- 2. Disconnect connector S1T and connect T-adapter to male side.
Resistance
3 13
cuit)
Between S1T (female) (1) and ground
Resistance
Min. 1 M
Ground fault of wiring har- 2. Disconnect connectors PTCN3 and S1T and connect T-adapter to female side of
ness
either of them.
(Contact with ground circuit) Between PTCN3 (female) (37) or S1T (female) (1)
Resistance
Min. 1 M
and ground
2. Disconnect connectors PTCN3 and S1T and connect T-adapter to female side of
Short circuit in wiring hareither of them.
ness
Resistance
Min. 1 M
S1T (female) (1) and (2)
troller
D375A-6
(01)
40-499
DRAFT
Failure code [DXH4KY] 1st clutch ECMV: Short circuit

Action code
E03
Detail of failure
Problem on
machine
Related information
q
q
q
q
q
q
q
q
Failure code
1st clutch ECMV: Short circuit
Failure
DXH4KY
Current flows constantly to transmission 1st clutch ECMV solenoid circuit.
Cause

40-500

2. Disconnect connector S1T and connect T-adapter to male side.
Resistance
3 - 13
Resistance Min. 1 M
2. Disconnect connector S1T and connect T-adapter to female side.
Voltage
Max. 1 V
PTCN3.
(37)
heard)
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
(female)
heard)
(female)
heard)
If cause is not found by the above checks, power train controller may be defective.
D375A-6
(01)
DRAFT
D375A-6
(01)
40-501
DRAFT
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection

Action code
E03
Detail of failure
Problem on
machine
Related information
q
q
q
q
q
q
q
q
Failure code
2nd clutch ECMV: Disconnection
Failure
DXH5KA
When power is output to transmission 2nd clutch ECMV solenoid circuit, no current flows.
Stops output to transmission 2nd clutch ECMV solenoid circuit.
Output condition to 2nd clutch ECMV solenoid can be checked with monitoring function.
(Code: 31613 T/M Clutch 2nd ECMV (F/B))
Cause
Defective 2nd clutch ECMV 1. Turn starting switch to OFF position.
1 solenoid (Internal discon2. Disconnect connector S2T and connect T-adapter to male side.
nection))
Resistance
3 - 13
2
a If resistance is above 1 M, wiring harness has disconnection. If resistance is becuit in wiring harness
Resistance
3 - 13
ness
3
sides.
Resistance
Max. 1
Resistance
Max. 1
4
troller
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
E03
Detail of failure
Problem on
machine
Related information
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Failure code
2nd clutch ECMV: Short circuit
Failure
DXH5KB
When power was output to transmission 2nd clutch ECMV solenoid circuit, abnormal current flowed.
Automatic gearshift system function does not operate.
(Code: 31613 T/M Clutch 2nd ECMV (F/B))
Cause

1 solenoid (Internal short cir- 2. Disconnect connector S2T and connect T-adapter to male side.
Resistance
3 - 13
cuit)
Resistance
Min. 1 M
Ground fault of wiring har- 2. Disconnect connectors PTCN3 and S2T and connect T-adapter to female side of
2 ness
either of them.
Resistance
Min. 1 M
and ground
either of them.
ness
Resistance
Min. 1 M
4
troller
D375A-6
(01)
40-503
DRAFT
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit

Action code
E03
Detail of failure
Problem on
machine
Related information
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Failure code
2nd clutch ECMV: Short circuit
Failure
DXH5KY
Current flows constantly to transmission 2nd clutch ECMV solenoid circuit.
Automatic gearshift system function does not operate.
Once machine is stopped, travel is restricted to F2 and R2.
Cause

Resistance
3 - 13
cuit)
Resistance
Min. 1 M
Hot short in wiring harness 2. Disconnect connector S2T and connect T-adapter to female side.
Voltage
Max. 1V
PTCN3.
Between PTCN3 (female) (28) and each pin other No continuity (No sound is
than (28)
heard)
ness
female side of PTCN1 to PTCN3.
PTCN1 (female)
heard)
PTCN2 (female)
heard)
troller
40-504
D375A-6
(01)
DRAFT
D375A-6
(01)
40-505
DRAFT
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection

Action code
E03
Detail of failure
Problem on
machine
Related information
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Failure code
3rd clutch ECMV: Disconnection
Failure
DXH6KA
When power is output to transmission 3rd clutch ECMV solenoid circuit, no current flows.
Stops output to transmission 3rd clutch ECMV solenoid circuit.
Output condition to 3rd clutch ECMV solenoid can be checked with monitoring function.
(Code: 31614 T/M Clutch 3rd ECMV (F/B))
Cause
Defective 3rd clutch ECMV 1. Turn starting switch to OFF position.
1 solenoid (Internal discon2. Disconnect connector S3T and connect T-adapter to male side.
nection)
Resistance
3 - 13
2
a If resistance is above1 M, wiring harness has disconnection. If resistance is
below1 , wiring harness has short circuit.
Resistance
3 - 13
ness
3
sides.
Resistance
Max. 1
Resistance
Max. 1
4
troller
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
E03
Detail of failure
Problem on
machine
Related information
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Failure code
3rd clutch ECMV: Short circuit
Failure
DXH6KB
When power was output to transmission 3rd clutch ECMV solenoid circuit, abnormal current flowed.
Cause

Defective 3rd clutch ECMV
Resistance
3 - 13
cuit)
Resistance
Min. 1 M
Ground fault of wiring har- 2. Disconnect connectors PTCN3 and S3T, and connect T-adapter to female side of
ness
either of them.
Resistance
Min. 1 M
and ground
ness
Resistance
Min. 1 M
troller
D375A-6
(01)
40-507
DRAFT
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit

Action code
E03
Detail of failure
Problem on
machine
Related information
Failure code
DXH6KY
Failure
3rd clutch ECMV: Short circuit

Current flows constantly to transmission 3rd clutch ECMV solenoid circuit.

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Cause

Defective 3rd clutch
ECMV solenoid (Internal 2. Disconnect connector S3T and connect T-adapter to male side.
Resistance
3 - 13
short circuit)
Resistance
Min. 1 M
Hot short in wiring har2. Disconnect connector S3T and connect T-adapter to female side.
ness
(Contact with 24 V circuit) 3. Turn starting switch ON position.
Voltage
Max. 1 V
PTCN3.
than (38)
Short circuit in wiring har- 1. Turn starting switch to OFF position.
ness
PTCN1 (female)
PTCN2 (female)
controller
40-508
D375A-6
(01)
DRAFT
D375A-6
(01)
40-509
DRAFT
Failure code [DXH7KA] R clutch ECMV: Disconnection
Failure code [DXH7KA] R clutch ECMV: Disconnection

Action code
E03
Detail of failure
Problem on
machine
Related information
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Failure code
Reverse clutch ECMV: Disconnection
Failure
DXH7KA
When power is output to transmission R clutch ECMV solenoid circuit, no current flows.
Stops output to transmission R clutch ECMV solenoid circuit.
Once machine stops, travel is restricted to F1.
Output condition to R clutch ECMV solenoid can be checked with monitoring function.
(Code: 31616 T/M Clutch R ECMV (F/B))
Method of reproducing failure code: Start engine and set gear to R (Reverse).
Cause
Defective R clutch ECMV

2. Disconnect connector SRT and connect T-adapter to male side.
Between SRT (male) (1) and (2)
Resistance
3 - 13
2
Resistance
3 - 13
ness
2. Disconnect connectors PTCN3 and SRT, and connect T-adapters to their female
3
sides.
Between PTCN3 (female) (27) and SRT (female) (1)
Resistance
Max. 1
Between PTCN3 (female) (3) and SRT (female) (2)
Resistance
Max. 1
4
troller
40-510
D375A-6
(01)
DRAFT
Failure code [DXH7KB] R clutch ECMV: Short circuit
Failure code [DXH7KB] R clutch ECMV: Short circuit

Action code
E03
Detail of failure
Problem on
machine
Related information
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Failure code
Reverse clutch ECMV: Short circuit
Failure
DXH7KB
When power was output to transmission R clutch ECMV solenoid circuit, abnormal current flowed.
Once machine is stopped, travel is restricted to F1.
Cause

solenoid (Internal short cir- 2. Disconnect connector SRT and connect T-adapter to male side.
Resistance
3 - 13
cuit)
Between SRT (female) (1) and ground
Resistance
Min. 1 M
Ground fault of wiring har- 2. Disconnect connectors PTCN3 and SRT, and connect T-adapter to female side of
ness
either of them.
(Contact with ground circuit) Between PTCN3 (female) (27) or SRT (female) (1)
Resistance
Min. 1 M
and ground
2. Disconnect connectors PTCN3 and SRT and connect T-adapter to female side of
ness
Resistance
Min. 1 M
SRT (female) (1) and (2)
troller
D375A-6
(01)
40-511
DRAFT
Failure code [DXH7KY] R clutch ECMV: Short circuit

Action code
E04
Detail of failure
Problem on
machine
Related information
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Failure code
Reverse clutch ECMV: Short circuit
Failure
DXH7KY
Current flows constantly to transmission R clutch ECMV solenoid circuit.
Once machine stops, machine does not travel at all.
Cause

40-512

2. Disconnect connector SRT and connect T-adapter to male side.
Resistance
3 - 13
Resistance
Min. 1 M
2. Disconnect connector SRT and connect T-adapter to female side.
Voltage
Max. 1 V
2. Disconnect connectors PTCN3 and SRT and connect T-adapter to female side of
PTCN3.
than (27)
heard)
2. Disconnect connectors PTCN1 to PTCN3 and SRT, and connect T-adapters to
PTCN1 (female)
heard)
PTCN2 (female)
heard)
D375A-6
(01)
DRAFT
D375A-6
(01)
40-513
DRAFT
Failure code [DXH8KA] F clutch ECMV: Disconnection
Failure code [DXH8KA] F clutch ECMV: Disconnection

Action code
E03
Detail of failure
Problem on
machine
Related information
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Failure code
Forward clutch ECMV: Disconnection
Failure
DXH8KA
When power is output to transmission F clutch ECMV solenoid circuit, no current flows.
Stops output to transmission F clutch ECMV solenoid circuit.
Once machine stops, travel is restricted to R1.
Output condition to F clutch ECMV solenoid can be checked with monitoring function.
(Code: 31622 T/M Clutch F ECMV (F/B))
Method of reproducing failure code: Start engine and set gear to F (Forward).
Cause
Defective F clutch ECMV

2. Disconnect connector SFT and connect T-adapter to male side.
Between SFT (male) (1) and (2)
Resistance
3 - 13
2
Resistance
3 - 13
ness
2. Disconnect connectors PTCN3 and SFT, and connect T-adapters to their female
3
sides.
Between PTCN3 (female) (17) and SFT (female) (1)
Resistance
Max. 1
Between PTCN3 (female) (13) and SFT (female) (2)
Resistance
Max. 1
4
troller
40-514
D375A-6
(01)
DRAFT
Failure code [DXH8KB] F clutch ECMV: Short circuit
Failure code [DXH8KB] F clutch ECMV: Short circuit

Action code
E03
Detail of failure
Problem on
machine
Related information
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Failure code
Forward clutch ECMV: Short circuit
Failure
DXH8KB
When power was output to transmission F clutch ECMV solenoid circuit, abnormal current flowed.
Once machine is stopped, travel is restricted to R1.
Cause

solenoid (Internal short cir- 2. Disconnect connector SFT and connect T-adapter to male side.
Resistance
3 - 13
cuit)
Between SFT (female) (1) and ground
Resistance
Min. 1 M
Ground fault of wiring har- 2. Disconnect connectors PTCN3 and SFT and connect T-adapter to female side of
ness
either of them.
(Contact with ground circuit) Between PTCN3 (female) (17) or SFT (female) (1) and
Resistance
Min. 1 M
ground
2. Disconnect connectors PTCN3 and F SET and connect T-adapter to female side
Short circuit in wiring harof either of them.
ness
Resistance
Min. 1 M
SFT (female) (1) and (2)
troller
D375A-6
(01)
40-515
DRAFT
Failure code [DXH8KY] F clutch ECMV: Short circuit

Action code
E04
Detail of failure
Problem on
machine
Related information
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Failure code
Forward clutch ECMV: Short circuit
Failure
DXH8KY
Current flows constantly to transmission F clutch ECMV solenoid circuit.
Once machine stops, machine does not travel at all.
Cause

solenoid (Internal short cir- 2. Disconnect connector SFT and connect T-adapter to male side.
Resistance
3 - 13
cuit)
Resistance
Min. 1 M
Hot short in wiring harnesss 2. Disconnect connector SFT and connect T-adapter to female side.
Voltage
Max. 1 V
2. Disconnect connectors PTCN3 and SFT and connect T-adapter to female side of
PTCN3.
than (17)
ness
2. Disconnect connectors PTCN1 to PTCN3 and SFT, and connect T-adapters to
PTCN1 (female)
PTCN2 (female)
troller
40-516
D375A-6
(01)
DRAFT
D375A-6
(01)
40-517
DRAFT
Failure code [DXH9KA] Right clutch ECMV: Disconnection
Failure code [DXH9KA] Right clutch ECMV: Disconnection

Action code
E03
Detail of failure
Problem on
machine
Related information
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Failure code
Right steering clutch ECMV disconnection
Failure
DXH9KA
When power is output to right steering clutch ECMV solenoid circuit, current does not flow.
Stops outputting to right steering clutch ECMV solenoid circuit.
Machine cannot be steered to right.
Output condition (current) to right steering clutch ECMV solenoid can be checked with moniitoring
funtion. (Code: 90601 Right steering clutch ECMV output current(F/B))
Method of reproducing failure code: Turn starting switch to ON position, release parking brake lever
and operate PCCS lever (to steer to right).
Cause
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
2
Between SRC (female) (35) and (23)
Resistance
3 - 13
ness
3 (Disconnection in wiring or 2. Disconnect connectors PTCN3 and SRC , and connect T-adapters to their female
sides.
defective contact in connecBetween
PTCN3 (female) (35) and SRC (female) (1)
Resistance
Max. 1
tor)
Between PTCN3 (female) (23) and SRC (female) (2)
Resistance
Max. 1
4
troller
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
E03
Detail of failure
Problem on
machine
Related information
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Failure code
Right steering clutch ECMV short circuit
Failure
DXH9KB
When power was output to right steering clutch solenoid circuit, abnormal current flowed.
Stops output to right steering clutch solenoid circuit.
Machine cannot be steered to right.
Output condition (current) to right steering clutch solenoid can be checked with moniitoring funtion.
(Code: 90601 Right steering clutch ECMV output current (F/B))
and operate PCCS lever (to steer to right).
Cause

Defective rihht steering
clutch ECMV solenoid (Inter- 2. Disconnect connector SRC and connect T-adapter to male side.
Resistance
3 - 13
nal short circuit)
Between SRC (male) (1) and ground
Resistance Min. 1 M
Ground fault in wiring har2. Disconnect connectors PTCN3 and SRC and connect T-adapter to female side of
ness
either of them.
(Contact with ground circuit) Between PTCN3 (female) (35) or SRC (female) (1) and Resistance Min. 1 M
ground
2. Disconnect connectors PTCN3 and SRC and connect T-adapter to female side of
ness
Resistance Min. 1 M
SRC (female) (1) and (2)
troller
D375A-6
(01)
40-519
DRAFT
Failure code [DXH9KY] Right clutch ECMV: Short circuit

Action code
E04
Detail of failure
Problem on
machine
Related information
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Failure code
Right steering clutch ECMV short circuit
Failure
DXH9KY
Current flows constantly to right steering clutch ECMV solenoid circuit.
Stops outputting to right steering clutch solenoid circuit.
Right clutch cannot be engaged (machine cannot travel straight).
Output (current) condition to right steering clutch ECMV solenoid can be checked with monitoring
function. (Code: 90601 Right steering clutch ECMV output current (F/B))
Method of reproducing failure code: Turn starting switch to ON position and release parking brake
lever.
Cause

clutch ECMV solenoid (Inter- 2. Disconnect connector SRC and connect T-adapter to male side.
Resistance
313
nal short circuit)
Between SRC (male) (1) and ground
Resistance Min. 1 M
Hot short in wiring harness 2. Disconnect connector SRC and connect T-adapter to female side.
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.)
ness
2. Disconnect connectors PTCN1 to 3 and SRC, and connect T-adapter to female
sides of PTCN1 to 3.
Between PTCN3 (female) (35) and each pin of PTCN1 No continuity (No sound is
(female)
heard.)
(female)
heard.)
troller
40-520
D375A-6
(01)
DRAFT
D375A-6
(01)
40-521
DRAFT
Failure code [DXHAKA] Left clutch ECMV: Disconnection
Failure code [DXHAKA] Left clutch ECMV: Disconnection

Action code
E03
Detail of failure
Problem on
machine
Related information
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Failure code
Left steering clutch ECMV disconnection
Failure
DXHAKA
When power is output to left steering clutch solenoid circuit, current does not flow.
Stops output to left steering clutch solenoid circuit.
Machine cannot be steered to left.
Output condition (current) to left steering clutch ECMV solenoid can be checked with moniitoring funtion. (Code: 90600 Left steering clutch ECMV output current (F/B))
and operate PCCS lever (to steer to left).
Cause
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
2
Resistance
3 - 13
ness
2. Disconnect connectors PTCN3 and SLC, and connect T-adapters to their female
3
sides.
Between PTCN3 (female) (25) and SLC (female) (1)
Resistance
Max. 1
Between PTCN3 (female) (23) and SLC (female) (2)
Resistance
Max. 1
4
troller
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
E03
Detail of failure
Problem on
machine
Related information
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Failure code
Left steering clutch ECMV short circuit
Failure
DXHAKB
When signal was output to left steering clutch ECMV solenoid circuit, abnormal current flowed.
Stops outputting to left steering clutch ECMV solenoid circuit.
Machine cannot be steered to left.
Output condition (current) to left steering clutch ECMV solenoid can be checked with moniitoring funtion. (Code: 90600 Left steering clutch ECMV output current (F/B))
and operate PCCS lever (to steer to left).
Cause

Defective left steering clutch
2. Disconnect connector SLC and connect T-adapter to male side.
ECMV solenoid (Internal
Resistance
3 - 13
short circuit)
Between SLC (male) (1) and ground
Resistance
Min. 1 M
Ground fault in wiring har2. Disconnect connectors PTCN3 and SLC, and connect T-adapter to female side of
ness
either of them.
(Contact with ground circuit) Between PTCN3 (female) (25) or SLC (female) (1) and
Resistance
Min. 1 M
ground
2. Disconnect connectors PTCN3 and SLC and connect T-adapter to female side of
ness
Resistance
Min. 1 M
SLC (female) (1) and (2)
troller
D375A-6
(01)
40-523
DRAFT
Failure code [DXHAKY] Left clutch ECMV: Short circuit

Action code
E04
Detail of failure
Problem on
machine
Related information
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Failure code
Left steering clutch ECMV circuit short
Failure
DXHAKY
Current flows constantly to left steering clutch ECMV solenoid circuit.
Stops outputting to left steering clutch ECMV solenoid circuit.
Left clutch cannot be engaged (machine cannot travel straight).
Output condition (current) to left steering clutch solenoid can be checked with moniitoring funtion.
(Code: 90600 Left steering clutch ECMV output current (F/B))
lever.
Cause

Defective left steering clutch
2. Disconnect connector SRC and connect T-adapter to male side.
Resistance
3 13
short circuit)
Between SLC (female) (1) and ground
Resistance Min. 1 M
Hot short in wiring harness 2. Disconnect connector SRC and connect T-adapter to female side.
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.)
ness
2. Disconnect connectors PTCN1 to PTCN3 and SLC, and connect T-adapters to
(female)
heard.)
(female)
heard.)
troller
40-524
D375A-6
(01)
DRAFT
D375A-6
(01)
40-525
DRAFT
Failure code [DXHBKA] Right brake ECMV: Disconnection
Failure code [DXHBKA] Right brake ECMV: Disconnection

Action code
E04
Detail of failure
Problem on
machine
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Related information
Failure code
Right brake ECMV disconnection
Failure
DXHBKA
When signal is output to right steering brake solenoid circuit, no current flows.
Stops outputting to right steering brake ECMV solenoid circuit.
Restricts operation of engine, transmission and brake.
Operates sudden stop prevention valve.
Right brake keeps applied.
Output condition (current) to right steering brake solenoid can be checked with moniitoring funtion.
(Code: 31618 output current (F/B) of right steering brake ECMV)
lever.
Cause
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
2
Resistance
3 - 13
ness
2. Disconnect connectors PTCN3 and SRB, and connect T-adapters to their female
3
sides.
Between PTCN3 (female) (15) and SRB (female) (1)
Resistance
Max. 1
Between PTCN3 (female) (13) and SRB (female) (2)
Resistance
Max. 1
4
troller
40-526
D375A-6
(01)
DRAFT
Failure code [DXHBKB] Right brake ECMV: Short circuit
Failure code [DXHBKB] Right brake ECMV: Short circuit

Action code
E04
Detail of failure
Problem on
machine
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Related information
Failure code
Right brake ECMV short circuit
Failure
DXHBKB
When power was output to right steering brake ECMV solenoid circuit, abnormal current flowed.
Restricts operation of engine, transmission, and brake.
Right brake keeps applied.
Output condition (current) to right steering brake ECMV solenoid can be checked with moniitoring
funtion. (Code: 31618 output current (F/B) of right steering brake ECMV)
Cause

brake ECMV solenoid (Inter- 2. Disconnect connector SRB and connect T-adapter to male side.
Resistance
3 - 13
nal short circuit)
Between SRB (male) (1) and ground
Resistance
Min. 1 M
Ground fault in wiring har2. Disconnect connectors PTCN3 and SRB, and connect T-adapter to female side of
ness
either of them.
(Contact with ground circuit) Between PTCN3 (female) (15) or SRB (female) (1) and
Resistance
Min. 1 M
ground
2. Disconnect connectors PTCN3 and SRB, and connect T-adapter to female side of
ness
Resistance
Min. 1 M
SRB (female) (1) and (2)
troller
D375A-6
(01)
40-527
DRAFT
Failure code [DXHBKY] Right brake ECMV: Short circuit

Action code
E04
Detail of failure
Problem that
appears on
machine
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Related information
Failure code
Right brake ECMV hot short
Failure
DXHBKY
When power is output to right steering brake ECMV solenoid circuit, no current flows.
Right brake does not operate.
Output condition (current) to right steering brake ECMV solenoid can be checked with moniitoring
funtion. (Code: 31618 output current (F/B) of right steering brake ECMV)
lever (Lock).
Cause

1 brake clutch ECMV solenoid 2. Disconnect connector SRB and connect T-adapter to male side.
Resistance
3 - 13
Between SRB (male) (1) and ground
Resistance
Min. 1 M
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)
Short circuit in wiring har1.
Turn
starting
switch
to
OFF
position.
3
ness
2. Disconnect connectors PTCN1 to PTCN3 and SRB, and connect T-adapters to
PTCN1 (female)
heard)
PTCN2 (female)
heard)
4
troller
(Since falure is in it, troubleshooting cannot be performed.)
40-528
D375A-6
(01)
DRAFT
D375A-6
(01)
40-529
DRAFT
Failure code [DXHCKA] Left brake ECMV: Disconnection
Failure code [DXHCKA] Left brake ECMV: Disconnection

Action code
E04
Detail of failure
Problem that
appears on
machine
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Related information
Failure code
Left brake ECMV disconnection
Failure
DXHCKA
When signal is output to left steering brake solenoid circuit, any current does not flow.
Stops outputting to left steering brake ECMV solenoid circuit.
Left brake keeps applied.
Output condition (current) to left steering brake ECMV solenoid can be checked with moniitoring funtion. (Code: 31619 output current (F/B)of left steering brake ECMV)
Cause
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
2
Resistance
3 - 13
ness
2. Disconnect connectors PTCN3 and SLB, and connect T-adapters to their female
3
sides.
Between PTCN3 (female) (5) and SLB (female) (1)
Resistance
Max. 1
Between PTCN3 (female) (13) and SLB (female) (2)
Resistance
Max. 1
4
troller
40-530
D375A-6
(01)
DRAFT
Failure code [DXHCKB] Left brake ECMV: Short circuit
Failure code [DXHCKB] Left brake ECMV: Short circuit

Action code
E04
Detail of failure
Problem on
machine
q
q
q
q
q
q
q
q
Related information
Failure code
Left brake ECMV short circuit
Failure
DXHCKB
When power was output to left steering brake ECMV solenoid circuit, abnormal current flowed.
Stops output to left steering brake solenoid circuit.
Restricts operation of engine, transmission, and brake.
Left brake keeps applied.
Output condition (current) to left steering brake solenoid can be checked with moniitoring funtion.
(Code: 31619 output current (F/B) of left steering brake ECMV)
lever.
Cause

2. Disconnect connector SLB and connect T-adapter to male side.
Resistance
3 - 13
short circuit)
Between SLB (male) (1) and ground
Resistance
Min. 1 M
Ground fault in wiring har2. Disconnect connectors PTCN3 and SLB, and connect T-adapter to female side of
ness
either of them.
(Contact with ground circuit) Between PTCN3 (female) (5) or SLB (female) (1) and
Resistance
Min. 1 M
ground
2. Disconnect connectors PTCN3 and SLB and connect T-adapter to female side of
ness
Between PTCN3 (female) (5) and (13), or between SLB
Resistance
Min. 1 M
troller
D375A-6
(01)
40-531
DRAFT
Failure code [DXHCKY] Left brake ECMV: Short circuit

Action code
E04
Detail of failure
Problem on
machine
q
q
q
q
q
q
q
q
Related information
Failure code
Left brake ECMV hot short
Failure
DXHCKY
When power is output left steering brake solenoid circuit,current flows.
Stops output to left steering brake ECMV solenoid circuit.
Left brake does not operate.
Output condition (current) to left steering brake ECMV solenoid can be checked with moniitoring funtion. (Code: 31619 Left brake ECMV output current(F/B))
lever (Lock).
Cause

ECMV solenoid (Internal dis- 2. Disconnect connector SLB and connect T-adapter to male side.
Resistance
3 - 13
connection)
Between SLB (male) (1) and ground
Resistance
Min. 1 M
Hot short in wiring harness 2. Disconnect connector SLB and connect T-adapter to female side.
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)
ness
2. Disconnect connectors PTCN1 to PTCN3 and SLB, and connect T-adapters to
PTCN1 (female)
heard)
PTCN2 (female)
heard)
troller
40-532
D375A-6
(01)
DRAFT
D375A-6
(01)
40-533
DRAFT
Failure code [DXJBKA] S/C ECMV: Disconnection
Failure code [DXJBKA] S/C ECMV: Disconnection

Action code
E02
Detail of failure
Problem on
machine
Related information
q
q
q
Failure code
Stator clutch ECMV: Disconnection
Failure
DXJBKA
When power is output to transmission stator clutch ECMV solenoid circuit, no current flows.
Stops output to transmission stator clutch ECMV solenoid circuit.
Restritcs operation of engine and transmission.
Engine speed may not be transmitted normally.
Output condition to stator clutch ECMV solenoid can be checked with monitoring function.
(Code: 90700 S/C ECMV output current (F/B))
Method of reproducing failure code: Start engine and travel.
Cause
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
2
Resistance
3 - 13
ness
3 (Disconnection in wiring or 2. Disconnect connectors PTCN3 and SSTC, and connect T-adapters to their female
sides.
defective contact in connecBetween PTCN3 (female) (6) and SSTC (female) (1) Resistance
Max. 1
tor)
Between PTCN3 (female) (3) and SSTC (female) (2) Resistance
Max. 1
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
E02
Detail of failure
Problem on
machine
Related information
q
q
q
Failure code
Stator clutch ECMV: Short circuit
Failure
DXJBKB
When power is output to stator clutch ECMV solenoid circuit, abnormal current flow.
Stops output to transmission stator clutch ECMV solenoid circuit.
Method of reproducing failure code: Start engine and travel.
Cause
1 ECMV solenoid (Internal
short circuit)

2. Disconnect connector SSTC and connect T-adapter to male side.
Resistance
3 13
Between SSTC (female) (1) and ground
Resistance
Min. 1 M
2. Disconnect connector PTCN3 and SSTC , and connect T-adapter to female side
of either of them.
Between PTCN3 (female) (6) or SSTC (female) (1)
Resistance
Min. 1 M
and ground
of either of them.
Between PTCN 3(female) (6) and (3) or between
Resistance
Min. 1 M
SSTC (female) (1) and (2)
D375A-6
(01)
40-535
DRAFT
Failure code [DXJBKY] S/C ECMV: Short circuit

Action code
E02
Detail of failure
Problem on
machine
Related information
q
q
q
Failure code
Stator clutch ECMV: Short circuit
Failure
DXJBKY
When power is output to transmission 1st clutch ECMV solenoid circuit, current flows constantly.
Cause
1 ECMV solenoid (Internal
short circuit)

40-536

2. Disconnect connector SSTC and connect T-adapter to male side.
Resistance
3 13
Resistance Min. 1 M
2. Disconnect connector SSTC and connect T-adapter to female side.
Voltage
Max. 1 V
of PTCN3.
heard)
2. Disconnect connector PTCN1 to 3 and SSTC , and connect T-adapters to female
sides of PTCN1 to 3.
(female)
heard)
(female)
heard)
D375A-6
(01)
DRAFT
D375A-6
(01)
40-537
DRAFT
Failure code [DY2HKA] Pre lub. motor: Disconnection

Action code
E02
Detail of failure
Problem on
machine
Related information
Failure code
DY2HKA
Failure
Pre-lubricating motor disconnection

After power train controller starts pre-lubrication, power is not supplied to pre-lubricating motor.
No particular action
Engine does not operate (It operates in skip mode, however).
Whether pre-lubricating motor is operating can be checked with monitoring function.

(Code: 40910 PT controller SW input 2)
Primary side of pre-lubricating relay is checked with failure codes [D1EFKA] and [D1EFKB].
Cause
Defective circuit breaker
1
(CBH1)
2

If circuit breaker is operating, the circuit probably has ground fault. In this case, perform troubleshooting for cause 6 first.
Loose terminal or disconnecCheck 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).
Defective relay (PLUB)
If pre-lubrication is completed, original relay (PLUB) is defective.
2. Disconnect connector PLS.
Defective diode (PLS)
If pre-lubrication is completed, diode (PLS) is defective.
Defective pre-lubricating
2. Disconnect terminal PM1.
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 abDisconnection in, or ground
normal and check result of cause 8 is normal, wiring harness has disconnection).
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
Voltage
20 30 V
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
relay
abnormal as check result of cause 6, pre-lubricating relay is defective.
Ground fault in wiring har3. Disconnect terminal PR3.
ness
4. If circuit breaker is turned OFF, reset it.
(Contact with ground circuit) Between PTCN1 (female) (23) and ground
Resistance
Min. 1 M
Between terminal PR1 and ground
Resistance
Min. 1 M
Between terminal PR3 (on wiring harness side) and
Resistance
Min. 1 M
ground
q Reference: Following shows standard values in normal condition.
Voltage
20 30 V
40-538
D375A-6
(01)
DRAFT
Circuit diagram related to pre-lubricating motor
D375A-6
(01)
40-539
Failure code [F@BBZL] ENG blow-by pressure high level
Failure code [F@BBZL] ENG blow-by pressure high level

Action code
Failure code
F@BBZL
Failure
Detail of failure
Problem on
machine
Related information
Engine blow-by pressure abnormally high level
Engine blowby pressure is higher than threshold value of 900 mmH2O {8.83 kPa}.
None in particular
If machine is used as it is, engine may be broken.
Blowby pressure can be checked with monitoring code 42801(kPa).

The LED of the VHMS controller displays "n3" and "38" alternately and repeatedly.
Cause
Abnormal increase of
engine blow-by pressure
Defective engine blow-by
2
pressure sensor
1
40-576

q
q
Check engine and then repair if necessary.

Check the breather hose outlet for clogging, bend, or break. If any, repair it.
Troubleshooting for failure codes [DHE5KB] and [DHE5KY].
40-540
D375A-6
(06)
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
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
than 10 seconds.
Detail of failure
(Exhaust gas temperature limit line 2: Straight line between 750 C at rated output speed at minimum
and 800 C at max. torque speed)
troller
Problem on
q If machine is used as it is, engine may be broken.
machine
Related infor- q Front exhaust temperature can be checked with monitoring code: 42610 (C).
mation
q The LED of the VHMS controller displays "n3" and "62" alternately and repeatedly.
Cause
front exhaust tempera1
Check the engine for abnormality. Correct, if any.
ture (When system is
normal)
Front exhaust tempera2 ture sensor system
Troubleshooting for failure codes "DGT5KA" and "DGT5KB".
defective
Defective VHMS control3
ler
D375A-6
(01)
40-541
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
q Signal voltage of exhaust temperature sensor for No. 1, 2 and 3 cylinders (front side)increased and
Detail of failthan 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 conq 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.
Cause
Abnormal increase of front
1 exhaust temperature
Check the engine for abnormality, Correct, if any.
Front exhaust tempera2 ture sensor system defecTroubleshooting for failure codes "DGT5KA" and "DGT5KB".
tive
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
q Signal voltage of exhaust temperature sensor for No. 4, 5 and 6 cylinders (rear side) increased and
than 10 seconds.
Detail of fialure
troller
Problem on
machine
Related infor- q Rear exhaust temperature can be checked with monitoring code: 42611 (C).
mation
Cause
1 rear exhaust temperature Check the engine for abnormality. Correct, if any.
Rear exhaust tempera2 ture sensor system
Troubleshooting for failure codess "DGT6KA" and "DGT6KB".
defective
ler
D375A-6
(01)
40-543
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
q Signal voltage of exhaust temperature sensor for No. 4, 5 and 6 cylinders (rear side) increased and
Detail of failthan 20 seconds.
ure
troller
Problem on
machine
Related infor- q Rear exhaust temperature can be checked with monitoring code: 42611 (C).
mation
Cause
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".
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 inforInformation related to detected trouble or troubleshooting
mation
Cause

<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.
- defective
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).
q After correction of a single failure, check to see that this problem has been solved.
Disconnection in wiring harThen, start the next troubleshooting.
ness
<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
chassis ground circuit.
Ground fault of wiring harq
Hot short
ness
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.
(Poor insulation of connector or others)
Hot short
<Precautions
for troubleshooting>
(Short circuit with 24 V cir(1) Method of indicating connector No. and handling of Tadapter
cuit)
Insert or connect T-adapter as explained below for troubleshooting, unless otherwise 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.
q If connector No. has marks of male and female, disconnect connector
Short circuit in wiring harand connect T-adapter to only male side or female side.
ness
(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.
Defective controller
D375A-6
(01)
40-545
DRAFT

This is the excerpted circuit diagram related to troubleshooting
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 machine.
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
q
Related information
q
q
The starting motor does not turn and accordingly the engine does not start.
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.
Before carrying out troubleshooting, check that no related failure code is displayed.
(If the failure code
[D110KB][D130KA][D130KB][D190KA][D190KB][D1EFKA][D1EFKB][DD14KA][DD14KB]
[7RFAKA][7RFAKB][DDE2KA][DY2HKA] is displayed, troubleshoot them first.)
In the case of "the battery relay does not make operating sound" when turning the starting switch
ON, perform E-1 also.
If engine does not stop, replace engine holding relay.
Cause
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, trouble2 Defective fuse FS31-5
shoot cause 16 first.
Loose terminal or disconnec3
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
Display of "P" on
Free position
Other than P is displayed.
adjustment)
Lock position
P is displayed.
monitor panel
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 M
7
Between terminals 250 and 260
ON
Resistance
Max. 1
OFF
Resistance
Min. 1 M
ON
Resistance
Max. 1
OFF
Resistance
Min. 1 M
START
Resistance
Max. 1
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
Continuity
D375A-6
(01)
40-547

Cause
12
Defective alternator
Detective starting motor

13
(internal defect)

Between terminal AL/R and ground
2. Start the engine for troubleshooting.
Power supply: Between terminal B and
chassis ground
Between charge terminal R and ground
Voltage
Max. 12 V
Voltage
20 30 V
Voltage
Max. 12 V
Between starting motor terminal C and

Voltage
20 30 V
ground
When voltages of power supply, charging and starting circuits are normal but starting
motor does not rotate, starting motor is defective.
q Battery relay
Between terminal BRE and ground
Resistance
Max. 1 z
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
Voltage
20 30 V
Open circuit in wiring har14

ness

15
(Does not turn ON)
1.
2.
3.
4.
5.
a
Alternator and starting motor

Disconnect ground strap.
Insert T-adapters into connectors NSF, ST1 and ST2.
Connect ground strap.
Turn starting switch to START position and troubleshoot.
Check to where 24 V is supplied to identify disconnected place.
Voltage
20 30 V
Between NSF (1) and ground
Voltage
20 30 V
Voltage
20 30 V
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
If only terminal BRC voltage is abnormal during battery relay check for cause 14, battery relay is defective.
3. Disconnect connectors NSF, PTCN1, WECN1, CM01 and ST.

Between terminal 280 or NSF (3) and ground
Between NSF (5), ST2 (1) or ST1 (1) and ground

harness
17
(Short circuit with 24 V circuit)
40-548

2. Disconnect terminal AL/R.
Between terminal AL/R (Wiring harness side) and
ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Voltage
Max. 1 V
D375A-6
(06)
DRAFT
Circuit diagram related to starting of engine
D375A-6
(01)
40-549
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 preheating 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 informapreheating monitor does not light up")
q If "the machine monitor does not light up" or "the battery relay does not make operating sound"
tion
when turning the starting switch ON, the main electric power supply system is supposed to be defective. So, troubleshoot E-3 and E-1.
q Before carrying out troubleshooting, check that no related failure code is displayed.
(If the failure code [CA153], [CA154], [D110KB] or [D182KZ] is displayed, firstly perform these troubleshooting.)
Cause
Defective circuit breaker
1
CBH1
Loose terminal or disconnec2
tion at terminal

If CBH1 circuit breaker is turned ON, circuit probably has ground fault. In this case,
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.
heater
2. Disconnect terminal HT/B.
Between terminal HT/B and ground
There is continuity
3. Disconnect connector KEY and connect T-adapter to male side.
4. Turn starting switch to OFF/HEAT position and troubleshoot.
OFF
Resistance
Min. 1 M
HEAT
Resistance
Max. 1
2. Disconnect connector CM01.
There is continuity
Disconnection in, or ground Between terminal HT/A and ground
Voltage
20 30 V
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
Ground fault of wiring har2. Disconnect connectors KEY and CM01 and terminals HT and BRC.
ness
Between terminal HT/A and ground
Resistance
Min. 1 M
Between terminal HT (on wiring harness side) and
Resistance
Min. 1 M
ground
Defective preheater relay
If cause 6 is not the cause for the trouble and preheater relay operation sound is not
(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
(01)
40-551
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)
q If automatic preheater does not operate, check if manual preheater operates.
tion
q Engine controller troubleshoots primary (coil) side of preheater relay by failure code [D182KZ].
Cause

If fuse FS22-4 is broken, circuit probably has ground fault. In this case, perform trouDefective fuse FS22-4
bleshooting for cause 5 first.
2. Replace preheater relay (connector: PHR) with backup alarm relay (connector:
Defective preheater relay
BKA).
3.
Turn
starting switch ON position.
short circuit)
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 M, wiring harness has disconnection. If resistance is befault of wiring harness
a Preheater relay coil resistance
Resistance 200 400
Disconnection in wiring har- 2. Disconnect connectors PHR and CM01, and connect T-adapter to female side of
ness
PHR.
(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
If fuse is not broken, this check is not required.
Ground fault of wiring har2. Disconnect connectors PHR, FSB and ASUS, and connect T-adapter to female
ness
side of PHR.
3. Remove fuse FS22-4.
Between PHR (female) (5) and ground
Resistance Min. 1 M
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 opertion
ated, the preheating lamp lights up.
Cause

Disconnection in wiring har2. Disconnect connectors PHR and CM01, and connect T-adapters to female side
ness
of them.
Between
PHR (female) (3) and CM01 (female) (16)
Resistance
Max. 1
contact)
Between terminal 255 and CM01 (female) (16)
Resistance
Max. 1
Ground fault of wiring har2. Disconnect connectors PHR, CM01 and terminal HT, and connect T-adapter to
ness
female side of CM01.
Resistance Min. 1 M
q Reference (the followings are standard values in normal condition)
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.
Resistance
20 30 V
40-552
D375A-6
(01)
DRAFT
Circuit diagram related to preheating of engine
D375A-6
(01)
40-553
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
q
Related information
When starting switch turned ON, machine monitor displays nothing

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.
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.
In the case of "the battery relay does not make operating sound" when turning the starting switch
ON, perform E-1.
Cause
Defective circuit breaker CB30 or
1
CB6
Loose terminal or disconnection at
2
terminal
3
Standard value in normal state/Remarks on troubleshooting

If CB30 or CB6 circuit breaker is turned ON, circuit probably has ground fault. In
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
(Numbers of pins of CM01 and
2. Remove machine monitor.
CM03 are same)
Check that connectors CM01 (white) and CM03 (green) are matched to connector colors of machine monitor unit.
Disconnection in or ground fault of 4. Connect ground strap.
wiring harness or defective start- a If voltage is 0 V, wiring harness has disconnection or ground fault.
Voltage
20 30 V
ing switch
Voltage
20 30 V
1 - 4 are same as above.
5. Turn starting switch to ON position (Connect ACC).
Voltage
20 30 V
3. Disconnect connector KEY.
4. Turn starting switch to ON/OFF position and troubleshoot.
When the
travel steerResistance
Min. 1 M
ing signal is
OFF
ON
Resistance
Max. 1
3. If circuit breaker is turned ON, reset it.
(Disconnection or defective con- Between CM01 (female) (3), (4) and ground
Resistance
Max. 1
tact)
Between CM01 (female) (1), (2) and battery (+)
Resistance
Max. 1
1 - 4 are same as above.
5. Turn starting switch to ON position (Connect ACC with ground strap disconnected).
Between CM01 (female) (14) and battery (+)
Resistance
Max. 1
40-554
D375A-6
(01)

E-3 When starting switch is turned ON, machine monitor displays nothing
Cause
Standard value in normal condition/Remarks on troubleshooting
a
1.
2.
Ground fault in wiring har- 3.
8 ness
4.
(Contact with ground circuit) a
If cause 5 is not the cause for the trouble, this check is not required.
Disconnect ground strap.
If circuit breaker is turned ON, reset it.
Disconnect connector CM01 and connect T-adapter to female side.
Check that condition is normal when starting switch is turned to ON position (Connect ACC with ground strap disconnected).

Min. 1 Mz
Circuit diagram related to machine monitor
D375A-6
(06)
Resistance
40-595
40-555
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
lights up.
q Engine oil pressure sensed by engine oil pressure sensor can be checked with monitoring funcRelated information.
tion
(Code: 37200 Engine Oil Pressure)
Trouble
Cause
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.
(Since trouble is in system, troubleshooting cannot be carried out.)
Trouble
Related information
2) When starting switch is turned to ON position (with engine stopped), engine oil level monitor lights
up.
q
Engine oil level monitor (oil level switch) is optional.
Cause
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 information
Cause
Radiator coolant level
1 decrease

The coolant level monitor may be insufficient. Check coolant level and add coolant if
necessary.

Defective coolant level sensor 2. Disconnect connector WLD and connect T-adapter to male side.
2
Between FULL and LOW Resistance
(Internal defect)
Between WLD (male) (1)
Value when coolant level
Resistance
and (2)
is low
ness
3
(Disconnection or defective a Add coolant.
contact)
Between CM02 (female) (3) and WLD (female) (1)
Resistance
Between FULL and LOW
Voltage
Between CM02 (female) (3)
Value when coolant level
Voltage
and ground
is low
40-556
Max. 1
Min. 1 M
Max. 1
Max. 1V
Min. 7V
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
(01)
40-557
DRAFT
E-5 Precaution item lights up while engine is running

Trouble
Related information
q
q
q
Precaution item lights up while engine is running.

Check item is charge level monitor.
State of generation signal of alternator can be checked with monitoring function.
(Code 04300: Battery Charge Volt.)
Cause
Loose terminal or discon1
nection at terminal
Defective alternator
2 (insufficient power generation)
Defective diode RSD
3 (Internal disconnection or
short circuit)
harness

Defective machine monitor panel
40-558

Check terminals of alternator etc.
2. Start engine and troubleshoot while running engine at medium speed or higher.
Between terminal AL/R and ground
Voltage
20 30V
2. Remove connector RSD and connect T-adapter to diode.
No continuity
Continuity
3. Disconnect connectors CM01 and RSD, and connect T-adapter to female side of
CM01.
Between CM01 (female) (11) and AL/R
Resistance
Max. 1
Between alternator terminal E and ground
Resistance
Max. 1
3. Disconnect connectors CM01, RSD, PTCN1, WECN1, ST1 and ST2, and connect
T-adapter to female side of CM01.
Resistance
Min. 1 M
5. Start engine and troubleshoot while running engine at medium speed or higher.
Voltage
20 30V
D375A-6
(01)
DRAFT
Circuit diagram related to charge level
D375A-6
(01)
40-559
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 informadata is transmitted to machine monitor through CAN communication system.
tion
q Engine coolant temperature can be checked with monitoring function
Cause
Overheating of engine cool1
ant (when system is normal)
Defective coolant tempera2
ture sensor system

Engine coolant may be overheated. If it is overheated, remove cause.
If cause 1 is not detected, engine coolant temperature sensor system may be
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 informato machine monitor through CAN communication system.
q Engine oil pressure can be checked with monitoring function.
tion
q (Code: 37200 Engine Oil Pressure)
Cause
Reduction of engine oil presCheck 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 informathen 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)
Cause
Overheating of torque con1 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
q (Code: 04401 Hyd Oil Temperature)
tion
Cause
Overheating of hydraulic oil
1
Defective hydraulic oil temper2 ature gauge system or
machine monitor
40-560

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 sensor system
or machine monitor may be defective. Perform troubleshooting for failure code
[DGS1KX].
D375A-6
(01)

E-7 Engine coolant temperature gauge does not indicate normally
E-7 Engine coolant temperature gauge does not indicate normally
40-601
1) While engine coolant temperature is rising normally, temperature gauge does not rise from white
range (C).
Trouble
2) While engine coolant temperature is stabilized normally, temperature gauge rises to red range
(H).
q Engine coolant temperature can be checked with monitoring function
tion
Cause
Defective coolant tempera- Engine coolant temperature sensor system may be defective. Perform troubleshootture sensor system
ing for failure codes [CA144] and [CA145].
3) Display of coolant temperature gauge is different from actual engine coolant temperature.
4) Display of engine coolant temperature gauge is different from display of engine coolant temperature monitor.
data is transmitted to machine monitor through CAN communication system.
Related informaq Engine coolant temperature can be checked with monitoring function
tion
Trouble
Cause

a Turn starting switch ON or start engine and troubleshoot.
Coolant temperature gauge

level
105 C
102 C
100 C
85 C
60 C
30 C
Color of monitor light (a)

Red
Blue
Engine coolant temperature gauge and coolant

40-601
temperature monitor
D375A-6
(06)
40-561

E-8 Fuel gauge does not indicate properly

Failure
40-602
1) Fuel gauge does not indicate properly.
Related information
The input state (voltage signal) from the fuel level sensor can be checked with monitoring function.
(Code: 04200 Fuel level sensor voltage)
Cause

2. Disconnect connector FGS and connect T-adapter to male side.
Defective fuel level sensor

1 (Internal open or short circuit in wiring)
Between FGS (male) (1) and (2)

a Fuel level sensor characteristics
FULL
EMPTY
Between FGS (male) (2) and ground
Resistance
Approx. 4 z
Resistance
Max. 1 z
1.
2.
3.
a

Disconnect connector FGS and connect T-adapter to female side.
Open circuit or short circuit
If voltage is 0 V, wiring harness has open circuit or ground fault or short circuit, and
2 or ground fault or hot short
if voltage is 24 V, wiring harness has hot short circuit.
circuit in wiring 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
Open or short circuit in wir- a Resistance accords with fuel level sensor characteristics table in cause 1.
3
ing harness
a If resistance is above 1 Mz, wiring harness has disconnection. If resistance is below 1 z, wiring harness has short circuit.
Approx. 4
Resistance
85 z
Open circuit in wiring har2. Disconnect connectors CM01 and FGS, and connect T-adapters to each female
ness
side.
4
Between
CM01 (female) (9) and FGS (female) (1)
Resistance
Max. 1 z
defective contact)
Between CM01 (female) (12) and FGS (female) (2)
Resistance
Max. 1 z
Ground fault in wiring har2. Disconnect connectors CM01 and FGS, and connect T-adapters to either female
5 ness
side.
Between CM01 (female) (9) or FGS (female) (1) and
Resistance
Min. 1 Mz
ground
2. Disconnect connectors CM01 and FGS, and connect T-adapter to female side of
Short circuit in wiring harCM01.
6
ness
No continuity
Between CM01 (female) (9) and each pin other than (9)
(No sound is heard)
40-562
If cause is not found by the above checks, machine monitor is defective.
D375A-6
(06)
DRAFT
Circuit diagram related to fuel level gauge
2) Display of fuel level gauge is different from actual fuel level.

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.
(Code: 04200 Fuel level sensor vol)
mation
Cause
Reading of fuel level
Quantity of fuel
gauge
1005 l
6
756 l
5
556 l
4
Blue
398 l
3
276 l
2
144 l
1
Red
Trouble
Fuel level gauge and fuel level monitor
D375A-6
(01)
40-563
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.
Cause
Defective torque converter oil
1
temperature sensor system

Power train oil temperature sensor system may be defective. Perform troubleshooting 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.
4) Display of power train oil temperature gauge is different from display of power train oil temperature 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
tion
q Torque converter (power train) oil temperature can be checked with monitoring function.
Cause
Power train oil tempera- Power train oil temperaColor of monitor light (a)
ture
ture gauge level
130 C
6
Red
120 C
5
118 C
4
90 C
3
Blue
50 C
2
0 C
1
Trouble
Power train oil temperature gauge and power train

oil temperature monitor
40-564
D375A-6
(01)

E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate

normally
40-605
1) While hydraulic oil temperature is rising normally, temperature gauge does not rise from white
range (C).
2) While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range.
tion
Trouble
Cause
1 Perform troubleshooting for failure code [DGS1KX].


3) Display of hydraulic oil temperature gauge is different from actual hydraulic oil temperature.
4) Display of hydraulic oil temperature gauge is different from display of hydraulic oil temperature
monitor.
tion
Trouble
Cause

Reading of hydraulic oil

temperature gauge
105 C
102 C
98 C
70 C
20 C
0 C

Red
Blue
Hydraulic oil temperature gauge and hydraulic

40-605
oil temperature monitor
D375A-6
(06)
40-565
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 applicable machine
Trouble
Related information
Contents of display by machine monitor are different from applicable machine.
Cause

Machine monitor may be defective.(Since trouble is in system, troubleshooting
cannot be performed.)
E-12 Machine monitor does not display some items

q
q
Trouble
Related information
Machine monitor does not display some items

The LCD panel sometimes has black points (points which are not lighted) and bright points
(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.
Cause
1
Defective machine monitor

(LCD panel)
Defective machine monitor

(body)

a Turn starting switch ON and carry out troubleshooting.
When following switches are operated, if all LCD panel is lighted up (all surface
becomes white), LCD panel is normal.
q Operation of switches: [4] + [F2] (Press simultaneously)
E-13 Function switch does not work

Trouble
Related information
Function switch does not work
Cause
40-566

D375A-6
(01)
DRAFT
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.)
Cause

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)
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.)
Cause

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.)
q
Cause
2 Defective power train controller

Power train controller may be defective. (Since trouble is in system, troubleshooting 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.)
q
Cause
D375A-6
(01)

40-567
DRAFT
E-16 Customize function does not operate normally

Trouble
1) When customize switch is operated, customize screen is not displayed.
Related information
Cause

Trouble
2) When setting is changed on customize screen, setting of machine is not changed.
Related information
Cause
2
Defective engine controller or

defective power train controller

Engine controller or power train controller may be defective. (Since trouble is in
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 information
Cause

Trouble
2) When selection is changed on customize memory screen, setting of machine is not changed.
Related information
Cause
2
Defective engine controller or

defective power train controller
40-568

Engine controller or power train controller may be defective. (Since trouble is in
system, troubleshooting cannot be performed.)
D375A-6
(01)
DRAFT
E-18 Alarm buzzer does not sound or does not stop

Trouble
Related information
Alarm buzzer does not sound or does not stop.
Cause

E-19 When starting switch is turned OFF, service meter is not displayed
q
Trouble
Related information
When starting switch is turned OFF, service meter is not displayed.

