Shop Manual D375A-6R Serial Numbers 65001 and Up SEN05214-01

SEN05214-01
BULLDOZER
D375A -6R
SERIAL NUMBERS
65001
and up
Notice of revision
Notice of revision
1st. 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
list below.
2010/3
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D375A-6R
SEN0521402-00
0-1
BULLDOZER
D375A-6R
Shop Manual
Machine model
Serial number
D375A-6R
0-1
65001 and up
00 Index and foreword
D375A-6R
0 -1
00-1
Shop Manual
Table of contents
Table of contents
0 -2
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 and function

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 lubrication 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..............................................................................................
10- 4
10- 4
10- 7
10- 28
10- 34
10- 34
10- 36
10- 38
10- 40
10- 42
10- 48
10- 50
10- 52
10- 57
10- 58
10- 60
10- 64
10- 78
10- 83
10- 84
10- 86
10- 92
10- 94
10- 102
10- 103
00-2
2
2
5
5
10
12
14
23
26
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39
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D375A-6R
(01)
Shop Manual
Table of contents
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 ........................................................................................................................
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 .............................................................................................................
10- 105
10- 110
10- 110
10- 112
10- 113
10- 114
10- 116
10- 119
10- 119
10- 123
10- 124
10- 126
10- 128
10- 129
10- 130
10- 142
10- 143
10- 145
10- 146
10- 148
10- 150
10- 162
10- 187
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10- 198
10- 198
10- 199
10- 208
10- 210
10- 212
10- 230
10- 231
10- 232
10- 235
10- 241
10- 247
20 Standard value table

Standard service value table .................................................................................................. 20Standard value table for engine........................................................................................... 20Standard value table for machine ........................................................................................ 2030 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....................................................................................................
D375A-6R
(01)
3
3
4
30- 4
30- 4
30- 6
30- 6
30- 9
30- 11
30- 14
00-3
Shop Manual
Table of contents
Adjusting valve clearance ....................................................................................................

Measuring compression pressure........................................................................................
Testing blow-by pressure.....................................................................................................
Testing engine 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 .........................................
Inspecting wear of sprocket .................................................................................................
Testing and adjusting track shoe tension.............................................................................
Hydraulic system.....................................................................................................................
Testing 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 ...................................................................................
Special functions of machine monitor (EMMS) ....................................................................
Handling of voltage circuit of engine controller ....................................................................
Adjustment method when controller has been replaced ......................................................
Preparation work for troubleshooting for electrical equipment 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 ..........................................................................
00-3-1
30- 16
30- 18
30- 21
30- 23
30- 24
30- 25
30- 26
30- 27
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30- 29
30- 32
30- 34
30- 35
30- 36
30- 37
30- 38
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30- 42
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30- 58
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30- 62
30- 64
30- 64
30- 65
30- 66
30- 66
30- 69
30- 70
30- 72
30- 73
30- 74
30- 75
30- 76
30- 77
30- 78
30- 80
30- 80
30- 81
30- 84
30- 84
30- 90
30- 90
30- 148
30- 149
30- 153
30- 157
30- 158
30- 159
30- 161
30- 175
30- 178
D375A-6R
(01)
Shop Manual
Table of contents
Pm Clinic................................................................................................................................. 30- 184

Pm Clinic service ................................................................................................................. 30- 184
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 ..............................................................................................................
Classification and procedures for troubleshooting numbers................................................
Information in troubleshooting table.....................................................................................
Troubleshooting method for disconnecting wiring harness of pressure sensor system ......
Connection table for connector pin numbers .......................................................................
T-branch box and T-branch adapter table ...........................................................................
Connector list and layout .....................................................................................................
Fuse locations table.............................................................................................................
Troubleshooting by failurecode...............................................................................................
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 ..........................................................................
D375A-6R
(01)
40- 10
40- 10
40- 11
40- 12
40- 37
40- 40
40- 50
40- 52
40- 54
40- 57
40- 93
40- 96
40- 110
40- 114
40- 114
40- 115
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- 168
40- 170
40- 172
40- 173
40- 174
40- 175
40- 176
40- 177
00-3-2
Shop Manual
Table of contents
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............................................................
Failure code [CA342] Calibration Code Incompatibility........................................................
Failure code [CA351] Injectors Drive Circuit 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 [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...............................................................
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D375A-6R
(01)
Shop Manual
Table of contents
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 24V reduction ........................................
Failure code [DBE7KK] PT cont.: Sensor voltage 5 V 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 ..........................................
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Table of contents
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 [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 [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 ......................................................................
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D375A-6R
(01)
Shop Manual
Table of contents
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..................................................
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Table of contents
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 ...............
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 ....................................................
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Shop Manual
Table of contents
H-16 Ripper lift cylinder speed is too slow or lacks power................................................... 40- 665
H-17 Ripper tilt cylinder speed is too slow or lacks power................................................... 40- 666
H-18 Excessive hydraulic drift of blade lift cylinder.............................................................. 40- 667
H-19 Excessive hydraulic drift of blade tilt cylinder.............................................................. 40- 668
H-20 Excessive hydraulic drift of ripper lift cylinder ............................................................. 40- 669
H-21 Ripper pin puller cylinder does not operate (machine with giant ripper) ..................... 40- 670
H-22 Blade pitch does not work (machine with dual tilt specification) ................................. 40- 671
H-23 Abnormal noise from around work equipment pump .................................................. 40- 672
H-24 Abnormal fan rotation(noise and/or vibration are abnormally large or engine overheats)40-673
Troubleshooting of engine (S-mode) ...................................................................................... 40- 674
Method of using troubleshooting chart................................................................................. 40- 674
S-1 Engine does not start easily .......................................................................................... 40- 678
S-2 Engine does not start .................................................................................................... 40- 679
S-3 Engine does not rev up smoothly (response-up is poor)............................................... 40- 682
S-4 Engine stops during operation ...................................................................................... 40- 683
S-5 Engine does not rotate smoothly (hunting) ................................................................... 40- 684
S-6 Engine lacks power (or output shortage) ...................................................................... 40- 685
S-7 Exhaust smoke is black (Incomplete combustion) ........................................................ 40- 686
S-8 Oil is consumption is excessive(or exhaust smoke is blue) .......................................... 40- 687
S-9 Engine oil becomes contaminated quickly .................................................................... 40- 688
S-10 Fuel consumption is excessive ................................................................................... 40- 689
S-11 Oil mixes into coolant(coolant blows back or is reduced) ........................................... 40- 690
S-12 Engine pressure monitor lights up (drop in engine oil pressure)................................. 40- 691
S-13 Oil level rises (Coolant or fuel mixes into oil) .............................................................. 40- 692
S-14 Coolant temperature rises too high (overheating)....................................................... 40- 693
S-15 Abnormal noise is heard ............................................................................................. 40- 694
S-16 Vibration is excessive.................................................................................................. 40- 695
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- 696
50 Disassembly and assembly
General information on disassembly and assembly ............................................................... 50How to read this manual ...................................................................................................... 50Coating materials list ........................................................................................................... 50Special tool list..................................................................................................................... 50Sketches of special tools ..................................................................................................... 50Engine and cooling system ..................................................................................................... 50Removal and installation of fuel supply pump assembly ..................................................... 50Removal and installation of fuel injector assembly .............................................................. 50Removal and installation of cylinder head assembly ........................................................... 50Removal and installation of radiator guard assembly .......................................................... 50Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler)50Removal and installation of radiator .................................................................................... 50Removal and installation of hydraulic oil cooler................................................................... 50Removal and installation of aftercooler................................................................................ 50Removal and installation of engine assembly...................................................................... 50Removal and installation of engine hood assembly............................................................. 50Removal and installation of engine front seal ...................................................................... 50Removal and installation of engine rear seal....................................................................... 50Removal and installation of fan drive assembly................................................................... 50Removal and installation of fan motor assembly ................................................................. 50Removal and installation of fuel tank assembly ................................................................... 50Power train.............................................................................................................................. 50Removal and installation of damper assembly .................................................................... 50D375A-6R
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Table of contents
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................................................................
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 ..............................................
Disassembly and assembly of master link ...........................................................................
Removal and installation of pivot shaft assembly ................................................................
Removal and installation of equalizer bar ............................................................................
Disassembly and assembly of equalizer bar bushing ..........................................................
Removal and installation of segment tooth ..........................................................................
Removal and installation of hydraulic tank assembly ..........................................................
Removal and installation of work equipment pump assembly .............................................
Removal and installation of fan pump assembly..................................................................
Removal and installation of control valve assembly ............................................................
Disassembly and assembly of control valve assembly ........................................................
Disassembly and assembly of blade PPC valve assembly..................................................
Disassembly and assembly of ripper PPC valve assembly .................................................
Disassembly and assembly of hydraulic cylinder assembly ................................................
Disassembly and assembly of ripper pin puller cylinder assembly ......................................
Work equipment......................................................................................................................
Removal and installation of blade assembly........................................................................
Disassembly and assembly of blade assembly ...................................................................
Disassembly and assembly of giant ripper assembly ..........................................................
Removal and installation of ROPS guard ............................................................................
Removal and installation of operator's cab assembly ..........................................................
Removal and installation of floor frame assembly ...............................................................
Removal and installation of air conditioner unit assembly ...................................................
00-3-9
50- 90
50- 93
50- 99
50- 108
50- 114
50- 123
50- 150
50- 166
50- 167
50- 168
50- 170
50- 183
50- 183
50- 188
50- 189
50- 193
50- 198
50- 200
50- 203
50- 206
50- 207
50- 211
50- 216
50- 218
50- 223
50- 227
50- 244
50- 245
50- 250
50- 254
50- 255
50- 259
50- 261
50- 262
50- 262
50- 265
50- 269
50- 271
50- 273
50- 278
50- 281
50- 283
50- 291
50- 294
50- 294
50- 296
50- 300
50- 303
50- 303
50- 304
50- 308
50- 313
D375A-6R
(01)
Shop Manual
Table of contents
Electrical system ..................................................................................................................... 50- 319

Removal and installation of transmission controller assembly and steering controller assembly
............................................................................................................................................. 50- 319
Removal and installation of engine controller assembly...................................................... 50- 320
Removal and installation of VHMS controller assembly ...................................................... 50- 322
Removal and installation of machine monitor assembly...................................................... 50- 323
60 Maintenance Standard
Engine mount.......................................................................................................................
Cooling fan pump.................................................................................................................
Cooling fan motor ................................................................................................................
Power train..............................................................................................................................
Power train unit....................................................................................................................
Main relief valve and torque converter relief valve ..............................................................
Scavenging pump ................................................................................................................
Transmission .......................................................................................................................
Transmission lubricating oil relief valve ...............................................................................
Power train and lubrication pump ........................................................................................
Transfer, bevel gear shaft and steering unit ........................................................................
Steering clutch ECMV and steering brake ECMV ...............................................................
Final drive ............................................................................................................................
Sprocket...............................................................................................................................
Track frame..........................................................................................................................
Idler cushion cushion ...........................................................................................................
Idler......................................................................................................................................
Track roller...........................................................................................................................
Carrier roller.........................................................................................................................
Track shoe ...........................................................................................................................
Main frame...........................................................................................................................
Suspension ..........................................................................................................................
Hydraulic system ....................................................................................................................
PPC valve ............................................................................................................................
Hydraulic cylinder ................................................................................................................
Quick drop valve ..................................................................................................................
Control valve........................................................................................................................
Work equipment......................................................................................................................
Cylinder stay ........................................................................................................................
Blade....................................................................................................................................
Cutting edge and end bit......................................................................................................
Ripper ..................................................................................................................................
60- 3
60- 3
60- 5
60- 12
60- 14
60- 14
60- 16
60- 19
60- 22
60- 23
60- 24
60- 25
60- 26
60- 31
60- 32
60- 34
60- 40
60- 41
60- 42
60- 43
60- 46
60- 48
60- 48
60- 50
60- 52
60- 54
60- 56
60- 57
60- 58
60- 62
60- 64
60- 68
60- 68
60- 74
60- 77
60- 78
60- 81
60- 94
60- 97
60- 97
60- 98
60- 102
60- 104
80 Appendix
Air conditioner ......................................................................................................................... 80D375A-6R
(01)
00-3-10
Shop Manual
Table of contents
Precautions for 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 ...................................................................................................................
Parts and connectors layout ................................................................................................
Testing temperature control .................................................................................................
Testing FRESH/RECIC air changeover ...............................................................................
Testing relay ........................................................................................................................
Troubleshooting chart 1 .......................................................................................................
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 ..................................................................................................
808080808080808080808080808080808080808080808080808080808080-
3
4
6
7
10
14
15
16
17
18
20
22
24
26
28
32
33
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 diagrams and drawings .....................................................................
Hydraulic circuit diagram......................................................................................................
Electrical diagrams and drawings ...........................................................................................
Symbols used in electrical circuit diagrams .........................................................................
Electrical circuit diagram ......................................................................................................
90- 3
90- 3
90- 5
90- 7
90- 11
90- 11
90- 15
Index .......................................................................................................................................
00-4
D375A-6R
(01)
Forword and general information

Safety notice
0 -5
Safety notice
0 -5
(Rev. 2010/02)
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.
D375A-6R
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.
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
Prohibition of operation and handling by unli5
censed workers
6 Safety check before starting work
Wearing protective goggles(for cleaning or grind7 ing work)
Wearing shielding goggles and protectors(for
8
welding work)
9 Good physical condition and preparation
Precautions against work which you are not used
10 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) Before starting work, remove the leads from
the battery. Always remove the lead from the
negative () terminal first.
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.
00-6
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.
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.
D375A-6R

Safety notice
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.
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}.
D375A-6R
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.
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.
00-7

Safety notice
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.
q
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.
10)Place the control switch on a position where
it will not be an obstacle to work and
passage.
11)After operating the hoist, do not swing the
control switch.
12)Remember the position of the main switch so
that you can turn off the power immediately in
an emergency.
00-8
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-6R

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-6R
00-9

How to read the shop manual
0 -10
(Rev. 2010/02)
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.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop. For
ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section contains the index, foreword and safety and basic information.If any revision 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 for the structure of each component, 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, as well as
the adjusting method of each part.The standard values and judgment criteria for "Testing and adjusting"
are explained in standard value table.
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
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not
classifiable in other sections.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of remanufacturing and repairing engine and replacing parts.
00-10
D375A-6R

2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
3. 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: (01), (02), (03)...)
q
Revisions
The revised pages are shown in the LIST OF REVISED PAGES.

4.Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will be
used practically.
Symbol
Item
Safety
Special safety precautions are necessary when performing work.
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
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.
5. 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-6R
00-11

Explanation of terms for maintenance standard
0 -12
(Rev. 2010/02)
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 dimension 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
Tolerance
Shaft
-0.030
-0.076
Hole
+0.046
0
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.
00-12
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.
D375A-6R

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 deviates from the allowable value, it must be checked or repaired. However,
since most of the allowable values are estimated from various tests or experiences in
most cases, it must be judged after considering the operating condition and customer's
requirement.
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.
D375A-6R
00-13

Handling of electric equipment and hydraulic components
0 -14
(Rev. 2010/02)
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.
0 -14
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defective
contact between male and female connectors)
Defective contact occurs due to improper
fitting between a male and female connectors, or displacement of one or both of the
connectors, or corrosion or oxidization on the
contact surfaces.When poor contact resulted
from a corroded or oxidized contact surfaces,
you can make it shiny again (normal condition is recovered) 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 and causes a
defective contact or the wire is broken.
00-14
D375A-6R

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
Since oil is not conductive, if oil or grease
adheres to the connector forms an oil film on
the mating surface of the male and female
connectors, it cause defective contact.If
adherence of oil or grease to a connector is
observed, wipe it off with a dry cloth or blow
it off with compressed air and then spray
contact restorer to the connector.
a When wiping the joint portion of the connector, be careful not to apply excessive
force or deform the pins.
a If oil or water is contained in the compressed air, contamination on the contacts is made worse. So remove such oil
and water from the compressed air completely before starting the cleaning process.
D375A-6R
00-15

3. Removing, installing, and drying connectors

and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when disconnecting.
When disconnecting a connector, hold
the connector.For connectors held by a
screw, loosen the screw fully, then hold
the male and female connectors in each
hand and pull them apart.For connectors
attached with 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 a connector, cover it with
a vinyl bag to prevent the entry of dust,
dirt, oil, or water to the contact 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-6R

2) Connecting connectors
1] Check the connector visually.
Check that no oil, dirt, or water is stuck to
connector pins (joint portion).
Check that connector pins are free from
deformation, defective contact, corrosion,
or damage.
Check that external surface of the
connectors is free from damage or
breakage.
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] Correcting protrusion of the boot and
misalignment of the wiring harness
For connectors fitted with the fuel spray
prevention caps, correct any extrusion of
the caps. In addition, if the wiring harness
is moved in laying, or the clamp is out of
position, correct it to its right 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-6R
00-17

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-6R

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 to be blown dry with
compressed air, there is the risk that
oil in the air may cause defective contact, remove oil and water in the air
before starting air blow.
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-6R
00-19

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 a place that can be heated to a high
temperature 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) Be sure to 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-6R

Points to remember when handling hydraulic components
0 -21
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. Therefore, special precaution is required when adding hydraulic oil,
or when disassembling or assembling hydraulic components.
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. Preventing intrusion of foreign materials

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 been collected during storage, so this is
an even more effective method.
D375A-6R
00-21

5. Replacing hydraulic oil while its 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
by use of flushing oil and secondary flushing is
carried out by use of the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic components (pump,
control valve, etc.) or when running the machine,
carry out oil cleaning to remove the sludge or
contaminants in the hydraulic oil circuit. The oil
cleaning components is used to remove the ultra
fine (about 3 m) particles that the filter built in the
hydraulic equipment cannot remove, so it is an
extremely effective device.
00-22
D375A-6R

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
0 -23
(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)
0 -23
(Rev. 2010/02)
Pull lock type (PACKARD-2)

0 -23
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.
0 -23
Disconnection
Disconnect the connector by pulling lock (B) (on the
wiring harness side) of connector (2) outward.
0 -23
Disconnection
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 pressing
lock L2, and then pull out connector (1) toward you.
Connection
Insert the connector straight until it "clicks".
Connection
D375A-6R
0 -23
0 -23
00-23

Push lock type (1)

95, 107, 114 engines
Example) Fuel pressure sensor in common rail
(BOSCH-03)
0 -24
While pressing up lock (C) of the connector with
flat-head screwdriver [1], pull out connector (3) in
the direction of the arrow.
0 -24
Disconnection
While pressing lock (C), pull out connector (3) in the
direction of the arrow.
q
114 engine
Connection
107 engine
0 -24
0 -24
Push lock type (2)
q 107, 114 engines
Example) Intake air pressure/temperature
sensor in intake manifold (SUMITOMO-04)
Disconnection
0 -24
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.
Connection
00-24
0 -24
D375A-6R

Push lock type (3)

q 95, 125 170, 12V140 engines
0 -25
0 -25
Disconnection
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)
0 -25
Turn-housing type (Round green connector)
q 140 engine
Example) Intake air pressure sensor in intake
manifold.
(CANNON-04): PIM, etc.
0 -25
Disconnection
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)
0 -25
Connection
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.
Connection
D375A-6R
0 -25
00-25

How to read electric wire code
0 -26
(Rev. 2010/02)
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
Using temperature
AV
AVS
Insulator
-30 +60

appliance
Insulator
General wiring
(nominal No. 5 and above.)
Conductor
CAVS
Conductor
AEX
Insulator

appliance
Heat-resistant crosslinked
polyethylene
Example of use
General wiring
(nominal No. 3 and below.)
For mid- to small-size excavators

(nominal No. 1.25 and below.)
-50 +110
General wiring in extremely cold

district, wiring at high ambient temperature place
For wiring in a place of high atmo-
D375A-6R

2. Dimensions
(Table 2)
Nominal No.
Conductor
Number of
strands/Diameter of strand
Sectional area
(mm2)
0.5f
(0.5)
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
Cover D
d (approx.)
Standard
2.0
2.2
2.7
3.0
3.1
3.8
4.6
Nominal No.
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
Cover D
Conductor
Number of
Sectional area
(mm2)
Nominal No.
40
50
60
85
100
85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
Cover D
CAVS
0.5
0.75f
0.85
1.25f
1.25
7/Circular compressed
0.56
0.88
1.29
d (approx.)
Conductor
0.5f
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-6R
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
AVS/AV/CAVS
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
D375A-6R

Precautions when carrying out work
0 -29
(Rev. 2010/02)
When removing, installing, disassembling or assembling a unit, be sure to follow the general precautions given below.
1. Precautions for 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
10
12
Plug (nut end)
Sleeve nut (elbow end)
07376 - 70210
07376 - 70315
07376 - 70422
07376 - 70522
07376 - 70628
07376 - 71034
07376 - 71234
02789 - 20210
02789 - 20315
02789 - 20422
02789 - 20522
02789 - 20628
07221 - 21034
07221 - 21234
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-6R
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
27
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

2. Precautions for 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 available.
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 and degrease the part, and coat the threaded portion with 2 - 3
drops of adhesive.
q When coating with liquid gasket, clean and degrease the surface, and apply it uniformly after making
sure the surface is free from dirt or damage.
q Clean all parts, and correct any damage, dents, burrs, or rust found on them.
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 you have removed the hydraulic equipment such as hydraulic cylinder and pump for repair, be
sure to bleed air in the following manner before operating the reassembled cylinder for the first time.
1] Start the engine and run at low idle.
2] Operate the work equipment control lever to operate the hydraulic cylinder 4 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3] Next, operate the hydraulic cylinder 3 4 times to the end of its stroke.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions for 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 When you have removed hydraulic piping or hydraulic equipment, always bleed air from the system
after reassembling the parts, by referring to "Testing and adjusting".
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" .
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.
00-30
D375A-6R

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-6R
00-31

Method of disassembling and connecting push-pull type coupler

k
k
0 -32
(Rev. 2010/02)
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
0 -32
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 fitting in the adapter
on the other side perfectly, pull it back to
check the 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-6R

Type 2
0 -3
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-6R
00-33

Type 3
0 -34
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 sliding prevention ring (8) contacts contact surface (b) of the hexagonal
00-34
D375A-6R

Standard tightening torque table
0 -35
(Rev. 2010/02)
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 diam- Width across
eter of bolt
flats
mm
mm
6
10
8
13
10
17
12
19
14
22
16
24
18
27
20
29
22
32
24
36
27
41
29
46
33
50
36
55
39
30
Tightening torque
Nm
11.814.7
27 34
5974
98123
157 196
245 309
343 427
490 608
662 829
824 1,030
1,180 1,470
1,5201,910
1,9602,450
2,4503,040
2,8903,630
kgm
1.21.5
2.83.5
6.07.5
10.012.5
16 20
25 31.5
35 43.5
50 62
67.5 84.5
84 105
120 150
155195
200250
250310
295370
a The following table applies to the bolts in Fig. B.

eter of bolt
flats
mm
mm
6
10
8
12
10
14
12
17
a Fig. A
Tightening torque
Nm
5.99.8
13.723.5
34.346.1
74.590.2
kgm
0.61.0
1.42.4
3.54.7
7.69.2
a Fig. B
Remarks: The width 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-6R
00-35

2. Table of tightening torque for split flanged bolts

a Unless there are special instructions, tighten split flanged bolts to the torque below.
eter of bolt
flats
mm
mm
10
14
12
17
16
22
Tightening torque
Nm
5974
98123
235285
kgm
6.07.5
10.012.5
23.529.5
3. Table of tightening torque 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

eter
flats
mm
mm
14
Varies
20
depending on
24
type of con33
nector.
42
Tightening torque Nm {kgm}

Range
3563 {3.5 6.5}
84132 {8.513.5}
128186 {13.019.0}
363480 {37.049.0}
7461,010 {76.0103}
Target
44 {4.5}
103 {10.5}
157 {16.0}
422 {43.0}
883 {90.0}
4. Table of tightening torque 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

eter
flats
mm
mm
8
14
10
17
12
19
14
22
16
24
18
27
20
29
24
32
29
32
33
36
36
42
52
Tightening torque Nm {kgm}

Range
5.888.82 {0.60.9}
9.812.74 {1.01.3}
14.719.6 {1.52.0}
19.624.5 {2.02.5}
24.534.3 {2.53.5}
34.344.1 {3.54.5}
44.153.9 {4.55.5}
58.878.4 {6.08.0}
93.1122.5 { 9.512.5}
107.8147.0 {11.015.0}
127.4176.4 {13.018.0}
181.3240.1 {18.524.5}
274.4367.5 {28.037.5}
Target
7.35 {0.75}
11.27 {1.15}
17.64 {1.8}
22.54 {2.3}
29.4 {3.0}
39.2 {4.0}
49.0 {5.0}
68.6 {7.0}
107.8 {11.0}
127.4 {13.0}
151.9 {15.5}
210.7 {21.5}
323.4 {33.0}
D375A-6R

5. Table of tightening torque for hoses (taper seal type and face seal type)
a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque
shown in the following table.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque (Nm {kgm})
Nominal
Width
number of across
hose
flats (mm)
02
03
04
05
06
(10)
(12)
(14)
19
22
24
27
32
36
41
46
55
Taper seal
Range
Target
Thread size
(mm)
3454 {3.5 5.5}

3463 {3.5 6.5}
5493 {5.59.5}
5998 {6.010.0}
84132 {8.513.5}
128186 {13.019.0}
177245 {18.025.0}
177245 {18.025.0}
197294 {20.030.0}
246343 {25.035.0}
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
29
33
36
42
Face seal
Nominal No.
Thread diameNumber of
ter (mm) (Refthreads, type of
erence)
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 torque 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).
Tightening torque (Nm {kgm})
Outer diam- Width across
eter of pipe
flats
(mm)
(mm)
8
10
12
15 (16)
22 (20)
19
22
24 (27)
30 (32)
36
Range
Target
1416 {1.41.6}
2427 {2.42.7}
4347 {4.44.8}
6068 {6.16.8}
9095 {9.29.7}
15 {1.5}
25.5 {2.6}
45 {4.6}
64 {6.5}
92.5 {9.4}
Face seal
Nominal No.
Thread diameter
Number of
(mm)
threads, type of
(mm)(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 also used, depending on the specification.
D375A-6R
00-37

7. Table of tightening torque for 102, 107 and 114 engine series (bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts used for the 102, 107 and 114
engine series to the torque below.
Tightening torque
Bolts and nuts
Thread size
mm
6
8
10
12
14
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
8. Table of tightening torque for 102, 107 and 114 engine series (eye joints)
a Unless there are special instructions, tighten the metric eye joints used for 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 torque for 102, 107 and 114 engine series (taper screws)
a Unless there are special instructions, tighten NPT screws used for 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-6R

List of Abbreviation
0 -39
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.
q Abbreviations that are used in general society
may not be included.
List of abbreviations used in the shop manual
q
Abbreviatio
n
Full Spelling
q
q
Purpose of use (major

applicable machine (*), or
component/system)
(Rev. 2010/02)
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.
Explanation
A.B.S.
Anti-skid Brake System
Travel and brake

(HD, HM)
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.
A.I.S.S.
Automatic Idling Setting

System
Engine
This function automatically sets the idling speed.
A.J.S.S.
Advanced Joystick Steer- Steering

ing System
(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)
Automatic Spin Regulator
Travel and brake

(HD, HM)
Attachment
Work equipment
A.S.R.
ATT.
B.C.V.
Brake Cooling oil control Brake

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 Module
Electronic control system
C.L.S.S.
E.C.M.V.
Electronic Control Modu- Transmission

lation
(D, HD, WA, etc.)
E.C.S.S.
Electronically Controlled Travel

(WA)
Suspension System
E.C.U.
Electronic Control Unit
Electronic control system
E.G.R.
Exhaust Gas Recirculation
Engine
D375A-6R
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.
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.
00-39

Abbreviatio
n
Full Spelling

component/system)
Equipment Management
E.M.M.S.
Machine monitor
Monitoring System
E.P.C.
Electromagnetic ProporHydraulic
tional Control
F-N-R
Forward-Neutral-Reverse Operation
G.P.S.
Global Positioning System
H.S.S.
Hydrostatic Steering Sys- Steering

tem
(D)
H.S.T.
Hydro Static Transmission
Transmission
(D, WA)
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
L.S.
M.M.S.
O.L.S.S.
P.C.
P.C.C.S.
Communication
(KOMTRAX, VHMS)
Open-center Load SensHydraulic

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

Pitch dozer
Work equipment
(D)
00-40
Explanation
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.
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.
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.
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.
D375A-6R

Abbreviatio
n
Full Spelling

component/system)
Explanation
International System of Units (abbreviated SI from

the French Le Systeme Internationale dUnites) is
the modern form of the metric system, and is the
Le System International
worlds most widely used system of measurement.
S.I.
Unit
d Unites
Therere 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
SOL.
Solenoid
Electronic
magnetic force when the solenoid is energized.
The word solenoid also often refers to a solenoid
valve.
T.W.V. Two Way Valve
Hydraulic and electronic
Solenoid valve that switches over direction of flow.
Communications system that transmits machine
data, such as the present position of the machine,
Monitoring and communica- daily or aggregate hours of operation, fuel conVehicle Health Monitoring
V.H.M.S.
tion
sumption, radiator water temperature, oil or filter
System
(D, HD, PC, WA : Large size) 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

D: bulldozer
HD: dump truck
HM: articulate dump truck
PC: hydraulic excavator
WA: wheel loader
D375A-6R
00-41

List of abbreviations used in the circuit drawings

Abbreviation
A/C
A/D
A/M
ACC
ADD
AUX
BR
CW
CCW
ECU
ECM
ENG
EXGND
F.G.
GND
IMA
NC
S/T
STRG
SIG
SOL
STD
OPT
OP
SW
T/C
T/M
00-42
Full Spelling
Air Conditioner
Analogue-to-Digital
Air Mix damper
Accessory
Additional
Auxiliary
Battery Relay
Clockwise
Counter Clockwise
Electronic Control Unit
Electronic Control Module
Engine
External Ground
Frame Ground
Ground
Inlet Metering Actruator
No Connection
Steering
Signal
Solenoid
Standard
Option
Switch
Torque Converter
Transmission
D375A-6R

Conversion table
Conversion table
0 -43
(Rev. 2010/02)
0 -43
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
(B)
0
10
20
30
40
(A)
D375A-6R
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

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
6
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-6R

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-6R
00-45

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-6R

Conversion table
Temperature
0 -47
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
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-6R
46
47
48
49
50
51
52
00-47

Conversion table
00-48
D375A-6R
D375A-6R
SEN0521404-00
01-
BULLDOZER
D375A-6R
Shop Manual
Machine model
Serial number
D375A-6R
01-
65001 and up
01 Specification
D375A-6R
01-
01-1
Contents
Contents
01 Specification
Specification and technical data .............................................................................................
Specification drawing ...........................................................................................................
Specifications.......................................................................................................................
Weight table .........................................................................................................................
Table of fuel, coolant and lubricants ....................................................................................
01-2
01-2
01- 3
01- 3
01- 4
01- 9
01- 11
D375A-6R
Specification and technical data

Specification drawing
01-3
01-3
Item
A
Overall
length
Overall
height
(with
ROPS)
Overall
width
D375A-6R
Unit
Sem i - U tilt dozer +

Giant ripper
Full - U tilt dozer + Giant

ripper
Semi - U tilt dozer +

Multi - shank ripper
Full - U tilt dozer +

mm
10,515
10,815
10,230
10,590
mm
4,215
(4,235)
4,215
(4,235)
4,215
(4,235)
4,215
(4,235)
mm
4,695
5,140
4,695
5,140
01-3

Specifications
Specifications
01-4
Machine model
D375A-6R
Serial number
65001
Machine weight
Bare tractor
51,800
Ditto with semi-U dozer
62,765
Ditto with variable multi-shank ripper
69,565
Ditto with ROPS cab, air conditioner, seat

belt, perforated side cover, and SSC
Bare tractor with full - U dozer
64,265
Ditto with variable giant ripper
70,465
Weight
Ditto with ROPS cab, air conditioner, seat

belt, perforated side cover, and SSC
71,735
m
deg.
deg.
4.2
29
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
70,835
1st
2nd
3rd
km/h
0 3.5
0 6.8
0 11.8
Reverse
Transmission speed ranges Transmission speed ranges

(manual gear shift mode) (automatic gear shift mode)
Performance
Min. turning radius

Gradeability
Stability (front, rear, left, right)
kg
1st
2nd
3rd
km/h
0 4.6
0 8.7
0 14.7
Ground pressure (610 shoe)
01-4
Bare tractor
103.95 {1.06}
With semi-U dozer
131.41 {1.34}
With full-U dozer
145.14 {1.48}
With semi-U dozer and variable

multi-shank ripper
Ditto with ROPS cab, air conditioner,
seat 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, and
SSC
q
q
148.08 {1.51}
(kPa
{kg/cm2})
134.35 {1.37}
147.10 {1.50}
150.04 {1.53}
D375A-6R

Specifications
Machine model
D375A-6R
Serial number
65001
Dimensions
Overall height Overall width
Dimensions
Overall length
Bare tractor
5,905
With semi-U dozer
7,820
With full-U dozer

With semi-U dozer + variable
multi-shank ripper
With full-U dozer + variable multi-shank
ripper
10,875
3,240
4,695
5,140
To tip of exhaust pipe

To top of air intake duct
mm
4,215
3,480
mm
2,500
3,980
610
605
No. of cylinders bore x stroke

Piston displacement
Flywheel horsepower (ISO 9249)
Max. torque
Max. high idle speed
Min. low idle speed
Performance
Engine
10,230
mm
Model
Type
Min. fuel consumption ratio
Starting motor
Alternator
Battery
Radiator core type
Torque converter
Transmission
Power train
8,180
Bare tractor
With semi-U dozer
With full-U dozer
Track gauge
Length of track on ground
Track shoe width
Maximum ground clearance
Bevel gear shaft

Steering clutch
Steering brake
Final drive
D375A-6R
mm
SAA6D170E-5
4-cycle, water-cooled, in-line vertical, direct injection type with turbocharger and aftercooler
mm
6 - 170 x 170
l {cc}
23.15 {23,150}
kW {HP} /rpm
455 {610} / 1,800
Nm {kgm} / rpm
2,730 {278} / 1,300
rpm
1,900
rpm
750
g/kWh
207.4 {154.7}
{g/HPh}
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

Specifications
Machine model
D375A-6R
Undercarriage
Serial number
65001
Suspension
Carrier roller
Track roller
Rigid, equalizer bar

2 each side
7 each side
Assembly type, single grouser, 40 each side
pitch: 280.0 mm, width: 610 mm
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
01-6
Control valve
Type
Delivery (engine speed at 1,800 rpm)
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
1 + 1 + 1 + 2 spool type, hydraulic assisted, PPC

type
+ Ripper tilt (in, back)
+ Ripper lift (raise, lower)
+ Blade tilt
+ Blade lift x 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 x 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
Hydraulic
pump
Max. pressure
Cylinder bore
Piston stroke
mm
140
90
1,721
2,495
774
mm
200
110
240
1,703
1,463
D375A-6R

Specifications
Dimensions of ripper Dimensions of ripper Dimensions of blade dual

tilt cylinder
lift cylinder
tilt cylinder
Hydraulic cylinder
D375A-6R
Serial number
Work equipment hydraulic system
Machine model
65001
Cylinder bore
(both right and left)
Piston stroke (both right and
left)
Max. distance between pins
200
110
mm
1,675
Min. distance between pins

1,490
Cylinder bore
200
110
Piston stroke
mm
1,855
1,360
Cylinder bore
180
110
Piston stroke
mm
1,800
1,250
Box type (control valve externally installed)
Hydraulic semi-U tilt dozer
Hydraulic full-U tilt dozer
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)
Dimensions Performance
Blade supporting method
Semi-U dozer
550
Type
Work equipment
495
Hydraulic tank
D375A-6R
185
Max. lift above ground

Max. drop below ground
Max. adjustment tilt
Hydraulic oil tilt
Blade capacity
mm
mm
mm
mm
m3
1,642
800
955
760
24.0 <SAE18.5>
Blade width
Blade height
Blade cutting angle
mm
mm
deg.
4,695
2,265 (with spill guard: 2,525)
55
01-7

Specifications
1,642
800
1,050
850
26.3 <SAE22.0>
Blade width
Blade height
Blade cutting angle
mm
mm
deg.
5,140
2,265 (with spill guard: 2,525)
55
Performance
Max. hydraulic oil tilt

Hydraulic oil tilt (single)
Max. pitch angle
Blade cutting angle
mm
deg.
deg.
deg.
1,150
580
Forward 4.7 / Backward 5.2
55
Max. hydraulic oil tilt

Hydraulic oil tilt (single)
Max. pitch angle
Blade cutting angle
mm
deg.
deg.
deg.
1,280
635
Forward 4.7 / Backward 5.2
55
Max. digging depth

Point digging angle
mm
mm
deg.
1,190
1,082
45 (Stepless adjustment between 31.4 54.7)
mm
No. of holes
2,910
3
mm
mm
deg.
1,538
1,050
45 (Stepless adjustment between 31.6 55.0)
mm
No. of holes
1,600
4
Dimensions Performance
mm
mm
mm
mm
m3
Dimensions
65001

Max. drop below ground
Max. adjustment tilt
Hydraulic oil tilt
Blade capacity
Dimensions Performance Dimensions Performance
Full-U dozer + pitch Semi-U dozer + Pitch

Giant ripper
Work equipment
01-8
D375A-6R
Serial number
Full-U dozer
Machine model
Max. beam width

Shank positions
Max. digging depth

Point digging angle
Max. beam width

Shank positions
D375A-6R

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-6R
Serial number
65001
Engine, damper assembly
3,320
Engine assembly
3,065
Damper assembly
185
Engine mounting parts
70
Radiator assembly
Oil cooler assembly
Fuel tank assembly (when full)
465
92
580 (1,600)
Power train unit

q
Torque converter and PTO assembly
Transmission assembly
Transmission valve assembly
Steering clutch and brake assembly
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-6R
4,220
795
1,000
13
1,712
13
2,200 x 2
5,541
7,259
2,038
478
150 x 4
160 x 3
71 x 2
258
742 x 3
4,200 x 2
210 x 2
500
236
119
125
01-9

Weight table
Unit: kg
Machine model
D375A-6R
Serial number
65001
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 x 2
275
270 x 2
6,755
470 x 3
270 x 2
240 x 2
6,155
650 x 1
270 x 2
240 x 2
2,870
1,342
290 x 2
140
275
220
320
337
331
372
703
591
570
64
58
D375A-6R

Table of fuel, coolant and lubricants
01- 1
For details of the notes (Note 1, Note 2 - - -) in the table, see Operation and Maintenance Manual.
D375A-6R
01-11

Unit: l
D375A-6R
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
230
Single tilt with variable rippers
275
Dual tilt with variable rippers
280
Cooling system
Fuel tank
01-12
130
120
1,200
D375A-6R
D375A-6R
SEN0521406-00
10-1
BULLDOZER
D375A-6R
Shop Manual
Machine model
Serial number
D375A-6R
1-01
65001 and up
D375A-6R
10-1
10-1
Contents
10-2
Contents
Cooling system ....................................................................................................................
Cooling fan pump.................................................................................................................
Power train..............................................................................................................................
Power train...........................................................................................................................
Overall drawing of power train unit ......................................................................................
Power train hydraulic equipment arrangement drawing.......................................................
Torque converter control valve ............................................................................................
Scavenging pump ................................................................................................................
PCCS lever ..........................................................................................................................
Transmission........................................................................................................................
Transmission ECMV ............................................................................................................
Transmission lubrication relief valve ....................................................................................
Steering and brake control...................................................................................................
Transfer unit, bevel gear shaft and steering ........................................................................
Steering clutch ECMV and Steering brake ECMV ...............................................................
Sudden stop prevention valve..............................................................................................
Final drive ............................................................................................................................
Track frame..........................................................................................................................
Idler cushion.........................................................................................................................
Main frame ...........................................................................................................................
Suspension ..........................................................................................................................
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)...................................
Control valve ........................................................................................................................
Work equipment......................................................................................................................
Cylinder stay ........................................................................................................................
10-2
10- 4
10- 4
10- 7
10- 28
10- 34
10- 34
10- 36
10- 38
10- 40
10- 42
10- 48
10- 50
10- 52
10- 57
10- 58
10- 60
10- 64
10- 78
10- 83
10- 84
10- 86
10- 92
10- 94
10- 102
10- 103
10- 105
10- 110
10- 110
10- 112
10- 113
10- 114
10- 116
10- 119
10- 119
10- 123
10- 124
10- 126
10- 128
10- 129
10- 130
10- 142
10- 143
10- 145
10- 146
10- 148
10- 150
10- 160
10- 187
10- 194
10- 194
D375A-6R
Contents
Cab .........................................................................................................................................
Cab mount ...........................................................................................................................
Cab ......................................................................................................................................
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-6R
10- 195
10- 195
10- 196
10- 198
10- 198
10- 199
10- 208
10- 210
10- 212
10- 230
10- 231
10- 232
10- 235
10- 241
10- 247
10-3
Engine and cooling system

Cooling system
10-4
Cooling system
10-4
10-4
D375A-6R

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
10-5
Specification
Radiator
Power train oil cooler Hydraulic oil cooler
Aftercooler
Core type
PTO-OL
Rectangle straight fin
Fin pitch (mm)
8.0/2
8.0/2
8.0/2
Total heat dissipation surface

(m2)
49.09 x 3
3.77
4.09
27.39 x 2
88.3 14.7
{0.9 0.15}
04.9
{00.05}
Cracking pressure of
pressure valve
(kPa {kg/cm2})
Cracking pressure of vacuum
valve
(kPa {kg/cm2})
D375A-6R
10-5

Cooling system
10-6
D375A-6R

Cooling fan pump
Cooling fan pump
10-6
Type: LPV90 + 30
Appearance
10-6
1. LPV90 Hydraulic pump

2. LPV30 Hydraulic pump
D375A-6R
10-7

Cooling fan pump
LPV90 Hydraulic pump 10-8

Appearance
10-8
10-8
10-8
D375A-6R

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
D375A-6R
10-9
1. Shaft
2. Cradle
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
10-9

Cooling fan pump
Function
10-10
The engine rotation and torque transmitted to
the pump shaft is converted into the hydraulic
pressure and the pressurized oil corresponding
to the load is discharged.
q The delivery of this pump can be changed by
changing the swash plate angle.
10-10
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.
q The hydraulic balance is maintained properly on
this face.
q
10-10
The oil is sucked into and discharged from each

cylinder in cylinder block (7) through valve plate
(8).
D375A-6R

Cooling fan pump
10-1
Operation of pump
10-1
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.
Operation
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.
D375A-6R
10-11

Cooling fan pump
10-12
Control of delivery
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.
q
10-12
D375A-6R

Cooling fan pump
D375A-6R
10-13

Cooling fan pump
10-14
PC valve, EPC valve, Servo piston

PEPC: EPC source pressure input port
10-14
10-14
10-14
EPC valve
10. EPC valve
Servo piston
1. Servo piston
2. Lever
3. Spring
PC valve
4. Piston
5. Seat
6. Spring
7. Spool
8. Sleeve
9. Plug
10-14
D375A-6R

Cooling fan pump
Function
10-15
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-6R
10-15

Cooling fan pump
When EPC output pressure is high [When EPC current (i) is large]
10-16
10-16
D375A-6R

Cooling fan pump
10-17
The relationship between the EPC valve input
current (i) and EPC valve output pressure (F) is
as shown in the figure below.
Operation
q
If the EPC discharge pressure rises, spool (7) is

pushed to the left because of the difference in
sectional areas between parts (S1) and (S2) of
the spool (S1 > S2).
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-6R
10-17

Cooling fan pump
When EPC output pressure is low [When EPC current (i) is small]
10-18
10-18
D375A-6R

Cooling fan pump
10-19
If EPC current (i) reduces and the EPC output
pressure lowers, spool (7) is pushed to the right
by the force of spring (6).
Port (g) is disconnected from port (f) and at the
same time port (f) is connected to the drain circuit.
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.
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.
Operation
q
D375A-6R
10-19

Cooling fan pump
10-20
LPV30 Hydraulic pump

Appearance

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
10-20
1. Piston pump
2. Servo valve
3. Bleeder
4. EPC valve
D375A-6R

Cooling fan pump
Sectional view
10-21
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-6R
10-21

Cooling fan pump
Function
10-2
The rotation and torque of the engine are transmitted to the shaft of this pump. Then, this pump
converts the rotation and torque into hydraulic
energy and discharges hydraulic oil according to
the load.
q The discharge of this pump can be changed by
changing the swash plate angle in it.
10-2
Structure
q Cylinder block (7) is connected to shaft (1)
through splines (B).
q Shaft (1) is supported by the front and rear bearings (12).
q Shoe (5) is kept pressed against plane (A) of
rocket cam (4) and slids circularly.
q Rocker cam (4) pivot on ball (11).
q Piston (6) in each cylinder of cylinder block (7)
q Cylinder block (7) rotates relatively against valve
plate (8) sealing the hydraulic oil.
q The hydraulic balance on the valve plate is maintained properly.
q
10-22

cylinder chamber of cylinder block (7) through
valve plate (8).
D375A-6R

Cooling fan pump
Operation
Operation of pump
q Cylinder block (7) rotates together with shaft (1)
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 If angle (a) is made between center line (X) of
q If angle (a) is made between center line (X) of
q Each piston (6) sucks and discharges oil by (F)
(E).
q If cylinder block (7) rotates and the volume of
from chamber (E).
q The volume of chamber (F) is increased and the
oil is sucked in chamber (F).
D375A-6R
10-23
10-23
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).
10-23

Cooling fan pump
10-24
Control of discharge
If swash plate angle (a) is increased, the difference between volumes (E) and (F) is increased,
or delivery (Q) is increased.
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).
q
10-24
D375A-6R

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-6R
10-25
1. Plug
2. Lever
3. Retainer
4. Sheet
5. Spool
6. Piston
7. Sleeve
10-25

Cooling fan pump
A: Drain side
B: Pump discharge pressure input side
C: EPC output pressure receiving pressure
10-26
D: EPC output pressure side

P: EPC source pressure input side
D375A-6R

Cooling fan pump
Function
10-27
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-6R
10-27
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.
10-27

Cooling fan motor
Cooling fan motor
10-28
Type: LMF180 (150)

Appearance
P: From fan pump

T: To tank through cooler
TC: To tank
10-28
10-28
Specifications
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}
10-28
D375A-6R

Cooling fan motor
Sectional view
1.
2.
3.
4.
5.
6.
Output shaft
Case
Thrust plate
Shoe
Piston
Cylinder block
D375A-6R
10-29
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
10-29

Cooling fan motor
Hydraulic motor
Function
10-30
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.
10-30
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 x 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 = (F3 x 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.
10-30
10-30
D375A-6R

Cooling fan motor
Suction safety valve
10-31
Function of suction valve

10-31
q When the fan pump stops rotating, the hydraulic
oil does not flow into the motor. Since the motor
continues rotation by the force of inertia the pressure at the outlet of the motor increases.
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.
10-31
At stop
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.
10-31
Operation
When pump is started
10-31
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-6R
10-31

Cooling fan motor
10-32
Function as safety valve
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.
q
10-32
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
10-32
D375A-6R

Cooling fan motor
Operation of reversible valve
10-3
When the ON/OFF solenoid is de-energized

10-3
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-6R
10-3
When 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).
10-33
Power train
Power train
Power train
10-34
Power train
10-34
Outline
10-34
The power generated by engine (1) is transmitted
through universal joint (3) to torque converter (8)
while damper (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.
10-34
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-6R
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-6R
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
10-35
Power train
Overall drawing of power train unit
10-36
10-36
D375A-6R
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)
N: Right steering clutch pressure pickup port (RC)
P: Transmission 1st clutch pressure pickup port
(1ST)
R: Main relief pressure pickup port (TM)
D375A-6R
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
16. Power train oil tank
Outline
q 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.
q The steering unit consists of transfer, bevel gear
shaft, steering clutch, and steering brake.
10-37
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)
10-38
10-38
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-6R
Power train
D375A-6R
10-39
Power train
Damper and universal joint
10-40
10-39
D375A-6R
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)
Outline
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
The power of engine is transmitted from flywheel (2)
through outer body (1) to rubber couplings (7). After
absorption of torsional vibrations of the engine by
the rubber coupling, power is then transmitted to the
coupling (4) via output shaft (3). Then, power is further transmitted from the coupling to the torque converter input shaft through universal joint (5).
D375A-6R
10-41
Power train
Torque converter and PTO
10-41
a PTO: Abbreviation for Power Take Off
10-42
D375A-6R
Power train
D375A-6R
10-43
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
10-44
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-6R
Power train
Outline
10-4
q 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.
q 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.
10-4
Structure
q 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.
q 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.
q 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.
q 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.
q 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.
q 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).
Conditions for lockup mode and torque converter

mode
Gear speed
Torque converter output shaft speed:

(rpm)
Lockup mode
Torque converter
mode
Forward 1st
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-6R
10-45
Power train
10-45
Power transmitting route

When lockup clutch is "disengaged" and stator
10-45
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)
10-46
10-45
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-6R
Power train
Oil flow
10-46
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-6R
10-47
Power train
Torque converter control valve
10-47
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
10-48
D375A-6R
Power train
Outline
10-48
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
10-48
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}
(Engine at rated 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

10-48
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}
10-48
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)
10-48
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-6R
10-49
Power train
Main relief valve and torque converter relief valve
10-49
1. Valve body
2. Torque converter relief valve
3. Main relief valve
4. Cover
5. Piston
6. Piston
10-50
D375A-6R
Power train
Operation of main relief valve
10-50
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
10-50
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-6R
10-51
Power train
Lockup clutch ECMV and stator clutch ECMV
10-51
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
10-52
D375A-6R
Power train
ECMV for lockup clutch
10-52
10-52
Operation
When traveling in torque converter drive mode 10-52
Outline
10-52
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)

When traveling in torque converter drive mode, current does not blow to proportional solenoid (1).
Pressure control valve (3) drains the oil from clutch
port (A) through drain port (T), and lockup clutch is
"released".
Also at this time, fill switch (5) is turned "off" because oil pressure is not applied to pressure detection valve (4).
D375A-6R
10-53
Power train
When traveling in direct drive mode

(Traveling in torque converter drive mode to traveling in lockup drive mode)
10-53
During filling
During 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".
10-54
10-53
10-53
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-6R
Power train
ECMV for stator clutch
10-54
Operation
When traveling in direct drive mode
10-54
10-54
Outline
10-54
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
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".
D375A-6R
10-55
Power train
When traveling in torque converter drive mode

(Traveling in direct drive mode to traveling in torque converter drive mode)
10-5
During filling
During 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".
10-56
10-5
10-5
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-6R
Power train
Scavenging pump
Scavenging pump
10-56
Model: BAR (3) 63 + 277
A: Discharge port
B: Small pump suction port
C: Large pump suction port
1. Small pump
2. Large pump
D375A-6R
10-57
Power train
Transmission control
10-57
a Regarding the steering-related description in the PCCS lever operations, refer to the "Steering and brake
control".
a PCCS: Abbreviation for the 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
10-58
Lever positions
[1]: Neutral
[2]: Forward
[3]: Reverse
[4]: OFF
[5]: Upshift
[6]: Downshift
[7]: Free
[8]: Lock
D375A-6R
Power train
Outline
10-58
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-6R
10-59
Power train
PCCS lever
PCCS lever
10-59
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
10-60
5. Screw
6. Lever
7. Connector
D375A-6R
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-6R
10-60
10-60
Operation for left and right steering
Free return
10-61
Power train
PCCS lever
Output voltage characteristics

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.
10-61
10-62
D375A-6R
Power train
PCCS lever
Gear shift of the machine

10-62
Since gear shift during travel is possible, there is no
need to stop the machine to shift gears.
10-62
Gear shift operation
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.
D375A-6R
10-63
Power train
Transmission
Transmission
10-64
10-63
D375A-6R
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-6R
10-65
Power train
Transmission
10-66
D375A-6R
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-6R
10-6
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 x 1st
F x 2nd
F x 3rd
(*1)
R x 1st
R x 2nd
R x 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.
10-67
Power train
Transmission
10-67
Disc clutch
Structure
q
q
10-67
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.
10-67
When clutch is "disengaged" (released)
q
q
q
10-68
10-67
10-67
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-6R
Power train
Transmission
Oil circuit of speed clutch
10-68
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-6R
10-69
Power train
Transmission
Power transmitting route

Forward 1st
10-70
10-69
10-69
D375A-6R
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
O
3rd ring gear (12)
O
O
2nd carrier (13)
O
O
2nd planetary pinion (14)
O
O
2nd ring gear (15)
O
O
1st clutch gear (16)
3rd sun gear (18)
O
O
Output shaft (19) i
i
i
D375A-6R
10-71
Power train
Transmission
Forward 2nd
10-72
10-71
D375A-6R
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 (10)
O
o
o
O
O
3rd clutch ring gear (12)
O
O
2nd clutch carrier (13)
O
O
2nd clutch planetary pinion (14)
O
O
2nd clutch sun gear (17)
3rd clutch sun gear (18)
O
O
Output shaft (19) i
i
i
D375A-6R
10-73
Power train
Transmission
Forward 3rd
10-74
10-73
D375A-6R
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
O
3rd clutch planetary pinion (11)
O
3rd clutch sun gear (18)
O
Output shaft (19)
D375A-6R
10-75
Power train
Transmission
Reverse 1st
10-76
10-75
D375A-6R
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
O
O
3rd clutch ring gear (12)
O
2nd clutch carrier (13)
O
2nd clutch planetary pinion (14)
O
2nd clutch ring gear (15)
O
1st clutch gear (16)
O
Output shaft (19) i
D375A-6R
o
O
O
O
O
O
3rd sun gear (18)
O
i
i
10-77
Power train
Transmission ECMV
Transmission ECMV
10-7

a Don't try to disassemble it since adjustment for maintaining the performance will be required
10-78
D375A-6R
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. Pressure detection valve
24. Spring for pressure control valve
D375A-6R
10-79
Power train
Transmission ECMV
10-79
Outline of ECMV
The ECMV consists of a pressure control valve and
a fill switch.
Pressure control valve
A proportional solenoid in this valve receives the

current sent from the controller and this valve converts it to oil pressure.
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 .
10-79
ECMV and proportional solenoid
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 of proportional solenoid - thrust characteristics
Thrust of proportional solenoid - characteristics of

hydraulic pressure
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).
10-80
ECMV and fill switch

10-79
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-6R
Power train
Transmission ECMV
Operation of ECMV
10-80
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.
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).
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-6R
Before shifting gear [when draining] (range A in chart)
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).
10-81
Power train
Transmission ECMV
During filling (range B in chart)
Pressure regulation (range C 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).
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.
10-82
D375A-6R
Power train
Transmission lubrication relief valve
1. Lubricating oil pressure measurement plug

2. Lubricating oil relief value spool
3. Valve body
10-82
Function
10-82
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-6R
10-83
Power train
Steering and brake control
10-83
a Regarding the transmission-related description of the operation of the PCCS lever, refer to the "Transmission control".
a PCCS: Abbreviation for the Palm Command Control System
10-84
D375A-6R
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
Lever and pedal locations
[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
D375A-6R
10-84
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.
q 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.
q The lock lever (2) is connected to parking brake
lever (8) and serves as a parking brake lever.
10-85
Power train
Transfer unit, bevel gear shaft and steering
10-85
Machines without VHMS controller
10-85
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
10-86
10. L.H. steering clutch ECMV

11. R.H. steering clutch ECMV
12. Sudden stop prevention valve
D375A-6R
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-6R
10-86
10. L.H. steering clutch ECMV

11. R.H. steering clutch ECMV
10-87
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)
10-88
10-87
10-87
10-87
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-6R
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-6R
10-8
10-8
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.
10-89
Power train
Bevel gear shaft, steering clutch and brake
10-90
10-89
D375A-6R
Power train
1. Output shaft
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-6R
10-90
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.
10-91
Power train
Steering control valve
10-92
10-91
D375A-6R
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-6R
10-92
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.
10-93
Power train
Steering clutch ECMV and Steering brake ECMV
10-93

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. Fill switch connector
2. Proportional solenoid connector
3. Pressure detection valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate (*1)
10-94
*1:
Clutch to use ECMV
Stamp of the name plate
Steering clutch, Steering brake
R*******
10-93
Outline
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.
D375A-6R
Power train
Outline of ECMV
10-94
The ECMV consists of a pressure control valve and
a fill switch.
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.
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.
10-94
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.
10-94
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.
10-94
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-6R
10-95
Power train
When PCCS lever is in "NEUTRAL" position, brake pedal is "RELEASED", and parking brake lever is
in "FREE" position: Straight travel
10-95
(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.
10-96
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-6R
Power train
When PCCS lever is in "HALFWAY TO LEFT" position, brake pedal is "RELEASED", and parking brake
lever is in "FREE" position: Gradual left turn
10-96
(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-6R
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".
10-97
Power train
10-98
D375A-6R
Power train
When PCCS lever is in "FULLY TO LEFT" position, brake pedal is "RELEASED", and parking brake
lever is in "FREE" position: Sharp left turn
10-98
(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-6R
q
q
The oil pressure in the clutch circuit, etc. is maintained by orifice (b).
10-99
Power train
When PCCS lever is in "NEUTRAL" position, brake pedal is "DELPRESSED", and parking brake lever
is in "FREE" position: Stop
10-9
(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.
10-100
D375A-6R
Power train
When PCCS lever is in "NEUTRAL" position, brake pedal is "RELEASED" and parking brake lever is
in "LOCK" position: Parking
10-101
(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".
D375A-6R
10-101
Power train
Parking brake valve
Parking brake valve
1. Spool
2. Valve body
10-102
10-10
Outline
10-10
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.
D375A-6R
Power train
Sudden stop prevention valve
10-102
Outline
10-102
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, also 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-6R
10-103
Power train
10-104
D375A-6R
Power train
Final drive
Final drive
10-103
Outline
10-103
q The final drive uses a single stage spur gear and
single stage planetary gear reduction system.
The lubrication is of splash type using the rotation of the gears.
The final drive can be removed and installed in 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-6R
10-105
Power train
Final drive
10-106
D375A-6R
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-6R
10-107
Power train
Final drive
Path of power transmission
10-108
10-106
D375A-6R
Power train
Final drive
The power from the bevel gear shaft and steering clutch is transmitted to 1st pinion (15) and
then to 1st gear(13) to rotate sun gear(2) being
meshed with the 1st gear.
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-6R
10-109
Undercarriage and frame

Track frame
10-108
Track frame
10-108
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
10-108
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.
10-108
Track roller arrangement

Track roller flange type
1st
2nd
3rd
4th
5th
6th
7th
S: Single flange type

D: Double flange type
10-110
D375A-6R

Track frame
D375A-6R
10-111

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
10-112
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-6R

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
9. Cartridge pin
D375A-6R
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).
10-113

Main frame
Main frame
10-114
10-1 2
D375A-6R

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-6R
10-115

Suspension
Suspension
10-116
10-1 4
D375A-6R

Suspension
*1. Shown in the figure is the left suspension of the single tilt specification machines.
*2. Shown in the figure are the right suspension of single tilt specification machines, and
the right and left suspensions of the dual tilt specification machines.
D375A-6R
10-117

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
11. Side pin
12. Center pin
13. Bushing
10-1 6
Outline
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).
10-118
D375A-6R
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-6R
10-119
Hydraulic system
Full-U dozer + Dual tilt
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
10-120
D375A-6R
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-6R
10-121
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)
10-122
D375A-6R
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-6R
10-123
Hydraulic system
Work equipment control
10-12
(Figure shows a dual tilt dozer specification machine equipped with pin puller cylinder)
10-124
D375A-6R
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
10-123
[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"
10-123
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 in "Lock" position,
work equipment lock switch (7) is turned OFF,
and the engine can be started..
And when work equipment lock lever (1) is in
"Free" position, work equipment lock switch (7)
is turned ON, and engine can not be started.
D375A-6R
10-125
Hydraulic system
Hydraulic tank
Hydraulic tank
10-126
10-124
D375A-6R
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 + Breather
11. Drain valve
12. Drain plug
13. Strainer (over flow)
Specified value
Tank capacity (l)
210
Hi (l)
Level inside
tank
Breather
144
Center (l)
130
Low (l)
Hydraulic tank
112
Cracking pressure of
pressure valve
(kPa {kg/cm2})
Operating pressure of
vacuum valve
(kPa {kg/cm2})
17 2.5
{0.17 0.025}
2 0.3
{0.02 0.003}
Specified value
Hydraulic
oil filter
Cracking pressure
(kPa {kg/cm2})
Mesh size (m)
Filtering area (cm2)
Filtering oil flow (l/min)
150 30
{1.5 0.3}
30/8
17600
720
Strainer
(over flow)
Mesh size (m)
40
Strainer
(suction)
Mesh size
(m)
Filtration area
(cm2)
D375A-6R
105
3,600
10-127
Hydraulic system
Accumulator
Accumulator
10-126
For PPC valve
10-126
10-126
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
10-126
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.
Function
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specification
10-126
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}
10-128
D375A-6R
Hydraulic system
PPC lock valve
PPC lock valve
10-127
10-127
Outline
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.
1. Lever
2. End cap
3. Ball
4. Sheet
5. Valve body
D375A-6R
10-129
Hydraulic system
PPC valve
PPC valve
Blade PPC valve
Appearance
P: From self-pressure reducing valve

P1: To blade lift valve (LOWER) PPC port
P2: To blade lift valve (RAISE) PPC port
10-130
10-128
10-128
10-128
P3: To blade tilt valve (LEFT TILT) PPC port

P4: To blade tilt valve (RIGHT TILT) PPC port
T: To hydraulic tank
D375A-6R
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
D375A-6R
10-129
8. Plate
9. Retainer
10. Valve body
11. Filter
10-131
Hydraulic system
PPC valve
Operation
Neutral
For blade lift
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).
10-132
10-130
10-130
10-130
For blade tilt
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).
D375A-6R
Hydraulic system
PPC valve
When blade control lever is in fine control range10-131

(Neutal o Fine control range)
10-131
q When piston (4) is pushed by disc (5), retainer
(9) is pushed and 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 spring (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.
D375A-6R
10-133
Hydraulic system
PPC valve
When blade control lever is in fine control range

10-132
(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.
10-134
10-132
At 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 return oil from port (A) flows through port
(P2) and fine control hole (f') into drain chamber
(D).
D375A-6R
Hydraulic system
PPC valve
When blade control lever is operated to

10-13
"FLOAT"
q Whenn 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 pressure in
chamber (E), the blade is kept in the "FLOAT"
state even if the lever is released.
D375A-6R
10-13
When canceling "FLOAT" condition
q Disc (5) is returned with a force larger 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) is
lost and the "FLOAT" state is reset.
10-135
Hydraulic system
PPC valve
10-136
D375A-6R
Hydraulic system
PPC valve
Ripper PPC valve

Appearance
10-135
10-135
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-6R
10-137
Hydraulic system
PPC valve
Sectional view
10-138
10-136
D375A-6R
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-6R
10-139
Hydraulic system
PPC valve
10-138
Operation
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).
10-140
D375A-6R
Hydraulic system
PPC valve
When blade control lever is in fine control range10-139

(When control lever is returned)
10-139
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 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 in
operated. The oil passes through port (P2) and
enters port (B) to replenish the port with pressurized oil.
D375A-6R
10-139
At 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 The pilot oil flows through fine control hole (f)
and port (P1) into port (A) and pushes the control
valve spool.
q The return oil from port (B) flows through port
(P2) and fine control hole (f') into drain chamber
(D).
10-141
Hydraulic system
Piston valve
Piston valve
10-140
For blade lift cylinder

10-140
Outline
10-140
The piston valve is installed on the piston in the
blade lift cylinder. When the piston reaches its
stroke end, the valve releases the oil from the hydraulic pump to reduce the oil pressure being exerted on the piston.
In addition the piston valve relieves the shock which
occurs when the piston comes into contact with the
cylinder head or the bottom and serves to reduce
the subsequent surge pressure in the cylinder by letting the oil escape from the cylinder.
10-140
Operation
Piston valve "CLOSED"
10-140
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
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.
10-142
D375A-6R
Hydraulic system
Quick drop valve
Quick drop valve

For blade lift cylinder
Outline
10-141
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.
10-141
10-141
10-141
Operation
Start of lowering
10-141
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.
1. Valve body
2. Spool
3. Check valve
4. Spring
D375A-6R
10-143
Hydraulic system
Quick drop valve
10-142
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.
10-144
D375A-6R
Hydraulic system
Pin puller switch
Pin puller switch
10-143
1. Connector
2. Wire
3. Switch
4. Knob
10-143
Function
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.
D375A-6R
10-145
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
10-146
10-14
A:
B:
P:
T:
To pin puller cylinder bottom end

To pin puller cylinder head end
From power train pump
To steering case
D375A-6R
Hydraulic system
Operation
When pin puller switch is set to "PUSH IN" posi10-145
tion
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.
D375A-6R
10-145
When pin puller switch is set to "PULL OUT" po10-145
sition
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.
10-147
Hydraulic system
Blade control lever (only for the machine with dual tilt specification)
10-146
1. Switch (Dual/single tilt selector)

2. Switch (pitch)
3. Cover
4. Connector (male)
5. Connector (female)
10-148
D375A-6R
Hydraulic system
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.
q 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.
q 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.
D375A-6R
10-147
10-149
Hydraulic system
Work equipment pump
Work equipment pump
10-148
Type: HPV190
Appearance
10-150
10-148
D375A-6R
Hydraulic system
Work equipment pump

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
10-149
Outline
This pump consists of a variable displacement
swash plate type piston pump and LS valve.
D375A-6R
10-151
Hydraulic system
Work equipment pump
Sectional view
10-150
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
10-152
D375A-6R
Hydraulic system
Work equipment pump
Function
10-151
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.
q
q
q
q
10-151
Structure
q Cylinder block (7) is supported by shaft (1) on
splined area (12).
q Shaft (1) is supported by each bearing (13).
q Shoe (5) is kept pressed against flat surface (A)
of rocker cam (4) and slides circularly.
q Rocker cam (4) leads high pressure oil to cylindrical surface (B) against cradle (2) fixed to the
case, and forms a static pressure bearing, and
slides.
D375A-6R
Piston (6) in each cylinder of cylinder block (7)

Cylinder block (7) seals the pressurized oil
against valve plate (8) and rotates relatively.
This surface is designed so that the oil pressure
balance is maintained at a suitable level.
cylinder in cylinder block (7) through valve plate
(8).
10-153
Hydraulic system
Work equipment pump
Operation of pump
Cylinder block (7) rotates together with shaft (1)
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
q
q
10-152
is 0), there is no difference between volumes (E)
and (F) in cylinder block (7). The hydraulic oil is
not sucked or discharged.
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)
If angle (a) is made between center line (X) of

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 subtracting (E) from (F).
If cylinder block (7) rotates and the volume of
from chamber (E) during this process.
The volume of chamber (F) is increased and the
oil is sucked in chamber (F) during this process.
10-154
D375A-6R
Hydraulic system
Work equipment pump
Control of discharge
q If swash plate angle (a) increases, the difference
between volumes (E) and (F) increases, and
pump delivery (Q) increases.
to the signal pressure from the LS valve.
q This linear movement is transmitted to rocker
cam (4) through slider (14).
q Rocker cam (4) supported on the cylindrical surface of cradle (2) slides circularly.
q The area receiving the pressure on the right and
left sides of servo piston (10) are different from
each other, and discharge pressure (self-pressure) (PP) of the main pump is constantly applied to the pressure chamber of the small
diameter piston side.
q Output pressure (PEN) of the LS valve is applied
to the pressure chamber of the large diameter
piston side.
q The movement of servo piston (10) is controlled
by the relationship of pressure between small diameter piston side (PP) and large diameter piston side (PEN) and by the ratio of the area
receiving the pressure of the small diameter piston and large diameter piston.
D375A-6R
10-153
10-155
Hydraulic system
Work equipment pump
10-154
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
10-154
Function
q The LS (load sensing) valve detects the load and
controls the pump delivery.
q This valve controls pump delivery (Q) with the
differential pressure between pump discharge
pressure (PP) and control valve outlet pressure
(PLS) (PLS) [= (PP) - (PLS)] (called the LS differential pressure).
q This valve receives pump discharge pressure
(PP) and pressure (PLS) (called the LS pressure) coming from the control valve output.
q The relationship between LS differential pressure (PLS)[=(PP)(PLS)], which is a differential
pressure between pump discharge pressure
(PP) and LS pressure (PLS), and delivery (Q) is
as shown in the figure.
10-156
D375A-6R
Hydraulic system
Work equipment pump
Operation
When control valve is in NEUTRAL position
q
q
q
q
The LS valve is a 3-way selector valve, and pressure (PLS) (LS pressure) from the control valve
inlet is applied to spring chamber (B) and pump
discharge pressure (PP) is supplied to port (H) of
sleeve (8).
The position of spool (6) is determined by the difference between the force caused by LS pressure (PLS), the force of spring (4), and the force
caused by pump discharge pressure (self pressure) (PP).
Before the engine is started, servo piston (10) is
pushed to the right. (See right drawing)
When engine is started, and if the control lever is
in NEUTRAL, LS pressure (PLS) is 0 MPa
{0 kg/cm2}. (The LS pressure is interconnected
to the drain circuit through the control valve
spool)
Spool (6) is pushed to the right, and ports (C)
and (D) are connected.
Pump discharge pressure (PP) applies to the
large diameter piston side through port (K) .
D375A-6R
10-15
10-15
The same pump discharge pressure (PP) is supplied to port (J) on the small diameter piston
side.
According to the area difference of servo piston
(10), the servo piston is moved in the direction
which makes the swash plate angle minimum.
10-157
Hydraulic system
Work equipment pump
Mechanism to make the pump delivery maximum
q
q
q
10-156
When the difference between pump discharge

pressure (PP) and LS pressure (PLS), in other
words, LS differential pressure (PLS) decreases (for example, when the control valve open
area increases and pump discharge pressure
(PP) decreases), the combined force of LS pressure (PLS) and the force of spring (4) pushes
spool (6) to the left.
As spool (6) moves, ports (D) and (E) are interconnected and also connected to the drain port.
The pressure between circuits (D) and (K) becomes drain pressure (PT).
The pressure on the large diameter piston side
of servo piston (10) becomes drain pressure
(PT) and pump discharge pressure (PP) is constantly applied to port (J) on the small diameter
side. Accordingly, servo piston (10) is pushed to
the left and the swash plate is moved to increase
the discharge.
10-158
D375A-6R
Hydraulic system
Work equipment pump
Mechanism to make the pump delivery minimum
10-157
When servo piston (10) moves to the right (the

direction that reduces pump delivery) and LS differential pressure (PLS) increases (for example, when the control valve open area decreases
and pump discharge pressure (PP) increases),
the force caused by pump discharge pressure
(PP) pushes spool (6) to the right.
As spool (6) moves, pump discharge pressure
(PP) flows through port (C) to port (D), and further flows through port (K) to the large diameter
piston side.
Although pump discharge pressure (PP) is applied to port (J) on the small diameter piston
side, servo piston (10) is pushed to the right by
the area difference between the large diameter
piston side and small diameter piston side of servo piston (10).As the result, servo piston (10)
moves into the direction to make the swash plate
angle smaller.
D375A-6R
10-159
Hydraulic system
Work equipment pump
10-158
When servo piston is balanced
The symbols (A1), (A0) and (PEN) represent the

area receiving the pressure on the large diameter piston side, the area receiving the pressure
on the small diameter piston side, and the pressure sent to the large diameter piston side, respectively.
When the force generated by pump discharge
pressure (PP) of the LS valve is balanced with
the combined force of LS pressure (PLS) and
spring (4), and the relationship becomes (A0) x
(PP) = (A1) x (PEN), servo piston (10) stops in
that position.
The swash plate of the pump is held at intermediate position.[The swash plate stops at a position where the open area between ports (D) and
(E) of spool (6) is almost equal to the open area
between ports (C) and (D).
The relationship between the area receiving the
pressure at both ends of servo piston (10) is
(A0):(A1) = 3:5, and the pressures applied to
both ends of the piston when the piston is balanced is (PP):(PEN)C 5:3.
10-160
The force of spring (4) is adjusted so that spool

(6) can be balanced at the specified center when
(PP) - (PLS) = 1.96 MPa {20 kg/cm2}.
D375A-6R
Hydraulic system
Work equipment pump
D375A-6R
10-161
Hydraulic system
Control valve
Control valve
6-spool valve for dual tilt
Appearance
10-162
10-159
10-159
10-159
D375A-6R
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-6R
10-163
Hydraulic system
Control valve
Sectional view (1/4)
10-161
1. Ripper tilt valve

2. Ripper lift valve
3. Blade left tilt valve
4. Blade right 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
10-164
D375A-6R
Hydraulic system
Control valve
(2/4)
10-162
1. LS check valve
2. Preset plug
D375A-6R
10-165
Hydraulic system
Control valve
(3/4)
10-163

2. LS relief valve
3. Unload valve
4. Suction valve
5. Check valve (built - in to spool)
10-166
D375A-6R
Hydraulic system
Control valve
(4/4)
10-164

3. Suction valve
4. Suction valve
D375A-6R
10-167
Hydraulic system
Control valve
5-spool valve for single tilt

Appearance
10-168
10-165
10-165
D375A-6R
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-6R
10-169
Hydraulic system
Control valve
10-167
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
10-170
D375A-6R
Hydraulic system
Control valve
(2/4)
10-168
1. LS check valve
2. Preset plug
D375A-6R
10-171
Hydraulic system
Control valve
(3/4)
10-169

2. LS relief valve
3. Unload valve
4. Suction valve
10-172
D375A-6R
Hydraulic system
Control valve
(4/4)
10-170

3. Suction valve
4. Suction valve
D375A-6R
10-173
Hydraulic system
Control valve
10-174
D375A-6R
Hydraulic system
Control valve
Operation of control valve
10-171
Function
10-171
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.
10-171
Operation
When set to "HOLD" position (operation of un10-171
load valve)
q When the main spool is at the HOLD position,
the pump pressure passes from chamber (A)
through oriffice (4) to chamber (D). Chambers
(C) and (C') are connected to the drain circuit.
q When oil is supplied from the pump, the pressure
in chamber (D) rises, and spool (1) is pushed to
the right by pressure (FO) which is determined
by the cross-sectional area of piston (3) receiving the pressure.
q When (FO) becomes larger than set force (FS)
of spring (2), the spool moves to the right and
connects the passage between chamber (A) and
chamber (B), so the oil from the pump is drained.
q Therefore, spool (1) is balanced at a position that
matches the supply of oil from the pump.
q Actually, the amount of oil supplied from the
pump is small, so the pressure in the circuit is almost the same as the set force of spring (2).
D375A-6R
10-175
Hydraulic system
Control valve
Control of flow rate

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.
10-172
When set to "HOLD" position (blade right tilt cylinder circuit on dual tilt specification machine)
10-172
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).
10-176
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.
D375A-6R
Hydraulic system
Control valve
When set to "HOLD" position (blade tilt cylinder circuit on single tilt specification machine)
q
q
10-173
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.
D375A-6R
10-177
Hydraulic system
Control valve
When set to RIGHT TILT position (blade right tilt cylinder circuit on dual tilt specification machine) 10-174
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).
10-178
q
q
PLS = differential pressure between ports

(L) and (K) = 1.96 MPa {20 kg/cm2}
PLS'= differential pressure between ports
(J) and (D)
PLS C PLS'
D375A-6R
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 (D)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:
(PLS)] 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 (PLS') is
equal to (PLS).
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.
D375A-6R
10-179
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).
10-180
q
q
10-176
PLS = differential pressure between ports

(K) and (J) = 1.96 MPa {20 kg/cm2}
PLS'= differential pressure between ports
(H) and (D)
PLS C PLS'
D375A-6R
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: (PLS)]
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 (PLS') is
equal to (PLS).
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.
D375A-6R
10-181
Hydraulic system
Control valve
10-178
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
P1 = P3 + P4 = Differential pressure between ports (M) and (P)

P2 = Differential pressure between ports (P)
and (N)
P3 = Differential pressure between ports (M)
and (B)
10-182
q
q
P4 = Differential pressure between ports (B)

and (P)
LS =P1 + P2 = Differential pressure between ports (M) and (N) =1.96 MPa {20 kg/cm2}
D375A-6R
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 (P2) 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 (P4) 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) (P1)
+ (P2) equal to LS differential pressure (LS).
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 MPa {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.
D375A-6R
10-183
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.
10-184
10-180
10-180
As a result, the right tilt cylinder does not move

and only the left tilt cylinder moves to carry out
the single tilt operation.
D375A-6R
Hydraulic system
Control valve
When dual tilt operation is carried out
10-181
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.
D375A-6R
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.
10-185
Hydraulic system
Control valve
When pitch operation is carried out
q
q
10-182
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.
10-186
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.
D375A-6R
Hydraulic system
Self-pressure reducing valve
10-183
General view
10-183
P1: From fan pump

P2: To fan motor
PR: To PPC valve and EPC valve, etc.
T: To tank
D375A-6R
10-187
Hydraulic system
10-184
Sectional view
1. Valve (sequence valve)

2. Spring
3. Valve (pressure reducing valve)
4. Spring (pressure reducing valve main)
5. Filter
10-188
6. Screw
7. Poppet
8. Spring (for pressure reducing valve pilot)
9. Spring (safety valve)
10. Ball
D375A-6R
Hydraulic system
Function
10-185
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-6R
10-189
Hydraulic system
Operation
When engine is stopped (When all the oil pressures in circuit are low)
q
q
q
10-186
10-186
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) .
10-190
D375A-6R
Hydraulic system
When load pressure (P2) is lower than output pressure (PR) of self-pressure reducing valve
The force of spring (3) and the force of exerted

by the (PR) pressure 0 MPa {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) x 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 (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-6R
10-187
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).
10-191
Hydraulic system
10-18
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) x 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 the 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).
10-192
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-6R
Hydraulic system
When abnormally high pressure is generated
10-189
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-6R
10-193
Work equipment
Cylinder stay
Work equipment
10-190
Cylinder stay
10-190
1. Yoke
2. Oil seal
3. Bushing
4. Bushing
10-194
D375A-6R
Cab
Cab mount
Cab
10-191
Cab mount
10-191
1. Support
2. Damper mount (front)
3. Damper mount (rear)
D375A-6R
Outline
10-191
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.
10-195
Cab
Cab
Cab
10-192
Cab assembly
10-192
1. Front wiper
2. Front glass
3. Rear wiper
4. Door
10-196
D375A-6R
Cab
Cab
ROPS
10-193
1. ROPS
D375A-6R
10-197
Electrical system
Engine control
Electrical system
10-194
Engine control
10-194
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
10-198
10-194
Outline
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-6R
Electrical system
Engine control system
Outline
10-195
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-6R
10-195
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).
10-199
Electrical system
10-200
D375A-6R
Electrical system
Engine controller
10-197
Outline
10-197
Mounting the engine controller on the engine 10-197
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.
Unifying the specification of engine controller 10-197
The common engine controller CM850 is adopted
which is co-developed by Komatsu and Cummins.
D375A-6R
10-201
Electrical system
Input/output signal
CN-CE01
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
Pin No.
Signal name
Input/outp
ut
Pin No.
Signal name
Input/outp
ut
NC (*)
37
Sensor power source (5 V)
38
GND
39
NC (*)
40
CN-CE01
36
NC (*)
41
NC (*)
42
NC (*)
NC (*)
43
NC (*)
NC (*)
44
Boost pressure sensor
Ambient pressure sensor
45
Injector #1 (+)
Supply pump #1 (+)
46
Injector #5 (+)
Supply pump #1 ()
47
Sensor GND
CAN (-)
48
Ne sensor ()
C
-
NC (*)
49
NC (*)
CAN(+)
50
NC (*)
Supply pump #2 (+)
51
Injector #2 ()
10
Supply pump #2 ()
52
Injector #3 ()
11
53
Injector #1 ()
12
NC (*)
54
Injector #2 (+)
13
Engine oil pressure sensor
55
Injector #3 (+)
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
20
NC (*)
21
NC (*)
22
23
Boost air temperature sensor
24
NC (*)
25
Common rail pressure sensor
26
BKup sensor (+)
27
NE sensor (+)
28
NC (*)
29
30
Fuel temperature sensor
31
32
NC (*)
33
34
NC (*)
35
NC (*)
10-202
*: Never connect to NC, or malfunctions or failures

will occur.
D375A-6R
Electrical system
CN-CE02
CN-CE02
Pin No.
Signal name
Input/outpu
t
Pin No.
42
Signal name
Input/outpu
t
43
Electrical intake air heater relay

return
NC (*)
44
NC (*)
45
NC (*)
46
CAN(+)
47
CAN (-)
48
NC (*)
49
NC (*)
50
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
Decelerator signal
10
NC (*)
11
NC (*)
12
NC (*)
13
NC (*)
14
NC (*)
CN-CE03
Pin No.
15
NC (*)
GND
GND
C
-

will occure.
Signal name
Input/output
16
NC (*)
17
NC (*)
Power source (+24 V constant)
18
NC (*)
Power source (+24 V constant)
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 (*)

will occur.
40
41
D375A-6R
D
-
10-203
Electrical system
Sensors
10-20
Fuel temperature sensor

10-20
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.
10-204
D375A-6R
Electrical system
Ne speed sensor (crank shaft angle sensor)

q If the signal hole made on the flywheel passes
over 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.

This sensor is used to correct altitude.
10-202
Oil pressure sensor
Bkup speed sensor (G sensor)

10-202
(cylinder sensor)
10-202
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.
10-202
D375A-6R
10-205
Electrical system
10-203
Boost temperature sensor
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
q
10-206
10-203
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-6R
Electrical system
Deceleration potentiometer
1. Connector
2. Lever
3. Body
4. Potentiometer
5. Coupling
6. Shaft
7. Stopper
D375A-6R
10-204
10-204
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.
10-207
Electrical system
CRI engine control system
10-205
a "CRI" is an abbreviation for Common Rail Injection.

System diagram
10-205
10-208
D375A-6R
Electrical system
1. NE speed sensor
3. Injector assembly
3A. Orifice
3B. Control chamber
3C. Hydraulic piston
3D. Injector
3E. Nozzle
4. Orifice (for air bleeding)
5. Fuel tank
6. Strainer
7. Pre-fuel filter (water separator)
8. Priming pump
9. Fuel filter
10. Engine throttle controller cooler
11. Pressure limiter
12. Flow damper
13. High pressure injection pipe
14. Common rail
15. Fuel supply pump
15A. PCV
15B. High pressure pump
15C. Priming pump
15D. Feed pump
15E. Bkup speed sensor (G sensor)
16. Overflow valve
17. Air bleeding valve
10-206
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-6R
10-206
System configuration
q The CRI system consists of fuel supply pump
(15), common rail (14), injector (3), engine controller (2) which controls those components 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
delivery is controlled by turning ON and OFF the
PCV (discharge control valve) (15A) of the fuel
supply pump according to the electric signals
from the engine 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) side and control chamber (3B)
side of the injector through the fuel injection pipe
of each cylinder.
q Injector controls the fuel injection rate and fuel
injection timing by turning ON and OFF the TWV
(two-way solenoid valve).If the TWV is turned
ON (energized), the fuel circuit is so changed
that the high-pressure fuel in the control chamber flows out through orifice (3A). As a 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 turned
OFF (de-energized), the fuel circuit is so
changed that the high-pressure fuel can be supplied 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 electronically controlled respectively by the timing to energize the
TWV and the duration of energizing the TWV.
10-209
Electrical system
Monitor system
Monitor system
Outline
q 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.
10-207
10-207
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)
1. Monitor unit which turns on the alarm when themachine 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. Current and voltage values of the sensors and
solenoids.
10-210
D375A-6R
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.
10-208
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-6R
10-211
Electrical system
Machine monitor
Machine monitor
Outline
10-209
q The machine monitor has monitor display function, mode selection function and switch function
for electrical parts etc.
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.
10-212
10-209
Precautions on the machine monitor display 10-209

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-6R
Electrical system
Machine monitor
Input and output signals
10-210
CN-CM01
CN-CM03
5
6
7
8
Input/output
RS232C CD for communication terminal
Input
RS232C RXD for communication terminal
Input
RS232C SG for communication terminal
GND for communication terminal control
signal
Communication terminal selection signal
Input
RS232C RTS for communication terminal
Output
RS232C TXD for communication terminal
Output
RS232C DTR for communication terminal Output
Fuel level
NC (*)
Input
9
10
RS232C DSR for communication terminal

RS232C CTS for communication terminal
Input
Input
11
12
Battery charge
Chassis analog signal GND
Input
11
12
Input
13
14
Light switch
Key switch (ACC)
Input
Input
13
15
16
17
18
Key switch (C)

Preheating
NC (*)
NC (*)
Input
Input
14
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
Pin No.
Signal name
1
2
3
4
Battery power (+24 V constant)

Battery power (+24 V constant)
Battery power GND
Battery power GND
Wake-up
Relay output
7
8
Chassis signal GND

Hydraulic oil pressure
9
10
Input/output
Input
Input
Input/output
Output

will occur.
Pin No.
1
2
3
4
15
16
17
18
Signal name
Input
Output
Output
Output
Input
Output
CN-CM02
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
NC (*)
Input/output
Input
Input/output
Input/output
12
NC (*)
Pin No.
Signal name

will occur.
CN-CM04
1
2
3
4
NC (*)
NC (*)
NC (*)
NC (*)
Input/output
5
6
7
8
9
10
11
12
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
Pin No.
Signal name

will occur.
CN-CM05
Pin No.
1
2
3
4
5
6
7
8
D375A-6R
Input/output
Power supply for camera
Output
Camera NTSC signal input 1
Input
Input
Input
Electric power supply GND for camera
Camera signal GND1
Camera signal GND2
Camera signal GND3
Signal name
10-213
Electrical system
Machine monitor
10-21
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
10-214
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-6R
Electrical system
Machine monitor
Machine monitor display

Display
category
Symbol
10-212
Display item
Contents
Radiator coolant level Below "low" line
Oil pressure
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
Lights up at low level or

below
Displays when starting switch is turned

to ON position with engine stopped.
Display when abnormal: OFF Display
when normal: ON
Hydraulic oil level (if

equipped)
Check
Engine oil level (if

equipped)
D375A-6R
Battery charge condiWhen charge is defective

tion
Displays when starting switch is set to

ON position and engine is running
Display when abnormal: ON CAUTION
lamp flashes
Lights up when oil level is

below suction limit
Displays when starting switch is turned

to ON position with engine stopped.
Display when normal: ON Display
when abnormal: OFF
10-215
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

Battery charge condiV and 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

Hydraulic oil temperAbove 110 C: Symbol ON +
ature
buzzer sounds
Air cleaner clogging
10-216
Lights up when -7,470 490

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

equipped)
Pilot
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
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-6R
Electrical system
Machine monitor
Display
category
Symbol
Display item
Contents
Description
Reads the temperature
Gauge
Torque converter oil

temperature
Hydraulic oil temperature
Fuel level
Service meter (Hours

From 0 to 99999
meter)
D375A-6R
Reads the level
Progresses when the engine is running
10-217
Electrical system
Machine monitor
10-215
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)
10-218
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-6R
Electrical system
Machine monitor
Machine speed
1. 0 km/h
2. 5 km/h
10-216
3. 10 km/h
4. 15 km/h
Hydraulic pump oil pressure
1. 0 MPa
2. 10 MPa
3. 20 MPa
1. 0 MPa
2. 0.2 MPa
3. 0.3 MPa
D375A-6R
1. 0 V
2. 17 V
3. 20 V
10-216
10-216
4. 0.4 MPa
5. 0.5 MPa
6. 0.7 MPa
10-216
4. 25 V
5. 30 V
6. 31 V
Engine speed
1. 500 rpm
2. 1000 rpm
3. 1500 rpm
4. 30 MPa
5. 40 MPa
6. 50 MPa
Engine oil pressure
Battery voltage
10-216
4. 2000 rpm
5. 2500 rpm
6. 3000 rpm
Drawbar pull
1. 0 W
2. 0.2 W
3. 0.4 W
10-216
4. 0.6 W
5. 0.8 W
6. 1.0 W
10-219
Electrical system
Machine monitor
10-217
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
Switch
power
Item
Function
F6
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
10-220
Enter
Change of multi-gauge
Changes display item for multi gauge
D375A-6R
Electrical system
Machine monitor
Service meter and clock switching function

10-218
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.
10-218
Maintenance reminder function
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 normal 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-6R
10-221
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.
Warning display
There is one or more items with
(white symbol on red less than 0-hour remaining time
background)
for maintenance.
q
To prevent careless reset of the maintenance interval, the screen is password protected.
10-222
D375A-6R
Electrical system
Machine monitor
User mode
10-2 0
q Pressing F6 on the standard screen enters the
user mode, switching to the User Menu screen.
q In user mode, you can perform setting for items
relating to the machine monitor and machine
shown below.
Utility screen select
Multi-gauge
Screen adjustment
Time adjustment
Language setting
Reverse-interlok Enabled Mode (When camera is set)
Fan reverse mode
Skipping pre-lubrication
10-2 0
Normal
q The standard screen is displayed.
10-2 0
Load display
q 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.
q The graph on the screen is updated and scrolled
to the left at intervals of several seconds.
10-2 0
Body pitch display
The horizontal axis indicates the time and the
vertical axis indicates the pitch angle of the body.
q The graph on the screen is updated and scrolled
to the left at intervals of several seconds.
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.)
10-2 0
If Utility Screen Select is selected with switch F6,
(1) Standard Display, (2) Load Display, or (3)
Body Pitch Display can be selected.
q Select the desired item with switch F3 or F4 and
enter that item with switch F6.
q
D375A-6R
Multi-gauge
10-2 0
On this screen, the display item assigned to the
gauge at the center can be selected.
10-223
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
Screen adjustment
10-2 1
Selecting the Screen Adjustment on the User
Menu screen and pressing F6 switches to the
Screen Adjustment screen.
q From this menu, you can adjust the brightness,
contrast, and luminance of the machine monitor
screen.
q When the light switch is set to "Night mode ON",
the night mode screen is adjustable.
q When the light switch is set to "Daytime mode
ON" or OFF, the daytime mode screen is adjustable.
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: Confirms 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 items 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.
10-224
D375A-6R
Electrical system
Machine monitor
Clock adjustment
10-2 2
q Select the Clock Adjustment on the User Menu
screen and press F6 to switch to the Clock Adjustment screen.
q On this screen, you can change the setting of the
time displayed on the standard screen.
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 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.
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.
10-2 2
Language setting
q Select the Language on the User Menu screen
and press F6 to switch to the Language setting
screen.
q From this menu, you can change the language to
be displayed on the monitor. Available languages are as follows.
English, Japanese, Chinese, French, Spanish,
Portuguese, Italian, German, Russian, and
Turkish

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
one hour. Setting OFF returns to the ordinary
time.
F3: Moves to the item one right.
F4: Moves to the item one left.
D375A-6R
10-225
Electrical system
Machine monitor
Setting of camera for reverse-interlock enabled

mode (applied to machines equipped with rear
10-2 3
view camera)
q 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))
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.
10-226
D375A-6R
Electrical system
Machine monitor
Fan reverse mode

10-2 4
q In this mode, the fan can be set to drive in reverse to clean the radiator core.
q While the starting switch is set to OFF, select the
menu with switch F3 or F4 and enter it with
switch F6.
q While screen (A) is displayed, press switch F6,
and the fan is ready to run in reverse.
q While screen (B) is displayed, start the engine.
10-2 4
Precautions for using fan reverse mode
The rotation direction of the fan cannnot be
changed while the engine is running.
q When running the fan in reverse, set the lock lever to the LOCK position.
q While the fan is running in reverse, the machine
cannot travel.
q When canceling the reverse mode, set the starting switch to OFF position to stop the engine.
q When using this mode, warm up the engine sufficiently. If the engine is not warmed up, the fan
may not supply sufficient air.
q
D375A-6R
10-227
Electrical system
Machine monitor
Pre-lubrication skip mode (applied to machines

10-2 5
equipped with pre-lubrication
q This mode is used for starting engine without activating pre-lubrication.
q 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.
q Press F6 on screen (B) to complete pre-lubrication skip.
After setting the mode, the display returns to
user menu automatically.
q Setting the starting switch to "START" position
initiates the starter rotation and starts up the engine without turning on the pre-lubrication operation.
10-2 5
Function of checking service meter
q 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.
10-228
D375A-6R
Electrical system
Machine monitor
Function of checking display LCD

10-2 6
q Continuously pressing the buzzer cancel switch
(1) and F2 at the same time on the standard
screen causes all the LCD elements to light in
white. Release F2 and buzzer cancel switch in
order.
q One of the features of liquid crystal display panel
is that there may be black spots (spots that do
not light up) or white spots (spots that stay lit up)
on the screen. If there are fewer than ten black
or white spots, the monitor is normal.
Pressing any function switch returns to the previous screen.
D375A-6R
10-229
Electrical system
Lamp system
Lamp system
10-2 7
Operation
10-2 7
Related electrical circuit diagram
10-2 7
10-230
D375A-6R
Electrical system
Engine preheat (electrical intake air heater) control
10-2 8
Operation
10-2 8
10-2 8
D375A-6R
10-231
Electrical system
Palm command control system
10-2 9
1. Machine monitor (Multi-information)

2. Gearshift mode switch
5. Engine speed sensor
10-232
D375A-6R
Electrical system
Gear shift mode function

10-230
Outline
10-230
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)
10-230
Gear shift operation
Select a gear speed by pressing (a) or (b) on the
PCCS lever (steering / directional / gearshift lever).
(a): Shift-up switch
(b): Shift-down switch
10-230
Screen display
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
D375A-6R
10-233
Electrical system
Setting the preset with the shift switch operation

10-231
in NEUTRAL
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)
10-234
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 with the shift switch oper10-231
ation during travel
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.
D375A-6R
Electrical system
Sensor
Sensor
10-232
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
D375A-6R
10-232
10-232
4. Tube
5. Wire
6. Connector
10-235
Electrical system
Sensor
10-23
Radiator coolant level sensor
1. Float
2. Sensor
3. Tube
Fuel level sensor
1. Connector
2. Float
3. Arm
4. Body
5. Spring
6. Contact
7. Spacer
10-236
4. Wire
5. Connector
10-23
10-23
Function
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.
D375A-6R
Electrical system
Sensor
Transmission output shaft speed sensor
10-234
1. Magnet
2. Terminal
3. Case
4. Boot
5. Connector
Pitch angle sensor
10-234
1. Body
2. Tube
3. Wire
4. Connector
D375A-6R
10-237
Electrical system
Sensor
Acceleration sensor
10-235
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.
10-238
10-235
D375A-6R
Electrical system
Sensor
Speed sensor
10-236
1. Sensor
2. O-ring
3. Connector
4. Wire
10-236
Function
q Speed sensor, which is installed in the case of
the cooling fan motor, detects gear speed as
pulse signals from cylinder block spline inside
the motor and sends them as converted electric
signals to the controller.
q Since the clearance between the sensor and
spline is controlled to the specified dimension,
adjustment at installation is not necessary.
D375A-6R
10-239
Electrical system
Sensor
Engine oil level sensor
1. Connector
2. Bracket
10-237
3. Float
4. Switch
10-237
Air cleaner clogging sensor
1. Spring
2. Switch
3. Hose
4. Wire
5. Connector
6. GND
10-237
Hydraulic oil level sensor
1. Stopper
2. Float
3. Sensor
10-240
4. Plug
5. Tube
6. Connector
D375A-6R
Electrical system
Vehicle health monitoring system (VHMS)

Outline
VHMS is a system consisting of a VHMS controller
and various types of sensors (some of them are
commonly used with other systems) and used for recording the operating state of the machine. It collects and records diverse information including the
machine's location and operation information as
well as data from measuring instruments for later
use in maintenance and servicing.Confirmation of
the collected data is done after it is downloaded to a
PC.
10-238
10-238
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 use of VHMS, see "Testing and adjusting".
VHMS controller
10-238
Note 1. VHMS is an abbreviation of Vehicle Health Monitoring System.
D375A-6R
10-241
Electrical system
10-239
Input/Output signal
CN1 [CN 1]
Pin No.
Signal name
CN1-1
NC
CN1-2
CN2 [CN2 A, B]
Input/out
put
Pin No.
Signal name
Input/out
put
CN2-A1 NC
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)
CN1-6
CN1-7
Power supply (Constant power

supply) (24 V)
Power supply (Constant power
supply) (24 V)
Input
CN2-A6 NC
Input
CN2-A7 Exhaust temperature (Front)
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
Input
CN1-10 NC
CN2-A10 Ambient temperature
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
Input
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
CN1-17 Start signal
CN2-B6 WAKE UP (Hi)
Input
CN2-B7 NC
CN2-B8 NC
CN2-B9 GND
CN2-B10 NC
CN2-B11 NC
CN2-B12 CONNECTOR SEL1 (GND)
10-242
Input
D375A-6R
Electrical system
CN3 [CN3 A, B]
Pin No.
CN4 [CN4 A, B]
Signal name
CN3-A1 NC
CN3-A2 CAB out D/L Sw
CN3-A3 NC
CN3-A4 NC
Model selection (See ORB connecCN3-A5
tion)
Input/out
put
Pin No.
Signal name
Input/out
put
CN4-A1 NC
Input
CN4-A2 NC
CN4-A3 NC
Input
CN4-A4 CAN (1) H (KOM-NET/c)

CN4-A5 CAN (0) shield (MMS)
Input/out
put
Input/out
put
CN3-A6 NC
CN4-A6 CAN (0) H (MMS)
CN3-A7 NC
CN4-A7 NC
CN3-A8 NC
CN4-A8 NC
CN4-A9 GND
CN3-A9 CONNECTOR SEL2 (GND)
Input
CN3-A10 NC
CN3-A11 NC
CN3-A12 NC
CN3-A13 NC
CN3-A14 NC
CN3-A15 NC
CN3-A16 NC
CN4-B1 NC
CN3-A17 NC
CN4-B2 NC
CN3-A18 NC
CN4-B3 GNG (Orbcomm)
CN3-B1 NC
CN4-B4 RS232C TX1 (Orbcomm)
CN3-B2 NC
CN4-B5 NC
CN3-B3 NC
CN4-B6 NC
CN3-B4 NC
CN4-B7 NC
CN3-B5 NC
CN4-B8 NC
CN3-B6 NC
CN4-B9 GND (Orbcomm)
CN3-B7 NC
CN4-B10 RS232C RX1 (Orbcomm)
CN3-B8 NC
CN5
CN3-B9 NC
Pin No.
CN3-B10 NC
CN5-1
LAN TX+
Input/out
put
Output
CN3-B11 NC
CN5-2
LAN TX-
Output
Input
CN5-3
LAN RX+
Input
CN5-4
LAN RT3
CN5-5
LAN RT4
CN5-6
LAN RX-
Input
CN5-7
LAN RT1
CN5-8
LAN RT2
CN5-9
NC
CN5-10 NC
CN3-B12 CONNECTOR SEL3 (OPEN)
CN4-A10 RS232C RXD (PC Tool)

CN4-A11 RS232C TXD (PC Tool)
Output
CN4-A12 CAN (1) L (KOM-NET/c)
Input/out
put
CN4-A13 CAN (1) SH (KOM-NET/c)

CN4-A14 CAN (0) L (MMS)
Signal name
CN5-11 PWR(LAN5 V)
CN5-12 GND (LAN)
D375A-6R
Input
Input/out
put
Output
Input
Output
10-243
Electrical system
Sensors
10-241
Exhaust gas temperature sensor/amplifier
10-241
Engine oil temperature sensor

Specification
Type of sensors: Thermistor
Measuring range: 40 130 C
80 130 C
(Assured accuracy: 2 C)
Maximum power consumption: 0.5 mW
Withstand pressure: 4.9 MPa {50 kg/cm2}
Operating temperature: -30 C - +140 C
Performance table
10-241
10-241
Specification
Rated voltage: DC24 V
Detectable temperature range: 100 1,000 C
300 800 C
(Assured accuracy: 10 C)
Output voltage characteristics
(Atmospheric temperature: 20 C)
Reference values
10-241
Temperature
( C)
Resistance
(kz)
Temperature
( C)
Resistance
(kz)
30
35.27
80
6.571
110
2.887
40
24.28
85
5.682
115
2.544
50
17.05
90
4.931
120
2.248
60
12.20
95
4.293
125
1.992
70
8.884
100
3.750
130
1.769
Temper- Resisature
tance
( C)
(kz)
a. Heat sensing part of sensor

Outside diameter of mounting part: R1/4
10-241
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.
10-244
Sensed
temperature
50
( C)
Output volt1.191
age (V)
100
400
700
800
1.397
2.626
3.899
4.316
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)
10-241
Function
The exhaust temperature sensor is a thermocouple
type sensr and installed to the turbocharger inlet. It
outputs the exhaust temperature data to the VHMS
controller.
D375A-6R
Electrical system
Ambient temperature sensor

10-242
Specification
10-242
Power consumption: Max. 0.5 mW
Withstand pressure: 0.98 MPa {10 kg/cm2}
Detectable temperature range (ambient temperature):
-30 +120 C
Storage temperature range: -50 +140 C
Performance table
Detected
temperature -20
-10
0
10
20
50
( C)
Resis30.32 18.58 11.74 7.623 5.077 1.712
tance(kz)

Outside diameter of mounting part: 16 x 1.5
10-242
Function
The ambient temperature sensor inputs the change
of the ambient temperature as the change of the
thermistor resistance to the VHMS controller.
D375A-6R
10-245
Electrical system
10-243
Engine blow-by pressure sensor
1. Sensor
2. Connector
3. Ambient pressure intake tube
A: GND (Black)
B: Power supply (Red)
C: Output (White)
10-243
Specification 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.
10-243
Transmission main oil pressure sensor

1. Sensor
2. Connector
10-246
D375A-6R
Electrical system
ORBCOMM system
ORBCOMM system
10-24
Outline
10-24
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 of procedures for launching the
station and others, see "Testing and adjusting".
q The ORBCOMM terminal system may or may
not be installed to the machine, depending on
the user's purchase specification.
D375A-6R
10-247
Electrical system
ORBCOMM system
10-245
ORBCOMM terminal system
1. Communication antenna connection

2. DRC connector connection (40 poles)
NC
19
10-245
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.
10-245
Input/Output signal
DRC conector
18
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
10-248
D375A-6R
Electrical system
ORBCOMM system
Antenna
10-246
Specification
Type: Helical whip antenna (1)
Impedance: 20
Input terminal: M-P type
Length: 165 20 mm
a. Communication antenna mounting part
10-246
10-246
Function
It transmits the data collected and stored with VHMS
controller to the computer center via the communication satellite.
D375A-6R
10-249
Electrical system
ORBCOMM system
10-250
D375A-6R
20-1
BULLDOZER
D375A-6R
Machine model
Serial number
D375A-6R
65001 and up
D375A-6R
(01)
20-1
20-1
Contents
Contents
20-2

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

Standard value table for engine
20-3
20-3
Machine model
D375A-6R
Engine
Item
Measurement conditions
Rotating speed
High idle
Low idle
Rated speed
Boost pressure
At rated horsepower
Whole speed range (Ambient temperature: 20 C)

At sudden acceleration
Exhaust gas color
At high idle
Valve clearance
Intake valve
(Normal temperature) Exhaust valve
Compression pressure Engine oil temperature: 40 - 60 C
(SAE15W-40 or SAE30
oil)
(Engine speed)
Blow-by pressure
At rated horsepower
(SAE15W-40 or SAE30 (Coolant temperature: Within operatoil)
ing range)
SAE0W30EOS,
At high idle
Hydraulic
SAE5W40EOS,
(Oil temperature: 90 SAE10W30DH,
110 C)
SAE15W40DH,
At low idle
SAE30DH
Exhaust temperature
Oil temperature
Alternator belt tension
Air conditioner compressor belt tension
D375A-6R
(01)
Whole speed range (inside oil pan)

Deflection when pressed with finger
force of approx. 58.8 N {6 kg}
Deflection when pressed with finger
force of approx. 98 N {10 kg}
SAA6D170E-5
kPa
{mmHg}
Standard value for

new machine
1,900 (0/-50)
750 50
1,800
Min. 144
{Min. 1,080}
Service limit
value
1,900 (0/-50)
750 50
1,800
Max. 130.6
{Max. 980}
Max. 680
Min. 700
MPa
{kg/cm2}
(rpm)
Max. 3.5
Max. 1.0
0.32
0.62
Min. 2.94
{Min. 30}
(210250)
Min. 4.5
Min. 2.0
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. 98.07
{Min. 1.0}
Max. 78.45
{Max. 0.8}
90 110
Min. 120
mm
(Auto-tension)
mm
(Auto-tension)
Unit
rpm
Bosch index
mm
kPa
{kg/cm2}
20-3

Standard value table for machine
20-4
Category
Machine model
Item
Engine speed
Decelerator pedal
low speed
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
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 depressed
Torque converter stall speed: F3
Torque converter + Work equipment speed:
F3 + Ripper raise
Measure with adjustment ID: 0530 (Stall mode)
Engine stopped
Center of lever knob
q
q
q
q
Brake pedal
Engine at low idling

Center of pedal
q
q

Hydraulic oil temperature: Neutral Raise
45 55 C
Neutral Float
Ripper lever
q
20-4

Neutral
Hydraulic oil temperature: Raise/Lower
45 55 C
Neutral Tilt forCenter of lever knob
ward/back
1,400
Max. 8.0
30 5
40 5
(Play: Max. 3)
40 5
(Play: Max. 3)
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
1,450
95
Full stroke
1,530 50
30 5
mm
Until oil pressure

becomes zero
q
Blade lever
Engine stopped
Center of pedal
900 50
30 5
mm
Service limit
value
1,500 50
rpm
Standard value
for new
machine
900 50
Unit
Neutral o Forward
Neutral o
Reverse
Full stroke
(Neutral
Right/Left)
Until clutch is
fully disengaged
Steering
Decelerator pedal
D375A-6R
mm
D375A-6R
(01)

Category
Machine model
Neutral o Forward
Left
Engine stopped
Steering
Right
PCCS lever
Control lever/pedal operating effort
56.9 6.9
{5.8 0.7}
56.9 6.9
{5.8 0.7}
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
Brake pedal
Control lever/pedal operating effort
Service limit
value
q
q
q
q
q
q
q
Blade lever
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}

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}
28.4 4.9
{2.90.5}
28.4 4.9
{2.90.5}
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}

Hydraulic oil temperature: Neutral o Raise
45 55 C
Neutral o Float
N
{kg}
Neutral
Left/Right tilt
q
q
Ripper lever
Min. speed
Fan
Standard value
for new
machine
Neutral o
Reverse
Item
Forward and
reverse
D375A-6R
Max. speed
Circuit oil pressure
D375A-6R
(01)
q
q

Neutral
Hydraulic oil temperature: Raise/Lower
45 55 C
Neutral Tilt forward/back
N
{kg}
Fan 100 % mode

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

Category
Machine model
Power train oil pressure
0.69 1.05
{7.0 10.7}
0.69 1.05
{7.0 10.7}
0.03 0.20
{0.3 2.0}
0.03 0.20
{0.3 2.0}
Engine at high
idling
0.44 0.70
{4.5 7.0}
0.44 0.70
{4.5 7.0}
Engine at high
idling
1.29 1.54
{13.2 15.7}
1.29 1.54
{13.2 15.7}
Engine at low
idling
2.25 2.87
{23.0 29.3}
2.25 2.87
{23.0 29.3}
Engine at high
idling
2.55 2.87
{26.0 29.3}
2.55 2.87
{26.0 29.3}
2.48 2.87
{25.3 29.3}
2.38 3.07
{24.3 31.3}
Engine at high
idling
2.68 2.87
{27.3 29.3}
2.58 3.07
{26.3 31.3}
Engine at low
idling
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
idling
2.55 2.87
{26.0 29.3}
2.35 3.16
{23.9 32.2}
Engine at low
idling
2.06 2.35
{21.0 24.0}
1.86 2.55
{18.9 26.0}
Engine at high
idling
2.06 2.35
{21.0 24.0}
1.86 2.55
{18.9 26.0}
Engine at low
idling
Torque converter
lockup clutch pressure
Torque converter
stator clutch pressure
q
MPa
{kg/cm2}
Power train oil temperature: Engine at low

Within operating range
idling
20-6
0.03 0.25
{0.3 2.5}
Unit

idling
Torque converter
outlet pressure
Transmission 1st
clutch pressure
0.03 0.25
{0.3 2.5}
Engine at low
idling
Torque converter
inlet pressure
Transmission R
clutch pressure
Service limit
value
q
Transmission F
clutch pressure
Standard value
for new
machine
Engine at high
idling
Item
Transmission main
relief pressure
D375A-6R
Adjustment ID:
5535
Measure in (both
steering clutch
disengage modes)
Engine at high
idling
Engine at low
idling
MPa
{kg/cm2}
D375A-6R
(01)

