Shop Manual

GENERAL
01 GENERAL
SPECIFICATION DRAWING ..................................................................................................................... 01- 2

SPECIFICATIONS ..................................................................................................................................... 01- 4
WEIGHT TABLE ........................................................................................................................................ 01-10
TABLE OF FUEL, COOLANT AND LUBRICANT ...................................................................................... 01-12
D375A-5 01-1
GENERAL SPECIFICATION DRAWING
SPECIFICATION DRAWING
Semi U-tilt dozer U-tilt dozer Semi U-tilt dozer U-tilt dozer
Item Unit
+ Giant ripper + Giant ripper + Multi-shank ripper + Multi-shank ripper
Overall
A mm 10,330 10,695 10,040 10,405
length
Overall
4,035 4,035 4,035 4,035
B height mm
(4,230) (4,230) (4,230) (4,230)
(with ROPS)
Overall
C mm 4,695 5,140 4,695 5,140
width
01-2 D375A-5
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model D375A-5
Serial number 18001 and up
Machine weight
Bare tractor with semi u-dozer 49,800
Ditto with variable multi-shank ripper kg 60,340
Ditto with ROPS cab + Air conditioner + 67,060
Seat belt + Perforated side cover + SSC 68,500
Minimum turning radius m 4.2

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

2nd speed km/h 0 6.8
3rd speed 0 11.8
1st speed 0 5.1

2nd speed km/h 0 9.2
3rd speed 0 15.8
Bare tractor 103.16 {1.06}

With semi U-dozer 125.53 {1.28}
With semi U-dozer + Variable multi- 140.37 {1.43}
shank ripper kPa {kg/cm2}
Ditto with ROPS cab + air conditioner 143.38 {1.46}
+ Seat belt + Perforated side cover +
SSC
Bare tractor 5,770

With semi U-dozer 7,635
With semi U-dozer + Variable multi- 10,040
mm
shank ripper
With U dozer + Variable multi-shank 10,405
ripper
Bare tractor 3,220

With semi U-dozer mm 4,695
With U-dozer 5,140
To top of exhaust pipe 4,035

mm
To top of air intake duct 3,429
01-4 D375A-5
Track gauge 2,500

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

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

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

Max. torque Nm {kgm}/rpm 2,648 {270}/1,300
Max. speed at no load rpm 1,900
Min. speed at no load rpm 720
Min. fuel consumption ratio g/kw.h 209 {156}

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

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

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

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

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

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

Carrier roller 2 each side
Track roller 7 each side
Track shoe Assembly type, single grouser, 40 each side,

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

Gear type (SAR(1) 022)
(work equipment pump and tandem)
Maximum pressure MPa {kg/cm2} 20.6 {210}
Type Gear type, double type (SAR(4) 140 + (3) 071)
Delivery ¬/min 405

(at engine speed of 1,800 rpm)
Type
For blade lift Single pilot spool type, with demand spool
For blade tilt, ripper LO Triple pilot spool type
For ripper HI Double pilot spool type
Type Double acting piston type
Cylinder bore 150

Piston rod outside diameter 90
Piston stroke mm 1,505
Max. distance between pins 2,650
Min. distance between pins 1,145
Cylinder bore 225

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

(both right and left)
Piston stroke 185
(both right and left) mm
Cylinder bore 225

Cylinder bore 200

Control valve assembly type

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

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

(from ground level)
Max. lowering depth mm 715
(from ground level)
Max. tilt mm 1,065
Blade cutting angle variation deg. ±5
3
Blade capacity m 24.0 <SAE18.5>
Blade width mm 4,695

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

(from ground level)
Max. lowering depth mm 715
(from ground level)
Max. tilt mm 1,165
Blade cutting angle variation deg. ±5
Blade capacity m3 26.3 <SAE22.0>
Blade width mm 5,140

Blade height mm 2,265
Max. tilt mm 1,150

Max. pitch angle deg. 5
Max. tilt mm 1,260

Max. pitch angle deg. 5
Max. digging depth mm 1,075

Point digging angle deg. 45 (Stepless adjustment is possible
between 32.5 and 55.5 deg.)
Max. beam width mm 2,854

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

Point digging angle deg. 45 (Stepless adjustment is possible
between 32.5 and 55.5 deg.)
Max. beam width mm 1,367

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

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

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

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

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

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

Pivot shaft 210 × 2
Equalizer assembly 490
Hydraulic tank assembly 370

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

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

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

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

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

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

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

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

Fuel tank Diesel fuel 1,050 —
ASTM D975
No. 1
Cooling system Coolant Komatsu genuine super coolant (AF-NAC added) 165 —
01-12 D375A-5
4
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
10 STRUCTURE, FUNCTION AND

POWER TRAIN ........................................................................................................................................ 10- 4

OVERALL DRAWING OF POWER TRAIN UNIT .................................................................................... 10- 6
POWER TRAIN HYDRAULIC PIPING DRAWING .................................................................................. 10- 8
DAMPER, UNIVERSAL JOINT ................................................................................................................ 10- 10
TORQUE CONVERTER, PTO ................................................................................................................. 10- 12
TORQUE CONVERTER VALVE .............................................................................................................. 10- 20
SCAVENGING PUMP ............................................................................................................................. 10- 31
TRANSMISSION CONTROL ................................................................................................................... 10- 32
TRANSMISSION ...................................................................................................................................... 10- 34
TRANSMISSION ECMV .......................................................................................................................... 10- 46
TRANSMISSION LUBRICATION RELIEF VALVE .................................................................................. 10- 52
POWER TRAIN PUMP + LUBRICATION PUMP .................................................................................... 10- 53
STEERING, BRAKE CONTROL ............................................................................................................. 10- 54
TRANSFER, BEVEL GEAR SHAFT, STEERING .................................................................................... 10- 57
STEERING ECMV ................................................................................................................................... 10- 64
STEERING CLUTCH, STEERING BRAKE ECMV .................................................................................. 10- 68
PARKING BRAKE VALVE ....................................................................................................................... 10- 75
SUDDEN STOPS PREVENTION VALVE ................................................................................................ 10- 76
FINAL DRIVE .......................................................................................................................................... 10- 77
TRACK FRAME ....................................................................................................................................... 10- 82
RECOIL SPRING .................................................................................................................................... 10- 84
IDLER ...................................................................................................................................................... 10- 86
TRACK ROLLER ...................................................................................................................................... 10- 88
CARRIER ROLLER ................................................................................................................................. 10- 89
TRACK ROLLER BOGIE ......................................................................................................................... 10- 90
TRACK SHOE .......................................................................................................................................... 10- 92
MAIN FRAME .......................................................................................................................................... 10- 94
SUSPENSION ......................................................................................................................................... 10- 96
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM ........................................................................... 10- 99
PPC CONTROL PIPING DIAGRAM ........................................................................................................ 10-103
WORK EQUIPMENT CONTROL ............................................................................................................ 10-104
HYDRAULIC TANK ................................................................................................................................. 10-106
PPC CHARGE VALVE ............................................................................................................................ 10-108
ACCUMULATOR ..................................................................................................................................... 10-111
PPC LOCK VALVE .................................................................................................................................. 10-112
PPC VALVE ............................................................................................................................................. 10-114
WORK EQUIPMENT CYLINDER ............................................................................................................ 10-124
PISTON VALVE ....................................................................................................................................... 10-127
QUICK DROP VALVE ............................................................................................................................. 10-128
PIN PULLER SWITCH ............................................................................................................................. 10-130
PIN PULLER SOLENOID VALVE ............................................................................................................ 10-131
BLADE CONTROL KNOB ....................................................................................................................... 10-133
PITCH, DUAL TILT SOLENOID VALVE .................................................................................................. 10-134
D375A-5 10-1
WORK EQUIPMENT + PPC CHARGE PUMP ........................................................................................ 10-136

MAIN CONTROL VALVE ......................................................................................................................... 10-138
CYLINDER STAY .................................................................................................................................... 10-168
BLADE ..................................................................................................................................................... 10-170
RIPPER EQUIPMENT ............................................................................................................................. 10-176
CAB MOUNT ........................................................................................................................................... 10-178
CAB .......................................................................................................................................................... 10-179
AIR CONDITIONER ................................................................................................................................. 10-181
ENGINE CONTROL ................................................................................................................................. 10-182
ENGINE CONTROL SYSTEM ................................................................................................................. 10-183
DECELERATOR POTENTIOMETER ...................................................................................................... 10-184
HPI ENGINE CONTROL SYSTEM .......................................................................................................... 10-186
MONITOR SYSTEM ................................................................................................................................ 10-188
MONITOR PANEL ................................................................................................................................... 10-190
SENSORS ............................................................................................................................................... 10-194
MODE SELECTION SYSTEM ................................................................................................................. 10-197
SENSORS ............................................................................................................................................... 10-200
ELECTRICAL DEVICE ............................................................................................................................ 10-203
STEERING ELECTRONIC CONTROL .................................................................................................... 10-206
10-2 D375A-5

MAINTENANCE STANDARD POWER TRAIN
POWER TRAIN
Outline
The power generated by engine (1) has its tor- el pinion and bevel gear of the bevel gear shaft,
sional vibration dampened by damper (2), and and it is then divided at right angles to the left
then passes through universal joint (3), and it and right and transmitted to the respective steer-
transmitted to torque converter (7). ing clutches (9).
The power from the engine is transmitted The power transmitted from the bevel gear shaft
through oil by torque converter (7) to the input to the final drive is used to steer the machine by
shaft (turbine shaft) of transmission (8) in accor- engaging on disengaging steering clutch (9).
dance with the change in the load. The steering lever is operated to disengage the
There is a lock-up clutch assembled to the steering clutch on the side to which the machine
torque converter, and when the rotating speed is to be steered in order to change the direction
beyond the torque converter becomes higher, of travel. The size of the turning radius is con-
the lock-up clutch is engaged. When this hap- trolled by steering brake (10) installed to the out-
pens, the drive case and turbine form one unit, side of the steering clutch.
so the power from the engine is transmitted di- Steering brake (10) uses the same disc system
rectly to the transmission input shaft. that is used for the steering clutch.
Transmission (8) uses a combination of a plane- The power output from the steering clutch enters
tary gear system and hydraulic equipment to re- final drive (11), where it is reduced, and rotates
duce the speed and shift the gears (forward: 3 sprocket (12).
gears, reverse: 3 gears). It connects two sets of Final drive (15) is a double reduction type con-
clutches selected with the gear shift lever ac- sisting of a single stage spur gear and single
cording to the change in the load, and transmits stage planetary gear system.
the power from the transmission to transfer (14) It rotates the sprocket to drive track shoe (13)
from the output shaft. and move the machine.
The power entering transfer (14) has its speed
reduced. Its speed is further reduced by the bev-
10-4 D375A-5
MAINTENANCE STANDARD POWER TRAIN
1. Engine (SA6D170E-3) 6. Hydraulic pump 11. Final drive

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

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

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

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

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

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

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

15 48 ± 0.1 47.7
and holder
D375A-5 10-11
MAINTENANCE STANDARD TORQUE CONVERTER, PTO
TORQUE CONVERTER, PTO
1. Coupling 14. Bearing cage 28. Scavenging pump gear

2. Seal cage 15. Retainer (63 teeth)
3. Input shaft 16. Shaft 29. Seal seat
[PTO drive gear (61 teeth)] 17. Transmission input shaft 30. Spacer
4. Front housing 18. Stator shaft boss 31. Cover
5. Idler gear (77 teeth) 19. Stator clutch housing 32. Hydraulic pump gear (57 teeth)
6. Idler gear shaft 20. Return spring 33. Power train pump gear
7. Clutch housing 21. Stator clutch plate (57 teeth)
8. Drive case 22. Stator clutch disc 34. Cover
9. Turbine 23. Stator clutch piston 35. Cover
10. Rear housing 24. Turbine boss
A. Hydraulic pump mount
11. Stator 25. Lock-up clutch disc
B. Power train pump mount
12. Pump 26. Lock-up clutch plate
C. Scavenging pump mount
13. Stator shaft 27. Lock-up clutch piston
10-12 D375A-5
D375A-5 10-13
10-14 D375A-5
Unit: mm
Standard size Tolerance Repair limit

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

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

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

5 0.204 0.516
and driven gear
Standard size Repair limit

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

7
Thickness of Replace
15.8 14.5
overall assembly
Thickness of disk 5.4 5.1
Thickness of plate 5.0 4.5

8
Thickness of
15.8 14.7
overall assembly
Installed Installed Installed

Free length Free length
9 Stator clutch spring length load load
125.5 N 106.9 N
54.1 37.0 52.5
{12.8 kg} {10.9 kg}
D375A-5 10-15
Outline Structure
The torque converter design employs 3-element, The pump (12) is united with the coupling (1),
1-stage and 3-phase arrangement. It is, structur- shaft (3), clutch housing (7) and drive case (8). It
ally, united with the transmission. is rotated by motive power from the engine.
In order to reduce consumption of fuel and en- The turbine (9) is united with the turbine boss
gine horsepower as well as increase operating (24) and transmission input shaft (turbine shaft)
performance, the torque converter incorporates (17). It is rotated by oil from the pump.
the wet type/double plate clutch type torque con- The stator (l1) is united with the stator shaft (13)
verter lock-up device plus the stator clutch de- and stator boss (18). It is fixed to the rear hous-
vice. ing (10) via the stator clutch device.
In continuous light load dozing operations or lev- The lock-up clutch device is consisted of the
eling operation, motive power of the engine can clutch plate (26) engaged with the drive case (8),
be more effectively utilized when it is transmitted the clutch disk (25) engaged with the turbine
directly to the transmissions input shaft. It is why boss (24), and the clutch piston (27) that slides
the hydraulically operated lock-up clutch is incor- in the housing (7) united with the drive case.
porated into the converter. When the torque con- The stator clutch device is consisted of the clutch
verter is locked up (when the pump and turbine disk (22) engaged with the boss (18) (the boss is
are united), oil supply from the converter relief connected to the stator shaft (13) via the spline),
valve is not stopped. Thus, the oil conducted out the clutch plate (21) being secured to the clutch
of the pump - turbine used to be provided with housing (19) and rear housing (10) with the pin,
unnecessary directivity by the stator, resulting in and the clutch piston (23) that slides in the rear
resisting against the pump and turbine rotation housing.
(stirring of oil). In order to return the oil dis- PTO device is consisted of the input shaft (3),
charged from the pump - turbine to the pump idler gear (5), scavenging pump drive gear (28),
with smaller resistance, the stator clutch has work equipment pump drive gear (32) and power
been installed to enable drag turning of the stator train pump drive gear (33).
accompanying the rotation of the pump and tur-
bine as the torque converter is locked up.
★ Following describes the lock-up mode of the
torque converter and the conditions to be met by
the torque converter mode.
Lock-up range
Torque converter output shaft rotation speed:
1,260 rpm minimum
Torque converter range
Torque converter output shaft rotation speed:
1,230 rpm maximum
★ The torque converter mode is maintained as
long as gear speed change from the trans-
mission is taking place.
10-16 D375A-5
Path of transmission of motive force
1. Lock-up clutch OFF, stator clutch ON

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

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

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

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

2 40 0.035 0.061 0.08
converter relief valve and valve 0.045 0
Clearance between stator clutch 0.035 +0.013

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

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

5 25 0.020 0.043 0.06
valve and valve body 0.030 0

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

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

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

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

10 80.5 80.5 78.09
spring (Inside)
55.9 N 53.1 N
11 Lock-up valve spring 66 54.0 64.0
{5.7 kg} {5.42 kg}
D375A-5 10-23
Operation of main relief valve

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

The oil relieved from the main relief valve flows
into the torque converter from port C, and at the
same time passes through orifice b and enters
port D.
When the oil fills the torque converter, the pres-
sure starts to rise.
If the pressure in the torque converter rises, the
oil entering port D pushes piston (9). The reac-
tion force compresses spring (3), moves relief
valve (2) to the right in the direction of the arrow,
and opens ports C and E.
When this happens, the oil at port C is relieved
to port E, and is drained to the oil tank.
The pressure in the circuit at this point is
0.88 MPa {9 kg/cm2}.
10-24 D375A-5
Torque Converter Lock-up Control System

System diagram
Operation
The torque converter lock-up control system au- The machine body controller receives the trans-
tomatically locks up the torque converter de- mission controller gear speed information, and
pending on the load of a machine by one sensor the transmission output shaft rotation sensor sig-
signal and controller. When the torque converter nal which is sent from the SSC controlle to con-
is locked up, the indicator lamp on the monitor nect or disconnect the lock-up solenoid and
panel lights up. indicator lamp, performing the ON/OFF of the
The transmission output shaft rotation sensor lock-up.
signal is input to the transmission controller.
Set the lock-up mode on the mode selection
panel.
D375A-5 10-25
The lock-up ON/OFF operation is carried out

when the sensor signal conforms to the condi-
tions below. (It is not turned ON during gear shift-
ing.)
1. Conditions for ON (AND circuit)
1) Not during gear shifting (The status that Gear speed
the clutch is completely engaged): F2, F3,
F1
The transmission controller recognizes R1, R2, R3
rpm
the status.
2) When the right-sided conditions for the 1,230 rpm 1,260 rpm
ON
ON rpm are conformed to: or less or more
When the both above conditions 1) and
2) are conformed to. 1,200 rpm 1,230 rpm
OFF
2. Conditions for OFF (OR circuit) or less or more
1) During gear shifting (The status that the
clutch is not completely engaged.) 2,140 rpm
ON
2) When the right-sided conditions for the or less
OFF rpm are conformed to.
2,200 rpm
The status quo is maintained when the conditions of OFF
or more
either 1 or 2 are not conformed to.
10-26 D375A-5
1. When the machine is in torque converter travel mode
When the machine enters torque converter travel Then, the oil from the pump goes through the port Q
mode, the solenoid valve is demagnetized to bring to the port S to function as the back pressure of the
back the plunger (34) upward by oil pressure, open- piston of the stator clutch. It turns ON the stator
ing the seats of valve (27) and ball (28), and the clutch after the oil pressure of the circuit goes up.
ports P and N. At the same time, the oil which has been functioning
Since the drain circuit of the port N is open, the oil at as the back pressure of the piston of the lock-up
the port M is drained as well. clutch is drained through the port L to the port R,
The lock-up selector valve (24) is pushed rightward turning OFF the lock-up clutch.
by the spring (22), closing the ports Q, L, S, and T The oil from the pump also enters the port P. Since
and opening the ports Q, S, L, and R. the solenoid valve is demagnetized, however, it is
drained through the orifice A.
The oil pressure at the port Q is kept by the orifice A
and regulated by the modulating valve (10).
D375A-5 10-27
2. When the machine is in direct travel mode
When the machine enters direct travel mode, the so- The oil from the pump goes through the port Q to the
lenoid valve is magnetized to push the plunger (34) port L to function as the back pressure of the piston
downward, closing the seats of ball (28) and valve of the lock-up clutch. It turns ON the lock-up clutch
(27) to open the ports P and M and close the drain after the oil pressure of the circuit goes up. At the
circuit of the port N. same time, the oil which has been functioning as the
Then, the oil from M moves the piston (25) and lock- back pressure of the piston of the lock-up clutch is
up selector valve (24) leftward to close the ports Q, drained through the port S to the port T, turning
S, L, and R, and open the ports Q, L, S, and T. OFF the stator clutch.
The oil pressure at the port L is regulated by the
lock-up clutch modulating valve (11).
10-28 D375A-5
Operation of the stator clutch and lock-up clutch

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

When the machine enters direct travel mode, the
solenoid valve is magnetized to cause the oil at
the port M of lock-up selector valve (24) to push
the piston (25) and valve (24) leftward.
Then, the lock-up selector valve (24) is pushed
leftward by an oil pressure larger than the ten-
sion of the spring (22) to close the ports Q and S
and open the ports S and T, draining the oil at the
port S through the port T.
When the oil pressure at the port S vanishes, the
modulating valve (10) is pushed back by the ten-
sion of spring (16) rightward to open the part B
of the port S completely. At that time, the operat-
ing pressure of the stator clutch is drained
through the port S to the port T to turn OFF the
clutch.
The oil from the pump flows through the port Q
to the port L to turn ON the lock-up clutch.
D375A-5 10-29
2. When the machine is in torque converter

travel mode
When the machine enters torque converter trav-
el mode, the solenoid valve is demagnetized
to drain the oil from the pump and at the port M.
The valve (24) moves the valve rightward by the
tension of the spring (22) to close the ports Q, L,
S, and T, and open the ports Q and S. By this op-
eration, the circuit from the port Q, the modulat-
ing valve (10), and up to the stator clutch is
created.
The oil from the pump flows to the stator clutch
through the port Q to start increasing the oil
pressure of the circuit.
When the oil pressure at the circuit is increased,
the oil which flowed through the orifice d of the
modulating valve (10) pushes the piston (13),
and its reaction force moves the modulating
valve leftward to throttle back the part B of the
port S.
The port S, which is connected to the port U
which applies a back pressure to the load piston
(19), moves the load piston rightward to shrink
the spring (16) to open the part B of the port S
by the tension of the spring.
The above operation is intermittently repeated to
increase the load of the spring (16), gradually in-
creasing the oil pressure until the oil pressure in-
crease stops at a position where the part B of the
port S closes.
The oil pressure of the stator clutch at that time
is 2.65 ± 0.1 MPa {27.0 ± 1 kg/cm2}.
The oil pressure of the lock-up clutch is
1.3 +0.1 +1
0 MPa {13 0 kg/cm }.
2
10-30 D375A-5
MAINTENANCE STANDARD SCAVENGING PUMP
SCAVENGING PUMP
BAR 63 + 277
A. Discharge port
B. Small pump suction port
C. Large pump suction port
Unit: mm
1 Spline shaft rotation torque
Rotating Discharge Standard Permissible

discharge discharge
Delivery Type speed pressure amount amount
(rpm) MPa {kg/cm } (¬/min) (¬/min)