While starting switch is at OFF position, if following switches are operated, service meter is displayed at top center of screen. Operation of switches: [4] + [1] (Press simultaneously)
Cause
1
Defective backup power supply

system

When starting switch is turned ON, if machine monitor displays nothing, backup
power supply system may be defective. In this case, perform troubleshooting
for "E-3 When starting switch is turned ON, machine monitor displays nothing".
E-20 Machine monitor cannot be set in service mode

q
Trouble
Related information
Machine monitor cannot be set in service mode

If following switches are operated, machine monitor is set in service mode.
Operation of switches: [4]+[1]o[2]o[3] (While pressing [4], press other switches in order)
Cause
D375A-6
(01)

40-569

E-21 The ripper pin puller cylinder does not operate

q
Failure
40-610
The ripper pin puller cylinder does not work.
Related information
Cause
Defective pin puller switch

(Internal defect)

If fuse FS22-4 is broken, circuit probably has ground fault. In this case, perform troubleshooting for cause 6 first.
2. Disconnect connector PLSW and connect T-adapter to male side.
3. Operate switch and troubleshoot.
Pull
Resistance
Max. 1 z
Blow out
Resistance
Min. 1 Mz
Between PLSW (male) (1) and (2)

2. Disconnect connector PPL and connect T-adapter to male side.
Defective pin puller solenoid

Between PPL (male) (1) and (2)
(Internal defect)
Between PPL (male) (1) and ground
Resistance
10 40 z
Resistance
Min. 1 Mz

2. Disconnect connectors ASUS and PHR.
Open or short circuit in wir- 3. Remove fuse FS22-4.
4
ing harness
4. Turn pin puller switch to ON position (lead-in).
Between terminal FS22-4 of fuse and ground
Resistance
10 40 z
a Pin puller solenoid resistance
3. Disconnect connectors PLSW and PPL, and connect T-adapters to each female
Open circuit in wiring harside.
5
ness
Between PPL (female) (2) and ground
Resistance
Max. 1 z


Between PPL (female) (1) and PLSW (female) (2)
Resistance
Max. 1 z
Between fuse FS22-4 and PLSW (female) (1)
Resistance
Max. 1 z
a
1.
2.
3.
Remove fuse FS22-4.
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 Mz
Between PLSW (female) (1) and ground
Resistance
Min. 1 Mz
1.
2.
3.
4.

Disconnect connectors PPL, and connect T-adapter to female side.
Turn pin puller switch to OFF position (pull-out).
Between PPL (female) (1) and (2)
40-570
Voltage
Max. 1 V
D375A-6
(06)
DRAFT
Circuit diagram related to ripper pin puller cylinder
D375A-6
(01)
40-571
DRAFT
E-22 Horn does not sound or does not stop

q
Trouble
Related information
The horn does not sound or does not stop.

Troubleshoot for causes 1 7 and 9, when horn does not sound and for causes 2, 8 and 9 when
horn does not stop.
Troubleshooting at connector HRN (female) does not perform but perform at connector RDG because T-adapter for connector HRN is not prepared.
Cause
2 Defective horn switch
3 Defective wiring harness
Disconnection in wiring harness or horn
5 Disconnection in horn

If fuse FS32-4 is broken, circuit probably has ground fault. In this case, troubleshoot cause 7 first.
2. Disconnect horn switch terminals (No polarity).
3. Turn horn switch ON/OFF and troubleshoot.
OFF
Resistance Min. 1 M
Between horn switch terminals
ON
Resistance
Max. 1
2. Disconnect connector RDG and connect T-adapter to female side.
4. Turn horn switch ON.
Between RDG (female) (3) and ground
Voltage
2030 V
Between FS32-4 and ground
Continuity
2. Disconnect connector HRN.
Between HRN(male) and ground
Continuity

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
2. Disconnect connector HRN and insert T-adapter into RDG.
Resistance Min. 1 M
2. Disconnect connector HRN and insert T-adapter into RDG.
8
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
(01)
40-573
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 failmation
ure code is displayed.
Cause

If fuse FS22-5 is broken, circuit probably has ground fault. In this case, trouDefective fuse FS22-5
bleshoot cause 6 first.
Defective backup alarm relay
2. Replace backup alarm relay (connector: BKA) with another relay.
(Internal disconnection or short
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.
4. Perform reverse travel operation.
Between BKAL (1) and (2)
Voltage
20 30V
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.
(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
Between BKAL (female) (2) and ground
Resistance Max. 1
Between BKA (female) (1), (3) and FS22-5
Resistance Max. 1
a If fuse is not broken, this check is not required.
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 M
Between BKA (female) (5) and ground
Resistance Min. 1 M
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 information
Cause
Defective backup alarm relay

circuit)


(Internal defect)

2. Replace backup alarm relay (connector: BKA) with another relay.
a The above can be checked with backup alarm relay removed only.
If backup alarm stops, original backup alarm relay is defective.
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
If cause cannot be found by above checks, back-up alarm may be defective.
Circuit diagram related to backup alarm
D375A-6
(01)
40-575
DRAFT
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 secmation
tion.
1
Cause
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 inforq 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.
1
2
Cause
Defective head lamp (Breakage
Since the head lamp may be defective, check its bulb for breakage.
of bulb)
Defective circuit breaker (CB105
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).
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.
3. Turn headlamp switch to ON/OFF position and troubleshoot.
Defective head lamp switch
a ON position is located in both directions.
Between FLSW (male) (5) and (6), or
OFF
Resistance Min. 1 M
ON
Resistance Max. 1
between (4) and (5)
2. Disconnect connectors LMD1 and LMD2, and connect T-adapter to diode.
Defective diode LMD1 or LMD2 a Measure in diode range of tester.
Between LMD1 (male) (1) (+) and (2) (-)
No continuity
circuit)
Continuity
No continuity
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.
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
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
(01)
40-577

Cause

2. Disconnect connectors FLSW, LMD1, LMD2, LMFL, LMFR, LHDR, LHDL and
KEY, and connect T-adapters to each female side.

7
contact)
Between LHDR (female) (2) and ground
Resistance
Max. 1 z
Between LHDL (female) (2) and ground
Resistance
Max. 1 z
Between LHDR (female) (1) and LMFR (female) (5)
Resistance
Max. 1 z
Between LHDL (female) (1) and LMFL (female) (5)
Resistance
Max. 1 z
Between LMFL (female) (1) and LMD1 (female) (1)
Resistance
Max. 1 z
Between LMD1 (female) (1) and LMD2 (female) (1)
Resistance
Max. 1 z
Between LMFL (female) (2) and ground
Resistance
Max. 1 z
Between LMFL (female) (3) and CB5 (2)
Resistance
Max. 1 z
Between LMFL (female) (1) and LMFR (female) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Between FLSW (female) (6) and LMD1 (female) (2)
Resistance
Max. 1 z
Between FLSW (female) (4) and LMD2 (female) (2)
Resistance
Max. 1 z
Between FLSW (female) (5) and KEY (female) (1)
Resistance
Max. 1 z
Between FLSW (female) (2) and ground
Resistance
Max. 1 z
2. Disconnect connectors LMD1, LMD2, LMFL, LHDR and LHDL, and connect
T-adapter to female side of LMFL.

Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
40-578
D375A-6
(06)
DRAFT
Circuit diagram related to ripper point lamp
D375A-6
(01)
40-579
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
1
2
Cause
Defective working lamp (Breakage
of bulb)

Since the working lamp may be defective, check its bulb for breakage.
When the fuse is blown, a ground fault may have probably occurred in the
circuit.
2. Replace relay (connector: LMW) with backup alarm relay (connector:
Defective working lamp relay
BKA).
(Internal disconnection or short cir3.
Turn
starting switch ON position.
cuit)
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
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
Between LWKL (female) (2) and ground
Resistance Max. 1
(Disconnection or defective contact) Between LWKR (female) (1) and LMW (female)
Resistance Max. 1
(5)
Between LWKL (female) (1) and LMW (female)
Resistance Max. 1
(5)
Between LMW (female) (1) and LMFL (female)
Resistance Max. 1
(1)
Between LMW (female) (2) and ground
Resistance Max. 1
Between LMW (female) (3) and FS22-2
Resistance Max. 1
3. Disconnect connectors LMW, LWKR and LWKL, and connect T-adapters
to female side of LMW.
Resistance Min. 1 M
Resistance Min. 1 M
Defective fuse (FS22-2)
40-580
D375A-6
(01)
DRAFT
Circuit diagram related to ripper point lamp
D375A-6
(01)
40-581
DRAFT
Trouble
3) Back-up lamp and ripper point lamp do not light.

If fuse, back-up lamp relay, back-up lamp switch or common wiring harness of back-up lamp and ripRelated inforper 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).
q
1
2
3
Cause
Defective rear lamp (Breakage of
bulb)
Defective ripper point lamp (Broken bulb)
Defective fuse FS22-1

Since the rear lamp may be defective, check its bulb for breakage.
Since the ripper point lamp may be defective, check its bulb for breakage.
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).
(Internal disconnection or short cir3.
cuit)
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.
Defective rear lamp switch
3. Turn back-up lamp switch to ON/OFF position and troubleshoot.
OFF
Resistance Min. 1 M
Between RLSW (female) (5) and (6)
ON
Resistance Max. 1
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.
wiring harness
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
Between LRER (female) (2) and ground
Resistance Max. 1
Between LREL (female) (2) and ground
Resistance Max. 1
Between LRP (female) (2) and ground
Resistance Max. 1
Between
LRER
(female)
(1)
and
LMRE
(female)
(5)
Resistance
Max. 1
(Disconnection or defective conBetween LREL (female) (1) and LMRE (female) (5) Resistance Max. 1
tact)
Between LRP (female) (1) and LMRE (female) (5) Resistance Max. 1
Between LRP (female) (2) and ground
Resistance Max. 1
Between LMRE (female) (1) and RLSW
Resistance Max. 1
(female)(1), (6)
Between LMRE (female) (2) and ground
Resistance Max. 1
Between LMRE (female) (3) and FS22-1
Resistance Max. 1
Between RLSW (female) (5) and KEY (female) (1) Resistance Max. 1
Between RLSW (female) (2) and ground
Resistance Max. 1
40-582
D375A-6
(01)
DRAFT

D375A-6
(01)
a
1.
2.
3.
Remove fuse FS22-1.
Disconnect connectors LRER, LREL, LRP, LMRE and RLSW, and connect
T-adapter to female side of LMRE.
Resistance Min. 1 M
Resistance Min. 1 M
Resistance Min. 1 M
40-583
DRAFT
E-26 Windshield wiper does not operate

Trouble
1) None of the wipers operate.
Related information
Cause
1
Defective CB105 circuit breaker
Disconnection in, or ground fault

of wiring harness

(Disconnection or defective contact)


If CB105 circuit breaker is turned ON, the circuit probably has ground fault. In
Between terminal (B) in cab fuse box and ground
Voltage
2030V
a If CB105 circuit breaker is turned ON, reset it first.
Between battery relay BRC terminal and cab fuse
Resistance Max. 1
box (B) terminal
a If neither of causes 1 and 2 is the cause for the trouble, this check is not
required.
2. Remove terminal (B) from cab fuse box.
Between terminal (B) in cab fuse box (Wiring harResistance Min. 1 M
ness side) and ground
Circuit diagram related to wiper
40-584
D375A-6
(01)

Trouble
Related
information
2) Front windshield wipers do not operate.

q
q
T-adapter is not prepared for each connector. (Perform troubleshooting without using T-adapters.)
For related circuit diagram, see Trouble 1).
Cause
Defective fuse 4 in cab fuse If fuse shown at left is broken, circuit probably has ground fault. In this case, perform
1
box
Defective front wiper motor 2. Disconnect connector CN-9 and connect T-adapter to male side.
2 (Internal open circuit in wirBetween CN-9 (male) (2) and (5)
Continuity
ing)
2. Disconnect connector CN-12.
3. Turn front wiper switch ON and OFF, and troubleshoot.
3 Defective front wiper switch Between CN-12 (male) (3) and (4)
OFF
Resistance
Min. 1 Mz
ON
Resistance
Max. 1 z
OFF
Resistance
Max. 1 z
ON
Resistance
Min. 1 Mz
Between CN-12 (male) (4) and (5)
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

5
contact)

2. Remove fuse 4 from cab fuse box.
3. Turn front wiper switch to ON position.
Between terminal (4) in cab fuse box (Wiring harness
side) and ground
Voltage
20 30 V
Continuity

Voltage
20 30 V
Ground fault in wiring har- a If cause 4 is not the cause for the trouble, this check is not required.
6 ness
(Contact with ground circuit) 2. Remove fuse 4 from cab fuse box.
3. Disconnect connectors CN-9 and CN-12.
Resistance
Min. 1 Mz
side) and ground
D375A-6
(06)
40-585

Trouble
Related
information
3) Rear wiper does not operate.

q
q
Cause
1
box

Defective rear wiper motor 2. Disconnect connector CN-4 and connect T-adapter to male side.
2 (Internal open circuit in wirBetween CN-4 (male) (2) and (1)
Continuity
ing)
3. Turn rear wiper switch ON and OFF, and troubleshoot.
3 Defective rear wiper switch Between CN-14 (male) (3) and (4)
OFF
Resistance
Min. 1 Mz
ON
Resistance
Max. 1 z
OFF
Resistance
Max. 1 z
ON
Resistance
Min. 1 Mz
4 Power supply line

Between terminal (2)in cab fuse box and ground

5
contact)

3. Turn rear wiper switch to ON position.
side) and ground
Voltage
20 30 V
Continuity

Between terminal (2)in cab fuse box and ground
Voltage
20 30 V
6 ness
Resistance
Min. 1 Mz
side) and ground
40-586
D375A-6
(06)

Trouble
Related
information
4) Left door wiper does not operate.

q
q
Cause
1
box

Defective left door wiper
2. Disconnect connector CN-18 and connect T-adapter to male side.
motor
2
(Internal open circuit in wirBetween CN-18 (male) (2) and (3)
Continuity
ing)
3. Turn left door wiper switch ON and OFF, and troubleshoot.
3
Defective left door wiper

switch
OFF
Resistance
Min. 1 Mz
ON
Resistance
Max. 1 z
OFF
Resistance
Max. 1 z
ON
Resistance
Min. 1 Mz
4 Power supply line


5
contact)

3. Turn left door wiper switch ON.
side) and ground
Voltage
20 30 V
Continuity

Voltage
20 30 V
6 ness
Resistance
Min. 1 Mz
side) and ground
D375A-6
(06)
40-587

Trouble
Related
information
5) Right door wiper does not operate.

q
Cause
1
box
Defective right door wiper

motor
2
(Internal open circuit in wirBetween CN-17 (male) (2) and (3)
Continuity
ing)
3. Turn right door wiper switch ON and OFF, and troubleshoot.
3
Defective right door wiper

switch
OFF
Resistance
Min. 1 Mz
ON
Resistance
Max. 1 z
OFF
Resistance
Max. 1 z
ON
Resistance
Min. 1 Mz
4 Power supply line


5
contact)

3. Turn right door wiper switch ON.
side) and ground
Voltage
20 30 V
Continuity

Voltage
20 30 V
6 ness
3. Disconnect the connectors CN-17 and CN-13.
Resistance
Min. 1 Mz
side) and ground
40-588
D375A-6
(06)
DRAFT
Circuit diagram related to wiper
D375A-6
(01)
40-589
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).
Cause
Defective front window washer

1 motor (Internal defect)
2 Defective front wiper switch

3 (Disconnection or defective contact)

40-590

a Check that rear window washer sprays water normally.
2. Replace connector WSFR with WSRR.
4. Turn front window washer switch to ON position.
If rear window washer sprays water, original front window washer motor is
defective.
4. Turn switch ON and OFF, and troubleshoot.
OFF
Resistance Min. 1 M
ON
Resistance
Max. 1
3. Turn front window washer switch to ON position.
Between terminal (4) in cab fuse box (Wiring harContinuity
2. Remove fuse 4 from fuse box.
3. Disconnect connectors CN-12 and WSFR.
Between terminal (4) in cab fuse box (Wiring harResistance Min. 1 M
D375A-6
(01)
DRAFT
Circuit diagram related to window washer
D375A-6
(01)
40-591
DRAFT
Trouble
2) Rear window washer does not operate.

Related inforq T-adapter is not prepared for window washer motor connector (Perform Troubleshooting without
mation
T-adapter).
Cause
Defective rear window washer

motor
Defective rear wiper switch

(Disconnection or defective contact)

40-592

a Check that front window washer sprays water normally.
2. Replace connector WSFR with WSRR.
4. Turn rear window washer switch to ON position.
If front window washer spouts water, original rear window washer motor is
defective.
OFF
Resistance Min. 1 M
ON
Resistance Max. 1
3. Turn rear window washer switch to ON position.
3. Disconnect connectors CN-14 and WSRR.
D375A-6
(01)
DRAFT
Circuit diagram related to window washer
D375A-6
(01)
40-593
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
T-adapter).
mation
Cause

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.
Defective right door wiper switch 3. Disconnect connector CN-13 and connect T-adapter to male side.
OFF
Resistance Min. 1 M
ON
Resistance Max. 1
Disconnection in wiring harness 2. Remove fuse 3 from cab fuse box.
(Disconnection or defective con- 3. Turn right door window washer switch to ON position.
tact)
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
T-adapter).
mation
Cause

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.
Defective left door wiper switch
OFF
Resistance Min. 1 M
ON
Resistance Max. 1
Disconnection in wiring harness 2. Remove fuse 5 from cab fuse box.
(Disconnection or defective con- 3. Turn left door window washer switch to ON position.
tact)
3. Disconnect connectors CN-11 and WSLH.
D375A-6
(01)
40-595
DRAFT
E-28 Electric priming pump does not operate or does not stop automatically
Trouble
Related information
1
2
Electric priming pump does not operate or does not stop automatically.
Cause
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
Defective circuit breaker CB7
cause No. 5)
2. Disconnect connectors EPP, and connect T-adapter to female side.
(Drive power supply system)
Between EPP (1) - (2)
Voltage
20 30V
(Disconnection in wiring or defec1.
Disconnect
ground
strap
(to
turn
constant
power
supply
OFF).
Between EPP (female) (2) and ground
Resistance Max. 1
1. Disconnect ground strap (to turn constant power supply OFF).
Ground fault in wiring harness
3. Disconnect connectors USB, EG1 and EFP.
Resistance Min. 1 M
Resistance Min. 1 M
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
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
* 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.
Trouble in electric priming pump Between EFP (male) (1) and (2)
Resistance
13
Between EFP (male) (1) pump body
Resistance Min. 1 M
Between EFP (male) (2) pump body
Resistance Min. 1 M
40-596
D375A-6
(01)
DRAFT
Circuit diagram related to electric priming pump
D375A-6
(01)
40-597
DRAFT
E-29 Orbcomm terminal does not operate normally (Data are not transmitted)
Trouble
Related information
q
q
The ORBCOMM terminal does not operate normally (Data are not transmitted).
Even if the ORBCOMM terminal is abnormal, it does not cause a trouble in the machine.
Cause

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 communiTerminal power supply is abnormal or OFF
cation with VHMS controller is abnormal.
Power is applied to ORBCOMM terminal and the communicasatellite is not captured
*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
a Constant power supply is used. When disconnecting connector and
carrying out troubleshooting, take care.
(Disconnection or defective contact in
Between
KOM1 (female) (36), (39) and VF2
connector)
Resistance Max. 1
(male) (5)
Between KOM1 (female) (37), (38) and ground Resistance Max. 1
Between V4B (female) (3)KOM1 (female) (11) Resistance Max. 1
Between V4B (female) (4)KOM1 (female) (4) Resistance Max. 1
Between V4B female) (10)KOM1 (female) (5) Resistance Max. 1
Defective ORBCOMM terminal
3. Disconnect connectors KOM1, and connect T-adapter to female side.
(When LED is turned OFF)
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
Circuit diagram related to ORBCOMM terminal
D375A-6
(01)
40-599
DRAFT
E-30 Gear cannot be shifted

Trouble
Related information
Gear cannot be shifted (Shift switch does not work).
Cause
Trouble in shift operation
switch
q Shift up switch
1
q Shift down switch
q Shift switch
(Optional-type lever)
Internal defect of transmis2
sion clutch
40-600

a When failure code related to shift operation switch is not displayed.
Press shift operation switch for more than 10 seconds. If any of following failure code
is displayed at this time, carry out troubleshooting for it.
[DD12KA], [DD12KB], [DD13KA], [DD13KB], [DDK5KA], [DDK5KB]
a When failure code related to shift operation switch is displayed.
Carry out troubleshooting for displayed failure code.
The inside of the transmission clutch is supposed to be defective, check it directly.
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 diagram. Before performing troubleshooting, understand that information fully.
Trouble
Trouble in machine
Related inforInformation related to detected trouble or troubleshooting
mation
Cause
Possible
causes and
standard value
for judgment
Possible causes of trouble

(Given numbers are reference
numbers, which do not indicate
priority)
<Contents of description>
q Standard value to determine possible causes
q Remarks on judgment
D375A-6
(01)
40-601
DRAFT
List of Failure Modes and Causes

Hydraulic components
Related to work equipment
Related to power train
40-602
Q Q
EPC valve
Q Q Q Q Q Q Q
Q Q Q Q
Q
Q Q Q Q Q Q
Q
Q Q
Q
Q
Hydraulic tank strainer
For steering clutch

For brake clutch
For gearshift clutch
Power train pump

Torque converter operation valve
Torque converter relief valve
Transmission main relief valve
Transmission operation valve
Steering valve
For lockup clutch
For forward-reverse clutch
Failure modes
No force (No drawbar pull).
No travel (at 2nd or 3rd speed).
No travel at all gear speeds.
Machine travels only in one direction forward or in reverse.
Large time lag at gear speed shifting or forward-reverse shifting.
Steering is not possible.
Steering is possible only on one side.
Steering overrun occurs.
Torque converter is not locked-up.
Power train oil overheats.
Blade lift speed is slow or lacks power.
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 attachment machine).
Blade pitch does not work (dual tilt attachment machine).
Abnormal sound comes out from around work equipment
pump.
Fan speed is abnormal (sound and/or vibration are abnormally large or engine overheats).
Servo valve
Main
pump
ECMV
Main body
Components causing failures
Q Q
Q
Q
Q
Q
Q
Q Q
Q
Q
Q Q Q Q Q
Q Q Q Q Q
Q Q Q Q
D375A-6
(01)
Q
Q
Q
Q
Q
D375A-6
(01)
Q
Q
Q
Q
Q Q
Q Q
Q Q
Q
Q Q Q
Q Q Q
Q
Fan pump
Fan motor
Brake pedal linkage
Parking brake linkage
Hydraulic cylinder
Ripper pin-puller solenoid valve
Pitch selection solenoid valve
LS check valve
Pressure compensation valve
Suction valve
LS relief valve
Main relief valve
Unload valve
Spool
Valve body
PPC valve
PPC lock valve
Hydraulic components
Control valve
Q Q Q
Q Q
Q Q Q
Q Q
Q Q Q Q Q Q
Q
Q Q
Q
Q
Q Q
Q
Q Q
Q
Q
Q
Q
Q
Q
Q
Q Q
QQ
Q QQ
Q
Q
Q
Q
Q
Q
Q
Q Q
Steering clutch (disc, plate, etc.)

Brake clutch (disc, plate, etc.)
Inside of transmission
Inside of torque converter
PTO
Engine
Cooling system
Loosening of piping clamp, air in hydraulic oil and oil leakage
Q
Q
Q Q Q
Q
QQ
Diagnosis codes
DRAFT
Mechanical system
H-1
H-2
H-3
H-4
H-5
H-6
H-7
H-8
H-9
H-10
H-11
H-12
H-13
H-14
H-15
H-16
H-17
H-18
H-19
H-20
H-21
H-22
H-23
Q Q
H-24
40-603
DRAFT
H-1 Machine lacks power(or drawbar pull)

Trouble
Related
information
q
q
q
Power is low (Insufficient drawbar pull)

When Manual transmission or show slip control is selected for the gear shift mode, and when operation
is in the E mode, the contents of this section are not applied.
Make sure that hydraulic oil level of power train is normal, and start troubleshooting.
Cause
Possible
causes and
standard
value in normal state
40-604

a Prepare by turning starting switch to OFF position, then troubleshoot by rotating engine at high idling speed.
Defective engine or transMeasuring conditions
Engine speed
F3 stall
1,450 rpm
mission
Stall in F3 + Relief of work equip1,400 rpm
ment system (Pitch back)
Defective power train pump The power train pump is assumed to be defective; directly check it.
Torque converter
Torque converter
Internal defect of torque conPCCS lever
inlet pressure
outlet pressure
verter
0.44 0.74 MPa
0.69 1.08 MPa
All neutral position
{4.5 7.5 kg/cm2}
{7.0 11.0 kg/cm2}
Transmission
PCCS lever
2.53 3.12 MPa
Defective set pressure of
{25.8
31.8 kg/cm2}
transmission main relief
a Prepare with starting switch OFF, then carry out troubleshooting
valve and internal defect
without turning starting switch ON.
Directly check that the spring length and the number of shims are normal and also that the spool rotates smoothly.
q Free length of spring: 120.3 mm
q
Number of shims: 4
a Prepare by turning starting switch to OFF position, then troubleshoot by rotating engine at low idling speed.
Transmission clutch
Clutch pressure
FWD
Min.
2.06
MPa {Min. 21.0 kg/cm2}
Operation failure of transREV
Min. 2.06 MPa {Min. 21.0 kg/cm2}
mission valve (ECMV)
1ST
2ND
3RD
a Move the machine to a flat ground and start the engine for troubleshooting.
Defective operation (dragIf 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
brake lever or brake pedal linkage is not assumed to be adjusted norlever or brake pedal linkage
mally. Directly check it.
D375A-6
(01)
DRAFT
Cause
Possible
causes and
standard
D375A-6
(01)

a After checking that the transmission main relief pressure is normal.
a Prepare by turning starting switch to OFF position, then troubleshoot 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}
0 MPa
Min. 2.4 MPa
8 Defective steering clutch
{0 kg/cm2}
{Min. 24 kg/cm2}
0 MPa
Min. 2.4 MPa
Left brake pressure
{0 kg/cm2}
{Min. 24 kg/cm2}
Min. 2.4 MPa
0 MPa
{Min. 24 kg/cm2}
{0 kg/cm2}
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.
40-605
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
q
Related information
q
q
Machine cannot start (at 2nd or 3rd gear speed)

Before performing troubleshooting, check that the power train oil level is normal.
Before performing troubleshooting, check that the transmission main relief pressure is normal. (See
H-1.)
If any one of failure code of [15SFL1], [15SFLH], [15SGL1] or [15SGLH] is displayed, perform troubleshooting for the failure code first.
Cause
Possible
causes and
standard value
for judgment
40-606
Standard value /Remarks on troubleshooting

a Prepare with starting switch to OFF position , then run the engine
at full speed to perform troubleshooting.
Torque converter
Torque converter outInternal defect of torque conPCCS lever
1
inlet pressure
let pressure
verter
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.
Transmission clutch
Clutch pressure
Defective operation of transMin. 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.
a Move the machine to flat ground and start the engine to perform
troubleshooting.
Defective operation (dragRun the engine at low speed and set the gear to F2. If the machine
4
ging) of brake
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
PCCS lever
Left stroke end
Right stroke end
0 MPa
Min. 2.4 MPa
{0 kg/cm2}
{Min. 24 kg/cm2}
0 MPa
Min. 2.4 MPa
Defective steering clutch, or Right clutch pressure
{0 kg/cm2}
{Min. 24 kg/cm2}
5
brake
0 MPa
Min. 2.4 MPa
Left brake pressure
{0 kg/cm2}
{Min. 24 kg/cm2}
Min. 2.4 MPa
0 MPa
{Min. 24 kg/cm2}
{0 kg/cm2}
When the oil pressure is abnormal, perform the troubleshooting for
"H-6 machine cannot turn."
Transmission may have an internal defect. Check it directly.
sion
D375A-6
(01)
DRAFT
H-3 Machine cannot travel at any gear speeds
H-3 Machine cannot travel at any gear speeds

Trouble
q
q
Related information
Machine can not travel at any gear speeds

Performing troubleshooting, check that the power train oil level is normal.
If any one of failure code of [1500L0], [2201L1], [2201LH], [2202L1], [2202LH], [DDT5KA],
[DDT5KB], [DK30KX], [DK30KZ], [DK55KX] or [DK55KZ] is displayed, perform troubleshooting for
the failure code first.
Cause
1
pump
Possible
causes and
standard value
for judgment
D375A-6
(01)

The power train pump is may be defective. Check it directly.
a Prepare with starting switch at OFF position, then run the engine at
full speed to perform troubleshooting.
Incorrect set pressure of
Transmission
PCCS lever
2 transmission main relief
valve
2.53 3.12 MPa
{25.8 31.8 kg/cm2}
a Prepare with starting switch at OFF position, then perform troubleshooting 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.
Transmission clutch
Clutch pressure
FWD
Min.
2.06
MPa {Min. 21.0 kg/cm2}
4 transmission valve
REV
(ECMV)
1ST
2ND
3RD
a Move the machine to level ground, raise parking the brake lever, run
the engine at full speed to perform troubleshooting.(Before starting
troubleshooting ,check that transmission main relief pressure is norDefective operation of
mal).
5
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 troubleshooting (Before starting troubleshooting ,check that transmission
main relief pressure is normal).
PCCS lever
Left stroke end
Right stroke end
Min. 2.4 MPa
0 MPa
Defective seal of steering Left clutch pressure
2}
6
{Min.
24
kg/cm
{0
kg/cm2}
clutch or brake
Min. 2.4 MPa
0 MPa
{Min. 24 kg/cm2}
{0 kg/cm2}
0 MPa
Min. 2.4 MPa
Left brake pressure
{0 kg/cm2}
{Min. 24 kg/cm2}
Min. 2.4 MPa
0 MPa
{Min. 24 kg/cm2}
{0 kg/cm2}
Internal defect of steer7
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 normally.
Internal defect of trans9
The inside of transmission clutch may be defective. Check it directly.
mission clutch
40-607
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
q
Related information
q
q
Machine travels only in one direction ,forward or in Reverse.

Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.)
If any one of failure code of [15SAL1], [15SALH], [15SBL1] or [15SBLH] is displayed, perform troubleshooting for the failure code first.
Cause
1
Possible
causes and
standard value
in normal state
2
3
40-608

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.)
Transmission clutch
Clutch pressure
Min. 2.06 MPa
FWD
{Min. 21.0 kg/cm2}
Defective operation of transMin. 2.06 MPa
REV
{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}
Defectively sealed of trans- If the result of the test for cause 4 shows malfunction of the brake,
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.
sion clutch
Check it directly.
troubleshooting.
Defective operation (dragRun 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 troubleshooting for "H-9 Brake does not work").
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
Related
information
Possible
causes and
standard
D375A-6
(01)
Large time lag at gear shifting or directional change.
Before performing troubeshooting ,check that the power train oil level is normal.
Cause
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 engine at full speed to perform troubleshooting.
Transmission
PCCS lever
Defective operation of trans2
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
normal and that the spool moves smoothly.
mission main relief valve
q Free length of spring: 120.3mm
q Number of shims: 4
a Prepare by turning starting switch at OFF position, then run the engine at low speed to perform troubleshooting .
Transmission clutch
Clutch pressure
Min. 2.06 MPa
FWD
{Min. 21.0 kg/cm2}
Min. 2.06 MPa
Operation failure of transREV
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.
Inside of transmission clutch may be defective. Check it directly.
sion clutch
troubleshooting.
Defective operation of brake
If machine does not move when engine is low-idling and F2 shift is
7
(dragging)
8 Type of oil used
Check if an oil other than the specified oil (T030) is being used.
40-609
DRAFT
H-6 Machine connot turn
H-6 Machine connot turn

Trouble
Related information
q
q
q
Machine connot turn.

H-1.)
Cause
Possible causes
and standard
value for judgment
3
4
5
40-610

a Prepare with engine started , then run the engine at low speed
whild performing troubleshooting.
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
PCCS lever
Left stroke end
Right stroke end
0MPa
Min. 2.4MPa
2}
{0 kg/cm2}
{Min. 24 kg/cm
0MPa
Min.
2.4MPa
steering clutch valve
2
{0 kg/cm }
{Min. 24 kg/cm2}
(ECMV)
0MPa
Min. 2.4MPa
Left brake pressure
2
{0 kg/cm }
{Min. 24 kg/cm2}
Min. 2.4MPa
0MPa
2
{Min. 24 kg/cm }
{0 kg/cm2}
Defectively sealed steering When standard values for the cause 2 are not satisfted, the clutch
clutch
seal may be sealed diffectively. Check it directly.
Internal defect of steering
Steering clutch may be defective, check it directly.
clutch
steering potentiometer of
Perform troubleshooting related to steering potentiometer.
travel control lever
D375A-6
(01)
DRAFT
H-7 Machine turns only to one side
H-7 Machine turns only to one side

Trouble
Related information
q
q
q
Machine turns only to one side.

H-1.)
Cause
Possible
causes and
standard value
for judement
3
4
5
D375A-6
(01)

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
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.
PCCS lever
Left stroke end
Right stroke end
0MPa
Min. 2.4MPa
2}
{0 kg/cm2}
{Min. 24 kg/cm
Defective operation of steerMin. 2.4MPa
0MPa
ing clutch valve (ECMV)
{Min. 24 kg/cm2}
{0 kg/cm2}
0MPa
Min. 2.4MPa
Left brake pressure
2
{0 kg/cm }
{Min. 24 kg/cm2}
Min. 2.4MPa
0MPa
2
{Min. 24 kg/cm }
{0 kg/cm2}
Defectively sealed steering When the standard the cause 2 are not satisfied , the clutch seal may
clutch
be sealed defectively. Check it directly.
Internal defect of steering
Steering clutch may be defective, check it directly.
clutch
Defective operation of steering potentiometer of travel Perform troubleshooting related to steering potentiometer.
control lever
40-611
DRAFT
H-8 Machine overruns at turnning
H-8 Machine overruns at turnning

Trouble
Related
information
Machine overruns at turnning.

H-1.)
q
q
Cause
Possible
causes and
standard
value for
judgment

a Prepare with starting switch OFF, then drive the engine in low idle
mode for troubleshooting.
Raise the machine by using the blade and run the engine with gear at
1 Defective operation of brake
F3 travel (or R3 travel) and make steering operation. If the shoe stops
running ,the brake is defective. (Perform the troubleshooting for H-9
Brake does not work.)
When track shoe does not stop running in the troubleshooting for the
Defective operation of steercause 1, the steering clutch is defective. (Perform the troubleshooting
2
ing clutch
fro H-6 Machine cannot turn.)
H-9 Brake does not work

Trouble
q
q
Related information
q
q

H-1.)
If failure code [DK40KA] or [DK40KB] is displayed, perform diagnoses for the failure code first .
Cause
1
2
Possible
causes and
standard value
for judgment
4
5
40-612

a Start the engine to perform troubleshooting.
Depress the brake pedal, shift the gear to F2 and run the engine at
Degradation of brake
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.
pedal
Check them directly.
a Prepare with starting switch at OFF position, then run the engine
at full speed to perfrom troubleshooting.
PCCS lever
Left stroke end
Right stroke end
Min. 2.4MPa
0MPa
{Min. 24 kg/cm2}
{0 kg/cm2}
Defective operation of steerMin. 2.4MPa
0MPa
ing brake valve (ECMV)
{Min. 24 kg/cm2}
{0 kg/cm2}
0MPa
Min. 2.4MPa
Left brake pressure
{0 kg/cm2}
{Min. 24 kg/cm2}
Min. 2.4MPa
0MPa
{Min. 24 kg/cm2}
{0 kg/cm2}
When standard the cause 3 are not satisfied , the brake seals may be
Defective brake seal
defective. Check it directly.
Internal defect of brake
Brakes may be defective. Check it directly.
D375A-6
(01)

H-10 Torque converter does not lock up
H-10 Torque converter does not lock up

Failure
Related information
40-6 1
The torque converter does not lock up.
Before performing troubleshooting, check that the transmission main relief pressure is normal.
(See H-1.)
If any one of failure code of [DDTSL1], [DDTSLH], [DXH1KA], [DXH1KB], [DXJBKA] or [DXJBKB]
is displayed, perform diagnoses for the failure code first.
q
q
Cause
Standard value in normal condition/Remarks on troubleshooting
1 Defective power train pump The power train pump may be defective. Check it directly.
Defective operation of torque

2 converter lock up valve
(ECMV)
Possible
causes and
standard value
for judgment
a Prepare with starting switch at OFF position, then run the engine at full speed to perform troubleshooting.
Clutch pressure
Torque converter
At lock up
Stator
clutch
Lockup clutch
2.50 2.79 MPa

{25.5 28.5 kg/cm2}
1.24 1.54 MPa
{12.7 15.7 kg/cm2}
Defectively sealed of lock up When standard value for the case 2 is not satisfied, the lock up
clutch
clutch may sealed defectively. Check it directly.
Internal defect of lock up

clutch
Lock up clutch may be defective. Check it directly.

a Prepare with starting at switch OFF position, then run the engine at full speed to perform troubleshooting.
Internal defect of torque con5
F3,torque converter stall
verter
F3,torque converter stall + Work
equipment relief
(pitch back)
D375A-6
(06)
Engine speed
1,450rpm
1,170rpm
40-613
DRAFT
H-11 Power train oil overheats

Trouble
q
q
Related
information
Overheating of power train oil

Make sure that hydraulic oil level of power train is normal, and start troubleshooting.
Make sure that power train oil temperature gauge indication matches actual oil temperature of torque
converter and start troubleshooting. (If no match, follow "E-9 Power train oil temperature gauge
(multi-gauge) does not indicate normally".)
Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.)
Cause
1 Defective engine system
Possible
causes and
standard
40-614
Defective power train pump

or air entry in suction circuit
Internal defect of torque converter
Defective operation (slide) of

transmission clutch

(dragging)
Defective operation (slide) of

steering clutch

(Slip)
Defective power train oil

cooler

Engine cooling system may be defective and engine output may be
increased abnormally. Carry out troubleshooting according to Engine
volume, Shop manual.
The power train pump is supposed to be defective, or air is supposed
to have entered from the suction circuit. Check them directly.
Torque converter
Torque converter
PCCS lever
inlet pressure
outlet pressure
0.69 1.08 MPa
0.44 0.74 MPa
{7.0 11.0 kg/cm2}
{4.5 7.5 kg/cm2}
The inside of the transmission clutch is supposed to be defective (the
clutch slides). Check it directly.
a Start the engine for troubleshooting.
If machine does not move when engine is low-idling and F2 shift is
The inside of the steering clutch is supposed to be defective (the clutch
slides). Check it directly.
a Start the engine for troubleshooting.
If the machine cannot be stopped completely while performing F3 stall,
the brake is slipping.
Check the filter element for clogging.
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
Related
information
Make sure that hydraulic oil level is normal, and start troubleshooting.
Cause
Defective PTO (work equip1
ment pump drive)
2
large pump
3
small pump
Possible
causes and
standard
10
11
12
D375A-6
(01)

The work equipment pump drive of the PTO is supposed to be defective. Check it directly.
The work equipment large pump is supposed to be defective. Check it
directly.
The work equipment small pump is supposed to be defective. Check it
directly.
Work equipment control levers
Unload pressure
unload valve
2.45 (+1.37/0) MPa
{25 (+14/0) kg/cm2}
Improper pressure set to
Blade lever
main relief valve for blade lift
Min. 26.5 MPa
valve
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
valve for blade lift valve
defective. Check it directly
Blade lever
main relief valve for blade tilt
Min. 26.5 MPa
ripper Lo valve
Raise
{Min. 270 kg/cm2}
Internal defect of main relief
The inside of the main relief valve for blade tilt ripper Lo valve is supvalve for blade tilt ripper Lo
posed to be defective. Check it directly.
valve
Defective pressure setting or
LS relief pressure
defective operation of LS
Min. 24.52 MPa
relief valve
At stroke end
{Min. 250 kg/cm2}
Malfunction of self pressure
Control relief pressure
reducing valve (PPC basic
Min. 3.1 MPa
pressure)
{Min. 32 kg/cm2}
If cause 8 is detected, oil may be leaking in PPC valve. Check PPC
Internal leak of PPC valve
valve directly.
Operation failure of check
Directly inspect the check valve for clogging.
valve of PPC control circuit
40-615
DRAFT
H-13 All work equipment does not operate

Trouble
Related
information
Make sure that hydraulic oil level is normal, and start troubleshooting.
Cause
Defective PTO (work equip1
ment pump drive)
2
large pump
3
small pump
6
Possible
causes and
standard
10
11
12
40-616

The work equipment pump drive of the PTO is supposed to be defective. Check it directly.
The work equipment large pump is supposed to be defective. Check it
directly.
The work equipment small pump is supposed to be defective. Check it
directly.
Prepare by turning starting switch to OFF position, then troubleshoot
by rotating engine at high idling speed.
Unload pressure
unload valve
2.45(+1.37/0) MPa
{25(+14/0) kg/cm2}
Blade lever
main relief valve for blade lift
Min. 26.5 MPa
valve
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
valve for blade lift valve
defective. Check it directly
Blade lever
main relief valve for blade tilt
Min. 26.5 MPa
ripper Lo valve
Raise
{Min. 270 kg/cm2}
Internal defect of main relief
The inside of the main relief valve for blade tilt ripper Lo valve is supvalve for blade tilt ripper Lo
posed to be defective. Check it directly.
valve
Defective pressure setting or
LS relief pressure
defective operation of LS
27.44 1.37 MPa
relief valve
At stroke end
{280 14 kg/cm2}
Malfunction of self pressure
reducing valve (PPC basic
Min. 3.1 MPa
pressure)
{Min. 32 kg/cm2}
Defective operation of PPC The PPC lock valve is supposed to operate abnormally. Check the
lock valve
lever linkage or the lock valve directly.
Operation failure of check
valve of PPC control circuit
Min. 3.1 MPa
{Min. 32 kg/cm2}
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
q
q
Related information
q
q
Blade lift cylinders speed is too slow or lacks power.

Before performing troubleshooting, check that hydraulic tank oil level is normal.
Check whether the blade is remodeled.
When hydraulic drift rate of the blade lift cylinders is also high, perform troubleshooting for H-18
Excessive hydraulic drift of blade Lift cylinders.
If either one of failure code of [DDNALD] or [DDNFLD] is displayed, troubleshooting corresponding to
such code are to be reformed.
Cause
Possible
causes and
standard value
for judgement

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
1
valve
Min. 3.1 MPa
Raise stroke end
{Min. 32 kg/cm2}
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
q
q
Related information
q
q
Blade tilt cylinders speed is too slow or lacks power.

Before performing troubleshooting, check the hydraulic oil level is normal.
When the hydraulic drift rate of the blade tilt cylinders is also high, perform troubleshooting for H-19
Excessive hydraulic drift of blade tilt cylinders.
If either one of failure code of [DDNZLD] or [DDN3LD] is displayed, troubleshooting corresponding to
such code are to be performed.
Cause
Possible
causes and
standard value
for judgement
D375A-6
(01)

a Prepare with starting switch OFF, then run the engine at the full
speed position to performe troubleshooting.
Blade control lever
1
valve
Min. 3.1 MPa
Raise stroke end
{Min. 32 kg/cm2}
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.
40-617
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
q
q
Related
information
q
q
Ripper lift cylinders speed is too slow or lacks power.

Before performing troubleshooting, check the hydraulic tank oil level is normal.
Check whether the ripper is remodeled.
When the hydraulic drift rate of the ripper lift cylinders is also high, perform troubleshooting for H-20
Excessive hydraulic drift of ripper Lift cylinders.
If either one of failure code of [DDNBLD] or [DDNCLD] is displayed, troubleshooting corresponding to
such code are to be performed.
Cause
1
Possible
causes and
standard
value for
judgement

speed position to perform troubleshooting
Ripper control lever
valve
Min. 3.1 MPa
Raise stroke end
{Min. 32 kg/cm2}
Defective operation of ripper Operation of the ripper lift control valve may be defective.Check it
lift control valve (Spool)
directly.
The operation of the suction valve for the ripper lift control valve may be
Defective operation of ripper
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
der
phenomenon changes.
H-17 Ripper tilt cylinder speed is too slow or lacks power

Trouble
q
q
Related
information
q
q
Ripper tilt cylinders speed is too slow or lacks power.

Before performing troubleshooting, check that the hydraulic oil level tank is normal.
If either one of [DDNDLD] or [DDNELD] is displayed, troubleshooting corresponding to such code are
to be performed first.
Cause
Possible
causes and
standard
value for
judgement
PPC valve
Defective operation of ripper tilt control valve(spool)
Defective operation of rip3 per tilt operation

valve(suction valve)
4
40-618
Air entering ripper tilt cylinders

a Prepare with starting switch OFF, then run the engine at full speed position to perform troubleshooting
Ripper lever
Min.3.1 MPa
Tilt stroke end
{Min. 32 kg/cm2}
Operation of the ripper tilt control valve spool may be defective. Check it
directly.
Operation of the suction valve for the ripper tilt control valve may be
a Judgement may be made by checking a change of phenomenon after
exchanging suction valves on the head side and on the bottom side.
Air may enter ripper tilt cylinders. Bleed air and check whether the phenomenon changes.
D375A-6
(01)
DRAFT
H-18 Excessive hydraulic drift of blade lift cylinder
H-18 Excessive hydraulic drift of blade lift cylinder

Trouble
Related
information
q
q
q
Excessive hydraulic drift of blade lift cylinders.

Before performing troubleshooting, check that no oil leaks in the work equipment circuit.
Cause
Possible
causes and
standard
value for
judgement
Defectively sealed blade lift

control valve (spool)
Defectively sealed of blade

lift cylinder

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
be sealed defectively.
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.
The blade lift cylinders may be sealed defectively. Check it directly.
Raise blade about 1,000 mm above the ground and check hydraulic
Defective fitting of quick drop
drift of its cutting edge.
valve
q 400 mm /15 min
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 pres4
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}
3
H-19 Excessive hydraulic drift of blade tilt cylinder

Trouble
Related
information
q
q
q
Excessive hydraulic drift of tilting blade tilt cylinder.

Before performing troubleshooting, check that no oil leaks in the work equipment circuit.
Cause
Possible
causes and
standard
value for
judgement
D375A-6
(01)
Defectively sealed blade tilt

control valve (spool)
Defectively sealed blade tilt

cylinder

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
may be defective.
1. Use the blade tilt cylinder to thrust the blade against the ground, and
raise the right of the machine.
3. Set the blade contorl lever to the right tilt side, and check whether
the speed changes.
speed position to perform troubleshooting
Blade tilt cylinder
Oil leak from cylinder
Right tilt stroke end
12 cc/min
40-619
DRAFT
H-20 Excessive hydraulic drift of ripper lift cylinder
H-20 Excessive hydraulic drift of ripper lift cylinder

Trouble
Related
information
q
q
q
Excessive hydraulic drift of ripper lift cylinders.

Before performing troubleshooting, check that no oil leaks the circuits in the work equipment before
troubleshooting.
Cause
Possible
causes and
standard
value for
judgement
Defectively sealed of ripper

lift control valve (spool)
Defectively sealed of ripper

lift cylinder

a Prepare with the engine started, then stop the engine for troubleshooting.
speed becomes higher, sealing of the ripper lift control valve (Hi) may
be defective.
1. Use the ripper lift cylinders to thrust the ripper against the ground,
and raise the rear of the machine.
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
position to perform troubleshooting
Oil leak from cylinder
LOWER stroke end
12 cc/min
H-21 Ripper pin puller cylinder does not operate (machine with giant
ripper)
Trouble
Related
information
The ripper pin puller cylinder does not operate.
Check that the transmission main relief pressure is normal before troubleshooting.
Cause
Possible
causes and
standard
value for
judgment
40-620

a Prepare with starting switch at OFF position, then run the engine at
high speed to perform troubleshooting
Pin puller working
Pin puller switch
Measuring position
pressure
Push-in
Cylinder bottom side
Min. 2.2 MPa
Pull-in
Cylinder head side
{Min. 22 kg/cm2}
Defective operation of pin

puller solenoid
Internal defect of pin puller

cylinder
Pin puller cylinder may be defective internally. Check it directly
Defective fuse FS2-2(20A)

for pin puller
Check fuse for breakage. If it is broken, short circuit has probably

occurred.
Check wiring harness of related circuit.
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)
q
Trouble
Related information
The blade pitch does not work.

If either one failure code of [DW5AKA] or [DW5AKB] is displayed, failure diagnoses corresponding
to such code are to be performed first.
Cause
Defective operation of blade
1
pitch selector solenoid valve
Defective function of blade
2
pitch control valve (Spool)
Defective operation of blade
3
pitch cylinder
Possible
causes and
standard value
for judgment
Defective function of blade

pitch switch

Operation of the blade pitch selector valve may be defective. Check it
directly .
Operation of the blade pitch cylinder may be defective. Check it
directly.
Operation of the blade pitch cylinder may be defective. Check it
directly.
Perform troubleshooting related to blade pitch switch.
Even if failure code is not displayed, check that switch operates normally.
H-23 Abnormal noise from around work equipment pump

Trouble
Related
information
Possible
causes and
standard
value for
judgment
Abnormal noise from around work equipment pump.
Befor performing troubleshooting , check hydraulic oil lever is normal.
Cause
1 Inappropriate oil
Clogged hydraulic tank
2
strainer
3 Air inhaled in suction circuit
4
D375A-6
(01)

The oil may be inappropriate. Check it directly.
The strainer of the hydraulic tank may be clogged. Check it directly.
Air may be inhaled in the suction circuit of the work machine pump.
Check the circuit directly.
Internal defect of work equipThe work equipment pump may be defective. Check it directly.
ment pump
40-621

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
40-675
or engine overheats)
Trouble
Related
information
Abnormal fan rotation (noise and/on vibration are abnormally large or engine overheats)
Before performing troubleshooting, check that oil level in hydraulic tank is normal.
Cause
1 Defective engine speed
Defective PTO (fan pump

drive)
Possible
causes and
standard
value for
judgment
Defect in fan pump or fan

motor

a Start engine to performing troubleshooting.
Measuring conditions
Engine speed
Engine at low idling
750 50 rpm
Engine at high idling
1,900 (0/-50) rpm
If engine speed is not increased to specification, perform troubleshooting for "S-5 Engine dose not rotate smoothly(hunting)".
Fan pump drive of PTO may be defective. Check it directly.
a Prepare with starting switch at OFF position, then run engine at high
idle to perform troubleshooting.
Fan pump EPC circuit source presMeasurement conditions
sure
Min. 3.1 MPa
{Min. 32 kg/cm2}
Fan drive circuit pressure
15.7 2.5 MPa
Fan 100 % mode
{160 25 kg/cm2}
Fan speed
Fan 100 % mode
Max. 1,110 rpm
The fan may be broken or installed defectively. Check itself directly.
4 Defective fan
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
H-25 Operator's seat isolator quakes abnormally or makes shocks

(Machine with operator's seat isolator)
Trouble
Related
information
q
q
Operator's seat isolator quakes abnormally.

When operator's seat isolator quakes largely, it makes shocks.
Cause
Possible
causes and
standard value
for judgment
40-622
Breakage of laminated rubber
Standard value in normal stage/Remarks on troubleshooting

The laminated rubber may be broken. Perform Testing and adjusting, "Breakage of rubber".
2 Malfunction of damper
The damper may malfunction. Perform Testing and adjusting, "Oil

leakage from damper".
3 Breakage of stopper rubber
The stopper rubber may be broken. Perform Testing and adjusting,

"Breakage of stopper rubber".
D375A-6
(07)

H-25 Operator's seat isolator quakes abnormally or makes shocks (Machine with operator's seat isolator)
D375A-6
(07)
40-623
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 probability 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 Questions 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.
Dont 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
(01)
40-625
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
(01)
40-627
DRAFT
S-1 Engine does not start easily

Cause
q
q
q
q
Electrical system is defective.