Category
Machine model
Item
D375A-6R
Standard value
for new
machine
Service limit
value
Engine at low
idling
2.25 2.84
{23.0 29.0}
2.06 3.13
{21.0 31.9}
Engine at high
idling
2.55 2.87
{26.0 29.3}
2.30 3.16
{23.4 32.2}
2.25 2.84
{23.0 29.0}
2.06 3.13
{21.0 31.9}
2.55 2.87
{26.0 29.3}
2.30 3.16
{23.4 32.2}
q
Transmission 2nd
clutch pressure
Adjustment ID:
5535
Measure in (both
steering clutch
disengage modes)
Unit
Engine at low
idling
Transmission 3rd
clutch pressure
MPa
{kg/cm2}
Engine at high
idling
Power train oil temperature: Engine at high
idling
0.08 0.25
{0.8 2.5}
0.08 0.25
{0.8 2.5}

idling
2.25 2.84
{23.0 29.0}
2.2 3.04
{22.4 31.0}
Engine at high
idling
2.55 2.87
{26.0 29.3}
2.4 3.07
{24.4 31.3}
Engine at low
idling
2.25 2.84
{23.0 29.0}
2.2 3.04
{22.4 31.0}
2.55 2.87
{26.0 29.3}
2.4 3.07
{24.4 31.3}
2.25 2.84
{23.0 29.0}
2.2 3.04
{22.4 31.0}
Engine at high
idling
2.55 2.87
{26.0 29.3}
2.4 3.07
{24.4 31.3}
Engine at low
idling
2.25 2.84
{23.0 29.0}
2.2 3.04
{22.4 31.0}
Engine at high
idling
2.55 2.87
{26.0 29.3}
2.4 3.07
{24.4 31.3}
2.55 0.10
{26.0 1.0}
Min. 2.2
{Min. 22}
F1
20.6 1.0
(3.50.2)
20.6 1.0
(3.50.2)
F2
10.6 0.6
(6.80.3)
10.6 0.6
(6.80.3)
F3L
9.0 0.4
(8.00.4)
9.0 0.4
(8.00.4)
F3
6.1 0.3
(11.80.6)
6.1 0.3
(11.80.6)
15.7 0.8
(4.60.2)
15.7 0.8
(4.60.2)
R2
8.1 0.4
(8.90.4)
8.1 0.4
(8.90.4)
R3L
7.4 0.3
(9.70.5)
7.4 0.3
(9.70.5)
R3
Power train oil pressure
Transmission lubricating oil pressure
4.9 0.3
(15.80.7)
4.9 0.3
(15.80.7)
Steering left clutch

pressure
Steering left brake

pressure
Engine at high
idling
Engine at low
idling
Steering right clutch

pressure
Steering right brake

pressure
Power train oil temperature: Engine at high

idling
Flat ground
range
Power train oil temperature: Within operating
range
Engine at high idling
Run up distance: 10 - 30
m
Measurement distance:
20 m
( ) indicates travel speed
Power train performance
q
q
Travel speed
D375A-6R
(01)
q
q
Automatic gear shift mode
Pin puller operating

pressure
R1
MPa
{kg/cm2}
MPa
{kg/cm2}
sec.
(km/h)
20-7

Category
Machine model
D375A-6R
10.6 0.6
(6.80.3)
10.6 0.6
(6.80.3)
6.1 0.3
(11.80.6)
6.1 0.3
(11.80.6)
15.7 0.7
(4.60.3)
15.7 0.7
(4.60.3)
R2
8.2 0.4
(8.70.4)
8.2 0.4
(8.70.4)
4.9 0.3
(14.70.7)
4.9 0.3
(14.70.7)
2.45 (+1.37/0)
{25 (+14/0)}
2.45 (+1.37/0)
{25 (+14/0)}
26.4 28.4
{270 290}
26.4 29.4
{270 300}
27.4 29.4
{280 300}
27.4 29.4
{280 300}
26.4 28.4
{270 290}
26.4 29.4
{270 300}
27.4 29.4
{280 300}
27.4 29.4
{280 300}
26.4 28.4
{270 290}
26.4 29.4
{270 300}
27.4 29.4
{280 300}
27.4 29.4
{280 300}
Engine at low
idling
q
q
Blade tilt relief pressure
Flat ground
range
Power train oil temperature: Within operating
range
Run up distance: 10 - 30
m
Measurement distance:
20 m
( ) indicates travel speed
Manual gear shift mode
Power train performance
F2
Engine at high
idling
q
q
Work equipment oil pressure
20.6 1.0
(3.50.2)
Engine at low
idling
q
q
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}
Unit
F3
R1
Engine at high
idling
Ripper tilt relief

pressure
LS pressure
(Load sensing pressure)
q
q
q
q
sec
(km/h)
Hydraulic oil temperature: Engine at low

45 55 C
idling
Cylinder stroke end
Engine at high
idling
Engine at low
idling
Ripper lift relief

pressure
20-8
20.6 1.0
(3.50.2)
Engine at high
idling
Control circuit oil

pressure
PPC valve output
pressure
F1
Engine at low
idling
Unload pressure
Service limit
value
q
Travel speed
Standard value
for new
machine
R3
Item
Engine at high
idling
Circuit oil pressure: Lever in neutral
Output pressure: Lever at stroke end
MPa
{kg/cm2}
MPa
{kg/cm2}
D375A-6R
(01)

Category
Machine model
Standard value
for new
machine
Service limit
value
Engine at low
idling
7 13
20
Engine at high
idling
3.7 4.7
Engine at low
idling
1.3 1.7
1.3 1.8
Engine at high
idling
1.3 1.7
1.3 1.8
Engine at low
idling
24
Engine at high
idling
2.5 3.5
Engine at low
idling
24
Engine at high
idling
2.5 3.5
Engine at low
idling
46
Engine at high
idling
2.5 3.5
46
Engine at high
idling
2.5 3.5
Engine at low
idling
24
Engine at high
idling
2.5 3.5
Engine at low
idling
24
Engine at high
idling
2.5 3.5
Raise
Item
D375A-6R
sec.
q
q
L.H. tilt

Apply no load to blade.
Between ground surface
and raised end of blade
Lower
Blade lift
sec.
L.H. tilt
q
q
Single tilt specification
Blade
dual tilt
L.H. tilt

Between left tilt end and
right tilt end
R.H. tilt
Dual tilt specification

right tilt end
Engine at low
idling
sec.
sec.
q
q
q

right tilt end
R.H. tilt
Work equipment speed
Work equipment
R.H. tilt
Blade tilt
D375A-6R
(01)
Unit
20-9

Category
Machine model
Dump
Item
D375A-6R
Blade pitch
Raise
Ripper lift
q
q
Ripper tilt
q
q
q
q
q
Time lag
Blade

Between forward tilt end
and backward tilt end
Tilt back
Tilt in
Work equipment

Apply no load to ripper.
Between ground level
and rising end of ripper
35
2.5 3.5
Hydraulic oil temperature:

45 55 C
Lever full stroke
Time required for the blade
to be lowered to the ground
from the highest RAISE position and to lift the idler.
Engine at high
idling
*G
Engine at high
idling
Engine at low
idling
46
*G
sec.
46
*M
Engine at low
idling
23
*M
2.5 3.5
7
5
1.5 2.5
1.5 2.5
Engine at high
idling
1.5 2.5
1.5 2.5
Engine at low
idling
10 16
20
Engine at high
idling
4.5 5.5
6 10
15
Engine at high
idling
2.8 3.8
Engine at low
idling
Max. 8
12
Engine at high
idling
Max. 1.8
2.0
Engine at low
idling
sec.
sec.
Engine at low
45 55 C
idling
q Lever full stroke
q Start lowering operation at
Ripper
ripper max. raising position
and measure time from Engine at high
when ripper reaches ground idling
until sprocket rises.
* G: Variable giant ripper specification, M: Variable multi-shank ripper specification
20-10
sec.
Lower

Between dump end and
back end
Back
Service limit
value
2.5 3.5
Engine at low
idling
Engine at high
idling
Engine at low
idling
Standard value
for new
machine
46
Unit
*G
Max. 1.0
*G
1.5
*M
Max. 1.5
*M
D375A-6R
(01)

Category
Machine model
q
q
Hydraulic drift
Work equipment
q
q
q
q
q
q
100
Max. 50
80
Max. 25
50

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

Engine stopped
Measure reduction of idler center height "h" (for
5 minutes).
Hydraulic drift
of machine
tilted by blade
q
130

Engine stopped
Measuring reduction of blade bottom height "h"
(for 5 minutes).
Hydraulic drift
of machine
lifted by blade
q
Max. 65
mm
Service limit
value
mm
Hydraulic drift
of lifted blade
Standard value
for new
machine
mm
Unit
mm
Item
D375A-6R
(01)
D375A-6R

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

Hydraulic drift
Hydraulic drift
of machine
lifted by ripper
q
q
q
20-12
Blade tilt cylinder

Ripper lift cylinder
Ripper tilt cylinder
D375A-6R
q
q
q
Unit
Standard value
for new
machine
Service limit
value
mm
Item
Cylinder internal leakage
Work equipment
Category
Machine model
Max. 30
60
Max. 3.0
12
Max. 3.6
12
Max. 3.2
12

Engine stopped
Measure reduction of sprocket center height "h"
(for 5 minutes).
Relieve cylinder and measure leakage for 1
minute.
cc/min.
D375A-6R
(01)
Shop Manual
30-1
BULLDOZER
D375A-6R
Machine model
Serial number
D375A-6R
65001 and up
30 Testing and adjusting
D375A-6R
(01)
30-1
30-1
Contents
Contents
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..................................................................................................
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 .........................................
Inspecting wear of sprocket .................................................................................................
Testing and adjusting track shoe tension.............................................................................
Testing 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 ....................................................................................................................
Testing and adjusting operator's cab ...................................................................................
30-2
30-2
3030303030303030303030303030303030303030303030303030303030303030303030303030303030303030303030303030-
4
4
6
6
9
11
14
16
18
21
23
24
25
26
27
28
29
32
34
35
36
37
38
39
42
42
56
57
58
61
62
64
64
65
66
66
69
70
72
73
74
75
76
77
78
80
80
81
84
84
D375A-6R
(01)
Contents

Special functions of machine monitor (EMMS)....................................................................
Handling of voltage circuit of engine controller ....................................................................
Adjustment method when controller has been replaced......................................................
Preparation work for troubleshooting for electrical equipment 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.................................................................................................................................
Pm Clinic service .................................................................................................................
D375A-6R
(01)
30- 90
30- 90
30- 148
30- 149
30- 153
30- 157
30- 158
30- 159
30- 161
30- 175
30- 178
30- 184
30- 184
30-3
Tools for testing, adjusting and troubleshooting

Diagnosis equipment list
30-4

Testing/Adjusting item
Symbol
Testing intake air pressure (boost pressure)
Testing exhaust gas

color
Qty
Remarks
799-201-2202 Boost gauge kit
-101 200 kPa {-760 1,500 mmHg}
799-101-1502 Digital thermometer
-99.9 1,299C
Testing exhaust temperature
799-201-1150 Adapter connector
For Pm clinic specification
799-201-9001
Commercially
available
Commercially
available
795-502-1590
Handy smoke checker
Smoke meter
Feeler gauge
Intake side: 0.32 mm,

Exhaust side: 0.62 mm
Compression gauge
0 7 MPa {0 70 kg/cm2}
1
C
Adjusting valve clearance
D
1
Testing compression
pressure
Part No.
Part name
30-4
795-611-1220 Adapter
Bosch index: 0 to 9
6261-71-6150 Gasket
795-799-5410 Adapter
795-799-5420 Remover
799-201-1504 Blow-by checker
799-101-5002 Hydraulic tester
790-261-1204 Digital hydraulic tester
799-401-2320 Gauge
799-101-5230 Nipple
6215-81-9720 O-ring
799-401-2320 Gauge
*As common as G2
799-101-5160 Nipple
R 1/8
795-471-1450 Adapter
M8 x 1.25
07005-00812
Gasket
6167-11-6640 Spacer
Inside diameter: 10 mm
6206-71-1770
Commercially
available
Commercially
available
Commercially
available
Commercially
available
799-101-5002
Joint
Joint diameter: 10 mm
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
3
Testing blow-by pressure
1
Testing engine oil presG
sure
2
3
1
Testing fuel pressure
2
3
3
Testing fuel return rate
and leakage
J 4
5
6
Testing power train oil

pressure
1
2
30-4
799-401-2320 Gauge
7824-66-6430 Resistor
*As common as G1
*As common as G1
1
1
790-190-1601 Pump assembly
Pressure gauge: 1.0 MPa {10 kg/cm2}
195-06-71220 Wiring harness

19M-06-32820 Switch assembly
Emergency escape
method when there is
failure in power train
Pressure gauge: 2.5, 6, 40, 60 MPa

{25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa
{600 kg/cm2}
*As common as G2
D375A-6R
(01)

Testing/Adjusting item
Symbol
Testing and adjusting

work equipment oil
pressure, Testing control circuit main pressure
Testing PPC valve output pressure
N 1
1
2
Testing output pressure

1
of ripper pin-puller sole- P
noid valve
2
Testing leakage inside
work equipment cylinQ
der
1
Testing fan circuit oil
pressure
Part No.
Part name
Qty

799-101-5220 Nipple
1
2
07002-11023
O-ring
799-401-3200 Adapter
Commercially
Measuring cylinder
available
Testing stroke and

hydraulic drift
Testing work equipment speed
Testing voltage and
resistance
Flange
S 2
790-301-1330
07372-21055
Bolt
M10 x 1.25
O-ring
*As common as G1
*As common as G1
Size 03
*As common as G1
Size: 10
07000-13035
79A-264-0021 Push-pull scale
T
U
V
W
1
Initialization of VHMS
controller
*As common as G1
4
Testing operating effort
and depressing force
Remarks
Z 2
3
0 294 N {0 30 kg}
79A-264-0091
Commercially
available
Commercially
available
Commercially
available
799-608-3211
Push-pull scale
0 490 N {0 50 kg}
Ruler
Stopwatch
Multimeter
Discket
799-608-3220
Commercially
available
799-601-7400
Wiring harness
Lap top type personal computer
T-adapter assembly
799-601-7500 T-adapter assembly
OS: Windoes98/2000/Me/XP/VISTA
[With RS232C terminal]
AMP040 Connector
AMP040 Connector
DT, HD30 connector
DRC26-24, 40-pin
799-601-7360 Adapter
Relay (5 pins)
799-601-3450 Adapter
VHMS download harness
Connected with engine
Engine coolant, oil, fuel temperature
799-799-5530
T-adapter
795-799-5540
Diagnosis sensor and
harness
q
q
T-adapter
Boost temperature sensor
799-601-4130
T-adapter
Ne sensor
799-601-4150
T-adapter
Oil pressure sensor
799-601-4211
T-adapter
Controller (50 poles)
799-601-4220
T-adapter
799-601-4240
Socket
799-601-4250
Socket
799-601-4260
T-adapter
799-601-9020
T-adapter
Injector
799-601-9420
T-adapter
799-601-9430
T-adapter
Supply pump PCV
G sensor
799-601-9030 T-adapter
D375A-6R
(01)
30-5

Testing engine speed

k
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 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
30-6
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 shift up (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) With the brake pedal depressed securely and
the parking brake lever in the free position,
set the 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 the brake pedal securely depressed 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-6R
(01)

a The top of the green range of the power

train oil temperature gauge indicates approximately 118 to 120 C.
7) Repeat above steps 3) 6) 3 times.
8) Perform steps 3) to 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)".
3)
4)
5)
6)
7)
8)
9)
to [F2-R2].
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)
to [F3-R3].
D375A-6R
(01)

[F3-R3] only while the adjustment function is selected.
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.
With the brake pedal depressed securely and
Press the decelerator pedal and set the fuel
Return the decelerator pedal slowly to stall
the torque converter with the engine at high
idle.
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 approximately 118 to 120 C.
Repeat above steps 4) 7) 3 times.
Perform steps 4) to 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


to [F2-R2].
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
D375A-6R
(01)

Testing intake air pressure (boost

30-9
pressure)
a Testing instruments of intake air pressure (boost
pressure)
Symbol
Part No.
Part name
A
799 - 201 - 2202 Boost gauge kit
k
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 starting switch to ON position and
switch machine monitor to "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.
D375A-6R
(01)
30-9

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 may 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 completing the test remove the testing
equipment and set to the original condition.
q Remove the remaiSning liquid gasket
from the thread part of the removed plug
with a wire brush, and then apply adhesive or liquid gasket and install the plug.
2 Plug: LT-2 or LG-5
3 Plug: 9.8 19.6 Nm {1.0 2.0 kgm}
30-10
D375A-6R
(01)

30-1
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 digital thermometer
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.
D375A-6R
(01)
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. Procedure for testing periodically by 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.
1) Turn the starting switch to the ON position
and switch the machine monitor to the
"Adjustment" function display of the service
mode.
functions of machine monitor (EMMS)"
section.
30-11

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.
4) Operate the shiftup (UP) switch of the PCCS
to [F3-R3].
[F3-R3] only while the Adjustment function is selected.
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.
6) 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.
7) Press the decelerator pedal and set the fuel
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.
9) Depress the decelerator pedal again.
10)Repeat Steps 8) and 9) several times and
record the highest exhaust gas temperature.
30-12
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

tools in order to return the machine status as
it was.
3. Testing for VHMS specification
D375A-6R
(01)

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.
4) Operate the shiftup (UP) switch of the PCCS
to [F2-R2].
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)".
D375A-6R
(01)
30-13

Testing exhaust gas color

a Checking tools for exhaust gas color
Symbol
1
C
2
Part No.
799-201-9001
Commercially
available
Part name
Handy smoke checker
30-14
2. Testing with C2smoke meter
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. Testing with C1handy smoke checker
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.
30-14
D375A-6R
(01)

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.
D375A-6R
(01)
30-15

30-16
a Adjusting tools for valve clearance

Symbol
D
k
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.
30-16
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 adjust adjustment
screw (7) to a degree that the feeler gauge is
hitched lightly.
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 locknut, check the valve
clearance again.
D375A-6R
(01)

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-6R
(01)
30-17

Measuring compression pressure

a Testing tools for compression pressure
Symbol
1
E
2
3
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
30-18
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 toolE3 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 "Testing and
adjusting valve clearance".
4. Disconnect fuel high-pressure tube (5) and
injector wiring harness (6).
30-18
D375A-6R
(01)

6. Install adapter E2 to the injector mounting hole

and connect 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 By coating a small amount of oil to the connecting portions of the adapter and gauge,
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 completing the test remove the testing
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-6R
(01)
2) Press injector (8) with adaptor (9) into the

cylinder head by hand.
3) Install holder (7) and tighten bolt (13) and

washer (14) lightly.
2 Spherical surface of washer: Engine oil
4) Install the fuel high-pressure tube, and
temporarily tighten sleeve nut (5).
5) Tighten bolt (13) to the specified torque.
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).
30-19

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}
30-20
D375A-6R
(01)


a Measuring tools for blow-by pressure
Symbol
F
k
Part No.
Part name
799- 201-1504 Blow-by checker
30-21
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-6R
(01)
4) Run the engine at high idle and test the

blow-by pressure when the torque converter
stalls.
a Blow-by pressure varies greatly with the
condition of the engine. Therefore, if the
value by the test is considered unusual,
make a check for excessive oil consumption, bad color of exhaust gas, early oil
deterioration, early oil contamination,
etc., which are related to improper
blow-by pressure.
30-21

2. Testing for VHMS specification

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".
30-22
D375A-6R
(01)

Testing engine oil pressure

a Measuring tools for engine oil pressure
Symbol
1
G
2
3
Part No.
799-101-5002
790-261-1204
799-401-2320
799-101-5230
6215-81-9720
Part name
30-23
2. Testing with oil pressure gauge
1) Open the engine left cover.
2) Remove oil pressure test plug (1).
Hydraulic tester
Digital 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
2) Run the engine and measure the engine oil

pressure at low idle and also at high idle.
D375A-6R
(01)
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.

30-23

Handling of fuel system devices
Handling of fuel system devices 30-24

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 checking 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 the Komatsu genuine fuel filter
cartridge
Since the common rail fuel injection system
(CRI) consists of more precise parts than the
conventional fuel injection pump and nozzles, it
employs a high-efficiency special filter to prevent
foreign matter from entering it. If a filter other
than the genuine one is used, the fuel system
may have a trouble. Accordingly, never use such
a filter.
30-24
D375A-6R
(01)

Releasing residual pressure from fuel system
Releasing residual pressure from

30-25
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: Supply pump Common
rail 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 checked and its parts
are removed, the remaining pressure in the fuel
circuit must be released completely. Accordingly, observe the following.
k Before checking 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-6R
(01)
30-25

30-26
a Measuring tools for fuel pressure

Symbol
Part No.
799-101-5002
790-261-1204
2 799-401-2320
799-101-5160
3 795-471-1450
07005-00812
1
3. Install nipple H3 and connect it to gauge H2.
Part name
Hydraulic tester
Gauge
Nipple (R 1/8)
Adapter (M8 x 1.25)
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).

30-26
D375A-6R
(01)

Handling of reduced cylinder mode operation
Handling of reduced cylinder

mode operation
30-27
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.
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 Leaking at 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-6R
(01)
30-27

Handling of no injection cranking operation
Handling of no injection cranking

30-28
operation
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 the above.
a To perform no-injection cranking operation, see
"Special functions of machine monitor (EMMS)".
30-28
D375A-6R
(01)

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
30-29
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
D375A-6R
(01)
30-29

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 Be sure to 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 cylinderJ5.
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
30-30
Leakage
(cc/min)
Max. 10
D375A-6R
(01)

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 container
(saucer).

and switch the machine monitor to "Adjustment" function display of the service mode.
D375A-6R
(01)
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 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.
Engine speed
(Equivalent to rated output
operation load)
(rpm)
1,600
1,700
1,800
1,900
2,000
Return (Spill) limit

(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.
30-31

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.
30-32
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.
30-32
D375A-6R
(01)

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 by cranking the engine.
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.
D375A-6R
(01)
30-33

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.
30-34
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.
30-34
D375A-6R
(01)

Replacing and adjusting alternator and air conditioner compressor belt
Replacing and adjusting alternator and air conditioner compressor belt30-35

k
a Since the alternator and air conditioner compressor belt is equipped with the auto-tensioner,
its tension does not usually need to be tested or
adjusted.
a Following describes the auto-tensioner adjustment procedure at the belt replacement.
1. Open the engine left side cover.
2. Loosen lock nut (1) and tighten push bolt (2) fully
to loosen tension pulley (4).
3. Replace belt (5).
4. After replacing the belt, loosen push bolt (2) until
installed length "a" is 90 mm.
5. Tighten locknut (1).
D375A-6R
(01)
30-35

Measuring fan speed
Measuring fan speed
30-36
a Testing the fan motor speed under the following
condition.
1. Start the engine and switch the machine monitor
to the "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.
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.
30-36
D375A-6R
(01)

Testing fan circuit oil pressure

a Testing tools for fan circuit oil pressure
Symbol
1
S
2
3
4
Part No.
799-101-5002
790-261-1204
790-301-1330
07372-21055
07000-13035
Part name
Hydraulic tester
q Flange
Bolt
O-ring
30-37
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 the "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.
D375A-6R
(01)
30-37

Bleeding air from fan pump
30-38
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 the left foot rest (1).
3. Loosen air bleeders (2) and (3), and leave it for

15 minutes.
4. After 15 minutes, start the engine and run at low

idle.
5. After oil flows out of air bleeder, tighten air
bleeders (2) and (3).
30-38
D375A-6R
(01)

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.
D375A-6R
(01)
30-39
[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 "Adjustment" function display of
the service mode.
30-39

3. Adjusting deceleration pedal speed

With the fuel control dial in the high idle position,
press decelerator pedal (4) until it touches the
stopper. Check that the decelerator pedal speed
is normal under this condition.
q Deceleration speed: 900 50 rpm
a If the deceleration speed is not correct, adjust installed dimension (a) of rod (8).
q Standard installed dimension (a) of rod: 123
mm (reference)
4. Adjusting full speed
Set the fuel control dial to the high idle position
and check that the high idle speed is correct.
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:
Raise the speed to the high idle speed by
adjusting stopper bolt (9).
5. After finishing all adjustment, return the removed
parts.
30-40
D375A-6R
(01)

D375A-6R
(01)
30-41
Power train
Testing power train oil pressure
Power train
30-42

a Testing tools for power train oil pressure
Symbol
K
Part No.
Part name
799 - 101 - 5002 Hydraulic tester
1
790 - 261 - 1204 Digital hydraulic tester
2 799 - 401 - 2320 Gauge
30-42
a Table of pressure pick-up port positions and

gauges to use
No. Mark
OUT
LU
SC
T/M
FWD
REV
1ST
2ND
10
3RD
LC
LB
13
RC
14
RB
15
30-42
12
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 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.
IN
11
LUB
Checked oil pressure

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
Right steering brake pressure
Output pressure of sudden
stop prevention valve
Transmission lubricating
oil 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}
6 {60}
1.0 {10}
D375A-6R
(01)
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.


D375A-6R
(01)
30-43
Power train
3. Measuring torque converter inlet pressure

and outlet pressure
[Checking with machine monitor (Pm clinic)]
4. Measuring torque converter lockup (LU)

clutch pressure
a For an analog oil pressure gauge, the
pressure must be 2.5 MPa {25 kg/cm2}.

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.
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)
30-44
D375A-6R
(01)
Power train
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 mode: F2 and R2
4) With the brake pedal depressed, set the
PCCS lever to forward 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.
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) Measure the torque converter stator clutch
pressure with the engine at low idle and high
idle.

D375A-6R
(01)
30-45
Power train
6. Testing transmission main relief pressure

(T/M)
[Testing using oil pressure gauge]
[Checking with machine monitor (for VHMS

specification)]

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

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

30-46
D375A-6R
(01)
Power train
7. Testing transmission F clutch pressure

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

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) Measure the F clutch pressure with the
engine at low idle and high idle.
D375A-6R
(01)
30-47
Power train
8. Testing transmission R clutch pressure

(REV)
tester K1 to nipple (7) for checking oil pressure.


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
6) Measure the R clutch pressure with the
30-48
D375A-6R
(01)
Power train
9. Testing transmission 1st clutch pressure

(1st)


q Adjustment ID:
clutches)

5) While pressing the brake pedal, set the direction of PCCS lever in the forward position.
6) Measure the 1st clutch pressure with the
D375A-6R
(01)
30-49
Power train
10. Testing transmission 2nd clutch pressure (2nd)



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.
6) Measure the 2nd clutch pressure with the
30-50
D375A-6R
(01)
Power train
11. Testing transmission 3rd clutch pressure

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



q Adjustment ID:
clutches)

5) With the brake pedal depressed, set the
PCCS lever in the reverse position and shift
up the gear speed to the 3rd with the shiftup
switch.
D375A-6R
(01)
30-51
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) Measure 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) Measure 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.

30-52

D375A-6R
(01)
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) Measure the right steering clutch pressure
when the PCCS lever steering is returned
to neutral.

3) Measure the right steering brake pressure
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.

D375A-6R
(01)

30-53
Power train
16. Testing transmission lubrication pressure

(LUB)
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

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)
30-54
D375A-6R
(01)
Power train
3) Set the parking brake lever in the FREE position and set the PCCS lever in the ALL
NEUTRAL position.
4) Measure 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 }

D375A-6R
(01)
30-55
Power train
Adjusting transmission output speed sensor

k
30-56
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.
30-56
D375A-6R
(01)
Power train
Simple test procedure for brake performance

k
a Carry out the simple performance test of the
brake under the following condition.
30-57
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.
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-6R
(01)
30-57
Power train
Adjusting brake pedal and parking brake lever
30-58
Adjusting brake pedal
30-58
Adjusting parking brake lever
30-58
30-58
D375A-6R
(01)
Power train
Adjusting brake pedal

30-59
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 installed 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:
34.358.8 Nm {3.56.0 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-6R
(01)
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 the checking port for 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.
30-59
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.)
30-60
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 the checking port for 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
1) Turn the starting switch ON and set the
machine monitor to Monitoring function of the
service mode.
q Monitoring code: 40905 (P/T SW Input 3)
a Set the working mode to P mode and set
the gear shift mode to Manual.
30-60
D375A-6R
(01)
Power train
Adjusting position of pccs lever console
30-61
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
a The locknut at the rear of the turnbuckle has
a left-handed thread (reverse thread)
D375A-6R
(01)
30-61
Power train
Emergency escape method when there is failure in power train
Emergency escape method when

30-62
there is failure in power train
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 with 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
30-62
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.

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.
D375A-6R
(01)
Power train
Emergency escape method when there is failure in power train
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.
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
5) Turn the starting switch ON and set the
parking brake lever in the FREE position.
6) Operate the vacuum pump to raise the brake
releasing oil pressure to the initial pressure.
q Initial pressure: Approx. 2.74 MPa {28
kg/cm2}
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.
3) Remove the fuel tank undercover and

disconnect supply hose (3) of the pin puller
solenoid valve.
D375A-6R
(01)
30-63

Inspecting wear of sprocket
30-64
30-64
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-size drawing of sprocket tooth shape" on a transparent paper or sheet
and apply it directly to the sprocket to see if the
sprocket can be used.
30-64
D375A-6R
(01)

Testing and adjusting track shoe tension

Inspection
30-65
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 shoe
between the idler and front carrier roller, and
check clearance (a) from the bottom of the steel
rod to the track shoe grouser.
q Standard clearance (a): 20 30 mm
30-65
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.
Adjusting
30-65
a If the track shoe tension is abnormal, adjust it according to the following procedure.
1. Remove cover (2).
D375A-6R
(01)
30-65
Hydraulic system
Testing and adjusting work equipment oil pressure
Hydraulic system
30-6
30-6
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 x 1.25 mm)
O-ring

a Open the cover of the main control valve (both
sides).
30-6
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 installed. (To protect the gauge from being damaged)
1. Measuring unload pressure

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

2. Testing 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.
30-66
D375A-6R
(01)
Hydraulic system

a The VHMS specification is shown as an
example in the figure.
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}.
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-6R
(01)
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.
30-67
Hydraulic system
Adjustment
1. Adjusting unload pressure
a The unload pressure cannot be adjusted.
30-68
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}
30-68
D375A-6R
(01)
Hydraulic system
Testing control circuit main pressure

Tools for testing control circuit main pressure
Symbol
M
Part No.
799-101-5002
790-261-1204
Part name
Hydraulic tester
30-69
30-69
Adjusting
a The self pressure reducing valve cannot be adjusted.
Inspection
30-69
k Stop the machine on level ground, lower the
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-6R
(01)
30-69
Hydraulic system

a Tools for testing PPC valve output pressure
4. Start the engine and set the work equipment lock

lever in the free position.
Symbol
N
k
Part No.
Part name
1
30-70
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
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 On the side of LOWER of the blade lift control, operate the lever to the FLOAT position.
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 testerN1, then

connect to oil pressure gauge [2].
a Use a 6 MPa {60 kg/cm2} oil pressure gauge.
30-70
D375A-6R
(01)
Hydraulic system
A. Blade RAISE
B. Blade TILT (Right)
C. Blade LOWER
D. Blade TILT (Left)
D375A-6R
(01)
E. Ripper TILT (In)

F. Ripper RAISE
G. Ripper TILT (Back)
H. Ripper LOWER
30-71
Hydraulic system
Adjusting play of PPC valve
30-72
a If there are excessive plays at the tips of the ripper control lever and blade control lever, adjust
the PPC valve according to the following procedure.
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 fuel spray prevention cap (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 rotate area of joint (4)
and to contact area of disc and piston.
2 Rotate area of the joint: G2-L1
2 Contact area of the disc and the piston: G2-L1
5. Install fuel spray prevention cap (1).
30-72
D375A-6R
(01)
Hydraulic system
Testing output pressure of ripper pin-puller solenoid valve
30-73
a Tools for testing output pressure of ripper

pin-puller solenoid valve
Symbol
Part No.
Part name

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

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.

3. Fit nipple [1] (R1/8) of hydraulic tester P1, then

connect to oil pressure gauge [2].
a Use a 6 MPa {60 kg/cm2} oil pressure gauge.
D375A-6R
(01)
30-73
Hydraulic system
Checking location of cause of hydraulic drift of blade and ripper
Checking location of cause of hydraulic drift of blade and ripper
30-74
a When the hydraulic drift of the blade or ripper occurs, check if the cause for the drift is in the cylinder packing or in the control valve according to
1. Set the cylinder to be inspected to the following
posture, then stop the engine.
1) Blade lift cylinder
Raise the front of the machine by thrusting
the blade.
a Do not extend the blade lift cylinder to the
stroke end since it is equipped with the
piston valve.
2. Operate the control lever in the direction to

extend the cylinder rod, and check the movement of the cylinder.
q If the lowering speed is increased at this time,
the cylinder 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.
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.
30-74
[Reference:]If the cause of the hydraulic drift is

in the packing, the blade lowering speed in the
above operation becomes 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) As the internal pressure on the head side
increases, both pressures come to balance
at a certain level of pressure (depending on
leakage), and the lowering speed becomes
slow.
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-6R
(01)
Hydraulic system
Testing leakage inside work equipment cylinder
Testing leakage inside work

equipment cylinder
30-75
a Tools for testing leakage from work equipment

cylinder
Symbol
Q
Part No.
Commercially
available
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
Part name
Measuring cylinder
a Test for 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.
4. After thirty seconds elapse, measure the amount

of leakage for the following one minute.
5. After finishing testing, return the machine status
as it was.
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-6R
(01)
30-75
Hydraulic system
Releasing remaining pressure in work equipment cylinders
Releasing remaining pressure in

30-76
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
1. Start the engine and lower the blade and ripper
to the ground.
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 back and forth and around.
a After the levers are operated 2 3 times, the
residual pressure in the accumulator is fully
released.
5. Tighten the oil filler cap of the hydraulic tank.
30-76
D375A-6R
(01)
Hydraulic system
Bleeding air from work equipment cylinders
Bleeding air from work equipment

30-7
cylinders
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
following procedure.
1. Run the engine at low idle for about five minutes.
2. Running the engine at low idle, extend and
retract the cylinder to be bled 4 5 times.
a Stop the piston about 100 mm before the
ends 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.
D375A-6R
(01)
30-77
Hydraulic system
Adjusting ripper lever position
30-78
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.
30-78
D375A-6R
(01)
Hydraulic system
D375A-6R
(01)
30-79
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.
30-80
30-80

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)
30-80
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-6R
(01)
Work equipment
Adjusting blade
Adjusting blade
30-81
a If the blade is removed and installed, or disassembled and assembled, adjust the various
places of the blade according to the following
procedure.
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-6R
(01)
30-81
Work equipment
Adjusting blade
2) Use shims to adjust the clearance at trunnion

portion (3).
Adjustment
location
Adjusted
clearance
Standard clearance
Standard
shim thickness
1.56 0.65 mm
Total clearance
12 mm
2. Adjusting blade tilt

(only for 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
30-82
D375A-6R
(01)
Work equipment
Adjusting blade
D375A-6R
(01)
30-83
Cab and its attachments

Testing and adjusting operator's cab

Check after installing cab assembly
30-84
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.
2) Prepare a transparent vinyl hose.

q Outside diameter: 10 mm,
Length: 3000 mm
3) Secure the end of the hose inside the cab to
the top of the backrest with tape.
4) Pour water in the hose up to approsimately
half of the length.
5) Remove slide glass lever lock (1) and insert
the other end of vinyl hose [1].
30-84
30-84
30-84
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).
D375A-6R
(01)

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 (Ambient pressure)
q Criteria
Measured 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.
D375A-6R
(01)
30-85

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 rubbers
(4). (Check 4 pieces on each side.)
(Check 4 locks on each side.)
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.
30-86
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) of latch center (y) and
striker center (x) from each other from the
direction of (A).
D375A-6R
(01)

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] Loosely tighten the mounting bolts of
striker (7), open and close the door two to
three times in order to align latch (6) with
striker (7).
2] Check the engaging condition of latch (6)
and striker (7).
3] Tighten the mounting bolts of striker (7) to
the specified torque.
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).
D375A-6R
(01)
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.
30-87

2) Adjust
1] Adjusting latch and striker
q Loosen the adjustment nut of striker
(10) and adjust striker (10) so that it
does 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.
30-88
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).
D375A-6R
(01)

D375A-6R
(01)
30-89
Electrical system
Special functions of machine monitor (EMMS)
Electrical system
30-90
30-90
30-90
D375A-6R
(01)
Electrical 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-6R
(01)
30-91
Electrical system
30-92
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
30-93
30-93
Display of check before starting
30-93
Operator mode (Outline)
A
A
A
A
B
Display of warning after check before starting

Display of ending of maintenance interval
Display of check of preset
Display of ordinary screen
Display of end screen
Selection of operation mode
Selection of gearshift mode
30-95
B
B
B
Customizing operation
Operation of customize memory
Operation to cancel alarm buzzer
Selection of dual tilt
(Dual tilt specification)
30-96
30-96
30-96
01 Monitoring
30-94
30-94
30-95
30-95
30-95
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 meter
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
30-94
30-96
OSpecial operations
Page
30-102
30-103
Service mode
Mechanical system "Abnor02 Abnormality mality Record"
Electrical system "AbnormalRecord
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
30-108
30-109
30-111
30-112
30-113
30-115
30-116
30-117
30-118
30-119
30-120
08 PM clinic
30-140
09 Cylinder Cut-Out
30-142
30-97
30-97
30-97
30-98
10 No Injection
11 Fuel Consumption
12 Display of saved load
13 Setting of VHMS
30-143
30-145
30-146
30-147
30-98
14 Snap shot (Machine equipped with VHMS) 30-147
30-96
30-100
30-100
30-101
a Classification of operator mode

A: Screen display and function from time when starting switch is turned to ON position to time when screen
changes to standard screen and screen display after starting switch is turned to OFF position
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
30-92
D375A-6R
(01)
Electrical system
t Operator mode (Outline)

30-93
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).
30-93
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 check before starting
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)
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
Check before starting screen
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 enabled
b: When engine start lock is disabled
c: When a check-before-starting item is unusual
d: When maintenance of maintenance item is
near specified time or overdue
D375A-6R
(01)
30-93
Electrical system
Warning after check before starting screen
Display of overdue maintenance
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 the display of check of preset is finished,
the screen changes to "display of ordinary
screen".
30-94
D375A-6R
(01)
Electrical 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 (The switch of the display is made 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 starting switch is turned OFF, the end screen

is displayed for 5 seconds.
D375A-6R
(01)
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] (if
equipped) 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.
30-95
Electrical 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.
The selection of the blade dual tilt mode is made by

changing the blade control lever knob switch while
the ordinary screen is displayed.
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
display on the screen does not change.
30-96
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-6R
(01)
Electrical 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 2-camera image display operation is made,
the images are displayed frame by frame at intervals of approximately one second on the right
and left side of the screen.
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-6R
(01)
30-97
Electrical system
a There are following items in the user menu.

Multi-gauge
Screen adjustment
Clock adjustment
Language setting
Reverse interlock selection mode
Fan reverse mode
Skipping pre-lubrication
Display function 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 number are
displayed only when the telephone number 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 "Abnormality Record" 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.
30-98
D375A-6R
(01)
Electrical 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
q
E01
Action code and failure

code are displayed.
The backup alarm does not

sound
The fan speed is always set to
the maximum.
Remedy given to operator to take

q
q
q
q
q
E02
q

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

code are displayed.
Telephone number is displayed (if registered).
q
q
q
q
q
E04
q
q
D375A-6R
(01)

code are displayed.
Telephone number is displayed (if registered).
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.
Contact 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.
repair.
Move machine to safe place.

repair.
Stop machine immediately.

repair.
30-99
Electrical 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.
30-100
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 Continuous operation of the machine monitor
may display blue bright spots (spots which do
not go off) on the screen; it is quite normal.
D375A-6R
(01)
Electrical system
30-101
When changing the maintenance password used for
the maintenance setting function, follow these procedures.
Function for changing maintenance password
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 by using the numeral input
switches and confirm it by using the function
switch.
q [F5]: Reset 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 request inputting the password again
is displayed.
q
q
(If it has only 3 or less digits or has 7 or more

digits, it is not accepted).
[F5]: Reset input numeral/Return to ordinary
screen
[F6]: Confirm input numeral
4. After the "New Password" screen is displayed

again, input a new password again by using the
numeral input switches and confirm it by using
the function switch.
q [F5]: Reset 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" 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-6R
(01)
30-101
Electrical system
30-102
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 by using the function switches or
numeral input switches.
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to standard 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].
30-102
D375A-6R
(01)
Electrical 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. Selection of 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 by using
the function switches or numeral input switches.
q [F1]: Move to next page (screen)
q [F2]: Move to previous page (screen)
q [F5]: Delete input numeral/Return to service
menu screen
a Selection with function switches: Select an
item with [F3] or [F4] and determine 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-6R
(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 keep presssing [F6] (for approximately 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.
30-103
Electrical 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 information (displayed data)
q [F5]:Return to monitoring selection menu
screen
30-104
D375A-6R
(01)
Electrical 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
40909
70700
70701
60200
60300
31200
43001
40910
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
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
D375A-6R
(01)
Unit (Default: SI)

SI
mV
mV
mV
mA
mA
mA
mA
mA
mV
mV
%
mV
mV
mV
mA
mA
mA
mA
mA
C
r/min
MPa
mV
MPa
mV
mA
mA
km/h
W
mV
mA
r/min
MPa
mV
mV
r/min
r/min
MPa
Metric
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
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
ON OFF
ON OFF
ON OFF
ON OFF
kg/cm2
mV
mV
rpm
rpm
kg/cm2
ON OFF
Component
Imperial in charge
mV
P/T
mV
P/T
mV
P/T
mA
P/T
mA
P/T
mA
P/T
mA
P/T
mA
P/T
P/T
mV
P/T
mV
P/T
%
P/T
mV
P/T
P/T
P/T
P/T
P/T
mV
P/T
mV
P/T
mA
P/T
mA
P/T
mA
P/T
mA
P/T
mA
P/T
F
P/T
rpm
P/T
psi
P/T
mV
P/T
psi
P/T
mV
P/T
mA
P/T
mA
P/T
MPH
P/T
W
P/T
mV
P/T
mA
P/T
rpm
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
psi
W/E
mV
W/E
mV
P/T
rpm
P/T
rpm
P/T
psi
VHMS
P/T
Remarks
30-105
Electrical system
Code
No.
70300
90802
31634
10007
40982
01501
40981
40983
37501
42610
42611
42612
42613
42801
20300
99003
20227
20402
20228
20242
20404
20243
20244
20405
20245
04200
04300
04401
04402
18900
37200
00201
20216
20217
20400
01002
36700
31701
31703
17500
30-106

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 Lever Oil
Blade Lift Lower
Blade Left Tilt
Press. Switch
Blade Right Tilt
Fan Pump Solenoid 2 (F/B)
Fan Speed
Ripper Lift Raise
Ripper Lever Oil
Ripper Lift Lower
Ripper Tilt in
Press. Switch
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
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
Unit (Default: SI)

SI
Metric Imperial
ON OFF
ON OFF
Component
in charge
W/E
W/E
ON OFF
W/E
ON OFF
W/E
ON OFF
W/E
ON OFF
W/E
ON OFF
mA
r/min
W/E
mA
rpm
mA
rpm
ON OFF
mA
mA
W/E
W/E
W/E
mA
W/E
ON OFF
W/E
ON OFF
C
C
C
V
V
KPa
W/E
C
C
C
V
V
kg/cm2
-
F
F
F
V
V
psi
VHMS
VHMS
VHMS
VHMS
VHMS
VHMS
VHMS
ON OFF
V
V
C
V
C
KPa
r/min
%
%
mV
Remarks
VHMS
V
V
C
V
C
kg/cm2
rpm
%
%
mV
-
MON
MON
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
V
V
F
V
F
psi
rpm
%
%
mV
D375A-6R
(01)
Electrical system
Code
No.
36400
36401
36200
36300
04107
04105
37400
37401

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
Metric
Imperial
Component
in charge
MPa
V
MPa
CA
C
V
kPa
V
kg/cm2
V
kg/cm2
CA
C
V
kg/cm2
V
psi
V
psi
CA
F
V
psi
V
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
36500 Charge Pressure-Abs
KPa
kg/cm2
psi
ENG
36501
03203
37300
31706
18500
18501
18600
17201
18700
37201
14200
14201
42700
42701
V
V
l/h
%
C
V
mg/st
CA
Nm
V
C
V
C
mV
V
V
l/h
%
C
V
mg/st
CA
kgm
V
C
V
C
mV
ON OFF
ON OFF
ON OFF
V
V
gal/h
%
F
V
mg/st
CA
lbft
V
F
V
F
mV
Remarks
Indicated in absolute pressure

(including ambient pressure)
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
P/T
P/T
P/T
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
Acc
40912 P/T SW Input 1
R-sig
C-sig
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.
D375A-6R
(01)
30-107
Electrical system
Abnormality Record (Mechanical Systems)
The machine monitor classifies and records the abnormalities which occurred in the past or which are
occurring at present into the mechanical system and
electrical system.
To check the mechanical system failure history, perform the following procedures.
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
q [F5]: Return to Service menu screen
a You may enter a 2-digit code with the numeral input switches to select the item of that
3. Information displayed on "Abnormality Record"

screen
On the "Mechanical Systems" screen, the
following information is displayed.
(a): Occurrence order of abnormalities from
latest one/Total number of records
(b): Failure code
(c): Detail of failure
(d): Occurrence number
(e): Service meter reading at first occurrence
(f): Service meter reading 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"

A contents of the mechanical system failure
history cannot be reset.
30-108
D375A-6R
(01)
Electrical system
"Abnormality Record" (Electrical system "Abnormality Record")

30-109
The machine monitor classifies and records the abnormalities which occurred in the past or which are
occurring at present into the mechanical system and
electrical system.
To check the electrical system abnormality record,
perform the following procedures.
Select "02 Abnormality Record" on the "Service
Menu" screen.

After the "Abnormality Record" screen is
displayed, select "02 Electrical Systems" with
3. Information displayed on "Abnormality Record"

screen
On the "Electrical Systems" screen, the following
information is displayed.
(a): Occurrence order of abnormalities from
latest one/Total number of records
(b): Failure code
(c): Detail of failure
(d): Occurrence number
(e): Service meter reading at first occurrence
(f): Service meter reading at last occurrence
q [F1]: Move to next page (screen) (if displayed)
q [F2]: Move to previous page (screen) (if displayed)
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-6R
(01)
30-109
Electrical 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 delete mode,
[CLEAR] graphic mark is indicated at
[F2].
q [F2]: Delete all items
q [F6]: Reset selected item
a To reset items one by one: Select the item
to be reset with [F3] or [F4] and press
[F6].
a To reset all items together: Press [F2],
and all the items are reset, 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 systems screen
(Reset mode)
q [F6]: Perform reset
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).
30-110
D375A-6R
(01)
Electrical 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.
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 Change of fuel pre-filter
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 by using
code.
D375A-6R
(01)
*: The menu is displayed on the screen, but the

corrosion resistor is not installed.
3. Items displayed on Maintenance Record screen.
The following items are displayed.
(a): Maintenance items
(b): Number of times of replacement up to now
(c): Service meter reading (SMR) at previous
replacement
30-111
Electrical 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
Select "04 Maintenance Mode Change" on the
"Service Menu" screen.
00 Maintenance Mode On/Off

01 Engine Oil Change Int
02 Eng Oil Filter Change Int
03 Fuel Main Filter Change Int
41 Change interval of fuel pre-filter
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
by using the function switches or numeral input
switches.
a The following items can be selected on the

change of maintenance mode screen.
30-112
3. Details of setting of use or non-use 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 Change screen
q [F6]: Confirm selection and return to Maintenance Mode Change screen
a Even if ON/OFF of each item has been set, if
the above setting is changed, it overrides the
individual setting.
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-6R
(01)
Electrical system
Initial value: Maintenance interval set in machine monitor (Recommended by manufacturer and not changeable).
q Set value: Maintenance interval which can be
set freely. Maintenance reminder function
works according to this set time in operator
mode (which is set in increments of 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]: Perform initialization
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.
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-6R
(01)
30-113
Electrical system
2. Registering and changing telephone number

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]: Reset 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 an input numeral is wrong, move the cursor
(orange background) to that digit and overwrite it with the correct numeral.
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.
30-114
D375A-6R
(01)
Electrical system
Default (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.
Select "06 Default" on the "Service Menu"
screen.
Default (ALL OFF): Default setting of all

modes (Power: P, other 3 items: OFF) is displayed when starting switch is turned to ON
position
q [F5]: Cancel selection and return to 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" by using the function switches or
a Select this item similarly to an item on the
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/OFF
q Blade slow down: ON/OFF
3. Selecting mode
After the "Key-on Mode" screen is displayed,
select the mode to be set by using the function
switches.
q Mode at previous key-OFF: Final modes in
previous operation are displayed when starting switch is turned to ON position
D375A-6R
(01)
30-115
Electrical system
Default (Unit)

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

Unit" by using the function switches or numeral
input switches.
3. Selecting unit
After the "Unit" screen is displayed, select the
unit to be set by using the function switches.
screen
screen
a When the machine is delivered, the SI unit
system is set.
30-116
D375A-6R
(01)
Electrical system
Default (Setting of maintenance password)

The function of the setting of the 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.
screen.
4. Display of 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" by using the function
switches or numeral input switches.
5. Change of maintenance password

The password can be changed with the special
switch operatin 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 by using the function switches.
q Disable: Password screen is not displayed
q Enable: Password screen is displayed
screen
screen
D375A-6R
(01)
30-117
Electrical system
Default (Camera)

The camera setting function is used to set default
setting and removal of a camera.
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 simultaneous display function of two images becomes effective when camera 1 and
camera 2 are set for use.
a When a camera is installed, check that the
displayed image is not inverted horizontally
in the operator mode.

Camera" by using the function switches or
3. Selecting camera setting

After the "Camera" setting screen is displayed,
select the setting by using the function switches.
q OFF: Camera is not used
q Original image: Image from 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 settings before confirmation and
return to Default setting screen
q [F6]: Confirm selection in each line
30-118
D375A-6R
(01)
Electrical system
Default (ECO Display)

The ECO display setting function is used to set the
display of the ECO gauge.
screen.
a Display of ECO gauge (a)

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

After the "ECO Display" screen is displayed,
select the setting by using 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
screen
a If ECO display is turned ON, ECO is displayed when the screen changes to the ordinary screen.
D375A-6R
(01)
30-119
Electrical system
Adjusting
You can adjust various items related to the machine

with the machine monitor.
When using an adjustment item, select it according
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 by using the numeral input switches.
q [F5]: To cancel adjustment and return to Service menu screen
q [F6]: To enter 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]
to [F6] vary depending 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).
30-120
D375A-6R
(01)
Electrical system
Adjustment items table

Adjustm
ent 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
Remarks
Resetting auto-decelerating function
Setting and resetting uni-direction lever

Recommended mode of torque converter
stall
Sudden stop prevent valve operation mode

High idle cut mode
Max. gear speed setting mode
D375A-6R
(01)
Fine adjustment of reverse slow mode

Control brake: Brake ECMV (Right and

left)
30-121
Electrical system
Adjustment ID: 0002 (Initialization of power train

controller)
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 perform this adjustment once.
Functions of function switches

[F3]: Unused
[F4]: Unused
[F5]: To return to adjustment item selection
screen (ID input screen)
[F6]: To save setting

[F3]: To increase specification value [CODE]
[F4]: To decrease specification value [CODE]
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.
30-122
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-6R
(01)
Electrical 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 perform this adjustment once.

[F3]: Unused
[F4]: Unused
[F6]: To 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 depressed) 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-6R
(01)
30-123
Electrical 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 inclination angle sensor is removed and
installed or replaced, be sure to perform this
adjustment once.

[F3]: Unused
[F4]: Unused
[F6]: To 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.
30-124

[F3]: To increase adjustment value [FAN 70
% SPEED MODE]
[F4]: To 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-6R
(01)
Electrical 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
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-6R
(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]:To return
[F4]: To 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 confirm the selection.
a At this time, check that alarm buzzer
sounds.
30-125
Electrical system
Adjustment ID:0041 (Travel lever code setting)
Adjustment ID: 0530 (Stall mode)
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
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.
30-126
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 when 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
45C.(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
D375A-6R
(01)
Electrical system
Adjustment ID: 1005(Fan 100% mode)
This adjustment code is used to set the cooling fan speed to about 100% forcibly.
It can also set the adjustment value of the
maximum speed.
a Functions of function switches
[F3]: To increase adjustment value [FAN 100
% SPEED MODE]
[F4]: To decrease adjustment value [FAN
100 % SPEED MODE]
[F6]: To save adjustment value
Adjustment ID: 1012 (Steering lever neutral position adjustment)
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-6R
(01)

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 perform this adjustment once.

[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.
30-127
Electrical system
Adjustment ID: 1013 (Steering lever leftmost

position adjustment)
Adjustment ID: 1014 (Steering lever rightmost

position adjustment)

power train controller recognize the leftmost
PCCS lever.

[F3]: Unused
[F4]: Unused

[F3]: Unused
[F4]: Unused
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.
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.
30-128

power train controller recognize the rightmost
PCCS lever.
D375A-6R
(01)
Electrical system
Adjustment ID: 1015 (Right brake oil pressure

offset)
Adjustment ID: 1016 (Left brake oil pressure

offset)
This adjustment code is used to adjust the

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

[F3]: To increase adjustment value
[F4]: To 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}.

kg/cm2}.
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.
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-6R
(01)

left brake oil pressure manually.
30-129
Electrical system
Adjustment ID: 2021 (Power train controller

voltage check mode)
Adjustment ID: 2022 (Work equipment controller

voltage check mode)
This adjustment code is used to check the

unswitched power supply voltage and accessory power supply voltage applied to the
power train controller.

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

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

[PT CONTROLLER UNSWITCH POWER]:
Unswitched power supply voltage
[PT
CONTROLLER
ACC
POWER]:
Switched power supply voltage

[WE CONTROLLER UNSWITCH POWER]:
Unswitched power supply voltage
[WE
CONTROLLER
ACC
POWER]:
Switched power supply voltage
Operating method:
function is effective and the unswitched
power supply voltage and accessory power
supply voltage are displayed simultaneously.
Operating method:
function is effective and the unswitched
power supply voltage and accessory power
supply voltage are displayed simultaneously.
30-130
This adjustment code is used to check the

unswitched power supply voltage and accessory power supply voltage applied to the
work equipment controller.
D375A-6R
(01)
Electrical system
Adjustment ID: 5535 (Both steering clutch disengage mode)
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-6R
(01)
30-131
Electrical 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


kg/cm2}.
MPa {-3 3 kg/cm2}.
Operating method:
buzzer sounds.
range.
30-132
D375A-6R
(01)
Electrical 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


kg/cm2}.
MPa {-3 3 kg/cm2}.
Operating method:
buzzer sounds.
range.
D375A-6R
(01)
30-133
Electrical 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.
(Factory default: 1,900 - 300 = 1,600 rpm)

in 50 rpm units.
a The adjustment value at shipment is 300
rpm.
Operating method:
buzzer sounds.
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.
30-134

D375A-6R
(01)
Electrical 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.
a The factory default of the adjustment value is 300 rpm (Display: 30).
Operating method:
buzzer sounds.
range.
D375A-6R
(01)

power train controller recognize the mechanical condition of the transmission.

[F3]: Unused
[F4]: Unused
[F6]: To start automatic correction
Conditions for correction work

1] [ENGINE SPEED]: 1,7001,950 rpm
2] [T/C TEMPERATURE]: 6585C
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".
30-135
Electrical system
6] If [End of teaching. Press F6] is displayed

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

manual initial correction)
Use this adjustment to perform the correction

manually when the correction is not finished
successfully by the IP automatic correction.
(Adjustment ID: 7842
a Use this adjustment code after the IP correction work, if necessary.
q
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).
30-136

a If [F2] is pressed while [F1] is pressed, all
the correction values are set to 0.
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-6R
(01)
Electrical 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 IP automatic correction (Adjustment ID: 7842) or IP
manual correction (Adjustment ID: 7843).
[F3]: To change display
[F4]: To 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 at 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
D375A-6R
(01)
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.
30-137
Electrical system
Adjustment ID: 9995 (Control brake release

mode)
Adjustment ID: 9996 (Sudden stop prevention

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.
30-138
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.
D375A-6R
(01)
Electrical 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]: To increase adjustment value [HI IDLE
RPM SET MODE]
[F4]: To 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.
D375A-6R
(01)
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]: To increase adjustment value [MAX
SHIFT]
[F4]: To 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.
30-139
Electrical system
3rd screen
4th screen (The figure shows VHMS installation specification)
PM clinic
5th screen
The machine monitor can check the condition of

the machine without connecting testing tools to
assist the Pm Clinic and other periodic inspections.
1) Selection of 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
30-140
2nd screen (The figure shows VHMS installation specification)
D375A-6R
(01)
Electrical system
6th screen (The figure shows VHMS installation specification)
[F1]: To switch screen

[F3]: Reset holding
[F4]:Hold information (displayed data)
[F5]: Return to Service menu screen
q
q
q
q
3) Holding displayed information

The displayed information can be held and
released with [F3] and [F4].
D375A-6R
(01)
30-141
Electrical system
Cylinder Cut-Out
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).
Select "09 Cylinder Cutout" on the "Service
Menu" screen.
2) Selecting cylinder to be disabled

After the "Cylinder Cutout" screen is
displayed, select a cylinder to be Cut out by
using the function switches.
q [F1]: Move selection mark (R) to left
q [F2]: 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 resets a cutout cylinder but the engine controller cannot reset that cutout cylinder, the background
(a) of the cylinder No. becomes yellow.
a One or more cylinders can be disabled.
30-142
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 resets a cutout cylinder but the engine controller cannot reset that cutout cylinder, the background
(a) 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 If [F3] is pressed with the condition of
hold, the holding function is canceled.
a The holding function is effective, regardless of setting or canceling the cylinder
cutout mode operation.
D375A-6R
(01)
Electrical 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.
No injection cranking
The machine monitor is equipped with the function capable of lubricating the engine through no
injection cranking. When a machine has been
stored for a long time, this function is used to
lubricate the engine prior to its restart in order to
prevent its wear or damage due to a lack of luburication oil.
Set the no-injection cranking while the engine is
stopped.
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.
D375A-6R
(01)
30-143
Electrical 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.
30-144
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 Press [F5] to return to the "Service Menu"
screen, stop the engine, and select no injection cranking again.
D375A-6R
(01)
Electrical system
Fuel Consumption
This function calculates the hourly fuel

consumption from the actual fuel consumption in
a measuring period and indicates it.
Select "11 Fuel Consumption" on the
2) Starting measurement
After the screen of "Fuel Consumption" is
displayed, start measurement by using 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
D375A-6R
(01)
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.
30-145
Electrical system

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 load record
This function displays the data accumulated

since the machine started operation.
(It displays the data saved in the controller.)
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
30-146
D375A-6R
(01)
Electrical system
Setting of VHMS
Snap shot (VHMS specification)
This function is used to set installation of VHMS.

If VHMS is installed when shipped, this setting
has been completed.
Select "13 Setting of VHMS" on the "Service
Menu" screen.
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.
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" by using 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 by using 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]: To select "ON"

[F4]: To select "OFF"
[F6]: Confirm selection
q
q
D375A-6R
(01)
[F1]: To start measurement

30-147
Electrical system
Handling of voltage circuit of engine controller
30-148
1. When disconnecting or connecting a connector

between engine controller and engine, be sure
to turn off the starting switch.
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 with T-adapter inserted in
or connected to a connector between engine
controller and engine for troubleshooting
a You may turn the starting switch to the OFF
or ON position but must not turn it to the
START position.
30-148
D375A-6R
(01)
Electrical system
Adjustment method when controller has been replaced

a After the machine is assembled or the power
train controller or the work equipment controller
is replaced, adjust the system according to the
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 approximately 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.
D375A-6R
(01)
30-149
6) Select "07 Adjustment" on 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 stored.
a Confirm that the displayed specification
code has changed from [1 x 1] to [111].
30-149
Electrical system
9) Press [F5] to return to the adjustment ID input

screen.
10)Input adjustment ID [0031] directly with the
numeral input switches. (Initial setting of
work equipment controller)
11)Press [F6].
a The buzzer sounds and the specification
selection is stored.
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

enter 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 approximately 30 seconds to shut
down the controller completely after the
battery relay is turned OFF.
14)Turn the starting switch to the ON position
again.
a The machine monitor lights up and displays normally.
a The engine can be started now.
2. VHMS device setting (VHMS specification)
a Set this item after the machine monitor was
replaced, too.
a Since the VHMS device is not installed in the
default setting, be sure to set this item if the
machine has the VHMS specification.
3. Shoe slip control setting

replaced, too.
1) Input "86" with the numeral input switches
and press [F6] in the "Service menu" screen.
1) Set the machine monitor in the service mode.

2) Select "13 VHMS Setting" in the "Service
menu" screen.
30-150
D375A-6R
(01)
Electrical 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 Abnormality Record" on the
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 abnormality recrd" and press [F6] to
D375A-6R
(01)
30-151
Electrical system
7. Work equipment specification selection

1) Select "07 Adjustment" in the "Service menu"
screen.
a For details, see "Special functions of monitor

panel (EMMS)", "Adjustment" function.
12. Trigger teaching value check
13. Steering lever neutral position adjustment
2) Input adjustment ID [0004] directly with the

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

15. Steering lever rightmost position adjustment
16. Shoe slip control specification setting
17. Setting of travel control lever codes
(Only for the machine with travel control
lever different from the standard one)
8. Brake pedal potentiometer initial correction

9. Pitch angle sensor standard setting
10. IP automatic correction and trigger automatic initial teaching
11. IP correction value check (Check of correction value of electric current)
30-152
D375A-6R
(01)
Electrical system
Preparation work for troubleshooting for electrical equipment system
Preparation work for troubleshooting for electrical equipment system 30-153

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.
D375A-6R
(01)
30-153
Electrical 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 Since the connectors are secured with
screws, loosen those screws before disconnecting.
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 to harness connector.
30-154
D375A-6R
(01)
Electrical 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.
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}
D375A-6R
(01)
30-155
Electrical 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
in or to connectors V1, V2A, V2B, V3A, V3B,
V4A, V4B 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).
30-156
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}
D375A-6R
(01)
Electrical system
Inspection procedure of diode

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

1) Set the tester in the diode range and check
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) Judge 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 a silicon diode, a value in
the range from 460 to 600 mV is indicated.
q Displayed value becomes 0 or near 0 :
Short-circuiting of diode internal part (defect)
D375A-6R
(01)
30-157
2. When using an analog multimeter
1) Set the tester in the resistance range.
2) Apply the leads of the tester as explained
below and check the movement of the
pointer.
1] Set red (+) test lead to diode anode (P)
side and black () test lead to cathode (N)
side.
2] Set red (+) test lead to diode cathode (N)
side and black () test lead to anode (P)
side.
3) Judge 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)
30-157
Electrical system
Handling of optional devices

a D375A-6R is equipped with the connectors in
the fuse box for optional equipment to be installed. Use these connectors to obtain the necessary signals or power for the equipment
without remodeling the machine wiring harness.
a For the locations of the connectors, see Troubleshooting, "Connector list and 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.
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.
30-158
4. Connecting C signal of starting switch
If the C signal (starting signal) of the starting
switch is necessary for an optional device such
as the pre-lubricator, take the signal out of the
following connector pin.
q CN-PRS (2-pole heavy duty wire connector)
a Remove the connector installed when the
machine is shipped, and connect pin (1) to
the starting signal to be finally output by the
pre-lubricator and connect pin (2) to the input
signal 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.
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.
30-158
D375A-6R
(01)
Electrical system
Request for opening ORBCOMM terminal
30-159
30-159
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.
D375A-6R
(01)
30-159
Electrical system
30-160
D375A-6R
(01)
Electrical system
Initializ
ation procedures for VHMS controller
Initialization procedures for VHMS controller

a Initialization tools for VHMS controller
SymPart name
Part No.
bol
1 799-608-3211 Discket
2 799-608-3220 Wiring harness
Notebook type personal comZ
Commercially puter: Windows
3
available
98/2000/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".
D375A-6R
(01)
30-161
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.
30-161
Electrical system
Initializ
2. Connection of personal computer

1) Make sure that starting switch is in OFF position.
k When connecting and disconnecting
the PC, be sure to turn the starting
switch to the OFF position.
2) Connect PC Z3 and download connectors
(VDW) and (DL1) with wiring harness Z2.
a The download connectors are installed to
the following places.
q VDW: At bottom of left rear of operator
seat
q DL1: Right rear of machine (Side of
backup lamp)
a Connect it to RS232C terminal on the PC.
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)
1) Turn the starting switch to ON position.
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.
30-162
3) Select "01 Monitoring".
D375A-6R
(01)
Electrical system
Initializ
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]

1) Turn the starting switch to ON position.
2) The 7-segment LED (indicated with the
arrow) of the VHMS controller flashes and
rotates, and then counts up.
D375A-6R
(01)
30-163
Electrical system
Initializ
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. Start-up of VHMS initialization tool

a This step is a work performed in the operator's cab (on the personal computer).
1) Turn on the PC and start the OS.
2) Click the icon of [VHMS Analysis Tool] on the
PC to start the VHMS analysis 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 the updated tool (Ver. 3.5.2.1
or after), configure 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: SERVICE MATE
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 [OK] button to proceed to the setting
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) When [Date/Time] information is not appropriate, correct it in the following procedure.
30-164
D375A-6R
(01)
Electrical system
Initializ
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 lower
right portion 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 enter the setting.
a If the [Apply] button(3) is pressed, the
screen for checking the setting appears.
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.
D375A-6R
(01)
30-165
Electrical system
Initializ
[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].
30-166
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.
D375A-6R
(01)
Electrical system
Initializ
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].
D375A-6R
(01)
30-167
Electrical system
Initializ
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.
30-168
D375A-6R
(01)
Electrical system
Initializ
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.
D375A-6R
(01)
7. Downloading of set data

1) Connect PC Z3 and download connectors
(VDW) in the cab or ground download
connector (DL1) with wiring harness Z2.
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.
30-169
Electrical system
Initializ
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) Click the icon of [VHMS Analysis Tool] on the
PC to start the VHMS analysis tool.
8. Check of downloaded data

1) Check the setting data by using [View] function.
a For the operation procedures, refer to the
Operation and Maintenance Manual for
VHMS Technical Analysis Tool.
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 are recorded.
a Input [User Name] and [Password].

2) After checking the set data, terminate [VHMS
Technical Analysis Tool].
9. Disconnection of Personal Computer
1) Make sure that starting switch is in OFF position.
k When connecting and disconnecting
the PC, be sure to turn the starting
switch to the OFF position.
2) End the OS of the PC and then turn the PC
OFF.
5) Using the [Download] function, download the
data currently recorded in the VHMS
controller to the personal computer.
a Make sure that downloading has completed before proceeding to the next step.
30-170
D375A-6R
(01)
Electrical system
Initializ
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).
10. Report to Komatsu

After completing steps 1 to 9 successfully, send
the "VHMS/WebCARE setting notification form"
prepared at the end of this section 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 first downloaded data of VHMS via
e-mail to the following address along with the
"VHMS/WebCARE setting notification form",
a When using the KOMTRAX functions on the
machine equipped with the ORBCOMM,
complete the radio station establishment on
the machine side and apply a checkmark to
the column "Do you use KOMTRAX services?" 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
D375A-6R
(01)
30-171
Electrical system
Initializ
[For storage]
VHMS initial setting work check sheet
Setting step
Check of nameplates of chassis and

components
Date of setting:
DB/branch
name:
Data entered by:
Check item
Result
Model name
Serial No.
Engine serial No.
Transmission controller serial No.
2 Connection of PC with VHMS controller
Is connection made securely?
yes
no
3 Check of operation VHMS controller
Is operation normal?
(Displays decimal counting in ascending-order succeeding
to 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 Performing 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
30-172
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
D375A-6R
(01)
Electrical system
Initializ
[For keeping]
ORBCOMM Station Establishment Check
Sheet
Setting step
Date of setting:
DB/branch name:
Data entered by:
Check item
Result
Model name
Serial No.
Engine serial No.
Transmission serial No.
ORBCOMM controller serial No.
Check of nameplates of chassis

and components
Connection of PC with VHMS conIs connection made securely?

troller
yes
no
Check of operation VHMS control- Is operation normal?

ler
(Displays counting in ascending-order succeeding to rotation)
yes
no
yes
no
On
hrs
Off
On
hrs
Off
On
Off
4 Starting of VHMS initialization Tool Is setting tool set in "Set up" mode?
Initialization 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)
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 blinking)
D375A-6R
(01)
day
30-173
Electrical system
Initializ
30-174
D375A-6R
(01)
Electrical system
Using method of KOMTRAX functions of ORBCOMM terminal

a The KOMTRAX functions are added to the ORBCOMM terminal of this machine.
a The ORBCOMM terminal equipped with the
KOMTRAX function can display the machine on
the control screen of the KOMTRAX system.
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 JPS
antenna are connected to the wiring harness
of the machine.
2) Turn the starting switch to the ON position.
3) Wait until LED1 lights up.
a LED1 keeps flashing until the sign-up test
is completed.
D375A-6R
(01)
30-175
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.
30-175
Electrical system
[LED display]
(1) LED-Green
KOMTRAX state
(2) LED-Red
ORBCOMM satellite capture
(3) LED Yellow VHMS start recognition

(4) LED Green ORBCOMM MODEM power
(5) LED Red
Unused
(6) LED Red
Unused
(7) 7 segment
(8) Dot
GPS satellite capture state
[State]
Waiting for server trigger: Lighting
Normal operating state: Turning off
Satellite not captured: Lighting
Satellite captured (No transmission data):Quick flashing
Satellite captured (There is transmission data): Slow flashing
Power OFF: Turning off
VHMS start recognized: Lighting
VHMS stop recognized: Turning off
ON: Lighting
OFF: Turning off
Kept Turning off
Kept Turning off
Number of mails waiting to be sent (Max. of 9)
Satellite not captured: Turning off
Satellite captured: Lighting
* Flashing interval
Quick flashing: Cycle of 1 sec (Lighting for 0.5 sec and Turning off for 0.5 sec repeatedly)
Slow flashing: Cycle of 4 sec (Lighting for 0.5 sec and Turning off for 1.5 sec repeatedly)
30-176
D375A-6R
(01)
Electrical 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 apply a checkmark to the
column of "Do you use KOMTRAX
services?" in the form.
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)".
D375A-6R
(01)
30-177
Electrical system
Precautions for replacing VHMS controller

a Tools for replacing VHMS controller
SymPart No.
Part name
bol
1 799-608-3211 Discket
2 799-608-3220 Wiring harness
Notebook type personal comZ
Commercially puter: Windows
3
available
98/2000/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 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".
30-178
[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".
30-178
30-178
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 PC and start the VHMS initial
setting 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.
D375A-6R
(01)
Electrical 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 PC.
a See "9. Disconnection Personal Computer" in "Initialization procedure for VHMS
controller".
8) Turn the PC OFF.
9) Replace the VHMS controller.
D375A-6R
(01)
30-179
Electrical system
4) The saved information is displayed. Press

the "OK" button.
7) After setting the time, press the "OK" button.
8) Press [Apply] button to display contents of

the setting. Check the setting again and, if it
is acceptable, press [OK] button.
5) The saved information is displayed on

another screen.
6) Press the [Edit] button to set the time.
30-180
D375A-6R
(01)
Electrical 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 PC and start the VHMS initial
setting 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.
D375A-6R
(01)
30-181
Electrical 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 PC.
a See "9. Disconnection Personal Computer" in "Initialization procedure for VHMS
controller".
7) Turn the PC 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.
30-182
D375A-6R
(01)
Electrical 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]

30-183
a Download the data referring to "7. Downloading
of set data" in "Initialization procedures for
VHMS ".
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 to the following address via e-mail.
7) The above completes modification of the

setting. Press [OK] button to end the VHMS
initial setting tool.
D375A-6R
(01)
30-183
Pm Clinic
Pm Clinic service
Pm Clinic
30-184
Pm Clinic service
30-184
Model
D375A-6R #65001-
Serial No.
Service meter reading

h
User name
Date of clinic
/
/
Inspector
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
Other
Operating conditions
Construction
Type of soil (specific gravity)
Construction, civil engi- Rock
neering
Gravel
Roads
Sand
Tunnels
Clay
Quarry, mine
Coal
Gold
Limestone
Existence of abnormalities
Oil, coolant level check
When necessary
Power train
Final drive
Engine coolant level

Engine oil level
Hydraulic oil level
Ambient temperature
Max.
Min.
Type of work
Dozing
Side cutting
Ripping
Travel
%
%
%
%
Damper case
(
)
Height above sea level
m
Operator's opinion
Visual check results
[
Content:
[
Content:
Failure code history

[
]
Content:
[
]
Content:
h
h
Operating mode
q Working mode: P- or E-mode
q Gear shift mode: Auto or Manual
q Preset: F or R
Comment
30-184
D375A-6R
(01)
Pm Clinic
Pm Clinic service
Measurement item for Pm Clinic of D375A-6R
30-185
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 pressure
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
D375A-6R
(01)
Transmission
lubricating oil
pressure
E
E
E
Fan circuit
Control source pressure
Pump pressure
Rotating speed
E
E
E
E
Q
Q
Q
Q
Q
30-185
Pm Clinic
Pm Clinic service
Testing points for Pm clinic (1/3)
30-186
For the measurement procedures, see the following pages.

*1. Enging speed:"Testing engine speed"
*2. Blow-by pressure: "Testing blow-by 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"
30-186
D375A-6R
(01)
Pm Clinic
Pm Clinic service
30-187

*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"
D375A-6R
(01)
30-187
Pm Clinic
Pm Clinic service
30-18

*9. Hydraulic pressure of work equipment: "Testing and adjusting work equipment oil pressure"
*10. Source pressure of control circuit: "Testing control circuit main pressure"
*11. Fan speed: "Measuring fan speed"
30-188
D375A-6R
(01)
Pm Clinic
Pm Clinic service
Pm Clinic check sheet

Work order No.
D375A-6R
Date of clinic
/
/
Item
Test conditions
Unit
Engine
Standard
Service limit
value for new
value
machine
700 800
Engine oil pressure

High idle
Boost pressure
At torque converter stall
Exhaust temperature
Torque converter stall +

Work equipment relief
No. 1, 2 , 3 cylinder
No. 4, 5, 6 cylinder
Remarks
i
1,450
1,400
Max. 3.43
{Max. 350}
Min. 9.41
{Min. 960}
Min. 98.07
{Min. 1.0}
Max. 78.45
{Max. 0.8}
Min. 343.23
{Min.3.5}
Max. 205.94
{Max. 2.1}
kPa
{mmHg}
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
Oil temperature:
Min.70C
Low idle
1,850 1,900
1,450 1,550
Min. 131
{Min. 980}
Max. 117
{Max. 880}
Max. 670
Min. 700
kPa
{mmH2O}
OK NG
1,480 1,580
rpm
High idle
Test
results
850 950
Deceleration pedal
depressed
Torque converter stall (Adjustment ID: 0530)

Torque converter stall + Work equipment relief (ripper raise) (Adjustment ID: 0530)
Blow-by pressure
Inspector
h
Low idle
Decel
Engine speed
Serial No.
kPa
{kg/cm2}
k For torque converter lockup clutch pressure, set both of the steering clutches to the disengage mode on the machine mon-
itor and check the pressure.

Item
Test conditions
Unit
Inlet oil pressure
Torque converter
Outlet oil pressure

Lockup clutch pressure
Stator clutch oil pressure
Transmission: Neutral
MPa
{kg/cm2}
Inlet oil pressure

Outlet oil pressure
Lockup clutch pressure
Stator clutch oil pressure
Lockup clutch pres- Transmission: F2
sure
(Adjustment ID: 5535)
Standard
Service limit
value for new
value
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}
Test
results
OK NG
Remarks
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

Main relief pressure
Transmission
Lubricating oil pressure
F clutch pressure
R clutch pressure
1st clutch pressure
2nd clutch pressure
3rd clutch pressure
D375A-6R
(01)

Transmission: F1
Transmission: R1
Transmission: F1
Transmission: F2
Transmission: F3

MPa
{kg/cm2}
Standard
Service limit
value for new
value
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}
Test
results
OK NG
Remarks
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}
30-189
Pm Clinic
Pm Clinic service

Work order No.
D375A-6R
Date of clinic
/
Item
Test conditions
Steering clutch & brake
Engine at high
idling
Left brake pressure

Right clutch pressure
Engine at low
idling
Right brake pressure
Hydraulic system
MPa
{kg/cm2}
Engine at high
idling
Engine at high idle, F2, brake actuated
Test conditions
Work equipment
pump
(Unload pressure)
Work equipment
pump
Ripper lift relief or

blade tilt relief
Unit
Control lever in NEU- Engine at high

TRAL position
idling
Engine at low
idling
Test conditions
Min. speed
Fan 100 % mode
Max. speed
Item
Blade RAISE
Blade tilt (left and right tilt)

[Single tilt model]

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

[Dual tilt model, Single setting]
Ripper tilt (ino out)
30-190
Engine at low
idling
Engine at high
idling
Test conditions
Engine at low
idling
Engine at high
idling
Engine at low
idling
Engine at high
idling
Engine at low
idling
Engine at high
idling
Engine at low
idling
Engine at high
idling
Engine at low
idling
Engine at high
idling
Engine at low
idling
Engine at high
idling
Standard value
Service limit
for new
value
machine
MPa
{kg/cm2}
Unit
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}
Engine at high
Control circuit source Control lever in NEU- idling
pressure
TRAL position
Item
Fan
Unit
Left clutch pressure
Item
Inspector
h
Engine at low
idling
Left brake pressure
Brake performance
Serial No.
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
Unit
Standard value
Service limit
for new
value
machine
7 13
20
3.7 - 4.7
24
2.5 3.5
46
2.5 3.5
46
2.5 3.5
24
2.5 3.5
6 10
15
2.8 3.8
sec.
D375A-6R
(01)
Pm Clinic
Pm Clinic service

Work order No.
Date of clinic
/
Hydraulic drift
Item
D375A-6R
Test conditions
Unit
Engine stopped
mm/5min.
45 55 C
Visual check of final

drive drain plug
Inspector
Blade lift cylinder
Item
Serial No.
Test conditions
Unit
Engine stopped
Standard
value for
new
machine
Service
limit value
Max. 65
Max. 25
Standard
value for
Service
new
limit value
machine
There must be no excessive metal particles
Test
results
OK NG Remarks
Test
results
OK NG Remarks
Always fill in the record when repairing, adjusting, or replacing main parts.
Date
D375A-6R
(01)
Repair record
Date
Repair record
30-191
Pm Clinic
Pm Clinic service
30-192
D375A-6R
(01)
Pm Clinic
Pm Clinic service
D375A-6R
(01)
30-193
Pm Clinic
Pm Clinic service
30-194
D375A-6R
(01)
SEN0521412-00
40-1
D375A-6R
BULLDOZER
D375A-6R
Shop Manual
Machine model
Serial number
D375A-6R
40-1
65001 and up
40 Troubleshooting
D375A-6R
(01)
40-1
40-1
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...............................................................................................................
Classification and procedures for troubleshooting numbers ................................................
Troubleshooting method for disconnecting wiring harness of pressure sensor system.......
Connection table for connector pin numbers .......................................................................
T-branch box and T-branch adapter table ...........................................................................
Connector list and layout .....................................................................................................
Fuse locations table .............................................................................................................
Troubleshooting by failurecode ...............................................................................................
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 ..........................................................................
40-2
40-2
40- 10
40- 10
40- 11
40- 12
40- 37
40- 40
40- 50
40- 52
40- 54
40- 57
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40- 110
40- 114
40- 114
40- 115
40- 116
40- 118
40- 120
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40- 128
40- 130
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40- 166
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40- 170
40- 172
40- 173
40- 174
40- 175
40- 176
40- 177
D375A-6R
(01)
Contents
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 [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 [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 [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 [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...............................................................
D375A-6R
(01)
40- 178
40- 179
40- 180
40- 182
40- 184
40- 186
40- 188
40- 190
40- 192
40- 194
40- 196
40- 198
40- 200
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40- 222
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40- 225
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40- 250
40- 251
40- 252
40- 256
40- 258
40- 259
40- 260
40- 262
40- 263
40- 264
40- 265
40-3
Contents
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 24V reduction ........................................
Failure code [DBE7KK] PT cont.: Sensor voltage 5 V 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 ..........................................
40-4
40- 266
40- 268
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40- 274
40- 276
40- 278
40- 280
40- 282
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D375A-6R
(01)
Contents
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 [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 [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 [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 ......................................................................
D375A-6R
(01)
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40-5
Contents
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 ..................................................
40-6
40- 477
40- 478
40- 479
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40- 482
40- 484
40- 485
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40- 572
D375A-6R
(01)
Contents
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-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 ....................................................
D375A-6R
(01)
40- 573
40- 574
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40- 576
40- 578
40- 578
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40- 584
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40- 600
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40- 663
40- 664
40-7
Contents
H-16 Ripper lift cylinder speed is too slow or lacks power................................................... 40- 665
H-17 Ripper tilt cylinder speed is too slow or lacks power................................................... 40- 666
H-18 Excessive hydraulic drift of blade lift cylinder.............................................................. 40- 667
H-19 Excessive hydraulic drift of blade tilt cylinder.............................................................. 40- 668
H-20 Excessive hydraulic drift of ripper lift cylinder ............................................................. 40- 669
H-21 Ripper pin puller cylinder does not operate (machine with giant ripper) ..................... 40- 670
H-22 Blade pitch does not work (machine with dual tilt specification) ................................. 40- 671
H-23 Abnormal noise from around work equipment pump .................................................. 40- 672
H-24 Abnormal fan rotation(noise and/or vibration are abnormally large or engine overheats)40-673
Troubleshooting of engine (S-mode) ...................................................................................... 40- 674
Method of using troubleshooting chart................................................................................. 40- 674
S-1 Engine does not start easily .......................................................................................... 40- 678
S-2 Engine does not start .................................................................................................... 40- 679
S-3 Engine does not rev up smoothly (response-up is poor)............................................... 40- 682
S-4 Engine stops during operation....................................................................................... 40- 683
S-5 Engine does not rotate smoothly (hunting).................................................................... 40- 684
S-6 Engine lacks power (or output shortage)....................................................................... 40- 685
S-7 Exhaust smoke is black (Incomplete combustion) ........................................................ 40- 686
S-8 Oil is consumption is excessive(or exhaust smoke is blue) .......................................... 40- 687
S-9 Engine oil becomes contaminated quickly .................................................................... 40- 688
S-10 Fuel consumption is excessive.................................................................................... 40- 689
S-11 Oil mixes into coolant(coolant blows back or is reduced)............................................ 40- 690
S-12 Engine pressure monitor lights up (drop in engine oil pressure) ................................. 40- 691
S-13 Oil level rises (Coolant or fuel mixes into oil) .............................................................. 40- 692
S-14 Coolant temperature rises too high (overheating) ....................................................... 40- 693
S-15 Abnormal noise is heard.............................................................................................. 40- 694
S-16 Vibration is excessive.................................................................................................. 40- 695
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- 696
40-8
D375A-6R
(01)
Contents
D375A-6R
(01)
40-9
General information on troubleshooting

Points to remember when troubleshooting

k
k
k
k
k
k
40-10
40-10
Stop the machine in a level place, and check that the lock 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 perform
any inspection 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 as a short term
fixing, if the root cause of the failure is not
removed, the same failure will occur again. In
order 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.
40-10
D375A-6R
(01)

Sequence of events in troubleshooting
40-1
(Rev. 2007. 12)
D375A-6R
(01)
40-11

Checks before troubleshooting

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)
a: Engine, lubricating oil and coolant
No.
Item
40-12
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
40-12
D375A-6R
(01)

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
20 30 V
Charge or 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 open and short circuit
Repair or replace
13 Check of fuse for breakage and corrosion
Replace
14 Check of circuit breaker
Push in reset button
After several
minutes operation: 27.5 29.5
V
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
4 Check 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
7
harness
c: Electrical equipment
Check of alternator voltage (When engine speed is medium or

15
higher)
e. Interior parts d. Exterior parts
16
Check of battery relay operation sound (When the starting switch is

turned to ON or OFF position)
D375A-6R
(01)
40-13

Testing procedure before troubleshooting

Walk-around check
40-14
40-14
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. Be sure to check thoroughly and repair any abnormalities.
a1. and 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 find any abnormality.
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)".
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
at 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 mounting hardware
Check the hooks, locks and hook fittings for
damage. If any of them has a problem, repair the
damage.
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 each clearance is within the normal range,
and then repair any abnormalities.
40-14
D375A-6R
(01)

Testing according to testing procedure

a. Engine lubricating oil and coolant
40-15
40-15
a7. Check of level and type of fuel

k 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.
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 contaminants 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.
D375A-6R
(01)
40-15

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 the pre-filter
cartridge, and perform the check. 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 apply oil lightly 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. Install transparent cup (3) to prefilter cartridge.
3 Tightening torque of transparent cup
(3):
10 Nm {1.0 kgm}
a Make sure that drain plug (5) at the bottom of
transparent cup (3) is secured.
3 Tightening torque of drain plug (5):
0.2 0.4 Nm {0.02 0.046 kgm}
40-16
11. Install the prefilter 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 is tightened excessively, fuel will leak because the O-ring will
be damaged. If the filter cartridge is not tightened sufficiently, fuel will also leak through
the clearance at the packing. Therefore, observe the tightening angle.
12. Then, proceed to "a10. Check of fuel filter".
D375A-6R
(01)

a10. Check of fuel filter

work.
k High pressure is generated in the engine fuel
piping system while the engine is running.
Wait for at least 30 seconds after stopping
the engine until the internal pressure 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.
4. Place the oil receiving container under filter

cartridge (3).
5. Using the filter wrench, rotate filter cartridge (3)
to the left to remove.
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.
6. Clean the filter bracket and apply oil lightly 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).
D375A-6R
(01)
40-17

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
head.
a If the filter cartridge is over tightened, the
O-ring is damaged to cause fuel leak. If the
filter cartridge is not tightened sufficiently,
fuel also leaks through the clearance at 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.
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).
40-18
6. If the oil level is above H

1) Remove the cover from the machine bottom
and place a oil container under 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.
3 Drain plug (1):
68.6 9.81 Nm {7 1 kgm}
3 Drain valve (2):
63.7 14.7 Nm {6.5 1.5 kgm}
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-6R
(01)

a12. Check of coolant level (in sub tank)

k The radiator cap does not need to be opened
for the usual check.. Check the coolant level
on the sub tank side while the engine is cold.
k Immediately after the engine is stopped, the
coolant will be hot and pressure will have 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).
D375A-6R
(01)
40-19

a13. Check of air cleaner for clogging

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.
k
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 the red piston in dust indicator (1) projects just
after the outer element is cleaned, replace both
outer and inner elements, even if the outer element has not been cleaned six 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 damage the
engine..
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.
40-20
D375A-6R
(01)

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. 196 kPa {2

kg/cm2}) along the inside pleats of the outer
element.
D375A-6R
(01)
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.
40-21

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 tips of hooks (2) to the projection of

the air cleaner body to lock.
a Hitch hooks (2) diagonally (top and bottom, or 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.
40-22
D375A-6R
(01)

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, also replace the inner element.
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. 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.
D375A-6R
(01)
40-23

b. Hydraulic and mechanical equipment
40-24
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 then 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.
40-24
Since the oil level fluctuates according to the oil

temperature, note the following when checking
it.
q Before operation (oil temperature: 10 to 30
C), the oil level should be at the center between lines H and L.
q During operation (oil temperature: 50 to 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 it 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.
D375A-6R
(01)

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.
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.
a Check the bottom of the filter case and remove dirt if there is. At this time, take extreme
care that dirt does not enter the hydraulic
tank.
D375A-6R
(01)
40-25

b6. Check of power train case oil level

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 to 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 two bolts (4) on the front side of the
machine.
2) Gradually remove two bolts (5) on the rear
side of the machine, while supporting 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).
40-26
D375A-6R
(01)

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 them with new parts.
4. Loosen bolt (7) to separate strainer (5) and
magnet (6).
5. Remove dirt from strainer (5) and clean it in
clean diesel fuel.
q Clean the inside of the case and plug, too.
6. Install strainer (5).
3 Tightening torque for bolt (7):
46 to 59 Nm {4.7 to 5.9 kgm}
D375A-6R
(01)
40-27

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
40-28
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.
D375A-6R
(01)

b9. Check of damper case oil level

q Check the oil level while the engine is stopped.
q When checking, park the machine on a level
ground.
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.
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.
D375A-6R
(01)
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. Performing 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
40-29

c. Electrical equipment
40-30
c1. Check of battery terminals for looseness and

corrosion
Open cover (1) at the left front of the machine and
check the cable terminals for 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 breakage, looseness and corrosion.
40-30
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 breakage, looseness
and corrosion.
Check starting motor (ST-U) similarly, too.
c4. Testing of battery voltage (when engine

stops)
Test the battery voltage by using the battery tester
while the engine is stopped.
D375A-6R
(01)

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 beyond the UPPER LEVEL mark. Excessive addition 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 through the
side face 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.
D375A-6R
(01)
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
through the side face 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
reaches to the sleeve bottom, the shape of
the electrode plates will appear distorted due
to the surface tension.
q (B) Low: Since the electrolyte level does not
reach 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.
40-31

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 hexagonal wrench with 4 mm width
across flats.
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.
40-32
D375A-6R
(01)

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 damaged, 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.
D375A-6R
(01)
40-33

c12. Check of wiring harness for open and short

circuiting
q Check the connections (crimped parts) between
each connector pin and wiring harness.
q If there is any open circuit in wiring harness or
connector as illustrated in (A), repair or replace
them.
Open inspection cover (A), and fuse boxes (1) to (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 breakage 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 the one of the same capacity.
40-34
Fuse box (4) is located overhead.
D375A-6R
(01)

c14. Check of circuit breaker

k 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.
Check of circuit breaker in each circuit
If the circuit breaker works, 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 starting switch to 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) to (E).
D375A-6R
(01)
3. Push reset buttons (A) to (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.
40-35

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.
40-36
c16. Check of battery relay operation sound

1. Open the battery cover.
2. Check whether the battery relay operation sound
is heard when starting switch is turned to
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.
D375A-6R
(01)

Classification and procedures for troubleshooting
40-37
Classification of troubleshooting
40-37
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

40-37
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 standard screen of themachine monitor, perform the
troubleshooting for the corresponding "Display of code" according to the displayed failure 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 failure 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 failure is eliminated
Clear all the failure codes in the electrical system abnormality record, referring to the next page.
D375A-6R
(01)
40-37

[*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.
40-38
4. Press [F6] switch ( ) on the panel switch to

confirm and go to "Mechanical system Abnormality Record" 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 failure code of the mechanical system cannot be deleted.
6. Press [F5] switch (RETURN) on the panel switch
to return to the "Failure history" 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.
to return to the "Electrical system failure record"
screen. See if any failure code is still displayed
and note down the displayed ones.
D375A-6R
(01)


to return to the "Failure history" screen.
D375A-6R
(01)
40-39

Failure codes table
Failure codes table

Failure
code
Failure (Displayed on screen)
1380MW Lock up clutch:Slip
40-40
Component
Category of
Action code
in charge
record
P/T
P/T
E03
15E0MW Transmission clutch:Slip
P/T
15SAL1
Forward clutch:Fill high
P/T
E03
15SALH
Forward clutch:Fill low
P/T
E03
15SBL1
Reverse clutch:Fill high
P/T
E03
15SBLH
Reverse clutch:Fill low
P/T
E03
15SEL1
Speed 1st clutch:Fill high
P/T
E03
15SELH
Speed 1st clutch:Fill low
P/T
E03
15SFL1
Speed 2nd clutch:Fill high
P/T
E03
15SFLH
Speed 2nd clutch:Fill low
P/T
E03
15SGL1
Speed 3rd clutch:Fill high
P/T
E03
15SGLH
Speed 3rd clutch:Fill low
P/T
E03
15SJL1
L/U :Fill high
P/T
E02
15SJLH
L/U :Fill low
P/T
E02
P/T
E02
1500L0
Transmission clutch:Abnormal
1800MW P/T clutch:Slip

2201L1
Right clutch:Fill high
P/T
E04
2201LH
Right clutch:Fill low
P/T
E04
2202L1
Left clutch:Fill high
P/T
E04
2202LH
Left cluth:Fill low
P/T
E04
2300NR
Brake Thermal Load Abnormality
P/T
2301L1
Right brake:Fill high
P/T
E04
2301LH
Right brake:Fill low
P/T
E04
2301NR
Steering Brake RH Thermal Load Abnormality
P/T
2302L1
Left brake:Fill high
P/T
E04
2302LH
Left brake:Fill low
P/T
E04
2302NR
Steering Brake LH Thermal Load Abnormality
P/T
7RFAKA ECM ACC CUT RELAY:Disconnection
W/E
7RFAKB ECM ACC CUT RELAY:Short circuit
W/E
40-40
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
Mechanical
system
Electrical
system
Electrical
system
Mechanical
system
Electrical
system
Electrical
system
Reference
document
page
40-114
40-115
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
40-168
D375A-6R
(01)

Failure codes table
Failure
code
Component
Category of
Action code
in charge
record
AA10NX Air Cleaner Clogging
MON
AB00MA Battery Charge Abnormal
MON
B@BAZG Eng Oil Press Low
ENG
B@BAZK Eng oil level low
MON
B@BCNS Eng Water Overheat
ENG
B@BCZK Eng water level low
MON
B@CENS T/C Oil Overheat
P/T
B@HANS Hyd Oil Overheat
P/T
B@HAZK Hyd Oil Level Low
W/E
CA111
ECM Critical Internal Failure
ENG
E03
CA115
Eng Ne and Bkup Speed Sens Error
ENG
E03
CA122
Chg Air Press Sensor High Error
ENG
E03
CA123
Chg Air Press Sensor Low Error
ENG
E03
CA131
Throttle Sensor High Error
ENG
E03
CA132
Throttle Sensor Low Error
ENG
E03
CA135
Eng Oil Press Sensor High Error
ENG
E02
CA141
Eng Oil Press Sensor Low Error
ENG
E01
CA144
Coolant Temp Sens High Error
ENG
E01
CA145
Coolant Temp Sens Low Error
ENG
E01
CA153
Chg Air Temp Sensor High Error
ENG
E01
CA154
Chg Air Temp Sensor Low Error
ENG
E01
CA187
Sens Supply 2 Volt Low Error
ENG
E03
CA212
Eng Oil Temp Sensor Low Error
ENG
E01
CA213
ENG
E01
CA221
Ambient Press Sens High Error
ENG
E01
CA222
Ambient Press Sens Low Error
ENG
E01
CA227
Sens Supply 2 Volt High Error
ENG
E03
CA234
Engine Overspeed
ENG
E02
CA238
Ne Speed Sens Supply Volt Error
ENG
E03
CA263
Fuel Temp Sensor High Error
ENG
E01
D375A-6R
(01)
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
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Reference
document
page
40-170
40-172
40-173
40-174
40-175
40-176
40-177
40-178
40-179
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
40-210
40-212
40-214
40-215
40-216
40-218
40-41

Failure codes table
Failure
code
Component
Category of
Action code
in charge
record
CA265
Fuel Temp Sensor Low Error
ENG
E01
CA271
IMV/PCV1 Short Error
ENG
E03
CA272
IMV/PCV1 Open Error
ENG
E03
CA273
PCV2 Short Error
ENG
E03
CA274
PCV2 Open Error
ENG
E03
CA322
Inj #1(L#1) Open/Short Error
ENG
E03
CA323
ENG
E03
CA324
ENG
E03
CA325
ENG
E03
CA331
ENG
E03
CA332
ENG
E03
CA342
Calibration Code Incompatibility
ENG
E03
CA351
Injectors Drive Circuit Error
ENG
E03
CA352
ENG
E03
CA386
Sens Supply 1 Volt High Error
ENG
E03
CA441
Battery Voltage Low Error
ENG
E03
CA442
Battery Voltage High Error
ENG
E03
CA449
Rail Press Very High Error
ENG
E03
CA451
Rail Press Sensor High Error
ENG
E03
CA452
Rail Press Sensor Low Error
ENG
E03
CA553
Rail Press High Error
ENG
E03
CA554
Rail Press Sensor In Range Error
ENG
E03
CA559
Rail Press Low Error
ENG
E03
CA689
Eng Ne Speed Sensor Error
ENG
E03
CA731
Eng Bkup Speed Sens Phase Error
ENG
E03
CA757
All Continuous Data Lost Error
ENG
E03
CA778
Eng Bkup Speed Sensor Error
ENG
E03
CA1633
KOMNET Datalink Timeout Error
ENG
E03
CA2185
Throt Sens Sup Volt High Error
ENG
E03
CA2186
Throt Sens Sup Volt Low Error
ENG
E03
40-42
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
Reference
document
page
40-220
40-222
40-223
40-224
40-225
40-226
40-228
40-230
40-232
40-234
40-236
40-238
40-239
40-240
40-242
40-243
40-244
40-245
40-246
40-248
40-250
40-251
40-252
40-256
40-258
40-259
40-260
40-262
40-263
40-264
D375A-6R
(01)

Failure codes table
Failure
code
Component
Category of
Action code
in charge
record
CA2249
Rail Press Very Low Error
ENG
E03
D110KB
Battery Relay:Drive Short Circuit
W/E
D130KA
Neutral relay:Disconnection
P/T
E02
D130KB
Neutral relay:Short circuit
P/T
E02
D161KA
Back-up alarm releay:Disconnection
P/T
E01
D161KB
Back-up alarm releay:Short circuit
P/T
E01
D182KZ
Preheater Relay Abnormality
P/T
E01
D190KA
ACC signal relay:Disconnection
W/E
D190KB
ACC signal relay:Short circuit
W/E
D1EFKA Pre lub. motor relay:Disconnection
P/T
E02
D1EFKB Pre lub. motor relay:Short circuit
P/T
E02
DAFRKR Monitor:Can communication lost(PT)
P/T
E03
dAFRKR Monitor:Can communication lost(WE)
W/E
E03
DAFRMC CAN Discon (Monitor Detected)
MON
E03
DB2RKR ENG cont.:Can communication lost(PT)
P/T
E03
dB2RKR ENG controller:Can communication lost(WE)
W/E
E03
DB90KT
W/E
E01
DB91KK WE controller:Source voltage reduction
W/E
E04
DB92KK WE controller:Output voltage reduction
W/E
E04
DB97KK WE cont.:Sensor voltage 5V (2) reduction
W/E
DB99KQ WE controller:Type select signal
W/E
E04
DB9RKR WE controller:CAN communication error (PT)
P/T
E03
DBB0KK VHMS controller:Source voltage reduction
VHMS
DBB0KQ VHMS Connector Connection Abnormality
VHMS
DBB3KK
VHMS
DBB5KP VHMS:Output sensor1 voltage reduction
VHMS
VHMS
VHMS
DBBQKR PT controller:CAN communication lost (VHMS)
VHMS
P/T
E01
WE controller:Abnormality in controller
VHMS controller:Source voltage reduction
DBE0KT PT controller:Abnormality in controller
D375A-6R
(01)
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
Reference
document
page
40-265
40-266
40-268
40-270
40-272
40-274
40-276
40-278
40-280
40-282
40-284
40-286
40-287
40-288
40-294
40-298
40-299
40-300
40-302
40-304
40-306
40-307
40-310
40-312
40-313
40-316
40-318
40-320
40-322
40-323
40-43

Failure codes table
Failure
code
Component
Category of
Action code
in charge
record
DBE1KK PT controller:Source voltage reduction
P/T
E04
DBE2KK PT controller:Output voltage reduction
P/T
E04
DBE5KK PT cont.:Sensor voltage5V (1) reduction
P/T
E03
DBE6KK PT cont.:Sensor voltage 24V reduction
P/T
E03
DBE7KK PT cont.:Sensor voltage 5V (2) reduction
P/T
E01
DBE9KQ PT controller:Type select signal
P/T
E04
DBERKR PT controller: CAN communication lost (WE)
W/E
E03
DD12KA Shift up Sw:Disconnection
P/T
E02
DD12KB Shift up Sw:Short circuit
P/T
E02
DD13KA Shift down Sw:Disconnection
P/T
E02
DD13KB Shift down Sw:Short circuit
P/T
E02
DD14KA Parking lever Sw:Dissconnection
P/T
E03
DD14KB Parking lever Sw:Short circuit
P/T
E03
DDB9L4
P/T
E03
DDE2KA Pre lub. oil press sw:Disconnection
P/T
E02
DDK3L4
P/T
E03
DDK5KA Shift switch disconnection
P/T
E02
DDK5KB Shift switch short circuit
P/T
E02
DDN2LD Blade tilt RH pressure SW abnormality
W/E
DDN3LD Blade tilt LH pressure SW abnormality
W/E
DDN7KA WEQ Knob Sw(down):Disconnection
W/E
E02
DDN7KB WEQ Knob Sw(down):Short circuit
W/E
E02
DDN9KA WEQ Knob Sw(up):Disconnection
W/E
E01
DDN9KB WEQ Knob Sw(up):Short circuit
W/E
E01
DDNALD Blade lift up pressure SW abnormality
W/E
DDNBLD Ripper lift up pressure SW abnormality
W/E
DDNCLD Ripper lift down pressure SW abnormality
W/E
DDNDLD Ripper tilt in pressure SW abnormality
W/E
DDNELD Ripper tilt back pressure SW abnormality
W/E
DDNFLD Blade lift down pressure SW abnormality
W/E
40-44
Reverse SW Signal disagreement
Forward SW Signal disagreement
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
Reference
document
page
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
D375A-6R
(01)

Failure codes table
Failure
code
Component
Category of
Action code
in charge
record
DDNLKA Weq lock Sw:Disconnection
W/E
E03
DDNLKB Weq lock Sw:Short circuit
W/E
E03
DDT5KA Neutral switch disconnection
P/T
E04
DDT5KB Neutral switch short circuit
P/T
E04
DDT5KQ Lever SPEC selection signal disagreement
P/T
E04
DDTSL1
P/T
E02
P/T
E02
VHMS
DGS1KX Hyd oil temp:signal abnormal
P/T
E01
DGT1KA T/C oil temp sensor:Abnormal
W/E
E01
DGT1KX T/C oil temp sensor:Abnormal
W/E
E01
DGT5KA F exhaust temp sensor disconnection
VHMS
DGT5KB F exhaust temp sensor short circuit
VHMS
DGT6KA R exhaust temp sensor disconnection
VHMS
DGT6KB R exhaust temp sensor short circuit
VHMS
DH21KA Weq pressure sensor:Disconnection
W/E
E01
DH21KB Weq pressure sensor:Short circuit
W/E
E01
DHE5KB ENG blow-by pressure sensor disconnection
VHMS
DHE5KY ENG blow-by pressure sensor short circuit
VHMS
DHT3KX T/M oil pressure sensor abnormality
VHMS
DHT5KA T/C in-pressure sensor:Disconnection
P/T
E02
DHT5KB T/C in-pressure sensor:Short circuit
P/T
E02
DHT7KA T/C out-pressure sensor:Disconnection
P/T
E02
DHT7KB T/C out-pressure sensor:Short circuit
P/T
E02
DK10KA Fuel control Dial:Disconnection
P/T
E03
DK10KB Fuel control Dial:Short circuit
P/T
E03
DK30KA ST lever1:Disconnection
P/T
E03
DK30KB ST lever1:Short circuit
P/T
E03
DK30KX ST lever:Out of normal range
P/T
E04
DK30KZ
P/T
E04
S/C :Fill high
DDTSLH S/C :Fill low

DGE5KX Ambient temp sensor abnormality
D375A-6R
(01)
ST lever:Disconnection or short circuit
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
Reference
document
page
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
40-441
40-45

Failure codes table
Failure
code
DK30L8
P/T
E03
DK31KA ST lever2:Disconnection
P/T
E03
DK31KB ST lever2:Short circuit
P/T
E03
DK40KA Brake potentiometer: Disconnection
P/T
E01
DK40KB Brake potentiometer: Short circuit
P/T
E01
DK55KX FR lever:Out of normal range
P/T
E04
DK55KZ
FR lever:Disconnection or short circuit
P/T
E04
DK55L8
FR lever:Signal mismatch
P/T
E03
DK56KA FR lever1:Disconnection
P/T
E03
DK56KB FR lever1:Short circuit
P/T
E03
DK57KA FR lever2:Disconnection
P/T
E03
DK57KB FR lever2:Short circuit
P/T
E03
DK60KA Acceleration sensor: Disconnection
P/T
E01
DK60KB Acceleration sensor:Short circuit
P/T
E01
DKH1KA Pitch angle sensor: Disconnection
P/T
E03
DKH1KB Pitch angle sensor: Short circuit
P/T
E03
DLF1KA T/C out-speed sensor:Disconnection
P/T
DLM3KA Fan rev. sensor:Disconnection
W/E
E02
DLM3MB Fan control:Decline
W/E
E02
DLT3KA T/M out-speed sensor:Disconnection
P/T
E01
DLT3KB T/M out-speed sensor:Abnormal
P/T
E01
DW59KA Blade dual selector SOL disconnection
W/E
E01
DW59KB Blade dual selector SOL short circuit
W/E
E01
DW59KY Blade dual selector SOL short circuit
W/E
E01
DW5AKA Blade pitch selector SOL disconnection
W/E
E02
DW5AKB Blade pitch selector SOL Short circuit
W/E
E02
DW5AKY Blade pitch selector SOL Short circuit
W/E
E02
DW7BKA Fan rev EPC:Disconnection
W/E
E01
DW7BKB Fan rev EPC:Short circuit
W/E
E01
DWN3KA Ssp solenoid:Disconnection
P/T
E04
40-46
ST lever:Signal mismatch
Component
Category of
Action code
in charge
record
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
Reference
document
page
40-442
40-444
40-446
40-448
40-450
40-452
40-453
40-454
40-456
40-458
40-460
40-462
40-464
40-466
40-468
40-470
40-472
40-474
40-476
40-477
40-478
40-479
40-480
40-482
40-484
40-485
40-486
40-488
40-489
40-490
D375A-6R
(01)

Failure codes table
Failure
code
Component
Category of
Action code
in charge
record
DWN3KB Ssp solenoid:Short circuit
P/T
E04
DWN3KY SSP solenoid:Short circuit
P/T
E04
DWN5KA Fan pump solenoid 1:Disconnection
W/E
E01
DWN5KB Fan pump solenoid 1:Short circuit
W/E
E01
DWN5KY Fan pump solenoid 1:Short circuit
W/E
E02
DWNCKA Fan pump solenoid 2:Disconnection
W/E
E01
DWNCKB Fan pump solenoid 2:Short circuit
W/E
E01
DWNCKY Fan pump solenoid 2:Short circuit
W/E
E02
DXH1KA Lock-up ECMV:Disconnection
P/T
E02
DXH1KB Lock-up ECMV:Short circuit
P/T
E02
DXH1KY Lock-up ECMV:Short circuit
P/T
E03
DXH4KA 1st clutch ECMV: Disconnection
P/T
E03
DXH4KB 1st clutch ECMV: Short circuit
P/T
E03
DXH4KY 1st clutch ECMV: Short circuit
P/T
E03
DXH5KA 2nd clutch ECMV: Disconnection
P/T
E03
DXH5KB 2nd clutch ECMV: Short circuit
P/T
E03
DXH5KY 2nd clutch ECMV: Short circuit
P/T
E03
DXH6KA 3rd clutch ECMV: Disconnection
P/T
E03
DXH6KB 3rd clutch ECMV: Short circuit
P/T
E03
DXH6KY 3rd clutch ECMV: Short circuit
P/T
E03
DXH7KA R clutch ECMV: Disconnection
P/T
E03
DXH7KB R clutch ECMV: Short circuit
P/T
E03
DXH7KY R clutch ECMV: Short circuit
P/T
E04
DXH8KA F clutch ECMV: Disconnection
P/T
E03
DXH8KB F clutch ECMV: Short circuit
P/T
E03
DXH8KY F clutch ECMV: Short circuit
P/T
E04
DXH9KA Right clutch ECMV:Disconnection
P/T
E03
DXH9KB Right clutch ECMV:Short circuit
P/T
E03
DXH9KY Right clutch ECMV:Short circuit
P/T
E04
DXHAKA Left clutch ECMV:Disconnection
P/T
E03
D375A-6R
(01)
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
Reference
document
page
40-492
40-494
40-496
40-498
40-500
40-502
40-504
40-506
40-508
40-509
40-510
40-512
40-514
40-516
40-518
40-520
40-522
40-524
40-526
40-528
40-530
40-532
40-534
40-536
40-538
40-540
40-542
40-544
40-546
40-548
40-47

Failure codes table
Failure
code
Component
Category of
Action code
in charge
record
DXHAKB Left clutch ECMV:Short circuit
P/T
E03
DXHAKY Left clutch ECMV:Short circuit
P/T
E04
DXHBKA Right brake ECMV:Disconnection
P/T
E04
DXHBKB Right brake ECMV:Short circuit
P/T
E04
DXHBKY Right brake ECMV: Short circuit
P/T
E04
DXHCKA Left brake ECMV:Disconnection
P/T
E04
DXHCKB Left brake ECMV:Short circuit
P/T
E04
DXHCKY Left brake ECMV:Short circuit
P/T
E04
DXJBKA S/C ECMV:Disconnection
P/T
E02
DXJBKB S/C ECMV:Short circuit
P/T
E02
DXJBKY S/C ECMV:Short circuit
P/T
E02
DY2HKA Pre lub. motor:Disconnection
P/T
E02
F@BBZL ENG blow-by pressure high level
VHMS
F@BYNR F exhaust temp high level (2)
VHMS
F@BYNS F exhaust temp high level (1)
VHMS
F@BZNR R exhaust temp high level (2)
VHMS
F@BZNS R exhaust temp high level (1)
VHMS
40-48
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
Mechanical
system
Mechanical
system
Mechanical
system
Mechanical
system
Reference
document
page
40-550
40-552
40-554
40-556
40-558
40-560
40-562
40-564
40-566
40-567
40-568
40-570
40-572
40-573
40-574
40-575
40-576
D375A-6R
(01)

Failure codes table
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 respective action code columns are not displayed on the standard
screen even when a failure related to them occurs. The failures are simply recorded in the abnormality
record (electrical equipment system or mechanical equipment system abnormality record) of the service
menu.
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.
D375A-6R
(01)
40-49

Classification and procedures for troubleshooting numbers
40-50
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
No.
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
29
30
31
32
33
34
35
36
37
38
39
Index
Troubleshooting
Reference document
page
Phenomena related to engine

Starting performance is poor
S-1
Engine does not start
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
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
The 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
The blade liftting speed is slow, or the lifting force is not enough.
H-14
Tilting blade speed is slow to be raised or the tilting force is not
H-15
enough.
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
The hydraulic drift of the blade is large.
H-18
40-50
40-678
40-580,40-679,40-696
40-682
40-683
40-684
40-685
40-686
40-687
40-688
40-689
40-690
40-691
40-692
40-693
40-694
40-695
40-584
40-638
40-648
40-650
40-651
40-653
40-654
40-655
40-656
40-657
40-658
40-659
40-660
40-661
40-662
40-663
40-664
40-665
40-666
40-667
D375A-6R
(01)

Troubleshooting
No.
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
Index
Hydraulic drift of tilted blade is large.