Oil: E010-CD
BAR 63 0.15 63.3
Oil temperature: 45 55°C
1,743
BAR 277 {1.5} 276.8
D375A-5 10-31
MAINTENANCE STANDARD TRANSMISSION CONTROL
TRANSMISSION CONTROL
★ Regarding the steering-related description of the
Palm Command Control System lever (PCCS le-
ver), refer to the Steering/Brake Control.
★ PCCS: Palm Command Control System
1. Brake pedal Lever position Outline

2. Safety lever 1: Neutral Control the transmission by the PCCS le-
3. PCCS lever 2: Forward ver (3).
(Forward-reverse, gear shift) 3: Reverse The PCCS lever operates forward/reverse
3A, UP switch 4: OFF shifting and gear shift operation.
(Shift up by every one pressing) 5: Shift UP The adopted safety mechanism does not
3B, DOWN switch 6: Shift DOWN cause the transmission neutral safety
(Shift down by every one pressing) 7: Free switch (4) to function except when the
4. Transmission neutral safety switch 8: Lock safety lever (2) is at the Lock position, not
5. Cable allowing the engine to start.
6. Transmission control valve
10-32 D375A-5
MAINTENANCE STANDARD TRANSMISSION CONTROL
Gear shift of the machine

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

Operate the gear shift lever by pressing the switches
(1) and (2) when the steering, forward/reverse, and
gear shift lever is at the forward or reverse position.
(1) One pressing the up shifts the gear speed one
up.
(2) One pressing the down shifts the gear speed
one down.
★ If you carry out the gear shift, the gear speed in
use is indicated on the display of the panel.
<Ex.> Neutral: Indicates N on the display.
Forward 2nd speed gear:
Indicates F2 on the display.
Reverse 3rd speed gear:
Indicates R3 on the display.
P is indicated when the safety lever is
placed at the Lock position.
D375A-5 10-33
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
1. Input shaft A. 2nd clutch operating pressure pick-up port

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

No. 1 clutch spring Free length Free length
1 length load load
(× 12)
125.5 N 107.9 N
66.0 57.0 64.0
{12.8 kg} {11.0 kg}
No. 2 clutch spring 218.7 N 196.1 N
2 70.0 60.3 68.0
(× 12) {22.3 kg} {20.0 kg}
No. 3, 4 clutch spring 149.1 N 127.5 N
3 97.0 82.4 95.0
(× 12) {15.2 kg} {13.0 kg}
No. 5 clutch spring 3,422.5 N 3,079.3 N
4 7.75 6.75
(× 3) {349 kg} {314 kg}
Overall assembled thickness of Standard size Tolerance Repair limit
5
No. 1 clutch 54.6 ±0.33 49.0
Overall assembled thickness of
6 50.3 ±0.33 45.0
No. 2 clutch
7 36.4 ±0.26 32.0
No. 3 clutch
8 27.3 ±0.22 24.0
No. 4 clutch
9 50.0 ±0.33 45.2
No. 5 clutch
Thickness of clutch disc
10 4.8 ±0.1 4.0
(No. 1 4 clutch)
Thickness of clutch disc
11 5.0 ±0.1 4.2 Replace
(No. 5 clutch)
Thickness of clutch plate
12 4.3 ±0.1 4.0
(No. 1 4 clutch)
Thickness of clutch plate
13 4.0 ±0.1 3.8
(No. 5 clutch)
0.01
Wear of seal ring on transmission Width: 3.0 Width: Width: 2.6
14 0.03
input shaft Thickness: 3.5 Thickness: 3.3
Thickness: ±0.15
0.01
Wear of seal ring on transmission Width: 4.5 Width: Width: 4.1
15 0.03
output shaft Thickness: 5.8 Thickness: 5.6
Thickness: ±0.1
0.01
Width: 5.0 Width: Width: 4.6
16 Wear of seal ring on No. 5 clutch 0.03
Thickness: 6.0 Thickness: 5.8
Thickness: ±0.15
Backlash between No. 1, 2 sun Standard clearance Clearance limit
17
gear and planet pinion 0.13 0.40
Backlash between No. 1 planet
18 0.13 0.40
pinion and ring gear inner teeth
Backlash between No. 2, 3, 4
19 planet pinion and ring gear inner 0.14 0.40
teeth
Backlash between No. 3, 4 sun
20 0.13 0.37
gear and planet pinion
Clearance between bearing and
21 0.16 1.59
thrust washer
D375A-5 10-39
Outline
The transmission is a forward 3 gear, reverse 3
gear transmission that consists of a combination
of a planetary gear system and disc clutches.
The transmission actuates the control valve to
use hydraulic pressure to fix two of the clutches
in the five sets pf planetary gears and disc
clutches to select one rotating direction and one
gear speed.
The clutches are locked as follows: No. 1 clutch
for REVERSE, No. 2 clutch for FORWARD, No. 3
clutch for 3rd, No. 4 clutch for 2nd and No. 5
clutch for 1st.
No. of plates and discs used
Clutch No. No. of plates No. of discs
No. 1 clutch 6 6
No. 2 clutch 5 6
No. 3 clutch 4 4
No. 4 clutch 3 3
No. 5 clutch 5 6
Gear speed, clutch combination.
Clutch combination
Gear speed
(engaged)
FORWARD 1st No. 2 . No. 5
FORWARD 2nd No. 2 . No. 4
FORWARD 3rd No. 2 . No. 3
NEUTRAL 1 . No. 5
REVERSE 1st No. 1 . No. 5
REVERSE 2nd No. 1 . No. 4
REVERSE 3rd No. 1 . No. 3
1: Only low pressure oil fills the 1st clutch.
10-40 D375A-5
Operation of disc clutch

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

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

When the supply of pressure oil from the control
valve is shut off, piston (36) is returned to its orig-
inal position by the force of piston return spring
(37). This relieves the frictional force between
plates (38) and discs (39), making the ring gear
(7) free.
Washer spring (43) installed between the plates
at the pin acts to speed up the return of the pis-
ton when the clutch is disengaged, and also to
separate the plate and disc cleanly to prevent
continued rotation.
D375A-5 10-41
1st clutch oil circuit

The 1st clutch is farthest from the control valve, and
the piping to the cylinder is longer, so it takes a long-
er time for the oil to fill the piping.
For this reason, even when the gear shift lever is in
neutral, oil still flows to the 1st clutch.
Therefore, when moving the gear shift lever from
neutral to F1, it is only necessary for the oil from the
pump to fill the FORWARD clutch.
When the gear shift lever is moved from F1 to F2, the
FORWARD clutch is already filled with oil, so the oil
from the pump only needs to fill the 2nd clutch. By
using the oil in this way, the time lag when shifting
gear is reduced.
10-42 D375A-5
OPERATION OF TRANSMISSION
FIRST FORWARD SPEED
For FORWARD 1st, No. 2 clutch and No. 5 clutch Ring gear (13) is locked in position by No. 2
are engaged. The motive force transmitted from clutch, so planet gear (12) rotates carrier (32),
the torque converter to input shaft (1) is transmit- which is on the inside of ring gear (13).
ted to output shaft (25). No. 5 clutch is also engaged, so the No. 5 gear
No. 2 clutch is actuated by the hydraulic pressure (22), sun gears (17) and (21), planet pinions, ring
applied by the clutch piston and locks ring gear gear (15) and (18), and No. 4 carrier (30) form
(13) in position. No. 5 clutch is actuated by hy- one unit. In addition, carrier (32) rotates as one
draulic pressure applied by the clutch piston and unit with the gears of No. 3, 4 and 5 clutches to
engaged No. 5 gear (22) and No. 4 ring gear rotate output shaft (25).
(18). Output shaft (25) rotates at the same speed as
The motive force from the torque converter is carrier (32).
transmitted to input shaft (1). The rotation of the
input shaft is transmitted through sun gear (11)
to planet pinion (12).
D375A-5 10-43
FIRST REVERSE SPEED
For REVERSE 1st, No. 1 clutch and No. 5 clutch Carrier (34) is locked in position by No. 1 clutch,
are engaged. The motive force transmitted from so the rotation of planet pinion (9) rotates ring
the torque converter to input shaft (1) is transmit- gear (10).
ted to output shaft (25). Ring gear (10) rotates in the opposite direction
No. 1 clutch is actuated by the hydraulic pressure from the input shaft, and it rotates carrier (32).
applied by the clutch piston and locks carrier (34) No. 5 clutch is also engaged, so the No. 5 gear
in position. No. 5 clutch is actuated by hydraulic (22), sun gears (17) and (21), planet pinions, ring
pressure applied by the clutch piston and en- gear (15) and (18), and No. 4 carrier (30) form
gaged No. 5 gear (22) and No. 4 ring gear (18). one unit.
The motive force from the torque converter is In addition, carrier (32) rotates as one unit with
transmitted to input shaft (1). The rotation of the the gears of No. 3, 4 and 5 clutches to rotate out-
input shaft is transmitted through sun gear (6) to put shaft (25).
planet pinion (9).
10-44 D375A-5
MAINTENANCE STANDARD TRANSMISSION ECMV
TRANSMISSION ECMV
(Electronic Control Modulation Valve)
10-46 D375A-5
1. Proportional solenoid valve for 3rd clutch ECMV

2. Proportional solenoid valve for 1st clutch ECMV
3. Proportional solenoid valve for R clutch ECMV
4. Proportional solenoid valve for 2nd clutch ECMV
5. Proportional solenoid valve for F clutch ECMV
6. Fill switch for 3rd clutch
7. Fill switch for 2nd clutch
8. Fill switch for 1st clutch
9. Fill switch for R clutch
10. Fill switch for F clutch
11. Connector for 1st proportional solenoid valve
12. Connector for 3rd proportional solenoid valve
13. Connector for R proportional solenoid valve
14. Connector for 2nd proportional solenoid valve
15. Connector for F proportional solenoid valve
16. Connector for 3rd fill switch
17. Connector for 2nd fill switch
18. Connector for 1st fill switch
19. Connector for R fill switch
20. Connector for F fill switch
21. Filter
22. Pressure control valve
23. Oil pressure detection valve
24. Pressure control valve spring
A. 1st operating pressure pick-up port
B. 3rd operating pressure pick-up port
C. R operating pressure pick-up port
D. 2nd operating pressure pick-up port
E. F operating pressure pick-up port
F. To clutch
P. From pump
T. Drain
D375A-5 10-47
10-48 D375A-5
Outline of ECMV ECMV and proportional solenoid

• The ECMV consists of a pressure regulator valve • One proportional solenoid is installed for one
and a fill switch. ECMV.
• Pressure control valve After receiving the command current from the
Converts a current sent from the transmission con- controller, it produces thrust shown in the graph
troller to the proportional solenoid valve, to an oil below.
pressure. By making the proportional solenoid-produced
• Fill switch thrust act on the pressure control valve spool, it
Detects that the clutch is filled with oil. It has the produces an oil pressure shown in the graph be-
functions below. low. By controlling the amount of command cur-
1) When the clutch is filled with oil, a signal (the rent, the thrust is changed to operate the pressure
fill signal) is sent to the controller to notify that control valve, controlling the oil flow and oil pres-
filling is finished. sure.
2) While oil pressure is being applied to the
clutch, a signal (the fill signal) is sent to the Current-Propulsion force characteristics of
controller to notify that oil pressure is being proportional solenoid
applied.
A range: Before shifting gear (when drained)
B range: Filling
C range: Pressure regulation
D range: Filling (triggering)
E point: Start of filling
F point: Finish of filling
Propulsion force-Hydraulic pressure char-

acteristics of proportional solenoid
ECMV and fill switch

★ The logic is such that the controller does not rec- • One fill switch is installed for one ECMV.
ognize finish of filling even if the fill switch is turned If the clutch finishes filling,the fill switch is turned
"ON" during the triggering operation (D range). "ON" by the pressure of the clutch. By this signal,
the oil pressure starts build-up.
D375A-5 10-49
(7)
ECMV operation 1. Before shifting gear (when drained)

• The ECMV is controlled with the command cur- (A range in chart)
rent sent from the controller to the proportional When a current is not carried to the proportional
solenoid and the output signal of the fill switch. solenoid (1), the pressure control valve (2) is
The relationship between the proportional com- draining the oil at the clutch port A through the
mand current for the ECMV, clutch input pressure, drain port Dr.
and output signal of the fill switch is shown in the Since oil pressure is not applied to oil pressure
graph below. detector valve (3) at this time,fill switch (4) is
turned "OFF".
A range:Before shifting gear (when drained)
B range:Filling
C range:Pressure regulation
D range:Filling (triggering)
E point:Start of filling
F point:Finish of filling
★ The logic is such that the controller does not rec-

ognize finish of filling even if the fill switch is turned
"ON" during the triggering operation (D range).
10-50 D375A-5
(7)
2. Filling (B range in chart) 3. Pressure regulation (C range in chart)

If you supply current to the proportional solenoid If you supply current to the proportional solenoid
(1) with no oil in the clutch, an oil pressure propor- (1), the solenoid produces thrust proportional to
tional to the solenoid force acts on the chamber B, the current. Pressure is regulated by balancing the
pushing the pressure control valve (2) rightward. thrust of the solenoid, the thrust of clutch port A,
As a result, pump port P and clutch port A are and reaction force of the pressure control spring
opened and oil starts filling the clutch. If the clutch (5).
is filled with oil,fill switch (4) is turned "ON".
D375A-5 10-51
(7)
MAINTENANCE STANDARD TRANSMISSION LUBRICATION RELIEF VALVE
TRANSMISSION LUBRICATION RELIEF VALVE
1. Lubrication oil pressure measurement plug Function

2. Lubrication relief spool
The lubrication relief valve is installed to the right
3. Valve body
side face of the transmission, and acts to prevent
any abnormal pressure in the transmission lubri-
cating oil.
Cracking pressure: 0.26 MPa {2.7 kg/cm2}
10-52 D375A-5
MAINTENANCE STANDARD POWER TRAIN PUMP + LUBRICATION PUMP
POWER TRAIN PUMP + LUBRICATION PUMP

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

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

discharge discharge
Delivery Type speed pressure amount amount
Oil: E010-CD
2.5 2.7
Oil temperature: 45 50°C BAL 180 2,033 334 308
{26 28}
(Engine speed: 1,900 rpm) 0.26
BAL 112 2,033 210 200
{2.7}
D375A-5 10-53
10 Structure, function and maintenance standard
MAINTENANCE STANDARD STEERING, BRAKE CONTROL
STEERING, BRAKE CONTROL

★ Regarding the transmission-related description
of the operation of the PCCS lever, refer to the
Transmission Control.
★ PCCS: Palm Command Control System
10-54 D375A-5
MAINTENANCE STANDARD STEERING, BRAKE CONTROL
1. Brake pedal Positions of lever and pedal

2. Safety lever 1: Neutral
3. PCCS lever (Steering) 2: Forward straight-travel
4. Limit switch 3: Reverse straight-travel
5. Steering controller 4: Left clutch OFF
6. Steering ECMV 5: Left clutch OFF
7. Brake valve Left brake ON
8. Parking brake lever (From safety lever) 6: Right clutch OFF
9. Cable 7: Right clutch OFF
10. Rod (From brake pedal) Right brake ON
11. Potentiometer 8: Brake RELEASE
9: Brake ON
:: Free
A: Lock
Outline
The PCCS lever (3) sends an electric signal to If you completely tilt the PCCS lever (3) leftward,
the steering controller (10). After receiving it, the the left steering clutch is turned OFF complete-
steering controller (10) sends a proportional cur- ly and the left steering brake is turned ON,
rent to the steering ECMV (6) to operate the causing the machine to make a sudden left
steering clutch and brake. swing.
The brake pedal (1) sends an electric signal to The safety bar (2) is connected to the parking
the steering controller (10) via the potentiometer brake lever (8) and it also serves as a parking
(11). After receiving it, the steering controller brake.
(10) sends a proportional current to the steering
ECMV (6) to operate the brake. In this case, the
right and left brakes operate at the same time to
activate braking. The rod (5) operates the brake
via the brake valve (9) for redundant use. (Only
at the time of complete braking)
If you slightly tilt the PCCS lever (3) leftward, the
left steering clutch is partially disengaged, caus-
ing the machine to make a slow left swing.
D375A-5 10-55
MAINTENANCE STANDARD TRANSFER, BEVEL GEAR SHAFT, STEERING
TRANSFER, BEVEL GEAR SHAFT, STEERING
1. Transmission unit
2. Input shaft
3. Steering unit
4. Breather
5. Parking brake valve
6. Left brake ECMV
7. Right brake ECMV
8. Transmission output rotation sensor
9. Filter
10. Left clutch ECMV
11. Right clutch ECMV
12. Sudden braking prevention valve
D375A-5 10-57
Transfer Bevel Gear Pinion
1. Input shaft Outline

2. Drive gear (35 teeth) The transfer bevel pinion is mounted at the rear
3. Transmission output rotation sensor part inside the steering case, which receives the
4. Rear cover power from the transmission output shaft by its
5. Bearing gauge input shaft (1). The transfer consists of the drive
6. Driven gear (33 teeth) gear (2) and the driven gear (6) to reduce the
7. Bevel pinion (23 teeth) power speed from the input shaft (1), transferring
8. Bevel gear (40 teeth) it to the bevel pinion (7). It is also provided with
the transmission output rotation sensor (3) to
send the pulse signal of the drive gear (2) to the
torque converter lock-up controller using an
electric signal.
10-58 D375A-5
Unit: mm
Standard clearance Clearance limit

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

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

3 2.0 Adjust
bearing cage mount
D375A-5 10-59
BEVEL GEAR SHAFT, STEERING CLUTCH, BRAKE
10-60 D375A-5
1. Clutch cage Outline

2. Clutch housing As steering clutches, wet-type, multiple disc
3. Clutch spring type, and spring-boosted types are adopted. If
4. Clutch piston you operate the PCCS lever, the controller out-
5. Torque pin puts a proportional solenoid current to hydrauli-
6. Clutch disc (One side: 9 sheets) cally operate the steering ECMV while
7. Clutch plate (One side: 9 sheets) interlocking with the brake.
8. Spacer As a lubrication method, forced lubrication is
9. Clutch stopper adopted, which makes oil from the power train oil
10. Clutch hub cooler flow through the passage in the steering
11. Bearing cage case to the housing and cage, and up to the disc
12. Bevel gear (Number of teeth: 40) plate.
13. Bevel gear shaft
14. Bevel gear shaft As steering brakes, wet-type, multiple disc type,
15. Bearing cage and spring-boosted types brakes are adopted. If
16. Pipe you operate the brake pedal and PCCS lever, the
17. Brake stopper controller outputs a proportional solenoid current
18. Brake hub to hydraulically operate the steering valve ECMV
19. Brake disc (One side: 9 sheets) while interlocking with the brake.
20. Spacer As a lubrication method, forced lubrication is
21. Brake plate (One side: 9 sheets) adopted, which makes oil from the power train oil
22. Torque pin cooler flow through the passage in the steering
23. Brake piston case to the housing and cage, and up to the disc
24. Brake case plate.
25. Brake spring When the engine is stopping, the steering brake
26. Brake cage is ON since the back pressure of the brake pis-
27. Sleeve ton lowers unless you press the brake pedal.
28. Output shaft Since the brake is released as the oil pressure in
the circuit goes up when the engine restarts, the
parking lock lever must be locked.
D375A-5 10-61
10-62 D375A-5
Unit: mm

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

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

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

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

Interference between bevel gear size Shaft Hole interference limit
13
and reamer bolt
+0.019 +0.027 0.026
16 0.02
+0.001 0 0.019
14 Runout of back face of bevel gear Repair limit: 0.05 (measure after installing to bevel gear) Repair or replace
Standard rotating torque: 4.9 5.9 Nm {0.5 0.6 kgm}
Preload of bevel gear shaft taper
15 (At tip of bevel gear teeth with bevel pinion and gear not meshed: Adjust
roller bearing
23.5 28.4 N {2.4 2.9 kg})
Standard shim thickness for bear-
16 2.0 Adjust shim
ing cage
D375A-5 10-63
MAINTENANCE STANDARD STEERING ECMV
STEERING ECMV
(Electronic Control Modulation Valve)
10-64 D375A-5
1. ECMV (For left clutch) A. Left clutch operating pressure pick-up port
2. ECMV (For right clutch) B. Right clutch operating pressure pick-up port
3. Sudden braking prevention valve C. Left brake operating pressure pick-up port
4. Parking brake valve D. Right brake operating pressure pick-up port
5. ECMV (For left brake) E. To left clutch
6. ECMV (For right brake) F. To left lubrication
7. Filter G. To left brake
8. Valve seat H. To right clutch
J. To right lubrication
K. To right brake
L. Bevel gear shaft lubrication inlet
M. To pin puller solenoid valve
N. From pin puller solenoid valve
P. From pump
D375A-5 10-65
10-66 D375A-5
Outline
This machine employs four ECMV (electronic-
controlled modulation valve) on the steering con-
trol valve.
The steering control valve is provided on respec-
tive valve sheets as the assembly.
The steering control valve is situated in the cir-
cuit between the power train pump via the main
relief valve and the piston of the steering clutch
and the brake. It is configured with two pairs of
the steering ECMV (right and left) and the brake
ECMV (right and left).
Shifting the PCCS lever (steering and forward/
reverse) right or left disconnects the steering
clutch. Shifting it further turns ON the brake.
The controller sends the instruction to respective
ECMV to cause the gradual or sudden turn
whichever is designated by the operating posi-
tion of the PCCS lever (steering lever).
Depending on depth of the pedal depression, the
controller instructs ECMV to apply the right and
left brakes to stop the machine.
The controller that is electrically connected to
the PCCS lever and pedal performs above oper-
ations by switching the steering control valves
(each ECMV).
The steering control valves feed the oil from the
power train pump to the steering clutch and
brake to operate their disk clutches.
The sudden stop prevention valve disables sud-
den braking that can result when a failure is de-
tected in the electric systems.
Shifting the parking brake lever to the Lock po-
sition switches the port of the parking brake
valve, thereby draining the oil between the
ECMV for left-and-right brakes and the brake. As
the result, the machine brake is turned on.
The parking brake is also connected to the brake
pedal via the linkage.
D375A-5 10-67
MAINTENANCE STANDARD STEERING CLUTCH, STEERING BRAKE ECMV
STEERING CLUTCH, STEERING BRAKE ECMV