Fuel level is low.
Air intake is in short supply.
Wrong fuel selection.
Coolant leaks into exhaust pipe.
Troubleshooting
Check items
Questions
a Common rail fuel injection system (CRI) controls the fuel

injection timing electrically. Therefore, there are cases
where the engine does not start before the crankshaft
makes two revolutions maximum after starting operation.
This is not an abnormal state, however.
Check recent repair history

Degree of use Operated for long period
Ease of start- Gradually became worse
Starts when warm
ing
Non-specified fuel is being used
Replacement of filters is not performed according to Operation & Maintenance Manual.
Engine oil must be added more frequently.
Preheat monitor does not light up during preheating or at low temperature.
Charge monitor indicates abnormal charging during operation.
Dust indicator lamp piston indicates red zone.
Clogged breather hole in fuel tank cap
Leaking from fuel piping
No response or heavy resistance is felt when operating priming pump.
Starting motor rotates engine slowly.
When engine and air bleeding plug is removed from fuel filter, fuel does
is rotated with not flow out.
starting motor, and spill hose is separated from injector, spill flow is small.
When exhaust manifold, are touched immediately after starting engine,
temperature of manifold for some cylinders is low.
Engine does not rey smoothly , and combustion is irregular.
Engine hunts (rotation is irregular).
Blowby gas is excessive.
Inspect air cleaner directly.
Removing EGR cooler inlet gas pipe causes coolant containing antifreeze
to flow out (*1).
When compression pressure is measured, the pressure is low.
Air is discharged when bleeding from fuel system.
Inspect fuel filter and strainer directly.
Inspect feed pump gauze filter directly.
Perform troubleshoot for "Rail Press Very Low Error" (*2)
Engine speed does not change even when running engine with some cylinder cut out.
Intake air heater mount does not warm up during preheating operation.
Does voltage B E appear between alternator terminals 25 Yes
and 30V with engine running at low idle?
None
Specific gravity of electrolyte and voltage of battery are low
Remedy
EE
QQww
EE
QQ
QQ Q Q
w
ww Q Q
w
w
w
ww
w
Q
wQQ
ww
w
w
QQ
w
QwQQ
q
q
qq
q
q
q
Clean
Replace
Correct
Replace
Clean
Correct
Clean
Clean
Replace
Replace
Replace
Replace
Replace
Replace
Clogged air cleaner element

Cracked EGR cooler (coolant mixing in the exhaust)
Defective contact between valve and valve seat
Wear of piston ring or cylinder
Leakage or clogging of fuel piping or air in the fuel piping
Clogged fuel filter element
Clogged feed pump gauze filter
Stuck or seized supply pump plunger
Defective injector
Defective intake air heater system
Defective alternator (regulator)
Defective alternator (generator)
Defective or deteriorated battery
General causes that engine does not start easily
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
(01)
40-629
DRAFT
S-2 Engine does not start

a) Engine does not crank
Defective starting motor (safety relay section)

Defective starting motor (motor section)
Defective wiring of starting circuit
Defective battery terminal connection
Q
Q
w
w
w
Q w
q
q
q
q
q
Replace
Replace
Perform troubleshooting for E-mode
Replace
Correct
Replace
Replace
Remedy
E EE
Replace

Degree of use of
Operated for long period
machine
When starting
Horn does not sound.
switch is set to
Horn volume is slow.
ON position.
Battery electrolyte is low.
Cable is loosely connected to battery terminal.
No operating sound from battery relay when starting switch is set to ON position.
When starting switch is set to START position, pinion does not come out.
When starting
Speed of rotation is low.
switch is set to
Grating noise is heard.
START position, Soon pinion again.
the starting pinion comes out,
Ratting noise is heard and engine does not turn.
but
Removing EGR cooler outlet gas pipe causes coolant containing antifreeze to flow
out (*1).
Inspect flywheel ring gear directly
Specific gravity of electrolyte and voltage of battery are low.
There is no voltage (B E) between battery relay terminals 20
Set starting
and 30V.
switch to OFF
When terminals B and C of starting switch are connected, engine
position, connect starts.
the cord, then set When safety relay outlet terminals B and C are connected, engine
starting switch to starts.
ON position to
perform trouble- When safety relay outlet terminals B and C are connected, engine
does not start.
shooting
Replace
Troubleshooting
Check items
Questions
General causes that engine does not rotate

q Seized inside engine
See the troubleshooting for "S-4 Engine stops during operations".
q Coolant leaking inside cylinder causes water hammer.
q Electrical system is defective.
Demaged flywheel ring gear
Cracked EGR cooler (coolant mixing in the exhaust)
Cause
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 coolant.
and transparent.
D375A-6
(01)
40-631
DRAFT
Cause
Improper fuel used
Insufficient fuel in tank
Leakage or clogging of air in fuel piping, or air in fuel piping
Clogged fuel filter element
Seizure or abnormally wear of feed pump
Broken supply pump shaft or key
Defective supply pump PCV
Wrong connection of supply pump PCV
Defective operation of overflow valve (does not close)
Defective operation of flow damper
Defective fuel injector
b) Engine rotates but no exhaust smoke comes out (Fuel

is not injected)

Degree of use of
EEE
machine
Exhaust smoke suddenly stopped coming out (when starting again).
wQ w w w
Replacement of filters is not performed according to Operation & Maintew w
E
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
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 startand spill hose is separated from injector, spill flow is
Q
w w w w
ing motor,
small.
Air is discharged when bleeding air from the fuel system.
Inspect the fuel filter directly.
Inspect the fuel feed pump gauze filter directly.
Inspect feed pump directly.
Perform troubleshoot for "Rail Press Very Low Error" (*1)
Perform troubleshoot for "PCV1 Error (*2) or PCV2 Error" (*3)
Inspect overflow valve directly.
Engine can start when operated in cylinder cut out mode.
Remedy
q q
EE
Q
q
q
qq
Replace
Add
Clean
Correct
Replace
Clean
Replace
Replace
Replace
Replace
Correct
Replace
Replace
Replace
Troubleshooting
Check items
Questions
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)
*1: Troubleshooting by failure code (Display of code), Code [CA559] and Code [CA2249]
40-632
D375A-6
(01)
DRAFT
Cause
Wear of valve system (valve, rocker lever, etc.)
Worn piston ring or cylinder liner
Improper fuel
Leakage or clogging of fuel piping, or air in fuel piping
Clogged fuel filter, strainer
Clogged injection nozzle or defective spray
Defective coolant temperature sensor or defective wiring harness
Defective intake air heater system
c) Exhaust smoke comes out but engine does not

start (Fuel is injected)

Degree of machine
E
EE
E
operation
Engine suddenly failed to start.
w
w
Q
Non-specified fuel is being used.
Q Q
Replacement of filters is not performed according to Operation & Maintew
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
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
When engine is
Q
ww
does not flow out.
rotated with starting
and spill hose is separated from injector, spill flow is
w
motor
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
Air is discharged when bleeding air from the fuel system.
Inspect the fuel filter, strainer directly.
Inspect the fuel feed pump gauze filter directly.
Perform troubleshoot or "Rail Press Very Low Error" (*1).
Testing a single unit injector indicates defective spraying.
Specific gravity of electrolyte and voltage of battery are low.
Coolant temperature gauge indication is not normal (if equipped the gauge).
Intake air heater mounting portion does not warm up during preheating.
Remedy
Clean
Replace
Replace
Replace
Clean
Correct
Clean
Clean
Replace
Replace
Replace
Replace
Replace
Troubleshooting
Check items
Questions
General causes that exhaust smoke comes out but

engine does not start
q Starting motor lacks in rotating force due to defective electrical system.
q Supply of fuel is small.
q Small air intake
q Improper selection of fuel
*1: Troubleshooting by failure code (Display of code) , Code [CA559], and Code [CA2249]
D375A-6
(01)
40-633
DRAFT
S-3 Engine does not rev up smoothly (response-up is poor)
Confirm recent repair history

Degree of use of machine Operated for long period
Engine pick-up suddenly became poor
Replacement of filters has not been carried out according to OperaEngine oil must be added more frequently
Dust indicator is red
Clogged air breather hole in fuel tank cap
Rust and water are observed when fuel tank is drained
No response or heavy resistance felt when operating priming pump
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
Blue under light load
Color of exhaust gas
Black
When engine is cranked, abnormal noise is heard from around cylinWhen engine is cranked, abnormal noise is heard from around turboHigh idle speed under no load is normal, but speed suddenly drops
when load is applied
There is hunting from engine (rotation is irregular)
Blow-by gas is excessive
EEE
Q
40-634
EE
w w w
w w
Q
w
w w
w
w Q Q
Q
w
w
w w
Inspect air cleaner directly

q
Carry out troubleshooting for "EGR valve abnormality (*1)" or
q
"Bypass valve abnormality (*1)".
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
Inspect the fuel filter, strainer directly
Inspect the fuel feed pump gauze filter directly
Carry out troubleshoot by "Rail Press Very Low Error (*2)"
Speed of some cylinders does not change when operated in reduced
Remedy
Q Q
Clean
Troubleshooting
Check items
Questions temperature

Defective operation of flow damper (excessive injector leakage)
Clogged injection nozzle, defective spray
w w
Q w
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Clean
Replace
Replace
Replace
Seizure and interference of turbocharger

Worn piston ring, cylinder liner
Leakage, clogging, air in fuel piping
Insufficient intake of air

Insufficient supply of fuel
Fuel injection condition not normal
Improper selection of fuel
Controller in derate control mode
(Controlling injection capacity (output) due to an error in
the electrical system)
EGR valve is stuck in open state
(Shortage of air intake due to excessive EGR gas)
Replace
Replace
Clean
Correct
Clean
Replace
Replace
Adjust
Cause
Defective EGR valve or bypass valve

Defective contact of valve and valve seat
Improper valve clearance
General causes why engine does not pick up smoothly
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
(01)
40-635
DRAFT
S-4 Engine stops during operation

General causes why engine stops during operations
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q
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Engine rotates when auxiliary equipment (pump, compressor) is removed
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Replace
Replace
Replace
Replace
Add
Clean
Correct
Clean
Clean
Replace
Replace
Replace
Replace
Inspect controller power supply wiring

Check starting switch wiring
Remedy
Carry out troubleshooting in H-mode
w
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Inspect valve system directly

Check piston and connecting rod directly
Check crankshaft bearing directly
Inspect gear train directly
Inspect fuel filter, strainer directly
Inspect feed pump gauze filter directly
Inspect feed pump directly
Trouble power train
EE
q
-

Degree of use
of machine
Abnormal noise was heard and engine
stopped suddenly
Condition when
Engine overheated and stopped
engine stopped
Engine stopped slowly
There was hunting and engine stopped
Replacement of filters not carried out according to Operation & Maintenance Manual
Fuel level monitor indicates low fuel level
Fuel tank is found to be empty
Rust and water are detected when fuel tank is drained
Metal particles are found when oid pan is drained
Does not turn at all
When engine is
Turns in opposite direction
cranked manuMoves by the amount of gear backlash
ally
Supply pump shaft does not turn
Engine rotates, but stops when load is applied to machine
Correct
Correct
Troubleshooting
Check items
Questions
Broken auxiliary equipment (pump, compressor, etc.)

Defective engine controller power supply
Seized parts inside engine

Overheating
Trouble in power train
Broken, seized piston or connecting rod

Broken, seized crankshaft metal
Broken, seized gear train
Leakage, clogging in fuel piping
Broken, seized feed pump
Broken supply pump shaft, key
Breakage of valve system (valve, rocker

lever, etc.)
Cause
40-636
D375A-6
(01)

S-5 Engine does not rotate smoothly (hunting)
40-68
Low setting of low idle speed

Malfunction of EGR valve
Occurs at a certain speed range
Occurs at low idle
Condition of hunting
Occurs even when speed is raised
Occurs on slopes
Replacement of filters not carried out according to Operation & Maintenance Manual
Fuel tank is found to be empty
Rust and water are found when fuel tank is drained
E
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Q
EE
Q
Q Q Q Q Q Q
Q
Q
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Q
Q
Q
Q
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Leakage from fuel pipe

Carry out troubleshoot by "EGR Valve Servo Error (*1)"
Carry out troubleshoot by "Bypass Valve Servo Error (*2)"
Air is discharged when the air is bled from the fuel system
Inspect fuel filter, strainer directly
Speed of some cylinders does not change when operated in reduced cylinder mode
Carry out troubleshooting according to Abnormality in engine Ne speed
sensor (*3)
Carry out troubleshooting according to Abnormality in engine Bkup speed
sensor (*4)
Remedy
q
q
q
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q
q
Repair
Replace
Troubleshooting
Check tems
Questions

Degree of use of machine
Replace
Replace
Correct or replace
Correct or replace
Air in fuel system

Defective speed sensor (Error at degree that it is not indicated)
Defective EGR valve

Leakage, clogging, air in fuel piping
Add
Clean
Repair
Clean
Replace, Clean
Cause
Defective operation of flow damper (excessive injector leakage)
Clogged injector and/or defective spray (dirt in injector)
Defective Ne speed sensor, defective wiring harness
Defective Bkup speed sensor, defective wiring harness
General causes why engine does not rotate smoothly
*3: Troubleshooting by failure code (Display of code), Code [CA689]
*4: Troubleshooting by failure code (Display of code), Code [CA778]
D375A-6
(06)
40-637
DRAFT
S-6 Engine lacks power (or output shortage)
Q Q
Q Q
Q Q Q
Q
Defective fuel temperature sensor and/or wiring harness
Defective charge pressure sensor or defective wiring harness
Defective mounting of charge pressure sensor (air leak)
Defective drive of injector (signal, solenoid)
EE
Clogged injector and/or defective spray (dirt in injector)
Clogged, leaking fuel piping
Clogged air breather hole of fuel tank cap
Defective contact of valve, valve seat
Seized turbocharger, interference of turbocharger
Q Q Q
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Q
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q
Replace
Replace
q q
Repair
Replace
Replace
Clean
Replace
Replace
q
q q q
Repair
Remedy
Clean

Inspect air intake piping directly
When charge (boost) pressure is measured, the oil pressure is low
When compression pressure is measured, it is found to be low
Inspect fuel filter and strainer directly
Carry out troubleshooting according to No-pressure feed by supply
When a cylinder is cut out for reduced cylinder mode operation, engine
Check the mount of charge (boost) pressure sensor directly
Carry out troubleshoot by "Chg Air Press Sensor Error (*2)"
Carry out troubleshooting according to Abnormality in fuel tempera-
Replace

Degree of use
Suddenly
Power was lost
Gradually
Replacement of filters has not been carried out according to Operation
Oil must be added more frequently
Air breather hole of fuel tank cap is clogged
Fuel is leaking from fuel piping
Output becomes insufficient after short stop of operation
Black
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
When engine is cranked, interference sound is generated around turboWhen engine is cranked, abnormal sound is generated around cylinder
High idle speed is too low
High idle speed under no load is normal, but speed suddenly drops
when load is applied
Engine does not pick up smoothly and combustion is irregular
There is hunting from engine (rotation is irregular)
Blow-by gas is excessive
Adjust
Troubleshooting
Check items
Questions
Replace
Replace

Defective condition of fuel injection
There is overheating
o See the troubleshooting for "S-14 Coolant
Temperature too High (Overheat)"
Controller is controlling in derate mode
(limiting injection rate (output) because of an error
in electrical system)
Clean
Repair
Cause
Air leakage from air intake piping
General causes why engine lacks output
For *1, *2 and *3, see the next page
40-638
D375A-6
(01)
DRAFT
D375A-6
(01)
40-639

S-7 Exhaust smoke is black (Incomplete combustion)
Troubleshooting
Check items
Questions

Degree of use
Suddenly became black
Gradually became black
Suddenly
Power was lost
Gradually
Muffler is crushed
Leakage of air between turbocharger and cylinder head,
loose clamp
Operates in low-temperature mode even at normal temperaWhen exhaust manifold is touched immediately after starting
engine, temperature of some cylinders is low
When engine is cranked, interference sound is generated
When engine is cranked, abnormal sound is generated
Torque converter stall speed or pump relief speed is high
(Fuel is injected excessively)
Exhaust noise is abnormal
Engine does not pick up smoothly , and combustion is irreguBlow-by gas is excessive
When hose from injector to spill collection portion is disconnected, spill flow is found to be abnormally high
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q
When turbocharger is rotated by hand, it is found to be heavy
q
Carry out troubleshooting for "EGR valve abnormality (*1)" or
q
"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
Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder mode
Inspect fuel spill piping (on cylinder head side) directly
Carry out troubleshooting according to Abnormality in coolRemedy
E
Q Q
Q Q
q
q
q
q
q
q
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Replace
Replace

Excessive injection of fuel
Defective condition of fuel injection
There is overheating
o See the troubleshooting for "S-14 Coolant Temperature
too High (Overheat)"
Controller is controlling in derate mode
(limiting injection rate (output) because of an error in electrical system)
EGR valve is stuck in open state
(There is much EGR gas and intake of air is insufficient.)
EGR gas pressure piping is clogged
(Exhaust gas is mixed in intake air during acceleration and
deceleration)
Repair
Clean
Replace
Replace
Replace
Adjust
Cause
Seized turbocharger, interference of turbocharger
Defective EGR valve
Defective contact of valve, valve seat
Leakage of air between turbocharger and cylinder head
Crushed, clogged muffler
Stuck, seized supply pump plunger
Clogged, seized injector
Worn fuel injector
Clogged fuel spill piping (on cylinder head side)
Improper fuel injection timing
Defective fuel injection pressure
General causes why exhaust smoke is black
40-690
For *1, *2 and *3, see the next page

40-640
D375A-6
(06)

*1: Troubleshooting by failure code (Display of code), Codes [CA1228] and [CA1625]
D375A-6
(06)
40-641

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
Troubleshooting
Check items
Questions
Abnormal oil combustion

Extended operation for long hours in low or high idle (continuous
no load operation for 20 minutes and longer inhibited)
Oil leakage to outside
Wear of lubricating system
Dust sucked in from intake system

Wear and damage of valve (stem,guide and seal)
Worn seal at turbine end
Turbocharger
Worn seal at blower end
Oil leakage from EGR valve system
Clogged breather or breather hose
Broken piston ring
Wear of piston ring and cylinder liner
Worn, damaged rear seal surface
Broken oil cooler
Leakage from oil cooler
Leakage from oil filter
Leakage from oil piping
Leakage from oil drain plug
Leakage from oil pan, cylinder head, etc.
Cause

Degree of use of machine Operated for long period
E EE E
E
Oil consumption suddenly increased
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Engine oil must be added more frequently
Q
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Engine oil becomes contaminated quickly
Q Q w
Outside of engine is dirty with oil
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Pipe clamps for intake system are loose
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Inside of turbocharger air intake outlet pipe is contaminated with oil
w
Inside of turbocharger exhaust outlet pipe is contaminated with oil
Q w
There is oil in coolant
w
Oil level in damper chambers on applicable machine side increasw
ing.
Color of exhaust gas blue under light load
Q
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Excessive
Q QQ
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Amount of blow-by gas
None
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When intake manifold is removed, dust is found inside
q
When intake manifold is removed, inside is contaminated abnorq
mally
Excessive play of turbocharger shaft
qq
When EGR valve is removed, exhaust port is contaminated with oil
q
Check breather and 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
Remedy
40-642
Correct
Correct
Replace
Replace
Replace
Clean
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
40-692
D375A-6
(06)
DRAFT
S-9 Engine oil becomes contaminated quickly

Degree of use
EEEE
Q
Q
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Even when engine oil temperature rises, oil filter clogging monitor indicates clogw Q
ging
Metal particles are found when oil filter is drained
Q Q
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Inside of exhaust pipe is dirty with oil
w
Engine oil temperature rises quickly
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Black
Excessive
Q
Q w
Amount of blow-by gas
None
w
D375A-6
(01)
(See S-7)
q
Clean
q
Replace
Replace
Clean
Clean
q q
Replace
Replace
Remedy
Replace
Excessive play of turbocharger shaft

When EGR valve is removed, exhaust port is found to be smeared with oil.
When compression pressure is measured, it is found to be low
Check breather and breather hose directly
Inspect oil cooler directly
Inspect oil filter directly
Spring of oil filter safety valve is hitched or broken
Inspect turbocharger lubrication drain tube directly
Exhaust smoke is bad
Clogged turbocharger lubrication drain tube
Defective oil filter safety valve
Clogged oil filter
Clogged oil cooler
Clogged breather, breather hose
Worn valve, valve guide
Worn EGR valve guide
Defective seal at turbocharger turbine end
Cause
Replace
Troubleshooting
Check items
Questions
General causes why oil becomes contaminated quickly

q Entry of exhaust gas into oil due to internal wear
q Clogging of lubrication passage
q Use of improper fuel
q Use of improper oil
q Operation under excessive load
40-643
DRAFT
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive
Defective injector operation
Defective common rail fuel pressure
Defective supply pump plunger
Defective feed pump oil seal
Defective injector spray
Q Q
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q q
q
q
Correct
Q Q
Q
q
Q
Q
Replace
Remedy
Q Q
w
Replace
Remove head cover and inspect directly

Inspect feed pump oil seal directly
Speed of some cylinders does not change when operated in reduced cylinder mode
Spill flow is excessive when spill hose is separated from injector
Carry out troubleshoot by "Coolant Temp Sensor Error (*2)"
Correct
Fuel leakage to outside

There is irregular combustion
Oil increasing, smelling of diesel oil
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low
Low idle speed is high
Torque converter stall or hydraulic pump relief speed is high
Black
White
E E
Replace
Condition of fuel consumption

More than for other machines of same model
Gradually increased
Suddenly increased
Replace

Correct
Troubleshooting
Check items
Questions
Leakage of fuel inside head cover
Leakage of fuel
Fuel injection condition (fuel pressure and injection timing) not normal
Excessive fuel injection
Fuel leakage from fuel filter, piping, etc
Correct
Cause
40-644
D375A-6
(01)

S-11 Oil mixes into coolant(coolant blows back or is reduced)
S-11 Oil mixes into coolant(coolant blows back or is reduced)
40-695
Broken hydraulic oil cooler, power train oil cooler
Broken oil cooler core/O-ring
Insufficient protrusion of cylinder liner
Cracks inside cylinder block
Broken cylinder head or cylinder head gasket
Clogged, broken oil cooler
Cause
General causes why oil is in coolant

q Internal leakage in lubrication system
q Internal leakage in cooling system
q Internal leakage in hydraulic oil cooler or power train oil cooler
Degree of use
Q Q
Q Q
Gradually occurred
Q Q
Hard water is being used as coolant
There are excessive air bubbles in radiator, coolant spurts back
w
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When hydraulic oil or power train oil is drained, water is found
q q
Inspect cylinder block directly
q q
Check cylinder liner directly
D375A-6
(06)
Replace
Replace
Remedy
Replace
Pressure-tightness test of oil cooler shows there is leakage
Pressure-tightness test of cylinder head shows there is leakage
Perform troubleshooting for H-mode
Hydraulic oil or power train oil on applicable machine side is milky
Replace
Check items
Oil level has risen and oil is milky
Troubleshooting
Sudden overheated
Oil level
Replace
Questions
40-645
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)
Troubleshooting
Check items
Questions
Leakage, clogging or wear of lubricating system

Defective hydralic control
Wrong oil selection (viscosity not appropriate)
Oil deteriorated by overheating

Engine oil pressure monitor lights up.
Non-specified oil is used.
Replacement of filters is not perform according to Operation & Maintenance. Manual
Lights up with engine at low dile.
Lights up with engine at low and idle.
Engine oil pressure monitor
Lights up with machine on a slope.
Lights up occasionally.
Oil level monitor indicates low amount of oil (when monitor is installed)
Oil level in oil pan is low
Leakage or crushing of external hydraulic pipe.
Oil is cloudy white or smells of diesel oil.
Metal particles are found when oil is drained from oil pan.
Q
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Q
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Metal particles are found in oil filter.

Inspect oil pan strainer and pipe directly.
Oil pump rotation is heavy or it has play.
Oil pump relief valve or spring is failed or damaged.
Inspect oil filter directly.
Relief valve of EGR oil pump is damaged or has oil leak.
Inspect EGR hydraulic piping visually.
Perform troubleshooting for "Eng Oil Press. Sensor Error"(*1)
Q
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Metal particles are found when oil is drained from oil filter.
Remedy
E
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Q
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Q
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Q
q q
See S - 13
Replace
Add
Clean
Clean
Replace
Adjust
Replace
Repair
Replace
Replace
Replace
Cause
Wear of metal journal
Lack of oil in oil pan
Water or fuel in oil
Clogged strainer inside oil pan
Clogged or brakage of pipe inside oil pan
Defective oil pump
Defective oil pump relief valve
Clogged oil filter
Leaking, crushed or clogging of hydraulic pipe
Defective EGR oil pump
Leakage from EGR oil pressure piping
Defective oil pressure sensor and/or defective wiring harness
General causes that oil pressure drops
*1: Troubleshooting by failure code, Codes [CA135] and [CA141]
40-646
D375A-6
(01)

S-13 Oil level rises (Coolant or fuel mixes into oil)
40-698
General causes that oil level rises
Q Q
Q Q
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Q Q
E
w
Defective seals for auxiliarise (pump or compressor)
Defect inside supply pump
Clogged water pump drain hole (breather hole) or defective seal
Internal cracks in cylinder block
Leakage of fuel inside head cover
Broken cylinder head or head gasket
Cracked EGR cooler (Entry of coolant)
Q Q
Q
Q
Q
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Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
Replace
Removing EGR cooler inlet gas piping causes coolant containing antifreeze to
q
flow out (*1)
When compression pressure is measured, pressure is low.
q
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
Questions
Check items
Troubleshooting
Check recent repair history.

Fuel consumption is increased.
Coolant must be added more frequently.
Oil in coolant.
Engine oil smells of diesel fuel.
Oil become clouded.
After starting engine, drops of water come out of muffler.
When engine is run at idle with radistor cap open a large number of air bubbles appear or coolant blows back.
Exhaust smoke is white.
Clogged water pump drain hole (weep hole).
Coolant comes out when water pump drain hole (weep hole) is cleaned.
Oil level in clutch or damper chambers of machine lower
Oil level in hydraulic tank of machine decreases.
Broken oil cooler core or O-ring
Coolant mixing into oil (oil becomes clouded)

Fuel mixing into oil (smells diluted diesel fuel)
a If oil mixes into the coolant, perform troubleshooting for "S-11 Oil is in coolant
(or coolant spurts back or coolant level goes down)"
q
Worn or damaged rear seal surface
Damagee O-ring for cylinder liner or pitted cylinder liner due to pitting corrosion.
Cause
For *1, see the next page.
D375A-6
(06)
40-647
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
Troubleshooting
Check items
Questions

Condition of overheating

Engine overheat suddenly
Engine tends to overheat.
Coolant temperature rises quickly.
Coolant temperature gauge Coolant temperature does not go down below
red range
Radiator coolant level monitor indicates low level
Engine oil level has risen, oil is cloudy white
Cloudy white oil is floating on coolant
Coolant in radiator has excessive air bubbles and blows backs.
When light bulb is held behind radiator, no light passes.
Radiator shroud and inside of under cover are clogged with dirt or mud.
Coolant leaks from cracks in the radiator hose or clamps are loosened.
Coolant flows out from radiator overflow hose.
Power train oil temperature gauge enters red range faster than engine coolant temperature gauge
Inspect EGR cooler directly for coolant leakage.
Inspect cylinder liner directly.
Inspect oil cooler directly.
Temperature difference between top and bottom radiator tanks is excessive.
When function test is preformed on thermostat, it does not open even at
cracking temperature.
Temperature difference between top and bottom radiator tanks is slight.
Inspect radiator core directly.
When function test is preformed on the radiator cap, cracking pressure is
low.
Inspect fan pulley directly.
When coolant temperature is measured, it is found to be normal.
Measured fan speed is low.
Remedy
D375A-6
(01)
EEE
Q
Qw
Q
EE
Q
Q
Qww
w
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Q
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wQ
w
w
w
w
w
w
q
q
q
q
q
q
q
q
Carry out troubleshooting in

Carry out troubleshooting in
Lack of cooling air (deformed or damaged fan)

Drop in heat dissipation efficiency
Defective coolant circulation system
Rise of power train oil temperature
Defective fan drive pump or fan motor
Water leakage from EGR cooler

Broken cylinder head, head gasket
Hole drilled by damages or pitching of cylinder liner O-ring
Clogged or broken oil cooler
Lack of coolant
Broken water pump
Defective operation of thermostat
Clogged or crushed radiator fins
Clogged radiator core
Defective radiator cap (pressure valve)
Wear of fan pulley
Defective coolant temperature gauge
Rise of power train oil temperature
Defective fan drive pump or fan motor
Replace
Replace
Replace
Replace
Add
Replace
Replace
Correct
Correct
Replace
Correct
Replace
-
Cause
40-649
DRAFT
S-15 Abnormal noise is heard
S-15 Abnormal noise is heard

General causes that abnormal noise is heard
q
Noise from defective parts

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
runs in the low temperature mode. This is not abnormal, however.
a When the engine is accelerated, it runs in the acceleration mode, where engine noise remains slightly higher for about 5 seconds maximum, This is not
abnormal, however.

Abnormal noise

Gradually occurred.
Sudden overheated.
E
QQ
QQQ
Non-specified fuel is used

Engien oil must be added more frequently.
w
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
When exhaust manifolds are touched immediately after starting engine, temperature 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.
Abnormal noise is loud when engine is accelerated.
Q
Q
Q
Blowby gas is excessive
w
When turbocharger is rotated by hand, it is found to be heavy.
Inspect EGR gas piping directly.
Inspect dynamic valve system directly
When muffler is removed, abnormal noise disappears.
Inspect valve clearance directly.
Inspect gear train directly.
Inspect fan directly.
Engine speed does not change when running engine with some cylinder cut
out.
Abnormal noise is heard only when engine is started.
Use real-time monitoring mode to check.
Remedy
40-650
qq
wQ
w
Q
q
qq
q
Replace
Replace
Replace
Repair
Replace
Adjust
Replace
Replace
Replace
Repair
Replace
Replace
Replace
Troubleshooting
Check items
Questions
Air leakage from piping between turbocharger and cylinder head

Brakage of turbocharger
Crack of or gas leakage from EGR gas piping
Seizave or interfevance of valve system (valve, rocker lever, etc.)
Defec inside muffler (dividing board out of position)
Excessive wear of piston ring or cylinder liner
Improper gear train backlash
Missing or seizure of gear train bushing
Deformed fan
Clogged or seized injector
Dirt caught in injector
Defective fuel injection timing (defective coolant temperature sensor)
Cause
D375A-6
(01)

S-16 Vibration is excessive
40-702
General causes that vibration is excessive
Remedy
D375A-6
(06)
Broken parts in damper
Wear of front support spigot joint
Misalignment of engine and torque convertor
Loose engine mounting bolts or broken cushions
Worn camshaft bushing
Improper gear train backlash
q
Replace
Inspect valve system directly.

Inspect main bearing and connecting rod metal directly.
Inspect gear train directly.
Inspect camshaft bushing directly.
Inspect engine mounting bolts and cushions directly.
When face runout and radial runout are inspected, they are found to be incorrect.
Inspect front support portion directly.
Inspect inside of damper directly.
Q
Q Q
Q
Q
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Q
Q
Q
Q
Q Q Q Q
Adjust
Replace
Exhaust smoke is black.
Q
Q
w
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Q
EE
Replace

Metal particles are found when oil is drained from oil pan.
Oil pressure is when running engine low at low idle.
Vibration occurs when running engine at mid-range speed.
Vibration follows engine speed.
Replace
Replace
Vibration

Suddenly increased.
Gradually increased.
Replace
Questions
Check items
Troubleshooting

Degree of use
Worn main bearing or connecting rod bearing
Defective parts (abnormal wear, breakage,etc)

Misalignment of engine and chassis
q Abnormal combustion
a If there is abnormal noise together with the vibration, perform troubleshooting also for
S-15 Abnormal noise is heard.
q
Replace
Stuck valve system (valve, rocker lever, etc.)
Cause
40-651
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

Degree of use of macine
EE
Q Q
Clogged water separator screen

Clogged fuel filter
Low battery charge level
Fuel tank is empty

w
Fuel tank breather cap is clogged
w
Fuel leaks from fuel piping
w
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
Fuel valve (supply side) is closed
Fuel valve (return side) is closed
Water drain valve and air intake plug of water separator are loosened
Water drain valve of fuel pre-filter is loosened
There is flaw or dirt on sealing face of fuel pre-filter or main filter
Check air bleeding pipe and orifice directly (see Note 1)
Check fuel piping (supply side and return side) directly (for clogging and
breakage)
Check electric priming pump directly
Check electric priming system directly (see E-28 in E-mode)
Check water separator screen directly
Check fuel filter for clogging (see failure code CA559, Note 2)
Remedy
40-652
q
q
q
q
q
q
q
q q
Clean
Replace
Charge
Troubleshooting
Check items
Questions
Leaking or clogging of fuel piping or air in it

Clogged air bleeding pipe
Malfunction of electric priming pump
Malfunction of electric priming pump switch
Defective wiring harness of electric priming pump
Correct
Correct
Replace
Replace
Replace
Electric priming pump does not operate.

Fuel is not supplied or is supplied very little.
Fuel valve or air bleeding valve is not set properly.
Air bleeding piping is clogged.
Fuel return piping is clogged.
Lack of fuel
Improper setting of air bleeding valve (closed)
Improper setting of fuel valve (closed)
Clogged fuel tank breather hole
Add
Correct
Correct
Correct
Cause
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
(03)
40-653
DRAFT
40-654
D375A-6
(01)
DRAFT
D375A-6
SEN001879-00
Bulldozer
D375A-6
Shop Manual
Machine model
Serial number
D375A-6
60001 and up
D375A-6
(02)
50-1
DRAFT
Contents
Contents
General information on disassembly and assembly .....................................................................
How to read this manual ............................................................................................................
Coating materials list..................................................................................................................
Special tools list .........................................................................................................................
Sketches of special tools ...........................................................................................................
Engine and cooling system ...........................................................................................................
Removal and installation of fuel supply pump assembly ...........................................................
Removal and installation of fuel injector assembly ....................................................................
Removal and installation of cylinder head assembly .................................................................
Removal and installation of radiator guard assembly ................................................................
Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler).
Removal and installation of radiator...........................................................................................
Removal and installation of hydraulic oil cooler .........................................................................
Removal and installation of aftercooler......................................................................................
Removal and installation of engine assembly............................................................................
Removal and installation of engine hood assembly...................................................................
Removal and installation of engine front seal ............................................................................
Removal and installation of engine rear seal .............................................................................
Removal and installation of fan drive assembly.........................................................................
Removal and installation of fan motor assembly .......................................................................
Removal and installation of fuel tank assembly .........................................................................
Power train....................................................................................................................................
Removal and installation of damper assembly ..........................................................................
Disassembly and assembly of damper assembly ......................................................................
Removal and installation of power train unit assembly ..............................................................
Disconnection and connection of power train unit assembly .....................................................
Disassembly and assembly of PTO assembly...........................................................................
Disassembly and assembly of torque converter assembly ........................................................
Disassembly and assembly of TORQFLOW transmission assembly ........................................
Disassembly and assembly of steering case assembly.............................................................
Removal and installation of power train pump and lubrication pump assembly ........................
Removal and installation of scavenging pump assembly ..........................................................
Removal and installation of final drive assembly .......................................................................
Disassembly and assembly of final drive assembly...................................................................
Undercarriage and frame ..............................................................................................................
Removal and installation of track frame assembly.....................................................................
Removal and installation of idler assembly................................................................................
Disassembly and assembly of idler assembly ...........................................................................
Removal and installation of recoil spring assembly ...................................................................
Disassembly and assembly of recoil spring assembly...............................................................
Removal and installation of track roller assembly......................................................................
Disassembly and assembly of track roller assembly .................................................................
Removal and installation of carrier roller assembly ...................................................................
Disassembly and assembly of carrier roller assembly ...............................................................
Removal and installation of bogie assembly..............................................................................
Disassembly and assembly of bogie assembly .........................................................................
Removal and installation of first bogie assembly .......................................................................
Separation and connection of track shoe assembly ..................................................................
Overall disassembly and assembly of track shoe ......................................................................
Link press press-fitting jig dimensions .......................................................................................
Disassembly and assembly of one link assembly in the field ....................................................
50-2
50 - 4
50 - 4
50 - 6
50 - 9
50 - 16
50 - 24
50 - 24
50 - 28
50 - 33
50 - 49
50 - 54
50 - 59
50 - 61
50 - 62
50 - 63
50 - 70
50 - 73
50 - 75
50 - 79
50 - 81
50 - 83
50 - 86
50 - 86
50 - 90
50 - 93
50 - 100
50 - 109
50 - 115
50 - 125
50 - 153
50 - 169
50 - 170
50 - 171
50 - 173
50 - 186
50 - 186
50 - 191
50 - 192
50 - 196
50 - 201
50 - 203
50 - 206
50 - 209
50 - 210
50 - 214
50 - 219
50 - 221
50 - 226
50 - 230
50 - 247
50 - 248
D375A-6
(02)
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 operators cab assembly................................................................ 50 - 309
Removal and installation of floor frame assembly ..................................................................... 50 - 313
Removal and installation of air conditioner unit assembly ......................................................... 50 - 318
Removal and installation of operator's seat isolator .................................................................... 50-323-1
Disassembly and assembly of operator's seat isolator................................................................ 50-323-2
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
(07)
(02)
50-3
DRAFT
General information on disassembly and assembly
How to read this manual

(Rev. 2009.01)
1. Removal and installation of assemblies
Special tools
q Special tools which are necessary for removal or
installation of parts are described as A1, ... X1
etc. and their part numbers, part names and
quantities are described in the special tool list.
q Also the following information is described in the
special tool list.
1) 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.
2) 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.
3) Circle mark Q in sketch column:
q The sketch of the special tool is presented 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).
Installation
q Unless otherwise instructed, installation of parts
is to be done in the reverse order to removal.
q Instructions and precautions for parts installion
is shown with the mark ([*1], [*2]...which corresponds to the mark in Removal section).
q Common tools that are necessary for installation
are described as [1], [2]etc. and their part
numbers, part names and quantities are not described.
q Marks shown in the Installation section stand
for the following.
k : Precautions related to work safety.
a : Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished.
Sketch of special tool
Various special tools are illustrated for the local
manufacture.
Removal
In Removal section, the work procedures, precautions and know-how to do the work and the
amount of oil and coolant to be drained are discribed.
q Common tools that are necessary for removal
are described as [1], [2]etc. and their part
numbers, part names and quantities are not described.
q Various symbols used in the Removal section
are explained and listed below.
k : Precautions related to work safety.
[*1]: This mark shows that instructions or precautions for parts installation work are given in
Installation section.
6 : This mark shows the amount of oil or coolant to be drained.
4 : Weight of part or component
q
50-4
D375A-6
(02)
DRAFT
2. Disassembly and assembly of assemblies

Special tools
q Special tools which are necessary for disassembly and assembly of parts are described as A1,
X1 etc. and their part numbers, part names
and quantities are described in the special tool
list.
q Also the following information is described in the
special tool list.
1) 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.
2) Distinction of new 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.
3) Circle mark Q in sketch column:
q The sketch of the special tool is presented 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).
Assembly
q In Assembly section, the work procedures,
precautions and know-how to do the work, and
amount of the oil and coolant to be replenished
are described.
q Common tools that are necessary for the disassembly 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
Assembly section are as follows.
k : Precautions related to work safety
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished
Sketch of special tool
Various special tools are illustrated for the local
manufacture.
Disassembly
In Disassembly section, the work procedures,
precautions and know-how to do the work, and
amount of the oil and coolant drained are described.
q Common tools that are necessary for the disassembly 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
6 : Amount of oil or coolant drained.
q
D375A-6
(02)
50-5
DRAFT
Coating materials list

(Rev. 2009. 08)
a The recommended coating materials such as adhesives, liquid gaskets, and greases used for disassembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Adhesive
Category
Komatsu
code
Part No.
Capacity
Container
LT-1A
790-129-9030
150 g
Tube
LT-1B
790-129-9050
20 g
(2 pcs.)
Polyethylene
container
LT-2
790-129-9040
50 g
LT-3
790-129-9060
(Set of adhesive and hardener)
LT-4
Holtz
MH 705
ThreeBond
1735
Main features and applications

q
Use to prevent rubber gaskets, rubber cushions,

and cork plugs from coming out.
Use for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl chloride), rubber, metal, and non-metal parts which require
immediate and strong adhesion.
Polyethylene
container
q
q
Features: Resistance to heat and chemicals.

Use to fix and seal bolts and plugs.
Adhesive:
1 kg
Hardener:
500 g
Can
Use to bond and seal metal, glass and plastics.
790-129-9040
250 g
Polyethylene
container
Use to seal plugs for blank holes
790-129-9120
75 g
Tube
Heat-resistant seal used to repair engines.
50 g
Polyethylene
container
2g
Polyethylene
container
Instanetaneous adhesive.
Curing time: From 5 sec. to 3 min.
Use mainly to bond metals, rubbers, plastics, and
woods.
Instanetaneous adhesive.
Quick-curing type (max. strength is obtained after
30 minutes)
Use mainly to bond rubbers, plastics, and metals.
Features: Resistance to heat and chemicals.
Use for fitted portions subjected to high temperature.
Use to seal various threaded portions, pipejoints,
and flanges.
Use to seal taper plugs, elbows, and nipples for
hydraulic piping.
Features: Silicon-based heat and cold-resistant
sealant.
Use to seal flange surfaces and threaded portions.
Use to seal oil pan, final drive case, etc.
Features: Silicon-based quick-curing sealant.
Use to seal flywheel housing, intake manifold,
thermostat old, oil pan, thermostat housing, etc.
Features: Silicon-based, heat and cold-resistant,
vibration-resistant, impact-resistant sealant.
Use to seal transfer case, etc.
Use for rough surfaces such as the circle gear top
seal which is not clamped by bolts, gaps in the
weld which must be caulked, etc.
Can be coated with paint.
790-129-9140
q
q
q
Aron-alpha
201
790-129-9130
q
q
Loctite
648-50
79A-129-9110
50 cc
Polyethylene
container
1 kg
Polyethylene
container
q
q
q
LG-5
790-129-9080
q
q
Liquid gasket
LG-6
200 g
Tube
q
q
q
LG-7
790-129-9170
1 kg
Tube
LG-8
ThreeBond
1207B
419-15-18131
100 g
Tube
LG-9
ThreeBond
1206D
50-6
790-129-9160
q
q
q
q
790-129-9310
200 g
Tube
q
D375A-6
(02)
DRAFT
Seizure
Molybdenum disulfide
prevention compound
lubricant
Liquid gasket
Category
Komatsu
code
LG-10
ThreeBond
1206E
LG-11
ThreeBond
1121
ThreeBond
1211
LM-P
Capacity
Container
790-129-9320
200 g
Tube

q
q
q
200 g
Tube
790-129-9090
100 g
Tube
Liquid gasket used to repair engine.
Use to prevent galling and seizure of press-fitted

portions, shrinkage-fitted portions, and threaded
portions.
Use to lubricate linkages, bearings, etc.
Spray type
Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from galling.
Use for the drive shaft splines, needle bearings,
various link pins, bolts, etc.
09940-00040
200 g
Tube
q
q
09995-00250
190 g
Can
q
LC-G
NEVER-SE
EZ
Can
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYGA-160CNLI
SYG0-400LI-A
(*)
SYG0-160CNLI
(*)
Various
Various
Molybdenum disulfide grease

LM-G
(G2-M)
SYG2-400M
SYG2-400M-A
SYGA-16CNM
400 g 10
400 g 20
16 kg
Hyper White
G2-T,
G0-T (*)
*: For cold
district
SYG2-400T-A
SYG0-400T-A
(*)
SYG2-16CNT
SYG0-16CNT
(*)
400 g
16 kg
Biogrease
G2-B
G2-BT (*)
*: For use at
high temperature and
under high
load
SYG2-400B
SYG2-400BT
(*)
SYGA-16CNB
SYGA-16CNBT
(*)
400 g
16 kg
G2-S
ThreeBond
1855
200 g
Feature: Lithium grease with extreme pressure lubrication performance, general purpose type.
Use for parts under heavy load.

Caution:
q Do not use this grease for rolling bearings like
swing circle bearings, etc. and spline.
q Use this grease for work equipment pins only
when installing them, but do not use it afterward.
Seizure resistance, heat resistance and water resistance higher than molybdenum disulfide
grease.
Not conspicuous on machine since color is white.
Bellows-type
container
Can
Bellows-type
container
Can
Bellows-type
container
Can
Feature: Seizure and galling prevention compound with metallic super-fine-grain, etc.
Use for the mounting bolt in the high temperature
area of the exhaust manifold and the turbocharger, etc.
Since this grease is biodegradable in short period,

it has less impact on microorganisms, animals,
and plants.
Feature: Silicone grease with wide usable temperature range, high resistance to thermal-oxidative
degradation and performance to prevent deterioration of rubber and plastic parts.
Use for oil seals of the transmission, etc.
Tube
q
D375A-6
(02)
Use as lubricant/sealant when installing the radiator hoses to the water tubes.
Can be coated with paint.
Feature: Can be used together with solid gaskets.
Use for covers of the transmission case and steering case etc.
790-129-9330
G2-LI
G0-LI (*)
*: For cold
district
Grease
Part No.
50-7
DRAFT
Category
Komatsu
code
Part No.
Capacity
Container
SUNSTAR
PAINT
PRIMER580
417-926-3910
SUPER
SUNSTAR
GLASS
PRIMER
580 SUPER
SUNSTAR
PAINT
22M-54-27230
PRIMER
435-95
Caulking material
Adhesive
SUNSTAR
GLASS
PRIMER
435-41
50-8
22M-54-27240
SUNSTAR
SASH
22M-54-27250
PRIMER
GP-402
SUNSTAR
PENGUINE
SEAL580
417-926-3910
SUPER
S" or W"
Sika Japan,
Sikaflex
20Y-54-39850
256HV
SUNSTAR
PENGUINE 22M-54-27210
SUPER 560
SUNSTAR
PENGUINE
417-926-3920
SEAL No.
2505
SEKISUI
SILICONE
20Y-54-55130
SEALANT
GE
TOSHIBA
SILICONES 22M-54-27220
TOSSEAL3
81
2 kg
Can
q
20 ml
Glass container
20 ml
Glass container
20 ml
Glass container
150 ml
Can
20 ml
Glass container
For adhered window glass
G2-U-S
427-12-11871
ENS grease
Feature: Urea (organic system) grease with heat

resistance and long life, can be packed into the
confined space and left intact until next overhaul.
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

surface.
(Effective period: four months after date of
manufacture)
Use as primer for glass.

manufacture)
Use as primer for painted cab sheet metal

surface.
manufacture)
Use as primer for black ceramic-coated
glass surface and for hard polycarbonate-coated surface.
manufacture)
Use as primer for sash (anodized aluminum
surface).
manufacture)
Use S" in high-temperature season and
W" in low-temperature season as adhesive
for glass.
manufacture)
Use as adhesive for glass.
(Effective period: six months after date of
manufacture)
Use as adhesive for glass.
manufacture)
320 ml
Polyethylene
container
310 ml
Polyethylene
container
320 ml
Ecocart (Special container)
320 ml
Polyethylene
container
333 ml
Polyethylene
container
333 ml
Cartridge
For adhered window glass
Primer
Grease
Use to seal glass-to-glass joints.

manufacture)
Use to seal front window.

manufacture)
Use to seal glass-to-glass joint. Translucent white seal.