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
The fan speed is abnormal (excessive noise from or vibration of fan, or
H-24
overheating).
Phenomena related to machine monitor
When starting switch turned ON, machine monitor displays nothing
E-3
When starting switch is turned to ON position (with engine stopped),
E-4
basic check item (radiator coolant level) lamp lights.
Precaution lights up while engine is running
E-5
Emergency stop item lights up while engine is running
E-6
Engine coolant temperature gauge does not indicate normally
E-7
Fuel gauge does not operate normally
E-8
The power train oil temperature gauge (multi-gauge) does not indicate
E-9
properly.
Hydraulic oil temperature gauge (multi-gauge) does not operate norE-10
mally
Contents of display by machine monitor are different from applicable
E-11
model.
Machine monitor does not display some items
E-12
The function switch does not work.
E-13
Operation mode does not change
E-14
Gear shift mode does not change
E-15
Customize function does not operate normally
E-16
Customize memory function does not operate normally
E-17
Alarm buzzer cannot be stopped
E-18
When starting switch is turned OFF, service meter is not displayed.
E-19
Machine monitor cannot be set in service mode
E-20
The horn does not sound or does not stop sounding.
E-22
The backup alarm does not sound or does not stop sounding
E-23
The fan does not rotate in reverse.
E-24
Headlamp, back-up lamp, and/or ripper point lamp does not light
E-25
Windshield wiper does not operate.
E-26
Window washer does not operate.
E-27
The ORBCOMM terminal does not operate normally (Data are not
E-29
transmitted).
Gear cannot be shifted
E-30
D375A-6R
(01)
Reference document
page
40-668
40-669
40-606,40-670
40-671
40-672
40-673
40-588
40-592
40-594
40-596
40-597
40-598
40-600
40-601
40-602
40-602
40-602
40-603
40-603
40-604
40-604
40-605
40-605
40-605
40-608
40-610
40-612
40-613
40-622
40-630
40-640
40-642
40-51

Information in troubleshooting table
40-52
a Troubleshooting Table and Circuit Diagram Related collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.
Action code
Display on
machine monitor
Failure
description
Action of
machine monitor or controller
Problem on
machine
Related information
Failure code
Display on
machine monitor
Failure
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 trouble or troubleshooting
Cause
Procedure, measuring location, criteria 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>
- 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).
Open circuit in wiring harness
q Check that the failure is fixed after a failure was found and repaired.
(Open circuit in wiring or
<Phenomenon of defective wiring harness>
defective contact in connecq Disconnection in wiring
tor)
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 in wiring harness q Hot short circuit
(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 of connector or others)
Hot short circuit
<Notes on troubleshooting>
(Contact with 24 V circuit)
(1)How to indicate connector number and handle T-branch
For troubleshooting, insert or connect T-branch adapter as shown below 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, disconnectthe
Short circuit in wiring harness
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.
q Connect positive (+) lead to pin No. or wiring harness entered on front side.
q Connect the minus () lead to a pin or harness indicated in the rear.
Defective controller
40-52
D375A-6R
(01)

Related circuit diagram
40-53
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
D375A-6R
(01)
40-53

Troubleshooting method for disconnecting wiring harness of pressure sensor system
Troubleshooting method for disconnecting wiring harness of pressure

40-54
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 open circuit
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".
a "Apparent difference" means a difference of 10 or more times.
40-54
D375A-6R
(01)

List of pressure sensor measuring locations and reference values
Charge pressure
sensor
Ambient pressure
sensor
Measuring location at
sensor pin
Internal resistance of measured

sensor
(Reference value)
R2: Between (1) and (3)
Approx. 2.9k
Approx. 4.3k
Sensor
Approx. 3.2k
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)
q When measuring R2' of charge pressure sensor
(CA123)
Connectors of resistance RES, engine oil pressure sensor, ambient pressure sensor, and G sensor
q When measuring R2' of ambient pressure sensor (CA222)
Connectors of charge pressure sensor, resistance RES, engine oil pressure sensor, and G sensor
D375A-6R
(01)
40-55

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
40-56

(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
D375A-6R
(01)

Connection table for connector pin numbers
40-57
(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.
D375A-6R
(01)
40-57

40-58
D375A-6R
(01)

D375A-6R
(01)
40-59

40-60
D375A-6R
(01)

D375A-6R
(01)
40-61

40-62
D375A-6R
(01)

D375A-6R
(01)
40-63

40-64
D375A-6R
(01)

D375A-6R
(01)
40-65

40-66
D375A-6R
(01)

D375A-6R
(01)
40-67

40-68
D375A-6R
(01)

D375A-6R
(01)
40-69

40-70
D375A-6R
(01)

D375A-6R
(01)
40-71

40-72
D375A-6R
(01)

D375A-6R
(01)
40-73

40-74
D375A-6R
(01)

D375A-6R
(01)
40-75

40-76
D375A-6R
(01)

D375A-6R
(01)
40-77

40-78
D375A-6R
(01)

D375A-6R
(01)
40-79

40-80
D375A-6R
(01)

D375A-6R
(01)
40-81

40-82
D375A-6R
(01)

D375A-6R
(01)
40-83

40-84
D375A-6R
(01)

D375A-6R
(01)
40-85

40-86
D375A-6R
(01)

D375A-6R
(01)
40-87

40-88
D375A-6R
(01)

D375A-6R
(01)
40-89

40-90
D375A-6R
(01)

D375A-6R
(01)
40-91

40-92
D375A-6R
(01)

T-branch box and T-branch adapter table
40-93
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
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
24
24
17
17
5
10
5
17
19
14
5
13
17
21
9
2
3
4
8
MIC-5P
MIC-13P
MIC-17P
MIC-21P
MIC-9P
ECONO2P
ECONO3P
ECONO4P
ECONO8P
ECONO12
P
DLI-8P
DLI-12P
DLI-16P
ECONO12
P
799-601-2810 Adapter for DLI

8
12
16
799-601-2840 Extension cable (ECONO type)
12
D375A-6R
(01)
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
X2P
X3P
X4P
SW6P
SW8P
SW12P
SW14P
SW16P
M2P
M3P
M4P
M6P
M8P
Out of 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
60
1
2
3
4
6
8
12
14
16
1
2
3
4
6
8
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
q q
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
MS-24P
MS-24P
MS-17P
MS-17P
MS-5P
MS-10P
MS-5S
MS-17P
MS-19P
MS-14P
12
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
21
37
37
799-601-2790 Adapter for ECONO
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
Identificati
on 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
40-93

799-601-7140
799-601-7150
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 M
Adapter for S (White)
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
40-94
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
q
q
799-601-9000
799-601-8000
q
q
q
q
799-601-7500
q
q
q
q
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
q
q
q
q
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
S8P
S10P
S12P
S16P
S16PW
S12PW
A8P
A12P
A16P
A20P
-
799-601-2800
8
10
12
16
16
12
8
12
16
20
2
799-601-2700
Identificati
on 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
D375A-6R
(01)

799-601-9440* Socket for engine (CRI-T2)

795-799-5520* Socket for engine (HPI-T2)
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3)
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540*
Socket for engine(CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2)
799-601-4110 Adapter for engine (140-T3) PIM
799-601-4130 Adapter for engine (CRI-T3) NE,CAM
799-601-4140
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL
799-601-4160
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA
799-601-4190*
Common rail pressure
799-601-4230*
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB
799-601-4250* Socket for engine (CRI-T3) PIM
799-601-4330* Socket for engine (CRI-T3) G
799-601-4340*
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380*
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG)
799-601-4390* Socket for controller (95 ENG)
799-601-4280* Box for controller (PUMP)
799-601-9720 Adapter for controller (HST)
799-601-9890 Multi-adapter for DT2 4 andDTM2
q q
FCIB
q q
4160
q q
4180
q q
1,2,3L
q q
1,2,3,4C
q q
3
3
3
1,2,3A
1,2,3B
1,2,3,G
q q
q q
q q
2,PA
q q
1,2,3,4T
4
DTP4
50
DRC50
60
DRC60
60
121
16 HST16A
16 HST16B
26 HST26A
2,
3,
4
Out of kit
FCIG
799-601-4201
799-601-4101
q q
q q
799-601-9300
ITT3N
FCIN
799-601-9200
3
3
3
4
3
799-601-9100
q q
799-601-9000
799-601-8000
799-601-7500
q q
799-601-7400
799-601-7100
799-601-7000
1,2,3
S
799-601-2800
3
2
799-601-2700
Identificati
on 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
"*" Shows not T-adapter but socket.
D375A-6R
(01)
40-95

Connector list and layout

Connector Connector Number
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
800
Plug
810
Plug
12S1
YAZAKI
12S2
YAZAKI
12VS
DT
AC1
MIC
17
AC2
AMP
16
AC3
AMP
12
ACS
DT
ACT
Relay
ADH
SWP
ADH1
Relay
40-96
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
12 V socket 1
12 V socket 2
Intermediate
connector
Air conditioner unit
Air conditioner control
panel
Air conditioner control
panel
Diode
(surge-killer)
ACC cutout
relay
Additional
heater switch
(if equipped)
Additional
power supply
1 relay
40-96
Address
F-1

No.
type
of pins
ADH2
Relay
ADHA
DT
AF1
DT
ALB
Terminal
ALR
Terminal
ASUS
DT
AT11
B105L
Terminal
B105S
Terminal
B30L
Terminal
B30S
Terminal
B7L
Terminal
B7S
Terminal
U-8
BH1L
Terminal
X-9
BH2S
Terminal
U-5
BKA
Relay
U-5
BKAL
DT
BLD
DT
BLU
DT
BRB
Terminal
BRB
Terminal
BRC
Terminal
BRC
Terminal
BRE
Terminal
BRE
Terminal
X-8
X-8
B-7
N-2
N-1
N-1
N-1
N-2
N-2
AB-3
X-9
N-4
N-5
N-5
AH-1
V-6
O-6
W-7
Location
Address
Additional
power supply
2 relay
Intermediate
connector
Air cleaner
clogging
switch
Alternator B
terminal
Alternator R
terminal
Air suspension seat (if
equipped)
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
Backup alarm
Blade
LOWER oil
pressure
switch
Blade RAISE
oil pressure
switch
Battery relay
1
Battery relay
2
Battery relay
1
Battery relay
2
Battery relay
1
Battery relay
2
W-7
U-4
C-1
AG-1
AG-1
U-6
L-5
L-4
K-5
K-4
K-5
J-4
K-5
K-4
U-7
J-8
P-9
P-9
J-2
L-3
K-3
L-3
J-1
L-1
D375A-6R
(01)


No.
type
of pins
BRK
BSW
DT
DT
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
CN-1
CN-10
CN-11
CN-12
CN-12V
CN-12VS
CN-13
CN-14
CN-15
D375A-6R
(01)
Location
Brake potentiometer
Intermediate
connector
(one-way
type model)
(if equipped)
Circuit
breaker (20A)
Circuit
breaker
(105A)
Circuit
breaker (20A)
Circuit
breaker (20A)
Circuit
breaker (30A)
Circuit
breaker (20A)
Circuit
breaker (40A)
(if equipped)
Circuit
breaker (20A)
Circuit
breaker (20A)
Circuit
breaker (30A)
Circuit
breaker
(105A)
Machine
monitor
Machine
monitor
Machine
monitor
Machine
monitor
Machine
monitor
Injector #1
Additional
light (if
equipped)
Radio
Left wiper
switch
Front wiper
switch
12 V power
supply
12 V power
supply
Right wiper
switch
Rear wiper
switch
Rear lamp
switch (if
equipped)
Address

No.
type
of pins
CN-19
DT
CN-2
CN-20
CN-22
CN-23
CN-25
L-4
CN-21
W-6
CN2
CN-17
CN-18
Q-1
CN-26
CN3
DT
CN-3
CN-34
CN4
DT
CN-4
CN5
DT
W-5
W-5
K-4
W-5
W-5
W-5
J-4
K-5
N-6
N-5
CN-5
CN6
DT
CN-6
CN-6_1
CN-6_2
CN-81
A-9
CN-9
CN-AL1
X-9
CN-AL2
A-9
CN-AL3
A-9
CN-AL4
CN-AL5
AF-4
B-9
G-9
A-9
B-9
Location
Right door
wiper motor
Left door
wiper motor
Washer system harness
Injector #2
Rear speaker
(right)
ACC power
supply
Battery power
supply
Cigarette
lighter power
port
Front lamp
switch (if
equipped)
Revolving
warning lamp
(if equipped)
Revolving
warning lamp
switch (if
equipped)
Injector #3
Rear speaker
(right)
Glass heating wire relay
Injector #4
Rear window
wiper motor
Injector #5
Rear speaker
(left)
Injector #6
Rear speaker
(left)
Glass with
heating wire
(machin with
EU spec.)
Glass with
heating wire
(machin with
EU spec.)
Room lamp
Front wiper
motor
Headlamp
(left)
Headlamp
(right)
Headlamp
(left rear)
Headlamp
(right rear)
Back-up lamp
(left)
Address
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
C-9
AI-5
C-8
AI-5
C-8
-
E-9
D-8
-
40-97


No.
type
of pins
CN-AL6
CN-SM1
CONV
DT
5
6
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
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
EHL
Relay
ENBP
DT
40-98

of pins
No.
type
Location
Address
Back-up lamp
(right)
ENG
DRC26-60
60
S-1
EPP
DT
ES2
DT
ESD
DT
EXAF
DT
EXAR
DT
EXHF
DT
EXHR
DT
EXTF
DT
EXTR
DT
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
Converter
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
Intermediate
connector
Electric priming pump
Intermediate
connector
Intermediate
connector
Intermediate
connector
Intermediate
connector
Intermediate
connector
Intermediate
connector
Engine controller
Engine controller
Engine holding relay
Blow-by pressure sensor
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
AJ-2
AI-1
AJ-3
AJ-3
AJ-3
C-7
C-8
C-7
AJ-3
AJ-2
W-7
AI-1
Address
Location
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
1st clutch
ECMV (fill
switch)
2nd clutch
ECMV (fill
switch)
3rd clutch
ECMV (fill
switch)
Intermediate
connector (if
equipped)
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
AJ-2
C-1
E-9
T-2
X-3
V-3
AE-8
AF-9
X-3
V-2
Z-9
Y-8
Y-8
Y-5
AA-7
A-3
J-5
K-7
T-2
AH-1
D375A-6R
(01)


of pins
No.
type
FFT
DT
FGS
DT
FLB
DT
FLC
DT
FLSW
SWP
FLUC
DT
FRB
DT
FRC
DT
FRT
DT
FRTS
Terminal
FRV
DT
FS11
FS12
FS21
FS22
FS31
FS32
FSB
24-31
31
FSTC
DT
FTS
DT
GND
GND01
GND02
GND03
1
1
1
1
D375A-6R
(01)
Location
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 (if
equipped)
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 (if
equipped)
Engine Bkup
speed (G)
sensor
Ground
Ground
Ground
Ground
Address

type
of pins
No.
AD-6
AB-7
Z-9
A-3
V-9
V-9
1
1
GND0A
Terminal
GND0B
Terminal
Terminal
GND11
Terminal
GND2
Terminal
H01
H02
DT
HHP
DT
HLS
DT
DT
HNSW
HRN
DT
-
HT
Terminal
HT/A
Terminal
HT/B
Terminal
HTD
DT
INJ
DT
12
INT
DT
J1939
DT
KEY
DT
DRC26-40A
40
KOM2
KOM3
Y-4
Terminal
Terminal
KOM1
O-7
GND06
GND07
JB1
AB-8
HLS
AD-5
Terminal
HDT
K-6
GND05
GND1
AA-9
LHD
DT
LHDL
DT
V-9
V-9
W-9
W-9
M-8
Y-5
R-1
AJ-4
E-1
N-7
N-7
N-7
Location
Ground
(fender)
Ground (floor)
Ground
Ground
(lamp)
Ground
(fender)
Ground (cab)
Ground
(engine)
Ground (cab)
Additional
heater PW1
Additional
heater PW2
Hydraulic oil
temperature
sensor
Hydraulic oil
pump pressure sensor
Intermediate
connector
(female)
Hydraulic oil
level sensor
(if equipped)
Horn switch
Horn
Preheater
relay
Preheater
relay
Preheater
relay
Diode
(surge-killer)
Intermediate
connector
(Injectors #1 #6)
Intake temperature sensor
Service connector
(engine)
Junction box
Starting
switch
Communication terminal
GPS antenna
Communication terminal
antenna
Intermediate
connector
Left headlamp
Address
H-2
S-1
A-5
A-6
H-2
B-8
AJ-2
B-8
R-8
R-8
AA-7
D-8
E-9
C-2
Q-8
A-3
C-8
E-1
E-1
I-3
AJ-5
B-2
AG-5
AF-4
N-6
P-7
Q-8
Q-8
A-3
A-2
40-99


No.
type
of pins
LHDL1
LHDR
LHDR1
DT
DT
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
NE
FRAMATONE
NSF
Relay
NSW
DT
OBC
DT-A
12
OLV
DT
OPSW
SWP
40-100
Location
Left headlamp (additional
headlamp
model) (if
equipped)
Right headlamp
Right headlamp (additional
headlamp
model) (if
equipped)
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) (if
equipped)
Intermediate
connector
Left working
lamp (70W)
Right working lamp
(70W)
Air conditioner controller (cab
model)
Intermediate
connector
(MMS device
(if equipeed))
Engine Ne
speed sensor
Neutral safety
relay
Parking brake
lever switch
Intermediate
connector
Engine oil
level switch (if
equipped)
Option switch
(if equipped)
Address

No.
type
of pins
OPT
Relay
P03
DT
PAMB
AMP
A-5
PCV1
-
PCV2
SUMITOMO
SUMITOMO
2
2
PFUEL
U-8
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
DT
PLSW
O-1
PLS
O-1
AMP
DT
PLUB
Relay
PM1
Terminal
PNL
24-31
31
POIL
FRAMATONE
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
Location
Address
Engine compartment
lamp relay (if
equipped)
Intermediate
connector
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 (if
equipped)
Emergency
evacuation
system circuit (C/B
model)
Engine oil
pressure sensor
W-7
P-7
AJ-3
AJ-4
AJ-4
AH-5
X-7
AJ-4
AD-6
AD-1
AD-1
AD-7
AD-1
A-6
C-1
I-3
Q-8
U-7
-
AB-3
AI-1
D375A-6R
(01)


No.
type
of pins
POP
Terminal
PPL
DT
PR1
Terminal
PR2
Terminal
PR3
Terminal
PR4
Terminal
PRE
DT
PRT1
DT-A
12
PRT2
DT
PRT3
DT
PT1
DT
PTCN1
DRC26-24A
24
PTCN2
DRC26-40A
40
PTCN3
DRC26-40B
40
PWR
DTHD
RB1
DT
RDG
DT-B
12
RES
DT
RLSW
SWP
RPD
DT
RPNL
RPU
DT
RSD
DT
RTB
DT
D375A-6R
(01)
Location
Pre-lubrication oil pressure switch (if
equipped)
Pin puller
solenoid
valve
Pre-lubrication relay (if
equipped)
equipped)
equipped)
equipped)
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
Address

No.
type
of pins
RTI
DT
RTS
S1T
DT
S2T
DT
S3T
DT
SFT
DT
SFTD
SFTU
SLB
DT
SLC
DT
SLUC
DT
SNC
DT
SOL1
DT
SOL2
DT
SRB
DT
SRC
DT
J-4
SRT
DT
P-8
SRV
DT-A
12
AH-1
I-9
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
Location
Ripper tilt in
oil pressure
switch
Intermediate
connector (if
equipped)
1st clutch
ECMV (solenoid valve)
2nd clutch
3rd clutch
Forward
clutch ECMV
(solenoid
valve)
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)
(if equipped)
Solenoid
valve for
pitching
Dual-tilt system solenoid
valve
Right steering brake
Right steering clutch
Reverse
clutch ECMV
(solenoid
valve)
KOMNET service connector
Address
P-8
R-1
Y-9
Y-7
Y-8
Z-7
R-1
R-1
AD-5
AB-8
Y-4
S-7
D-8
D-8
AD-5
AB-8
Y-8
P-1
40-101


of pins
No.
type
SSA
DT
SSTC
DT
ST/B1
Terminal
ST/B2
Terminal
ST1
DT
ST2
DT
STB
DT
STF
SW
Terminal
SW
Terminal
SX-8
Terminal
TC1
DT
TFUEL
PACKARD
TIM
PACKARD
TIP
DT
TL1
24-31
31
TL2
DT-B
TL3
DT
TL3
DT
TLS
TM1
40-102
DT
DT
Location
Address
Acceleration
sensor (dediE-1
cate SSC
model option)
clutch left
Y-5
Starting motor
AE-6
A
Starting motor
AE-5
B
Starting motor
AG-5
A (top)
Starting motor
AG-5
B (bottom)
Sudden stop
prevention
AC-8
solenoid
valve
Data writing
connector
T-7
(S/T controller)
Battery relay
K-1
1
Battery relay
L-1
2
Ground
F-1
(fender)
Torque converter output
AC-7
speed sensor
Fuel temperaAG-1
ture sensor
Boost temperature senAI-5
sor
Y-6
pressure sensor
Intermediate
M-9,U-5
connector
Intermediate
T-7
connector
Intermediate
T-7
connector
(one-way
type model)
T-7
(if equipped)
Left oil pressure switch
P-9
for tilting
blade
Transmission
outlet shaft
speed sensor
AD-7
(VHMS installation model
only)

No.
type
of pins
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
VDW
BENDIX
Location
Address
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
Right oil pressure switch
for tilting
blade
Intermediate
connector
VHMS controller
VHMS controller
VHMS controller
VHMS controller
VHMS controller
VHMS controller
VHMS controller
Intermediate
connector
Intermediate
connector
Intermediate
connector
VHMS download connector
T-7
Z-7
AA-7
AJ-2
AB-3
K-3
K-3
K-3
P-9
AE-7
U-3
V-2
W-2
X-2
W-2
W-2
X-2
W-2
L-9
K-7
I-3
S-2
D375A-6R
(01)


No.
type
of pins
VED
DT-C
12
VEG
DT-C
12
VF1
DT-B
12
VF2
24-31
31
WECN1 DRC26-24A
24
WECN2 DRC26-40A
40
WECN3 DRC26-40B
40
WELK
DT
WLD
DT
WSFR
YAZAKI
WSLH
YAZAKI
WSRH
YAZAKI
WSRR
YAZAKI
TAJIMI
D375A-6R
(01)
Location
Address
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 (if
equipped)
40-103

40-104
D375A-6R
(01)

D375A-6R
(01)
40-105

40-106
D375A-6R
(01)

D375A-6R
(01)
40-107

40-108
D375A-6R
(01)

D375A-6R
(01)
40-109

Fuse locations table
40-1 0
Connection table of circuit breakers and fuse boxes

40-1 0
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 ON position and an unswitched power supply is a device which supplies power while the starting switch
is in 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)
40-1 0
Mounting location of circuit breakers (5) to (10)
40-1 0
40-110
D375A-6R
(01)

Circuit breakers CB1CB7, CB30, CB105 and CBH1
1
2
3
4
5
6
7
8
9
10
Power breaker
Circuit
Capacity (A)
Destination of power
(Power supply type)
breaker No.
(Main power supply)
105
CB105
Main power supply
(Unswitched power supply)
30
CB30
Unswitched power supply
(Main power supply)
105
CBH1
Preheater relay
Engine controller unswitched power supply
30
CB7
Power supply of electric priming pump timer
CB105
20
CB1
Power train controller
(Main power supply)
Starting switch
20
CB2
Machine monitor (ACC)
(ACC)
20
CB3
Work equipment controller
CB105
20
CB4
Air conditioner
(Main power supply)
20
CB5
Headlamp
CB30
20
CB6
Unswitched 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.
D375A-6R
(01)
40-111

Mounting location of fuse boxes FS11 to FS31
40-1 2
Mounting location of fuse box (Cab top end)
40-1 2
40-112
D375A-6R
(01)

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
Unswitched power supply of VHMS, power train, and work
20
CB30 (Unswitched power
equipment controllers
supply)
20
Unswitched power supply of cab
10
12V converter unswitched 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
D375A-6R
(01)
Fuse capacity
(A)
10
10
15
10
15
20
20
20
CB30 (Unswitched power
10
supply)
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
40-113
Troubleshooting by failurecode
Failure code [1380MW] Lock up clutch: Slip
40-1 4

Action code
Failure code
1380MW
Failure
40-1 4
Lockup clutch slip

(Power train controller system)
When torque converter is locked up, sensed engine speed does not match with sensed torque converter output speed.
Action of controller
None in particular.
Problem on
machine
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.
Detail of failure
Related information
q
Cause
Lockup clutch slip(When system is

Check for cause of lockup clutch slip and damage of machine.
normal)
Defective engine speed sensor

system
Defective torque converter speed

If failure code [DLF1KA] is displayed, carry out troubleshooting for it.
sensor
4 Defective power train controller
40-114
If failure code[CA689] or [CA778] is displayed, carry out troubleshooting for it.
Since failure is in it, troubleshooting cannot be carried out.
D375A-6R
(01)
Failure code [1500L0] Transmission clutch: Abnormal

Action code
Failure code
E03
1500L0
q
Detail of failure
Failure
40-1 5
Transmission clutch: Abnormal

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].
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] and [DXH4KB]
(4)[15SALH] and [15SBLH]
(5) Either of [15SAL1] and [DXH8KY], and either of [15SBL1] and [DXH7KY]
(6) [15SELH] and [15SFLH] and [15SGLH]
(7) Either of [15SEL1] and [DXH4KY], and either of [15SFL1] and [DXH5KY]
(8) Either of [15SEL1] and [DXH4KY], and either of [15SGL1] and [DXH6KY]
(9) Either of [15SFL1] and [DXH5KY], and either of [15SGL1] and [DXH6KY]
Related information
Cause
Limits operation of engine and transmission.
Problem on machine
q
q
The auto shift down function does not start.

Once machine is stopped, engine speed is limited to medium (half) speed.
Once machine is stopped, it can travel only by the minimum gear speed which can operate.
Method of reproducing failure code: Engine start + Run
If another failure code is displayed, carry out troubleshooting for it.

[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]
D375A-6R
(01)
40-115
Failure code [15E0MW] Transmission clutch: Slip

Action code
Failure code
15E0MW
Failure
40-1 6
Transmission clutch slip

Detail of failure
Sensed torque converter output speed does not match with sensed transmission output speed.
None in particular.
Problem on
machine
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
Cause
Transmission clutch slip (When

system is normal)
Defective torque converter speed Check if failure code [DLF1KA] is displayed

sensor
Carry out troubleshooting for it.
Defective transmission speed sen- Check if failure code [DLT3KA], [DLT3KB] is displayed
sor
Carry out troubleshooting for it.
40-116
Check for cause of transmission clutch slip and damage of machine.
Since failure is in it, troubleshooting cannot be carried out.
D375A-6R
(01)
D375A-6R
(01)
40-117
Failure code [15SAL1] Forward clutch: Fill high

Action code
Failure code
E03
15SAL1
Detail of failure
Problem on
machine
q
q
q
q
q
q
q
Related information
q
q
q
q
Failure
40-1 8
Forward clutch fill dwitch signal is ON.

Nevertheless controller does not output command current to transmission F clutch ECMV solenoid
circuit, fill switch signal is ON.
Sets transmission to neutral when operator sets it to reverse position (Prevention of double engagement).
Once machine is stopped, travel is limited to F1.
Automatic gear shifting function does not operate.
State (ON/OFF) of F clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 40906 T/M Fill Sw Input 1)
Method of reproducing failure code: Start engine and set PCCS lever in neutral position.
Remove seat (approx. 50 kg) and seat bottom cover.
First, check 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
1
switch (Internal short circuit)
Ground fault in wiring harness or

defective power train controller
Ground fault in wiring harness


2. Disconnect connector FFT and connect T-adapter to male side.
Between FFT (female) (1) and ground
(Fill switch OFF)
Resistance
Min. 1 Mz

2. Disconnect connector FFT.
3. Start engine.
If failure code [15SAL1] is still displayed, there is ground fault in wiring harness
or power train controller is defective.
(If failure code [15SAL1] is not displayed, F clutch fill switch is defective)
a If cause 2 is not the cause for the trouble, this check is not required.
2. Disconnect connectors PTCN2 and FFT, and connect T-adapter to female
side of either of them.
Between PTCN2 (female) (5) or FFT (female)
Resistance
Min. 1 Mz
(1) and 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 standard values in normal condition.
2. Insert T-adapter into connector PTCN2.
3. Start engine.
a Keep PCCS lever in N position.
Between PTCN2 (5) and ground
Voltage
711 V
1 3 are same as above.

4. While depressing brake pedal, operate PCCS lever (to select gear speed)
and perform troubleshooting.
Between PTCN2 (5) and
F1/F2/F3
Voltage
Max. 1 V
ground
40-118
D375A-6R
(01)
Circuit diagram related to forward clutch ECMV
D375A-6R
(01)
40-1 9
40-119
Failure code [15SALH] Forward clutch: Fill Low

Action code
Failure code
E03
15SALH
Detail of failure
Problem on
machine
q
q
q
q
q
q
q
Related information
q
q
q
q
Failure
Forward clutch fill switch signal is OFF.

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).
Once machine is stopped, travel is limited to R1.
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.
Cause

1.
2.
3.
a
40-120
Defective F clutch ECMV fill

switch (It does not turn ON)
Turn starting switch to OFF position.

Disconnect connector FFT and connect T-adapter to male side.
Start engine.
Keep PCCS lever in N position.
Between FFT (male) (1) and ground
Resistance
Min. 1 Mz

4. While depressing brake pedal, operate PCCS lever (gear speed) and perform troubleshooting.
Between FFT (male) (1) and
F1/F2/F3
Resistance
Max. 1 z
ground
2. Disconnect connectors PTCN2 and FFT, and connect T-adapters to female
2
side of them.
(open circuit or defective contact)
Between PTCN2 (female) (5) and FFT
Resistance
Max. 1 z
(female) (1)
3. Start engine.
40-120
Voltage
711 V

F1/F2/F3
Voltage
Max. 1 V
ground
D375A-6R
(01)
Circuit diagram related to forward clutch ECMV
D375A-6R
(01)
40-121
40-121
Failure code [15SBL1] Reverse clutch: Fill high

Action code
Failure code
E03
15SBL1
Detail of failure
Problem on
machine
q
q
q
q
q
q
q
Related information
q
q
q
q
Failure
40-12
Reverse clutch fill switch signal is ON.

Nevertheless controller does not output command current to transmission R clutch ECMV solenoid
circuit, fill switch signal is turned ON.
Sets transmission to neutral when operator sets it to forward position (Prevention of double engagement).
State (ON/OFF) of R clutch ECMV fill switch signal can be checked with monitoring function.
Cause
Defective R clutch ECMV fill
1



2. Disconnect connector FRT and connect T-adapter to male side.
Between FRT (female) (1) and ground
(Fill switch OFF)
Resistance
Min. 1 Mz

2. Disconnect connector FRT.
3. Start engine.
If failure code [15SBL1] is still displayed, there is ground fault in wiring harness
(If failure code [15SBL1] is not displayed, R clutch fill switch is defective.)
2. Disconnect connectors PTCN2 and FRT and connect T-adapter to female
Between PTCN2 (female) (36) or FRT
Resistance
Min. 1 Mz
(female) (1) and ground
3. Start engine.
Voltage
711 V

R1/R2/R3
Voltage
Max. 1 V
ground
40-122
D375A-6R
(01)
Circuit diagram related to reverse clutch ECMV
D375A-6R
(01)
40-123
40-123
Failure code [15SBLH] Reverse clutch: Fill Low

Action code
Failure code
E03
15SBLH
Detail of failure
Problem on
machine
q
q
q
q
q
q
q
Related information
q
q
q
q
Failure
Reverse clutch fill switch signal is OFF.

Nevertheless controller outputs command current to transmission R clutch ECMV solenoid circuit,
Sets transmission to neutral when operator sets it to reverse position (Prevention of defective engagement).
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.
Cause
1.
2.
3.
a
1
40-124
Defective R clutch ECMV fill


Disconnect connector FRT and connect T-adapter to male side.
Start engine.
Between FRT (male) (1) and ground
Resistance
Min. 1 Mz

Between FRT (male) (1) and
R1/R2/R3
Resistance
Max. 1 z
ground
2. Disconnect connectors PTCN2 and FRT, and connect T-adapters to female
2
side of them.
Between PTCN2 (female) (36) and FRT
Resistance
Max. 1 z
(female) (1)
3. Start engine.
40-124
Voltage
711 V

R1/R2/R3
Voltage
Max. 1 V
ground
D375A-6R
(01)
D375A-6R
(01)
40-125
40-125
Failure code [15SEL1] Speed 1st clutch: Fill high

Action code
Failure code
E03
15SEL1
Detail of failure
Problem on
machine
Speed 1st clutch: fill switch signal is ON.

Nevertheless controller does not output command current to transmission 1st clutch ECMV solenoid circuit, fill switch signal is turned ON.

Once machine is stopped, travel is limited to F1 and R1.
State (ON/OFF) of 1st clutch ECMV fill switch signal can be checked with monitoring function.
q
q
q
Related information
Failure
40-126
q
q
q
q
Cause
Defective 1st clutch ECMV fill
1



2. Disconnect connector F1T and connect T-adapter to male side.
Between F1T (female) (1) and ground
(Fill switch OFF)
Resistance
Min. 1 Mz

2. Disconnect connector F1T.
3. Start engine.
If failure code [15SEL1] is still displayed, there is ground fault in wiring harness
(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
Between PTCN2 (female) (35) or F1T
Resistance
Min. 1 Mz
3. Start engine.
Voltage
711 V
1. 3. are same as above.

F1/R1
Voltage
Max. 1 V
ground
40-126
D375A-6R
(01)
Circuit diagram related to 1st clutch ECMV
D375A-6R
(01)
40-127
40-127
Failure code [15SELH] Speed 1st clutch: Fill Low

Action code
Failure code
E03
15SELH
Detail of failure
Problem on
machine
Nevertheless controller outputs command current to transmission 1st clutch ECMV solenoid circuit,

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.
Remove seat (approx. 50 kg) and cover under seat.
Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train
oil pressure".
q
q
q
q
q
q
Cause

1.
2.
3.
a
Speed 1st clutch fill switch signal is OFF.

Related information
Failure
40-128
Defective 1st clutch ECMV fill


Insert T-adapter into connector PTCN2.
Start engine.
Between F1T (male) (1) and ground
Resistance
Min. 1 Mz

Between F1T (male) (1) and
F1/R1
Resistance
Max. 1 z
ground
2. Disconnect connectors PTCN2 and F1T, and connect T-adapters to female
2
side of them.
Between PTCN2 (female) (35) and F1T
Resistance
Max. 1 z
(female) (1)
3. Start engine.
40-128
Voltage
711 V

F1/R1
Voltage
Max. 1 V
ground
D375A-6R
(01)
D375A-6R
(01)
40-129
40-129
Failure code [15SFL1] Speed 2nd clutch: Fill high

Action code
Failure code
E03
15SFL1
Detail of failure
Problem on
machine
Nevertheless controller does not output command current to transmission 2nd clutch ECMV solenoid circuit, fill switch signal is turned ON.

The condition (ON/OFF) of the 2nd clutch ECMV fill switch signal can be checked with the monitoring function.
Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train
oil pressure".
q
q
q
q
q
q
Cause
2nd clutch oil pressure 1

Related information
Failure
40-130
Defective 2nd clutch ECMV fill

switch (internal short circuit)



(Fill switch OFF)
Resistance
Min. 1 Mz

3. Start engine.
If failure code [15SFL1] is still displayed, there is ground fault in wiring harness
(If failure code [15SFL1] is not displayed, 2nd clutch fill switch is defective)
2. Disconnect connectors PTCN2 and F2T, and connect T-adapter to female
Resistance
Min. 1 Mz
3. Start engine.
Voltage
711 V

F2/R2
Voltage
Max. 1 V
ground
40-130
D375A-6R
(01)
D375A-6R
(01)
40-131
40-131
Failure code [15SFLH] Speed 2nd clutch: Fill Low

Action code
Failure code
E03
15SFLH
Detail of failure
Problem on
machine
Nevertheless controller outputs command current to transmission 2nd clutch ECMV solenoid circuit, fill switch signal is turned OFF.
Restricts operation of engine and transmission.
Once machine is stopped, engine speed is limited to half of full speed.

Once machine stops, travel is restricted to F1 and R1.
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.
q
q
q
q
q
q
Cause

1.
2.
3.
a
2nd clutch oil pressure 2

Related information
Failure
40-132
Defective 2nd clutch ECMV fill


Disconnect connector F2T and connect T-adapter to male side.
Start engine.
Resistance
Min. 1 Mz

F2/R2
Resistance
Max. 1 z
ground
2. Disconnect connectors PTCN2 and F2T and connect T-adapters to female
2
side of them.
Resistance
Max. 1 z
(female) (1)
3. Start engine.
40-132
Voltage
711 V

F2/R2
Voltage
Max. 1 V
ground
D375A-6R
(01)
D375A-6R
(01)
40-13
40-133
Failure code [15SGL1] Speed 3rd clutch: Fill high

Action code
Failure code
E03
15SGL1
Detail of failure
Problem on
machine
3rd clutch oil pressure 1

Nevertheless controller does not output command current to transmission 3rd clutch ECMV solenoid circuit, fill switch signal is turned ON.

Once machine is stopped, travel is restricted to F3 and R3.
Signal (ON/OFF) from 3rd clutch ECMV fill switch can be checked by using monitoring function.
q
q
q
Related information
Failure
40-134
q
q
q
q
Cause
Defective 3rd clutch ECMV fill
1



(Fill switch OFF)
Resistance
Min. 1 Mz

3. Start engine.
If failure code[15SGL1] is still displayed, there is ground fault in wiring harness or power train controller is defective.
(If failure code[15SGL1] is not displayed, 3rd clutch fill switch is defective)
a If cause 2 is not the cause for the failure, this check is not required.
2. Disconnect connectors PTCN2 and F3T, and connect T-adapter to female
Resistance
Min. 1 Mz
q Reference; the followings are criteria in normal condition.
3. Start engine.
Voltage
711 V

F3/R3
Voltage
Max. 1 V
ground
40-134
D375A-6R
(01)
Circuit diagram related to 3rd clutch ECMV
D375A-6R
(01)
40-135
40-135
Failure code [15SGLH] Speed 3rd clutch: Fill Low

Action code
Failure code
E03
15SGLH
Detail of failure
Problem on
machine
Nevertheless controller outputs command current to transmission 3rd clutch ECMV solenoid circuit,

Condition (sending/shutting 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.
q
q
q
q
q
q
Cause

1.
2.
3.
a
3rd clutch oil pressure 2

Related information
Failure
40-136
Defective 3rd clutch ECMV fill

switch (It is not turned ON.)

Disconnect connector F3T and connect T-adapter to male side.
Start engine.
Resistance
Min. 1 Mz

F3/R3
Resistance
Max. 1 z
ground
2. Disconnect connectors PTCN2 and F3T and, connect T-adapters to female
2
side of them.
Resistance
Max. 1 z
(female) (1)
3. Start engine.
40-136
Voltage
7 11 V

F3/R3
Voltage
Max. 1 V
ground
D375A-6R
(01)
D375A-6R
(01)
40-137
40-137
Failure code [15SJL1] L/U: Fill high

Action code
Failure code
E02
15SJL1
Failure
40-138
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.
Problem on
machine
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).
Detail of failure
Related information
q
q
q
Cause

Defective lockup clutch ECMV fill 2. Disconnect connector FLUC, and connect T-adapter to male side.
1
Between FLUC (female) (1) and ground
Resistance
Min. 1 Mz
(Fill switch OFF)


40-138
1.
2.
3.
a

Disconnect connector FLUC.
Start engine.
If failure code [15SJL1] is still displayed, there is ground fault in wiring harness or power train controller is defective.
(If failure code [15SJL1] is not displayed, lockup clutch fill switch is defective)
2. Disconnect connectors PTCN2 and FLUC, and connect T-adapter to female
Between PTCN2 (female) (38) or FLUC
Resistance
Min. 1 Mz
3. Start engine.
Voltage
711 V

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).
R1
Voltage
Max. 1 V
ground
D375A-6R
(01)
Circuit diagram related to lockup clutch ECMV
D375A-6R
(01)
40-139
40-139
Failure code [15SJLH] L/U: Fill low

Action code
Failure code
E02
15SJLH
Failure
40-140
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.
Problem on
machine
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).
Detail of failure
Related information
q
q
q
Cause
1.
2.
3.
4.
Defective lockup clutch ECMV fill 5.
1
a

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 operation.
See Testing and adjusting, "Testing power train oil pressure", 4. Testing
Between FLUC (female) (1) and ground
Resistance
Max. 1 z
(Fill switch: ON)
2. Disconnect connectors PTCN2 and FLUC and connect T-adapters to
2
female side of them.
Between PTCN2 (female) (38) and FLUC
Resistance
Max. 1 z
(female) (1)
If cause is not found by the above checks, power train controller is defective.
q Reference: the followings are standard values in normal condition.
3. Start engine.
40-140
Voltage
711 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
R1
Voltage
Max. 1 V
ground
D375A-6R
(01)
Circuit diagram related to lockup clutch ECMV
D375A-6R
(01)
40-141
40-141
Failure code [1800MW] P/T clutch: Slip

Action code
Failure code
E02
1800MW
Failure
40-142
Power train clutch slip

Detail of failure
When torque converter is locked up, engine speed does not match sensed transmission output.
None in particular.
Engine state (speed) and torque converter state (speed) can be checked with monitoring funtion.
Code 01002: Engine speed, Code 31200: Transmission input speed (Torque converter speed)
Method of reproducing failure code: Engine start + Turn lockup clutch ON + Drive machine.
Problem on
machine
Related information
Cause
1
Power train clutch slip (When the a Clutch slip was detected; check the cause and machine damage state, then
system is normal)
repair the machine.
2 Defective engine rotation sensor

3
Check whether failure codes [CA689] and [CA778] are displayed. If they are
displayed, carry out the troubleshooting.
Defective transmission speed sen- Check whether failure codes [DLT3KA] or [DLT3KB] is displayed. If it is dissor
played, carry out the troubleshooting.
40-142
Since this is internal failure, troubleshooting cannot be performed.
D375A-6R
(01)
D375A-6R
(01)
40-143
Failure code [2201L1] Right clutch: Fill high

Action code
Failure code
E04
2201L1
Detail of failure
Problem on
machine
Right clutch fill switch signal is ON.

Nevertheless controller does not output command current to right steering clutch ECMV solenoid
Restricts operations of engine, transmission, and brake.

Once machine is stopped, it cannot travel any more.
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.
q
q
Related information
Failure
40-14
q
q
q
q
Cause

Defective right steering clutch
2. Disconnect connector FRC and connect T-adapter to male side.
1 ECMV fill switch (Internal short cirBetween FRC (female) (1) and ground
cuit)
Resistance
Min. 1 Mz
(Fill switch OFF)



2. Disconnect connector FRC.
3. Start engine.
If failure code [2201L1] is still displayed, there is ground fault in wiring harness
(If failure code [2201L1] is not displayed, right steering clutch fill switch is
defective.)
2. Disconnect connectors PTCN2 and FRC and connect T-adapter to female
Between PTCN2 (female) (16) or FRC
Resistance
Min. 1 Mz
3. Start engine.
Voltage
7 11 V

4.While depressing brake pedal, operate PCCS lever (steering) and perform
troubleshooting.
Left Max.
Voltage
Max. 1 V
ground
40-144
D375A-6R
(01)
Circuit diagram related to right clutch ECMV
D375A-6R
(01)
40-145
40-145
Failure code [2201LH] Right clutch: Fill low

Action code
Failure code
E04
2201LH
Detail of failure
Problem on
machine
Right steering clutch fill switch signal is OFF.

Nevertheless controller outputs command current to right steering clutch ECMV solenoid circuit, fill
switch signal is turned OFF.

State (ON/OFF) of right steering clutch ECMV fill switch signal can be checked with monitoring
function.
Method of reproducing failure code: Start engine and release parking brake lever and operate
PCCS lever (right steering).
q
q
Related information
Failure
40-146
q
q
q
q
Cause

1 ECMV fill switch (It does not turn
ON)

1.
2.
3.
a

Disconnect connector FRC and connect T-adapter to male side.
Start engine.
Between FRC (male) (1) and ground
Resistance
Min. 1 Mz

troubleshooting.
Between FRC (male) (1) and
Left Max.
Resistance
Max. 1 z
ground
2. Disconnect connectors PTCN2 and FRC, and connect T-adapters to female
2
side of them.
Between PTCN2 (female) (16) and FRC
Resistance
Max. 1 z
(female) (1)
3. Start engine.
40-146
Voltage
7 11 V

troubleshooting.
Left Max.
Voltage
Max. 1 V
ground
D375A-6R
(01)
Circuit diagram related to right clutch ECMV
D375A-6R
(01)
40-147
40-147
Failure code [2202L1] Left clutch: Fill high

Action code
Failure code
E04
2202L1
Detail of failure
Problem on
machine
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.
q
q
q
q
Cause
Speed Left clutch fill switch signal is ON.

Related information
Failure
40-148
Defective left steering ECMV fill




2. Disconnect connector FLC and connect T-adapter to male side.
Between FLC (female) (1) and ground
(Fill switch OFF)
Resistance
Min. 1 Mz

2. Disconnect connector FLC.
3. Start engine.
(If failure code [2202L1] is not displayed, left steering fill switch is defective)
2. Disconnect connectors PTCN2 and FLC, and connect T-adapter to female
Between PTCN2 (female) (26) or FLC
Resistance
Min. 1 Mz
3. Start engine.
Voltage
7 11 V

troubleshooting.
Left Max.
Voltage
Max. 1 V
ground
40-148
D375A-6R
(01)
Circuit diagram related to left clutch ECMV
D375A-6R
(01)
40-149
40-149
Failure code [2202LH] Left clutch: Fill low

Action code
Failure code
E04
2202LH
Detail of failure
Problem on
machine
Nevertheless controller outputs command current to left steering ECMV solenoid circuit, fill switch
signal is turned OFF.

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).
q
q
q
q
Cause

1.
2.
3.
a
Left cluth fill switch is OFF.

Related information
Failure
40-150
Defective left steering ECMV fill


Disconnect connector FLC and connect T-adapter to male side.
Start engine.
Between FLC (male) (1) and ground
Resistance
Min. 1 Mz

troubleshooting.
Between FLC (male) (1) and
Left Max.
Resistance
Max. 1 z
ground
2. Disconnect connectors PTCN2 and FLC and connect T-adapters to female
2
side of them.
Between PTCN2 (female) (26) and FLC
Resistance
Max. 1 z
(female) (1)
3. Start engine.
40-150
Voltage
711 V

troubleshooting.
Left Max.
Voltage
Max. 1 V
ground
D375A-6R
(01)
Circuit diagram related to left clutch ECMV
D375A-6R
(01)
40-151
40-151
Failure code [2300NR] Brake Themal Load Abnormality

Action code
Failure code
2300NR
Detail of failure
Failure
40-152
Brake thermal load abnormality

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.
None in particular.
Problem on
machine
Related information
Cause
1 Improper braking during downhill travel (Machine traveled down a slope with brake pedal pressed)
40-152
When the operation in cause 1 is not performed
D375A-6R
(01)
D375A-6R
(01)
40-153
Failure code [2301L1] Right brake: Fill high

Action code
Failure code
E04
2301L1
Detail of failure
Problem on
machine
Speed right brake fill switch signal is ON.

Nevertheless controller does not output command current to right steering brake ECMV solenoid

State (ON/OFF) of right steering brake ECMV fill switch signal can be checked with monitoring function.
q
q
Related information
Failure
40-154
q
q
q
q
Cause

Defective right steering brake
2. Disconnect connector FRB and connect T-adapter to male side.
1 ECMV fill switch (Internal short cirBetween FRB(female) (1) and ground
cuit)
Resistance
Min. 1 Mz
(Fill switch OFF)



2. Disconnect connector FRB.
3. Start engine.
(If failure code [2301L1] is not displayed, right steering brake fill switch is
defective.)
2. Disconnect connectors PTCN2 and FRB, and connect T-adapter to female
Between PTCN2(female )(37) or FRB
Resistance
Min. 1 Mz
3. Start engine.
4. Release the parking brake.
Voltage
Max. 1 V

5. While depressing the brake and perform troubleshooting.
40-154
Voltage
7 11 V
D375A-6R
(01)
Circuit diagram related to right brake ECMV
D375A-6R
(01)
40-15
40-155
Failure code [2301LH] Right brake: Fill low

Action code
Failure code
E04
2301LH
Detail of failure
Problem on
machine
Right brake fill switch signal is OFF.

Nevertheless controller outputs command current to right steering brake ECMV solenoid circuit, fill

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.
q
q
Related information
Failure
40-156
q
q
q
q
Cause

2. Disconnect connector FRB and connect T-adapter to male side.

ON)
Between FRB (male) (1) and ground
Resistance
Min. 1 Mz

3. Start the engine.
4. Release parking brake and perform troubleshooting.
Between FRB (male) (1) and ground
Resistance
Max. 1 z

2. Disconnect connectors PTCN2 and FRB, and connect T-adapters to female
2
side of them.
Between PTCN2 (female) (37) and FRB
Resistance
Max. 1 z
(female) (1)
3. Start engine.
Voltage
Max. 1 V
40-156
Voltage
7 11 V
D375A-6R
(01)
D375A-6R
(01)
40-157
40-157
Failure code [2301NR] Steering Brake RH Themal Load Abnormality

Action code
Failure code
2301NR
Detail of failure
Failure
40-158
Right steering brake thermal load abnormality

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.
Problem on
machine
Related information
Cause
1 Improper steering during downhill travel (Machine traveled down a slope and was steered to right continuously)
40-158
D375A-6R
(01)
D375A-6R
(01)
40-159
Failure code [2302L1] Left brake: Fill high

Action code
Failure code
E04
2302L1
Detail of failure
Problem on
machine
Left brake fill switch signal is ON.

Nevertheless controller does not output command current to left steering brake clutch ECMV solenoid circuit, fill switch signal is turned ON.

State (ON/OFF) of left steering brake cluth ECMV fill switch signal can be checked with monitoring
function.
q
q
Related information
Failure
40-160
q
q
q
q
Cause

Defective left steering brake clutch 2. Disconnect connector FLB and connect T-adapter to male side.
1 ECMV fill switch (Internal short cirBetween FLB(female) (1) and ground
cuit))
Resistance
Min. 1 Mz
(Fill switch OFF)



2. Disconnect connector FLB.
3. Start engine.
(If failure code [2302L1] is not displayed, left steering brake clutch fill switch is
defective.)
2. Disconnect connectors PTCN2 and FLB and connect T-adapter to female
Between PTCN2(female) (6) or FLB(female)
Resistance
Min. 1 Mz
(1) and ground
3. Start engine.
Voltage
Max. 1 V

40-160
Voltage
7 11 V
D375A-6R
(01)
Circuit diagram related to left brake ECMV
D375A-6R
(01)
40-161
40-161
Failure code [2302LH] Left brake: Fill low

Action code
Failure code
E04
2302LH
Detail of failure
Problem on
machine
Left brake fill switch signal is OFF.

Nevertheless controller outputs command current to left steering brake clutch ECMV solenoid circuit, fill switch signal is turned OFF.

State (ON/OFF) of left steering brake cluth ECMV fill switch signal can be checked with monitoring
function.
Method of reproducing failure code: Engine start and release parking bake lever.
q
q
Related information
Failure
40-162
q
q
q
q
Cause

2. Disconnect connector FLB and connect T-adapter to male side.
Between FLB(male) (1) and ground

Resistance
Defective left steering brake clutch
3. Starting engine
ON)
4. Release the parking brake and carry out troubleshooting.
Between FLB (male) (1) and ground
Resistance
Min. 1 Mz
Max. 1 z

2. Disconnect connectors PTCN2 and FLB, and connect T-adapters to female
2
side of them.
Between PTCN2 (female) (6) and
Resistance
Max. 1 z
FLB(female) (1)
3. Start engine.
Voltage
Max. 1 V
40-162
Voltage
7 11 V
D375A-6R
(01)
D375A-6R
(01)
40-163
40-163
Failure code [2302NR] Steering Brake LH Themal Load Abnormality

Action code
Failure code
2302NR
Detail of failure
Indication of
problem on
machine
Related information
Failure
40-164
Left steering brake thermal load abnormality

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)
40-164
D375A-6R
(01)
D375A-6R
(01)
40-165
Failure code [7RFAKA] ECM ACC CUT RELAY: Disconnection

Action code
Failure code
7RFAKA
Detail of failure
Problem on
machine
Open circuit in engine controller ACC cut relay

(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
Failure
40-16
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 open or short
Between ACT (male) (1) and (2)
Resistance
200 400 z
circuit)
2. Disconnect connectors WECN2 and KEY, and connect T-adapters to female side of
them.
Open or short circuit in
2
a If resistance is 1 Mz or above, wiring harness has disconnection. If resistance is 1 z or
wiring harness
below, wiring harness has short circuit.
Between KEY (female) (1) and WECN2 (female) (8)
Resistance
200 400 z
2. Disconnect connectors WECN2, ACT and KEY, and connect T-adapters to female side
of them.
Open circuit in wiring

harness
3
(open circuit or defecBetween WECN2 (female) (8) and ACT (female) (2)
tive contact)
Between KEY (female) (1) and ACT (female) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z

Ground fault in 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
Resistance
Min. 1 Mz
circuit)
ground
If cause is not found by the above checks, work equipment controller is defective.
Defective work equip- 1. Turn starting switch to OFF position.
5
2. Insert T-adapter into connector WECN2.
ment controller
3. Turn starting switch to ON position.
Between WECN2 (8) and ground
40-166
Voltage
Max. 1 V
D375A-6R
(01)
Circuit diagram related to engine controller shut down
D375A-6R
(01)
40-167
40-167
Failure code [7RFAKB] ECM ACC CUT RELAY: Short circuit

Action code
Failure code
7RFAKB
Failure
40-168
Engine controller ACC cut relay disconnection

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.
Problem on
machine
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 starting switch to ON position.
This failure code detects failure on primary side (coil side) of engine controller ACC cut relay, but
Detail of failure
Related information
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 open or short
Between ACT (male) (1) and (2)
Resistance
200 400 z
circuit)
2. Disconnect connectors WECN2 and KEY and connect T-adapters to female side of
them.
2
a If resistance is above 1 Mz, wiring harness has disconnection. If resistance is below
wiring harness
1 z, wiring harness has short circuit.
Resistance
200 400 z

Hot short circuit in wir- 2. Disconnect connectors WECN2 and ACT, and connect T-adapter to female side of
ing harness
WECN2.
3
(Contact with 24 V cir- 3. Turn starting switch to ON position.
cuit)
Between WECN2 (female) (8) and ground
Voltage
Max. 1 V
Reference: the followings are criteria in normal condition.
Defective work equip4
ment controller
q
40-168
Voltage
Max. 1 V
D375A-6R
(01)
Circuit diagram related to engine controller shut down
D375A-6R
(01)
40-169
40-169
Failure code [AA10NX] Air Cleaner Clogging

Action code
Failure code
AA10NX
Detail of failure
Problem on
machine
Related information
Failure

(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
1
40-170

(When system is normal)

Air cleaner may be clogged. Check it for clogging and then clean or replace if
clogged.

2. Disconnect connector AF1 and connect T-adapter to male side.
3. Start engine.
When air
Defective air cleaner clogging
2
cleaner is norResistance
Max. 1 z
switch (Internal disconnection)
Between AF1 (male) (1) and
mal *1
When air
(2)
cleaner is
Resistance
Min. 1 Mz
clogged *2
2. Disconnect connectors CM01, CM02 and AF1, and connect T-adapters to
3 (Open circuit in wiring or defective Between CM02 (female) (4) and AF1 (female)
Resistance
Max. 1 z
contact in connector)
(1)
Between CM01 (female) (7) and AF1 (female)
Resistance
Max. 1 z
(2)
2. Insert T-adapters into connectors CM01 and CM02.
3. Start engine.
When air
cleaner is norVoltage
Max. 1 V
Between CM02 (4) and
mal
CM01 (7)
Air cleaner is
Voltage
7 11 V
clogged
Air cleaner suction resistance

*1: Max. -3,430 Pa {-350 mmH2O}
*2: -7,470 490 Pa {-762 50 mmH2O}
40-170
D375A-6R
(01)
Circuit diagram related to air cleaner
D375A-6R
(01)
40-171
40-171
Failure code [AB00MA] Battery Charge Abnormal
Failure code [AB00MA] Battery Charge Abnormal

Action code
Failure code
AB00MA
Failure
40-172
Battery Charge Abnormal

While engine was running, voltage from alternator lowered, and machine monitor detected that battery charge voltage was low.
Displays charge level monitor red on machine monitor.
Problem on
machine
If machine is used as it is, battery may not be charged.
Battery voltage can be checked with monitoring function.

(Code: 04300 Charge voltage)
Detail of failure
Related information
Cause
Defective charge by alternator

It is suspected that malfunction of battery charge is occurring at present or

occurred in past. Investigate cause and damage condition, and correct it.
Defective charge level monitor

system
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.
40-172
D375A-6R
(01)
Failure code [B@BAZG] Eng Oil Press Low

Action code
Failure code
B@BAZG
Failure
40-173
Eng Oil Press Low

(Engine controller system)
While engine was running, signal voltage from engine oil pressure sensor dropped, and engine
controller detected engine oil pressure too low.
Displays engine oil pressure monitor red on machine monitor.
Problem on
machine
If machine is used as it is, engine may be seized.
Engine oil pressure sensor signal is input to engine controller and then transmitted to machine monitor through communication system.
Engine oil pressure can be checked with monitoring function.
(Code: 37200 Engine Oil Pressure Sensor)
Detail of failure
Related information
q
q
Cause
Lowering of engine oil pressure

If cause 1 is not the cause for the trouble, engine oil pressure sensor system
Defective engine oil pressure caumay be defective. Perform troubleshooting for failure codes [CA135] and
tion lamp circuit
[CA141].
D375A-6R
(01)
Engine oil pressure may be low. Check it and remove cause if it is low.
40-173
Failure code [B@BAZK] Eng Oil Level Low

Action code
Failure code
B@BAZK
Detail of failure
Problem on
machine
Related information
Failure
Eng oil level low

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).
Displays radiator coolant level monitor red on machine monitor.
Method of reproducing failure code:Start engine
Cause
1
40-174
Engine oil level low

Defective engine oil level sensor
(Internal defect)

Check engine oil level. If it is low, remove cause.
2. Disconnect connector OLV.
Between OLV (male) (1) and ground
Resistance
Max. 1 z

Disconnection in wiring harness
2. Disconnect connector CM02 and connect T-adapter to female side.
3 (Open circuit in wiring or defective
Between CM02 (female) (2) and OLV(female)
Resistance
Max. 1 z
(1)
If cause is not found by above checks, machine monitor is defective.
q Reference: the followings are criteria in normal condition.
4 Defective machine monitor
2. Insert T-adapter into connector CM02.
Between CM02 (female) (2) and ground
Circuit diagram related to engine oil level
40-174
Voltage
Max. 1 V
40-174
D375A-6R
(01)
Failure code [B@BCNS] Eng Water Overheat

Action code
Failure code
B@BCNS
Failure
40-175
Eng Coolant Overheat

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.
Problem on
machine
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 Engine coolant temperature)
Detail of failure
Related information
q
q
Cause
Overheated engine coolant (when

Check engine coolant for overheating. If it is overheated, remove cause.
system is normal)
Defective engine coolant tempera- If cause 1 is not detected, engine coolant temperature sensor may be defecture sensor system
tive. Perform troubleshooting for failure codes [CA144] and [CA145].
D375A-6R
(01)
40-175
Failure code [B@BCZK] Eng Water Level Low

Action code
Failure code
B@BCZK
Failure
40-176
Eng coolant level low

While starting switch was ON (and engine was stopped) or engine was running, radiator coolant
level switch signal was not 1 V or less, machine monitor detected that radiator coolant level was
low (sensor contact was open).
Displays radiator coolant level monitor red on machine monitor.
If machine is used as it is, engine may be overheated.
Detail of failure
Problem on
machine
Related information
Cause
Coolant level low

Check radiator sub tank for lowering of coolant level. If coolant level is low, add
coolant.
Defective radiator coolant level

monitor system
If cause 1 is not detected, radiator coolant level monitor may be defective.

Carry out "E-4 Caution item lights up while starting switch is ON (and engine is
stopped)" in E mode.
40-176
D375A-6R
(01)
Failure code [B@CENS] T/C Oil Overheat

Action code
Failure code
B@CENS
Failure
40-17
Torque converter overheating

While engine was running, voltage from torque converter oil temperature sensor dropped, and power train controller detected that power train oil was overheated.
Displays power train oil temperature monitor red on machine monitor.
Problem on
machine
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)
Detail of failure
Related information
q
q
Cause
Overheating of torque converter

oil (When system is normal)
Torque converter oil may be overheated. If it is overheated, remove cause.
Defective torque converter oil

temperature sensor system
If cause 1 is not detected, torque converter oil temperature sensor system may
be defective. Perform troubleshooting for failure code [DGT1KA] or [DGT1KX]
.
D375A-6R
(01)
40-177
Failure code [B@HANS] Hyd Oil Overheat

Action code
Failure code
B@HANS
Failure
40-178
Hydraulic Oil overheating

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.
Problem on
machine
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)
Method of reproducing failure code:Start engine
Detail fo failure
Related information
q
q
Cause
1
Hyd Oil Overheat

Defective hydraulic oil temperature gauge system
40-178

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 be defective. Perform troubleshooting for failure code [DGS1KX] or
"E-10 Hydraulic oil temperature gauge (Multi-gauge) does not display normally" in E-mode.
D375A-6R
(01)
Failure code [B@HAZK] Hyd Oil Level Low

Action code
Failure code
B@HAZK
Failure
40-179
Hyd Oil Level Low

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.
Problem on
machine
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
Related information
q
q
Cause
1
Hydraulic oil level low (during norHydraulic oil may be low. Check it and add oil if necessary.
mal system operation)

Defective hydraulic oil level switch 2. Disconnect connector HLS and connect T-adapter to male side.
2
(internal failure)
Between HLS (male) (1) and (2)
Resistance
Max. 1 z

2. Disconnect connectors WECN1 and WECN2, and connect T-adapters to
Between WECN2 (female) (28) and WECN1
Resistance
Max. 1 z
(female) (4)
If cause is not found by above checks, work equipment controller is defective.
Defective work equipment control- 1. Turn starting switch to OFF position.
4
2. Insert T-adapter into connectors WECN1 and WECN2
ler
Between WECN2 (28) and WECN1 (4)
Circuit diagram related to hydraulic oil level switch
D375A-6R
(01)
Voltage
Max. 1 V
40-179
40-179
Failure code [CA111] ECM Critical Internal Failure

Action code
Failure code
E03
CA111
Failure
40-180
Abnormality in engine controller

Detail of failure
Trouble occurred in engine controller.
None in particular.
Problem on
machine
Engine continues running, but it may stop during operations or may not restart once it is in stopped.
Power supply voltage of engine controller can be checked with moniitoring funtion.
(Code: 03203 Battery voltage)
Method of reproducing failure code: Turn starting switch to ON position
Related information
Cause
1 Loose or corroded battery terminal Battery cable terminal may be loose or corroded. Check it directly.
2
Loosened terminal or partial disconnection at terminal
Check terminals of alternator, battery relay, ground (GND11) etc. for looseness.
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec3
in "Checks before troubleshooting" of "General information on troubleshoottor
ing", and check them directly.
1. Turn starting switch to OFF position, then carry out troubleshooting.
2. Perform troubleshooting when engine is cranked.
4 Improper battery voltage
Between battery terminal
Voltage
20 30 V
(+) and (-).
5 Defective alternator
6 Defective engine controller
40-180

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 30.5 V
ground
If no abnormality is found by above checks, engine controller is defective.
(Since failure is in it, 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
Voltage
20 30 V
(1)
Voltage
20 30 V
(2)
D375A-6R
(01)
Circuit diagram related to engine controller power supply
D375A-6R
(01)
40-181
40-181
Failure code [CA115] Eng Ne and Bkup Speed Sens Error

Action code
Failure code
E03
CA115
Failure
40-182
Abnormality in engine Ne/Bkup speed sensor

Detail of failure
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.)
Problem on
machine
Related information
Cause
1 Defective Ne speed sensor system
Carry out troubleshooting for failure code [CA689].
2 Defective Bkup speed sensor system
Carry out troubleshooting for failure code [CA778].
If cause is not found by above checks,, engine controller may be

defective. (Since failure is in it, troubleshooting cannot be performed.)
40-182
D375A-6R
(01)
D375A-6R
(01)
40-183
Failure code [CA122] Chg Air Press Sensor High Error

Action code
Failure code
E03
CA122
Failure
40-184
Charge pressure sensor too high

Detail of failure
High voltage occurred in charge pressure sensor (boost pressure sensor) signal circuit.
Takes it that boost pressure is at fixed value (400 kPa {4.1 kg/cm2}), and allows engine to run.
Problem on
machine
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)).
If sensor connector is disconnected, code [CA123] for "Low Error" is displayed, even in normal condition.
Related information
q
q
q
Cause

Defective sensor power supply
If failure code [CA187] or [CA227] is displayed at the same time, carry out
2
system
troubleshooting for that first.
2. Disconnect connector PIM.
Defective charge pressure (boost 3. Turn starting switch to ON position.
3
pressure) sensor
If failure code changes from [CA122] to [CA123], charge pressure (boost pressure) sensor is defective.
2. Disconnect connectors ENG and PIM, and connect T-adapter to female
side of ENG.
4 Short circuit in wiring harness
Between ENG (female)
Resistance
Min. 1 Mz
(37) - (44)
2. Disconnect connector PIM, and insert T-adapter into connector ENG.
Hot short circuit in wiring harness
5
3. Turn starting switch to ON position (with connector PIM disconnected).
(Short circuit with 24 V circuit)
Between ENG (44) and
Voltage
Max. 1V
(47)
40-184
D375A-6R
(01)
Circuit diagram related to charge pressure sensor
D375A-6R
(01)
40-185
40-185
Failure code [CA123] Chg Air Press Sensor Low Error

Action code
Failure code
E03
CA123
Failure
40-186
Charge pressure sensor too low

Detail of failure
Low voltage occurred in charge pressure sensor (boost pressure sensor) signal circuit.
Takes it that boost pressure is at fixed value (400 kPa {4.1 kg/cm2}), and allows engine to run.
Problem on
machine
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)).
Because troubleshooting "socket" for this sensor features female connector alone, it is not usable
for checking open circuit in wiring harness and voltage at sensor connector (not designed as a
T-adapter).
If sensor connector is disconnected, this code is displayed.
Related information
q
q
Cause

Defective wiring harness connecin "Checks before troubleshooting" of "General information on troubleshoottor
Defective power supply system of
If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
2 charge pressure sensor (boost
for it first.
pressure sensor)
2. Disconnect connectors ENG and PIM.
3. Connect T-adapter to female side of ENG.
Resistance
Min. 1 Mz
(44) and (47)
2. Disconnect connectors ENG and PIM, and connect T-adapter to female
side of ENG.
4
Resistance
Min. 1 Mz
(44) and ground
If cause is not found by the above checks, there may be open circuit in wiring
5 Open circuit in wiring harness
harness. (*)
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 (boost 2. Connect T-adapter to connector ENG.
pressure) sensor
6
(Improper input voltage to engine Between
ENG
controller)
Sensor out(female)
Voltage
0.3 4.7 V
put
(44) and
(47)
1
*: See "Troubleshooting method for disconnected wiring harness of pressure sensor system" of "Related troubleshooting information".
40-186
D375A-6R
(01)
Circuit diagram related to charge pressure sensor
D375A-6R
(01)
40-187
40-187
Failure code [CA131] Throttle Sensor High Error

Action code
Failure code
E03
CA131
Failure
40-18
Throttle sensor too high

Detail of failure
High voltage occurred in decelerator pedal potentiometer signal circuit.
Operate the decelerator pedal at a fixed value.
Problem on
machine
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).
Related information
q
q
Cause

Defective throttle sensor power
2
If failure code [CA2185] is displayed, troubleshoot it first.
supply system
2. Disconnect connector DEC and connect T-adapter to male side.
Defective decelerator pedal (throt- Between DEC (male) (B) and (C)
tle 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 wiring harBetween EGC2 (female) (22) and (23)
ness
Between EGC2 (female) (9) and (23)
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-adapter to female
Between EGC2 (female) (9) and (22), or
Resistance
Min. 1 Mz
between DEC (female) (A) and (B)

Hot short circuit in wiring harness 2. Disconnect connector DEC and connect T-adapter to female side.
6
Between DEC (female) (B) and ground
Voltage
Max. 1 V
40-188
If no abnormality is found by the above checks, the engine controller is defective. (Since the faliure is in it, troubleshooting cannot be performed.)
4. Operate decelerator pedal, and troubleshoot.
Between
EGC2 (22)
Power supply
Voltage
4.75 5.25 V
and (23)
Between
Depress decelerator pedal.
Voltage
Approx. 4.7 V
EGC2 (9)
Release decelerator pedal.
Voltage
Approx. 0.4 V
and (23)
D375A-6R
(01)
Circuit diagram related to decelerator pedal
D375A-6R
(01)
40-189
40-189
Failure code [CA132] Throttle Sensor Low Error

Action code
Failure code
E03
CA132
Failure
40-190
Throttle sensor too low

Detail of failure
Decelerator potentiometer signal circuit of throttle sensor detected abnormally low voltage.
Problem on
machine
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).
Related information
q
q
Cause

Defective throttle sensor power
2
If failure code [CA2186] is also indicated, perform troubleshooting for it first.
supply system
2. Disconnect connector DEC and connect T-adapter to male side.
Defective decelerator pedal (throt- Between DEC (male) (B) and (C)
tle 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 wiring harBetween EGC2 (female) (22) and (23)
ness
Resistance
4.06.0 kz
Resistance
0.25.0 kz

2. Disconnect connector EGC2 and DEC and connect T-adapter to each
female side.
Between EGC2 (female) (22) and DEC
Resistance
Max. 1 z
(female) (A)
Resistance
Max. 1 z
(female) (B)
Resistance
Max. 1 z
(female) (C)
Between EGC2 (female) (9) and (23), or
Resistance
Min. 1 Mz
between DEC (female) (B) and (C)
7
Between EGC2 (female) (9) or DEC (female)
Resistance
Min. 1 Mz
(B) and ground
40-190
D375A-6R
(01)
Cause

If no abnormality is found by above checks, engine controller is defective. (Since failure is in it, troubleshooting cannot be performed.)
4. Operate decelerator pedal, and troubleshoot.
Power supply
Voltage
4.75 5.25 V
(23)
Depress decelerator
Voltage
Approx. 4.7 V
pedal.
Between EGC2 (9) and (23)
Release decelerator
Voltage
Approx. 0.4 V
pedal.
D375A-6R
(01)
40-191
40-191
Failure code [CA135] Eng Oil Press Sensor High Error

Action code
Failure code
E02
CA135
Failure
40-192
Eng Oil Press Sensor High Error

Detail of failure
High voltage was detected in engine oil pressure sensor signal circuit.
Takes it that engine oil pressure is default (250 kPa {2.5 kg/cm2}), and allows engine to run.
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)).
Problem on
machine
Related information
q
q
Cause

Defective power supply system of If failure code [CA187] or [CA227] indicated, carry out troubleshooting for
2
engine oil pressure sensor
itfirst.

Defective engine oil pressure sen- 2. Disconnect connector POIL.
3
sor
If failure code changes from [CA135] to [CA141],sensor is defective.
2. Disconnect connectors ENG and POIL, and connect T-adapter to female
side of either one of them.
Between ENG (female) (13) and (37), or
Resistance
Min. 1 Mz
between POIL (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.
5
4. Turn starting switch to ON position (with connector POIL disconnected).
Voltage
Max. 1 V
40-192

D375A-6R
(01)
Circuit diagram related to engine oil pressure sensor
D375A-6R
(01)
40-193
40-193
Failure code [CA141] Eng Oil Press Sensor Low Error

Action code
Failure code
E02
CA141
Failure
40-194
Eng Oil Press Sensor Low Error

Detail of failure
Low voltage was detected in engine oil pressure sensor signal circuit.
Takes it that engine oil pressure is default (250 kPa {2.5 kg/cm2}), and allows engine to run.
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)).
Problem on
machine
Related information
q
q
Cause
1

for it first.
Defective power supply system of 2. Disconnect connector POIL and connect T-adapter to each female side of
engine oil pressure sensor
them.
Between POIL(female)(1)
Power supply
Voltage
4.75 5.25 V
and (2)
input
2. Disconnect connectors ENG and POIL and connect T-adapter to female
side.
a If power supply 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)
(Open circuit in wiring or defective
a If power supply input in checks on cause
2 is normal, this check is not required.
Resistance
Max. 1 z
(female) (2)
Resistance
Max. 1 z
(female) (3) (Sensor output)
Between ENG (female) (13) or POIL (female)
Resistance
Min. 1 Mz
(3) and ground
Resistance
Min. 1 Mz
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 engine oil pressure sen1. Turn starting switch to OFF position.
sor (Improper input voltage to
2. Insert T-adapter into connector ENG.
engine controller)
Between ENG (13) and (47) Sensor output
Voltage
0.3 4.7 V
40-194

D375A-6R
(01)
Circuit diagram related to engine oil pressure sensor
D375A-6R
(01)
40-195
40-195
Failure code [CA144] Coolant Temp Sens High Error

Action code
Failure code
E02
CA144
Failure
40-196
Coolant Temp Sens High Error

Detail of failure
High voltage was detected in engine coolant temperature sensor signal circuit.
Sets coolant temperature to fixed 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 by using monitoring
function. (Code: 04107 (C))
This failure code is displayed if temperature sensor connector is disconnected.
Because troubleshooting "socket" for this sensor features female connector alone, it is not connectable to female connector of sensor wiring harness, and thus not usable for checking open circuit
(not designed as a T-adapter).
Problem on
machine
q
q
q
Related information
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 temperature
2
and (B)
50 C
Resistance
3.2 3.8 kz
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 wiring har- Between ENG (female) (15) and (38) (Cool3
ant temperature: Min. 0 C)
ness
a Use coolant temperature -Resistance Resistance
700 z 37 kz
characteristics table shown above as resistance criteria.
40-196
D375A-6R
(01)
Circuit diagram related to coolant temperature sensor
D375A-6R
(01)
40-197
40-197
Failure code [CA145] Coolant Temp Sens Low Error

Action code
Failure code
E02
CA145
Failure
40-198
Coolant Temp Sens Low Error

Detail of failure
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 by using monitoring
function. (Code: 04107 ( C))
If temperature sensor connector is disconnected, this failure code is not displayed but failure code
[CA144] for "High Error" is displayed.
Problem on
machine
q
q
Related information
q
q
q
Cause
1

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)
and (B)
50 C
Resistance
3.2 3.8 kz
a Coolant
sensor
80 C
Resistance
1.0 1.3 kz
temperature
-Resistaure
95 C
Resistance
700 800 z
characteristics
Between
All coolant tem(B) and
Resistance
Min. 1 Mz
perature range
ground
Between ENG (female) (15) and (38) (CoolShort circuit in wiring harness
ant temperature: Min. 0 C)
a Use coolant temperature -Resistance Resistance
700 z 37 kz
characteristics table shown above as resistance criteria.
2. Disconnect connectors ENG and TWTR, and connect T-adapter to female
side of ENG.
Between ENG (female) (15) and ground
Resistance
Min. 1 Mz
40-198

D375A-6R
(01)
Circuit diagram related to coolant temperature sensor
D375A-6R
(01)
40-19
40-199
Failure code [CA153] Chg Air Temp Sensor High Error

Action code
Failure code
E01
CA153
Failure
40-20
Charge (Boost) temperature sensor signal voltage is too high.

Detail of failure
High voltage was detected in charge (boost) temperature sensor signal circuit.
Set charge temperature to fixed temperature (70 C) ,and allow for operation.
Problem on
machine
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
by using monitoring function. (Code: 18500 ( C))
Related information
q
q
Cause

2. Disconnect connector TIM and connect socket to male side of connector.
a If temperature sensor has resistance of 280 z 382 kz, regard charge temperature sensor as normal.
Between
Resistance
-40 C
291 382 kz
TIM (male)
Resistance
-20 C
85 109 kz
(A) and (B)
Defective charge temperature
2
a Charge
Resistance
0 C
29 36 kz
sensor
temperResistance
30 C
7.3 8.8 kz
ature
-ResisResistance
60 C
2.3 2.7 kz
tance
Resistance
90 C
860 970 z
chariacterisResistance
130 C
280 320 z
tic
Open or short circuit in wiring har- Between ENG (female) (23) and (47)
3
ness
a Use "charge temperature-Resistance
280 z
Resistance
characteristics" table shown above as re382 kz
sistance criteria.
1
40-200
D375A-6R
(01)
Circuit diagram related to charge temperature sensor
D375A-6R
(01)
40-201
40-201
Failure code [CA154] Chg Air Temp Sensor Low Error

Action code
Failure code
E01
CA154
Failure
40-202
Charge (Boost) temperature sensor signal volatge too low

Detail of failure
Low voltage was detected in charge (boost) temperature sensor signal circuit.
Set charge temperature to fixed temperature (70 C) ,and allow for operation.
Problem on
machine
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
by using monitoring function. (Code: 18500 ( C))
Related information
q
q
q
Cause
1

2. Disconnect connector TIM and connect socket to male side of connector.
a If temperature sensor has resistance of 280 z - 382 kz, regard charge temperature sensor as normal.
Between
-40 C
Resistance
291 382 kz
TIM (male)
-20 C
Resistance
85 109 kz
(A) and (B)
Defective charge temperature
a Charge
0 C
Resistance
29 36 kz
sensor
temper30 C
Resistance
7.3 8.8 kz
ature
-Resis60 C
Resistance
2.3 2.7 kz
tance
90 C
Resistance
860 970 z
chariacteris130 C
Resistance
280 320 z
tic
Between ENG (female) (23) and (47)
a Use "charge temperature-Resistance
280 z
Resistance
characteristics" table shown above as re382 kz
sistance criteria.
2. Disconnect connectors ENG and TIM and connect T-adapter to female side
of ENG.
Resistance
Min. 1 Mz
40-202

D375A-6R
(01)
Circuit diagram related to charge temperature sensor
D375A-6R
(01)
40-203
40-203
Failure code [CA187] Sens Supply 2 Volt Low Error

Action code
Failure code
E03
CA187
Detail of failure
Failure
40-204

Low voltage appears in sensor power supply 2 (5 V) circuit.
Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor signals.
Ignores signals from engine oil pressure sensor, takes it that engine oil pressure is default value
(250 kPa {2.5 kg/cm2}), and allows engine to run.
Ignores signals from ambient pressure sensor, takes it that ambient pressure is default value (52.44
kPa {0.53 kg/cm2}), and allows engine to run.
Ignores signals from boost pressure sensor, takes it that boost pressure is at fixed value (400 kPa
{4.1 kg/cm2}), and allows engine to run.
q
q
Problem on
machine
Related information
Engine output drops.
Cause
1

2. Disconnect following connectors sequentially one by one and turn starting
switch to ON position each time.
3. After troubleshooting, return to 1.
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].
G connector
POIL connector
Charge (boost) pressure

sensor
PIM connector
PAMB connector
Engine harness
Connector
Oil pressure sensor
3 Defect in related system
Sensor, harness
Bkup speed sensor
2 Defective sensor or wiring harness
ENG
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)
40-204
Voltage
4.75 5.25 V
D375A-6R
(01)
Circuit diagram related to sensor power supply 2
D375A-6R
(01)
40-205
40-205
Failure code [CA212] Eng Oil Temp Sensor High Error

Action code
Failure code
E01
CA212
Failure
40-206

Detail of failure
High voltage was detected 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)).
Problem on
machine
Related information
q
q
q
Cause
1

2. Disconnect connectors TOIL and connect socket to male side of connector.
a If oil temperature sensor resistance is 700 z - 37 kz with oil temperature is
above0 C, regard oil temperature sensor as normal.
0 C
Between TOIL (male)
(A) and (B)
a Oil temperature -Resistance characteristics
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
2 Defective oil temperature sensor
Resistance
700 800 z

Open or short circuit in wiring har- Between ENG (female) (17) and (47) (Oil temper3
ness
ature: Min. 0 C)
Resistance 700 z 37 kz
a UseOil temperature -Resistance charactenis
table shown above as resistance criteria.
40-206
D375A-6R
(01)
Circuit diagram related to engine oil temperature sensor
D375A-6R
(01)
40-207
40-207
Failure code [CA213] Eng Oil Temp Sensor Low Error

Action code
Failure code
E01
CA213
Failure
40-208

Detail of failure
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)).
Problem on
machine
Related information
q
q
q
Cause

2. Disconnect connectors TOIL and connect socket to male side of connector.
a If oil temperature sensor resistance is 700 z 37 kz with oil temperature is
above 0 C, regard oil temperature sensor as normal.
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
2 Defective oil temperature sensor
Between TOIL (male) (A)

and (B)
a Oil temperature -Resistance characteristics
Resistance
700 800 z
All oil temperature Resistance

Min. 1 Mz
range
Between ENG (female) (17) and (47) (Oil temperature: Min. 0 C)
Resis700 z
a UseOil temperature -Resistance charactenis tance
37 kz
table shown above as resistance criteria.
2. Disconnect connectors ENG and TOIL, and connect T-adapter to female
side of ENG.
ResisBetween ENG (female) (17) and ground
Min. 1 Mz
tance
Between (B) and ground

40-208
D375A-6R
(01)
Circuit diagram related to engine oil temperature sensor
D375A-6R
(01)
40-209
40-209
Failure code [CA221] Ambient Press Sens High Error

Action code
Failure code
E03
CA221
Failure
40-210
Ambient Press Sens High Error

Detail of failure
High voltage was detected in ambient pressure sensor signal circuit .
Takes it that ambient pressure value is default value (52.44 kPa {0.53 kg/cm2}), and allows engine
to run.
Signal voltage from ambient pressure sensor can be checked with monitoring function (Code:
37401 (V)).
Ambient pressure sensed by the ambient pressure sensor can be checked with monitoring function
(Code: 37400 (kPa)).
Problem on
machine
Related information
q
q
Cause

Defective power supply line of
2
ambient pressure sensor
for it first.
1
Defective ambient pressure sen3

sor

2. Disconnect connector PAMB.
If failure code changes from [CA221] to [CA222] ,sensor is defective.

2. Disconnect connector ENG and PAMB, and connect T-adapter to female
side of ENG.
1.
2.
Hot short circuit in wiring harness 3.
5
4.
Between ENG (3) and (38)

40-210
Resistance
Min. 1 Mz

Disconnect connector PAMB.
Insert T-adapter into connector ENG.
Turn starting switch to ON position (with connector PAMB disconnected).
Voltage
Max. 1 V

D375A-6R
(01)
Circuit diagram related to ambient pressure sensor
D375A-6R
(01)
40-21
40-211
Failure code [CA222] Ambient Press Sens Low Error

Action code
Failure code
E03
CA222
Failure
40-212
Ambient Press Sens Low Error

Detail of failure
Low voltage was detected ambient pressure sensor signal circuit .
Takes it that ambient pressure value is default value(52.44 kPa {0.53 kg/cm2}), and allows engine
to run.
Signal voltage from ambient pressure sensor can be checked with monitoring function (Code:
37401 (V)).
Ambient pressure sensed by the ambient pressure sensor can be checked with monitoring function
(Code: 37400 (kPa)).
Because troubleshooting "socket" for this sensor features female connector alone, it is not usable
for checking open circuit in wiring harness and voltage at sensor connector (not designed as a
T-adapter).
If sensor connector is disconnected, this code is displayed.
Problem on
machine
Related information
q
q
Cause

Defective power supply line of
2
ambient pressure sensor
for it first.

2. Disconnect connectors PAMB and ENG.

4
Resistance
Min. 1 Mz

2. Disconnect connectors PAMB and ENG and connect T-adapter to female
side of ENG.
Resistance
Min. 1 Mz
If cause is not found by the above checks, there may be open circuit in wiring
harness. (*)
a If causes 1 - 5 are not the cause for the trouble and check result of cause 6
is abnormal, sensor is defective.
Defective ambient pressure sen1. Turn starting switch to OFF position.
sor
6
(Improper input voltage to engine
controller)
Sensor outBetween ENG (3) and (38)
Voltage
0.3 - 4.7 V
put
If no abnormality is found by above checks, the engine controller is defective.
*: See "Troubleshooting method for disconnected wiring harness of pressure sensor system" of "Related troubleshooting information".
40-212
D375A-6R
(01)
Circuit diagram related to ambient pressure sensor
D375A-6R
(01)
40-213
40-213
Failure code [CA227] Sens Supply 2 Volt High Error

Action code
Failure code
E03
CA227
Detail of failure
Failure
40-214
Sensor power supply circuit valtage is too high

High voltage appears in sensor power supply 2 (5 V) circuit.
Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor signals.
Ignores signals from engine oil pressure sensor, takes it that engine oil pressure is default value
(250 kPa {2.5 kg/cm2}), and allows engine to run.
Ignores signals from ambient pressure sensor, takes it that ambient pressure is default value (52.44
kPa {0.53 kg/cm2}), and allows engine to run.
Ignores signals from boost pressure sensor, takes it that boost pressure is at fixed value (400 kPa
{4.1 kg/cm2}), and allows engine to run.
q
q
Problem on
machine
Related information
Cause

Perform troubleshooting for failure code [CA187].
40-214
D375A-6R
(01)
Failure code [CA234] Eng Overspeed

Action code
Failure code
Failure
CA234
40-215
Engine overspeed
(Engine controller defective)
Detail of failure
Engine speed exceeded operating range.
Reduce fuel injection rate until engine speed lowers in operating range.
Problem on
machine
Engine speed fluctuates.
Engine speed can be checked by using monitoring function. (Code: 01002 (rpm))
Method of reproducing failure code: Start engine and keep it running at high idle.
Related information
Cause
1 Use of improper fuel
Improper fuel may be used. Check it directly.
3 Usage is improper
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 failure is in it , troubleshooting cannot be performed.)
D375A-6R
(01)
40-215
Failure code [CA238] Ne Speed Sens Supply Volt Error

Action code
Failure code
E03
CA238
40-216
Ne Speed Sens Supply Volt Error

Failure
Detail of failure
Abnormality occurred in Ne speed sensor power supply (5 V) circuit.
Controls engine by using signals from Bkup speed sensor.

Limits engine output and continues operation.
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)
Problem on
machine
Related information
q
q
q
Cause

2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
If this failure code is not displayed when a connector is disconnected, that sensor or engine wiring harness is defective.
2 Defective sensor or wiring harness a Other failure codes are displayed, too. This is because the connector is disconnected. Ignore failure codes other than [CA238].
Sensor, harness
Ne speed sensor
NE
Engine harness
Connector
ENG

Between ENG(male)(16) and (48)
Circuit diagram related to Ne speed sensor
40-216
Voltage
4.75 to 5.25 V
40-216
D375A-6R
(01)
D375A-6R
(01)
40-217
Failure code [CA263] Fuel Temp Sensor High Error

Action code
Failure code
E01
CA263
Detail of failure
Fuel temperature sensor signal voltage is too high

Failure
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
40-218
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 by using monitoring function.
(Code: 14200 ( C))
Cause

in "Checks before troubleshooting" of "General information on troubleshooting",
tor
and check them directly.
2. Disconnect connector TFUEL and connect socket to male side of connector.
a If coolant temperature sensor resistance is 700 z 37 kz with coolant temperature is above 0 C, regard coolant temperature sensor as normal.
Between TFUEL
2 Defective fuel temperature sensor (male)
(A) and (B)
a Fuel temperature
-Resistance
characteristic
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

Open or short circuit in wiring har- Between ENG (female) (30) and (47) (Fuel tem3
perature: Min. 0 C)
ness
700 z
a Use Fuel temperature - Resistance charac- Resistance
37 kz
teristics table shown above as resistance critaeria.
40-218
D375A-6R
(01)
Circuit diagram related to fuel temperature sensor
D375A-6R
(01)
40-219
40-219
Failure code [CA265] Fuel Temp Sensor Low Error

Action code
Failure code
E01
CA265
Detail of failure
40-2 0
Fuel Temp Sensor Low Erro

Failure
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 fuel temperature value to fixed value (95 C) and allows engine to run.
Signal voltage from fuel temperature sensor can be checked by using monitoring function. (Code:
14201 (V))
Temperature sensed by fuel temperature sensor can be checked by using monitoring function.
(Code: 14200 ( C))
Problem on
machine
Related information
q
q
q
Cause

tor
2. Disconnect connector TFUEL and connect socket to male side of connector.
a If coolant temperature sensor resistance is 700 z 37 kz with coolant temperature is above 0 C, regard coolant temperature sensor as normal.
Between TFUEL
(male)
2 Defective fuel temperature sensor (A) and (B)
a Fuel temperature
-Resistance
characteristic

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 fuel temBetween (B) and

perature
Resistance
Min. 1 Mz
ground
range
Between ENG (female) (15) and (38) (fuel temperature: Min. 0 C)
700 z
a Use Fuel temperature - Resistance charac- Resistance
37 kz
teristics table shown above as resistance critaeria.
2. Disconnect connector TFUEL, and connect T-adapter to female side of
ENG.
40-220
Resistance
Min. 1 Mz

D375A-6R
(01)
Circuit diagram related to fuel temperature sensor
D375A-6R
(01)
40-2 1
40-221
Failure code [CA271] IMV/PCV1 Short Error

Action code
Failure code
E03
CA271
Detail of failure
Failure
40-2 2
IMV/PCV1 Short Error

Short circuit was detected in supply pump PCV1 circuit.
Under normal conditions, pulse voltage of approx. 24 V is applied to PCV1 (1) while engine is running. However, it cannnot be measured with multimeter since it is pulse voltage.
Problem on
machine
Related information
Cause

2. Disconnect connector PCV1.
Defective supply pump PCV1
2
(internal short circuit)
If failure code changes from [CA271] to [CA272], supply pump PCV1 is defective.
Between ENG (female) (4) and (5) (PCV1 resisResistance 2.3 5.3 z
tance)
2. Disconnect connector ENG and PCV1, and connect Tadapter to female
4
side of ENG.
1

1.
2.
5
4.
Circuit diagram related to PCV1
40-222
Min. 1 Mz

Disconnect connector PCV1.
Turn starting switch to ON position (with connector PCV1 disconnected).

Resistance
Voltage
Max. 3 V

(Since failure is in it troubleshooting cannot be performed.)
40-2 2
D375A-6R
(01)
Failure code [CA272] IMV/PCV1 Open Error

Action code
Failure code
E03
CA272
Detail of failure
Failure
40-2 3
IMV/PCV1 Open Error

Disconnection was detected in supply pump PCV1 circuit.

Under normal conditions, pulse voltage of approx. 24 V is applied to PCV (1) while engine is running
. However it cannot be measured with multimeter since it is pulse voltage.
Because troubleshooting "socket" for PCV1 features female connector alone, it is not connectable
to female connector of sensor wiring harness, and thus not usable for checking open circuit (not
designed as a T-adapter).
Problem on
machine
Related information
Cause

2. Disconnect connectors PCV1 and connect socket to male side.
2
(Internal disconnection)
Between PCV1 (male) (1) and (2)
Resistance 2.3 5.3 z
Open or short circuit in wiring har- 2. Disconnect connector ENG and connect T-adapter to female side.
3
ness
tance)
2. Disconnect connectors ENG and PCV1.
4
3. Connect T-adapter to female side of connector ENG.
D375A-6R
(01)
Resistance
Min. 1 Mz

40-2 3
40-223
Failure code [CA273] PCV2 Short Error

Action code
Failure code
E03
CA273
Detail of failure
Failure
40-2 4
PCV2 short circuit error

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.
Problem on
machine
Related information
Cause
1

2. Disconnect connector PCV2.
(Internal short)
If failure code changes from [CA273] to [CA274], supply pump PCV2 is defective.
tance)
2. Disconnect connector ENG and PCV2, and connect Tadapter to female
side of ENG.
Resistance Min. 1 Mz
1.
2.
5
4.

Disconnect connector PCV2.
Turn starting switch to ON position (with connector PCV2 disconnected).

40-224
Voltage
Max. 3 V

40-2 4
D375A-6R
(01)
Failure code [CA274] PCV2 Open Error

Action code
Failure code
E03
CA274
Detail of failure
Failure
40-2 5
PCV2 disconnection
Disconnection 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.
Problem on
machine
Related information
Cause

2. Disconnect connector PCV2 and connect socket to male side.
2
(internal open circuit)
Between PCV2 (male) (1) and (2)
Open or short circuit in wiring har- 2. Disconnect connector ENG and connect T-adapter to female side.
3
ness
tance)
2. Disconnect connector ENG and PCV2.
4
3. Connect T-adapter to female side of connector ENG.
D375A-6R
(01)
Resistance
Min. 1 Mz

(Since the failure is in it, troubleshooting cannot be performed.)
40-2 5
40-225
Failure code [CA322] Inj #1 (L#1) Open/Short Error

Action code
Failure code
E03
CA322
Detail of failure
Failure
40-2 6
Injector #1(L#1) open/short circuit error

Disconnection or short circuit was detected in injector #1 circuit.

Engien speed does not stabilize
Problem on
machine
Related information
q
q
q

While engine is running normally, approximately 65 V of pulse voltage is applied to injector (positive) side. But it is pulse voltage and cannot be measured by using multimeter.
Cause

2. Disconnect connector CN1 and connect T-adapter to male side.
2 Defective injector #1
Between CN1 (male) (1) and (2)
Between CN1 (male) (1) and ground
Resistance
Min. 1 Mz

Open circuit or ground fault of wirBetween ENG (female) (45) and (53)
ing harness

Resistance
Min. 1 Mz

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 z

Defective other cylinder injectors

or wiring harness
40-226
Max. 1 z

2. Disconnect connectors ENG and CN1, and connect T-adapter to female
Between ENG (female) (45) or CN1 (female) (1)
and ground
side of ENG.
a Check with circuit tester in continuity mode.
Between ENG (female) (45) and each pin other than
No continuity
(45)
(No sound is heard)
(53)
Resistance
No continuity
(No sound is heard)
If the failure codes for other injectors are displayed, perform troubleshooting of
them, too.
(Since failure is in it , troubleshooting cannot be performed.)
D375A-6R
(01)
Circuit diagram related to injector #1
D375A-6R
(01)
40-2 7
40-227

Action code
Failure code
E03
CA323
Detail of failure
Failure
40-2 8
Injector #5(L#5) open/short circuit error


Engine speed does not stabilize.
Problem on
machine
Related information
q
q
q

Cause

Resistance
Min. 1 Mz

ing harness
Resistance
0.4 - 1.1 z
Resistance
Min. 1 Mz

female side.
Resistance Max. 1 z


or wiring harness
40-228
Max. 1 z

and ground
side of ENG.
No continuity
(46)
(No sound is heard)
(60)
Resistance
No continuity
(No sound is heard)
If failure codes for other injectors are displayed, perform troubleshooting for
them, too.
D375A-6R
(01)
D375A-6R
(01)
40-2 9
40-229

Action code
Failure code
E03
CA324
Detail of failure
Failure
40-230
Injector #3(L#3) open /short circuit error


Problem on
machine
Related information
q
q
q

Cause

Resistance
Min. 1 Mz

ing harness

Resistance
Min. 1 Mz

female side.
Resistance Max. 1 z


or wiring harness
40-230
Max. 1 z

and ground
side of ENG.
No continuity
(55)
(No sound is heard)
(52)
Resistance
No continuity
(No sound is heard)
them, too.
D375A-6R
(01)
D375A-6R
(01)
40-231
40-231

Action code
Failure code
E03
CA325
Detail of failure
Failure
40-232
Injector #6 (L#6) open / short circuit error

Opening or short circuit was detected in drive circuit of No. 6 injector.

Problem on
machine
Related information
q
q
q

Cause

Resistance
Min. 1 Mz

ing harness

Resistance
Min. 1 Mz

female side.
Resistance Max. 1 z

Defective injector or wiring harness of another cylinder
40-232
Max. 1 z

and ground
side of ENG.
Between ENG1 (female) (57) and each pin other
No continuity
than (57)
(No sound is heard)
Between ENG1 (female) (59) and each pin other
than (59)
Resistance
No continuity
(No sound is heard)
If the failure codes for other injectors are displayed, perform troubleshooting
for them, too.
D375A-6R
(01)
D375A-6R
(01)
40-23
40-233

Action code
Failure code
E03
CA331
Detail of failure
Failure
40-234
Injector #2 Open/Short circuit error


Problem on
machine
Related information
q
q
q

Cause

Resistance
Min. 1 Mz

ing harness

Resistance
Min. 1 Mz

female side.
Resistance Max. 1 z


or wiring harness
40-234
Max. 1 z

and ground
2. Disconnect connectors ENG and CN, and connect T-adapter to female side
of ENG.
No continuity
(54)
(No sound is heard)
(51)
Resistance
No continuity
(No sound is heard)
them, too.
D375A-6R
(01)
D375A-6R
(01)
40-235
40-235

Action code
Failure code
E03
CA332
Detail of failure
Failure
40-236
Injector #4 (L#4) open / short circuit error


Problem on
machine
Related information
q
q
q

Cause

Resistance
Min. 1 Mz

ing harness

Resistance
Min. 1 Mz

female side.
Resistance Max. 1 z


or wiring harness
40-236
Max. 1 z

and ground
side of ENG.
No continuity
(56)
(No sound is heard)
(58)
Resistance
No continuity
(No sound is heard)
them, too.
D375A-6R
(01)
D375A-6R
(01)
40-237
40-237
Failure code [CA342] Calibration Code Incompatibility

Action code
Failure code
E04
CA342
Detail of failure
Failure
40-238
Engine controller data inconsistency

Data inconsistency occurres in engine controller.
Engine continues running ordinarily, but it may stop during operation or may not restart once it is
stopped.
Problem on
machine
Related information
Cause

Preform troubleshooting for failure code [CA111].
40-238
D375A-6R
(01)
Failure code [CA351] Injectors Drive Circuit Error
Failure code [CA351] Injectors Drive Circuit Error

Action code
Failure code
E03
CA351
Failure
40-239
Injectors drive circuit error

Detail of failure
Abnormality has occurred in injector drive circuit.
Limits engine output for travel (Limits common rail pressure) and allows engine to run
Problem on
machine
Related information
Cause

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]
D375A-6R
(01)
40-239

Action code
Failure code
E03
CA352
Failure
40-240
Sensor power supply 1voltage is too low

Detail of failure
Low voltage appears in sensor power supply 1 (5 V) circuit.
Limits engine output (limits common rail pressure) and allows engine to run.
Problem on
machine
Related information
Cause

tor
position each time.
3. After each troubleshooting, turn starting swith to OFF position.
If this failure code is not displayed when sensor connector is disconnected, that
sensor or engine wiring harness is defective.
Defective sensor or wiring harness a Other failure code(s) is(are) displayed at the same time. This is because the
2
sensor connector is disconnected. Therefore, ignore failure codes other
than [CA352].
Sensor, harness
Connector
PFUEL
Engine harness
ENG

Between ENG (male) (33) and (47)
40-240
Voltage
4.75 5.25 V
D375A-6R
(01)
Circuit diagram related to sensor power supply 1 circuit
D375A-6R
(01)
40-241
40-241

Action code
Failure code
E03
CA386
Failure
40-242
Sensor power supply 1 voltage is too high

Detail of failure
High voltage is detected in sensor power supply 1 (5 V) circuit.
Limits engine output (limits common rail pressure) and allows engine to run
Problem on
machine
Related information
Cause

Perform troubleshooting for failure code[CA352]
40-242
D375A-6R
(01)
Failure code [CA441] Battery Voltage Low Error
Failure code [CA441] Battery Voltage Low Error

Action code
Failure code
E04
CA441
Contents of
trouble
Problem on
machine
Related information
Failure
40-243
Battery power circuit voltage is to low

Low voltage (5.7 V or below) is detected in power supply circuit.
Engine contionues running ordinarily, but it may stop during operation or may not restart once it is
stopped.
Cause

D375A-6R
(01)
40-243
Failure code [CA442] Battery Voltage High Error
Failure code [CA442] Battery Voltage High Error

Action code
Failure code
E04
CA442
Detail of failure
Problem on
machine
Related information
Failure
40-24
Battery Voltage High Error

High voltage (36 V or higher) appears in power supply circuit.

Power supply voltage of engine controller can be checked by using monitoring function. (Code: 03203
(V))
Cause

Preform troubleshooting for failure code [CA111].
40-244
D375A-6R
(01)
Failure code [CA449] Rail Press Very High Error
Failure code [CA449] Rail Press Very High Error

Action code
Failure code
E03
Failure
CA449
40-245
Rail Press Very High Error

Common rail pressure sensor circuit detects abnormally high pressure (pressure exceeding set
maximum level).
Problem on
machine
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
function (Code: 36400 (MPa)).
Detail of failure
Related information
q
q
Cause

D375A-6R
(01)
40-245
Failure code [CA451] Rail Press Sensor High Error

Action code
Failure code
E03
CA451
Failure
40-246
Rail Press Sensor High Error

Detail of failure
High voltage was detected in signal circuit of common rail pressure sensor.
Problem on
machine
36401 (V)).
This failure code is displayed if common rail pressure sensor connector is disconnected.
Related information
q
q
q
Cause

tor
a If failure code [CA352] (Ground fault in sensor power supply line) or [CA386]
is displayed, perform troubleshooting for it first.
2
Defective common rail pressure

sensor power supply line

2. Disconnect connector PFUEL and connect T-adapter to female side.
Power supVoltage 4.75 5.25 V

ply 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, this check is not required.
Resistance Max. 1 z
Between ENG(female) (33) and PFUEL(female) (1)
a If power supply input in checks on cause 2 is norcontact in connector)
mal, this check is not required.
Resistance Max. 1 z
Between ENG (female) (47) and PFUEL (female)
(3)
Between ENG (female) (25) and PFUEL (female)
Resistance Max. 1 z
(2) (Sensor output)
2. Disconnect connectors PFUEL and ENG
4
Between PFUEL (female) (1) and (3)

1.
2.
5
a
Resistance
Min. 1 Mz

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 5 V power supply through resistor in engine
controller.
Voltage
Approx. 5 V
a If causes 1 5 are not cause of failure and check result of cause 6 is abnormal, sensor is defective.
sensor
6
(Improper input voltage to engine
controller)
Sensor outBetween ENG (25) and (47)
Voltage
0.2 4.6 V
put
40-246
D375A-6R
(01)
Circuit diagram related to common rail pressure
D375A-6R
(01)
40-247
40-247
Failure code [CA452] Rail Press Sensor Low Error

Action code
Failure code
E03
CA452
Failure
40-248
Rail Press Sensor Low Error

Detail of failure
Low voltage was detected in signal circuit of common rail pressure sensor.
Problem on
machine
36401 (V)).
Even under normal conditions, if sensor connector is disconnected, this failure code is not displayed
but other failure code for High Error, namely , [CA451], appears.
Related information
q
q
q
Cause

a If failure code [CA352] (Ground fault in sensor power supply line) or [CA386]
is displayed, perform troubleshooting for it first.
2

sensor power supply line

sensor

2. Disconnect connector PFUEL and connect T-adapter to female side.
Power supBetween PFUEL (female) (1) and (3)
Voltage 4.75 5.25 V
ply input
2. Disconnect connector PFUEL
If failure code changes from [CA452] to [CA451] , sensor is defective.

4

2. Disconnect connectors ENG and PFUEL , and connect T-adapter to female
side of ENG

2. Disconnect connectors ENG and PFUEL , and connect T-adapter to female
side of ENG

40-248
Resistance
Resistance
Min. 1 Mz
Min. 1 Mz

D375A-6R
(01)
Circuit diagram related to common rail pressure
D375A-6R
(01)
40-249
40-249
Failure code [CA553] Rail Press High Error

Action code
Failure code
E02
CA553
Failure
40-250
Common rail pressure is high

Abnormal high pressure (higher than set pressure) was detected more than 10 seconds in the signal circuit of common rail pressure sensor.
Detail of failure
36401 (V)).
Problem on
machine
Related information
q
q
Cause
Check fuel used directly (for high viscosity).
Defective electrical system of

common rail pressure sensor
Electrical system of common rail pressure sensor may be defective. Perform

troubleshooting for failure codes [CA451] and [CA452].
Defective mechanical system of

common rail pressure sensor
Check mechanical system of common rail pressure sensor directly.
5 Defective overflow valve
Check overflow valve directly for broken spring, worn seat, and stuck ball.
6 Clogging of overflow piping
Check overflow piping directly for clogging.
7 Defective pressure limiter
A mechanical defect of the pressure limiter may exist, check the limiter
directly.
40-250
D375A-6R
(01)
Failure code [CA554] Rail Press Sensor In Range Error

Action code
Failure code
E03
CA554
Failure
40-251
Common rail pressure sensor signal voltage is beyond input range

Detail of failure
Signal voltage of common rail pressure sensor is beyond input range.
Problem on
machine
36401 (V)).
Related information
q
q
Cause

Perform troubleshooting for failure code [CA451], [CA452]
D375A-6R
(01)
40-251
Failure code [CA559] Rail Press Low Error

Action code
Failure code
E02
CA559
Failure
40-252
Rail Press Low Error

Detail of failure
Supply pump does not pressure feed fuel (level1).
Limits common rail pressure.
Problem on
machine
Related information
Cause
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".
3 Defect in low pressure circuit parts
Fuel pressure in low-pressure circuit
0.15 0.3 MPa
(At high idle or under load equivalent
{1.53.0 kg/cm2}
to rated output operation)
4 Clogged fuel filter,or strainer
a For more information on troubleshooting, see Note 2.
Defective electrical system of sup- Electrical system of supply pump PCV may be defective. Perform troubleply pump PCV
shooting for failure code [CA271], [CA272], [CA273], or [CA274].

sensor
7 Defective pressure limiter
Common rail pressure sensor may be defective. Check wiring harness for
damage.
a For check of leakage from pressure limiter, see Testing and adjusting,
"Checking fuel return rate and leakage".
Leakage from pressure limiter
(Rated output operation or equiralent
Max. 10 cc/min
(load at 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
Injector return
operation or equivalent
(spill) limit
(load at stalling)
960 cc/min
1,020 cc/min
1,800 rpm
1,080 cc/min
1,900 rpm
1,140 cc/min
2,000 rpm
9 Defective supply pump
1,600 rpm
1,700 rpm
8 Defective injector
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.
40-252
D375A-6R
(01)
Note 1: To determine if low-pressure circuit parts is defective, check following items.

1) Fuel level
2) Clogging of fuel tank breather
3) Seizure and wear of feed pump and clogging of filter
4) Leakage or clogging of low-pressure fuel piping
5) Defective operation of bypass valve and installation of wrong part (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 visible through both holes.
q Bypass valve (2): Spring is visible through nut side hole.
q Fuel inlet joint (3): Gauze filter is visible 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-6R
(01)
40-253
Model
Machine serial No.
Engine
Engine serial No.
#
#
Check sheet for no-pressure feed

D375A-6R
Work No.
Date of check
SAA6D170E-5
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 value Measured
Code
Display item
Checking condition
SI unit
Good NG
(Reference value)
value
Low idle
r/min
700 800
01002 Engine speed
High idle
r/min
1,850 1,900
r/min
1,490 1,580
Low idle
%
0
31701 Decel pedal position
High idle
%
100
Inject fueling com4 18600
mg/st
mand
36200 Rail press command At torque converter stall
MPa
36400 Reil pressure
MPa
Low idle
CA
Injection timing com36300
High idle
CA
mand
CA
36500 Charge pressure -Abs At torque converter stall
kPa
04107 Coolant temperature Low idle
C
14200 Fuel temperature
Low idle
C
Cylinder cut out mode operation (Engine speed)
Good NG
Function
Cut out cylinder
Checking condition
Unit
(Reference value)
value
No. 1 cylinder
Low idle
r/min
5
No. 2 cylinder
Low idle
r/min
Set by No. 3 cylinder
Low idle
r/min
Low idle
r/min
cylinder No. 4 cylinder
No. 5 cylinder
Low idle
r/min
No. 6 cylinder
Low idle
r/min
C.Check of fuel circuit pressure
6
Fuel low-pressure circuit pressure
Checking condition
High idling or under load
equivalent to rated output
operation(stalling)
Unit
MPa
{kg/cm2}

Good NG
(Reference value)
value
0.15 0.3
{1.5 3.0}
D. Check of strainers and filters

7 Visual inspection of strainer
8 Visual inspection of gauze filter
9 Visual check of fuel filter
E. Check of leakage and fuel return
rate
10 Leakage from pressure limiter
11 Return rate from injector
40-254
Good NG
Checking condition
Under load equivalent to
rated output operation(stalling)
Torque converter stall at
1,600 rpm
1,700 rpm
1,800 rpm
1,900 rpm
2,000 rpm
Unit

Good NG
(Reference value)
value
cc/min
Max. 10
cc/min
960
cc/min
1,020
cc/min
1,080
cc/min
1,140
cc/min
1,200
Speed:
Return
rate:
D375A-6R
(01)
D375A-6R
(01)
40-255
Failure code [CA689] Eng Ne Speed Sensor Error

Action code
E03
Detail of failure
Problem on
machine
Failure code
Eng Ne Speed Sensor Error

CA689
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 speed sensor outputs 5 V pulse voltage during normal operation, it cannot be measured with
multimeter.
Speed sensor calculates engine speed by detecting holes made in the flywheel.
q
q
q
Related information
Failure
40-256
q
q
Cause
1
2
3

Defective wiring harness connecin "Checks before troubleshooting" of "General information on troubleshooting",
tor
Defective Ne speed sensor power
If failure code [CA238] is also displayed, perform troubleshooting for it first.
supply line
Breakage or improper installation
Engine Ne speed sensor may be damaged or improperly installed (loose).
(looseness) of engine Ne speed
Check sensor directly.
sensor
2. Disconnect connector NE and connect T-adapter to female side.
Defective Ne speed sensor power 3. Turn starting switch to ON position.
Power supsupply input
Between NE (female) (1) and (2)
Voltage 4.75 5.25 V
ply input
2. Disconnect connectors ENG and NE.
If no abnormality is found in checks on cause 4, this
check is not required.
Resistance Max. 1 z
(Open circuit in wiring 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)
Resistance Max. 1 z
Between ENG (female) (16) and (27), or between
NE (female) (1) and (3)
Between ENG (female) (27) and (48), or between
NE (female) (2) and (3)
Between ENG (female) (27) or NE (female) (3) and
ground
Hot short circuit in wiring harness 2. Disconnect connector NE.
Between NE (female) (3) and ground
9 Defective engine Ne speed sensor

40-256
Voltage
Max. 1 V
If failure is not found by above checks, engine Ne speed sensor may be defective. (Since failure is in it, troubleshooting cannot be performed.)
If cause is not found by above checks,, engine controller may be defective.
D375A-6R
(01)
Circuit diagrams related to engine Ne speed sensor
40-257
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-6R
(01)
40-257
Failure code [CA731] Eng Bkup Speed Sens Phase Error

Action code
Failure code
E03
CA731
Detail of failure
Failure
40-258
Engine Bkup speed sensor phase error

Engine Bkup speed sensor circuit detects phase error.