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

P: From pump 2. Proportional solenoid connector
T: Drain 3. Pressure detection valve
Dr: Drain 4. Fill switch
P1: Clutch or brake pressure pick-up port 5. Proportional solenoid
P2: Pilot pressure pick-up port 6. Pressure control valve
10-68 D375A-5
Outline of ECMV
The ECMV (Electronic Control Modulating valve)
consists of a pressure control valve and a fill
switch.
Pressure control valve
This valve allows a proportional solenoid to re-
ceive a current sent from a steering controller
and converts it to oil pressure.
Fill switch
This component detects that a clutch is filled with
oil and has the following functions.
1) When the clutch is filled with the oil, at the
same time, a signal (fill signal) is output to
the controller and transmits filling termina-
tion.
2) While oil pressure is applied to the clutch,
the signal (fill signal) is output to the control-
ler and transmits the presence of oil pres-
sure.
ECMV and Proportional Solenoid

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

Brake
Outline
This valve sets the steering clutch oil pressure or
the steering brake oil pressure to a set pressure
and switches a circuit to the clutch chamber and
the brake chamber.
D375A-5 10-69
Operation
1. In case of PCCS lever Neutral, brake pedal Released: Straight travel

(Left and right clutch ON, left and right brake Released, parking brake OFF)
In the position of PCCS lever Neutral and brake Further, the proportional solenoid valve (5) of the
pedal Released, because the solenoid valve (1) of brake ECMV is energized and pushes the ball (6) to
the steering ECMV is deenergized, the sealing por- the left direction, then closes the sealing portion.
tion of the ball (2) is opened. The oil that entered the pump port 2> enters the -
The oil from the power train pump enters the port port, pushes the valve (7) left, opens the 2> and *
2? of the steering ECMV via the main relief valve. ports, and closes the * and ,H ports. The oil that
The oil that entered the port 2? passes through the entered the 2> port passes through the * port and
orifice = and passes through the sealing portion of flows into the back pressure port of the brake pis-
the ball (2), then is drained. ton. Subsequently, the piston moves to the left di-
The valve (3) is moved right by the tension of the rection waiting for the rise of the circuit oil pressure
spring (4) and closes the 2? and + ports, then and compresses the brake spring, then sets the
opens the + and ,H ports. At this time, the oil from brake Released.
the back pressure port of a clutch piston is drained In the parking brake OFF, the parking brake is
from the port + and the clutch is set to ON by the closed and the oil of the brake circuit is not drained.
tension of the clutch spring. The oil pressure of the
brake circuit is ensured by the orifice =.
10-70 D375A-5
2. When the PCCS lever is actuated halfway to the left: Slow swing
(Left clutch OFF, left brake Semi-released, right clutch ON, right brake Released, parking
brake OFF)
When the PCCS lever is actuated halfway to the proportional solenoid valve (5) in accordance with
left, the solenoid valve (1) of the left steering ECMV the stroke of the PCCS lever. When the current
is energized and pushes the ball (2) to the left direc- flows into the proportional solenoid (5), the sole-
tion, then closes the sealing portion. noid generates a thrust in proportion to the current.
The oil from the power train pump passes through The sum of the thrust of this solenoid, the thrust
the orifice = from the port 2? and enters .. Subse- caused by the brake port oil pressure, and the res-
quently, the oil pushes the valve (3) to the left and titution of the pressure control valve spring (8) is
opens the 2? and + ports, then closes the + and ,H balanced and pressure-adjusted.
ports. The oil of the + port flows into the clutch pis- Accordingly, if the stroke of the PCCS lever is small,
ton port and becomes the back pressure, then sets the oil pressure of the port * and later is also spec-
the left clutch to OFF. ified high and the brake changes from Released
Further, the proportional solenoid valve (5) of the to Semi-released. If the stroke is large, the oil
left ECMV is energized and pushes the ball (6) to pressure is specified low and the brake changes
the left direction, then closes the sealing portion. from Semi-released to ON.
The oil that entered the pump port 2> enters the - In the parking brake OFF, the parking brake valve
port and pushes the valve (7) to the left. is closed and the oil of the brake circuit is not
Besides, the oil pressure of the port * and later out- drained.
puts a command current from the controller to the
D375A-5 10-71
3. When the PCCS lever is actuated fully to the left: Sudden swing
(Left clutch OFF, left brake ON, right clutch ON, right brake Released, parking brake OFF)
When the PCCS lever is actuated fully to the left The left brake is set to ON by the tension of the
from the state of Section 2, the proportional so- brake spring.
lenoid valve (5) of the left brake ECMV is deen- In the parking brake OFF, the parking brake
ergized and sets the ball (6) free, then opens the valve is closed and the oil of the brake circuit is
sealing portion. not drained.
Because the oil of the port E passes through the
sealing portion and is drained, the valve (7) is
moved right by the tension of the spring (8).
At this time, the port Pb closes and the port B
and drain port Dr open.
The oil from the power train pump passes
through the orifice b from the port Pb and pass-
es through the sealing portion, then is drained.
The oil pressure of the clutch circuit is ensured
by the orifice b. On the other hand, the oil that
flows into the brake piston port and reached the
back pressure is drained from the port B to Dr.
10-72 D375A-5
4. In case of brake pedal Stepped on

(Clutch ON, brake ON, parking brake OFF)
When the brake pedal is stepped on, the propor- steering ECMVs is deenergized and the left and
tional solenoid valve (5) of the left and right brake right clutches are set to ON.
ECMVs is deenergized from energization by the Further, when the brake pedal is stepped on, the
pedal full actuation. parking brake valve linked using a linkage is ac-
A command current is output from the controller tuated and drains the oil of the brake circuit.
to the proportional solenoid valve (5) in accor-
dance with the actuation stroke of the brake ped-
al. When the current flows into the proportional
solenoid valve (5), the solenoid generates a
thrust that is proportional to the current. The sum
of the thrust of this solenoid, the thrust caused by
the oil pressure of the brake port, and the resti-
tution of the pressure control valve spring (8) is
balanced and oil pressure is specified, thereby
enabling adjustment of the effect of the brake.
Besides, because the PCCS lever is not actuat-
ed, the solenoid valve (1) of the left and right
D375A-5 10-73
5. In case of parking brake ON

(Clutch ON, brake ON, PCCS lever Neutral, braking pedal Released)
When the safety lever for the PCCS lever is set port A, port B, and drain port C, then the brake
to the position of Locked, the parking brake is set Released by oil pressure.
valve (1) moves to the left direction and the ports
A, B, and C open. Accordingly, the oil that flows
into the brake piston port and reached the back
pressure passes through the port C from the
ports A and B and is drained. The back pressure
of the brake piston port continues decreasing
and the brake is fully set to ON, then is held in
the state.
Further, because the ports A and B continue be-
ing opened together with the drain port C even if
the engine is restarted, the state of the brake
ON is held.
In the parking brake OFF, the parking brake
valve (1) moves right and is closed between the
10-74 D375A-5
MAINTENANCE STANDARD PARKING BRAKE VALVE
PARKING BRAKE VALVE
Unit: mm

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

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

3 Parking brake valve spool spring length load load Replace
38.2 N 36.3 N
65 47.7 63.1
{3.9 kg} {3.71 kg}
D375A-5 10-75
MAINTENANCE STANDARD SUDDEN STOPS PREVENTION VALVE
SUDDEN STOPS PREVENTION VALVE
Outline
This sudden stops valve is installed to prevent a
vehicle from being braked suddenly when an er-
ror occurs in an electrical system.
When the sudden stops prevention valve (1) is
installed in the drain circuit of the brake ECMV
and the solenoid valve (2) of the brake ECMV is
deenergized, the oil of the brake circuit D is
drained and sudden braking is prevented from
being applied. Accordingly, when the solenoid
valve (3) of the sudden stops prevention valve (1)
is deenergized, the brake is set to Semi-re-
leased by throttling the brake drain circuit D that
works as the orifice a circuit.
10-76 D375A-5
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
Outline
The final drive is a single stage spur gear, single
stage planetary gear reduction type.
The lubrication is of splash type using the rota-
tion of the gears.
The final drive can be removed and installed as
a single unit.
Floating seal (1) is installed to the rotating sliding
portion of the sprocket to prevent the entry of dirt
or sand and to prevent leakage of lubricating oil.
D375A-5 10-77
10-78 D375A-5
1. Floating seal 8. Floating seal guard 15. First pinion

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

22
first gear 0.25 0.99 1.5
Backlash between sun gear and

23 0.22 0.81 1.5
planetary pinion
Backlash between planetary

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

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

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

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

28 24.0 22.5
face to button head

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

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

31 7
surface and bearing end surface 0.2
32 Clearance of floating seal guard 4.1 5.3
D375A-5 10-79
PATH OF POWER TRANSMISSION
10-80 D375A-5
The power from the bevel gear and steering

clutch is transmitted to No. 1 pinion (15). It then
passes through No. 1 gear (13), which is meshed
with the No. 1 pinion, and is transmitted to sun
gear (2) to rotate it.
The rotation of sun gear (2) is transmitted to
planet pinion (10), but ring gear (11), which is
meshed with the planet pinion, is fixed to cover
(9), so the planet pinion rotates on its own axis
and moves around the sun gear along the ring
gear.
Then, the rotating force of sun gear (2) forms the
rotating force of carrier (3), which supports the
planet pinion, and is transmitted to sprocket hub
(4).
The direction of rotation of carrier (3) is the same
as that of sun gear (2).
The rotating force transmitted to sprocket hub (4)
is transmitted to sprocket teeth (7).
D375A-5 10-81
MAINTENANCE STANDARD TRACK FRAME
TRACK FRAME
1. Idler Outline
2. Recoil spring assembly The track roller adopts a K type bogie mount, thereby increasing
3. Carrier roller the actual ground contact area between a road surface and a
4. Track frame track shoe in an uneven ground and increasing drawbar pull.
5. Sprocket Because a rubber pad is mounted on a K type bogie, the shock
6. Sprocket cover from a road surface is absorbed.
7. Track roller bogie
8. Track roller Track roller bogie
9. Gap
10. Idler yoke
11. Cylinder Track roller flange type and bogie arrangement
12. Guide
No. 1 No. 2 No. 3 No. 4 No. 5 No. 6 No. 7
S D S D S D S
10-82 D375A-5
MAINTENANCE STANDARD TRACK FRAME
Unit: mm
Item Repair limit
Deformation of track frame outer Bend 7 (Per length 3,000) Correct or

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

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

14 Adjust
and guide 0 0.5 3.0
15 Press fit force of cartridge pin 245 441 kN {25 45 ton}
D375A-5 10-83
MAINTENANCE STANDARD RECOIL SPRING
RECOIL SPRING
1. Yoke Outline
2. Nut Recoil spring (4) is used to adjust the track ten-
3. Retainer sion by pumping in or releasing grease from lu-
4. Recoil spring br icator (10) to move rod ( 5) forwar d or
5. Rod backward. The recoil spring (4) also acts to
6. Spring cylinder dampen any sudden shock brought to bear on
7. Retainer the idler.
8. Holder
9. Piston
10. Lubricator (for pumping in and releasing grease)
11. Grease chamber cylinder
10-84 D375A-5
MAINTENANCE STANDARD RECOIL SPRING
Unit: mm

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

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

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

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

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

16 0 1.0
mounting nut and lockplate
D375A-5 10-85
MAINTENANCE STANDARD IDLER
IDLER
10-86 D375A-5
MAINTENANCE STANDARD IDLER
Unit: mm
Outside diameter of protruding Standard size Repair limit

1
portion 927 —
2 Outside diameter of tread 880 855

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

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

8 Collar width of shaft
252 — replace

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

10 End play Adjust or replace
0.49 – 0.86 —
D375A-5 10-87
4
MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
Unit: mm
Outside diameter of flange Standard size Repair limit

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

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

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

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

12 Replace
ring
+0.046 0.13 0.130
75
0 0.18 0.226
13 End play Adjust or replace
0.44 0.91
10-88 D375A-5
MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
Unit: mm

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

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

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

Replace
7
support
0 +0.350
86 0 0.550
0.2 0

8 Axial play of roller
0.01 0.22
D375A-5 10-89
MAINTENANCE STANDARD TRACK ROLLER BOGIE
TRACK ROLLER BOGIE
1. Guide 6. Small bogie Outline

2. Gap 7. Track roller assembly The track roller is mounted on
3. Track roller assembly (Double) 8. Cover the small bogie (6) respectively
4. Large bogie 9. Cartridge pin so that the track roller and track
5. Rubber mount shoe can be touched constantly.
The vehicle body vibration from
a road surface is absorbed by
the rubber mount (5).
10-90 D375A-5
MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
★ Portion P shows the link on the side where the bushing is pressed fitted.
10-92 D375A-5
MAINTENANCE STANDARD TRACK SHOE
Unit: mm
Standard size Repair limit Reverse or

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

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

98.5 90 92.5 replace
5 Thickness of bushing 18.8 10.3 12.8

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

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

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

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

a. Regular link (Nm {kgm}) (Angle)
11 Shoe bolt
1,372 ± 137 {140 ± 14} 120 ± 10
Retightening
b. Master link 686.4 ± 68.6 {70 ± 7} 180 ± 10
D375A-5 10-93
MAINTENANCE STANDARD MAIN FRAME
MAIN FRAME
10-94 D375A-5
MAINTENANCE STANDARD MAIN FRAME
1. Main frame 6. Cage 11. Gap

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

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

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

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

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

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

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

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

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

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

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

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

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

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

31 31.4-105.9 kN {3.2 10.8 ton}
shaft mounting bushing
D375A-5 10-95
MAINTENANCE STANDARD SUSPENSION
SUSPENSION
1. Equalizer 8. Cover Outline

2. Pivot shaft assembly 9. Seal For the track frame, the front is set upside down cen-
3. Cover 10. Bushing tering around the pivot shaft (6) at the tail.
4. Thrust plate 11. Side pin Further, the equalizer (1) is swung centering around
5. Thrust plate 12. Center pin the center pin (12) and linked with the left and right
6. Pivot shaft 13. Busing track frames using the side pin (11).
7. Seal cage
10-96 D375A-5
Unit: mm

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

15 95 1.0 Replace bushing
bushing 0.078 0.015 0.093

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

17 49.0-186.3 kN {5 9 ton}
bushing
18 Press fit force of side pin bushing 34.3-73.5 kN {3.5 7.5 ton}
D375A-5 10-97
1. Indicates the left of the blade single tilt specifications.

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

Interference between thrust size Shaft Hole interference limit
19
washer and seal +0.213 0.180 0.278
230
+0.098 0.226 0.439
Replace
Interference between thrust +0.140 0.061 0.161
20 165
washer and seal +0.100 0.124 0.264
Interference between pivot shaft +0.096 0.115 0.165
21 213
and seal +0.050 0.187 0.283
Clearance between pivot shaft size Shaft Hole clearance limit
22
and busing 0.145 +0.097 0.174
175 1.0 Replace bushing
0.208 +0.029 0.305
Clearance between pivot shaft 0.170 +0.072 0.170
23 210 1.0
and bushing 0.242 0 0.314
10-98 D375A-5
MAINTENANCE STANDARD WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM

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

2. R.H. blade lift cylinder 7. Ripper Hi valve
3. Blade lift valve 8. Work equipment + PPC charge pump
4. Blade tilt, ripper Lo valve (SAR(4)140 + (3)071 + (1)022)
5. Hydraulic filter 9. L.H. blade lift cylinder
D375A-5 10-99
U-DOZER + DUAL TILT
1. Blade tilt cylinder 8. Hydraulic tank

2. R.H blade lift cylinder 9. Ripper Hi valve
3. Pitch solenoid valve 10. Work equipment + PPC charge pump
4. Dual tilt solenoid valve (SAR(4)140 + (3)071 + (1)022)
5. Blade lift valve 11. L.H. blade lift cylinder
6. Blade tilt, ripper Lo valve 12. Blade pitch cylinder
7. Hydraulic filter
10-100 D375A-5
RIPPER SYSTEM
MULTIPLE SHANK RIPPER
1. Ripper Hi valve
2. Ripper tilt cylinder
3. Ripper lift cylinder
D375A-5 10-101
GIANT RIPPER

2. Ripper Hi valve
3. Ripper tilt cylinder
4. Ripper lift cylinder
5. Pin puller cylinder
(from power train hydraulic circuit)
6. Solenoid valve
(for pin-puller)
10-102 D375A-5
MAINTENANCE STANDARD PPC CONTROL PIPING DIAGRAM
PPC CONTROL PIPING DIAGRAM

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

2. Blade tilt, ripper Lo valve 9. Hydraulic pump (SAR(4)140 + (3)071)
3. PPC charge valve 10. Oil cooler (for PPC)
4. Accumulator
5. Ripper control PPC valve
6. Blade control PPC valve
7. PPC lock valve
D375A-5 10-103
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL
WORK EQUIPMENT CONTROL
The drawing shows a pitch dozer and pin puller installed vehicle.
10-104 D375A-5
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL
1. Work equipment safety lever

2. Blade control lever
3. Tilt/pitch selector switch
4. Ripper control lever
5. Pin puller switch
6. PPC lock valve
Lever positions
: Blade HOLD
: Blade LOWER
!: Blade FLOAT
": Blade RAISE
#: Blade (left tilt/pitch)
$: Blade (right tilt/pitch)
%: Ripper HOLD
&: Ripper RAISE
': Ripper LOWER
(: Ripper TILT IN
): Ripper TILT BACK
*: FREE
+: LOCK
,: Pitch selector switch OFF
-: Pitch selector switch ON
.: Dual tilt selector switch OFF
/: Dual tilt selector switch ON
0: Pin puller switch PUSH IN
1: Pin puller switch PULL OUT
Outline
The work equipment control employs a PPC sys-
tem which uses a PPC valve to move the spools
of the control valve.
Work equipment safety lever (1) is interconnect-
ed with PPC lock valve (6), and when it is at the
LOCK position, the flow of oil in the PPC circuit
is stopped.
D375A-5 10-105
MAINTENANCE STANDARD HYDRAULIC TANK
HYDRAULIC TANK
1. Sight gauge Outline

2. Oil filler The hydraulic tank has an assembled type (ex-
3. Valve ternally installed) main control valve and a built-
4. Hydraulic filter in hydraulic filter. The tank capacity is 230 ¬ and
5. Baffle tube the amount of oil inside the tank is set at 120 ¬.
6. Blade tilt, ripper Lo valve
7. Blade lift valve
P1. From large pump
A. To blade lift cylinder head
B. To blade lift cylinder bottom
P. From small pump
A1. To blade tilt cylinder bottom
B1. To blade tilt cylinder head
A2. To ripper tilt cylinder bottom
B2. To ripper lift cylinder head
A3. To ripper lift cylinder head
B3. To ripper lift cylinder bottom
T. From ripper Hi valve
10-106 D375A-5
MAINTENANCE STANDARD PPC CHARGE VALVE
PPC CHARGE VALVE
10-108 D375A-5
1. Strainer
2. Body Item Specified value
3. Piston
4. Valve Cracking pressure MPa {kg/cm2} 3.78 {38.5}
Relief valve
5. Spring Relief valve Set pressure MPa {kg/cm2} 4.46 {45.5}
6. Sleeve
7. Screw Oil cooler bypass 490 ± 49
Cracking pressure KPa {kg/cm2}
8. Accumulator valve {5 ± 0.5}
9. Accumulator check valve Accumulator 24.5 ± 4.9
10. Oil cooler bypass valve Cracking pressure KPa {kg/cm2}
check valve {0.25 ± 0.05}
C. Oil cooler Filter mesh size µm 24 × 110
P. From PPC pump Strainer
P2. To valve Filtering area cm2 62.2
T. To hydraulic tank
Unit: mm