(Effective period: 12 months after date of
manufacture)
D375A-6
(02)
DRAFT
Special tools list
Special tools list
Device
Symbol
Part No.
Part name
795-799-5410 Adapter
795-799-5420 Remover
795T-675-1110 Socket
795-931-1100
Seal puller assembly
Engine assembly
6
7
Torque converter valve
assembly
1
2
TORQFLOW
transmission
assembly
D375A-6
(02)
Work item and remarks
t 1
Removal and installation of
t 1
fuel injector assembly
q 1 NQ
t 1
engine front seal and rear
seal
Push tool
(For oil seal)
Push tool
795T-621-1171
(For dust seal)
795-902-1460 Bolt
01582-02218
Nut
Push tool
795T-621-1161 (For standard seal and sleeved
seal)
Push tool
795T-621-1190
(For sleeved seal)
01050-32235
Bolt
01050-32245
Bolt
t 1
t 1
790-331-1120
Wrench (angle)
q 1
791-451-1000
790-101-2102
790-101-1102
790-413-1010
Remover
Puller (294 kN {30 ton})
Pump
Bracket
t
t
t
t
790-501-5000
Repair stand(100 V)
t 1
790-415-1011
Bracket
t 1
750-501-5000
Repair stand(100 V)
t 1
791-615-1130
Push tool
t 1
791-615-1200
791-615-1210
135-A90-1150
01580-01008
01641-51032
791-615-1101
791-615-1111
135-A90-1150
01580-01008
01641-51032
799-301-1600
Ring assembly
q Ring
q Bolt
q Nut
q Washer
Ring assembly
q Ring
q Bolt
q Nut
q Washer
Oil leak checker
t 1
1
1
1
2
t 1
1
1
1
2
t 1
795T-621-1180
4
Necessity
Q'ty
N/R
Sketch
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 "Sketches of special tools")
t 3
t 3

engine front seal
t 1
t 1
Q engine rear seal
t 5
t 5
1
1
1
1
Tightening of cylinder head

bolt
radiator guard assembly
Disassembly and assembly of
torque converter assembly
TORQFLOW transmission
assembly
snap ring
Installation of No.3 ring gear
Installation of No.1 ring gear
Checking actuation of piston
50-9
DRAFT
Device
Symbol
1
2
3
Final drive
assembly
4
J
5
7
8
1
Idler assembly
2
3
4
1
Recoil spring
assembly
M
2
22
Track frame
assembly
L
23
24
50-10
Part No.
Part name
Necessity
Q'ty
N/R
Sketch

Special tools list
790-337-1001
Lifting tool
t 1
791-580-3200
790-101-2102
790-101-1102
791-580-3300
790-101-2102
790-101-1102
790-431-1071
791-580-3400
790-101-2102
790-101-1102
791-580-3500
790-101-2102
790-101-1102
790-431-1230
790-101-2102
790-101-1102
790-431-1250
791T-630-2210
792-530-1630
790-101-2510
790-101-2570
01580-01613
01643-31645
790-101-2102
790-101-1102
791-515-1520
791-685-8310
791-601-1000
791-730-1110
01580-12722
01643-32780
790-101-2102
790-101-1102
791-685-8501
790-101-1600
790-101-1102
791-635-3160
195-30-68610
01010-62450
01010-62455
19M-54-11770
01643-32460
198-30-66190
195-30-69540
01011-82410
01011-82420
19M-54-11770
195-30-69550
Remover
Pump
Installer
Pump
Installer
Remover
Pump
Installer
Pump
Remover and installer
Pump
Guide
Plate
Stud
Block
Washer
Nut
Washer
Pump
Installer
Push tool
Oil pump
Bolt
Nut
Washer
Pump
Compressor
Cylinder (686 kN {70 ton})
Pump
Extension
Plate
Bolt
Bolt
Washer
Washer
Collar
Plate
Bolt
Bolt
Washer
Collar
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
791-685-1320
Lifting tool
t 1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
2
2
1
1
1
1
1
4
4
1
1
1
1
1
1
1
6
6
6
6
6
6
2
2
2
4
2

final drive assembly
Separation of sprocket hub
assembly and bearing
Press-fitting of bearing
(sprocket hub assembly)
Installation of floating seal

Disassembly of hub shaft
assembly
Press-fitting of bearing (hub
shaft assembly)
planetary gear shaft
Installation of gear assembly
Press fitting of bushing

Press fitting of seal guide
Adding oil
Removal of pin

recoil spring assembly
N
N
N
N
Locking bogie assembly
N
N
track frame assembly
D375A-6
(02)
DRAFT
Device
Symbol
8
9
10
11
12
Track roller
assembly
L
22
23
Carrier roller
assembly
4
5
6
7
1
2
3
14 4
5
6
7
1
2
3
4
15
5
6
Bogie assembly L
7
8
1
2
3
16
4
5
6
791T-630-2220
796-670-1020
791T-630-2230
791-601-1000
790-401-1700
790-401-1761
790-401-1540
790-401-1770
195-30-68610
01010-62450
01010-62455
19M-54-11770
01643-32460
198-30-66190
195-30-69540
01011-82410
01011-82420
19M-54-11770
195-30-69550
791-601-1000
791-515-1520
791-830-1770
791-630-1270
791-630-2260
790-201-2730
791-630-2270
01580-12419
01643-32460
790-101-4000
790-101-1102
791-630-2280
790-201-2770
791-630-2250
790-434-1070
01580-13629
01643-33690
790-101-4000
790-101-1102
791-630-2260
791-630-2270
01580-12419
01643-32460
790-101-4000
790-101-1102
Part name
Plate
Installer
Push tool
Oil pump
Lifting tool
Adapter
Shackle
T-bolt
Plate
Bolt
Bolt
Washer
Washer
Collar
Plate
Bolt
Bolt
Washer
Collar
Oil pump
Installer
Push tool
Wrench
Plate
Spacer
Screw
Nut
Washer
Pump
Adapter
Spacer
Plate
Screw
Nut
Washer
Pump
Plate
Screw
Nut
Washer
Pump
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
1
1
1
1
1
1
2
2
6
6
6
6
6
6
2
2
2
4
2
1
1
1
1
1
1
3
3
3
1
1
1
1
1
1
2
2
1
1
1
3
3
3
1
1
17
791T-630-2290 Guide
t 2
18
19
791-530-1510
791-601-1000
195-30-68610
01010-62450
01010-62455
19M-54-11770
01643-32460
198-30-66190
195-30-69540
01011-82410
0101-82420
19M-54-11770
195-30-69550
t
t
t
t
t
t
t
t
t
t
t
t
t
22
Bogie assembly L
23
D375A-6
(02)
Part No.
Necessity
Q'ty
N/R
Sketch

Special tools list
Installer
Oil pump
Plate
Bolt
Bolt
Washer
Washer
Collar
Plate
Bolt
Bolt
Washer
Collar
1
1
6
6
6
6
6
6
2
2
2
4
2
Q Press fitting of bushing

Q Press fitting of seal guide

Supplying oil
Lifting of rack roller assembly

N
N
Locking bogie assembly
N
N
N
N
carrier roller assembly
Pulling out shaft and ring
Press fitting of pin assembly
Alignment of track frame and

bogie pin holes
Supplying oil
N
N
N
Fixing of bogie assembly
N
N
50-11
DRAFT
Device
No. 1 bogie
assembly
Symbol
1
2
3
14 4
5
6
7
1
2
3
4
15
5
6
7
8
1
2
3
16
4
L
5
6
50-12
Plate
Spacer
Screw
Nut
Washer
Puller (490kN {50ton})
Pump
Adapter
Spacer
Plate
Screw
Nut
Washer
Pump
Plate
Screw
Nut
Washer
Pump
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
1
1
3
3
3
1
1
1
1
1
1
2
2
1
1
1
3
3
3
1
1
Pulling out shaft and ring
Press fitting of pin assembly
Alignment of track frame and

bogie pin holes
Supplying oil
791T-630-2290 Guide
t 2
18
19
791-646-7900
Installer
Oil pump
Bracket (L. H)
Bracket (R.H)
Bolt
Washer
Lifting tool
q Tube
q Plate
q Grip
q Eyebolt
q Washer
q Washer
q Nut
Push tool
Pin brush
Push tool
(For large plug)
t
t
t
t
t
t
1
2
790-434-1350
791-601-1000
791-630-1860
791-630-1870
01010-62760
01643-32780
791T-630-1900
791T-630-1910
791T-630-1920
07283-38973
04530-11628
01643-31645
01643-31232
01582-01210
791-646-7351
791-660-7460
t 1
Drive-in of large plug
791-701-3000
or
791-601-1000
Seal checker
Oil pump
t 2
Filling with oil
791-932-1110
t 1
Drive-in of small plug
791-632-1021
791-632-1300
791-632-1260
791-632-1270
791-632-1220
791-632-1230
791-632-1240
791-685-5730
791-632-1250
791-632-1280
01252-30605
01580-01210
Push tool
(For small plug)
Installer
Push tool assembly
q Push tool
q Adapter
q Adapter (small)
q Ring
q Plate
q Bar
q Ring
q Spring
q Bolt
q Nut
t 1
t 1 N
1
1
1
1
1
1
1
1
1
1
Installation of seal assembly
21
791-630-2260
790-201-2730
791-630-2270
01580-12419
01643-32460
790-101-4000
790-101-1102
791-630-2280
790-201-2770
791-630-2250
790-434-1070
01580-13629
01643-33690
790-101-4000
790-101-1102
791-630-2260
791-630-2270
01580-12419
01643-32460
790-101-4000
790-101-1102
Part name
17
1
2
20
3
4
Track shoe
assembly
Part No.
Necessity
Q'ty
N/R
Sketch

Special tools list
1
2
3
4
5
8 6
7
8
9
10
11
1
1
1 N
Setting bogie to installed posi1 N
2
tion
2
q 1
Q
1
Q
1
Q
Installation of track roller
1
assembly
1
1
2
2
t 1
Removal of pin small plug
t 1
Cleaning of pin hole
Assembly of link
D375A-6
(02)
DRAFT
Device
Symbol
1
2
3
4
5
9 6
7
8
9
10
11
1
10 2
3
1
2
3
4
5
6
Track shoe
assembly
D375A-6
(02)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
7
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Part No.
791-632-1200
791-632-1260
791-632-1270
791-631-1210
791-632-1230
791-632-1240
791-685-5730
791-632-1250
791-632-1280
01252-30650
01580-01210
791-632-1290
791-685-5730
01580-01210
791-646-7351
791-660-7460
791-646-7900
791-701-3000
or
791-601-1000
791-932-1110
791-632-1021
791-632-1100
791-632-1130
790-434-1610
01010-51440
791-685-9510
791-685-9520
791-685-9520
791-685-9550
04530-12030
791-685-9560
791-126-0150
791-685-9540
791-632-1140
791-680-5520
01010-51030
791-632-1150
791-685-9620
791-632-1180
791-680-5543
791-632-1170
791-680-5551
791-680-9630
791-632-1160
195-32-61210
790-101-4300
790-101-1102
790-101-4200
791-680-1630
Part name
Necessity
Q'ty
N/R
Sketch

Special tools list
Push tool assembly

Push tool
q Adapter
q Adapter (large)
q Ring
q Plate
q Bar
q Ring
q Spring
q Bolt
q Nut
Push tool assembly
Bar
Nut
Push tool
Pin brush
Push tool (for large plug)
t 1 N
1
1
1
1
1
1
1
1
1
1
t 2 N
1
1
t 1
t 1
t 1
Seal checker
Oil pump
t 2
Push tool (for small plug)

Installer
Remover & installer assembly
q Adapter
q Guide
q Bolt
q Frame
q Rod
q Frame
q Nut
q Eyebolt
q Bolt
q Adapter
q Rod
q Adapter
q Guide
q Bolt
q Pusher
q Extension
q Adapter
q Adapter
q Guide
q Guide
q Adapter
q Guide
Bolt
Cylinder (1,470 kN {150 ton})
Pump
Spacer
t 1
t 1
t 1
1
1
2
1
1
1
3
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
t 1
t 1
t 1
t 1 N
Assembly of link

one link assembly in field
50-13
DRAFT
Device
Symbol
1
2
3
4
5
6
7
Track shoe
assembly
9
Track shoe
assembly
10
50-14
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
1
2
3
4
5
6
7
8
9
10
11
1
2
3
4
5
6
7
8
9
10
11
1
2
3
Part No.
791-646-7351
791-660-7460
791-646-7900
791-701-3000
or
791-601-1000
791-932-1110
791-632-1021
791-632-1100
791-632-1130
790-434-1610
01010-51440
791-685-9510
791-685-9530
791-685-9520
791-685-9550
04530-12030
791-685-9560
791-126-0150
791-685-9540
791-632-1140
791-680-5520
01010-51030
791-632-1150
791-685-9620
791-632-1180
791-630-5543
791-632-1160
791-680-5551
791-680-9630
791-632-1160
195-32-61210
790-101-4300
790-101-1102
790-101-4200
791-680-1630
791-632-1300
791-632-1260
791-632-1270
791-632-1220
791-632-1230
791-632-1240
791-685-5730
791-632-1250
791-632-1280
01252-30605
01580-01210
791-632-1200
791-632-1260
791-632-1270
791-632-1210
791-632-1230
791-632-1240
791-685-5730
791-632-1250
791-632-1280
01252-30650
01580-01210
791-632-1290
791-632-1260
01580-01210
Part name
Push tool
Pin brush
Push tool (for large plug)
Seal checker
Necessity
Q'ty
N/R
Sketch

Special tools list
t 1
t 1
t 1
t 2
Oil pump
Push tool (for small plug)
Installer
Remover & installer assembly
q Adapter
q Guide
q Bolt
q Frame
q Rod
q Frame
q Nut
q Eyebolt
q Bolt
q Adapter
q Rod
q Adapter
q Guide
q Bolt
q Pusher
q Extension
q Adapter
q Adapter
q Guide
q Guide
q Adapter
q Guide
Bolt
Cylinder (1,470 kN {150 ton})
Pump
Spacer
Push tool assembly
q Push tool
q Adapter
q Pin (small)
q Ring
q Plate
q Bar
q Ring
q Spring
q Bolt
q Nut
Push tool assembly
q Push tool
q Adapter
q Pin (large)
q Ring
q Plate
q Bar
q Ring
q Spring
q Bolt
q Nut
Push tool assembly
Bar
Nut
t 1
t 1
t 1
1
1
2
1
1
1
3
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
2
t 1
t 1
t 1
t 1
t 1 N
1
1
1
1
1
1
1
1
1
1
t 1 N
1
1
1
1
1
1
1
1
1
1
t 2 N
1
1

master link

master link
D375A-6
(02)
DRAFT
Device
Pivot shaft
assembly
Equalizer bar
Equalizer bar
bushing
Symbol
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
2
Hydraulic cylinU
der assembly
Hydraulic cylinU
der assembly
2
Ripper pin
puller cylinder
assembly
U
3
4
5
7
D375A-6
(02)
Part No.
791T-650-2330
791T-650-2340
790-201-3310
790-101-2510
790-101-2570
01580-01613
01643-31645
790-105-2300
790-101-1102
791-650-1300
791-735-1123
790-434-1050
01580-02419
01643-32460
790-101-2102
790-101-1102
791T-650-2410
791T-650-2420
790-438-1110
791-112-1180
790-101-2540
790-101-2102
791-101-1102
Part name
Necessity
Q'ty
N/R
Sketch

Special tools list
t
t
t
t
t
t
t
t
t
790-201-1702
790-201-1841
790-201-1861
790-101-5021
01010-50816
790-201-1500
790-201-1650
790-201-1670
790-101-5021
01010-50816
790-720-1000
796-720-1680
07281-01589
796-720-1720
07281-02429
796-720-1690
07281-02169
790-102-4300
Sleeve
Plate
Bolt
Block
Washer
Nut
Washer
Jack assembly
Pump
Remover
q Sleeve
q Screw
q Nut
q Washer
Pump
Bracket
Bracket
Screw
Nut
Washer
Pump
Cylinder
Repair stand
Push tool kit
q Push tool
q Push tool
q Grip
q Bolt
Push tool kit
q Plate
q Plate
q Grip
q Bolt
Expander
Ring
Clamp
Ring
Clamp
Ring
Clamp
Wrench
t 1
1
1
1
1
t 1
1
1
1
1
t 1
t 1
t 1
t 1
t 1
t 1
t 1
t 1
790-102-4310
Pin
t 2
790-502-1003
Cylinder
Repair stand
q 1
790-201-1702
790-201-1721
790-101-5021
01010-50816
790-201-1500
790-201-1530
790-101-5021
01010-50816
790-720-1000
796-720-1630
07281-00709
790-102-2302
Push tool kit

q Push tool
q Grip
q Bolt
Push tool kit
q Plate
q Grip
q Bolt
Expander
Ring
Clamp
Wrench
t 1
1
1
1
t 1
1
1
1
t 1
t 1
t 1
t 1
790-502-1003
q
q
t
t
t
t
t
t
t
1
1
2
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
q 1
N Q
N Q

pivot shaft assembly

equalizer bar assembly
N Q
N Q
equalizer bar bushing

hydraulic cylinder assembly
Press fitting of seal
Installation of bearing

ripper cylinder piston assembly
Assembly and disassembly of
ripper pin puller cylinder
assembly
Press fitting of dust seal
Press fitting of dust seal

Tightening cylinder head
50-15
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
(02)
50-17
DRAFT
A5 Push tool (for sleeved seal)
L1 Plate
50-18
D375A-6
(02)
DRAFT
L8 Plate
L10 Push tool
D375A-6
(02)
50-19
DRAFT
L17 Guide
L21 Lifting tool
50-20
D375A-6
(02)
DRAFT
L21 Tube
L21 Plate
D375A-6
(02)
50-21
DRAFT
P1 Sleeve
P2 Plate
50-22
D375A-6
(02)
DRAFT
N2-1 Bracket
N2-2 Bracket
D375A-6
(02)
50-23
DRAFT
Removal and installation of fuel supply pump assembly

Removal
k Park the machine on a level surface and lower the work equipment to the ground.
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.
a Remove the wiring clamp and move the wiring
aside.
5. Remove common rail cover (5).

a Pull up the cover at an angle toward the front
side to remove.
6. Disconnect wiring connectors (6).
a Wiring connectors: PCV1, PCV2
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-pressure 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)

8. Remove the fuel pre-filter.

a The fuel pre-filter may be removed first.
11. Remove the mounting bolts of brackets (16) and

(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.
4)
5)
6)
7)
D375A-6
(07)
(02)
Nut (23)
Washer (24)
Coupling (25)
Key (26)
50-25

Installation
1. Install the following parts to fuel supply pump
assembly (18).
1) Key (26)
2) Coupling (25)
3) Washer (24)
4) Nut (23)
3 Nut (23):
176 196 Nm {18 20 kgm}
5) Plate (20)
6) Oil tube (19)
a Replace gaskets (GA) and (G10) with
new ones.
q GA : Accessory to supply pump
q G10: Part No. (07005-01012)
7) Overflow valve (21)
3 Plate (20) mounting bolt:
19.6 29.4 Nm {2.0 3.0 kgm}
3 Oil tube (19) joint bolt:
Upper side: 7.9 12.7 Nm {0.8 1.3
kgm}
Lower side: 9.8 12.7 Nm {1.0 1.3
kgm}
3 Overflow valve (21):
14.8 19.6 Nm {1.51 1.99 kgm}
3. Install fuel supply pump assembly (18) and lower

bracket (17).
3 Fuel supply pump mounting bolt:
59 74 Nm {6.0 7.5 kgm}
3 Lower bracker (17) mounting bolt:
59 74 Nm {6.0 7.5 kgm}
4. Install oil tube (22).
a Replace 4 gaskets (G) with new ones.
(Part number: 07005 -01012.)
3 Oil tube (22) joint bolt:
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)
(07)

High-pressure pipe
k When handling the high-pressure pipe
and clamp, observe the following.
q Never bend the high-pressure pipe to install 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-pressure pipe sleeve nuts and the threads of
the mating part.
a Axial force in the tightening can be excessive, potentially damaging the high-pressure pipe.
k Before installing the high-pressure pipe,
check it for the following defects. If it has
any defect, replace it with new one since
fuel may leak.
q Check the taper seal of the connecting
part (Part (a): Part of 2 mm from the end)
for visible lengthwise slit (b) and dent (c).
q Check part (d) (End of the taper seal: Part
at 2 mm from the end) for stepped-type
wear (fatigue) which your nail can feel.
Carry out the subsequent installation in the reverse order to removal.
[*1]
5. Connect G sensor connector (15).

6. Tighten high-pressure pipe (7) partially.
7. Tighten clamps (8) to (10) partially.
8. Tighten high-pressure pipe (7) to the specified
torque.
3 High-pressure pipe sleeve nut:
39.2 44.1 Nm {4.0 4.5 kgm}
Tube (12)
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}
Tube (13)
Joint bolt (Overflow valve):
14.8 19.6 Nm {1.51 1.99 kgm}
24.5 34.3 Nm {2.5 3.5 kgm}
Sleeve nut (Fuel block side):
24 27 Nm {2.4 2.7 kgm}
Tube (14)
14.8 19.6 Nm {1.51 1.99 kgm}
Sleeve nut: 43 47 Nm {4.4 4.8 kgm}
Make sure that a clearance of 10 mm minimum is provided between the high-pressure

pipe and adjacent wiring harness. If not, secure the clearance by repositioning the wiring harness.
Air bleeding
Bleed air from the fuel circuit. For details, see
Testing and adjusting, "Bleeding air from fuel
circuit".
9. Tighten clamps (8) to (10) to the specified

torque.
3 Clamp bolt: 9.8 1.0 Nm {1 0.1 kgm}
10. Install cover (11) at 2 places.
a When installing it ,direct the slit down ward.
D375A-6
(07)
(02)
50-27
DRAFT
Removal and installation of fuel injector assembly

35. Disconnect high-pressure pipe clamps (7) and
(8).
a A clamp is provided on the fuel supply pump
side.
Symbol
Part No.
795-799-5410
795-799-5420
2 795T-675-1110
1
Part name
Adapter
Remover
Socket
Necessity
Q'ty
New/remodel
Sketch
Special tools
t 1
t 1
q 1 N Q
Removal
36. Remove clamp (9).
1. Perform steps 1 to 31 of Removal and installation of cylimder head assembly. (See "Removal
and installation of cylinder head assembly")
37. Remove covers (10).
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

each.
41. Remove terminal mounting nuts (15).

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
(02)
50-29
DRAFT
Installation
1. Fuel injector
a Check that the injector mounting bore is free
from dirt.
2 O-ring: Engine oil (EO30)
2) Install terminal mounting nuts (15) and wiring

harness fixing bolts (16).
a Tighten the terminal mounting nuts alternately
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
tightening the high-pressure pipe pantially.
3. High-pressure pipe
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,

fuel may leak.
5) Tighten high-pressure pipe sleeve nuts (11)

and (12) 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 (32) is not projected from the
end of the sleeve nut (12).
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-pressure pipe (13).

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
(02)
50-31
DRAFT
4. High-pressure pipe clamp

1) Install the clamps on the high-pressure pipes
1] Finger-tighten 17 high-pressure pipe
clamps (33) in the position indicated in
the figure.
2] Finger-tighten common rail side clamp
bracket (34) and clamp (9) and then
tighten clamp (9).
3 Common rail side clamp bolt:
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 downward.

pipe and adjacent wiring harness. If not, secure the clearance by repositioning the wiring harness.
Bleeding air
Bleed air from the fuel circuit. For details, see
circuit".
[*1]
3
3
Tube (4) joint bolt:

7.8 9.8 Nm {0.8 1.0 kgm}
Tube (5) sleeve nut:
24.5 34.3 Nm {2.5 3.5 kgm}
a Refer to the precautions in "Installation of cylinder 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
(2).
Adapter
Remover
Socket
Wrench (angle)
5. Disconnect exhaust temperature sensor wiring

(3).
t 1
t 1
q 1 N Q
q 1
6. Remove front heat insulation cover (4), center

heat insulation cover (5), and rear heat insulation cover (6).
Q'ty
Sketch
795-799-5410
795-799-5420
A
2 795T-675-1110
6 790-331-1120
1
Part name
New/remodel
Part No.
Necessity
Symbol
Special tools
7. Disconnect the muffler drain tube.

Removal
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.
8. Lift off muffler (7).

4 Muffler assembly: 75 kg
9. Remove muffler mounting bracket (8).
1. Drain the coolant.

6 Coolant: 120 l
2. Remove the engine hood assembly. For details,
see "Removal and installation of hood
assembly".
3. Remove left and right lower side covers (1).
4 Left lower side cover: 40 kg
Right lower side cover: 50 kg
10. Disconnect fuel hoses (9) and (11).
[*1]
11. Disconnect tube (10).
[*2]
12. Remove fuel pre-filter assembly (12).
D375A-6
(02)
50-33
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 connector.
16. Disconnect connector POIL (21) according to
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.

q Lubricating oil tube (28)
q Lubricating oil drain tube (29)
q Coolant tube (30)
q Coolant drain tube (31).
[*4]
24. Lift off turbocharger and exhaust manifold

assembly (32).
[*5]
4 Turbocharger and exhaust mainfold assembly:120 kg
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
(02)
50-35
DRAFT
29. Disconnect 6 injector connectors (38).
30. Disconnect connector CN6 (39).
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).
50-36
[*7]
D375A-6
(02)
DRAFT
44. Disconnect wiring harness clamp (59) from rear

side of the fuel supply pump.
50. Disconnect sleeves (69).

45. Disconnect the connector from the bottom of

clamp (59).

46. Disconnect connectors PCV1 (60) and PCV2
(61).
53. Remove 4 mounting bolts (73) of air intake manifold 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
(02)
50-37
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.
a Tool A2

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].
60. Remove air intake connector (76).

a Since the tube convexly bites into the inside
of the air intake connector (part A), take care
not to damage the tube when removing the
air intake connector.
61. Lift off air intake manifold assembly (72).

4 Air intake manifold assembly:110 kg
57. Remove the mounting bolts of air intake manifold assembly (72), leaving some of them tightened.
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 connector by using the guide bolts. (See the following 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 visually.
a For above operation, see Testing and adjusting, "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
(02)
50-39
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 retighten. 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):
93.2 103 Nm {9.5 10.5 kgm}
D375A-6
(02)
a After tightening the bolt, make punch

mark "(a)" on the main bolt head (Do not
make it when new bolt is used, however).
50-41
DRAFT
2. Fuel injector
a Check that the fuel injector mounting bore is
free from dirt or other particles.
a Do not forget to install O-ring (OR).

3 Rocker arm housing mounting bolt:
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 intake manifold and tightening the
high-pressure pipe partially.
4) Install push rods (88).
a Check that the push rod end is securely
placed in the cam follower socket.
5) Apply liquid gasket and then install rocker
arm housing (90).
2 Rocker arm housing: Liquid gasket
(LG-7)
a Apply the liquid gasket 2 to 3 mm in bead
diameter along the housing groove as
50-42
7) Adjust the crossheads according to the

1] Loosen locknut (102) and then loosen
adjustment screw (103) to a position
where it will not touch valve stem (104).
2] Hold the rocket arm contact face on the
crosshead with the finger to keep the
crosshead in contact with valve stem
(105) on the push rod side.
3] Slowly tighten adjustment screw (103)
and check the position at which adjustment screw (103) touches valve stem
(104).
4] Screw in adjustment screw (103) further
by 20 30 from the contacting position
against valve stem (104).
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

1) Install spacer (84).
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 Theaded portion and seat surface of
rocker arm assembly mounting bolt:
Engine oil (EO30)
3 Rocker arm assembly mounting bolt :
235.2 254.8 Nm {24 26 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
(02)
2) Install terminal mounting nuts (82) and wiring

harness fixing bolts (83).
a Tighten the terminal mounting nuts alternately
3 Terminal mounting nut:
2 0.2 Nm {0.2 0.02 kgm}
50-43
DRAFT
5. Air intake manifold assembly:

1) Place connector (76) on air lifted intake manifold assembly (72) being lifted.
a Since the tube convexly bites into the inside of the air intake connector (part A),
take care not to damage the tube when installing the air intake connector.
4 Air intake manifold and connector assembly: 135 kg
2) Install air intake manifold assembly (72).

Before installing the high-pressure pipe,

fuel may leak.
1) Install O-ring (106) to high-pressure pipe

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.
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
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}
D375A-6
(02)
DRAFT
5) Tighten high-pressure pipe sleeve nuts (69)

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).
6) Install cylinder head cover (81).

a A different tightening torque is employed
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
(02)
9) Install brackets (77).
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.
a When installing it, direct the slit downward.
50-45
DRAFT
8. Fuel supply pump

a If overflow valve (ofv) is loosened or oil tube
(t) and plate (p) are removed, install them, referring to "Removal and installation of fuel
supply pump assembly".
1) 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.
3
3
Fuel supply pump (66) mounting bolt:

59 74 Nm {6 7.5 kgm}
Lower bracket (111) mounting bolt:
59 74 Nm {6.0 7.5 kgm}
k Handle the high-pressure pipe and clamp
in the same way as the pipe between the
fuel injector and common rail (noted in
the foregoing) is handled.
1) Tighten high-pressure pipes (57) partially.
2) Tighten clamps (55), (56) and (109) partially.
3) Tighten bracket (110) partially.
4) Tighten high-pressure pipes (57) to the specified 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
[*1]
3
3
Fuel hose (9):90 95 Nm {9.2 9.7 kgm}

Sleeve nut of fuel hose (11):
43 47 Nm {4.4 4.8 kgm}
[*2]

2 Exhaust manifold mounting bolt:
Seizure prevention compound (LC-G)
(NEVER-SEEZ (BOSTIK) or equivalent)
3 Exhaust manifold mounting bolt:
1st time:39.2 58.8 Nm {4.0 6.0 kgm}
2nd time:98.1 122.6 Nm {10 12.5
kgm}

19.6 29.4 Nm {2.0 3.0 kgm}
[*3]
3
3
3
3
Tube (18-1) joint bolt (filter side):

24.5 34.3 Nm {2.5 3.5 kgm}
Tube (18-1) joint bolt (supply pump side):
14.8 19.6 Nm {1.51 1.99 kgm}
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]
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}
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
(02)
50-47
DRAFT
Reference
Installation of turbocharger assembly
1. Lift and install turbocharger assembly (112).
4 Turbocharger:55 kg
2 Turbocharger mounting bolt and nut:
Seizure prevention compound (LC-G)
(NEVER-SEEZ (BOSTIK) or equivalent)
3 Turbocharger mounting bolt and nut:
78.5 88.3 Nm {8.0 9.0 kgm}

pipe and adjacent wiring harness. 10 mm not,
secure the clearance by repositioning the
wiring harness.
Bleeding air
Bleed air from the fuel circuit. For detail, see
circuit".
[*6]
3
3
3
Oil tube (44) joint bolt:

7.8 9.8 Nm {0.8 1.0 kgm}
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
3
3
50-48
Oil tube (63) joint bolt (supply pump side):

9.8 12.7 Nm {1.0 1.3 kgm}
Oil tube (63) joint bolt (block side):
9.8 12.7 Nm {1.0 1.3 kgm}
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}
Tube (64):19.6 29.4 Nm {2.0 3.0 kgm}
D375A-6
(02)
DRAFT
Removal and installation of radiator guard assembly
791-451-1000 Remover
Puller
A 7 790-101-2102
(294 kN {30 ton})
790-101-1102 Pump
Sketch
Part name
N/R
Part No.
Q'ty
Symbol
Necessity
Special tools
t 1
t 1
t 1
Removal
a Move the machine forward and backward to set
the master link of the track shoe away from the
radiator guard.
k If the radiator coolant temperature is high,
wait until the temperature decreases to avoid
getting scalded, and then drain the coolant or
disconnect the radiator hoses/tubes.
1. Sling the blade lift cylinders.
2. Remove the lock plate and remove connecting
pin (1) on the piston rod side of the blade lift
cylinder.
5. Drain the hydraulic oil and coolant.

6 Hydraulic:130 l
6 Coolant: 120 l
see "Removal and installation of engine hood
assembly".
7. Disconnect radiator inlet hose (4).
[*1]
a Disconnect the hose from the radiator and reposition the hose on the engine side.
8. Disconnect air vent hose (5).
[*2]
a Disconnect the hose from the radiator, remove the 2 clamps, and reposition the hose
on the engine side.
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
(02)
50-49
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

pin lock bolt, and push rear pin (12) toward the
inside of the radiator guard to take it out using
tool A7.
a Remove the shoe plates to secure a working
space.
20. Lift off radiator guard and blade lift cylinder

assembly (14).
a When removing, take extreme care not to
damage the wiring, pipes, etc.
4 Radiator guard and blade lift cylinder assembly: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
Carry out installation in the reverse order to removal.
[*1]
Radiator inlet hose clamp:

8.8 0.5 Nm {0.9 0.05 kgm}
[*2]
D375A-6
(02)
Air vent hose clamp:

3.3 0.5 Nm {0.34 0.05 kgm}
50-51
DRAFT
[*3]
MIKALOR clamps (MC10), (MC20), (MC23)
a Use a new MIKALOR clamp.
1) Set each hose to the original position.
(Hose insertion depth: 80 mm)
2) Set bridge (BR) under the clamp bolt and
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 tightening.
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}
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
Constant torque clamp (CTC)

3 10.5 0.5 Nm {1.07 0.05 kgm}
(TC): Turbocharger
50-52
D375A-6
(02)
DRAFT
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
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
(02)
50-53
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)
Removal
disconnect the radiator hoses.
a Place air conditioner condenser on the track

shoes.
assembly".

6 Coolant: 120 l
2. Drain the hydraulic oil.
6 Hydraulic: 130 l
assembly".
10. Open the undercover. For details, see "Removal

and installation of engine assembly".
[*1]
11. Disconnect hydraulic oil cooler upper hose (7)

and lower hose (7-1).
[*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 disconnect 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).

13. Disconnect aftercooler outlet tube (9).
a Do not loosen clamp (MC).
16. Remove two upper mounting bolts (12) on both

the left and right sides.
[*4]
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
(02)
50-55
DRAFT
Installation
q Carry out installation in the reverse order to removal.
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]
50-56

3.3 0.5 Nm {0.34 0.05 kgm}
D375A-6
(02)
DRAFT
[*3][*4]
2) Set bridge (BR) under the clamp bolt and
secure at least 5 mm of overlap (b) between
the bridge and band (BD).
3) Tighten the clamp.
2 Clamp bolt (BC):
PANDO 18B)
3 Clamp bolt (BC):
Min. 6 Nm {0.6 kgm}
When using a new hose

is as follows.
MC10: 7 - 10 mm
MC20: 17 - 20 mm
MC23: 20 - 23 mm

3 10.5 0.5Nm {1.07 0.05 kgm}
(TC): Turbocharger
D375A-6
(02)
50-57
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
(02)
50-59
DRAFT
Installation
1. Install the radiator unit.
a Replace O-rings (10) with new ones.
a Apply detergent (undiluted) to the O-rings.
a Remove the fan net and check that the convex part of the radiator is matched with the
concave part of the lower tank, and then install the radiator securely.
2) Install collar (5) upside down (with 13 mm

side up) and tighten mounting bolt (4).
a This compresses cushion (7). (L1oL2)
3) Tighten mounting bolts (3) of bracket (6).
4) Remove mounting bolt (4).
5) Install collar (5) again in the normal direction

(with 6 mm side up).
6) Tighten mounting bolt (4).
7) Check clearance (L3).
q Clearance (L3): Approx. 7 mm
2. Install radiator mounting brackets (6) and cushions (7) according to the following procedure.
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.
q
50-60
5 Coolant: 120 l
D375A-6
(02)
DRAFT
Removal and installation of hydraulic oil cooler

Removal
6 Hydraulic:130 l
cover (1).
4 Lower side cover: 40 kg
Installation
q

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
(02)
50-61
DRAFT
Removal and installation of aftercooler

5. Open the undercover.
Removal
6. Remove lower mounting bolts (4) of the aftercooler.
1. Remove the radiator upper cover. For details,

assembly".
2. Remove right stay (1).
3. Remove upper mounting bolts (2) of the aftercooler.
4. Open the right side cover and disconnect aftercooler inlet duct (3).
a Loosen the mounting bolts of the aftercooler
that is not being removed, too.
7. Lift off aftercooler (5).

4 Aftercooler: 40 kg
Installation
50-62
D375A-6
(02)
DRAFT
Removal and installation of engine assembly

Removal
6 Coolant: 120 l
2. Using sling [1], gradually open the undercover of
the engine and power train.
5. Disconnect starting motor wiring (2) and wiring

clamp (3).
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
(02)
50-63
DRAFT
11. Disconnect radiator outlet hose (10) from the

engine.
15. Disconnect fuel supply hose (15).
[*2]
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.
assembly".
[*3]
[*4]
20. Disconnect aftercooler ducts (20) and air hose

(21).
[*5]
50-64
D375A-6
(02)
DRAFT
21. Disconnect aftercooler outlet tube (22).

[*6]
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 conditioner 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
(02)
50-65
DRAFT
8) While slinging bulkhead bracket (39), disconnect starting motor cable clamps (41) from
bulkhead bracket (39).
9) Remove bulkhead bracket (39) and sub tank

(42) as a unit.
4 Bulkhead bracket assembly: 250 kg
25. Remove dashboard front duct (44).
26. Sling universal joint (45), remove the mounting

bolts, and remove the universal joint.
[*7]
4 Universal joint assembly: 40 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

1) Install the lifting tools to parts [A] and [B].
Installation
[*1]
a Install the belt. For details, see Testing and adjusting (Part 1), "Replacement and adjusting of
alternator and air conditioner compressor belts".
[*2]
Fuel supply hose:90 95 Nm {9.2 9.7

kgm}
[*3]
2) Lift up engine assembly (48).

4 Engine assembly:3,320 kg
3) While moving engine assembly (48) toward
the front of the machine, operate the chain
block to raise the front of the engine to slant
the engine assembly.
4) After the front and rear portions of the engine
assembly (48) clear the machine body parts
(the aftercooler assembly), turn the engine
assembly toward the right of the machine by
90 degrees to allow it to clear the blade lift
cylinder and cab, and then remove it.
a When removing, take care not to damage
the wiring and hoses.
D375A-6
(02)

8.8 0.5 Nm {0.9 0.05 kgm}
[*4]

3.3 0.5 Nm {0.34 0.05 kgm}
[*5] [*6]
2) Adjust the position of bridge (BR) so that the
bridge is under the band.
a Secure at least 5 mm of overlap (b) between the bridge and band (BD).
3) Tighten clamp bolt (BC).
2 Clamp bolt (BC):
PANDO 18B)
3 Clamp bolt (BC):
Min. 6 Nm {0.6 kgm}
q When using a new hose
is as follows.
MC10:7 10 mm
MC20:17 20 mm
MC23: 20 23 mm
50-67
DRAFT

3 10.5 0.5 Nm {1.07 0.05 kgm}
(TC): Turbocharger
50-68
D375A-6
(02)
DRAFT
[*7]
Universal joint mounting bolt:

156.9 196.1 Nm {16 20 kgm}
[*8]
Engine mounting bolt:

823 1,029 Nm {84 105 kgm}
5 Coolant: 120 l
D375A-6
(02)
50-69
DRAFT
Removal and installation of engine hood assembly

5. Remove right cover (3-1) and left cover (3-2).
Removal
1. Remove radiator upper inspection cover (1).

7. Remove precleaner cover (4).
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

hood.
16. Remove rear mounting bolts (11).

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 turbocharger to prevent foreign matter from entering.
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
(02)
50-71
DRAFT
18. Lift up engine hood assembly (12).

4 Engine hood assembly: 350 kg
Installation
[*1]
3 Air cleaner hose clamp:
10.5 0.5 Nm {1.07 0.05 kgm}
[*2]
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).
Seal puller
assembly
Push tool (for oil
795T-621-1180
seal)
A
Push tool (for
4 795T-621-1171
dust seal)
795-902-1460 Bolt
01582-02218 Nut
3 795-931-1100
Sketch
Part name
New/remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
5. Remove front seal (8) according to the following
procedure.
t 1
t 1
t 1
t 3
t 3
Removal
1. Remove the radiator guard assembly. For
details, see "Removal and installation of radiator
guard assembly".
1) Change the end of tool A3 to the hook type

one.
2) Hitch the hook to the metal ring of front seal
(8).
3) Remove the front seal with impact of slide
hammer (SH).
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
(02)
50-73
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 crankshaft).
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
procedure.
a Before installing the seal, check that crankshaft end face corners, seal lip sliding surfaces and housing are free from flaws, burr, fins,
rust, etc.
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 toward the outside of the engine.
3) Using tool A4 (for dust seal), press fit dust

seal (7) to the front cover to dimension (b)
a Dust seal press fitting dimension (b): 2
mm (Projection from the front cover end
face)
[*1]
a Take care not to install the wrong end.

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
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}
3rd time: 617.4 656.6 Nm {63 67 kgm}
D375A-6
(02)
DRAFT
Removal and installation of engine rear seal
Removal and installation of engine

rear seal
Symbol
Part No.
Part name
Seal puller assembly

Push tool
795T-621-1161 (for standard seal
A
and sleeved seal)
5
Push tool
795T-621-1190
(for sleeved seal)
01050-32235 Bolt
01050-32245 Bolt
3 795-931-1100
Necessity
Q'ty
New/remodel
Sketch
Special tools
t 1
t 1
t 1
t 5
t 5
Removal
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
D375A-6
(02)
5. Remove rear seal (2).

a Take care not to damage the seal installation
position on the flywheel housing and the seal
contact surface on the crankshaft.
a Before removing, slightly tap the front seal
once to unstick it.
a When rear seal (2) is fixed too hard to the flywheel housing (FWH), perform the following
procedure.
a The left one in the following figure shows
the standard seal and the right one shows
the sleeved seal.
1] Change the end of tool A3 to the drill type
one.
2] Drill several holes about 3 mm in diameter
in rear seal (2).
3] Set tool A3 to the drilled hole.
4] Remove the rear seal with impact of slide
hammer (SH).
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.
Tool A3
50-75
DRAFT
Installation
a Check the wear of the crankshaft and select the
type of the Teflon seal (laydown lip seal) to install, "standard seal" or "sleeved seal", depending 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.
a Handle rear seal (2) and sleeve (5) as a unit.
Don't try to separate them.
a Clean, degrease and then dry the flywheel housing contact surface on the rear seal.
a Clean, degrease, and dry the seal lip sliding surface (peripheral surface of the crankshaft).
a Check that the crankshaft end face corners, seal
lip sliding surface and housing are free from
burrs, dents, rust, etc.
50-76
Installation procedure for standard seal

a Do not apply grease, oil, etc. to the seal lip sliding 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.
2) Hold the metal ring of rear seal (2) with both

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.
D375A-6
(02)
DRAFT
4) Tighten the bolts evenly to press fit rear seal

(2) until the end face of tool A5 touches the
end face of crankshaft (4).
a Oil seal press fitting dimension (when
measured from the crankshaft end face)
(a):20 mm
a After press fitting the rear seal, remove the
red sealant layer from its periphery.
Installation procedure for sleeved seal

a When installing the rear seal, do not apply oil,
grease, etc. to the crankshaft, the inside cylindrical 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
face of crankshaft (4) and tighten the five
bolts evenly to press fit sleeve and rear seal
assembly (6) until the end face of tool A5
touches the end face of the crankshaft (4).
D375A-6
(02)
3) Remove tool A5 (for press fitting the sleeved

seal) and install tool A5 (for press fitting the
standard seal).
4) Tighten the five bolts evenly to press fit
sleeve and rear seal assembly (6) until the
end face of tool A5 (for press fitting the standard seal) touches the end face of crankshaft
(4).
a Use the bolts (stem length: 45 mm) to
tighten tool A5 (for press fitting the standard 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 crankshaft end face): 20 mm
a After press fitting the rear seal, remove
the red sealant layer from its periphery.
[*1]
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 flywheel 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
50-77
DRAFT
3
Flywheel assembly mounting bolt:

1st time: 196.1 19.6 Nm {20 2 kgm}
2nd time: 460.9 19.6 Nm {472kgm}
3rd time: 90 120 Retightening
a After tightening the bolt, make a punch mark (a)
on its head. (When a new bolt is used, do not
make a punch mark on its head.)
Measure radial runout and facial runout of the

flywheel using dial gauge [1].
a Standard radial and facial runout:
Measurement
items
Radial runout
Facial runout
Tolerance (mm)
Approx. 0.13
0.0005 Diameter of
measuring point
a When the measured value is out of the standard,

determine the cause by disassembling the flywheel.
50-78
D375A-6
(02)
DRAFT
Removal and installation of fan drive assembly

Removal
6 Hydraulic oil: 130 l
5. Remove fan nets (4), (5), and (6).

6. Remove wiring harness clamp (7) and disconnect the connector.
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 remove it.
D375A-6
(02)
50-79
DRAFT
8. Lift off fan drive assembly (11). [*1]

4 Fan drive assembly: 200 kg
a Install the wire to the left and right of the fan
drive, lift it at a point, and pull out it evenly to
remove.
Installation
[*1]
a Ensure that position (m) of the reflector tape for
measuring the fan speed is of the specified dimension.
Distance (m) from fan blade end: Max. 5 mm
a After installing the fan, check clearance (l) between the fan blade and the shroud. If the clearance 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
(02)
50-81
DRAFT
Installation
[*1]
Be sure to adjust the hole of lock plate (1) by turning
nut (2) in the tightening direction.
[*2]
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.
5. Close fuel drain valve (3), and disconnect hose
clamps (8).
6. Remove mounting bolt (10) of bracket (9), and
disconnect fuel drain hose (11).
D375A-6
(02)
9. Disconnect wiring connector FGS (14) of the fuel

level sensor.
50-83
DRAFT
10. Remove three mounting bolts (15) from each

side of the fuel tank.
Installation
q
(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
(02)
50-85
DRAFT
Power train
Removal and installation of damper assembly
Power train
Removal
k
k
k
Park the machine on a level surface and lower the work equipment to the ground.
Set the parking brake lever and work equipment lock lever in the lock position.
Stop the engine and disconnect the cable
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]

a Sling the universal joint assembly and lower
it to remove.
9. Remove divider board (11).
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
(02)
50-87
DRAFT
Power train
12. Remove the damper cover according to the

[*3]
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 cover, use forcing screws [3] (M12 x 1.75).
a Install forcing screws [3] at 3 places, and
tighten them evenly.
4 Damper cover: 75 kg
a Tighten forcing screws [3] evenly.

Damper assembly: 70 kg
14. If bearing (19) is damaged, remove bearing (19).
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
q
[*5]
Fill gap (a) at the hatched area in the illustration with
grease (G2-LI) by approx. 50% (11 g).
[*1]
Universal joint mounting bolt:

156.8 - 196 Nm {16 - 20 kgm}
[*2]
Holder mounting bolt :

245 - 309 Nm {25 - 31.5 kgm}
[*3]
a Install the damper cover according to the following procedure.
1) Using guide bolts [2] (M12 x 1.75 x 200 mm),
position the damper cover.
2) Finger-tighten twelve mounting bolts (16)
(indicated by * mark).
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.
(Refilling)
Fill the damper case with oil.
5 Damper case: 2.1 l (engine oil EO-DH)
[*4]
a Using guide bolts [5] (M12 x 2 x 200 mm), position the damper.
D375A-6
(02)
50-89
DRAFT
Power train
Disassembly and assembly of damper assembly

Disassembly of damper assembly
1. Place the damper assembly on block [1].
6. Remove seal (7) from each of flanges (2) and

(5).
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
2. Install flange (5) to body (6), while matching their

bolt holes with each other.
2 Mating face of flange: Liquid gasket
(LG-4)
a Check that the mating faces are free from
dents, rust, oil, grease and water, and apply
the liquid gasket to the surfaces of both the
flange and the body.
5. Install flange (2).

2 Mating face of flange: Liquid gasket
(LG-6)
a Check that the mating faces are free from
dents, rust, oil, grease and water, and apply
the liquid gasket to the surfaces of both the
flange and the body.
6. Set the bolts and tighten mounting nuts (1).
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
(02)
50-91
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 inside 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 inside of the cover and wipe off any liquid gasket 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 completely.
k Release the residual pressure in the hydraulic 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,

see "Removal and installation of floor frame
assembly".
7. Sling universal joint assembly (2) and lower it to

remove.
[*1]
6. Using sling [1], open undercover (1) gradually.
D375A-6
(02)
50-93
DRAFT
Power train
8. Disconnect wiring connectors (3) from bracket

(3a).
12. Disconnect wiring connectors VDA (9), LRR

(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).
18. Disconnect return hoses (21) to (24) running to

the hydraulic tank.
21. Disconnect work equipment hose (29) from the

work equipment valve.
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
(02)
50-95
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
[*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
(02)
50-97
DRAFT
Power train
28. Remove left and right rear mount caps (40).
29. Loosen left and right rear coupling clamps (41).

[*2]
a Reposition the clamp toward the main frame,
and open the coupling to reposition the seal
toward the main frame.
32. Remove four power train mounting bolts (44)

each on the left and right sides.
[*4]
33. Lift off power train assembly (45).

a Install sling to parts [A] and [B] and lift up the
power train assembly while balancing it horizontally.
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
Testing and adjusting, "Bleeding air from work
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]
3 Universal joint mounting bolt:
156.8 196 Nm {16 20 kgm}
[*2]
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 counterclockwise, 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.

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
(02)
50-99
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 locations.
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.
1) SSTC (2), FSTC (3), SLUC (4), FLUC (5),
FA1 (6)
50-100
4) STB (17), TM1 (18), TC1 (19)
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
(02)
50-101
DRAFT
Power train
5. Disconnect the fifteen pressure pickup hoses

and remove them together with the central pressure pickup bracket according to the following
procedure.
1) Remove suction tube (37).
2) Remove covers (38) and (39).
3) Disconnect steering clutch pressure pickup

hoses (40) and (42) and brake pressure
pickup hoses (41) and (43).
(Hose band color)
Left clutch pressure (40): Black
Left brake pressure (41): White
Right clutch pressure (42): White/Black
Right brake pressure (43): Yellow
4) Disconnect transmission gear shift clutch

pressure pickup hoses (44) to (48).
(Hose band color)
1st (44): Red
3rd (45): Yellow/Black
Reverse (46): Red/Blue
2nd (47): White/Yellow
Forward (48): White/Blue
5) Disconnect torque converter output pressure

pickup hose (49).
(Hose band color): White/Red
50-102
D375A-6
(02)
DRAFT
Power train
6) Disconnect pressure pickup hoses (50) to

(53) connected to the ECMV valves.
(Hose band color)
Transmission main relief pressure (50): Torque converter inlet pressure (51): Blue
Lockup clutch pressure (52): Yellow/Red
Stator clatch pressure (53): Yellow/Blue
7) Disconnect power train lubrication pressure
pickup hose (54).
8) Remove pressure pickup hose (55) and pressure pickup block (56) as a unit.
6. Remove hydraulic tube (88) between the torque
converter and transmission.
D375A-6
(02)
7. Remove the following parts.

1) Oil level gauge (57)
2) Oil filler pipe (58)
3) Oil filter assembly (59)
4 Oil filter assembly: 120 kg
4) Strainer assembly (60)
4 Strainer assembly: 50 kg
5) Work equipment pump assembly (61)
4 Work equipment pump assembly: 110
kg
6) Power train pump and lubrication pump
assembly (62)
4 Power train pump and lubrication
pump assembly: 40 kg
7) Scavenging pump assembly (63)
4 Scavenging pump assembly: 25 kg
8) Fan pump assembly (64)
4 Fan pump assembly: 80 kg
50-103
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 assembly, remove the guide bolts.
50-104
D375A-6
(02)
DRAFT
Power train
3) Remove bracket (72).
4) Remove eye plates (73), reverse them, and

install them in the same positions at the left
and right.
2] Shorten sling [7] to slant PTO, torque

converter and transmission assembly
(74).
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 adjustable.
D375A-6
(02)
50-105
DRAFT
Power train
6) Sling oil pan case (75) and remove two

mounting bolts (76), eight mounting bolts
(77) and four mounting bolts (78).
7) Lift off oil pan case (75).
[*3]
4 Oil pan case: 110 kg
9) Remove retainer (80).

[*4]
a Note the thickness and quantity of the
shims.
10)Remove snap ring (81) and spacer (82).
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
3
Connection
q
Steering case mounting bolt:

245 309 Nm {25 31.5 kgm}
Carry out connection in the reverse order to disconnection.
[*1]
a Check that shaft (68) is inserted in boss (83) at
the end of the transmission input shaft.
[*3]
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 figure.
(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)
B x H = 2 to 5 cc
a When installing case (66) and bearing cage assembly (67), check that shaft (68) is inserted in
drum (84) of the bearing cage assembly securely and then install the case mounting bolts.
(OUT): Outside face of oil pan case

(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
(02)
50-107
DRAFT
Power train
a Set shims (87) as shown in the figure so

that they do not block forcing screw tap
holes (H) of retainer (80).
[*4]
q Adjust the retainer shim according to the following procedure.
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]
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

Disassembly
3) Using puller [2], remove bearings (5) and (6)

from gear (7).
1. PTO lubrication tube

Sling PTO assembly and remove lubrication
tube (1).
a Remove the three lubrication tubes installed
on the opposite side, then lower the assemble 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
(02)
50-109
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 assembly 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)

from race (28).
Assembly
a Clean all parts, and check them for dirt and damage 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 rotate the bearing approximately 10 turns.
2) Install snap ring (31).
3) Remove bearing outer race (29).

4) Remove sleeve (30).
7. Bearing
Remove snap ring (31) and bearing (32).
D375A-6
(02)
2. PTO case
1) Install sleeve (30) to the case.
a Install the sleeve with the chamfered inside edge facing down.
a Expand-fit the sleeve.
2) Using the push tool, press fit bearing outer
race (29).
50-111
DRAFT
Power train
3) Using the push tool, press fit bearing inner

races (27) and (26) to race (28).
4) Install race assembly (24).

2 Inside surface of race:
(LM-P)
race (25).
2) Using push tool [4], press fit bearing inner

race (20) to the shaft.
3) Fit the O-ring and install shaft assembly (18).
4) Turn over the PTO case and install gear

assembly (33).
5) Press fit bearing spacer (34) and bearing
inner race (35).
.
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 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
110.35 12.25 Nm {11.25 1.25
kgm}
2) Using push tool [5], press fit bearings (11)

and (12) to gear (13).
4. Scavenging pump gear

1) Install gear (16).
2 Spline: Grease (G2-LI)
2) Install snap ring (15) from under the PTO

case.
5. Power train pump gear assembly
1) Fit the O-ring and install cover (14).
D375A-6
(02)
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 plastic hammer to install.
50-113
DRAFT
Power train
6. Work equipment pump and PPC pump gear

assembly
1) Using push tool [5], press fit bearings (5) and
(6) to gear (7).
7. Lubrication tube
Sling the PTO assembly and install lubrication
tube (1).
a Install three lubrication tubes also on the opposite 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 plastic 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
Symbol
Part No.
790-413-1010
C
790-501-5000
Part name
Bracket
Repair stand
(100 V)
Necessity
Quantity
New/remodel
Sketch
Special tools
t 1
t 1
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. Lockup clutch and drive case assembly
1) Leaving two mounting bolts (3) in position,
remove other mounting bolts, then place the
assembly with the input shaft side up and
remove the remaining two mounting bolts.
D375A-6
(02)
3] Remove snap ring (7) and plate (8).

4] Set the assembly with the clutch housing
side down, and using forcing screws [3],
remove turbine (9).
50-115
DRAFT
Power train
5] Set the assembly with the clutch housing

side up and remove the housing and
piston assembly (10) by using eyebolts
[4].
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).
7] Remove seal ring (13) from the piston.

8] Remove seal ring (14) from the housing.
9] Using push tool [5], remove bearing (15)

from the housing.
10] Remove two discs (16) and one plate (17)

from drive case (18).
a Keep the disc and plate on a flat surface so that they do not warp.
4. Stator assembly
1) Remove snap ring (19), then remove stator
assembly (20).
2) Disassemble the stator assembly as follows.
1] Remove snap ring (21), then remove race
(22) from stator (23).
2] Remove snap ring (24) from stator (23).
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.

1] Remove retainer (27).
2] Remove bearing and guide assembly
(28) from pump (29).
7. Spring
Remove springs (33).
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
(02)
50-117
DRAFT
Power train
1) Remove seal ring (42) from the piston.

2) Remove seal ring (43) from the case.
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.
1] Using push tool [6], remove shaft
assembly (45) from the stator shaft
assembly.
50-118
2] Remove snap ring (47) and remove

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).
5] Using push tool [7], remve bearing (55).
D375A-6
(02)
DRAFT
Power train
Assembly
a Check that the snap ring is fitted securely into
the groove.
q
Preparatory work
Set case (41) to tool C..
1. Stator shaft assembly

1) Assemble the stator shaft assembly
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
(02)
4] Install seal ring (50) to the shaft.

a After installing the seal ring, apply
grease (G2-LI) to securely fix the seal
ring to the shaft.
5] Using push tool [9], press fit bushing (49).
a When press fitting the bushing, take
care not to deform it.
6] Using push tool [10], press fit bearing

inner race (48).
7] Install snap ring (47) to fix the bearing
inner race.
50-119
DRAFT
Power train
2) Tap stator shaft (52) with a plastic hammer to

press fit the bearing portion to the case.
3) Set shaft (46) to the stator shaft and press fit
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}
a Install the seal ring as shown in the figure

since it has directional properties.
(P: Direction of pressure)
3) Install piston (40) to case (41).

2 Seal ring contact surface:
Grease (G2-LI)
2. Piston
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
3. Inner gear
Install inner gear (39) and secure it with snap
ring (38).
D375A-6
(02)
DRAFT
Power train
4. Pin
Install pins (37).
5. Plate, disc, and spring
Install one plate (36), two discs (35), and springs
(34).
6. Spring
Install springs (33).
2] Set bearing and guide assembly (28) to

pump (29), then tap the assembly with a
plastic hammer to press fit the bearing
portion.
3] Install retainer (27).
3 Mounting bolt:
66.15 7.35 Nm {6.75 0.75
kgm}
2) Install pump assembly (26),
a When installing the pump, take care not
to damage the seal ring fitted to the shaft.
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.
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
(02)
50-121
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 Seal ring contact surface:
Grease (G2-LI)
a When installing, take care not to damage 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}
2) Using eyebolt [1], install lockup clutch and

drive case assembly (4).
a When installing, match oil groove (a) of
the turbine with drain plugs (2).
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
(02)
50-123
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
1) Remove nut (2-1) from connector (P).
a Note that cover (2) is wired.
1
2
3
D
790-415-1011 Bracket
Repair stand (100
750-501-5000
V)
791-615-1130 Push tool
791-615-1200 Ring assembly
791-615-1210 q Ring
135-A90-1150 q Bolt
01580-01008 q Nut
01641-51032 q Washer
791-615-1101 Ring assembly
791-615-1111 q Ring
135-A90-1150 q Bolt
01580-01008 q Nut
01641-51032 q Washer
799-301-1600 Oil leak tester
t
t
1
1
1
1
1
2
1
1
1
1
2
1
Sketch
Part name
New/remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
Disassembly
3) Remove sleeves (3).