(Bkup speed sensor signal is out of phase with Ne speed sensor signal.)
Controls the engine by using signals from engine Ne speed sensor.
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).
q Method of reproducing failure code: Start engine.
Related infora To replace Bkup speed sensor, fuel supply pump must be replaced as a unit. (See Disassembly
mation
and assembly, "Removal and installation of fuel supply pump".)
Problem on
machine
q
q
Cause
Defective engine Ne speed sensor

1
system
Defective engine Bkup speed sen2
sor 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]
40-258
D375A-6R
(01)
Failure code [CA757] All Continuous Data Lost Error

Action code
Failure code
E03
CA757
Detail of failure
Failure
40-259
All engine controller data lost error

All data in engine controller are lost.
Problem on
machine
Related information
Cause

D375A-6R
(01)
40-259
Failure code [CA778] Eng Bkup Speed Sensor Error

Action code
Failure code
E03
CA778
Failure
40-260
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.
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".)
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 speed sensor outputs 5 V pulse voltage during normal operation, it cannot be measured with
multimeter.
Problem on
machine
q
q
Related information
q
q
Cause


system
If failure code [CA187] or [CA227] is also displayed, troubleshoot it first.
Damage or improper installation

Engine Bkup speed (G) sensor may be damaged or improperly installed
3 (loose) of engine Bkup speed (G)
(loose). Check sensor directly.
sensor
4 Defective resistor (RES)

2. Disconnect connector RES and connect T-adapter to male side.
Between RES (male) (1) and (2)
Resistance
620 z

2. Disconnect connector G and connect T-adapter to female side.
Defective engine Bkup speed sen- 3. Turn starting switch to ON position.
5
sor power supply input
Power sup4.75 Between G (female) (A) and (B)
Voltage
ply input
5.25V
Open or short circuit in wiring har- 2. Disconnect connectors ENG and G, and connect T-adapter to female side
6 ness
of ENG.
(Resistor RES line)
Resistance
620 z
2. Disconnect connectors ENG, G and RES, and connect T-adapters to
female side of each one of them.
a If check result on cause 5 shows normal power
supply voltage, this check is not required. Be- Resistance Max. 1 z
tween ENG (female) (37) and G (female) (A)
a If check result on cause 5 shows normal power
supply voltage, this check is not required. Be- Resistance Max. 1 z
tween ENG (female) (47) and G (female) (B)
Between ENG (female) (26) and G (female) (C)
Resistance
Max. 1 z

2. Disconnect connectors ENG, G and RES, and connect T-adapter to female
side of ENG or G.
40-260
Between ENG (female) (26) and (37), or between G

Resistance
(female) (A) and (C)
Min. 1 Mz
Between ENG (female) (26) and (47), or between G

Resistance
(female) (B) and (C)
Min. 1 Mz
D375A-6R
(01)
Cause

(contact with ground circuit)

2. Disconnect connectors ENG and G and connect T-adapter to female side
of either of them.
Between ENG (female) (26) or G (female) (C) and
ground
Resistance
Min. 1 Mz

Hot short in wiring harness (Con- 2. Disconnect connectors G and RES, and connect T-adapter to female side.
10
tact with 24 V circuit)
Between G (female) (C) and ground
Voltage
Max. 1 V
11
Defective engine Ne speed sensor
If engine failure is not found by above checks, engine Bkup speed sensor may
be defective. (Since failure is in it, troubleshooting cannot be performed.)
If engine failure is not found by above checks, engine controller may be defective. (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to engine Bkup speed sensor
D375A-6R
(01)
40-261
40-261
Failure code [CA1633] KOMNET Datalink Timeout Error

Action code
Failure code
E03
CA1633
Detail of failure
Problem on
machine
Related information
Failure
40-262
CAN (KOMNET) communication disconnection

Engine controller detected communication error in CAN (KOMNET) communication circuit between
engine controller and power train controller ,work equipment controller or machine monitor.
q
q
Controls engine in default mode, and holds state at the time of abnormally.
If cause of failure disappears, machine becomes normal by itself.
Information may not be transmitted normally through CAN (KOMNET) communication and machine
may not operate normally.
(Trouble phenomenon depends on failed section.)
Cause

Perform troubleshooting for failure code [DB2RKR].
40-262
D375A-6R
(01)
Failure code [CA2185] Throt Sens Sup Volt High Error

Action code
Failure code
E03
CA2185
Failure
40-263

Detail of failure
High voltage (approx. 5.25 V) was detected in throttle sensor power supply circuit.
Engine speed cannot be controlled with decelerator pedal.
Problem on
machine
Related information
Cause
1
Defective wiring harness connector

See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks
before troubleshooting" of "General information on troubleshooting", and check them
directly.
2. Disconnect connector DEC and turn starting switch to ON position.
Defective throttle sensor (decelerator pedal) 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
Short circuit in wiring
of EGC2 and EGC3.
3
harness
Between EGC2 (female) (22) and each pin other than
Resistance
Min. 1 Mz
EGC2 (female) (22)
Between EGC2 (female) (22) and EGC3 (female) (3)
Resistance
Min. 1 Mz
Hot short circuit in wir- 1. Turn starting switch to OFF position.
ing harness
2. Disconnect connector DEC and connect T-adapter to female side.
4
cuit)
Between DEC (female) (A) and ground
Voltage
4.75 5.25 V
Defective engine con- 2. Disconnect connector EGC2 and connect T-adapter to male side.
5
troller
Between EGC2 (male) (22) and (23)
Voltage
4.75 5.25 V
D375A-6R
(01)
40-263
40-263
Failure code [CA2186] Throt Sens Sup Volt Low Error

Action code
Failure code
E03
CA2186
Failure
40-264

Detail of failure
Low voltage was detected in throttle sensor power supply circuit.
Problem on
machine
Engine speed cannot be controlled with decelerator pedal.
Related information
Cause
1
See descriptions of wiring harness and connectors in "c: Electrical equipment" in

Defective wiring harness
"Checks before troubleshooting" of "General information on troubleshooting", and
connector
check them directly.
2. Disconnect connector DEC and turn starting switch to ON position.
Defective throttle sensor
If this failure code is not displayed, throttle sensor is defective.
(decelerator pedal)
a Other failure code is displayed together. This is because that the sensor connector
is disconnected. Ignored except the failure code other than [CA2186].
2. Disconnect connector EGC2 and DEC and connect T-adapter to female side of
harness
either one of them.
(Contact with ground cirBetween EGC2 (female) (22) or DEC (female) (A) and
Resistance
Min. 1 Mz
cuit)
ground
2. Disconnect connector EGC2 and DEC and connect T-adapter to female side of
EGC2.
Short circuit in wiring har3. Turn starting switch to ON position.
ness
Between EGC2 (female) (22) and each pin other than
Resistance
Min. 1 Mz
EGC2 (female) (22)
2. Disconnect connector EGC2 and connect T-adapter to male side.
Defective engine control- 3. Turn starting switch to ON position with connecting engine wiring harness disconler
nected.
40-264
Voltage
4.75 5.25 V
40-264
D375A-6R
(01)
Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2249] Rail Press Very Low Error

Action code
Failure code
E03
CA2249
Failure
40-265
Supply pump no-pressure feed error 2

Detail of failure
No-pressure feed error (level 2) in supply pump was detected.
Limits common rail pressure.
Problem on
machine
The signal voltage from the common rail pressure sensor can be checked with the monitoring function (Code: 36401 (V)).
Related information
q
q
Cause

Perform troubleshooting for failure code [CA559] .
D375A-6R
(01)
40-265
Failure code [D110KB] Battery Relay: Drive Short Circuit

Action code
Failure code
D110KB
Failure
40-26
Short circuit in battery relay drive circuit

Detail of failure
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 on
machine
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
1
Defective battery relay

(Internal short circuit)

2

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 Mz
q Reference: the following is standard value in normal condition.
3
ler
40-266
Voltage
20 30 V
D375A-6R
(01)
Circuit diagram related to battery relay
D375A-6R
(01)
40-267
40-267
Failure code [D130KA] Neutral relay: Disconnection

Action code
Failure code
E02
Failure
D130KA
40-268
Open cricuit in neutral safety relay

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).
Problem on
machine
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 the starting switch to ON position, and operate parking
brake lever (FREE).
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.
Detail of failure
Related information
q
q
q
Cause
Defective neutral
safety relay
2. Disconnect connector NSF and connect T-adapter to male side.
1
(internal open circuit or
Between NSF (male) (1) and (2)
Resistance
200 400 z
short circuit)
2. Disconnect connectors PTCN2 and KEY, and connect T-adapters to female side of
them.
2
a If resistance is above 1 Mz, wiring harness is broken. If resistance is below 1 z, wiring
wiring harness
harness has short circuit.
Between KEY (female) (1) and PTCN2 (female) (8)
Resistance
200 400 z
2. Disconnect connectors PTCN2, NSF and KEY, and connect T-adapters to female side
of them.

harness
3
(open circuit or defecBetween PTCN2 (female) (8) and NSF (female) (2)
tive contact)
Between KEY (female) (1) and NSF (female) (1)
harness
4
circuit)
Defective power train

controller
Max. 1 z
Resistance
Max. 1 z

2. Disconnect connectors PTCN2 and NSF, and connect T-adapters to female side of
them.
Between NSF (female) (2) or PTCN2 (female) (8) and
Resistance
Min. 1 Mz
ground
q Reference: The following are standard values in normal condition.
4. Operate parking brake lever and troubleshoot.
40-268
Resistance
Lever: FREE
Voltage
20 30 V
Lever: LOCK
Voltage
Max. 1 V
D375A-6R
(01)
Circuit diagram related to neutral safety relay
D375A-6R
(01)
40-269
40-269
Failure code [D130KB] Neutral relay: Short circuit

Action code
Failure code
E02
Failure
D130KB
40-270
Short circuit in neutral safety relay

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).
Problem on
machine
Output to neutral safety relay primary circuit (coil side) can be checked with monitoring function.
brake lever (LOCK).
This failure code detects failure on primary side (coil side) of neutral safety relay, but not on secondary side (contact side).
Detail of failure
Related information
q
q
Cause
Defective neutral
safety relay
2. Disconnect connector NSF and connect T-adapter to male side.
1
Between NSF (male) (1) and (2)
Resistance
200 400 z
short circuit)
them.
2
wiring harness
Resistance
200 400 z

Hot short circuit in wir- 2. Disconnect connectors PTCN2 and NSF, and connect T-adapter to female side of
ing harness
PTCN2.
3
cuit)
Between PTCN2 (female) (8) and ground
Voltage
Max. 1 V

controller
q Reference: the following are standard values in normal condition.
40-270
Lever: FREE
Voltage
20 30 V
Lever: LOCK
Voltage
Max. 1 V
D375A-6R
(01)
Circuit diagram related to neutral safety relay
D375A-6R
(01)
40-271
40-271
Failure code [D161KA] Back-up alarm releay: Disconnection

Action code
Failure code
E01
Failure
D161KA
40-272
Backup alarm releay:Disconnection

No voltage is applied to backup alarm relay primary circuit (coil side) when controller stopped
grounding.
Stops grounding to backup alarm relay primary circuit.
Problem on
machine
The backup alarm does not sound
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 move PCCS lever (to
NEUTRAL).
This failure code detects failure on primary side (coil side) of backup alarm relay, but not on secondary side (contact side).
If pin PTCN2(18) has ground fault, backup alarm keeps sounding.
Detail of failure
Related information
q
q
q
Cause
1 Defective fuse FS22-5
Defective backup alarm relay
2 (internal open circuit or short circuit)

If fuse FS22-5 is broken, 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.
Resistance 200 400 z
Between BKA (male) (1) and (2)
1.
2.
Open or short circuit in wiring har- 3.
3
a
ness

Disconnect fuse FS22-5.
Disconnect connector PTCN2 and connect T-adapter to female side.
If resistance is above 1 Mz, wiring harness has disconnection. If resistance
is below 1 z, wiring harness has short circuit.
Between PTCN2 (female) (18) and FS22-5

2. Disconnect connectors PTCN2 and BKA, and connect T-adapters to female
side of them.

Max. 1 z
Between FS22-5 and BKA (female) (1)
Between PTCN2 (female) (18) and BKA (female) (2) Resistance
Max. 1 z

2. Disconnect fuse FS22-5.
3. Disconnect connector PTCN2 and connect T-adapter to female side.
Between BKA (female) (1) and ground
Resistance
Min. 1 Mz
Between BKA (female) (2) or PTCN2 (female) (18)

and ground
4. Operate PCCS lever and perform troubleshooting.
Between PTCN2 (18)
and ground
40-272
Resistance
Voltage
20 30 V
R(Reverse)
Voltage
Max. 1 V
D375A-6R
(01)
Circuit diagram related to backup alarm relay
D375A-6R
(01)
40-273
40-273
Failure code [D161KB] Back-up alarm releay: Short circuit

Action code
Failure code
E01
Failure
D161KB
40-274
Short circuit in backup alarm relay

Abnormal current flowed in backup alarm relay circuit when controller grounded backup alarm relay.
Stops grounding to backup alarm relay primary circuit.
Problem on
machine
The backup alarm does not sound
Output condition to backup alarm relay can be checked by monitoring function.

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).
Detail of failure
Related information
q
q
Cause

2. Disconnect connector BKA and connect T-adapter to male side.
Resistance 300600 z
Between BKA (male) (1) and (2)
1.
2.
3.
Open or short circuit in wiring har- a
2
ness

Disconnect fuse FS22-5.
If resistance is above1 Mz, wiring harness is broken. If resistance is
below1 z, wiring harness has short circuit.
Resistance 300600 z
Between PTCN2 (female) (18) and FS22-5

2. Disconnect connector PTCN2 and BKA , and connect T-adapter to female
Hot short in wiring harness (Conside of PTCN2.
3
40-274
Voltage
Max. 1 V
4. Operate PCCS lever and perform troubleshooting.
N
Voltage
2030 V
R(Reverse)
Voltage
Max. 1 V
D375A-6R
(01)
Circuit diagram related to back-up alarm relay
D375A-6R
(01)
40-275
40-275
Failure code [D182KZ] Preheater Relay Abnormality

Action code
Failure code
E01
D182KZ
Detail of failure
Problem on
machine
Preheater relay open or short circuit

Abnormal current flowed when preheater relay primary is grounded circuit (coil side) or no voltage
is applied when it is not grounded.
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.
Output to preheater relay primary circuit (coil side) can be checked with monitoring function.
(Code: 40909 P/T controller SW Output)
brake lever (FREE).
This failure code detects failure on primary side (coil side) of preheater relay, but not on secondary
side (contact side).
q
q
Related information
Failure
40-276
q
q
Cause
Defective preheater
relay
2. Disconnect connector PHR and connect T-adapter to male side.
1
Between PHR (male) (1) and (2)
Resistance
200 400 z
short circuit)
them.
2
wiring harness
Resistance
200 400 z
2. Disconnect connectors PTCN2, PHR and KEY, and connect T-adapters to female side
of them.

harness
3
(open circuit or defecBetween PTCN2 (female) (19) and PHR (female) (2)
tive contact)
Between KEY (female) (1) and PHR (female) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z

2. Disconnect connectors PTCN2 and PHR, and connect T-adapters to female side of
them.
Between PHR (female) (2) or PTCN2 (female) (19) and
Resistance
Min. 1 Mz
ground
Hot short circuit in wir- 2. Disconnect connectors PTCN2 and PHR, and connect T-adapter to PTCN2 female
ing harness
connector.
5
cuit)
Voltage
Max. 1 V

harness
4
circuit)
Reference: The following are standard values in normal condition.
Auto preheater
Voltage
20 30 V
not operated
Auto preheater
Voltage
Max. 1 V
operated
q

controller
40-276
D375A-6R
(01)
Circuit diagram related to preheater relay
D375A-6R
(01)
40-27
40-277
Failure code [D190KA] ACC signal relay: Disconnection

Action code
Failure code
E00
D190KA
Failure
40-278
ACC signal drive relay disconnection

Detail of failure
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 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.
Problem on
machine
q
q
Related information
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 z
circuit)
them.
2
a If resistance is above 1 Mz, wiring harness has disconnection. If resistance is below
wiring harness
1 z, wiring harness has short circuit.
Resistance
200 400 z
2. Disconnect connectors WECN2, EHL and KEY, and connect T-adapters to female side
of them.

harness
3
(open circuit or defecBetween WECN2 (female) (8) and EHL (female) (2)
tive contact)
Between KEY (female) (1) and EHL (female) (1)
harness
4
circuit)
5
Resistance
Max. 1 z
Resistance
Max. 1 z

2. Disconnect connectors WECN2 and EHL, and connect T-adapters to female side of
them.
Between EHL (female) (2) or WECN2 (female) (18) and
Resistance
Min. 1 Mz
ground
Defective work equipIf cause is not found by the above checks, work equipment controller is defective.
ment controller
40-278
D375A-6R
(01)
Circuit diagram related to ACC signal drive relay
D375A-6R
(01)
40-279
40-279
Failure code [D190KB] ACC signal relay: Short circuit

Action code
Failure code
E00
D190KB
Detail of failure
Problem on
machine
ACC signal drive relay short circuit

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 control SW Output)
This failure code detects failure on primary side (coil side) of engine shutoff delay relay (EHL), but
q
q
Related information
Failure
40-280
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 z
circuit)
them.
2
wiring harness
Resistance
200 400 z

Hot short circuit in wir- 2. Disconnect connectors WECN2 and EHL, and connect T-adapter to female side of
ing harness
WECN2.
3
cuit)
Voltage
Max. 1 V
4
Defective work equipIf cause is not found by the above checks, work equipment controller is defective.
ment controller
40-280
D375A-6R
(01)
Circuit diagram related to ACC signal drive relay
D375A-6R
(01)
40-281
40-281
Failure code [D1EFKA] Pre lub. motor relay: Disconnection

Action code
Failure code
E02
D1EFKA
Detail of failure
Problem on
machine
Pre-lubricating motor relay open circuit

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 (23) has ground fault, pre-lubricating motor keeps running.
q
q
Related information
Failure
40-282
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 z
short circuit)
them.
2
wiring harness
harness
3 (Wire breakage or
defective contact of
connector)
harness
4
circuit)

controller
40-282
Resistance
200 400 z
a If cause item 2 is not the cause for the trouble, this check is not required.
2. Disconnect connectors PTCN2, PLUB and KEY, and connect T-adapters to female side
of them.
Between PTCN2 (female) (9) and PLUB (female) (2)
Resistance
Max. 1 z
Between KEY (female) (1) and PLUB (female) (1)
Resistance
Max. 1 z

2. Disconnect connectors PTCN2 and PLUB, and connect T-adapter to female side of
them.
Between PLUB (female) (2) or PTCN2 (female) (9) and
Resistance
Min. 1 Mz
ground
When pre-lubrication has
Voltage
20 30 V
been comBetween PTCN2 (9) and ground
pleted
Pre-lubrication
Voltage
Max. 1 V
is in operation.
D375A-6R
(01)
Circuit diagram related to pre-lubricating motor relay
D375A-6R
(01)
40-283
40-283
Failure code [D1EFKB] Pre lub. motor relay: Short circuit

Action code
Failure code
E02
D1EFKB
Detail of failure
Problem on
machine
Pre-lubricating motor short circuit

When the pre-lubricating motor relay primary (coil side) circuit was grounded extraordinary current
flowed.
Stops grounding to pre-lubricating motor relay primary circuit (coil side).
The 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
Related information
Failure
40-284
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 z
short circuit)
them.
2
wiring harness
Resistance
200 400 z

Hot short circuit in wir- 2. Disconnect connectors PTCN2 and PLUB, and connect T-adapter to female side of
ing harness
PTCN2.
3
cuit)
Voltage
Max. 1 V
Reference: The following are standard values in normal condition.
When pre-lubrication has
Voltage
20 30 V
been comBetween PTCN2 (9) and ground
pleted
Pre-lubrication
Voltage
Max. 1 V
is in operation.
q

controller
40-284
D375A-6R
(01)
Circuit diagram related to pre-lubricating motor relay
D375A-6R
(01)
40-285
40-285
Failure code [DAFRKR] Monitor: Can communication lost (PT)
Failure code [DAFRKR] Monitor: Can communication lost (PT)

Action code
Failure code
E03
DAFRKR
Failure
40-286
CAN communication with machine monitor is impossible

(detected by power train controller)
Detail of failure
Power train controller cannot recognize machine monitor with CAN communication circuit.
System may not operate properly.

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.
Problem on
machine
q
q
q
q
q
Related information
q
q
Cause
Defective power supPerform troubleshooting for E mode, "E-3".

ply to machine monitor
Defective CAN com2
Perform troubleshooting for failure code [DAFRMC], cause 10 and after.
munication
1
40-286
D375A-6R
(01)
Failure code [dAFRKR] Monitor: CAN communication lost (WE)
Failure code [dAFRKR] Monitor: CAN communication lost (WE)

Action code
Failure code
E03
dAFRKR
Failure
40-287
CAN communication with machine monitor is impossible

(detected by work equipment controller)
Detail of failure
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.
Problem on
machine
q
q
q
q
q
Related information
q
q
Cause
Defective power supPerform troubleshooting for E mode, "E-3".

ply to machine monitor
Defective CAN com2
Perform troubleshooting for failure code [DAFRMC], cause 10 and after.
munication
1
D375A-6R
(01)
40-287
Failure code [DAFRMC] CAN Discon (Monitor Detected)

Action code
Failure code
E03
DAFRMC
Detail of failure
Problem on
machine
CAN communication is impossible (Machine monitor Detected)

(Mechane monitor power train control system)
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.
q
q
q
q
q
q
q
Related information
Failure
40-28
q
q
q

Failure code is sent to machine monitor by CAN communication. Accordingly, if other CAN-related
failure code such as [DB2RKR] is displayed on machine monitor, 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 con1 troller circuit breaker If circuit breaker is turned OFF, controller probably has short circuit in it.
(CB7)
a
1.
Defective engine con- 2.
2 troller (Internal short
a
circuit)
a
If circuit breaker has tripped, 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).
Defective power 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 control- 2. Remove the fuse in fuse box FS32-5.
4
ler ACC fuse
If fuse has blown out, the circuit probably has ground fault. In this case, perform troubleshooting for cause 14 first.
Defective ACC cutout
If failure code [7RFAKA] or [7RFAKB] is also displayed, perform troubleshooting for it
5 relay (for engine confirst.
troller) drive
40-288
D375A-6R
(01)
Cause

Defective ACC cutout 2. Replace ACC cutout relay (connector ACT) with another relay (backup alarm relay;
relay (for engine conconnector BKA, etc.)
6 troller) (Internal dis3. Turn starting switch to ON position.
connection or short
circuit)
If this failure code goes off, original ACC cutout relay (for engine controller) is defective.
Defective power sup7 ply to power train controller
Defective power sup8 ply to work equipment
controller
Defective power sup9
ply to VHMS controller
Defective CAN terminating resistor
10
(internal open circuit
or short circuit)
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
q CAN communication line

a 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.
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
11
circuit between wiring harnesses or in controller.
wiring harness
Approx. 60 z
Between PTCN2 (female) (32) and (22)
Resistance
Approx. 60 z
Between WECN2 (female) (32) and (22)
Resistance
Approx. 60 z
Between V4A (female) (12) and (4)
Resistance
Approx. 60 z
Between CT2 (female) (A) and (B)
Resistance
Approx. 120 z
Between CM02 (female) (9) and (10)
D375A-6R
(01)
Resistance
Resistance
Approx. 120 z
40-289
Cause

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)
Max. 1 z
Between PTCN2 (female) (22) and CM02 (female) (10)
Resistance
Max. 1 z
Between PTCN2 (female) (32) and EGC2 (female) (46)
Resistance
Max. 1 z
Between PTCN2 (female) (22) and EGC2 (female) (47)
Resistance
Max. 1 z
Between PTCN2 (female) (32) and WECN2 (female)

(32)
Resistance
Max. 1 z
Between PTCN2 (female) (22) and WECN2 (female)

(22)
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)

harness
12 (Open circuit in wiring
or defective contact in
connector)
Resistance
Resistance
Max. 1 z
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 wiring Between PTCN3 (14) or (24) and (31)

harness
13 (Open circuit in wiring Between WECN3 (14) or (24) and (31)
or defective contact in 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

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-adapter to female side of one of them.

harness
14
circuit)
Between PTCN2 (female) (32), WECN2 (female) (32),

V4A (female) (4), CM02 (female) (8), (9) or EGC2
Resistance
Min. 1 Mz
Between PTCN2 (female) (22) , WECN2 (female) (22),

V4A (female) (12), CM02 (female) (10) or EGC2
Resistance
Min. 1 Mz

2. Disconnect connectors PTCN3, WECN3, V1, CM01 and ACT, and connect T-adapter
to female side of one of them.
3. Disconnect connectors EGC2 and connect T-adapter to female side.
Between PTCN3 (female) (14), (24), WECN3 (female)

(14), (24), V1 (female) (17) or CM01 (female) (14) and
ground
Min. 1 Mz
Between EGC2 (female) (39) and ground
40-290
Resistance
Resistance
Min. 1 Mz
D375A-6R
(01)
Cause
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.
Short circuit or hot
2. Insert T-adapter into connector PTCN2, WECN2, V4A, CM02 or EGC2.
short circuit in wiring 3. Connect ground strap.
15 harness
(Contact with 24 V cir- a Since voltages of CAN H and CAN L are 2.5 1 V even while communication is concuit)
tinued, they are judged to be normal if they are 1 - 4 V.
Between PTCN2 (32), WECN2 (32), V4A (4), CM02 (8),
(9) or EGC2(46) and ground
Voltage
14V
Between PTCN2 (22), WECN2 (22), V4A(12),

CM02( 10), or EGC2 (47) and ground
Voltage
14V
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).
NO
Defective
power train
controller
YES
Defective
engine controller
NO
Defective work
equipment
controller
Is failure code [DB2RKR] displayed?
Defective engine con- Is failure code [dB2RKR] displayed?

troller, power train
Defective
16 controller, work equipYES
engine controlment controller and
ler
VHMS controller
q Step 2
2. Disconnect power train controller (connector PTCN2).
NO
Defective work
equipment
controller
YES
Defective
power train
controller
NO
Defective
VHMS controller
YES
Defective
power train
controller
Is failure code [DBERKR] displayed?
Is failure code [DBBQKR] displayed?
17
Defective machine
monitor
D375A-6R
(01)
If Failure is not found by above checks, machine monitor is defective.

(Since trouble is in system, troubleshooting cannot be performed.)
40-291
Circuit diagram related to CAN
40-292
40-292
D375A-6R
(01)
D375A-6R
(01)
40-293
Failure code [DB2RKR] ENG cont.: Can communication lost (PT)

Action code
Failure code
E03
DB2RKR
Failure
40-294
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
Defective engine con1 troller circuit breaker If circuit breaker is turned OFF, controller probably has short circuit in it.
(CB7)
a If circuit breaker has tripped, this check is not required.
Defective engine con- 2. Disconnect connectors EGC3 and connect T-adapter to male side.
2 troller (Internal short
a Measured value: approximately 9-20 kz
circuit)
a If measured value is below 10 z, engine controller is defective (internal short circuit).
Defective power supply to engine controller
1.
2.
3.
a
Resistance
Max. 10 z

Disconnect connectors EGC3 and connect T-adapter to female side.
If result is abnormal, perform troubleshooting for [CA111].
Voltage
20 30 V
Voltage
20 30 V

Broken engine control- 2. Remove the fuse in fuse box FS32-5.
4
ler ACC fuse
If fuse has blown out, the circuit probably has ground fault. In this case, perform troubleshooting for cause item 11 first.
Defective ACC cutout
If failure code [7RFAKA] or [7RFAKB] is also displayed, perform troubleshooting for it
5 relay (for engine confirst.
troller) drive
Defective ACC cutout 2. Replace ACC cutout relay (connector ACT) with another relay (backup alarm relay;
relay (for engine conconnector BKA, etc.)
6 troller)
3. Turn starting switch to ON position .
short circuit)
If this failure code goes off, original ACC cutout relay (for engine controller) is defective.
40-294
D375A-6R
(01)
Cause
Defective CAN terminating resistor (Inter7
nal open or short
circuit)

2. Disconnect connectors CT2 and CM02 and connect T-adapters to male side of them.
Resistance
120 12 z
Resistance
120 12 z

a 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.
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
8
circuit between wiring harnesses or in controller.
wiring harness
Resistance
Approx. 60 z
Resistance
Approx. 60 z
Resistance
Approx. 60 z
Resistance
Approx. 60 z
Resistance
Approx. 120 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
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
Identifying open circuit Between PTCN2 (female) (32) and EGC2 (female) (46)
in wiring harness (Wire Between PTCN2 (female) (22) and EGC2 (female) (47)
9
breakage or defective
contact of connector) Between PTCN2 (female) (32) and WECN2 (female) (32)
Resistance
Max. 1 z
Resistance
Max. 1 z
Between PTCN2 (female) (22) and WECN2 (female) (22)
Resistance
Max. 1 z
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
D375A-6R
(01)
40-295
Cause

2. Insert T-adapters into connectors PTCN3, WECN3, V1, CM01, ACT and EGC2.
Open circuit in wiring Between PTCN3 (14) or (24) and (31)

harness
10 (Open circuit in wiring Between WECN3 (14) or (24) and (31)
or defective contact in 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
Voltage
20 30 V

2. Disconnect connectors PTCN3, WECN3, V1, CM01 and ACT, and connect T-adapter
to female side of one of them.
11 harness (Contact with 3. Disconnect connectors EGC2 and connect T-adapter to female side.
Between PTCN3 (female) (14), (24), WECN3 (female)
ground circuit)
(14), (24), V1 (female) (17) or CM01 (female) (14) and
Resistance
Min. 1 Mz
ground
Resistance
Min. 1 Mz
12
If cause is not found by above checks and failure code [DAFRMC] is displayed, engine
Defective engine concontroller is defective.
troller
13

controller
40-296
D375A-6R
(01)
D375A-6R
(01)
40-297
40-297
Failure code [dB2RKR] ENG controller: CAN communication lost (WE)
Failure code [dB2RKR] ENG controller: CAN communication lost (WE) 40-298
Action code
Failure code
E03
dB2RKR
Failure
CAN communication with engine controller is impossible

(detected by work equipment controller)
Detail of failure
Work equipment controller cannot recognize engine controller in CAN communication circuit.
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 circuit in CAN communication line.
If failure code [DAFRMC] is also displayed, cause of this failure is probably engine controller problem.
Problem on
machine
q
q
q
q
q
Related information
q
q
q
Cause

Perform troubleshooting for failure code [DB2RKR].
40-298
D375A-6R
(01)
Failure code [DB90KT] WE controller: Abnormality in controller
Failure code [DB90KT] WE controller: Abnormality in controller

Action code
Failure code
E01
DB90KT
Failure
40-29
Data recorded in work equipment controller are abnormal

Detail of failure
Information in ROM (non-volatile memory) in work equipment controller is abnormal.
Reset internal adjustment values to default values.
q
q
Operating feel of work equipment may become bad.

Adjusting function by machine monitor may not operate properly.
Problem on
machine
Related information
Cause
Use Adjustment function in service mode, and perform operation of reproducDefective adjustment of work
1
ing trouble. If "E" of failure code disappears at this time, system is normal.
equipment controller
q Adjustment code: 0031 (Initialization of work equipment controller)
Defective work equipment control- Troubleshooting cannot be carried out since defect is in work equipment con2
ler
troller. (If there is no visible trouble in machine, controller may be used as it is.)
D375A-6R
(01)
40-299
Failure code [DB91KK] WE controller: Source voltage reduction

Action code
Failure code
E04
DB91KK
Failure
40-30
Battery direct voltage drop of work equipment controller

Detail of failure
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)
Problem on
machine
q
q
q
Related information
q
q
Cause
1
Trip of circuit breaker

(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 troubleshooting for cause 7 first.
Loose terminal or dis- 1. Turn starting switch to OFF position.

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.
age
Between battery (+) and (-)
Voltage
20 30 V

2. Disconnect the ground cable.
3. Disconnect connector WECN3 and connect T-adapter to female side.
Open circuit or ground 4. Connect the ground cable.
5
fault of wiring 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
20 30 V
Voltage
Open circuit in wiring 3. If the fuse is blown, replace it.
4. If circuit breaker has tripped, reset it.
harness
6
(open circuit or defec- 5. Disconnect connector WECN3 and connect T-adapter to female side.
Between WECN3 (female) (21), (31), (32) or (33) and
tive contact)
ground
Resistance
Max. 1 z
a Check terminal GND01 for looseness and rust.
Between WECN3 (female) (1) or (11) and battery (+)
40-300
Resistance
Max. 1 z
D375A-6R
(01)
Cause

harness
7
circuit)

a
1.
2.
3.
4.
5.
If cause 4 is not the cause for the trouble, this check is not required.
Disconnect ground strap.
If fuse is blown out, replace it.
Disconnect connector WECN3 and connect T-adapter to female side.
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

2. Disconnect ground strap.
Defective work equip3. Insert T-adapter into connector WECN3.
8
ment controller
4. Connect ground strap.
Between WECN3 (1) and (21)/(31)
Voltage
20 30 V
Between WECN3 (11) and (32)/(33)
Voltage
20 30 V
Circuit diagram related to power supply for work equipment controller
D375A-6R
(01)
40-301
40-301
Failure code [DB92KK] WE controller: Output voltage reduction

Action code
Failure code
E04
DB92KK
Detail of failure
Problem on
machine
Related information
Failure
40-302
Voltage drop in power supply for work equipment controller-related actuators

Power supply (battery relay output) voltage for the actuators related to work equipment controller
(relay, solenoid or others) is below 17 V.
q
q
q
q
Power source voltage of work equipment controller can be checked in adjusting function.
(Code: 2022 Work equipment controller voltage check mode)
Cause

CB3 or CB105
Loose terminal or dis- 1. Turn starting switch to OFF position.

connection at terminal Check terminals of battery, battery relay, etc.
age
Voltage
20 30 V
Defective wiring har4 ness or power train

controller
If CB3 or CB105 circuit breaker has tripped, circuit probably has ground fault. In this case,
perform troubleshooting for cause 6 first.
1.
2.
3.
4.
5.

Disconnect the ground cable.
Insert T-adapter into connector WECN3.
Connect the ground cable.
Turn starting switch to ON position.
Between WECN3 (2) and (21)
Voltage
20 30 V
Voltage
20 30 V
Voltage
20 30 V
2. Disconnect ground strap (in order not to make short circuit).
harness
5
(open circuit or defec- Between ground and WECN3 (female) (21)/(31)/(32)/
(33) respectively
Resistance
Max. 1 z
tive contact)
Between terminal BRC and WECN3 (female)
Resistance
Max. 1 z
(2)/(12)/(22) respectively
Ground fault in wiring 1. Turn starting switch to OFF position.
2. Disconnect ground strap (in orde not to make short circuit).
harness
6
(Contact with ground 3. If circuit breaker has tripped, reset it.
4. Disconnect connector WECN3.
circuit)
Between terminal BRC and ground
7
Resistance
Min. 1 Mz
Defective work equipIf cause is not found by above checks, work equipment controller is defective.
ment controller
40-302
D375A-6R
(01)
Circuit diagram related to power supply for work equipment controller
D375A-6R
(01)
40-303
40-303
Failure code [DB97KK] WE cont.: Sensor voltage 5 V (2) reduction

Action code
Failure code
DB97KK
Failure
Work equipment sensor 5 V power supply abnormality

Voltage of 5 V power supply circuit for work equipment controller sensor is below 4.5 V or above
5.5 V.
Abnormal current flowed in 5 V power supply circuit for work equipment controller sensor.
Stops output to 5 V power supply circuit if abnormal voltage flows.
Hydraulic pressure of work equipment pump cannot be monitored correctly (but machine operations are not affected).
Detail of failure
Problem on
machine
Related information
40-304
Cause
Defective hydraulic pump pressure sensor (Internal defect)


2. Disconnect connector HHP.
q If this code is not displayed when hydraulic pump pressure sensor is disconnected, that sensor is defective.
a Other failure codes are displayed, too. This is because the connector is disconnected. Ignore failure codes other than [DB97KK].
2. Disconnect connectors WECN3 and HHP, and connect T-adapter to female
WECN3 (female) (34) or HHP (female) (B) and
ground
2. Disconnect connector HHP and connect T-adapter to female side.
Between HHP (female) (B) and (A)
Voltage
4.5 5.5 V
Defective work equipment control- 2. Insert T-adapters into connectors WECN1 and WECN3.
4
ler
a Since 24 V power is supplied to connector WECN3, 5 V output cannot be
checked with connector WECN3 disconnected.
40-304
Voltage
4.5 5.5 V
D375A-6R
(01)
Circuit diagram related to work equipment controller sensors 5 V power supply
D375A-6R
(01)
40-305
40-305
Failure code [DB99KQ] WE controller: Type select signal

Action code
Failure code
E04
DB99KQ
Detail of failure
Problem on
machine
Related information
Failure
40-306
Machine model selection error on work equipment

Specification setting in work equipment controller does not match specification setting memory (Initial setting of work equipment controller has not yet been performed).
Turns all outputs from work equipment controller OFF.

Machine does not move at all.

Once machine stops, it cannot travel at all.
q
q
Cause
1
Defective adjustment of work

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 (Initialization of work equipment controller)
40-306
D375A-6R
(01)
Failure code [DB9RKR] WE controller: Can communication lost (PT)

Action code
Failure code
E03
DB9RKR
Failure
40-307
CAN communication with work equipment controller (detected

power train controller)
Detail of failure
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 can not be short circuit, ground fault or hot short
circuit in CAN communication line.
Problem on
machine
q
q
q
q
q
Related information
q
q
Cause
1
Defective power supply to work

If failure code [DAFRMC] is also displayed, perform troubleshooting for failure

code [DB91KK] and [DB92KK] first.
2. Disconnect connectors CT2 and CM02 and connect T-adapters to male
side of them.

2
(internal open circuit or short circuit)
Resistance
120 12 z
Resistance
120 12 z
1.
2.
a
Open or short circuit in wiring har3
ness
CAN communication line

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.
Turn starting switch to OFF position and disconnect ground strap.
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.
Approx. 60 z
Resistance
Approx. 60 z
Resistance
Approx. 60 z
Resistance
Approx. 60 z
Resistance
Approx. 120 z
Between CM02 (female ) (9) and (10)
D375A-6R
(01)
Resistance
Resistance
Approx. 120 z
40-307
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
Resistance
Max. 1 z
(female) (9)/(8)
Resistance
Max. 1 z
(female) (10)
Between PTCN2 (female) (32) and EGC2
Resistance
Max. 1 z
(female) (46)
Resistance
Max. 1 z
(female) (47)
Between PTCN2 (female) (32) and WECN2
Resistance
Max. 1 z
(female) (32)
Resistance
Max. 1 z
(female) (22)
Between PTCN2 (female) (32) and V4A
Resistance
Max. 1 z
(female) (4)
Resistance
Max. 1 z
(female) (12)
Between EGC2 (female) (46) and CT2
Resistance
Max. 1 z
(female) (A)
Resistance
Max. 1 z
(female) (B)
2. Insert T-adapters into connectors PTCN3, WECN3, V1, CM01, ACT and
EGC2.
Between PTCN3 (14) or (24) and (31)
5 (Open circuit in wiring or defective Between WECN3 (14) or (24) and (31)
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
ACC signal from starting switch

2. Disconnect connectors PTCN3, WECN3, V1, CM01 and ACT, and connect
q

Resistance
Min. 1 Mz

7
Between PTCN3 (female) (14), (24), WECN3

(female) (14), (24), V1 (female) (17) or CM01
Resistance
Min. 1 Mz
If cause is not found by above checks and failure code [DAFRMC] is disDefective work equipment controlplayed, work equipment controller is defective.
ler
40-308
D375A-6R
(01)
D375A-6R
(01)
40-309
40-309
Failure code [DBB0KK] VHMS controller:Source voltage reduction

Action code
Failure code
DBB0KK
Detail of failure
Problem on
machine
Related information
Failure
40-310
Voltage drop in power supply to VHMS controller

( VHMS controller system)
When engine was running, the switch power voltage from battery relay to VHMS controller dropped
below 19.5 V.
None in particular
VHMS controller LED displays "n9" o "C01".
Cause
1 Trip of circuit breaker (CB105)
If circuit breaker trips, circuit probably has ground fault. In this case, perform
troubleshooting for cause 7 first.
Loose terminal or disconnection at 1. Turn starting switch to OFF position.

terminal
Check terminals of battery, battery relay, TR1S, TR2L, etc.

1.
2.
3.
4.
5.
Open circuit or ground fault of wir6.
5
ing harness
7.
a
Voltage
20 30 V

Disconnect connector V1 and connect T-adapter to female side.
If the fuse is blown, replace it.
If circuit breaker trips, reset it.
If voltage is 0 V, wiring harness is open-cricuited or ground fault.
Between V1 (female) (8) and (11), (12)
Voltage
20 30 V
Voltage
20 30 V
3. If the fuse is blown, replace it.
4. If circuit breaker trips, reset it.
5. Disconnect connector V1 and connect T-adapter to female side.
6
(open circuit or defective contact) Between ground and V1 (female) (11) or (12) or (19)
or (20)
Resistance Max. 1 z
a Check terminal GND01 for looseness and rusting.
Between V1 (female) (8), (9) and battery relay BRC
Resistance Max. 1 z
terminal
7
5. Disconnect connector V1 and connect T-adapter to female side.
Between V1 (female) (9) and ground
40-310
D375A-6R
(01)
Cause
8 Defective VHMS controller

3. Connect T-adapter to connector V1.
Between V1 (8) and (11), (12)
Voltage
20 30 V
Between V1 (9) and (19), (20)
Voltage
20 30 V
Circuit diagram related to power supply for VHMS controller
D375A-6R
(01)
40-31
40-311
Failure code [DBB0KQ] VHMS connector connection abnormality
Failure code [DBB0KQ] VHMS connector connection abnormality

Action code
Failure code
DBB0KQ
Failure
40-312
VHMS connector connection abnormality

(VHMS controller system)
Detail of failure
Incorrect connection of connector V2A, V2B, V3A or V3B of VHMS controller
None in particular
Sensor signal value may not be indicated properly.
VHMS controller LED displays "n9" o "05".
Problem on
machine
Related information
Cause
1 Wrong connector connection
40-312

Check if connectors "V2A" and "V3A" as well as connectors "V2B" and "V3B"
of VHMS controller are connected incorrectly.
D375A-6R
(01)
Failure code [DBB3KK] VHMS controller: Source voltage reduction

Action code
Failure code
DBB3KK
Failure
40-313
Voltage drop in unswithed power supply to VHMS controller

Detail of failure
24 V power supply voltage from battery to VHMS controller is below 12.5 V.
None in particular
VHMS does not operate.
Problem on
machine
Related information
Cause
1 Trip of circuit breaker (CB30)
If circuit breaker trips, circuit probably has ground fault. In this case, perform
Loose terminal
or disconnection at terminal

Check terminals of battery, battery relay, etc.
1.
2.
3.
4.
Open circuit or ground fault of wir- 5.
5
6.
ing harness
a
Voltage
20 30 V

If the fuse is blown, replace it.
Voltage
20 30 V
Voltage
20 30 V
6
(open circuit or defective contact) 5. Disconnect connector V1 and connect T-adapter to female side.
Between ground and V1 (female) (11) or (12) or (19)
or (20)
Resistance Max. 1 z
a Check terminal GND0I for looseness and rust.
Between each of V1 (female) (6), (7) and battery (+) Resistance
D375A-6R
(01)
Max. 1 z
40-313
Cause


a
1.
2.
3.
4.
5.
Min. 1 Mz
Voltage
Voltage
Min. 1 Mz
If cause is not found by the above checks, VHMS controller is defective.

Between V1 (6) and (11), (12)
20 30 V
Between V1 (7) and (19), (20)
40-314
Voltage
Voltage
20 30 V
D375A-6R
(01)
Circuit diagram related to power supply for VHMS controller
D375A-6R
(01)
40-315
40-315
Failure code [DBB5KP] VHMS: Output sensor1 voltage reduction

Action code
Failure code
E00
DBB5KP
Detail of failure
Problem on
machine
Related information
Failure
40-316
VHMS sensor 5 V power supply abnormality

Voltage of 5 V power supply circuit from VHMS controller to sensors is below 4.5 V or above 5.5 V.
Abnormal current flowed in 5 V power supply circuit for VHMS controller sensor.
None in particular
A part of VHMS does not operate.
VHMS controller LED displays "N9" o "04".
Cause

2. Disconnect connector ENBP.
Defective blowby pressure sensor 3. Turn starting switch to ON position.
1
q If this code is not displayed, blowby pressure sensor is defective.
(Internal defect)
a Other failure codes are displayed, too. This is because the connector is disconnected. Ignore failure codes other than [DBB5KP].
2. Disconnect connectors V1 and ENBP, and connect T-adapter to female
2
Between V1 (female) (4) or ENBP (female) (B) and
ground
Hot short in wiring harness (Con- 2. Disconnect connectors ENBP and connect T-adapter to female side.
3
Between ENBP (female) (B) and (A)
Voltage
4.5 5.5 V

2. Insert T-adapter into connector V1 and V2A.
a Since 24 V power is supplied to connector V1, 5 V output cannot be
checked with connector V1 disconnected.
Between V1 (4) and V2A (12)
4.5 5.5 V
Between V1(5) and V2A(12)
40-316
Voltage
Voltage
4.5 5.5 V
D375A-6R
(01)
Circuit diagram related to power supply for VHMS controller sensors 5V
D375A-6R
(01)
40-317
40-317
Failure code [DBB6KP] VHMS:Output sensor2 voltage reduction

Action code
Failure code
DBB6KP
Failure
40-318

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.
VHMS controller LED displays "n9" o "02".
Detail of failure
Problem on
machine
Related information
Cause

2. Disconnect following connectors one by one and turn starting switch to ON position
each time.
Defective transmission main oil pressure 3. After troubleshooting, return to 1.
sensor, front (cylinder q If this code is not displayed when a sensor or a device is disconnected, that sensor or
device is defective.
Nos. 1 - 3) exhaust
a Other failure codes are displayed, too. This is because the connector is disconnected.
temperature sensor,
Ignore failure codes other than [DBB6KP].
rear (cylinder Nos. 4 1 6) exhaust temperaDevice or sensor
Connector
ture sensor, front
TMMD
exhaust temperature Transmission main oil pressure sensor
sensor amplifier or
Front (cylinder Nos. 1 - 3) exhaust temperature sensor
EXHF
rear exhaust temperaEXHR
ture sensor amplifier Rear (cylinder No. 4 - 6) exhaust temperature sensor
(Internal defect)
EXAF
Rear exhaust temperature sensor amplifier

harness
2
circuit)
Front 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 Mz
ground
Between EXHF (female) (1) and (2), or between EXTF
Resistance
Min. 1 Mz
(male) (1) and (2)
Between EXHR (female) (1) or EXTR (male) (1) and
Resistance
Min. 1 Mz
ground
Between EXHR (female) (1) and (2), or between EXTR
Resistance
Min. 1 Mz
(male) (1) and (2)
Resistance
Min. 1 Mz
Between V1 (female) (2) and V2A (female) (12)/(13)
Resistance
Min. 1 Mz

q Reference: Following shows 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)
40-318
Voltage
20 30 V
D375A-6R
(01)
Circuit diagram related to VHMS controller sensor 24V power supply
D375A-6R
(01)
40-319
40-319

Action code
Failure code
DBB7KP
Failure
40-320

Voltage of 12 V power supply circuit from VHMS controller to sensors is below 11.5 V or above 12.5
V.
Abnormal current flowed in 12 V sensor power supply circuit to VHMS controller.
None in particular
When downloading from VHMS controller, LED (Download light) does not light up.
VHMS controller LED displays "N9" o "03".
Detail of failure
Problem on
machine
Related information
Cause

2. Disconnect connector DLT.
Defective download LED (Internal 3. Turn starting switch to ON position.
1
defect)
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].
2. Disconnect connectors V1 and DLT, and connect T-adapter to female side
2
of either of them.
Between V1 (female) (3) or DLT (female) (1) and
ground
2. Disconnect connector DLT and connect T-adapter to female side.
Hot short in wiring harness (Con- 3. Turn starting switch to ON position.
3
Between DLT (female) (1) and (2)
Voltage
11.512.5V

a Since 24 V power is supplied to connector V1, 12 V output cannot be
checked with connector V1 disconnected.
40-320
Voltage
11.512.5V
D375A-6R
(01)
Circuit diagram related to VHMS controller sensor 24 V power supply
D375A-6R
(01)
40-321
40-321
Failure code [DBBQKR] PT cont.: Can communication lost (VHMS)
Failure code [DBBQKR] PT cont.: Can communication lost (VHMS)

Action code
Failure code
E00
DBBQKR
Detail of failure
Problem on
machine
Related information
Failure
40-32
CAN communication with power train controller is impossible

(detected by VHMS controller)
VHMS controller cannot recognize engine controller, power train controller, work equipment controller, and machine monitor in CAN communication.
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].
40-322
D375A-6R
(01)
Failure code [DBE0KT] PT controller: Abnormality in controller
Failure code [DBE0KT] PT controller: Abnormality in controller

Action code
Failure code
E01
DBE0KT
Failure
40-323
Data recorded in power train controller are abnormal

Detail of failure
Information in ROM (non-volatile memory) in power train controller is abnormal.
Resets internal adjustment values to default values.
q
q
Transmission gear shift feel may become bad.

Adjusting function by power train controller may not operate properly.
Problem on
machine
Related information
Cause
1
Defective adjustment of power

train controller
D375A-6R
(01)

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: 0002 (Initialization of power train controller)
Troubleshooting cannot be performed since defect is in power train controller.
(If there is no any visible trouble in machine, controller may be used as it is.)
40-323
Failure code [DBE1KK] PT controller: Source voltage reduction

Action code
Failure code
E04
DBE1KK
Failure
40-324
Battery direct power supply voltage drop for power train controller
Detail of failure
The voltage of battery direct power supply to power train controller is below 17 V.
Machine monitor may not display correctly.

Problem on
machine
q
q
q
Related information
q
q
Power source voltage of power train controller can be checked by adjusting function.
(Code: 2021: Power train controller voltage check mode)
Cause
1

(CB30)

If circuit breaker has tripped, circuit probably has ground fault. In this case, perform troubleshooting for cause 7 first.
Loose terminal,
3 or disconnection at terCheck terminals of battery, battery relay, etc.
minal
4
age
Voltage
20 30 V
1.
2.
3.
Open circuit or ground 4.
5
fault in wiring harness a

Connect ground strap.
Between PTCN3 (female) (1) and (21), (31)
Voltage
20 30 V
Between PTCN3 (female) (11) and (32), (33)
Voltage
20 30 V
Open circuit in wiring 3. If fuse has blown out, replace it.
harness
4. If circuit breaker has tripped, reset it.
6
(open circuit or defec- 5. Disconnect connector PTCN3 and connect T-adapter to female side.
tive contact)
Between PTCN3 (female) (21)/(31)/(32)/(33) and ground
Resistance
Between PTCN3(female) (1), (2) and battery (+)
40-324
Resistance
Max. 1 z
Max. 1 z
D375A-6R
(01)
Cause

harness
7
circuit)

a
1.
2.
3.
4.
5.
Between PTCN3 (female) (1) and (21)/(31)
Resistance
Min. 1 Mz
Between PTCN3 (female) (11) and (32)/(33)
Resistance
Min. 1 Mz
Reference: the followings are standard values in normal condition.
q

controller
Between PTCN3 (1) and (21)/(31)
D375A-6R
(01)
20 30 V
Between PTCN3 (11) and (32)/(33)
Voltage
Voltage
20 30 V
40-325
40-325
Failure code [DBE2KK] PT controller: Output voltage reduction

Action code
Failure code
E04
DBE2KK
Detail of failure
Problem on
machine
Power supply (battery relay output) voltage for the actuators related to power train controller (relay,
solenoid or others) is below 17 V.
Relay and solenoid may not drive be actuated and therefore, system may not operate properly.
q
q
q
q
Main power source voltage of power train controller can be checked by adjusting function.
(Code: 2021: Power train controller voltage check mode)
If the battery relay is not turned ON, see E-mode, E-1.
Cause
1
Voltage drop in power supply for power train controller-related

actuators
Related information
Failure
40-326

CB1 or CB105

If CB1 or CB105 circuit breaker has tripped circuit probably has ground fault. In this case,
Loose terminal,
2 or disconnection at terCheck terminals of battery, battery relay, etc.
minal
3
age
Voltage
20 30 V
Defective wiring har4 ness or power train

controller
1.
2.
3.
4.
5.

Insert T-adapter into connector PTCN3.
Between PTCN3 (2) and (21)
Voltage
20 30 V
Voltage
20 30 V
Voltage
20 30 V
a
1.
2.
3.
Disconnect ground strap (in order not to make short circuit).

harness
5
(open circuit or defec- Between PTCN3 (female) (21)/(31)/(32)/(33) and ground
tive contact)
Between PTCN3 (female) (2), (12) or (22) and BRC
harness
6
circuit)
a
1.
2.
3.
4.

controller
40-326
Max. 1 z
Resistance
Max. 1 z
Disconnect ground strap (in order not to make short circuit).
Disconnect connector PTCN3.

7
Resistance
Resistance
Min. 1 Mz
D375A-6R
(01)
D375A-6R
(01)
40-327
40-327
Failure code [DBE5KK] PT cont.: Sensor voltage 5 V (1) reduction

Action code
Failure code
E03
DBE5KK
q
Detail of failure
q
Problem on
machine
Related information
q
q
Failure
Power train controller 5 V power supply (1) abnormality

Voltage of 5 V power supply (1) circuit from power train controller to sensors is below 4.5 V or
above 5.5 V.
Abnormal current flowed in 5 V power supply (1) circuit for power train controller sensors.
Stops output to 5 V power supply (1) circuit, if abnormal current flows.

q
q
Cause
Defective fuel control dial, brake

1 pedal or PCCS lever (Internal
defect)

position each time.
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
DIAL
PCCS lever
TL2
Brake pedal
Connector
Fuel control dial
BRK

40-328

Voltage
4.5 5.5 V

2. Disconnect all of connectors PTCN1, DIAL, and TL2, and connect
T-adapter to female side of either of them.
Between ground and PTCN1 (female) (22), TL2
(female) (4) and (5), BRK (C) or DIAL (female) (1)
Resistance
Min. 1 Mz

2. Disconnect all of connectors DIAL, TL2, and BRK, and connect T-adapter
to female side of either of them.
Hot short circuit in wiring harness 3. Turn starting switch ON.
4
Between TL2 (female) (4) and (1) or between
(female) (5) and (8) or between BRK (C) and (A), or
Voltage
4.5 5.5 V
between DIAL (female) (1) and (3)
40-328
D375A-6R
(01)
D375A-6R
(01)
40-329
40-329
Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction

Action code
Failure code
E03
DBE6KK
q
Detail of failure
q
Problem on
machine
Related information
q
q
Failure
Power train controller sensor 24 V power supply abnormality

Voltage of 24 V power supply circuit from power train controller to sensors is below 17 V or above
30 V.
Abnormal current flowed in 24 V power supply circuit for power train controller sensors.
Stops output to 24 V power source circuit if abnormal voltage flows.

Once machine stops, travel is limited to F1 and R1.
q
q
Cause
Defective inclination angle sensor, torque converter inlet pres1 sure sensor or torque converter
outlet pressure sensor (Internal
defect)

position 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, too. This is because the connector is disconnected. Ignore failure codes other than [DBE6KK].
Connector
PT1
Torque converter inlet pressure sensor
Sensor
Pitch angle sensor
TIP
Torque converter outlet pressure senTOP

sor

40-330
40-3 0
Voltage
20 30 V

2. Disconnect connectors PTCN1, PT1, TIP, and TOP, and connect T-adapter
to female side of either of them.
Between ground and PTCN1 (female) (16) or TIP
(B) or TOP (B) or PT1 (female) (C)
2. Disconnect connectors PT1, TIP, and TOP, and connect T-adapter to
female side of either of them.
Between TIP (B) and (A) or between TOP (B) and
Voltage
20 30 V
(A) or between PT1 (female) (C) and (A)
D375A-6R
(01)
D375A-6R
(01)
40-3 1
40-331
Failure code [DBE7KK] PT cont.: Sensor voltage 5 V reduction

Action code
Failure code
E01
DBE7KK
Failure
40-3 2
Power train controller sensor 5 V power supply (2) abnormality

Voltage of 5 V power supply (2) circuit from power train controller to sensors is below 4.5 V or above
5.5 V.
Abnormal current flowed in 5 V power supply (2) circuit for power train controller sensor.
Stops output to 5 V power supply (2) circuit, if abnormal current flows.
Shoe slip control function may not operate properly (only for machine with shoe slip control).
Detail of failure
Problem on
machine
Related information
Cause

2. Disconnect connector SSA.
Defective acceleration sensor
1
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].
2. Disconnect connectors PTCN3 and SSA and connect T-adapter to female
2
Between PTCN3 (female) (34) or SSA (female) (1)
and ground
Hot short circuit in wiring harness 2. Disconnect connector SSA and connect T-adapter to female side.
3
Between SSA(female)(1) and (3)
Voltage
4.5 5.5 V
a Since 24 V power is supplied to connector PTCN3, 5 V output cannot be
checked with connector PTCN3 disconnected.
40-332
Voltage
4.5 5.5 V
D375A-6R
(01)
Circuit diagram related to power train controller sensor 5 V (2) power supply
D375A-6R
(01)
40-3 3
40-333
Failure code [DBE9KQ] PT controller: Type select signal

Action code
Failure code
E04
DBE9KQ
Detail of failure
Problem on
machine
Related information
Failure
40-3 4
Power train controller: Type select signal

The specification set in power train controller does not agree with the specification set in memory
(Initialization of the power train controller is not performed).
Turns all outputs of power train controller to OFF position.

Machine does not move at all.

q
q
Cause
1
Defective adjustment of power

train controller
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)
40-334
D375A-6R
(01)
Failure code [DBERKR] PT controller: Can communication lost (WE)

Action code
Failure code
E03
DBERKR
Failure
40-3 5
CAN communication with power train controller is impossible.

(detected by work equipment controller )
Detail of failure
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.
[DBERKR] is displayed on the machine monitor, CAN communication between work equipment
controller and machine monitor is normal. That is, there can not be short circuit, ground fault or hot
short circuit in CAN communication line.
The CAN communication line signal in operation is pulse voltage, so it cannot be measured by using multimeter.
Problem on
machine
q
q
q
q
q
Related information
q
q
Cause
1
Defective power supply to power

train controller

2

If failure code [DBBQKR] is also displayed, perform troubleshooting for failure
code [DBE1KK] and [DBE2KK] first.
2. Disconnect connectors CT2 and CM02 and connect T-adapters to male
side of them.
Resistance
120 12 z
Resistance
120 12 z
1.
2.
a
ness
CAN communication line

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 wiring harness.
Turn starting switch to OFF position and disconnect ground strap.
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 is 1 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.
Approx. 60 z
Resistance
Approx. 60 z
Resistance
Approx. 60 z
Resistance
Approx. 60 z
Resistance
Approx. 120 z
D375A-6R
(01)
Resistance
Resistance
Approx. 120 z
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
Resistance
Max. 1 z
(female) (9)/(8)
Resistance
Max. 1 z
(female) (10)
Resistance
Max. 1 z
(female) (46)
Resistance
Max. 1 z
4 (Open circuit in wiring or defective (female) (47)
Resistance
Max. 1 z
(female) (32)
Resistance
Max. 1 z
(female) (22)
Resistance
Max. 1 z
(female) (4)
Resistance
Max. 1 z
(female) (12)
Resistance
Max. 1 z
(female) (A)
Resistance
Max. 1 z
(female) (B)
2. Insert T-adapters into connectors PTCN3, WECN3, V1, CM01, ACT and
EGC2.
Between PTCN3 (14) or (24) and (31)
5 (Open circuit in wiring or defective Between WECN3 (14) or (24) and (31)
Voltage
20 30 V
Voltage
20 30 V
Voltage
20 30 V
Voltage
20 30 V
Voltage
20 30 V
Voltage
20 30 V
ACC signal from starting switch

2. Disconnect connectors PTCN3, WECN3, V1, CM01 and ACT, and connect
Between PTCN3 (female) (14), (24), WECN3
(female) (14), (24), V1 (female) (17) or CM01
Resistance
Min. 1 Mz
q


8
Resistance
Min. 1 Mz
If cause is not found by above checks and failure code [DAFRMC] is displayed, power train controller is defective.
Defective work equipment control- If cause is not found by above checks, work equipment controller is defective.
ler
40-336
D375A-6R
(01)
D375A-6R
(01)
40-3 7
40-337
Failure code [DD12KA] Shift up Sw: Disconnection

Action code
Failure code
E02
DD12KA
Failure
40-3 8
Shift up switch: Disconnection

Detail of failure
Both lines of NO* and NC* for shift up switch circuit are OPEN (switch: OFF) at the same time.
Recognizes that the shift up switch is not pressed.
Problem on
machine
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.
Related information
q
q
q
Cause

1.
2.
3.
a
Defective shift up switch


Disconnect connector SFTU.
Turn shift up switch to ON or OFF position and troubleshoot.
"Switch OFF": Release, "Switch ON": Press
Disconnection or hot short in wiring harness
Between SFTU (male)

(3) and (2)
Switch: OFF
Resistance
Max. 1 z
Switch: ON
Resistance
Min. 1 Mz
Between SFTU (male)

(1) and (2)
Switch: OFF
Resistance
Min. 1 Mz
Switch: ON
Resistance
Max. 1 z
1.
2.
3.
4.
a

Insert T-adapter into connector TL3.
Turn starting switch ON position.
When voltage is 0V, it shows open circuit, and when voltage is 24 V, it
shows hot short circuit 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
711 V
Voltage
711 V

2. Disconnect connectors PTCN1 and PTCN3, and connect T-adapters to
3. Turn shift up switch to ON or OFF position and troubleshoot.
3
(open circuit or defective contact) Between PTCN3 (female) (29) and
Switch: OFF Resistance Max. 1 z
PTCN1 (female) (10)
PTCN1 (female) (10)
40-338
Switch: ON Resistance
Max. 1 z
D375A-6R
(01)
Cause

2. Insert T-adapters into connectors PTCN1 and PTCN3.
4. Turn shift down switch to ON or OFF position and troubleshoot.
a Voltage of apporximately 9 V is applied to PTCN3 pin (29) and PTCN3 pin
(39) through resistor in power train controller.
Between PTCN3 (29)
and PTCN1 (10)
Switch: OFF
Voltage
Max. 1 V
Switch: ON
Voltage
711 V
Between PTCN3 (39)

and PTCN1 (10)
Switch: OFF
Voltage
711 V
Switch: ON
Voltage
Max. 1 V
*NO: Normally Open

*NC: Normally Closed
Circuit diagram related to shift up switch
D375A-6R
(01)
40-3 9
40-339
Failure code [DD12KB] Shift up Sw: Short circuit

Action code
Failure code
E02
DD12KB
Detail of failure
Failure
40-340
Shift up switch: Short circuit

Both lines of NO* and NC* for shift up switch circuit are 0 V (switch: ON) at the same time.
Transmission gear cannot be shifted up.
Problem on
machine
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.
Related information
q
q
Cause

1.
2.
3.
a

(Internal open circuit in wiring)

Turn shift switch to ON or OFF position and troubleshoot.

Between SFTU (male)

(3) and (2)
Switch: OFF
Resistance
Max. 1 z
Switch: ON
Resistance
Min. 1 Mz
Between SFTU (male)

(1) and (2)
Switch: OFF
Resistance
Min. 1 Mz
Switch: ON
Resistance
Max. 1 z

2. Disconnect connectors PTCN3 and SFTU and connect T-adapter to female
side of PTCN3.
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

2. Disconnect connectors PTCN3 and SFTU and connect T-adapter to female
side of PTCN3.
a Check with multimeter in continuity mode.
Between PTCN3 (female) (29) and each pin other
No continuity
than (29)
(No sound is heard)
No continuity
than (39)
(No sound is heard)
4. Turn shift switch to ON or OFF position and troubleshoot.
a Voltage of apporx.9 V is applied to PTCN3 pin (29) and PTCN3 pin (39)
through resistor in power train controller.
Between PTCN3 (29)
Switch: OFF
Voltage
Max. 1 V
Switch: ON
Voltage
711 V
and PTCN1 (10)
Between PTCN3 (39)
Switch: OFF
Voltage
711 V
Switch: ON
Voltage
Max. 1 V
and PTCN1 (10)
*NO: Normally Open

40-340
D375A-6R
(01)
D375A-6R
(01)
40-341
40-341
Failure code [DD13KA] Shift down Sw: Disconnection

Action code
Failure code
E02
DD13KA
Failure
40-342
Shift-down switch Disconnection

Detail of failure
Both linens of NO* and NC* for shift down switch circuit are OPEN (switch: OFF) at the same time.
Problem on
machine
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 up switch)
Connector SFTD has no T-adapters, don't perform troubleshooting in female side.
Related information
q
q
q
Cause

1.
2.
3.
4.
a

Disconnect connector SFTD.
When voltage is 0 V, it shows open circuit, and when voltage is 24 V, it
shows hot short circuit in wiring harness.
a Voltage of apporximately 9 V is applied to signal lines of "NO" and "NC"
Voltage
711 V
Voltage
711 V

2. Disconnect connector PTCN1, PTCN3 and SFTD, and connect T-adapters
to female side of them.

Between PTCN3 (female) (19) and SFTD (male) (1) Resistance
Between PTCN1 (female) (10) and SFTD (male) (2) Resistance
Between PTCN3 (female) (9) and SFTD (male) (3)
1.
2.
3.
a
Defective shift down switch
Resistance
Max. 1 z
Max. 1 z
Max. 1 z

Disconnect connectors TL3 and connect T-adapters to female side.
Switch OFF: Release, Switch ON: Press
40-342
Between TL3 (male) (5)

and (6)
Switch: OFF
Resistance
Max. 1 z
Switch: ON.
Resistance
Min. 1 Mz

and (5)
Switch: OFF
Resistance
Min. 1 Mz
Switch:ON
Resistance
Max. 1 z
D375A-6R
(01)
Cause

a Voltage of apporximately 9 V is applied to PTCN3 pin (19) and pin (9)
Between PTCN3 (19)
and PTCN1 (10)
Switch: OFF
Voltage
711 V
Switch: ON
Voltage
Max. 1 V

PTCN1 (10)
Switch: OFF
Voltage
Max. 1 V
Switch: ON
Voltage
711 V
*NO: Normally Open

D375A-6R
(01)
40-343
40-343
Failure code [DD13KB] Shift down Sw: Short circuit

Action code
Failure code
E02
DD13KB
Failure
40-34
Shiftdown switch: short circuit

Detail of failure
Both lines of NO* and NC* for shift down switch circuit are 0 V (switch: ON) at the same time.
Problem on
machine
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 perform troubleshooting in female side.
Related information
q
q
q
Cause
Ground fault of wiring harness

(Contact with GND circuit)

2. Disconnect connectors PTCN3 and SFTD and connect T-adapter to female
side of PTCN3.
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

2. Disconnect connectors PTCN3 and SFTD and connect T-adapter to female
side of PTCN3.
No continuity
than (9)
(No sound is heard)
than (19)
No continuity
(No sound is heard)

2. Disconnect connectors TL3 and connect T-adapters to female side.
Defective shift down switch
a Switch OFF: Release, Switch ON: Press
3
Switch: OFF
Resistance Max. 1 z
Switch: ON
and (6)
Switch: OFF
Switch: ON
Resistance Max. 1 z
and (5)
q Reference; the followings are cirteria in normal condition.
4. Turn shift down switch to ONor OFF position and troubleshoot.
4 Defective transmission controller
a Voltage of apporx.9 V is applied to PTCN3 pin (19) and pin (9) through resistor in power train controller.
Between PTCN3 (19)
Switch: OFF
Voltage
711 V
Switch: ON
Voltage
Max. 1 V
and PTCN1 (10)
Switch: OFF
Voltage
Max. 1 V
Switch: ON
Voltage
711 V
PTCN1 (10)
*NO: Normally Open

40-344
D375A-6R
(01)
Circuit diagram related to shift down switch
D375A-6R
(01)
40-345
40-345
Failure code [DD14KA] Parking lever Sw: Dissconnection

Action code
Failure code
E03
DD14KA
Detail of failure
Problem on
machine
Parking lever switch: Disconnection

Both lines of NO* and NC* for parking brake lever switch circuit are OPEN (switch: OFF) at the
same time.
Recognizes parking brake lever is in Free position.

q
q
q
q
q
q
Related information
Failure
40-346
q
q

Engine cannot start.
NC* line is used for sensing operation and NO* line is used for detecting error.
Condition of parking brake lever switch signal can be checked with monitoring function.
Method of reproducing failure code:Turn starting switch to ON position and operate parking brake
lever.
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

Between NSW (male) (A) Lever: LOCK

and (B)
Lever: FREE
Resistance
Min. 1 Mz
Resistance
Max. 1 z

and (C)
Lever: FREE
Resistance
Max. 1 z
Resistance
Min. 1 Mz
1.
2.
3.
a

Disconnect connector NSW and connect T-adapter to female side.
If voltage is 0 V, it shows open circuit, and if voltage is 24 V, it shows hot
short circuit in wiring harness.
Open circuit or hot short circuit in
2
a Voltage of approximately 9 V is applied to signal lines of "NO" and "NC"
wiring harness
Between NSW (female) (B) and (A)
Voltage
711 V
Between NSW (female) (C) and (A)
Voltage
711 V
2. Disconnect connectors PTCN1 and NSW, and connect T-adapters to
Between PTCN1 (female) (12) and NSW (female)
3
Resistance Max. 1 z
(open circuit or defective contact) (C)
Between PTCN1 (female) (18) and NSW (female)
Resistance Max. 1 z
(B)
Between NSW (female) (A) and ground
40-346
Resistance
Max. 1 z
D375A-6R
(01)
Cause

4. Operate shiftup switch and troubleshoot.
a The voltage of approximately 9 V is applied to PTCN1 pin (12) and pin (18)
through the resistor in the power train controller.
Between PTCN1 (18)
and ground
Lever: LOCK
Voltage
711 V
Lever: FREE
Voltage
Max. 1 V
Between PTCN1 (12)

and ground
Lever: LOCK
Voltage
Max. 1 V
Lever: FREE
Voltage
711 V
*NO: Normally Open

Circuit diagram related to parking brake lever switch
D375A-6R
(01)
40-347
40-347
Failure code [DD14KB] Parking lever Sw: Short circuit

Action code
Failure code
E03
DD14KB
Detail of failure
Problem on
machine
Parking lever switch: Short circuit

Both lines of NO* and NC* for parking brake lever switch circuit are 0 V (switch: ON) at the same
time.
Recognizes parking brake lever is in FREE position.

q
q
q
q
q
q
Related information
Failure
40-348
q
q

Engine cannot start.
NC* line is used for sensing opration and NO* line is used for detecting error.
Condition of parking brake lever 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 parking brake
lever.
When parking brake lever is FREE, parking brake lever switch becomes ON.
Cause
Defective parking brake lever



2. Disconnect connector NSW and connect T-adapter to male side.
Lever: FREE
Resistance Max. 1 z
and (B)
Resistance Max. 1 z
Lever: FREE
and (C)
2. Disconnect connectors PTCN1 and NSW, and connect T-adapter to female
Between NSW (female) (B) or PTCN1 (female) (18)
and ground
Between NSW (female) (C) or PTCN1 (female) (12)
and ground
2. Disconnect connectors PTCN1 and NSW, and connect T-adapter to female
side of either of PTCN1.
a Check with multimeter continuity mode.
Between PTCN1 (female ) (12) and each pin other
No continuity
than (12)
(No sound is heard)
Between PTCN1 (female ) (18) and each pin other
No continuity
than (18)
(No sound is heard)
4. Operate shiftup switch and troubleshoot.
through the resistor in the power train controller.
Between PTCN1 (18)
Lever: LOCK
Voltage
711 V
Lever: FREE
Voltage
Max. 1 V
and ground
Between PTCN1 (12)
Lever: LOCK
Voltage
Max. 1 V
Lever: FREE
Voltage
711 V
and ground
*NO: Normally Open

40-348
D375A-6R
(01)
Circuit diagram related to parking brake lever switch
D375A-6R
(01)
40-349
40-349
Failure code [DDB9L4] Reverse SW Signal disagreement

Action code
Failure code
E03
DDB9L4
Failure
40-350
Inconsistent reverse switch signal

Detail of failure
There is inconsistency in line 2 of NO* for reverse switch circuit.
Recognizes that reverser switch is not pressed.

Condition of reverse switch signal can be checked with monitoring function.
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.
Problem on
machine
q
q
Related information
q
q
Cause
1
Wrong selection of travel lever

type

If failure code [DDT5KQ] is displayed, carry out troubleshooting for it.
1.
2.
3.
4.
a

Disconnect connector RTS.
If voltage is 0 V, it shows open circuit in wiring harness, and if voltage is 24
V, it shows hot short circuit in wiring harness.
2
wiring harness
a Voltage of approximately 9 V is applied to two signal lines of "NO" through
Voltage
711 V
Voltage
711 V

2. Disconnect connectors PTCN1, PTCN3, TL3, and RTS, and connect
T-adapters to female side of PTCN1, PTCN3, and PL3.
3
Between PTCN3 (female) (19) and RTS (male) (1) Resistance

(open circuit or defective contact) Between PTCN1 (female) (10) and TL3 (female) (2) Resistance
Max. 1 z
Max. 1 z
Between PTCN1 (female) (10) and RTS (male) (2)


Resistance
Max. 1 z
Resistance
Max. 1 z

2. Disconnect connectors PTCN3 and RTS, and connect T-adapter to female
side of PTCN3.
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

2. Disconnect connectors PTCN3 and RTS, and connect T-adapter to female
side of PTCN3.
No continuity
than (9)
(No sound is heard)
than (19)
40-350
No continuity
(No sound is heard)
D375A-6R
(01)
Cause
Defective reverse switch


1.
2.
3.
4.
a

Disconnect connector FTS.
Turn reverse switch ON/OFF, and troubleshoot.
Switch: OFF
Resistance
Min. 1 Mz
Switch: ON
Resistance
Max. 1 z

and FTS (female) (2)

and (6)
Switch: OFF
Resistance
Min. 1 Mz
Switch: ON
Resistance
Max. 1 z
4. Turn reverse switch ON/OFF, and troubleshoot.
a Voltage of approximately 9 V is applied to PTCN3 pin (19) and pin (9)
Between PTCN3 (19)
and PTCN1 (10)
Switch: OFF
Voltage
711 V
Switch: ON
Voltage
Max. 1 V

PTCN1 (10)
Switch: OFF
Voltage
711 V
Switch: ON
Voltage
Max. 1 V
*NO: Normally Open

Circuit diagram related to reverse switch
40-351
a Exclusive for single-direction lever
D375A-6R
(01)
40-351
Failure code [DDE2KA] Pre lub. oil press sw: Disconnection

Action code
Failure code
E02
Failure
DDE2KA
40-352
Pre-lubricating oil pressure switch open circuit

(Power train controller)
Power train controller has started pre-lubrication, pre-lubricating motor is operating, and voltage is
detected at pre-lubricating motor. However, pre-lubricating oil pressure switch is not turned to OFF
position.
None in particular
Problem on
machine
Engine does not run (It runs in skip mode, however).
Pre-lubricating oil pressure switch is turned to ON position when oil pressure is not applied.
Whether pre-lubricating oil pressure switch is turned to ON position can be checked with monitoring
function.
(Code: 40910 PT controller SW Input 2)
Whether pre-lubricating motor is in operation can be checked with monitoring function.
(Code: 40909 P/T controller SW Output)
Detail of failure
Related information
q
Cause

2. Disconnect terminal POP.
Defective pre-lubricating oil pres- 3. Turn starting switch to ON position.
1
sure switch
a During pre-lubrication
Between terminal POP (on pre-lubricating oil presNot conductive
sure switch side) and ground
2
Resistance Max. 1 z
3

3. Disconnect terminal POP.
Resistance
Min. 1 Mz
If cause is not found by above checks, power train controller is defective.

Reference: Following shows criteria in normal condition.
a Between PTCN2 (13) and (29) during pre-lubriVoltage
711 V
cation
q
Circuit diagram related to pre-lubricating oil pressure switch
40-352
40-352
D375A-6R
(01)
D375A-6R
(01)
40-353
Failure code [DDK3L4] Forward SW Signal disagreement

Action code
Failure code
E03
DDK3L4
Failure
40-354
Inconsistent forward switch signal

Detail of failure
There is inconsistency in line 2 of NO* for forward switch circuit.
Recognizes that forward switch is not pressed.

Condition of forward switch signal can be checked with monitoring function.
Method of reproducing failure code: Turn starting switch to ON position (and operate forward
switch).
Problem on
machine
q
q
Related information
Cause
1

type
Defective forward switch


1.
2.
3.
4.
a

Between FTS (male) (3)

and TL3 (male) (5)
Switch: OFF
Resistance
Min. 1 Mz
Switch: ON
Resistance
Max. 1 z
Between FTS (male) (1)

and (2)
Switch: OFF
Resistance
Min. 1 Mz
Switch: ON
Resistance
Max. 1 z
1.
2.
3.
4.
a

3
wiring harness
a Voltage of about 9 V is applied to signal lines of NO and NC through resistor in power train controller.
Voltage
711 V
Voltage
711 V
2. Disconnect connector PTCN1, PTCN3 and TL3, and connect T-adapters to
3. Disconnect connector RTS.

(open circuit or defective contact) Between PTCN3 (female) (39) and TL3 (female) (1) Resistance
Between PTCN1 (female) (10) and TL3 (female) (2) Resistance
Max. 1 z
Max. 1 z
Between PTCN3 (female) (29) and TL3 (female) (3) Resistance


Max. 1 z
Max. 1 z
Resistance

2. Disconnect connectors PTCN3 and FTS, and connect T-adapter to female
side of PTCN3.
Resistance
Min. 1 Mz
40-354
Resistance
Min. 1 Mz
D375A-6R
(01)
Cause

2. Disconnect connectors PTCN3 and FTS, and connect T-adapter to female
side of PTCN3.
No continuity
than (29)
(No sound is heard)
No continuity
than (39)
(No sound is heard)
through the resistor in power train controller.
Between PTCN3 (29)
and PTCN1 (10)
Switch: OFF
Voltage
711 V
Switch: ON
Voltage
Max. 1 V
Between PTCN3 (39)

and PTCN1 (10)
Switch: OFF
Voltage
711 V
Switch: ON
Voltage
Max. 1 V
*NO: Normally Open

Circuit diagram related to forward switch
40-35
D375A-6R
(01)
40-355
Failure code [DDK5KA] Shift switch disconnection

Action code
Failure code
E02
DDK5KA
Failure
40-356
Shift switch disconnection

(Transmission controller system)
Both lines of NO: Normally Open and NC: Normally Closed for shift up switch circuit are OPEN
(switch: OFF) at the same time.
Recognizes that switch is not pressed.
Problem on
machine
Gear cannot be shifted up and down (1st io2nd).
NO: Normally Open line is used for sensing operation and NC: line is used for detecting error.
Detail of failure
Related information
q
q
Cause
1
type

1.
2.
3.
a
Defective shift switch


Disconnect connector SNC and connect T-adapter to male side.
Turn shift switch to ON or OFF position and troubleshoot.
Between SNC (male) (1) and

(3)
Switch: OFF
Resistance
Max. 1 z
Switch: ON
Resistance
Min. 1 Mz
Between SNC (male) (1) and

(2)
Switch: OFF
Resistance
Min. 1 Mz
Switch: ON
Resistance
Max. 1 z
1.
2.
3.
a

Disconnect connector SNC and connect T-adapter to female side.
3
a Voltage of about 9 V is applied to signal lines of NO and NC through rewiring harness
sistor in power train controller.
Between SNC (female) (2) and (1)
Voltage
711 V
Voltage
711 V
2. Disconnect connectors PTCN1, PTCN2 and SNC, and connect T-adapter
Between PTCN1 (female) (10) and SNC
4
Resistance
Max. 1 z
(open circuit or defective contact) (female) (1)
Resistance
Max. 1 z
(female) (2)
Resistance
Max. 1 z
(female) (3)
40-356
D375A-6R
(01)
Cause

a Voltage of about 9 V is applied to PTCN1 pin (6) and PTCN2 pin (7) through
PTCN1(10)
Switch: OFF
Voltage
711 V
Switch: ON
Voltage
Max. 1 V

PTCN1(10)
Switch: OFF
Voltage
Max. 1 V
Switch: ON
Voltage
711 V
Circuit diagram related to shift switch
40-357
D375A-6R
(01)
40-357
Failure code [DDK5KB] Shift switch short circuit

Action code
Failure code
E02
DDK5KB
Failure
40-358
Shift switch short circuit

Both lines of NO: Normally Open and NC: Normally Closed for shift up switch circuit are 0 V (switch:
ON) at the same time.
Recognizes that switch is not pressed.
Problem on
machine
Gear cannot be shifted up and down (1st io2nd).
(Code: 40905 Power train control Input 3)
Detail of failure
Related information
q
q
Cause
1
type

1.
2.
3.
a


Between SNC (male) (1) and Switch: OFF

(3)
Switch: ON
Between SNC (male) (1) and Switch:OFF
(2)
Switch: ON

(Contact with rround circuit)
40-358
Max. 1 z
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Max. 1 z

2. Disconnect connectors STC1, STC3 and SNC and connect T-adapter to
female side of one of them.
Between SNC (female) (2) and ground , or
Resistance
Min. 1 Mz
between PTCN2(female) (7) and ground
Between SNC (female) (3) and ground , or
between PTCN1 (female) (6) and ground
Resistance
Resistance
Min. 1 Mz

2. Disconnect connectors PTCN1, PTCN2 and SNC and connect T-adapters
to female side of PTCN1 and PTCN2.
Between PTCN1 (female) (6) and each pin
No continuity (No sound is
other than (6)
heard)
other than (7)
heard)
D375A-6R
(01)
Cause

a Voltage of about 9 V is applied to PTCN1 pin (6) and PTCN2 pin (7) through
PTCN1(10)
Switch: OFF
Voltage
711 V
Switch: ON
Voltage
Max. 1 V

PTCN1(10)
Switch: OFF
Voltage
Max. 1 V
Switch: ON
Voltage
711 V
Circuit diagram related to shift switch
D375A-6R
(01)
40-359
40-359
Failure code [DDN2LD] Blade tilt RH pressure SW abnormality

Action code
Failure code
DDN2LD
Failure
40-360
Blade tilt right hand oil pressure switch is pressed for long time
Detail of failure
The signal of the blade tilt right oil pressure switch circuit is kept turned 0 V (ON) for 60 seconds.
Recognizes that the oil pressure switch is turned to OFF position.
Problem on
machine
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".
Related information
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Cause
1
Wrong operation of lever

If failure code (reset indication) is displayed even after reset operation, incor(When electrical system is normal) rect shift lever operation might be made.

Defective blade tilt right hand oil 2. Disconnect connector TRS and connect T-adapter to male side.
2 pressure switch (Internal short cirBetween TRS (female) (1) and ground
cuit)
(Oil pressure switch is OFF position.)
2. Disconnect connector TRS.
Ground fault of wiring harness or 3. Turn starting switch to ON position (and wait for longer than 60 sec.).
3 defective work equipment control- If failure code [DDN2LD] is still displayed, there is ground fault of wiring harler
ness or work equipment controller is defective.
(If failure code [DDN2LD] is not displayed, blade tilt right oil pressure switch is
defective.)
2. Disconnect connector WECN2 and TRS, and connect T-adapter to female
4
Between WECN2 (female) (7) or TRS (female) (1)
and ground
If check result of cause 3 is abnormal and check result of cause 4 is normal,
2. Insert T-adapters into connectors WECN1 and WECN2.
3. Start engine.
Defective work equipment control- a Keep PCCS lever in N position.
5
ler
Voltage
711 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-6R
(01)
Circuit diagram related to Blade tilt right hand oil pressure switch
D375A-6R
(01)
40-361
40-361
Failure code [DDN3LD] Blade tilt LH pressure SW abnormality

Action code
Failure code
DDN3LD
Failure
40-362
Blade tilt left hand oil pressure switch is pressing for long time
Detail of failure
The signal of the blade tilt left oil pressure switch circuit is kept turned ON (0 V) for 60 seconds.
Recognizes that oil pressure switch is turned to OFF position.
Problem on
machine
Data communication of VHMS may become 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)
after 60 seconds).
Related information
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Cause
If failure code lamp still lights up (resetting is still urged) after the resetting
1
operation is performed, it is suspected that the lever was operated to cause an
(When electrical system is normal)
error.
Defective blade tilt left hand oil
2. Disconnect connector TLS and connect T-adapter to male side.
2 pressure switch (Internal short cirBetween TLS (female) (1) and ground
cuit)
2. Disconnect connector TLS.
Ground fault in wiring harness or 3. Turn starting switch to ON position (and wait for longer than 60 sec.).
3 defective work equipment control- If failure code [DDN3LD] is still displayed, there is ground fault in wiring harler
(If failure code [DDN3LD] is not displayed, blade tilt left oil pressure switch is
defective.)
2. Disconnect connector WECN2 and TLS, and connect T-adapter to female
4
Between WECN2 (female) (17) or TLS (female) (1)
and ground
3. Start engine.
Defective work equipment control- a Keep PCCS lever in N position.
5
ler
Voltage
7 11 V
4.While depressing brake pedal, operate blade lever and perform troubleshooting.
Between WECN2 (17)
L.H. tilt
Voltage
Max. 1 V
and WECN1 (4)
40-362
D375A-6R
(01)
Circuit diagram related to blade tilt left hand oil pressure switch
D375A-6R
(01)
40-363
40-363
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection

Action code
Failure code
E02
DDN7KA
Failure
40-364
Work equipment knob switch (lower): Disconnection

Both lines of NO: Normally Open and NC: Normally Closed for blade knob lower switch circuit are
OPEN (switch: OFF) at the same time.
Recognizes that blade knob switch lower is not pressed.
Problem on
machine
Blade knob switch lower does not work.
NO: Normally Open line is used for sensing operation and NC: Normally Closed line is used for detecting error.
Condition of blade knob switch lower signal can be checked with monitoring function.
(Code: 70300 Blade Knob Sw Input)
Method of reproducing failure code: Turn the starting switch to ON position and (operate blade pitch
switch).
Connector WNBL has no T-adapters, don't perform troubleshooting in female side.
Detail of failure
Related information
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Cause

1.
2.
3.
4.
a

Disconnect connector WNBL.
Insert T-adapter into connector P03.
1
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 (female) (2) and (1)
Voltage
7 11 V
Voltage
7 11 V
2. Disconnect connectors WECN1, WECN2 and WNBL, and connect
Between WECN2 (female) (26) and WNBL (female)
2
Resistance Max. 1 z
(open circuit or defective contact) (1)
Resistance Max. 1 z
(2)
Resistance Max. 1 z
(3)
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 knob switch for blade
Switch: OFF
Resistance Max. 1 z
Between P03 (female)
3
down (internal disconnection)
(5) and (1)
Switch: ON
(1) and (2)
40-364
Switch: OFF
Resistance
Min. 1 Mz
Switch: ON
Resistance
Max. 1 z
D375A-6R
(01)
Cause

Defective work equipment control- a Voltage of approx.9 V is applied to WECN2 pin (26) and pin (36) through
4
ler
Between WECN2 (36)
and WECN1 (4)
Switch: OFF
Voltage
Max. 1 V
Switch: ON
Voltage
7 11 V
Between WECN2 (26)

and WECN1 (4)
Switch: OFF
Voltage
7 11 V
Switch: ON
Voltage
Max. 1 V
Circuit diagram related to work equipment knob switch
D375A-6R
(01)
40-365
40-365
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit

Action code
Failure code
E02
DDN7KB
Failure
40-36
Work equipment knob switch (Lower): Short circuit

Both lines of NO: Normally Open and NC: Normally Closed for blade knob switch lower circuit are
0 V (switch: ON) at the same time.
Recognizes that blade knob lower switch is not pressed.
Problem on
machine
Blade knob switch (lower) does not work.
Condition of blade knob switch lower signal can be checked with monitoring function.
Method of reproducing failure code: Turn the starting switch to ON position and (operate blade pitch
switch).
Connector WNBL has no T-adapters, don't perform troubleshooting in female side.
Detail of failure
Related information
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Cause


2. Disconnect connectors WECN2 and WNBL, and connect T-adapter to
female side of WECN2.
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

2. Disconnect connectors WECN2 and WNBL, and connect T-adapter to
a Check with tester in continuity mode.
Between WECN2 (female) (26) and each pin other
No continuity
than (26)
(No sound is heard)
than (36)
1.
2.
3.
a
No continuity
(No sound is heard)

Disconnect connector P03 and connect T-adapter to male side.
Turn blade knob switch (lower) to ON or OFF position and troubleshoot.
Defective blade knob switch lower

(5) and (1)
Switch: OFF
Resistance
Max. 1 z
Switch: ON
Resistance
Min. 1 Mz

(1) and (2)
Switch: OFF
Resistance
Min. 1 Mz
Switch: ON
Resistance
Max. 1 z
4. Turn blade knob lower switch (lower) to ON or OFF position and troubleshoot.
Defective work equipment control4
a Voltage of approx.9 V is applied to WECN2 pin (26) and pin (36) through
ler
Between WECN (36) and Switch: OFF
WECN (4)
Switch: ON
Max. 1 V
Voltage
7 11 V
Between WECN (26) and Switch: OFF

WECN (4)
Switch: ON
40-366
Voltage
Voltage
7 11 V
Voltage
Max. 1 V
D375A-6R
(01)
D375A-6R
(01)
40-367
40-367
Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection

Action code
Failure code
E01
DDN9KA
Failure
40-368
Work equipment knob switch (raise): Disconnection

Both lines of NO: Normally Open and NC : Normally Closed for blade knob upper switch circuit are
OPEN (switch: OFF) at the same time.
Recognizes that blade knob upper switch is not pressed.
Problem on
machine
Blade knob switch (raise) does not work.
Condition of blade knob switch signal can be checked with monitoring function.
Method of reproducing failure code: Turn starting switch to ON position and operate blade knob
switch (raise).
Connector WNBU has no T-adapters, don't perform troubleshooting in female side.
Detail of failure
Related information
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Cause

2. Disconnect connector WNBU.
3. Turn blade upper knob switch (raise) to ON or OFF position and troubleshoot.
Defective blade knob switch raise

Between WNBU (female) Switch: OFF
(3) and (2)
Switch: ON
Between WNBU (female) Switch: OFF
(1) and (2)
Switch:ON
Resistance
Max. 1 z
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Max. 1 z
1.
2.
3.
4.
a

Disconnect connector WNBU.
Insert T-adapter into connector P03.
If voltage is 0 V, it shows disconnection in wiring harness, and if voltage is
24 V, it shows hot short in wiring harness.
a Voltage of apporx.9 V is applied to signal lines of NO and NC through
Voltage
7 11 V
Voltage
7 11 V

2. Disconnect connectors WECN1 and WECN2, and connect T-adapters to
3. Turn blade knob switch (raise) to ON or OFF position and troubleshoot.
3
(open circuit or defective contact) Between WECN2 (female) (15) and
Switch: OFF Resistance Max. 1 z
WECN1 (female) (4)
Between WECN2 (female) (5) and
Switch: ON Resistance Max. 1 z
WECN1 (female) (4)
40-368
D375A-6R
(01)
Cause

Defective work equipment control- a Voltage of apporx.9 V is applied to WECN2 pin (5) and pin (15) through re4
sistor in work equipment controller.
ler
Between WECN2 (5) and Switch: OFF
WECN1 (4)
Switch: ON
Voltage
7 11 V
Voltage
Max. 1 V
Switch: OFF
Voltage
Max. 1 V
Switch: ON
Voltage
7 11 V
Between WECN2 (15)

and WECN1 (4)
D375A-6R
(01)
40-369
40-369
Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit

Action code
Failure code
E01
DDN9KB
Failure
40-370
Work equipment knob switch (raise): Disconnection

Both lines of NO: Normally Open and NC : Normally Closed for blade knob switch raise circuit are
0 V (switch: ON) at the same time.
Recognizes that blade knob upper switch is not pressed.
Problem on
machine
Blade knob switch (raise) does not work.
Condition of blade knob switch signal can be checked with monitoring function.
Method of reproducing failure code: Turn starting switch to ON position and operate blade knob
switch (raise).
Connector WNBU has no T-adapters, don't perform troubleshooting in female side.
Detail of failure
Related information
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Cause

1.
2.
3.
a

Disconnect connector WNBU and connect T-adapter to male side.
Turn blade knob switch (raise) to ON or OFF position and troubleshoot.
Defective blade knob switch raise

Between WNBU (male)
(3) and (2)
Switch: OFF
Resistance
Max. 1 z
Switch: ON
Resistance
Min. 1 Mz
Between WNBU (male)

(1) and (2)
Switch: OFF
Resistance
Min. 1 Mz
Switch: ON
Resistance
Max. 1 z

(Contact with groung circuit)

2. Disconnect connectors WECN1, WECN2 and WNBU and connect
T-adapter to female side of either of them.
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

2. Disconnect connectors WECN2 and WNBU, and connect T-adapter to
No continuity
than (5)
(No sound is heard)
than (15)
40-370
No continuity
(No sound is heard)
D375A-6R
(01)
Cause

Defective work equipment control- a Voltage of apporx.9 V is applied to WECN2 pin (5) and pin (15) through re4
sistor in work equipment controller.
ler
Between WECN2 (5) and Switch: OFF
WECN1 (4)
Switch: ON
Voltage
7 11 V
Voltage
Max. 1 V
Switch: OFF
Voltage
Max. 1 V
Switch: ON
Voltage
7 11 V
Between WECN2 (15)

and WECN1 (4)
D375A-6R
(01)
40-371
40-371
Failure code [DDNALD] Blade lift up pressure SW abnormality

Action code
Failure code
DDNALD
Failure
40-372
Blade lift raise oil pressure switch is pressed for long time
The signal of blade lift raise (full stroke) oil pressure switch circuit is kept turned to ON position for
60 seconds.
Problem on
machine
Data of the VHMS may become abnormal.
Input state (ON/OFF) from blade raise (full stroke) oil pressure switch can be checked with monitoring function. (Code: 90802 Blade oil pressure switch input)
after 60 seconds).
Detail of failure
Related information
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q
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Cause
1

If failure code (reset indication) is displayed even after reset operation, incor(When electrical system is normal) rect lever operation might be made.

Defective blade raise oil pressure 2. Disconnect connector BLU and connect T-adapter to male side.
2
Between BLU (female) (1) and ground
(Oil pressure switch: OFF)
2. Disconnect connector BLU.
3 defective work equipment control- If failure code [DDNALD] is still displayed, there is ground fault in wiring harler
(If failure code [DDNALD] is not displayed, blade raise oil pressure switch is
defective.)
2. Disconnect connector WECN2 and BLU, and connect T-adapter to female
4
Between WECN2 (female) (16) or BLU (female) (1)
and ground
work equipment controller is defective.
3. Start engine.
a Keep the blade control lever in the neutral position.
ler
Voltage
7 11 V
4. Operate blade lever and perform troubleshooting.
Between WECN2 (16)
Blade lever: Raise
and WECN1 (4)
40-372
Voltage
Max. 1 V
D375A-6R
(01)
Circuit diagram related to blade raise oil pressure switch
D375A-6R
(01)
40-373
40-373
Failure code [DDNBLD] Ripper lift up pressure SW abnormality

Action code
Failure code
DDNBLD
Failure
40-374
Ripper lift raise oil pressure switch is pressed for long time
Detail of failure
The signal of the ripper raise oil pressure switch circuit is kept turned to ON position for 60 seconds.
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 )
after 60 seconds).
Problem on
machine
q
q
Related information
q
q
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Cause
1
operation is performed, it is suspected that the lever was operated to cause an
error.
Defective ripper raise oil pressure 2. Disconnect connector RPU and connect T-adapter to male side.
2
Between RPU (female) (1) and ground
(Oil pressure switch: OFF.)
2. Disconnect connector RPU.
3 defective work equipment control- If failure code [DDNBLD] is still displayed, there is ground fault of wiring harler
(If failure code [DDNBLD] is not displayed, ripper raise oil pressure switch is
defective)
2. Disconnect connector WECN2 and RPU, and connect T-adapter to female
4
Between WECN2 (female) (13) or RPU (female) (1)
and ground
3. Start engine.
a Keep ripper lever in neutral position.
ler
Voltage
7 11 V
4.Operate ripper lever and perform troubleshooting.
Between WECN2 (13)
Ripper lever: Raise
and WECN1 (4)
40-374
Voltage
Max. 1 V
D375A-6R
(01)
Circuit diagram related to ripper raise oil pressure switch
D375A-6R
(01)
40-375
40-375
Failure code [DDNCLD] Ripper lift down pressure SW abnormality

Action code
Failure code
DDNCLD
Failure
40-376
Ripper lower oil pressure switch is pressed for long time

Detail of failure
Signal of ripper lift lower oil pressure switch circuit is kept turned to ON position for 60 seconds.

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)
after 60 seconds).
Problem on
machine
q
q
Related information
q
q
q
Cause
1

2. Disconnect connector RPD and connect T-adapter to male side.
Defective ripper lower oil pressure switch (Internal short circuit) Between RPD (female) (1) and ground
Resistance
Min. 1 Mz

2. Disconnect connector RPD.
3 defective work equipment control- If failure code [DDNCLD] is still displayed, there is ground fault in wiring harler
(If failure code [DDNCLD] is not displayed, ripper lift lower oil pressure switch
is defective.)
2. Disconnect connector WECN2 and RPD, and connect T-adapter to female
4
Between WECN2 (female) (3) or RPD (female) (1)
and ground
3. Start engine.
ler
Voltage
7 11 V
4. Operate ripper lever and perform troubleshooting.
Ripper lever: Lower
WECN1 (4)
40-376
Voltage
Max. 1 V
D375A-6R
(01)
Circuit diagram related to ripper lower oil pressure switch
D375A-6R
(01)
40-37
40-377
Failure code [DDNDLD] Ripper tilt in pressure SW abnormality

Action code
Failure code
DDNDLD
Failure
40-378
Ripper tilt in oil pressure switch is pressed for long time

Detail of failure
Signal of ripper tilt in oil pressure switch circuit is kept turned to ON position for 60 seconds.

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)
after 60 seconds).
Problem on
machine
q
q
Related information
q
q
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Cause
1


Defective ripper tilt in oil pressure 2. Disconnect connector RTI and connect T-adapter to male side.
2
Between RTI (female) (1) and ground
(Oil pressure switch: OFF.)
2. Disconnect connector RTI.
3 defective work equipment control- If failure code [DDNDLD] is still displayed, there is ground fault in wiring harler
(If failure code [DDNDLD] is not displayed, ripper tilt in oil pressure switch is
defective.)
2. Disconnect connector WECN2 and RTI, and connect T-adapter to female
4
Between WECN2 (female) (2) or RTI (female) (1)
and ground
work equipment controller is defective.
3. Start engine.
ler
Voltage
7 11 V
4. Operate ripper lever and perform troubleshooting.
Ripper lever:
WECN1 (4)
Tilt in
40-378
Voltage
Max. 1 V
D375A-6R
(01)
Circuit diagram related to ripper tilt in oil pressure switch
D375A-6R
(01)
40-379
40-379
Failure code [DDNELD] Ripper tilt back pressure SW abnormality

Action code
Failure code
DDNELD
Failure
40-380
Ripper tilt back oil pressure switch is pressed for long time
Detail of failure
Signal of the ripper tilt back oil pressure switch circuit is kept turned to ON position for 60 seconds.
Recognizes that the oil pressure switch is turned OFF.

VHMS data may become abnormal.
Input state (ON/OFF) from the ripper tilt back oil pressure switch can be checked moniitoring funtion. (Code 40982: Ripper oil pressure switch input )
after 60 seconds).
First, check the power train oil filter for clogging etc.
Problem on
machine
q
q
Related information
q
q
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Cause
1
operation is performed, it is suspected that lever was operated to cause an
error.
Defective ripper tilt back oil pres- 2. Disconnect connector RTB and connect T-adapter to male side.
2
sure switch (Internal short circuit) Between RTB (female) (1) and ground
(Oil pressure switch: OFF)
2. Disconnect connector RTB.
3 defective work equipment control- If failure code [DDNELD] is still displayed, there is ground fault of wiring harler
(If failure code [DDNELD] is not displayed, ripper tilt back oil pressure switch is
defective)
2. Disconnect connector WECN2 and RTB, and connect T-adapter to female
4
Between WECN2 (female) (38) or RTB (female) (1)
and ground
3. Start engine.
ler
Voltage
7 11 V
4.Operate ripper lever and perform troubleshooting.
Between WECN2 (38)
Ripper lever: Tilt back
and WECN1 (4)
40-380
Voltage
Max. 1 V
D375A-6R
(01)
Circuit diagram related to ripper tilt back oil pressure switch
D375A-6R
(01)
40-381
40-381
Failure code [DDNFLD] Blade lift down pressure SW abnormality

Action code
Failure code
DDNFLD
Failure
40-382
Blade lift lower oil pressure switch is pressed for long time
Indication of
problem on
machine
Related information
Signal of blade lower (full stroke) oil pressure switch circuit is kept turned to ON position for 60 seconds.
Detail of failure
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)
Method of reproducing failure code: Turn starting switch to ON position (and wait for longer than
180 sec.).
q
q
q
Cause
1


Defective blade lower oil pressure 2. Disconnect connector BLD and connect T-adapter to male side.
2
Between BLD (female) (1) and ground
2. Disconnect connector BLD.
3 defective work equipment control- If failure code [DDNFLD] is still displayed, there is ground fault in wiring harler
(If failure code [DDNFLD] is not displayed, blade lower oil pressure switch is
defective.)
2. Disconnect connector WECN2 and BLD, and connect T-adapter to female
4
Between WECN2 (female) (6) or BLD (female) (1)
and ground
3. Start engine.
a Keep blade lever in neutral position.
ler
Voltage
7 11 V
4. Operate lever and troubleshoot.
Blade lever: Lower
WECN1 (4)
40-382
Voltage
Max. 1 V
D375A-6R
(01)
Circuit diagram related to blade lower oil pressure switch
D375A-6R
(01)
40-383
40-383
Failure code [DDNLKA] Weq lock Sw: Disconnection

Action code
Failure code
E03
Detail of failure
DDNLKA
q
q
q
q
Problem on
machine
q
q
q
q
q
Related information
Failure
q
q
40-384
Work equipment lock switch: Disconnection

Both lines of NO* and NC* for work equipment lock lever switch circuit are OPEN (switch: OFF) at
the same time.
Recognizes that work equipment lock lever is in LOCk position.
Once machine is stopped, engine speed is limited to medium (half).
Work equipment operation is impossible.
Engine does not run.
Condition of work equipment lock lever switch signal can be checked with monitoring function.
(Code: 70300 Blade knob switch Input)
Method of reproducing failure code: Turn starting switch to ON position and operate work eqiupment lock lever.
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.
3. Operate work equipment lock lever and troubleshoot.
Defective work equipment lock

1 lever switch (Internal disconnection)
Between WELK (male)

(A) and (B)
Lever: FREE
Resistance
Min. 1 Mz
Lever: LOCK
Resistance
Max. 1 z
Between WELK (male)

(A) and (C)
Lever: FREE
Resistance
Max. 1 z
Lever: LOCK
Resistance
Min. 1 Mz
1.
2.
3.
a

Disconnect connector WELK and connect T-adapter to female side.
2
a Voltage of about 9 V is applied to signal lines of NO and NC through rewiring harness
sistor in power train controller.
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
Between WECN1 (female) (10) and WELK (female)
3
Resistance Max. 1 z
(open circuit or defective contact) (A)
Resistance Max. 1 z
(B)
Resistance Max. 1 z
(C)
40-384
D375A-6R
(01)
Cause
4. Operate work equipment lock lever switch and troubleshoot.
Defective work equipment control- a Voltage of approximately 9 V is applied to WECN2 pin (25) and pin (35)
4
ler
Between WECN2 (25)
and WECN1 (10)
Lever: FREE
Voltage
7 11 V
Lever: LOCK
Voltage
Max. 1 V
Between WECN2 (35)

and WECN1 (10)
Lever: FREE
Voltage
Max. 1 V
Lever: LOCK
Voltage
7 11 V
*NO: Normally Open

Circuit diagram related to equipment lock switch
D375A-6R
(01)
40-385
40-385
Failure code [DDNLKB] Weq lock Sw: Short circuit

Action code
Failure code
E03
Detail of failure
DDNLKB
q
q
q
q
Problem on
machine
q
q
q
q
q
Related information
q
q
Failure
40-386
Work equipment lock switch: Short circuit

(Power train controller systerm)
Both lines of NO* and NC* for work equipment lock lever switch circuit are 0 V (switch: ON) at the
same time.
Recognizes that work equipment lock lever is in Lock position.
Work equipment operation is impossible.
Engine does not run.
NO* line is used for sensing operation and NC line is used for detecting error.
Condition of work equipment lock lever switch signal can be checked with monitoring function.
(Code: 70300 Blade knob switch Input)
Method of reproducing failure code: Turn starting switch to ON position and operate work equipment lock lever.
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.
3. Operate work equipment lock lever and troubleshoot.

1 lever switch (Internal disconnection)

Lever: FREE
Resistance
Min. 1 Mz
Lever: LOCK
Resistance
Max. 1 z
Between WELK (male)

(A) and (C)
Between WELK (male)

(A) and (B)
Lever: FREE
Resistance
Max. 1 z
Lever: LOCK
Resistance
Min. 1 Mz

2. Disconnect connectors WECN1, WECN2 and WELK and connect
Between WELK (female) (B) and ground or between
WECN2 (female) (35) and ground.
Between WELK (female) (C) and ground or
between WECN2 (female) (25) and ground.
2. Disconnect connectors WECN2 and WELK, and connect T-adapter to
No continuity
than (25)
(No sound is heard)
than (35)
40-386
No continuity
(No sound is heard)
D375A-6R
(01)
Cause

Defective work equipment control- a Voltage of apporx.9 V is applied to WECN2 pin (25) and pin (35) through
4
ler
Between WECN2 (25)
and WECN1 (10)
Lever: FREE
Voltage
7 11 V
Lever: LOCK
Voltage
Max. 1 V
Between WECN2 (35)

and WECN1 (10)
Lever: FREE
Voltage
Max. 1 V
Lever: LOCK
Voltage
7 11 V
*NO: Normally Open

Circuit diagram related to work equipment lock switch
D375A-6R
(01)
40-387
40-387
Failure code [DDT5KA] Neutral switch disconnection

Action code
Failure code
E04
DDT5KA
Detail of failure
Problem on
machine
Both lines of NO: Normally Open and NC: Normally Closed for neutral switch circuit are OPEN
(switch: OFF) at the same time.
Recognizes that neutral switch is not pressed.

Method of reproducing failure code: Turn starting switch to ON position and operate neutral switch.
First, check the power train oil filter for clogging etc.
q
q
q
Cause
1
Neutral switch disconnection

Related information
Failure
40-38

type
Procedure, measuring location, standard (value) and remarks

1.
2.
3.
a
Defective neutral switch (Internal

disconnection)

Turn neutral switch to ON or OFF position and troubleshoot.
Between SNC (female)

(4) and (6)
Switch: OFF
Resistance
Max. 1 z
Switch: ON
Resistance
Min. 1 Mz
Between SNC (female)

(4) and (5)
Switch: OFF
Resistance
Min. 1 Mz
Switch: ON
Resistance
Max. 1 z
1.
2.
3.
a
3

Disconnect connector SNC and connect T-adapter to female side.
If voltage is 0 V, it shows disconnection in wiring harness, and if voltage is
24 V, it shows hot short in wiring harness.
a Voltage of apporx.9 V is applied to signal lines of NO and NC through
Voltage
711 V
Voltage
711 V
2. Disconnect connectors PTCN1, PTCN2 and SNC, and connect T-adapter
Between PTCN1 (female) (10) and SNC (female)
4
Resistance Max. 1 z
(open circuit or defective contact) (4)
Resistance Max. 1 z
(5)
Resistance Max. 1 z
(6)
40-388
D375A-6R
(01)
Cause

4. Turn neutral switch to ON or OFF position and troubleshoot.
Between PTCN2 (27)
and PTCN1 (10)
Switch: OFF
Voltage
Max. 1 V
Switch: ON
Voltage
7 11 V
Between PTCN2 (17)

and PTCN1 (10)
Switch: OFF
Voltage
7 11 V
Switch: ON
Voltage
Max. 1 V
Circuit diagram related to neutral switch
D375A-6R
(01)
40-389
40-389
Failure code [DDT5KB] Neutral switch short circuit

Action code
Failure code
E04
DDT5KB
Detail of failure
Problem on
machine
Related information
Failure
Neutral switch short circuit

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

Method of reproducing failure code: Turn starting switch to ON position and operate neutral switch.
Cause
1
40-390

type

1.
2.
3.
a
Defective neutral switch


Turn neutral switch to ON or OFF position and troubleshoot.

Between SNC (male) (4)

and (6)
Switch: OFF
Resistance
Max. 1 z
Switch: ON
Resistance
Min. 1 Mz
Between SNC (male) (4)

and (5)
Switch: OFF
Resistance
Min. 1 Mz
Switch: ON
Resistance
Max. 1 z

Between SNC (female) (5) or PTCN2 (female) (17)
and ground
Between SNC (female) (6) and PTCN2 (female)
(27) and groud
to female side of PTCN2.
No continuity
each pin other than (17)
(No sound is heard)
No continuity
(No sound is heard)
3. Turn starting switch ON position.
Between PTCN2 (27)
and PTCN1 (10)
Voltage
Max. 1 V
Switch: ON
Voltage
711 V
Between PTCN2 (17)

and PTCN1 (10)
40-390
Switch: OFF
Switch: OFF
Voltage
711 V
Switch: ON
Voltage
Max.1 V
D375A-6R
(01)
Circuit diagram related to meutral switch
D375A-6R
(01)
40-391
40-391
Failure code [DDT5KQ] Lever SPEC selection signal disagreement

Action code
Failure code
E04
DDT5KQ
Detail of failure
Failure
40-392
Lever specification selection signal disagreement

While optional travel lever is installed, optional travel lever device is not set.
q
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Problem on
machine
Related information
Cause
1 Wrong selection of travel lever


Check type of travel lever in
Select optional travel lever.
adjustment mode: 0041.
2. Disconnect connectors PTCN2 and SNC and connect T-adapters to female
side of them.
Between PTCN2 (female)(17) and ground or
Resistance
Min. 1 Mz
between SNC (female) (5) and ground
Between PTCN2 (female)(27) and ground or
between SNC (female) (6) and ground
Min. 1 Mz
If causes 1 and 2 are not detected, power train controller may be defective.
(Since failure is in it, troubleshooting cannot be carried out.)
Circuit diagram related to lever specification selection
40-392
Resistance
40-392
D375A-6R
(01)
D375A-6R
(01)
40-393
Failure code [DDTSL1] S/C: Fill high

Action code
Failure code
E02
DDTSL1
Failure
40-394
Stator clutch oil pressure 1

Nevertheless controller does not output to torque converter stator clutch ECMV solenoid circuit, fill
switch signal is turned to ON position.
None in particular
Problem on
machine
Sufficient traveling torque may not be obtained
Stator clutch ECMV fill switch signal status (ON/OFF) can be checked by using the monitoring function.
(Code: 31520 T/M fill SW Input 2)
Detail of failure
Related information
q
q
q
q
Cause
Defective stator clutch ECMV fill
1



2. Disconnect connector FSTC and connect T-adapter to male side.
Between FSTC (female) (1) and ground
(Fill switch OFF)
1.
2.
3.
a
Resistance
Min. 1 Mz

Disconnect connector FSTC.
Start engine.
Keep PPC lever in N position.
If failure code [DDTSL1] is still displayed, there is ground fault in wiring harness or power train controller is defective.
(If failure code [DDTSL1] is not displayed, stator clutch fill switch is defective.)
2. Disconnect connectors PTCN2 and FSTC, and connect T-adapter to female
Between PTCN2 (female) (2) and ground or
Resistance
Min. 1 Mz
between FSTC (female) (1) and ground
Voltage
7 11 V
Voltage
Max. 1 V

3. Starting engine
40-394
D375A-6R
(01)
Circuit diagram related to stator clutch oil pressure
D375A-6R
(01)
40-395
40-395
Failure code [DDTSLH] S/C: Fill low

Action code
Failure code
E02
DDTSLH
Failure
40-396
Stator clutch oil pressure 2

Nevertheless controller does not output to torque converter stator clutch ECMV solenoid circuit, fill
None in particular
Problem on
machine
Sufficient traveling torque may not be obtained
Stator clutch ECMV fill switch signal status (ON/OFF) can be checked by using the monitoring function.
(Code: 31520 T/M fill SW Input 2)
Detail of failure
Related information
q
q
q
q
Cause

Defective stator clutch ECMV fill 2. Disconnect connector FSTC and connect T-adapter to male side.
1 switch (Fill switch dose not turn to 3. Start engine.
ON position)
Between FSTC (female) (1) and ground
Resistance
Max. 1 z
(Fill switch: ON)
2. Disconnect connectors PTCN2 and FSTC and connect T-adapter to female
Between PTCN2 (female) (2) and FSTC
contact)
Resistance
Max. 1 z
(female) (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. Starting engine
40-396
Voltage
Max. 1 V
D375A-6R
(01)
Circuit diagram related to stator clutch oil pressure
D375A-6R
(01)
40-397
40-397
Failure code [DGE5KX] Ambient temp sensor abnormality

Action code
Failure code
Failure
DGE5KX
40-398
Ambient temp 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.
Problem on
machine
Monitoring function fails to monitor the atmospheric temperature.
The LED of the VHMS controller displays "n4"o"01".