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

12 14 0.11
and body 0.059 0 0.086

Replace
13 Relief valve spring length load load
215.7 N 204.9 N
39.3 33.1 38.1
{22.0 kg} {20.9 kg}
37.3 N 35.3 N
14 Oil cooler bypass valve spring 26.3 19.1 25.4
{3.8 kg} {3.6 kg}
1.96 N 1.77 N
15 Accumulator check valve spring 20.6 19.1 20.0
{0.2 kg} {0.18 kg}
D375A-5 10-109
1. Adjustment screw
2. Lock nut
3. Sleeve
4. Main valve spring
5. Pilot piston
6. Main valve
Set pressure:
4.46 MPa {45.5 kg/cm2} (At 44.5 ¬/min)
Outline
The PPC charge valve acts to relieve the oil sent
from the pump when the PPC valve is at NEU-
TRAL.
It also acts to set the pressure sent to the PPC
valve to the set pressure.
Operation
Chamber A is connected to the pump circuit and
chamber C is connected to the tank drain circuit.
The oil passes through the orifice in the main
valve and fills chamber B.
When the pressure in chamber A rises, and the

π
differential pressure [ 4 (D2d2) × pressure of
chamber A] caused by the difference in the area
of diameter D and d reaches the pressure set by
the main valve spring, the main valve opens. The
pressurized oil in chamber A then escapes to
chamber C, so the pressure in chamber A drops.
10-110 D375A-5
MAINTENANCE STANDARD ACCUMULATOR
ACCUMULATOR
FOR PPC VALVE
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications:
Type of gas: Nitrogen
Gas volume: 300 cc
Max. autuation pressure:
3.1 MPa {32 kg/cm2}
Min. autuation pressure:
1.2 MPa {12 kg/cm2}
Function
The accumulator is installed between the PPC
charge pump and the PPC valve. Even if the en-
gine is started with the work equipment still
raised, the pressure of the nitrogen gas com-
pressed inside the accumulator sends the pilot
pressure to the main control valve to actuate it
and enable the work equipment to move down
under its own weight.
Operation
After the engine is stopped, when the PPC valve
is at neutral, chamber A inside the bladder is
compressed by the oil pressure in chamber B.
When the PPC valve is operated, the oil pres-
sure in chamber B goes below 2.9 MPa {30 kg/
cm 2}, and the pressure of the nitrogen gas in
chamber A expands the bladder, so the oil in
chamber B acts the pilot pressure and actuates
the main control valve.
D375A-5 10-111
MAINTENANCE STANDARD PPC LOCK VALVE
PPC LOCK VALVE
1. Lever
2. End cap
3. Ball
4. Seat
5. Body
Outline
The PPC lock valve is installed in the PPC circuit
between the PPC charge valve and PPC valve. If
the work equipment safety lever is placed at the
LOCK position, the PPC lock valve is actuated
together with the work equipment safety lever.
This stops the oil in the PPC circuit and makes it
impossible to operate the work equipment.
10-112 D375A-5
MAINTENANCE STANDARD PPC VALVE
PPC VALVE
FOR BLADE LIFT, TILT
1. Spool 6. Nut (for lever joint) P. From PPC charge valve port P2
2. Metering spring 7. Joint (through PPC lock valve)
3. Centering spring 8. Plate T. To hydraulic tank
4. Piston 9. Retainer P1. To blade lift valve (LOWER) port PA
5. Disc 10. Body P2. To blade lift valve (RAISE) port PB
P3. To blade tilt valve (left tilt) port PA1
P4. To blade tilt valve (Right tilt) port PB1
10-114 D375A-5
4
TESTI
TESTING AND ADJUSTING MEASURING FUEL PUMP OUTLET PORT PRESSURE
5. Run the engine at each speed and check that the

signal voltage of the fuel pump pressure sensor
★ Sensor signal voltage (between C and B):

is within the range in the table.
Engine Fuel pump outlet port

Signal voltage
speed pressure (Reference)
0.55 ± 0.14 MPa
700 rpm 1.38 ± 0.21 V
{5.62 ± 1.41 kg/cm2}
0.55 ± 0.14 MPa
800 rpm 1.38 ± 0.21 V
{5.62 ± 1.41 kg/cm2}
1.25 ± 0.14 MPa
1,000 rpm 2.48 ± 0.21 V
{12.70 ± 1.41 kg/cm2}
1.57 ± 0.14 MPa
1,300 rpm 3.00 ± 0.21 V
{16.00 ± 1.41 kg/cm2}
6. After completing the measurement, remove the

measuring equipment and set to the original
condition.
4. Run the engine at low idling and check that the

power source voltage of the fuel pump pressure
★ Sensor signal voltage (between A and B):

sensor is within the following range.
4.75 – 5.25 V
D375A-5 20-114-1
4
MEASURING FUEL PUMP INLET PORT PRESSURE
TESTING AND ADJUSTING (NEGATIVE PRESSURE)
MEASURING FUEL PUMP INLET PORT PRESSURE

(NEGATIVE PRESSURE)
★ Tools for measuring fuel pump inlet port pres-
sure (negative pressure)
Symbol Part No. Part Name

799-101-5002 Hydraulic tester
1
790-261-1203 Digital hydraulic tester
H 3 795-799-5550 Adapter
Negative pressure gauge
4 795-799-5560 (0 – –0.1 MPa)
{0 – –1 kg/cm2}
1. Fit adapter H3 to pump inlet port pressure mea-

suring nipple (3). ★ If Pm kit (A) is available, the air bleed
coupling (790-261-1130) inside the kit
2. Fit nipple [1] of hydraulic tester H1 to adapter H3, can be used.
install them to coupler (3) of the fuel pump, and ★ If there is oil inside the hose, the gauge
connect negative pressure gauge H4. will not work, so always bleed the oil.
4. Run the engine at each engine speed and mea-

sure the pump inlet port pressure.
★ Fuel pump inlet port pressure
Fuel filter Fuel pump inlet port pressure

Max. –13.60 kPa
New
{Max. –102 mmHg}
Max. –27.10 kPa
Used
{Max. –203 mmHg}
3. Run the engine at a medium speed to bleed the

oil from the hose.
★ Insert the connection of the hose and
negative pressure gauge about halfway,
repeat the action to open the self-seal
portion at the hose end, and bleed the
oil.
20-114-2 D375A-5
4
Unit: mm

Free length Installed Installed Installed
Free length
11 Centering spring (for P1) × O.D. length load load
94 N 75.2 N
34.0 × 15.5 31.9
{9.6 kg} {7.67 kg}
16.7 N 13.7 N
12 Metering spring (for P1, P2) 27.23 × 8.14 24.9
{1.7 kg} {1.4 kg}
96.1 N 76.5 N Replace spring
13 Centering spring (for P2) 43.2 × 15.5 31.9
{9.8 kg} {7.8 kg} if damaged or
111.8 N 89.4 N deformed
14 Centering spring (for P3, P4) 48.57 × 15.5 31.9
{11.4 kg} {9.1 kg}
16.7 N 13.7 N
15 Metering spring (for P3, P4) 26.53 × 8.15 24.9
{1.7 kg} {1.4 kg}
159.36 N 127.5 N
16 Detent spring (for P1) 20.39 × 19.5 13.1
{16.25 kg} {13 kg}
38.44 N 30.79 N
17 Detent spring (for P2) 45.36 × 7.5 26
{3.92 kg} {3.14 kg}
D375A-5 10-115
Operation
1) At neutral
(i) PPC valve for blade lift
Ports PA and PB of the blade lift control valve,
and ports P1 and P2 of the PPC valve are con-
nected to drain chamber D through fine control
hole f in spool(1).
(ii) PPC valve for blade tilt

Ports PA1 and PB1 of the blade tilt control valve,
and ports P3 and P4 of the PPC valve are con-
nected to drain chamber D through fine control
hole f in spool (1).
10-116 D375A-5
2) During fine control (neutral → fine control)

When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed; spool (1) is also pushed
by metering spring (2), and moves down.
When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same
time, it is connected to pump pressure chamber
PP, so pilot pressure oil from the charging pump
passes through fine control hole f and goes from
port P1 to port PB.
When the pressure at port P1 becomes higher,
spool (1) is pushed back and fine control hole f
is shut off from pump pressure chamber PP.
At almost the same time, it is connected to drain
chamber D to release the pressure at port P1.
When this happens, spool (1) moves up or down
so that the force of metering spring (2) is bal-
anced with pressure at port P1.
The relationship in the position of the spool (1)
and body (10) (fine control hole f is at a point
midway between drain hole D and pump pres-
sure chamber PP) does not change until retainer
(9) contacts spool (1).
Therefore, metering spring (2) is compressed
proportionally to the amount of movement of the
control level, so the pressure at port P1 also ris-
es in proportion to the travel in the control lever.
In this way the control valve spool moves to a po-
sition where the pressure in chamber PB (the
same as the pressure at port P1) and the force
of the control valve spool return spring are bal-
anced.
D375A-5 10-117
3) During fine control

(When control lever is returned)
When disc (5) starts to be returned, spool (1) is
pushed up to the force of centering spring (3)
and the pressure at port P1.
When this happens, fine control hole f is con-
nected to drain chamber D, and the pressure oil
at port P1 is released.
If the pressure at port P1 drops too far, spool (1)
is pushed down by metering spring (2), and fine
control hole f is shut off from drain chamber D. At
almost the same time it is connected to pump
pressure chamber PP, and the pump pressure is
supplied until the pressure at port P1 recovers to
a pressure that corresponds to the lever position.
When the spool of the control valve returns, oil in
drain chamber D flows in from fine control hole f'
in the valve on the side that is not working.
The oil passes through port P2 and enters cham-
ber PA to fill the chamber with oil.
4) At full stroke
When disc (5) pushed down piston (4), and re-
tainer (9) pushes down spool (1), fine control
hole f is shut off from drain chamber D, and is
connected with pump pressure chamber PP.
Therefore, the pilot pressure oil from the charg-
ing pump passes through fine control hole f and
flows to chamber PB from port P1, and pushes
the control valve spool.
The oil returning from chamber PA from port P2
through fine control hole f' and flows to drain
chamber D.
10-118 D375A-5
5) Blade operated to FLOAT

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

When disc (5) is retuned from the FLOAT posi-
tion, it is pushed down by a force greater than the
pressure of the oil in chamber E.
For this reason, chamber E is shut off from pas-
sage d and is connected to the drain chamber.
Therefore, the oil pressure inside chamber E is
lost, and the FLOAT, position is released.
D375A-5 10-119
FOR RIPPER
1. Spool 7. Joint P. From PPC charge valve port P2

2. Metering spring 8. Plate (through PPC lock valve)
3. Centering spring 9. Retainer T. To hydraulic tank
4. Piston 10. Body P1. To ripper tilt valve (TILT BACK) port PB2
5. Disc 11. Filter P2. To ripper tilt valve (TILT IN) port PA2
6. Nut (for lever joint) P3. To ripper tilt valve (LOWER) port PA3
P4. To ripper tilt valve (RAISE) port PB3
10-120 D375A-5
Unit: mm

Free length Installed Installed Installed
Free length
12 Centering spring (for P3, P4) × O.D. length load load
55.9 N 45.1 N Replace spring
50.4 × 15.5 34
{5.7 kg} {4.6 kg} if damaged or
deformed
16.7 N 13.7 N
13 Metering spring 26.6 × 7.5 24.9
{1.7 kg} {1.4 kg}
71.6 N 56.9 N
14 Centering spring (for P1, P2) 50.1 × 15.5 34
{7.3 kg} {5.8 kg}
D375A-5 10-121
Operation
1) At neutral
Ports PA2, PA3, PB2 and PB3 of the ripper con-
trol valve and ports P1, P2, P3, and P4 of the
PPC valve are connected to drain chamber D
Through fine control hole f of spool (1).
2) During fine control (neutral → fine control)

When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed; spool (1) is also pushed
by metering spring (2), and moves down.
When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same
time, it is connected to pump pressure chamber
PP, so pilot pressure oil from the charging pump
passes through fine control hole f and goes from
port P2 to port PA2.
When the pressure at port P2 becomes higher,
spool (1) is pushed back and fine control hole f
is shut off from pump pressure chamber PP.
At almost the same time, it is connected to drain
chamber D to release the pressure at port P2.
When this happens, spool (1) moves up or down
so that the force of metering spring (2) is bal-
anced with the pressure at port P2.
The relationship in the position of the spool (1)
and body (10) (fine control hole f is at a point
midway between drain hole D and pump pres-
sure chamber PP) does not change until retainer
(9) contacts spool (1).
Therefore, metering spring (2) is compressed
proportionally to the amount of movement of the
control lever, so the pressure at port P2 also ris-
es in proportion to the travel in the control lever.
In this way the control valve spool moves to a po-
sition where the pressure in chamber PA2 (the
same as the pressure at port P2) and the force
of the control valve spool return spring are bal-
anced.
10-122 D375A-5
3) During fine control

(When control lever is returned)
When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port P2.
When this happens, fine control hole f is con-
nected to drain chamber D, and the pressure oil
at port P2 is released.
If the pressure at port P2 drops too far, spool (1)
is pushed down by metering spring (2), and fine
control hole f is shut off from drain chamber D. At
almost the same time, it is connected to pump
pressure chamber PP, and the pump pressure is
supplied until the pressure at port P2 recovers to
a pressure that corresponds to the lever position.
When the spool of the control valve returns, oil in
drain chamber D flows in from fine control hole f'
in the valve on the side that is not working.
The oil passes through port P1 and enters cham-
ber PB1 to fill the chamber with oil.
4) At full stroke
When disc (5) pushed down piston (4), and re-
tainer (9) pushes down spool (1), fine control
hole f is shut off from drain chamber D, and is
connected with pump pressure chamber PP.
Therefore, the pilot pressure oil from the charg-
ing pump passes through fine control hole f and
flows to chamber PA1 from port P2, and pushes
the control valve spool.
The oil returning from chamber PB1 passes from
port P1 through fine control hole f' and flows to
drain chamber D.
D375A-5 10-123
MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
WORK EQUIPMENT CYLINDER

BLADE LIFT CYLINDER
BLADE TILT CYLINDER
PIN PULLER CYLINDER
10-124 D375A-5
Unit: mm

size Shaft Hole clearance limit
Blade 0.036 +0.270 0.097

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

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

Clearance between size clearance limit
Shaft Hole
5 piston rod support shaft
and bushing Blade 0.200 +0.200 0.200
75 1.0
TILT 0.300 0 0.500
Clearance between
Blade 0.200 +0.174 0.300
6 cylinder bottom support 75 1.0
TILT 0.300 +0.100 0.474 Replace
shaft and bushing
Clearance between
Pin 0.100 +1.300
7 piston rod spherical 29 1.3 1.5
puller 0.200 +1.200
surface and cap
Clearance between
Pin 1.1
8 cylinder bottom support 26 ±0.1 1.0 1.3
puller 1.2
shaft and boss
D375A-5 10-125
RIPPER LIFT CYLINDER
RIPPER TILT CYLINDER
Unit: mm

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

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

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

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

Clearance between 100 1.0
LIFT 0.090 +0.120 0.297
3 cylinder bottom support
shaft and bushing Ripper 0.036 +0.207 0.156
100 1.0
TILT 0.090 +0.120 0.297
10-126 D375A-5
MAINTENANCE STANDARD PISTON VALVE
PISTON VALVE
(BLADE LIFT CYLINDER)
Outline
The piston valve is installed on the piston in the
blade lift cylinder. When the piston reaches its
stroke end, the valve releases the oil from the hy-
draulic pump to reduce the oil pressure being ex-
erted on the piston.
In addition the piston valve relieves the shock
which occurs when the piston comes into contact
with the cylinder head or the bottom and serves
to reduce the subsequent surge pressure in the
cylinder by letting the oil escape from the cylin-
der before the piston reaches its stroke end.
Operation
1. Piston valve CLOSED

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

Just before piston rod (1) reaches the end of its
stroke, the tip of valve (6) contacts the cylinder
bottom, so valve (6) and piston valve (3) stop at
that position and do not move further. Only pis-
ton (2) moves further.
When this happens, the oil at the cylinder head,
which was sealed by piston valve (3), escapes
from piston valve seats (4) and (5), and the pres-
sure inside the cylinder stops rising.
D375A-5 10-127
MAINTENANCE STANDARD QUICK DROP VALVE
QUICK DROP VALVE

(BLADE LIFT CYLINDER)
Structure
The quick drop valve consists of valve body (1),
spool (2), check valve (3), and spring (4).
The quick drop valve serves to increase the
blade lowering speed and to reduce the occur-
rence of vacuum when the blade is lowering,
thereby shortening the time lag before digging is
started.
The blade lowering speed, which is generally de-
termined by the pump discharge, can be made
faster with the quick drop valve.
1. Valve body 3. Check valve
2. Spool 4. Spring
Operation
1. Start of lowering
When the blade lever is operated to LOWER, the
oil from the control valve enters the cylinder bot-
tom through port A and pushes the piston. In the
meantime, the oil in the cylinder head is pushed
out into the piston, enters valve port B, and flows
into the tank from port C.
2. While lowering
Pressurized oil from the cylinder head flows into
port C through port B.
At this time, the oil flow is restricted by an orifice
a provided along the way, causing a differential
pressure between front and back of orifice.
When the pressure of port B becomes greater
than the force of spring (4), it compresses the
spring and moves spool (2) and check valve (3)
to the right.
When the spool and the check valve have
moved, the circuit of port B and A is opend, part
of the oil flowing from the cylinder head to port C
enters the passage port A, and merged with the
oil from the control valve, and flows to the cylin-
der bottom.
Thus, the blade lowering speed increases in ac-
cordance with the amount of oil that flows to the
bottom of the cylinder and reduces the formation
of vacuum at the bottom of the cylinder.
10-128 D375A-5
MAINTENANCE STANDARD QUICK DROP VALVE
Unit: mm

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

2 Valve spring length load load
136.3 N 122.6 N
75.2 55.9 67.7
{13.9 kg} {12.5 kg}
D375A-5 10-129
MAINTENANCE STANDARD PIN PULLER SWITCH
PIN PULLER SWITCH
Function
The pin puller solenoid valve is controlled by 1. Connector
turning the pin puller switch ON/OFF. 2. Wire
This changes the oil circuit to the pin puller cylin- 3. Switch
der and sets the shank mounting pin to the 4. Knob
PUSH IN or PULL OUT position.
10-130 D375A-5
MAINTENANCE STANDARD PIN PULLER SOLENOID VALVE
PIN PULLER SOLENOID VALVE
1. Plug A. To pin puller cylinder bottom

2. Spring B. To pin puller cylinder head
3. Spring retainer P. From power train pump
4. Valve body T. To steering case
5. Spool
6. Spring retainer
7. Spring
8. Push pin
9. Solenoid assembly
D375A-5 10-131
MAINTENANCE STANDARD PIN PULLER SOLENOID VALVE
Operation
1. Pin puller switch at PUSH IN position

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

When the pin puller switch is set to the PULL
OUT position, electricity flows to solenoid (9) and
it is excited.
Then, the solenoid pushes out push pin (8) and
spool (5) moves to the left in the arrow direction.
At this point, ports P and A and ports B and T
close, and ports P and B and ports A and T
open, so the oil from the power train pump flows
from port P to port B and enters the head end of
pin puller cylinder (10).
When the oil enters the cylinder head end and
the pressure in the circuit rises, the cylinder re-
tracts and pulls shank mounting pin (11) out of
shank (12).
10-132 D375A-5
MAINTENANCE STANDARD BLADE CONTROL KNOB
BLADE CONTROL KNOB
1. Switch (Dual, single tilt switching) When the switch (2) is pressed and the lever is
2. Switch (Pitch) actuated, the blade is pitched. When the lever is
3. Cover set to the left, the blade is pitched back. When
4. Connector (Male) the lever is set to the right, the blade is pitch-
5. Connector (Female) damped.
When the switch (1) is set to the DUAL side and
Outline the lever is actuated, the blade is dually tilted.
By setting the blade control knob to the front and When the lever is set to the left, the blade is du-
the rear or the left and the tight, the blade is ally tilted left. When the lever is set to the right,
raised or lowered and tilted left or right. Further, the blade is dually tilted right.
by setting the switch (1) to the DUAL side and Even if the switch (1) is switched to either DUAL
setting the lever to the left and right, the dual tilt or SINGLE, the blade is pitched when the lever
actuation is performed. Also by setting the lever is set left and right pressing the switch (2).
to the left and right pressing (2), the pitch actua-
tion is performed.
D375A-5 10-133
MAINTENANCE STANDARD PITCH, DUAL TILT SOLENOID VALVE
PITCH, DUAL TILT SOLENOID VALVE

MACHINES EQUIPPED WITH DUAL TILT
1. Main spool assembly Function

2. Pilot solenoid assembly This valve is installed between the blade tilt,
3. Connector pitch cylinder and the blade tilt, ripper Lo valve. It
A. To R.H. blade pitch (dual tilt) cylinder bottom acts to open or close the hydraulic circuit to the
B. To R.H. blade pitch (dual tilt) cylinder head blade tilt or pitch cylinder according to the pitch
T1. To L.H. blade pitch (dual tilt) cylinder bottom or dual tilt switch signal.
T2. To L.H. blade pitch (dual tilt) cylinder head
P1, P2. From blade tilt control valve
P. From PPC charge valve
T. To hydraulic tank
10-134 D375A-5
MAINTENANCE STANDARD PITCH, DUAL TILT SOLENOID VALVE
Operation
Pitch switch ON
When pitch switch (1) is operated, electricity
flows to pitch solenoid valve (2) and it is excited.
When this happens, main spool (4) opens the
circuit between port T1 and B and between A
and P1, and the hydraulic circuit is connected to
the bottom end of left pitch cylinder (5) and to the
head end of right pitch cylinder (6). As a result,
both the right pitch cylinder and left pitch cylinder
are retracted and the blade is pitched to the rear.
Dual tilt switch ON