4) Remove control valve assembly (4).
(G): Gasket
1. Preparatory work
Set transmission assembly (1) to tool D1.
3. Lubrication valve assembly

Remove lubrication valve assembly (5).
D375A-6
(02)
50-125
DRAFT
Power train
4. Front case
1) Set the transmission assembly with the input
shaft up.
2) Using eyebolts, remove front case (6).
3) Using eyebolt [2], lift off input shaft and No. 1

carrier assembly (8).
4) Reverse the input shaft and No. 1 carrier
assembly and remove seal ring (9).
5. Input shaft and No. 1 carrier assembly

1) Remove seventeen tie bolts (7).
2) Using forcing screws [1], disconnect input
shaft and No. 1 carrier assembly (8).
a Tighten the forcing screws evenly and
take care not to twist the input shaft and
No. 1 carrier assembly.
5) Disassemble the input shaft and No. 1 carrier

assembly according to the following procedure.
1] Remove snap ring (10) and remove No. 2
sun gear (11).
2] Remove spacer and bearing 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).
6] Using eyebolt [3], sling housing and No. 1

carrier assembly (18) and set it on the
blocks.
a Lower the input shaft end to the
ground and make a clearance of approx. 20 mm between the "housing
and No. 1 carrier assembly" and the
blocks.
7] Remove snap ring (19).
10] Remove snap ring (24) from housing and

No. 1 carrier assembly (20).
11] Set the housing and No. 1 carrier
assembly on the blocks and remove
housing (25) from No. 1 carrier assembly
(26) by using push tool [4].
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
(02)
50-127
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).
16] Reverse the No. 1 carrier assembly,

remove snap ring (30), and remove collar
(31).
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.
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
plate.
a Keep the disc and plate on a flat place so
that they do not warp.
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
1) Using eyebolt [5], remove No. 1 housing
assembly (42).
9. No. 2 disc, plate, and spring

1) Remove twelve springs (47).
2) Remove six discs (48), five plates (49), and
six springs (50) in turn.
2) Disassemble the No. 1 housing assembly

3) Remove seventeen sleeves (51).
2] Remove seal ring (45) from piston (43).

3] Remove seal ring (46) from housing (44).
D375A-6
(02)
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).
50-129
DRAFT
Power train
10. No. 1 ring gear and No. 2 and No. 3 carrier

assembly
1) Using eyebolts [6], lift off "No. 1 ring gear, No.
2 and No. 3 carrier" assembly (55).
2) Disassemble the "No. 1 ring gear, No. 2 and

No. 3 carrier" assembly according to the
1] Remove seal rings (57) and (58).
2] Remove ring (59).
50-130
3] Pull out shafts (61) halfway from carrier

(60), remove balls (62), and remove
shafts (61).

5] Remove needle bearings (65) from gears
(63).
a Since No. 2 and No. 3 carrier assembly (60) is embedded in No. 1 ring
gear (66), they cannot be disassembled.
D375A-6
(02)
DRAFT
Power train
11. No. 2 ring gear

Remove No. 2 ring gear (67).

12. No. 2 and No. 3 housing assembly

1) Using eyebolts [7], remove No. 2 and No. 3
housing assembly (68) together with the
upper and lower pistons.
a Bind the lower piston with a wire to prevent it from coming off.
4] Remove seal rings (74) and (75) from

housing (71).
2) Disassemble the No. 2 and No. 3 housing

1] Remove pistons (69) and (70) from
housing (71).
D375A-6
(02)

1) Remove the guide plate and remove twelve
springs (76).
2) Remove four discs (77), four springs (79),
and three plates (78) in turn.
a Keep the disc and plate on a flat surface
so that they do not warp.
50-131
DRAFT
Power train
14. No. 3 and No. 4 clutch plate

Using eyebolts [8], remove plate (80).

1) Remove three discs (81), three springs (83),
and two plates (82) in turn and remove guide
plate (147).
2) Remove six torque pins (84).
16. No. 4 housing assembly

1) Using eyebolts [9], remove housing
assembly (85) and the piston as a unit.
2) Disassemble the No. 4 housing assembly


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"

assembly
1) Operate tool D1 to turn the transmission
assembly sideways.
3) Remove snap ring (91) and plate (92).
7) Disassemble the "No. 3 ring gear, No. 4

carrier and No. 5 clutch" assembly according
1] Remove two seal rings (56) from the
housing.
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
(02)
50-133
DRAFT
Power train
5] Using the push too, remove ball bearing

(99) from collar (100).
6] Using eyebolts [11], remove No. 3 ring

gear and No. 4 carrier assembly (101)
together with the No. 4 sun gear.
7] Remove No. 4 sun gear (102) from No. 3
ring gear and No. 4 carrier assembly
(101).

collar (107) from No. 3 ring gear and No.
4 carrier assembly (101).
11] Remove seal ring (108) from collar (107).
12] Pull out shaft (110) halfway from carrier

(109), remove balls (111), and remove
shafts (110).
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

ring (115).
16] Reverse the carrier and remove ball
bearing (116) by using the push tool.
a Since No. 4 carrier (109) is embedded
in No. 3 ring gear (117), they cannot
be disassembled.
17] Set output shaft and housing assembly

(118) on the blocks with the output side of
the output shaft up.
18] Using the forcing screws, disconnect
input shaft and housing assembly (118)
and remove it by using eyebolts [12].
a Tighten the forcing screws evenly to
disconnect the output shaft and housing assembly.
D375A-6
(02)
19] Remove six discs (119), six springs (121),

and five plates (120) from housing (122)
in turn.
20] Set the output shaft and housing

assembly to the press and remove
housing assembly (123) from output shaft
assembly (124) by using push tool [13].
a Set blocks [14] under the housing assembly to prevent the housing assembly from falling out.
50-135
DRAFT
Power train
21] Set housing assembly (123) to the press

and compress the spring to remove snap
ring (125) by using tool D2.
a Operate the press slowly to push up
the spring evenly.
22] Remove retainer (126) and spring (127)
from housing (128).
23] Remove piston (129) from the housing.

Remove seal ring (130) from piston (129).
50-136
24] Remove seal ring (131) from housing

(128).
25] Remove snap ring (132) from the
housing.
26] Using the push tool, remove ball bearing
(133) from the housing.

needle bearing (135) from input shaft
(124).
28] Reverse the output shaft, remove snap
ring (136), and remove the roll bearing
(137) from the output shaft.
D375A-6
(02)
DRAFT
Power train
18. Rear case assembly

1) Remove collar (138) from rear case (139).
Assembly
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 installing.
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
(02)
50-137
DRAFT
Power train
2) Reverse rear case (139) and install collar

(138).
a Take care not to get the seal ring caught.
3. Output shaft assembly

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.
6) Reverse rear case (139), set output shaft

assembly (124) to the case, and press fit the
bearing portion by using the push tool.
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)
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"

assembly
1) Assemble the "No. 3 ring gear, No. 4 carrier
and No. 5 clutch" assembly according to the
q When No. 3 ring gear and No. 4 carrier
are supplied individually:
Using tool D3, compress ring (143), set
No. 3 ring gear (117) on No. 4 carrier
(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.
1] Using the push tool, press fit ball bearing

(116) to carrier (109) and fix it with snap
ring (115).
D375A-6
(02)
2] Reverse the carrier.

3] Install needle bearings (114) to gears
(112), fit thrust washers (113) to both
sides of the gears, and set them to the
carrier.
4] Fit balls (111) and install shafts (110) to
the carrier.
a Check that each gear rotates smoothly.
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
dowel hole with the dowel pin, and fix it
a Tap the dowel pin fitting portion with a
plastic hammer until the clearance between the mating faces is eliminated.
50-139
DRAFT
Power train
7] Install seal rings (105) and (104) to hub

(103).
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.
10] Install six discs (119), six springs (121),

and five plates (120) in turn.
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 figure below.
50-140
D375A-6
(02)
DRAFT
Power train
13] Install seal ring (130) to piston (129).

a Install the seal ring as shown in the figure below.
14] Install piston (129) to housing (128).
a Take care not to get the spring caught.
15] Set springs (127) and retainer (126) to the

housing.
a Set the three springs as shown in the
following figure.
16] Set housing assembly (123) to the press
and compress the springs to install snap
ring (125) by using tool D2.
a Installed load of spring:
2,175 N {222 kg}
D375A-6
(02)
17] Using bolt [16], install housing assembly

(123).
3 Mounting bolt:
176.4 19.6 Nm {18 2 kgm}
18] Install two seal rings (56) to the housing.
2) Reverse rear case (139) and "No. 3 ring

gear, No. 4 carrier and No. 5 clutch"
assembly (95).
3) Using eyebolts [10], set "No. 3 ring gear, No.
4 carrier and No. 5 clutch" assembly (95) to
the rear case and output shaft.
50-141
DRAFT
Power train
4) Using push tool [17], press fit the bearing

portion of "No. 3 ring gear, No. 4 carrier and
No. 5 clutch" assembly (95) to the output
shaft.
5. No. 4 sun gear

Install No. 4 sun gear (102).
2 Spline:
(LM-P)
2) Install collar and bearing assembly (98).

a Install the assembly with collar flange
side up.
3) Install No. 3 sun gear (97) and fix it with snap
ring (96).
2 Spline:
(LM-P)

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).

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
9. No. 3 and No. 4 clutch plate

Using eyebolts [8], install plate (80) aligning the
dowel holes with the dowel pins.
a Tap the dowel pin fitting portions with a plastic hammer until the clearance between 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
(02)
50-143
DRAFT
Power train
11. No. 1 ring gear and No. 3 housing assembly

1) Install seal rings (74) and (75) to housing
(71).
a Install the seal ring as shown in the figure.
4) Install pistons (70) and (69) to housing (71).

a Bind piston (70) with a fine wire to prevent
it from falling when the housing is lifted
up.

a Direct the seal ring as shown in the figure.
5) Install housing assembly (68) aligning the

dowel holes with the dowel pins.
50-144
D375A-6
(02)
DRAFT
Power train
12. No. 2 ring gear

Install ring gear (67).
13. "No. 1 ring gear and No. 2 and No. 3 carrier"

assembly
1) Assemble the "No. 1 ring gear and No. 2 and
No. 3 carrier" assembly according to the
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
(02)
1] Install needle bearings (65) to gears (63),

fit thrust washers (64) to both sides of the
gears, and set them to carrier (60).
2] Fit balls (62) and install shafts (61) to the

carrier.
a Check that each gear rotates smoothly.
50-145
DRAFT
Power train
3] Install ring (59) to the carrier.

a Check that the ring is fitted securely
into the groove.
4] Install seal rings (58) and (57) to the
carrier.
a Align seal ring (58) with the carrier and
fix it with grease (G2-LI).

1) Install six torque pins (53).
a Torque pin length: 199 mm
2) Install seal ring (52) to the No. 2 and No. 3
carrier.
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.
4) Install twelve springs (47).

5) Install six discs (48), four springs (50), and
five plates (49) in turn.
a Align the notches of the oil grooves on the
periphery of the discs.
3) Install piston (43) to housing (44).

4) Using eyebolts [5], install housing (42)

aligning the dowel holes with the dowel pins.
a Check that the springs are fitted securely
into the grooves of the housing.

1) Install seal ring (46) to housing (44).
a Install the seal ring as shown in the figure.
D375A-6
(02)
50-147
DRAFT
Power train
16. No. 1 clutch ring gear

Install No. 1 clutch ring gear (41).

1) Install the guide plate and install twelve
springs (37).
2) Install six discs (38), six springs (40), and five
plates (39) in turn.
2] Fit balls (34) and install shafts (33) to the

carrier.
3] Install collar (31) to the carrier and fix it
4] Using push tool [19], press fit ball bearing

(28) to plate (25) and fix it with snap ring
(27).
18. Input shaft and No. 1 carrier assembly

1) Assemble the input shaft and No. 1 carrier
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 lubricant (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
(02)
50-149
DRAFT
Power train
14] Using the push tool, press fit ball bearings

(13) and (14) to spacer (15).
15] Install spacer and bearing assembly (12).

a Install the assembly with the small-diameter bearing toward the No. 1 sun
gear.
2 Spline:
16] Install No. 2 sun gear (11) and fix it with
snap ring (10).
2 Spline:
3) Evenly tighten four tie bolts (12) on the diagonal line.

4) Tighten remaining tie bolts (12).
3 Tie bolt:
259.7 14.7 Nm {26.5 1.5 kgm}
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 checking that its end does not interfere with the
output shaft bearing.
50-150
D375A-6
(02)
DRAFT
Power train
19. Checking piston stroke

Using tool D5, check the stroke of each clutch
piston.
a Air pressure: 490 588 kPa {5 6 kg/cm2}
a Standard stroke of piston
Piston
Stroke (mm)
No. 1 No. 2 No. 3 No. 4

6.7
7.0
5.6
4.7
No. 5
7.0
20. Front case

Fit the O-ring and install front case (6) by using
the eyebolts.
a Lower the front case gradually while checking that it does not interfere with other parts.
D375A-6
(02)
21. Output shaft bearing

1) Set the transmission assembly with the
output shaft side up.
2) Using the push tool, press fit roller bearing
(137) to the output shaft and fix it with snap
ring (136).
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.
22. Lubrication valve assembly

Install lubrication valve assembly (5).
50-151
DRAFT
Power train
23. Control valve assembly

1) Install gasket (G) to the control valve.
3 Mounting bolt:
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)
(OUT): Outside face of cover

(IN): Inside face of cover
(HL): Bolt holes
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 assembly, take care not to scratch or damage 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
3] Using forcing screws [1], remove sleeve

(7).
4] Using puller [2], pull out bearing inner
race (8) from the sleeve.
D375A-6
(02)
50-153
DRAFT
Power train
3] Remove torque pins (15).

4] Using eyebolts, remove clutch hub (16).
5] Remove plate (17), using forcing screws
[4].
6] Remove outer race (18) from the plate.

7] Remove bearing and cage assembly
(19).
8] Remove plate (21) and nut (22) from cage

(20).
9] Remove bearing and inner race (23),
spacers (24) and (25), and bearing outer
race (26).
50-154
10] Remove clutch cage (27) by using

eyebolts.
11] Remove seal ring (28) from the clutch
cage.
12] Remove piston (29).
14] Remove bearing outer race (31) from the

clutch cage.
15] Remove Belleville springs (32).
D375A-6
(02)
DRAFT
Power train
16] Using eyebolts [6], remove brake hub

(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
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
(02)
50-155
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 removed.
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
(02)
50-157
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
a Apply engine oil to the rotating part of the bearing, and rotate it several times.
a Also, apply engine oil to the sliding parts before
installing.
a Check that the snap ring securely fit into the
groove.
1. Left cage
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}
2. Bevel gear and shaft assembly

1) Assemble the bevel gear and shaft assembly
as follows:
inner races (78) and (77).
2] Set bevel gear (75) to shaft (76), and
secure them by tightening the reamer
bolts.
3 Reamer bolt :
274.4 29.4 Nm {28 3 kgm}
2) Install bevel gear and shaft assembly (74)
using the eyebolts.
3. Right cage
1) Using eyebolts [14], install cage (73) in position.
D375A-6
(02)
50-159
DRAFT
Power train
2) Install the shims and install cage and bearing

assembly (72).
a Standard thickness of shims: 2 mm
3 Cage and bearing assembly mounting
bolts:
176.4 19.6 Nm {28 2 kgm}
3] Press fit bearing outer race (69) into the

cage using the push tool.
4] Install bearing inner races (67), (66) and
collar (68).
outer race (65).
4. Preload adjustment
Adjust the rotating force of the bevel gear shaft
by adjusting the thickness of shims on the cage.
a Rotate the bevel gear two or three times, and
place the push-pull scale onto the tip of the
gear teeth to measure the force.
a Rotating force (when bevel gear is not engaged):
4.9 5.88 N {0.5 0.6 kg}
(Rotating torque: 23.52 28.42 Nm {2.4
2.9 kgm})
6] Using push tool [18], press fit inner race

(61) to pinion gear (60).
7] Install the holder.
276.85 31.85 Nm {28.25
3.25 kgm}
8] Install gear (64) and collar (63) to the
pinion gear.
2 Spline of gears:
5. Transfer and gear housing assembly

1) Assemble the transfer and gear housing
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

bearing assembly (62).
10] Install holder (59).
276.85 31.85 Nm {28.25
3.25 kgm}
11] Tighten the mounting bolts of cover (58)

in the order shown in the following figure
and to the torque shown below, to install
the cover temporarily.
3 Mounting bolts: 49 Nm {5 kgm}
D375A-6
(02)
12] Check clearance (A) between the cover

and cage, and check that it is as follows.
a Clearance (A) : 0.48 0.27 mm
a Make sure that the variation of entire
periphery is 0.05 mm maximum, bearings have been press fitted completely
and are not at an angle.
13] Tighten the mounting bolts of cover (58)

to the specified toque in the following
order.
3 Mounting bolt:
66.15 7.35 Nm {6.75 0.75
kgm}
50-161
DRAFT
Power train
14] Installing the shims to pinion housing

assembly (57), and install the housing
using eyebolts [11].
a Standard thickness of shims: 2 mm
15] Install lubrication tube (56).

(53).
19] Install bearing assembly (52) to the case.
20] Install lubrication tube (51) together with
the block.

inner races (55) to both sides of the drive
gear.
17] Set drive gear (54) to the case.
2 Spline of gear:
2) Install guide bolt [8] to the steering case.

Using eyebolts [9], install transfer and gear
housing assembly (50) in position.
3 Mounting bolt:
276.85 31.85 Nm {28.25 3.25
kgm}
50-162
D375A-6
(02)
DRAFT
Power train
6. Adjusting backlash and tooth contact

1) Adjusting backlash
Testing
Apply the probe of dial gauge [22] to the tooth
surface at the top of the bevel gear at right
angle to the surface. Holding the bevel pinion
stationary, wiggle the bevel gear forward and
and backward, and read the gauge at this
time.
a Standard backlash: 0.3 0.4 mm
a Measure the backlash at diagonal three
points or more.
Adjusting
If the measured backlash is out of the standard range, adjust it according to the
following procedure:
1] When backlash is too small
Adjust the thickness of the shim pack for
the bevel pinion to move it in direction (A).
Or, adjust the thickness of the shim packs
for the bearing cages of the bevel gear
shaft to move the bevel gear in direction
(B).
D375A-6
(02)
2] When backlash is too large

the bevel pinion to move it in direction (C).
Or, adjust the thickness of the shim packs
for the bearing cages of the bevel gear
shaft to move the bevel gear in direction
(D).
a When adjusting the thickness of the shim
packs for the bearing cages of the bevel
gear shaft, if the thickness of the shim
pack on one side is decreased, increase
the thickness on the other side by the
same quantity and vice versa, in order not
to change the preload of the bearings.
2) Adjusting tooth contact

Testing
1] Apply red lead thinly to the tooth surfaces
of the bevel pinion and turn the bevel gear
in the forward and reverse directions,
then check the tooth contact pattern left
on tooth surfaces of the bevel gear.
(Be): Big end
(Se): Small end
(Rt): Root of tooth
(Tt): Top of tooth
50-163
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 conditions; the taper roller bearings supporting the bevel gear are given with the
preload, the bevel gear is meshed only
with the bevel pinion, and no load is applied.
a Check that the center of tooth contact is at
the center of the tooth height and there is
not a strong contact at the dedendum.
The contact pattern must be made in
almost the same position when the bevel
gear is rotated in forward and reverse
directions.
(Be): Big end
(Se): Small end
2] If the bevel pinion is too close to the

center line of the bevel gear, the contacts
are at the convex faces close to the big
end and concave faces close to the small
end of the bevel gear.
[Adjustment]
The adjustment is the same as that
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 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 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]
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

1) Install steering control valve and seat
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}
8. Pipes
1) Install pipe (49).
2) Install left and right pipes (48).
9. Shaft
Install left and right shafts (46).
10. Lubrication tube

Install lubrication tubes (47), (47-1), and (47-2).
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.
2] Install seal ring (44) to piston (43).
3] Install piston (43).

4] Install torque pins (42).
5] Install seal ring (41) and bearing outer
race (40) to the brake cage using the
push tool.
D375A-6
(02)
50-165
DRAFT
Power train
6] Using eyebolts [7], install brake cage (39)

in position.
3 Mounting bolt:
110.25 12.25 Nm {11.25
1.25 kgm}
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.
2] Install brake hub (33) to the clutch

housing, using eyebolts [6].
3] Install Belleville springs (32).
a Set the Belleville springs back to back
to 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).

a Using the push tool, hold the cage
with the press, and use a hook wrench
to tighten the nut.
11] Install bearing and cage assembly (19) in

position.
12] Using the push tool, install outer race (18)
to the plate.
D375A-6
(02)
13] Install plate (17).

3 Mounting bolt:
110.25 12.25 Nm {11.25
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.
18] Install stopper (11).
3 Mounting bolt:
276.85 31.85 Nm {28.25
3.25 kgm}
50-167
DRAFT
Power train
3) Connect the clutch assembly to the brake

assembly as follows:
1] Using eyebolts [13], install brake
assembly (10) to clutch assembly (9).
inner race (8) to the sleeve.
4] Install plate (6).

3 Mounting bolt:
110.25 12.25 Nm {11.25
1.25 kgm}
5] Fit collar (5) and install plate (4).
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 position.
a If the bevel gear is locked and it is hard to insert 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
k Stop the engine, and disconnect the cable
from the negative terminal of the battery.
Installation
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
(02)
50-169
DRAFT
Power train
Removal and installation of scavenging pump assembly

Removal
Installation
q
Refilling (Power train case)

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
Symbol
Part No.
Part name
J 1 790-337-1001 Lifting tool
Necessity
Q'ty
New/remodel
Sketch
Special tools
t 1
Removal
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 backward 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
(02)
50-171
DRAFT
Power train
Installation
[*1]
a If it is difficult to insert the shaft into position,
push up the shoe grouser by using a jack or other 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
3
Final drive assembly mounting bolt :

Adhesive (LT-2)
Final drive assembly mounting bolt :
1,720 190 Nm {175 20 kgm}
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
3
4
791-580-3200 Remover
Puller
790-101-2102
(294 kN {30 ton})
790-101-1102 Pump
791-580-3300 Installer
Puller
790-101-2102
(294 kN {30 ton})
790-101-1102 Pump
791-580-3400 Remover
Puller
790-101-2102
(294 kN {30 ton})
790-101-1102 Pump
Puller
790-101-2102
(294 kN {30 ton})
790-101-1102 Pump
Remover and
790-431-1230
installer
Puller
790-101-2102
(294 kN {30 ton})
790-101-1102 Pump
790-431-1250 Guide
D375A-6
(02)
t 1
t 1
t 1
t 1
Sketch
Part name
Q'ty
Part No.
New/remodel
Symbol
Necessity
Special tools
1. Draining oil
Remove the drain plug and drain the oil from the
final drive case.
6 Final drive case: Approx. 61 l
2. Sprocket
1) Place the final drive assembly on blocks
(approx. 50 mm high).
2) Remove sprocket (1).
t 1
t 1
t 1 N
t 1
t 1
t 1
t 1
t 1
t 1
t 1
t 1
t 1
t 1
3. Cover
Using eyebolts [1], remove cover (2).
50-173
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).
2) Using tool J2, disconnect sprocket hub

assembly (6) at the press-fitting portion of
bearing (7).
3) Using eyebolts [3], remove sprocket hub
assembly (6).
50-174
5) Turn over the sprocket hub assembly, then

remove floating seal cover (9) and bearing
outer races (10) and (11).
6) Remove floating seal (12) from the floating
seal cover.
a Take care not to damage the floating
seal, and keep it in a safe place.
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
(02)
50-175
DRAFT
Power train
3] Remove holders (21).

4] Using tool J7, remove planetary gear
shafts (22).
5] Remove planetary gears (23), bearing

inner races (24A) and (24B), and spacers
(24C).
9. Sun gear and shaft assembly

1) Remove sun gear and shaft (25).
2) Remove plate (25-1) and bearing inner race
(26-2).
3) Remove plate (25-2) and sun gear (27).
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

1] Remove gear (32) from hub (33).
2] Remove hub (33) from boss (34).
3] Using the puller, remove bearing outer
races (35) from boss (34).
11. Cage assembly

1) Using eyebolts [7], remove cage assembly
(39).
2) Remove shims (40).
a Note the quantity and thickness of shims
for installation purpose.
4) Using eyebolts [6], pull out shaft assembly

(31) from the case.
5) Disassemble the shaft assembly as follows.
1] Remove collar (36).
2] Remove bearing inner race (37) and
collar (38).
3) Disassemble the cage assembly as follows:

1] Using puller [8], remove bearing outer
race (41).
2] Remove oil seal (42).
D375A-6
(02)
50-177
DRAFT
Power train
12. Gear assembly

1) Remove gear assembly (44).
2) Using puller [9], remove bearing inner races
(45) and (46) from the gear.
Assembly
a Clean all parts, and check them for dint and
dents. Apply engine oil to the sliding surface before 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 inside 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
1) Using push tool [14], press fit bearing inner
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 installed.
2] Press fit bearing outer race (41) with push

tool [15].
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 pressure 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
(02)
50-179
DRAFT
Power train
3) Using feeler gauge [16] as shown in the

figure below, measure the clearances (a) and
(b) between cage (A) and case (B), at the two
points "m" distance away from bolts (C) and
(D), respectively.
4) Determine total thickness (c) of the shim
pack and select shims to use according the
table below.
5) Insert the shims selected in Step 4 in position, 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.
4. Hub and shaft assembly

1) Assemble the shaft assembly as follows.
1] Install collar (38).
2] Press fit bearing inner race (37) by using
push tool [17].
3] Install collar (36).
2) Using eyebolts [6], install shaft assembly (31)

to the case.
3) Assemble the hub assembly as follows.
outer race (35) to boss (34).
(a) + (b) [mm]

Larger
than
Below
1.6
1.8
2.0
2.2
2.4
2.6
2.8
3.0
3.2
3.4
3.6
3.8
4.0
4.2
4.4
4.6
4.8
5.0
5.2
5.4
5.6
1.8
2.0
2.2
2.4
2.6
2.8
3.0
3.2
3.4
3.6
3.8
4.0
4.2
4.4
4.6
4.8
5.0
5.2
5.4
5.6
5.8
50-180
Number of shims to be
used
t=
0.1
t = 0.5
1
2
3
4
1
2
3
4
1
1
1
1
1
1
2
3
4
1
2
3
4
5
1
1
1
1
1
1
t = 1.0
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
Total thickness of
shims
(c) [mm]
1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3.0
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.
5) Tighten mounting bolts of hub assembly (29).

3 Mounting bolt:
276.85 31.85 Nm {28.25 3.25
kgm}
3 Mounting bolt:
548.8 58.8 Nm {56 6 kgm}
7) Install gear (32).
3 Mounting bolt:
539 49 Nm {55 5 kgm}
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
marks on the inner race, outer race and
spacer when assembling.
*1. Bearing ID mark
*2. Spacer ID mark
(ID mark "MZ-12B" is an example in this
figure.)
1] Install the rings and spacer to the planetary 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
(02)
50-181
DRAFT
Power train
2] Install spacer (24C) and bearing inner

races (24B) and (24A) to each planetary
gear (23), and set it to the carrier.
3] Using tool J7, press fit planetary gear

shaft (22) in position.
a Press fit the shaft gradually matching
the holes of the bearing and spacer.
4] Install holder (21).
3 Mounting bolt:
548.8 58.8 Nm {56 6 kgm}
a After tightening the bolts, check that
each gear rotates smoothly.
50-182
2) Install bearing (26-1) and spacer (26) to

carrier assembly (20).
3) Using eyebolts [5] , install carrier assembly

(20).
7. Cover assembly
1) Assemble the cover assembly as follows.
1] Fit ring gear (19) and install the plate.
a Install the plate with its chamfered surface up.
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
(02)
50-183
DRAFT
Power train
9. Sprocket hub assembly

1) Using tool J4, install floating seal (12) 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.
4) Set bearing (8) to the sprocket hub

assembly.
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.
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).

3 Mounting bolt:
276.85 31.85 Nm {28.25 3.25
kgm}
12. Sprocket
Install sprocket (1).
2 Mounting bolt:
(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
(02)
50-185
DRAFT
Removal and installation of track frame assembly

Symbol
Part No.
195-30-68610
01010-62450
01010-62455
22
19M-54-11770
01643-32460
198-30-66190
L
195-30-69540
01011-82410
23 01011-82420
19M-54-11770
195-30-69550
24 791-685-1320
Part name
Plate
Bolt
Bolt
Washer
Washer
Collar
Plate
Bolt
Bolt
Washer
Collar
Lifting tool
Necessity
Q'ty
New/remodel
Sketch
Special tools
t
t
t
t
t
t
t
t
t
t
t
t
6
6
6
6
6
6
2
2
2
4
2
1
N
N
N
N
N
5. Using tools L22 and L23, lcok the bogies.

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

8. Remove grease tube (4).
10. Loosen front and rear bolts (6-1).
a Bolt: M30; Width across flats: 46 mm
[*1]
13. Remove the mounting bolts and remove cover

(7) from the track frame.
[*1]
[*2]
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 removed easily. Adjust the lifting height of
the track frame properly.
a Put "UP" mark on the top of the pin for installation 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 specification 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
(02)
50-187
DRAFT
17. Disconnect hoses (12) and (13) from the inside

face of cover (11), and remove cover (11). [*4]
or both track frames of the dual tilt specifications machine.
a Note the color of hose band for installation
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
19. Remove seal (15) and cover (14) as a unit. [*6]

or both track frames of the dual tilt specifications machine.
20. Remove washer (16) and spacer (17).

RH: Both dual tilt and single tilt specifications
21. Using tool L24, lift off track frame assembly (18).
4 Track frame: 7,940 kg (each)

[*5]
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
a Take care not to install seal (19) twisted to the
track frame.
a When replacing seal (19), see "Removal and installation of pivot shaft assembly".
[*1]
a Install covers (2) and (3), and tighten bolts (6-1).
3 Covers (2) and (3):
245 309 Nm {25 31.5 kgm}
[*2]
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:
a When replacing the pivot shaft bushing of track
frame assembly, install a new bushing with its
abutment joint up.
D375A-6
(02)
50-189
DRAFT
[*4]
q Install the hoses taking care not to install hoses
with wrong band colors.
a Hose band colors
(Single tilt specification)
(12a) (13a)
Right track frame: Red (Dual tilt specification)
(12a) (13a)
Right track frame: Red (12a) (13a)
Left track frame: Blue RH: Both dual tilt and single tilt specifications
[*5]
a Install cover (14) using three bolts (indicated by
arrows).
[*6]
a Completely degrease the contact surface (15) of
seal when mounting it.
2 Contact surface of seal (15): Liquid gasket
(LG-6)
a Be careful not to twist the seal when installing it.
50-190
Refilling (Pivot shaft case)

level.
5 Pivot shaft case: 18 l (EO30)
D375A-6
(02)
DRAFT
Removal and installation of idler assembly

Removal
see "Separation and connection of track shoe
assembly".
2. Remove scraper (1).
a Remove the inside scraper, too.
a Remove the inside cover, too.
Installation
a For both the right and left idler assemblies,
install the assembly with the oil filler plug facing the left side of machine.
a Tighten idler cap mounting bolts in the following order.
Tightening order:
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
(02)
50-191
DRAFT
Disassembly and assembly of idler assembly

4. Turn over idler assembly (1).
Symbol
Part No.
791T-630-2210
791-530-1630
790-101-2510
790-101-2570
1 01580-01613
01643-31645
L
790-101-2102
790-101-1102
2 791-515-1520
3 791-685-8310
4 791-601-1000
Part Name
Necessity
Quantity
N/R
Sketch
Special tools
Plate
Rod
Block
Washer
Nut
Washer
t
t
t
t
t
t
Puller
(294 kN {30 ton})
t 1
Pump
Installer
Push tool
Oil pump
1
2
1
2
2
2
5. Remove the mounting bolts. Using eyebolts [3],

remove shaft (5) and the retainer as a unit.
6. Using puller [4], remove retainers (3) and (7),
and seal guide (6).
t 1
t 1
t 1
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.
140 mm high).
7. Remove seal guides (2) and (6) from retainers

(3) and (7) respectively.
3. Remove mounting bolts, then using forcing

screws [2], remove seal guide (2), retainer (3)
and plate (4) as a unit.
8. Remove plates (4) and (8) from the respective

retainers.
50-192
D375A-6
(02)
DRAFT
9. Remove respective floating seals (9) from seal

guides (2) and (6).
a Keep the floating seal in a safe place so that
it does not get damaged.
10. Remove respective floating seals (10) from
retainers (3) and (7).
a Keep the floating seal in a safe place so that
it does not get damaged.
Assembly
a Clean all parts and check them for dirt and damage before installing.
1. Place bushings (11) and tool L1 on idler (12),
and press fit bushings (11) in position.
a First, center the bushing with a plastic hammer, then press fit with the puller.
a Press fit the bushing so that press-fitting dimension (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 portions) 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 protrusion (a) of the seal is between 7 to 11 mm.
D375A-6
(02)
50-193
DRAFT
3. Install retainer (3) with the O-ring and plate (4) to

the idler.
a Check that the plate can be turned smoothly
with the hand.
4. Using eyebolts [3], install idler (12) to shaft (5).

a Place blocks (approx. 140 mm high) under
the idler.
5. Turn over the idler assembly.
a Tie the shaft with wire to prevent it from falling out.
50-194
6. Install retainer (7) with the O-ring and plate (8) to

the idler.
7. Using tool L2 install respective floating seals (9)

to seal guides (2) and (6).
a For installation procedures, refer to Step 2.
8. Set seal guide (2) to the shaft, and press fit seal
guide (2) by using tool L3.
a Press-fitting force of seal guide: 43 71 kN
{4.4 7.2 tons}
D375A-6
(02)
DRAFT
a Press fit the seal guide so that press-fitting dimension (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
(02)
50-195
DRAFT
Removal and installation of recoil spring assembly

5. Lift off trunnion (3).
4 Trunnion: 75 kg
791-730-1110 Bolt
01580-12722 Nut
01643-32780 Washer
M 1
Puller
790-101-2102
(294 kN {30 ton})
790-101-1102 Pump
t 6
t 6
t 1
Sketch
Part name
New/remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
t 1
t 1
Removal
see Separation and connection of track shoe
assembly.
k Set the parking brake lever and work
equipment lock lever in the lock position.
2. Drain the oil from the recoil cylinder chamber by
using the oil pump.
6 Recoil cylinder chamber: Approx. 50 l

a Remove both the inside and outside covers.
7. Using tool M1, remove pin (5).
[*1]
a Remove both the inside and outside pins.
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]
a Keep the assembly horizontal by using lever
blocks, and take care not to damage the oil
seal installed on the track frame during removal.
4 Idler and idler cushion assembly:
2,180 kg
2) Loosen idler yoke assembly mounting bolts

(9) on diagonally opposite sides gradually in
turn.
[*4]
k For safety reasons, no one is allowed
to be in front of the idler yoke during
the work.
k The recoil spring mounted in the recoil
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
(02)
50-197
DRAFT
3) Check that the loosening torque of all the

bolts suddenly drop. If so, it indicates that the
installed load of the recoil spring is not
applied on the mounting bolts. Then, remove
all bolts.
a If the torque increases (the installed load
of the recoil spring is applied) during the
loosening operation, stop the loosening
operation and disassemble as follows.
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 assembly 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 assembly is separated from the idler
cushion assembly and the recoil
spring is removed.
50-198
1] Prepare the following parts of tool M1:

q Bolt
[1] (6 bolts): Part No.
791-730-1110
q Nut [2] (6 nuts): Part No. 01580-12722
q Washer [3] (6 washers): Part No.
01643-32780 (may be used ones)
2] Remove six bolts marked with*, then

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.
D375A-6
(02)
DRAFT
5] Loosen bolts until the recoil spring is

extended completely and the loosening
torque of nuts [2] is reduced. Then,
remove bolts [1].
a When clearance (b) reaches approx.
230 mm, the spring is extended completely.
12. Disassemble piston assembly (15) as follows.

1) Remove wear rings (16) from the piston.
2) Remove snap ring (17), then remove packing
(18).
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
(02)
50-199
DRAFT
Installation
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 assembly of idler cushion assembly".
[*4]
2
3
Idler yoke assembly mounting bolt :

Adhesive (LT-2)
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
pilot (8) from spring (4).
Symbol
M 2
Part No.
Part Name
Necessity
Quantity
N/R
Sketch
Special tools
791-685-8501
Compressor
t 1
790-101-1600
Cylinder
(980 kN {100 ton})
t 1
790-101-1102
791-635-3160
Pump
Extension
t 1
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 {approx. 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
(02)
50-201
DRAFT
Assembly
1. Install pilot (8), bolt (7), spacer (6), and rear pilot
(5) to spring (4), and set them to tool M2.
3. Install nut (3), and install lock plate (2) in position.

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.
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
790-401-1700
790-401-1761
12
790-401-1540
790-401-1770
195-30-68610
01010-62450
01010-62455
22
L
19M-54-11770
01643-32460
198-30-66190
195-30-69540
01011-82410
23 01011-82420
19M-54-11770
195-30-69550
D375A-6
(02)
Lifting tool
Adapter
Shackle
T-bolt
Plate
Bolt
Bolt
Washer
Washer
Collar
Plate
Bolt
Bolt
Washer
Collar
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
1
1
2
2
6
6
6
6
6
6
2
2
2
4
2
Sketch
Part name
Q'ty
Part No.
New/remodel
Symbol
Necessity
Special tools
Removal
1. Decrease the track tension. For details, see
"Separation and connection of track shoe
assembly".
N
N
N
2. Install tools L22 or L23 to lock bogie assembly

(1) to be removed.
[*1]
S: Single flange type
D: Double flange type
N
N
50-203
DRAFT
3. Raise the machine until track roller assembly (2)

leaves the track by operating the blade and
ripper.
4. Place steel plate [1] on the track and operate the
blade and ripper to lower the machine until the
track roller assembly comes in contact with the
steel plate.
a Operate the blade and ripper slowly, running
the engine at the low speed.
7. Using the crane and tool L12, pull out track roller
assembly (2) on the steed plate to the outside of
the machine.
4 Track roller assembly:
150 kg (single flange)
160 kg(double flange)
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
[*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 between 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
(02)
50-205
DRAFT
Disassembly and assembly of track roller assembly

6. Using the press, remove seal guide (6), retainer
(7) and plate (8) as a unit from the shaft.
Symbol
Part No.
8
9
L
10
11
791T-630-2220
796-670-1020
791T-630-2230
791-601-1000
Part Name
Plate
Installer
Push tool
Oil pump
Necessity
Qty
New/remodel
Sketch
Special tools
t
t
t
t
1
1
1
1
7. Remove seal guides (2) and (6) from retainers

(3) and (7).
Q
Q
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
screws [2], remove seal guide (2), retainer (3)
and plate (4) as a unit.
8. Remove respective floating seals (9) from seal

guides (2) and (6).
a Keep the floating seal in a safe place to protect it from damage.
4. Turn over the track roller assembly.

5. Remove the mounting bolts, then using eyebolts
[3], remove shaft (5) and the retainer as a unit.
50-206
9. Remove respective floating seals (10) from

retainers (3) and (7).
a Keep the floating seal in a safe place to protect it from damage.
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
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
hammer, then press fit it with the press.
a Press fit the bushing so that press-fitting dimension (a) from the end face of the roller to
the top surface of the bushing is as follows .
q Press-fitting dimensions (a): 17 0.5 mm
2. Set shaft (5) to the roller.
D375A-6
(02)
5. Using tool L9, install respective floating seals (9)

to seal guides (2) and (6).
6. Using tool L10, press fit seal guide (2) to the
shaft.
a Seal guide press-fitting force:
36 63 kNm {3.7 6.4 ton}
50-207
DRAFT
a Press fit the seal guide so that press-fitting dimension (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 according 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

Removal
1. Decrease the track tension. For details, see
"Sepatation and connection of track shoe
assembly".
Installation
[*1]
a Make a clearance (a) of 1.75 mm between the
carrier roller and support.
2 Carrier roller assembly mounting bolt :
Adhesive (LT-2)
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).
4 Carrier roller assembly: 75 kg
D375A-6
(02)
[*1]
50-209
DRAFT
Disassembly and assembly of carrier roller assembly

5. Using tool L7, remove nut (4).
Symbol
4
5
L
6
7
Part No.
791-601-1000
791-515-1520
791-830-1770
791-630-1270
Part Name
Oil pump
Installer
Push tool
Wrench
Necessity
Quantity
N/R
Sketch
Special tools
t
t
t
t
6. Using puller [2], remove the press-fitted seal

guide, and remove bearing (5) and roller (6) as a
unit using eyebolts.
1
1
1
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
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
(02)
50-211
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 protrusion (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 position.
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
(02)
50-213
DRAFT
Removal and installation of bogie assembly
Symbol
1
2
3
4
14
5
Part No.
791-630-2260
790-201-2730
791-630-2270
01580-12419
01643-32460
6 790-101-4000
L
7
1
2
3
4
15 5
6
790-101-1102
791-630-2280
790-201-2770
791-630-2250
790-434-1070
01580-13629
01643-33690
7 790-101-4000
8 790-101-1102
Part name
Plate
Spacer
Screw
Nut
Washer
Puller
(490 kN {50 ton})
Pump
Adapter
Spacer
Plate
Screw
Nut
Washer
Puller
(490kN {50ton})
Pump
Necessity
Q'ty
New/remodel
Sketch
Special tools
t
t
t
t
t
Symbol
1
2
3
16 4
1
1
3
3
3
1
1
1
1
1
2
2
6
17
18
19
22
t 1
t 1
791-630-2260
791-630-2270
01580-12419
01643-32460
5 790-101-4000
t 1
t
t
t
t
t
t
t
Part No.
23
790-101-1102
791T-630-2290
791-530-1510
791-601-1000
195-30-68610
01010-62450
01010-62455
19M-54-11770
01643-32460
198-30-66190
195-30-69540
01011-82410
01011-82420
19M-54-11770
195-30-69550
Part name
Necessity
Q'ty
New/remodel
Sketch
Plate
Screw
Nut
Washer
Puller
(490 kN {50
t
t
t
t
Pump
Guide
Installer
Oil pump
Plate
Bolt
Bolt
Washer
Washer
Collar
Plate
Bolt
Bolt
Washer
Collar
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
1
3
3
3
t 1
1
2
1
1
6
6
6
6
6
6
2
2
2
4
2
Q
N
N
N
N
N
N
Removal
1. Decrease the track tension. For details, see "Separation and connection of track shoe assembly".
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

leave the track links, by operating the blade and
ripper.
k Place a block between the track roller and
the track link so that the machine does
not lower.
4. Set block [1] outside of the track shoes,
matching it to the height of the track link.
8. Removal of shaft and ring

1) Set tool L14 in position.
2) Push out shaft (3) and ring (4) to the opposite
side simultaneously.
a Pressing force: 137.2 274.4 kN {14 28
tons}
Pressing force C 1.8 x Average pressure
(Set the pressing force by adjusting the
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
(02)
50-215
DRAFT

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).
7) Remove spacer (9) and floating seals (10)
between rings (7) and (8).
8) Pull out the shaft and rings on the opposite
side of the bogie according to above steps 1)
to 7).
2) Sling bogie assembly (1).

3) Loosen roller cap bolts (20) for approx. 20
mm. (Loosen both the inside and outside
bolts.)
4) Hit the end of shaft (21) with a hammer to
remove track roller assembly (22).
a Take care not to damage the dowel pin installed to the shaft of the track roller assembly. (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.
12. Sling bogie assembly (1), slide it on steel plate
[2] to remove.
4 Bogie assembly: 720 kg
50-216
7) Perform Steps 9 to 13 to remove bogie

assembly (1).
D375A-6
(02)
DRAFT
Installation
1. Assembly of pin assembly.
1) Using tool L18, install respective floating
seals (5) to rings (4) and (7). Also, install
respective floating seals (10) to the opposite
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.
2. Apply lever block [3] between the guard of bogie

assembly (1) and that of the bogie assembly on
the opposite side, slide bogie assembly (1) on
the steel plate, and place it in the mounting position.
3. Align pin holes of the track frame and bogie with

each other, and set guidance tool L17 in position.
2)
3)
4)
5)
6)
Press fit shaft (3) to ring (8).

Install spacer (9).
Press fit ring (7) to shaft (3).
Install spacer (6).
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
(02)
50-217
DRAFT
2) Press fit the pin assembly.

a Install the pin assembly with arrow (a) on
its end face up (when it is mounted on the
machine).
a Push in the pin assembly with cover (2).
a Push in the pin assembly to machined
face (b) of the bogie.
2 Periphery of pin:
a Press-fitting force of pin assembly:
245 441 kN {25 45 tons}
6. Press fit the pin assembly on the opposite side of

the bogie according to above steps 3 and 4.
7. Tighten the mounting bolts of pin assembly
cover (2) (2 covers on inside and outside).
927 103 Nm {94.5 10.5 kgm}
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
Symbol
1
2
3
16 4
Part No.
791-630-2260
791-630-2270
01580-12419
01643-32460
5 790-101-4000
6 790-101-1102
19 791-601-1000
Part Name
Plate
Screw
Nut
Washer
Puller
(490 kN {50 ton})
Pump
Oil pump
Necessity
Qty
New/remodel
Sketch
Special tools
t
t
t
t
1
3
3
3
3. Remove the pin assembly following the same

procedure as described in the "Removal of bogie
assembly".
(See Step 8.)
4. Disconnection of bogie
Disconnect inner bogies (4) from outer bogie (5).
t 1
t 1
t 1
Disassembly
Reverse bogie assembly (1). Then, lift off two
track roller assemblies (2).
D375A-6
(02)
50-219
DRAFT
Assembly
1. Assembly of pin assembly
Assembly the pin assembly following the same
procedure as described in the "Installation of
bogie assembly".
(See Steps 3 to 5.)
4. Refilling
Using tool L19, supply the specified amount of
oil.
2. Set inner bogies (4) to outer bogie (5).

3. Press-fitting of pin assembly
machine).
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.
2 Periphery of pin:
a Total press fitting force of pin assembly :
245 441 kN {25 45 ton}
5. Press fit the pin assembly at the opposite side of

bogie in the same way as shown in Steps 3 and
4.
a After press-fitting of pin assembly, rock the
small bogie so that it can move smoothly.
6. Tighten the mounting bolts of pin assembly
cover (3) (two covers, inside and outside).
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
Symbol
1
2
3
4
14 5
Part No.
791-630-2360
790-201-2730
791-630-2270
01580-12419
01643-32460
6 790-101-4000
7
1
2
3
4
5
15
6
790-101-1102
791-630-2280
790-201-2770
791-630-2250
790-434-1070
01580-13629
01643-33690
7 790-101-4000
L
16
8
1
2
3
4
790-101-1102
791-630-2260
791-630-2270
01580-12419
01643-32460
5 790-101-4000
6
17
18
19
790-101-1102
791T-630-2290
790-434-1350
791-601-1000
1 791-630-1860
20 2 791-630-1870
3 01010-62760
4 01643-32780
791T-630-1900
791T-630-1910
791T-630-1920
21 07283-38973
04530-11628
01643-31645
01643-31232
01582-01210
D375A-6
(02)
Part name
Plate
Spacer
Screw
Nut
Washer
Puller
(490 kN {50
ton})
Pump
Adapter
Spacer
Plate
Screw
Nut
Washer
Puller
(490 kN {50
ton})
Pump
Plate
Screw
Nut
Washer
Puller
(490 kN {50
ton})
Pump
Guide
Installer
Oil pump
Bracket
(L, H)
Bracket
(R, H)
Bolt
Washer
Lifting tool
q Tube
q Plate
q Grip
q Eyebolt
q Washer
q Washer
q Nut
Necessity
Q'ty
New/remodel
Sketch
Special tools
t
t
t
t
t
1
1
3
3
3
t 1
t
t
t
t
t
t
t
1
1
1
1
1
2
2
Removal
assembly.
2. Raise the machine so that the track rollers of the
second bogie assembly leave the track link, by
operating the blade and ripper.
k Place a block between track roller and
track link so that the machine does not
lower.
3. Install eyebolts to the pad mounting bolts (two
M12 bolts) at the rear of the first bogie assembly,
and lift the first bogie assembly (1).
t 1
t
t
t
t
t
1
1
3
3
3
t 1
t
t
t
t
1
2
1
1
t 1 N
t 1 N
t 2
t 2
q 1
1
1
1
1
1
2
2
Q
Q
50-221
DRAFT
4. Place an steel plate between the track shoe and

roller, and loosen roller cap bolts (2) for approx.
20 mm.
(both inside and outside)
5. Hit the end face of shaft (3) with a hammer to
remove track roller assembly (4).
a Take care not to break the dowel pin installed
on the front side (oil plug side) of the track
roller assembly.
(Insertion depth of dowel pin: 5 6 mm)
9. Pulling out shaft and ring

2) Push out shaft (7) and ring (8) to the opposite
side simultaneously.
a Pressing force: 137.3 274.6 kN {14 28
tons}
a To avoid an interference with the idler
when pressing the ring, pump grease in
the track tension adjusting section in advance to move the idler cushion forward.
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
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}
7) Remove spacer (14) and floating seals (10)
between rings (12) and (13).
2)
3)
4)
5)
6)
Press fit shaft (7) to ring (13).

Install spacer (14).
Install spacer (11).
2 Part (a) of ring (13) and ring (8) (approx. 10 mm):
(LM-P)
10. Lower bogie (5) on the steel plate and pull it out.
D375A-6
(02)
50-223
DRAFT
2. Place bogie (5) on steel plate [1], and slide them

beneath the center of the mounting position.
3. Using tool L20, set the bogie to the mounting
position.

machine).
a Push in the pin assembly to machined
surface (b) of the bogie and maintain step
of 5 mm between bogie and pin assembly.
2 Periphery of pin:
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.
5. Press-fitting of pin assembly

50-224
D375A-6
(02)
DRAFT
7. Press fit the pin assembly at the opposite side of

the bogie following the same procedure in Steps
5 and 6.
8. Install covers (6) (two covers, inside and
outside).
9. Install eyebolts to the bolt holes of the pad
mounting bolts (M12 x 2 pieces) of bogie (5) and
sling the bogie.
10. Insert tool L21 into the shaft of track roller

assembly (4), lift and balance the track roller
assembly, and place it on the track shoes.
D375A-6
(02)
11. Gradually lower the machine and when the

clearance between bogie (5) and shaft (3)
becomes approx. 20 mm, install cap (15) and
tighten bolts (2) partially.
12. Matching the dowel hole with the dowel pin,
tighten bolts (2) to the specified torque.
2 Cap mounting bolt: Adhesive (LT-2)
3 Cap mounting bolt:
1,180 1,470 Nm {120 150 kgm}
13. Adjust the track tension. For details, see Testing

and adjusting, "Inspection and adjustment of
track tension".
50-225
DRAFT
Separation and connection of track shoe assembly

Separation
1. Remove the blade assembly. For details see
"Removal and installation of blade assembly".
Checking before separation of the track shoe assembly

k In some cases, it may be extremely dangerous to separate the track shoe assembly. To
prevent danger, perform the following
checks before separation of the track shoe
assembly.
k Do not loosen the lubricator more than one
turn.
q Loosen lubricator (2) of the adjustment cylinder 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, follow the procedure in the "Separation of
track shoe assembly (normal)".
a Because the machine needs to move later,

do not disconnect battery cables.
50-226
If the track tension is not decreased and is

still high, a problem may have occurred inside 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, follow the procedure in the "Separation of
track shoe assembly (when track frame
has internal defect)".
D375A-6
(02)
DRAFT
Separation of track shoe assembly

(When track frame has internal defect)
a If any abnormality is detected by "Checking before separation of track shoe assembly", perform
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 dangerous. Be sure to separate the track shoe assembly as follows.
4. Sling the front end of master link (3), move the

machine backward slowly to spread track shoe
assembly (5).
a Length of track: Approx. 12.5 m
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
(02)
50-227
DRAFT
Separation of track shoe assembly (normal)

a If no abnormality is detected by "Checking before separation of track shoe assembly", perform
1. Position the master link properly.
a Locate master link (3) above the idler (a little
backward from the center).
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.
2. Loosen lubricator (2).

[* 1]
k Do not loosen lubricator (2) more than
one turn.
50-228
3. Remove track shoe (4).