Under normal conditions, input (temperature) from ambient temperature sensor can be checked by
using monitoring function. (Code: 37501 ATR TEMP)
Detail of failure
Related information
q
q
Cause

2. Disconnect connector INT and connect T-adapter to male side.
a If ambient temperature sensor resistance is 2.2 kz - 34 kz, regard ambient
temperature sensor as normal.
Defective atmospheric temperature sensor
INT (male)
Resistance
-20 C
Between (1)
and (2)
Ambient temperature
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 wiring har- Between V2A (female) (10) and (12)
2
ness
a Resistance accords with ambient temperResistance
2.2 - 34 kz
ature - resistance characteristics table of
ambient temperature sensor in cause 2.
2. Disconnect connectors V2A and INT and connect T-adapters to female side
of them.
Between V2A (female) (10) and INT (female)
Resistance
Max. 1 z
(1)
Between V2A (female) (12) and INT (female)
Resistance
Max. 1 z
(2)
2. Disconnect connectors INT and V2A and connect T-adapter to female side
4
of either of them.
Between INT (female) (1) and ground or
Resistance
Min. 1 Mz
between V2A (female) ( 10) and ground
Hot short circuit or short circuit in 2. Disconnect connectors INT and connect T-adapter to female side.
5
wiring harness
Between INT (female) (1) and (2)
Voltage
Approx. 5 V
40-398
If cause is not found by above checks, the VHMS controller is defective.

D375A-6R
(01)
Circuit diagram related to ambient temperature sensor
D375A-6R
(01)
40-39
40-399
Failure code [DGS1KX] Hyd oil temp: signal abnormal

Action code
Failure code
E01
DGS1KX
Failure
40-40
Hydraulic oil temperature sensor: Abnormal

(Machine monitor power train control system)
Detail of failure
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.
Signal voltage of hydraulic oil temperature sensor is input to machine monitor, and then the data is
transmitted to power train controller.
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.
Problem on
machine
q
q
Related information
q
q
Cause
Procedure, measuring location, crit and remarks

2. Disconnect connector HDT and connect T-adapter to male side.
10 C
Between HDT (male) (1)
and (2)
a Temperature characteristics of oil temperature sensor
1.
2.
3.
Disconnection, short circuit or hot a
2 short in or ground fault of wiring
harness
a
Resistance
30 C
Resistance
80 C
Resistance
100 C
Defective hydraulic oil temperature sensor

1
Resistance
Approx.
90 kz
Approx.
35 kz
Approx.
6.5 kz
Approx.
3.5 kz

Disconnect connector HDT and connect T-adapter to female side.
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.
Voltage of approximately 3.3 V is applied to temperature sensor signal lines
through resistor in machine monitor.
Between HDT (female) (1) and (2)
Voltage
Approx. 5 V
a
1.
2.
a
a
Disconnect connector CM01 and connect T-adapter to female side.
Disconnection or short circuit in
Resistance accords with temperature characteristics table in cause 1.
3
wiring harness
If resistance is above1 Mz, wiring harness has disconnection. If resistance
Approx.3.5
Resistance
90 kz
a If neither of causes 2 and 3 is the cause for the trouble, this check is not required.
2. Disconnect connectors CM01 and HDT, and connect T-adapters to female
4
side of them.
Between CM01 (female) (8) and HDT
Resistance
Max. 1 z
(female) (1)
Between CM01 (female) (12) and HDT
Resistance
Max. 1 z
(female) (2)
2. Disconnect connectors CM01 and HDT, and connect T-adapter to female
5
Between CM01 (female) (8) and (3), or
Resistance
Min. 1 Mz
between HDT (female) (1) and ground
40-400
D375A-6R
(01)
Cause

2. Disconnect connectors CM01 and HDT, and connect T-adapter to female
side of CM01.
Between CM01 (female) (8) and each
No continuity (No sound is heard.)
pin other than (8)
Circuit diagram related to hydraulic oil temperature sensor
D375A-6R
(01)
40-401
40-401
Failure code [DGT1KA] T/C oil temp sensor: Abnormal

Action code
Failure code
E01
DGT1KA
Failure
40-402
Torque converter oil temperature sensor: Disconnection

Detail of failure
Torque converter oil temperature sensor signal is out of normal range.
None in particular.
Power train oil temperature gauge may not indicate normally.

The fan speed is limited to a half.
Gear shift shock of transmission increases.
Problem on
machine
q
q
q
Related information
q
q
Torque converter oil temperature is considered to be power train oil temperature.

(Code: 30100 T/C oil temperature)
Method of reproducing failure code: Turn starting switch to ON position or start engine.
Cause

2. Disconnect connector 453 and connect T-adapter to male side.
Defective torque converter oil temBetween 453 (male) (1) and

perature sensor
1
(2)
(Internal open or short circuit in
a Temperature characterwiring)
istics of oil temperature
sensor
Open circuit or short circuit or

2 ground fault or hot short circuit in
wiring harness
25 C
Resistance
Approx. 42 kz
30 C
Resistance
Approx. 35 kz
80 C
Resistance
Approx. 6.5 kz
100 C
Resistance
Approx. 3.5 kz
1.
2.
3.
a

Disconnect connectors 453 and connect T-adapter to female side.
If voltage is 0 V, wiring harness has open circuit or ground fault or short circuit, and if voltage is 24 V, wiring harness has hot short circuit.
a Voltage of apporx.5 V is applied to temperature sensor signal lines through
Between 453 (female) (1) and (2)
Voltage
Approx. 5 V
a
1.
2.
Open or short circuit in wiring har- a
3
ness
a
Disconnect connectors WECN1 and connect T-adapter to female side.
Resistance accords with temperature characteristics table in cause 1.
If resistance is above 1 Mz, wiring harness has disconnection. If resistance
Approx. 3.5
Resistance
90 kz
2. Disconnect connectors WECN1 and 453, and connect T-adapters to female
side of them.
contact)
Between (female) (20) and 453 (female) (1)
Resistance
Max. 1 z
Between WECN1 (female) (21) and 453

Resistance
Max. 1 z
(female) (2)
2. Disconnect connectors WECN1 and 453, and connect T-adapter to female
side of WECN1.
Between WECN1 (female) (20) and each pin
other than (20)
heard.)
Defective work equipment controlIf cause is not found by above checks, work equipment controller is defective.
ler
40-402
D375A-6R
(01)
D375A-6R
(01)
40-403
40-403
Failure code [DGT1KX] T/C oil temp sensor: Abnormal

Action code
Failure code
E01
DGT1KX
Failure
40-404
Torque converter oil temperature sensor: Short circuit

Detail of failure
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.
Problem on
machine
q
q
q
Related information
q
q
Cause

2. Disconnect connector 453.
Defective torque converter oil tem- 3. Turn starting switch ON position.
perature sensor
(internal open circuit or short cir- If failure code[DGT1KX] goes off and disconnection code [DGT1KA] is displayed, torque converter oil temperature sensor is defective.
cuit)
(If failure code [DGT1KX] is still displayed, it shows that wiring harness or
power train controller is defective.)
Resistance
Min. 1 Mz
or between 453 (female) (1) and ground
side of WECN1.
Between WECN1 (female) (20) and each pin
other than (20)
heard)
Defective work equipment control- If no failure is detected by the above checks, work equipment controller is
ler
defective.
40-404
D375A-6R
(01)
D375A-6R
(01)
40-405
40-405
Failure code [DGT5KA] F exhaust temp sensor disconnection

Action code
Failure code
Failure
DGT5KA
40-406
F exhaust temp sensor disconnection

Input signal voltage from the exhaust gas temperature sensor on the engine front side is below 0.5
V.
None in particular.
Problem on
machine
Monitoring function fails to monitor the exhaust gas temperature on the engine front side
The LED of the VHMS controller displays n3" o "12".

Under normal conditions, input (temperature) from front exhaust temperature sensor can be
checked by using monitoring function. (Code: 42610 EXHAUST TEMP FRONT)
Detail of failure
Related information
q
q
Cause

If failure code [DBB6KP] is displayed, troubleshoot it first.

system
Defective front (cylinder Nos. 1 3) exhaust temperature sensor
1.
2.
3.
a

Disconnect connector EXAF and connect T-adapter to female side.
If power supply voltage is abnormal, go to cause 4 or after.
Power supBetween EXAF (A) and (C)
Voltage
20 30 V
ply
a Check that failure code [DGT6KA] is not displayed.
2. Replace connector EXHF with EXHR.
If failure code [DGT5KA] changes to [DGT6KA], original front (cylinder Nos. 1
- 3) exhaust temperature sensor is defective.
2. Disconnect connectors EXTF, EXHF, V1 and V2A, and connect T-adapters
to female side of them or male side of EXTF.
a If cause 1 is not the cause for the trouble, this
Resistance Max. 1 z
Between V1 (female) (2) and EXAF (female) (A)

3 (Open circuit in wiring or defective Between V2A (female) (7) and EXAF (female) (B)
Resistance
Resistance
Between V2A (female) (13) and EXAF (female) (C)
Max. 1 z
Max. 1 z
Between EXHF (female) (1) and EXTF (male) (1)

Max. 1 z
Between EXHF (female) (2) and EXTF (male) (2)
Resistance
Resistance
Max. 1 z

2. Disconnect connectors EXHF, EXTF,EXAF, V1 and V2A, and connect
T-adapters to female side of them or male side of EXTF.
Between EXHF (female) (1) or EXTF (male) (1) and
ground
Between EXHF (female) (1) and (2), or between
EXTF (male) (1) and (2)
Between V2A (female) (7) and ground
Min. 1 Mz
40-406
Resistance
Resistance
Min. 1 Mz
D375A-6R
(01)
Cause
Defective front (cylinder Nos. 1 5 3) exhaust temperature sensor

amplifier

a
1.
2.
3.
Check that failure code [DGT6KA] is not displayed.

Replace connector EXAF with EXAR.
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.
100 C - 200 C
D375A-6R
(01)
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
Voltage
3.4 3.9 V
700 C - 800 C
Circuit diagram related to exhaust temperature sensor
Voltage
600 C - 700 C
Between V2A (7) and

(13)
a Exhaust temperature
characteristics
1.4 1.8 V
200 C - 300 C
Voltage
Voltage
3.9 4.3 V
40-407
40-407
Failure code [DGT5KB] F exhaust temp sensor short circuit

Action code
Failure code
Failure
DGT5KB
40-408
F exhaust temp sensor short circuit

Input signal voltage from the exhaust gas temperature sensor on the engine front side is above 4.9
V.
None in particular.
Problem on
machine
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".
Under normal conditions, input (temperature) from front exhaust temperature sensor can be
checked by using monitoring function. (Code: 42610 EXHAUST TEMP FRONT)
Detail of failure
Related information
q
q
q
Cause
1
system
Defective front (cylinder Nos. 1 3) exhaust temperature sensor

a
1.
2.
3.
Check that failure code [DGT6KB] is not displayed.

Replace connector EXHF with EXHR.
If failure code [DGT5KB] changes to [DGT6KB], original front (cylinder Nos. 1

- 3) exhaust temperature sensor is defective.
Hot short circuit in wiring harness 2. Disconnect all connectors EXAF and connect T-adapter to female side.
3
Between EXAF (female) (B) and (C)
Voltage
Max. 1 V
Defective front (cylinder Nos. 1 4 3) exhaust temperature sensor

amplifier
a
1.
2.
3.

Replace connector EXAF with EXAR.
If failure code [DGT5KB] changes to [DGT6KB], original front (cylinder Nos. 1

- 3) exhaust temperature sensor amplifier is defective.
100 C - 200 C
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
Voltage
3.4 3.9 V
700 C - 800 C
40-408
Voltage
600 C - 700 C
Between V2A (7) and

(13)
characteristics
1.4 1.8 V
200 C - 300 C
Voltage
Voltage
3.9 4.3 V
D375A-6R
(01)
D375A-6R
(01)
40-409
40-409
Failure code [DGT6KA] R exhaust temp sensor disconnection

Action code
Failure code
DGT6KA
Failure
40-410
R exhaust temp sensor disconnection

Detail of failure
Input signal voltage from exhaust temperature sensor on the engine rear side is below 0.5 V.
None in particular.
Problem on
machine
Monitoring function fails to monitor the exhaust gas temperature on the engine rear side
The LED of the VHMS controller displays n3 o 22.

Under normal conditions, input (temperature) from rear exhaust temperature sensor can be
checked by using monitoring function. (Code: 42611 EXHAUST TEMP REAR)
Related information
q
q
Cause


system
1.
2.
3.
a
a
1.
Defective rear (cylinder Nos. 4 - 6) 2.
2
3.
exhaust temperature sensor

Disconnect connector EXAR and connect T-adapter to female side.
Power supBetween EXAR (A) and (C)
Voltage
20 30 V
ply
Check that failure code [DGT5KA ]is not displayed.
If failure code [DGT5KA] changes to [DGT6KA], original rear (cylinder Nos,

4-6) exhaust temperature sensor is defective.
2. Disconnect connectors EXTR, EXHR, V1 and V2A, and connect T-adapters
to female side of them or male side of EXTR.
Resistance Max. 1 z
Between V1 (female) (2) and EXAR (female) (A)

3 (Open circuit in wiring or defective Between V2A (female) (5) and EXAR (female) (B)
Resistance
Resistance
Between V2A (female) (13) and EXAR (male) (C)
Max. 1 z
Max. 1 z
Between EXHR (female) (1) and EXTR (male) (1)

Max. 1 z
Between EXHR (female) (2) and EXTR (male) (2)
Resistance
Resistance
Max. 1 z

2. Disconnect connectors EXHR, EXTR, EXAR, V1 and V2A, and connect
T-adapters to female side of them or male side of EXTR.
Between EXHR (female) (1) or EXTR (male) (1) and
ground
Between EXHR (female) (1) and (2), or between
EXTR (male) (1) and (2)
V2A (female) (5) and ground
Min. 1 Mz
V2A (female) (5) and (13)
40-410
Resistance
Resistance
Min. 1 Mz
D375A-6R
(01)
Cause
a Check that failure code [DGT5KA ]is not displayed.

Defective rear (cylinder Nos. 4 - 6) 2. Replace connector EXAF with EXAR.
5 exhaust temperature sensor
amplifier
If failure code [DGT6KA] changes to [DGT5KA], original rear (cylinder Nos. 4 6) exhaust temperature sensor amplifier is defective.
100 C - 200 C
D375A-6R
(01)
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
Voltage
3.4 3.9 V
700 C - 800 C
Voltage
600 C - 700 C
Between V2A(5) and (13)

characteristics
1.4 1.8 V
200 C - 300 C
Voltage
Voltage
3.9 4.3 V
40-41
40-411
Failure code [DGT6KB] R exhaust temp sensor short circuit

Action code
Failure code
DGT6KB
Failure
40-412
Rear exhaust gas temperature sensor (R): Short circuit

Detail of failure
Input signal voltage from rear exhaust temperature sensor is above 4.9 V.
None in particular.
Problem on
machine
Monitoring function fails to monitor the exhaust gas temperature on the engine rear side
The LED of the VHMS controller displays "n3 o "21".

Under normal conditions, input (temperature) from rear exhaust temperature sensor can be
checked by using monitoring function. (Code: 42611 EXHAUST TEMP REAR)
Related information
q
q
Cause
1

system

a
1.
Defective rear (cylinder Nos. 4 - 6) 2.
2
3.
exhaust temperature sensor

If failure code [DGT6KB] changes to [DGT5KB], original rear (cylinder Nos. 4 6) exhaust temperature sensor is defective.
Hot short circuit in wiring harness 2. Disconnect connector EXAR and connect T-adapter to female side.
3
Between EXAR (female) (B) and (C)
Voltage
Max. 1 V
a Check that failure code [DGT5KB] is not displayed.
Defective rear (cylinder Nos. 4 - 6) 2. Replace connector EXAF with EXAR.
4 exhaust temperature sensor
amplifier
If failure code [DGT6KB] changes to [DGT5KB], original rear (cylinder Nos. 4 6) exhaust temperature sensor amplifier is defective.
100 C - 200 C
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
Voltage
3.4 3.9 V
700 C - 800 C
40-412
Voltage
600 C - 700 C
Between V2A(5) and (13)

characteristics
1.4 1.8 V
200 C - 300 C
Voltage
Voltage
3.9 4.3 V
D375A-6R
(01)
D375A-6R
(01)
40-413
40-413
Failure code [DH21KA] Weq pressure sensor: Disconnection

Action code
Failure code
E01
DH21KA
Failure
40-414
Work equipment pump oil pressure sensor : Disconnection

Detail of failure
Signal voltage of work equipment pump oil pressure sensor is below 0.2 V.
None in particular
Problem on
machine
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)
Related information
q
Cause

If failure code [DB97KK] is also displayed, troubleshoot it first.

Defective sensor 5 V power suplly 2. Disconnect connector HHP and connect T-adapter to female side.
system
a If power supply voltage is abnormal, go to cause 3 or after.
Between HHP (female) (B)
Power supply
Voltage
4.5 5.5 V
and (A)
2. Insert T-adapter into connector HHP.
a If power supply voltage is normal and sensor output voltage is abnormal
Defective work equipment pump
(below 0.5 V), internal disconnection and ground fault cannot be identified.
oil pressure sensor (Internal disIn this case, go to cause 4.
connection) or ground fault
If check result of cause 4 is normal, work equipment pump oil pressure
sensor is defective.
Between HHP (female) (C)
Sensor output
Voltage
0.5 4.5 V
and (A)
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 z
Between WECN1 (female) (21) and HHP
(Open circuit in wiring or defective (female) (A)
a If power supply voltage in checks 1 is norcontact in connector)
Resistance
Max. 1 z
(female) (B)
Resistance
Max. 1 z
(female) (C)
2. Disconnect connectors STC1 and HHP, and connect T-adapter to female
Between WECN1 (female) (9) and (21), or
Resistance
Min. 1 Mz
between HHP (female) (C) and (A)
Between WECN1 (female) (9) and ground, or
between HHP (female) (C) and ground
40-414
Resistance
Min. 1 Mz
D375A-6R
(01)
Cause

5
2. Insert T-adapter into connector WECN1
ler
Circuit diagram related to work equipment pump oil pressure
D375A-6R
(01)
Voltage
0.5 4.5 V
40-415
40-415
Failure code [DH21KB] Weq pressure sensor: Short circuit

Action code
Failure code
E01
DH21KB
Failure
40-416
Work equipment pump oil pressure sensor: Disconnection

Detail of failure
Signal voltage of work equipment pump oil pressure sensor is above 4.8 V.
None in particular
Problem on
machine
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.
Related information
q
q
Cause

If failure code [DB97KK] is also displayed, troubleshoot it first.

2. Disconnect connector HHP and connect T-adapter to female side.
Between HHP (female) (B)
Power supply
Voltage
4.5 5.5 V
and (A)
2. Disconnect connector HHP
Defective work equipment pump 3. Turn starting switch to ON position.
2 oil pressure sensor (Internal dis- If failure code [DH21KB] is not displayed but [DH21KA] of disconnection is disconnection) or ground fault
played, work equipment pump oil pressure sensor is defective. (If failure code
[DH21KB] is still displayed, it shows that wiring harness or power train controller is defective.)
Hot short circuit in wiring harness 2. Disconnect connector HHP and connect T-adapter to female side.
3
Between HHP (female) (C) and (A) or ground
Voltage
Max. 1 V
Defective sensor 5 V power sup1
ply system

2. Disconnect connectors WECN1 and HHP, and connect T-adapter to female
side of WECN1.
Between WECN1 (female) (9) and each pin No continuity (No sound is
other than (9)
heard)
2. Insert T-adapter into connector WECN1
ler
40-416
Voltage
0.5 4.5 V
D375A-6R
(01)
Circuit diagram related to work equipment pump oil pressure
D375A-6R
(01)
40-417
40-417
Failure code [DHE5KB] ENG blow-by pressure sensor disconnection

Action code
Failure code
DHE5KB
Failure
40-418
Engine blow-by pressure sensor: Disconnection

Detail of failure
Input signal voltage from the blow-by pressure sensor is below 0.1 V.
None in particular
Problem on
machine
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 blowby pressure sensor can be checked with the monitoring
function (Code: 42801 BLOWBY PRESS).
Method of reproducing failure code: Start engine and performs troubleshooting
Related information
q
q
Cause


ply system
1.
2.
3.
a

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 Mz
between V2A (female) (18) and (12)
Defective blow-by pressure sen3 sor

Between ENBP (female) (C) or V2A (female)

Resistance
Min. 1 Mz
(18) and ground
2. Insert T-adapter into connector ENBP.
3. Turn starting switch to ON position, start engine, and then perform troubleshooting.
Between
Sensor output (Normal)
Voltage
0.5 4.5 V
ENBP (C)
At 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 Mz
ground
2. Disconnect connectors ENBP, V1 and V2A and connect T-adapters to
a If power supply voltage in cause 1 is normal, this check is not required.
Resistance
Max. 1 z
Between V1 , V2A (female) (12) and ENBP
4
(female) (A)
Resistance
Max. 1 z
Between V1 (female) (4) and ENBP (female)
(B)
Between V2A (female) (18) and ENBP
Resistance
Max. 1 z
(female) (C)
40-418
D375A-6R
(01)
Cause

Between V1 (4) and V2A
Power supply
Voltage
4.85 5.15 V
(12)
Between
Voltage
0.5 4.7 V
V2A (18)
At high idle
Voltage
0.5 0.9 V
and (12)
Circuit diagram related to engine blow-by pressure sensor
D375A-6R
(01)
40-419
40-419
Failure code [DHE5KY] ENG blow-by pressure sensor short circuit

Action code
Failure code
DHE5KY
Failure
40-420
Engine blow-by pressure sensor: Short circuit

Detail of failure
Input signal voltage from the blow-by pressure sensor is above 4.7 V.
None in particular
Problem on
machine
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 blowby pressure sensor can be checked with the monitoring
function (Code: 42801 BLOWBY PRESS).
Method of reproducing failure code: Start engine and performs troubleshooting
Related information
q
q
Cause

Defective sensor 5 V power supply system

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
2
(Contact with 24V circuit)
Between ENBP (female) (C) and (A) , or
Voltage
Max. 1 V
between V2A (female) (18) and (12)
2. Insert T-adapter into connector ENBP.
Defective blow-by pressure sen- Between
Voltage
0.5 4.5 V
ENBP (C)
3 sor
At high idle
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
Resistance
Min. 1 Mz
ground
q Reference: The following shows standard values in the normal condition.
3. Turn starting switch to ON position, start engine, and then perform trouble4 Defective VHMS controller
shooting.
Between V1 (4) and V2A
Power supply
Voltage
4.85 5.15 V
(12)
Between
Voltage
0.5 4.7 V
V2A (18)
At high idle
Voltage
0.5 0.9 V
and (12)
40-420
D375A-6R
(01)
Circuit diagram related to engine blow-by pressure sensor
D375A-6R
(01)
40-421
40-421
Failure code [DHT3KX] T/M oil pressure sensor abnormality

Action code
Failure code
40-42
DHT3KX
Failure
Transmission oil pressure sensor input signal out of range
Detail of failure
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".
Problem on
machine
Related information
Cause


1
system
1.
2.
3.
a

Disconnect connectors TMMD and connect T-adapter to female side.
Between TMMD (B) and (C)

Defective transmission main oil
2
pressure sensor
Power supply
Voltage
20 30 V

2. Disconnect connectors TMMD and connect T-adapter to female side.
Between TMMD (A) and (C)
Voltage
15V

2. Disconnect connectors TMMD,V1 and V2A and connect T-adapters to
a If cause 1 is not the cause for the failure,
this check is not required.
Resistance
Max. 1 z
Between V1 (female) (2) and TMMD (female)
3
(B)
a If cause 1 is not the cause for the failure,
this check is not required.
Resistance
Max. 1 z
Between V2A (female) (12) and TMMD
(female) (C)
Between V2A (female) (15) and TMMD
Resistance
Max. 1 z
(female) (A)
2. Disconnect connectors TMMD,V1 and V2A and connect T-adapter to
Between V2A (female) (15) or TMMD
4
Resistance
Min. 1 Mz
(female) (A) and ground
Between V2A (female) (15) and (12) , or
between TMMD (female) (A) and (C)
Hot short circuit or short circuit in

wiring harness
Voltage
Max. 1 V
If cause is not found by above checks, VHMS controller is defective.

2. Insert T-adapter into connector V2A.
Between V2A (15) and (12)
40-422
Min. 1 Mz

2. Disconnect connectors TMMD and connect T-adapter to female side.
Between TMMD (female) (A) and (C)
Resistance
Voltage
15V
D375A-6R
(01)
Circuit diagram related to transmission oil pressure sensor
D375A-6R
(01)
40-423
40-423
Failure code [DHT5KA] T/C in-pressure sensor: Disconnection

Action code
Failure code
E02
DHT5KA
Failure
40-424
Torque converter inlet pressure sensor: Disconnection

Detail of failure
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.

Problem on
machine
Related information
q
q
q
Signal voltage of torque converter inlet pressure sensor can be checked with monitoring function.
(Code 32602: Torque converter inlet pressure sensor voltage)
Cause

If failure code [DBE6KK] is also displayed, troubleshoot it first.

ply system
Defective torque converter inlet

2 pressure sensor (internal failure)
or ground fault

(Disconnection or defective con3
tact in connector)


2. Disconnect connector TIP and connect T-adapter to female side.
Between TIP (female) (B)
Power supply
Voltage
20 30 V
and (A)
2. Insert T-adapter into connector TIP.
In this case, go to cause 4. If check result of cause 4 is normal, torque converter inlet pressure sensor is defective.
Between TIP (female) (C)
Sensor output
Voltage
0.5 6.0 V
and (A)
2. Disconnect connectors PTCN1 and TIP, and connect T-adapters to female
side of them.
Resistance
Max. 1 z
Between PTCN1 (female) (16) and TIP
(female) (B)
Resistance
Max. 1 z
(female) (A)
Resistance
Max. 1 z
(female) (C)
2. Disconnect connectors PTCN1 and TIP, and connect T-adapter to female
Between PTCN1 (female) (13) and (21), or
Resistance
Min. 1 Mz
between TIP (female) (C) and (A)
Between PTCN1 (female) (13) and ground,
or between TIP (female) (C) and ground
40-424
Resistance
Min. 1 Mz
D375A-6R
(01)
Cause

D375A-6R
(01)
Voltage
0.5 6.0 V
40-425
40-425
Failure code [DHT5KB] T/C in-pressure sensor: Short circuit

Action code
Failure code
E02
DHT5KB
Failure
40-426
Torque converter inlet pressure sensor: short circuit

Detail of failure
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)
If the sensor connector is disconnected in the normal condition and turn starting switch to ON position, failure code [DHT5KA] is displayed.
Problem on
machine
q
q
Related information
q
q
Cause

Defective torque converter inlet

or ground fault

2. Disconnect connector TIP and connect T-adapter to female side.
Between TIP (female) (B)
Power supply
Voltage
20 30 V
and (A)
2. Disconnect connector TIP.
If failure code [DHT5KB] is not displayed, torque converter inlet pressure sensor is defective. (If failure code [DHT5KB] is still displayed, it shows that wiring
harness or power train controller is defective.)

Hot short circuit in wiring harness 2. Disconnect connector TIP and connect T-adapter to female side.
3 (Contact with 24 V circuit)
Between TIP (female) (C) and (A) or ground
40-426
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 No continuity (No sound is
other than (13)
heard.)
Voltage
0.5 6.0 V
D375A-6R
(01)
D375A-6R
(01)
40-427
40-427
Failure code [DHT7KA] T/C out-pressure sensor: Disconnection

Action code
Failure code
E02
DHT7KA
Failure
40-428
Torque converter outlet pressure sensor: Disconnection

Detail of failure
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)
Problem on
machine
Related information
q
q
q
Cause


2. Disconnect connector TOP and connect T-adapter to female side.
Between TOP (female) (B)
Power supply
Voltage
20 30 V
and (A)
2. Insert T-adapter into connector TOP.
Defective torque converter outlet a If power supply voltage is normal and sensor output voltage is abnormal
or ground fault
In this case, go to cause 4. If check result of cause 4 is normal, torque converter outlet pressure sensor is defective.
Between TOP (female) (C)
Sensor output
Voltage
0.5 4.5 V
and (A)
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 z
Between PTCN1 (female) (16) and TOP
3
(female) (B)
a If power supply voltage in checks on
cause 1 is normal, this check is not required.
Resistance
Max. 1 z
(female) (A)
Resistance
Max. 1 z
(female) (C)
2. Disconnect connectors PTCN1 and TOP, and connect T-adapter to female
4
Resistance
Min. 1 Mz
between TOP (female) (C) and (A)
ply system
Between PTCN1 (female) (7) and ground, or

between TOP (female) (C) and ground
40-428
Resistance
Min. 1 Mz
D375A-6R
(01)
Cause

Circuit diagram related to torque converter outlet pressure sensor
D375A-6R
(01)
Voltage
0.5 6.0 V
40-429
40-429
Failure code [DHT7KB] T/C out-pressure sensor: Short circuit

Action code
Failure code
E02
DHT7KB
Failure
40-430
Torque converter outlet pressure sensor: short circuit

Detail of failure
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.

Problem on
machine
q
q
Related information
q
q
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.
Cause


ply system
Defective torque converter outlet

or ground fault

2. Disconnect connector TOP and connect T-adapter to female side.
Between TOP (female) (B)
Power supply
Voltage
20 30 V
and (A)
2. Disconnect connector TOP.
If failure code [DHT7KB] is not displayed, torque converter outlet pressure
sensor is defective.(If failure code [DHT7KB] is still displayed, it shows that
wiring harness or power train controller is defective.)

Hot short circuit in wiring harness 2. Disconnect connector TOP and connect T-adapter to female side.
3 (Contact with 24 V circuit)
Between TOP (female) (C) and (A) or ground
40-430
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)
2. Insert T-adapter into connector PTCN1
Voltage
0.5 6.0 V
D375A-6R
(01)
D375A-6R
(01)
40-431
40-431
Failure code [DK10KA] Fuel control Dial: Disconnection

Action code
Failure code
E03
DK10KA
Failure
40-432
Fuel control Dial: Disconnection

Detail of failure
Signal voltage of fuel control dial is below 0.5 V.
Continues control with signal of decelerator pedal potentiometer.

Problem on
machine
Related information
q
q
q

Signal voltage of fuel control dial signal can be checked with monitoring function.
(Code 03000: Fuel Dial Sensor)
Method of reproducing failure code:Turn the starting switch to ON position)
Cause


ply system
1.
2.
3.
a

Disconnect connector DIAL and connect T-adapter to female side.
Between DIAL (female)

(1) and (3)
Defective fuel dial

2 (internal open circuit or ground
fault)
1.
2.
3.
4.
Power
supply
Voltage
4.5 5.5 V

Disconnect connector DIAL and connect T-adapter to male side.
Rotate fuel control dial and troubleshoot.
Between DIAL (male) (1) and (3)
Resistance
Approx. 5 z
Resistance
0.5 - 4.5 kz
Resistance
0.5 - 4.5 kz
Between DIAL(male) (2) and

Resistance
Min. 1 Mz
ground
2. Disconnect connectors PTCN1, TL1 and BRK, and connect T-adapter to
female side of PTCN1
a Resistance is same as table in cause 2.
Open or short circuit in wiring har- a If resistance is above 1 Mz, wiring harness has disconnection. If resistance
3
ness
Between PTCN1 (female) (22)
Resistance
Approx. 5 z
and (21)
Resistance
0.5 - 4.5 kz
(21)
40-432
D375A-6R
(01)
Cause

2. Disconnect connectors PTCN1 and DIAL, and connect T-adapters to
a If power supply voltage in
cause 1 or check result of
cause 3 is normal, this check is
Resistance
Max. 1 z
not required.
and DIAL(female) (1)
4
Resistance
Max. 1 z
not required.
and DIAL (female) (3)
a If check result of cause 3 is
normal, this check is not required.
Resistance
Max. 1 z
DIAL (female) (2)
2. Disconnect connectors PTCN1 and DIAL, and connect T-adapter to female
PTCN1 (female) (8) and (21), or
5
Resistance
Min. 1 Mz
between DIAL (female) (2) and (3)
PTCN1 (female) (8) and ground ,
or between DIAL (female) (2) and
Resistance
Min. 1 Mz
ground
4. Rotate fuel control dial and troubleshoot.
PTCN1 (8) and (21)
Circuit diagram related to fuel control dial
D375A-6R
(01)
Voltage
0.5 4.5 V
40-43
40-433
Failure code [DK10KB] Fuel control Dial: Short circuit

Action code
Failure code
E03
DK10KB
Failure
40-434
Fuel control Dial: Short circuit

Detail of failure
Signal voltage of fuel control dial is above 4.5 V.
Continues control with signal of decelerator pedal potentiometer..

Problem on
machine
Related information
q
q
q

Signal voltage of fuel control dial signal can be checked with monitoring function.
(Code 03000: Fuel Dial Sensor)
Method of reproducing failure code:Turn the starting switch to ON position)
Cause


ply system
1.
2.
3.
a

Disconnect connector DIAL and connect T-adapter to female side.
Between DIAL (female)

(1) and (3)
Defective fuel dial

1.
2.
3.
4.
Power
supply
Voltage
4.5 5.5 V

Disconnect connector DIAL and connect T-adapter to male side.
Rotate fuel control dial and troubleshoot.
Resistance
Approx. 5 z
Resistance
0.5 - 4.5 kz
Resistance
0.5 - 4.5 kz

2. Disconnect connector DIAL and connect T-adapter to male side.
Hot short circuit in wiring harness 3. Turn starting switch to ON position.
3
Between DIAL (female) (2) and (3)
Voltage
Max. 1 V
or ground
2. Disconnect connectors PTCN1 and DIAL, and connect T-adapter to female
side of PTCN1.
No continuity (No sound is heard)
4. Rotate fuel control dial and troubleshoot.
PTCN1 (8) and (21)
40-434
Voltage
0.5 4.5 V
D375A-6R
(01)
Circuit diagram related to fuel control dial
D375A-6R
(01)
40-435
40-435
Failure code [DK30KA] ST lever 1: Disconnection

Action code
Failure code
E03
DK30KA
Failure
40-436
Steering potentiometer 1: Disconnection

Detail of failure
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).
Problem on
machine
q
q
Related information

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.
Between TL2 (female)
Power
Voltage
4.5 5.5 V
(5) and (8)
supply
2. Insert T-adapter into connector TL2.
4. Operate PCCS lever (steering) and troubleshoot.
Defective PCCS lever steering
(0.5 V or below), internal disconnection and ground fault cannot be identi2 potentiometer 1 (Internal disconfied. In this case, go to cause 4.
nection) or ground fault
If check result of cause 4 is normal, PCCS lever steering potentiometer 1 is
defective.
Between TL2 (female) Sensor
Voltage
0.964.04 V
(7) and (8)
output
2. Disconnect connectors PTCN1 and TL2, and connect T-adapters to female
side of them.
Resistance
Max. 1 z
not required.
and TL2 (female) (5)
3
(open circuit or defective contact) a If power supply voltage in
not required.
Resistance
Max. 1 z
Resistance
Max. 1 z
TL2 (female) (7)
2. Disconnect connectors PTCN1 and TL2, and connect T-adapter to female
4
(21), or between TL2 (female) (7)
Resistance
Min. 1 Mz
ground (8)
ground, or between TL2 (female)
Resistance
Min. 1 Mz
(7) and ground
1
40-436
D375A-6R
(01)
Cause

Circuit diagram related to steering potentiometer
D375A-6R
(01)
Voltage
0.964.04 V
40-437
40-437
Failure code [DK30KB] ST lever 1: Short circuit

Action code
Failure code
E03
DK30KB
Failure
40-438
Steering potentiometer 1: Short circuit

Detail of failure
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).
problem on
machine
q
q
Related information
Once machine stops, engine speed is limited to medium (half).

steering direction)
Cause
1

potentiometer 1 (Internal discon2

2. Disconnect connector TL2.
If failure code [DK30KB] is not displayed, PCCS lever steering potentiometer
is defective. (If failure code [DK30KB] is still displayed, wiring harness or
a Since connector TL2is disconnected, many failure codes are displayed. Ignore all displayed failure codes other than [DK30KB].

Hot short in wiring harness (Con- 3. Turn starting switch to ON position.
3
Between TL2 (female) (7) and (8)
Voltage
Max. 1 V
or ground
side of PTCN1.
40-438
Voltage
0.964.04 V
D375A-6R
(01)
D375A-6R
(01)
40-439
40-439
Failure code [DK30KX] ST lever: Out of normal range

Action code
Failure code
E04
DK30KX
Failure
40-4 0
Steering potentiometers 1 and 2: Out of normal range

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.

Signal voltage of PCCS lever steering potentiometer 1 and 2 can be checked with monitoring function.
steering direction)
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-6R
(01)
Failure code [DK30KZ] ST lever: Disconnection or short circuit
Failure code [DK30KZ] ST lever: Disconnection or short circuit

Action code
E04
40-4 1
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.
Method of reproducing failure code: Turn starting switch to ON position and operate PCCS lever
(in steering direction).
Detail of failure
Problem on
machine
q
q
Related information
q
Cause
Perform troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA]and [DK31KB].
D375A-6R
(01)
40-441
Failure code [DK30L8] ST lever: Signal mismatch

Action code
Failure code
E03
DK30L8
Detail of failure
Problem on
machine
Steering potentiometer: Signal mismatch

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).
q
q
q
q
Related information
Failure
40-4 2

Signal voltage of PCCS lever steering potentiometer can be checked with monitoring function.
steering direction))
Cause
40-442
D375A-6R
(01)
D375A-6R
(01)
40-443

Action code
Failure code
E03
DK31KA
Failure
40-4 4
Steering potentiometer 2: Disconnection

Detail of failure
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).
Problem on
machine
q
q
Related information

Cause


Power
Voltage
4.5 5.5 V
(5) and (8)
supply
2 potentiometer 2 (Internal disconIn this case, go to cause 4.
If check result of cause 4 is normal, PCCS lever steering potentiometer 2 is
defective.
Between TL2 (female) Sensor
Voltage
0.964.04 V
(6) and (8)
output
side of them.
Resistance
Max. 1 z
not required.
3
not required.
Resistance
Max. 1 z
and TL2 (female)(8)
Resistance
Max. 1 z
2. Disconnect connectors PTCN1 andTL2, and connect T-adapter to female
4
and (21) , or between TL2
Resistance
Min. 1 Mz
(female) (6) and (8)
and ground , or between TL2
Resistance
Min. 1 Mz
ply system
40-444
D375A-6R
(01)
Cause

Between PTCN1(19) and (21)
D375A-6R
(01)
Voltage
0.964.04 V
40-4 5
40-445

Action code
Failure code
E03
DK31KB
Failure
40-4 6
Steering potentiometer 2: Short circuit

Detail of failure
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).
Problem on
machine
q
q
Related information

Cause
1

2 potentiometer 2 (Internal disconnection) or ground fault

If failure code [DK31KB] is not displayed, PCCS lever steering potentiometer
is defective.( If failure code [DK31KB] is still displayed, wiring harness or
a Since connector TL2 is disconnected, many failure codes are displayed.Ignore all displayed failure codes other than [DK31KB]

2. Disconnect connectors TL2 and connect T-adapter to female side.
Hot short of wiring harness (Con- 3. Turn starting switch to ON position.
3
Voltage
Max. 1 V
or ground
side of PTCN1.
and each pin other than (19)
2. Insert T-adapter into connector PTCN1
40-446
Voltage
0.964.04 V
D375A-6R
(01)
D375A-6R
(01)
40-4 7
40-447
Failure code [DK40KA] Brake potentiometer: Disconnection

Action code
Failure code
E03
DK40KA
Failure
40-4 8
Brake potentiometer: Disconnection

Detail of failure
Signal voltage of brake pedal potentiometer is below 0.5 V.
travel is limited to F1 and R1.

Problem on
machine
Related information
q
q
q
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.
Cause
If failure code [DBE5KK]is also displayed, troubleshoot it first.

ply system
1.
2.
3.
a

Disconnect connector BRK and connect T-adapter to female side.
Between BRK (female)

(C) and (A)
Power
supply
Voltage
4.5 5.5 V

2. Disconnect connector BRK and connect T-adapter to male side.
Defective brake pedal potentiome- 4. Depress brake pedal and troubleshoot.
ter
Between BRK (male) (C) and (A)
Resistance
Approx. 5 kz
2
(Internal disconnection or ground
Between BRK (male) (A) and (B)
Resistance
0.25 - 7.0 kz
fault)
Between BRK (male) (B) and (C)
Resistance
0.25 - 7.0 kz

wiring harness
40-448
Between BRK (male) B)and

Resistance
Min. 1 Mz
ground
2. Disconnect connectors PCTN1 and TL1, and connect T-adapters to female
side of them PTCN1.
a Resistance is same as table in cause 2.
a If resistance is above 1 Mz, wiring harness has disconnection. If resistance
Resistance
Approx. 2 kz
and (21)
Resistance
0.2 - 1.8 kz
(21)
D375A-6R
(01)
Cause

2. Disconnect connectors PTCN1 and BRK, and connect T-adapters to female
side of them.
Resistance
Max. 1 z
not required.
and BRK (female) (A)
4
Resistance
Max. 1 z
not required.
and BRK (female) (C)
a If check result of cause 3 is
normal, this check is not required.
Resistance
Max. 1 z
BRK (female) (B)
Circuit diagram related to brake potentiometer
D375A-6R
(01)
40-4 9
40-449
Failure code [DK40KB] Brake potentiometer: Short circuit

Action code
Failure code
E03
DK40KB
Failure
40-450
Brake potentiometer: Short circuit

Detail of failure
Signal voltage of brake pedal potentiometer is above 4.8 V.
travel is limited to F1 and R1.

Problem on
machine
Related information
q
q
q
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.
Cause

If failure code [DBE5KK]is also displayed, troubleshoot it first.

ply system
1.
2.
3.
a

Disconnect connector BRK and connect T-adapter to female side.
Between BRK (female)

(C) and (A)
Power
supply
Voltage
4.5 5.5 V

Defective brake pedal potentiome- 4. Depress brake pedal and troubleshoot.
ter
Between BRK (female) (C) and
2
Resistance
Approx. 5 kz
(Internal disconnection or short
(A)
circuit)
Between BRK (female) (A) and
Resistance
0.25 - 7.0 kz
(B)
Between BRK (female) (B) and
Resistance
0.25 - 7.0 kz
(C)
Hot short in wiring harness (Con- 3. Turn starting switch ON position.
3
Between BRK (female) (B) and
Voltage
Max. 1 V
(A) or ground
2. Disconnect connector PTCN1 and BRK , and connect T-adapter to female
side of PTCN1.
q
Reference: the followings are standard values in normal condition.
4. Depress brake pedal and troubleshoot.
Between PTCN1(3) and (21)
40-450
Voltage
0.5 4.5 V
D375A-6R
(01)
Circuit diagram related to brake potentiometer
D375A-6R
(01)
40-451
40-451
Failure code [DK55KX] FR lever: Out of normal range

Action code
Failure code
E04
DK55KX
Failure
40-452
Front/Rear potentiometers 1 and 2: Out of normal range

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)
Method of reproducing failure code:Turn starting switch to ON position and operate PCCS lever (in
F-R direction).
Detail of failure
Problem on
machine
q
q
Related information
Cause
40-452
D375A-6R
(01)
Failure code [DK55KZ] FR lever: Disconnection or short circuit
Failure code [DK55KZ] FR lever: Disconnection or short circuit

Action code
Failure code
E04
DK55KZ
Failure
40-453
Front/Rear potentiometer: Abnormal at key ON

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.

F-R direction).
Detail of failure
Problem on
machine
q
q
Related information
Cause
D375A-6R
(01)
40-453
Failure code [DK55L8] FR lever: Signal mismatch

Action code
Failure code
E03
DK55L8
Failure
40-454
Front/Rear potentiometer: Signal mismatch

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.
Problem on
machine
Detail of failure
q
q
Related information

F-R direction).
Cause
Perform troubleshooting for failure codes [DK56KA], [DK56KB],[DK57KA] and [DK57KB].
40-454
D375A-6R
(01)
D375A-6R
(01)
40-455
Failure code [DK56KA] FR lever 1: Disconnection

Action code
Failure code
E03
DK56KA
Failure
40-456
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
Continues control with signal of PCCS lever F-R potentiometer 2 (F/R lever 4).
Problem on
machine
q
q
Related information

Signal voltage of PCCS lever F-R potentiometer 1 can be checked with monitoring function.
F-R direction).
Cause


Power
Voltage
4.5 5.5 V
(4) and (1)
supply
4. Operate PCCS lever (F-R) and troubleshoot.
Defective PCCS lever F-R potenti- a If power supply voltage is normal and sensor output voltage is abnormal
ometer 1 (Internal disconnection)
2
or ground fault
In this case, go to cause 4.
If check result of cause 4 is normal, PCCS lever F-R potentiometer 1 is
defective.
Between TL2 (3) and
Sensor
Voltage
1.393.61 V
(1)
output
side of them.
Resistance
Max. 1 z
not required.
3
not required.
Resistance
Max. 1 z
Resistance
Max. 1 z
4
and (21), or between
Resistance
Min. 1 Mz
TL2(female)(3) and (1)
and ground, or between TL2
Resistance
Min. 1 Mz
ply system
40-456
D375A-6R
(01)
Cause

Circuit diagram related to forward-reverse potentiometer
D375A-6R
(01)
Voltage
1.393.61 V
40-457
40-457
Failure code [DK56KB] FR lever 1: Short circuit

Action code
Failure code
E03
DK56KB
Failure
40-458
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
q
q
Related information

F-R direction).
Cause
1


2. Disconnect connectors TL2.
Defective PCCS lever F-R potenti4. Operate PCCS lever (F-R) and troubleshoot.
ometer 1
2
(Internal disconnection) or ground If failure code [DK56KB] is not displayed, PCCS lever steering potentiometer
is defective. (This failure code is still displayed, wiring harness or power train
fault
controller is defective.)
a Since connector TL2 is disconnected, many failure codes are displayed. Ignore all displayed failure codes other than [DK56KB].
2. Disconnect connectors TL2, and connect T-adapter to female side.
Hot short of wiring harness (Con- 3. Turn starting switch ON position.
3
Voltage
Max. 1 V
or ground
side of PTCN1.
40-458
Voltage
1.393.61 V
D375A-6R
(01)
D375A-6R
(01)
40-459
40-459

Action code
Failure code
E03
DK57KA
Failure
40-460
Front/Rear potentiometer 2: Disconnection

Detail of failure
Signal voltage of PCCS lever F-R potentiometer 2 (F/R lever 4) is below 0.5 V.
Problem on
machine
q
q
Related information

F-R direction).
Cause


Power
Voltage
4.5 5.5 V
(4) and (1)
supply
Defective PCCS lever F-R potenti- a If power supply voltage is normal and sensor output voltage is abnormal
2
or ground fault
If check result of cause 4 is normal, PCCS lever F-R potentiometer 2 is
defective.
Between TL2 (2) and
Sensor
Voltage
1.39 3.61 V
(1)
output
side of them.
Resistance
Max. 1 z
not required.
3
(open circuit or defective contact) a If power supply voltage on
not required.
Resistance
Max. 1 z
Between PTCN1(female) (21) and
TL2 (female) (1)
Between PTCN1(female) (14) and
Resistance
Max. 1 z
TL2 (female) (2)
4
and (21), or between TL2 (female)
Resistance
Min. 1 Mz
(2) and (1)
Between (female) (14) and ground
, or between TL2 (female) (2) and
Resistance
Min. 1 Mz
ground
1
40-460
D375A-6R
(01)
Cause

Circuit diagram related to Front/Rear potentiometer
D375A-6R
(01)
Voltage
1.39 3.61 V
40-461
40-461

Action code
Failure code
E03
DK57KB
Failure
40-462
Front/Rear potentiometer 2: Short circuit

Detail of failure
Signal voltage of PCCS lever F-R potentiometer 2 (F/R lever 4) is above 4.5 V.
Problem on
machine
q
q
Related information

F-R direction).
Cause
1


Defective PCCS lever F-R potenti4. Operate PCCS lever (F-R) and troubleshoot.
2
If failure code [DK57KB]is not displayed, PCCS lever F-R potentiometer is
or ground fault
defective. (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 displayed failure codes other than [DK57KB].
Hot short of wiring harness (Con- 3. Turn starting switch to ON position.
3
Voltage
Max. 1 V
or ground
side of PTCN1.
40-462
Voltage
1.393.61 V
D375A-6R
(01)
D375A-6R
(01)
40-463
40-463
Failure code [DK60KA] Acceleration sensor: Disconnection

Action code
Failure code
E01
DK60KA
Failure
40-464
Acceleration sensor: Disconnection

Detail of failure
Signal voltage of acceleration sensor is below 0.5 V.
Turns shoe slip control(SSC) function OFF.
Problem on
machine
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)
Related information
Cause

If failure code [DBB7KP] is also displayed, troubleshoot it first.

2. Disconnect connector SSA and connect T-adapter to female side.
Between SSA(female)(1)
Power supply
Voltage
4.5 5.5 V
and (3)
2. Insert T-adapter into connectorSSA.
2 sensor (Internal disconnection) or
ground fault
In this case, go to cause 4. If check result of cause 4 is normal, acceleration
sensor sensor is defective.
Between SSA (female) (2)
Sensor output
Voltage
0.75 4.25 V
and (3)
2. Disconnect connector PTCN1, PTCN3 and SSA, and connect T-adapters to
Resistance
Max. 1 z
Between PTCN3 (female) (34) and SSA
3 (Open circuit in wiring or defective (female) (1)
a If power supply voltage in cause 1 is norcontact in connector)
Resistance
Max. 1 z
Between PTCN 1(female) (21) and SSA
(female) (3)
Between PTCN1 (female) (1) and SSA
Resistance
Max. 1 z
(female) (2)
2. Disconnect connector PTCN1, SSA, and connect T-adapter to female side
of either of them.
4
Resistance
Max. 1 Mz
between SSA (female) (2) and (3)
Defective 5 V power supply sys1
tem

between SSA (female) (2) and ground
40-464
Resistance
Max. 1 Mz
D375A-6R
(01)
Cause

Circuit diagram related to acceleration sensor
D375A-6R
(01)
Voltage
0.75 4.25 V
40-465
40-465
Failure code [DK60KB] Acceleration sensor: Short circuit

Action code
Failure code
E01
DK60KB
Failure
40-46
Acceleration sensor: Short circuit

Detail of failure
Signal voltage of acceleration sensor is above 4.5 V.
Turns shoe slip control(SSC) function OFF.
Problem on
machine
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)
Related information
Cause

If failure code [DBB7KP] is also displayed, troubleshoot it first.

ply system

Between SSA (female) (1)
Power supply
Voltage
4.5 5.5 V
and (3)
2. Disconnect connector SSA.

2 sensor (Internal disconnection) or
If failure code [DK60KB] is not displayed , acceleration sensor is defective. (If
ground fault
failure code [DK60KB] is still displayed, it shows that wiring harness or power
train controller is defective.)
Hot short in wiring harness
3

Between SSA (female) (2) and (3) or ground
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
No continuity(No sound is
each pin other than
heard)
40-466
Voltage
Voltage
0.75 4.25 V
D375A-6R
(01)
Circuit diagram related to acceleration sensor
D375A-6R
(01)
40-467
40-467
Failure code [DKH1KA] Pitch angle sensor: Disconnection

Action code
Failure code
E03
DKH1KA
Failure
40-468
Pitch angle sensor: Disconnection

Detail of failure
Signal voltage of inclination angle sensor is below 0.15 V.
Cannot sense pitch angle of machine.

Problem on
machine
q
q
q
q
q
Related information
q
q
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 sys- 2. Disconnect connector PT1 and connect T-adapter to female side.
tem
Between PT1 (female) (C)
Power supply
Voltage
20 30 V
and (A)
2. Insert T-adapter into connector PT1.
Defective pitch angle sensor
2
(Internal defect) or ground fault
If check result of cause 4 is normal, pitch angle sensor is defective.
Between PT1 (female) (B)
Sensor output
Voltage
0.24 4.76 V
and (A)
2. Disconnect connectors PTCN1 and PT1, and connect T-adapters to female
side of them.
Resistance
Max. 1 z
Between PTCN3 (female) (16) and PT1
3 (Open circuit in wiring or defective (female) (C)
a If power supply voltage in cause 1 is norcontact in connector)
Resistance
Max. 1 z
Between PTCN1(female) (21) and PT1
(female) (A)
Between PTCN1 (female) (9) and PT1
Resistance
Max. 1 z
(female) (B)
2. Disconnect connectors PTCN1 and PT1, and connect T-adapters to female
4
Resistance
Max. 1 Mz
between PT1 (female) (B) and (A)
1

between PT1 (female) (B) and ground
40-468
Resistance
Max. 1 Mz
D375A-6R
(01)
Cause

Circuit diagram related to inclination angle sensor
D375A-6R
(01)
Voltage
0.24 4.76 V
40-469
40-469
Failure code [DKH1KB] Pitch angle sensor: Short circuit

Action code
Failure code
E03
DKH1KB
Failure
40-470
Pitch angle sensor: Short circuit

Detail of failure
Signal voltage of inclination angle sensor is above 4.85 V.
Cannot sense pitch angle of machine.

Problem on
machine
q
q
q
q
q
Related information
q
q
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


Defective sensor 24 V power sup- 2. Disconnect connector PT1 and connect T-adapter to female side.
ply system
Between PT1 (female) (C)
Power supply
Voltage
20 30 V
and (A)
2. Disconnect connector PT1.
Defective pitch angle sensor
2
If failure code [DKH1KB] is not displayed but [DKH1KA] of disconnection is
(Internal defect)
displayed, pitch angle sensor is defective.
(If failure code [DKH1KB] is still displayed, it shows that wiring harness or
1

3

2. Disconnect connector PT1 and connect T-adapter to female side.
Between PT1 (female) (B) and (A) or ground
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)
40-470
Voltage
Voltage
0.24 4.76 V
D375A-6R
(01)
Circuit diagram related to inclination angle sensor
D375A-6R
(01)
40-471
40-471
Failure code [DLF1KA] T/C out-speed sensor: Disconnection

Action code
Failure code
DLF1KA
Failure
40-472
Torque converter oil temperature sensor disconnection

Detail of failure
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).
Problem on
machine
Related information
Cause

Defective torque converter output 2. Disconnect connector C1 and connect T-adapter to male side.
Approx.
1 shaft speed sensor (Internal open
Between TC1 (male) (1) and (2)
Resistance
560 z
or short circuit)
Between TC1 (male) (1) and ground
2
ness
Approx.
Resistance
560 z
2. Disconnect connectors PTCN2 and TC1, and connect T-adapters to female
side of them.
3
Between PTCN2 (female) (29) and TC1 (female) (2) Resistance Max. 1 z
Between PTCN2 (female) (20) and TC1 (female) (1) Resistance
Max. 1 z

Hot short circuit in wiring harness 2. Disconnect connector TC1 and connect T-adapter to female side.
4
Between TC1 (female) (1) and (2)
Voltage
34V
If cause is not found by above checks, power train controller may be defective.
Circuit diagram related to torque converter output speed sensor
40-472
40-472
D375A-6R
(01)
D375A-6R
(01)
40-473
Failure code [DLM3KA] Fan rev. sensor: Disconnection

Action code
Failure code
E02
DLM3KA
Failure
40-474
Fan speed sensor: Disconnection

Detail of failure
No signal is input from the fan speed sensor.
Recognizes that fan speed is 0 rpm.
The fan speed cannot be monitored.

Fan PID control cannot be started.
Problem on
machine
Related information
q
q
q
The fan speed can be checked with the monitoring function.

(Code: 10007 Fan speed)
Cause

2. Disconnect connector FRV and connect T-adapter to male side.
Defective fan speed sensor (InterBetween FRV (male) (1) and (2)
nal open circuit or short circuit)
Between FRV (male) (1) and ground
Resistance
Approx.
2 kz
Resistance
Min. 1 Mz

2
ness
Approx.
Resistance
2 kz
2. Disconnect connectors WECN2 and FRV, and connect T-adapters to
3
(open circuit or defective contact) Between WECN2 (female) (39) and FRV (female)
Resistance Max. 1 z
(2)
Between WECN2 (female) (40) and FRV (female)
Resistance Max. 1 z
(1)
Hot short circuit in wiring harness 2. Disconnect connector FRV and connect T-adapter to female side.
4
Between FRV (female) (1) and (2)
5
Voltage
34V
Defective work equipment control- If cause is not found by above checks, work equipment controller may be
ler
40-474
D375A-6R
(01)
Circuit diagram related to fan speed sensor
D375A-6R
(01)
40-475
40-475
Failure code [DLM3MB] Fan control: Decline

Action code
Failure code
E02
DLM3MB
Failure
40-476
Fan speed control function low

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.
Detail of failure
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).
Problem on
machine
Related information
q
q
Cause
1 Defective hydraulic system
40-476

Perform Testing and adjusting, "Testing fan hydraulic circuit".
D375A-6R
(01)
Failure code [DLT3KA] T/M out-speed sensor: Disconnection
Failure code [DLT3KA] T/M out-speed sensor: Disconnection

Action code
Failure code
E01
DLT3KA
Failure
40-47
Transmission output speed sensor: Disconnection

Detail of failure
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 is stopped, 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)
Method of reproducing failure code: Turn starting switch to ON position and travel (travel machine
Problem on
machine
q
q
q
q
Related information
Cause

Defective transmission bevel gear 2. Disconnect connector TM1 and connect T-adapter to male side.
Approx.
1 (output) speed sensor (Internal
Between TM1 (male) (1) and (2)
Resistance
560 z
disconnection or short circuit)
Between TM1 (male) (1) and ground
Resistance
Min. 1 Mz

2
ness
Approx.
Resistance
560 z
2. Disconnect connector PTCN2 and TM1, and connect T-adapters to female
side of them.
3
Between PTCN2 (female) (39) and TM1 (female) (2) Resistance Max. 1 z
Between PTCN2 (female) (30) and TM1(female) (1) Resistance
Max. 1 z

Hot short circuit in wiring harness 2. Disconnect connector TM1 and connect T-adapter to female side.
4
Between TM1 (female) (1) and (2)
Voltage
34V
Circuit diagram related to transmission output speed sensor
D375A-6R
(01)
40-47
40-477
Failure code [DLT3KB] T/M out-speed sensor: Abnormal

Action code
Failure code
E01
DLT3KB
Failure
40-478
Transmission output speed sensor: Disconnection

Detail of failure
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)
Method of reproducing failure code:Turn starting switch to ON position and travel (travel machine
Problem on
machine
q
q
q
q
Related information
Cause

Defective transmission bevel gear 2. Disconnect connector TM1 and connect T-adapter to male side.
Approx.
1 (output) speed sensor (Internal
Between TM1 (male) (1) and (2)
Resistance
560 z
disconnection or short circuit)
Between TM1 (male)(1) and ground

wiring harness

Circuit diagram related to transmission output speed sensor
40-478
Resistance
Min. 1 Mz

Approx.
Resistance
560 z
2. Disconnect connector PTCN2 and TM1, and connect T-adapter to female
Between PTCN2 (female) (30) or TM1 (female) (1)
and ground
If cause is not found by the above checks, power train controller may be defective. (Since failure is in it, troubleshooting cannot be performed.)
40-478
D375A-6R
(01)
Failure code [DW59KA] Blade dual selector SOL disconnection
Failure code [DW59KA] Blade dual selector SOL disconnection

Action code
Failure code
E01
DW59KA
Failure
40-479
Dual tilt selector solenoid: Disconnection

Detail of failure
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.
Problem on
machine
Related information
Cause
1
Defective dual tilt selector solenoid (Internal disconnection)

wiring harness

2. Disconnect connector SOL2 and connect T-adapter to male side.
SOL2 (male) (1) and (2)
Resistance
10 40 z

Resistance
10 40 z
2. Disconnect connector WECN3 and SOL2, and connect T-adapters to
Between WECN3 (female) (7) and SOL2 (female)
Resistance Max. 1 z
(1)
Resistance Max. 1 z
(2)
Defective work equipment control- If cause is not found by the above checks, work equipmet controller may be
4
ler
Circuit diagram related to dual tilt selector solenoid
D375A-6R
(01)
40-479
40-479
Failure code [DW59KB] Blade dual selector SOL short circuit

Action code
Failure code
E01
DW59KB
Failure
40-480
Dual tilt selector solenoid: Short circuit

Detail of failure
Abnormal current flowed when power is output to dual tilt selector solenoid circuit.
Dual tilt cannot be selector.
switch.
Problem on
machine
Related information
Cause
Defective dual tilt selector solenoid (Internal short circuit)

2. Disconnect connector OL2 and connect T-adapter to male side.

Resistance
10 40 z
Between SOL2 (female) (1) and ground
Between SOL2 (male) (1) and (2)
Resistance
Min. 1 Mz

Between WECN3 (female) (7) or SOL2 (female) (1)
and ground
female side of either of them.
Between WECN3 (female) (7) and (23) or between
SOL2 (female) (1) and (2)
Defective work equipment control- If cause is not found by the above checks, work equipment controller may be
ler
40-480
40-480
D375A-6R
(01)
D375A-6R
(01)
40-481
Failure code [DW59KY] Blade dual selector SOL hot short

Action code
Failure code
E01
DW59KY
Failure
40-482
Dual tilt selector solenoid: Short circuit

Detail of failure
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.
Problem on
machine
Related information
q
q
Cause
Defective dual tilt selector solenoid (Internal short circuit)

Resistance
10 40 z
Resistance
Min. 1 Mz

Hot short circuit in wiring harness 2. Disconnect connector SOL2 and connect T-adapter to female side.
2
Voltage
Max. 1 V
2. Disconnect connectors WECN3 and SOL2, and connect T-adapter to
No continuity (No sound
than (7)
is 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 No continuity (No sound
(3)
is heard.)
Between RB1 (male) (3) and each pin other than (3)
is heard.)
4
ler
40-482
D375A-6R
(01)
D375A-6R
(01)
40-483
40-483
Failure code [DW5AKA] Blade pitch selector SOL disconnection
Failure code [DW5AKA] Blade pitch selector SOL disconnection

Action code
Failure code
E02
DW5AKA
Failure
40-484
Work equipment pitch select solenoid: Disconnection

Detail of failure
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 selector
switch.
Problem on
machine
Related information
Cause
Defective work equipment pitch
1 select solenoid (Internal disconnection)

Resistance
10 40 z

2
ness
Resistance
10 40 z
Resistance Max. 1 z
(1)
Resistance Max. 1 z
(2)
4
ler
Circuit diagram related to work equipment pitch select solenoid
40-484
40-484
D375A-6R
(01)
Failure code [DW5AKB] Blade pitch selector SOL short circuit
Failure code [DW5AKB] Blade pitch selector SOL short circuit

Action code
Failure code
E02
DW5AKB
Failure
40-485
Work equipment pitch select solenoid: Short circuit

Detail of failure
Abnormal current flowed when power was output to work equipment pitch select solenoid circuit.
Blade pitch cannot be changed.
switch.
Problem on
machine
Related information
Cause

1 select solenoid (Internal short cirBetween SOL1 (male) (1) and (2)
Resistance 10 40 z
cuit)
Between SOL1 (male) (1) and ground


2. Disconnect connector WECN3 and SOL1, and connect T-adapter to female
WECN3 (female) (17) or SOL1 (female) (1) and
ground
2. Disconnect connector WECN3 and SOL1, and connect T-adapter to female
SOL1 (female) (1) and (2)
ler
Circuit diagram related to work equipment pitch select solenoid
D375A-6R
(01)
40-485
40-485
Failure code [DW5AKY] Blade pitch selector SOL Short circuit

Action code
Failure code
E02
DW5AKY
Failure
40-486
Work equipment pitch select solenoid: Short circuit

Detail of failure
Current flows constantly to work equipment pitch select solenoid circuit.
Only pitch operation can be changed and tilt operation cannot be changed.
switch.
Problem on
machine
Related information
Cause

1 select solenoid (Internal short cirBetween SOL1 (male) (1) and (2)
Resistance 10 40 z
cuit)
Hot short circuit in wiring harness 2. Disconnect connector SOL1 and connect T-adapter to female side.
2
Voltage
Max. 1 V
2. Disconnect connector WECN3 and SOL1 and connect T-adapter to female
side of WECN3.
Between WECN3 (female) (17) and each pin other No continuity (No sound
than (17)
is 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 No continuity (No sound
(1)
is heard.)
Between RB1 (male) (1) and each pin of (1)
is heard.)
4
ler
40-486
D375A-6R
(01)
Circuit diagram related to work equipment pitch selector solenoid
D375A-6R
(01)
40-487
40-487
Failure code [DW7BKA] Fan rev EPC: Disconnection

Action code
Failure code
E01
DW7BKA
Failure
40-48
Fan reverse solenoid: Disconnection

Detail of failure
When power is output to fan reverse solenoid circuit, no current flows.
Stops output to fan reverse solenoid circuit.
Problem on
machine
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.
Related information
Cause
Defective fan reverse solenoid
1

wiring harness

2. Disconnect connector FAR2 and connect T-adapter to male side.
Between FAR2 (male) (1) and (2)
Resistance
34 44 z

Between WECN3 (female) (18) amd (13)
Resistance
34 44 z
2. Disconnect connector WECN3 and FAR2, and connect T-adapters to their
female sides.
Between WECN3 (female) (18) and FAR2 (female)
Resistance Max. 1 z
(1)
Between WECN3 (female) (13) and FAR2 (female)
Resistance Max. 1 z
(2)
2. Disconnect connector FAR2 and connect T-adapter to female side.
4
Between FAR2 (female) (1) and ground
Voltage
Max. 1 V
5
ler
Circuit diagram related to fan reverse EPC
40-488
40-48
D375A-6R
(01)
Failure code [DW7BKB] Fan rev EPC: Short circuit

Action code
Failure code
E01
DW7BKB
Failure
40-489
Fan reverse solenoid: Short circuit

Detail of failure
When power was output to fan reverse solenoid circuit, abnormal current flowed.
Stops output to fan reverse solenoid circuit.
Problem on
machine
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.
Related information
Cause
Defective fan reverse solenoid


2. Disconnect connector FAR2 and connect T-adapter to male side.

Resistance
34 44 z
Between FAR2 (female) (1) and ground
Between FAR2 (male) (1) and (2)
Resistance
Min. 1 Mz

2. Disconnect connector WECN3 and FAR2, and connect T-adapter to female
Between WECN3 (female) (18) or FAR2 (female)
(1) or ground
2. Disconnect connector WECN3 and FAR2, and connect T-adapter to female
Between WECN3 (female) (18) and (13) or betwen
FAR2 (female) (1) and (2)
ler
Circuit diagram related to fan reverse EPC
D375A-6R
(01)
40-489
40-489
Failure code [DWN3KA] Ssp solenoid: Disconnection

Action code
Failure code
E04
DWN3KA
Failure
40-490
Sudden stop prevention solenoid disconnection

Detail of failure
When power is output to sudden stop prevention solenoid circuit, no current flows.
Stops output to sudden stop prevention solenoid circuit.

Problem on
machine
Related information
q
q
q
Once machine is stopped, engine speed is restricted to medium (half).

Once machine is stopped, it becomes impossible to travel.
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 prevention 1. Turn starting switch to OFF position.

2. Disconnect connector STB and connect T-adapter to male side.
1 solenoid
Between STB (male) (1) and (2)
Resistance 5 15 z
2
ness
Resistance
5 15 z
2. Disconnect connectors PTCN3 and STB, and connect T-adapters to their
female sides.
Between PTCN3 (female) (7) and STB (female) (1) Resistance Max. 1 z
Between PTCN3 (female) (13) and STB (female) (2) Resistance
40-490
Max. 1 z
D375A-6R
(01)
Circuit diagram related to sudden stop prevention solenoid
D375A-6R
(01)
40-491
40-491
Failure code [DWN3KB] Ssp solenoid: Short circuit

Action code
Failure code
E04
DWN3KB
Failure
40-492
Sudden stop prevention solenoid short circuit

Detail of failure
When power is output to sudden stop prevention solenoid circuit, abnormal current flowed.

Problem on
machine
Related information
q
q
q
Once machine stops, engine speed is restricted to medium (half).

Once machine is stopped, it becomes impossible to travel.
Output condition to sudden stop prevention solenoid can be checked with monitoring function.
Cause

Defective sudden stop prevention 2. Disconnect connector STB and connect T-adapter to male side.
1 solenoid
Resistance 5 15 z
Between STB (female) (1) and ground

40-492

2. Disconnect connector PTCN3 and STB, and connect T-adapter to female
Between PTCN3 (female) (7) or STB (female) (1)
and ground
Between PTCN3 (female) (7) and (13) ro between
STB (female) (1) and (2)
If cause is not found by the above checks, work equipment controller may be
D375A-6R
(01)
D375A-6R
(01)
40-493
40-493
Failure code [DWN3KY] SSP solenoid: Short circuit

Action code
Failure code
E04
DWN3KY
Failure
40-494
Sudden stop prevention solenoid short circuit

Detail of failure
When power is output to sudden stop prevention solenoid circuit, current flows.

Problem on
machine
Related information
q
q
q
q
q
q
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
Cause

Defective sudden stop prevention 2. Disconnect connector STB and connect T-adapter to male side.
1 solenoid
Resistance 5 15 z
Hot short circuit in wiring harness 2. Disconnect connector STB and connect T-adapter to female side.
2
Voltage
Max. 1 V
40-494

side of PTCN3.
than (7)
is heard)
2. Disconnect connectors PTCN3, STB, PL2 and PL2, and connect T-adapter
to female side and male side of RB1 separately in 2 times
Between PL2 (female) (23) and each pin other than No continuity (No sound
(23)
is heard)
Between PL2 (male) (23) and each pin other than
(23)
is heard)
D375A-6R
(01)
D375A-6R
(01)
40-495
40-495
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection

Action code
Failure code
E01
DWN5KA
Failure
40-496
Fan pump solenoid 1: Disconnection

Detail of failure
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).
Problem on
machine
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))
Related information
Cause
1
Defective fan pump solenoid 1


wiring harness

2. Disconnect connector FA1 and connect T-adapter to male side.
Between FA1 (male) (1) and (2)
Resistance
2 12 z

Resistance
2 12 z
2. Disconnect connector WECN3 and FA1, and connect T-adapters to their
female sides.
Between WECN3 (female) (36) and FA1 (female)
Resistance Max. 1 z
(1)
Resistance Max. 1 z
(2)
4
ler
40-496
D375A-6R
(01)
Circuit diagram related to fan pump solenoid 1
D375A-6R
(01)
40-497
40-497
Failure code [DWN5KB] Fan pump solenoid 1: Short circuit

Action code
Failure code
E01
DWN5KB
Failure
40-498
Fan pump solenoid 1: Short circuit

Detail of failure
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.
Problem on
machine
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.
Related information
Cause
Defective fan pump control sole1 noid 1


Resistance
2 12 z
Between FA1 (female) (1) and ground
Resistance
Min. 1 Mz

2. Disconnect connector WECN3 and FA1, and connect T-adapter to female
Between WECN3 (female) (36) or FA1 (female) (1)
and ground
FA1 (female) (1) and (2)
ler
40-498
D375A-6R
(01)
D375A-6R
(01)
40-49
40-499
Failure code [DWN5KY] Fan pump solenoid 1: Short circuit

Action code
Failure code
E02
DWN5KY
Failure
40-50

Detail of failure
Current flows constantly to fan pump EPC solenoid 1 (LPV90)circuit.
Stops output to fan pump control solenoid 1 (LPV90) circuit.
The output of fan pump (LPV90) is always at minimum speed.

Machine may be overheat.
Problem on
machine
Related information
q
q
q
Output condition to fan pump control solenoid 1 can be checked with monitoring function.
Cause
Defective fan pump control sole1 noid 1

Resistance
2 12 z
Resistance
Min. 1 Mz

Hot short circuit in wiring harness 2. Disconnect connector FA1 and connect T-adapter to female side.
2
Voltage
Max. 1 V
side of WECN3.
than (36)
is heard.)
2. Disconnect connectors WECN3, FA1 and PL3, and connect T-adapter to
female side and male side of PL3 separately in 2 times
(21)
is heard.)
(21)
is heard.)
4
ler
40-500
D375A-6R
(01)
D375A-6R
(01)
40-501
40-501
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection

Action code
Failure code
E01
DWNCKA
Failure
40-502
Fan pump solenoid 2: Disconnection

Detail of failure
When power is output to fan pump EPC solenoid 2 (LPV30) circuit, no current flows.
Stops output to fan pump EPC solenoid 2 circuit.
Problem on
machine
Fan pump solenoid 2 (LPV30) is always at maximum speed.
Output condition to fan pump EPC solenoid 2 can be checked with monitoring function.
(Code: 31634 Fan pump Solenoid 2 (F/B))
Related information
Cause
Defective fan pump EPC solenoid 1. Turn starting switch to OFF position.
1 2
Resistance 2 12 z
2
ness
Resistance
2 12 z
2. Disconnect connector WECN3 and FA2, and connect T-adapters to their
female sides.
Resistance Max. 1 z
(1)
Resistance Max. 1 z
(2)
4
ler
40-502
D375A-6R
(01)
D375A-6R
(01)
40-503
40-503
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit

Action code
Failure code
E01
DWNCKB
Failure
40-504

Detail of failure
When power is output to fan pump EPC solenoid 2 (LPV30) circuit, abnormal current flows.
Problem on
machine
Outputto fan pump solenoid 2 (LPV30) is kept at maximum.
Related information
Cause

Defective fan pump EPC solenoid 2. Disconnect connector FA2 and connect T-adapter to male side.
1 2
Resistance 2 12 z


Between WECN3 (female) (26) or FA2 (female) (1)
and ground
FA2 (female) (1) and (2)
ler
40-504
D375A-6R
(01)
D375A-6R
(01)
40-505
40-505
Failure code [DWNCKY] Fan pump solenoid 2: Short circuit

Action code
Failure code
E02
DWNCKY
Failure
40-506

Detail of 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.
Problem on
machine
Related information
q
q
q
Cause

Defective fan pump EPC solenoid 2. Disconnect connector FA2 and connect T-adapter to male side.
1 2
Resistance 2 12 z
2

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)
is heard.)
2. Disconnect connectors WECN3, PL3 and FA2, and connect T-adapter to
female side and male side of PL3 separately in 2 times.
(24)
is heard.)
(24)
is heard.)
4
ler
40-506
D375A-6R
(01)
D375A-6R
(01)
40-507
40-507
Failure code [DXH1KA] Lock-up ECMV: Disconnection

Action code
Failure code
E02
DXH1KA
Failure
40-508
Lock-up solenoid: Disconnection

Detail of failure
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.
Problem on
machine
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
Defective lockup clutch ECMV
1
solenoid (Internal disconnection)

wiring harness

2. Disconnect connector SLUC and connect T-adapter to male side.
Between SLUC (male) (1) and (2)
Resistance
3 13 z

Resistance
3 13 z
2. Disconnect connector PTCN3 and SLUC, and connect T-adapters to their
female sides.
Between PTCN3 (female) (16) and SLUC (female)
Resistance Max. 1 z
(1)
Between PTCN3 (female) (23) and SLUC (female)
Resistance Max. 1 z
(2)
If cause is not found by the above checks, power train controller may be defec4 Defective power train controller
tive. (Since failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to lockup solenoid
40-508
40-508
D375A-6R
(01)
Failure code [DXH1KB] Lock-up ECMV: Short circuit

Action code
Failure code
E02
Failure
DXH1KB
40-509
Lock-up solenoid: Short circuit

When power is output to torque converter lockup clutch ECMV solenoid circuit, abnormal current
flows.
Problem on
machine
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).
Detail of failure
Related information
q
Cause



Resistance
3 13 z
Between SLUC (female) (1) and ground
Resistance
Min. 1 Mz

2. Disconnect connector PTCN3 and SLUC, and connect T-adapter to female
Between PTCN3 (female) (16) or SLUC (female) (1)
and ground
Between PTCN3 (female) (16) and (23)or between
SLUC (female) (1) and (2)
Circuit diagram related to lock-up solenoid
D375A-6R
(01)
40-509
40-509
Failure code [DXH1KY] Lock-up ECMV: Short circuit

Action code
Failure code
E03
DXH1KY
Failure
40-510
Lock-up solenoid: Short circuit

Detail of failure
Current flows constantly to torque converter lockup clutch ECMV solenoid circuit.

q
q
Problem on
machine
q
q
q
q
Related information
Torque converter lockup function operates constantly.

Engine may stall during travel.
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).
Cause



Resistance
3 13 z
Resistance
Min. 1 Mz

2. Disconnect connector SLUC and connect T-adapter to female side.
40-510
Voltage
Max. 1 V

side of PTCN3.
than (16)
is heard)
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)
is heard)
PTCN2 (female)
is heard)
D375A-6R
(01)
Circuit diagram related to lock-up solenoid
D375A-6R
(01)
40-51
40-511
Failure code [DXH4KA] 1st clutch ECMV: Disconnection

Action code
Failure code
E03
DXH4KA
Failure
40-512
1st clutch ECMV: Disconnection

Detail of failure
When power is output to transmission 1st clutch ECMV solenoid circuit, no current flows.
Stops output to transmission 1st clutch ECMV solenoid circuit.

Problem on
machine
Related information
q
q
q
q
q
q

Output condition to 1st clutch ECMV solenoid can be checked with monitoring function.
(Code: 31612 1st ECMV output current (F/B))
Method of reproducing failure code:Start engine and travel at F1 or R1.
Cause
Defective 1st clutch ECMV sole1
noid (Internal disconnection)

2. Disconnect connector S1T and connect T-adapter to male side.
Between S1T (male) (1) and (2)
Resistance
3 - 13 z

Open or short circuit in wiring har- a If resistance is above 1 Mz, wiring harness has disconnection.If resistance
2
ness
Resistance
3 - 13 z
2. Disconnect connectors PTCN3 and S1T, and connect T-adapters to their
female sides.
Between PTCN3 (female) (37) and S1T
Resistance
Max. 1 z
(female) (1)
Resistance
Max. 1 z
(female) (2)
40-512
D375A-6R
(01)
D375A-6R
(01)
40-513
40-513
Failure code [DXH4KB] 1st clutch ECMV: Short circuit

Action code
Failure code
E03
DXH4KB
Failure
40-514
1st clutch ECMV: Short circuit

Detail of failure
When power was output to transmission 1st clutch ECMV solenoid circuit, abnormal current flowed.

Problem on
machine
Related information
q
q
q
q
q
q

Cause
Defective 1st clutch ECMV solenoid (Internal short circuit)


40-514
Resistance
3 13 z
Between S1T (female) (1) and ground
Resistance
Min. 1 Mz

2. Disconnect connectors PTCN3 and S1T and connect T-adapter to female
Between PTCN3 (female) (37) or S1T
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
between S1T (female) (1) and (2)
D375A-6R
(01)
D375A-6R
(01)
40-515
40-515
Failure code [DXH4KY] 1st clutch ECMV: Short circuit

Action code
Failure code
E03
DXH4KY
Failure
40-516
1st clutch ECMV: Short circuit

Detail of failure
Current flows constantly to transmission 1st clutch ECMV solenoid circuit.

Problem on
machine
Related information
q
q
q
q
q
q

Cause
Defective 1st clutch ECMV solenoid (Internal short circuit)

Resistance
3 - 13 z
Resistance
Min. 1 Mz

Hot short circuit in wiring harness 2. Disconnect connector S1T and connect T-adapter to female side.
2
Voltage
Max. 1 V
40-516

side of PTCN3.
Between PTCN3 (female) (37) and each pin No continuity (No sound is
other than (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 No continuity (No sound is
PTCN1 (female)
heard)
Between PTCN3 (female) (6) and each pin of No continuity (No sound is
PTCN2 (female)
heard)
D375A-6R
(01)
D375A-6R
(01)
40-517
40-517
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection

Action code
Failure code
E03
DXH5KA
Failure
40-518
2nd clutch ECMV: Disconnection

Detail of failure
When power is output to transmission 2nd clutch ECMV solenoid circuit, no current flows.
Stops output to transmission 2nd clutch ECMV solenoid circuit.

Problem on
machine
Related information
q
q
q
q
q
q

Output condition to 2nd clutch ECMV solenoid can be checked with monitoring function.
(Code: 31613 T/M Clutch 2nd ECMV (F/B))
Cause
1

Defective 2nd clutch ECMV sole- 2. Disconnect connector S2T and connect T-adapter to male side.
noid (Internal disconnection))
Resistance
3 - 13 z

wiring harness

Resistance
3 - 13 z
female sides.
Resistance
Max. 1 z
(female) (1)
Resistance
Max. 1 z
(female) (2)
40-518
D375A-6R
(01)
Circuit diagram related to 2nd clutch ECMV
D375A-6R
(01)
40-519
40-519
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit

Action code
Failure code
E03
Detail of failure
Problem on
machine
Related information
DXH5KB
q
q
q
q
q
q
q
q
Failure
40-520
2nd clutch ECMV: Short circuit

When power was output to transmission 2nd clutch ECMV solenoid circuit, abnormal current
flowed.
Cause

Defective 2nd clutch ECMV sole- 2. Disconnect connector S2T and connect T-adapter to male side.
1
noid (Internal short circuit)
Resistance
3 - 13 z
Resistance
Min. 1 Mz
2
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
40-520
D375A-6R
(01)
Circuit diagram related to 2nd clutch ECMV
D375A-6R
(01)
40-521
40-521
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit

Action code
Failure code
E03
DXH5KY
Failure
40-52
2nd clutch ECMV: Short circuit

Detail of failure
Current flows constantly to transmission 2nd clutch ECMV solenoid circuit.

Problem on
machine
Related information
q
q
q
q
q
q

Cause

Defective 2nd clutch ECMV soleBetween S2T (male) (1) and (2)
noid (Internal short circuit)

3 - 13 z
Resistance
Min. 1 Mz

2. Disconnect connector S2T and connect T-adapter to female side.
Resistance
Voltage
Max. 1 V

side of PTCN3.
other than (28)
heard)
to female side of PTCN1 to PTCN3.
of PTCN1 (female)
heard)
of PTCN2 (female)
heard)
40-522
D375A-6R
(01)
D375A-6R
(01)
40-523
40-523
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection

Action code
Failure code
E03
DXH6KA
Failure
40-524
3rd clutch ECMV: Disconnection

Detail of failure
When power is output to transmission 3rd clutch ECMV solenoid circuit, no current flows.
Stops output to transmission 3rd clutch ECMV solenoid circuit.

Problem on
machine
Related information
q
q
q

Output condition to 3rd clutch ECMV solenoid can be checked with monitoring function.
(Code: 31614 T/M Clutch 3rd ECMV (F/B))
Cause
1
Defective 3rd clutch ECMV solenoid (Internal disconnection)

wiring harness

Resistance
3 13 z

a If resistance is above1 Mz, wiring harness has disconnection. If resistance
is below1 z, wiring harness has short circuit.
Resistance
3 13 z
female sides.
Resistance
Max. 1 z
(female) (1)
Resistance
Max. 1 z
(female) (2)
40-524
D375A-6R
(01)
D375A-6R
(01)
40-525
40-525
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit

Action code
Failure code
E03
DXH6KB
Failure
40-526
3rd clutch ECMV: Short circuit

Detail of failure
When power was output to transmission 3rd clutch ECMV solenoid circuit, abnormal current flowed.

Problem on
machine
Related information
q
q
q

Cause
Defective 3rd clutch ECMV solenoid (Internal short circuit)


40-526
Resistance
3 13 z
Resistance
Min. 1 Mz

2. Disconnect connectors PTCN3 and S3T, and connect T-adapter to female
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
D375A-6R
(01)
D375A-6R
(01)
40-527
40-527
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit

Action code
Failure code
E03
DXH6KY
Failure
40-528
3rd clutch ECMV: Short circuit

Detail of failure
Current flows constantly to transmission 3rd clutch ECMV solenoid circuit.

Problem on
machine
Related information
q
q
q

Cause
Defective 3rd clutch ECMV solenoid (Internal short circuit)

Resistance
3 - 13 z

2
Resistance
Min. 1 Mz

2. Disconnect connector S3T and connect T-adapter to female side.
Voltage
Max. 1 V

side of PTCN3.
other than (38)
heard)
to female sides of PTCN1 to PTCN3.
of PTCN1 (female)
heard)
of PTCN2 (female)
heard)
40-528
D375A-6R
(01)
D375A-6R
(01)
40-529
40-529
Failure code [DXH7KA] R clutch ECMV: Disconnection

Action code
Failure code
E03
DXH7KA
Failure
40-530
Reverse clutch ECMV: Disconnection

Detail of failure
When power is output to transmission R clutch ECMV solenoid circuit, no current flows.
Stops output to transmission R clutch ECMV solenoid circuit.

Problem on
machine
Related information
q
q
q

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 travel at R (Reverse).
Cause
1

Defective R clutch ECMV solenoid 2. Disconnect connector SRT and connect T-adapter to male side.
Between SRT (male) (1) and (2)
Resistance
3 13 z

wiring harness

Resistance
3 13 z
2. Disconnect connectors PTCN3 and SRT, and connect T-adapters to their
female sides.
Between PTCN3 (female) (27) and SRT
Resistance
Max. 1 z
(female) (1)
Between PTCN3 (female) (3) and SRT
Resistance
Max. 1 z
(female) (2)
40-530
D375A-6R
(01)
Circuit diagram related to reverse clutch ECMV40-531
D375A-6R
(01)
40-531
Failure code [DXH7KB] R clutch ECMV: Short circuit

Action code
Failure code
E03
DXH7KB
Failure
40-532
Reverse clutch ECMV: Short circuit

Detail of failure
When power was output to transmission R clutch ECMV solenoid circuit, abnormal current flowed.

Problem on
machine
Related information
q
q
q

Once machine is stopped, travel is restricted to F1.
Cause

2. Disconnect connector SRT and connect T-adapter to male side.
Defective R clutch ECMV solenoid

Between SRT (female) (1) and ground

40-532
Resistance
3 13 z
Resistance
Min. 1 Mz

2. Disconnect connectors PTCN3 and SRT, and connect T-adapter to female
Between PTCN3 (female) (27) or SRT
Resistance
Min. 1 Mz
2. Disconnect connectors PTCN3 and SRT and connect T-adapter to female
Resistance
Min. 1 Mz
between SRT (female) (1) and (2)
D375A-6R
(01)
Circuit diagram related to reverse clutch ECMV40-53
D375A-6R
(01)
40-533
Failure code [DXH7KY] R clutch ECMV: Short circuit

Action code
Failure code
E04
DXH7KY
Failure
40-534
Reverse clutch ECMV: Short circuit

Detail of failure
Current flows constantly to transmission R clutch ECMV solenoid circuit.

Problem on
machine
Related information
q
q
q

Once machine stops, machine does not travel at all.
Cause

2. Disconnect connector SRT and connect T-adapter to male side.
Defective R clutch ECMV solenoid


2
3 13 z
Resistance
Min. 1 Mz

2. Disconnect connector SRT and connect T-adapter to female side.
Resistance
Voltage
Max. 1 V

2. Disconnect connectors PTCN3 and SRT and connect T-adapter to female
side of PTCN3.
other than (27)
heard)
2. Disconnect connectors PTCN1 to PTCN3 and SRT, and connect
T-adapters to female side of PTCN1 to PTCN3.
of PTCN1 (female)
heard)
of PTCN2 (female)
heard)
40-534
D375A-6R
(01)
D375A-6R
(01)
40-535
40-535
Failure code [DXH8KA] F clutch ECMV: Disconnection

Action code
Failure code
E03
DXH8KA
Failure
40-536
Forward clutch ECMV: Disconnection

Detail of failure
When power is output to transmission F clutch ECMV solenoid circuit, no current flows.
Stops output to transmission F clutch ECMV solenoid circuit.

Problem on
machine
Related information
q
q
q

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 travel at F (Forward).
Cause
1
Defective F clutch ECMV solenoid (Internal disconnection)

wiring harness

2. Disconnect connector SFT and connect T-adapter to male side.
Between SFT (male) (1) and (2)
Resistance
3 13 z

Resistance
3 13 z
2. Disconnect connectors PTCN3 and SFT, and connect T-adapters to their
female sides.
Between PTCN3 (female) (17) and SFT
Resistance
Max. 1 z
(female) (1)
Between PTCN3 (female) (13) and SFT
Resistance
Max. 1 z
(female) (2)
40-536
D375A-6R
(01)
Circuit diagram related to forward clutch ECMV40-537
D375A-6R
(01)
40-537
Failure code [DXH8KB] F clutch ECMV: Short circuit

Action code
Failure code
E03
DXH8KB
Failure
40-538
Forward clutch ECMV: Short circuit

Detail of failure
When power was output to transmission F clutch ECMV solenoid circuit, abnormal current flowed.

Problem on
machine
Related information
q
q
q

Once machine is stopped, travel is restricted to R1.
Cause
Defective F clutch ECMV solenoid (Internal short circuit)


40-538
Resistance
3 13 z
Between SFT (female) (1) and ground
Resistance
Min. 1 Mz

2. Disconnect connectors PTCN3 and SFT and connect T-adapter to female
Between PTCN3 (female) (17) or SFT
Resistance
Min. 1 Mz
2. Disconnect connectors PTCN3 and F SET and connect T-adapter to female
Resistance
Min. 1 Mz
between SFT (female) (1) and (2)
D375A-6R
(01)
D375A-6R
(01)
40-539
Failure code [DXH8KY] F clutch ECMV: Short circuit

Action code
Failure code
E04
DXH8KY
Failure
40-540
Forward clutch ECMV: Short circuit

Detail of failure
Current flows constantly to transmission F clutch ECMV solenoid circuit.

Problem on
machine
Related information
q
q
q

Once machine stops, machine does not travel at all.
Cause
Defective F clutch ECMV solenoid (Internal short circuit)

Resistance
3 13 z

Hot short in wiring harnesss
2
Resistance
Min. 1 Mz

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.
other than (17)
heard)
2. Disconnect connectors PTCN1 to PTCN3 and SFT, and connect
T-adapters to female sides of PTCN1 to PTCN3.
of PTCN1 (female)
heard)
of PTCN2 (female)
heard)
40-540
D375A-6R
(01)
D375A-6R
(01)
40-541
Failure code [DXH9KA] Right clutch ECMV: Disconnection

Action code
Failure code
E03
DXH9KA
Failure
40-542
Right steering clutch ECMV disconnection

Detail of failure
When power is output to right steering clutch ECMV solenoid circuit, current does not flow.
Stops outputting to right steering clutch ECMV solenoid circuit.

Problem on
machine
q
q
q
q
q
Related information
Machine cannot be steered to right.

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, release parking brake lever,
and operate PCCS lever (to steer right)
Cause

1 ECMV solenoid (Internal short cir- 2. Disconnect connector SRC and connect T-adapter to male side.
cuit)
Between SRC (male) (1) and (2)
Resistance
3 - 13 z
2
ness
Between SRC (female) (35) and (23)
Resistance
3 - 13 z
2. Disconnect connectors PTCN3 and SRC , and connect T-adapters to their
female sides.
Between PTCN3 (female) (35) and SRC (female)
Resistance Max. 1 z
(1)
Between PTCN3 (female) (23) and SRC (female)
Resistance Max. 1 z
(2)
40-542
D375A-6R
(01)
Circuit diagram related to right steering clutch ECMV
D375A-6R
(01)
40-543
40-543
Failure code [DXH9KB] Right clutch ECMV: Short circuit

Action code
Failure code
E03
DXH9KB
Failure
40-54
Right steering clutch ECMV short circuit

Detail of failure
When power was output to right steering clutch solenoid circuit, abnormal current flowed.
Stops output to right steering clutch solenoid circuit.

Problem on
machine
q
q
q
q
q
Related information
Machine cannot be steered to right.

and operate PCCS lever (to steer right)
Cause

2. Disconnect connector SRC and connect T-adapter to male side.
Defective rihht steering clutch
1 ECMV solenoid (Internal short cirBetween SRC (male) (1) and (2)
Resistance 3 13 z
cuit)
Between SRC (male) (1) and ground

40-544

2. Disconnect connectors PTCN3 and SRC and connect T-adapter to female
Between PTCN3 (female) (35) or SRC (female) (1)
and ground
2. Disconnect connectors PTCN3 and SRC and connect T-adapter to female
Between PTCN3 (female) (35) and (23), or between
SRC (female) (1) and (2)
D375A-6R
(01)
D375A-6R
(01)
40-545
40-545
Failure code [DXH9KY] Right clutch ECMV: Short circuit

Action code
Failure code
E04
DXH9KY
Failure
40-546
Right steering clutch ECMV short circuit

Detail of failure
Current flows constantly to right steering clutch ECMV solenoid circuit.
Stops outputting to right steering clutch solenoid circuit.

Problem on
machine
q
q
q
q
q
Related information
Right clutch cannot be engaged (machine cannot travel straight).

Once machine is stopped, engine speed is restricted to medium (half).
Method of reproducing failure code: Turn starting switch to ON position and release parking brake
lever.
Cause

1 ECMV solenoid (Internal short cirBetween SRC (male) (1) and (2)
Resistance
313 z
cuit)
Between SRC (male) (1) and ground
Hot short circuit in wiring harness 2. Disconnect connector SRC and connect T-adapter to female side.
2
Between SRC (female) (1) and ground
Voltage
Max. 1V
40-546

2. Disconnect connectors PTCN3 and SRC, and connect T-adapter to female
side of PTCN3.
Between PTCN3 (female) (35) and each pin other No continuity (No sound
than (35)
is heard.)
2. Disconnect connectors PTCN1 to 3 and SRC, and connect T-adapter to
female sides of PTCN1 to 3.
PTCN1 (female)
is heard.)
PTCN2 (female)
is heard.)
D375A-6R
(01)
D375A-6R
(01)
40-547
40-547
Failure code [DXHAKA] Left clutch ECMV: Disconnection

Action code
Failure code
E03
DXHAKA
Failure
40-548
Left steering clutch ECMV disconnection

Detail of failure
When power is output to left steering clutch solenoid circuit, current does not flow.
Stops output to left steering clutch solenoid circuit.

Problem on
machine
q
q
q
q
q
Related information
Machine cannot be steered to left.

Output condition (current) to left steering clutch ECMV solenoid can be checked with monitoring
function. (Code: 90600 Left 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 left)
Cause
Defective left steering clutch

1 ECMV solenoid (Internal disconnection)

2. Disconnect connector SLC and connect T-adapter to male side.
Between SLC (male) (1) and (2)
Resistance 3 13 z
ness
Resistance 3 13 z
2. Disconnect connectors PTCN3 and SLC, and connect T-adapters to their
female sides.
Between PTCN3 (female) (25) and SLC (female)
Resistance Max. 1 z
(1)
Between PTCN3 (female) (23) and SLC (female)
Resistance Max. 1 z
(2)
40-548
D375A-6R
(01)
Circuit diagram related to left steering clutch ECMV
D375A-6R
(01)
40-549
40-549
Failure code [DXHAKB] Left clutch ECMV: Short circuit

Action code
Failure code
E03
DXHAKB
Failure
40-5 0
Left steering clutch ECMV short circuit

Detail of failure
When signal was output to left steering clutch ECMV solenoid circuit, abnormal current flowed.
Stops outputting to left steering clutch ECMV solenoid circuit.

Problem on
machine
q
q
q
q
q
Related information
Machine cannot be steered to left.

and operate PCCS lever (to steer left)
Cause

2. Disconnect connector SLC and connect T-adapter to male side.
1 ECMV solenoid (Internal short cirBetween SLC (male) (1) and (2)
Resistance 3 13 z
cuit)
Between SLC (male) (1) and ground

40-550

2. Disconnect connectors PTCN3 and SLC, and connect T-adapter to female
Between PTCN3 (female) (25) or SLC (female) (1)
and ground
2. Disconnect connectors PTCN3 and SLC and connect T-adapter to female
SLC (female) (1) and (2)
D375A-6R
(01)
D375A-6R
(01)
40-5 1
40-551
Failure code [DXHAKY] Left clutch ECMV: Short circuit

Action code
Failure code
E04
DXHAKY
Failure
40-5 2
Hot short circuit in left steering clutch ECMV

Detail of failure
Current flows constantly to left steering clutch ECMV solenoid circuit.
Stops outputting to left steering clutch ECMV solenoid circuit.

Problem on
machine
q
q
q
q
q
Related information
Left clutch cannot be engaged (machine cannot travel straight).

Method of reproducing failure code:Turn starting switch to ON position and release parking brake
lever.
Cause

1 ECMV solenoid (Internal short cirBetween SLC (male) (1) and (2)
Resistance 3 13 z
cuit)
Between SLC (female) (1) and ground
Hot short circuit in wiring harness 2. Disconnect connector SRC and connect T-adapter to female side.
2
Between SLC (female) (1) and ground
Voltage
Max. 1V
40-552

2. Disconnect connectors PTCN3 and SLC and connect T-adapter to female
side of PTCN3.
than (25)
is heard.)
2. Disconnect connectors PTCN1 to PTCN3 and SLC, and connect
T-adapters to female side of PTCN1 to PTCN3.
PTCN1 (female)
is heard.)
PTCN2 (female)
is heard.)
D375A-6R
(01)
D375A-6R
(01)
40-5 3
40-553
Failure code [DXHBKA] Right brake ECMV: Disconnection

Action code
Failure code
E04
DXHBKA
Detail of failure
Problem on
machine
Right brake ECMV disconnection

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.
q
q
q
q
q
q
Related information
Failure
40-5 4
Right brake keeps applied.

Output condition (current) to right steering brake ECMV solenoid can be checked with monitoring
function. (Code: 31618 Right steering brake ECMV output current (F/B))
lever.
Cause

2. Disconnect connector SRB and connect T-adapter to male side.
Between SRB (male) (1) and (2)
Resistance
3 13 z

2
ness
Resistance
3 13 z
2. Disconnect connectors PTCN3 and SRB, and connect T-adapters to their
female sides.
Between PTCN3 (female) (15) and SRB (female)
Resistance Max. 1 z
(1)
Between PTCN3 (female) (13) and SRB (female)
Resistance Max. 1 z
(2)
40-554
D375A-6R
(01)
D375A-6R
(01)
40-5 5
40-555
Failure code [DXHBKB] Right brake ECMV: Short circuit

Action code
Failure code
E04
DXHBKB
Detail of failure
Problem on
machine
Right brake ECMV short circuit

When power was output to right steering brake ECMV solenoid circuit, abnormal current flowed.

q
q
q
q
q
q
Related information
Failure
40-5 6
Right brake keeps applied.

Output condition (current) to right steering brake ECMV solenoid can be checked with monitoring
function. (Code: 31618 Right steering brake ECMV output current (F/B))
lever.
Cause

1 ECMV solenoid (Internal short cirBetween SRB (male) (1) and (2)
Resistance 3 13 z
cuit)
Between SRB (male) (1) and ground

40-556

2. Disconnect connectors PTCN3 and SRB, and connect T-adapter to female
Between PTCN3 (female) (15) or SRB (female) (1)
and ground
2. Disconnect connectors PTCN3 and SRB, and connect T-adapter to female
SRB (female) (1) and (2)
D375A-6R
(01)
D375A-6R
(01)
40-5 7
40-557
Failure code [DXHBKY] Right brake ECMV: Short circuit

Action code
Failure code
E04
DXHBKY
Detail of failure
Problem on
machine
Right brake ECMV hot short circuit

When power is output to right steering brake ECMV solenoid circuit, no current flows.

q
q
q
q
q
q
Related information
Failure
40-5 8
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 clutch ECMV solenoid (Internal
short circuit)

Between SRB (male) (1) and (2)
Resistance
3 13 z
Between SRB (male) (1) and ground
Resistance
Min. 1 Mz

Hot short circuit 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
40-558

2. Disconnect connectors PTCN3 and SRB and connect T-adapter to female
side of PTCN3.
a Use continuity check mode of the tester.
than (15)
is heard)
2. Disconnect connectors PTCN1 to PTCN3 and SRB, and connect
a Use continuity check mode of the tester.
PTCN1 (female)
is heard)
PTCN2 (female)
is heard)
If cause is not found by the above checks, power train controller may be defective. (Since falure is in it, troubleshooting cannot be performed.)
D375A-6R
(01)
D375A-6R
(01)
40-5 9
40-559
Failure code [DXHCKA] Left brake ECMV: Disconnection

Action code
Failure code
E04
DXHCKA
Detail of failure
Problem on
machine
Left brake ECMV:Disconnection

When power was output to left steering brake ECMV solenoid circuit, abnormal current flowed.
Stops output to left steering brake ECMV solenoid circuit.

q
q
q
q
q
q
Related information
Failure
40-560
Left brake keeps applied.

Output (current) to left steering brake ECMV solenoid can be checked by using monitoring function.
(Code: 31619 Left brake ECMV output current (F/B))
Method of reproducing failure code:Turn starting switch to ON position and set parking brake lever
to FREE position.
Cause
Defective left steering brake

2. Disconnect connector SLB and connect T-adapter to male side.
Between SLB (male) (1) and (2)
Resistance
3 13 z

2
ness
Resistance
3 13 z
2. Disconnect connectors PTCN3 and SLB, and connect T-adapters to their
female sides.
3 (Open circuit: Defective contact of
connectors)
Between PTCN3 (female) (5) and SLB (female) (1) Resistance Max. 1 z
Between PTCN3 (female) (13) and SLB (female) (2) Resistance
40-560
Max. 1 z
D375A-6R
(01)
D375A-6R
(01)
40-561
40-561
Failure code [DXHCKB] Left brake ECMV: Short circuit

Action code
Failure code
E04
DXHCKB
Detail of failure
Problem on
machine
Left brake ECMV short circuit

When power was output to left steering brake ECMV solenoid circuit, abnormal current flowed.

q
q
q
q
q
q
Related information
Failure
40-562
Left brake keeps applied.

Output (current) to left steering brake ECMV solenoid can be checked by using monitoring function.
(Code: 31619 Left brake ECMV output current (F/B))
Method of reproducing failure code:Turn starting switch to ON position and set parking brake lever
to FREE position.
Cause


40-562
Resistance
3 13 z
Between SLB (male) (1) and ground
Resistance
Min. 1 Mz

2. Disconnect connectors PTCN3 and SLB and connect T-adapter to female
Between PTCN3 (female) (5) or SLB (female) (1)
and ground
2. Disconnect connectors PTCN3 and SLB and connect T-adapter to female
SLB (female) (1) and (2)
D375A-6R
(01)
D375A-6R
(01)
40-563
40-563
Failure code [DXHCKY] Left brake ECMV: Short circuit

Action code
Failure code
E04
DXHCKY
Detail of failure
Problem on
machine
Hot short circuit in left brake ECMV

When power is output left steering brake solenoid circuit,current flows.

q
q
q
q
q
q
Related information
Failure
40-564
Left brake does not operate.

Output condition (current) to left steering brake ECMV solenoid can be checked with monitoring
function. (Code: 31619 Left brake ECMV output current(F/B))
lever (LOCK).
Cause

Resistance
3 13 z
Between SLB (male) (1) and ground
Resistance
Min. 1 Mz

Hot short circuit in wiring harness 2. Disconnect connector SLB and connect T-adapter to female side.
2
Between SLB (female) (1) and ground
Voltage
Max. 1 V
40-564

2. Disconnect connectors PTCN3 and SLB, and connect T-adapter to female
side of PTCN3.
than (5)
is heard)
2. Disconnect connectors PTCN1 to PTCN3 and SLB, and connect
PTCN1 (female)
is heard)
PTCN2 (female)
is heard)
D375A-6R
(01)
D375A-6R
(01)
40-565
40-565
Failure code [DXJBKA] S/C ECMV: Disconnection

Action code
Failure code
E02
DXJBKA
Failure
40-56
Open circuit in stator clutch ECMV

Detail of failure
Although the current is output to stator clutch ECMV solenoid circuit, no current flows.
q
q
Stops output to 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: Engine started + Travel
Problem on
machine
Related information
Cause
1
Defective stator clutch ECMV

solenoid (internal short circuit)

2. Disconnect connector SSTC and connect T-adapter to male side.
Between SSTC (male) (1) and (2)
Resistance
3 - 13 z

2
ness
Resistance
3 - 13 z
2. Disconnect connectors PTCN3 and SSTC, and connect T-adapters to their
female sides.
Between PTCN3 (female) (6) and SSTC
Resistance
Max. 1 z
(female) (1)
Between PTCN3 (female) (3) and SSTC
Resistance
Max. 1 z
(female) (2)
4 Defective transmission controller
(Since fialure is in it, troubleshooting cannot be performed.)
Circuit diagram related to stator clutch ECMV 40-56
40-566
D375A-6R
(01)
Failure code [DXJBKB] S/C ECMV: Short circuit
Failure code [DXJBKB] S/C ECMV: Short circuit

Action code
Failure code
E02
DXJBKB
Failure
40-567
Stator clutch ECMV: Short circuit

Detail of failure
When power is output to stator clutch ECMV solenoid circuit, abnormal current flow.
q
q
Stops output to transmission stator clutch ECMV solenoid circuit.

Output condition to stator clutch ECMV solenoid can be checked with monitoring function.
Method of reproducing failure code: Engine started + Travel
Problem on
machine
Related information
Cause

solenoid (Internal short circuit)


Resistance
3 13 z
Between SSTC (female) (1) and ground
Resistance
Min. 1 Mz

2. Disconnect connector PTCN3 and SSTC , and connect T-adapter to female
Between PTCN3 (female) (6) or SSTC
Resistance
Min. 1 Mz
Between PTCN 3(female) (6) and (3) or
Resistance
Min. 1 Mz
between SSTC (female) (1) and (2)
Circuit diagram related to stator clutch ECMV 40-567
D375A-6R
(01)
40-567
Failure code [DXJBKY] S/C ECMV: Short circuit

Action code
Failure code
E02
DXJBKY
Failure
40-568
Short circuit in stator clutch ECMV

Detail of failure
Electric current is always flowing to stator clutch ECMV solenoid circuit.
q
q
Stops output to stator clutch ECMV solenoid circuit.