When dual pitch switch (2) is operated, electricity
flows to dual tilt solenoid valve (3) and it is excit-
ed. When this happens, main spool (4) opens
the circuit between port T2 and B and between
A and P2, and the hydraulic circuit is connected
to the head end of left tilt cylinder (5) and to the
bottom end of right tilt cylinder (6). As a result,
the left dual tilt cylinder is extended and the right
dual tilt cylinder is retracted to tilt the blade.
D375A-5 10-135
MAINTENANCE STANDARD WORK EQUIPMENT + PPC CHARGE PUMP
WORK EQUIPMENT + PPC CHARGE PUMP

SAR(4)140 + (3)071 + (1)022
10-136 D375A-5
MAINTENANCE STANDARD WORK EQUIPMENT + PPC CHARGE PUMP
Unit: mm
Type Standard clearance Clearance limit
SAR(4)-140 0.11 0.16 0.19

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

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

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

BLADE LIFT VALVE
Outline
Demand valve (14) is assembled to the blade lift P1. From large pump
valve, and the oil from the two hydraulic pumps P2. From small pump
is merged by check valve (4). A. To blade lift cylinder head
With the demand valve, the oil from the large B. To blade lift cylinder bottom
pump becomes the pilot pressure, and at the T. To hydraulic tank
same time, the oil from the ripper circuit or the PA. From blade lift PPC valve port P2
blade lift circuit through shuttle valve (18B) also PB. From blade lift PPC valve port P1
becomes the pilot pressure, so the oil from the PL. From ripper Lo valve
two hydraulic pumps is used efficiently.
10-138 D375A-5
1. Check valve spring 9. Shuttle valve ball 17. Suction valve spring
2. Small pump circuit check valve 10. Shuttle valve seat (plug) 18. LOWER suction valve
3. Check valve 11. Retainer 19. Main relief, shuttle valve
4. Check valve spring 12. Return spring (for FLOAT) assembly
5. Valve body 13. Case 19A. Main relief valve
6. Return spring 14. Demand valve spring 19B. Shuttle valve
7. Blade lift valve 15. Demand valve
8. Shuttle valve seat (plug) 16. RAISE suction valve
D375A-5 10-139
Unit: mm

Free Installed Installed Free Installed
1 Spool return spring length length load length load
431.5 N 345.2 N
69.9 63
{44 kg} {35.2 kg}
400.1 N 319.7 N
2 Spool return spring 80.69 76.5
{40.8 kg} {32.6 kg}
588.4 N 470.7 N
3 Spool return spring (for floating) 43.82 32.5
{60 kg} {48 kg} Replace
9.8 N 7.9 N
4 Check valve spring 75.7 43.5 69.3
{1.0 kg} {0.8 kg}
44.1 N 35.3 N
{4.5 kg} {3.6 kg}
11.38 N 9.12 N
6 Suction valve spring 75.9 38.5 68.4
{1.16 kg} {0.93 kg}
235 N
7 Demand spool spring 74.5 55
{24 kg}
10-140 D375A-5
MAIN RELIEF, SHUTTLE VALVE
10-142 D375A-5
1. Valve body Overview

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

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

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

10 8 (1 turn of screw adjusts by 2.4 MPa {24.8 kg/cm2}) Adjust
adjustment screw
D375A-5 10-143
BLADE TILT, RIPPER LO VALVE
P. From small pump CO. To demand valve

A1. To blade tilt cylinder bottom PL. To shuttle valve inside blade lift valve
B1. To blade tilt cylinder head PA1. To blade tilt PPC valve P3 (left tilt)
A2. To ripper tilt cylinder bottom PA2. To ripper tilt PPC valve P2 (tilt in)
(through ripper Hi valve PA1) PA3. To ripper lift PPC valve P3 (lower)
B2. To ripper tilt cylinder head PB1. To blade tilt PPC valve P4 (right tilt)
(through ripper Hi valve PB1) PB2. To ripper tilt PPC valve P1 (tilt back)
A3. To ripper lift cylinder head PB3. To ripper lift PPC valve P4 (raise)
(through ripper Hi valve PB2)
B3. To ripper lift cylinder bottom
(through ripper Hi valve PA2)
10-144 D375A-5
1. Blade tilt valve 9. Sleeve 17. Check valve

2. Ripper tilt valve 10. Main relief valve body 18. Check valve spring
3. Ripper lift valve 11. Poppet spring 19. Valve seat
4. Valve body 12. Main relief valve poppet 20. Shuttle valve seat (plug)
5. Return spring 13. Valve seat 21. Shuttle valve ball
6. O-ring 14. Main relief valve spring 22. Shuttle valve seat
7. Case 15. Main relief valve
8. Main relief pressure 16. Valve seat
adjustment screw
D375A-5 10-145
Unit: mm

1 Spool return spring length length load length load
117.7 N 94.1 N
52.18 50.0
{12.0 kg} {9.6 kg}
6.9 N 5.5 N Replace
{0.7 kg} {0.56 kg}
31.4 N 25.1
3 Main relief valve spring 24.2 18.3 23.0
{3.2 kg} {2.56 kg}
258.9 N 206.9 N
4 Main relief valve poppet spring 41.1 32.6 39.4
{26.4 kg} {21.1 kg}
Height of main relief pressure
5 8 (1 turn of screw adjusts by 2.4 MPa {24.8 kg/cm2}) Adjust
adjustment screw
10-146 D375A-5
RIPPER HI VALVE
P. From small pump

PA1. From Lo valve tilt in
PB1. From Lo valve tilt back
PA2. From Lo valve ripper raise
PB2. From Lo valve ripper lower
A1-1. To L.H. tilt cylinder bottom
B1-1. To L.H. tilt cylinder head
A1-2. To R.H. tilt cylinder bottom
B1-2. To R.H. tilt cylinder head
A2-1. To L.H. lift cylinder bottom
B2-1. To L.H. lift cylinder head
A2-2. To R.H. lift cylinder bottom
B2-2. To R.H. lift cylinder head
D375A-5 10-147
1. Valve body 11. Plug

2. Shuttle valve seat 12. Check valve spring
3. Shuttle valve ball 13. Check valve
4. Valve body 14. Valve return spring
5. Plug 15. Plug
6. Fixed differential pressure valve spring 16. Ripper lift Hi valve
7. Fixed differential pressure valve 17. Suction valve spring
8. Fixed differential pressure valve 18. Suction valve
9. Fixed differential pressure valve 19. Ripper tilt Hi valve
10. Fixed differential pressure valve
10-148 D375A-5
Unit: mm

1 Hi valve return spring length length load length load
152.0 N 121.6 N
79.5 42.0 72.0
{15.5 kg} {12.4 kg}
30.2 N 24.1 Replace
{3.08 kg} {2.46 kg}
9.8 N 7.9 N
3 Suction valve spring 75.7 43.5 69.3
{1.0 kg} {0.8 kg}
Constant differential pressure 169.7 N 135.3 N
4 57.4 33.5 52.6
valve spring {17.3 kg} {13.8 kg}
D375A-5 10-149
Operation
1. Blade lever at HOLD, ripper lever at HOLD
10-150 D375A-5
When the blade is at the HOLD position, the When oil is drained
spool of the PPC valve directly connected to the In the condition already explained, if the hydrau-
control lever is not actuated; blade lift spool (5) lic pressure in the circuit rises, the surface pres-
closes the circuit from port B to ports C and D, sure (force pushing the demand valve to the left)
and opens the circuits of ports H and E and ports on port L of demand valve (1) becomes greater
J and F; blade tilt spool (16) close the circuit from than the combined force (force pushing the de-
port B3 to ports C3 and D3. mand valve to the right) of the surface pressure
Therefore, the circuits for blade lift cylinder (9) bearing on port M and tension of spring (2), it
and blade tilt cylinder (17) become closed cir- moves the demand valve to the left, opens the
cuits, and the cylinders are held in the same po- circuit between ports A and E, and ports R and
sition. F. The oil from the large and small pumps is then
If the ripper lever is placed at the HOLD position, relieved to ports E and F and is drained from port
the spool of the PPC valve directly connected to G to the hydraulic tank.
the control lever does not move; ripper tilt spool Therefore, both the large and small pumps are
(19) closes the circuit from port B4 to ports C4 put in an unload condition.
and D4, and ripper lift spool (21) closes the cir-
cuit from port B5 to ports C5 and D5. Therefore,
the circuits for ripper tilt cylinder (45) and ripper
lift cylinder (33) become closed circuits through
the two ripper valves, and the cylinders are kept
in the same position.
If the engine is started in this condition, the oil
from the large pump enters port A of the blade lift
valve. Some of the oil pushes open check valve
(3) and enters port B where it stops. The rest of
the oil passes through orifice a of demand valve
(1), and enters ports L and M. (The demand
valve is pushed to the right by the tension of
spring (2).)
The oil from the large pump flows to the blade lift
valve, but it also enters port A1 of the ripper Hi
valve, pushes open the two check valve (23) and
(35), then enters ports B1 and B2 and stops.
The oil from the small pump flows from port A2
of the ripper Lo valve and blade tilt valve to ports
A3, A4, and A5. Some of the oil pushes open
check valves (15), (18) and (20), then enters
ports B3, B4 and B5, and stops. The rest of the
oil flows from port A5, enters port R of the blade
lift valve, pushes open check valve (4), and flows
to port A where it merges with the oil from the
large pump.
D375A-5 10-151
2. Blade lever at RAISE (blade operating at high speed)
10-152 D375A-5
When the blade lever is moved fully to the RAISE

position, the spool of the PPC valve directly con-
nected to the control lever is actuated. When this
happens, the pilot pressure entering the PPC
valve from the PPC pump is sent to port PB of
the blade lift valve. This pilot pressure moves
spool (5) to the left to the end of its stroke, and
fully opens the circuits between ports B and C,
ports C and H, and ports D and F.
When this happens, the oil from the two pumps
passes from ports A and B and enters port C.
Some of the oil flows to the head end of cylinder
(9), and the rest flows from ports H and H', push-
es shuttle valve (8) to the right and opens it,
flows to port K, and enters ports N, O, and P of
shuttle valve (10). It then enters port Q of de-
mand valve (1) and becomes the pilot pressure.
At the same time, the oil from the pump passes
through orifice a of demand valve (1), enters
ports L and M, and becomes the pilot pressure.
The oil at the bottom end of cylinder (9) flows
from port D to port F, and returns from port G to
the hydraulic tank. When the hydraulic pressure
in the circuit rises in this way, spool (5) opens the
circuit between ports B and C fully, so the resis-
tance of the oil flowing from port B to port C is
small, and there is little pressure difference gen-
erated between port B and port C.
Therefore, no pressure difference is generated
between port L and ports M and Q of the de-
mand valve. The surface pressure acting on the
left and right of the demand valve is equal, so the
demand valve is moved to the right by the ten-
sion of spring (2).
When this happens, the circuits between ports A
and E', and ports R and F' are closed, and all the
oil from both the large and small pumps flows to
the head end of the cylinder to increase the
speed of movement of the cylinder.
D375A-5 10-153
3. Blade lever at RAISE (blade operating at low speed)
10-154 D375A-5
When the blade lever is operated slightly to the If it is opened only slightly, the flow of oil beyond
RAISE position the spool of the PPC valve di- port C is throttled, so the oil flow is reduced, the
rectly connected to the control lever is actuated. hydraulic pressure becomes low, and the speed
When this happens, the pilot pressure entering of movement is slow.
the PPC valve from the PPC pump is sent to port In other words, the hydraulic pressure and oil
PB of the blade lift valve. This pilot pressure flow beyond port C is proportional, so this pro-
moves spool (5) slightly to the left to a point vides operation of the blade that follows the fine
where the pilot pressure and the force of the movement of the blade lever.
spring are in balance, and partially opens the cir-
cuit between ports B and C, ports C and H, and When cylinder is at stroke end
Ports D and F. If cylinder (9) moves to the end of its stroke from
When this happens, the oil from the two pumps the condition in items 2 and 3, the hydraulic pres-
passes from ports A and B, is throttled by spool sure in the whole circuit rises.
(5) and enters port C. Some of the oil flows to the Therefore, the hydraulic pressure beyond port C
head end of cylinder (9), and the rest flows from rises, and the oil entering the main relief valve
ports H and H', pushes shuttle valve (8) to the through shuttle valves (8) and (10) (that is, the oil
right and opens it, flows to port K, and enters at port P) pushes open poppet (13) and is re-
ports N, O, and P of shuttle valve (10). It then en- lieved to port T.
ters port Q of demand valve (1) and becomes the At this point, the circuit from port O to port P is
pilot pressure. throttled by orifice c, so the supply of oil to port P
At the same time, the oil from the pump passes is delayed. As a result, the hydraulic pressure of
through orifice a of demand valve (1), enters pilot port Q of demand valve (1) drops, and the
ports L and M, and becomes the pilot pressure. demand valve moves to the left.
The oil at the bottom end of cylinder (9) flows When this happens, the circuit between ports A
from port D to port F, and returns from port G to and E' and ports R and F' are opened, and the
the hydraulic tank. When the hydraulic pressure oil from the two pumps is relieved to prevent the
in the circuit rises in this way the situation is dif- hydraulic pressure from rising any further.
ferent from in item 2: spool (5) is throttling the cir- The hydraulic pressure at this point is 20.6 MPa
cuit between ports B and C, so the flow of oil {210 kg/cm2}.
from port B to port C is restricted, and a pressure
difference is generated between port B and port
C. The hydraulic pressure in the circuit up to port
B becomes higher.
Therefore, when the surface pressure acting on
port L of the demand valve becomes greater
than the combined force of the surface pressure
acting on port M, the surface pressure (low pres-
sure) acting on port Q, and the tension of spring
(2), the demand valve is moved to the left.
When this happens, the circuits between ports A
and E', and ports R and F' are opened, and the
oil from both the large and small pumps is re-
lieved to the hydraulic tank. This suppresses the
rise in the hydraulic pressure at ports A and B,
and the cylinder moves slowly.
As explained in the items above, the speed of
movement of the cylinder is determined by the
amount of opening of ports B and C, which cor-
responds to the movement of the lever. If it is
wide open, the flow of oil beyond port C increas-
es, the hydraulic pressure rises, and the speed
of movement becomes faster.
D375A-5 10-155
TESTING AND ADJUSTING ADJUSTMENT OF PCCS LEVER POTENTIOMETERS
ADJUSTMENT OF PCCS LEVER POTENTIOMETERS

When adjusting the lever assembly
independently X kΩ
1. Position lever in “NEUTRAL (both forward & re-
verse, steering)”
2. Using tester (2), measure resistance between
5 V pin and signal pin. (See table 1).
(ex. For ST1, measure resistance between pins
A (5 V) and H (SIG))
signal pin and GND pin. (See table 1).
(ex. For ST1, measure between pins H (SIG) and
G (GND))
4. Adjust resistance to be X = Y (tolerance: X – Y ≤
0.04 kΩ) by slightly turning the potentiometer Y kΩ
body.
(Loosen screws (1) before adjusting)
5. Secure the potentiometer in place by tightening
screw (1).
Table 1
PIN No.
POTENTIOMETER No.
5V SIG GND
1 ST1 A H G
2 ST2 M E F
3 FR3 L K J
4 FR4 O P Q
20-155-1 D375A-5
4
Related electrical circuit diagram
D375A-5 20-155-2
4
TESTING AND ADJUSTING CHECKING THE ADJUSTMENT OF PCCS LEVER
CHECKING THE ADJUSTMENT OF PCCS LEVER

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

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

power source.
2. Screw 6. Controller
B. Wiring connection of adjustment for external
3. PCCS lever 7. Machine power source
power source.
4. Tester 8. External power source (5 V)
20-155-3 D375A-5
4
TESTING AND ADJUSTING DISASSEMBLY AND ASSEMBLY OF PCCS LEVER
DISASSEMBLY AND ASSEMBLY OF PCCS LEVER

DISASSEMBLY
1. Open armrest and remove screws (1) (4 places/
hexagon socket head).
2. Remove armrest & box assembly.
3. Remove screws (3).
4. Remove cover (4).
D375A-5 20-155-4
4
5. Remove screws (5) (6 places).
6. Sling cover (6) and disconnect wiring for fuel dial.
7. Peel boot, remove bolts (7) (4 places/hexagon

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

(11).
9. Loosen screw (9), then adjust voltage by turning
potentiometer (10) slightly.
ASSEMBLY
• For assembly, procedure in reverse order.
20-155-5 D375A-5
4
4. Blade lever at LEFT TILT
10-156 D375A-5
When the blade lever is moved to the LEFT TILT

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

From the above condition, if cylinder (17) is
moved to the end of its stroke, the hydraulic pres-
sure in the whole circuit rises.
flows from port A2, and pushes open main relief
valve poppet (14). It is then relieved to port E2,
so the hydraulic pressure does not rise any fur-
ther.
The hydraulic pressure at this point is 20.6 MPa
{210 kg/cm2}.
D375A-5 10-157
5. Ripper lever at TILT IN (ripper Lo valve, shuttle valve actuated)
10-158 D375A-5
When the ripper lever is moved to the TILT IN po-

sition, the spool of the PPC valve directly con-
spool (19) down, opens the circuits between
ports B4 and C4, and ports D4 and F4, and ports
A3 and G4, and closes the circuit between ports
A3 and A4.
enters ports A2 and A3. Some of the oil pushes
open check valve (18), flows from port B4 into
port C4, and the flows to port H2 of the ripper Hi
valve. The rest of the oil passes through the
groove in spool (19), enters port G4, pushes
shuttle valve (22) down fully, then flows from port
H5 to port S of shuttle valve (10).
The oil entering port S passes through orifice b,
and pushes piston (11). The reaction moves
shuttle valve (10) to the left, closes the circuit be-
tween ports N and O, and opens the circuit be-
tween ports S and O.
The oil entering port O from port S then passes
through orifice c, and enters ports P and Q. It be-
comes the pilot pressure of demand valve (1),
and moves the demand valve to the right.
When this happens, the circuit between ports A
and E' is closed, so the oil from the large pump
is not drained to the hydraulic tank.
The whole amount of the oil flows to port A1 of
the ripper Hi valve.
D375A-5 10-159
6. Ripper lever at TILT IN (ripper Hi valve actuated)
10-160 D375A-5
As explained in item 5, the oil from the large

pump enters A1 of the ripper Hi valve, pushes
open check valves (23) and (35), flows to ports
B1 and B2, and stops.
The oil from the small pump flows from port C4
of the ripper Lo valve and enters port H2.
Some of the oil entering port H2 passes through
the passage inside valve (42), flows to port L2,
and pushes shuttle valve (44) fully to the right. It
then enters port O2, pushes spool (36) up, and
becomes the pilot pressure.
The rest of the oil is throttled by orifice g and en-
ters port D2.
Some of the oil entering port D2 passes through
the passage inside valve (42), flows to port J2,
and pushes shuttle valve (41) fully to the left. It
then enters port N2, pushes spool (36) down,
and becomes the pilot pressure.
The rest of the oil flows from port D2 to the bot-
tom end of ripper tilt cylinder (45).
When all the above hydraulic circuits are filled
with oil, the hydraulic pressure starts to rise.
From the condition previously explained, if the
hydraulic pressure continues to rise, the oil at
port H2 is throttled by orifice g and enters port
D2. Because of the resistance, the hydraulic
pressure at port H2 becomes higher than the
pressure beyond port D2.
Therefore, the hydraulic pressure at pilot port O2
of spool (36) becomes higher than the hydraulic
pressure at port N2, so when this pressure differ-
ence becomes greater than the tension of spring
(38), it pushes spool (36) up.
When this happens, the circuits between ports
B2 and D2, and ports C2 and F1 open, the oil
from the large pump flows from port B2 to port
D2, enters the bottom end of ripper tilt cylinder
(45), and merges with the oil from the small
pump to extend the cylinder.
Some of the oil at the head end of the cylinder re-
turns from port C2 to port F1, and is drained to
the hydraulic tank. The rest of the oil flows from
port C2, is throttled by orifice f of valve (39), and
returns to port G2. It then flows from port D4 of
the ripper Lo valve, returns to port F4, and is
drained to the hydraulic tank.
D375A-5 10-161
7. Ripper level at LOWER (ripper Lo valve, shuttle valve actuated)
10-162 D375A-5
When the ripper lever is moved to the LOWER

position, the spool of the PPC valve directly con-
spool (21) moves down, opens the circuits of
ports B5 and C5, and ports D5 and F5, and ports
A4 and G5 and closes the circuit of ports A4 and
A5.
enters ports A2, A3, and A4. Some of the oil
pushes open check valve (20), flows from port
B5 into port C5, and the flows to port H1 of the
ripper Hi valve. The rest of the oil passes through
the groove in the spool, enters port G5, pushes
shuttle valve (22) up fully, then flows from port H5
to port S of shuttle valve (10).
The oil entering port S passes through orifice b,
and pushes piston (11). The reaction moves
shuttle valve (10) to the left, closes the circuit be-
tween ports N and O, and opens the circuit be-
tween ports S and O.
The oil entering port O from port S then passes
through orifice c, and enters ports P and Q. It be-
comes the pilot pressure of demand valve (1),
and moves the demand valve to the right.
and E is closed, so the oil from the large pump is
not drained to the hydraulic tank.
The whole amount of the oil flows to port A1 of
the ripper Hi valve.
D375A-5 10-163
8. Blade lever at HOLD, ripper lever at LOWER (ripper Hi valve actuated)
10-164 D375A-5
As explained in item 7, the oil from the large

pump enters A1 of the ripper Hi valve, pushes
open check valves (23) and (35), flows to ports
B1 and B2, and stops.
The oil from the small pump flows from port C5
of the ripper Lo valve and enters port H1.
Some of the oil entering port H1 passes through
the passage inside valve (30), flows to port M1,
and pushes shuttle valve (32) fully to the left. It
then enters port O1, pushes spool (24) up, and
becomes the pilot pressure.
The rest of the oil is throttled by orifice e and en-
ters port D1.
Some of the oil entering port D1 passes through
the passage inside valve (30), flows to port K1,
and pushes shuttle valve (29) fully to the right. It
then enters port N1, pushes spool (24) down,
and becomes the pilot pressure.
The rest of the oil flows from port D1 to the bot-
tom end of ripper tilt cylinder (33).
When all the above hydraulic circuits are filled
with oil, the hydraulic pressure starts to rise.
From the condition previously explained, if the
hydraulic pressure continues to rise, the oil at
port H1 is throttled by orifice e and enters port
D1. Because of the resistance, the hydraulic
pressure at port H1 becomes higher than the
pressure beyond port D1.
Therefore, the hydraulic pressure at pilot port O1
of spool (24) becomes higher than the hydraulic
pressure at port N1, so when this pressure differ-
ence becomes greater than the tension of spring
(25), it pushes spool (24) up.
When this happens, the circuits between ports
B1 and D1, and ports C1 and E1 open, the oil
from the large pump flows from port B1 to port
D1, enters the bottom end of ripper lift cylinder
(33), and merges with the oil from the small
pump to extend the cylinder.
Some of the oil at the head end of the cylinder re-
turns from port C1 to port E1, and is drained to
the hydraulic tank. The rest of the oil flows from
port C1, is throttled by orifice d of valve (27), and
returns to port G1. It then flows from port D5 of
the ripper Lo valve, returns to port E5, and is
drained to the hydraulic tank.
D375A-5 10-165
9. Ripper lever at LOWER (cylinder at stroke end)
10-166 D375A-5
From the condition in items 7 and 8. if cylinder