[*2]
a Loosen each of four bolts by one or two turns.
Check that they can be unscrewed smoothly,
and then remove them. Do not remove only
one bolt without loosening the other three.
a If a bolt does not turn smoothly and it is unscrewed forcibly, the threads of the bolt and
master link (3) may be damaged.
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
k For purposes of safety, check that no one
remains in front of the idler.
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 faces of the master link are fitted.
a If the bolts are tightened forcibly before the master 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:
(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
(02)
50-229
DRAFT
Overall disassembly and assembly of track shoe
Symbol
1
2
3
Part No.
Part name
791-646-7351 Push tool

791-660-7460 Pin brush
Push tool
791-646-7900
(For large plug)
791-701-3000 Seal checker

or
791-601-1000 Oil pump
791-932-1110
Push tool
(For small plug)
Necessity
Q'ty
New/remodel
Sketch
Special tools
t 1
t 1
t 1
t 2
t 1
t 1
Push tool assem1 791-632-1300
t 1 N
bly
1
2 791-632-1260 q Push tool
3 791-632-1270
4 791-632-1220
Adapter
A d a p t e r
(small)
5 791-632-1230
Ring
7 6 791-632-1240
Plate
7 791-685-5730
Bar
8 791-632-1250
Ring
9 791-632-1280
Spring
10 01252-30605
Bolt
11 01580-01210
Nut
Overall disassembly
a For the overall disassembly of the track shoe assembly,
see
Parts
judgment
guide,
Undercarriage, Lubricated track" and Parts
judgment guide, Undercarriage, Reversing procedure for pin and bushing.".
1. Removal of track shoe
Lift the track shoe assembly and place the
assembly on the floor with shoes (1) up. Remove
the track shoes by using shoe bolt impact
wrench [1].
a If shoe bolt (2) is not loosened (if its rotational
torque is not reduced to zero) even after it is
loosened by one turn, loosen other bolts so
that the bolt can be loosened smoothly.
a Forcibly rotating the bolt the rotational torque
of which is not reduced to zero may cause
adhesive transformation between the bolt
and link, which may require repairs.
a When repositioning the track shoe assembly,
take care not to damage the master links.
a If the shoe nut needs to be removed by gas
cut, keep the temperature in the seal section
below 80 C to prevent thermal deterioration of the seals and take measures to prevent the spatters from entering through the
clearances between the links.
Push tool assemt 1 N

bly
1
2 791-632-1260 q Push tool
1 791-632-1200
3 791-632-1270
4 791-632-1210
Adapter
A d a p t e r
(large)
5 791-632-1230
Ring
8 6 791-632-1240
Plate
7 791-685-5730
Bar
8 791-632-1250
Ring
9 791-632-1280
Spring
10 01252-30650
Bolt
11 01580-01210
Nut
Push tool assemt 2 N

bly
9
2 791-685-5730 Bar
1
3 01580-01210 Nut
1
1 791-632-1290
50-230
2. Disassembly of track links

1) Place the link assembly on the link press and
hit it with a hammer to fit the bushing to jaw
[2] firmly.
a If the link tread or outer periphery of the
bushing is worn, adjust the height of jaw
[2] or guide plate to align the pin or bushing with the disassembly jigs so that the
pin-bore or bushing-bore in the link is not
damaged during disassembly.
D375A-6
(02)
DRAFT
a If the pin or bushing is not aligned with the

jig, the bore in the link may be damaged
or the pin or bushing may be broken during disassembly.
a Using tool R5, drive in the small plug of
the pin after disassembly so that the work
place does not become dirty.
3) Return the left cylinder and operate the right

cylinder to pull out the pin and bushing from
the right link simultaneously.
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. Accordingly, 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
(02)
50-231
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
and the inside diameter of the link bores
where the pin and bushing are press fitted to
by using micrometer [5] and cylinder gauge
[6], to see if the allowable interference is
obtained. Note that the standard interference
must be secured between the pin and link
when they are reused for a lubricated track.
a If the allowable interference is not obtained, replace the parts with new ones.
a For the dimensional criteria, see "Maintenance standard".
50-232
a Precautions for storage

1) Store the seal without removing it from the
link so that the link bore does not rust, and
take care not to damage the seal lip.
2) Apply rust-preventive oil to the pin and
bushing press-fitting bores, shoe mounting
surface of the link, and mating face of the
master link.
3) Apply rust-preventive oil to the all surfaces of
the pin, bushing, and spacer prior to storage.
Take extreme care not to damage the
bushing end faces.
D375A-6
(02)
DRAFT
Overall assembly
a For the overall assembly of the track shoe assembly,
see
Parts
judgment
guide,
Undercarriage, Lubricated track" and Parts
judgment guide, Undercarriage, Reversing procedure 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) quickly because they are easily deteriorated by
the cleaning agent (trichloroethylene,
etc.). Wipe off the cleaning agent with a
cloth from them.
2) When reusing the pin, chamfer the edges of

its end faces with a grinder. Remove the
nodules formed on its press-fitting portions
with the grinder.
a If the edge of its end face is worn and
sharpened, the press-fitting portion of the
pin may cause galling, resulting in oil
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 because doing so may cause oil leak.
D375A-6
(02)
4) If the large plug was removed from the pin,

drive in large plug (5) by using tool R3.
At this time, clean the pin hole in advance by
using tool R2.
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
is not damaged.
a If the hole face of the pin is chamfered
with the grinder, clean the pin hole
again by using tool R2.
a Apply oil (GO90) on the outside periphery of the plug, and drive it with its
smaller diameter end facing pin (6).
50-233
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. Accordingly, take care not to allow any oil to adhere 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 installed 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

that the pressing force of the press does not
exceed the standard value.
a If the pressing force is excessive, the
spacer is pressed against the bushing excessively. As a result, the spacer may be
broken or abnormal wear may occur between the spacer and bushing end face.
a Pressing force for pin and bushing:
980 kN {100 ton}
Pressing force C 1.8 x Average pressure
(Adjust the relief pressure of the link
press to obtain the pressing force.)
2. Assembly of link
1) Apply oil (GO90) on the mating faces of pin
and bushing with a clean brush and
assemble them, then set them on the
bushing jaw of the link press.
a When reusing the bushing (by turning it
180 degree), set it with the worn outside
surface facing the shoe mounting face of
the link (set the bushing on the link press
with the face up).
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
(02)
50-235
DRAFT
3) While checking the distance between the

shoe bolt holes of the right and left master
links by using the shoe bolt pitch gage, press
fit the master links to the bushing until the
distance is the standard value.
a Remove all steel chips generated by the
press-fitting process completely with
compressed air.
4) Turn over the master links and check that

they are press fitted in parallel.
5) Measure the right and left protrusions of the
bushing by using depth gauge [7].
a Adjust the link press press-fitting jigs so
that the right and left protrusions of the
bushing are even.
50-236
6) Send out the master link portion, and then set

the next pins and bushings.
a Install the pin, even it is reused, with its
cross hole (its direction is indicated with
mark (e)) facing the link tread as in the
case of new one.
If it is not installed so, the strength of the
assembly may be lowered. Accordingly,
indicate the direction of the cross hole on
the end face to prevent wrong installation.
7) Apply liquid gasket (198-32-19890) to all

surfaces of pin press-fitting portion (f) and
link bore (g).
a This prevents the galling of the pin
press-fitting portion that may cause oil to
seep out.
D375A-6
(02)
DRAFT
8) Set the right link and install the spacer to the

pin.
a Check that the seal surfaces and bushing
end faces are free from dirt, then apply oil
(GO90) on them using a clean cloth or
brush.
a Wipe the spacer with a clean cloth before
installing.
9) Using the right jig as receiver jig and the left

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}
10)Use minor adjustment spacer (8) to press fit

the pin until its end face reaches the bottom
of the receiver jig.
a Adjust the depth of the receiver jig hole so
that the right and left protrusions of the pin
are even.
11)Set the left link and install the spacer to the

pin.
a Apply oil similarly to the right link.
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
(02)
50-237
DRAFT
13)Perform the press fitting until the link,

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.
15)Set the ring on jig R8.
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 abnormality is found.
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 relevant part.
50-238
17)Using jig R9, install the ring into the pin

groove on the other side similarly.
D375A-6
(02)
DRAFT
18)Press the ring by using jig R10.

a Pressing force: 294 372 kN {30 38
ton}
a For cold or extremely cold district, supply

Komatsu
genuine
engine
oil
(150-09-19270 or 195-32-61990), which
has excellent low-temperature characteristics, 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 196.1294.2 kPa
{23 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
(02)
50-239
DRAFT
3. Installation of track shoe

1) Place the link assembly on the bed, and
install track shoes (1) by using shoe bolt
impact wrench [1] and torque wrench.
3 Shoe bolt (2) (Regular link)
Initial torque:
1,372 140 Nm {140 14 kgm}
2 Shoe bolt:
(LM-P)
2) For the track that has two master link joints

and consists of two track shoe assemblies,
connect the two track shoe assemblies as
follows. 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].
50-240
D375A-6
(02)
DRAFT
Reusing the link assembly for grease lubricated

track
1. Cleaning of seal assembly
1) Cleaning of seal assembly
q Remove 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)
quickly because they are easily deteriorated by the cleaning agent. Wipe off
the cleaning agent with a cloth from
them.
3) Clean any dirty surfaces among the outside

periphery of the pin, spacer surface, and end
faces and inside surface of the bushing.
4) Drive in the large plug by using tool R3.
1] Insert the plug in the hole of the guide
through the plug inserting window. (Apply
oil to the plug.)
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:
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
(02)
50-241
DRAFT
5) Apply grease on the outside periphery of the

pin and surfaces of the spacer.
6) Installation of seal assembly
q Clean the bores of the link, and push in
the seal to the bottom by using tool R6.
a Do not apply grease to the link bores
and the seal assembly because any
adhered grease causes the seal to
turn and its sealing performance is
lowered.
2. Assembly of link
1) Apply lithium grease (G2-LI) on the mating
faces of the pin and bushing and assemble
them, then set them on the bushing jaw of the
link press.
a When reusing the bushing (by turning it
180 degree), set it with the worn outside
surface facing the shoe mounting face of
the link (set the bushing on the link press
with the face up).
7) 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 For the standard dimensions of the link
press press-fitting jigs, see "Link press
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 installed dimensions of the press-fitting jigs
so that the right and left protrusions of the
pin and bushing are even.
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.
196 343 kN {20 35 ton}
50-242
D375A-6
(02)
DRAFT
3) While checking the distance between the

shoe bolt holes of the right and left master
links by using the shoe bolt pitch gage, press
fit the master links to the bushing until the
distance is the standard value.
a Remove all steel chips generated by the
press-fitting process completely with
compressed air.
4) Turn over the master links and check that
they are press fitted in parallel.
5) Measure the right and left protrusions of the

bushing by using depth gauge [7].
a Adjust the link press press-fitting jigs so
that the right and left protrusions of the
bushing are even.
D375A-6
(02)
6) Send out the master link portion, and then set

the next pins and bushings.
a Install the pin, even it is reused, with its
cross hole (its direction is indicated with
mark (e)) facing the link tread as in the
case of new one.
If it is not installed so, the strength of the
assembly may be lowered. Accordingly,
indicate the direction of the cross hole on
the end face to prevent wrong installation.
a If a pin has worn outside periphery, it is to

be installed with its un-worn periphery toward the traction side. Even in this case,
the pin must be installed with its cross
hole facing the link tread.
50-243
DRAFT
7) Set the left and right links, and operate the

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.)
9) Set the ring on jig R8.
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.
a Pump in grease (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).
a Dimension (L): 40 70 mm
3. Installation of track shoe (to regular links)

Place the link assembly on the bed, and install
track shoes (1) by using shoe bolt impact wrench
[1] and torque wrench.
2 Shoe bolt (2):
(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
(02)
50-245
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)
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
Unit: mm
(a)
(b)
(c)
Jig dimensions
4.2
2.0
52.1
Precaution
The link receiving face of jaw(1) must be vertical.
Replaceable wear plate (2) shown below is desirable.
D375A-6
(02)
50-247
DRAFT
Disassembly and assembly of one link assembly in the field
1
2
3
4
5
6
1
2
3
4
R
5
6
7
8
9
7 10
11
12
13
14
15
16
17
18
19
20
50-248
Part No.
Part name
791-646-7351 Push tool

791-660-7460 Pin brush
Push tool (for
791-646-7900
large plugs)
791-701-3000
Seal checker oil
or
pump
791-601-1000
Push tool (for
791-932-1110
small plug)
Remover &
791-632-1100
installer assembly
791-632-1130 q Adapter
790-434-1610 q Guide
01010-51440 q Bolt
791-685-9510 q Frame
791-685-9530 q Rod
791-685-9520 q Frame
791-685-9550 q Nut
04530-12030 q Eyebolt
791-685-9560 q Bolt
791-126-0150 q Adapter
791-685-9540 q Rod
791-632-1140 q Adapter
791-680-5520 q Guide
01010-51030 q Bolt
791-632-1150 q Pusher
791-685-9620 q Extension
791-632-1180 q Adapter
791-680-5543 q Adapter
791-632-1170 q Guide
t 1
t 1
t 1
Symbol
21
22
23
24
t 2
R 7 25
t 1
26
t 1
27
t 1
28
1
1
2
1
1
1
3
1
4
1
1
1
1
1
1
1
1
1
1
Part No.
Part name
791-680-5551 q Guide
791-680-9630 q Adapter
791-632-1160 q Guide
195-32-61210 Bolt
Cylinder
790-101-4300 (1,470 kN {150
ton})
790-101-1102 Pump
Cylinder
790-101-4200
(294 kN {30 ton})
791-680-1630 Spacer
Necessity
Q'ty
New/remodel
Sketch
Symbol
Necessity
Q'ty
New/remodel
Sketch
Special tools
1
1
1
2
t 1
t 1
t 1
t 1 N Q
Disassembly
q Separate the track shoe assembly. For details,
assembly.
a Move the machine forward or backward to
bring the link assembly to be disassembled
to a position where tool 7 can be easily installed on the link when the track shoe assembly is separated.
1. Install tool R7-2 on link (1) with R7-24, and install
tool R7-3 to the link with R7-4.
a Use the shoe bolts for installing R7-24.
D375A-6
(02)
DRAFT
2. Assemble tools R7-25 and R7-5 to R7-11, then

sling them to place on the shoe.
4. Set tools R7-13 to R7-16, connect tool R7-26,

and then apply oil pressure to pull out the pin (2).
3. Insert tool R7-12 from the cylinder side, and

install it by using two R7-8.
a If cylinder reaches its stroke end, connect

tool R7-17 and repeat the work.
D375A-6
(02)
50-249
DRAFT
5. Set tools R7-27 and R7-28 in the middle of the

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.
6. Repeat steps 1 to 4 to pull out another pin (3) on

the other side.
7. Repeat step 5 to remove links (4).
Assembly
1. Assemble the link sub-assembly according to
1) Set tool R7-18 to the bushing-bore end of link
(5), and press fit bushing (6).
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) facing 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

connected.
4. Similarly to the disassembly procedure, set tools

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 installed in step 3, then press fit the bushing-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
(02)
50-251
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
1
2
3
4
5
6
1
2
3
4
5
6
7
R
8
9
10
11
12
7 13
14
15
16
17
18
19
20
21
22
23
24
25
D375A-6
(02)
Part name
791-646-7351 Push tool

791-660-7460 Pin brush
Push tool (for
791-646-7900
large plug)
791-701-3000
Seal checker oil
or
pump
791-601-1000
Push tool (for
791-932-1110
small plug)
Remover &
791-632-1100 installer assembly
791-632-1130 q Adapter
790-434-1610 q Guide
01010-51440 q Bolt
791-685-9510 q Frame
791-685-9530 q Rod
791-685-9520 q Frame
791-685-9550 q Nut
04530-12030 q Eyebolt
791-685-9560 q Bolt
791-126-0150 q Adapter
791-685-9540 q Rod
791-632-1140 q Adapter
791-680-5520 q Guide
01010-51030 q Bolt
791-632-1150 q Pusher
791-685-9620 q Extension
791-632-1180 q Adapter
791-680-5543 q Adapter
791-632-1160 q Guide
791-680-5551 q Guide
791-680-9630 q Adapter
791-632-1160 Guide
195-32-61210 Bolt
Cylinder
790-101-4300 (1,470 kN {150
ton})
t 1
t 1
Sketch
Part No.
New/remodel
Symbol
Necessity
Q'ty
Special tools
Symbol
t 1
t 2
t 1
t 1
t 1
1
1
2
1
1
1
3
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
2
10
Part No.
Part name
26 790-101-1102 Pump
Cylinder
27 790-101-4200
(294 kN {30 ton})
28 791-680-1630 Spacer
bly
2 791-632-1260 q Push tool
3 791-632-1270 q Adapter
4 791-632-1220 q Pin (small)
5 791-632-1230 q Ring
6 791-632-1240 q Plate
7 791-685-5730 q Bar
8 791-632-1250 q Ring
9 791-632-1280 q Spring
10 01252-30605 q Bolt
11 01580-01210 q Nut
bly
2 791-632-1260 q Push tool
3 791-632-1270 q Adapter
4 791-632-1210 q Pin (large)
5 791-632-1230 q Ring
6 791-632-1240 q Plate
7 791-685-5730 q Bar
8 791-632-1250 q Ring
9 791-632-1280 q Spring
10 01252-30650 q Bolt
11 01580-01210 q Nut
bly
2 791-685-5730 Bar
3 01580-01210 Nut
N
N
e S
e
Q w/ k
c
't re et
e
y m c
ss
od h
ity
el
t 1
t 1
t 1
t 1 N
1
1
1
1
1
1
1
1
1
1
t 1 N
1
1
1
1
1
1
1
1
1
1
t 2 N
1
1
t 1
50-253
DRAFT
Disassembly
a For the method of using tool R7, see "Disassembly of one link assembly in the field."
1. Removal of track shoe assembly
Remove the track shoe assembly from the track
frame. For details, see Separation of track shoe
assembly.
2. Disassembly of track shoe assembly
Disconnect the all master link joints to divide the
track into two track shoe assemblies.
3. Removal of master link
q For master pin type
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 machine
2) Removal of regular link

Press pin (1) downward as shown by the
arrow by using the press to pull it out from link
(2), and then pull out the pin (1) and the other
link (2) as a unit from bushing (3).
50-254
For master link type

1) Gas cut and removal of master link with
bushing-bore.
Gas cut the pin and bushing along the wavy
lines and remove the hatched parts. Move
master links (4) vertically as shown by the
arrow to remove them, and then pull out
remaining pins (5a) and (5b) press fitted in
respective regular links (2) by moving them
vertically as shown by the arrow using the
press.
q Necessary special tools:
1. Gas cutting machine
2. Tool R7
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
out pin (6) and link (2b) as a unit from bush
(3).
q Special tools:
1. Gas cutting machine
2. Tool R7
D375A-6
(02)
DRAFT
Assembly
a For the method of using tool R7, see "Disassembly of one link assembly in the field."
2) Set spacers (6) and seal assemblies (7) to

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 master 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
253.40.7
D1
33 Drill
D2
30 2.0
2. Installation of master link with bushing-bore

1) Increase the space between the links at the
centers of their treads by using tool R7 as
a: 5 mm
(Increase by 10 mm between the ends of the
links.)
D375A-6
(02)
3) Match the pin bores of the links and the bores

for bushing (3) of the master links, and fix
them with guide pin [1].
4) Press fit pin (5) by using tool R7 to install

master links with bushing bore (4).
2 Pin press-fitting bore in link:
Liquid gasket (198-32-19890)
a Install the pin with its cross hole facing the
link tread.
5) Install the rings by using tool R7 and tools
R8, R9, and R10.
50-255
DRAFT
6) Install the track shoe to the links of the

connecting part.
7) 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 master links, take care so that the links are in
parallel (both for master links with bushing bore and pin-bore).
a Do not damage the mating face of the
master link and the end faces of the
bushing.
a Adjust the end play of the connecting part
(the thrust end play between the links
connected with the pin) to 0 - 0.13 mm.
a Take care not to allow dirt, sand, or dust
to attach the seal, spacer, end face of the
bushing, and the master link mating face
with tap holes.
3. Assembly of master link with pin-bore
1) Set spacers (6) and seal assemblies (7) to
the bores of master links (4a).
(3): Bushing
50-256
2) Pass pin (5) through bushing (3), set right

and left master links with pin-bore (4), and
press fit them from both sides by using tool
R7.
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.
4. Connection of master links

Place the two track shoe assemblies on a level
place in a line with the track shoes up. Pull
master links with pin-bore (4a) of one assembly
and master links with bushing-bore (4b) together
to contact their mating faces each other. Place
the track shoe on the master links, and
finger-tighten the shoe bolts for master link so
that their mating faces are in close contact. Then
tighten the bolts to the specified torque to
complete the connection.
Initial torque: 686 68.6 Nm {70 7
kgm}
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]
791T-650-2330
791T-650-2340
790-201-3310
790-101-2510
790-101-2570
01580-01613
01643-31645
790-105-2300
790-101-1102
Sleeve
Plate
Bolt
Block
Washer
Nut
Washer
Jack assembly
Pump
t
t
t
t
t
t
t
t
t
1
1
2
1
2
2
2
1
1
Sketch
1
2
3
4
P 5
6
7
8
9
Part name
Q'ty
Part No.
New/remodel
Sym
-bol
Necessity
Special tools
N Q
N Q
Removal
1. Remove the track frame assembly.
For details, see "Removal of track frame
assembly".
2. Sling pivot shaft assembly (1), remove the
mounting bolts, and pull out the pivot shaft
assembly using forcing screws [1].
[*1]
4 Pivot shaft assembly: 390 kg
D375A-6
(02)
Installation
[*1]
Pivot shaft press-fitting surface:

[*2]
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 dimension.
q Press-fitting dimension (a) : 665 1.0 mm
50-257
DRAFT
Removal and installation of equalizer bar
791-650-1300
791-735-1123
790-434-1050
01580-02419
N 1
01643-32460
790-101-2102
790-101-1102
Remover
Sleeve
Screw
Nut
Washer
Puller
(294 kN {30 ton})
Pump
Sketch
Part name
New/remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
4. Remove washer (4), then remove spacer (5).

a Oil will flow out from the pivot case, so use a
container to receive the oil.
6 Pivot case: 18 l
t 1
1
1
1
t 1
t 1
Removal
5. Place hydraulic jack [1] (490 kN {50 ton }) under

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]
[*2]
7. Remove grease tube (7-1).

[*2]
9. Loosen clamping bolts (9-1) and (9) of the equalizer bar side pin.
[*3]
a Bolt: M30, Width accross flats: 46 mm
50-258
D375A-6
(02)
DRAFT
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 removed easily. Adjust the height of the equalizer by operating hydraulic jack [1].
a Put an "UP" mark at the top of the pin.
D375A-6
(02)
50-259
DRAFT
17. Raise the front of the machine by operating the

blade, and place stand [3] under the radiator
guard.
Installation
[*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]
18. Sling equalizer bar (15) and remove it clearing

the main frame and the track frames.
k Do not lower the machine after removing
the equalizer bar.
4 Equalizer bar assembly: 500 kg
50-260
Bolts (9) and (9-1):

1,960 2,450 Nm {200 250 kgm}
[*4]
2 Inside surface of bushing: Grease (G2-LI)

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.
D375A-6
(02)
DRAFT
[*5]
Lock plate mounting bolt :

549 59 Nm {56 6 kgm}
[*6]
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
(02)
50-261
DRAFT
Disassembly and assembly of equalizer bar bushing

3) Set tool N2 to remove side bushing (4) from
equalizer bar (5).
Symbol
Part No.
1
2
3
N 2 4
5
791T-650-2410
791T-650-2420
790-438-1110
791-112-1180
790-101-2540
Part name
Bracket
Bracket
Screw
Nut
Washer
Puller
6 790-101-2102
(294kN {30ton})
7 790-101-1102 Pump
Necessity
Q'ty
New/remodel
Sketch
Special tools
t
t
t
t
t
1 N Q
1 N Q
1
2
2
t 1
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
1. Side bushing
1) Set side bushing (4) and tool N2 to press fit
side bushing (4) to equalizer bar (5).
2 Outside surface of side bushing:
(LM-P)
a Install the side bushing in the direction
shown in the following figure.
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:
34.3 73.5 kN {3.5 7.5 ton}
D375A-6
(02)

a After installing the snap ring, fill parts (c)
before and after the side bushing with
grease (G2-LI).
2 Grease to be supplied to side bushing:
0.3 l
3) Press fit seals (2) by using the press.
a Press-fitting force for seal:
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)
2. Center bushing
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}
50-263
DRAFT
Removal and installation of segment tooth

Removal
1. Set the segment tooth to be removed to a position where it can be removed easily (between the
track and track frame).
k Park the machine on a level surface and
lower the work equipment to the ground.
Installation
2
Seat of segment tooth mounting nut:

(LM-P)
Segment tooth mounting nut:
1,813 98 Nm {185 10 kgm}
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
(02)
50-265
DRAFT
Hydraulic system
Removal and installation of hydraulic tank assembly
Hydraulic system
Removal
k
k
k
Park the machine on a level surface and lower the work equipment to the ground.
Set the parking brake lever and work equipment lock lever in the lock position.
Release the internal pressure of the hydraulic tank and residual pressure inside the piping. For details, see Testing and adjusting
"Releasing residual pressure of hydraulic
circuit".
Stop the engine and disconnect the cable
1. Drain the hydraulic tank.

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.
3. Loosen drain valve (2) to drain oil in the suction

hose.
a Prepare a container to catch the oil, and take
care not to allow the drained oil to splash any.
50-266
D375A-6
(02)
DRAFT
Hydraulic system
5. Disconnect main valve return hose (5) and fan

motor return hose (6) from the hydraulic tank.
6. Disconnect suction tube (8).

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
(02)
8. Remove four hydraulic tank mounting bolts (16).
9. Lift off hydraulic tank assembly (17).

4 Hydraulic tank assembly: 240 kg
[*1]
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Hydraulic system
Installation
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 system. 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
k Release the internal pressure of the hydraulic tank and residual pressure inside piping.
For details, see Testing and adjusting "Releasing residual pressure of hydraulic circuit".
1. Drain the hydraulic tank.
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.
3. Loosen drain valve (2) to drain oil in the suction

hose.
a Prepare a container to catch the oil, and take
care not to allow the drained oil to splash any.
4. Remove the floor plate and brake pedal

1) Remove inspection cover (3).
D375A-6
(02)
50-269
DRAFT
Hydraulic system
2) Disconnect connectors DEC (4) and BRK (5).

3) Remove the mounting bolts of floor plate (6).
4) Remove brake rod (7) according to the
[*1]
1] Raise floor plate (6) and support it with a
block.
2] Remove cotter pin (8), and then remove
nut (9) under floor plate (6).
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).
5. Remove the cover according to the following

procedure.
1) Remove covers (10), (11) and (12).
2) Remove headlamp protection cover (13).
3) Remove the mounting bolts of battery case
(14) and reposition battery case (14)
outward.
4) Remove covers (15) and (16).
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).

a Also disconnect two hose clamps.
8. Disconnect mounting bracket (20) of the wiring

clamp from filter assembly (21).
9. Disconnect wiring clamps (22), (23), and (24)
from filter assembly (21).
10. Remove twelve mounting bolts (25) and (25a) of
the filter assembly.
Never operate the crane while implementing steps 2) and 3). This is very
dangerous.
4) Pull out filter assembly (21) toward frame

(29) keeping the assembly level.
5) Lift off filter assembly (21) at an angle gradually.
11. Remove filter assembly (21) according to the

[*2]
1) Lift filter assembly (21) to the position very
close to frame (26).
2) Disconnect tube (27).
3) Disconnect connector (28).
D375A-6
(02)
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DRAFT
Hydraulic system
12. Remove hose (30).

13. Disconnect suction tube clamp (31).
[*3]
[*1]
a Install the brake rod according to the installed dimensions noted when it is removed.
a Be sure to bend the split pin installed on the cotter pin.
a Adjust the brake rod. For details, see Testing
and adjusting "Adjusting brake pedal and parking brake lever".
[*2]
a Install the filter assembly aligning it with the
block so that the O-ring does not come off.
15. Disconnect tube (33) from work equipment
pump assembly (34).
[*3]
Clamp mounting bolt:

24.5 29.4 Nm {2.5 3.0 kgm}
Refilling (hydraulic tank)

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

.
Removal
k Loosen the oil filler cap of the hydraulic oil
tank gradually to release the internal pressure of the hydraulic tank.
9. Loosen suction tube clamp (8) and disconnect

suction tube (9).
1. Drain the oil from the hydraulic tank.

"Removal and installation of fuel tank assembly."
"Removal and installation of ROPS guard
assembly."
4. Remove the operator cab assembly. For details,
see "Removal and installation of operator cab
assembly."
10. Remove two mounting bolts (10) and lift off fan
pump assembly (11).
4 Fan pump assembly: 80 kg
a Steps 2 to 5 are not required when removing
the pump unit only.
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
(02)
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DRAFT
Hydraulic system
Installation
q
(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

.
Removal
.
k Release the internal pressure of the hydraulic tank and residual pressure inside piping.
For details, see Testing and adjusting "Releasing residual pressure of hydraulic circuit".
a Note the connection points of each disconnected
hose.
3. Disconnect three hose clamps (9).
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
(02)
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Hydraulic system
5. Disconnect hoses (11) to (24).

(11): Ripper tilt BACK
(12): Ripper tilt IN
(13): Ripper lift RAISE
(14): Ripper lift LOWER
(15): Blade left tilt BACK (Only for dual tilt specification machine)
(16): Blade left tilt DUMP (Only for dual tilt specification 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
6. Remove four control valve mounting bolts (25).

7. Lift off control valve assembly (26).
4 Control valve assembly: 130 kg
Installation
(Refilling)
q
Air bleeding
Testing and adjusting "Bleeding air from the
work equipment cylinder".
.
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D375A-6
(02)
(06)
Hydraulic system
Disassembly and assembly of control valve assembly
a This section provides only the precautions when

assembling the control valve assembly.
Assembly
a Clean all parts, check them for dirt and damage,
and apply oil to the sliding surfaces before installing.
3. Assembly of suction valve assembly

Check that O-ring (38) is fitted to suction valve
assembly (37), and install suction valve
assembly (37) to valve body (1).
3 Suction valve assembly (37):
176.6 196.1 Nm {18 20 kgm}
1. Assembly of main relief valve assembly

Check that O-ring (3) is fitted to main relief valve
assembly (2), and install main relief valve
assembly (2) to valve body (1).
3 Main relief valve assembly (2):
176.6 196.1 Nm {18 20 kgm}
4. Assembly of check valve assembly

1) Install valve (39) and spring (40) to valve
body (1).
2) Fit backup ring (42) and O-ring (41) to plug
(43), and install plug (43) to valve body (1).
3 Plug (43):
176.6 196.1 Nm {18 20 kgm}
2. Assembly of LS relief valve assembly

a Install backup ring (15), O-rings (16) and (17)
to LS relief valve assembly (14), and install
LS relief valve assembly (14) to valve body
(1).
3 LS relief valve assembly (14):
137 157 Nm {14 16 kgm}

Check that O-ring (45) is fitted in check valve
assembly (44), and install check valve assembly
(44) to valve body (1).
3 Check valve assembly (44):
58.8 78.5 Nm {6 8 kgm}
D375A-6
(06)
(02)
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Hydraulic system
6. Installation of plug
1) Installation of plug (46)
1] Install retainer (50) to valve body (1).
2] Install O-ring (47) and backup ring (42) to
plug (46).
3 Plug (46):
274.6 367.7 Nm {28 37.5 kgm}
2) Installation of plugs (51) to (60)
a Check that O-ring or backup ring is fitted
to each plug, and then install the plug to
valve body (1).
3 Plug:
(51) (2 places):
176.6 196.1 Nm {18 20 kgm}
(52) (2 places), (53) and (58) (2
places):
19.6 27.5 Nm {2 2.8 kgm}
(Blade tilt valve)

1) Install spool (19a) to valve body (1a).
2) Fit spring (20a), O-ring (23a), backup ring
(22a) and O-ring (21a) to plug (24a), and
install plug (24a) to valve body (1a).
3 Plug (24a):
372.7 465.8 Nm {38 47.5 kgm}
50-278
(54), (55):
107.8 140.7 Nm {11.0 15.0
kgm}
(56): 29.4 39.2 Nm {3 4.8 kgm}
(57):
107.7 161.8 Nm {12 16.5 kgm}
3) Installation of plugs (58) and (59)
1] If plugs (58) (2 places) are removed, wrap
sealing tape around the thread portion
when installation.
3 Plug (58):
58.9 6.9 Nm {6 0.7 kgm}
2] If plugs (59) (11 places) have been
removed, replace with new ones.
a The plug is a dry-seal type with special nylon coated on its threads.
3 Plug (59):
7.8 13.7 Nm {0.8 1.4 kgm}
8. Assembly of suction safety valve assembly

Fit O-ring (31a) to suction safety valve assembly
(30a), and install suction safety valve assembly
(30a) to valve body (1a).
3 Suction safety valve assembly (30a):
176.6 196.1 Nm {18 20 kgm}
D375A-6
(02)
DRAFT
Hydraulic system

1) Install valve (25a) and spring (24a) to valve
body (1).
2) Fit backup ring (28a) and O-ring (27a) to plug
(29a), and install plug (29a) to valve body (1).
3 Plug (29a):
176.6 196.1 Nm {18 20 kgm}
Fit O-ring (33a) to check valve assembly (32a),
and install check valve assembly (32a) to valve
body (1).
3 Check valve assembly (32a):
58.8 78.5 Nm {6 8 kgm}

1) Fit O-ring (35a), O-ring (36a), backup ring
(37a) to plug (34a), and install plug (34a) to
valve body (1).
3 Check valve assembly (32a):
58.8 78.5 Nm {6 8 kgm}
2) If plugs (38a) (2 places) are removed,
replace with new ones.
a The plug is a dry-seal type with special
nylon coated on its threads.
3 Plug (38a):
7.8 13.7 Nm {0.8 1.4 kgm}
(Ripper lift valve)

1) Install valve (14b) and spring (15b) to valve
body (1b).
2) Fit spring (15b), backup ring (17b) and O-ring
(16b) to plug (18b), and install plug (18b) to
valve body (1b).
3 Plug (18b):
176.6 196.1 Nm {18 20 kgm}

Fit O-ring (20b) to check valve assembly (19b),
and install check valve assembly (19b) to valve
body (1b).
3 Check valve assembly (19b):
58.8 78.5 Nm {6 8 kgm}

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
(02)
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Hydraulic system
3

1) Installation of plug (27b)
1] Install plug (23b) to valve body (1b).
2] Fit O-ring (24b), backup ring (25b) and
O-ring (26b) to plug (27b), and install plug
(27b) to valve body (1b).
Plug (27b):
176.6 196.1 Nm {18 20 kgm}
2) If plug (28b) is removed, replace with new
one.
a The plug is a dry-seal type. Special nylon
is coated on its threads.
3 Plug (28b):
7.8 13.7 Nm {0.8 1.4 kgm}
(Ripper tilt valve)

1) Install valve (14c) and spring (15c) to valve
body (1c).
2) Fit spring (15c), backup ring (17c) and O-ring
(16c) to plug (18c), and install plug (18c) to
valve body (1c).
3 Plug (18c):
176.6 196.1 Nm {18 20 kgm}
Fit O-ring (22c) to suction valve assembly (21c),
and install suction valve assembly (21c) to valve
body (1c).
3 Suction valve assembly (21c):
176.6 196.1 Nm {18 20 kgm}
Fit O-ring (20c) to check valve assembly (19c),
and install check valve assembly (19c) to valve
body (1c).
3 Check valve assembly (19c):
58.8 78.5 Nm {6 8 kgm}

1) Installation of plug (27c)
1] Install plug (23c) to valve body (1c).
2] Fit O-ring (24c), backup ring (25c) and
O-ring (26c) to plug (27c), and install plug
(27c) to valve body (1c).
3 Plug (27c):
176.6 196.1 Nm {18 20 kgm}
2) Installation of plug (28c)
Fit O-ring (29c), backup ring (30c) and O-ring
(31c) to plug (28c), and install plug (28c) to
valve body (1c).
3 Plug (28c):
176.6 196.1 Nm {18 20 kgm}
50-280
3) If plugs (32c) and (33c) are removed, replace

with new ones.
a The plug is a dry-seal type with special
nylon coated on its threads.
3 Plug:
(32c)(4 places):
16.7 2.9 Nm {1.7 0.3 kgm}
D375A-6
(02)
DRAFT
Hydraulic system
(33c)(3 places):
7.8 13.7 Nm {0.8 1.4 kgm}
D375A-6
(02)
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Hydraulic system
Disassembly and assembly of blade PPC valve assembly

.

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 replaced, 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.
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Hydraulic system
Assembly
1. Install the blade RAISE valve.
1) Install valve (2) to valve body (1).
2) Install shims (3) and spring (4) to valve (2).
a Install spring (4) with its small diameter
(inside diameter) end facing shims (3).
3) Install spring (5), retainer (6), piston (7),
spring (8), shim (3), piston (9) and seat (10).
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.
2. Install the blade LOWER valve.
shims (42), retainer (15), balls (16), collar
(17), spring (18), spacers (19) and piston
(44).
bore.
3. Install the blade tilt valve.
shim (43) and piston (24).
bore.
8. Install plates (31) and (32).

3 Mounting bolt:
11.8 14.7 Nm {1.2 1.5 kgm}
9. Install joint (33).
a When installing joint (33) to body (29), 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
female threads of the valve body with
Drysol and dry them.
2] Drop LOCTITE to the following positions.
(L): 5 7 mm from end surface
2 Body female threads (A):
Adhesive (Loctite No. 648)
3 Joint (33):
39 49 Nm {4 5 kgm}
a Apply gear oil grease (G2-LI) to the sliding

portion 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 joint and
pin.
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
(02)
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Hydraulic system
10. Install boot (37) and disc (35), and tighten nut
(36).
1) Install disc (35), so that each bolt (38) is positioned 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 adjusting, "Adjusting PPC valve".
50-284
D375A-6
(02)
DRAFT
Hydraulic system
Disassembly and assembly of ripper PPC valve assembly

assembling the ripper PPC valve assembly.
a Spare part is not available for nipples (18) and
(19). Do not remove them unless necessary.
Assembly
a Install spring (4) with its small diameter end

(inside diameter) facing shims (3).
3. Install springs (5) and (6), retainer (7) and piston
(8).
a Springs (5) and (6) having different number
of turns are used for the oil pressure ports
shown below. Take care not to install wrong
springs.
Port
P1, P2
P3, P4
Total number of turns

11
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): Adhesive (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
(02)
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Hydraulic system
a Apply gear oil and grease (G2-LI) to the sliding 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 adjusting, "Adjusting PPC valve".
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Hydraulic system
Disassembly and assembly of hydraulic cylinder assembly

Disassembly
Symbol
Part No.
1 790-502-1003
790-201-1702
790-201-1841
2 790-201-1861
790-101-5021
01010-50816
790-201-1500
790-201-1650
3 790-201-1670
U
790-101-5021
01010-50816
4 790-720-1000
796-720-1680
07281-01589
796-720-1720
5
07281-02429
796-720-1690
07281-02169
790-102-4300
6
790-102-4310
D375A-6
(02)
Part name
Stand
Push tool kit
q Push tool
q Push tool
q Grip
q Bolt
Push tool kit
q Plate
q Plate
q Grip
q Bolt
Expander
Ring
Clamp
Ring
Clamp
Ring
Clamp
Wrench
Pin
Necessity
Q'ty
New/remodel
Sketch
Special tools
t 1
t 1
1
1
1
1
t 1
1
1
1
1
t 1
t 1
t 1
t 1
t 1
t 1
t 1
t 1
t 2
1. Cylinder tube
Remove the cylinder tube.
2. Quick drop valve assembly
a Perform this procedure for only the blade lift
cylinder.
1) Remove quick drop valve assembly (1).
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).
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Hydraulic system
3. Piston rod assembly

1) Set cylinder assembly (8) to tool U1.
2) Remove head assembly (9).
3) Pull out piston rod assembly (10).
a Put an oil container under the cylinder to
receive the oil.
2) Remove bolt (11).

4) Remove valve (13) from spacer (12). (Only
for lift cylinder)
5) Remove piston assembly (14).
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
1) Set piston rod assembly (10) to tool U1.
.
8) Disassemble the piston assembly according
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
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(02)
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Hydraulic system
Ripper lift cylinder and ripper tilt cylinder

1) Set piston rod assembly (10) to tool D1.
2) Remove lock screw (31) of piston assembly

(30).
q Screw size: M12 pitch 1.75
a If screw (31) cannot be removed because

it is punched too tight, screw in it deeply
into the hole once, tap the hole by using
tap [1], then remove the screw.
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
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1) Remove cylinder head assembly (20) from
the piston rod.
Assembly
a Apply engine oil to the sliding surfaces of each
part and install the packings, dust seals, and
O-rings, taking care not to damage them.
1) 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).
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Hydraulic system
6] Install backup ring (22) and O-ring (21).
2) Install cylinder head assembly (20) to the

piston rod.
a Replace valve (V) and seat (S)with

new ones.
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
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Hydraulic system
2) Install retainer (17). (Only for lift cylinder)

3) Install O-ring (16) and backup rings (15).
a Apply grease to the O-ring and backup
rings so that the backup rings do not separate from each other.
4) Install piston assembly (14).
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
98122.6 Nm {1012.5 kgm}
Tilt cylinder
157 196 Nm {16 20 kgm}
5] Install backup rings and O-ring (33).

a Install the backup rings after warming
it in hot water at about 50 60C.
a Apply grease to the O-ring and backup rings, so that the backup rings do
not separate from each other.
2) Install the piston assembly to piston rod (10),

and set the piston rod to tool U1.
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).

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(02)
DRAFT
Hydraulic system
3) When reusing piston rod (32) and piston

assembly (30), take the following steps for
installation.
a Remove any flash or burr on the threaded
portion by using a file or other tool.
a Clean the parts thoroughly and remove
metal chips and dust.
1] Screw piston assembly (30) into piston
rod (32) by using tool U6, and tighten the
piston assembly until the tapped holes
are aligned.
4) When using new parts for either or both of

piston rod (10) and piston assembly (30),
take the following steps for installation.
1] Using tool U6, tighten piston assembly
(30).
3 Piston assembly:
294 29.4 Nm {30 3.0 kgm}
2] Make a hole to install the screw.
a Apply the drill tip to the groove where
the piston and piston rod are engaged, 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
(02)
50-293
DRAFT
Hydraulic system
4] Install screw (31).

a Install the screw after degreasing and
drying the threads completely.
a After tightening the screw, punch it at
four points on its periphery.
2 Threads of screw:
Adhesive (Loctite No.262)
3 Screw:
58.9 73.6 Nm {6.0 7.5 kgm}
4. Quick drop valve assembly

a Perform this procedure for only the blade lift
cylinder.
1) Install the quick drop valve assembly as
follows.
1] Install collar (7), and install valves (6) and
(5), washer (4), and spring (3).
2) Install quick drop valve assembly (1).

1) Set cylinder (8) to tool U1.
2) Install piston rod (10) to cylinder (8).
a Apply grease to the sealing part of the piston.
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
5. Cylinder tube
Install the cylinder tube.
D375A-6
(02)
DRAFT
Hydraulic system
Disassembly and assembly of ripper pin puller cylinder assembly
Symbol
Part No.
1 790-502-1003
790-201-1702
790-201-1721
2
790-101-5021
01010-50816
790-201-1500
790-201-1530
U
3
790-101-5021
01010-50816
4 790-720-1000
796-720-1630
5
07281-00709
7 790-102-2302
Part name
Cylinder repair stand

Push tool kit
q Push tool
q Grip
q Bolt
Push tool kit
q Plate
q Grip
q Bolt
Expander
Ring
Clamp
Wrench
Necessity
Q'ty
New/remodel
Sketch
Special tools
t 1
t 1
1
1
1
t 1
1
1
1
t 1
t 1
t 1
t 1
Disassembly
1. Cylinder assembly
1) Set pin puller cylinder assembly (1) to tool
U1.
2) Using tool U7, remove cylinder head
assembly (2) and piston rod (3) as a unit.
a Put an oil container under the cylinder to
receive the oil.

1) Remove cylinder head assembly (2) from
piston rod (3).
D375A-6
(02)
50-295
DRAFT
Hydraulic system
2) Remove O-ring (5) and backup ring (6).

3) Remove O-ring (7).
4) Remove snap ring (8), then remove dust seal
(9).
5) Remove rod packing (10), and remove
bushing (11).
Assembly
a Apply engine oil to the sliding surfaces of each
part and install the packings, dust seals, and
O-rings, taking care not to damage them.
1) 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).

Remove piston ring (12) from piston rod (3).
50-296
D375A-6
(02)
DRAFT
Hydraulic system

1) Using tool U2, press fit bushing (11) to
cylinder head (4).
2) Using tool U3, press fit dust seal (9) to

cylinder head (4).
6) Install cylinder head assembly (2) to piston

rod (3).
3. Cylinder assembly
1) Set the cylinder to tool U1 and support the
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 piston.
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
(02)
50-297
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 completely.
1. Set blocks [1] securely under left and right

straight frames (9).
Release the residual pressure from the

piping. For details, see "Releasing residual pressure of work equipment cylinder"
in Testing and adjusting.
6. Remove right and left covers (5).
2. Sling lift cylinder assembly (2).

3. Remove lock plate (1), and remove connecting
pin (1a) on the piston rod side of the blade lift
cylinder.
4. Start the engine and retract piston rod (3) fully.

a Plug the hose to prevent dust etc. from entering the piping.
8. Remove left and right trunnion caps (7).
9. Remove blade assembly (8).
[*1]
a Start the engine and move the machine slowly 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 cylinder on the opposite side from the blade.
50-298
D375A-6
(02)
DRAFT
Work equipment
Installation
[*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
Refilling (hydraulic tank)

D375A-6
(02)
50-299
DRAFT
Work equipment
Disassembly and assembly of blade assembly

Disassembly
k
Place blocks [1] and [2] under the right and

left straight frames and blade to support the
blade securely.
1. Remove right frame covers (1) and (2).

2. Disconnect tilt cylinder hoses (3).
50-300
3. Sling tilt cylinder assembly (4), remove the lock

plate, and remove pin (5).
4. Remove the lock plate, remove pin (6), and
remove tilt cylinder assembly (4).
4 Tilt cylinder assembly: 380 kg
5. Set block [3] under right center brace (7), and

remove the mounting bolt of cap (8) on the right
straight frame side.
a Shims are fitted in the cap. Note the quantity
and thickness of the shims for installation
purpose.
D375A-6
(02)
DRAFT
Work equipment
6. Sling right straight frame (9) and disconnect right

center brace (7).
7. Remove the lock plate, remove pin (10), and
remove right straight frame (9).
4 Straight frame: 1,150 kg
8. Sling tilt brace (11), remove the lock plate, and

remove pin (12) from the blade.
11. Sling center brace (15), remove the mounting

bolts to remove cap (16). Then remove right and
left center braces (15) and (7).
a Shims are fitted in the cap. Note the quantity
and thickness of the shims for installation
purpose.
4 Center brace: 220 kg
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
(02)
50-301
DRAFT
Work equipment
Assembly
a Check the quantity and thickness of the removed
shims, and fit shims of the same quantity and
same thickness to the original locations.
a To adjust the shims, see Testing and adjusting,
"Adjusting blade".
3. Sling right straight frame (9), install pin (10), and

secure with the lock plate.
4 Straight frame: 220 kg
4. Sling right straight frame (9) and set the ball of
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

secure with the lock plate.
10. Install left straight frame (14) using the same

procedure as steps 3 to 5, and connect the left
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
(02)
50-303
DRAFT
Work equipment
Disassembly and assembly of giant ripper assembly

Disassembly
1. Stop the machine with its track riding on blocks
[1], and lower the blade to the ground.
k Set the parking brake to the lock position.
2. Sling the shank, then operate the pin-puller
switch to pull out the shank pin.
3. Raise the ripper fully, and lower the shank to
remove.
4 Shank: 470 kg
a Start the engine, retract the piston rod fully,

and lower the tilt cylinder assemble on top of
the lift cylinder.
k After stopping the engine, release the residual pressure from the piping. For details, see Testing and adjusting
"Releasing residual pressure of work
equipment cylinder".
7. Disconnect four lift cylinder hoses (4), four tilt
cylinder hoses (5), and two pin puller cylinder
hoses (6).
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
(02)
50-305
DRAFT
Work equipment
Assembly
1. Sling arm (13) and set it to the mounting position,
install right and left pins (14), and secure them
with the lock plates.
4 Arm: 1,000 kg
a Set a stand under the arm.
2. Sling beam (11) and set it to the mounting position, 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.
4. Sling tilt cylinder assembly (7) and set it to the

mounting position. Install pin (8), and secure it
5. Connect two pin puller cylinder hoses (6), four tilt

cylinder hoses (5), and four lift cylinder hoses
(4).
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
mounting position. Install pin (10), and secure it
4 Lift cylinder assembly : 350 kg
50-306
7. Sling the lift cylinder assembly, start the engine

to extend the piston rod to align the pin holes.
Install pin (2), and secure it with the lock plate.
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
(02)
50-307
DRAFT
Removal and installation of ROPS guard

Removal
Installation
[*1]
ROPS guard mounting bolt :

1,5191,911 Nm {155195 kgm}
[*2]
q
1. Remove antenna (1).
Installed direction of ROPS guard
2. Sling ROPS guard (2), and remove the twelve

mounting bolts.
[*1]
3. Lift off ROPS guard (2).
4 ROPS guard: 700 kg
50-308
[*2]
D375A-6
(02)
DRAFT
Removal and installation of operators 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
operators cab.
5. Remove three mounting bolts (8) of lower angle
(7).
3. Disconnect wiring connectors CN19

CN12VS (3), CN21 (4) and CN20 (5).
(2),
4. Disconnect four window washer hoses (6). [*1]

a Pull the wires and window washer hoses into
the operators cab.
D375A-6
(02)
6. Remove back side cover (9) of the monitor

panel.
50-309
DRAFT
7. Remove angle (10).
10. Remove covers (13), (14) and (15).
8. Remove the operators cab mounting bolt

1) Remove right and left covers (11).
11. Remove twenty-one mounting bolts (indicated

by * mark) and lift off operators cab assembly
(16).
4 operators cab assembly: 500 kg
50-310
D375A-6
(02)
DRAFT
Installation
a Before installing the operators cab, loosen the
mounting bolts of angle (7) and those of angle
(10) inside the operators cab.
2) Sling operators cab assembly (16), and bond

seal (19) to the mating face.
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
(02)
50-311
DRAFT
2. Operators cab assembly

1) Lower the operators 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 conditioner duct of the dashboard.
a Lower the operators cab assembly carfully, as the clearance between the air
conditioner duct on the cab and the monitor 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
washer size from other mountinh bolts.
a Check that air conditioner bracket (20) is
fitted securely to the seal installed to the
cab (21).
a Check joint (B) between the seal and floor
frame for gap.
If a clearance is found, remove the cab,
and reinstall it correctly. If the clearance is
small, seal it with sealant.
50-312
3) Tighten the mounting bolts to the specified

torque, that are tightened partially in step 2.
4) Tighten the mounting bolts of angle (7) and
those of angle (10) inside the cab to the specified torque.
a Perform the subsequent installation in the reverse order to removal from step 7.
[*1]
a When connecting the window washer hoses,
match their band colors.
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 heater hose.
a Note the installed positions of the hoses and wirings 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 collecting 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 operators cab assembly. For
details, see "Removal and installation of
operators cab assembly."
7. Remove the covers according to the following
procedure.
D375A-6
(02)
50-313
DRAFT

9. Disconnect clamp (6).
17. Disconnect two clamps (23).
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)

19. Disconnect PPC hose (26) (band color: green).

20. Disconnect hydraulic hose (27).
21. Disconnect clamp (28).
22. Disconnect ripper PPC hose (29).
23. Remove wiring connectors RT1 (30), RPU (31),

RTB (32), and BLD (33).
a Take care not to loosen the turnbuckle in

wrong direction since it has left-hand
threads.
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
console cover.
5) Remove console cover (40).
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
(02)
(06)
50-315

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]
q Disconnect ground wire (46)
31. Lift off floor frame assembly (50).

a Lift the assembly while checking all the hoses and wirings are disconnected.
a After removing the floor frame assembly, remove the spacer on the right front mount.
4 Floor frame assembly: 600 kg
50-316
D375A-6
(02)
(06)
DRAFT
Installation
[*1]
a Install the hose without twisting it.
a When installing the air conditioner circuit hose,
take care not to allow dint, dust and water to enter it.
a Check that the O-ring is fitted to the air conditioner hose adapter before tightening the adapter
a When connecting the refrigerant hose, apply
compressor oil for new refrigerant (R134a) (Denso: ND-OIL8 or Zexcel: ZXL100PG (equivalent
to PAG 46)) to the O-ring.
[*4]
a Install the brake rod to the turnbuckle, set it to
the installed dimension noted when it was removed.
a Be sure to bend the cotterpin securely.
a Adjust the brake rod. For details, see testing and
adjusting,Adjusting brake pedal and parking
brake parking brake lever.
[*5][*6]
3
Mounting bolts at the right rear, left rear and

left front sides:
338.1 39.2 Nm {34.5 4 kgm}
[*7]
Mounting bolt at right front:

1,370 - 1,666 Nm {140 - 170 kgm}
5 Coolant:120 l
Charging air conditioner with refrigerant

Charge the air conditioner circuit with refrigerant
(R134a).
a Quantity of refrigerant: 1,100 100 g
Tightening torque for air conditioner gas

piping.
Thread size
16 x 1.5
22 x 1.5
24 x 1.5
Tightening torque
12.23 1.47 Nm {1.35 0.15
kgm}
22.05 2.45 Nm {2.25 0.25
kgm}
31.85 2.45 Nm {3.25 0.25
kgm}
5.39 1.47 Nm {0.55 0.15
kgm}
M6 bolt
(receiver portion)
M6 bolt
9.8 1.96 Nm {1.0 0.2 kgm}
(compressor portion)
[*2]
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 dimension noted when the cable was removed.
a Be sure to bend the cotter pin securely.
a Adjust the parking brake. For details, see Testing and adjusting, "Adjusting PCCS lever".
D375A-6
(02)
50-317
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 wirings 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. Accordingly, put on safety glasses, safety gloves
and long sleeved work clothes when collecting or charging the refrigerant.
q Quantity of refrigerant: 1,100 100 g
6 Radiator: 120 l
4. Disconnect two air conditioner hoses (5).