Output to stator clutch ECMV solenoid can be checked by using the monitoring function.
Problem on
machine
Related information
Cause

solenoid (internal short circuit)

Resistance
3 13 z
Resistance
Min. 1 Mz

Hot short circuit in wiring harness 2. Disconnect connector SSTC and connect T-adapter to female side.
2
Voltage
Max. 1 V
40-568

side of PTCN3.
other than (6)
heard)
2. Disconnect connector PTCN1 to 3 and SSTC , and connect T-adapters to
female sides of PTCN1 to 3.
PTCN1 (female)
heard)
PTCN2 (female)
heard)
D375A-6R
(01)
Circuit diagram related to stator clutch ECMV
D375A-6R
(01)
40-569
40-569
Failure code [DY2HKA] Pre lub. motor: Disconnection

Action code
Failure code
E02
DY2HKA
Failure
40-570
Pre-lubricating motor open circuit

Detail of failure
After power train controller starts pre-lubrication, power is not supplied to pre-lubricating motor.
None in particular
Problem on
machine
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].
Related information
Cause
1 Defective circuit breaker (CBH1)
If circuit breaker is operating, the circuit probably has ground fault. In this case,

Loose terminal or disconnection at
Check the terminals of battery relay, preheater relay, pre-lubricating relay,
terminal
pre-lubricating motor, etc.
3 Defective relay (PLUB)

2. Replace relay (PLUB) with another relay (e.g. backup alarm relay: BKA).
If pre-lubrication is completed, original relay (PLUB) is defective.
4 Defective diode (PLS)

2. Disconnect connector PLS.
If the pre-lubrication is completed, diode (PLS) is defective.
5 Defective pre-lubricating motor

2. Disconnect terminal PM1.
Between terminal PM1 (on pre-lubricating motor
Continuity
side) and ground
2. Insert T-adapter into connector PLUB.
a If voltage is 0 V, wiring harness has disconnection or ground fault (If voltage
is abnormal and check result of cause 8 is normal, wiring harness has disconnection).
Open circuit or ground fault in wir- Between PLUB (3) and ground
ing harness
Between PLUB (5) and ground
Voltage
20 30 V
Voltage
20 30 V
Voltage
20 30 V
Between PR3 and ground
Voltage
20 30 V
Between PM1 and ground
40-570
20 30 V
7 Defective pre-lubrication relay
Voltage
Voltage
20 30 V
If voltages at terminals PR1 and PR3 are normal and voltage at terminal PR2
is abnormal as check result of cause 6, pre-lubricating relay is defective.
D375A-6R
(01)
Cause


a
1.
2.
3.
4.
Disconnect terminal PR3.
Resistance
Min. 1 Mz
Between terminal PR1 and ground
Resistance
Min. 1 Mz
Between terminal PR3 (on wiring harness side) and

ground
Circuit diagram related to pre-lubricating motor
D375A-6R
(01)
Voltage
20 30 V
40-571
40-571
Failure code [F@BBZL] ENG blow-by pressure high level

Action code
Failure code
40-572
F@BBZL
Failure
Engine blow-by pressure abnormally high level
Detail of failure
Engine blowby pressure is higher than threshold value of 900 mmH2O{8.83 kPa}.
None in particular
Problem on
machine
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.
Related information
Cause
Abnormal increase of engine
blow-by pressure
Defective engine blow-by pres2
sure sensor
1

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].
40-572
D375A-6R
(01)
Failure code [F@BYNR] F exhaust temp high level (2)

Action code
Failure code
F@BYNR
Failure
40-573
Front exhaust temperature abnormal increase (2)

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.
(Exhaust gas temperature limit line 2: Straight line between 750 C at rated output speed at
minimum and 800 C at max. torque speed at maximum)
None in particular
Problem on
machine
Front exhaust temperature can be checked with monitoring code: 42610 ( C).
Detail of failure
Related information
Cause
Abnormal increase of front

1 exhaust temperature (When sys- Check the engine for abnormality. Correct, if any.
tem is normal)
Front exhaust temperature sensor
2
system defective
Troubleshooting for failure codes [DGT5KA] and [DGT5KB].
D375A-6R
(01)
40-573
Failure code [F@BYNS] F exhaust temp high level (1)

Action code
Failure code
F@BYNS
Failure
40-574
Front exhaust temperature abnormal increase (1)

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 1 for more
than 20 seconds.
None in particular.
Problem on
machine
Front exhaust temperature can be checked with monitoring code: 42610 ( C).
VHMS controller LED indicates "n3" and "61" alternately and repeatedly.
Detail of failure
Related information
Cause
Abnormal increase of front

1 exhaust temperature (When sys- Check the engine for abnormality, Correct, if any.
tem is normal)
Front exhaust temperature sensor
2
system defective
Troubleshooting for failure codes [DGT5KA]and [DGT5KB].
40-574
D375A-6R
(01)
Failure code [F@BZNR] R exhaust temp high level (2)

Action code
Failure code
F@BZNR
Failure
40-575
Rear exhaust temperature abnormal increase (2)

Signal voltage from exhaust temperature sensor for No. 4, 5 and 6 cylinders (rear side) increases
and VHMS controller detects unusual high temperatures above exhaust temperature limit line 2 for
more than 10 seconds.
(Exhaust gas temperature limit line 2: Straight line connecting point of 750 C at rated output speed
and point of 800 C at max. torque speed)
Flashes warning lamp and turns on caution buzzer. (Function of monitor panel)
Problem on
machine
Exhaust temperature of rear cylinders can be checked by using monitoring function. (Code: 42611
( C)
Detail of failure
Related information
Cause
Abnormal increase of rear exhaust

1 temperature (When system is nor- Check the engine for abnormality, Correct, if any.
mal)
Rear exhaust temperature sensor
2
system defective
Troubleshooting for failure codes[DGT6KA] and [DGT6KB]
D375A-6R
(01)
40-575
Failure code [F@BZNS] R exhaust temp high level (1)

Action code
Failure code
F@BZNS
Failure
40-576
Rear exhaust temperature abnormal increase (1)

Signal voltage from exhaust temperature sensor for No. 4, 5 and 6 cylinders (rear side) increases
and VHMS controller detects unusual high temperatures above exhaust temperature limit line 1 for
more than 20 seconds.
Flashes warning lamp and turns on caution buzzer. (Function of monitor panel)
Problem on
machine
Exhaust temperature of rear cylinders can be checked by using monitoring function. (Code: 42611
( C)
Detail of failure
Related information
Cause
Abnormal increase of rear exhaust

1 temperature (When system is nor- Check the engine for abnormality, Correct, if any.
mal)
Rear exhaust temperature sensor
2
system defective
Troubleshooting for failure codes [DGT6KA] and [DGT6KB].
40-576
D375A-6R
(01)
D375A-6R
(01)
40-577
Troubleshooting of electrical system (E-mode)

Information contained in troubleshooting table

40-578
40-578
a Troubleshooting Table and Circuit Diagram Related collectively include the following information. Perform
troubleshooting work after fully grasping their contents.
Failure
Problem on machine
Related inforInformation related to detected failure 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 Criteria 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).
Open circuit in wiring harq After correction of a single failure, check to see that this problem has been solved.
ness
Then, start the next troubleshooting.
(Open circuit in wiring or
<Troubles in wiring harness>
defective contact in connec- q Disconnection
tor)
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 in wiring harq Hot short circuit
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 circuit
<Precautions for troubleshooting>
(Short circuit with 24 V cir(1) Method of indicating connector No. and handling of T-adapter
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 and
Short circuit in wiring harconnect 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.
q Connect positive (+) lead to pin No. or wiring harness entered on front side.
q Connect negative (-) lead to pin No. or harness entered on rear side.
Defective controller
40-578
D375A-6R
(01)

40-579
This is the excerpted circuit diagram related to troubleshooting
q Connector No.: Indicates (Type-number of pin) (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
D375A-6R
(01)
40-579

E-1 Engine does not start (starting motor does not turn)
Failure
40-580
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.
Related information
q
q
Cause
1
Defective circuit breaker CB30 or

CB6

If CB30 or CB6 circuit breaker is turned ON, circuit probably has ground fault.
In this case, perform troubleshooting for cause 16 first.
If fuse FS31-5 is blown, the circuit probably has ground fault. Troubleshoot for
cause 16 first.

Loose terminal or disconnection at
3
Check the terminals of battery relay, alternator, starting motor, ground, ground
terminal
01, ground 11 etc.
4 Insufficient battery capacity
Battery voltage
Min. 24 V
Electrolyte specific gravity
Min. 1.26

Defective parking lever switch
5 (internal defect or defective adjustFree position
Display of "P" on monitor
ment)
panel
Lock position
Other than "P"

"P" is displayed.

lever switch
6
Free position
Symbol OFF
(internal defect or defective adjust- Display of "Lock work
equipment" symbol on
ment)
Lock position
Symbol ON
monitor panel
3. Disconnect connector KEY.
4. Turn starting switch to ON, OFF and START positions and troubleshoot.
Defective starting switch

Between terminals 250 and 260
8 Defective neutral safety relay
OFF
Resistance
Min. 1 Mz
ON
Resistance
Max. 1 z
OFF
Resistance
Min. 1 Mz
ON
Resistance
Max. 1 z
OFF
Resistance
Min. 1 Mz
START
Resistance
Max. 1 z

2. Replace neutral safety relay (NSF) with another relay (such as BKA).
3. Start engine.
If engine starts, original neutral safety relay (NSF) is defective.
40-580
D375A-6R
(01)

Cause

2. Replace engine ACC cutout relay (ACT) with another relay (such as BKA).
9 Defective engine ACC cutout relay 3. Start engine.
If engine starts, original engine ACC cutout relay (ACT) is defective.
10 Defective engine holding relay
a
1.
2.
3.
4.
If the engine does not stop

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.
a Measure in diode range of tester.
13
Defective alternator
Detective starting motor (internal

defect)
D375A-6R
(01)
No continuity
Between RSD (male) (2) (+) and (1) (-)

12
Continuity

Between terminal AL/R and ground
Voltage
Max. 12 V

2. Start the engine for troubleshooting.
Power supply: Between terminal B
Voltage
20 30 V
and chassis ground
Between charge terminal R and
Voltage
Max. 12 V
ground
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.
40-581

Cause

q Battery relay
Between terminal BRE and ground
Resistance
Max. 1 z
q Battery relay
2. Turn starting switch to START position.
a Check to where 24 V is supplied to identify disconnected place.
Between terminal 260 and ground
Voltage
20 30 V
Between terminal SW and ground
Voltage
20 30 V
Between terminal BRB and ground
Voltage
20 30 V
Voltage
20 30 V
1.
2.
3.
4.
5.
a
Alternator and starting motor

Insert T-adapters into connectors NSF, ST1 and ST2.
Turn starting switch to START position and troubleshoot.
Check to where 24 V is supplied to identify disconnected place.
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

20 30 V
Between NSF (5) and ground
16
Voltage

(Does not turn ON)
20 30 V
15
Voltage
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.
40-582
Min. 1 Mz
Resistance
Min. 1 Mz
Between NSF (5), ST2 (1) or ST1 (1) and ground

Resistance
Between terminal 280 or NSF (3) and ground
17
Resistance
Min. 1 Mz
Voltage
Max. 1 V

2. Disconnect terminal AL/R.
Between terminal AL/R (Wiring harness side) and
ground
D375A-6R
(01)

Circuit diagram related to engine start circuit
D375A-6R
(01)
40-583
40-583

E-2 Preheater does not operate

Failure
40-584
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 lamp does not light up, perform troubleshooting "3) While the preheater
Related informais operating, the preheating monitor does not light up")
tion
q If "the machine monitor does not light up" or "the battery relay does not make operating sound"
when turning the starting switch ON, the main electric power supply system is supposed to be 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
1
Defective circuit breaker

CBH1
If CBH1 circuit breaker is turned ON, circuit probably has ground fault. In this case,
Loose terminal or disconnec- 1. Turn starting switch to OFF position.

tion at terminal
Check terminals of heater relay, battery relay, etc.
2. Remove connector HTD and connect T-adapter to diode.
Defective diode HTD
3 (internal open circuit or short
Between HTD (male) (1) (+) and (2) (-)
circuit)
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.
4
(Internal open circuit in wirBetween terminal HT/B and ground
There is continuity
ing)
3. Disconnect connector KEY and connect T-adapter to male side.
5 Defective starting switch
4. Turn starting switch to OFF/HEAT position and troubleshoot.
OFF
HEAT
Resistance
Max. 1 z
2. Disconnect connector CM01.
There is continuity
Voltage
20 30 V
Open circuit or ground fault in Between terminal HT/A and ground
6
wiring harness
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 in wiring har2. Disconnect connectors KEY and CM01 and terminals HT and BRC.
7 ness
Between terminal HT/A and ground
Between terminal HT (on wiring harness side) and
ground
Defective preheater relay
If cause 6 is not the cause for the trouble and preheater relay operation sound is not
8 (Does not turn ON) (Terminal
heard, preheater relay is defective.
HT/B)
40-584
D375A-6R
(01)

Circuit diagram related to preheating of engine 40-585
D375A-6R
(01)
40-585

Failure
2) Automatic preheater does not operate.

q
Related information
q
q
Automatic preheater operates when intake air (boost) temperature is below -5 C.

(Monitoring code: Engine coolant temperature 04107)
If automatic preheater does not operate, check if manual preheater operates.
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 troubleshooting for cause 5 first.
2. Replace the preheater relay (connector: PHR) with the backup alarm relay
Defective preheater relay
(connector: BKA).
(internal open circuit or short
circuit)
If automatic preheater operates when intake air (boost) temperature is below -5 C,
original preheater relay is defective.
Open circuit or ground fault a If resistance is above 1 Mz, wiring harness has disconnection. If resistance is beof wiring harness
low 1 z, wiring harness has short circuit.
a Preheater relay coil resistance
Open circuit in wiring har2. Disconnect connectors PHR and CM01, and connect T-adapter to female side of
ness
PHR.
(open circuit 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 z
If the fuse is not blown, this check is not required.
Ground fault in wiring har2. Disconnect connectors PHR, FSB and ASUS, and connect T-adapter to female
ness
side of PHR.
Between PHR (female) (5) and ground
Failure
3) While preheater is operating, the preheating monitor does not light up.
Related information
Cause
There are "Automatic preheater" and "Manual preheater" installed. When either function is operated, the preheating lamp lights up.

Open circuit in wiring har2. Disconnect connectors PHR and CM01, and connect T-adapters to female side
ness
1
of them.
(open circuit or defective
Between PHR (female) (3) and CM01 (female) (16)
Resistance
Max. 1 z
contact)
Between terminal 255 and CM01 (female) (16)
Resistance
Max. 1 z
Ground fault in wiring har2. Disconnect connectors PHR, CM01 and terminal HT, and connect T-adapter to
2 ness
female side of CM01.
q Reference (the followings are standard values in normal condition)
3 Defective machine monitor 3. Disconnect terminal HT.
a Disconnect so that current will not flow in heater when starting switch is turned to
HEAT position.
4. Turn the starting switch to the HEAT position.
Resistance
20 30 V
40-586
D375A-6R
(01)

Circuit diagram related to preheating of engine
D375A-6R
(01)
40-587
40-587

E-3 When starting switch is turned ON, machine monitor displays nothing
E-3 When starting switch is turned ON, machine monitor displays

nothing
Failure
40-58
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.
Related information
Cause
Standard value in normal condition/Remarks on troubleshooting
Defective circuit breaker CB30 or If CB30 or CB6 circuit breaker is turned ON, circuit probably has ground fault.
CB6
In this case, perform troubleshooting for cause 8 first.
Loose terminal or disconnection at 1. Turn starting switch to OFF position.

terminal
Check terminals of battery, battery relay, etc.
3 Insufficient battery capacity
Min. 24 V
Electrolyte specific gravity

Misalignment of wiring harness
4 (Numbers of pins of CM01 and
CM03 are same)
Battery voltage (two pieces)
Min. 1.26
a If machine monitor has not been replaced, this check is not required.
2. Remove machine monitor.
Check that connectors CM01 (white) and CM03 (green) are matched to connector colors of machine monitor unit.
a If voltage is 0 V, wiring harness has disconnection or ground fault.
Open circuit or ground fault in wir5 ing harness or defective starting Between CM01 (female) (1) and (3)
switch
Voltage
20 30 V
Voltage
20 30 V
1 - 4 are same as above.

5. Turn starting switch to ON position (Connect ACC).
6 Defective starting switch
1.
2.
3.
4.
40-588
Voltage
20 30 V

Disconnect connector KEY.
Turn starting switch to ON/OFF position and troubleshoot.
OFF
Resistance
Min. 1 Mz
ON
Resistance
Max. 1 z
D375A-6R
(01)

Cause


3. If circuit breaker is turned ON, reset it.
Between CM01 (female) (3), (4) and ground
Resistance
Max. 1 z
Between CM01 (female) (1), (2) and battery (+)
Resistance
Max. 1 z
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 (+)

a
1.
2.
3.
4.
a
D375A-6R
(01)
Max. 1 z
If circuit breaker is turned ON, reset it.
Check that condition is normal when starting switch is turned to ON position
(Connect ACC with ground strap disconnected).

Resistance
Resistance
Min. 1 Mz
40-589

Circuit diagram related to machine monitor
40-590
40-590
D375A-6R
(01)

D375A-6R
(01)
40-591

E-4 When starting switch is turned ON (before starting engine), basic

check item lights up
40-592
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.
Failure
Cause
Defective engine oil pressure

1 caution lamp circuit
(Engine controller circuit)
Perform troubleshooting for failure codes [CA135], [CA141].
If cause 1 is not detected, machine monitor may be defective.

2) When starting switch is turned to ON position (with engine stopped), engine oil level monitor
lights up.
Failure
Related information
Engine oil level monitor (oil level switch) is optional.
Cause
Defective engine oil level switch

1 system (machine monitor sysPerform troubleshooting for failure code [B@BAZK].
tem)
Failure
3) Radiator coolant level monitor lights.
Related information
Cause
1
Radiator coolant level decrease The coolant level monitor may be insufficient. Check coolant level and add cool(When system is normal)
ant if necessary.
Defective coolant level sensor

(Internal defect)

3 (open circuit or defective contact)

2. Disconnect connector WLD and connect T-adapter to male side.
Between FULL and LOW Resistance
Max. 1 z
Between WLD (male) (1)
Value when coolant level
and (2)
is low
a Add coolant.
Between CM02(female)(3)and WLD(female)(1)
Resistance
Max. 1 z

Reference; the followings are standard values in normal condition.
q
Between CM02 (female)

(3) and ground
40-592
Between FULL and LOW
Voltage
Max. 1 V
Value when coolant level

is low
Voltage
Min. 7 V
D375A-6R
(01)

Circuit diagram related to radiator coolant level
D375A-6R
(01)
40-593
40-593

E-5 Precaution item lights up while engine is running

Failure
40-594
q
q
Related information
Precaution item lights up while engine is running.

Check item is only charge level monitor.
State of generation signal of alternator can be checked with monitoring function.
(Code: 04300 Charge voltage)
Cause
1
Loose terminal or disconnection 1. Turn starting switch to OFF position.

at terminal
Check terminals of alternator etc.
Defective alternator
(insufficient power generation)

2. Start engine and troubleshoot while running engine at medium speed or
higher.
Between terminal AL/R and ground
Voltage
20 30 V

2. Remove connector RSD and connect T-adapter to diode.
Defective diode RSD

3 (internal open circuit or short cirBetween RSD (male) (1) (+) and (2) (-)
cuit)
No continuity
Continuity

3. Disconnect connectors CM01 and RSD, and connect T-adapter to female side
of CM01.
4 (Open circuit in wiring or defec4. Disconnect terminal AL/R.
tive contact in connector)
Between CM01 (female) (11) and AL/R
Resistance
Max. 1 z
Between alternator terminal E and ground

Resistance
Max. 1 z

3. Disconnect connectors CM01, RSD, PTCN1, WECN1, ST1 and ST2, and
connect T-adapter to female side of CM01.
4. Disconnect terminal AL/R.
Resistance
Min. 1 Mz

6 Defective machine monitor panel 3. Insert T-adapter into connector CM01.
5. Start engine and troubleshoot while running engine at medium speed or
higher.
40-594
Voltage
20 30 V
D375A-6R
(01)

Electrical diagram related to charging cricuit
D375A-6R
(01)
40-595
40-595

E-6 Emergency stop item lights up while engine is running

Failure
40-596
1)Engine coolant temperature monitor lights up.

q
Related information
Signal voltage of engine coolant temperature sensor is input to engine controller and then the
data is transmitted to machine monitor through CAN communication system.
Engine coolant temperature can be checked with monitoring function
Cause
Overheating of engine coolant

(when system is normal)
Engine coolant may be overheated. If it is overheated, remove cause.

sensor system
If cause 1 is not detected, engine coolant temperature sensor system may be

defective. Perform troubleshooting for failure codes [CA144] and [CA145].

Failure
If causes 1 2 are not detected, machine monitor may be defective

(Since trouble is in system, troubleshooting cannot be carried out.)
2) Engine oil pressure monitor lights up.

q
Related information
q
q
Signal of engine oil pressure sensor is input to engine controller and then the data is transmitted
to machine monitor through CAN communication system.
Engine oil pressure can be checked with monitoring function.
Cause
Reduction of engine oil pressure Check the engine oil pressure as the drop of engine oil pressure is detected.
q Perform troubleshooting "S-12 (Oil pressure drop)".
Defective engine oil pressure

system

Failure
If cause 1 is not the cause for the trouble, engine oil pressure switch system may
be defective. Perform troubleshooting for failure codes [CA135] and [CA141].
3) Torque converter oil temperature monitor lights up.

q
Related information
q
q
Signal voltage of torque converter oil temperature sensor is input to power train controller and
then the data is transmitted to machine monitor through CAN communication system.
Cause
Overheating of torque converter

Torque converter oil may be overheated. If it is overheated, remove cause.
oil (When system is normal)
If cause 1 is not the cause for the trouble, torque converter oil temperature senDefective torque converter oil
2
sor system may be defective. Perform troubleshooting for failure codes
[DGT1KA] and [DGT1KX].
1
Failure
4) Hydraulic oil temperature monitor lights up.
Related information
q
q
Hydraulic oil temperature can be checked with monitoring function

Cause
Overheating of hydraulic oil
Defective hydraulic oil tempera2 ture gauge system or machine
monitor
1
40-596

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-6R
(01)

E-7 Engine coolant temperature gauge does not indicate normally
E-7 Engine coolant temperature gauge does not indicate normally
40-597
1) While engine coolant temperature is rising normally, temperature gauge does not rise from
white range (C).
Failure
2) While engine coolant temperature is stabilized normally, temperature gauge rises to red range
(H).
q Signal of engine coolant temperature sensor is input to engine controller and then the data is
transmitted to machine monitor through CAN communication system.
Related information
q Engine coolant temperature can be checked with monitoring function
Cause
1

sensor system

Engine coolant temperature sensor system may be defective. Perform troubleshooting 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.
q Signal voltage of engine coolant temperature sensor is input to engine controller and then the
data is transmitted to machine monitor through CAN communication system.
Related information
q Engine coolant temperature can be checked with monitoring function
Failure
Cause

a Turn starting switch ON or start engine and troubleshoot.
105 C
102 C
100 C
85 C
60 C
30 C
Coolant temperature
gauge level
Color of monitor light (a)

Red
Blue
Engine coolant temperature gauge and coolant

temperature monitor
40-597
D375A-6R
(01)
40-597

E-8 Fuel gauge does not indicate properly

Failure
40-598
1) Fuel gauge does not indicate properly.
Related information
Input (signal voltage) from fuel level sensor can be checked by using 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 circuit or short cir- Between FGS (male) (1) and (2)
a Fuel level sensor characteristics
cuit)
FULL
EMPTY
Between FGS (male) (2) and ground
Resistance
Approx. 4 z
Resistance Approx. 85 z
Max. 1 z
Resistance
1.
2.
3.
a

Disconnect connector FGS and connect T-adapter to female side.
Open circuit or short circuit or
If voltage is 0 V, wiring harness has open circuit or ground fault or short circuit,
2 ground fault or hot short circuit in
and if voltage is 24 V, wiring harness has hot short circuit.
wiring harness
a Voltage of approx. 3.3 V is applied to fuel level sensor signal lines through resistor inside machine monitor.
Between FGS (female) (1) and (2)
Open or short circuit in wiring

harness

Voltage
Approx. 3.3 V
a
1.
2.
a
a
Resistance accords with fuel level sensor characteristics table in cause 1.
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
2. Disconnect connectors CM01 and FGS, and connect T-adapters to female
side of them.

40-598
Resistance
Max. 1 z
Between CM01 (female) (12) and FGS (female) (2)
Between CM01 (female) (9) and FGS (female) (1)
Resistance
Max. 1 z
2. Disconnect connectors CM01 and FGS, and connect T-adapter to female side
of either of them.
Between CM01 (female) (9) or FGS (female) (1) and
ground
2. Disconnect connectors CM01 and FGS, and connect T-adapter to female side
of CM01.
Between CM01 (female) (9) and each pin other than
No continuity
(9)
(No sound is heard)
D375A-6R
(01)

Circuit diagram related to fuel level gauge
40-59
2) Display of fuel level gauge is different from actual fuel level.

3) The indication of the fuel level gauge is different from the display of the fuel level monitor.
Failure
Related information
Signal voltage of fuel sensor can be checked with monitoring function.

(Code: 04200 Fuel level sensor voltage)
Cause

Fuel level
1005 l
556 l
4
3
2
144 l
D375A-6R
(01)
756 l
276 l
Fuel level gauge and fuel level monitor
398 l
Reading of fuel level

gauge
Blue
Red
40-59
40-599

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
40-60
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
the data is transmitted to machine monitor through CAN communication system.
Related information
q Torque converter (power train) oil temperature can be checked with monitoring function.
Cause
1
Defective torque converter oil


Power train oil temperature sensor system may be defective. Perform troubleshooting for failure codes [DGT1KA] and [DGT1KX].
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
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.
Trouble
Cause

Power train oil temperature
130 C
120 C
118 C
90 C
50 C
0 C
Power train oil temperature gauge level

Red
Blue
Power train oil temperature gauge and power

train oil temperature monitor
40-60
40-600
D375A-6R
(01)

E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate

normally
40-601
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.
q Hydraulic oil temperature can be checked with monitoring function
Related information
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.
q Hydraulic oil temperature can be checked with monitoring function
Related information
Trouble
Cause

105 C
102 C
98 C
70 C
20 C
0 C
Reading of hydraulic oil

temperature gauge

Red
Blue
Hydraulic oil temperature gauge and hydraulic

oil temperature monitor
40-601
D375A-6R
(01)
40-601

E-11 Contents of display by machine monitor are different from applicable machine
E-11 Contents of display by machine monitor are different from appli40-602

cable machine
Trouble
Contents of display by machine monitor are different from applicable machine.
Related information
Cause
Machine monitor may be defective.(Since trouble is in system, troubleshooting

cannot be performed.)
E-12 Machine monitor does not display some items

Trouble
40-602
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.
Related information
Cause
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
40-602
Function switch does not work
Related information
Cause
40-602

D375A-6R
(01)

E-14 Operation mode does not change

Trouble
40-603
1) When operation mode switch is operated, display of operation mode monitor does not change.
Related information
(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
Related information
Engine output mode recognized by engine controller can be checked with monitoring function.
(Code: 17500 Engine Power Mode)
(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

Failure
1) When gearshift mode switch is operated, display of speed mode section does not change.
q
Related information
(If failure codes [DAFRMC], [DK40KA], [DK40KB], [DLT3KA] and/or [DLT3KB] are displayed,
troubleshoot them first.)
Cause

Failure

The power train controller may be defective. (Since the trouble is in the system,
the troubleshooting cannot be performed.)
2) When gearshift mode is changed, gearshift setting of power train is not changed.
q
Related information
(If failure codes [DAFRMC], [DK40KA], [DK40KB], [DLT3KA] and/or [DLT3KB] are displayed,
troubleshoot them first.)
Cause
D375A-6R
(01)
40-603

The power train controller may be defective. (Since the trouble is in the system,
the troubleshooting cannot be performed.)
40-603

E-16 Customize function does not operate normally

Trouble
40-604
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


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
40-604
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

40-604

Engine controller or power train controller may be defective. (Since trouble is in
system, troubleshooting cannot be performed.)
D375A-6R
(01)

E-18 Alarm buzzer does not sound or does not stop

Trouble
40-605
Alarm buzzer does not sound or does not stop.
Related information
Cause


Power train controller may be defective. (Since trouble is in system, troubleshooting cannot be performed.)
E-19 When starting switch is turned OFF, service meter is not displayed40-605
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

When starting switch is turned ON, if machine monitor displays nothing, backup
Defective backup power supply
1
power supply system may be defective. In this case, perform troubleshooting for
system
"E-3 When starting switch is turned ON, machine monitor displays nothing".

E-20 Machine monitor cannot be set in service mode

Trouble
Related information
Machine monitor cannot be set in service mode
If following switches are operated, machine monitor is set in service mode.

Switch operation: [4] + [1] o [2] o [3] (While pressing [4], press [1], [2], and [3] in order)
Cause
D375A-6R
(01)
40-605

40-605

E-21 The ripper pin puller cylinder does not operate

Failure
40-606
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
2. Disconnect connector PLSW and connect T-adapter to male side.
3. Operate switch and troubleshoot.
Between PLSW (male) (1) and (2)
Defective pin puller solenoid

(Internal defect)
Pull
Resistance
Max. 1 z
Blow out
Resistance
Min. 1 Mz

2. Disconnect connector PPL and connect T-adapter to male side.
Open or short circuit in wiring

harness
Resistance
10 40 z
Between PPL (male) (1) and ground
Between PPL (male) (1) and (2)
Resistance
Min. 1 Mz

2. Disconnect connectors ASUS and PHR.
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 female
side of them.
Between PPL (female) (2) and ground
Resistance
Max. 1 z
Between fuse FS22-4 and PLSW (female) (1)

Max. 1 z
Between PPL (female) (1) and PLSW (female) (2)
Resistance
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)

Min. 1 Mz
Between PLSW (female) (1) and ground
Resistance
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)
40-606
Voltage
Max. 1 V
D375A-6R
(01)

Circuit diagram related to ripper pin puller cylinder
D375A-6R
(01)
40-607
40-607

E-22 Horn does not sound or does not stop

Trouble
40-608
q
q
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

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.
Between horn switch terminals
3 Defective wiring harness
1.
2.
3.
4.
Resistance
Min. 1 Mz
ON
Resistance
Max. 1 z

Disconnect connector RDG and connect T-adapter to female side.
Turn horn switch ON.
Between RDG (female) (3) and ground

Disconnection in wiring harness 2. Remove fuse FS32-4.
4
3. Turn horn switch ON.
or horn
Between FS32-4 and ground
5 Disconnection in horn
OFF
Voltage
20 30 V
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 (open circuit or defective condisconnected.
tact)
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.


9 Defective horn (Internal defect)
40-608
Resistance
Min. 1 Mz

2. Disconnect connector HRN and insert T-adapter into RDG.
3. Turn horn switch ON.
Voltage
Max. 1 V
If the cause cannot be found by above checks, horn may be defective.
D375A-6R
(01)

Circuit diagram related to horn
D375A-6R
(01)
40-609
40-609

E-23 Back-up alarm does not sound or does not stop

Trouble
Related information
40-610
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
[D161KA], [D161KB] are displayed, but in case of failure on the secondary side (contact side), no
failure code is displayed.
Cause
If fuse FS22-5 is broken, circuit probably has ground fault. In this case, troubleshoot cause 6 first.
2. Replace backup alarm relay (connector: BKA) with another relay.
2 (internal open circuit or short cir- 3. Turn starting switch ON position.
4. Perform reverse travel operation.
cuit)
If backup alarm sounds, original backup alarm relay is defective.
3 Defective wiring harness
1.
2.
3.
4.

Disconnect connector BKAL and connect T-adapter to female side.
Perform reverse travel operation.
Between BKAL (1) and (2)
Voltage
20 30 V

Disconnection in wiring harness 2. Disconnect connector BKA and connect T-adapter to female side.
4
or backup alarm
Continuity
Disconnection in wiring harness 3. Disconnect connectors BKA and BKAL and connect T-adapters to female side
5 (open circuit or defective conof them.
tact)
Between BKA (female) (5) and BKAL (female) (1)
Resistance
Max. 1 z
Between BKAL (female) (2) and ground

Max. 1 z
Between BKA (female) (1), (3) and FS22-5
Resistance
Resistance
Max. 1 z
a
1.
2.
3.
If fuse is not broken, this check is not required.

Remove fuse FS22-5.
Disconnect connectors BKA and BKAL and connect T-adapter to female side
of either of them.
Between BKA (female) (1) or (3) and ground
Defective backup alarm

(Internal defect)
40-610
Min. 1 Mz

7
Resistance
Resistance
Min. 1 Mz
If cause cannot be found by above checks, back-up alarm may be defective.
D375A-6R
(01)

Trouble
2) Back-up alarm does not stop.
Related information
Cause

2. Replace backup alarm relay (connector: BKA) with another relay.
a The above can be checked with backup alarm relay removed only.
1 (internal open circuit or short cir3. Turn starting switch ON position.
cuit)
If backup alarm stops, original backup alarm relay is defective.


2. Disconnect connector BKAL and connect T-adapter to female side.
Defective backup alarm

(Internal defect)
Voltage
Max. 1 V
Between BKAL (female) (1) and ground

3
Between BKAL (female) (1) and (2)
Voltage
Max. 1 V
If cause cannot be found by above checks, back-up alarm may be defective.
Circuit diagram related to backup alarm
D375A-6R
(01)
40-61
40-611

E-24 Fan does not reverse

Failure
Related
information
40-612
The fan does not rotate in reverse.

q
See "Reverse rotation of hydraulic fan" in Machine monitor sections of Structure and Operation section.
Cause
1 Defective fan reverse solenoid Perform troubleshooting for failure codes [DW7BKA] and [DW7BKB].
Circuit diagram related to fan
40-612
40-612
D375A-6R
(01)

E-25 The head lamp and rear lamp do not light up

Failure
Related
information
40-613
1) Head lamp does not light up.

q
q
If section between headlamp relay and headlamps, one headlamp lights up.
If headlamp switch, diode or wiring harness common to right and left headlamps is defective, right and
left headlamps and working lamp do not light up.
Cause
Defective head lamp (Breakage

Since the head lamp may be defective, check its bulb for breakage.
of bulb)
Defective circuit breaker (CB105
2
If circuit breaker is turned ON, circuit probably has ground fault etc.
or CB5)
2. Replace relay (connector: LMFL or LMFR) with backup alarm relay
Defective head lamp relay
(connector: BKA).
(LMFR, LMFL)
3
(internal open circuit or short cir4. Turn headlamp switch to ON position.
cuit)
1
If headlamp lights up, original headlamp relay is defective.
4 Defective head lamp switch
1.
2.
3.
a

Disconnect connector FLSW and connect T-adapter to male side.
Turn headlamp switch to ON/OFF position and troubleshoot.
ON position is located in both directions.
Between FLSW (male) (5) and (6), or

between (4) and (5)
OFF
Resistance
Min. 1 Mz
ON
Resistance
Max. 1 z

2. Disconnect connectors LMD1 and LMD2, and connect T-adapter to diode.
Defective diode LMD1 or LMD2 Between LMD1 (male) (1) (+) and (2) (-)
5 (internal open circuit or short cirBetween LMD1 (male) (2) (+) and (1) (-)
cuit)
No continuity
Between LMD2 (male) (1) (+) and (2) (-)
No continuity
Between LMD2 (male) (2) (+) and (1) (-)
Continuity
D375A-6R
(01)
Continuity
40-613

Cause

a Check location where voltage abnormality occurs and locate defective point of
wiring harness.
2. Disconnect connectors LHDR and LHDL, and connect T-adapters to female
side of them.
4. Turn headlamp switch to ON position.
Between LHDL (female) (1) and (2)
Open circuit or ground fault in

wiring harness
20 30 V
Between LHDR (female) (1) and (2)
Voltage
Voltage
20 30 V
a If no failure is detected by above checks, this check is not required.

2. Disconnect connectors LMFL and LMFR, and connect T-adapter to female
side.
Between LMFL (female) (1) and (2)
Voltage
20 30 V
Between LMFL (female) (3) and (2)
Voltage
20 30 V
Between LMFR (female) (1) and (2)
Voltage
20 30 V
Between LMFR (female) (3) and (2)
Voltage
20 30 V
a If no failure is detected by above checks, this check is not required.

2. Disconnect connector FLSW and connect T-adapter to female side.
Between FLSW (female) (5) and (2)
Voltage
20 30 V
2. Disconnect connectors FLSW, LMD1, LMD2, LMFL, LMFR, LHDR, LHDL and
KEY, and connect T-adapters to female side of them.
Between LHDR (female) (2) and ground
Resistance
Max. 1 z
Between LHDL (female) (2) and ground
Max. 1 z
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
Between LHDL (female) (1) and LMFL (female) (5)
Max. 1 z
Between LHDR (female) (1) and LMFR (female) (5)

Resistance
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.
Min. 1 Mz
40-614
Resistance
Resistance
Min. 1 Mz
D375A-6R
(01)

Circuit diagram related to headlamp, backup lamp and ripper point lamp
D375A-6R
(01)
40-615
40-615

Failure
Related
information
2) Working lamp does not light up.

q
If headlamps do not light up, see "1) Headlamp does not light up" first.
Cause
Defective working lamp (BreakSince the working lamp may be defective, check its bulb for breakage.
age of bulb)
2 Defective fuse (FS22-2)
When the fuse is blown, a ground fault may have probably occurred in the circuit.
1.
2.
Defective working lamp relay
3 (internal open circuit or short cir- 3.
4.
cuit)

Replace relay (connector: LMW) with backup alarm relay (connector: BKA).
Turn headlamp switch to ON position.
If working lamp lights up, original working lamp relay is defective.

wiring harness.
2. Disconnect connectors LWKR and LWKL, and connect T-adapters to female
side of them.
Between LWKL (female) (1) and (2)
Open circuit or ground fault of

wiring harness
20 30 V
Between LWKR (female) (1) and (2)

4
Voltage
Voltage
20 30 V
a
1.
2.
3.
4.
If no failure is detected by above checks, this check is not required.

Disconnect connector LMW and connect T-adapter to female side.
Turn headlamp switch to ON position.
Between LMW (female) (1) and (2)
Voltage
20 30 V
Between LMW (female) (3) and (2)
Voltage
20 30 V
a
1.
2.
3.

Disconnect connector FLSW and connect T-adapter to female side.
Between FLSW (female) (5) and (2)

a
1.
2.
3.
Voltage
20 30 V
Remove fuse FS22-2.
Disconnect connectors LMW, LWKR and LWKL, and connect T-adapters to
Between LWKR (female) (2) and ground
Resistance
Max. 1 z
Between LWKR (female) (1) and LMW (female) (5)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Between LMW (female) (2) and ground
Resistance
Max. 1 z
Between LMW (female) (3) and FS22-2

Between LWKL (female) (2) and ground
Between LMW (female) (1) and LMFL (female) (1)
Max. 1 z
Between LWKL (female) (1) and LMW (female) (5)

Resistance
Resistance
Max. 1 z
a
1.
2.
3.
Remove fuse FS22-2.
Disconnect connectors LMW, LWKR and LWKL, and connect T-adapters to
female side of LMW.
Min. 1 Mz
40-616
Resistance
Resistance
Min. 1 Mz
D375A-6R
(01)

D375A-6R
(01)
40-617
40-617

Failure
3) Back-up lamp and ripper point lamp do not light.

q
Related
information
q
If fuse, back-up lamp relay, back-up lamp switch or common wiring harness of back-up lamp and ripper
point lamp is defective, neither of back-up lamp and ripper point lamp does not light up (If either of
back-up lamp and ripper point lamp lights up, this check is not required).
For related circuit diagram, see 2).
Cause
Defective rear lamp (Breakage

Since the rear lamp may be defective, check its bulb for breakage.
of bulb)
Defective ripper point lamp (Bro2
Since the ripper point lamp may be defective, check its bulb for breakage.
ken bulb)
1
If fuse FS22-1 is broken, circuit probably has ground fault.
1.
2.
Defective back-up lamp relay
4 (internal open circuit or short cir- 3.
4.
cuit)

Replace relay (connector: LMRE) with backup alarm relay (connector: BKA).
Turn back-up lamp switch to ON position.
If back-up lamp lights up, original back-up lamp relay is defective.
5 Defective rear lamp switch

2. Disconnect connector RLSW and connect T-adapter to male side.
3. Turn back-up lamp switch to ON/OFF position and troubleshoot.
Between RLSW (female) (5) and (6)
OFF
Resistance
Min. 1 Mz
ON
Resistance
Max. 1 z
wiring harness.
2. Disconnect connectors LREL, LRER and LRP, and connect T-adapter to
4. Turn back-up lamp switch to ON position.
Between LREL (female) (1) and (2)
Voltage
20 30 V
Between LRP (female) (1) and (2)

wiring harness
20 30 V
Between LRER (female) (1) and (2)
Voltage
Voltage
20 30 V
a
1.
2.
3.
4.

Disconnect connector LMRE and connect T-adapter to female side.
Turn back-up lamp switch to ON position.
Between LMRE (female) (1) and (2)
Voltage
20 30 V
Between LMRE (female) (3) and (2)
Voltage
20 30 V
a
1.
2.
3.

Disconnect connector RLSW and connect T-adapter to female side.
Between RLSW (female) (5) and (2)
40-618
Voltage
20 30 V
D375A-6R
(01)

Cause

a
1.
2.
3.
Remove fuse FS22-1.
Disconnect connectors FLSW, DIODE, FLP, LHDR, LHDL and KEY, and
Between LRER (female) (2) and ground
Max. 1 z
Resistance
Max. 1 z
Between LRER (female) (1) and LMRE (female) (5)
Resistance
Max. 1 z
Between LREL (female) (1) and LMRE (female) (5)
Resistance
Max. 1 z
Between LRP (female) (1) and LMRE (female) (5)
Resistance
Max. 1 z
Between LRP (female) (2) and ground
Resistance
Max. 1 z
Between LMRE (female) (1) and RLSW (female)(1),

(6)
Resistance
Max. 1 z
Between LMRE (female) (2) and ground
Resistance
Max. 1 z
Between LMRE (female) (3) and FS22-1
Resistance
Max. 1 z
Between RLSW (female) (5) and KEY (female) (1)
Resistance
Max. 1 z
Between RLSW (female) (2) and ground

Resistance
Between LRP (female) (2) and ground
Max. 1 z
Between LREL (female) (2) and ground

Resistance
Resistance
Max. 1 z
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 Mz
Resistance
Min. 1 Mz
D375A-6R
(01)
Resistance
Min. 1 Mz
40-619

40-620
40-620
D375A-6R
(01)

D375A-6R
(01)
40-621

E-26 Windshield wiper does not operate
40-62
Trouble 1) None of the wipers operate.

Related
information
Cause

If CB105 circuit breaker is turned ON, the circuit probably has ground fault. In this
1 Defective CB105 circuit breaker
case, perform troubleshooting for cause 4 first.
2

wiring harness


Circuit diagram related to wiper
40-622

Between terminal (B) in cab fuse box and ground
Voltage
20 30 V
a If CB105 circuit breaker is turned ON, reset it first.
Between battery relay BRC terminal and cab fuse box
Resistance
Max. 1 z
(B) terminal
2. Remove terminal (B) from cab fuse box.
Between terminal (B) in cab fuse box (Wiring harness
side) and ground
40-62
D375A-6R
(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
1 Defective fuse 4 in cab fuse box
If fuse shown at left is broken, circuit probably has ground fault. In this case, perform troubleshooting for cause 6 first.
Defective front wiper motor

3 Defective front wiper switch

2. Disconnect connector CN-9 and connect T-adapter to male side.
Between CN-9 (male) (2) and (5)
2. Disconnect connector CN-12.
3. Turn front wiper switch ON and OFF, and troubleshoot.
4 Power supply line
OFF
Resistance
Min. 1 Mz
ON
Resistance
Max. 1 z
OFF
Resistance
Max. 1 z
ON
Resistance
Min. 1 Mz

a If any abnormality occurs, go to Cause 6 and Trouble 1).
Between terminal (4) in cab fuse box and ground

Continuity

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

6

D375A-6R
(01)
Voltage
20 30 V
3. Disconnect connectors CN-9 and CN-12.
side) and ground
40-623

Trouble
Related
information
3) Rear wiper does not operate.

q
q
Cause

2
Defective rear wiper motor

3 Defective rear wiper switch

Continuity
3. Turn rear wiper switch ON and OFF, and troubleshoot.
4 Power supply line
OFF
Resistance
Min. 1 Mz
ON
Resistance
Max. 1 z
OFF
Resistance
Max. 1 z
ON
Resistance
Min. 1 Mz

Between terminal (2)in cab fuse box and ground


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
6

40-624
Voltage
20 30 V
side) and ground
D375A-6R
(01)

D375A-6R
(01)
40-625
40-625

Trouble
Related
information
4) Left door wiper does not operate.

q
q
Cause

2
Defective left door wiper motor


Continuity
3. Turn left door wiper switch ON and OFF, and troubleshoot.
3 Defective left door wiper switch Between CN-11 (male) (3) and (4)
4 Power supply line
OFF
Resistance
Min. 1 Mz
ON
Resistance
Max. 1 z
OFF
Resistance
Max. 1 z
ON
Resistance
Min. 1 Mz



3. Turn left door wiper switch ON.
side) and ground
Voltage
20 30 V
Continuity

6

40-626
Voltage
20 30 V
side) and ground
D375A-6R
(01)

D375A-6R
(01)
40-627
40-627

Trouble
Related
information
5) Right door wiper does not operate.

q
Cause

Defective right door wiper motor 2. Disconnect connector CN-17 and connect T-adapter to male side.
2
Continuity
3. Turn right door wiper switch ON and OFF, and troubleshoot.
3 Defective right door wiper switch Between CN-13 (male) (3) and (4)
4 Power supply line
OFF
Resistance
Min. 1 Mz
ON
Resistance
Max. 1 z
OFF
Resistance
Max. 1 z
ON
Resistance
Min. 1 Mz



3. Turn right door wiper switch ON.
side) and ground
Voltage
20 30 V
Continuity

6

40-628
Voltage
20 30 V
3. Disconnect the connectors CN-17 and CN-13.
side) and ground
D375A-6R
(01)

D375A-6R
(01)
40-629
40-629

E-27 Window washer does not operate

Failure
Related
information
1) Front window washer does not operate.

q
q
If wiper also does not operate, see E-26 1) or 2).

T-adapter is not prepared for window washer motor connector (Perform Troubleshooting without
T-adapter).
Cause
Defective front window washer

1 motor
2 Defective front wiper switch

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.


40-630
40-630
OFF
Resistance
Min. 1 Mz
ON
Resistance
Max. 1 z

3. Turn front window washer switch to ON position.
Continuity
side) and ground
2. Remove fuse 4 from fuse box.
3. Disconnect connectors CN-12 and WSFR.
side) and ground
D375A-6R
(01)

Circuit diagram related to window washer
D375A-6R
(01)
40-631
40-631

Trouble
Related
information
2) Rear window washer does not operate.

q
q

T-adapter).
Cause
Defective rear window washer

1 motor
2 Defective rear wiper switch

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.
4. Turn switch ON and OFF, and troubleshoot.


40-632
OFF
Resistance
Min. 1 Mz
ON
Resistance
Max. 1 z

3. Turn rear window washer switch to ON position.
Continuity
side) and ground
3. Disconnect connectors CN-14 and WSRR.
side) and ground
D375A-6R
(01)

D375A-6R
(01)
40-63
40-633

Trouble
3) Right door window washer does not operate.

q
Related
information
q
q

T-adapter).
Cause
a Check that left door window washer sprays water normally.

Defective right door washer
2. Replace connector WSLH with WSRH.
1 motor
(Internal open circuit in wiring) 4. Turn right door window washer switch to ON position.
If left door window washer sprays water, original right door window washer motor
is defective.
2 Defective right door wiper switch 4. Turn switch ON and OFF, and troubleshoot.
OFF
ON
Resistance
Max. 1 z

40-634

3. Turn right door window washer switch to ON position.
Continuity
side) and ground
3. Disconnect connectors CN-13 and WSRH.
side) and ground
D375A-6R
(01)

D375A-6R
(01)
40-635
40-635

Trouble
4) Left door window washer does not operate.

q
Related
information
q
q

T-adapter).
Cause
a Check that right door window washer sprays water normally.

2. Replace connector WSLH with WSRH.
Defective left door washer motor 3. Turn starting switch to ON position.
1
(Internal open circuit in wiring) 4. Turn left door window washer switch to ON position.
If right door window washer sprays water, original left door window washer motor
is defective.
2 Defective left door wiper switch 4. Turn switch ON and OFF, and troubleshoot.
OFF
ON
Resistance
Max. 1 z

40-636

3. Turn left door window washer switch to ON position.
Continuity
side) and ground
3. Disconnect connectors CN-11 and WSLH.
side) and ground
D375A-6R
(01)

D375A-6R
(01)
40-637
40-637

E-28 Electric priming pump does not operate or does not stop automatically
E-28 Electric priming pump does not operate or does not stop automati40-638
cally
Failure
Electric priming pump does not operate or does not stop automatically.
Related
information
Cause
1 Low battery charge level
2 Defective circuit breaker CB7

The battery charge level may be low. Check the battery itself.
If circuit breaker CB7 is turned OFF, circuit probably has ground fault. (Check
cause No. 5)
2. Disconnect connectors EPP, and connect T-adapter to female side.

Between EPP (1) - (2)
Voltage
20 30 V
(Drive power supply system)
3
(open circuit or defective contact
1. Disconnect ground strap (to turn constant power supply OFF).
in connector)
Between EPP (female) (2) and ground

Resistance
Max. 1 z
1. Disconnect ground strap (to turn constant power supply OFF).

3. Disconnect connectors USB, EG1 and EFP.
Resistance
Min. 1 Mz
5 Defective electric priming pump
Resistance
Min. 1 Mz
1.
2.
3.
4.

Disconnect connectors EPP, and connect T-adapter to female side.
Defective electric priming pump ON
Between EPP (3) and (4)
Voltage
20 30 V
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 pump
6 switch (Malfunction or autoswitch may be defective.
matic 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 cir7
pump
cuit (Priming switch is reset automatically).
2. Disconnect connectors EPP, and connect T-adapter to male side.
q
8 Trouble in electric priming pump Between EFP (male) (1) and (2)
Between EFP (male) (1) and pump body
Resistance
13z
Resistance
Min. 1 Mz
Between EFP (male) (2) and pump body
Resistance
Min. 1 Mz
40-638
D375A-6R
(01)

E-28 Electric priming pump does not operate or does not stop automatically
Circuit diagram related to electric priming pump
D375A-6R
(01)
40-639
40-639

E-29 Orbcomm terminal does not operate normally (Data are not transmitted)
E-29 Orbcomm terminal does not operate normally (Data are not trans40-640
mitted)
Failure
The ORBCOMM terminal does not operate normally (Data are not transmitted).
Related information
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 communication
Terminal power supply is abnor- OFF
with VHMS controller is abnormal.
1
mal or satellite is not captured
*1 Lamp is Power is applied to ORBCOMM terminal and the communication
ON
with VHMS controller is normal. But it does not capture satellite.
Power is applied to ORBCOMM terminal, capturing satellie and the
communication with VHMS controller is normal.
3. Disconnect connectors KOM1 and V4B, and connect T-adapters to female
side of them.
a Unswitched power supply is used. When disconnecting connector and carrying out troubleshooting, take care.
Between KOM1 (female) (36), (39) and VF2 (male)
Resistance
Max. 1 z
2 (Disconnection or defective con(5)
tact in connector)
Between KOM1 (female) (37), (38) and ground
Resistance
Max. 1 z
*1 Blinking
Between V4B (female) (3) KOM1 (female) (11)
Resistance
Max. 1 z
Between V4B female) (10) KOM1 (female) (5)
Defective ORBCOMM terminal

(When LED is turned off)
Max. 1 z
Between V4B (female) (4) KOM1 (female) (4)
Resistance
Resistance
Max. 1 z
1.
2.
3.
4.

Disconnect connectors KOM1, and connect T-adapter to female side.
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".
40-640
D375A-6R
(01)

E-29 Orbcomm terminal does not operate normally (Data are not transmitted)
Circuit diagram related to ORBCOMM terminal
D375A-6R
(01)
40-641
40-641

E-30 Gear cannot be shifted

Trouble
40-642
Gear cannot be shifted (Shift switch does not work).
Related information
Cause

a When failure code related to shift operation switch is not displayed.
Trouble in shift operation switch

q Shift up switch
1 q Shift down switch
q Shift switch
(Optional-type lever)
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.
Internal defect of transmission

clutch
40-642
The inside of the transmission clutch is supposed to be defective, check it

directly.
D375A-6R
(01)

D375A-6R
(01)
40-643
Troubleshooting of hydraulic and mechanical system (H-mode)


40-64
40-64
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 failure or troubleshooting

mation
Cause
2
Possible
causes and
standard value
for judgment
Possible causes for trouble

<Contents of description>
(Given numbers are referq Standard value to determine possible causes
ence numbers, which do not
q Remarks on judgment
indicate priority)
3
40-644
D375A-6R
(01)

D375A-6R
(01)
40-645

List of Failure Modes and Causes
40-646
Hydraulic components
Related to work equipment
Power train system
40-646
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
Transmission main relief valve
Transmission operation valve
Steering valve
For lockup clutch
For forward and reverse clutch
Failure
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.
The brake does not work.
Torque converter is not locked-up.
The 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.
The fan speed is abnormal (excessive noise from or vibration
of fan, or overheating).
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-6R
(01)
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q Q
Q Q
Q Q
D375A-6R
(01)
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
Q Q
Q Q Q
Q
Q
Q
Q
Q
Q
Q
Q Q
Q Q
Steering clutch (discs, plates, etc.)

Steering brake (discs, plates, 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
Diagnosis codes

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
Q H-23
H-22
Q Q H-24
40-647

H-1 Machine lacks power(or drawbar pull)

Failure
Related information
40-648
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

a Prepare by turning starting switch to OFF position, then troubleshoot by rotating engine at high idling speed.
Defective engine or transmission
Measuring conditions
Engine speed
F3 stall
1,450 rpm
Stall in F3 + Relief of work equip1,400 rpm

ment system (Pitch back)
The power train pump is suspected to be defective. Check it
2 Defective power train pump
directly.
Torque converter
Torque converter
Internal defect of torque conPCCS lever
3
inlet pressure
outlet pressure
verter
0.44 0.74 MPa
0.69 1.08 MPa
{4.5 7.5 kg/cm2}
{7.0 11.0 kg/cm2}
Transmission
PCCS lever
main relief pressure
All neutral position
Possible
causes and
standard value
in normal state
Defective set pressure of

4 transmission main relief
valve and internal defect
2.53 3.12 MPa

{25.8 31.8 kg/cm2}
a Prepare with starting switch OFF, then carry out troubleshooting
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
FWD
Min. 2.06 MPa {Min. 21.0 kg/cm2}
REV
1ST
2ND
Operation failure of trans5

mission valve (ECMV)
Clutch pressure

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
6
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 parkDefective parking brake
7
ing brake lever or brake pedal linkage is not assumed to be
lever or brake pedal linkage
adjusted normally. Directly check it.
3RD
40-648
D375A-6R
(01)

Cause

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
Possible
causes and
standard value
in normal state
8 Defective steering clutch

Left brake pressure
Left stroke end
Right stroke end
Min. 2.4 MPa

{Min. 24 kg/cm2}
0 MPa
{0 kg/cm2}
0 MPa
{0 kg/cm2}
Min. 2.4 MPa
{Min. 24 kg/cm2}
0 MPa
{0 kg/cm2}
Min. 2.4 MPa
{Min. 24 kg/cm2}
Min. 2.4 MPa
{Min. 24 kg/cm2}
0 MPa
{0 kg/cm2}
When the oil pressure is abnormal, execute the troubleshooting of

"H-6 Steering is not possible."
9
D375A-6R
(01)
Internally defective transmis- The transmission is assumed to be defective internally; directly

sion
check it.
40-649

H-2 Machine cannot travel (at 2nd or 3rd each speed)

Failure
40-650
Machine cannot start (at 2nd or 3rd gear speed)
Related information
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.
q
q
Cause
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
0.44 0.74 MPa
0.69 1.08 MPa
Neutral for all controls
{4.5 7.5 kg/cm2}
{7.0 11.0 kg/cm2}
a Prepare with starting at switch OFF positon , then run the engine at low speed to perform troubleshooting.
Transmission clutch
Defective operation of trans2
Min. 2.06 MPa

{Min. 21.0 kg/cm2}
Min. 2.06 MPa
{Min. 21.0 kg/cm2}
2ND
3RD
3
Possible
causes and
standard value
for judgment
Defective operation (dragging) of parking brake

Defective operation (dragging) of brake
Defective operation (dragging) is supposed, check linkage valves.

a Move the machine to flat ground and start the engine to perform
troubleshooting.
Run the engine at low speed and set the gear to F2. If the machine
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
Defective seal of steering

clutch or brake
Clutch pressure

Left brake pressure
Left stroke end
Right stroke end
Min. 2.4 MPa

{Min. 24 kg/cm2}
0 MPa
{0 kg/cm2}
0 MPa
{0 kg/cm2}
Min. 2.4 MPa
{Min. 24 kg/cm2}
0 MPa
{0 kg/cm2}
Min. 2.4 MPa
{Min. 24 kg/cm2}
Min. 2.4 MPa
{Min. 24 kg/cm2}
0 MPa
{0 kg/cm2}
When the oil pressure is abnormal, perform the troubleshooting for

"H-6 machine cannot turn."
6
40-650
Internal defect of transmission
Transmission may have an internal defect. Check it directly.
D375A-6R
(01)

H-3 Machine cannot travel at any gear speeds

Failure
40-651
Machine does not start at all gear speeds
Related information
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 Defective power train pump
Incorrect set pressure of

2 transmission main relief
valve

The power train pump is suspected to be defective. Check it
directly.
a Prepare with starting switch at OFF position, then run the engine
at full speed to perform troubleshooting.
Transmission
PCCS lever
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 trans- Directly check that the spring length and the number of shims are
3
normal and also that the spool moves smoothly.
mission main relief valve
q Number of shims: 4 sheets
a Prepare with starting at OFF position, then run the engine at low
speed to perform troubleshooting.
Possible
causes and
standard value
for judgment
Transmission clutch
Clutch pressure
Min. 2.06 MPa

{Min. 21.0 kg/cm2}
Defective operation of transMin. 2.06 MPa
4
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}
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 normal).
5 Defective operation of brake
Brake pedal
Brake oil pressure (right and left)
FWD
Release
Depressed
D375A-6R
(01)
Min. 2.4 MPa {Min. 24 kg/cm2}

0 MPa
{0 kg/cm2}
40-651

Cause

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
Defective seal of steering

clutch or brake
Possible
causes and
standard value
for judgement

Left brake pressure
Internal defect of steering

clutch and brake
Left stroke end
Right stroke end
Min.2.4 MPa
{Min. 24 kg/cm2}
0 MPa
{0 kg/cm2}
0 MPa
{0 kg/cm2}
Min.2.4 MPa
{Min. 24 kg/cm2}
0 MPa
{0 kg/cm2}
Min.2.4 MPa
{Min. 24 kg/cm2}
Min.2.4 MPa
{Min. 24 kg/cm2}
0 MPa
{0 kg/cm2}
Steering clutch may be defective, check it directly.
Perform troubleshooting for the failure codes [DDQ2KA],

Malfunction of parking brake [DDQ2KB], [DDQ2L4] and [dDQ2L4].
8
lever switch
Even if failure code is not displayed, check that switch operates
normally.
9
40-652
Internal defect of transmission clutch
The inside of transmission clutch may be defective. Check it

directly.
D375A-6R
(01)

H-4 Machine travels only in one direction, forward or reverse
H-4 Machine travels only in one direction, forward or reverse

Trouble
40-653
Machine travels only in one direction ,forward or in Reverse.
Related information
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.
q
q
Cause

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
FWD
Defective operation of transmission valve (ECMV)
Possible
causes and
standard value
in normal state
REV
1ST
2ND
3RD
Defectively sealed of transmission clutch
Clutch pressure
Min. 2.06 MPa
{Min. 21.0 kg/cm2}
Min. 2.06 MPa
{Min. 21.0 kg/cm2}
Min. 1.86 MPa
{Min. 19.0 kg/cm2}
Min. 2.06 MPa
{Min. 21.0 kg/cm2}
Min. 2.06 MPa
{Min. 21.0 kg/cm2}
If the result of the test for cause 4 shows malfunction of the brake,
the clutch seal may be defective. Check it directly.
The inside of the transmission clutch is supposed to be defective.

Check it directly.
troubleshooting.
Defective operation of brake
Run the engine at low speed mode and set to gear to F2. If the
4
(dragging)
machine does not move, the brake drags. (Perform the troubleshooting for "H-9 Brake does not work").
3
D375A-6R
(01)
40-653

H-5 Large time lag at gear shifting or directional change
40-654
Failure
Large time lag at gear shifting or directional change.
Related information
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.
Possible
causes and
standard value
in normal state
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
{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
3
are normal and that the spool moves smoothly.
q Number of shims: 4 sheets
a Prepare by turning starting switch at OFF position, then run the
engine at low speed to perform troubleshooting .
Transmission clutch
FWD
4
Operation failure of transmission valve (ECMV)
REV
1ST
2ND
3RD
Clutch pressure
Min. 2.06 MPa
{Min. 21.0 kg/cm2}
Min. 2.06 MPa
{Min. 21.0 kg/cm2}
Min. 1.86 MPa
{Min. 19.0 kg/cm2}
Min. 2.06 MPa
{Min. 21.0 kg/cm2}
Min. 2.06 MPa
{Min. 21.0 kg/cm2}
Defectivly sealed transmission clutch
When the standard values for the cause 3 are not satisfied, the
clutch seal may be defective. Check it directly.
Inside of transmission clutch may be defective. Check it directly.
troubleshooting.
If machine does not move when engine is low-idling and F2 shift is
7
(dragging)
selected, braking is applied (troubleshoot by referring to "H-9
Brake system does not operate".
8 Type of oil used
40-654
Check if an oil other than the specified oil (T030) is being used.
D375A-6R
(01)

H-6 Machine connot turn

Trouble
Related information
40-65
Machine connot turn.
(See H-1.)
Cause
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 (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
Possible
causes and
standard value
for judgment

2
Defective operation of steering clutch valve (ECMV)

Left brake pressure
Left stroke end
Right stroke end
Min. 2.4MPa
{Min. 24 kg/cm2}
0MPa
{0 kg/cm2}
0MPa
{0 kg/cm2}
Min. 2.4MPa
{Min. 24 kg/cm2}
0MPa
{0 kg/cm2}
Min. 2.4MPa
{Min. 24 kg/cm2}
Min. 2.4MPa
{Min. 24 kg/cm2}
0MPa
{0 kg/cm2}
Defectively sealed steering

clutch
When standard values for the cause 2 are not satisfted, the clutch
seal may be sealed diffectively. Check it directly.

clutch
Defective operation of steer5 ing potentiometer of travel

Perform troubleshooting related to steering potentiometer.
control lever
D375A-6R
(01)
40-655

H-7 Machine turns only to one side

Trouble
Related information
40-656
Machine turns only to one side.
(See H-1.)
Cause
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 OFF, then run the engine at full
speed position to perform troubleshooting
PCCS lever
Possible
causes and
standard value
for judement

2
Defective operation of steering clutch valve (ECMV)

Left brake pressure
Left stroke end
Right stroke end
Min. 2.4MPa
{Min. 24 kg/cm2}
0MPa
{0 kg/cm2}
0MPa
{0 kg/cm2}
Min. 2.4MPa
{Min. 24 kg/cm2}
0MPa
{0 kg/cm2}
Min. 2.4MPa
{Min. 24 kg/cm2}
Min. 2.4MPa
{Min. 24 kg/cm2}
0MPa
{0 kg/cm2}
Defectively sealed steering

clutch
When the standard the cause 2 are not satisfied , the clutch seal
may be sealed defectively. Check it directly.

clutch
Defective operation of steer5 ing potentiometer of travel

Perform troubleshooting related to steering potentiometer.
control lever
40-656
D375A-6R
(01)

H-8 Machine overruns at turnning

Trouble
Related information
Machine overruns at turnning.
(See H-1.)
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 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.)
2
D375A-6R
(01)
40-657
When track shoe does not stop running in the troubleshooting for
Defective operation of steerthe cause 1, the steering clutch is defective. (Perform the troubleing clutch
shooting fro H-6 Machine cannot turn.)
40-657

H-9 Brake does not work

Trouble
40-658
Brake does not work.
Related information
(See H-1.)
If failure code [DK40KA] or [DK40KB] is displayed, perform diagnoses for the failure code first .
q
q
Cause

a Start the engine to perform troubleshooting.
Depress the brake pedal, shift the gear to F2 and run the engine at
full speed. If the machine moves, the brake performance is
degraded.
Defective operation of brake Brake pedal, linkage and the brake valve may have a malfunction.
2
pedal
Check them directly.
a Prepare with starting switch at OFF position, then run the engine at full speed to perfrom troubleshooting.
1 Degradation of brake
Possible
causes and
standard value
for judgment
PCCS lever
3
Defective operation of steering brake valve (ECMV)

Left brake pressure
Left stroke end
Right stroke end
Min. 2.4MPa
{Min. 24 kg/cm2}
0MPa
{0 kg/cm2}
0MPa
{0 kg/cm2}
Min. 2.4MPa
{Min. 24 kg/cm2}
0MPa
{0 kg/cm2}
Min. 2.4MPa
{Min. 24 kg/cm2}
Min. 2.4MPa
{Min. 24 kg/cm2}
0MPa
{0 kg/cm2}
4 Defective brake seal

5 Internal defect of brake
40-658
When standard the cause 3 are not satisfied , the brake seals may
be defective. Check it directly.
Brakes may be defective. Check it directly.
D375A-6R
(01)

H-10 Torque converter does not lock up

Failure
40-659
The torque converter does not lock up.
Related information
(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
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-6R
(01)
Engine speed
1,450 rpm
1,170 rpm
40-659

H-11 Power train oil overheats

Failure
40-6 0
Overheating of power train oil
Related information
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
Engine cooling system may be defective and engine output may be

1 Defective engine system
increased abnormally. Carry out troubleshooting according to
Engine volume, Shop manual.
Defective power train pump Since the defective power train pump or air mixing in from the suc2
or air mixing in suction circuit tion circuit is suspected, check it directly.
Torque converter
Torque converter
Internal defect of torque conPCCS lever
3
inlet pressure
outlet pressure
verter
Possible
causes and
standard value
in normal state

4
0.69 1.08 MPa

{7.0 11.0 kg/cm2}
0.44 0.74 MPa

{4.5 7.5 kg/cm2}
Defective operation (slide) of The inside of the transmission clutch is supposed to be defective
transmission clutch
(the clutch slides). Check it directly.
a Start the engine for troubleshooting.

Defective operation of brake If machine does not move when engine is low-idling and F2 shift is
5
(dragging)
selected, braking is applied (troubleshoot by referring to "H-9
Brake system does not operate".
Defective operation (slide) of The inside of the steering clutch is supposed to be defective (the
6
steering clutch
clutch slides). Check it directly.
a Start the engine for troubleshooting.
7
If the machine cannot be stopped completely while performing F3
(Slip)
stall, the brake is slipping.
8
40-660
Defective power train oil

cooler
Check the filter element for clogging.
D375A-6R
(01)

H-12 All work equipment operates too slow or lacks power

Failure
Related information
40-6 1
Make sure that hydraulic oil level is normal, and start troubleshooting.
Cause
Defective PTO (work equipment pump drive)

Defective work equipment
2
large pump
3
small pump
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.
Defective operation of
unload valve
Improper pressure set to

5 main relief valve for blade lift
valve
Possible
causes and
standard value
in normal state
Work equipment control levers
Unload pressure
2.45 (+1.37/0) MPa

{25 (+14/0) kg/cm2}
Blade control lever
Raise
Min. 26.5 MPa

{Min. 270 kg/cm2}
Internal failure of main relief

The main relief valve for the blade lift control valve may have a fail6 valve for blade lift control
ure inside. Check it directly.
valve
Blade control lever
7 main relief valve for blade tilt
and ripper Lo valve
Min. 26.5 MPa
Raise
{Min. 270 kg/cm2}
The main relief valve for blade tilt and ripper Lo valve may have a
8 valve for blade tilt and ripper
failure inside. Check it directly.
Lo valve
Defective pressure setting or
LS relief pressure
9 defective operation of LS
relief valve
Malfunction of self pressure

10 reducing valve (PPC basic
pressure)
11 Internal leak of PPC valve

12
D375A-6R
(01)
Operation failure of check

valve of PPC control circuit
Min. 24.52 MPa

{Min. 250 kg/cm2}
At stroke end
Control relief pressure
Min. 3.1 MPa

{Min. 32 kg/cm2}
If cause 8 is detected, oil may be leaking in PPC valve. Check

PPC valve directly.
Directly inspect the check valve for clogging.
40-661

H-13 All work equipment does not operate

Failure
Related information
40-6 2
Make sure that hydraulic oil level is normal, and start troubleshooting.
Cause
Defective PTO (work equipment pump drive)

2
large pump
3
small pump
1
unload valve

5 main relief valve for blade lift
control valve
Possible
causes and
standard value
in normal state

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
2.45(+1.37/0) MPa
{25(+14/0) kg/cm2}
Blade control lever
Raise
Min. 26.5 MPa

{Min. 270 kg/cm2}

The main relief valve for the blade lift control valve may have a fail6 valve for blade lift control
ure inside. Check it directly.
valve
Blade control lever
7 main relief valve for blade tilt
and ripper Lo valve
Min. 26.5 MPa
Raise
{Min. 270 kg/cm2}
The main relief valve for blade tilt and ripper Lo valve may have a
8 valve for blade tilt and ripper
failure inside. Check it directly.
Lo valve
Defective pressure setting or
LS relief pressure
9 defective operation of LS
relief valve
Malfunction of self pressure

10 reducing valve (PPC basic
pressure)
11
Defective operation of PPC

lock valve
12
Operation failure of check

valve of PPC control circuit
27.44 1.37 MPa

{280 14 kg/cm2}
At stroke end
Min. 3.1 MPa

{Min. 32 kg/cm2}
The PPC lock valve is supposed to operate abnormally. Check the

lever linkage or the lock valve directly.
40-662
Min. 3.1 MPa

{Min. 32 kg/cm2}
D375A-6R
(01)

H-14 Blade lift cylinder speed is too slow or lacks power

Trouble
40-6 3
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.
Related information
q
q
Cause
Possible
causes and
standard value
for judgement
Blade control lever
PPC valve output pressure
Min. 3.1 MPa

{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.
Raise stroke end
D375A-6R
(01)

valve

a Prepare with starting switch OFF, then run the engine of the full
speed position to perform troubleshooting.
Air entering blade lift cylinders
Air blade lift cylinders.Bleed air and check whether the phenomenon changes.
40-663

H-15 Blade tilt cylinder speed is too slow or lacks power

Trouble
40-6 4
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.
Related information
q
q
Cause

a Prepare with starting switch OFF, then run the engine at the full
speed position to performe troubleshooting.
Possible
causes and
standard value
for judgement

valve
Blade control lever
Raise stroke end
Min. 3.1 MPa

{Min. 32 kg/cm2}
2
3
40-664
Defective operation of blade Operation of the blade tilt valve spool may be defective.Check it
tilt control valve (spool)
directly.
Air entering blade tilt cylinders
Air may enter the blade tilt cylinders.Bleed air and check wether the
phenomenon changes.
D375A-6R
(01)

H-16 Ripper lift cylinder speed is too slow or lacks power

Failure
40-6 5
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.
Related information
q
q
Cause

Possible
causes and
standard value
for judgement
D375A-6R
(01)

valve
Ripper control lever
Raise stroke end
Min. 3.1 MPa

{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
Defective operation of ripper may be defective. Check it directly.
3 lift control valve (suction
a Judgment may be made by checking a change of phenomenon
valve)
after 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
4
der
the phenomenon changes.
2
40-665

H-17 Ripper tilt cylinder speed is too slow or lacks power

Trouble
40-6 6
Ripper tilt cylinders speed is too slow or lacks power.
Related information
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.
q
q
Cause

Possible
causes and
standard value
for judgement
40-666
PPC valve
Ripper lever
Tilt stroke end
Min.3.1 MPa
{Min. 32 kg/cm2}
Defective operation of rip- Operation of the ripper tilt control valve spool may be defective.
per tilt control valve(spool) Check it directly.
Operation of the suction valve for the ripper tilt control valve may
Defective operation of rip- be defective. Check it directly.
3 per tilt operation
a Judgement may be made by checking a change of phenomevalve(suction valve)
non after exchanging suction valves on the head side and on
the bottom side.
Air entering ripper tilt cylin- Air may enter ripper tilt cylinders. Bleed air and check whether the
4
ders
phenomenon changes.
D375A-6R
(01)

H-18 Excessive hydraulic drift of blade lift cylinder
H-18 Excessive hydraulic drift of blade lift cylinder
40-6 7
Failure
Excessive hydraulic drift of blade lift cylinders.
Related information

Before performing troubleshooting, check that no oil leaks in the work equipment circuit.
Cause
2
Possible
causes and
standard value
for judgement
Defectively sealed blade lift

control valve (spool)
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.
Defectively sealed of blade

lift cylinder
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
4
valve
pressure.
3. If pump pressure is within the limit, cylinder piston valve is defective.
4. Disassemble the cylinder, and check piston valve.
Blade lever
Pump pressure
Raising stroke end
D375A-6R
(01)
Blade
Cannot move
24.5 MPa
{250 kg/cm2}
40-667

H-19 Excessive hydraulic drift of blade tilt cylinder
H-19 Excessive hydraulic drift of blade tilt cylinder
40-6 8
Failure
Hydraulic drift of tilted blade is large.
Related information
Check whether or not the blade is modified.

Before performing troubleshooting, check that no oil leaks in the work equipment circuit.
Cause
Defective seal of blade tilt

control valve (Spool)
Possible
causes and
standard value
for judgement
Defective seal of blade tilt

cylinder

a Prepare with the engine started, then stop the engine to performing troubleshooting.
Follow the troubleshooting procedure shown below. If the hydraulic
drift speed becomes higher, the sealing of the blade tilt valve spool
is defective.
1. Use the blade tilt cylinder to thrust the blade against the ground,
and raise the right of the machine.
3. Check the phenomenon when the blade control lever is operated to the right tilt.
Oil leak from cylinder
Right tilt stroke end
40-668
Blade tilt cylinder
12 cc/min
D375A-6R
(01)

H-20 Excessive hydraulic drift of ripper lift cylinder
H-20 Excessive hydraulic drift of ripper lift cylinder

Failure
Related information
Excessive hydraulic drift of ripper lift cylinders.

Before performing troubleshooting, check that no oil leaks the circuits in the work equipment before
troubleshooting.
Cause
Defectively sealed of ripper

lift control valve (spool)
Possible
causes and
standard value
for judgement
40-6 9
Defectively sealed of ripper

lift cylinder

a Prepare with the engine started, then stop the engine for troubleshooting.
Follow the troubleshooting procedure shown below. If the hydraulic
drift speed becomes higher, the sealing of the ripper lift (Hi) valve
spool is 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.
Oil leak from cylinder
LOWER stroke end
D375A-6R
(01)
12 cc/min
40-669

H-21 Ripper pin puller cylinder does not operate (machine with giant ripper)
H-21 Ripper pin puller cylinder does not operate (machine with giant
ripper)
Failure
The ripper pin puller cylinder does not operate.
Related information
40-670
Check that the transmission main relief pressure is normal before troubleshooting.
Cause
Possible
causes and
standard value
for judgment
Defective operation of pin

puller solenoid
a Prepare with starting switch at OFF position, then run the engine at high speed to perform troubleshooting
Pin puller operating
Pin puller switch
Measuring position
pressure
Internal defect of pin puller

cylinder
Defective fuse FS2-2 (20 A)
3
for pin puller
Push-in
Cylinder bottom side
Pull-in
2
40-670
Cylinder head side
Min. 2.2 MPa

{Min. 22 kg/cm2}
The pin puller cylinder is suspected to be defective internally.

Check it directly.
Check that the fuse is not blown.
Check wiring harness of related circuit.
D375A-6R
(01)

H-22 Blade pitch does not work (machine with dual tilt specification)
H-22 Blade pitch does not work (machine with dual tilt specification)
Trouble
The blade pitch does not work.
Related information
40-671
If either one failure code of [DW5AKA] or [DW5AKB] is displayed, failure diagnoses corresponding
to such code are to be performed first.
Cause
D375A-6R
(01)
Defective function of blade

pitch control valve (Spool)
Defective operation of blade Operation of the blade pitch cylinder may be defective. Check it
pitch cylinder
directly.
Possible
causes and
standard value
for judgment
Defective operation of blade Operation of the blade pitch selector valve may be defective.
pitch selector solenoid valve Check it directly .
Defective function of blade

pitch switch
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.
40-671

H-23 Abnormal noise from around work equipment pump

Failure
Abnormal noise from around work equipment pump.
Related information
40-672
Befor performing troubleshooting , check hydraulic oil lever is normal.

Cause
1 Inappropriate oil
Possible
causes and
standard value
for judgment
The oil may be inappropriate. Check it directly.
Clogged hydraulic tank

strainer
The strainer of the hydraulic tank may be clogged. Check it directly.
3 Air inhaled in suction circuit
Air may be inhaled in the suction circuit of the work machine pump.
Check the circuit directly.
40-672
Internal defect of work equipThe work equipment pump may be defective. Check it directly.
ment pump
D375A-6R
(01)

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

40-673
or engine overheats)
Failure
The fan speed is abnormal (excessive noise from or vibration of fan, or overheating).
Related information
Before performing troubleshooting, check that the hydraulic oil level tank is normal.
Cause

a Start engine to performing troubleshooting.
750 50 rpm
1 Defective engine speed
Engine speed
1,900 (0/-50) rpm
If engine speed does not increase to the specified level, perform

troubleshooting for "S-5 Engine dose not rotate smoothly(hunts)".
2
Defective PTO (fan pump

drive)
Possible
causes and
standard value
for judgement
3
Defect in fan pump or fan

motor
Fan pump drive of PTO may be defective. Check it directly.

Fan pump EPC circuit source
pressure
Min.3.1 MPa
{Min. 32 kg/cm2}
Fan drive circuit pressure
15.7 2.5 MPa

{160 25 kg/cm2}
Fan 100 % mode
Fan 100 % mode
4 Defective fan
Fan speed
Max. 1,110 rpm
The fan may be broken or installed defectively. Check itself directly.
Defective sensor for engine

water temperature, power
5
Any of these sensors may be defective. Check them directly.
train oil temperature, or
hydraulic oil temperature
D375A-6R
(01)
40-673
Troubleshooting of engine (S-mode)

Method of using troubleshooting chart

40-674
40-674
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.
40-674
D375A-6R
(01)

D375A-6R
(01)
40-675

40-676
<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".
40-676
D375A-6R
(01)

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-6R
(01)
40-677

S-1 Engine does not start easily
40-678
General causes that engine does not start easily
Q w w
Q Q
Q Q Q Q
w
Defective or deteriorated battery
Defective alternator (generator section)
Defective alternator (regulator section)
Defective intake air heater system
Defective injector
Clogged, seized injector
Clogged feed pump gauze filter
Clogged fuel filter, strainer
Leaking or clogged fuel piping or entry of air
Clogged air breather hole in fuel tank cap
E E
w
w w Q Q
w
w
w w
w
Q
w Q Q
w w
w
w
Q Q
w
q
Q w Q Q
q q
q
q
q
Replace
q
Replace
Replace
Replace
Replace
Replace
Clean
Replace,
Clean
Remedy
Correct
Inspect air cleaner directly

When compression pressure is measured, it is found to be low
Air is discharged when the air is bled from the fuel system
Check fuel filter or strainer.
Inspect feed pump gauze filter directly.
Carry out troubleshoot by "Rail Press Very Low Error (*1)"
Speed of some cylinders does not change when operated in reduced cylinder
mode
Intake air heater mounting portion does not warm up during preheating.
Yes
Does voltage (25 30 V) appear between alternator terminals B
and E with engine at low idle?
None
Specific gravity of electrolyte and voltage of battery are low.
Worn piston ring or cylinder
Clogged air cleaner element
Confirm recent repair history

Degree of use of
Operated for long period
machine
Became worse gradually
Starting performance
Engine starts easily when warm
Non-specified fuel is being used
Replacement of filters has not been carried out according to Operation and Maintenance Manual
Oil must be added more frequently
When engine is preheated or when temperature is low, preheating monitor does
not indicate normally
Charge monitor indicates abnormal charging during operation.
Dust indicator is red
Leaking from fuel piping
No response or heavy resistance felt when operating priming pump
Starting motor rotates engine slowly.
and air bleeding plug is removed from fuel filter, fuel does
When engine is
rotated with starting not flow out.
and spill hose is separated from injector, spill flow is small.
motor,
When exhaust manifold is touched immediately after starting engine, temperature
of some cylinders is low
Engine does not pick up smoothly , and combustion is irregular
There is hunting from engine (rotation is irregular)
Blow-by gas is excessive
Clean
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.
Defective contact of valve with valve seat
Replace
Electrical system is defective.

Insufficient supply of fuel
Insufficient intake of air
Improper selection of fuel
Replace
Clean
Cause
*1: Troubleshooting for failure codes [CA559] and [CA2249] described in "Troubleshooting by failure code
(Display of code)"
40-678
D375A-6R
(01)

S-2 Engine does not start
40-679
D375A-6R
(01)
Defective hydraulic pump or PTO
Defective wiring of starting circuit
Defective starting motor (motor section)
Replace
Replace
Correct
Perform troubleshooting for E-mode
Perform troubleshooting for H-mode
Replace
Defective starting motor (safety relay section)
w
w
Q w
Inspect flywheel ring gear directly

q
q
Voltage (20 30 V) does not appear between battery
relay terminal B and terminal E.
When terminal B and terminal C of starting switch are
Set starting switch to OFF connected, engine cranks.
position, connect the cord, When terminal B at safety relay outlet and terminal C
are connected, engine cranks.
then set starting switch to
ON position to perform troubleshooting
Even if terminals B and C at safety relay outlet are
connected, engine does not start.
Remedy
Q
Q
w
Replace
w
w
Replace
EE
Demaged flywheel ring gear

Degree of use of machine
Horn does not sound.
Condition of horn when
starting switch is turned ON Horn volume is slow.
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.
Speed of rotation is low.
When starting switch is
Grating noise is heard.
turned to START, starting
Soon pinion again.
pinion moves out, but
Ratting noise is heard and engine does not turn.
Replace
Troubleshooting
Check items
Questions
General causes that engine does not rotate

q Seized parts inside engine
o See "S-4 Engine stops during operations".
q Coolant leaking inside cylinder causes water hammer.
q Electrical system is defective.
q Defective hydraulic pump or PTO
Defective battery terminal connection
Cause
a) Engine does not crank
40-679

b) Engine rotates but no exhaust smoke comes out

(Fuel is not injected)
Remedy
E
wQ w w w
w
QQ
Q Q
wQ
w w w w
q q
q
q
Replace,
Clean
Clean
Replace
Replace
Replace
Replace
Correct
Replace
Inspect feed pump gauze filter directly
Inspect feed pump directly
Perform troubleshoot for "PCV1 Error (*2) or PCV2 Error" (*3)
Inspect overflow valve directly.

Seized or prematurely worn feed pump
Broken supply pump shaft key
Defective supply pump PCV
Wrong connection of supply pump PCV
Defective operation of overflow valve (does not close)
Improper fuel
Insufficient fuel in tank

Degree of use of
E E
machine
Exhaust smoke suddenly stopped coming out (when starting again).
Replacement of filters has not been carried out according to Operation and
w
Maintenance Manual
Fuel tank is found to be empty
w
Q w
Rust and water are detected when fuel tank is drained
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,
Q
Q
When engine is rotated fuel does not flow out.
and spill hose is separated from injector, spill
with starting motor,
Q
flow is small.
Replace
Add
Clean
Correct
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)
Clogging of fuel filter strainer
Cause
*1: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
*2: Troubleshooting by failure code (Display of code), Code [CA271] and Code [CA272]
*3: Troubleshooting by failure code (Display of code), Code [CA273] and Code [CA274]
40-680
D375A-6R
(01)

Clogged injection nozzle, or defective spray

Defective coolant temperature sensor or wiring harness
Defective intake air heater system
E
w
Q Q
w
w
w
w
w
w
w
q
q
Replace
Replace
Replace
Replace
Replace
q
Clean
Remedy
E E
Replace,
Clean

Degree of use of
E
machine
Engine suddenly failed to start.
w
Replacement of filters has not been carried out according to Operaw
tion and Maintenance Manual
w
When engine is preheated or when temperature is low, preheating
monitor does not indicate normally
w
w
When fuel filter is removed, no fuel is inside the fuel filter.
w
w
Starting motor rotates engine slowly.
When engine is rotated, abnormal sound is generated around cylinw
der head.
and air bleeding plug is removed from fuel filter,
When engine is
Q
fuel does not flow out.
rotated with startand spill hose is separated from injector, spill
ing motor,
flow is small.
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
q
Inspect valve system directly
q
q
q
Testing a single unit injector indicates defective spraying.
Coolant temperature gauge indication is not normal (if equipped the
gauge).
Intake air heater mounting portion does not warm up during preheating.
Clean
Replace
Replace
Replace
Clean
Correct
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
Cause
Worn valve system (valve, rocker lever, etc.)
Clogged breather, breather hose
Improper fuel
Leakage or clogging of fuel piping or air in the fuel system
c) Exhaust smoke comes out but engine does

not start (Fuel is injected)
D375A-6R
(01)
40-681

S-3 Engine does not rev up smoothly (response-up is poor)
S-3 Engine does not rev up smoothly (response-up is poor)

General causes why engine does not pick up
smoothly
w w
w
Q
w
w
w
w
Q
w Q
w w
q
Clogged injection nozzle, or defective spray
Defective operation of flow damper (excessive injector leakage)
Q Q
Seizure or interference at turbocharger
q
q
q
Replace
Replace
Replace
Clean
Replace,
Clean
Correct
q q
Clean
Remedy
Replace

Inspect valve clearance directly
When turbocharger is rotated by hand, it is found to be heavy
Speed of some cylinders does not change when operated in reduced cylinder
mode
EE
Replace

Degree of use of
machine
Engine pick-up suddenly became poor
Replacement of filters has not been carried out according to Operation & Maintenance Manual
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 sound is generated around cylinder head
When engine is cranked, abnormal noise is heard from around turbocharger
High idle speed under no load is normal, but speed suddenly drops when load is
applied
Clean
Troubleshooting
Check items
Questions
Improper valve clearance
Defective contact of valve, valve seat

Defective condition of fuel injection
Controller is controlling in derate mode
(limiting injection rate (output) because of
an error in electrical system)
Adjust
Cause
Replace
40-682
*1: Troubleshooting for failure codes [CA559] and [CAss49] described in "Troubleshooting by failure code
(Display of code)"
40-682
D375A-6R
(01)

S-4 Engine stops during operation
40-683
General causes why engine stops during operations
QwQ w
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Q QQ
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Q
Q
Q
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Engine operates if auxiliary equipment (pump, air compressor, etc.) is removed.
q
q
Replace
Replace
Replace
Replace
Add
Clean
Correct
Replace,
Clean
Clean
Replace
Replace
Replace
Remedy
Replace
Inspect controller power supply wiring

Check starting switch wiring
q
Correct
-

Inspect piston connecting rod.
Check crankshaft bearing directly
Inspect gear train directly
Inspect feed pump directly
E E

Degree of use of
machine
Abnormal noise was heard and engine
w www
stopped suddenly
Condition when
Engine overheated and stopped
wQ
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
Metal particles are found when oid pan is drained
www
Does not turn at all
ww
Turns in opposite direction
w
When engine is
cranked manually Moves by the amount of gear backlash
w
Supply pump shaft does not turn
Engine rotates, but stops when load is applied to machine
Correct
Troubleshooting
Check items
Questions

Broken or seized feed pump
Broken supply pump shaft key
Broken auxiliary equipment (pump or air
compressor, etc.)
Defective engine controller power supply
wiring
Trouble power train
Seized parts inside engine

Overheating
Trouble in power train
Damage of valve system (valve, rocker

lever, etc.)
Broken or seized piston connecting rod
Broken or seized crankshaft bearing
Broken or seized gear train
Clogged or leaking fuel piping
Cause
D375A-6R
(01)
40-683

S-5 Engine does not rotate smoothly (hunting)
40-684
General causes why engine does not rotate smoothly
Low setting of low idle speed

Defective operation of flow damper (excessive injector leakage)
Clogged injector nozzle, or defective spray (dirt in injector)
Defective Ne speed sensor, or wiring harness
Defective Bkup speed sensor, or wiring harness
Cause
Air in fuel system

Defective speed sensor (Error at degree that it is not indicated)

EE
Occurs at a certain speed range
Q
Q Q
Occurs at low idle
w
Q Q Q Q Q Q Q
Condition of hunting
Occurs even when speed is raised
Q
Q Q
Occurs on slopes
w
Q Q
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Maintenance Manual
w
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Q Q
Speed of some cylinders does not change when operated in reduced cylinder mode
Perform troubleshooting according to "Abnormality in engine Ne speed
sensor (*1)"
Perform troubleshooting according to "Abnormality in engine Bkup speed
sensor (*2)".
Remedy
q
q q
q
q
Correct
Add
Clean
Correct
Clean
Replace, Clean
Replace
Replace
Correct or replace
Correct or replace
Troubleshooting
Check items
Questions

*1: "Troubleshooting for failure code [CA689] described in "Troubleshooting by failure code (Display of code)"
*2: Troubleshooting for failure code [CA778] described in "Troubleshooting by failure code (Display of code)"
40-684
D375A-6R
(01)

S-6 Engine lacks power (or output shortage)
40-685
General causes why engine lacks output
Power was lost

Suddenly
Gradually

Maintenance Manual
Q Q
Q Q
QQ Q
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Air breather hole of fuel tank cap is clogged

Fuel is leaking from fuel piping
Output becomes insufficient after short stop of operation
w w w
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 turbocharger
w
w
When engine is cranked, abnormal sound is generated around cylinder head

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
Q
w wQ
Q Q
Q Q Q Q
q
q q q
Inspect air intake piping directly

When charge (boost) pressure is measured, the oil pressure is low
q
q

Carry out troubleshooting according to No-pressure feed by supply pump (*1)

When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change
Check the mount of charge (boost) pressure sensor directly
q
q q
q
Carry out troubleshoot by "Chg Air Press Sensor Error (*2)"

Carry out troubleshooting according to Abnormality in fuel temperature sensor
(*3)
Repair
Replace
Replace
Replace
Clean
Replace,
Clean
Repair
Clean
Replace
Adjust
Replace
Replace
Repair
q
Clean
Remedy
q
Replace
Replace
Check items
Troubleshooting
Defective fuel temperature sensor, wiring harness
Defective boost pressure sensor or defective wiring har-
Q Q Q
Q
Defective mounting of boost pressure sensor

(air leak)
Stuck or seized supply pump plunger
Clogged or leaking fuel piping
Clogged air breather hole of fuel tank cap
Defective contact of valve, valve seat
E E
Defective injector drive (signal or solenoid)
Questions
Degree of use
Clogged injector nozzle, or defective spray (dirt in injector)
Air leakage from air intake piping

There is overheating
o See the troubleshooting for "S-14 Coolant Temperature too High (Overheat)"
(limiting injection rate (output) because of an error in
electrical system)
q
q
q
q
q
Cause
D375A-6R
(01)
40-685

S-7 Exhaust smoke is black (Incomplete combustion)
40-686
General causes why exhaust smoke is black
Q
w
E
Q
Q
w
w
Q
w
Q
Clogged fuel spill piping (on cylinder head side)
Worn fuel injector
Dirt caught in injector
Crushed or clogged muffler
Leakage of air between turbocharger and cylinder head
Defective contact of valve with valve seat
E
Q Q
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Q Q
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Q
Q
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Q
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q
q
q
q
Replace
Correct
Replace
Replace
Replace
q
Replace
Remedy
Replace

When turbocharger is rotated by hand, it is found to be heavy.
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 troubleshoot by "Coolant Temp Sensor Error (*2)"
Adjust

Degree of use of machine Operated for long period
Suddenly became black
Gradually became black
Engien oil must be added more frequently.
Suddenly
Power was lost
Gradually
Muffler is crushed
Air leaks between turbocharger and cylinder head, clamp worked loose
Operates in low-temperature mode even at normal temperatures
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low
When engine is rotated, abnormal noise is heard from around cylinder head.
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 irregular
When hose from injector to spill collection portion is disconnected, spill flow is found to
be abnormally high
Correct
Troubleshooting
Check items
Questions
Replace

Excessive injection of fuel
There is overheating
o See the troubleshooting for "S-14 Coolant Temperature too High (Overheat)"
(limiting injection rate (output) because of an error in electrical system)
Clean
Replace
Cause
40-686
D375A-6R
(01)

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

Worn/damaged valve (stem, guide, seal)
Worn seal at turbine end
Turbocharger
Worn seal at blower end
Clogged breather or breather hose
Broken piston ring
Worn or damaged rear oil seal
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

E EE
E
Oil consumption suddenly increased
w
Q
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Q
Oil contaminates 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
Oil in coolant.
w
Oil level in damper chamber is high
w
Color of exhaust gas blue under light load
w w
Excessive
Q QQ
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Amount of blow-by gas
None
w
When intake manifold is removed, dust is found inside
When intake manifold is removed, inside is contaminated abnormally
Excessive play of turbocharger shaft
Check breather or breather hose.
Inspect rear oil seal directly.
Pressure-tightness test of oil cooler shows there is leakage
There is external leakage of oil from engine
Remedy
D375A-6R
(01)
q
q
qq
q q
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Correct
Replace
Replace
Replace
Clean
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
40-687
40-687

S-9 Engine oil becomes contaminated quickly

EEE
Q
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Even when engine oil temperature rises, oil filter clogging monitor indicates clogging
w Q
Metal particles are found when oil is drained from oil filter.
Q Q
Inside of exhaust pipe is dirty with oil
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Engine oil temperature rises quickly
w
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Black
Excessive
Q Q w
Amount of blow-by gas
None
w
40-688
(See S-7)
q
-
Clean
Replace
Replace
Clean
Replace
Replace
Remedy
q q
Replace
Excessive play of turbocharger shaft

Check breather or breather hose.
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 or breather hose
Worn valve or 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
40-68
D375A-6R
(01)

S-10 Fuel consumption is excessive
40-689
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
w w
q q
q
q
Correct
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)"
Replace
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
D375A-6R
(01)
40-689

S-11 Oil mixes into coolant(coolant blows back or is reduced)
S-11 Oil mixes into coolant(coolant blows back or is reduced)
Hard water is being used as coolant

Oil level has risen and oil is milky
There are excessive air bubbles in radiator, coolant spurts back
Power train oil is milky
E
Q Q
Q
Q Q
E
Q Q
Q
w
w
q q
Inspect cylinder block directly
q q
Check cylinder liner directly
Replace
Replace
Replace
Remedy
Replace
Pressure-tightness test of cylinder head shows there is leakage
When power train oil is drained, water is found
40-690
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
Replace
Questions
Check items
Troubleshooting
Oil level

Sudden overheated
Gradually occurred
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
40-690
D375A-6R
(01)

S-12 Engine pressure monitor lights up (drop in engine oil pressure)
S-12 Engine pressure monitor lights up (drop in engine oil pressure)

General causes that oil pressure drops
Troubleshooting
Check items
Questions
Leakage, clogging or wear of lubricating system

Defective hydralic control
Wrong oil selection (viscosity not appropriate)
Oil deteriorated byoverheating

Engine oil pressure monitor lights up.
Non-specified oil is used.
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
External lubrication piping is leaking or crushed.
Oil is cloudy white or smells of diesel oil.
Metal particles are found when oil is drained from oil pan.
Q
w
Q
w w w Q
Q
w
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w
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Metal particles are found in oil filter.
Inspect oil pan strainer and pipe.
Oil pump rotation is heavy or it has play.
Valve spring of oil pump relief valve is fatigued, damaged
Inspect oil filter directly.
Perform troubleshooting for "Eng Oil Press. Sensor Error"(*1)
Q
w
w
q
Remedy
E
Q w
Q
w
Q
See S - 13
Wear of metal journal

Lack of oil in oil pan
Coolant or fuel in oil
Clogged strainer inside oil pan
Clogged, broken pipe in oil pan
Defective oil pump
Defective oil pump relief valve
Clogged oil filter
Leaking, crushed, clogged oil piping
Defective oil pressure sensor and/or defective wiring harness
Cause
q q
Replace
Add
Clean
Clean
Replace
Replace
Replace
Replace
Replace
40-691
*1: Troubleshooting by failure code, Codes [CA135] and [CA141]
D375A-6R
(01)
40-691

S-13 Oil level rises (Coolant or fuel mixes into oil)
S-13 Oil level rises (Coolant or fuel mixes into oil)
40-692
General causes that oil level rises
Cause
Coolant mixing into oil (oil becomes clouded)

Fuel mixing into oil (smells diluted diesel fuel)
a If oil is in coolant, perform troubleshooting for "S-11 Oil mixes into coolant"(or
coolant spurts back or coolant level goes down)
Q
Q
w
w
q
Replace
Replace
Replace
q q
Replace
Replace
Defect inside supply pump
Defects in thermostat seat section
Broken oil cooler core/O-ring
Worn or damaged rear oil seal
Leakage of fuel inside head cover
Cracks inside cylinder block
Q Q
Replace
Remedy
Replace
Q
Q

Remove head cover and inspect directly
Inspect cylinder block and liner directly
Inspect rear oil seal directly.
Remove water pump and inspect directly.
Remove supply pump and inspect directly.
Inspect seals for auxiliaries directly.
40-692
Q
Q
E E
Correct

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 radiator cap is removed and engine is run at low idle, an abnormal number
of bubbles appears, or coolant spurts 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.
Replace
Troubleshooting
Check items
Questions
Defective seal of auxiliary equipment (pump, compressor)
D375A-6R
(01)

S-14 Coolant temperature rises too high (overheating)

General causes that coolant temperature becomes too high
q
q
q
q
Cause
Lack of cooling air (deformation or damage of fan)

Drop in heat dissipation efficiency
Defective coolant circulation system
Rise of power train oil temperature
Defective fan drive pump or fan motor

q
Inspect cylinder block and liner directly
q
Inspect oil cooler directly.
q
Temperature difference between upper and lower tanks of radiator is
large.
When function test is preformed on thermostat, it does not open even at
cracking temperature.
Temperature difference between upper and lower tanks of radiator is
slight.
Inspect radiator core directly.
When function test is preformed on the radiator cap, cracking pressure
is low.
When coolant temperature is measured, it is found to be normal.
Measured fan speed is low.
Remedy
D375A-6R
(01)
q
q
q
q
q
q
q


EE
EE
Sudden overheated
Q w
Q
Q
Condition of overheating
Engine tends to overheat.
Q w w
Q
Q
Coolant temperature rises quickly.
Q
w
Coolant temperature gauge Coolant temperature does not go down
w
below red range
Radiator coolant level monitor indicates low level
w
Engine oil level has risen, oil is cloudy white
w Q
Cloudy white oil is floating on coolant
w
There are excessive air bubbles in radiator, coolant spurts back
w
When light bulb is held behind radiator, no light passes.
w
Radiator shroud and inside of under cover are clogged with dirt or mud.
w
w
Coolant leaks from cracks in the radiator hose or clamps are loosened.
w
Coolant flows out from radiator overflow hose.
w
The power train oil temperature gauge reaches the red range faster
w
than the engine coolant temperature gauge.
Replace
Replace
Replace
Add
Replace
Replace
Correct
Correct
Replace
Correct
Replace
-
Troubleshooting
Check items
Questions

Lack of coolant
Lack of coolant
Broken water pump
Defective operation of thermostat
Clogged radiator core
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
40-693
40-693

S-15 Abnormal noise is heard
40-694
General causes that abnormal noise is heard
Defective coolant sensor (improper fuel injection timing)
Deformed fan
Deformed cooling fan, loose fan belt, interference of fan belt
Improper gear train backlash
Defec inside muffler (dividing board out of position)
Damage of valve system (valve or rocker lever)
w
w
Q
Q
w
w
w
w
w Q
Q
Q
w
q
When turbocharger is rotated by hand, it is found to be heavy.

When muffler is removed, abnormal noise disappears.
Inspect fan directly.
Speed of some cylinders does not change when operated in reduced
cylinder mode
Abnormal noise is heard only when engine is started.
Perform troubleshoot for "Coolant Temp Sensor Error (*1)".
w
Q Q
q q
q
q q
q
Replace
Replace
Replace
Correct
Replace
Replace
Replace
Adjust
q
Replace
Remedy
E
Q Q
Q Q
Replace

Gradually occurred
Abnormal noise
Sudden overheated
Leakage of air between turbocharger and cylinder head
When engine is rotated, abnormal noise is heard from around cylinder
head.
When engine is rotated, abnormal noise is heard from around muffler.
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
Black
Engine rev-up is poor and combustion is abnormal.
Abnormal noise is loud when engine is accelerated.
Replace
Troubleshooting
Check items
Questions
Replace
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.
q
Air leakage from piping between turbocharger and cylinder

head
Cause
*1: Troubleshooting for failure codes [CA144] and [CA145] described in "Troubleshooting by failure code (Display of code)"
40-694
D375A-6R
(01)

S-16 Vibration is excessive
40-695
General causes that vibration is excessive
Cause
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.

Vibration

Suddenly increased.
Gradually increased.

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.
Broken parts in damper
Wear of front support spigot joint
Loose engine mount bolts or broken cushions
Worn camshaft bushing
Misalignment between engine and torque converter
Q
Q Q
Q
Q
w
w
Q
Q
Q
Q
Q Q Q Q
D375A-6R
(01)
q
Replace
Adjust
Replace
Replace
Replace
Remedy
Replace
Q
Q
w
w
Q
EE

Check main bearing and connecting rod bearing.
Inspect camshaft bushing directly.
Check engine mounting bolts and cushions.
When face runout and radial runout are inspected, they are found to be incorrect.
Inspect front support portion directly.
Inspect inside of damper directly.
Replace
Exhaust smoke is black.
Replace
Troubleshooting
Check items
Questions
Stuck valve system (valve, rocker arm)
Wear of main bearing and connecting rod bearing
40-695

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)
40-696
General causes why that cannot be bled
q
q
Troubleshooting
Check items
Questions
Lack of fuel
Improper setting of air bleeding valve (closed)
Improper setting of fuel valve (closed)
Clogged fuel tank breather hole
Clogged air bleeding pipe
Malfunction of electric priming pump
Malfunction of electric priming pump switch
Defective wiring harness of electric priming pump
Clogged water separator screen
Clogged fuel filter
Low battery charge level
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.
Check recent repair history

Degree of use of macine
EE
Q Q
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 piping 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
40-696
q
q
q
q
q
q
q
q q
Add
Correct
Correct
Correct
Correct
Correct
Replace
Replace
Replace
Clean
Replace
Charge
Cause
D375A-6R
(01)

Note 1: Check of air bleeding piping for clogging

q Remove joint bolt (1) and blow clean compressed air into hole (a) of the orifice to check for clogging.
q Remove both ends of air bleeding pipes (2) and (3), and blow compressed air to check for clogging.
D375A-6R
(01)
40-697

40-698
D375A-6R
(01)
50-1
BULLDOZER
D375A-6R
Shop Manual
Machine model
Serial number
D375A-6R
50-1
65001 and up
50 Disassembly and assembly 50-1
D375A-6R
(01)
50-1
Contents
Contents
50-2
50 Disassembly and assembly

General information on disassembly and assembly ............................................................... 50- 4
How to read this manual ...................................................................................................... 50- 4
Coating materials list............................................................................................................ 50- 6
Special tool list ..................................................................................................................... 50- 9
Sketches of special tools ..................................................................................................... 50- 17
Engine and cooling system ..................................................................................................... 50- 25
Removal and installation of fuel supply pump assembly ..................................................... 50- 25
Removal and installation of fuel injector assembly .............................................................. 50- 30
Removal and installation of cylinder head assembly ........................................................... 50- 35
Removal and installation of radiator guard assembly .......................................................... 50- 50
Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler)50- 55
Removal and installation of radiator..................................................................................... 50- 60
Removal and installation of hydraulic oil cooler ................................................................... 50- 62
Removal and installation of aftercooler................................................................................ 50- 63
Removal and installation of engine assembly...................................................................... 50- 64
Removal and installation of engine hood assembly............................................................. 50- 71
Removal and installation of engine front seal ...................................................................... 50- 74
Removal and installation of engine rear seal ....................................................................... 50- 76
Removal and installation of fan drive assembly................................................................... 50- 80
Removal and installation of fan motor assembly ................................................................. 50- 82
Removal and installation of fuel tank assembly ................................................................... 50- 84
Power train.............................................................................................................................. 50- 86
Removal and installation of damper assembly .................................................................... 50- 86
Disassembly and assembly of damper assembly ................................................................ 50- 90
Removal and installation of power train unit assembly ........................................................ 50- 93
Disconnection and connection of power train unit assembly ............................................... 50- 99
Disassembly and assembly of PTO assembly..................................................................... 50- 108
Disassembly and assembly of torque converter assembly .................................................. 50- 114
Disassembly and assembly of TORQFLOW transmission assembly .................................. 50- 123
Disassembly and assembly of steering case assembly....................................................... 50- 150
Removal and installation of power train pump and lubrication pump assembly .................. 50- 166
Removal and installation of scavenging pump assembly .................................................... 50- 167
Removal and installation of final drive assembly ................................................................. 50- 168
Disassembly and assembly of final drive assembly............................................................. 50- 170
Undercarriage and frame ........................................................................................................ 50- 183
Removal and installation of track frame assembly............................................................... 50- 183
Removal and installation of idler assembly.......................................................................... 50- 188
Disassembly and assembly of idler assembly ..................................................................... 50- 189
Removal and installation of recoil spring assembly ............................................................. 50- 193
Disassembly and assembly of recoil spring assembly......................................................... 50- 198
Removal and installation of track roller assembly................................................................ 50- 200
Disassembly and assembly of track roller assembly ........................................................... 50- 203
Removal and installation of carrier roller assembly ............................................................. 50- 206
Disassembly and assembly of carrier roller assembly ......................................................... 50- 207
Removal and installation of bogie assembly........................................................................ 50- 211
Disassembly and assembly of bogie assembly ................................................................... 50- 216
Removal and installation of first bogie assembly ................................................................. 50- 218
Separation and connection of track shoe assembly ............................................................ 50- 223
Overall disassembly and assembly of track shoe ................................................................ 50- 227
Link press press-fitting jig dimensions ................................................................................. 50- 244
50-2
D375A-6R
(01)
Contents
Disassembly and assembly of one link assembly in the field .............................................. 50- 245
Disassembly and assembly of master link........................................................................... 50- 250
Removal and installation of pivot shaft assembly ................................................................ 50- 254
Removal and installation of equalizer bar............................................................................ 50- 255
Disassembly and assembly of equalizer bar bushing.......................................................... 50- 259
Removal and installation of segment tooth.......................................................................... 50- 261
Hydraulic system .................................................................................................................... 50- 262
Removal and installation of hydraulic tank assembly .......................................................... 50- 262
Removal and installation of work equipment pump assembly ............................................. 50- 265
Removal and installation of fan pump assembly ................................................................. 50- 269
Removal and installation of control valve assembly ............................................................ 50- 271
Disassembly and assembly of control valve assembly........................................................ 50- 273
Disassembly and assembly of blade PPC valve assembly ................................................. 50- 278
Disassembly and assembly of ripper PPC valve assembly ................................................. 50- 281
Disassembly and assembly of hydraulic cylinder assembly ................................................ 50- 283
Disassembly and assembly of ripper pin puller cylinder assembly ...................................... 50- 291
Work equipment...................................................................................................................... 50- 294
Removal and installation of blade assembly........................................................................ 50- 294
Disassembly and assembly of blade assembly ................................................................... 50- 296
Disassembly and assembly of giant ripper assembly .......................................................... 50- 300
Cab and its attachments ......................................................................................................... 50- 303
Removal and installation of ROPS guard ............................................................................ 50- 303
Removal and installation of operator's cab assembly.......................................................... 50- 304
Removal and installation of floor frame assembly ............................................................... 50- 308
Removal and installation of air conditioner unit assembly ................................................... 50- 313
Electrical system ..................................................................................................................... 50- 319
Removal and installation of transmission controller assembly and steering controller assembly50-319
Removal and installation of engine controller assembly...................................................... 50- 320
Removal and installation of VHMS controller assembly ...................................................... 50- 322
Removal and installation of machine monitor assembly...................................................... 50- 323
D375A-6R
(01)
50-3
General information on disassembly and assembly

How to read this manual

1. Removal and installation of assemblies

Special tools
50-4
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 In the special tools table, the follwing information
is described, as well as the above items.
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) New/redesign
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 Tools with part number 79*T-***-****
means that they are not available from
Komatsu Ltd. (i.e. tools to be made locally).
50-4
50-4
50-4
50-4
50-4
Connection
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] which corresponds
to the mark in "Removal" section).
q General purpose tools that are necessary for removal 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 : Know-how or precautions for work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished
50-4
Sketches of special tools
Various special tools are illustrated for the local
manufacture.
D375A-6R
(01)

2. Disassembly and assembly of assemblies

Special tools
50-5
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 In the special tools table, the follwing information
is described, as well as the above items.
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) New/redesign
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).
D375A-6R
(01)
50-5
50-5
Assembly
q In "Assembly" section, the work procedures, precautions and know-how to do the work, and the
amount of 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
a : Know-how or precautions for work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished
50-5
Various special tools are illustrated for the local
manufacture.
50-5

Coating materials list
50-6
(Rev. 2009. 02)

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.
Cate
Komatsu code
gory
Part No.
Capacity
Container
LT-1A
790-129-9030
150 g
Tube
LT-1B
20 g
Polyethyl790-129-9050
(2 pcs.
ene concontained )
tainer
LT-2
Adhesive
LT-3
790-129-9040
50 g
Adhesive:
790-129-9060
1 kg
(Set of adhesive
Hardener:
and hardener)
500 g
Polyethylene container
Main features and applications

q
q
Features: Resistance to heat and chemicals.

Use to fix and seal bolts and plugs.
Can
Use to bond and seal metal, glass and plastics.
LT-4
790-129-9040
250 g
Use to seal plugs for blank holes
Holtz
MH 705
790-129-9120
75 g
Tube
Heat-resistant seal used to repair engines.
50 g
2g
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.
50 cc
1 kg
ThreeBond
1735
Aron-alpha 201
Loctite 648-50
LG-5
790-129-9140
790-129-9130
79A-129-9110
790-129-9080
q
q
q
q
q
q
q
q
q
q
Liquid gasket
LG-6
790-129-9160
200 g
Tube
LG-7
790-129-9170
1 kg
Tube
419-15-18131
100 g
Tube
q
q
q
q
LG-9
ThreeBond
1206D
Liquid gasket
q
q
LG-8
ThreeBond
1207B
790-129-9310
LG-10
ThreeBond
1206E
790-129-9320
200 g
Tube
q
q
200 g
Tube
q
q
LG-11
790-129-9330
ThreeBond 1121
200 g
Tube
ThreeBond 1211 790-129-9090
50-6
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.
100 g
Tube
Features: Resistance to heat and chemicals.