(33) is moved to the end of its stroke, the hydrau-
lic pressure in the whole circuit rises.
When this happens, in the same way as in item
4, the oil from the small pump flows from port A2
and pushes open main relief valve poppet (14).
It is then relieved to port E2, so the hydraulic
pressure does not rise any further.
{210 kg/cm2}.
The oil passing through shuttle valves (22) and
(10), and flowing from ports S and O to port P
also pushes open main relief valve poppet (13),
and is relieved to port T.
The circuit from port O to port P is throttled by or-
ifice c, so the supply of oil to port P is delayed.
As a result, the hydraulic pressure at pilot port Q
of demand valve (1) also drops, and the demand
valve moves to the left.
and E' opens, and the oil from the large pump is
relieved, so the hydraulic pressure in the circuit
of the large pump does not rise any further.
{210 kg/cm2}. When the hydraulic pressure in the
whole circuit is set at 20.6 MPa {210 kg/cm2}, the
pressure difference on both sides of orifice e of
valve (30) (that is, the difference in pressure be-
tween ports H1 and D1) disappears.
The pilot pressure at port O1 that is pushing
spool (24) up becomes the same pressure as the
pressure at port N1. When this happens, spool
(24) is pushed down by the tension of spring (25)
to a position where it is in balance with the ten-
sion of spring (26).
At this point, the circuits between ports B1 and
D1 and ports C1 and E1 are closed.
The oil from the large pump goes as far as port
B1, and stops. The oil at the head end of cylinder
(33) flows from port C1, passes through orifice d
of valve (27), and returns only to port G1.
D375A-5 10-167
MAINTENANCE STANDARD CYLINDER STAY
CYLINDER STAY
1. Yoke
2. Oil seal
3. Bushing
4. Bushing
Unit: mm

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

7 105 0.5
support shaft and bushing 0.207 0 0.242
10-168 D375A-5
MAINTENANCE STANDARD BLADE
BLADE
SEM-U DOZER
10-170 D375A-5
Unit: mm

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

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

3 75 0.2 0.6 1
bracket 0.3 0

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

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

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

7 100 0.3 0.8 3
joint 0.5 0

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

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

10 200 0.5 1.5 8
cap spherical surface 1.0 0

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

12 100 0.3 0.8 3
joint 0.5 0

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

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

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

16 280 0.3 0.7 2
and blade bracket 0.4 +0.1

17 170 0.2 0.6 1
spherical surface and cap 0.3 0 replace
D375A-5 10-171
U-DOZER
10-172 D375A-5
Unit: mm

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

2 75 0.3 0.6 2
bracket 0.3 +0.1

3 75 0.2 0.6 1
bracket 0.3 0

4 75 0.2 0.5 1
bushing 0.3 0

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

6 200 0.3 1.0 3
bracket 0.7 +0.1

7 100 0.3 0.8 3
joint 0.5 0

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

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

10 200 0.5 1.5 8
cap spherical surface 1.0 0

11 200 0.3 1.0 3 Replace
bracket 0.7 +0.1

12 100 0.3 0.8 3
joint 0.5 0

13 100 0.5 1.0 2
bracket 0.5 +0.2

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

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

16 280 0.3 0.7 2
and blade bracket 0.4 +0.1

17 170 0.2 0.6 1
spherical surface and cap 0.3 0 replace
D375A-5 10-173
CUTTING EDGE, END BIT
Unit: mm

1 Height of end bit outside
478 380
Replace
2 Width of end bit 734 600
3 Height of end bit inside 393 300
4 Height of cutting edge 406 335 (264 after turned) Replace or turn
10-174 D375A-5
MAINTENANCE STANDARD RIPPER EQUIPMENT
RIPPER EQUIPMENT
VARIABLE MULTIPLE SHANK RIPPER
10-176 D375A-5
MAINTENANCE STANDARD RIPPER EQUIPMENT
GIANT RIPPER
Unit: mm
Standard Tolerance Standard Clearence

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

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

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

4
mount pin 82 ±0.3

5 Wear of point
420 255
6 Wear of protector 155 115
D375A-5 10-177
MAINTENANCE STANDARD CAB MOUNT
CAB MOUNT
1. Support Outline
2. Damper mount (Front) The cab mount is installed at two places in the
3. Damper mount (Rear) front and at two places in the rear, and the floor
frame and the cab are secured.
The cab mount adopts an oil seal type damper
mount and absorbs vibration.
10-178 D375A-5
MAINTENANCE STANDARD CAB
CAB
CAB ASEMBLY
1. Front wiper
2. Front glass
3. Rear wiper
4. Door
D375A-5 10-179
MAINTENANCE STANDARD CAB
ROPS GUARD
1. ROPS guard
10-180 D375A-5
MAINTENANCE STANDARD AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
1. Air conditioner compressor 10. Valve (hot water outlet)

2. Window defroster 11. Hot water return piping
3. Side defroster 12. Valve (hot water inlet)
4. Air conditioner unit 13. Refrigerant piping
5. Blower port
A. Fresh air
6. Blower motor
B. Recirculated air
7. Hot water pick-up piping
C. Hot air/cold air
8. Condenser
9. Receiver tank
D375A-5 10-181
MAINTENANCE STANDARD ENGINE CONTROL
ENGINE CONTROL
1. Decelerator pedal Outline

2. Starter switch The throttle signal of the throttle dial enters the
3. Decelerator potentiometer steering controller and the transmission control-
4. Steering controller ler and is processed together with another infor-
5. Transmission controller mation, then sent to the engine controller as a
6. Fuel throttle dial throttle command. The engine controller controls
7. Battery the control valve unit and the fuel pump in accor-
8. Battery relay dance with the command.
9. Starter
10. Engine controller
11. Fuel pump
10-182 D375A-5
MAINTENANCE STANDARD ENGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM
Outline
The engine controller receives the manual signal The engine control system shares the informa-
of the second throttle and the third throttle signal tion about the engine controller with another con-
that is the control signal from a vehicle body and troller through networks and contributes to the
selects a low engine speed, then controls the optimum control between the engine and the ve-
control valve unit. hicle body.
The third throttle control signal includes the fol- As the auto decelerator function, the engine
lowing items: speed is temporarily set to 1,000 rpm when for-
1 First throttle signal ward and reverse from F3, R3, and R2 are
2 SSC (Shoe Slip Control) control switched. (For transmission clutch protection)
3 Auto decelerators (F3, R3, R2)
The steering controller selects the lowest engine
speed from the information 1, 2, and 3 and
sends it to the engine controller as the third throt-
tle.
D375A-5 10-183
MAINTENANCE STANDARD DECELERATOR POTENTIOMETER
DECELERATOR POTENTIOMETER
1. Connector Outline
2. Lever The decelerator potentiometer is mounted on
3. Body the lower front of the operator cab and connect-
4. Potentiometer ed with the decelerator pedal using a linkage.
5. Coupling
6. Shaft When the decelerator pedal is actuated, the
7. Stopper shaft of the throttle potentiometer rotates via the
linkage and a resistance value is changed.
Fixed voltage is applied between the pins A to C
of the potentiometer and a voltage signal that
matches the actuation position of the decelerator
pedal is sent from the B pin to the engine control-
ler.
10-184 D375A-5
MAINTENANCE STANDARD HPI ENGINE CONTROL SYSTEM
HPI ENGINE CONTROL SYSTEM

★ HPI is an abbreviation of High Pressure Injection.
System drawing
Outline
The signals detected by various sensors are in-
put to the engine controller.
The input signals are operated arithmetically by
the controller. A signal is issued to each actuator
and controls a fuel injection level and fuel injec-
tion timing.
10-186 D375A-5
MAINTENANCE STANDARD HPI ENGINE CONTROL SYSTEM
1. Fuel tank OUTLINE OF HPI SYSTEM

2. Fuel filter The HPI system consists of injector assembly
3. Fuel pump assembly (5), control valve assembly (4), and fuel pump
3A. Gear pump assembly (3).
3B. Pump regulator Injector assembly (5) controls the amount of fuel
3C. Check valve injection and the injection timing by controlling
3D. Fuel pump actuator the amount of fuel passing through fuel orifice
3E. Fuel pump pressure sensor (5B).
4. Control valve assembly In order to control the fuel flow, it is necessary to
4A. Timing rail actuator valve control the fuel rail pressure and timig rail pres-
4B. Fuel leak throttle (220 cc/min) sure. To control these pressures, control valve
4C. Timing rail pressure sensor assembly (4) has 2 pressure sensors and 2 ac-
4D. Shut-off valve tuator valves built in. These carry out control so
4E. Fuel rail actuator valve that the fuel rail rail pressure and timing rail pres-
4F. Fuel leak throttle (110 cc/min) sure become the target value. Shut-off valve
4G. Fuel rail pressure sensor (4D), used to stop the engine, is installed in the
5. Injector assembly fuel rail line.
5A. Timing orifice Fuel pump assembly controls the basic pressure
5B. Fuel orifice of the fuel. The fuel supplied from fuel tank (1)
5C. Gravity check valve passes through fuel filter (2), is then sucked up
5D. Bypass orifice by gear pump (3A), and is supplied to control
5E. Injector valve assembly (4). The discharge pressure of
5F. Plunger the fuel pump is controlled to a suitable level by
5G. Gravity check valve adjusting the opening angle of fuel pump actua-
6. Fuel cooler tor (3D).
7. ECM controller
8. Engine speed sensor
9. Atmospheric pressure sensor
10. Boost pressure sensor
11. Boost temperature sensor
D375A-5 10-187
MAINTENANCE STANDARD MONITOR SYSTEM
MONITOR SYSTEM
The monitor system monitors the state of the ve- Further, the monitor panel incorporates the vari-
hicle by the sensor mounted on each portion of ous mode selection switches of the SSC (shoe
the vehicle and quickly processes the informa- slip control) and has the function of the control
tion, then displays it on the panel, thereby report- portion of the vehicle control system.
ing the state of the vehicle to the operator. The monitor panel has the monitor display func-
The contents displayed on the panel are roughly tion and the switch function for the SSC mode
divided as follows: selection.
1. Monitor portion that issues an alarm when A CPU (central processing unit) is installed in-
an error occurred in the vehicle. side. The CPU processes information and dis-
2. Gauge portion (coolant temperature, torque plays and outputs it. The CPU uses an LCD as
converter oil temperature, fuel level) that al- the monitor display portion. Further, the switch is
ways displays the state. a flat sheet switch.
3. Function that displays error codes.
4. Function that monitors current and voltage
values of each sensor and solenoid.
10-188 D375A-5
MAINTENANCE STANDARD MONITOR SYSTEM
Monitor Panel Processing (All Specifications)
Monitor panel display
1 Processing contents and condition 2 System 3 Flow of signal
1) Display of forward-reverse, number of gear S-NET communication Transmission controller → Steering

ratios controller → Monitor panel
F1 and R3 are reported by S-NET based on
the information about the transmission con-
troller.
2) Gauge display of engine speed S-NET communication Engine speed sensor → Engine
The pulse of the engine speed sensor is controller → Steering controller →
substituted for the number of gauges and Monitor panel
the number of gauges is reported to the
monitor panel by S-NET.
3) Troubleshooting display S-NET communication Each sensor, solenoid → Controller

At fault, the relevant failure code is reported → Monitor panel
to the monitor panel by S-NET.
The information as to whether the buzzer
sounds or the caution lamp comes on ac-
cording to the failure contents is also report-
ed.
1 At normal time
User codes
2 In failure history display mode
Service codes
The monitor panel alternatively displays
codes and hour meter values on the hour
meter display portion.
Monitoring display
1 Processing contents and condition 2 System 3 Flow of signal
1) The communication states of each sensor, S-NET communication Each sensor → Controller → Moni-
each solenoid, and S-NET are displayed. tor panel
An item number and an equipment state are
reported to the monitor panel by S-NET.
The monitor panel displays an item on the
speed display portion and the relevant value
on the hour meter portion.
2) An item advances by the reverse slow but- Monitor panel → Controller → Mon-
ton of the monitor panel. itor panel
The item returns by the buzzer cancel
switch.
D375A-5 10-189
MAINTENANCE STANDARD MONITOR PANEL
MONITOR PANEL
Monitor portion
1. Display plate (Speed range display) 8. Power train oil temperature caution lamp
2. Power train oil temperature gauge 9. Hydraulic oil temperature caution lamp
3. Engine water temperature gauge 10. Preheat pilot lamp
4. Charge lamp 11. Dual tilt display lamp
5. Fuel thermometer gauge 12. Radiator water level check lamp
6. Engine oil pressure caution lamp 13. Fuel gauge
7. Engine water temperature caution lamp 14. Service meter
Outline 2) Start-up inspection items comes off when

The monitor portion consists of a monitor that is- the engine starts.
sues an alarm when an error occurred in a vehi- (Whether the engine is operating or not is
cle, a gauge that always displays the state of the decided depending on whether the engine oil
vehicle, and the service meter. pressure is raised or the voltage from the al-
The monitor portion installs a microcomputer ternator exceeds 10 V.)
and processes and displays signals from each
3. Cautions
sensor.
Caution items are checked until the engine stops
Besides, the items displayed on the monitor por-
after the engine starts.
tion and gauge portion are listed in the table on
If an error occurs, the error is displayed by flash-
the next page.
ing and the alarm lamp synchronously flashs.
Operation Further, if an emergency item flashs, the alarm
buzzer also sounds synchronously.
1. When the power turns on (When the starter ★ Flashing of the monitor and alarm lamp is re-
switch is ON) peated. They come on and off for about 0.8 sec-
1) All items of the gauge and monitor portions ond.
come on for three seconds. ★ The flashing period of the monitor slightly chang-
2) The alarm lamp comes on for two seconds. es when atmospheric temperature is low (below
about 10°C), but this case is not abnormal.
2. Start-up inspection
1) After all lighting of Section 1 is terminated, if
there is an error in a start-up inspection item,
the item flashs.
10-190 D375A-5
Monitor Panel Display

Cate-
Symbol Display item Display range Display method
gory
The monitor panel is displayed when the
engine is stopped and the starter switch
is ON.
Radiator water level Below low level
For the display, the monitor panel comes
off at normal time and flashes at abnor-
mal time.

At sensor error or har-
Engine oil pressure off at normal time and flashes at abnor-
ness disconnection
mal time.
When the start switch is ON and the en-

gine is rotating, the monitor panel is dis-
played.
Charge level At faulty charge
off at normal time and flashes at abnor-
SAP00522
mal time.
At the same time, the alarm lamp flash-
es.
49.0 kPa {0.5 kg/cm2}

Engine oil pressure
or less
Radiator water level Below low level

When the start switch is ON and the en-
gine is rotating, the monitor panel is dis-
When the engine cool-
played.
ant temperature
Engine coolant temper- For the display, the monitor panel comes
gauge is in the maxi-
ature off at normal time and flashes at abnor-
mum level (108°C or
mal time.
more)
At the same time, the alarm lamp flash-
When the torque con- es and the alarm buzzer sounds.
Torque converter oil verter oil temperature
temperature is in the maximum lev-
el (130°C or more)
Hydraulic oil tempera-

103 ± 3°C or higher
ture
When the atmospheric temperature is

below about 5°C, the switch panel
comes on for 36 seconds with the sheet
Preheat Preheat time
switch (ENGINE HEAT) ON. Subse-
quently, it flashes for 16 seconds and
displays the completion of preheat.
D375A-5 10-191
Cate-
Symbol Display item Display range Display method
gory
Engine coolant temper-

ature
The relevant one place comes

on.
Torque converter oil

temperature
All places come on below the rel-

Fuel level
evant level.
Actuated when the alternator is

Time meter 0 to 99,999 hours
charged.

10-192 D375A-5
Switch Portion
1. Switch functions
a) ON-OFF switching in lock-up mode
b) Economy mode setting - OFF, mode 1, mode 2
c) ON-OFF switching in reverse slow mode
d) ON-OFF switching in SSC mode
e) SSC mode level setting - Mode 1 to 5
a, b, and c are mounted for all specifications and d and e are mounted for the SSC specifications.
SSC specifications
Without SSC specifications
Economy Mode Function

In a field, such as a rock-bed place where many shoe 2. Initial Setup at key ON
slips are generated, the following power is output in The function the operator desires according to
each mode so that the frequency of decelerator op- the situation of an operating place is selected
eration can decrease. and all functions shall be set to the OFF state.
Economy mode 1 → Set to about 90% of the full
power.
Economy mode 2 → Set to about 70% of the full
power.
Reverse slow mode → Set to about 80% of the
full travel speed at reverse time.
D375A-5 10-193
MAINTENANCE STANDARD SENSORS
SENSORS
Sensor and type Sensor system Normal time Abnormal time

Engine oil pressure Contact OFF ON
Engine water temperature Resistor
Resistor
temperature
Hydraulic oil temperature Contact ON OFF
Radiator water level Contact ON OFF
Fuel level Resistor
Engine oil pressure sensor
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
10-194 D375A-5
Engine Water Temperature Sensor
Torque converter oil temperature sensor
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
Hydraulic oil temperature sensor
1. Switch 4. Wire
2. Plug 5. Connector
3. Tube
Radiator water level sensor
1. Float 4. Wire
2. Sensor 5. Connector
3. Tube
D375A-5 10-195
Fuel level sensor
1. Connector Function
2. Float The fuel level sensor is installed to the bottom
3. Arm right of the front face of the fuel tank.
4. Body Float (2) moves up and down according to the
5. Spring fuel level. This movement of the float is transmit-
6. Contact ted by arm (3) and actuates a variable resis-
7. Spacer tance. This sends a signal to the monitor panel
to indicate the remaining fuel level. When the
display on the monitor panel reaches a certain
level, a warning lamp flashes.
10-196 D375A-5
MAINTENANCE STANDARD MODE SELECTION SYSTEM
MODE SELECTION SYSTEM

(SSC (Shoe slip control) system)
System drawing
Outline
The mode selection system automatically per- The lock-up control mode is the same mode as
forms the engine control that matches the work the conventional lock-up function and cannot
condition selected by the operator. It reduces a perform simultaneous selection with the above
fuel cost, makes the life of the track longer, and mode.
reduces the frequency of decelerator operation.
The engine control mode includes the economy
mode control used at dozing time, the SSC used
at ripping time, and the reverse slow mode con-
trol that can be used in both.
D375A-5 10-197
Mode selection function 4. The transmission controller sends the lock-up

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

transmission controller
1. The steering controller computes the machine
bodys ground speed based on the input signal
from the acceleration sensor and then computes
the shoe speed by adding the signal from the
transmission output speed sensor to the ground
speed. The steering controller then calculates
the shoe slip rate based on above information.
2. Then the steering controller computes the draw-
bar pull using the input signals from the engine
speed sensor and the transmission output speed
sensor.
3. This controller calculates an optimum engine
speed using above 1 and 2 plus the set mode
signal and the speed information from the trans-
mission controller. This optimum value is then
sent from the speed controller to the engine con-
troller as the SSC instruction.
10-198 D375A-5
Operation of mode selection system