[*1]
a Plug the hoses to prevent entry of dirt, dust
and water.
5. Disconnect heater hose clamp (6).
6. Disconnect two heater hoses (7).
a Close the heater valve on the engine side.
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

(11), DS2 (12), DS4 (13), and DS5 (14).
10. Remove monitor cover (16).

[*3]
a Four connectors are installed at the back of
the cover. Disconnect the connectors before
removing the cover.
(From left top)
(17): FLSW
(18): RLSW
(From right top)

(19): ADH
(20): OPSW
9. Open air conditioner filter cover (15).
D375A-6
(02)
50-319
DRAFT
11. Remove covers (21a) and (21b).

12. Remove right and left foot rests (22).
13. Remove right and left ducts (23).
[*4]
16. Disconnect wiring connector AC1 (26).
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 carefully.

18. Disconnect wiring connectors CM01 (29) and

CM02 (30).
50-320
D375A-6
(02)

19. Disconnect wiring connectors AC2 (31) and AC3

(32).
23. Remove back side cover (36) of the monitor

panel.
20. Disconnect four relay wiring connectors (33).

21. Disconnect wiring connector (34) of the servomotor.
22. Disconnect wiring connector M26 (35).
24. Disconnect dummy connector (37) from clip

(38).
25. Disconnect clamp (40) of wiring (39).
D375A-6
(02)
(06)
50-321
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
[*1]
a Install the hose without twisting it.
a When installing the air conditioner circuit hose,
take care not to allow dint, dust and water to enter it.
a Check that the O-ring is fitted to the air conditioner hose adapter before tightening the adapter.
a When connecting the refrigerant hose, apply
compressor oil for new refrigerant (R134a) (Denso: ND-OIL8 or Zexcel: ZXL100PG (equivalent
to PAG 46)) to the O-ring.
Tightening torque for air conditioner gas plping.
Thread size
16 x 1.5
22 x 1.5
24 x 1.5
Tightening torque
12.23 1.47 Nm {1.35 0.15
kgm}
22.05 2.45 Nm {2.25 0.25
kgm}
31.85 2.45 Nm {3.25 0.25
kgm}
5.39 1.47 Nm {0.55 0.15
kgm}
M6 bolt
(receiver portion)
M6 bolt
9.8 1.96 Nm {1.0 0.2 kgm}
(compressor portion)
[*2]
[*3][*4]
a Adjust the monitor panel plate position according
1) Tighten bolts (A) and (B) partially.
2) Tighten bolts (A) so that gaps (C) are set
uniform in horizontal and vertical directions to
prevent interference between the monitor
panel, SW panel, and cover.
3) Tighten bolts (B).
Air hose clamp:

6.8 0.49 Nm {0.69 0.05 kgm}
D375A-6
(02)
Charging air conditioner with refrigerant

Charge the air conditioner circuit with refrigerant
(R134a).
5 Coolant:120 l
50-323

Removal and installation of operator's seat isolator

3. Remove operator's seat (1).

4 Operator's seat:
Removal
1. Disconnect power connector (2) of operator's
seat (1).
50 kg
2. Remove four M8 nuts (4) securing operator's

seat (1) and bracket (3).
4. Remove four M12 nuts (6) securing operator's

seat isolator (5) and turntable.
Installation
Perform installation in the reverse order to removal.
50-324
50-323-1
D375A-6
(07)
(02)

Disassembly and assembly of operator's seat isolator

Disassembly
q Perform disassembly in the reverse order to assembly.
Assembly
1. Install stopper rubbers (3) to two stopper bosses
(2) of base plate (1).
a Hitch one side of stopper rubber (3) to the
groove of the boss and press it with a round
bar to install it to the boss.
2. Install four laminated rubbers (4) to base plate

(1) with eight M10 bolts (5).
3 Laminated rubber mounting bolt:
40 Nm {4.08 kgm}
3. Install collar (7) to damper mounting pin (6) of

the base plate with the tapered side down.
D375A-6
(02)
(07)
50-323-2
50-325

4. Install protection tube (9) side of damper (8) to

the mounting pin of the base plate.
5. Install slotted head nut (10) and pass cotter pin

(11) and bend it to secure. (2 places)
7. Insert the top plate mounting pin into free side

(15) of the damper installed to the top plate and
remove the tape.
8. Match the holes of the top plate with the

mounting screws of the laminated rubbers and
secure them with eight M10 bolts (5).
3 Laminated rubber mounting bolt:
40 Nm {4.08 kgm}
6. Put collar (13) to the damper mounting pin of top

plate (12) with the tapered side down and secure
it with tape (14) to prevent it from falling.
9. Place plate (16) on the stopper pin and secure it
with two M10 bolts (17).
10. Turn over the top plate, install slotted head nut
(10) to the mounting pin, and pass cotter pin (11)
and bend it to secure. (Two places)
50-323-3
50-326
D375A-6
(07)
(02)

D375A-6
(02)
(07)
50-323-4
50-327
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
Removal
Installation
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

Removal
3. Disconnect
wiring
connectors
EGC1(4) and EGC2(5).
a E: Ground cable
EGC3(3),
[*1]

cover (1).
4. Remove the mounting bolt and remove engine

controller assembly (6).
2. Remove controller box cover (2).
Installation
[*1]
Screw: 2.82 Nm {0.288 kgm}
D375A-6
(02)
50-325
DRAFT
Electrical system
a Reference
q Power supply connector EGC3(5) seal replacement 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
5. Remove the mounting bolts and remove

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
D375A-6
(02)
50-327
DRAFT
Electrical system
Removal and installation of machine monitor assembly

Installation
k Set the parking brake lever and work equipment lock lever to lock position.
2. Remove four mounting bolts (6) and disconnect

machine monitor assembly (7) from the dashboard.
a Wrings are connected in the back side. Be
careful of this when pulling it toward you.
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
[*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
(02)
50-329
DRAFT
Electrical system
50-330
D375A-6
(02)
60-1
D375A-6
Bulldozer
D375A-6
Shop Manual
Machine model
Serial number
D375A-6
60001 and up
60 Maintenance standard
D375A-6
(06)
6-01
60-1
60-1
DRAFT
Contents
Contents
60 Maintenance Standard
Engine mount............................................................................................................................................... 60 3
Cooling fan pump......................................................................................................................................... 60 5
Cooling fan motor......................................................................................................................................... 60 - 12
Power train
Power train unit ............................................................................................................................................
Scavenging pump ........................................................................................................................................
Transmission................................................................................................................................................
Power train and lubrication pump ................................................................................................................
Transfer, bevel gear shaft and steering unit ................................................................................................
Steering clutch ECMV and steering brake ECMV........................................................................................
Final drive ....................................................................................................................................................
Sprocket.......................................................................................................................................................
60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 -
14
16
19
22
23
24
25
26
30
31
32
38
39
40
41
44
Track frame.................................................................................................................................................. 60 Idler cushion................................................................................................................................ 60 Idler .............................................................................................................................................................. 60 Track roller ................................................................................................................................................... 60 Carrier roller ................................................................................................................................................. 60 Track roller bogie ......................................................................................................................................... 60 Track shoe ................................................................................................................................................... 60 Main frame ................................................................................................................................................... 60 Suspension .................................................................................................................................................. 60 -
46
48
50
52
54
55
56
60
62
Hydraulic system
PPC valve ....................................................................................................................................................
Hydraulic cylinder.........................................................................................................................................
Quick drop valve ..........................................................................................................................................
Control valve ................................................................................................................................................
60 60 60 60 60 60 -
67
72
75
76
79
85
60 60 60 60 -
87
88
92
94
Work equipment
Cylinder stay ................................................................................................................................................
Blade............................................................................................................................................................
Cutting edge and end bit..............................................................................................................................
Ripper ..........................................................................................................................................................
60-2
D375A-6

Engine mount
60-3
Engine mount
60-3
Unit: mm
No.
Item
Clearance between bracket and

cushion

bushing
3 Free height of mount rubber
D375A-6
(08)
Criteria
Standard
size
Tolerance
Shaft
Hole
+ 0.018
+ 0.078
70
- 0.012
+ 0.032
0
+ 0.1
180
- 0.25
0
Standard size
102
Remedy
Standard
clearance
0.014
0.090
Clearance
limit
0 0.35
0.75
0.2
Replace
Repair limit
100
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
Standard size
Spool return spring
Free length
Installed length
outside diameter
83.8 19
D375A-6
67.5
Repair limit
Installed load
Free length
Installed load
172 N
{17.5}
137 N
{14}
Replace spring
if damaged or
deformed.
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
(04)
60-15
DRAFT
Power train
60-16
D375A-6
DRAFT
Power train
Unit: mm
No.
Item
Clearance between flywheel

housing and cover
Clearance between flywheel and

damper
Outside diameter of oil seal contact surface of coupling
Criteria
Tolerance
Standard
size
Remedy
Standard clearance
Clearance limit
Shaft
Hole
647.7
- 0.024
- 0.105
+ 0.080
0
0.024 0.185
0.2
546.0
- 0.022
- 0.092
+ 0.110
0
0.022 0.202
0.25
Standard size
Tolerance
Repair limit
110
0
- 0.035
109.9
Outside diameter of oil seal contact surface of output shaft
110
0
- 0.035
109.9
Dimension between bearing and

holder
53
0.1
52.7
D375A-6
Replace
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
No.
Item
Criteria
Remedy
Standard size
Tolerance
Repair limit
125
0
- 0.063
124.8
Inner diameter of seal ring

contact surface of retainer
190
+ 0.046
0
190.5
Inside diameter of seal ring

contact surface of sleeve
110
+ 0.035
0
110.2
Backlash between PTO drive

gear and scavenging pump
gear
0.25 0.42
Backlash between PTO drive

gear and idler gear
0.204 0.516
Outside diameter of coupling

oil seal contact surface
Thickness of lockup clutch

disc
5.4
0.1
4.9
Thickness of lockup clutch

plate
5.0
0.1
4.5
Total thickness of lockup

clutch assembly
15.8
0.17
14.3
Thickness of stator clutch disc
5.4
0.1
4.9
Thickness of stator clutch

plate
5.0
0.05
4.5
Total thickness of stator clutch

assembly
15.8
0.15
14.7
Apply hard
chrome plating
or replace
Replace
Standard size
Stator clutch return spring
Free length Installed length Installation load Free length Installation load
54.1
D375A-6
Repair limit
37.0
125.5 N
{12.8 kg}
50.9
106.9 N
{10.9 kg}
60-21
DRAFT
Power train
Unit: mm
No.
Item
Criteria
Tolerance
Clearance between main

relief valve and valve body
Clearance between torque
converter relief valve and
valve body
Remedy
Standard clearance
Clearance limit
+ 0.016
0
0.035 0.061
0.08
+ 0.016
0
0.035 0.061
0.08
Standard size
Shaft
Hole
40
- 0.035
- 0.045
40
- 0.035
- 0.045
Replace
Standard size
Main relief valve spring
Torque converter relief

valve spring
60-22
Free length
Repair limit
Installed length Installation load
120.3
102
1,419 N
{144.7 kg}
116.92
86.3
645.1 N
{65.83 kg}
Free length
Installation load
116.7
1,348 N
{137.5 kg}
113.4
613 N
{62.5 kg}
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
No.
1
Item
Criteria
-
Spline shaft rotating torque
Type
Delivery
Oil: TO10
Oil temperature: (45 - 50 C)
Rotating
speed (rpm)
Discharge
pressure
MPa {kg/cm2}
BAR 63
1,743
BAR 277
60-24
Remedy
Standard
delivery
(l/min)
Acceptable
delivery
(l/min)
63.3
276.8
0.15
{1.5}
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
No.
Item
Standard size
R clutch spring (12 pcs)
F clutch spring (12 pcs)
3rd and 2nd clutch spring (12 pcs)
1st clutch spring (3 pcs)
5
6
7
8
9
Total thickness of R clutch consisting of 6

discs and 6 plates
Total thickness of F clutch consisting of 6
discs and 5 plates
Total thickness of 3rd clutch consisting of 4
discs and 4 plates
Total thickness of 2nd clutch consisting of 3
discs and 3 plates
Total thickness of 1st clutch consisting of 6
discs and 5 plates
10 Thickness of clutch disc

11 Thickness of clutch plate
12
13
Wear of transmission input shaft

seal ring
Wear of front cover and R clutch
carrier seal ring
Wear of F clutch and 3rd clutch

14
carrier seal ring (small)
15
Wear of F clutch and 3rd clutch

carrier seal ring (large)
R, F,
3rd, 2nd
1st
R, F,
3rd, 2nd
1st
50.3
0.33
47.1
36.4
0.28
34.3
27.3
0.24
25.7
50.0
0.33
46.8
4.8
0.1
4.3
5.0
0.1
4.5
4.3
0.1
3.9
4.0
0.1
- 0.01
- 0.03
3.6
Width
3.0
Thickness
3.5
0.1
3.35
Width
4.0
- 0.01
- 0.04
3.6
Thickness
4.0
0.15
3.85
Width
4.0
- 0.01
- 0.03
3.6
Thickness
5.0
0.15
4.85
Width
4.0
- 0.01
- 0.04
3.6
Thickness
4.0
0.15
3.85
Width
4.0
- 0.01
- 0.04
3.6
Thickness
5.0
0.15
4.85
Width
4.0
- 0.01
- 0.03
3.6
Thickness
5.1
0.12
4.95
Width
4.5
- 0.01
- 0.03
4.1
Thickness
6.0
0.15
5.85
Width
4.5
- 0.01
- 0.03
4.1
Thickness
5.8
0.15
5.65
Width
5.0
- 0.01
- 0.03
4.5
Thickness
6.0
0.15
5.85
17 Wear of 1st clutch gear seal ring
18 Wear of 1st clutch gear seal ring
20
Wear of transmission output shaft

seal ring
Wear of 1st clutch piston housing
seal ring
Backlash between R and F clutch sun gear

and planetary pinion
Backlash between R clutch planetary pinion
22
and ring gear teeth
Backlash between F, 3rd and 2nd clutch
23
planetary pinion and ring gear teeth
Backlash between 3rd and 2nd clutch plane24
tary pinion and ring gear
21
D375A-6
Repair limit
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
70.0
60.3
65.8
{22.3kg}
{19.0 kg}
149 N
127 N
97.0
82.4
91.2
{15.2 kg}
{12.9 kg}
2,910 N
3,420 N
7.75
6.75
{297 kg}
{349 kg}
Standard size
Tolerance
Repair limit
54.6
0.35
51.4
16 Wear of 1st clutch collar seal ring
19
Unit: mm
Remedy
Criteria
2.7
Replace
0.13 0.40
0.13 0.40
0.14 0.40
0.13 0.37
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
No.
Item
Side clearance
Clearance between plain bearing

inside diameter and gear shaft outside diameter
Criteria
Type
Standard clearance
Clearance limit
BAL180
0.07 0.12
0.15
BAL112
0.04 0.10
0.13
0.060 0.145
0.20
BAL180
BAL112
Type
Pin driving depth
Remedy
Standard size
Tolerance
Repair limit
14
0
- 0.5
Replace
BAL180
BAL112
Spline shaft rotating torque
Delivery
(Oil: E010-CD
Oil temperature: 45 50 C)
(Engine speed at 1900 rpm)
D375A-6
5.9 Nm {0.6 kgm} or less
Type
Rotating speed
(rpm)
Discharge
pressure
MPa {kg/cm2}
Standard
delivery
(l/min)
Acceptable
delivery
(l/min)
BAL180
2,033
2.5 2.7
{26 28}
334
308
BAL112
2,033
0.26
{2.7}
210
200
60-31
DRAFT
Power train
Transfer, bevel gear shaft and steering unit

60-32
D375A-6
DRAFT
Power train
Unit: mm
No.
Item
Criteria
Standard clearance
Clearance limit
Adjust or
replace
Backlash between transfer gears

0.24 - 0.63
Remedy
Thickness of collar between

transfer gear and bearing
Standard shim thickness for bearing cage mount
D375A-6
0.75
Standard size
Tolerance
Repair limit
24
0.1
23.6
Replace
2.0
Adjust shim
60-33
DRAFT
Power train
60-34
D375A-6
DRAFT
Power train
Unit: mm
No.
Item
Criteria
Standard clearance
Clearance limit
Adjust or
replace
Backlash between transfer gears

0.24 - 0.63
Remedy
Thickness of collar between

transfer gear and bearing
Standard shim thickness for bearing cage mount
D375A-6
0.75
Standard size
Tolerance
Repair limit
24
0.1
23.6
Replace
2.0
Adjust shim
60-35
DRAFT
Power train
Bevel gear shaft, steering clutch, and steering brake
60-36
D375A-6
DRAFT
Power train
Unit: mm
No.
Item
Plate for steering brake and

clutch
Disc for steer-
Criteria
Remedy
Standard size
Tolerance
Repair limit
Thickness
2.9
0.1
2.6
Strain
Max. 0.3
0.4
Repair or
replace
Thickness
4.7
0.1
4.2
Replace
Strain
Max. 0.3
0.4
Repair or
replace
Replace
2 ing brake and

clutch
Total thickness of brake

plate and disc assembly
68.4
0.42
65.4
Total thickness of clutch

plate and disc assembly
68.4
0.42
65.4
Backlash between brake
Standard clearance
Repair limit
0.17 - 0.52
1.0
0.3 - 0.4
0.75
Replace
5 or clutch disc and brake

hub
Backlash between bevel

gear and pinion
Tolerance
Standard
clearance
Clearance limit
+ 0.081
0
0.5 - 0.781
+ 0.072
0
0.100 - 0.244
Standard size
Inside diameter of seal ring

contact surface of cage
Shaft
Hole
290
- 0.5
- 0.7
245
- 0.100
- 0.172
Inside diameter of piston
8 seal ring contact surface of

piston
Standard size
9 Brake spring
10 Clutch spring
Adjust or
replace
Repair limit
Free length
Installed length
Installed load
Free length
Installed load
17.1
11.2
38.7 kN
{3,950 kg}
16.6
36.8 kN
{3,750 kg}
17.55
11.6
37.9 kN
{3,860 kg}
17.0
36.0 kN
{3,670 kg}
Standard
interference
Interference
limit
- 0.026 - 0.019
0.019 or less
Tolerance
Standard size
Interference between
11
bevel gear and reamer bolt
16
Shaft
Hole
+ 0.019
+ 0.001
+ 0.027
0
12
Runout of back face of

bevel gear
13
Preload of bevel gear shaft

Standard rotating torque: 4.9 5.9 Nm {0.5 0.6 kgm}
taper roller bearing
(At tip of bevel gear teeth not meshed with bevel pinion: 23.5 28.4 N {2.4 2.9 kg})
14
Standard shim thickness of

bearing cage
D375A-6
Repair limit: 0.05 (measure after installing to bevel gear shaft)
2.0
Replace
Repair or
replace
Adjust
Adjust shim
60-37
DRAFT
Power train
60-38
D375A-6
DRAFT
Power train
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
No.
Item
Criteria
Tolerance
Shaft
Hole
Standard
clearance
- 0.020
- 0.030
+ 0.011
0
0.020
0.041
Standard size
Clearance between parking brake

valve spool and valve body
14
Outside diameter of dust seal and Standard size

U-packing contact surface of park14
ing brake valve spool
Parking brake valve spool spring
Free length
65
60-40
Replace
0.05
Repair limit
- 0.020
- 0.030
13.9
Repair hard
chrome plating
or replace
Repair limit
Installed length Installed load

47.7
Clearance
limit
Tolerance
Standard size
Remedy
38.2 N
{3.9 kg}
Free length Installed load

63.1
Replace
36.4 N
{3.71 kg}
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
No.
Item
Backlash between No.1 pinion and

No.1 gear
Criteria
Remedy
Standard clearance
Clearance limit
0.25 - 0.99
1.5
Backlash betwee sun gear and

planetary pinion
0.22 - 0.81
1.5
Backlash between planetary pinion

and ring gear
0.25 - 0.81
1.5
Standard size
Repair limit
Outside diameter of oil seal contact

surface of No.1 pinion
115.0
114.9
Replace
Thickness of thrust collar of inner

body roller bearing
25.14
24.9
Thickness of thrust coller of No.1

gear boss roller bearing
10.0
9.5
Dimensions from cover mounting

face to button head
24.0
22.5
Clearance between pinion shaft and

carrie
85
9
10
Tolerance
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
- 0.036
- 0.058
- 0.024
- 0.059
- 0.023
- 0.034
0.1
Standard shim thickness for No.1

pinion bearing cage
Dimension of end face of final drive

cover and end face of bearing
Adjust
7 (0/-0.2)
11 Clearance of floating seal guard
4.1 - 5.3
Standard size
Repair limit
47
18
12 Wear of wear guard
D375A-6
Rebuild or replace
60-43
DRAFT
Power train
Sprocket
Sprocket
Unit: mm
No.
Item
Criteria
Remedy
Standard size
Repair limit
433
417
28.7
22.7
Wear of tooth tip
Thickness of tooth root
60-44
Replace or rebuild by
build up welding
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
No.
Item
Criteria
Remedy
Item
Repair limit
Bend
7 (per length 3,000)
Torsion
3 (per level length 300)
Dents (pipe portion)
12
Deformation of track frame outer

casing
Clearance between inner casing

and stopper protruding portion
Clearance between track frame

and stopper
Press-fitting force for cartridge pin
D375A-6
Standard
size
Tolerance
Repair or replace
Standard
clearance
Clearance
limit
+ 0.3
0
0.15 - 0.65
3.0
+ 0.063
0
0.043 0.163
1.0
Shaft
Hole
60
- 0.15
- 0.35
161
- 0.043
- 0.106
245 441 kN {25 45 ton}
60-47
DRAFT
Idler cushion
Idler cushion
60-48
D375A-6
DRAFT
Idler cushion
Unit: mm
No.
Item
Criteria
Remedy
Standard size
Recoil spring
Free length Installed length Installed load

1,461
Clearance between outer diameter of outer sleeve bushing and

inner diameter of outer sleeve
Repair limit
Standard
size
1,230.5
499.7 kN
{50,994 kg}
Tolerance
Free length
Installed load
1,440
458.5 kN
{46,790 kg}
Standard
clearance
Clearance limit
Outer bushing
Outer sleeve
380
- 0.058
- 0.228
+ 0.317
+ 0.060
0.118 0.545
0.8
135
- 1.000
- 1.300
+ 0.063
0
1.000 1.363
Clearance between adjustment

cylinder and bushing
Press-fitting force for inserting

outer sleeve bushing into outer
sleeve
49.0 109.8 kN {5.0 11.2 ton}
Press-fitting force for installing

outer sleeve bushing to spring
cylinder
91.2 322.6 kN {9.3 32.9 ton}
Clearance between recoil spring

mounting nut and lock plate
Press-fitting force for cartridge

pin
Clearance between bogie and

idler cap
Clearance between bogie and

roller cap
D375A-6
Replace
Adjust
0 1.0
245 441 kN {25 45 ton}
Standard clearance
Clearance limit
0.266 0.940
0.05
0.42 1.4
0.05
Replace
60-49
DRAFT
Idler
Idler
60-50
D375A-6
DRAFT
Idler
Unit: mm
No.
Item
Criteria
Standard size
Repair limit
Outside diameter of protuding

portion
927
Outside diameter of tread
880
855
Depth of tread
23.5
36
Thickness of tread
32.5
20
Total width
294
Overall with of tread
79.0
87.5
Tolerance
Standard size
Clearance between shaft and

bushing
155
Shaft
Hole
- 0.350
- 0.413
+ 0.198
- 0.053
Rebuild by build-up
welding or replace
Standard
clearance
Clearance
limit
Replace bushing
0.297 - 0.611
Standard size
Repair limit
252
Rebuild by build-up
welding or replace
Collar width of shaft
Tolerance
Standard size
Remedy
Interference between shaft

and ring
95
Shaft
Hole
+ 0.046
0
- 0.15
- 0.20
Standard
interference
Interference
limit
Replace ring
0.15 - 0.246
Standard clearance
Clearance limit
0.49 - 0.86
10 End play
Adjust or replace
Standard size
Tolerance
Repair limit
95
- 0.410
- 0.484
- 0.5
11 Outside diameter of shaft
D375A-6
Replace
60-51
DRAFT
Track roller
Track roller
2nd 7th track roller (double flanged roller)
Unit: mm
No.
Item
Criteria
Remedy
Standard size
Repair limit
310
Outer diameter of flange (inside

flange)
300
270
210
Thickness of tread
60
30
Overall width
358
Width of tread
82
Width of flange (outside flange)
29
14
Width of flange (inside flange)
27
12
Collar width of shaft
306
Outer diameter of flange (outside

flange)
Clearance between shaft and

10
bushing
Standard size
140
Interference between shaft and

11
seal ring
Standard size
75
60-52
Shaft
Hole
Standard
clearance
Clearance
limit
- 0.350
- 0.413
+ 0.260
+ 0.010
0.360
0.673
Tolerance
Shaft
Hole
+ 0.046
+0
- 0.13
- 0.18
Standard
Interference
interference
limit
0.130
0.226
Replace bushing
Replace
Standard clearance
Clearance limit
0.44 - 0.91
12 End play
13 Outside diameter of shaft
Tolerance
Rebuild by build-up
welding or replace
Adjust or replace
Standard size
Tolerance
Repair limit
74.5
0
- 0.12
- 0.2
Replace
D375A-6

Track roller
1st and 8th track roller (single flanged roller)
Unit: mm
No.
Item
Criteria
Remedy
Standard size
Repair limit
314
2 Outside diameter of tread
280
205
3 Thickness of tread
65
27.5
4 Overall width
358
5 Width of tread
82
6 Width of flange
29
14
7 Collar width of shaft
306
1 Outside diameter of flange
Clearance between shaft and bushing
9 Interference between shaft and ring
10 End play
D375A-6
(04)
Tolerance
Shaft
Hole
-0.350
+0.260
140
-0.413
+0.010
Tolerance
Standard
size
Shaft
Hole
+0.046
-0.13
75
0
-0.18
Standard clearance
Standard
size
0.44 0.91
Rebuild by build-up
welding or replace
Standard
clearance
Clearance
limit
0.350
0.673
Standard
Interference
interference
limit
0.130
0.226
Clearance limit
Replace bushing
Replace
Adjust or replace
60-53
DRAFT
Carrier roller
Carrier roller
Unit: mm
No.
Item
Criteria
Remedy
Standard size
Repair limit
242
Outside diameter of flange
210
185
Width of tread
79
Thickness of tread
40
27.5
Width of flange
23
12
Standard
size
Interference between shaft and ring
90
Clearance between shaft and support
Standard
size
86
Rebuild by build-up
welding or replace
Tolerance
Standard interference
Shaft
Hole
+ 0.245
+ 0.185
+ 0.035
0
0.150 - 245
Tolerance
Standard clearance
Shaft
Hole
0
- 0.2
+ 0.350
0
Replace
0 - 0.550
Standard clearance
Clearance limit
0 - 0.22
Axial play of roller
60-54
D375A-6

Track roller bogie
Track roller bogie
60-5
Unit: mm
No.
Item
1 Press-fitting force for cartridge pin

Clearance between bogie and cap
2 (average of front and rear clearances)
D375A-6
(04)
Criteria
Remedy
245441 kN {2545 ton}
Standard clearance
Clearance limit
0.421.4
0.05
Replace
60-55
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
No.
Item
Criteria
Remedy
Standard size
Repair limit
280.3
283.3
Link pitch
Reverse
Standard size
Light load
Heavy load
98.5
90
92.5
18.8
10.3
12.8
Outside diameter of bushing
Thickness of bushing
Standard size
Repair limit
181
163
56
38
Height of link
Thickness of link (bushing press-fitting portion)

One side
Both side
1.4
2.8
Clearance between links
Tolerance
Interference between bushing and

link
Interference between regular pin and

link
Rebuild by build-up
welding or replace
Standard
interference
Standard size
Turn 180 or replace
Shaft
Hole
98
+ 0.622
+ 0.522
+ 0.087
0
0.435 - 0.622
60
+ 0.426
+ 0.366
+ 0.127
+ 0.053
0.239 - 0.373
Tightening torque
(Nm {kgm})
Retightening angle
(Degree)
1,372 137 {140 14}
120 10
686.4 68.6 {70 7}
180 10
Adjust or replace
a. Regular link
Shoe bolt
b. Master link
D375A-6
Retighten
60-57
DRAFT
Track shoe
Single grouser shoe
Unit: mm
No.
Item
Criteria
Remedy
Standard size
Repair limit
93
30
116
53
Height of grouser
Overall height of shoe
60-58
Repair by lug welding or replace
D375A-6
DRAFT
Track shoe
D375A-6
60-59
DRAFT
Main frame
Main frame
60-60
D375A-6
DRAFT
Main frame
Unit: mm
No.
Item
Interference between steering case

and bushing
Criteria
275
Clearance between steering case

and final drive cage
Tolerance
Standard
size
Shaft
Hole
+ 0.108
+ 0.056
+ 0.052
0
Tolerance
Standard
size
Remedy
Standard
Interference
interference
limit
0.004 0.108
Min. 0
Clearance
limit
Shaft
Hole
Standard
clearance
332
- 0.018
- 0.075
+ 0.057
0
0.018 0.132
0.2

cushion
70
+ 0.018
- 0.012
+ 0.046
0
- 0.018 0.058
0.1
Clearance between ripper beam

mounting pin and bushing
120
- 0.036
- 0.090
+ 0.166
+ 0.028
0.064 0.256
1.5
Clearance between ripper

cylinder mounting pin and bushing
100
- 0.036
- 0.090
+ 0.287
+ 0.200
0.236 0.377
1.5
Clearance between radiator guard

80
- 0.030
- 0.076
+ 0.371
+ 0.269
0.299 0.477
1.5
Clearance between radiator guard

90
- 0.036
- 0.090
+ 0.369
+ 0.267
0.303 0.459
1.0
Clearance between equalizer bar

shaft and bushing
120
- 0.036
- 0.090
+ 0.243
+ 0.101
0.137 0.333
1.0
Protrusion of rubber on seal end

face
Standard size
Repair limit
0.5
10
Free height of front cab mount rubber
105
103
11
Free height of rear cab mount rubber
58
56
12
Press-fitting force for ripper beam

mounting bushing
44.1 117.6 kN {4.5 12 ton}
13
Press-fitting force for ripper cylinder mounting bushing
58.8 171.6 kN {6 17.5 ton}
14
Press-fitting force for radiator guard

mounting bushing
98.0 181.4 kN {10 18.5 ton}
15
Press-fitting force for radiator guard

mounting bushing
58.8 137.3 kN {6 14 ton}
16
Press-fitting force for equalizer bar

shaft mounting bushing
31.4 105.9 kN {3.2 10.8 ton}
D375A-6
Replace
Adjust
60-61
DRAFT
Suspension
Suspension
60-62
D375A-6
DRAFT
Suspension
Unit: mm
No.
Item
Clearance between center pin and

bushing
Clearance between side pin and

bushing
Interference between side pin boss

and bushing
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
120
- 0.036
- 0.090
+ 0.243
+ 0.101
0.137 0.333
1.0
95
- 0.048
- 0.078
+ 0.015
- 0.015
0.033 0.093
1.0
Standard
size
160
Tolerance
Shaft
Hole
+ 0.045
+ 0.027
- 0.028
- 0.068
Clearance
limit
Replace bushing
Standard
Interference
interference
limit
0.055 0.113
Press-fitting force for center pin

bushing
49.0 186.3 kN {5 19 ton}
Press-fitting force for side pin bushing
34.3 73.5 kN {3.5 7.5 ton}
D375A-6
60-63
DRAFT
Suspension
*1
*2
. Indicates the left suspension of single tilt specification machine.

. 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
No.
Item
Criteria
Tolerance
Standard size
Interference between thrust

washer and seal
Remedy
Standard
Interference
interference
limit
Shaft
Hole
230
+ 0.213
+ 0.098
- 0.180
- 0.226
0.278 0.439
Interference between thrust

washer and seal
165
+ 0.140
+ 0.100
- 0.061
- 0.124
0.161 0.264
Interference between pivot shaft

and seal
213
+ 0.096
+ 0.050
- 0.115
- 0.187
0.165 0.283
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
175
- 0.145
- 0.208
+ 0.097
+ 0.029
0.174 0.305
1.0
210
- 0.170
- 0.242
+ 0.072
0
0.170 0.314
1.0
Standard size
10
Clearance between pivot shaft

and bushing
Clearance between pivot shaft

and bushing
D375A-6
Replace
Replace bushing
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
No.
Item
Criteria
Remedy
Standard size
Centering spring
(for ports P3 and P4)
Free length x
Installed length
Outside diameter
Repair limit
Installed load
Free length
Installed load
50.35 15.5
34
55.9 N
{5.7 kg}
44.7 N
{4.56 kg}
Centering spring
(for ports P1 and P2)
50.05 15.5
34
71.4 N
{7.28 kg}
57.1 N
{5.82 kg}
Metering spring
26.53 8.15
24.9
16.7 N
{1.7 kg}
13.3 N
{1.36 kg}
D375A-6
If damaged or
deformed, replace
spring
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
Standard
size
Blade lift
90
0.096
0.364
Pin puller
30
- 0.065
- 0.117
+ 0.133
+ 0.007
0.072
0.250
0.55
Blade tilt
(Dual tilt )
110
- 0.036
- 0.090
+ 0.261
+ 0.047
0.083
0.351
Blade lift
65
- 0.3
- 0.5
+ 0.5
+ 0.2
0.5 1.0
105
- 0.120
- 0.207
+ 0.035
0
0.120
0.242
0.5
75
- 0.200
- 0.300
+ 0.200
0
0.200
0.500
1.0
75
- 0.200
- 0.300
+ 0.200
0
0.200
0.500
1.0
75
- 0.200
- 0.300
+ 0.423
+ 0.342
0.542
0.723
1.0
75
- 0.200
- 0.300
+ 0.423
+ 0.342
0.542
0.723
1.0
29
- 0.100
- 0.200
+ 1.300
+ 1.200
1.3 1.5
26
- 1.1
- 1.2
0.1
1.0 1.3
and bushing
Clearance between cylBlade lift
inder support shaft
bushing and yoke
Clearance between pis- (Single tilt)
ton rod supporting shaft
and bushing
Blade tilt
(Dual tilt)
Blade tilt
Clearance between cyl- (Single tilt)

inder bottom support
Blade tilt
shaft and bushing
(Dual tilt)
Clearance between pis-
6 ton rod spherical sur7
Pin puller
face and cap

Clearance between cylPin puller
inder bottom support
shaft and boss
D375A-6
(04)
0.693
+ 0.274
+ 0.060
Blade tilt
Clearance
limit
- 0.036
- 0.090
Clearance between pis-
Standard
clearance
0.084
0.347
110
Clearance between pis- Blade tilt

(Single tilt)
ton rod and bushing
2 ton rod supporting shaft
Tolerance
Shaft
Hole
- 0.036
+ 0.257
- 0.090
+ 0.048
Remedy
Replace
60-73
DRAFT
Hydraulic system
Hydraulic cylinder
Ripper tilt cylinder
Unit: mm
No.
Item
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
110
- 0.036
- 0.090
+ 0.274
+ 0.060
0.096 0.364
0.697
Ripper tilt
110
- 0.036
- 0.090
+ 0.274
+ 0.060
0.096 0.364
0.697
Ripper lift
100
- 0.036
- 0.090
+ 0.207
+ 0.120
0.156 0.297
1.0
Ripper tilt
100
- 0.036
- 0.090
+ 0.207
+ 0.120
0.156 0.297
1.0
Ripper lift
Clearance between
cylinder bottom support shaft and bushing Ripper tilt
100
- 0.036
- 0.090
+ 0.207
+ 0.120
0.156 0.297
1.0
100
- 0.036
- 0.090
+ 0.207
+ 0.120
0.156 0.297
1.0
Clearance between
piston rod and bushing Ripper lift
Clearance between
piston rod support
shaft and bushing
60-74
Clearance
limit
Replace
D375A-6
DRAFT
Hydraulic system
Quick drop valve
Quick drop valve
Unit: mm
No.
Item
Criteria
Tolerance
Standard size
Clearance between spool

and valve body
38.0
Shaft
Hole
- 0.011
- 0.016
+ 0.010
0
Remedy
Standard clearClearance limit
ance
0.011 - 0.026
0.03
Replace
Standard size
Valve spring
D375A-6
Repair limit
Free length
Installed length
Installed load
Free length
Installed load
75.2
55.9
136.3 N
{13.9 kg}
67.7
122.6 N
{12.5 kg}
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
6-spool valve for dual tilt
Appearance
D375A-6
(04)
60-79
60-79
60-79
60-79
DRAFT
Hydraulic system
Control valve
Sectional view(1/4)
60-80
D375A-6
DRAFT
Hydraulic system
Control valve
Unit:mm
No.
Item
Criteria
Remedy
Standard size
Steering signal spring

(only for blade lift)
Repair limit
Freelength x
Outside
diameter
Installed
length
Installation
load
Free length
Installation
load
73.9 30
68.5
202 N
{20.6 kg}
162 N
{16.5 kg}

(for blade tilt)
51.12 31.3
47.8
279 N
{28.5 kg}
224 N
{22.8 kg}
Spool return spring (for ripper)
51.7 31.3
50
140 N
{14.3 kg}
112 N
{11.4 kg}

54.7 36.5
33.5
217 N
{22.1 kg}
174 N
{17.7 kg}
Load check valve spring
20.8 12.2
13.5
12.7 N
{1.3 kg}
10.2 N
{1.04 kg}
Pressure compensation valve

spring
108.3 29.5
81
562 N
{57.3 kg}
449 N
{45.8 kg}
Unload valve spring
86.7 30
66
193 N
{19.63 kg}
154 N
{15.7 kg}
D375A-6
If damaged or
deformed, replace
spring
60-81
DRAFT
Hydraulic system
Control valve
(2/4)
60-82
D375A-6
DRAFT
Hydraulic system
Control valve
(3/4)
Unit:mm
No.
Item
Criteria
Remedy
Repair limit
Standard size
Suction valve spring
Check valve spring
D375A-6
Freelength x
Outside diameter
Installed
length
Installation
load
Free length
Installation
load
64.9 12.5
56
6.37 N
{0.65 kg}
5.10 N
{0.52 kg}
9.4 4.6
7.75
0.49 N
{0.05 kg}
0.39 N
{0.04 kg}
If damaged or
deformed, replace
spring
60-83
DRAFT
Hydraulic system
Control valve
(4/4)
Unit:mm
No.
Item
Criteria
Remedy
Repair limit
Standard size
Check valve spring
60-84
Freelength x
Outside diameter
Installed
length
Installation
load
Free length
Installation
load
27.9 6.5
22.5
14.7 N
{1.5 kg}
11.8 N
{1.2 kg}
46.8 7.5
40.6
5.49 N
{0.56 kg}
If damaged or
deformed,
replace spring
4.41 N
{0.45 kg}
D375A-6
Hydraulic system
Control valve
5-spool valve for single tilt

Appearance
D375A-6
(04)
60-84-1
60-84-1
60-84-1
Hydraulic system
Control valve
60-84-2
60-84-2
D375A-6
(04)
Hydraulic system
Control valve
Unit: mm
No.
2
3
4
5
6
Item
Criteria
Standard size
Free length x OutLoad at
Installed length
side diameter
installed length
202 N
73.9 30
68.5
{20.6 kg}
94.1 N
51.12 31.3
50
(for blade tilt)
{9.6 kg}
Spool return spring (for
140 N
51.7 31.3
50
ripper)
{14.3 kg}
217 N
54.7 36.5
33.5
{22.1 kg}
Load check valve
12.7 N
20.8 12.2
13.5
spring
{1.3 kg}
193 N
Unload valve spring
86.7 30
66
{19.63 kg}
D375A-6
(04)
Remedy
Repair limit
Load at
Free length
installed length
162 N
{16.5 kg}
75.3 N
If damaged or
{7.7 kg}
deformed, replace
112 N
spring
{11.4 kg}
174 N
{17.7 kg}
10.2 N
{1.04 kg}
154 N
{15.7 kg}
60-84-3
Hydraulic system
Control valve
(2/4)
60-84-4
60-84-
D375A-6
(04)
Hydraulic system
Control valve
60-84-5
(3/4)
Unit: mm
No.
Item
1 Suction valve spring
2 Check valve spring
D375A-6
(04)
Criteria
Remedy
Standard size
Repair limit
Load at
Free length x
Load at
Installed length
Free length
If damaged or
installed length
Outside diameter
installed length
deformed, replace
5.10 N
6.37 N
64.9 12.5
56
spring
{0.52 kg}
{0.65 kg}
0.49 N
0.39 N
9.4 4.6
7.75
{0.05 kg}
{0.04 kg}
60-84-5
Hydraulic system
Control valve
60-84-6
(4/4)
Unit: mm
No.
Item
Check valve spring
60-84-6
Criteria
Standard size
Free length x OutLoad at installed
Installed length
side diameter
length
14.7 N
27.9 6.5
22.5
{1.5 kg}
5.49 N
46.8 7.5
40.6
{0.56 kg}
Remedy
Repair limit
Free length
Load at installed
length
11.8 N
{1.2 kg}
4.41 N
{0.45 kg}
If damaged or
deformed,
replace spring
D375A-6
(04)
DRAFT
Hydraulic system

General view
D375A-6
60-85
DRAFT
Hydraulic system
Sectional view
No.
Item
Criteria
Remedy
Standard size
Pressure reducing value main

spool spring
Repair limit
Free length x
Outside
diameter
Installed
length
Installed load
Free length
Installed load
70.91 18
56
250 N
{25.52 kg}
200 N
{20.4 kg}
Pressure reducing valve pilot

spring
17.8 7.2
12.7
28.0 N
{2.86 kg}
22.5 N
{2.29 kg}
Safety valve spring
16.13 7.8
13.4
61.8 N
{6.3 kg}
49.4 N
{5.04 kg}
Spool return spring
19.15 7.2
16.05
19.6 N
{2.0 kg}
15.7 N
{1.6 kg}
60-86
If damaged or
deformed, replace
spring
D375A-6
DRAFT
Work equipment
Cylinder stay
Work equipment
Cylinder stay
Unit: mm
No.
Item
Criteria
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
150
- 0.085
- 0.148
+ 0.063
0
0.085 0.211
0.5
Clearance between cylinder yoke

and bushing
115
- 0.072
- 0.126
+ 0.054
0
0.072 0.180
0.5
Clearance between lift cylinder

support shaft and bushing
105
- 0.120
- 0.207
+ 0.035
0
0.120 0.242
0.5
Clearance between cylinder yoke

and bushing
D375A-6
Standard
size
Remedy
Replace
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
No.
Item
Clearance between brace pin and

brace
Criteria
Standard
size
Tolerance
Remedy
Standard
clearance
Clearance
limit
Shaft
Hole
75
- 0.2
- 0.3
+ 0.3
+ 0.1
0.3 - 0.6

bracket
75
- 0.2
- 0.3
+ 0.3
+ 0.1
0.3 - 0.6

bracket
75
- 0.2
- 0.3
+ 0.3
0
0.2 - 0.6

bushing
75
- 0.2
- 0.3
+ 0.2
0
0.2 - 0.5
Clearance between spherical surfaces of center brace and cap
170
- 0.2
- 0.3
+ 0.3
0
0.2 - 0.6
Clearance between joint and

bracket
200
- 0.2
- 0.7
+ 0.3
+ 0.1
0.3 - 1.0
Clearance between frame pin and

joint
100
- 0.3
- 0.5
+ 0.3
0
0.3 - 0.8

bracket
100
- 0.3
- 0.5
+ 0.5
+ 0.2
0.5 - 1.0
Clearance between straight frame

joint bushings
160
+ 0.063
0
+ 0.174
+ 0.134
0.071 0.174
10
Clearance between spherical surfaces of trunnion and cap
200
- 0.5
- 1.0
+ 0.5
0
0.5 - 1.5
11

bracket
200
- 0.2
- 0.7
+ 0.3
+ 0.1
0.3 - 1.0
12
Clearance between blade pin and

joint
100
- 0.3
- 0.5
+ 0.3
0
0.3 - 0.8
13

bracket
100
- 0.3
- 0.5
+ 0.5
+ 0.2
0.5 - 1.0
14
Clearance between center link pin

and blade bracket
125
- 0.3
- 0.5
+ 0.5
+ 0.2
0.5 - 1.0
15

and center link
125
- 0.3
- 0.5
+ 0.5
+ 0.2
0.5 - 1.0
16
Clearance between center link and

blade bracket
280
- 0.2
- 0.4
+ 0.3
+ 0.1
0.3 - 0.7
17
Clearance between center brace

spherical surfaceand cap
170
- 0.2
- 0.3
+ 0.3
0
0.2 - 0.6
18

head pin and cylinder
65
- 0.3
- 0.5
+ 0.5
+ 0.2
0.5 - 1.0
19

head pin and cross joint
65
- 0.3
- 0.5
+ 0.3
0
0.3 - 0.8
20

side pin
65
- 0.3
- 0.5
+ 0.3
0
0.3 - 0.8
21
Clearance between cross joint and

side pin
65
- 0.3
- 0.5
+ 0.5
+ 0.2
0.5 - 1.0
Replace
Adjust shims or
replace
Replace
Adjust shims or
replace
Replace
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
No.
Item

brace
Criteria
Standard
size
Tolerance
Remedy
Standard
clearance
Clearance
limit
Shaft
Hole
75
- 0.2
- 0.3
+ 0.3
+ 0.1
0.3 - 0.6

bracket
75
- 0.2
- 0.3
+ 0.3
+ 0.1
0.3 - 0.6

bracket
75
- 0.2
- 0.3
+ 0.3
0
0.2 - 0.6

bushing
75
- 0.2
- 0.3
+ 0.2
0
0.2 - 0.5
Clearance between spherical surfaces of center brace and cap
170
- 0.2
- 0.3
+ 0.3
0
0.2 - 0.6

bracket
200
- 0.2
- 0.7
+ 0.3
+ 0.1
0.3 - 1.0

joint
100
- 0.3
- 0.5
+ 0.3
0
0.3 - 0.8

bracket
100
- 0.3
- 0.5
+ 0.5
+ 0.2
0.5 - 1.0
Clearance between straight frame

joint bushings
160
+ 0.063
0
+ 0.174
+ 0.134
0.071 0.174
10
Clearance between spherical surfaces of trunnion and cap
200
- 0.5
- 1.0
+ 0.5
0
0.5 - 1.5
11

bracket
200
- 0.2
- 0.7
+ 0.3
+ 0.1
0.3 - 1.0
12

joint
100
- 0.3
- 0.5
+ 0.3
0
0.3 - 0.8
13

bracket
100
- 0.3
- 0.5
+ 0.5
+ 0.2
0.5 - 1.0
14

and blade bracket
125
- 0.3
- 0.5
+ 0.5
+ 0.2
0.5 - 1.0
15

and center link
125
- 0.3
- 0.5
+ 0.5
+ 0.2
0.5 - 1.0
16
Clearance between center link and

blade bracket
280
- 0.2
- 0.4
+ 0.3
+ 0.1
0.3 - 0.7
17
Clearance between center brace

spherical surface and cap
170
- 0.2
- 0.3
+ 0.3
0
0.2 - 0.6
18

head pin and cylinder
65
- 0.3
- 0.5
+ 0.5
+ 0.2
0.5 - 1.0
19

head pin and cross joint
65
- 0.3
- 0.5
+ 0.3
0
0.3 - 0.8
20

side pin
65
- 0.3
- 0.5
+ 0.3
0
0.3 - 0.8
21
Clearance between cross joint and

side pin
65
- 0.3
- 0.5
+ 0.5
+ 0.2
0.5 - 1.0
Replace
Adjust shims or
replace
Replace
Adjust shims or
replace
Replace
D375A-6
60-91
DRAFT
Work equipment
Cutting edge and end bit

(Standard)
Unit: mm
No.
Item
Criteria
Remedy
Standard size
Repair limit
495
340
Height of end bit, outside

Replace
Width of end bit
740
600
Height of end bit, inside
395
335
Height of cutting edge
406
335 (264 after reversed)
60-92
Reverse or replace
D375A-6
DRAFT
Work equipment
(If equipped)
Unit: mm
No.
Item
Criteria
Remedy
Standard size
Repair limit
478
380
Height of end bit, outside

Replace
Width of end bit
734
600
Height of end bit, inside
393
300
Height of cutting edge
406
335 (264 after reversed)
D375A-6
Reverse or replace
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
No.
2
3
4
Item
Clearance between bushing and pin
for bracket and arm connection
Clearance between bushing and pin
for beam and arm connection
Clearance between cylinder mounting
pin and bushing
Clearance between shank and mounting pin
5 Wear of point
6 Wear of protector
D375A-6
(04)
Criteria
Tolerance
Shaft
Hole
- 0.036
+ 0.208
120
- 0.090
+ 0.125
- 0.036
+ 0.208
120
- 0.090
+ 0.125
- 0.036
+ 0.207
100
- 0.090
+ 0.120
Standard size
Tolerance
Standard
size
82
Remedy
Standard
clearance
Clearance
limit
0.161
1.5
0.298
0.161
1.5
0.298
0.156
1.5
0.207
Repair limit
0.3
Replace
Standard size
Repair limit
420
255
155
115
60-95
DRAFT
Work equipment
Ripper
60-96
D375A-6
DRAFT
D375A-6
SEN07777A-00
BULLDOZER
D375A-6
Shop Manual
Machine model
D375A-6
Serial number
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
(01)
80-1
DRAFT
Contents
Contents
80 Appendix
Air Conditioner..................................................................................................................................................
Caution about refrigerant ..............................................................................................................................
Air conditioner component ............................................................................................................................
Configuration and function of refrigeration cycle...........................................................................................
Outline of refrigeration cycle .........................................................................................................................
Air conditioner unit ........................................................................................................................................
Blower unit ....................................................................................................................................................
FRESH/RECIRC air changeover damper .....................................................................................................
Compressor ..................................................................................................................................................
Condenser ....................................................................................................................................................
Receiver drier................................................................................................................................................
Air conditioner control panel .........................................................................................................................
Procedure for testing and troubleshooting ....................................................................................................
Circuit diagram and arrangement of connector pins .....................................................................................
System diagram ............................................................................................................................................
Part and connector locations ........................................................................................................................
Testing temperature control ..........................................................................................................................
Testing FRESH/RECIC air changeover ........................................................................................................
Testing relay .................................................................................................................................................
Troubleshooting chart 1 ................................................................................................................................
Troubleshooting chart 2 ................................................................................................................................
Information in troubleshooting table..............................................................................................................
Troubleshooting for power supply system (Air conditioner does not operate) ..............................................
Troubleshooting for compressor system (Air is not cooled)..........................................................................
Troubleshooting for blower motor system (Air does not come out or air flow is abnormal) ..........................
Troubleshooting for temperature control.......................................................................................................
Troubleshooting for FRESH/RECIRC air changeover ..................................................................................
Troubleshooting with gauge pressure...........................................................................................................
Connection of service tool.............................................................................................................................
Precautions for disconnecting and connecting .............................................................................................
Handling of compressor oil ...........................................................................................................................
80-2
80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 -
3
3
4
6
7
10
14
15
16
17
18
20
22
24
26
28
32
32
34
36
38
40
42
44
48
54
56
58
60
62
64
D375A-6
(01)
DRAFT
Air Conditioner
Caution about refrigerant
Air Conditioner
k
Collect the air conditioner refrigerant (R134a)

from air conditioner circuit before disconnecting 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
a Never release the refrigerant (R134a) to the atmosphere.
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. Accordingly, 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 refrigerant (R134a). Collecting and filling work
must be conducted by a qualifier person.
D375A-6
(01)
80-3
DRAFT
Air Conditioner
Air conditioner component
80-4
D375A-6
(01)
DRAFT
Air Conditioner
A:
B:
C:
D:
E:
F:
Front window glass warm/cool air outlet