Used for fitted portions used at high temperatures.
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.
To be used to seal threaded portions on flange
surface
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.
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.
Liquid gasket used to repair engine.
D375A-6R
(01)

Seizure
Molybdenum disulphide
prevention compound
lubricant
Cate
Komatsu code
gory
Part No.
Capacity
Container

q
LM-P
09940-00040
200 g
Tube
q
q
q
09995-00250
190 g
Can
q
LC-G
NEVER-SEEZ
G2-LI
G0-LI (*)
*: For cold district
Can
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYGA-160CNLI
SYG0-400LI-A
(*)
SYG0-160CNLI
(*)
Various
Various
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.
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.
Hyper White
G2-T,
G0-T (*)
*: For cold district
SYG2-400T-A
SYG0-400T-A
(*)
(*)
SYG0-16CNT
(*)
400 g
16 kg
Biogrease
G2-B
G2-BT (*)
*: For use at
high temperature and under
high load
Grease
SYG2-400M
SYG2-400M-A
SYGA-16CNM
SYG2-400B
SYG2-400BT
(*)
(*)
SYGA-16CNBT
(*)
400 g
16 kg
400 g x 10
400 g x 20
16 kg
Feature: Lithium grease with extreme pressure lubrication performance, general purpose type.
Molybdenum
disulphide
grease
LM-G (G2-M)
Used 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 disulphide
grease.
Not conspicuous on machine since color is white.
Bellows-type
container
Can
Bellows-type
container
Can
Bellows-type
container
Can
200 g
Since this grease is biodegradable in short period,

it has less impact on microorganisms, animals,
and plants.
G2-S
ThreeBond
1855
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.
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.
Tube
q
Grease
G2-U-S
ENS grease
D375A-6R
(01)
427-12-11871
2 kg
Can
q
50-7

SUNSTAR
PAINT PRIMER
435-95
20 ml
Adhesive
Glass container
20 ml
Glass container
20 ml
Glass container

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)
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)
417-926-3910
22M-54-27230
150 ml
Can
20 ml
SUNSTAR PENGUINE
SEAL580
417-926-3910
SUPER S" or
W"
320 ml
Sika Japan,
Sikaflex 256HV
310 ml
Glass container
SUNSTAR
SASH PRIMER
GP-402
Caulking material
Container
q
SUNSTAR
GLASS
22M-54-27240
PRIMER 435-41
50-8
Capacity
22M-54-27250
20Y-54-39850
SUNSTAR PENGUINE SUPER 22M-54-27210

560
SUNSTAR PENGUINE SEAL
417-926-3920
No. 2505
SEKISUI SILICONE SEAL20Y-54-55130
ANT
GE TOSHIBA
SILICONES
TOSSEAL381
320 ml
320 ml
333 ml
Ecocart
(Special
container)
For adhered window glass
Primer
SUNSTAR
PAINT
PRIMER580
SUPER
SUNSTAR
GLASS
PRIMER 580
SUPER
Part No.
For adhered window glass
Cate
Komatsu code
gory
22M-54-27220
333 ml
Cartridge
D375A-6R
(01)

Special tool list
Special tool list
50-9
Part name
795-799-5410
795-799-5420
795T-675-1110
Adapter
Remover
Socket
795-931-1100
Seal puller assembly
01050-32235
01050-32245
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
4
Engine assembly
Bracket
750-501-5000
Repair stand (100 V)
791-615-1130
Push tool
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
Ring assembly
Ring
q Bolt
q Nut
q Washer
Ring assembly
q Ring
q Bolt
q Nut
q Washer
1
1
1
1
2
1
1
1
1
2
799-301-1600
Oil leak checker
795T-621-1171
795-902-1460
01582-02218
795T-621-1161
5
6
7
Torque converter valve
assembly
C
1
2
TORQFLOW
transmission
assembly
D375A-6R
(01)
795T-621-1190
Nature of work, remarks
t 1
Removal and installation of
t 1
fuel injector assembly
q 1 N Q
t 1
engine front seal and rear
seal
Push tool
(For oil seal)
Push tool
(For dust seal)
Bolt
Nut
Push tool
(for standard seal and
sleeved seal)
Push tool
(for sleeved seal)
Bolt
Bolt
795T-621-1180
Sketch
Part No.
New/redesign
Symbol
Quantity
Device
Necessity
a Tools with part number 79*T-***-**** means that they are not available from Komatsu Ltd. (i.e. tools to be
made locally).
a Necessity:
t. . . . . . Cannot be substituted, must always be installed (used).
q. . . . . . Extremely useful if available or, can be substitutable with commercially available part.
a New/redesign:
N: . . . . . . Tools with new part numbers, newly developed for this model.
R: . . . . . . Tools with upgraded part numbers, remodeled from items already available for other models.
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 1
t 1
t 3
t 3

engine front seal
t 1
t 1
Q engine rear seal
t 6
t 6
1
1
1
1
Tightening of cylinder head

bolt
radiator guard assembly
Disassembly and assembly
of torque converter assembly
of TORQFLOW transmission assembly
snap ring
Installation of No.3 ring gear
Installation of No.1 ring gear

Checking actuation of piston
50-9
1
2
3
Final drive
assembly
4
J
5
6
7
8
1
Idler assembly
L
2
3
4
1
Recoil spring
assembly
M
2
Track frame
assembly
13
L
24
50-10
790-337-1001
Lifting tool
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
195-30-66611
01010-62490
01010-62455
01643-32460
19M-54-11770
198-30-66190
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
Grip
Bolt
Bolt
Washer
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
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
3
5
5
5
5
5
791-685-1320
Lifting tool
Part No.
Part name
Sketch
Quantity
Symbol
New/redesign
Device
Necessity

Special tool list

final drive assembly
Separation of sprocket hub
assembly and bearing
Press-fitting of bearing
(sprocket hub assembly)
N
Installation of floating seal

Disassembly of hub shaft
assembly
Press-fitting of bearing (hub
shaft assembly)
planetary gear shaft
Installation of gear assembly
Press fit of bushing

Press fitting of seal guide
Supplying oil
Removal of pin

of recoil spring assembly
N
Secure bogie assembly
(For 7 track roller)
N
N
track frame assembly
D375A-6R
(01)
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
5
5
5
5
5
5
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
791T-630-2290
Guide
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
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
1
1
5
5
5
5
5
5
2
2
2
4
2
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
7
8
1
2
3
Bogie assembly L 16
4
5
6
22
23
D375A-6R
(01)
Part No.
Part name
Sketch
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
New/redesign
Quantity
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
17
Device
Necessity

Special tool list
Q Press fit of bushing

Q Press fitting of seal guide

Supplying oil
Lifting of track roller assembly

N
N
Fixing of bogie assembly
N
N
N
N
Carrier roller assembly
Removal of shaft and ring
Press-fitting of pin assembly
Alignment of track frame

and bogie pin holes
Supplying oil
N
N
N
N
Fixing of bogie assembly
N
N
50-11
1
1
3
3
3
1
1
1
1
1
1
2
2
1
1
1
3
3
3
1
1
791T-630-2290
Guide
791-646-7900
791-701-3000
or 791-601-1000
791-932-1110
791-632-1021
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)
Seal checker
Oil pump
Push tool
(For small plug)
Installer
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
040-11628
01643-31645
01643-31232
01582-01210
791-646-7351
791-660-7460
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
21
Track shoe
assembly
50-12
Part No.
Part name
Sketch
Quantity
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
New/redesign
Plate
Spacer
Screw
Nut
Washer
Puller (490kN {50 ton})
Pump
Adapter
Spacer
Plate
Screw
Nut
Washer
Pump
Plate
Screw
Nut
Washer
Pump
18
19
1
2
20
3
4
No. 1 bogie
assembly
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
17
Device
Necessity

Special tool list
Removal of shaft and ring
Press-fitting of pin assembly
Alignment of track frame

and bogie pin holes
Supplying oil
1
1
1 N
Setting bogie to installed
1 N
2
position
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
t
Drive-in of large plug
Filling with oil
Drive-in of small plug
Installation of seal assembly
D375A-6R
(01)
Track shoe
assembly
1
2
3
4
5
8 6
7
8
9
10
11
1
2
3
4
5
9 6
7
8
9
10
11
1
10 2
3
R
1
2
3
4
5
6
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
791-631-1210
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
1 791-632-1100
2
3
4
5
6
7
7
8
9
10
11
12
13
14
15
D375A-6R
(01)
791-632-1130
790-434-1610
01010-51440
791-685-9510
791-685-9520
791-685-9520
791-685-9550
040-12030
791-685-9560
791-126-0150
791-685-9540
791-632-1140
791-680-5520
01010-51030
Part name
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
Push tool assembly
q 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
t
t
1 N
1
1
1
1
1
1
1
1
1
1
1 N
1
1
1
1
1
1
1
1
1
1
2 N
1
1
1
1
1
Push tool (for small plug)

t
Installer
t
Remover & installer assemt
bly
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
Sketch
Part No.
New/redesign
Symbol
Quantity
Device
Necessity

Special tool list
1
1
Seal checker
Oil pump
Assembly of link
1
1
1
2
1
1
1
3
1
4
1
1
1
1
1

of one link assembly in field
50-13
16
17
18
19
20
21
22
7
23
24
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
25 790-101-4300
26
27
28
1
2
3
790 - 101 - 1102

790-101-4200
791-680-1630
791-646-7351
791-660-7460
791-646-7900
791-701-3000
or 791-601-1000
5
6
Track shoe
assembly
791-932-1110
791-632-1021
1 791-632-1100
2
3
4
5
6
7
8
9
10
11
12
7 13
14
15
16
17
18
19
20
21
22
23
24
791-632-1130
790-434-1610
01010-51440
791-685-9510
791-685-90
791-685-9520
791-685-9550
040-12030
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
25 790-101-4300
50-14
Part name
Pusher
Extension
q Adapter
q Adapter
q Guide
q Guide
q Adapter
q Guide
Bolt
Cylinder (1,470 kN {150
ton})
Pump
Spacer
Push tool
Pin brush
Push tool (for large plug)
Seal checker
1
1
1
1
1
1
1
1
1
q
q

of one link assembly in field
t 1
t 1
t 1 N
t 1
t 1
t 1
t
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})
Sketch
Part No.
Quantity
Symbol
New/redesign
Device
Necessity

Special tool list
t
t
1
1
1
1
1
2
1
1
1
3
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
2

of master link
D375A-6R
(01)
Track shoe
assembly
Pivot shaft
assembly
Equalizer bar
Equalizer bar
bushing
D375A-6R
(01)
26
7 27
28
1
2
3
4
5
8 6
7
8
9
10
11
R
1
2
3
4
5
9 6
7
8
9
10
11
1
10 2
3
1
2
3
4
P
5
6
7
8
9
N 2
1
2
3
4
5
6
7
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
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
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
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
t
t
t
t
1
1
1
1
1
1
1
1
1
1
1
1
1
1
t 1
1
1
1
1
1
1
1
1
1
1
t 2
1
1
t 1
t 1
t 2
t 1
t 2
t 2
t 2
t 1
t 1
q 1
1
1
1
1
q 1
q 1
t 1
t 1
t 1
t 2
t 2
t 1
t 1
Sketch
Part No.
New/redesign
Symbol
Quantity
Device
Necessity

Special tool list

of master link
N
N Q
N Q
pivot shaft assembly

equalizer bar assembly
N Q
N Q
of equalizer bar bushing
50-15
Hydraulic cylinder assembly
3
U
4
6
1
2
Ripper pin puller
cylinder assem- U
bly
3
4
5
7
50-16
Part name
790-502-1003
Cylinder
Repair stand
q 1
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
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
t
t
t
t
t
t
t
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
790-102-4310
Pin
790-502-1003
Cylinder
Repair stand
q 1
790-201-1702
790-201-1721
790-101-5021
01010-50816
790-201-1500
790-201-10
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
t
t
t
1
1
1
1
1
1
1
1
1
1
1
1
Sketch
Part No.
Quantity
Symbol
New/redesign
Device
Necessity

Special tool list

of hydraulic cylinder assembly
Press fitting of seal
Installation of piston ring

of 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
D375A-6R
(01)

50-17
Caution: Komatsu will not accept any responsibility for any special tools manufactured according to these
sketches.
50-17
A2 socket
A4 Push tool (For oil seal)
D375A-6R
(01)
50-17
50-17

A4 push tool (For dust seal)
50-18
A5 push tool (For both standard and sleeved seal)
50-18
50-18
D375A-6R
(01)

A5 push tool (For sleeved seal)
50-19
L1 Plate
50-19
D375A-6R
(01)
50-19

L8 Plate
50-20
L10 Push tool
50-20
50-20
D375A-6R
(01)

L17 Guide
50-21
L21 Lifting tool
50-21
D375A-6R
(01)
50-21

L21 Tube
50-2
L21 Plate
50-2
50-22
D375A-6R
(01)

P1 Sleeve
50-23
P2 Plate
50-23
D375A-6R
(01)
50-23

N2-1 Bracket
50-24
N2-2 Bracket
50-24
50-24
D375A-6R
(01)

Removal and installation of fuel supply pump assembly
50-25
50-25
Removal
50-25
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.
1. Close the fuel valve under the fuel tank.
2. Open the left side cover and remove lower side
cover (1).
3. Remove mounting bolt (4-2), and disconnect

clamp of breather tube (4-1).
Portion Y
4. Disconnect breather hose (4-3) in the same way.

5. Remove mounting bolts (4-4), and lift breather
assembly slightly to remove.
6. Remove wiring covers (5-1) - (5-3).
a The washer falls off as the rear side bolt is removed. Thus, reasonable care is needed in
this operation.
a Carefully remove cover (5-3).
Cover (5-3) is made of plastic. Avoid applying
a large force but lift it off gradually to prevent
cracks at (B).
a An O-ring instead of a gasket is installed at
the breather mounting portion.
D375A-6R
(01)
50-25

13. Disconnect connector (15).

LEFT: PCV2, RIGHT: PCV1
7. Remove bracket (6).

a 5 mounting bolts
14. Disconnect connector G (16).

15. Disconnect connector INJ (17).
16. Remove tube (18).
a Before removing the tube, clean the area
around carefully so that inside of the supply
pump and common rail may not be contaminated by foreign substances.
17. Disconnect clamp (19).
8. Disconnect connector PFUEL (7)

11. Remove clamps (10) - (12).

12. Remove covers (13) and (14).
50-26
D375A-6R
(01)

18. Remove the fuel pre-filter.

a The fuel pre-filter may be removed first.
21. Remove the bracket (16) mounting bolts and oil

pipings (17), then remove the fuel supply pump
assembly (18).
19. Remove tubes (11), (12), (13), and (14).

[*1]
22. Remove the following parts from fuel supply

pump assembly (18).
1) Oil tube (19)
2) Plate (20)
3) Overflow valve (21)
20. Disconnect G sensor connector (15) on the

opposite side of the supply pump.
D375A-6R
(01)
50-27

50-28
Connection
1. Install the following parts to fuel supply pump
assembly (18).
1) Plate (20)
2) Oil tube (19)
a Replace gaskets (GA) and (G10) with
new ones.
q GA: Accessories of supply pump
q G10: Part No. (07005-01012)
3) Overflow valve (21)
3 Plate (20) mounting bolt:
19.6 29.4 Nm {2.0 3.0 kgm}
3 Oil tube (19) joint bolt
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):
14.819.6 Nm {1.511.99 kgm}
3. Install fuel supply pump assembly (18) and lower

bracket (17).
3 Fuel supply pump mounting bolt:
5974 Nm {67.5 kgm}
3 Lower bracket (17) mounting bolt:
5974 Nm {6.07.5 kgm}
4. Install oil tube (22).
a Replace 4 gaskets (G) with new ones.
(Part No.: 07005-01012)
3 Oil tube (22) joint bolt:
9.812.7 Nm {1.01.3 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 set the fuel supply pump assembly.
50-28
D375A-6R
(01)

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 Taper seal (a) at connecting part: Check
for visible lengthwise slits (b) and dents
(c) at area within 2 mm from the end.
q Make sure that there are no deformation
or wear which your fingernail can feel on
the portion (d) (end of taper seal: portion
at 2 mm from the tip). (Namely, this portion must be free from fatigue.)
Carry out the subsequent installation in the reverse order to removal.
[*1]
5. Connect G sensor connector (15).

q
6. Tighten high-pressure pipes (7) lightly.

7. Tighten clamps (8) - (10) lightly.
Tube (12)
Joint bolt (Supply pump side):
14.819.6 Nm {1.511.99 kgm}
Sleeve nut:
4347 Nm {4.44.8 kgm}
Tube (13)
Joint bolt (Overflow valve):
14.819.6 Nm {1.511.99 kgm}
24.534.3 Nm {2.53.5 kgm}
Sleeve nut (Fuel block side):
2427 Nm {2.42.7 kgm}
Tube (14)
14.819.6 Nm {1.511.99 kgm}
Sleeve nut:
4347 Nm {4.44.8 kgm}
Check that each high-pressure pipe and wiring harness are at least 10 mm apart from
each other.If not, secure the clearance by repositioning the wiring harness.
Air bleeding
Bleed air from the fuel circuit. For detail, see
Testing and adjusting, "Bleeding air from fuel
circuit".
8. Tighten high-pressure pipe (7) to the specified

torque.
3 High-pressure pipe sleeve nut:
39.244.1 Nm {4.04.5 kgm}
9. Tighten clamps (8) - (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 downward.
D375A-6R
(01)
50-29

Removal and installation of fuel injector assembly
Part No.
795-799-5410
795-799-5420
2 795T-675-1110
Part name
Adapter
Remover
Socket
Quantity
N/R
Sketch
Symbol
50-30
Necessity
Special tools
50-30
35. Disconnect high-pressure pipe clamps (7) and

(8).
a A clamp is provided on the fuel supply pump
side.
t 1
t 1
q 1 N Q
Removal
50-30
1. Perform steps 1 to 31 of Removal and installation of cylimder head assembly. (See "Removal
and installation of cylinder head assembly")
36. Remove clamp (9).
32. Disconnect high-pressure pipe clamps (1) to (3).
33. Remove tubes (4) and (5).

[*1]
50-30
D375A-6R
(01)

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-6R
(01)
50-31

50-32
Connection
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 (24) and O-rings (25) and (26)

to fuel injector (22).
a Take care not to fit O-ring (25) to center
groove (A).
2) Fit fuel injector (22) to adapter (27) and
injector holder (21).
3) Tighten bolt (29) with spherical washer (30)
to fix injector holder (31) lightly.
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 partially.
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.
50-32
D375A-6R
(01)

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:
39.244.1 Nm {44.5 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.
No. 1, 3, 4, 5, and 6 cylinders:
9.8 1.0 Nm {1.0 0.1 kgm}
No. 2 cylinder:
5974 Nm {67.5 kgm}
1) Install O-ring (32) to high-pressure pipe(13)

sleeve (31).
2 O-ring:
Engine oil (EO30)
2) Tighten sleeve nut (12) partially aligning it
with connector (28) of the injector.
a If sleeve nut (12) does not catch the
threads, press the end of sleeve nut (12)
with a small rod, etc. toward the injector
and turn the spanner.
3) Tighten sleeve nut (11) on the common rail
side partially, too.
4) Tighten injector holder (21) to the specified
torque.
3 Injector holder mounting bolt:
5974 Nm {6.07.5 kgm}
D375A-6R
(01)
50-33

4. High-pressure pipe clamp

1) Install the clamps on the high-pressure pipes
1] Finger-tighten seventeen 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 side clamp
bolt:
11.814.7 Nm {1.21.5 kgm}
5] Install covers (10) on the common rail
side sleeve nuts.
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.
Bleeding air
circuit".
[*1]
3
3
Tube (4) joint bolt:

7.89.8 Nm {0.81.0 kgm}
Tube (5) sleeve nut:
2427 Nm {2.42.7 kgm}
Joint bolt:
24.534.3 Nm {2.53.5 kgm}
a Refer to the precautions in "Installation of cylinder head" for the installation.
50-34
D375A-6R
(01)

Removal and installation of cylinder head assembly
795-799-5410
1
795-799-5420
A
2 795T-675-1110
6 790-331-1120
Adapter
Remover
Socket
Wrench (angle)
Sketch
Part name
Quantity
Part No.
New/Remodel
Sym
bol
50-35
Necessity
Special tools
t 1
t 1
q 1 N Q
q 1
Removal
50-35
k You should disconnect the heater hose or
drain the engene coolant after the engine
coolant temperature goes down as you may
be scalded if you do the works while the engine coolant in the radiator is hot.
1. Drain the coolant.
6 Coolant:
4. Loosen the clamp and disconnect boost tube (2).

5. Disconnect exhaust temperature sensor wiring
(3).
6. Remove front heat insulation cover (4), center
heat insulation cover (5), and rear heat insulation cover (6).
7. Disconnect the muffler drain tube.
8. Sling and remove muffler (7).
4 Muffler assembly:
95 kg
9. Remove muffler mounting bracket (8).
120 l
2. Remove the engine hood assembly. For details,

see "Removal and installation of engine hood
assembly".
3. Remove right and left lower side covers (1).
4 Left lower side cover:
40 kg
Right lower side cover:
50 kg
D375A-6R
(01)
50-35
10. Disconnect fuel hoses (9) and (11).

[*1]
11. Disconnect tube (10).
[*2]
12. Remove fuel pre-filter assembly (12).
50-35

13. Remove fuel tube clamps (17).

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).
20. Remove each tube of the turbocharger.

[*4]
q
q
q
q
Lubrication tube (28)

Lubrication drain tube (29)
Coolant tube (30)
Coolant drain tube (31)
18. Sling and remove engine oil filter assembly (23).
19. Disconnect wiring harnesses (24).

50-36
D375A-6R
(01)

21. Disconnect connector V30 (31-1) and V29

(31-2).
25. Disconnect connector PFUEL (36)

26. Remove common rail cover (37).
22. Sling and remove turbocharger and exhaust

manifold assembly (32).
[*5]
4 Turbocharger and exhaust mainfold
assembly:
120 kg
23. Remove breather and tube assembly (33).

24. Remove harness covers (34) and (35).
27. Disconnect six injector connectors (38).

28. Disconnect connector CN6 (39).
29. Remove harness bracket (40).
30. Disconnect high-pressure pipe clamps (41) (43).

31. Remove tubes (44) - (46).
[*6]
32. Remove brackets (47) and (48).
D375A-6R
(01)
50-37

33. Disconnect high-pressure pipe clamps (49) and

(50).
34. Remove fuel tube (51).
[*7]
42. Disconnect wiring harness clamp (59) from rear

side of the fuel supply pump.
43. Disconnect the connector from the bottom of
clamp (59).
37. Loosen clamps (55) and (56).
38. Remove high-pressure tube assembly (57).
a Before removal, thoroughly wash the area to
prevent foreign materials from entering the
supply pump and common rail.
39. Disconnect connector (58).
40. Disconnect fuel hose (120).
41. Disconnect connector PIM (121).
44. Disconnect connectors PCV1 (60) and PCV2

(61).
45. Disconnect wiring harness clamp (62).
46. Remove tubes (63) - (65).
[*8]
47. Remove fuel supply pump assembly (66).
a Do not loosen overflow valve (ofv).
a Do not remove oil tube (t) and plate (p).
50-38
D375A-6R
(01)

50. Remove high-pressure pipe (70).
48. Disconnect sleeve (69).

49. 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.

52. Remove four mounting bolts (73) of air intake
manifold assembly (72) from the radiator side.
a Tool A2
D375A-6R
(01)
50-39

53. Remove high-pressure pipe (74).

54. Sling air intake manifold assembly (72).
a Install eyebolt [1] to the mounting hole of
bracket (71) (described above) and sling by
using lifting tool [2].
55. Remove the mounting bolts of air intake manifold assembly (72), leaving some of them tightened.
56. Install guide bolts [3].
a Use the filter mounting bolt as the guide bolt.
57. Remove the remaining mounting bolts of air
intake manifold assembly (72).

61. Remove turbocharger lubrication tube (78) and
coolant tube (79).
62. Remove air vent tube (80).
58. Disconnect air intake connector (76).
63. Remove pin (A) and then push in bolt (B).

64. 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".
59. Sling and remove air intake manifold assembly
(72).
4 Air intake manifold assembly:
110 kg
50-40
D375A-6R
(01)

65. 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.
66. Remove terminal mounting nuts (82).

a Loosen the nuts alternately.
67. Remove wiring harness assembly mounting
bolts (83) and spacer (84).
68. Loosen locknut (85) and loosen adjustment
screw (86).
74. Using tool A1, remove fuel injector assembly

(92).
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.
69. Remove the rocker arm and shaft assembly (87).
75. Sling and remove cylinder head assembly (93).

4 Cylinder head assembly:
50 kg
76. Remove the cylinder head gasket.
70. Remove push rods (88).
71. Remove cross head assembly (89).
72. Remove rocker housing (90).
73. Remove fuel injector holder (91).
D375A-6R
(01)
50-41

Connection
1. Cylinder head assembly
1) Install the cylinder head gasket.
50-42
2) Sling and install cylinder head assembly (93).

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 disulphide lubricant
(LM-P)
bolts (1 7):
1st time: 245 9.8 Nm {25 1 kgm}
2nd time: 382.5 9.8 Nm {39 1
kgm}
3rd time: Retighten 90120
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
90120 (target: 120).
bolts (8, 9):
93.2103 Nm {9.510.5 kgm}
50-42
a After tightening the bolt, make punch

mark "(a)" on the main bolt head (Do not
make it when new bolt is used, however).
D375A-6R
(01)

2. Fuel injector
a Check that the fuel injector mounting bore is
free from dirt or other particles.
2 O-ring:
Engine oil (EO30)
a Do not forget to install O-ring (OR).

3 Rocker arm housing mounting bolt:
78.493.2 Nm {8.09.5 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)
a Injector holder (91) is to be tightened to

the specified torque after installing the intake manifold and tightening the
high-pressure pipe lightly.
4) Install push rod (88).
a Check that the push rod end is securely
placed in the cam follower socket.
5) Apply liquid gasket and then install rocker
housing (90).
2 Rocker housing:
Liquid gasket (LG-7)
a Apply the liquid gasket 2 to 3 mm in bead
diameter along the housing groove as
D375A-6R
(01)
6) Install cross head (89).
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 contact face to the rocker arm
with the finger to keep 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).
50-43

5] While holding adjustment screw (103) to

prevent it from moving, tighten locknut
(102).
3 Locknut:
53.064.7 Nm {5.46.6 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 Threaded part and seat of rocker
arm assembly mounting bolt:
Engine oil (EO30)
3 Rocker arm assembly mounting
bolt :
235.2254.8 Nm {2426 kgm}
a Adjust the valve clearance. For details,
see Testing and adjusting, "Testing and
adjusting valve clearance".
3 Locknut (85):
57.877.4 Nm {5.97.9 kgm}
a After tightening the locknut, check the
valve clearance again.
50-44
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}
D375A-6R
(01)

5. Air intake manifold assembly:

1) Place air intake connector (76) on air intake
manifold assembly (72) being slung.
4 Air intake manifold, connector assembly:
135 kg
Before installing the high-pressure pipe,

fuel may leak.
2) Install air intake manifold assembly (72).

1) Install O-ring (106) to high-pressure pipe

sleeve (101).
2 O-ring:
Engine oil (EO30)
2) Tighten sleeve nut (75) lightly 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.
D375A-6R
(01)
3) Tighten the common rail side sleeve nuts

(69) lightly, too.
4) Tighten injector holder (91) to the specified
torque.
3 Injector holder mounting bolt:
58.973.5 Nm {6.07.5 kgm}
50-45
E g ea dc o gs s m
n in n o lin y te
5) Tighten high-pressure pipe sleeve nuts (69)

and (75) to the specified torque by using the
spanner type torque wrench.
3 Sleeve nut:
39.244.1 Nm {44.5 kgm}
a After finishing the work, check that
O-ring (106) is not projected from the
end of the sleeve nut (75).
6) Install the cylinder head cover (81).

a A different tightening torque is employed
for No. 2 cylinder head cover mounting
bolt alone.
No. 1, 3, 4, 5, and 6 cylinders:
9.8 1.0 Nm {1.0 0.1 kgm}
No. 2 cylinder:
5974 Nm {67.5 kgm}
7) Install air vent tube (80).
3 Air bleeding tube joint bolt (cylinder head side):
9.812.7 Nm {1.01.3 kgm}
8) Install turbocharger coolant tube (79) and
lubricant tube (78).
50-46
9) Install brackets (77).
7. High-pressure pipe clamp

1) Install the high-pressure pipe clamps
1] Finger-tighten seventeen 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:
11.814.7 Nm {1.21.5 kgm}
5] Install covers (53) on the common rail
side sleeve nuts.
D375A-6R
(01)

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".
Fuel supply pump (66) mounting

bolt:
5974 Nm {67.5 kgm}
3 Lower bracket (111) mounting bolt:
5974 Nm {6.07.5 kgm}
2) Install oil tube (112).
Replace four gaskets (G) with new ones.
(Part No.: 07005-01012)
3 Oil tube (112) joint bolt:
9.812.7 Nm {1.01.3 kgm}
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.
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) lightly.
2) Tighten clamps (55), (56), and (109) lightly.
3) Tighten bracket (110) lightly.
4) Tighten high-pressure pipes (57) to the specified torque.
3 High-pressure pipe sleeve nut:
39.244.1 Nm {4.04.5 kgm}
D375A-6R
(01)
50-47

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 cover (54).
[*4]
Coolant tube (30)

Joint bolt:
24.534.3 Nm {2.53.5 kgm}
Sleeve nut:
24.559 Nm {2.56.0 kgm}
Lubrication tube (28), coolant tube (31)
joint bolt:
24.534.3 Nm {2.53.5 kgm}
[*5]
Exhaust manifold assembly
1. If the exhaust manifold assembly was divided,
apply liquid adhesive (heat-resistant sealant) to
joints (A) (2 places) when assembling.
2 Exhaust manifold joint:
Liquid adhesive (HOLTS MH705)
[*1]
Fuel hose (9):
9095 Nm {9.29.7 kgm}

Fuel hose (11) sleeve nut:
4347 Nm {4.44.8 kgm}
[*2]

19.6 29.4 Nm {2.0 3.0 kgm}
[*3]
3
3
3
3
3
50-48
Tube (18-1) joint bolt (filter side):

24.534.3 Nm {2.53.5 kgm}
Tube (18-1) joint bolt (supply pump side):
14.819.6 Nm {1.511.99 kgm}
Tube (18-2) joint bolt:
24.534.3 Nm {2.53.5 kgm}
Tube (18) sleeve nut:
2427 Nm {2.42.7 kgm}
7.89.8 Nm {0.81.0 kgm}

2 Exhaust manifold mounting bolt:
Seizure prevention compound (LC-G)
(NEVER-SEEZ [Bostik Inc] or equivalent)
3 Exhaust manifold mounting bolt:
1st time: 39.258.8 Nm {4.06.0 kgm}
2nd time: 98.1122.6 Nm {1012.5
kgm}
D375A-6R
(01)

Reference
50-49
Installation of turbocharger assembly
1. Sling and install turbocharger assembly (112).
4 Turbocharger assembly:
55 kg
2 Turbocharger mounting bolt and nut:
Seizure prevention compound (LC-G)
(NEVER-SEEZ [Bostik Inc] or equivalent)
3 Turbocharger mounting bolt and nut:
78.588.3 Nm {8.09.0 kgm}
Confirm that each high-pressure pipe and

adjacent wiring harness are at least 10 mm
apart from each other.If not, secure the clearance by repositioning the wiring harness.
Bleeding air
circuit".
[*6]
3
3
3
Air vent tube (44) joint bolt:

7.89.8 Nm {0.81.0 kgm}
Tube (45), (46) sleeve nut:
2427 Nm {2.42.7 kgm}
Tube (45), (46) joint bolt:
24.534.3 Nm {2.53.5 kgm}
[*7]

19.6 29.4 Nm {2.0 3.0 kgm}
[*8]
3
3
3
Oil tube (63) joint bolt (supply pump side):

9.812.7 Nm {1.01.3 kgm}
Oil tube (63) joint bolt (block side):
9.812.7 Nm {1.01.3 kgm}
Tube (65)
14.819.6 Nm {1.511.99 kgm}
Sleeve nut:
4347 Nm {4.44.8 kgm}
19.6 29.4 Nm {2.0 3.0 kgm}
D375A-6R
(01)
50-49

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.
Quantity
Symbol
50-50
Necessity
Special tools
50-50
t 1
t 1
t 1
Removal
50-50
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 oil:
6
Coolant:
130 l
120 l

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).
3. Start the engine and retract the piston rod fully

and bind it with a wire so that it does not come
off.
[*2]
a Disconnect the hose from the radiator, remove the 2 clamps, and reposition the hose
on the engine side.
4. Sling blade lift cylinder (2) and fix bracket (2-1) to

cylinder fixing portion (A) of the radiator guard.
50-50
D375A-6R
(01)


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).
a Do not loosen hose clamp (MC).
[*3]
17. Disconnect blade piping (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 hoses (6) for the fan motor.
14. Disconnect radiator outlet tube (7).
D375A-6R
(01)
50-51

18. Sling the radiator guard assembly, remove the

lock bolt of the pin, and push rear pin (12) toward
the inside of the radiator guard to remove it by
using tool A7.
a Remove the shoe plates to secure a working
space.
19. Remove the lock plate and pull front pin (13)
toward the outside of the radiator to remove it by
using tool A7.
20. Lift off the 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)
50-52
Connection
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]
50-52
Air vent hose clamp:

3.3 0.5 Nm {0.34 0.05 kgm}
D375A-6R
(01)

[*3]
MIKALOR clamps (MC10), (MC20), and (MC23)
a Use a new MIKALOR clamp.
1) Set the hose to the original position.
(Hose insertion depth: 80 mm)
2) Set the clamp with 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):
6 Nm {0.6 kgm} or more
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
D375A-6R
(01)
50-53

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
50-54
D375A-6R
(01)

Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler)
Removal and installation of cooling assembly (radiator, after cooler, and

50-5
hydraulic oil cooler)
Removal
50-5
disconnect the radiator hoses.
6 Coolant:
2. Drain the hydraulic oil.
6 Hydraulic oil:

9. Remove air conditioner condenser (21) without
disconnecting the air conditioner hoses.
a Place air conditioner condenser on the track
shoes.
assembly".
120 l
130 l

assembly".
[*1]
10. Open the undercover. For details, see "Removal

and installation of engine assembly".

[*2]
6. Remove the mounting bolts and disconnect
aftercooler duct (5).
[*3]
a Do not loosen clamp (MC).
7. Disconnect 4 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
D375A-6R
(01)
50-55

11. Disconnect hydraulic oil cooler upper hose (7)

and lower hose (7-1).
16. Remove 2 upper mounting bolts (12) on both

right and left sides.
12. Disconnect radiator outlet tube (8).

a Do not loosen clamp (MC).
[*4]
14. Remove radiator mask (10) and remove right

and left fan nets (11).
50-56
15. Remove shroud (22).
17. Remove lower mounting bolts (12-1) on both

right and left sides.
a Remove the bolts through the fan.
18. Sling and remove cooling assembly (13).

4 Cooling assembly:
480 kg
D375A-6R
(01)

Connection
50-57
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]

3.3 0.5 Nm {0.34 0.05 kgm}
D375A-6R
(01)
50-57

[*3][*4]
MIKALOR clamps (MC10), (MC20) and (MC23)
1) Set the hose to the original position.
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):
3 Clamp bolt (BC):
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
50-58
D375A-6R
(01)

5 Coolant:
120 l

5 Hydraulic tank:
130 l
D375A-6R
(01)
50-59

Removal and installation of radiator

Removal
50-60
6 Coolant:
50-60
7. Remove cushion (7) and plate (8).
120 l
2. Remove the radiator upper cover. For details,

assembly".
3. Remove stay (1).
8. Sling and remove 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).
50-60
D375A-6R
(01)

Connection
50-61
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).(L1 o L2)
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 bolts (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) lightly)
3. Carry out the subsequent installation in the

reverse order to removal.
q
D375A-6R
(01)
5 Coolant:
120 l
50-61

Removal and installation of hydraulic oil cooler

Removal
50-62
6 Hydraulic oil:
50-62
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
130 l
cover (1).
4 Lower side cover:
40 kg
50-62
Connection
3. Disconnect upper hydraulic oil cooler hose (2).
50-62

the supply. Then, check the oil level again.
5 Hydraulic tank:
130 l
D375A-6R
(01)

Removal and installation of aftercooler

Removal
50-63
50-63
5. Open the undercover.

6. Remove lower mounting bolts (4) of the aftercooler.
1. Remove the radiator upper cover. For details,

assembly".
2. Remove right side 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 (one cooler):
40 kg
50-63
Connection
D375A-6R
(01)
50-63

Removal and installation of engine assembly

Removal
50-64
6 Coolant:
50-64
4. Remove right and left lower side covers (1).

4 Left lower side cover:
40 kg
Right lower side cover:
50 kg
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
pipings (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".
50-64
D375A-6R
(01)

11. Disconnect radiator outlet hose (10) from the

engine.
17. Disconnect wiring connector (17).

12. Loosen locknut (11) and fully tighten belt tension
adjustment bolt (12).
[*1]
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 duct (20) and air hose
(21).
[*5]
15. Disconnect fuel supply hose (15).

[*2]
16. Disconnect fuel return hoses (16a) and (16b).
a Disconnect the hose clamps.
D375A-6R
(01)
50-65


[*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).
50-66
D375A-6R
(01)

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) and remove the

mounting bolts.
[*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.
D375A-6R
(01)
50-67

28. Remove the engine assembly according to the

1) Install the lifting tools to parts [A] and [B].
50-68
Connection
[*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:

9095 Nm {9.29.7 kgm}
[*3]
2) Sling 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.
50-68

8.8 0.5 Nm {0.9 0.05 kgm}
[*4]

3.3 0.5 Nm {0.34 0.05 kgm}
[*5] [*6]
MIKALOR clamps (MC10), (MC20) and (MC23)
1) Set each hose to the original position.
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):
3 Clamp bolt (BC):
q When using a new hose
is as follows.
MC10: 7 - 10 mm
MC20: 17 - 20 mm
MC23: 20 - 23 mm
D375A-6R
(01)


3 10.5 0.5 Nm {1.07 0.05 kgm}
(TC): Turbocharger
D375A-6R
(01)
50-69

[*7]
Universal joint mounting bolt:

156.9196.1 Nm {1620 kgm}
[*8]
Engine mounting bolt:

8231,029 Nm {84105 kgm}
5 Coolant:
120 l
50-70
D375A-6R
(01)

Removal and installation of engine hood assembly

Removal
50-71
1. Remove radiator upper inspection cover (1).
50-71
5. Remove right cover (3-1) and left cover (3-2).

7. Remove pre-cleaner 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.
D375A-6R
(01)
50-71

10. Disconnect connector RDG (6) at the front of the

hood.
13. Disconnect reservoir tank hose (9) from the

reservoir tank.
14. Disconnect reservoir tank hose clamp (9a).
15. Disconnect duct (10).
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.
50-72
D375A-6R
(01)

18. Lift up engine hood assembly (12).

4 Engine hood assembly:
350 kg
50-73
Connection
[*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).
D375A-6R
(01)
50-73

Removal and installation of engine front seal
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
N/R
Part No.
Quantity
Symbol
50-74
Necessity
Special tools
50-74
4. Remove dust seal (7).

5. Remove front seal (8) according to the following
procedure.
t 1
t 1
t 1
t 3
t 3
Removal
50-74
1. Remove the radiator guard assembly. For
details, see "Removal and installation of radiator
guard assembly".
2. Sling damper assembly (1).
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 rear seal with impacts of slide
hammer (SH).
q
Tool A3
3. Lift off damper assembly (1).

4
[*1]
Damper assembly (1):
40 kg
a CS: Crankshaft
50-74
D375A-6R
(01)

Connection
50-75
1. Clean, degrease, and dry the contacting surface
against the front cover.
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)
D375A-6R
(01)
Mounting bolt:
1st time: 53.993.1 Nm {5.59.5 kgm}
2nd time: 225.4264.6 Nm {2327 kgm}
3rd time: 617.4656.6 Nm {6367 kgm}
50-75

Removal and installation of engine rear seal
Removal and installation of engine

50-76
rear seal
Symbol
Part No.
50-76
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
Quantity
N/R
Sketch
Special tools
t 1
t 1
t 1
t 5
t 5
Removal
50-76
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
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 impacts of
slide hammer (SH).
a If the seal is sleeved, cut and remove sleeve
(5) with a chisel and a hammer.
a Take care not to damage crankshaft (4).
a Remove all the broken pieces of the rear
seal.
50-76
Tool A3
D375A-6R
(01)

Connection
50-7
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 Do not remove installation guide (3) from rear
seal (2) before installing it.
a Handle rear seal (2) and sleeve (5) as an assembly and never separate them from each other.
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 (b) of
plastic inside cylinder (3) of rear seal (2) 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 the rear seal, remove plastic
inside cylinder (3).
a When removing the inside cylinder, take
care not to damage the seal lip.
a Clean, degrease, and dry the contacting surface

against the flywheel housing.
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.
D375A-6R
(01)
50-77

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 the sleeve and rear seal assembly (6) to
tool A5 (for press fitting the sleeved seal).
3 Inside surface (C) of sleeve:
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).
50-78
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 of 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 of 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 (EO30)
D375A-6R
(01)

3
Flywheel assembly mounting bolt:

1st time: 196.1 19.6 Nm {20 2 kgm}
2nd time: 460.9 19.6 Nm {47 2 kgm}
3rd time: Retighten 90 120
a After tightening, put a punch mark (a) on the bolt
head to indicate the number of uses.(do not
mark when a new bolt is used).
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)
0.13
0.0005 x Diameter of
measuring point
a When the measured value is out of the standard,

determine the cause by disassembling the flywheel.
D375A-6R
(01)
50-79

Removal and installation of fan drive assembly
50-80
Removal
50-80
6 Hydraulic oil:
130 l
2. Remove radiator mask (1).
5. Remove fan nets (4), (5), and (6).

6. Remove wiring harness clamp (7) and disconnect the connector.
3. Remove mark plate (2).
7. Disconnect fan motor pipes (8), (9), and (10).

a Disconnect the horn connector and then remove it.
50-80
D375A-6R
(01)

8. Sling and remove fan drive assembly (11).

4
[*1]
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.
50-81
Connection
[*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
D375A-6R
(01)
Refilling (hydraulic tank)

5 Hydraulic tank:
130 l
50-81

Removal and installation of fan motor assembly
50-82
Removal
50-82
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
50-82
D375A-6R
(01)

Connection
50-83
[* 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.
D375A-6R
(01)
50-83

Removal and installation of fuel tank assembly

Removal
50-84
50-84
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).
50-84
9. Disconnect wiring connector FGS (14) of the fuel

level sensor.
D375A-6R
(01)

10. Remove three mounting bolts (15) from each

side of the fuel tank.
Connection
q
50-85
(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)
D375A-6R
(01)
50-85
Power train
Removal and installation of damper assembly
Power train

Removal
50-86
50-86
50-86
4. Remove covers (4), (5) and (6).
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].

50-86
D375A-6R
(01)
Power train
8. Remove oil level gauge (10) and bracket as a

unit.
6. Remove universal joint assembly (8).

[*1]
a Sling the universal joint assembly and lower
it to remove.
40 kg
9. Remove divider board (11).
10. Remove bolt (12) and remove holder (13).

[*2]
7. Loosen drain plug (9) to drain damper case oil.
6 Damper case:
2.1 l
11. Remove coupling (14).
D375A-6R
(01)
50-87
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 sling
down damper cover (15) to remove.
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
13. Remove the damper according to the following

procedure.
[*4]
1) Sling damper (17) by using eyebolt [4].
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].
a Tighten forcing screws [3] evenly.
4 Damper assembly:
70 kg
14. If bearing (19) is damaged, remove bearing (19).
50-88
D375A-6R
(01)
Power train
Connection
q
50-89
Fill gap (a) at the hatched area in the illustration with

grease (G2-LI) by approximately 50% (11 g).
[*1]
Universal joint mounting bolt:

156.8196 Nm{1620 kgm}
[*2]
Holder mounting bolt :

245309 Nm{2531.5 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.
[*5]
D375A-6R
(01)
50-89
Power train
Disassembly and assembly of damper assembly

Disassembly of damper assembly
1. Place the damper assembly on block [1].
50-90
50-90
6. Remove seals (7) from flanges (2) and (5).
2. Remove mounting nuts (1) and remove flange

(2) by using forcing screws [2].
50-90
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-6R
(01)
Power train
Assembly of damper assembly

50-91
1. Install seals (7) to 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 surface of flange:
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 surface of flange:
Gasket sealant (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% (approx. 190 g) to
gaps (CL) (16 places) between the shaft and
body.
D375A-6R
(01)
50-91
Power train
50-92
Assembly of damper cover assembly
1. Use push tool [3] to press fit oil seal (11) to
retainer (12).
2 Oil seal press-fitting surface:
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. Press fit bearing (8) to cover (10) by using push

tool [4].
3. Press fit oil seal (9) to cover (10) by using push

tool [5].
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:
Grease(G2-LI)
50-92
D375A-6R
(01)
Power train
Removal and installation of power train unit assembly
50-93
Removal
50-93
k Park the machine on a level place and lower
the work equipment to the ground completely.
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 oil from the hydraulic tank.
6 Hydraulic tank:
130 l
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".
6. Using sling [1], open undercover (1) gradually.
D375A-6R
(01)
7. Sling universal joint assembly (2) and lower it to

remove.
[*1]
40 kg
50-93
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-6R
(01)
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-6R
(01)
50-95
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.
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.
25. Remove damper oil level gauge (36).
50-96
D375A-6R
(01)
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.
D375A-6R
(01)
50-97
Power train
Installation
q
50-98
Bleed air from the piping. For details, see

Testing and adjusting "Bleeding air from
hydraulic circuit".
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:
156.8196 Nm {1620 kgm}
[* 2]
Mounting nut of rear coupling clamp:

4.98.82 Nm {0.50.9 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)
q
Bleeding air
50-98
D375A-6R
(01)
Power train
Disconnection and connection of power train unit assembly
50-9
Disconnection
a Before disconnecting the wires and hoses, fit
them with tags to show their connecting locations.
50-9
2) FA2 (7), intermediate connector (8)
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)
D375A-6R
(01)
4) STB (17), TM1 (18), TC1 (19)
50-99
Power train
5) TOP (20), 453 (21)
4. Remove hydraulic hoses (22) to (36).

a Remove hoses (24) and (28) as a unit.
50-100
D375A-6R
(01)
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 cluth oil pressure (40): Black
Left brake oil pressure (41): White
Right clutch oil pressure (42): White/Black
Right brake oil 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
D375A-6R
(01)
50-101
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 clutch 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.
50-102
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 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
D375A-6R
(01)
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) Sling steering case assembly (69) to disconnect it.
[*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.
D375A-6R
(01)
3) Remove bracket (72).
50-103
Power train
4) Remove eye plates (73), reverse them, and

install them in the same positions at the left
and right.
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.
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
2] Shorten sling [7] to slant PTO, torque

converter and transmission assembly
(74).
8) Sling PTO assembly (79).

3] Disconnect sling [6] from the transmission
and connect sling [6] to the PTO unit.
50-104
D375A-6R
(01)
Power train
9) Remove retainer (80).

[*4]
a Note the thickness and quantity of the
shims.
10)Remove snap ring (81), then remove spacer
(82).
11)Remove PTO assembly mounting bolts.

12)Lift off PTO assembly.
4 PTO Ass'y:
300 kg
10. Sling torque converter assembly (89) and
remove the 19 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
D375A-6R
(01)
50-105
Power train
Connection
q
50-106
Carry out connection in the reverse order to disconnection.
Steering case mounting bolt:

245309 Nm{2531.5 kgm}
[*1]
a Check that shaft (68) is inserted in boss (83) at
the end of the transmission input shaft.
[*3]
q
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.
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): Intermediate position between inside
and outside faces of oil pan case
(Quantity of liquid gasket to apply)
B x H = 2 to 5 cc
(OUT): Outside of oil pan case
(IN): Inside of oil pan case
(TP): Tap holes
(HL): Bolt holes
[*2]
a When installing steering case (69), install guide
bolts [5] and install the steering case along them.
50-106
D375A-6R
(01)
Power train
[*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.
3) Determine the total thickness of the shim

pack and select shims to tbe installed in
clearance (a).
a Thickness of shim pack: (a) + 00.05 mm
a Available shims: 0.15 mm?0.2 mm?and
0.5 mm
4) Install the shims of the calculated thickness
and tighten the mounting bolts of retainer
3 Retainer mounting bolt :
58.873.5 Nm {67.5 kgm}
a Determine the quantity and thickness of
the shims so that the thickness is the
same on both the left and right sides.
a Set shims (87) as shown in the figure so
that they do not block forcing screw tap
holes (H) of retainer (80).
[*5]
Torque converter assembly mounting

bolt:
245 to 309 Nm {25 to 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)
D375A-6R
(01)
50-107
Power train
Disassembly and assembly of PTO assembly

Disassembly
50-108
1. PTO lubrication tube
50-108
3) Using puller [2], remove bearings (5) and (6)

from gear (7).
Sling the 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 pump 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).
50-108
D375A-6R
(01)
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.
D375A-6R
(01)
50-109
Power train
2) Remove bearing inner races (26) and (27)

from race (28).
50-1 0
Assembly
a Clean all parts, and check them for dirt and damage before installing.
a Make sure that the snap ring is settled in the
groove completely.
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).
50-110
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).
D375A-6R
(01)
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) Reverse 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).
D375A-6R
(01)
50-111
Power train
6) Install plate (17).

2 Mounting bolt:
3
2) Using push tool [5], install bearings (11) and

(12) to gear (13).
Adhesive (LT-2)
Mounting bolt:
110.35 12.25 Nm {11.25 1.25
kgm}
4. Scavenging pump gear

1) Install gear (16).
2 Spline:
Grease(G2-LI)
2) Install snap ring (15) from under the PTO

case.
3) Using push tool [6], press fit gear assembly

(10) to cover (9).
2 Gear spline:
Grease(G2-LI)
4) Hoist cover assembly (8) with the O-ring and
install it to the case.
a If the cover assembly does not fit in the
case, tap its periphery evenly with a plastic hammer to install.
5. Power train pump gear assembly

1) Fit the O-ring and install cover (14).
50-112
D375A-6R
(01)
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:
(LM-P)
3) Hoist cover assembly (2) with the O-ring and
install it to the case.
a If the cover assembly does not fit in the
case, tap its periphery evenly with a plastic hammer to install.
D375A-6R
(01)
50-113
Power train
Disassembly and assembly of torque converter assembly
Symbol
Part No.
790-413-1010
C
790-501-5000
50-1 4
Part name
Bracket
Repair stand
(100 V)
Necessity
Quantity
New/redesign
Sketch
Special tools
t 1
t 1
Disassembly
q
50-1 4
2) Using eyebolts [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).
50-1 4
Preparatory work
Set torque converter assembly (56) to tool C.
3] Remove snap ring (7) to remove plate (8).

4] Set the assembly with the clutch housing
side down, and use forcing screws [3] to
remove turbine (9).
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.
50-114
D375A-6R
(01)
Power train
5] Set the assembly with the clutch housing

side up and remove 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) to remove stator
assembly (20).
2) Disassemble the stator assembly according
1] Remove snap ring (21) to 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).
D375A-6R
(01)
50-115
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 spring (33).
8. Spring, disc, and plate
Remove springs (34), two discs (35), and one
plate (36) in turn.
a Keep the disc and plate on a flat place so that
they do not warp.
9. Pin
Remove pin (37).
3] Remove bearing outer race (30) from

guide (31).
Set the assembly with the stator clutch housing
up and remove stator clutch housing (32).
10. Inner gear
Remove snap ring (38) to remove inner gear
(39).
11. Piston
Remove piston (40) from case (41).
50-116
D375A-6R
(01)
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
accoring to the following procedure.
1] Using push tool [6], remove shaft
assembly (45) from the stator shaft
assembly.
D375A-6R
(01)
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), then remove plate
(54).
4] Remove snap ring (53) to remove plate
(54).
5] Using the push tool [7], remove bearing

(55).
50-117
Power train
50-1 8
Assembly
groove completely.
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 seal ring (51).
a After installing the seal ring, apply
grease (G2-LI) to securely fix the seal
ring to the shaft.
50-118
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.
D375A-6R
(01)
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 portion 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)
3. Inner gear
Install inner gear (39) and secure it with snap
ring (38).
2. Piston
1) Install seal ring (43) to the case.
Grease(G2-LI)
a Install the seal ring as shown in the figure
since it has directional properties.
2) Install seal ring (42) to the piston.
Grease(G2-LI)
D375A-6R
(01)
50-119
Power train
4. Pin
Install pin (37).
5. Plate, disc, and spring
Install one plate (36), two discs (35), and spring
(34).
6. Spring
Install spring (33).

Install stator clutch housing (32).
a Check that the springs are fitted securely in
the holes in the housing and piston.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
110.35 12.25 Nm {11.25 1.25
kgm}
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).
2 Mounting bolt:
Adhesive (LT-2)
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.
9. Stator assembly
1) Assemble the stator assembly according to
1] Install snap ring (24) to stator (23).
8. Pump assembly
1) Assemble the pump assembly as follows.
1] Using the push tool, press fit bearing
outer race (30) to guide (31).
(TO-10 or TO-30) on the bearing and
rotate the bearing approximately 10
turns.
50-120
D375A-6R
(01)
Power train
2] Install race (22) to stator (23) and secure

it with snap ring (21).
2) Install stator assembly (20) to the stator
shaft, and secure it with snap ring (19).
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.
3] Install seal ring (14) to the housing.

Grease(G2-LI)
4] Install seal ring (13) to the piston.
Grease(G2-LI)
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 eyebolt [4], install housing and
piston assembly (10).
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
110.35 12.25 Nm {11.25 1.25
kgm}
2] Install two discs (16) and one plate (17).
D375A-6R
(01)
50-121
Power train
7] Using the push tool, press fit bearing (15).

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).
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.
2) Using eyebolts [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}
50-122
D375A-6R
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly
1
2
3
D
4
5
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
Sketch
Part name
N/R
Part No.
Quantity
Symbol
50-123
Necessity
Special tools
50-123
2. Control valve assembly

1) Remove nut (2-1) from connector (P).
a Note that cover (2) is wired.
t 1
t 1
t 1
t 1
1
1
1
2
t 1
1
1
1
2
t 1
Disassembly
1. Preparatory work
Set transmission assembly (1) to toolD1.
50-123
3) Remove sleeve (3).

4) Remove control valve assembly (4).
(G): Gasket
3. Lubrication valve assembly

Remove lubrication valve assembly (5).
D375A-6R
(01)
50-123
Power train
4. Front case
1) Set the transmission assembly with the input
shaft up.
2) Using eyebolts, remove front case (6).
3) Using eyebolts [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 17 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).
50-124
D375A-6R
(01)
Power train
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-6R
(01)
50-125
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 gear (34) and thrust washer (34)

from the carrier.
19] Remove needle bearings (36) from gears
(34).
50-126
D375A-6R
(01)
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-6R
(01)
4) Remove seal ring (52) from the No. 2 and No.

3 carrier.
5) Remove six torque pins (53).
6) Remove twelve guide pins (54).
50-127
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).
4] Remove gear (63) and thrust washer (64)

from the carrier.
5] Remove needle bearings (65) from gears
(63).
a Since No. 2 and No. 3 carrier (60) is
embedded in No. 1 ring gear (66),
they cannot be disassembled.
11. No. 2 ring gear

Remove No. 2 ring gear (67).
3] Pull out shafts (61) halfway from carrier

(60), remove balls (62), and remove
shafts (61).
50-128
D375A-6R
(01)
Power train
12. No. 2 and No. 3 housing assembly

1) Using eyebolts [7], remove No. 2 and No. 3
housing assembly (68) and the upper and
lower pistons as a unit.
a Bind the lower piston with a wire to prevent it from coming off.
2) Disassemble the No. 2 and No. 3 housing

1] Remove pistons (69) and (70) from
housing (71).

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.
14. No. 3 and No. 4 clutch plate

Using eyebolts [8], remove plate (80).

4] Remove seal rings (74) and (75) from

housing (71).
D375A-6R
(01)
50-129
Power train

1) Remove three discs (81), three springs (83),
and two plates (82) in turn, and then remove
the guide plate (147).
2) Remove six torque pins (84).
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) to remove plate (92).
16. No. 4 housing assembly
1) Using eyebolts [9], remove housing
assembly (85) and the piston as a unit.
4) Remove snap ring (93) and spacer (94).
2) Disassemble the No. 4 housing assembly


3] Remove seal ring (89) from housing (87).
50-130
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-6R
(01)
Power train
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.
6] Using eyebolts [11], remove No. 3 ring

gear and No. 4 carrier assembly (101)
and the No. 4 sun gear as a unit.
7] Remove No. 4 sun gear (102) from No. 3
ring gear and No. 4 carrier assembly
(101).
3] Remove snap ring (96) and remove No. 3

sun gear (97).
4] Remove collar and bearing assembly
(98).
5] Using the push tool, remove ball bearings

(99) from collar (100).
D375A-6R
(01)
50-131
Power train
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).
10] Remove snap ring (106) to remove collar

(107) from No. 3 ring gear and No. 4
carrier assembly (101).
11] Remove seal ring (108) from collar (107).
12] Pull out shafts (110) halfway from carrier

(109), remove balls (111), and remove
shafts (110).
13] Remove gear (112) and thrust washer
(113) from carrier.
14] Remove needle bearings (114) from
gears (112).
50-132
15] Reverse carrier (109) and remove snap

ring (115).
16] Reverse the carrier and remove ball
bearing (119) 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-6R
(01)
Power train
19] Remove six discs (119), six springs (121),

and five plates (120) in turn from housing
(122).
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.
D375A-6R
(01)
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).
50-133
Power train
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.
3) Reverse the rear case, remove snap ring

(141), and remove ball bearing (142).
27] Remove snap ring (134) and remove

needle bearings (135) from input shaft
(124).
28] Reverse the output shaft, remove snap
ring (136), and remove roller bearing
(137) from the output shaft.
18. Rear case assembly

1) Remove collar (138) from rear case (139).
2) Remove seal ring (140) from collar (138).
50-134
D375A-6R
(01)
Power train
Assembly
50-135
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.
2) Reverse rear case (139) and install collar

(138).
a Take care not to get the seal ring caught.
1. Preparatory work
Set rear case (139) to tool D1.
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.
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) Install spacer (94) and secure it with snap

ring (93).
2 Inside surface of spacer:
(LM-P)
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
66.15 7.35 Nm {6.75 0.75 kgm}
5) Install seal ring (118).
2 Seal ring:
Grease(G2-LI)
D375A-6R
(01)
50-135
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.
6) Reverse rear case (139), set output shaft
assembly (124) to the case, and press fit the
bearing portion by using the push tool.
1] Using the push tool, press fit ball bearing

(116) to carrier (109) and fix it with snap
ring (115).
8) Install plate (92) and secure it with snap ring

(91).
50-136
D375A-6R
(01)
Power train
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
with snap ring (106).
a Tap the dowel pin fitting portion with a
plastic hammer until the clearance between the mating faces is eliminated.
D375A-6R
(01)
7] Install seal rings (105) and (104) to hub

(103).
2 Seal ring:
Grease(G2-LI)
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.
9] Using eyebolts [15], install housing (122)

to No. 3 ring gear and No. 4 carrier
assembly.
50-137
Power train
10] Install six discs (119), six springs (121),

and five plates (120) in turn.
13] Install seal ring (130) to piston (129).

a Install the seal ring as shown in the figure below.
2 Seal ring:
Grease(G2-LI)
14] Install piston (129) to housing (128).
a Take care not to get the spring caught.
11] Using the push tool, press fit ball bearing

(133) to housing (128) and fix it with snap
ring (132).
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 spring to install snap
ring (125) by using tool D2.
a Load at installed length of spring:
2,175 N {222 kg}
12] Install seal ring (131) to the housing.

a Install the seal ring as shown in the figure below.
2 Seal ring:
Grease(G2-LI)
50-138
D375A-6R
(01)
Power train
17] Using bolt [16], install housing assembly

(123).
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
176.4 19.6 Nm {18 2 kgm}
18] Install two seal rings (56) to the housing.
2 Seal ring:
Grease(G2-LI)
4) Using eyebolts [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) 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.
6. No. 3 sun gear

1) Using the push tool, press fit ball bearing (99)
to collar (100).
2 Spline:
(LM-P)
D375A-6R
(01)
50-139
Power train
2) Install collar and bearing assembly (98).

a Install the assembly with collar flange
side up.
3) Install No. 3 sun gear (97) and secure it with
snap ring (96).
2 Spline:
(LM-P)

1) Install seal ring (89) to housing (87).
below.
2 Seal ring:
Grease(G2-LI)
2) Install seal ring (88) to piston (86).
below.
2 Seal ring:
Grease(G2-LI)
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

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.
50-140
D375A-6R
(01)
Power train
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.
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.
2 Seal ring:
Grease(G2-LI)

1) Install four discs (77), four springs (79), and
three plates (78) in turn.
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

a Direct the seal ring as shown in the figure.
2 Seal ring:
Grease(G2-LI)
2 Seal ring:
Grease(G2-LI)
D375A-6R
(01)
50-141
Power train
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.
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 No. 1 ring gear (66)
with a plastic hammer to install.
a Check that the ring is fitted securely into
the groove.
5) Install housing assembly (68) aligning the

dowel holes with the dowel pins.
1] Install needle bearings (65) to gears (63),

fit thrust washers (64) to both sides of the
gears, and set them to carrier (60).
12. No. 2 ring gear

Install ring gear (67).
50-142
D375A-6R
(01)
Power train
2] Fit balls (62) and install shafts (61) to the

carrier.
a Check that each gear rotates smoothly.
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.
2 Seal ring:
Grease(G2-LI)
a Align seal ring (58) with the carrier and
fix it with grease(G2-LI).
2) Using eyebolts [6], install "No. 1 ring gear,

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).

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.
2 Seal ring:
Grease(G2-LI)
D375A-6R
(01)
50-143
Power train
3) Install 17 sleeves (51).

1) Install seal ring (46) to housing (44).
a Install the seal ring as shown in the figure.
2 Seal ring:
Grease(G2-LI)
2 Seal ring:
Grease(G2-LI)
a Install sleeve (51) into the bolt hole

marked with *, with the slit (part S) down.
3) Install piston (43) to housing (44).

4) Install twelve springs (47).

5) Install six discs (48), six springs (50), and five
plates (49) in turn.
a Align the notches of the oil grooves on the
periphery of the discs.
50-144
D375A-6R
(01)
Power train
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.
16. No. 1 clutch ring gear

Install No. 1 clutch ring gear (41).
D375A-6R
(01)

1) Install the guide plate and install twelve
springs (37).
2) Install six discs (38), six springs (40), and five
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).
50-145
Power train
2] Fit balls (34) and install shafts (33) to the

carrier.
3] Install collar (31) to the carrier and secure
it with snap ring (30).
4] Using push tool [19], press fit ball bearing

(28) to plate (25) and fix it with snap ring
(27).
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).
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).
50-146
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.
11] Install snap ring (19).
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)
D375A-6R
(01)
Power train
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.
14] Using the push tool, press fit ball bearings

(13) and (14) to spacer (15).
3) Evenly tighten four tie bolts (12) diagonally.

4) Tighten remaining tie bolts (12).
3 Tie bolt:
259.7 14.7 Nm {26.5 1.5 kgm}
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 secure it
with snap ring (10).
2 Spline:
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
17] Install seal ring (9) to the No. 1 carrier.

D375A-6R
(01)
50-147
Power train
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.
20. Front case

Install front case (6) with the O-ring by using the
eyebolts.
a Lower the front case gradually while checking that it does not interfere with other parts.
22. Lubrication valve assembly

Install lubrication valve assembly (5).
50-148
D375A-6R
(01)
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): Intermediate position between
inside and outside faces of cover
(Quantity of liquid gasket to apply)
B x H = 2 - 5 cc
D375A-6R
(01)
50-149
Power train
Disassembly and assembly of steering case assembly
50-150
Disassembly
50-150
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 discs (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.
50-150
D375A-6R
(01)
Power train
3] Remove torque pin (15).

4] Using eyebolts, remove clutch hub (16).
5] Using forcing screws [4], remove plate
(17).
6] Remove outer race (18) from the plate.

7] Remove bearing and cage assembly
(19).
8] Remove plate (20) and nut (22) from cage

(20).
9] Remove bearing and inner race (23),
spacers (24) and (25), and bearing outer
race (26).
D375A-6R
(01)
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).
50-151
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 right and left shafts (46).
3] Using eyebolts [7], remove brake cage

(39).
4] Remove bearing outer race (40) and seal
ring (41) from the brake cage.
5] Remove torque pin (42).

6] Remove piston (43).
50-152
D375A-6R
(01)
Power train
3. Lubrication tube
Remove lubrication tubes (47), (47-1), and
(47-2).
6. Transfer and gear housing assembly

1) Install guide bolts [8] to housing assembly
(50). Lift off the housing assembly by using
eyebolts [9].
2) Disassemble transfer and gear housing
assembly (50) as follows:
1] Place the transfer and gear assembly
onto blocks.
2] Remove lubrication tubes (51).
4. Pipe
1) Remove right and left pipes (48).
2) Remove pipe (49).
3] Using the push tool, remove bearing (53).

4] Remove drive gear (54).
5. Steering control valve and seat assembly

Remove steering control valve and valve seat
assembly (2).
4 Steering control valve and valve seat
assembly:
75 kg
a Check that lubrication tubes are already removed.
D375A-6R
(01)
50-153
Power train
5] Using puller [10], remove bearing inner

races (55) on both sides.
6] Remove lubrication tubes (56).
7] Using eyebolt [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).
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).
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 with 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).
50-154
D375A-6R
(01)
Power train
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).
8. Bevel gear and shaft assembly

1) Remove bevel gear and shaft assembly (74)
by using eyebolts.
2) Disassemble the bevel gear and shaft
assembly (74) as follows.
1] Pull out the reamer bolts, and remove
bevel gear (75) from shaft (76).
D375A-6R
(01)
2] Using puller [15], remove bearing inner

races (77) and (78) from the shaft.
9. Left cage
1) Turn the steering case to set 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.
50-155
Power train
50-156
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.
groove completely.
1. Left cage
race (80).
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:
1] Press fit bearing inner races (78) and (77)
by using push tool [16].
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) by
using eyebolts.
3. Right cage
1) Using eyebolts [14], install cage (73).
50-156
D375A-6R
(01)
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 by using the push tool.
4] Install bearing inner races (67) and (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] Press fit inner race (61) to pinion gear

(60) by using push tool [18].
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 gear:
5. Transfer and gear housing assembly

1) Assemble the transfer and gear housing
1] Press fit transfer gear bearing (71) into
the case by using push tool [16].
2] Using push tool [17], press fit pinion
bearing (70) into the case.
D375A-6R
(01)
50-157
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 bolt:
49 Nm {5 kgm}
50-158
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}
D375A-6R
(01)
Power train
14] Install the shims to pinion housing

assembly (57), and install the housing by
using eyebolts [11].
a Standard thickness of shims: 2 mm
15] Install lubrication tube (56).
18] Press fit bearing (53) by using push tool

[21].
19] Install bearing assembly (52) to the case.
20] Install lubrication tube (51) and the block
as a unit.
16] Press fit bearing inner race (55) to both

sides of the drive gear by using push tool
[20].
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}
D375A-6R
(01)
50-159
Power train
6. Adjusting backlash and gear 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.
Adjustment
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).
50-160
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
D375A-6R
(01)
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.
Adjustment
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 bevel 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.
D375A-6R
(01)
50-161
Power train
7. Steering control valve and seat assembly

1) Install the steering control valve and valve
seat assembly (2).
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 right and left pipes (48).
9. Shaft
Install right and left 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 by using the
push tool.
.
6] Using eyebolts [7], install brake cage
(39).
50-162
D375A-6R
(01)
Power train
3
Mounting bolt:
110.25 12.25 Nm {11.25 1.25
kgm}
7] Install plates (38), springs (37), and discs
(36).
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.
2] Install brake hub (33) to the clutch

housing by 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).
10] Tighten nut (22) and install plate (21).
D375A-6R
(01)
50-163
Power train
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).

12] Using the push tool, install outer race (18)
to the plate.
50-164
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).
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}
D375A-6R
(01)
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).
2] Press fit bearing inner race (8) to the
sleeve by using push tool [14].
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) Using the eyebolts, install the clutch and
brake assembly.
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 right and left shafts (83).
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.
D375A-6R
(01)
50-165
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
50-16
k Stop the engine, and disconnect the cable
from the negative terminal of the battery.
50-16
50-16
Connection
1. Remove the power train underguard (front).

4 Power train underguard (front):
280 kg
3. Disconnect tube (2).

4. Sling and remove power train and lubrication
pump assembly (3).
4 Power train and lubrication pump assembly:
50 kg
50-166
D375A-6R
(01)
Power train
Removal and installation of scavenging pump assembly

Removal
50-167
50-167
50-167
Connection
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).
D375A-6R
(01)
50-167
Power train
Removal and installation of final drive assembly
Sym
- bol
Part No.
50-168
Part name
J 1 790-337-1001 Lifting tool
Necessity
Quantity
N/R
Sketch
Special tools
50-168
t 1
Removal
50-168
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.
3. Remove (1) and (2).
5. Remove three bolts from the final drive, and

install tool J1 instead.
4. Pull out drive shaft (4) as follows:
6. Sling final drive assembly (5), remove the

mounting bolts, and remove the final drive
assembly.
[*2]
4 Final drive assembly:
2,300 kg
[*1]
Remove cover (3).
Install eyebolts [2] to the drive shaft.
Pull out drive shaft (4).
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.
1)
2)
3)
a
50-168
D375A-6R
(01)
Power train
Connection
50-169
[*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)
D375A-6R
(01)
50-169
Power train
Disassembly and assembly of final drive assembly
791-580-3200 Remover
Puller
2 790-101-2102
(294 kN {30 ton})
790-101-1102 Pump
791-580-3300 Installer
Puller
3 790-101-2102
(294 kN {30 ton})
790-101-1102 Pump
t 1
4 790-431-1071 Installer
t 1
t 1
8 790-431-1250 Guide
Disassembly
50-170
1. Draining oil
Remove the drain plug and drain the oil from the
final drive case.
6 Final drive case:
approx. 61 l
t 1 N
791-580-3400 Remover
Puller
5 790-101-2102
(294 kN {30 ton})
790-101-1102 Pump
Puller
6 790-101-2102
(294 kN {30 ton})
790-101-1102 Pump
Remover and
790-431-1230
installer
7 790-101-2102 Puller
(294 kN {30 ton})
790-101-1102 Pump
t 1
Sketch
Part name
N/R
Part No.
Q'ty
Symbol
50-170
Necessity
Special tools
50-170
t 1
50-170
t 1
t 1
t 1
2. Sprocket
1) Place the final drive assembly on blocks
(approx. 50 mm high).
2) Remove sprocket (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).
D375A-6R
(01)
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) and the bearing (7) portion.
3) Using eyebolt [3], remove sprocket assembly
(6).
D375A-6R
(01)
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.
50-171
Power train
6. Wear guard
Lift off wear guide (13).
3] Remove spacer (17) and bearing inner

race (18).
7. Cover assembly
1) Using eyebolts [4], remove cover assembly
(14).
4] Remove the plate, then remove ring gear

(19).
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.
8. Carrier assembly
1) Remove carrier assembly (20) by using
eyebolts [5].
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).
50-172
D375A-6R
(01)
Power train
3] Remove holder (21).

4] Using tool J7 , remove planetary gear
shafts (22).
5] Remove planetary gear (23), bearing

inner races (24A) and (24B), and spacer
(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] Remove bearing outer race (24D).

2) Using tool J5, pull out hub assembly (29) and
bearing inner race (30) from shaft assembly
(31).
D375A-6R
(01)
50-173
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 shim (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).
50-174
D375A-6R
(01)
Power train
12. Gear assembly

1) Remove gear assembly (44).
2) Using puller [9], remove bearing inner races
(45) and (46) from the gear.
50-175
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 tool [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)
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].
D375A-6R
(01)
50-175
Power train
2. Gear assembly
1) Press fit bearing inner races (46) and (45) to
the gear with push tool [14].
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 cage assembly (39) to

the case, and equally tighten portions (C)
and (D) with cage mounting bolts.
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.
50-176
D375A-6R
(01)
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) with push
tool [17].
3] Install collar (36).
2) Using eyebolts [6], install shaft assembly (31)

to the case.
3) Make the hub assembly according to the
outer race (35) to boss (34).
(a) + (b) [mm]

Larger
than
Number of shims to be
used
Below t = 0.1 t = 0.5
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
D375A-6R
(01)
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
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
2] Set boss (34) to hub (33).
50-177
Power train
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}
2 Mounting bolt:
Adhesive (LT-2)
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).
50-178
D375A-6R
(01)
Power train
2] Install spacer (24C) and bearing inner

races (24B) and (24A) to each planetary
gear (23), and set it to the carrier.
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.
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.
2] Using tool J3, press fit bearing inner race

(18).
3] Install spacer (17).
2) Install bearing (26-1) and spacer (26) to

carrier assembly (20).
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.
3) Using eyebolts [5], install carrier assembly

(20).
D375A-6R
(01)
50-179
Power train
5] Install floating seal cover (15).

a Fit a cork plug in the forcing tap.
a Install the floating seal cover with its

cut-out portion facing down as shown
in the diagram below.
8. Wear guard
Lift and install wear guide (13).
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.
2) Using eyebolts [4], lift and install cover

assembly (14).
a Apply the 1216 ThreeBond adhesive to
the mating surfaces.
races (11) and (10).
3) Install floating seal cover (9).
50-180
D375A-6R
(01)
Power train
4) Set bearing (8) to the sprocket

assembly.
hub
7) Install holder (5).

2 Mounting bolt:
3
5) Using eyebolt [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.
6) Using tool J3, press fit bearing (7) portion.

a Press fit the sprocket hub assembly while
rotating it by hand.
D375A-6R
(01)
Adhesive (LT-2)
Mounting bolt:
276.85 31.85 Nm {28.25 3.25
kgm}
10. Hub
1) Lift and install hub (4) using eyebolts [2].
11. Cover
Using eyebolts [1], install cover (2).
50-181
Power train
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 l
a After installing the final drive assembly on the
machine, finally check that the oil is at the
specified level.
50-182
D375A-6R
(01)

Removal and installation of track frame assembly
Symbol
Part No.
50-183
Part name
L 24 791-685-1320 Lifting tool
Necessity
Q'ty
N/R
Sketch
Special tools
50-183
50-183
6. Using tool L13, lock the bogie assembly.

t 1
Removal
50-183
1. Remove the track shoe assembly. For details,
see Separation and connection of track shoe
assembly.
2. Place blocks [3] (at right and left sides) between
the equalizer bar and frame, to lock the equalizer
bar.
[*1]
9. Remove grease tube (4).
[*1]
11. Loosen front and rear bolts (6-1).
a Bolt: M30, width across flats: 46 mm
[*2]
3. 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 .
4. 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.
5. Sling the track frame assembly.
D375A-6R
(01)
50-183

13. 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 an "UP" mark at the top of the pin.
14. Remove the mounting bolts and remove cover

(7) from the track frame.
a Perform this step for only the right track

frame of the single tilt specification machine,
or both track frames of the dual tilt specifications machine.
17. Remove the mounting bolts and cover (11).
a Take care not to damage the hose connected
to the inside face of the cover.
18. Disconnect hoses (12) and (13) from the inside

face of cover (11), and remove cover (11).
[*4]
a Note the color of hose band for installation
purpose.
(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
LH: Dual tilt specification
16. Disconnect lower hose (9) and upper hose (10)

of the blade tilt cylinder.
50-184
D375A-6R
(01)


RH: Both single tilt and dual tilt specifications

[*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
20. Remove seal (15) and cover (14) as a unit.
[*6]
22. Using tool L24, sling and remove track frame

assembly (18).
4 Track frame:
7,940 kg (each)
21. Remove washer (16) and spacer (17).
D375A-6R
(01)
50-185

50-186
Connection
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), then tighten bolts (6-1).
3 Covers (2) and (3):
245 to 309 Nm {25 to 31.5 kgm}
[*2]
Bolt (6-1):
1,9602,450 Nm {200250 kgm}
[*3]
Bushing inner surface:
Grease(G2-LI)
a Install pin (6) with the "UP" mark up, which was
put upon removal.
a Align the notch of pin (6) with the mark of machine.
Apply grease (G2-LI) 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 center of equalizer
bar (EB) hole matches that of track frame hole.
a When aligning the pin holes, never insert your
fingers in the holes.
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.
50-186
D375A-6R
(01)

[*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 Seal contact surface (15):
a Be careful not to install the seal twisted.
D375A-6R
(01)
Refilling (Pivot shaft case)

level.
5 Pivot case:
18 l (EO30)
50-187

Removal and installation of idler assembly

Removal
50-18
1. Remove the track shoe assembly. For details,
assembly.
2. Remove scraper (1).
a Remove the inside scraper, too.
a Remove the inside cover, too.
50-18
Connection
50-18
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.
2 Mounting bolt:
Adhesive (LT-2)
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. Sling and remove idler assembly (4).
4 Idler assembly:
480 kg
50-188
D375A-6R
(01)

Disassembly and assembly of idler assembly
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
Plate
Rod
Block
Washer
Nut
Washer
t
t
t
t
t
t
1
2
1
2
2
2
Puller
(294 kN {30 ton})
5. Remove the mounting bolts. Using eyebolts [3],

remove shaft (5) and the retainer as a unit.
t 1
Part name
Pump
Installer
Push tool
Oil pump
Sketch
Quantity
Part No.
New/redesign
Symbol
50-189
Necessity
Special tools
50-189
6. Using puller [4], remove retainers (3) and (7) and

seal guide (6).
t 1
t 1
t 1
1
Disassembly
50-189
1. Remove the oil filler plug to drain oil.
6 Idler:
0.951.05 l
7. Remove seal guides (2) and (6) from retainers

(3) and (7).
2. Place idler assembly (1) on blocks [1] (approximately 140 mm high).
8. Remove plates (4) and (8) from the respective

retainers.
3. Remove mounting bolts, then using forcing

screws [2], remove seal guide (2), retainer (3)
and plate (4).
4. Turn over the idler assembly (1).
D375A-6R
(01)
50-189

9. Remove floating seal (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 floating seal (10) from retainers (3) and
(7).
a Keep the floating seal in a safe place so that
it does not get damaged.
50-190
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 Dimension (a): 17 0.5 mm
11. Remove bushing (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.
50-190
D375A-6R
(01)

3. Install retainer (3) with the O-ring and plate (4) to

the idler.
a Check that the plate can be turned smoothly
by hand.
4. Using eyebolts [3], set idler (12) to shaft (5).

a Place blocks (approximately 140 mm high)
under the idler.
5. Turn over the idler assembly.
a Tie the shaft with wire to prevent it from falling out.
D375A-6R
(01)
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) using tool L3.
a Seal guide press-fitting force: 43 71 kN {4.4
7.2 ton}
50-191

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 Dimension (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:
0.951.05 l(GO140)
3 Oil filler plug:
206 49 Nm {21 5 kgm}
VT: To vacuum tank
OP: To oil pump
50-192
D375A-6R
(01)

Removal and installation of recoil spring assembly
791-730-1110
01580-12722
01643-32780
M 1 790 - 101 2102
790 - 101 1102
Bolt
Nut
Washer
Puller
(294 kN {30 ton})
Pump
Sketch
Part name
N/R
Part No.
Q'ty
Symbol
50-193
Necessity
Special tools
50-193

5. Sling and remove trunnion (3).
4 Trunnion:
75 kg
t 5
t 5
t 1
t 1
t 1
Removal
50-193
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 pins.
7. Remove pin (5) using tool M1.
[*1]
a Remove both the inside and outside pins.
3. Using eyebolts [1], remove cover (1).

4 Cover:
40 kg
D375A-6R
(01)
50-193

8. Sling and remove the idler and recoil spring

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 recoil spring 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 load of approximately 500 kN {approx. 51 tons} at installed length. 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 recoil cylinder assembly (7) from

idler yoke assembly (8) according to the
[*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.
50-194
D375A-6R
(01)

3) Check that the loosening torque of all the

bolts suddenly drop. If so, it indicates that the
force of the recoil spring is not applied on the
mounting bolts. Then, remove all bolts.
a If the torque increases (the force 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.
D375A-6R
(01)
1] Prepare the following parts of tool M1:

q Six bolts [1]: 791-730-1110
q Six nuts [2]: 01580-12722
q Six washers [3]: 01643-32780 (reuse)
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.
50-195

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 approximately 230 mm, the spring is extended completely.
12. Disassemble the piston assembly (15) according

1) Remove wear ring (16) from the piston.
2) Remove snap ring (17) and packing (18).
13. Remove recoil spring assembly (19).

4 Recoil spring assembly:
550 kg
10. Remove ring (12).
11. Pump in grease through lubricator (13), and

remove cylinder (14) and piston assembly (15).
50-196
14. Remove holder (20) from the recoil spring

assembly.
D375A-6R
(01)

Connection
50-197
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 approximately 1.3 l 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.
D375A-6R
(01)
50-197

Disassembly and assembly of recoil spring assembly
Symbol
Part No.
50-198
Part name
Necessity
Quantity
New/redesign
Sketch
Special tools
791-685-8501
M 2
Compressor
790-101-1600
t 1
790-101-1102
791-635-3160
Pump
Extension
4. Remove rear pilot (5), spacer (6), bolt (7), and

pilot (8) from spring (4).
t 1
Cylinder
(980 kN {100 tons})
50-198
t 1
t 1
Disassembly
50-198
1. Set recoil spring assembly (1) to tool M2.
k Since the load at installed length of the
spring is large and dangerous, set the
spring securely to the tool.
a Load at installed length 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.
50-198
D375A-6R
(01)

Assembly
50-19
1. Install pilot (8), bolt (8), spacer (6), and pilot (5)
to spring (4), and set them to tool M2.
3. Install nut (3) and install lock plate (2).

a To prevent the nut from protruding from the
end of bolt (7), make a clearance of 01.0
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 then remove recoil spring
assembly (1) from tool M2.
Since the load at installed length of the

spring is large and dangerous, set the
spring securely to the tool.
2. Apply hydraulic pressure gradually to compress

the spring until the spring installed length is the
standard length.
a Installing length (a) of spring: 1,329.5 mm
a Load at installed length of spring: 500 kN
{50,994 kg}
D375A-6R
(01)
50-199

Removal and installation of track roller assembly
790-401-1700
790-401-1761
12
790-401-1540
790-401-1770
195-30-66611
L
01010-62490
01010-62455
13
01643-32460
19M-54-11770
198-30-66190
50-200
Lifting tool
Adapter
Shackle
T-bolt
Grip
Bolt
Bolt
Washer
Washer
Collar
t
t
t
t
t
t
t
t
t
t
1
1
2
2
3
5
5
5
5
5
N/R
Part name
Sketch
Part No.
Quantity
Symbol
50-20
Necessity
Special tools
50-20
Removal
50-20
1. Decrease the track tension. For details, see
"Separation and connection of track shoe
assembly".
2. Install tool L13 to lock the bogie assembly (1).
[*1]
S: Single flange
D: Double flange
D375A-6R
(01)

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 steel 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.
D375A-6R
(01)
50-201

50-202
Connection
[*1]
a After removing tool L13, 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.
50-202
D375A-6R
(01)

Disassembly and assembly of track roller assembly
Symbol
Part No.
8
9
L
10
11
791T-630-2220
796-670-1020
791T-630-2230
791-601-1000
50-203
Part name
Plate
Installer
Push tool
Oil pump
Disassembly
1. Remove oil filler plug to drain oil.
6 Track roller:
Necessity
Quantity
New/redesign
Sketch
Special tools
t
t
t
t
1
1
1
1
50-203
6. Using the press, remove seal guide (6), retainer

(7) and plate (8) from the shaft.
7. Remove seal guides (2) and (6) from retainers
(3) and (7).
Q
Q
50-203
1.4 1.5 l
2. Place track roller assembly (1) on block [1].

3. Remove mounting bolts, then using forcing
screws [2], remove seal guide (2), retainer (3)
and plate (4) as a unit.
4. Turn over the track roller assembly.
5. Remove the mounting bolts. Using eyebolts [3],
remove shaft (5) and the retainer as a unit.
D375A-6R
(01)
8. Remove floating seal (9) from seal guides (2)

and (6).
a Keep the floating seal in a safe place to prevent it from damaging.
9. Remove floating seal (10) from retainers (3) and
(7).
a Keep the floating seal in a safe place to prevent it from damaging.
50-203

10. Remove bushing (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
by hand.
50-204
Assembly
1. Set roller (12) to the press, and press fit bushing
(11) using tool L8.
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 Dimension (a): 17 0.5 mm
2. Set shaft (5) to the roller.
50-204
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}
D375A-6R
(01)

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 Dimension (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}
D375A-6R
(01)
50-205

Removal and installation of carrier roller assembly
Removal and installation of carrier roller assembly

Removal
50-206
1. Decrease the track tension. For details, see
"Sepatation and connection of track shoe
assembly".
2. Push up the track shoe by using hydraulic jack
[1].
50-206
50-206
Connection
[*1]
a Make a clearance of 1.75 mm between the carrier roller and support (a).
2 Carrier roller assembly mounting bolt :
Adhesive (LT-2)
3 Carrier roller assembly mounting bolt :
662829 Nm {67.584.5 kgm}
3. Sling and remove carrier roller assembly (1).

4
[*1]
Carrier roller assembly:
75 kg
50-206
D375A-6R
(01)

Disassembly and assembly of carrier roller assembly
791-601-1000
791-515-1520
791-830-1770
791-630-1270
Oil pump
Installer
Push tool
Wrench
t
t
t
t
5. Remove nut (4) using tool L7.
1
1
1
1
Sketch
4
5
L
6
7
Part name
Quantity
Part No.
New/redesign
Symbol
50-207
Necessity
Special tools
50-207
6. Using puller [2], remove the press-fitted seal

guide, and remove bearing (5) and roller (6) as a
unit using eyebolts.
Disassembly
50-207
1. Remove the oil filler plug to drain oil.
a Drain the oil while rotating the shaft.
6 Carrier roller :
0.70.8 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. Using puller [3], remove seal guide (8) and

bearing inner race (9) as a unit.
D375A-6R
(01)
50-207

9. Remove floating seal (10) from seal guide (8).
50-208
Assembly
1. Press fit bearing inner race (9) using push tool
[5].
2. Press fit bearing outer race (7) using push tool
[6].
10. Using push tool [4], remove seal guide (11).

11. Remove floating seal (12) from seal guide (11).
3. Set roller (6) and bearing inner race (5) to the

shaft.
4. Press fit bearing inner race (5) to the shaft using
push tool [7].
a Press-fit the bearing inner race while turning
the roller, until the roller becomes a little hard
to turn.
.
50-208
D375A-6R
(01)

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 0.010.22 mm.
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
leaning is less than 1 mm and that the protrusion (a) of the seal is between 7 to 11 mm.
7. Fit the O-ring and install cover (2).
D375A-6R
(01)
50-209

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).
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.
50-210
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-6R
(01)

Removal and installation of bogie assembly
50-21
13
1
2
3
4
14
5
195-30-66611
01010-62490
01010-62455
01643-32460
19M-54-11770
198-30-66190
791-630-2260
790-201-2730
791-630-2270
01580-12419
01643-32460
6 790-101-4000
7 790-101-1102
Part name
Grip
Bolt
Bolt
Washer
Washer
Collar
Plate
Spacer
Screw
Nut
Washer
Puller
(490 kN {50 ton})
Pump
t
t
t
t
t
t
t
t
t
t
t
3
5
5
5
5
5
1
1
3
3
3
t 1
t 1
Symbol
1
2
3
4
15 5
6
Part No.
791-630-2280
790-201-2770
791-630-2250
790-434-1070
01580-13629
01643-33690
7 790-101-4000
L
8
1
2
3
16 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
791-530-1510
791-601-1000
Part name
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
t
t
t
t
t
t
1
1
1
1
2
2
t
t
t
t
t
1
1
3
3
3
t
t
t
t
1
2
1
1
Removal
1. Decrease the track tension. For details, see "Sepatation and connection of track shoe assembly".
k Stop the engine and disconnect the cable from the negative (-) terminal of the battery.
2. Install tool L13 to lock the bogie assembly.
D375A-6R
(01)
N/R
Part No.
Sketch
Symbol
Quantity
Special tools
Necessity
50-21
Necessity
Quantity
N/R
Sketch
50-21
50-211

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
(Adjust the relief pressure of the link
press to obtain the pressing force.)
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 floating seal (5) from the end face 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).
50-212
D375A-6R
(01)


5) Pull out spacer (6) and rings (7) and (8).
a Pulling force: 205.8 382.2 kN {21 39
tons}
6) Remove spacer (6).

7) Remove spacer (9) and floating seal (10)
from 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).
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] towards outside to remove.
4 Bogie assembly:
720 kg
D375A-6R
(01)
50-213

50-214
Connection
1. Assembly of pin assembly.
1) Using tool L18, install floating seal (5) to rings
(4) and (7). Also, install floating seal (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 Portion (a) of ring (8) and ring (4)
(approximately 10 mm):
(LM-P)
4. Press-fitting of pin assembly

1) Set tool L16 and cover (2) in position.
50-214
D375A-6R
(01)

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:
245441 kN {2545 ton}
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).(two places, 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 with oil
Using tool L19, supply the specified amount of
oil.
a Refilling oil pressure: 0.49 MPa {5 kg/cm2}
5 Pin assembly:
95 115 cc(GO140)
D375A-6R
(01)
50-215

Disassembly and assembly of bogie assembly
1
2
3
4
791-630-2260
791-630-2270
01580-12419
01643-32460
Plate
Screw
Nut
Washer
16
Puller
L
5 790-101-4000 (490 kN {50
ton})
790 - 101 6
Pump
1102
19 791-601-1000 Oil pump
t
t
t
t
1
3
3
3
Sketch
Part name
New/redesign
Part No.
Quantity
Symbol
50-216
Necessity
Special tools
50-216
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 bogie (4) and outer bogie (5).
t 1
t 1
t 1
Disassembly
50-216
Turn over bogie assembly (1). Then, sling off two
track roller assemblies (2).
50-216
D375A-6R
(01)

Assembly
50-217
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 of oil
oil.
5 Pin assembly:
90 115 cc(GO140)
2. Set inner bogie (4) to outer bogie (5).

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:
Molybdenum disulfide lubricant
(LM-P)
a Full press-fitting force for pin assembly :
245441 kN {2545 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 places, inside and outside)
8241,030 Nm {84105 kgm}
Sling and install two track roller assemblies (2) to
bogie assembly (1).
2 Track roller mounting bolt:
Adhesive (LT-2)
3 Track roller mounting bolt:
1,1801,470 Nm {120150 kgm}
D375A-6R
(01)
50-217
Removal and installation of first bogie assembly
Symbol
14
1
2
3
4
5
6
7
1
2
3
4
5
15 6
7
8
1
2
3
4
L 16
5
6
17
18
19
1
20 2
3
4
21
50-218
Part No.
791-630-2360
790-201-2730
791-630-2270
01580-12419
01643-32460
50-218
Part name
Plate
Spacer
Screw
Nut
Washer
Puller
790-101-4000 (490 kN {50
ton})
790 - 101 Pump
1102
791-630-2280 Adapter
790-201-2770 Spacer
791-630-2250 Plate
790-434-1070 Screw
01580-13629 Nut
01643-33690 Washer
Puller
790-101-4000 (490 kN {50
ton})
790 - 101 Pump
1102
791-630-2260 Plate
791-630-2270 Screw
01580-12419 Nut
01643-32460 Washer
Puller
790-101-4000 (490 kN {50
ton})
790 - 101 Pump
1102
791T-630-229
Guide
0
791-601-1000 Oil pump
Bracket
791-630-1860
(L, H)
Bracket
791-630-1870
(R, H)
01010-62760 Bolt
01643-32780 Washer
791T-630-190
Lifting tool
0
791T-630-191
q Tube
0
791T-630-192
q Plate
0
07283-38973 q Grip
q Eyebolt
040-11628
01643-31645 q Washer
01643-31232 q Washer
01582-01210 q Nut
Necessity
Quantity
N/R
Sketch
Special tools
t
t
t
t
t
1
1
3
3
3
Removal
50-218
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.
t 1
t 1
t
t
t
t
t
t
50-218
1
1
1
1
2
2
3. Install eyebolts to the pad mounting bolts (two

M12 bolts) at the rear of the first bogie assembly
(1), and lift the first bogie assembly (1).
t 1
t 1
t
t
t
t
1
3
3
3
t 1
t 1
t 2
t 1
t 1
t 1 N
t 1 N
t 2
t 2
q 1
1
1
1
1
2
2
D375A-6R
(01)

4. Place a steel plate between the track shoe and

roller, and loosen roller cap bolts (2) for approximately 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 Push out force: 137.3274.6 kN {1428
ton}
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.
150 kg
3) Remove floating seal (9) from the end face of

rings (8) and (12).
7. Sling first bogie (5) by using tool L20.

D375A-6R
(01)
50-219

50-2 0
Connection
1. Assembly of pin assembly
1) Using tool L18, install floating seal (9) to rings
(8) and (12). Also, install floating seal (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: 205.8382.2 kN {2137
ton}
7) Remove spacer (14) and floating seal (10)
from between rings (12) and (13).
2)
3)
4)
5)
6)
Press fit shaft (7) to ring (13).

Install spacer (14).
Install spacer (11).
2 Portion (a) of ring (13) and ring (8)
(approximately 10 mm):
(LM-P)
10. Lower bogie (5) on the steel plate and pull it out.
4 Bogie assembly:
110 kg
50-220
D375A-6R
(01)

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 the machined
surface (b) of the bogie and maintain step
of 5 mm between the bogie and the pin
assembly.
2 Periphery of pin:
a Press-fitting force of pin assembly:
245441 kN {2545 ton}
4. Align the pin holes of the track frame and bogie,

and install guidance tool L17 in position.
6. Refilling of oil
oil.
5 Pin assembly:
95 115 cc(GO140)
D375A-6R
(01)
50-221

7. Press fit the pin assembly at the opposite side of

the bogie following the same procedure in Steps
5 and 6.
11. Gradually lower the machine and when the

clearance between bogie (5) and shaft (3)
becomes approximately 20 mm, install cap (15)
and tighten bolts (2) lightly.
8. Install cover (6). (two places, 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), sling and balance the track roller
assembly, and place it on the track shoes.
150 kg
50-222
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:
1,1801,470 Nm {120150 kgm}
13. Adjust the track tension. For details, see Testing

and adjusting, "Inspection and adjustment of
track tension".
D375A-6R
(01)

Separation and connection of track shoe assembly

Separation
50-2 3
1. Remove the blade assembly. For details see
"Removal and installation of blade assembly".
50-2 3
Checking before separation of the track shoe assembly

50-2 3
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.
D375A-6R
(01)
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)".
50-223

50-2 4
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: Approximately 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

track 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 chain block [4] between the carrier roller support and link to assure safety.
3. Remove track shoe (4) and separate master link
(3).
[*2]
50-224
D375A-6R
(01)

Separation of track shoe assembly (normal)

50-2 5
a If no abnormality is detected by "Checking before separation of track shoe assembly", perform
1. Position the master link.
a Locate master link (3) above the idler (a little
backward from the center).
a Place block [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).

k
[* 1]
Do not loosen lubricator (2) more than
one turn.
D375A-6R
(01)
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: Approximately 12.5 m
k For purposes of safety, check that no one
remains in front of the idler.
50-225

50-2 6
Connection
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}
Retightening angle: 120 10
50-226
D375A-6R
(01)

Overall disassembly and assembly of track shoe
Symbol
50-2 7
Part No.
Part name
791-646-7351 Push tool
791-660-7460 Pin brush

Push tool
3 791-646-7900
(For large plug)
791-701-3000 Seal checker
4
or
791-601-1000 Oil pump
Push tool
5 791-932-1110
(For small plug)
6 791-632-1021 Installer
Push tool assem1 791-632-1300
bly
2 791-632-1260 q Push tool
t 1
t 1
t 1
t 2
t 1
t 1
t 1 N
1
5 791-632-1230
Adapter
Adapter
(small)
Ring
6 791-632-1240
Plate
3 791-632-1270
4 791-632-1220
7
Necessity
Quantity
New/Remodel
Sketch
Special tools
q
q
1
1
1
7 791-685-5730
Bar
Ring
9 791-632-1280
8 791-632-1250
Spring
Bolt
50-2 7
Overall disassembly
50-2 7
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
Sling 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.
10 01252-30605
11 01580-01210
q Nut
1
t 1 N
bly
1
2 791-632-1260 q Push tool
3 791-632-1270
5 791-632-1230
Adapter
Adapter
(large)
Ring
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
4 791-632-1210
8
q
q
1
1
1
Nut
1
t 2 N
bly
9 2 791-685-5730 Bar
1
3 01580-01210 Nut
D375A-6R
(01)
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.
50-227

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 out the small plug of
the pin towards inside after disassembly
so that the work place does not become
dirty.
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
50-228
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.
D375A-6R
(01)

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".
D375A-6R
(01)
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.
50-229

50-230
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.".
Rebuilding the link assembly for lubricated
50-230
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.
50-230
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: 4560) 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).
D375A-6R
(01)

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.
D375A-6R
(01)
50-231

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
2. Assembly of link
1) Apply oil (GO90) between pin (3) and
bushing (4) 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:
196343 kN {2035 ton}
50-232
D375A-6R
(01)

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-6R
(01)
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.
50-233

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:
392686 kN {4070 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:
392686 kN {4070 ton}
13)Perform the press fitting until the link,

spacers, and bushing are mutually fitted.
50-234
D375A-6R
(01)

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.
D375A-6R
(01)
17)Using jig R9, install the ring into the pin

groove on the other side similarly.
50-235

18)Press the ring by using jig R10.

a Pressing force: 294372 kN {3038 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 (L) Dimension: 4070 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.
Press-fitting length 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.
50-236
D375A-6R
(01)

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}
Retightening angle:
120 10
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}
Retightening angle:
180 10
a Tighten the bolts in the order of [1] [4].
D375A-6R
(01)
50-237

Rebuilding the link assembly for grease lubri50-238

cated 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.
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.
50-238
D375A-6R
(01)

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. Assembly of link
1) Apply lithium grease (G2-LI) between pin (3)
and bushing (4) 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.
196343 kN {2035 ton}
D375A-6R
(01)
50-239

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.
50-240
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.
D375A-6R
(01)

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
forceC 1.8
x
Average
press-fitting 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:
294372 kN {3038 ton}
D375A-6R
(01)
50-241

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 (L) Dimension: 4070 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}
Retightening angle:
120 10
13)After filling grease, drive in the small plug to

the specified position by using tool R5.
a Drive in the plug to the following depth.
Press-fitting length 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.
50-242
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}
Retightening angle:
180 10
a Tighten the bolts in the order of [1] [4].
D375A-6R
(01)

D375A-6R
(01)
50-243

Link press press-fitting jig dimensions
50-24
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.
50-244
D375A-6R
(01)

Disassembly and assembly of one link assembly in the field
Special tools
50-245
Symbol
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
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
D375A-6R
(01)
t 1
t 1
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
Symbol
21
22
23
24
R 7 25
26
27
28
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
Quantity
New/Remodel
Sketch
50-245
Necessity
Quantity
New/Remodel
Sketch
1
1
1
2
t 1
t 1
t 1
t 1 N Q
Disassembly
50-245
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 R7-3to the link withR7-4.
a Use the shoe bolts for installing tool R7-24.
50-245

2. Assemble tools R7-25 and R7-5 to R7-11, then

sling them to place on the shoe.
a If cylinder reaches its stroke end, connect

tool R7-17 and repeat the work.
3. Insert tool R7-12 from the cylinder side, and

install it by using two tools R7-8.
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 56 mm to disconnect them.
4. Set tools R7-13 to R7-16, connect tool R7-26,

and then apply oil pressure to pull out the pin (2).
6. Repeat steps 1 to 4 to pull out another pin (3) on

the other side.
7. Repeat step 5 to remove links (4).
50-246
D375A-6R
(01)

Assembly
50-247
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).
196294 kN {2035 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:
206323 kN {2133 ton}
D375A-6R
(01)
50-247

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, and R7-17 to the links.
5. Use tools R7-19 and R7-21 to press fit the
pin-bore end and use toolR7-22, R7-18,
andR7-21 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.
206323 kN {2133 ton}
a Press-fitting force for bushing:
196294 kN {2030 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.
50-248
D375A-6R
(01)

7. Set link (11) to be connected to link (10), connect

them by using tool R7-23, and then remove tools
R7-27and R7-28.
8. Similarly to the disassembly procedure, set tool

R7-2 and press fit pin R7-12 (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.
412646 kN {4266 ton}
a When the cylinder reaches its stroke end,
add tool R7-17, and R7-14 toR7-16, then repeat the work.
D375A-6R
(01)
50-249

Disassembly and assembly of master link
Special tools
50-250
Symbol
1
Part No.
Part name
791-646-7351 Push tool
791-660-7460 Pin brush

Push tool (for
3 791-646-7900
large plug)
791-701-3000
Seal checker oil
4
or
pump
791-601-1000
Push tool (for
5 791-932-1110
small plug)
6 791-632-1021 Installer
Remover &
1 791-632-1100
installer assembly
2 791-632-1130 q Adapter
Symbol
t 1
Part No.
Part name
26 790-101-1102 Pump
Cylinder
7 27 790-101-4200
(294 kN {30 ton})
28 791-680-1630 Spacer
bly
2 791-632-1260 q Push tool
t 1
t 1
t 2
Necessity
Quantity
N/R
Sketch
50-250
Necessity
Quantity
N/R
Sketch
t 1
t 1
t 1
t 1 N
1
t 1
3 791-632-1270
Adapter
t 1
4 791-632-1220
Pin (small)
t 1
5 791-632-1230
Ring
8 6 791-632-1240
Plate
7 791-685-5730
Bar
3 790-434-1610
Guide
8 791-632-1250
Ring
4 01010-51440
Bolt
9 791-632-1280
Spring
5 791-685-9510
Frame
10 01252-30605
Bolt
6 791-685-9530
Rod
11 01580-01210
7 791-685-9520
Frame
8 791-685-9550
Nut
9 04530-12030
Eyebolt
10 791-685-9560
Bolt
11 791-126-0150
Adapter
12 791-685-9540
7
q
q
Rod
13 791-632-1140
Adapter
14 791-680-5520
Guide
15 01010-51030
Bolt
16 791-632-1150
Pusher
17 791-685-9620
Extension
18 791-632-1180
Adapter
19 791-680-5543
Adapter
20 791-632-1160
Guide
21 791-680-5551
Guide
22 791-680-9630
Adapter
Nut
1
t 1 N
bly
1
2 791-632-1260 q Push tool
3 791-632-1270
Adapter
4 791-632-1210
Pin (large)
5 791-632-1230
9 6 791-632-1240
Ring
Plate
7 791-685-5730
Bar
8 791-632-1250
Ring
9 791-632-1280
Spring
10 01252-30650
Bolt
11 01580-01210
Nut
1
t 2 N
bly
10 2 791-685-5730 Bar
1
23 791-632-1160 Guide
Nut
24 195-32-61210 Bolt
Cylinder
25 790-101-4300 (1,470 kN {150
ton})
3 01580-01210
50-250
t 1
D375A-6R
(01)

Disassembly
50-251
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) from bushing (3) at the same time.
D375A-6R
(01)
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. ToolR7
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) from bushing (3)
simultaneously.
q Special tools:
1. Gas cutting machine
2. ToolR7
50-251

50-252
Assembly
a For the method of using tool R7, see "Disassembly of one link assembly in the field."
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.
2) Set spacers (6) and seal assemblies (7) to

the bores of links (2a) to be connected.
(3): Bushing
Unit: mm
L1
184 0.7
L2
253.4 0.7
D1
33 drill
D2
30 x 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.))
50-252
3) Match the pin bores of the links and the bores

for bushing (3) of the master links, and
connect them with guide pin [1].
4) Press fit pin (5) by using tool R7 to install

master links (4) with bushing bore.
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.
D375A-6R
(01)

6) Install the track shoe to the links of the

connecting part.
7) Drive in large plug (8) by using tool R3, fill 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 00.13 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
D375A-6R
(01)
2) Pass pin (5) through bushing (3), set right

and left master links (4) with pin-bore, 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, fill 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 (4a) with pin-bore of one assembly
and master links (4b) with bushing-bore 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}
Retightening angle:
180 10
50-253

Removal and installation of pivot shaft assembly
Removal and installation of pivot shaft assembly
Quantity
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
[*2]
N Q
N Q
Removal
50-254
1. Remove the track frame assembly.
Separate the track shoe assembly from the track
frame. For details, see "Separation and connection track shoe assembly.
[*1]
Pivot shaft assembly:
390 kg
50-254
50-254
Connection
[*1]
2. Sling pivot shaft assembly (1), remove the

mounting bolts, and pull out the pivot shaft
assembly using forcing screws [1].
4
3. Remove seal (2), then remove cover (3).
Sketch
Part name
New/redesign
Part No.
Sym-b
ol
1
2
3
4
5
6
7
8
9
50-254
Necessity
Special tools
50-254
Press-fitting surface of pivot shaft :

[*2]
a Press fit the seal (2) to the pivot shaft using tool
P.
2 Press-fitting surface of seal:
a Check that press-fitting dimension (a) of the seal
from the end face of the shaft is the specified dimension.
q Dimension (A): 665 1.0 mm
D375A-6R
(01)

Removal and installation of equalizer bar
Sketch
Part name
Quantity
Part No.
New/redesign
Symbol
50-25
Necessity
Special tools
50-25
4. Remove washer (4) and spacer (5).

a Oil will flow out from the pivot case, so use a
container to receive the oil.
6 Pivot case:
18 l
Remover
t 1
Sleeve
1
Screw
1
Nut
1
Washer
Puller
790-101-2102
t 1
(294 kN {30 ton})
790-101-1102 Pump
t 1
791-650-1300
791-735-1123
790-434-1050
01580-02419
1
01643-32460
Removal
50-25
1. Remove the engine underguard and the power
train underguard (front).
4 Engine underguard:
290 kg
Power train underguard (front):
280 kg
5. Place hydraulic jack [1] (490 kN {50 ton}) under

the radiator guard.
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 across flats: 46 mm
D375A-6R
(01)
50-255

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 equalizer bar
touches right and left track frames.
14. Disconnect lubrication tube (12).
15. Remove two lock plates (13).
[*5]
11. Remove side pin (10).
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].
[ *4]
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 bar by operating hydraulic jack [1].
a Put an "UP" mark at the top of the pin.
50-256
D375A-6R
(01)

17. Raise the front of the machine by operating the

blade, and place stand [3] under the radiator
guard.
50-257
Connection
[*1]
a Degrease the press-fitting surface of the seal.
2 Press-fitting surface of seal:
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
D375A-6R
(01)
Bolts (9) and (9-1):

1,960 2,450 Nm {200 250 kgm}
[*4]
Bushing inner surface:
Grease(G2-LI)
a Before installing the pin, adjust the height of the
main frame by operating hydraulic jack [1] to
align the center of the equalizer bar hole with
that of track frame hole.
a Install pin (10) with the "UP" mark up, which was
put upon removal.
50-257

[*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 of oil
level.
5 Pivot case:
18 l (SAE30)
50-258
D375A-6R
(01)

Disassembly and assembly of equalizer bar bushing
Symbol
N 2
Part No.
50-259
Part name
1 791T-650-2410 Bracket
2 791T-650-2420 Bracket
3 790-438-1110 Screw
4 791-112-1180 Nut
5 790-101-2540 Washer
Puller
6 790-101-2102 (294 kN {30
ton})
7 790-101-1102 Pump
Disassembly
1. Center bushing
1) Remove center bushing (1).
Necessity
Q'ty
New/redesign
Sketch
Special tools
t
t
t
t
t
50-259
3) Set toolN2 to remove side bushing (4) from

equalizer bar (5).
1 N Q
1 N Q
1
2
2
t 1
t 1
50-259
2. Guide bushing
1) Remove seal (2).
2) Remove snap ring (3).
D375A-6R
(01)
50-259

50-260
Assembly
1. Side bushing
1) Set side bushing (4) and tool N2, and 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.

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:
9.829.4 kN {13 ton}
a Press fit the seal so that its metal ring
does not protrude from the end face of the
equalizer bar.
2 Seal lip:
Grease(G2-LI)
1] Set the outer bushing with split faces

(a) (mating face) level.
2] Set the greasing holes (b) of the inner
and outer bushings at an angle.
a Press-fitting force for side bushing:
34.373.5 kN {3.57.5 ton}
2. Center bushing
Press fit bushing (1) by using the press.
2 Outside surface of center bushing:
(LM-P)
a Press-fitting force for center bushing:
4.9186.2 kN {519 ton}
50-260
D375A-6R
(01)

Removal and installation of segment tooth

Removal
50-261
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.
50-261
50-261
Connection
2 Seat of segment tooth mounting nut:
(LM-P)
3 Segment tooth mounting nut:
1,813 98 Nm {185 10 kgm}
3. Remove the mounting bolts and remove

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
D375A-6R
(01)
50-261
Hydraulic system
Removal and installation of hydraulic tank assembly
Hydraulic system
50-262
50-262
Removal
50-262
k 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".
1. Drain the hydraulic tank.
6 Hydraulic tank:
130 l
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.
50-262
D375A-6R
(01)
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-6R
(01)
8. Remove four hydraulic tank mounting bolts (16).
9. Sling and remove hydraulic tank assembly (17).

[*1]
4 Hydraulic tank assembly:
240 kg
50-263
Hydraulic system
50-264
Connection
a Install the tank assembly properly, so that the
tank side is flush with the fender outside surface.
Step (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.
5 Hydraulic tank:
130 l
q
Air bleeding
hydraulic circuit".
50-264
D375A-6R
(01)
Hydraulic system
Removal and installation of work equipment pump assembly

Removal
50-265
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.
6 Hydraulic tank:
130 l
2. Sling undercover (1) and lower it by using lifting
tool [1].
a Because one side of the undercover is
hinged, remove bolts on the other side to
sling the undercover.
50-265
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-6R
(01)
50-265
Hydraulic system
2) Disconnect connectors DEC (4) and BRK (5).

3) Remove the mounting bolts of floor plate (6).
4) Disconnect 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.
50-266
D375A-6R
(01)
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-6R
(01)
50-267
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.
[*3]
15. Disconnect tube (33) from work equipment
pump assembly (34).
Clamp mounting bolt:

24.529.4 Nm {2.53.0 kgm}

5 Hydraulic tank:
130 l
Air bleeding
hydraulic circuit".
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
50-268
D375A-6R
(01)
Hydraulic system
Removal and installation of fan pump assembly

.
50-269
Removal
k Loosen the oil filler cap of the hydraulic oil
tank gradually to release the internal pressure of the hydraulic tank.
50-269
9. Loosen suction tube clamp (8) and disconnect

suction tube (9).
1. Drain the oil from the hydraulic tank.

6 Hydraulic tank: 130 l
"Removal and installation of ROPS guard
assembly."
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-6R
(01)
50-269
Hydraulic system
Installation
q
50-270
(Refilling)
5 Hydraulic tank: 130 l
q
Air bleeding
a Bleed air from the piping. For details, see
Testing and adjusting "Bleeding air from fan
pump".
50-270
D375A-6R
(01)
Hydraulic system
Removal and installation of control valve assembly

.
50-271
Removal
k Release the internal pressure of the hydraulic tank and remaining pressure inside piping. For details, see Testing and adjusting
"Releasing remaining pressure of hydraulic
cylinder".
a Note the connection points of each disconnected
hose.
50-271
3. Disconnect three hose clamps (9).
2. Disconnect PPC hoses (3) to (8).