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

Work neous Mode work condition Mode operation, characteristic
switch selection selection
ON/OFF switching is automatically per- 1. When the torque converter approaches to the
formed in accordance with a load. stall area or performs gear shaft operation,
Speed number F2, F3 lock-up is set to OFF. When the torque convert-
F1 er reaches a light lode, lock-up is set to ON.
of gear ratios R1, R2, R3
1,230 rpm 1,260 rpm 2. Can be used in all number of gear ratios.
ON 3. Simultaneous selection disabled with another
or more or more
mode
1,200 rpm 1,230 rpm
OFF 4. Suitable for dozing work of comparatively a few
or more or more
load fluctuations
2,140 rpm
ON
or more
2,200 rpm
OFF
or more
1. When F1 is shifted with the economy 1. When the economy mode (1 or 2) and SSC
mode switch 1 or 2 ON are set simultaneously, the F1 shift economy
control is performed. When the ripper lever is
actuated and the switch is turned on, the slip
control is performed.
2. The engine output can be suppressed in two
stages without performing the decelerator op-
eration of the engine.
Mode 1: 90% (at 1.5 km/h)
Mode 2: 65% (at 1.5 km/h)
3. At neutral time, the engine speed can be sup-
pressed partially
1. When R1, R2, and R3 are shifted 1. The engine speed can be suppressed without
performing the decelerator operation of the en-
gine.
2. Target travel speed at reverse time
R1
R2 70% at full operation
R3
The following conditions are satisfied: 1. At start, to prevent rashing out, the modulating
1 When F1 is shifted. valve is actuated. At this time, the steering con-
2 After the ripper down, ripper tilt levers are troller performs index characteristic down of
actuated and the switch is set to ON about 40% and performs the engine outpuut
control if a ripper down signal is input.
2. The seering controller performs the engine out-
put control in accordance with the index force
characteristic (refer to the rock-bed selection
shown below) selected by the operator among
the index force characteristics set in five stages
and suppresses the generation of a slip.
3. The steering controller regards the index force
immediately before the slip (exceeding the
shoe ripping ratio of 30% is generated, as the
maximum, and performs the engine output
control. At this time, the steering controller per-
forms index characteristic down of about 30 to
80% and performs the engine outpuut control if
a ripper tilt or ripper up signal is input.
4. At neutral time, the engine speed is sup-
pressed partially.
Set to ON in connection with SSC 1. When the SSC is set to ON, the selection mode
3 comes on.
2. 1 ⇔ 3 ⇔ 5 is selected in accordance with the
state and load of the rock-bed.
★ When the above mode is set, the throttle lever and decelerator operations are enabled. In that case, the engine
output control is performed in accordance with the command having the smallest value among the control com-
mand, throttle command, and decelerator command.
D375A-5 10-199
SENSORS
Engine speed sensor
Transmission output shaft speed sensor
1. Magnet
2. Terminal
3. Case
4. Boots
5. Connector
10-200 D375A-5
Acceleration sensor
1. Sensor portion
2. Wire
3. Connector
Outline
The acceleration sensor is mounted at the lower
front of the operator cab.
The acceleration sensor changes the position of
a ball inside the sensor in accordance with accel-
eration.
The coil that detects the position of this ball is
provided inside the sensor. This is amplified by
an amplifier to change voltage and the result is
sent to the SSC controller.
Refer to the drawing at the right for the sensor in-
put/output chatacteristics.
D375A-5 10-201
Pitch angle sensor
1. Body
2. Tube
3. Wire
4. Connector
10-202 D375A-5
MAINTENANCE STANDARD ELECTRICAL DEVICE
ELECTRICAL DEVICE
Relay box
D375A-5 10-203
OPERATION OF LAMP SYSTEM
ELECTRICAL CIRCUIT OF LAMP SYSTEM
10-204 D375A-5
OPERATION OF ELECTRICAL INTAKE AIR HEATER
ELECTRCAL CIRCUIT OF PREHEATING
D375A-5 10-205
MAINTENANCE STANDARD STEERING ELECTRONIC CONTROL
STEERING ELECTRONIC CONTROL
1. Monitor panel (Speed range display) 6. Steering control valve

2. Auto shift down switch 7. Transmission output shaft speed sensor
3. Engine controller 8. Transmission control valve
4. Transmission controller 9. Engine speed sensor
5. Steering controller
10-206 D375A-5
MAINTENANCE STANDARD STEERING ELECTRONIC CONTROL
Shift Mode Function

1. Function
If you shift the lever to the forward or reverse, the
gear speed selected from the shift mode is
turned on.
A: Shift mode 1
B: Shift mode 2
2. Type of Modes
1 F1-R2
2 F2-R2A
3 F1-R1 (Manual mode)
Shift the steering or forward-reverse lever to N.
3. Selecting method
Shift up switch ON Shit up switch ON
Manual mode Shift mode 1 Shift mode 2
Shift down switch ON Shift down switch ON
4. Displaying method
Monitor panel
Auto Shift-down Function

1. Operating condition
This function automatically shifts the gear speed
down if load is increased while the machine is
travelling at 2nd or 3rd speed or while the ma-
chine is in operation.
2. Selecting method
Turn the auto shift-down switch (1) ON.
3. Operation and features of the mode
1) This function turns on the shift-down auto-
matically by calculating the drawbar pull
(load to the machine body) based the engine
speed, transmission speed and throttle infor-
mation from the steering controller.
2) Once the machine is automatically shifted
down, shit-up wont be turned on automati-
cally (shift up from the manual switch is avail-
able, though).
3) This function is available for both the forward
and reverse travel.
D375A-5 10-207
TESTING AND ADJUSTING
20 TESTING AND ADJUSTING
STANDARD VALUE TABLES

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

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

HPI control devices
Name of Connector Inspection Measurement
Judgment table
component No. method conditions
If the condition is as shown in the table below, it is normal 1) Connect T-adapter

to connector.
Atmospheric 2) Turn starting
Pin Altitude Voltage
pressure switch ON.
Between (A)
— — 4.75 – 5.25 V
and (B)
101.0 kPa
0m 4.42 ± 0.12 V
{760 mmHg}
Atmospheric
AAPR 89.9 kPa
pressure sensor 1,000 m 3.97 ± 0.12 V
{674 mmHg}
Between (C) 79.5 kPa
2,000 m 3.57 ± 0.12 V
and (B) {596 mmHg}
70.1 kPa
3,000 m 3.21 ± 0.12 V
{526 mmHg}
61.6 kPa
4,000 m 2.88 ± 0.12 V
{462 mmHg}

to connector.
Pin Boost pressure Voltage 2) Turn starting
Between (A) and (B) — 4.75 – 5.25 V switch ON.
Boost pressure
IMPR 0 kPa
sensor 0.5 ± 0.03 V
{0 mmHg}
Between (C) and (B)
345 kPa
4.5 ± 0.08 V
{2,590 mmHg}
If the condition is as shown in the table below, it is normal 1) Turn starting

switch OFF.
Intake air 2) Disconnect con-
Pin Resistance
temperature nector.
0ºC 30 k – 36 kz
Intake air
25ºC 9 k – 11 kz
temperature IMTP
sensor Between (A) and (B) 50ºC 3 k – 4 kz
75ºC 1,350 – 1,500 z
100ºC 600 – 675 z
Between (A), (B)
— Min. 1 Mz
and ground

to connector.
Pin Oil pressure Voltage 2) Turn starting
Oil pressure
OPS 0 kPa
sensor 0.5 ± 0.08 V
{0 kg/cm2}
Between (C) and (B)
689 kPa
4.5 ± 0.08 V
{7.03 kg/cm2}
D375A-5 20-2-1
(5)

Judgment table

switch OFF.
Fuel 2) Disconnect con-
Pin Resistance
temperature nector.
0ºC 30 k – 36 kz
Fuel temperature 25ºC 9 k – 11 kz
FLTP
75ºC 1,350 – 1,500 z
100ºC 600 – 675 z
Between (A), (B)
— Min. 1 Mz
and ground

switch OFF.
Water 2) Disconnect con-
Pin Resistance
temperature nector.
0ºC 30 k – 36 kz
Water
25ºC 9 k – 11 kz
temperature CLTP
75ºC 1,350 – 1,500 z
100ºC 600 – 675 z
Between (A), (B)
— Min. 1 Mz
and ground

switch OFF.
Engine speed SP1 · Pin Resistance 2) Disconnect con-
sensor SP2 Between (A) and (B) 1,000 – 2,000 z nector.
Between (A) (B) and ground Min. 1 Mz

to connector.
Pin Fuel pressure Voltage 2) Turn starting
Fuel pump
PMPR 0 kPa
pressure sensor 0.5 ± 0.04 V
{0 kg/cm2}
Between (C) and (B)
2,582 kPa
4.5 ± 0.06 V
{26.33 kg/cm2}

to connector.
Fuel rail pressure
RPR 103 kPa
sensor 0.5 ± 0.04 V
{10.5 kg/cm2}
Between (C) and (B)
1,722 kPa
4.5 ± 0.06 V
{17.56 kg/cm2}
20-2-2 D375A-5
(5)

Judgment table

to connector.
Timing rail
TPR 0 kPa
pressure sensor 0.5 ± 0.04 V
{0 kg/cm2}
Between (C) and (B)
2,582 kPa
4.5 ± 0.06 V
{26.33 kg/cm2}

switch OFF.
Fuel pump Pin Resistance 2) Disconnect con-
PUMP
actuator Between (A) and (C) 7–9z nector.
Between (A) (C) and ground Min. 1 Mz

switch OFF.
Fuel shut-off FSO+ · Pin Resistance 2) Disconnect con-
valve FSO– Between FSO+ and FSO– 23 – 40 z nector.
Between FSO+, FSO– and ground Min. 1 Mz

switch OFF.
Pin Resistance 2) Disconnect con-
Fuel rail actuator RAIL
Between (A) and (C) 7–9z nector.

switch OFF.
Timing rail Pin Resistance 2) Disconnect con-
TIMG
actuator Between (A) and (C) 7–9z nector.
D375A-5 20-2-3
(5)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR MACHINE RELATED PARTS
STANDARD VALUE TABLE FOR MACHINE RELATED PARTS

En- Standard value for Service limit
Item Measurement conditions Unit
gine new machine value
Deceleration speed • Engine water temperature: Within operating 900 ± 50 900 ± 50
Torque converter stall range 1,520 ± 50 1,430
• Torque converter oil temperature: Within op-
erating range
Torque converter stall • Hydraulic oil temperature: 45 - 55°C rpm
+ work equipment re- • Deceleration speed: Pedal depressed 1,300 ± 60 1,160
lief speed • Torque converter stall speed: F3
• Torque converter stall + work equipment
speed: F3 + ripper RAISE
• Engine stopped Neutral →
30 ± 5 Max. 8.0
• Center of lever knob FORWARD
Direction
Neutral →
30 ± 5 30 ± 5
REVERSE
Full stroke (Neu- mm 40 ± 5 40 ± 5
tral - Left, right) (Play: Max. 3) (Play: Max. 3)
Steering Until clutch is
completely dis- 9±5 9±5
engaged
• Engine stopped
Deceleration pedal mm 45 ± 15 45 ± 15
• Center of lever knob
• Engine at low idling
Full stroke 75 ± 10 75 ± 10
• Center of lever knob
Brake pedal Stroke until oil mm
pressure be- 75 ± 10 75 ± 10
comes 0
• Engine at low idling HOLD - RAISE,
72 ± 10 72 ± 10
• Hydraulic oil temperature: FLOAT
Blade lever 45 - 55°C mm
HOLD - Left,
• Center of lever knob 53 ± 10 53 ± 10
right tilt
• Engine at low idling HOLD - RAISE,
78 ± 10 78 ± 10
• Hydraulic oil temperature: LOWER
Ripper lever 45 - 55°C mm
HOLD - Tilt in,
• Center of lever knob 81 ± 10 81 ± 10
tilt out
• Engine stopped Neutral ! 53.9 ± 9.8 53.9 ± 9.8
• Center of lever knob FORWARD {5.5 ± 1.0} {5.5 ± 1.0}
Direction
Neutral ! 53.9 ± 9.8 53.9 ± 9.8
REVERSE {5.5 ± 1.0} {5.5 ± 1.0}
Until clutch is
14.7 ± 4.9 14.7 ± 4.9
completely dis-
{1.5 ± 0.5} {1.5 ± 0.5}
engaged
Until brake N
{kg} 26.5 ± 4.9 26.5 ± 4.9
takes effect and
{1.5 ± 0.5} {1.5 ± 0.5}
machine turns
Steering
Until clutch is
16.7 ± 4.9 16.7 ± 4.9
completely dis-
{1.7 ± 0.5} {1.7 ± 0.5}
engaged
Until brake
29.4 ± 4.9 29.4 ± 4.9
takes effect and
{3.0 ± 0.5} {3.0 ± 0.5}
machine turns
• Engine stopped N 49.0 ± 9.8 49.0 ± 9.8
Deceleration pedal
• Center of pedal {kg} {5.0 ± 1.0} {5.0 ± 1.0}
D375A-5 20-3
4
1

• Engine at low idling N 460.6 ± 49.0 460.6 ± 49.0
Brake pedal
• Center of pedal {kg} {47.0 ± 5.0} {47.0 ± 5.0}
Control lever, pedal operating effort
• Engine at low idling HOLD→ 39.2 ± 4.9 39.2 ± 4.9

• Hydraulic oil temperature: 45 - RAISE {4.0 ± 0.5} {4.0 ± 0.5}
55°C
• Center of lever knob HOLD→ N 83.3 ± 9.8 83.3 ± 9.8
Blade lever FLOAT {kg} {8.5 ± 1.0} {8.5 ± 1.0}
HOLD –
28.4 ± 4.9 28.4 ± 4.9
Left, right
{2.9 ± 0.5} {2.9 ± 0.5}
tilt
• Engine at low idling HOLD –
21.6 ± 4.9 21.6 ± 4.9
• Hydraulic oil temperature: 45 - RAISE,
N {2.2 ± 0.5} {2.2 ± 0.5}
Ripper lever 55°C LOWER
• Center of lever knob {kg}
HOLD – Tilt 20.6 ± 4.9 20.6 ± 4.9
in, tilt out {2.1 ± 0.5} {2.1 ± 0.5}
• Torque converter oil tempera- 0.03 – 0.15 0.03 – 0.15
ture: Within operating range Low idling
Torque converter inlet {0.3 – 1.5} {0.3 – 1.5}
pressure 0.9 ± 0.10 0.9 ± 0.10
High idling
{9.0 ± 1.0} {9.0 ± 1.0}
0.01 – 0.15 0.01 – 0.15
Low idling {0.1 – 1.5} {0.1 – 1.5}
Torque converter outlet
pressure 0.39 – 0.64 0.39 – 0.64
High idling
MPa {4.0 – 6.5} {4.0 – 6.5}
{kg/cm2}
Low idling — —
Torque converter lock-
up clutch pressure 1.27 – 1.47 1.27 – 1.47
Power train oil pressure
High idling
{13.0 – 15.0} {13.0 – 15.0}
2.45 ± 0.20 2.45 ± 0.20
Low idling {25.0 ± 2.0} {25.0 ± 2.0}
Torque converter sta-
tor clutch pressure 2.65 ± 0.20 2.65 ± 0.20
High idling
{27.0 ± 2.0} {27.0 ± 2.0}
• Torque converter oil tempera- 2.55 ± 0.15 2.35 – 2.94
Low idling
Transmission main re-
ture: Within operating range {26.0 ± 1.5} {24.0 – 30.0}
lief pressure 2.70 ± 0.15 2.45 – 2.94
High idling
{27.5 ± 1.5} {25.0 – 30.0}
2.55 ± 0.15 2.35 – 2.94
Low idling
Transmission F clutch MPa {26.0 ± 1.5} {24.0 – 30.0}
pressure {kg/cm2} 2.70 ± 0.15 2.45 – 2.94
High idling {27.5 ± 1.5} {25.0 – 30.0}
2.55 ± 0.15 2.35 – 2.94
Low idling
Transmission R clutch {26.0 ± 1.5} {24.0 – 30.0}
pressure 2.70 ± 0.15 2.45 – 2.94
High idling {27.5 ± 1.5} {25.0 – 30.0}
20-4 D375A-5
1

• Torque converter oil tempera- 2.25 ± 0.2 1.96 – 2.55
Low idling
Transmission 1st ture: Within operating range {23.0 ± 2.0} {20.0 – 26.0}
clutch pressure 2.25 ± 0.2 1.96 – 2.55
High idling
{23.0 ± 2.0} {20.0 – 26.0}
2.55 ± 0.15 2.35 – 2.94
Low idling
Transmission 2nd {26.0 ± 1.5} {24.0 – 30.0}
clutch pressure MPa 2.70 ± 0.15 2.45 – 2.94
High idling
{kg/cm 2} {27.5 ± 1.5} {25.0 – 30.0}
2.55 ± 0.15 2.35 – 2.94
Low idling
Transmission 3rd {26.0 ± 1.5} {24.0 – 30.0}
clutch pressure 2.70 ± 0.15 2.45 – 2.94
High idling
{27.5 ± 1.5} {25.0 – 30.0}
Transmission lubrica- 0.20 ± 0.05 0.20 ± 0.05
Power train oil pressure
High idling
tion pressure {2.0 ± 0.5} {2.0 ± 0.5}
• Torque converter oil tempera- 2.55 ± 0.15 Min. 2.4
Low idling
Steering left clutch ture: Within operating range {26.0 ± 1.5} {Min. 24}
pressure 27.0 ± 0.15 Min. 2.4
High idling
{27.5 ± 1.5} {Min. 24}
2.50 ± 0.15 Min. 2.4
Low idling
Steering left brake {25.5 ± 1.5} {Min. 24}
pressure 2.65 ± 0.15 Min. 2.4
High idling
MPa {27.0 ± 1.5} {Min. 24}
{kg/cm 2} 2.55 ± 0.15 Min. 2.4
Low idling
Steering right clutch {26.0 ± 1.5} {Min. 24}
pressure 27.0 ± 0.15 Min. 2.4
High idling
{27.5 ± 1.5} {Min. 24}
2.50 ± 0.15 Min. 2.4
Low idling
Steering right brake {25.5 ± 1.5} {Min. 24}
pressure 2.65 ± 1.5 Min. 2.4
High idling
{27.0 ± 1.5} {Min. 24}
Pin puller actuation • Torque converter oil tempera- MPa 2.55 ± 0.10 Min. 2.2
High idling
pressure ture: Within operating range {kg/cm 2} {26.0 ± 2.0} {Min. 22}
• Flat ground 18.9 ± 1.0 18.9 ± 1.0
F1
• Engine water tempera- (3.8 ± 0.2) (3.8 ± 0.2)
When lock-up switch is OFF
ture: Within operating 10.6 ± 0.6 10.6 ± 0.6

Power train performance
range F2
(6.8 ± 0.3) (6.8 ± 0.3)
• Torque converter oil tem-
perature: Within operat- 6.1 ± 0.3 6.1 ± 0.3
F3
ing range Sec. (11.8 ± 0.6) (11.8 ± 0.6)
Travel speed
• Engine at high idling (km/h) 15.0 ± 0.8 15.0 ± 0.8
R1
• Run-up distance: 10 - 30 (4.8 ± 0.2) (4.8 ± 0.2)
m 8.3 ± 0.4 8.3 ± 0.4
• Measuring distance: 20 R2
(8.7 ± 0.4) (8.7 ± 0.4)
m
4.9 ± 0.3 4.9 ± 0.3
R3
(14.7 ± 0.7) (14.7 ± 0.7)
D375A-5 20-5
1

• Flat ground 18.9 ± 1.0 18.9 ± 1.0
F1
• Engine water tempera- {3.8 ± 0.2} {3.8 ± 0.2}
ture: Within operating
10.6 ± 0.6 10.6 ± 0.6
When lock-up switch is ON

Power train performance
range F2
• Torque converter oil tem- {6.8 ± 0.3} {6.8 ± 0.3}
perature: Within operat- 6.1 ± 0.3 6.1 ± 0.3
ing range F3
Sec. {11.8 ± 0.6} {11.8 ± 0.6}
Travel speed • Engine at high idling
(km/h) 14.1 ± 0.7 14.1 ± 0.7
• Run-up distance: R1
10 - 30 m {5.1 ± 0.3} {5.1 ± 0.3}
• Measuring distance:
7.8 ± 0.4 7.8 ± 0.4
20 m R2
{9.2 ± 0.5} {9.2 ± 0.5}
4.6 ± 0.3 4.6 ± 0.3
R3
{15.8 ± 0.8} {15.8 ± 0.8}
+0.98
• Hydraulic oil temperature: 19.6 0 Min. 18.6
45 - 55°C Low idling
Blade lift relief pres- {200 +100 } {Min. 190}
• Cylinder at stroke end
sure 20.6 0
+0.98
Min. 19.6
• Standard value measured with High idling
oil pressure gauge {210 +100 } {Min. 200}
+0.98
19.6 0 Min. 18.6
Low idling
Blade tilt relief pres- {200 +100 } {Min. 190}
sure 20.6 0
+0.98
Min. 19.6
High idling {210 +100 } {Min. 200}
MPa
{kg/cm2} 19.6 0
+0.98
Min. 18.6
Low idling
Ripper lift relief pres- {200 +100 } {Min. 190}
sure 20.6 0
+0.98
Min. 19.6
High idling {210 +100 } {Min. 200}
Work equipment oil pressure
+0.98
19.6 0 Min. 18.6
Low idling
Ripper tilt relief pres- {200 +100 } {Min. 190}
sure 20.6 0
+0.98
Min. 19.6
High idling {210 +100 } {Min. 200}
• Hydraulic oil temperature: 18.6 – 20.6 Min. 17.6
45 - 55°C Low idling
Blade lift relief pres- {190 – 210} {Min. 180}
• Cylinder at stroke end
sure 19.6 – 21.6 Min. 18.6
• Standard value measured with High idling
monitor panel {200 – 220} {Min. 190}
18.6 – 20.6 Min. 17.6
Low idling
Blade tilt relief pres- {190 – 210} {Min. 180}
sure 19.6 – 21.6 Min. 18.6
High idling {200 – 220} {Min. 190}
MPa
{kg/cm2} 18.6 – 20.6 Min. 17.6
Low idling
Ripper lift relief pres- {190 – 210} {Min. 180}
sure 19.6 – 21.6 Min. 18.6
High idling {200 – 220} {Min. 190}
18.6 – 20.6 Min. 17.6
Low idling
Ripper tilt relief pres- {190 – 210} {Min. 180}
sure 19.6 – 21.6 Min. 18.6
High idling
{200 – 220} {Min. 190}
20-6 D375A-5
1
3

Work equipment
Control circuit oil pres- • Hydraulic oil temperature: 45 - 55°C 4.51 ± 0.29 Min. 3.9
oil pressure
sure • Engine at high idling {46.0 ± 3.0} {Min. 40.0}

• Circuit oil pressure: Lever at HOLD MPa
• Output pressure: Lever at full stroke {kg/cm 2}
PPC valve output pres-
sure
High idling 9 – 15 26
RAISE
Low idling 3.5 – 4.5 6
Blade lift Sec.