Overhead warm/cool air outlet
Side warm/cool air outlet
Front warm/cool air outlet
Recirculation air inlet
Fresh air inlet
Specifications
Refrigerant
Refrigerant refill capacity (g)
R134a
Approx. 1,100 100
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
(01)
80-5
DRAFT
Air Conditioner
Configuration and function of refrigeration cycle
Configuration and function of refrigeration cycle

Cycle
(Component)
Location
Compressor
Condenser
Expansion valve
Evaporator
Engine compartment
Front of radiator
In operators cab
(In air conditioner unit)
In operators cab
(In air conditioner unit)
Condenses refrigerant
to discharge heat
absorbed in evaporator.
(condensation of refrigerant)
Lowers temperature and

pressure of refrigerant liquid and gas for easy evaporation with throttle.
Controls flow rate, too.
(Throttle of refrigerant)
Evaporates refrigerant to
absorb heat from (or
cool) air around evaporator.
(Evaporation of refrigerant)
GasoLiquid
Constant pressure
change
LiquidoLiquid and gas

Adiabatic expansion
Liquid and gas oGas

Cnstant pressure change
Circulates refrigerant
gas and increases its
temperature and pressure so that it can be
Function
liquefied easily in condenser.
(Compression of
refrigerant)
GasoGas
State of refrigerAdiabatic compresant
sion
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
been vaporized in the evaporator and
compresses it into a state where it can be easily
liquefied at the ambient temperature.
The gaseous refrigerant sucked into the
compressor cylinder is compressed to a temperature and pressure at which it can be easily
liquefied when cooled to the ambient temperature.
2. Condensation (Condenser)
The condenser cools and liquefies the high pressure and high-temperature gaseous refrigerant
sent from the compressor.
The heat released to the outside from the
condenser is called condensation heat.
The amount of condensation heat is the sum
total of the heat absorbed by the evaporator from
the air in the cab and the quantity of the work
applied (the value converted into a heat quantity)
by compression of the compressor.
The refrigerant liquefied in the condenser is sent
to the receiver drier, where moisture is removed.
In the compression cycle, the gaseous refrigerant and liquid refrigerant coexist.
The temperature (condensation temperature)
and the pressure (condensation pressure) at
which the gaseous refrigerant is liquefied are
proportional to each other.
Reference: The pressure varies depending on
the condensation temperature of the refrigerant.
3. Expansion (Expansion valve)
The expansion valve reduces the liquid refrigerant pressure to a level where liquid refrigerant
can be easily evaporated by the throttle action
(*1).
The action of reducing the liquid refrigerant pressure 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 refrigerant 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 temperature (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
(01)
(*1) Throttle action

If there is a narrow section in the passage
through which liquid is flowing at a constant rate,
a resistance to the flow will be generated.
The liquid expands when it passes through the
narrow section and rushes into the passage
where the sectional area is larger,and consequently, its pressure and temperature are
reduced.
Heat is not transferred from or to the outside
during the throttle action.
4. Evaporation (Evaporator)
The evaporator evaporates the liquid refrigerant
(superheated vapor).
The refrigerant evaporates, while absorbing an
amount of heat necessary for evaporation (evaporation heat) from the air around the cooling fins
(air in the cab).
After the heat has been removed, the cooled air
is sent into the cab by the blower fan, reducing
the temperature inside the cab.
The mist refrigerant that has been sent from the
expansion valve coexists with the evaporated
refrigerant in the evaporator
The temperature (evaporation temperature) and
the pressure (evaporation pressure) at which the
liquid refrigerant is evaporated are proportional
to each other.
The compressor sucks in the evaporated refrigerant in order to keep the pressure level in the
evaporator as low as possible so that the liquid
refrigerant can be evaporated at a much lower
temperature.
80-7
DRAFT
Air Conditioner
Relationship between refrigerant and defective

air conditioning
q The refrigerant circulates in the refrigeration circuit while repeating the refrigeration cycle to expel 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 defective 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 defective air conditioning.
80-8
D375A-6
(01)
DRAFT
Air Conditioner
D375A-6
(01)
80-9
DRAFT
Air Conditioner
80-10
D375A-6
(01)
DRAFT
Air Conditioner
A:
B:
C:
D:
Refrigerant inlet (From condenser)

Refrigerant outlet (To compressor)
Hot water inlet
Hot water outlet
1: Evaporator
2: Heater core
3: Expansion valve
4: Air mix servomotor
5: Air mix door
6: Blower resistor
7: Evaporator temperature sensor
8: Hot water valve
9: Dual pressure switch
10: Compressor clutch relay
11: Condenser relay (Not used)
Functions of major components

Evaporator
q Evaporator (1) is cooled by the low-pressure,
low-temperature refrigerant gas being sent from
expansion valve (3). Air from the blower fan is
cooled and dehumidified when passing through
the evaporator fins.
Heater core
Heater core (2) is warmed by the hot water (engine coolant ) being sent from the engine. Air
from the blower fan is warmed as it passes
through the heater core fins.
Air mix servomotor
Outline
q The air conditioner unit consists of the evaporator (1) and heater core (2), and is used to cool
down or warm up the air in the cab.
Temperature control
When the temperature control switch on the air
conditioner control panel is operated, the air
conditioner control panel controls the air mix servomotor (4) which opens or closes the air mix
door (5) and hot water valve (8) to adjust the
temperature.
Overcooling (freeze) prevention

q Evaporator temperature sensor (7) varies its
electrical resistance according to temperature.
q The air conditioner control panel converts the
variation in resistance of the evaporator temperature sensor (7) into voltage and uses the voltage for detecting the evaporator (1)
temperature.
q The air conditioner control panel activates the
compressor clutch relay (10) to stop the compressor and to prevent the evaporator (1) from
freezing.
Air flow control
When the air flow control switch on the air conditioner control panel is operated, the air conditioner control panel controls the blower motor of
the blower unit through blower resistor (6) to adjust the air flow.
D375A-6
(01)
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 according to the terminal that receives the power.
q The variable resistor is built into the servomotor,
and its resistance changes as the motor rotates.
q A voltage of 5V is supplied to the variable resistor from the air conditioner control panel, and the
air conditioner control panel detects the motor
rotation angle based on the potential difference.
q When the air mix door reaches the position specified by the air conditioner control panel, the air
conditioner control panel stops current output to
the servomotor to stop the air mix door.
a Do not supply power directly between terminals
(3) and (5) of the servomotor to drive the servomotor for testing purposes.
q
80-11
DRAFT
Air Conditioner
Expansion valve
A: When evaporator outlet temperature is high

B: When evaporator outlet temperature is low
C: From receiver drier (high-pressure refrigerant)
D: To compressor (low-pressure refrigerant)
1. Expansion valve
1a. Needle valve
1a-1. Diaphragm
1a-2. Thermoprobe
1b. Spring
2. Refrigerant gas
3. Evaporator
Outline
The expansion valve converts high pressure and
high-temperature liquid refrigerant from the receiver 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 temperature in the cab.
q The temperature of the air blown out of the air
vent is adjusted depending on the volume of refrigerant circulating in the evaporator (3).
q
80-12
Structure
q Box-shape expansion valve (1) consists of needle valve (1a), spring (1b), etc.
q Refrigerant gas (2) is sealed in the diaphragm
chamber (hatched area) outside diaphragm
(1a-1) of needle valve (1a).
q The opening angle of needle valve (1a) is determined based on the balance between the reaction force exerted by spring (1b) in a rightward
direction, and force (Fg) of refrigerant gas (2)
pushing needle valve (1a) through diaphragm
(1a-1) in a leftward direction.
q The refrigerant flow rate flowing from the receiver drier to evaporator (3) is determined based on
the opening angle of needle valve (1a).
D375A-6
(01)
DRAFT
Air Conditioner
Operation
q Thermoprobe (1a-2) senses the refrigerant temperature after it passes through the evaporator
(3).
q After the refrigerant passes through evaporator
(3), its temperature is transferred to the refrigerant gas (2) in the diaphragm chamber (hatched
area) through the thermoprobe (1a-2).
q The pressure of the refrigerant gas (2) sealed in
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 determined based on the balance between the reaction force exerted by the spring (1b) in a
rightward direction, and the force (Fg) of the refrigerant gas (2) pushing the needle valve (1a)
through the diaphragm (1a-1) in a leftward direction.
When evaporator (3) outlet temperature is high
[Air in the cab is not cooled: condition (A) in the
figure]
q The refrigerant gas (2) pressure and the volume
are increased.
q The force (Fg) of the refrigerant gas (2) pushing
the needle valve (1a) is increased, and the needle valve (1a) moves leftward.
q As a result, the opening angle of the needle
valve (1a) is increased and the refrigerant flow
rate to the evaporator (3) is increased to improve
cooling capacity.
When evaporator (3) outlet temperature is low
[Air in the cab is already cooled: condition (B) in
the figure]
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 reduced and the refrigerant flow rate to the evaporator (3) is reduced to lower the cooling capacity.
D375A-6
(01)
Dual pressure switch

q The dual pressure switch turns "OFF" when the
refrigerant circuit pressure becomes abnormally
low or abnormally high.
q Turning the dual pressure switch "OFF" causes
the compressor clutch relay to turn "OFF". Then
the magnetic clutch of the compressor is released in order to protect air conditioner components.
a LA or low: Abnormally low pressure

a HA or high: Abnormally high pressure
LA: 0.20 MPa {2 kg/cm2}
LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
Evaporator temperature sensor
To prevent the evaporator from freezing, the
evaporator temperature sensor varies its electrical resistance with the evaporator temperature,
and the temperature is monitored via the air conditioner control panel.
80-13
DRAFT
Air Conditioner
Blower unit
Blower unit
1. Blower motor
2. Blower fan
3. FRESH/RECIRC air changeover servomotor
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 operated, the air conditioner control panel supplies
a current to the servomotor (3).
Functions of major components
Blower motor
q The blower motor (1) rotates the blower fan (2)
to suck air and send it to the evaporator and
heater core.
80-14
The FRESH/RECIRC air changeover servomotor (3) receives the drive current from the air conditioner control panel, and opens or closes the
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 according to the terminal that receives the power.
a Do not supply power directly to drive the servomotor for testing purposes.
q
D375A-6
(01)
DRAFT
Air Conditioner
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
(01)
80-15
DRAFT
Air Conditioner
Compressor
Compressor
A: Refrigerant inlet (From air conditioner unit)

B: Refrigerant outlet (To condenser)
1. Pulley
2. Magnetic clutch
3. Relief valve
Function
q The compressor circulates the refrigerant and
compresses the gaseous refrigerant from the
evaporator into a misty refrigerant at high pressure and high temperature so that it will be easily
regenerated (liquefied) at the normal temperature.
q Its built-in magnetic clutch (2) is engaged or disengaged according to the evaporator temperature and refrigerant pressure.
q If the clutch is engaged, the power of the engine
rotates the compressor shaft to drive the compressor.
Specifications
Number of cylinder Bore x
Stroke
(mm)
Piston capacity
(cc/rev)
Allowable maximum speed
(rpm)
80-16
10 - 32 x 20.8
157.3
6,000
Refrigerant oil used
Denso:ND-OIL8 (For
R134a)
Compressor oil refill capacity

(cc)
180
D375A-6
(01)
DRAFT
Air Conditioner
Condenser
Condenser
A: Refrigerant inlet (From compressor)

B: Refrigerant outlet (To receiver drier)
Function
q The condenser cools and liquefies the high pressure and high temperature misty refrigerant from
the compressor.
Specifications
Fin pitch (mm)
Height width thickness
(mm)
Max. working pressure
(MPa{kg/cm2})
4.0
350 x 570 x 16
3.6 {36}
a If the fin is crushed or is clogged with dust, heat

exchange efficiency is reduced and complete liquefaction of refrigerant becomes impossible.
If the heat exchange efficiency is reduced, pressure 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
(01)
80-17
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 liquefied completely ever when it contains bubbles
due to the lowerd heat dissipation of the condenser.
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)
Weight of desiccating agent
(g)
370
290
A: Refrigerant inlet (From condenser)

B: Refrigerant outlet (To air conditioner unit)
80-18
D375A-6
(01)
DRAFT
Air Conditioner
Receiver drier
D375A-6
(01)
80-19
DRAFT
Air Conditioner
Air conditioner control panel
NO
Model
1 Air conditioner switch
2 RECIRC/FRESH switch
3 Fan switch
4 Temperature control switch
80-20
Function
Switch to start and stop cooling, drying or heating function
(When the fan switch is turned "ON" and the air conditioner
switch is pressed, the indicator lamp above the switch lights
up.)
Switch to select RECIRC or FRESH air
(When the switch is pressed, the indicator lamp above the
selected switch lights up.)
Operation
OFFioON
RECIRC
IO
FRESH
OFF: Off
Switch to adjust fan speed in 4 levels
LO: Low
(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(The rough outlet air temperature is indicated by the tempera- tureioHigh temperture level indicator lamp above the switch.)
ature
D375A-6
(03)
DRAFT
Air Conditioner
Outline
q The air conditioner control panel has a CPU
(Central Processing Unit) that processes the input signals from each sensor and the control signals from each switch, and displays them on the
panel and controls the servomotors and relays.
Input/Output signal
AMP 172021-2-16P
Pin No.
Signal name
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Power supply
Blower main relay
Blower medium 1 relay
Blower high relay
Compressor clutch relay
NC (*)
NC (*)
Air mix servomotor potentiometer
signal
NC (*)
NC (*)
Sensor GND
DIS_SEL0 (GND)
NC (*)
Air mix servomotor potentiometer
power supply
D375A-6
(01)
Input/Output signal
Input
Output
Output
Output
Output
Output
Input
Input
Input
Output
-
AMP 172245-2-12P
Pin No.
Signal name
17
18
19
20
21
22
23
24
25
26
27
28
NC (*)
NC (*)
Air mix servomotor (B)
Air mix servomotor (A)
FRESH/RECIRC air changeover
servomotor (FRESH)
FRESH/RECIRC air changeover
servomotor (RECIRC)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
Input/Output signal
Output
Output
Output
Output
-
Output
80-21
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 defective 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 refrigerant 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.
1
2
3
4
5
6
7
8
Code
24V
RL-BM
RL-ME1
RL-ME2
RL-HI
RL-CC
NC
NC
TH-F
10
S-AM
11
12
13
14
15
NC
NC
GS
GND
NC
16
AMP-5V
AC3
Pin No.
17
18
19
20
Code
NC
NC
M-AMB
M-AMA
21
M-RFF
22
M-RFR
23
24
25
26
27
28
NC
NC
NC
NC
NC
NC
q
q
q
q
q
Signal name
24V power supply
Blower main relay
Blower HI relay
Compressor clutch relay

(Thermistor voltage)
A/M servo potentiometer voltage
Input/output
Input
Output
Output
Output
Output
Output
Input
Input
Sensor GND
GND
Output
Input
A/M servo potentiometer 5V

power supply
Output
Signal name
A/M servo B terminal

A/M servo A terminal
Fresh air terminal of
Recirculated air terminal of
Input/output
Output
Output
Output
Output
NC: No connection
RL-: Relay
M-: Servomotor
AM: Air mix
RF: Recirculation/Fresh (recirculated/fresh air)
D375A-6
(01)
80-25
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-diagnosis 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
(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 compressor clutch relay is turned OFF and the compressor stops.
D375A-6
(03)
80-27
DRAFT
Air Conditioner
Part and connector locations

The air conditioner unit, blower unit and various relays are in the dashboard.
a Right figure shows condition with cover (1)
removed.
q Circuit breaker CB4 (4th from the top) :
For power supply for blower motor, air conditioner 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 problem. 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")
a Condition with cover (4) removed

q AC2, AC3: Air conditioner control panel
connectors
q CP: Air conditioner control panel
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)

removed
q BM: Blower motor
q CN-B: Blower motor connector
q R/FS: FRESH/RECIRC air changeover
servomotor
q CN-S: Connector of FRESH/RECIRC air
changeover servomotor
q MAIN: Blower main relay
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
(01)
6. Disconnect connectors AC2 and AC3 and

remove air conditioner control panel CP and its
bracket as a unit. (Described above)
a Condition with air conditioner control panel
CP removed
q AC1: Connector between air conditioner control panel and air conditioner unit
7. Remove brackets (7) and (8).
80-29
Air conditioner
Parts and connectors layout
a Condition with brackets (7) and (8) removed

A/MS: Air mix servomotor
q CCR: Compressor clutch relay
q CDR: Condenser relay (Not applicable for this machine)
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
q [6]: Condenser relay connector (Not applicable for this machine)
q
80-30
D375A-6
(06)
DRAFT
Air Conditioner
8. Remove the cover between operator cab and

engine hood.
10. Remove duct (10).
q
q
A/C UNIT: Air conditioner unit

BR: Blower resistor
D375A-6
(01)
80-31
DRAFT
Air Conditioner
Testing temperature control

Outline
The angle of the door (damper) in the air conditioner
unit is changed with air mix servomotor (AM/S) in order to switch the air path between the hot air path to
the heater and the cold air path to the evaporator.
Moreover, for heating, the hot water valve changes
the quantity of the hot water from engine by controlling the opening angle of valve through the shaft and
controls the outlet air temperature.The shaft and hot
water valve lever can be seen from outside.
.
1. With reference to "Parts and connector locations", remove the air conditioner control panel
and its bracket as a unit.
Testing FRESH/RECIC air changeover

Outline
changes the angle of FRESH/RECIRC air changeover door (damper) through the lever and cable to
switch the air between the recirculated air and fresh
air. Visually check the operation of the lever and
opening and closing of the door (damper).
1. Remove the recirculated air filter cover from
lower part of the dashboard.
2. Check that cable (1) is not disconnected from the
level. (Check its connection to the
FRESH/RECIRC air changeover door (R/FD),
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 positions 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 visually 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 "Troubleshooting for temperature control".
80-32
D375A-6
(03)
DRAFT
Air Conditioner
Testing FRESH/RECIC air changeover
D375A-6
(01)
80-33
Air conditioner
Testing relay
Testing relay
a If the air conditioner compressor is normal and
the cool air flow rate is adjusted to the four levels, skip this test.
a Listen closely to the relay to check the operation
sound.
Condenser relay CDR among six relays is not used.
q Compressor clutch relay CCR, connector [5]:
For ON/OFF of air conditioner compressor
(clutch)
q Blower main relay MAIN, connector R1:
For ON/OFF of blower motor
q Blower relays of HI, ME2 and ME1:
For air flow adjustment
1. Remove the recirculated air filter cover from
lower part of the dashboard.
2. With reference to the parts and connectors
arrangement, remove cover (1).
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 compressor relay ON in the following cases.
q When the evaporator temperature is 3C or
below (temperature sensed by the evaporator temperature sensor)
a Compressor clutch relay (CCR) does not turn
ON in the following cases.
q When the dual pressure switch detects abnormal pressure (the dual pressure switch is
OFF)
80-34
80-34
a If the fan sound is so large that you cannot
hear the operation sound of the compressor
relay, set the starting switch to OFF position
and disconnect connector R1 and then perform the test.(*)
7. Operation check of relay responding to air flow
switch operation
a If the fan sound is so large that you cannot
hear the operation sound of the compressor
relay, set the starting switch to OFF position
and disconnect connector R1 and then perform the test.(*)
1) Set starting switch to ON position (with
engine stopped) and turn air conditioner
switch ON.
2) Set the air flow to HI, ".." and "." in order to
turn relays HI, ME2 and ME1 ON respectively. Check their operation sounds (click).
a If the air flow is set to LO, ME1 relay turns
OFF.
q
X view
Y view
*: Since the connector R1 is disconnected, the

blower does not start and the pressure in air
compressor hose (high-pressure hose) may rise.
D375A-6
(06)
DRAFT
Air Conditioner
Testing relay
Testing for relay units

a Since no T-adapter is available, it is actually
impossible to check each relay while applying 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
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
(01)
80-35
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
(01)
80-37
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
Defective blower main relay
Check method
See Testing relay
Check connector of blower fan motor for disconnection.
Open circuit or defective conSee "Troubleshooting of blower motor system" and "Parts and
nection of wiring harness
connector locations".
Check two lead wires of motor by using circuit tester. If there is
not continuity, motor is defective.
Defective blower fan motor
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
relay, blower HI relay
relay".
Remedy
Replace
Repair broken parts and
connect correctly
Replace
Replace
2. Blower fan motor is normal but air flow is insufficient.

Probable causes
Large airflow resistance
Check method
Check duct for crushing and clogging and filter for clogging
Check duct joints.
Air leakage through duct joints
Check for defective duct seal and disconnection of duct
Obstruction on suction side of
Check evaporator for dirt and obstruction
evaporator
Defective evaporator tempera- Check evaporator for freeze.
Check sensor clip. Check sensor for dirt.
ture sensor
Defective contact of evaporaCheck for frost on the hose near pressure switch (when freeztor temperature sensor or
ing advances furthermore)
defective expansion valve*
* The evaporator temperature sensor and expansion valve are in the air conditioner unit.
Remedy
Repair
Repair
Remove obstruction
and clean
Repair or replace
3. Low/high pressure
Probable causes
Check method
Excessive or insufficient refrigerant

Insufficient refrigerant
Check the normal refrigerant quantity through sight glass.

To be exact, check by connecting gauge manifold.
Excessive refrigerant
Judgment by pressure at
inlet/outlet of compressor
80-38
Normal refrigerant pressure

Low pressure side: Approx. 0.13-0.2 MPa {1.32.0 kg/cm2}
High pressure side: Approx. 1.5-1.7 MPa {15-17 kg/cm2}
Under following conditions:
Temperature inside cab: 30 - 35 C
Engine speed: Approx.1,500 rpm
Remedy
Collect the refrigerant
and refill with proper
amount of refrigerant.
Repair leaking part,
then refill with proper
Collect the refrigerant
and refill with proper
See Troubleshooting
with gauge pressure
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
Compressor
Loosened compressor belt
belt
Trouble in compressor
Insufficient compressor oil or
Compressor
seizure in the compressor
Low battery voltage
Disconnection or short circuit
in coil
Magnet clutch
Disconnection of wiring harness or defective connection
of ground wire
Defective compressor clutch
Relay
relay
Refrigerant
Low/high pressure (Operation
pressure
of pressure switch)
Pressure
Defective pressure switch
switch
Diode
Defective diode(ACS)
Check method
Remedy
Check for excessive deflection of belt.
Adjust tension
Check for slipping of belt.
Repair or replace
Check for compressor overheat
See "Handling compressor oil"
Slip of clutch
Charge battery
Inspect with circuit tester (10 - 20 )
Replace
Check ground wire and connections

Repair
See "Troubleshooting of compressor system".
See Testing relay
Replace
Troubleshooting with gauge pressure
Troubleshooting with
gauge pressure
See "Troubleshooting of compressor system". Replace

Check diode (ACS). See "Troubleshooting of
compressor system".
Replace
5. Blower fan motor is normal but air flow is insufficient.

Possible causes
Large airflow resistance
Check method
Remedy
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.

Possible causes
Low engine coolant temperature
Low engine coolant level
Insufficient circulation of
engine coolant
Contrary connection of IN and
OUT heater hoses
Check method
Remedy
Warm up engine, and then check engine coolant temperature Find out cause
Check coolant level in radiator
Check engine coolant piping for clogging
(Hose, pipe, and core)
Add coolant
Check the destination of heater hoses
Repair
Bleed air and repair
7. Fan speed is abnormal.

Possible causes
Fan speed is low
(Defective fan motor EPC or
hydraulic system)
Check method
Remedy
See "Testing fan motor speed" and "Testing fan pump circuit
pressure" in chapter 30 "Testing and adjusting" of Shop Man- Repair
ual.
8. Other abnormalities
Possible causes
Temperature cannot be controlled
Fresh air and recirculated air
cannot change.
Excessive compressor oil
Water leakage into the cab
D375A-6
(01)
Check method
Remarks
See "Testing temperature control" and "Troubleshooting for
Common to cooling and
temperature control"
See "Testing Recirc/Fresh air changeover" and "Troubleshoot- heating
ing for Recirc/Fresh air changeover"
See "Handling compressor oil"
Cooling only
Clogging of drain hole
80-39
DRAFT
Air Conditioner

a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before troubleshooting, understand the information fully.
Trouble
Related information
Cause
Possible causes for

trouble
(Perform troubleshooting according
to these numbers,
however.)
4 defective
Problem that appears on machine

Information related to detected trouble or troubleshooting
<Information described>
q Procedure
a "Between A B" means Measure voltage or resistance and so on between A B.
q Standard value in normal condition to evaluate possible cause if it is applicable or not
q Remarks requiredfor to evaluate the cause is correct
<Notes on troubleshooting>
(1) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus () leads as shown below unless otherwise 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
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 location.
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
(01)
80-41
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 equipment 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 "Troubleshooting for compressor system" and "Troubleshooting for blower motor system".
Probable causes
Activation of circuit breaker
1
(CB4)
2
(ground)
3 Defective wiring harness

If circuit breaker trips, circuit probably has ground fault etc.
2. Disconnect connector AC2 from control panel.
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.
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
a Perform the following when circuit breaker trips during test "A" above and the
test results "B" and "C" above are normal.
4. Disconnect connectors CN-B, R1 - R4 and [5].
Voltage
20 30 V
D
a If the test result "D" above is abnormal, air conditioner wiring harness is defective.
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 "Troubleshooting for compressor system" and "Troubleshooting for blower motor system".

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
(01)
80-43
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
machine
When engine is started and A/C switch is pressed while the blower is turned ON, air is not cooled.
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".
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 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.
q
Probable causes

2. Disconnect connector FEN from air conditioner compressor and connect
Defective air conditioner compresT-adapter to male side.
1
sor
Between FEN (1) and ground (air conditioner com- ResisApprox. 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
3
(on machine side)

4 (Contact with ground circuit)
(on machine side)
Defective compressor clutch relay

(It does not turn ON)
Defective evaporator temperature

sensor
80-44

2. Disconnect connector M26 and connect T-adapter to female side.
Between M26 (female) (3) and ground
ResisApprox. 15
(air conditioner compressor coil resistance)
tance
a If circuit breaker does not trip, this check is not required.
2. Disconnect connector FEN.
3. Insert T-adapter into connector M26.
ResisBetween M26 (female) (3) and ground
Min. 1 M
tance
ResisBetween 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.
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.
Resis0C
4.6 - 5.1 k
tance
Resis15C
2.1 - 2.6 k
Between AC1 (female) (15) and (17)
tance
Resis25C
1.5 k
tance
D375A-6
(03)
Air conditioner
Probable causes
7 Defective pressure switch
Check of voltage
8 (Defective wiring harness or
defective control panel)

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 conditioner compressor and check refrigerant pressure. (See "Troubleshooting with gauge pressure".)
Resistance 240 40 z
(compressor relay coil resistance)
k
When replacing pressure switch, collect refrigerant in advance.
1.
2.
3.
4.

Insert T-adapter into connector AC1.
Turn air conditioner switch ON.

a
1.
2.
3.
a
Voltage
Max. 1 V
Disconnect connectors M26, AC2, R1 - R4 and [5].
Insert T-adapter into connector AC1.
Check with circuit tester in continuity mode.
Between AC1 (10) and each pin other than (10)
No continuity
No continuity
10 Open circuit in wiring harness a Check with circuit diagram.

D375A-6
(06)
If check result for cause 8 is abnormal and check results for causes 9 and 10 are
normal, control panel is defective.
80-45
DRAFT
Air Conditioner
80-46
D375A-6
(01)
DRAFT
Air Conditioner
D375A-6
(01)
80-47
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)
Trouble
Problem that
appears on the
machine
Air does not come out or air flow is abnormal because of trouble in blower motor system
1) Air does not come out in any air flow setting.
q
When any fan switch is pressed, air does not come out.
Related information
For connectors, relays, etc., see "Parts and connector locations".

Since condenser relay is not used, it may be used as replacement when replacing other relays.
q
Causes
1 Defective blower (fan) motor
Defective blower main relay

(It does not turn ON)
Check of voltage
5 Disconnection in wiring harness

80-48

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.
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
Between AC1(11) and (1)
Voltage
Max. 1 V
2. Disconnect connectors M26, AC2, R1 - R4 and [5].
No continuity
a Check with circuit diagram.
D375A-6
(01)
DRAFT
Air Conditioner
D375A-6
(01)
80-49
DRAFT
Air Conditioner
Trouble
Air does not come out or air flow is abnormal because of trouble in blower motor system
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 frozen. 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 condiRelated infortioner 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.
Causes

3. Set air flow to each level in order.
If air comes out only in air flow HI, blower resistor is defective.
Defective blower resistor
q Reference: Between [1] (male) (1) and (2)
Approx.
1 (Breakage of fuse in blower
Resistance
a
Fuses
600
resistor)
Approx.
Resistance
900
Approx.
Resistance
530
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, orig2 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
5. Press each air flow switch and perform troubleshooting.
Check of voltage
HI
Voltage
Max. 1 V
Other
than
Voltage
20 30 V
HI
""
Voltage
Max. 1 V
Other than
Voltage
20 30 V
".."
""
Voltage
Max. 1 V
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].
4 Short circuit in wiring harness 3. Insert T-adapter into connector AC1.
No continuity
No continuity
No continuity
5 Disconnection in wiring harness a Check with circuit diagram.
D375A-6
(01)
80-51
DRAFT
Air Conditioner
80-52
D375A-6
(01)
DRAFT
Air Conditioner
D375A-6
(01)
80-53
DRAFT
Air Conditioner
Troubleshooting for temperature control

Failure
Problem on
machine
Temperature cannot be controlled
When temperature control switch is operated, temperature does not change.
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".
q T-adapter for connector CN-M26: 799-601-7130, T-adapter for connector AC1: 799-601-2730,
mation
T-adapter for connector [2]: 799-601-2710
Probable causes

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 defective.
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.
a Voltage appears for only approximately 1 second (only while hot water
valve is moving) and polarity is reversed when right triangle and left triVoltage
24 V
B
angle temperature control switch is
pressed. When right triangle switch
(WARM side) is pressed, polarity of
pin 3 becomes +.
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
Resistance Max. 1
Resistance Max. 1
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.
No continuity
No continuity
No continuity
No continuity
No continuity

4
D375A-6
(01)
80-55
DRAFT
Air Conditioner
Troubleshooting for FRESH/RECIRC air changeover

Trouble
Problem that
appears on
the machine
Fresh air and recirculated air cannot switch between them.

When FRESH/RECIRC air changeover switch on control panel is operated, fresh air or recirculated
air does not switch between them.
(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 (desconnection of cable, interference of lever, etc.)
Related inforq 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
q
Causes
4
5

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
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 recirVoltage
24 V
culated air
From recirBetween CN-S(5) (-) and (3) (+)
culated air to
Voltage
24 V
fresh air
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
Between AC1(6) and CN-S(5)
Resistance
Max. 1
2. Disconnect connectors M26, AC2, AC3 and [2].
Short circuit in wiring harness 3. Insert T-adapter into connector AC1.
No continuity
No continuity
If check result for cause 1 is abnormal and check results for causes 2 to 4 are norDefective control panel
mal, control panel is defective.
80-56
D375A-6
(01)
DRAFT
Air Conditioner
D375A-6
(01)
80-57
DRAFT
Air Conditioner

Referring to Connection of service tool, perform
troubleshooting by reading the gauge pressure of
the high-pressure and low-pressure lines in the refrigeration cycle.
a The gauge pressure varies largely with the
weather condition and operating condition of the
machine. Check the gauge pressure under the
pressure measurement conditions.
q High-pressure line pressure is too high: Above
approx. 2.5 MPa {25 kg/cm2}
q High-pressure line pressure is too low: Below
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 approx. 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.
<Measurement condition for pressure>

Item
Condition value
Ambient temperature
20 50 C
Engine speed
1,500 rpm
Air conditioner switch
ON
Fan switch
HI
Set temperature
Full cool
Dual pressure switch

a The swiths is normally "ON", and becomes
"OFF" for compressor operation when it detects
abnormal pressure.
LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
80-58
D375A-6
(01)
Air conditioner
Indicated gauge
pressure
Pressure is normal
Cause
Check method
Air conditioner cycle is normal.

If there is any trouble (cooling trouble), there is another cause.
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}
Remedy
Collect refrigerant, then

Bubble can be seen through sight glass
refill with proper amount
Insufficient refrigerant
(*1)(*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)
Replace
low-pressure lines Refrigerant leakage from thermoprobe
Low pressure gauge reads vacuum
tube of expansion valve
(*2)
are too low>
Repair or replace
Evaporator is frozen
Replace receiver drier
Low-pressure gauge
Defective evaporator temperature sensor Flow rate of refrigerant is reduced due to
reads vacuum
or defective contact of sensor (coming off freezing.
of mounting 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 compressor is clogged or crushed.
Clean or replace
Clogged or crushed piping
If clogged completely, low-pressure gauge
(*2)
reads vacuum
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 conDefective cooling of condenser
high-pressure and
fins, or defective revolution of cooling fan denser
low-pressure lines
(*2)
Defective adjustment of expansion valve Bubble can be seen through sight glass
Replace
are too high>
(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 differand 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
(06)
80-59
DRAFT
Air Conditioner
Connection of service tool

Symbol
X
Part No.
799-703-1200
Part name
Service tool kit
a Use the service tool kit for R134a.

Service tool kit X
(1): Gauge manifold
(2): High pressure charging hose (red)
(3): Low pressure charging hose (blue)
(4): Quick joint (Hi) (Large diameter)
(5): Quick joint (Lo) (Small diameter)
(a): The thread is rough. So be careful not to loosen.
80-60
Connect the gauge manifold, hoses and other service tools according to the following procedure.
1. Close the high-pressure valve (6) and low-pressure valve (7) of gauge manifold (1).
2. Connect red charging hose (2) to the (HI) side
and blue charging hose (3) to the (LO) side of the
gauge manifold.
3. Connect quick joints (4) and (5) to each hose.
4. Connect the quick joints (4) and (5) to the service
valves (8) and (9) of the high and low-pressure
pipings.
D375A-6
(01)
DRAFT
Air Conditioner
D375A-6
(01)
80-61
DRAFT
Air Conditioner
Precautions for disconnecting and connecting

Precautions for disconnecting
Precautions for connecting
Collect the air conditioner refrigerant (R134a)

from air conditioner circuit before disconnecting 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
a Never release the refrigerant (R134a) to the atmosphere.
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. Accordingly, put on protective goggles, gloves
and working cloth with long sleeves while
you are collecting the refrigerant (R134a) or
filling the air conditioner circuit with the refrigerant (R134a). Collecting and filling work
must be conducted by a qualified person.
q
q
q
When connecting the piping, apply compressor

oil NDOIL-8 for R134a to the O-rings. (See item
4. in Handling of compressor oil)
Do not apply oil to the threads of a bolt, nut or
union, however.
Once an O-ring is used, it is deformed and deteriorated. Accordingly, do not reuse it. When removing it, use a soft tool (such as a toothpick) so
that the piping will not be damaged.
Push in each pipe to the stopper and tighten the
bolt or nut fully with your fingers.
Be sure to use two wrenches to tighten each nut
(Use a torque wrench for tightening). Use one
wrench to fix and tighten the nut with the other
wrench to the specified torque.
When loosening the air conditioner hose nuts after collecting the refrigerant, be sure to use 2
wrenches; use one wrench to fix and use the other one to loosen the nuts.
80-62
D375A-6
(01)
DRAFT
Air Conditioner
Table of tightening torque for refrigerant pipe joint.

Screw size
Approx. M6 1.0
Approx. M16 1.5
Approx. M24 1.5
Unit: Nm {kgm}
Tightening torque
3.9 6.9 {0.4 - 0.7} (Receiver drier)
8 - 12 {0.8 - 1.2} (A/C unit and compressor)
12 - 15 {1.2 - 1.5}
30 - 35 {3.1 - 3.6}
1. Engine
2. Compressor
3. Condenser
4. Receiver drier
5. Air conditioner unit
D375A-6
(01)
80-63
DRAFT
Air Conditioner
Handling of compressor oil

1. Control of compressor oil (Denso: ND-OIL8:
For R134a)
Compressor oil does not need to be checked or added so frequently as engine oil. Insufficiency or excess of compressor oil can cause the following
troubles.
Condition
Contents
Insufficiency of Lubrication trouble and seizure of comoil
pressor
Cooling trouble
Excess of oil
(Excessive oil stick to parts and lower
heat exchange performance)
Accordingly, compressor oil must be filled to the

specified level, similarly to refrigerant.
2. Adding of compressor oil

k
Since refrigerant is dangerous and bad for

environment, collect the refrigerant before
disconnecting the air conditioner hose. See
Caution about refrigerant.
a If oil for CFC-12 (R-12) is used, lubrication trouble will occur and the compressor may be broken
or seized.
Be sure to use the specified oil for R134a
(Denso: ND-OIL8)
a Oil for R134a absorbs moisture very easily. Accordingly, fit the cap to the oil container immediately after using the oil to shield against the
atmosphere.
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 plastics.
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 replaced

Air conditioner par
Air conditioner unit, evaporator
Condenser
Receiver drier
Hose (Compressor Cab)
Hose (Compressor Condenser)
Hose(Condenser
Receiver driver)
Hose (Cab Receiver driver)
80-64
Quantity to be
added (cc)
Approx. 40
Approx. 40
Approx. 20
Approx. 30
Approx. 10
Approx. 10
Approx. 20
D375A-6
(01)
DRAFT
Air Conditioner
3. Compressor replacement
q
In case of compressor seizure or breakage.

Metal chips will circulate through the air conditioner circuit and contaminate the compressor oil
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 specified quantity (180 cc) filled in it.
4. Applying compressor oil to O-ring

When connecting a pipe or hose, apply oil (Denso:
ND-OIL8) to its O-ring to prevent refrigerant leakage.
Other cases
a New compressor has 180 cc compressor oil in it.
So drain excessive compressor oil before installing 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
(01)
80-65
DRAFT
Air Conditioner
80-66
D375A-6
(01)
SEN0500633-03
90-1
D375A-6
Bulldozer
D375A-6
Shop Manual
Machine model
Serial number
D375A-6
60001 and up
90 Diagrams and drawings
D375A-6
(06)
9-01
90-1
90-1
Contents
Contents
90 Diagrams and drawings
Hydraulic diagrams and drawings ...........................................................................................
Symbols used in hydraulic circuit diagrams .........................................................................
Power train hydraulic diagrams and drawings .....................................................................
Hydraulic circuit diagram......................................................................................................
Electrical diagrams and drawings ...........................................................................................
Symbols used in electrical circuit diagrams .........................................................................
Electrical circuit diagram ......................................................................................................
90-2
90-2
90- 3
90- 3
90- 5
90- 7
90- 9
90- 9
90- 13
D375A-6
(06)
Hydraulic diagrams and drawings

Symbols used in hydraulic circuit diagrams
90-3
90-3
(Rev. 2010/02)
Symbol
Substance
Main piping line
Pilot or drain line
Flexible pipe (hose, etc.)
Lines intersecting without joining
Lines joining (junction with a round black mark)
Direction of flow
Throttle in passage.
Variable
Electricity
Spring
Take-off port
Take-off port and pressure gauge
Check valves
Suction (with strainer)
Tank and return pipe
Filter
Oil cooler
Stop valve
Drive shaftunidirectional
Drive shaftbidirectional
D375A-6
(06)
90-3
DRAFT
Symbols used in hydrauric cirxuit diagrams
Symbols
Substance
Pump
Note : Black triangle shows outlet port
Variable capacity hydraulic pump

Hydraulic motor (The figure shows bidirectional type.)
NoteTwo black triangles in the figure show direction of oil entering hydraulic motor
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
When the figure shows air pressure, being released to atmosphere.
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)

D375A-6
DUAL TILT SPEC.

D375A-6
(04)
90-7

D375A-6
SINGLE TILT SPEC.

D375A-6
(04)
90-7-1
DRAFT
Electrical diagrams and drawings
Symbol use in electric circuit diagram

Symbol
Substance
Electric wire
Electric wire Wires intersecting without connecting
Electric wire Wires intersecting and connecting (junction) with a round

black mark
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
Note
Convex side of connecting portion (right in figure): male
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)

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
Accumulator
10-126
Adjusting blade
30-75
30-54
30-38
30-68
Adjusting position of PCCS lever console
30-57
30-73
30-52
30-14
30-74
30-140
80-4
80-20
80-10
B
Blade
60-88
Blade control lever (only for the machine with dual tilt
specification)
10-145
30-37
30-31
Bleeding air from work equipment cylinders
30-72
Blower unit
80-14
C
Cab
10-182
Cab mount
10-181
Carrier roller
60-54
80-3
Checking location of cause of hydraulic drift of blade and
ripper
30-70
40-11
Circuit diagram and arrangement of connector pins 80-24
Classification and procedures for troubleshooting 40-36
50-6
Compressor
80-16
Condenser
80-17
Configuration and function of refrigerating cycle
80-6
80-60
40-52
40-88
Control valve
10-158, 60-79
Conversion table
00-43
Cooling fan motor
10-26, 60-12
Cooling fan pump
10-6, 60-5
Cooling system
10-4
10-194
60-92
Cylinder stay
10-180, 60-87
D
10-38, 60-16
50-300
50-282
50-219
50-210
D375A-6
(07)

50-277
Disassembly and assembly of damper assembly 50-90
50-262
50-173
50-304
Disassembly and assembly of hydraulic cylinder
assembly
50-287
50-192
50-253
Disassembly and assembly of one link assembly in the
field
50-248
50-323-2
50-109
50-201
Disassembly and assembly of ripper pin puller cylinder
assembly
50-295
50-285
50-153
Disassembly and assembly of TORQFLOW transmission
assembly
50-125
50-115
50-206
Disconnection and connection of power train unit
assembly
50-100
E
40-547
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
40-558
40-560
E-7 Engine coolant temperature gauge does not indicate
normally
40-561
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
40-567
Index
E-15 Gearshift mode does not change

40-567
40-568
E-17 Customize memory function does not operate
normally
40-568
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
40-570
40-572
40-574
40-576
40-577
40-584
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
40-600
90-13
Emergency escape method when there is failure in power
train
30-58
10-4, 30-6
Engine control
10-184
10-185
Engine mount
60-3
Engine preheat (electrical intake air heater)control
10-216
00-12
F
Failure code ([DK60KA) Acceleration sensor:
Disconnection
40-460
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

40-168
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
Failure code (CA1228) EGR Valve Servo Error 1 40-256
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 (CA1625) EGR Valve Servo Error 2 40-257
Failure code (CA1633) KOMNET Datalink Timeout Error
40-258
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 (CA2185) Throt Sens Sup Volt High Error
40-259
Failure code (CA2186) Throt Sens Sup Volt Low Error
40-260
Failure code (CA221) Ambient Press Sens High Error
40-204
Failure code (CA222) Ambient Press Sens Low Error
40-206
Failure code (CA2249) Rail Press Very Low Error 40-261
D375A-6
(07)
Index
Failure code (CA227) Sens Supply 2 Volt High Error

40-208
Failure code (CA2271) EGR Valve Pos Sens High Error
40-262
Failure code (CA2272) EGR Valve Pos Sens Low Error
40-264
Failure code (CA234) Eng Overspeed
40-209
Failure code (CA2351) EGR Valve Sol Current High Error
40-266
Failure code (CA2352) EGR Valve Sol Current Low Error
40-268
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
40-222
40-224
40-226
40-228
40-226
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 (D110KB) Battery Relay Drive Short Circuit
40-270
Failure code (D130KA) Neutral relay Disconnection
40-272
D375A-6
(07)
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
reduction
40-320
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
reduction
40-332
Index
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
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 (DK60KB) Acceleration sensor Short circuit
40-462
Failure code (DKH1KA) Pitch angle sensor Disconnection
40-464
D375A-6
(07)
Index
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 hot
short
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 Hot Short
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 Hot Short
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
D375A-6
(07)
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 ECMVDisconnection
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 Hot Short
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 Hot Short
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
Failure codes table
40-39
Final drive
10-103, 60-41
80-15
40-105
Index
H
H-1 No force (no drawbar pull)
40-604
H-2 No travel (at 2nd or 3rd speed)
40-606
H-3 No travel at all gear speeds
40-607
H-4 Machine travels only in one direction forward or in
reverse
40-608
H-5 Large time lag at gear speed shifting or
forward-reverse shifting
40-609
H-6 Steering is not possible
40-610
H-7 Steering is possible only on one side
40-611
H-8 Steering overrun occurs
40-612
H-9 Brake does not work
40-612
H-10 Torque converter is not lock-up
40-613
40-614
H-12 All work equipment operates slowly or lacks power
40-615
40-616
H-14 Blade lift speed is slow or lacks power
40-617
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
H-18 Excessive hydraulic drift of blade lift
40-619
H-19 Excessive hydraulic drift of blade tilt
40-619
H-20 Excessive hydraulic drift of ripper lift
40-620
H-21 Ripper pin puller cylinder does not work (giant ripper
attachment machine)
40-620
H-22 Blade pitch does not work (dual tilt attachment
machine)
40-621
H-23 Abnormal sound comes out from around work
equipment pump
40-621
H-24 Fan speed is abnormal (Sound and/or vibration are
abnormally large or engine over heats)
40-622
H-25 Operator's seat isolator quakes abnormally or
makes shocks (Machine with operator's seat isolator)
40-622
80-64
00-23
Handling of electric equipment and hydraulic component
00-14
30-24
Handling of no injection cranking operation
30-27
30-149
Handling of reduced cylinder mode operation
30-27
30-139
00-26
00-10
50-4
Hydraulic circuit diagram
90-7
Hydraulic cylinder
60-72
Hydraulic tank
10-124
I
Idler
60-50
Idler cushion
10-110, 60-48
40-545
Information in troubleshooting table 40-47,40-601,80-40
30-152
30-60
30-148
M
Machine monitor
10-198
Main frame
10-112, 60-60
10-48, 60-22
30-62
30-16
Measuring fan speed
30-35
Method of disassembling and connecting push-pull type
coupler
00-32
40-624
Monitor system
10-196
N
Notice of revision
O
ORBCOMM system
10-230
Outline of refrigerating cycle
80-7
Overall disassembly and assembly of track shoe 50-230
10-34
P
10-217
Parking brake valve
10-99, 60-40
80-28
PCCS lever
10-58
10-143
Pin puller switch
10-142
Pm Clinic service
30-181
40-9
Power train
10-32
Power train and lubricating pump
60-31
Power train hydraulic circuit diagram
90-5
10-36
Power train unit
60-14
10-121
PPC lock valve
10-127
PPC valve
10-129, 60-67
Precautions for disconnecting and connecting in air
conditioner piping
80-62
30-175
00-29
30-144
80-22
Q
Quick drop valve
10-141, 60-75
L
Lamp system

50-247
00-39
40-602
10-50, 60-23
10-215
Receiver drier
80-18
D375A-6
(07)
Index
Releasing remaining pressure in work equipment

cylinders
30-72
Releasing residual pressure from fuel system
30-25
50-63
50-318
50-298
50-214
Removal and installation of carrier roller assembly50-209
50-275
Removal and installation of cooling assembly (radiator,
after cooler, and hydraulic oil cooler)
50-54
50-33
50-86
50-63
50-325
50-73
Removal and installation of engine hood assembly 50-70
50-75
50-258
50-79
50-81
Removal and installation of fan pump assembly 50-273
Removal and installation of final drive assembly 50-171
Removal and installation of first bogie assembly 50-221
Removal and installation of floor frame assembly 50-313
Removal and installation of fuel injector assembly 50-28
50-24
50-83
50-61
50-266
50-192
50-328
Removal and installation of operator's cab assembly
50-309
50-323-1
Removal and installation of pivot shaft assembly 50-257
Removal and installation of power train pump and
lubrication pump assembly
50-169
50-93
50-59
50-49
50-196
50-308
50-170
50-264
Removal and installation of track frame assembly 50-186
Removal and installation of track roller assembly 50-203
Removal and installation of transmission controller
assembly and steering controller assembly
50-324
50-327
D375A-6
(07)
Removal and installation of work equipment pump

assembly
50-269
Replacing and adjusting alternator and air conditioner
compressor belt
30-34
30-150
Ripper
60-94
S
40-628
40-630
S-3 Engine does not pick up smoothly (follow-up is poor)
40-634
40-636
40-637
S-6 Engine lacks output (or lacks power)
40-638
40-640
S-8 Oil is consumed much (or exhaust gas color is blue)
40-642
40-643
40-644
S-11 Coolant contains oil (blows back or reduces)40-645
S-12 Oil pressure monitor lights up (drop in oil pressure)
40-646
S-13 Oil level rises (Water, fuel in oil)
40-647
S-14 Coolant temperature rises too high (Overheating)
40-649
S-15 Abnormal noise is made
40-650
40-651
S-17 Air cannot be bled from fuel circuit (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
Safety notice
00-5
Scavenging pump
10-55, 60-24
10-173, 60-85
Sensor
10-220
40-10
50-226
Simple test procedure for brake performance
30-53
50-16
30-82
Special tool list
50-9
01-3
Specifications
01-4
Sprocket
60-44
00-35
20-3
20-4
10-82
10-92, 60-39
10-90, 60-38
10-101
Suspensions
10-114, 60-62
Symbols used in electrical circuit diagrams
90-9
90-3
System diagram
80-26
T
Table of contents
40-102
00-2
01-11
Index

30-77
30-81-1
30-61
30-19
30-65
30-22
30-21
30-6
30-12
30-10
30-36
Testing FRESH/RECIC changeover
80-32
30-33
30-26
30-8
Testing leakage from pressure limiter and return rate from
injector
30-28
30-71
30-69
30-40
30-66
Testing relay
80-34
80-32
Tools for testing, adjusting, and troubleshooting
30-4
10-40, 60-19
10-46
Track frame
10-108, 60-46
Track roller
60-52
Track roller bogie
10-111, 60-55
Track shoe
60-56
10-84
60-32
Transmission
10-62, 60-26
10-56, 60-25
Transmission ECMV
10-76
10-81, 60-30
80-36
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
80-54
Troubleshooting method for disconnecting wiring harness
of pressure sensor system
40-49
80-58
Using method of KOMTRAX functions of ORBCOMM
terminal
30-172
V
10-224
W
Weight table
01-9
10-122
10-117
Work equipment pump
10-146, 60-76
D375A-6
(07)
Shop Manual
D375A-6 BULLDOZER
Form Number: SEN05006-09
2012 KOMATSU
All Rights Reserved
Printed in Japan 02-12

Komatsu D 375A-6

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SEN05006-09

Page to be newly added

List of revised pages

00 Index and Foreword

00 Index and Foreword

10 Structure,function and maintenance standard

Work equipment control ...............................................................................................................................

20 Standard value table

30 Testing and adjusting

Power train ......................................................................................................................................................

Failure code [15SBLH] Reverse clutch: Fill Low..........................................................................................

Failure code [CA342] Calibration Code Incompatibility................................................................................

Failure code [DD12KB] Shift up Sw: Short circuit ........................................................................................

Failure code [DK57KB] FR lever 2: Short circuit..........................................................................................

Failure code [F@BYNS] F exhaust temp high level (1) ...............................................................................

Troubleshooting of engine (S-mode)...............................................................................................................

50 Disassembly and assembly

Disassembly and assembly of track roller assembly ................................................................................... 50 -206

90 Diagrams and Drawings

Electrical diagrams and drawings.................................................................................................................... 90 - 9

Forword and general information

Forword and general information

Important safety notice

7) If welding repairs are needed, always have a

Forword and general information

5) When raising a heavy component (heavier

Forword and general information

12)When assembling or installing parts, always

7) Limit the hanging angle to 60 , as a rule.

8) When installing wire ropes to an angular

Forword and general information

11)Do not use twisted or kinked wire ropes.

10)Place the control switch on a position where

a The allowable load is one-sixth of the

Forword and general information

How to read the shop manual

Composition of shop manual

Revision and distribution

Special technical precautions or other precautions for preserving standards are

Weight of parts of component or parts. Caution necessary when selecting hoisting

Special safety precautions are necessary when performing work.

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

Places where oil, etc. must be added, and capacity.

Places where oil, etc. must be drained, and quantity to be drained.

Explanation of terms for maintenance standard

a The tolerance may be indicated in the text

2. Standard clearance and standard value

4. Repair limit and allowable value or allowable

Handling of electric equipment and hydraulic components

4) High-pressure water entering connector

3. Removing, installing, and drying connectors

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

3] Carry out a continuity test on the connector.

5. Points to remember when troubleshooting electric circuits

Points to remember when handling hydraulic components

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

5. Change hydraulic oil when the temperature is high

Handling of connectors newly used for engines

Pull lock type (PACKARD-2)

Push lock type (1)

While pressing up lock (C) of the connector with