(hose band color)
(3): White
(4): Green
(5): Black/Blue
(6): Brown
(7): Black
(8): Yellow
D375A-6R
(01)
50-271
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
50-272
Connection
(Refilling)
5 Hydraulic tank:
130 l
q Bleeding air
hydraulic circuit".
.
50-272
D375A-6R
(01)
Hydraulic system
Disassembly and assembly of control valve assembly
50-273
a This section provides only the precautions when assembling the control valve assembly.
50-273
Assembly
a Clean all parts, check them for dirt and flaw, and
apply oil to the sliding surfaces before assembling.
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):
176.6196.1 Nm {1820 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):
137157 Nm {1416 kgm}
D375A-6R
(01)
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):
176.6196.1 Nm {1820 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):
176.6196.1 Nm {1820 kgm}
Check that O-ring (45) is fitted in check valve
assembly (44), and install check valve assembly
(41) to valve body (1).
3 Check valve assembly (44):
58.878.5 Nm {68 kgm}
50-273
Hydraulic system
6. Installation of plug
1) Installation of plug (46)
1] Install retainer (50) to valve body (1).
2] Fit O-ring (47) and backup ring (48) to
plug (46), and install plug (46) to valve
body (1).
3 Plug (46):
274.6367.7 Nm {2837.5 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):
176.6196.1 Nm {1820 kgm}
(52) (2 places), (53), and (58) (2
places):
19.627.5 Nm {22.8 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):
372.7465.8 Nm {3847.5 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).
50-274
(54) and (55):

107.8140.7 Nm {11.015.0 kgm}
(56):
29.439.2 Nm {34.8 kgm}
(57):
107.7161.8 Nm {1216.5 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):
7.813.7 Nm {0.81.4 kgm}
Suction safety valve assembly (30a):

176.6196.1 Nm {1820 kgm}
D375A-6R
(01)
Hydraulic system

1) Install valve (25a) and spring (24a) to valve
body (1a).
2) Fit backup ring (28a) and O-ring (27a) to plug
(29a), and install plug (29a) to valve body
(1a).
3 Plug (29a):
176.6196.1 Nm {1820 kgm}
Fit O-ring (33a) to check valve assembly (32a),
and install check valve assembly (32a) to valve
body (1a).
3 Check valve assembly (32a):
(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):
176.6196.1 Nm {1820 kgm}
D375A-6R
(01)
58.878.5 Nm {68 kgm}

1) Fit O-ring (35a), O-ring (36a), backup ring
(37a) to plug (34a), and install plug (34a) to
valve body (1a).
3 Check valve assembly (32a):
58.878.5 Nm {68 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):
7.813.7 Nm {0.81.4 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):
176.6196.1 Nm {1820 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):
58.878.5 Nm {68 kgm}
50-275
Hydraulic system

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).
(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):
176.6196.1 Nm {1820 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):
176.6196.1 Nm {1820 kgm}
50-276
Plug (27b):
176.6196.1 Nm {1820 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):
7.813.7 Nm {0.81.4 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):
58.878.5 Nm {68 kgm}
D375A-6R
(01)
Hydraulic system

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):
176.6196.1 Nm {1820 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):
176.6196.1 Nm {1820 kgm}
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}
(33c)(3 places):
7.813.7 Nm {0.81.4 kgm}
D375A-6R
(01)
50-277
Hydraulic system
Disassembly and assembly of blade PPC valve assembly
50-278
a This section provides only the precautions when

assembling the blade PPC valve assembly.
a As the parts look alike, note the locations to
which they are installed during disassembly.
a Spare part cannot be supplied individually for the
following parts. If any of them needs to be 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.
50-278
D375A-6R
(01)
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.
grease(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).
body bore.
3. Install the blade tilt valve.
shim (43) and piston (24).
body bore.
4. Install orifice (25).
3 Orifice:
11.814.7 Nm {1.21.5 kgm}
D375A-6R
(01)
5. Fit O-rings (26) and (27), and install plate (28).
50-279
6. Fit O-rings (26) and (27), and install valve body

(29).
7. Install seal (30) to valve body (29).
8. Install plates (31) and (32).
3 Mounting bolt:
11.814.7 Nm {1.21.5 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): 57 mm from end face
2 Body female threads (A):
Liquid adhesive (Loctite No.
648)
3 Joint (33):
3949 Nm {45 kgm}
a Apply gear oil grease(G2-LI) to the sliding

portion of the joint.
(J area): Apply grease (G2-LI) 710 ml to
entire surface.
(P portion): Apply gear oil 0.20.4 ml to the
sliding portions (4 places) between joint and
pin.
50-279
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 combined 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):
93.1112.7 Nm {9.511.5 kgm}
a After installing the disc, adjust the disc

height. For details, see Testing and adjusting, "Adjusting PPC valve".
50-280
D375A-6R
(01)
Hydraulic system
Disassembly and assembly of ripper PPC valve assembly

a This section provides only the precautions when
assembling the ripper PPC valve assembly.
a Spare part is not available for nipples (18) and
(19). Do not remove them unless necessary.
Assembly
50-281
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 end
(inside diameter) facing shims (3).
50-281
3. Install spring (5), (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 pistons (8), apply grease to
their outside and the inside of the valve body
holes.
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:
11.814.7 Nm {1.21.5 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): 57 mm from end face
2 Body female threads (A):
Liquid adhesive (Loctite No.
648)
3 Joint (13):
3949 Nm {45 kgm}
D375A-6R
(01)
50-281
Hydraulic system
.
a Apply gear oil and grease(G2-LI) to the sliding portions of the joint.
(J area): Apply grease (G2-LI) 710 ml to
entire surface.
(P area): 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:
6988 Nm {79 kgm}
a After installing the disc, adjust the disc
height. For details, see Testing and adjusting, "Adjusting PPC valve".
50-282
D375A-6R
(01)
Hydraulic system
Disassembly and assembly of hydraulic cylinder assembly
50-283
Special tools
50-283
Part No.
Part name
1 790-502-1003 Stand
790-201-1702 Push tool kit
Necessity
Quantity
New/redesign
Sketch
Symbol
50-283
t 1
Disassembly
1. Cylinder tube
Remove the cylinder tube.
2. Quick drop valve assembly
a Blade lift cylinder only.
1) Remove quick drop valve assembly (1).
t 1
790-201-1841
Push tool
2 790-201-1861
Push tool
790-101-5021
Grip
01010-50816
Bolt
1
t 1
790-201-1650
Plate
3 790-201-1670
Plate
790-101-5021
Grip
01010-50816
Bolt
4 790-720-1000 Expander
t 1
796-720-1680 Ring
07281-01589 Clamp
796-720-1720 Ring
t 1
07281-02429 Clamp
t 1
t 1
07281-02169 Clamp
6
t 1
796-720-1690 Ring
t 1
t 1
790-102-4300 Wrench
t 1
790-102-4310 Pin
t 2
D375A-6R
(01)
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).
50-283
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.
4. Piston assembly
q Blade lift cylinder, and blade tilt cylinder
1) Set piston rod assembly (10) to toolU1.
50-284
2) Remove bolt (11).

4) Remove valve (13) from spacer (12). (Only
for lift cylinder)
5) Remove piston assembly (14).
6) Remove the backup ring (15) and O-ring
(16).
7) Remove retainer (17).(lift cylinder only)
.
8) Disassemble the piston assembly according
1] Remove wear ring (18).
2] Remove piston ring (19).
a Do not reuse valve (V) and seat (S).
BL: Blade lift cylinder
BT: Blade tilt cylinder
D375A-6R
(01)
Hydraulic system
Ripper lift cylinder and ripper tilt cylinder

1) Set piston rod assembly (10) to toolD1.
3) Using tool U6, remove piston assembly (30)

from piston rod (32).
2) Remove lock screw (31) of piston assembly

(30).
q Screw size: M12 x pitch 1.75
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).
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.
D375A-6R
(01)
50-285
Hydraulic system

1) Remove cylinder head assembly (20) from
the piston rod.
50-286
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) and dust seal

(24).
3] Remove rod packing (25) and buffer ring
(26).
4] Take off snap ring (27) and remove
bushing (28).
50-286
D375A-6R
(01)
Hydraulic system
6] Install backup ring (22) and O-ring (21).
2) Install cylinder head assembly (20) to the

piston rod.
a Use new valve (V) and new seat (S).
2) Install retainer (17).(lift cylinder only)

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)
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 on the tool and turn
the handle of the tool by eighy to ten
turns to expand the piston ring.
2] Remove piston ring (19) from tool U4 and
intall it to the piston.
3] Using tool U5, compress piston ring (19).
4] Install wear ring (18) to the piston.
D375A-6R
(01)
50-287
Hydraulic system
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.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
Lift cylinder
98122.6 Nm {1012.5 kgm}
Tilt cylinder
157196 Nm {1620 kgm}
4] Install wear ring (34).

5] Install backup rings and O-ring (33).
a Install the backup rings after warming
it in hot water at about 5060 C.
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 them 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 rotate the handle 8 -10 turns to expand
the piston ring.
2] Remove piston ring (35) from tool U4 and
intall it to the piston.
3] Using tool U5, compress piston ring (35).
50-288
D375A-6R
(01)
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: 12x1.75
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:
Liquid adhesive (Loctite No.262)
3 Screw:
58.973.6 Nm {6.07.5 kgm}
D375A-6R
(01)
50-289
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:
Liquid adhesive (Loctite No.262)
3 Screw:
58.973.6 Nm {6.07.5 kgm}
4. Quick drop valve assembly

a Blade lift cylinder only.
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 Retract 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.
50-290
5. Cylinder tube
Install the cylinder tube.
D375A-6R
(01)
Hydraulic system
Disassembly and assembly of ripper pin puller cylinder assembly
Cylinder repair
stand
1 790-502-1003
790-201-1721
Push tool
Grip
Bolt

U
1
t
790-201-1530
Plate
790-101-5021
Grip
01010-50816
Bolt
1
t
796-720-1630 Ring
07281-00709 Clamp
4 790-720-1000 Expander
5
Disassembly
50-291
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.
790-101-5021
01010-50816
Sketch
Part name
New/redesign
Part No.
Quantity
Symbol
50-291
Necessity
Special tools
50-291
7 790-102-2302 Wrench

1) Remove cylinder head assembly (2) from
piston rod (3).
D375A-6R
(01)
50-291
Hydraulic system
2) Remove O-ring (5) and backup ring (6).

3) Remove O-ring (7).
4) Take off snap ring (8) and remove dust seal
(9).
5) Take off rod packing (10) and remove
bushing (11).
50-292
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 toolU5, compress piston ring (12).

Remove piston ring (12) from piston rod (3).
50-292
D375A-6R
(01)
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 Retract the piston fully.
3) Using tool U7, tighten cylinder head
assembly (2).
441 44.1 Nm {45 4.5 kgm}
3) Install snap ring (8) and rod packing (10).

4) Install O-ring (7).
5) Install backup ring (6) and O-ring (4).
D375A-6R
(01)
50-293
Work equipment
Removal and installation of blade assembly
Work equipment
50-294
50-294
Removal
50-294
k Park the machine on a level place and lower
the work equipment to the ground completely.
1. Set blocks [1] securely under right and left
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.
5. Sling up 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.
50-294

a Plug the hose to prevent dust etc. from entering the piping.
8. Remove right and left 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.
D375A-6R
(01)
Work equipment
Connection
50-295
[*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): 863 mm
q Distance between frames (c): 3,484 mm

D375A-6R
(01)
50-295
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.
50-296
50-296
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
1. Remove right frame covers (1) and (2).

2. Disconnect tilt cylinder hoses (3).
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.
50-296
D375A-6R
(01)
Work equipment
6. Sling right straight frame (9) and disconnect right

center brace (7).
remove right straight frame (9).
4 Straight frame:
1,150 kg
8. Sling tilt brace (11), remove the lock plate, and

remove the pin from the blade.
sling and remove 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-6R
(01)
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
50-297
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".
50-298
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 securely 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 shim thickness: 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 shim thickness: 4.5 mm
4 Center brace:
220 kg
a Install center brace (7) of the opposite side in
the same manner.
50-298
D375A-6R
(01)
Work equipment
6. Sling tilt cylinder (4), install pin (6), and secure

with the lock plate.
380 kg
7. Install pin (5), 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.
11. Sling tilt brace (11), install pin (13), and secure
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 Each portion of the work equipment:
Grease(G2-LI)
D375A-6R
(01)
50-299
Work equipment
Disassembly and assembly of giant ripper assembly

Disassembly
1. Make both tracks of the machine ride blocks [1],
stop the machine 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
4. Set stand [2] under the arm and beam.
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.
50-30
50-30
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).
8. Sling tilt cylinder assembly (7), remove pin (8),

and remove tilt cylinder assembly (7).
270 kg
6. Sling the tilt cylinder assembly and remove pin

(3).
50-300
D375A-6R
(01)
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
Assembly
50-301
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.
11. Sling arm (13), remove right and left pins (14),
and remove arm (13).
4 Arm:
1,000 kg
D375A-6R
(01)
50-301
Work equipment
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
4. Sling tift cylinder assembly (7) and set it to the

mounting position. Install pin (8), and secure it
270 kg
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.
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.
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].
5. Connect two pin puller cylinder hoses (6), four tilt

cylinder hoses (5), and four lift cylinder hoses
(4).
50-302
12. Bleed air from the cylinders. For details, see

hydraulic cylinder".
D375A-6R
(01)

Removal and installation of ROPS guard
50-303

Removal
50-303
1. Remove antenna (1).
50-303
Connection
50-303
[*1]
ROPS guard mounting bolt :

1,5191,911 Nm {155195 kgm}
[*2]
Installed direction of ROPS guard
2. Sling ROPS guard (2), and remove the twelve

mounting bolts.
[*1]
3. Sling and remove ROPS guard (2).
[*2]
4 ROPS guard:
700 kg
D375A-6R
(01)
50-303

Removal and installation of operator's cab assembly
50-304
Removal
50-304

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.
50-304
6. Remove back side cover (9) of the monitor

panel.
D375A-6R
(01)

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 sling and remve operator's cab
assembly (16).
4 Operator cab assembly:
500 kg
D375A-6R
(01)
50-305

Connection
a Before installing the operators cab, loosen the
mounting bolts of angle (7) and those of angle
(10) inside the operators cab.
1. Seal
1) Fit seal (17) to guide plate (18) of the air
conditioner box.
2 Part (A) on outside of seal (sealing
face agaist cab):
Grease(G2-LI)
50-306
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) lightly.
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.
2) Sling operators cab assembly (16), and bond

seal (19) to the mating face.
50-306
D375A-6R
(01)

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-6R
(01)
50-307

Removal and installation of floor frame assembly
50-308
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.
50-308
1. Collect the air conditioner refrigerant (R134a)

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 Collected amount of refrigerant:1,100 100
g
6 Hydraulic tank:
130 l(refill capacity)

6 Radiator:
120 l

assembly."
7. Remove the covers according to the following
procedure.
50-308
D375A-6R
(01)


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)
17. Disconnect two clamps (23).
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]
18. Disconnect clamps (24) and (25).
19. Disconnect PPC hose (26) (band color: green).

20. Disconnect hydraulic hose (27).
D375A-6R
(01)
50-309

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 (38).
6) Roll up lever cover (41) and remove four
mounting bolts (44) of each lever.
7) Lower the levers and PPC valve as a unit
below the console.
27. Remove left console cover (45).
24. Remove pin (34) and disconnect parking brake

cable (35) from lever (36).
[*3]
a Note the installed dimensions of the cable
before disconnecting.(Nut position: N)
25. Remove pin (37) and disconnect brake rod (38)
from lever (39).
[*4]
a Note the installed dimension of the brake rod
before disconnecting it.
50-310
D375A-6R
(01)

29. Remove four mounting bolts (48) at the left front

of the floor frame.
[*6]
30. Remove mounting bolt (49) at the right front of
the floor frame.
[*7]
31. Sling and remove 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
28. Remove four mounting bolts (47) each at the
right rear and left rear of the floor frame.
[*5]
D375A-6R
(01)
50-311

50-312
Connection
[*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 pipes, apply
compressor oil for new refrigerant (R134a)
(DENSO: ND-OIL8) or ZEXEL:ZXL100PG
(PAG46 or the equivalent) to the O-rings.
[*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}
Tightening torque for air conditioner

gas piping.
Thread size
16 x 1.5
22 x 1.5
24 x 1.5
M6 bolt
(receiver portion)
M6 bolt
(compressor portion)
5 Coolant:
120 l
Charging air conditioner with refrigerant
Charge the air conditioner circuit with refrigerant
(R134a).
a Refill capacity: 1,100 100 g
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}
9.8 1.96 Nm {1.0 0.2 kgm}
[*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".
50-312
D375A-6R
(01)
Cab and its attachm

ents
Rem
oval and installation of air conditioner unit assem
bly
Removal and installation of air conditioner unit assembly
50-313
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.
50-313
1. Collect the air conditioner refrigerant (R134a).

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 Collected amount of refrigerant: 1,100 100
g
6 Radiator:
120 l
3. Remove the covers according to the following
procedure.
D375A-6R
(01)
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]
50-313

8. Disconnect wiring connectors DS3 (10), DS1

(11), DS2 (12), DS4 (13), and DS5 (14).
11. Remove covers (21a) and (21b).

[*4]
9. Open air conditioner filter cover (15).
12. Remove right and left foot rests (22).

13. Remove right and left ducts (23).
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
50-314
(From right top)

(19): ADH
(20): OPSW
D375A-6R
(01)


18. Disconnect wiring connectors CM01 (29) and

CM02 (30).
16. Disconnect wiring connector AC1 (26).
19. Disconnect wiring connectors AC2 (31) and AC3

(32).
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.
D375A-6R
(01)
20. Disconnect four relay wiring connectors (33).

21. Disconnect wiring connector (34) of the servomotor.
22. Disconnect wiring connector M26 (35).
50-315

23. Remove back side cover (36) of the monitor

panel.
26. Remove each two mounting bolts (41a), (41b),

and (41c) of the air conditioner unit assembly,
and remove air conditioner unit assembly (42).
(41a): 2 places, lower left and lower right of this
side
(41b): 2 places, lower left and lower right of
engine side
(41c): 2 places, engine upper side
24. Disconnect dummy connector (37) from clip

(38).
25. Disconnect clamp (40) of wiring (39).
50-316
D375A-6R
(01)

(a): Installed position of bolts (41a)

(b): Installed position of bolts (41b)
(c): Installed position of bolts (41c)
Connection
50-317
[*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 pipes, apply
compressor oil for new refrigerant (R134a)
(DENSO: ND-OIL8) or ZEXEL: ZXL100PG
(PAG46 or the equivalent) to the O-rings.
Tightening torque for air conditioner gas

plping.
Thread size
16 x 1.5
22 x 1.5
24 x 1.5
M6 bolt
(receiver portion)
M6 bolt
(compressor portion)
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}
9.8 1.96 Nm {1.0 0.2 kgm}
[*2]
D375A-6R
(01)
Air hose clamp:

6.8 0.49 Nm {0.69 0.05 kgm}
50-317

[*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).
Charging air conditioner with refrigerant

Charge the air conditioner circuit with refrigerant
(R134a).
5 Coolant:
120 l
50-318
D375A-6R
(01)
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
50-319
50-319
50-319
50-319
Connection
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).
D375A-6R
(01)
50-319
Electrical system
Removal and installation of engine controller assembly

Removal
50-320
50-320
3. Disconnect wiring connector GC3 (3), EGC1 (4)
and EGC2 (5).
[*1]
a E: ground cable

cover (1).
4. Remove the mounting bolt and remove engine

controller assembly (6).
2. Remove controller box cover (2).
50-320
Connection
.
[*1]
Screw:
2.82 Nm {0.288 kgm}
50-320
D375A-6R
(01)
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) Using tweezers [1], remove seal (9).
D375A-6R
(01)
50-321
Electrical system
Removal and installation of VHMS controller assembly

Removal
50-32
50-32
5. Remove the mounting bolts and remove
controller case cover (4).
1. Sling and remove cover (1) on the left side of the

operator's cab.
6. Remove the mounting bolts and remove VHMS

controller assembly (5).

3. Disconnect wiring clamp (2a).
4. Disconnect main harness cap (3).
50-32
Connection
50-322
D375A-6R
(01)
Electrical system
Removal and installation of machine monitor assembly

Connection
k Set the parking brake lever and work equipment lock lever to lock position.
50-323
50-323
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).
D375A-6R
(01)
50-323
Electrical system
Connection
50-324

[*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.
50-324
D375A-6R
(01)
D375A-6R
SEN0521429-00
60-1
BULLDOZER
D375A-6R
Shop Manual
Machine model
Serial number
D375A-6R
6-01
65001 and up
60 Maintenance standard
D375A-6R
60-1
60-1
Contents
60-2
Contents
60 Maintenance standard
Engine mount.......................................................................................................................
Cooling fan pump.................................................................................................................
Power train..............................................................................................................................
Power train unit ....................................................................................................................
Scavenging pump ................................................................................................................
Transmission........................................................................................................................
Transmission lubricating oil relief valve ...............................................................................
Power train and lubrication pump ........................................................................................
Transfer, bevel gear shaft and steering unit ........................................................................
Steering clutch ECMV and steering brake ECMV................................................................
Final drive ............................................................................................................................
Sprocket...............................................................................................................................
Track frame..........................................................................................................................
Idler cushion.........................................................................................................................
Idler ......................................................................................................................................
Track roller ...........................................................................................................................
Carrier roller .........................................................................................................................
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 ..................................................................................................................................
60-2
60- 3
60- 3
60- 5
60- 12
60- 14
60- 14
60- 16
60- 19
60- 22
60- 23
60- 24
60- 25
60- 26
60- 31
60- 32
60- 34
60- 40
60- 41
60- 42
60- 43
60- 46
60- 48
60- 48
60- 50
60- 52
60- 54
60- 56
60- 57
60- 58
60- 62
60- 64
60- 68
60- 68
60- 74
60- 77
60- 78
60- 81
60- 94
60- 97
60- 97
60- 98
60- 102
60- 104
D375A-6R

Engine mount
60-3
Engine mount
60-3
Unit: mm
No.
Item
Clearance between bracket and
cushion
2 Free height of mount rubber
D375A-6R
Criteria
Tolerance
Shaft
Hole
+0.018
+0.078
-0.012
+0.032
Standard size
Remedy
Standard
size
Standard
clearance
Clearance
limit
70
0.014 0.090
0.2
102
Replace
Repair limit
100
60-3

Engine mount
60-4
D375A-6R

Cooling fan pump
Cooling fan pump
60-4
Type: LPV90 + 30
Appearance
D375A-6R
60-4
60-5

Cooling fan pump
LPV90 Hydraulic pump 10-8

Appearance
60-6
60-6
60-6
D375A-6R

Cooling fan pump
Sectional view
D375A-6R
60-7
60-7

Cooling fan pump
LPV30 Hydraulic pump

Appearance
60-8
60-8
60-8
D375A-6R

Cooling fan pump
Sectional view
D375A-6R
60-9
60-9

Cooling fan pump
Servo valve
60-10
60-10
D375A-6R

Cooling fan pump
D375A-6R
60-11

Cooling fan motor
Cooling fan motor
60-12
Type: LMF180 (150)

Appearance
60-12
60-12
D375A-6R

Cooling fan motor
Sectional view
60-13
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
D375A-6R
Installed
length
83.8 x 19
1 Spool return spring
Free length x
outside diameter
67.5
Repair limit
Load at
installed
length
172 N
{17.5}
Free length
Replace spring if
Load at
damaged or
installed length
deformed.
137 N
{14}
60-13
Power train
Power train unit
Power train
60-14
Power train unit
60-14
60-14
D375A-6R
Power train
Power train unit
D375A-6R
60-15
Power train
60-16
60-16
D375A-6R
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
4
5

surface of output shaft
Dimension between bearing and
holder
D375A-6R
Criteria
Tolerance
Standard
size
Shaft
-0.024
-0.105
-0.022
546.0
-0.092
Standard size
647.7
110
110
53
Hole
Remedy
Standard
clearance
Clearance
limit
+0.080
0.024 0.185
0.2
0
+0.110
0.022 0.202
0.25
0
Tolerance
Repair limit
0
109.9
-0.035
0
109.9
-0.035
0.1
Replace
52.7
60-17
Power train
60-18
D375A-6R
Power train
D375A-6R
60-18
60-19
Power train
60-20
D375A-6R
Power train
Unit: mm
No.
1
2
3
4
5
Item
Outside diameter of coupling
oil seal contact surface
Criteria
Standard size
125
Inner diameter of seal ring

contact surface of retainer
Inside diameter of seal ring
contact surface of sleeve
Backlash between PTO drive
gear and scavenging pump
gear
Backlash between PTO drive
gear and idler gear
190
110
190.5
Apply hard
chrome plating or
replace
110.2
5.4
0.1
4.9
5.0
0.1
4.5
15.8
0.17
14.3
5.4
0.1
4.9
5.0
0.05
4.5
15.8
0.15
14.7
Replace
Thickness of stator clutch disc
7 Thickness of stator clutch plate

Total thickness of stator clutch
assembly
Free length
54.1
D375A-6R
124.8
0.204 0.516
Thickness of lockup clutch

plate
Total thickness of lockup clutch
assembly
8 Stator clutch return spring
Repair limit
0.25 0.42
Thickness of lockup clutch disc
Tolerance
0
-0.063
+0.046
0
+0.035
0
Remedy
Standard size
Installed
Installation load
length
125.5 N
37.0
{12.8 kg}
Repair limit
Installation
Free length
load
106.9 N
50.9
{10.9 kg}
60-21
Power train
60-21
Unit: mm
No.
Item
Clearance between main relief

valve and valve body
Criteria
Standard size
40
Clearance between torque
2 converter relief valve and valve
40
body
3 Main relief valve spring
Free length
Tolerance
Shaft
-0.035
-0.045
Hole
+0.016
0
-0.035
-0.045
+0.016
0
Standard size
Installed
length
120.3

spring
60-22
102
116.92
86.3
Installation
load
1,419 N
{144.7 kg}
645.1 N
{65.83 kg}
Remedy
Standard
clearance
Clearance
limit
0.035 0.061
0.08
0.035 0.061
0.08
Repair limit
Installation
Free length
load
1,348 N
116.7
{137.5 kg}
613 N
113.4
{62.5 kg}
Replace
D375A-6R
Power train
60-2

a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
D375A-6R
60-23
Power train
Scavenging pump
Scavenging pump
60-23
Unit: mm
No.
Item
Criteria
1 Spline shaft rotating torque
Type
Delivery
Rotating
speed (rpm)
BAR 63
1,743
BAR 277
60-24
Delivery
pressure
MPa
{kg/cm2}
Oil: TO10
Oil temperature: 45 50 C
Remedy
0.15
{1.5}
Standard
delivery
(l/min)
Allowable
delivery
(l/min)
63.3
276.8
D375A-6R
Power train
60-24
PCCS lever
a Don't try disassemble PCCS lever because, adjustments will be required for the characteristics of voltage
output and operating efforts.
D375A-6R
60-25
Power train
Transmission
Transmission
60-26
60-25
D375A-6R
Power train
Transmission
D375A-6R
60-27
Power train
Transmission
60-28
D375A-6R
Power train
Transmission
Unit: mm
NO
Item
Criteria
Standard size
Remedy
Repair limit
Load at
Free length
installed
length
107 N
62.0
{10.9 kg}
186 N
65.8
{19.0 kg}
127 N
91.2
{12.9 kg}
2,910 N
{297 kg}
Repair limit
Standard size
Load at
installed
length
126 N
{12.8 kg}
219 N
{22.3kg}
149 N
{15.2 kg}
3,420 N
{349 kg}
Tolerance
54.6
0.35
51.4
50.3
0.33
47.1
36.4
0.28
34.3
27.3
0.24
25.7
50.0
0.33
46.8
R, F,
3rd, 2nd
4.8
0.1
4.3
1st
5.0
0.1
4.5
R, F,
3rd, 2nd
4.3
0.1
3.9
1st
4.0
0.1
3.6
Width
3.0
-0.01
-0.03
2.7
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
Free length
Installed
length
66.0
57.0
2 F clutch spring (12 pcs)
70.0
60.3
3 3rd and 2nd clutch spring (12 pcs)
97.0
82.4
4 1st clutch spring (3 pcs)
7.75
6.75
1 R clutch spring (12 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
Thickness of clutch
11
plate
Wear of transmission
12
input shaft seal ring
13
Wear of front cover and

R clutch carrier seal ring
Wear of F clutch and

14 3rd clutch carrier seal
ring (small)
Wear of F clutch and
15 3rd clutch carrier seal
ring (large)
Wear of 1st clutch col16
lar seal ring
Wear of 1st clutch gear

17
seal ring
18
19
Wear of 1st clutch gear

seal ring
Wear of transmission
output shaft seal ring
D375A-6R
Replace
60-29
Power train
Transmission
Unit: mm
NO
Item
Wear of 1st clutch pis20

ton housing seal ring
Criteria
Width
5.0
-0.01
-0.03
4.5
Thickness
6.0
0.15
5.85
Backlash between R and F clutch

sun gear and planetary pinion
Backlash between R clutch plane22
tary pinion and ring gear teeth
Backlash between F, 3rd and 2nd
23 clutch planetary pinion and ring
gear teeth
Backlash between 3rd and 2nd
24 clutch planetary pinion and ring
gear
21
60-30
Remedy
0.130.40
0.130.40
Replace
0.140.40
0.130.37
D375A-6R
Power train
Transmission lubricating oil relief valve
D375A-6R
60-30
60-31
Power train
Power train and lubrication pump
60-31
BAL180 + 112
Unit: mm
No.
Item
Criteria
Remedy
Type
Clearance between plain
Clearance limit
BAL180
0.070.12
0.15
BAL112
1 Side clearance
Standard clearance
0.040.10
0.13
0.0600.145
0.20
BAL180
2 bearing inside diameter and

gear shaft outside diameter
BAL112
Type
3 Pin driving depth
Standard size
Tolerance
Repair limit
14
0
-0.5
BAL180
BAL112
4 Spline shaft rotating torque
Delivery
(Oil: E010-CD
Oil temperature: 45 50 C)
(Engine speed at 1900 rpm)
5.9 Nm {0.6 kgm} or less

Type
Rotating speed
(rpm)
BAL180
2,033
BAL112
60-32
Replace
2,033
Delivery pressure
MPa {kg/cm2}
2.52.7
{2628}
0.26
{2.7}
Standard
delivery
(l/min)
Allowable
delivery
(l/min)
334
308
210
200
D375A-6R
Power train
D375A-6R
60-33
Power train
Transfer, bevel gear shaft and steering unit
60-32
60-32
60-34
D375A-6R
Power train
Unit: mm
NO
Item
Criteria
Remedy
Standard clearance
1 Backlash between transfer gears
Thickness of collar between transfer gear and bearing
Standard shim thickness for bearing cage mount
D375A-6R
Clearance limit
0.240.63
0.75
Adjust or replace
Standard size
Tolerance
Repair limit
24
0.1
23.6
2.0
Replace
Adjust shim
60-35
Power train
60-36
60-34
D375A-6R
Power train
Unit: mm
NO
Item
Criteria
Remedy
Standard clearance
1 Backlash between transfer gears
Thickness of collar between transfer gear and bearing
Standard shim thickness for bearing cage mount
D375A-6R
Clearance limit
0.240.63
0.75
Adjust or replace
Standard size
Tolerance
Repair limit
24
0.1
23.6
2.0
Replace
Adjust shim
60-37
Power train
Bevel gear shaft, steering clutch and brake
60-38
60-36
D375A-6R
Power train
Unit: mm
NO
Item
Criteria
Remedy
Standard size
2
3
4
Disc for steering brake

and clutch
Tolerance
Repair limit
Thickness
2.9
0.1
2.6
Strain
Plate for steering

brake and clutch
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
68.4
0.42
65.4
68.4
0.42
65.4
Total thickness of brake plate

and disc assembly
Total thickness of clutch plate
and disc assembly
Backlash between brake or

clutch disc and brake hub
0.170.52
1.0
0.30.4
Inside diameter of piston seal

ring contact surface of piston
9 Brake spring
10 Clutch spring
Interference between bevel gear
11
and reamer bolt
Runout of back face of bevel
12
gear
Replace
Repair limit
0.75
Backlash between bevel gear

and pinion
Inside diameter of seal ring contact surface of cage
Standard clearance
Replace
Tolerance
Shaft
Hole
-0.5
+0.081
290
-0.7
0
-0.100
+0.072
245
-0.172
0
Standard size
Load at
Installed
Free length
installed
length
length
38.7 kN
17.1
11.2
{3,950 kg}
37.9 kN
17.55
11.6
{3,860 kg}
Tolerance
Standard
size
Shaft
Hole
Standard
size
16
+ 0.019
+ 0.001
+ 0.027
0
Adjust or replace
Standard
clearance
Clearance limit
0.50.781
0.1000.244
Repair limit
Free length
16.6
17.0
Load at
installed length
36.8 kN
{3,750 kg}
36.0 kN
{3,670 kg}
Standard
interference
Interference
limit
-0.0260.01
9
Max. 0.019
Repair limit: 0.05 (to be measured after installation to bevel gear shaft)
Standard rotation torque: 4.9 - 5.9 Nm {0.5 - 0.6 kgm}

Preload of bevel gear shaft taper
(At tip of bevel gear teeth when bevel pinion and gear are not engaged:
13
roller bearing
23.528.4 N {2.42.9 kg})
Standard shim thickness of bear2.0
14
ing cage
D375A-6R
Replace
Repair or replace
Adjust
Adjust shim
60-39
Power train
60-40
60-38
D375A-6R
Power train
Steering clutch ECMV and steering brake ECMV
Steering clutch ECMV and steering brake ECMV
60-39

a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
D375A-6R
60-41
Power train
Parking brake valve
Parking brake valve
60-40
Unit: mm
No.
Item
Clearance between parking brake
valve spool and valve body
Outside diameter of contact surface
of dust seal and U-packing on parking brake valve spool
3 Parking brake valve spool spring
60-42
Criteria
Standard
size
14
Standard
size
Tolerance
Shaft
Hole
-0.020
+0.011
-0.030
0
Tolerance
-0.020
-0.030
Standard size
Installed
Free length
Installed load
length
38.2 N
65
47.7
{3.9 kg}
Remedy
Standard
clearance
Clearance
limit
0.020 0.041
0.05
Repair limit
14
13.9
Replace
Repair hard
chrome plating or
replace
Repair limit
Free length
Installed load
63.1
36.4 N
{3.71 kg}
Replace
D375A-6R
Power train
Final drive
Final drive
D375A-6R
60-41
60-43
Power train
Final drive
60-44
D375A-6R
Power train
Final drive
Unit: mm
No.
Item
Backlash between No.1 pinion and

No.1 gear
2
3
4
5
6
7
Criteria
Standard clearance
Clearance limit
0.25 0.99
1.5
0.22 0.81
1.5
0.25 0.81
1.5
Standard size
Repair limit
115.0
114.9
25.14
24.9
10.0
9.5
24.0
22.5
Backlash betwee sun gear and

planetary pinion
Backlash between planetary pinion
and ring gear
surface of No.1 pinion
Replace
Thickness of thrust collar of inner

body roller bearing
Thickness of thrust coller of No.1
gear boss roller bearing
Dimensions from cover mounting
face to button head
Clearance between pinion shaft
and carrie
Remedy
Standard
size
85
Tolerance
Shaft
Hole
-0.036
-0.024
-0.058
-0.059
Standard shim thickness for No.1

pinion bearing cage
Dimension of end face of final drive
10
cover and end face of bearing
Standard
clearance
Clearance
limit
-0.023 0.034
0.1
3
7 (0/-0.2)
11 Clearance at floating seal guard
Adjust
4.1 5.3
Standard size
12 Wear of wear guard
D375A-6R
Repair limit
47
18
Rebuild or replace
60-45
Power train
Sprocket
Sprocket
60-4
Unit: mm
No.
Item
Criteria
Remedy
Standard size
1 Wear of tooth tip

2 Thickness of tooth root
60-46
Repair limit
433
417
28.7
22.7
Replace or rebuild by
build up welding
D375A-6R
Power train
Sprocket
Full-scale drawing of sprocket tooth profile
D375A-6R
60-47

Track frame
60-46
Track frame
60-46
60-48
D375A-6R

Track frame
Unit: mm
NO
Item
Criteria
Remedy
Item
Bend
7 (per length 3,000)
Torsion
3 (per level length 300)
Dents (pipe portion)
Repair limit
12
Deformation of track frame outer

casing
Clearance between inner casing

and stopper protruding portion
Clearance between track frame and

stopper
Standard
size
30
128
Tolerance
Shaft
Hole
-0.15
+0.3
-0.35
0
+0.02
+0.063
-0.106
0
4 Press-fitting force for cartridge pin

5
Clearance between track frame and

idler guide
D375A-6R
Repair or replace
Standard
clearance
Clearance
limit
0.150.65
2.0
0.0430.163
245441 kN {2545 ton}
Standard clearance
Clearance limit
00.5
3.0
Adjust
60-49

Idler cushion
Idler cushion
60-50
60-48
D375A-6R

Idler cushion
Unit: mm
NO
Item
Criteria
Remedy
Standard size
1 Recoil spring
Free length
1,461
3
4
5
6
Clearance between outer diameter of outer sleeve bushing and

inner diameter of outer sleeve
Clearance between adjustment
cylinder and bushing
Press-fitting force for inserting
outer sleeve bushing into outer
sleeve
Press-fitting force for installing
outer sleeve bushing to spring cylinder
Clearance between recoil spring
mounting nut and lock plate
D375A-6R
Standard
size
380
135
Repair limit
Load at
Installed
installed
length
length
499.7 kN
1,230.5
{50,994 kg}
Tolerance
Shaft
-0.058
-0.228
-1.000
-1.300
Hole
+0.317
+0.060
+0.063
0
Free length
Load at
installed length
1,440
458.5 kN
{46,790 kg}
Standard
clearance
Clearance limit
0.1180.545
0.8
1.0001.363
Replace
49.0109.8 kN {5.011.2 ton}
91.2322.6 kN {9.332.9 ton}
Adjust
01.0
60-51

Idler
Idler
60-52
60-50
D375A-6R

Idler
Unit: mm
No.
Item
Outside diameter of protuding portion
Criteria
Remedy
Standard size
Repair limit
927
2 Outside diameter of tread
880
855
3 Depth of tread
23.5
36
4 Thickness of tread
32.5
20
5 Total width
294
6 Overall with of tread
79.0
87.5
Clearance between shaft and

bushing
Tolerance
Shaft
Hole
-0.350
+0.198
155
-0.413
-0.053
Standard size
Standard
size
8 Collar width of shaft
Interference between shaft and

ring
10 End play
Tolerance
Shaft
Hole
+0.046
-0.15
95
0
-0.20
Standard clearance
Standard
size
D375A-6R
Clearance
limit
0.297 0.611
Repair limit
Tolerance
-0.410
-0.484
Replace bushing
Rebuild by build-up
welding or replace
Standard
interference
Interference
limit
0.15 0.246
Replace ring
Clearance limit
Adjust or replace
0.490.86
95
Standard
clearance
252
Standard size
11 Outside diameter of shaft
Rebuild by build-up
welding or replace
Repair limit
- 0.5
Replace
60-53

Track roller
Track roller
60-52
2nd, 4th, and 6th track roller (double flanged roller)
Unit: mm
NO
Item
Criteria
Remedy
Standard size
Repair limit
310
300
270
210
30
29
5 Total width
358
82
7 Width of flange (outside flange)
29
14
8 Width of flange (inside flange)
27
12
306
Outer diameter of flange (outside

flange)
Outer diameter of flange (inside

flange)
Clearance between shaft and bush10

ing
11

seal ring
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
12 End play
0.44 0.91
Standard size
60-54
74.5
Rebuild by build-up
welding or replace
Standard
Clearance
clearance
limit
0.360
0.673
Standard
Interference
interference
limit
0.130
0.226
Clearance limit
Replace
Adjust or replace
Tolerance
0
-0.12
Replace bushing
Repair limit
-0.2
Replace
D375A-6R

Track roller
1st, 3rd, 5th, and 7th track roller (single flanged roller)
Unit: mm
NO
Item
Criteria
Remedy
Standard size
Repair limit
310
270
210
30
29
4 Total width
358
82
6 Width of flange
29
14
306
1 Outside diameter of flange
Clearance between shaft and

bushing

ring
10 End play
Tolerance
Standard
size
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
0.440.91
Standard size
D375A-6R
74.5
Rebuild by build-up
welding or replace
Standard
clearance
Clearance
limit
0.3600.673
Standard
interference
Interference
limit
0.1300.226
Replace
Clearance limit
Adjust or replace
Tolerance
0
-0.12
Replace bushing
Repair limit
-0.2
Replace
60-55

Carrier roller
Carrier roller
60-54
Unit: mm
No.
Item
Criteria
Remedy
Standard size
Repair limit
242
210
185
3 Width of tread
79
40
27.5
5 Width of flange
23
12
1 Outside diameter of flange
6 Interference between shaft and ring
Clearance between shaft and support
8 Axial play of roller
60-56
Tolerance
Shaft
Hole
+0.245
+0.035
90
+0.185
0
Tolerance
Standard
size
Shaft
Hole
0
+0.350
86
-0.2
0
Standard clearance
Standard
size
00.22
Rebuild by build-up
welding or replace
Standard interference
0.150 245
Standard clearance
Replace
0 0.550
Clearance limit
D375A-6R

Track roller bogie
Track roller bogie
60-5
Unit: mm
NO
Item
1 Press-fitting force for cartridge pin
D375A-6R
Criteria
Remedy
245441 kN {2545 ton}
60-57

Track shoe
Track shoe
60-58
a Portion P shows the link on the side where the bushing is pressed fitted.
60-58
D375A-6R

Track shoe
Unit: mm
No.
Item
Criteria
Remedy
Standard size
Repair limit
280.3
283.3
1 Link pitch
Reverse
Standard size
Light load
Heavy load
98.5
90
3 Thickness of bushing
18.8
10.3
12.8
Standard size
Repair limit
181
163
56
38
4 Height of link
5
Thickness of link (bushing press-fitting portion)

One side
6 Clearance between links
Interference between bushing and

link
Interference between regular pin

and link
a. Regular link
9 Shoe bolt
D375A-6R
1.4
2.8
Rebuild by build-up
welding or replace
Both side
Standard size
Shaft
+0.622
98
0.522
+0.426
30
+0.366
Tightening torque
(Nm {kgm})
Tolerance
Standard interference
Hole
+0.087
0.435 0.622
0
+0.127
0.239 0.373
+0.053
Retightening angle
(Degree)
1,372 137 {140 14}

b. Master link
Turn 180 or replace
92.5
2 Outside diameter of bushing
120 10
686.4 68.6{70 7}
Adjust or replace
Retighten
180 10
60-59

Track shoe
60-58
Single grouser shoe
Unit: mm
No.
Item
Criteria
Remedy
Standard size
1 Height of grouser
2 Overall height of shoe
60-60
Repair limit
93
29
116
53
Repair by lug welding or replace
D375A-6R

Track shoe
D375A-6R
60-61

Main frame
Main frame
60-62
60-60
D375A-6R

Main frame
Unit: mm
No.
Item
Interference between steering case

and bushing
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Clearance between steering case

and final drive cage
cushion
Clearance between ripper beam
mounting pin and bushing
Clearance between ripper cylinder
Clearance between radiator guard
Clearance between radiator guard
Clearance between equalizer bar
shaft and bushing
Protrusion of rubber on seal end
face
Free height of front cab mount rubber
Free height of rear cab mount rubber
Press-fitting force for ripper beam
mounting bushing
Press-fitting force for ripper cylinder
mounting bushing
Press-fitting force for radiator guard
mounting bushing
Press-fitting force for radiator guard
mounting bushing
Press-fitting force for equalizer bar
shaft mounting bushing
D375A-6R
Criteria
Tolerance
Shaft
Hole
+0.108
+0.052
275
+0.056
0
Tolerance
Standard
size
Shaft
Hole
-0.018
+0.057
332
-0.075
0
+0.018
+0.046
70
-0.012
0
-0.036
+0.166
120
-0.090
+0.028
-0.036
+0.287
100
-0.090
+0.200
-0.030
+0.371
80
-0.076
+0.269
-0.036
+0.369
90
-0.090
+0.267
-0.036
+0.243
120
-0.090
+0.101
Standard size
Standard
size
Remedy
Standard inter- Interference
ference
limit
0.004 0.108
Min. 0
Standard
clearance
Clearance
limit
0.018 0.132
0.2
0.018 0.058
0.1
0.064 0.256
1.5
0.236 0.377
1.5
0.299 0.477
1.5
0.303 0.459
1.0
0.137 0.333
1.0
Replace
Repair limit
0.5
105
103
58
56
44.1 117.6 kN {4.5 12 ton}
58.8 171.6 kN {6 17.5 ton}
98.0 181.4 kN {10 18.5 ton}
Adjust
58.8 137.3 kN {6 14 ton}

31.4 105.9 kN {3.2 10.8 ton}
60-63

Suspension
Suspension
60-64
60-62
D375A-6R

Suspension
Unit: mm
No.
Item
Clearance between center pin and

bushing
Clearance between side pin and

bushing
Interference between side pin boss

and bushing
4
5
Press-fitting force for center pin

bushing
Press-fitting force for side pin bushing
D375A-6R
Criteria
Standard
size
120
95
Standard
size
160
Tolerance
Shaft
Hole
-0.036
+0.243
-0.090
+0.101
-0.048
+0.015
-0.078
-0.015
Tolerance
Shaft
Hole
+0.045
-0.028
+0.027
-0.068
Remedy
Standard
clearance
Clearance
limit
0.137 0.333
1.0
0.033 0.093
1.0
Replace bushing

ference
limit
0.055 0.113
49.0 186.3 kN {5 19 ton}
34.3 73.5 kN { 3.5 7.5 ton}
60-65

Suspension
*1. Shown in the figure is the left suspension of the single tilt specification machines.
*2. Shown in the figure are the right suspension of the single tilt specification machines, and
the right and left suspensions of the dual tilt specification machines.
60-66
D375A-6R

Suspension
Unit: mm
No.
Item
Interference between thrust washer

and seal
7
8
10
Interference between thrust washer

and seal
Interference between pivot shaft
and seal
Clearance between pivot shaft and
bushing
Clearance between pivot shaft and
bushing
D375A-6R
Criteria
Standard
size
230
165
213
Standard
size
175
210
Tolerance
Shaft
Hole
+0.213
-0.180
+0.098
-0.226
+0.140
-0.061
+0.100
-0.124
+0.096
-0.115
+0.050
-0.187
Tolerance
Shaft
Hole
-0.145
+0.097
-0.208
+0.029
-0.170
+0.072
-0.242
0
Remedy
ference
limit
0.278 0.439
0.161 0.264
0.165 0.283
Standard
clearance
Clearance
limit
0.174 0.305
1.0
0.170 0.314
1.0
Replace
Replace bushing
60-67
Hydraulic system
PPC valve
Hydraulic system
60-6
PPC valve
60-6
Blade PPC valve

Appearance
60-6
60-6
60-68
D375A-6R
Hydraulic system
PPC valve
Sectional view
D375A-6R
60-67
60-69
Hydraulic system
PPC valve
60-70
D375A-6R
Hydraulic system
PPC valve
Ripper PPC valve

Appearance
D375A-6R
60-69
60-69
60-71
Hydraulic system
PPC valve
Sectional view
60-72
60-70
D375A-6R
Hydraulic system
PPC valve
Unit: mm
NO
Item
Criteria
Centering spring
(for ports P1 and P2)
3 Metering spring
D375A-6R
Free length x
Outside diame-
Standard size
Installed
length
50.35 x 15.5
Centering spring
(for ports P3 and P4)
34
50.05 x 15.5
34
26.53 x 8.15
24.9
Load at
installed
55.9 N
{5.7 kg}
71.4 N
{7.28 kg}
16.7 N
{1.7 kg}
Remedy
Repair limit
Load at
Free length
installed
44.7 N
{4.56 kg}
57.1 N
{5.82 kg}
13.3 N
{1.36 kg}
If damaged or
deformed, replace
spring
60-73
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)
60-74
D375A-6R
Hydraulic system
Hydraulic cylinder
Unit: mm
No.
Item
Criteria
Standard
size
Blade lift
Clearance between pis- Blade tilt

ton rod and bushing
(Single tilt)
90
110
Tolerance
Shaft
-0.036
-0.090
-0.036
-0.090
-0.065
-0.117
-0.036
-0.090
Hole
+0.257
+0.048
+0.274
+0.060
+0.133
+0.007
+0.261
+0.047
Remedy
Standard
clearance
Clearance
limit
0.084 0.347
0.693
0.096 0.364
0.072 0.250
0.55
0.083 0.351
Pin puller
29
Blade tilt
(Dual tilt )
110
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
-0.200
-0.300
-0.200
-0.300
-0.200
-0.300
-0.200
-0.300
+0.200
0
+0.200
0
+0.423
+0.342
+0.423
+0.342
0.200 0.500
1.0
0.200 0.500
1.0
0.542 0.723
1.0
0.542 0.723
1.0
Clearance between pis-
2 ton rod supporting shaft

3
and bushing
Clearance between cylBlade lift
inder support shaft
bushing and yoke
Blade tilt
Clearance between pis- (Single tilt)

ton rod supporting shaft
Blade tilt
and bushing
(Dual tilt)
Blade tilt
Clearance between cyl- (Single tilt)
5 inder bottom support

shaft and bushing
75
75
75
Blade tilt
(Dual tilt)
75
Pin puller
29
-0.100
-0.200
+1.300
+1.200
1.3 1.5
26
-1.1
-1.2
0.1
1.0 1.3
Clearance between pis-
6 ton rod spherical sur7
face and cap

Clearance between cylPin puller
inder bottom support
shaft and boss
D375A-6R
Replace
60-75
Hydraulic system
Hydraulic cylinder
Ripper tilt cylinder
Unit: mm
No.
Item
Criteria
Standard
size
Clearance between pisRipper lift

ton rod and bushing
110
Ripper tilt
110
Clearance between pis- Ripper lift
100
2 ton rod support shaft

and bushing
Ripper tilt
100
Clearance between cyl- Ripper lift
100
3 inder bottom support

shaft and bushing
60-76
Ripper tilt
100
Tolerance
Shaft
Hole
-0.036
+0.274
-0.090
+0.060
-0.036
+0.274
-0.090
+0.060
-0.036
+0.207
-0.090
+0.120
-0.036
+0.207
-0.090
+0.120
-0.036
+0.207
-0.090
+0.120
-0.036
+0.207
-0.090
+0.120
Remedy
Standard
clearance
Clearance
limit
0.096 0.364
0.697
0.096 0.364
0.697
0.156 0.297
1.0
0.156 0.297
1.0
0.156 0.297
1.0
0.156 0.297
1.0
Replace
D375A-6R
Hydraulic system
Quick drop valve
Quick drop valve
60-75
Unit: mm
No.
Item
Clearance between spool and
valve body
2 Valve spring
Criteria
Standard size
38.0
Free length
75.2
D375A-6R
Tolerance
Shaft
Hole
-0.011
+0.010
-0.016
0
Standard size
Load at
Installed
installed
length
length
136.3 N
55.9
{13.9 kg}
Remedy
Standard
clearance
Clearance
limit
0.011 0.026
0.03
Repair limit
Load at
Free length
installed
length
122.6 N
67.7
{12.5 kg}
Replace
60-77
Hydraulic system
Work equipment pump
Work equipment pump

Model: HPV190
Appearance
60-78
60-76
60-76
60-76
D375A-6R
Hydraulic system
Work equipment pump
Sectional view
D375A-6R
60-7
60-79
Hydraulic system
Work equipment pump
60-80
D375A-6R
Hydraulic system
Control valve
Control valve
6-spool valve for dual tilt
Appearance
D375A-6R
60-79
60-79
60-79
60-81
Hydraulic system
Control valve
60-82
60-80
D375A-6R
Hydraulic system
Control valve
Unit: mm
No.
Item
Spool return spring

(only for blade lift)
Spool return spring

(for blade tilt)
3 Spool return spring (for ripper)

4
Spool return spring

5 Load check valve spring

6
Pressure compensation valve

spring
7 Unload valve spring
D375A-6R
Criteria
Remedy
Standard dimension
Allowable limit
Free length x
Installed
Outside diameInstalled load Free length Installed load
length
ter
202 N
162 N
73.9 x 30
68.5
{20.6 kg}
{16.5 kg}
279 N
224 N
51.12 x 31.3
47.8
{28.5 kg}
{22.8 kg}
140 N
112 N
51.7 x 31.3
50
{14.3 kg}
{11.4 kg}
217 N
174 N
54.7 x 36.5
33.5
{22.1 kg}
{17.7 kg}
12.7 N
10.2 N
20.8 x 12.2
13.5
{1.3 kg}
{1.04 kg}
562 N
449 N
108.3 x 29.5
81
{57.3 kg}
{45.8 kg}
193 N
154 N
86.7 x 30
66
{19.63 kg}
{15.7 kg}
If damaged or
deformed, replace
spring
60-83
Hydraulic system
Control valve
(2/4)
60-84
60-82
D375A-6R
Hydraulic system
Control valve
(3/4)
60-83
Unit: mm
No.
Item
1 Suction valve spring
2 Check valve spring
D375A-6R
Criteria
Standard dimension
Free length x
Installed
Outside diameInstalled load
length
ter
6.37 N
64.9 x 12.5
56
{0.65 kg}
0.49 N
9.4 x 4.6
7.75
{0.05 kg}
Remedy
Allowable limit
Free length
Installed load
5.10 N
{0.52 kg}
0.39 N
{0.04 kg}
If damaged or
deformed, replace
spring
60-85
Hydraulic system
Control valve
60-84
(4/4)
Unit: mm
No.
Item
Check valve spring
Suction valve spring
60-86
Criteria
Standard dimension
Free length x
Outside diame- Installed length Installed load
ter
14.7 N
27.9 x 6.5
22.5
{1.5 kg}
5.49 N
46.8 x 7.5
40.6
{0.56 kg}
Remedy
Allowable limit
Free length
Installed load
11.8 N
{1.2 kg}
4.41 N
{0.45 kg}
If damaged or
deformed,
replace spring
D375A-6R
Hydraulic system
Control valve
5-spool valve for single tilt

Appearance
D375A-6R
60-85
60-85
60-87
Hydraulic system
Control valve
60-88
60-86
D375A-6R
Hydraulic system
Control valve
Unit: mm
No.
Item
Steering signal spring

Criteria
Standard size
Free length x
Installed
Outside diamelength
ter
73.9 x 30
68.5
51.12 x 31.3
50
51.7 x 31.3
50

54.7 x 36.5
33.5
5 Load check valve spring
20.8 x 12.2
13.5
86.7 x 30
66

(for blade tilt)
3 Spool return spring (for ripper)

4
6 Unload valve spring
D375A-6R
Load at
installed
length
202 N
{20.6 kg}
94.1 N
{9.6 kg}
140 N
{14.3 kg}
217 N
{22.1 kg}
12.7 N
{1.3 kg}
193 N
{19.63 kg}
Remedy
Repair limit
Load at
Free length
installed
length
162 N
{16.5 kg}
75.3 N
{7.7 kg}
112 N
{11.4 kg}
174 N
{17.7 kg}
10.2 N
{1.04 kg}
154 N
{15.7 kg}
If damaged or
deformed, replace
spring
60-89
Hydraulic system
Control valve
(2/4)
60-90
60-8
D375A-6R
Hydraulic system
Control valve
(3/4)
60-89
Unit: mm
No.
Item
Criteria
Standard size
D375A-6R
Installed
length
64.9 x 12.5
Free length x
Outside diameter
56
9.4 x 4.6
7.75
Load at
installed
length
6.37 N
{0.65 kg}
0.49 N
{0.05 kg}
Remedy
Repair limit
Load at
Free length
installed
length
5.10 N
{0.52 kg}
0.39 N
{0.04 kg}
If damaged or
deformed, replace
spring
60-91
Hydraulic system
Control valve
60-90
(4/4)
Unit: mm
No.
Item
Criteria
Remedy
Standard size
60-92
Installed
length
27.9 x 6.5
Free length x
Outside diameter
22.5
46.8 x 7.5
40.6
Repair limit
Load at
Load at
Free length
installed length
installed length
14.7 N
{1.5 kg}
5.49 N
{0.56 kg}
11.8 N
{1.2 kg}
4.41 N
{0.45 kg}
If damaged or
deformed, replace
spring
D375A-6R
Hydraulic system
Control valve
D375A-6R
60-93
Hydraulic system
60-92
Appearance
60-92
60-94
D375A-6R
Hydraulic system
Sectional view
60-93
Unit: mm
No.
Item
Criteria
Standard size
Free length x
Pressure reducing value main Outside diamespool spring
ter
Installed
length
70.91 x 18
56
17.8 x 7.2
12.7
3 Safety valve spring
16.13 x 7.8
13.4
4 Spool return spring
19.15 x 7.2
16.05
Pressure reducing valve pilot

spring
D375A-6R
Load at
installed
length
250 N
{25.52 kg}
28.0 N
{2.86 kg}
61.8 N
{6.3 kg}
19.6 N
{2.0 kg}
Remedy
Repair limit
Load at
Free length
installed
length
200 N
{20.4 kg}
22.5 N
{2.29 kg}
49.4 N
{5.04 kg}
15.7 N
{1.6 kg}
If damaged or
deformed, replace
spring
60-95
Hydraulic system
60-96
D375A-6R
Work equipment
Cylinder stay
Work equipment
60-95
Cylinder stay
60-95
Unit: mm
No.
2
3
Item
Clearance between cylinder yoke
and bushing
Clearance between cylinder yoke
and bushing
Clearance between lift cylinder support shaft and bushing
D375A-6R
Criteria
Standard
size
150
115
105
Tolerance
Shaft
Hole
-0.085
+0.063
-0.148
0
-0.072
+0.054
-0.126
0
-0.120
+0.035
-0.207
0
Remedy
Standard
clearance
Clearance
limit
0.085 0.211
0.5
0.072 0.180
0.5
0.120 0.242
0.5
Replace
60-97
Work equipment
Blade
Blade
60-96
Semi-U dozer
(The figure shows a single tilt specification machine. The spill guard is optional.)
60-96
60-98
D375A-6R
Work equipment
Blade
Unit: mm
No.
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Item
Clearance between brace pin and
brace
bracket
bracket
bushing
Clearance between spherical surfaces of center brace and cap
Clearance between joint and
bracket
Clearance between frame pin and
joint
bracket
Clearance between straight frame
joint bushings
Clearance between spherical surfaces of trunnion and cap
bracket
Clearance between blade pin and
joint
bracket
Clearance between center link pin
and blade bracket
and center link
Clearance between center link and
blade bracket
Clearance between center brace
spherical surfaceand cap
Clearance between lift cylinder
head pin and cylinder
head pin and cross joint
side pin
Clearance between cross joint and
side pin
D375A-6R
Criteria
Standard
size
75
75
75
75
170
200
100
100
160
200
200
100
100
125
125
280
170
65
65
65
65
Tolerance
Shaft
Hole
-0.2
+0.3
-0.3
+0.1
-0.2
+0.3
-0.3
+0.1
-0.2
+0.3
-0.3
0
-0.2
+0.2
-0.3
0
-0.2
+0.3
-0.3
0
-0.2
+0.3
-0.7
+0.1
-0.3
+0.3
-0.5
0
-0.3
+0.5
-0.5
+0.2
+0.063
+0.174
0
+0.134
-0.5
+0.5
-1.0
0
-0.2
+0.3
-0.7
+0.1
-0.3
+0.3
-0.5
0
-0.3
+0.5
-0.5
+0.2
-0.3
+0.5
-0.5
+0.2
-0.3
+0.5
-0.5
+0.2
-0.2
+0.3
-0.4
+0.1
-0.2
+0.3
-0.3
0
-0.3
+0.5
-0.5
+0.2
-0.3
+0.3
-0.5
0
-0.3
+0.3
-0.5
0
-0.3
+0.5
-0.5
+0.2
Remedy
Standard
clearance
Clearance
limit
0.3 0.6
0.3 0.6
0.2 0.6
0.2 0.5
0.2 0.6
0.3 1.0
0.3 0.8
0.5 1.0
0.071
0.174
0.5 1.5
0.3 1.0
0.3 0.8
0.5 1.0
0.5 1.0
0.5 1.0
0.3 0.7
0.2 0.6
0.5 1.0
0.3 0.8
0.3 0.8
0.5 1.0
Replace
Adjust shims or
replace
Replace
Adjust shims or
replace
Replace
60-99
Work equipment
Blade
Full-U dozer
(The figure shows a dual tilt specification machine)
60-100
60-98
D375A-6R
Work equipment
Blade
Unit: mm
No.
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Item
brace
bracket
bracket
bushing
Clearance between spherical surfaces of center brace and cap
bracket
joint
bracket
Clearance between straight frame
joint bushings
Clearance between spherical surfaces of trunnion and cap
bracket
joint
bracket
and blade bracket
and center link
Clearance between center link and
blade bracket
Clearance between center brace
spherical surface and cap
head pin and cylinder
head pin and cross joint
side pin
Clearance between cross joint and
side pin
D375A-6R
Criteria
Standard
size
75
75
75
75
170
200
100
100
160
200
200
100
100
125
125
280
170
65
65
65
65
Tolerance
Shaft
Hole
-0.2
+0.3
-0.3
+0.1
-0.2
+0.3
-0.3
+0.1
-0.2
+0.3
-0.3
0
-0.2
+0.2
-0.3
0
-0.2
+0.3
-0.3
0
-0.2
+0.3
-0.7
+0.1
-0.3
+0.3
-0.5
0
-0.3
+0.5
-0.5
+0.2
+0.063
+0.174
0
+0.134
-0.5
+0.5
-1.0
0
-0.2
+0.3
-0.7
+0.1
-0.3
+0.3
-0.5
0
-0.3
+0.5
-0.5
+0.2
-0.3
+0.5
-0.5
+0.2
-0.3
+0.5
-0.5
+0.2
-0.2
+0.3
-0.4
+0.1
-0.2
+0.3
-0.3
0
-0.3
+0.5
-0.5
+0.2
-0.3
+0.3
-0.5
0
-0.3
+0.3
-0.5
0
-0.3
+0.5
-0.5
+0.2
Remedy
Standard
clearance
Clearance
limit
0.3 0.6
0.3 0.6
0.2 0.6
0.2 0.5
0.2 0.6
0.3 1.0
0.3 0.8
0.5 1.0
0.071
0.174
0.5 1.5
0.3 1.0
0.3 0.8
0.5 1.0
0.5 1.0
0.5 1.0
0.3 0.7
0.2 0.6
0.5 1.0
0.3 0.8
0.3 0.8
0.5 1.0
Replace
Adjust shims or
replace
Replace
Adjust shims or
replace
Replace
60-101
Work equipment
Cutting edge and end bit
60-10
(Standard)
60-10
Unit: mm
No.
Item
Criteria
Remedy
Standard size
Repair limit
478
380
2 Width of end bit
734
600
3 Height of end bit, inside
393
300
4 Height of cutting edge
406
335 (264 after reversed)
1 Height of end bit, outside
60-102
Replace
Turn 180 or
replace
D375A-6R
Work equipment
(if equipped)
60-101
Unit: mm
No.
Item
Criteria
Remedy
Standard size
Repair limit
495
340
2 Width of end bit
740
600
3 Height of end bit, inside
395
335
4 Height of cutting edge
406
335 (264 after reversed)
1 Height of end bit, outside
D375A-6R
Replace
Turn 180 or
replace
60-103
Work equipment
Ripper
Ripper
60-102
Variable multi-shank ripper
60-102
60-104
D375A-6R
Work equipment
Ripper
Giant ripper
60-103
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
Criteria
Tolerance
Standard
size
Shaft
-0.036
120
-0.090
-0.036
120
-0.090
-0.036
100
-0.090
Standard size
82
Hole
+0.208
+0.125
+0.208
+0.125
+0.207
+0.120
Tolerance
Remedy
Standard
clearance
Clearance
limit
0.161 0.298
1.5
0.161 0.298
1.5
0.156 0.207
1.5
Repair limit
0.3
Standard size
5 Wear of point
6 Wear of protector
D375A-6R
Replace
Repair limit
420
255
155
115
60-105
Work equipment
Ripper
60-106
D375A-6R
D375A-6R
80-1
BULLDOZER
D375A-6R
Shop Manual
Machine model
Serial number
D375A-6R
80-1
65001 and up
80 Appendix
D375A-6R
(01)
80-1
80-1
Contents
Contents
80 Appendix
Air conditioner .........................................................................................................................
Precautions for 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 ...................................................................................................................
Parts and connectors layout ................................................................................................
Testing temperature control .................................................................................................
Testing FRESH/RECIC air changeover ...............................................................................
Testing relay ........................................................................................................................
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
80-2
80808080808080808080808080808080808080808080808080808080808080-
3
3
4
6
7
10
14
15
16
17
18
20
22
24
26
28
32
33
34
36
38
40
42
44
48
54
56
58
60
62
64
D375A-6R
(01)
Air conditioner
Precautions for refrigerant
Air conditioner
80-3
80-3
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-6R
(01)
80-3
Air conditioner
Air conditioner component
80-4
80-4
D375A-6R
(01)
Air conditioner
A: Front window glass warm/cool air outlet

B: Overhead warm/cool air outlet
C: Side warm/cool air outlet
D: Front warm/cool air outlet
E: Recirculation air inlet
F: Fresh air inlet
1. Condenser
2. Air conditioner unit
3. Fresh air filter
4. Blower unit
5. Refrigerant piping
6. Receiver drier
7. Compressor
8. Air intake cap
9. Hot water return piping
10. Hot water supply piping
11. FRESH/RECIRC air changeover damper
12. Recirculation air filter
13. Air conditioner control panel
14. Sight glass
D375A-6R
(01)
80-5
Specification
Refrigerant
Refrigerant refill capacity (g)
R134a
1,100 100
80-5
Air conditioner
Configuration and function of refrigeration cycle

Cycle
(Component)
Location
Compressor
Condenser
Expansion valve
Evaporator
Engine compartment
Front of radiator
In operators cab
(Built-In air conditioner
unit)
In operators cab
(Built-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 action 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
80-6
D375A-6R
(01)
Air conditioner
Outline of refrigeration cycle
80-7
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).
D375A-6R
(01)
The expansion valve controls the refrigerant

feed rate so that the optimum quantity of liquid
refrigerant is supplied to the evaporator.
(*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.
Relationship between refrigerant and defective
80-7
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.
80-7
Air conditioner
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-6R
(01)
Air conditioner
D375A-6R
(01)
80-9
Air conditioner
80-10
80-10
D375A-6R
(01)
Air conditioner
A: Refrigerant inlet (from condenser)

B: Refrigerant outlet (to compressor)
C: Hot water inlet
D: 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)
80-1
Functions of major components
Evaporator
80-1
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.
80-1
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
80-1
80-1
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.
80-1
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.
80-1
Over-cooling(Freezing) 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.
80-1
Air flow adjustment
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-6R
(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
Air conditioner
Expansion valve
80-12
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
80-12
Outline
q The expansion valve converts high pressure and
high-temperature liquid refrigerant from the receiver drier to low-pressure, low-temperature
misty refrigerant through the throttle 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).
80-12
80-12
Structure
q The box-type 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-6R
(01)
Air conditioner
Operation
80-13
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 80-13
[Air in the cab is not cooled: condition (A) in the
80-13
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 80-13
[Air in the cab is already cooled: condition (B) in
80-13
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-6R
(01)
80-13
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}
80-13
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
Air conditioner
Blower unit
Blower unit
1. Blower motor
2. Blower fan
3. FRESH/RECIRC air changeover servomotor
80-14
FRESH/RECIRC air changeover servomotor
80-14
80-14
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).
80-14
Functions of major components
Blower motor
80-14
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-6R
(01)
Air conditioner
FRESH/RECIRC air changeover damper
80-15
1. 1. Door open/close lever

2. FRESH/RECIRC air changeover door
80-15
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-6R
(01)
80-15
Air conditioner
Compressor
Compressor
A: Refrigerant inlet port from air conditioner unit

B: Refrigerant outlet port to condenser
1. Pulley
2. Magnetic clutch
3. Relief valve
80-16
80-16
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.
80-16
Specification
Number of cylinder Bore x
Stroke
(mm)
Piston capacity
(cc/rev)
10 - 32 x 20.8
157.3
Allowable maximum speed

(rpm)
Refrigerant oil used
Denso:ND-OIL8 (For
R134a)
Compressor oil refill capacity

(cc)
80-16
6,000
180
D375A-6R
(01)
Air conditioner
Condenser
Condenser
A: Refrigerant inlet (from compressor)

B: Refrigerant outlet (to receiver drier)
80-17
Function
q The condenser cools and liquefies the high pressure and high temperature misty refrigerant from
the compressor.
80-17
80-17
Specification
Fin pitch (mm)
Height x width x 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-6R
(01)
80-17
Air conditioner
Receiver drier
Receiver drier
80-18
80-18
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.
80-18
Specification
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-6R
(01)
Air conditioner
Receiver drier
D375A-6R
(01)
80-19
Air conditioner
Air conditioner control panel
NO
Model
80-20
Function
Switch to start and stop cooling, drying or heating function

(When the fan switch is turned "ON" and the air conditioner
1 Air conditioner switch
switch is pressed, the indicator lamp above the switch lights
up.)
Switch to select RECIRC or FRESH air
FRESH/RECIRC air selector
2
(When the switch is pressed, the indicator lamp above the
switch
selected switch lights up.)
3 Fan switch
4 Temperature control switch
80-20
Operation
OFFioON
RECIRC
IO
FRESH
OFF: Off
Switch to adjust fan speed in four 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-6R
(01)
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.
80-21
Input/Output signal
AMP 172021-2-16P
AMP 172245-2-12P
Pin No.
Signal name
1
2
3
4
5
6
7
8
9
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
10
11
12
13
14
15
16
D375A-6R
(01)
Input/Output signal
Input
Output
Output
Output
Output
Output
Input
Input
Input
Output
Pin No.
Signal name
17
18
19
20
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 (*)
21
22
23
24
25
26
27
28
Input/Output signal
Output
Output
Output
Output
Output
80-21
Air conditioner
Procedure for testing and troubleshooting
80-2
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-6R
(01)
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-6R
(01)
80-23
Air conditioner
Circuit diagram and arrangement of connector pins
80-24
80-24
D375A-6R
(01)
Air conditioner
Input/output signals 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)
80-25
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
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
AC3
Pin No.
17
18
19
20
21
q
q
q
M-RFR
23
24
25
26
27
28
q
M-RFF
22
Code
NC
NC
M-AMB
M-AMA
Signal name
NC
NC
NC
NC
NC
NC
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-6R
(01)
80-25
Air conditioner
System diagram
System diagram
80-26
a This air conditioner has manual temperature control only. (It is not Automatic air conditioner)
80-26
D375A-6R
(01)
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
FRESH/RECIRC air changeover servo motor
(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 and 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-6R
(01)
80-27
80-27
Air conditioner
Parts and connectors layout

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")
80-28
a Condition with cover (4) removed
q AC2 and 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-6R
(01)
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
servo motor
q CN-S: Connector of FRESH/RECIRC air
change over servo motor
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-6R
(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
a Condition with brackets (7) and (8) removed

A/MS: Air mix servomotor
q CCR:Compressor clutch relay
q CDR: Condenser relay (Not used)
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 used)
q
80-30
D375A-6R
(01)
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-6R
(01)
80-31
Air conditioner
Testing temperature control
80-32
Outline
80-32
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.
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 temperature control".
80-32
D375A-6R
(01)
Air conditioner
Testing FRESH/RECIC air changeover
80-3
Outline
80-3
FRESH/RECIRC air changeover servo motor
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 FRESH/RECIRC air selector 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
a For an electrical failure, see "Troubleshooting for

FRESH/RECIRC air changeover".
D375A-6R
(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.
Out of six relays, condenser relay CDR 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).
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
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
X view
Y view
*: Since connector R1 is disconnected, blower

does not operate. Therefore pressure of air
conditioner hose in high-pressure line may
increase.
D375A-6R
(01)
Air conditioner
Testing relay
Checking relay unit

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) Coil resistance between terminals (1) and (2)
is 140 340 z.
2) While the voltage (20 to 30 VDC) is not
applied between terminals (1) (+) and (2),
terminals (3) and (4) are disconnected.
3) While the voltage (20 to 30 VDC) is applied
between terminals (1) (+) and (2), terminals
(3) and (4) are connected.
D375A-6R
(01)
80-35
Air conditioner
Troubleshooting chart 1
80-36
The numbers in the boxes are the item numbers in the troubleshooting table.
1. Defective cooling
80-36
80-36
D375A-6R
(01)
Air conditioner
2. Defective heating
D375A-6R
(01)
80-37
80-37
Air conditioner
80-38
1. The blower fan motor does not rotate or the fan speed is different from the set value.
a See "Troubleshooting of blower motor system (Air does not come out or air flow is abnormal)".
Probable cause
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,
Operate the fan switches in order and check the 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. The blower fan motor works properly but the air flow is insufficient.
Probable cause
Large airflow resistance
Check method
Check the filter for clogging and the duct for crushing.
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 cause
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 {1.3 - 2.0 kg/cm2}
High-pressure: Approx. 1.5 - 1.7 MPa {15 - 17 kg/cm2}
However, under the following condition;
Temperature inside cab: 30 -35 C
Engine speed: Approx. 1,500 rpm
Remedy
Collect refrigerant, then
refill with proper amount
of refrigerant again
Repair leaking part,
then refill with proper
amount of refrigerant.
See Troubleshooting
with gauge pressure
D375A-6R
(01)
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
Probable cause
Compressor
Slack of belt
belt
Trouble in compressor
Insufficient compressor oil or
Compressor
seizure in the compressor
Seizing on compressor
Drop of battery voltage
Disconnection or short circuit
in coil
Magnet clutch
or defective connection of
ground cable
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
Deflection of belt is large.
Adjust tension
Slip of belt
Repair or replace
Check for compressor overheat
See "Handling compressor oil".
Slip of clutch
Charge battery
Inspect with multimeter (10 to 20 z)
Replace
Check ground wire and connections

Repair
See "Troubleshooting of compressor system".
See "Testing relay"
See "Troubleshooting with gauge pressure".
Replace
See "Troubleshooting
with gauge pressure".
See "Troubleshooting of compressor system". Replace

Check diode (ACS). See "Troubleshooting of
compressor system".
Replace
5. The blower fan motor works properly but the air flow is insufficient.
Probable cause
Large airflow resistance
Check method
Remedy
Check the filter for clogging and the duct for crushing.
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.

Probable cause
Low engine coolant temperature
Low engine coolant level
Insufficient circulation of
engine coolant
The connection of IN and OUT
heater hoses is in reverse.
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)
Check the destination of heater hoses
Add coolant
Bleed air and repair
Repair
7. Abnormal fan speed

Probable cause
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
Probable cause
Temperature cannot be controlled
FRESH/RECIRC air cannot be
changed over
Excessive compressor oil
Water leakage into the cab
D375A-6R
(01)
Check method
Remarks
See "Testing temperature control" and "Troubleshooting for
Common to cooling and
temperature control".
See "Testing FRESH/RECIRC air changeover" and "Trouble- heating
shooting for FRESH/RECIRC air changeover"
See "Handling compressor oil".
Cooling only
Clogging of drain hole
80-39
Air conditioner
80-40

80-40
a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before troubleshooting, understand the information fully.
Failure
Related information
Cause
Possible causes for

trouble
(Perform troubleshooting according
to these numbers,
however.)
3 defective
Description of failure code

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 and B.
q Standard value in normal condition to evaluate probable 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.

<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)
80-40
This is the excerpted circuit diagram related to trouble

q Connector No.: Indicates (Model No. of pins).
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-6R
(01)
Air conditioner
D375A-6R
(01)
80-41
Air conditioner
Troubleshooting for power supply system (Air conditioner does not operate)
Troubleshooting for power supply system (Air conditioner does not

operate)
Failure
Problem on
machine
80-42
Air conditioner does not operate due to failure in power supply system
q
When control panel is operated, related LED does not light up.
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".
q
Cause
1
Activation of circuit breaker

(CB4)
(ground)

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
a
1.
2.
3.
4.
Max. 1 z
If circuit breaker trips, press its reset button in advance.

Disconnect connector AC2 from control panel.
Insert T-adapter into connector AC1.
Between AC1 (10) and (1)

a
a
1.
2.
3.
a
Resistance
Voltage
20 30 V
Perform the following when the test result "A" above is abnormal
If circuit breaker trips, press its reset button in advance.
Disconnect connector M26 and connect T-adapter to female side.
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)

20 30 V
Between M26 (5) and (6)
Voltage
Voltage
20 30 V
a Perform the following when circuit breaker trips during test "A" above and the
test results "B" and "C" above are normal.
a If circuit breaker trips, press its reset button in advance.
2. Disconnect connector AC2 from control panel.
4. Disconnect connectors CN-B, R1 - R4 and [5].
Voltage
20 30 V
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".
4

(on control panel side)
5 Defective control panel
80-42
a If circuit breaker does not trip, check with circuit diagram.

If cause is not found by above checks, control panel may be defective.
D375A-6R
(01)
Air conditioner
Troubleshooting for power supply system (Air conditioner does not operate)
D375A-6R
(01)
80-43
80-43
Air conditioner
Troubleshooting for compressor system (Air is not cooled)

Failure
Problem on
machine
80-4
Air is not cooled because of trouble in compressor or refrigerant system
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
q
Cause

2. Disconnect connector FEN from air conditioner compressor and connect
Defective air conditioner com1
T-adapter to male side.
pressor
Between FEN (1) and ground (air conditioner comResistance Approx. 15 z
pressor coil resistance)
2. Remove diode ACS.
a Measure with circuit tester in diode range.
2 Defective diode
No continuity
Between ACS (male) (1) (+) and (2) (-)
Max. 1 z
Between ACS (male) (2) (+) and (1) (-)
Continuity

Open circuit in wiring harness 2. Disconnect connector M26 and connect T-adapter to female side.
3
(on machine side)
Between M26 (female) (3) and ground
Resistance Approx. 15 z
(air conditioner compressor coil resistance)
a If circuit breaker does not trip, this check is not required.
Ground fault in wiring harness 2. Disconnect connector FEN.
4 (Contact with ground circuit) 3. Insert T-adapter into connector M26.
(on machine side)
Between M26 (female) (3) and ground
Resistance
Min. 1 Mz
Between M26 (female) (3) and (6)
q
Defective compressor clutch

relay (It does not turn ON)
a
a
1.
2.
3.
4.
Resistance
Referring to "Testing relay", check operation sound

Click is
of compressor clutch relay.
heard.
If the test result "A" above is normal, this check is not required.
Check that air flow can be controlled.
Replace compressor clutch relay with blower Me2 relay (CN-R4).
Turn air conditioner switch ON.
Min. 1 Mz
A
If compressor operates (air is cooled), original compressor clutch relay is defective.

2. Disconnect connector AC1 and insert T-adapter into female side.
Defective evaporator temperature sensor
80-44
0 C
Between AC1 (female) (15) and (17)
Resistance
4.6 - 5.1 kz
15 C
Resistance
2.1 - 2.6 kz
25 C
Resistance
1.5 kz
D375A-6R
(01)
Air conditioner
Cause
7 Defective pressure switch

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)
Check of voltage
8 (Defective wiring harness or
defective control panel)
When replacing pressure switch, collect refrigerant in advance.
1.
2.
3.
4.


a
1.
2.
3.
a
Voltage
Max. 1 V
Disconnect connectors M26, AC2, R1 - R4 and [5].
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-6R
(01)
If check result for cause 8 is abnormal and check results for causes 9 and 10 are
normal, control panel is defective.
80-45
Air conditioner
80-46
80-46
D375A-6R
(01)
Air conditioner
D375A-6R
(01)
80-47
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
80-48
flow is abnormal)
Failure
Problem on
machine
No air comes out or air flow is improper due to blower motor system failure
1) Air does not come out in any air flow setting.
q
When any fan switch is pressed, air does not come out.
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
Related information
Cause
1 Defective blower (fan) motor

2. Disconnect connector CN-B.
Between CN-B (male) (1) and (2)
q
Defective blower main relay

(Does not turn ON)
a
1.
2.
3.
4.
Continuity
Referring to testing of relay, check turn-on sound of Click is

blower main relay.
heard.
If the test result "A" above is normal, this check is not required.
Replace the blower main relay with blower Me2 relay (CN-R4).
If air comes out, original blower main relay is defective.

q
Check of voltage
1.
2.
3.
4.
Primary output to relay from control panel

a
1.
2.
3.
a
Voltage
Max. 1 V
Disconnect connectors M26, AC2, R1 to R4, and [5].
No continuity
a Check with circuit diagram.
80-48
D375A-6R
(01)
Air conditioner
D375A-6R
(01)
80-49
80-49
Air conditioner
Failure
Problem on
machine
No air comes out or air flow is improper due to blower motor system failure
2) Air does not come out or air flow is abnormal in certain air flow setting.
Air does not come out or air flow is abnormal in certain air flow setting.
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
conditioner unit).
Related infor3) Expansion valve is not adjusted properly (Remove air conditioner unit and replace expansion
mation
valve).
q For connectors, relays, etc., see "Parts and connector locations".
q Since condenser relay is not used, it may be used as replacement when replacing other relays.
q
Cause

2. Turn air conditioner switch ON.
3. Set air flow to each level in order.
Defective blower resistor

1 (Breakage of fuse in blower
resistor)
If air comes out only in air flow HI, blower resistor is defective.
Reference: Between [1] (male) (2) and (3)
Resistance
80-50
Resistance
Defective blower HI relay,

2 blower Me2 relay or blower
Me1 relay
q Reference: Between [1] (male) (1) and (2)

a Fuses
Reference: Between [1] (male) (3) and (4)
Resistance
Approx.
600 z
Approx.
900 z
Approx.
530 z

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.
q Replace blower HI relay with condenser relay. If air flow becomes normal, original blower HI relay is defective.
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.
D375A-6R
(01)
Air conditioner
Cause

q
1.
2.
3.
4.
5.
Primary output to relay from control panel

Press each air flow switch and perform troubleshooting.
HI
Voltage
Max. 1 V
Other than
HI
Voltage
20 30 V
""
Voltage
Max. 1 V
Other than
".."
Voltage
20 30 V
Check of voltage
""
Voltage
Max. 1 V
Other than
Voltage
20 30 V
"."
2. Disconnect connectors M26, AC2, CN-B, R1-R4, and [5]
No continuity
No continuity
No continuity
D375A-6R
(01)
80-51
Air conditioner
80-52
80-52
D375A-6R
(01)
Air conditioner
D375A-6R
(01)
80-53
Air conditioner
Troubleshooting for temperature control
80-54
Failure
Temperature cannot be controlled
Problem on
machine
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".
mation
q T-adapter for connector CN-M26: 799-601-7130, T-adapter for connector AC1: 799-601-2730,
T-adapter for connector [2]: 799-601-2710
q
Cause

2. Disconnect connector [2] and connect T-adapter to male side.
Between connector [2] (male) (4) and (1)
Resistance
6 kz
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)
Defective air mix servomotor
Voltage
5V
1.
2.
3.
4.
5.

Insert T-adapter in connector [2]
Press left triangle temperature control switch many times to set to minimum temperature in advance.
6. Perform troubleshooting while pressing right triangle temperature control switch.
7. Press right triangle temperature control switch many times to set to maximum temperature in advance.
8. Perform troubleshooting while pressing left triangle temperature control switch.
Between connector [2] (3) and (5)
a Voltage appears for only approximately 1
second (only while hot water valve is
moving) and polarity is reversed when
Voltage
24 V
B
right triangle and left triangle temperature control switch is pressed. When right
triangle switch (WARM side) is pressed,
polarity of pin 3 becomes +.
Between [2] (2) and (1)
a Voltage changes only while hot water
Varies below
Voltage
C
valve is moving (Voltage settles after the
5V
door stops).
2. Disconnect connectors AC1 and [2], and connect T-adapters to female side of them.
Resistance
Max. 1 z
Between AC1 (3) and [2] (5)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
80-54

2
harness
Resistance
Max. 1 z
D375A-6R
(01)
Air conditioner
Cause

a
1.
2.
3.
a
Disconnect connectors M26, AC2, AC3, and [2]
Short circuit in wiring har- Between AC1 (2) and each pin other than (2)
ness
No continuity
No continuity
No continuity
No continuity
No continuity

4 harness
If check result for cause 1 is abnormal and check results for causes 2 to 4 are normal,
control panel is defective.
D375A-6R
(01)
80-5
80-55
Air conditioner
Troubleshooting for FRESH/RECIRC air changeover

Failure
80-56
FRESH/RECIRC air cannot be changed over
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 Operate FRESH/RECIRD selector switch and check that there is not mechanical trouble (removal or
interference of lever, etc ) in fresh/recircculated air changeover door (damper). For details, see "Testing FRESH/RECIRC changeover".
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 S: 799-601-2710
Problem on
machine
Cause
a If FRESH/RECIRC air changeover servo motor does not operate while following
is normal (See Testing FRESH/RECIRC air changeover), FRESH/RECIRC air
changeover servo motor is defective.
2. Insert T-adapter into connector CN-S.
5. Perform troubleshooting while pressing RECIRC air switch and FRESH air
Defective FRESH/RECIRC air
1
switch.
changeover servo motor
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
2. Disconnect connectors AC1 and [2], and connect T-adapters to female side of
them.
Between AC1 (5) and CN-S (3)
Resistance
Max. 1 z
Between AC1 (6) and CN-S (5)
a
1.
2.
3.
a
Resistance
Max. 1 z
Disconnect connectors M26, AC2, AC3, and [2]
No continuity
No continuity
Disconnection in wiring har4 ness

If check result for cause 1 is abnormal and check results for causes 2 to 4 are normal, control panel is defective.
80-56
D375A-6R
(01)
Air conditioner
D375A-6R
(01)
80-57
80-57
Air conditioner
Troubleshooting with gauge pressure

Perform troubleshooting according to the high and
low gauge pressures of the cooling cycle. For details, see "Connection of service tool".
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: Above
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: Approx.
0.05 MPa {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.
80-58
<Measurement condition for pressure>

Item
Ambient temperature
Engine speed
Air conditioner switch
Fan switch
Set temperature
Condition value
2050 C
1,500 rpm
ON
HI
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-6R
(01)
Air conditioner
Indicated gauge
pressure
Pressure is normal
Cause
Check method
Remedy
Air conditioner cycle is normal.

If there is any trouble (cooling trouble), there is another cause.
High-pressure line pressure: Approx 1.5 - 1.7 MPa {15 17 kg/cm2}

2
Low-pressure line pressure: Approx 0.13 - 0.2 MPa {1.3 2.0 kg/cm }
Insufficient refrigerant
Clogging of receiver drier

<Pressure of both
high-pressure and
low-pressure lines
are too low>
Clogging of expansion valve

Refrigerant leakage from thermoprobe
tube of expansion valve
Bubbles can be seen through sight glass

*1, *3
There is a temperature difference between

Replace
inlet and outlet pipes of receiver drier.
Tank is frosty
Clean or replace
Expansion valve is frosty
Low pressure gauge reads vacuum
Evaporator is frozen
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
speed, air becomes not to be cooled.)
<Pressure of both
high-pressure and
low-pressure lines
are too high>
<High-pressure line
pressure is too high
and low-pressure
line pressure is too
low>
<High-pressure line
pressure is too low
and low-pressure
line pressure is too
high>

*2
*2
*2
Replace
*2
Repair or replace
Replace receiver drier
*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
*2
Clean, repair fins, or
Dirty condenser, clogging or crushing of
repair or replace conDefective cooling of condenser
fins, or defective revolution of cooling fan denser
*2
Defective adjustment of expansion valve
Replace
Bubbles can be seen through sight glass *3
(Valve is opened too wide)
*2
Vacuum and then refill
with proper amount of
Air in cycle parts
Bubbles can be seen through sight glass *3
refrigerant again
*2
Clogged or crushed piping between com- There is a remarkable temperature differpressor and condenser
ence across clogged part
Defective compressor (Compression

trouble of compressor)
Clean inside of cycle

parts or replace
Both high-pressure and low-pressure lines

stop while compressor is in operation.
Replace
Compressor has seized and is extremely
hot.
*2
*2
*1 Where 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-6R
(01)
80-59
Air conditioner
Connection of service tool
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).
Symbol
Part No.
Part name
X
799 - 703 - 1200 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)
80-60
(a): As the thread is coarse, care should be taken

with regard to loosening.
80-60
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-6R
(01)
Air conditioner
D375A-6R
(01)
80-61
Air conditioner
Precautions for disconnecting and connecting
80-62
Precautions for disconnecting
80-62
80-62
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 safety glasses, gloves and
working cloth with long sleeves while you are
collecting the refrigerant (R134a) or filling
the air conditioner circuit with the refrigerant
(R134a).
q
Precautions for connecting

q
q
q
When connecting the piping, apply compressor

oil (ND-OIL8) 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-6R
(01)
Air conditioner
Table of tightening torque for refrigerant pipe joint.

Unit: Nm {kgm}
Screw size
Tightening torque
M6 x 1.0
3.9 - 6.9 {0.4 - 0.7} (Receiver drier)

8 - 12 {0.8 - 1.2} (Air conditioner unit and compressor)
M16 x 1.5
12 15 {1.2 1.5}
M24 x 1.5
30 35 {3.1 3.6}
1. Engine
2. Compressor
3. Condenser
4. Receiver drier
5. Air conditioner unit
D375A-6R
(01)
80-63
Air conditioner
Handling of compressor oil

1. Compressor oil management (DENSO:
ND-OIL8 for R134a)
80-64
80-64
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
Content
Insufficiency of Lubrication trouble and seizure of comoil
pressor
Cooling trouble
Excess of oil
(Excessive oil stick to parts and lower
heat exchange performance)
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)
Quantity to be
added (cc)
Approx. 40
Approx. 40
Approx. 20
Approx. 30
Approx. 10
Approx. 10
Approx. 20
Accordingly, compressor oil must be filled to the

specified level, similarly to refrigerant.
2. Adding of compressor oil
80-64
Since refrigerant is dangerous and bad for

environment, collect the refrigerant before
disconnecting the air conditioner hose. See
"Precaution for connecting and disconnecting air conditioner piping".
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.
80-64
D375A-6R
(01)
Air conditioner
3. Compressor replacement
q
80-65
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
80-65
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.
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 - "Noted quantity"
Example:If 30 cc was drained from the
removed compressor, the amount to be
drained from the new compressor would be
150 cc (i.e., 180 - 30 cc).
D375A-6R
(01)
80-65
Air conditioner
80-66
D375A-6R
(01)
D375A-6R
SEN0521433-00
90-1
BULLDOZER
D375A-6R
Shop Manual
Machine model
Serial number
D375A-6R
9-01
65001 and up
90 Diagrams and drawings
D375A-6R
90-1
90-1
Contents
Contents
90 Diagrams and drawings
Hydraulic diagrams and drawings ...........................................................................................
Symbols used in hydraulic circuit diagrams .........................................................................
Power train hydraulic circuit diagram ...................................................................................
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- 11
90- 11
90- 15
D375A-6R
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 shaft unidirectional
Drive shaft bidirectional
D375A-6R
90-3

Symbol
Substance
Pump
Note : Black triangle shows outlet port
Variable capacity hydraulic pump

Hydraulic motor (The figure shows bidirectional type.)
Note Two 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-6R
Power train hydraulic circuit diagram

D375A-6R
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
D375A-6R
90-5
Hydraulic circuit diagram(1/2)

D375A-6R
DUAL TILT SPEC.

D375A-6R
90-7

D375A-6R
SINGLE TILT SPEC.

D375A-6R
90-9
Electrical diagrams and drawings

Symbols used in electrical circuit diagrams
90-1
90-1
(Rev. 2010/02)
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
Chassis ground
Chassis ground using terminal
Contact
Switch
Push-button type switch (N.O. type)
*N.O.: Normally Open
Push-button type switch (N.C. type)
*N.C.: Normally Close
Pull-button type switch (N.O. type)
Pull-button type switch (N.C. type)
Variable
Resistance (resistor)
Variable resistance (variable resistor)
D375A-6R
90-11

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
90-12
D375A-6R

Symbol
Substance
Lamp
Pressure switch (N.O. type)

Pressure switch (N.C. type)
Potentiometer
Fuel dial
Temperature sensor
Starting switch
Backup alarm
Horn
Buzzer
Antenna
D375A-6R
90-13

90-14
D375A-6R
Electrical circuit diagram (1/14)

D375A-6R

D375A-6R
90-15

D375A-6R

D375A-6R
90-17

D375A-6R

D375A-6R
90-19

D375A-6R

D375A-6R
90-21

D375A-6R

D375A-6R
90-23

D375A-6R

D375A-6R
90-25

D375A-6R

D375A-6R
90-27

D375A-6R

D375A-6R
90-29

D375A-6R

D375A-6R
90-31

D375A-6R

D375A-6R
90-33

D375A-6R

D375A-6R
90-35

D375A-6R

D375A-6R
90-37

D375A-6R

D375A-6R
90-39

D375A-6R

D375A-6R
90-41
Index
Index
A
Accumulator
10-128
Adjusting blade
30-81
30-58
30-39
30-72
30-61
30-78
30-56
30-16
30-80
30-149
80-4
80-20
80-10
B
Blade
60-98
Blade control lever (only for the machine with dual tilt
specification)
10-148
30-38
30-32
Bleeding air from work equipment cylinders
30-77
Blower unit
80-14
C
Cab
10-196
Cab mount
10-195
Carrier roller
60-56
Checking location of cause of hydraulic drift of blade and
ripper
30-74
40-12
80-24
Classification and procedures for troubleshooting 40-37
40-50
numbers
50-6
Compressor
80-16
Condenser
80-17
80-6
80-60
40-57
40-96
Control valve
10-162,60-81
Conversion table
00 -43
Cooling fan motor
10-28,60-12
Cooling fan pump
10-7,60-4
Cooling system
10-4
10-208
60-102
Cylinder stay
10-194,60-97
D
10-40,60-16
30-4
50-297
D375A-6R
(01)

50-279
50-216
50-207
50-274
Disassembly and assembly of damper assembly 50-90
50-260
50-170
50-301
Disassembly and assembly of hydraulic cylinder
50-284
assembly
50-189
50-251
Disassembly and assembly of one link assembly in the
50-246
field
50-108
50-198
Disassembly and assembly of ripper pin puller cylinder
assembly
50-292
50-282
50-150
Disassembly and assembly of TORQFLOW transmission
assembly
50-123
50-114
50-203
Disconnection and connection of power train unit
assembly
50-99
E
40-580
40-584
E-3 When starting switch is turned ON, machine monitor
displays nothing
40-588
E-4 When starting switch is turned ON (before starting
engine), basic check item lights up
40-592
40-594
40-596
E-7 Engine coolant temperature gauge does not indicate
normally
40-597
40-598
E-9 Power train oil temperature gauge (multi-gauge) does
40-600
not indicate normally
E-10 Hydraulic temperature gauge (multi-gauge) does not
40-601
indicate normally
E-11 Contents of display by machine monitor are different
from applicable machine
40-602
E-12 Machine monitor does not display some items
40-602
Index
E-13 Function switch does not work

40-602
40-603
E-15 Gearshift mode does not change
40-603
40-604
E-17 Customize memory function does not operate
40-604
normally
40-605
E-19 When starting switch is turned OFF, service meter is
40-605
not displayed
E-20 Machine monitor cannot be set in service mode
40-605
40-606
40-608
40-610
40-612
E-25 The head lamp and rear lamp do not light up40-613
40-622
40-630
E-28 Electric priming pump does not operate or does not
40-638
stop automatically
E-29 Orbcomm terminal does not operate normally (Data
40-640
are not transmitted)
40-642
Electrical circuit diagram
90 -15
Emergency escape method when there is failure in power
30-62
train
Engine control
10-198
10-199
Engine mount
60-3
10-231
00 -12
F
40-114
40-115
Failure code [15E0MW] Transmission clutch: Slip 40-116
Failure code [15SAL1] Forward clutch: Fill high 40-118
Failure code [15SALH] Forward clutch: Fill Low 40-120
Failure code [15SBL1] Reverse clutch: Fill high 40-122
Failure code [15SBLH] Reverse clutch: Fill Low 40-124
Failure code [15SEL1] Speed 1st clutch: Fill high 40-126
Failure code [15SELH] Speed 1st clutch: Fill Low 40-128
Failure code [15SFL1] Speed 2nd clutch: Fill high 40-130
Failure code [15SFLH] Speed 2nd clutch: Fill Low 40-132
Failure code [15SGL1] Speed 3rd clutch: Fill high 40-134
Failure code [15SGLH] Speed 3rd clutch: Fill Low 40-136
40-138
40-140
40-142
40-144
40-146
40-148
40-150
40-152
40-154
40-156
Failure code [2301NR] Steering Brake RH Themal Load

40-158
Abnormality
40-160
40-162
Failure code [2302NR] Steering Brake LH Themal Load
40-164
Abnormality
Failure code [7RFAKA] ECM ACC CUT RELAY:
Disconnection
40-166
Failure code [7RFAKB] ECM ACC CUT RELAY: Short
40-168
circuit
40-170
Failure code [AB00MA] Battery Charge Abnormal 40-172
40-173
40-174
40-175
40-176
40-177
40-178
40-179
40-180
40-182
40-184
40-186
Failure code [CA131] Throttle Sensor High Error 40-188
Failure code [CA132] Throttle Sensor Low Error 40-190
40-192
40-194
40-196
40-198
40-200
40-202
40-204
40-206
40-208
40-210
40-212
40-214
40-215
40-216
40-218
40-220
40-222
40-223
40-224
D375A-6R
(01)
Index

40-225
40-226
40-228
40-230
40-232
40-234
40-236
40-238
Failure code [CA351] Injectors Drive Circuit Error 40-239
40-240
40-242
Failure code [CA441] Battery Voltage Low Error 40-243
Failure code [CA442] Battery Voltage High Error 40-244
Failure code [CA449] Rail Press Very High Error 40-245
40-246
40-248
40-250
40-251
40-252
40-256
40-258
40-259
40-260
40-262
40-263
40-264
Failure code [CA2249] Rail Press Very Low Error 40-265
40-266
40-268
Failure code [D130KB] Neutral relay: Short circuit 40-270
Failure code [D161KA] Back-up alarm releay:
40-272
Disconnection
40-274
40-276
40-278
40-280
Failure code [D1EFKA] Pre lub. motor relay:
40-282
Disconnection
D375A-6R
(01)

40-284
Failure code [DAFRKR] Monitor: Can communication lost
40-286
(PT)
Failure code [dAFRKR] Monitor: CAN communication lost
(WE)
40-287
40-288
Failure code [DB2RKR] ENG cont.: Can communication
40-294
lost (PT)
Failure code [dB2RKR] ENG controller: CAN
40-298
communication lost (WE)
Failure code [DB90KT] WE controller: Abnormality in
controller
40-299
Failure code [DB91KK] WE controller: Source voltage
40-300
reduction
Failure code [DB92KK] WE controller: Output voltage
40-302
reduction
Failure code [DB97KK] WE cont.: Sensor voltage 5 V (2)
40-304
reduction
40-306
Failure code [DB9RKR] WE controller: Can
40-307
communication lost (PT)
Failure code [DBB0KK] VHMS controller:Source voltage
reduction
40-310
Failure code [DBB0KQ] VHMS connector connection
abnormality
40-312
Failure code [DBB3KK] VHMS controller: Source voltage
40-313
reduction
Failure code [DBB5KP] VHMS: Output sensor1 voltage
40-316
reduction
Failure code [DBB6KP] VHMS:Output sensor2 voltage
reduction
40-318
Failure code [DBB7KP] VHMS:Output sensor3 voltage
40-320
reduction
Failure code [DBBQKR] PT cont.: Can communication
40-322
lost (VHMS)
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
40-326
reduction
Failure code [DBE5KK] PT cont.: Sensor voltage 5 V (1)
reduction
40-328
Failure code [DBE6KK] PT cont.: Sensor voltage 24V
40-330
reduction
Failure code [DBE7KK] PT cont.: Sensor voltage 5 V
40-332
reduction
40-334
Failure code [DBERKR] PT controller: Can
40-335
communication lost (WE)
40-338
Failure code [DD12KB] Shift up Sw: Short circuit 40-340
40-342
40-344
40-346
Index

40-348
40-350
Failure code [DDE2KA] Pre lub. oil press sw:
40-352
Disconnection
40-354
Failure code [DDK5KA] Shift switch disconnection40-356
Failure code [DDK5KB] Shift switch short circuit 40-358
Failure code [DDN2LD] Blade tilt RH pressure SW
40-360
abnormality
Failure code [DDN3LD] Blade tilt LH pressure SW
abnormality
40-362
Failure code [DDN7KA] WEQ Knob Sw (down):
40-364
Disconnection
Failure code [DDN7KB] WEQ Knob Sw (down): Short
40-366
circuit
Failure code [DDN9KA] WEQ Knob Sw (up):
40-368
Disconnection
40-370
Failure code [DDNALD] Blade lift up pressure SW
40-372
abnormality
Failure code [DDNBLD] Ripper lift up pressure SW
40-374
abnormality
Failure code [DDNCLD] Ripper lift down pressure SW
abnormality
40-376
Failure code [DDNDLD] Ripper tilt in pressure SW
40-378
abnormality
Failure code [DDNELD] Ripper tilt back pressure SW
40-380
abnormality
Failure code [DDNFLD] Blade lift down pressure SW
abnormality
40-382
40-384
40-386
40-388
40-390
Failure code [DDT5KQ] Lever SPEC selection signal
disagreement
40-392
40-394
40-396
40-398
40-400
40-402
40-404
Failure code [DGT5KA] F exhaust temp sensor
40-406
disconnection
Failure code [DGT5KB] F exhaust temp sensor short
circuit
40-408
Failure code [DGT6KA] R exhaust temp sensor
40-410
disconnection
Failure code [DGT6KB] R exhaust temp sensor short
40-412
circuit
Failure code [DH21KA] Weq pressure sensor:

Disconnection
40-414
Failure code [DH21KB] Weq pressure sensor: Short
40-416
circuit
Failure code [DHE5KB] ENG blow-by pressure sensor
40-418
disconnection
Failure code [DHE5KY] ENG blow-by pressure sensor
short circuit
40-420
Failure code [DHT3KX] T/M oil pressure sensor
40-422
abnormality
Failure code [DHT5KA] T/C in-pressure sensor:
40-424
Disconnection
Failure code [DHT5KB] T/C in-pressure sensor: Short
circuit
40-426
Failure code [DHT7KA] T/C out-pressure sensor:
40-428
Disconnection
Failure code [DHT7KB] T/C out-pressure sensor: Short
40-430
circuit
40-432
40-434
Failure code [DK30KA] ST lever 1: Disconnection 40-436
Failure code [DK30KB] ST lever 1: Short circuit 40-438
40-440
Failure code [DK30KZ] ST lever: Disconnection or short
40-441
circuit
Failure code [DK30L8] ST lever: Signal mismatch 40-442
Failure code [DK31KA] ST lever 2: Disconnection 40-444
Failure code [DK31KB] ST lever 2: Short circuit 40-446
Failure code [DK40KA] Brake potentiometer:
Disconnection
40-448
40-450
40-452
Failure code [DK55KZ] FR lever: Disconnection or short
40-453
circuit
Failure code [DK55L8] FR lever: Signal mismatch 40-454
Failure code [DK56KA] FR lever 1: Disconnection 40-456
Failure code [DK56KB] FR lever 1: Short circuit 40-458
Failure code [DK57KA] FR lever 2: Disconnection 40-460
Failure code [DK57KB] FR lever 2: Short circuit 40-462
Failure code [DK60KA] Acceleration sensor:
40-464
Disconnection
40-466
Failure code [DKH1KA] Pitch angle sensor:
40-468
Disconnection
40-470
Failure code [DLF1KA] T/C out-speed sensor:
40-472
Disconnection
40-474
40-476
Failure code [DLT3KA] T/M out-speed sensor:
40-477
Disconnection
40-478
Failure code [DW59KA] Blade dual selector SOL
40-479
disconnection
D375A-6R
(01)
Index
Failure code [DW59KB] Blade dual selector SOL short

circuit
40-480
40-482
Failure code [DW5AKA] Blade pitch selector SOL
disconnection
40-484
Failure code [DW5AKB] Blade pitch selector SOL short
circuit
40-485
Failure code [DW5AKY] Blade pitch selector SOL Short
circuit
40-486
40-488
40-489
40-490
40-492
40-494
Failure code [DWN5KA] Fan pump solenoid 1:
40-496
Disconnection
Failure code [DWN5KB] Fan pump solenoid 1: Short
40-498
circuit
Failure code [DWN5KY] Fan pump solenoid 1: Short
40-500
circuit
Failure code [DWNCKA] Fan pump solenoid 2:
Disconnection
40-502
Failure code [DWNCKB] Fan pump solenoid 2: Short
40-504
circuit
Failure code [DWNCKY] Fan pump solenoid 2: Short
40-506
circuit
40-508
40-509
40-510
40-512
40-514
40-516
40-518
40-520
40-522
40-524
40-526
40-528
40-530
40-532
40-534
D375A-6R
(01)

40-536
40-538
40-540
Failure code [DXH9KA] Right clutch ECMV:
40-542
Disconnection
40-544
40-546
40-548
40-550
40-552
Failure code [DXHBKA] Right brake ECMV:
Disconnection
40-554
40-556
40-558
40-560
40-562
40-564
40-566
Failure code [DXJBKB] S/C ECMV: Short circuit 40-567
Failure code [DXJBKY] S/C ECMV: Short circuit 40-568
40-570
40-572
40-573
40-574
40-575
40-576
Failure codes table
40-40
Final drive
10-105,60-43
80-15
40-110
H
40-648
40-650
40-651
H-4 Machine travels only in one direction, forward or
40-653
reverse
40-654
40-655
40-656
Index

40-657
40-658
40-659
40-660
40-661
40-662
40-663
40-664
40-665
40-666
H-18 Excessive hydraulic drift of blade lift cylinder40-667
H-19 Excessive hydraulic drift of blade tilt cylinder40-668
H-20 Excessive hydraulic drift of ripper lift cylinder40-669
H-21 Ripper pin puller cylinder does not operate (machine
40-670
with giant ripper)
H-22 Blade pitch does not work (machine with dual tilt
40-671
specification)
40-672
H-24 Abnormal fan rotation(noise and/or vibration are
40-673
abnormally large or engine overheats)
80-64
00 -23
00 -14
30-24
Handling of fuel system devices
Handling of no injection cranking operation
30-28
30-158
Handling of reduced cylinder mode operation
30-27
30-148
00 -26
00 -10
50-4
Hydraulic circuit diagram
90 -7
Hydraulic cylinder
60-74
Hydraulic tank
10-126

10-50,60-22
30-18
Measuring fan speed
30-36
Method of disassembling and connecting push-pull type
00 -32
coupler
40-674
Monitor system
10-210
O
ORBCOMM system
10-247
80-7
Overall disassembly and assembly of track shoe 50-227
10-36
P
10-232
Parking brake valve
10-102,60-42
80-28
PCCS lever
10-60
10-146
Pin puller switch
10-145
Piston valve
10-142
Pm Clinic service
30-184
40-10
Power train
10-34
60-32
Power train hydraulic diagrams and drawings
90 -5
10-38
Power train unit
60-14
10-123
PPC lock valve
10-129
PPC valve
10-130,60-68
80-62
80-3
30-178
00 -29
Preparation work for troubleshooting for electrical
equipment system
30-153
80-22
I
Idler
60-52
Idler cushion
10-112,60-50
40-578
Information in troubleshooting table 40-52,40-644,80-40
Initialization procedures for VHMS controller
30-161
30-64
30-157
L
Lamp system
10-230
50-245
00 -39
40-646
10-52,60-23
M
Machine monitor
Main frame
10-212
10-114,60-61
Q
Quick drop valve
10-143,60-77
R
Receiver drier
80-18
Releasing remaining pressure in work equipment
cylinders
30-76
30-25
Releasing residual pressure from fuel system
50-63
50-314
50-295
50-211
Removal and installation of carrier roller assembly50-206
50-272
Removal and installation of cooling assembly (radiator,
50-55
after cooler, and hydraulic oil cooler)
50-35
D375A-6R
(01)
Index

50-86
50-64
50-321
50-74
Removal and installation of engine hood assembly 50-71
50-76
50-256
50-80
50-82
Removal and installation of fan pump assembly 50-270
Removal and installation of final drive assembly 50-168
Removal and installation of first bogie assembly 50-218
Removal and installation of floor frame assembly 50-309
Removal and installation of fuel injector assembly 50-30
50-25
50-84
50-62
50-263
50-188
50-324
50-305
Removal and installation of pivot shaft assembly 50-255
Removal and installation of power train pump and
50-166
lubrication pump assembly
50-93
50-60
50-50
50-193
50-304
50-167
50-262
Removal and installation of track frame assembly 50-183
Removal and installation of track roller assembly 50-200
Removal and installation of transmission controller
50-320
assembly and steering controller assembly
50-323
Removal and installation of work equipment pump
50-266
assembly
Replacing and adjusting alternator and air conditioner
30-35
compressor belt
30-159
Ripper
60-104
S
40-678
40-679
S-3 Engine does not rev up smoothly (response-up is
40-682
poor)
40-683
40-684
40-685
40-686
D375A-6R
(01)
S-8 Oil is consumption is excessive(or exhaust smoke is

blue)
40-687
40-688
40-689
S-11 Oil mixes into coolant(coolant blows back or is
40-690
reduced)
S-12 Engine pressure monitor lights up (drop in engine oil
pressure)
40-691
S-13 Oil level rises (Coolant or fuel mixes into oil) 40-692
40-693
40-694
40-695
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)
40-696
Safety notice
00 -5
Scavenging pump
10-57,60-24
10-187,60-94
Sensor
10-235
50-223
40-11
30-57
50-17
30-90
Special tool list
50-9
01 -3
Specifications
01 -4
Sprocket
60-46
00 -35
20-3
20-4
10-84
10-94,60-41
10-92,60-40
10-103
Suspension
10-116,60-63
Symbols use in electric circuit diagrams
90 -11
90 -3
System diagram
80-26
T
01 -11
40-93
30-84
30-65
Testing and adjusting work equipment oil pressure 30-66
30-21
30-69
30-23
30-6
30-14
30-11
30-37
80-33
30-34
30-26
30-9
Testing leakage from pressure limiter and return rate from
30-29
injector
Index
Testing leakage inside work equipment cylinder

30-75
30-73
30-42
30-70
Testing relay
80-34
80-32
10-42,60-19
10-48
Track frame
10-110,60-48
Track roller
60-54
Track roller bogie
10-113,60-58
Track shoe
60-58
10-86
60-34
Transmission
10-64,60-26
10-58,60-25
Transmission ECMV
10-78
60-31
10-83
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
40-54
of pressure sensor system
80-58
U
Using method of KOMTRAX functions of ORBCOMM
terminal
30-175
V
10-241
W
Weight table
01 -9
10-124
10-119
Work equipment pump
10-150,60-78
D375A-6R
(01)
Shop Manual
DRAFT
D375A-6R BULLDOZER
Form Number: SEN05214-01
2010 KOMATSU
All Rights Reserved
Printed in Japan 03-10

Shop Manual D375A-6R Serial Numbers 65001 and Up SEN05214-01

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Shop Manual D375A-6R Serial Numbers 65001 and Up SEN05214-01

Enviado por

Direitos autorais:

Formatos disponíveis

SEN05214-01

Page to be newly added

List of revised pages

00 Index and foreword

Notice of revision ....................................................................................................................

00 Index and Foreword

10 Structure and function

Final drive ............................................................................................................................

20 Standard value table

Adjusting valve clearance ....................................................................................................

Pm Clinic................................................................................................................................. 30- 184

Failure code [B@HANS] Hyd Oil Overheat..........................................................................

Failure code [D110KB] Battery Relay: Drive Short Circuit...................................................

Failure code [DDNBLD] Ripper lift up pressure SW abnormality.........................................

Failure code [DLT3KA] T/M out-speed sensor: Disconnection............................................

Failure code [F@BYNR] F exhaust temp high level (2) .......................................................

Disassembly and assembly of damper assembly ................................................................

Electrical system ..................................................................................................................... 50- 319

Precautions for refrigerant ...................................................................................................

90 Diagrams and Drawings

Forword and general information

Forword and general information

Important safety notice

6) Keep all tools in good condition, learn the

Forword and general information

6) When removing a cover which is under

Forword and general information

4. Precautions for slinging work and making signals

8) When installing wire ropes to an angular

11)Do not use twisted or kinked wire ropes.

Forword and general information

If the load is unstable or the wire rope or

5. Precautions for using mobile crane

13)If the hoist stops because of a power failure,

a The allowable load is one-sixth of the

Forword and general information

Forword and general information

How to read the shop manual

1. Composition of shop manual

Forword and general information

2. Revision and distribution

When a manual is revised, revision number of each page is increased by 1.

The revised pages are shown in the LIST OF REVISED PAGES.

Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving standards are

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

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.

Forword and general information

Explanation of terms for maintenance standard

a The tolerance may be indicated in the text

2. Standard clearance and standard value

Forword and general information

4. Repair limit and allowable value or allowable

Forword and general information

Handling of electric equipment and hydraulic components

2. Main failures occurring in wiring harness

Forword and general information

4) High-pressure water entering connector

Forword and general information

3. Removing, installing, and drying connectors

When removing a connector from a