LOWER High idling 1.1 – 1.6 1.1 – 1.6
• Hydraulic oil tempera-
ture: 45 - 55°C
• Blade: No load
Low idling 1.1 – 1.6 1.1 – 1.6
• Ground level - Max.
height
Low idling 10 – 15 17
Work equipment speed
Left tilt
Work equipment
High idling 4–5 6

Blade tilt Sec.
Right tilt

ture: 45 - 55°C
• Blade: No load High idling 3–4 5
• Full left tilt - Full right tilt
Low idling
Left tilt
High idling
Blade dual tilt Sec.
Low idling
Right tilt

ture: 45 - 55°C
• Blade: No load
High idling
• Full left tilt - Full right tilt
D375A-5 20-7
1
3

Low idling
Dump
High idling
Blade pitch Sec.
• Hydraulic oil tempera- Low idling
Back
ture: 45 - 55°C
• Blade: No load
• Full dump - Full back High idling
RAISE
High idling 2.5 – 3.5 5
Ripper lift Sec.
• Hydraulic oil tempera- Low idling 2–3 2–3

LOWER
ture: 45 - 55°C
• Blade: No load
• Ground level - Max. High idling 2–3 2–3
height
Work equipment
Tilt in
High idling 4.5 – 5.5 7

Ripper tilt Sec.
Tilt back

ture: 45 - 55°C
• Blade: No load High idling 3–4 6
• Full tilt in - Full tilt out
• Hydraulic oil temperature: Low idling Max. 8 12
45 - 55°C
• Lever at full stroke
• Raise blade to maximum
Blade height, then lower blade and
measure time taken from point High idling Max. 1.8 2.0
where blade contacts ground to
point where idler comes off
Time lag
ground
Sec.
• Hydraulic oil temperature: Low idling — —
45 - 55°C
• Lever at full stroke
• Raise ripper to maximum
Ripper height, then lower ripper and
measure time taken from point High idling Max. 1.0 1.5
where ripper contacts ground
to point where sprocket comes
off ground
20-8 D375A-5
1

3

Blade lift mm Max. 200/15 min 400/15 min
• Hydraulic oil temperature: 45 - 55°C

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

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

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

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

• Engine stopped
• Hydraulic drift for 15 minutes at tip of shank
(change in height h)
D375A-5 20-9
1
3

Hydraulic drift
Hydraulic drift of
chassis (ripper mm Max. 30/5 min 60/5 min
lift)
Work equipment

• Engine stopped
• Hydraulic drift for 5 minutes at center of
sprocket (change in height h)
Oil leakage from cylinder
• Engine at high idling

Blade tilt cylinder • Hydraulic oil temperature: 45 - 55°C Max. 3.0 12
• Measure oil leakage during 1 minute at cyl-
inder relief
Ripper lift
cc/min Max. 3.6 12
cylinder
Ripper tilt
Max. 3.2 12
cylinder
20-10 D375A-5

1
3
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

★ Measure the engine speed under the following 3. Measuring high idling speed
condition. 1) Start the engine and set the fuel control dial
• Engine water temperature: Within operating in the high idling position.
range 2) Set the PCCS lever and work equipment
• Torque converter oil temperature: Within op- control lever in neutral and measure the en-
erating range gine speed.
4. Measuring decelerator pedal speed

1. Preparation work 1) Start the engine and set the fuel control dial
Turn the starting switch ON and set the monitor in the high idling position.
panel in the "Monitoring mode" to prepare for 2) Set the PCCS lever and work equipment
measurement of the engine speed. control lever in neutral and press the decel-
★ For the operating method, see "Special func- erator pedal and measure the engine speed.
tions of monitor panel (EMMS)".
• Monitoring code: 99 (Engine speed)
★ The engine speed is displayed on the ser- 5. Measuring torque converter stall speed
vice meter display section in 1 rpm. 1) Start the engine and set the fuel control dial
in the low idling position.
2) Press the brake pedal securely and set the
parking brake lever in the FREE position and
set the PCCS lever in the FORWARD and
3rd gear speed position.
★ Before going to the next step, check that
the upper display unit of the monitor pan-
el is set in the normal display state and it
displays [F3].
★ Keep the steering unit in neutral.
3) Press the decelerator pedal and set the fuel
control dial in the high idling position.
4) Return the decelerator pedal slowly to stall
the torque converter with the engine at high
idling.
¤ Keep pressing the brake pedal securely
and keep your right foot on the decelera-
tor pedal for safety until the work is fin-
ished.
5) Just after the torque converter oil tempera-
ture gauge reads the top line of the green
range, return the direction of the PCCS lever
into neutral.
2. Measuring low idling speed

1) Start the engine and set the fuel control dial
in the low idling position.
2) Set the PCCS lever and work equipment
control lever in neutral and measure the en-
gine speed.
★ When measuring the low idling speed after
lowering the engine speed sharply from the
high speed range, wait for several seconds
until the engine speed is stabilized.
20-102 D375A-5
1
(5)
TESTING AND ADJUSTING MEASURING ENGINE SPEED
6) Repeat above steps 2) - 5) 3 times. 5) Just after the torque converter oil tempera-
7) Perform steps 2) - 4) again and measure the ture gauge reads the top line of the green
engine speed about 5 seconds after the range, return the direction of the PCCS lever
torque conver ter oil temperature gauge into neutral.
reads the top line of the green range.
★ After finishing measurement, return the
direction of the PCCS lever into neutral
and lower the torque converter oil tem-
perature with the engine at high idling.
6) Repeat above steps 2) - 5) 3 times.

7) Perform steps 2) - 4) again and relieve the
ripper in the raising direction and measure
the engine speed about 5 seconds after the
torque conver ter oil temperature gauge
6. Torque converter stall + Work equipment re- reads the top line of the green range.
lief speed (Full stall speed) ★ After finishing measurement, return the
1) Start the engine and set the fuel control dial direction of the PCCS lever into neutral
in the low idling position and raise the ripper and lower the torque converter oil tem-
to the stroke end. perature with the engine at high idling.
2) Keep pressing the brake pedal securely and
set the parking brake lever in the FREE posi-
tion and set the PCCS lever in the FOR-
WARD and 3rd gear speed position.
★ Before going to the next step, check that
the upper display unit of the monitor pan-
el is set in the normal display state and it
displays [F3].
★ Set the steering unit in neutral.
3) Press the decelerator pedal and set the fuel
control dial in the high idling position.
4) Return the decelerator pedal slowly to stall
the torque converter with the engine at high
idling.
¤ Keep pressing the brake pedal securely
and keep your right foot on the decelera-
tor pedal for safety until the work is fin-
ished.
D375A-5 20-103
1
TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)

★ Tools for measuring intake air pressure (boost 4. Run the engine at a mid-range speed or above to
pressure) bleed the oil from the hose.
★ Insert the connection of the hose and pres-
Symbol Part No. Part Name sure gauge about half way, repeat the action
A 799-201-2202 Boost gauge kit to open the self-seal portion at the hose end,
and bleed the oil.
★ A nipple (quick coupler) is installed to the intake ★ If Pm kit (A) is available, the air bleed cou-
air pressure (boost pressure) pickup port of the pling (790-261-1130) inside the kit can be
Pm clinic specification machine. used.
¤ Be careful not to touch any hot parts when re- ★ If there is oil inside the hose, the gauge will
moving or installing the measuring tools. not work, so always bleed the oil.
★ Measure the intake air pressure (boost pressure) 5. Run the engine at high idling to stall the torque
under the following conditions. converter, and measure the intake air pressure
• Coolant temperature: Within operating range (boost pressure).
• Torque converter oil temperature: Within op- ★ For details of the procedure for stalling the
erating range t o r q u e c o n ve r t e r, s e e M E A S U R I N G
• Hydraulic oil temperature: 45 - 55°C TORQUE CONVERTER STALL SPEED.
★ The intake air pressure (boost pressure)
1. Open the engine left side cover. should be measured with the engine running
at rated output. However, when measuring
2. Remove intake air pressure measurement plug in the field, a similar value can be obtained at
(1). torque converter stall speed.
3. Fit nipple 1 of boost gauge kit A, then connect 6. After completing the measurement, remove the
gauge 2. measuring equipment and set to the original
condition.
20-104 D375A-5
1
(5)
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST TEMPERATURE

★ Tools for measuring exhaust temperature

B 799-101-1502 Digital temperature gauge
★ Measuring instruments for exhaust temperature

(Pm clinic specification)
Since the exhaust temperature sensor is in-
stalled to the Pm clinic specification machine,
prepare an adapter connector to connect the ex-
haust temperature sensor and digital tempera-
ture gauge.

4. Procedure when measuring the maximum value
B 799-101-1502 Digital temperature gauge during troubleshooting
— 799-201-1150 Adapter connector Carry out actual work and measure the maxi-
mum value during operation.
¤ Wait for the manifold temperature to go down be- ★ Use the PEAK mode of the digital tempera-
fore removing or installing the measuring equip- ture gauge.
ment. ★ The exhaust temperature varies greatly ac-
★ Measure the exhaust temperature under the fol- cording to the ambient temperature (temper-
lowing conditions. ature of the engine intake air), so if any
• Coolant temperature: Within operating range abnormal value is obtained, carry out tem-
• Torque converter oil temperature: Within op- perature compensation using the following
erating range formula.
• Hydraulic oil temperature: 45 - 55°C • Compensation value [°C] = Measured
value + 2 x (20 - ambient temperature)
1. Open the engine right side cover, then remove
the adiabatic cover.
2. Remove exhaust temperature measurement

plug (1).
5. Procedure when measuring periodically or dur-

ing preventive maintenance
★ If only torque converter stall is used, the
power train oil temperature will overheat be-
fore the exhaust temperature stabilizes, so
3. Fit sensor 1 of digital temperature gauge B, always use the following procedure when
then connect to meter 2. measuring.
★ Clamp the wiring harness of the digital tem- 1) Use the following procedure to carry out full
perature gauge to prevent it from touching stall and raise the exhaust temperature to
any hot part during measurement. approx. 650°C. (Condition a in the diagram).
i) Start the engine, set the fuel control dial
to the low idling position, then operate
the ripper lever to move the ripper lift cyl-
inder to the end of the RAISE stroke.
ii) Keep the brake pedal firmly depressed,
operate the PCCS lever to the F position
and set the speed to 3.
D375A-5 20-105
1
(5)
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
iii) Depress the decelerator pedal and set

the fuel control dial to high idling.
iv) Let the decelerator pedal back slowly,
run the engine at high idling, stall the
torque converter, and at the same time,
operate the ripper lever to RAISE relief.
¤ Keep the brake pedal depressed firmly
during operation. For safety reasons, al-
ways keep your right foot on the deceler-
ator pedal until the completion of the
measurement operation.
2) From the above condition, cancel the hy-
draulic pump relief and carry out only torque
converter relief to lower the exhaust temper-
ature. (Condition b in the diagram).
★ If the exhaust temperature does not go
down but rises, use the procedure in
Step 1) to make the set temperature
higher.
3) When the exhaust temperature goes down
and becomes stable, record the tempera-
ture. (Condition c in the diagram).
¤ If the torque converter oil temperature gauge
enters the red range, return the directional
lever immediately to the neutral position and
lower the torque converter oil temperature.

condition.
20-106 D375A-5
1
(5)
TESTING AND ADJUSTING MEASURING EXHAUST COLOR
MEASURING EXHAUST COLOR

6) Start the engine.
7) Accelerate the engine suddenly or run at
high idling, and depress the accelerator ped-
al of Smoke Meter C2 at the same time to
collect the exhaust gas color on the filter.
8) Place the filter paper used to catch the ex-
haust gas color on top of at least 10 sheets
of unused filter paper inside the filter paper
holder, and read the value shown.
9) After completing the measurement, remove
the measuring equipment and set to the orig-
inal condition.
20-107-1 D375A-5
(5)
TESTING AND ADJUSTING TROUBLESHOOTING FOR INJECTOR
TROUBLESHOOTING FOR INJECTOR

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

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

★ A guideline for judging if the engine has
cooled down is that the temperature of the
exhaust manifold is less than 20°C above the 6. Compensate the measured value for each cylin-
ambient temperature. der 12 minutes after starting the engine and
judge if there is any cylinder with a problem.
2. Make measurement marks a to the exhaust ★ Compensation value
manifold outlets of the all cylinders. Unit: °C
★ Make the marks at the same points of the Cylinder No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
tops or bottoms of the exhaust manifolds of Compensation
+20 +5 0 0 +5 +20
the all cylinders. value
★ Method of judgement
After compensating, add up the values for
the exhaust gas temperature and calculate
the average value. Any cylinder that is more
than 20°C lower than the average value can
be considered abnormal.
★ Measurement and judgement example 1
No. 2 cylinder is more than 20°C lower than
the average value, so judge it as abnormal.
Unit: °C
Cylinder No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
Measured value 85 62 79 112 89 82
Compensated
3. Using heat gun D, measure the temperature at value
105 67 79 112 94 102
the exhaust manifold outlet port of each cylinder Average value 93
before starting the engine.
★ Apply the measurement light (center) of the ★ Measurement and judgement example 2
heat gun to mark a of each cylinder to pre- No. 3 cylinder is more than 20°C lower than
vent dispersion of the measurement results the average value, so judge it as abnormal.
caused by difference of the measuring Unit: °C
points. Cylinder No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
Measured value 86 96 73 91 94 103
4. Run the engine at low idling speed. Compensated
106 101 73 91 99 123
value
5. Using heat gun D, measure the temperature at Average value 99
the exhaust manifold outlet port of each cylinder
3 minutes, 6 minutes, 9 minutes, and 12 minutes ★ Measurement and judgement example 3
after starting the engine. No cylinder is more than 20°C lower than the
★ Apply the measurement light (center) of the average value, so judge all cylinders as nor-
heat gun to mark a of each cylinder to pre- mal.
Unit: °C
vent dispersion of the measurement results
Cylinder No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
caused by difference of the measuring
Measured value 70 88 88 93 86 72
points.
Compensated
90 93 88 93 91 92
value
Average value 91
20-108 D375A-5
4
1
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

★ Tools for adjusting valve clearance

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

cover.
2. Remove all cylinder head covers (1).
4. Insert thickness gauge E2 into clearance b be-

tween rocker arm (3) and crosshead (4), and ad-
just the valve clearance with adjustment screw
(5).
★ Insert the thickness gauge and turn the ad-
justment screw until the clearance is a slid-
ing fit.
5. Hold adjustment screw (5) in position, then tight-

en locknut (6).
3 Locknut:
3. Rotate the crankshaft in the normal direction, to
set the No. 1 cylinder at compression top dead
center, and align [1.6TOP] line a on the damper 57.8 - 77.4 Nm {5.9 - 7.9 kgm}
with pointer (2). ★ After tightening the locknut, check the valve
★ Crank the engine with barring device 1 of clearance again.
the flywheel housing.
6. Rotate the crankshaft 120 ° each time in the nor-

★ At compression top dead center, the rocker mal direction and repeat the procedure in Steps
arm of the No. 1 cylinder can be moved by 3 - 5 to adjust the valve clearance of each cylin-
hand an amount equal to the valve clear- der according to the firing order.
ance. If the rocker arm does not move, it is • Firing order: 1-5-3-6-2-4
not at compression top dead center, so ro-
tate the crankshaft one more turn. 7. After completing the adjustment, set to the origi-
nal condition.
3 Cylinder head cover mounting bolt:
9.8 ± 1.0Nm{1.0 ± 0.1kgm}
D375A-5 20-109
1
(5)
TESTING AND ADJUSTING ADJUSTING INJECTOR SET LOAD
ADJUSTING INJECTOR SET LOAD

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

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

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

edly in the following order, then tighten it finally.
3 Adjustment screw:
1st pass: 29.4 - 34.3 Nm {3.0 - 3.5 kgm}
2nd pass: Loosen completely
3rd pass: 29.4 - 34.3 Nm {3.0 - 3.5 kgm}
4th pass: Loosen completely
★ At compression top dead center, the rocker 5th pass: 29.4 - 34.3 Nm {3.0 - 3.5 kgm}
arm of the No. 1 cylinder can be moved by
hand and amount equal to the valve clear-
ance. If the rocker arm does not move, it is
not at compression top dead center, so ro-
tate the crankshaft one more turn.
★ The cylinder where the injector is adjusted is
different from the cylinder at compression
top dead center, so check the chart below
when carrying out the operation.
20-110 D375A-5
1
(5)
TESTING AND ADJUSTING ADJUSTING INJECTOR SET LOAD
6. Hold adjustment screw (3) in position, then tight-

en locknut (4).
3 Locknut: 205.8 - 245 Nm {21 - 25 kgm}
7. After completing the adjusting, set to the original

condition.
9.8 ± 1.0Nm{1.0 ± 0.1kgm}
D375A-5 20-111
1
(5)
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE

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

1 795-502-1590 Compression gauge
795-611-1210 Adapter
6560-11-8410 O-ring (TOP)
6560-11-8310 O-ring (2ND)
2
F 6560-11-8210 O-ring (3RD)
6560-11-8510 O-ring (4TH)
6560-11-7310 Gasket
795-799-5410 Adapter
3
795-799-5420 Remover
4. Remove injector push rods (2) and injectors (3)
k When measuring the compression pressure, of all the cylinders.
take care not to burn yourself on the exhaust a Using remover F3, pull out each injector.
manifold, muffler, etc. or get caught in a rotating
part.
a Measure the compression pressure after the en-
gine is warmed up.
(Engine oil temperature: 40 – 60ºC)
a Since the compression pressure of all the cylin-
ders should be measured at the same time for ef-
ficiency, preapre 6 adapter assemblies F2.
1. Open the right side cover and left side cover of

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

5. Install adapter assemblies F2 to the all cylinders
and secure them with the holders.
a Install the adapter assemblies with the forc-
ing screw holes directed in the diagonal di-
rection of the holders.
a Secure the adapter assemblies with the in-
3 Holder mounting bolt:

jector holders.
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
20-111-1 D375A-5
(5)
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
6. Install rocker arm assemblies (1) and adjust the 8. Connect compression gauge F1 to adapter as-
2 Threads and seat of mounting bolt:

valve clearance. sembly F2 of the cylinder to be measured.
3 Mounting bolt:
Engine oil (EO30CD)
235.2 – 254.8 Nm {24 – 26 kgm}

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

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

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

replace the bolt.
holder mounting bolt:

Engine oil (EO30CD)
1st time:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
2nd time:
2 Threads and seat of rocker arm

Tighten by 90 – 120º
assembly mounting bolt:
3 Rocker arm assembly mounting bolt:

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

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

TOR.
9.8 ± 1.0 Nm {1 ± 0.1 kgm}
D375A-5 20-111-2
(5)
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE

★ Tools for measuring blow-by pressure ★ Blow-by varies greatly according to the con-
dition of the engine. Therefore, if the blow-by
Symbol Part No. Part Name value is considered abnormal, check for
G 799-201-1504 Blow-by kit problems connected with defective blow-by,
such as excessive oil consumption, defective
★ Measure the blow-by pressure under the follow- exhaust gas color, and prematurely dirty or
ing conditions. deteriorated oil.
• Coolant temperature: Within operating range
erating range
1. Open the engine left side cover and pull out

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

hose (1), then connect to gauge 2.

condition.
3. Run the engine at high idling and measure the

blow-by pressure when the torque converter
stalls.
★ For details of the procedure for stalling the
t o r q u e c o nv e r t e r, s e e M E A S U R I N G
TORQUE CONVERTER STALL SPEED.
★ The blow-by should be measured with the
engine running at rated output. However,
when measuring in the field, a similar value
can be obtained at torque converter stall.
★ If it is impossible to check at rated output or
torque conver ter stall, measure at high
idling.
In this case, the blow-by value will be about
80% of the value at rated output.
20-112 D375A-5
1
TESTING AND ADJUSTING HANDLING EQUIPMENT IN FUEL SYSTEM
HANDLING EQUIPMENT IN FUEL SYSTEM

★ Precautions for inspection and maintenance of
fuel system
The HPI type fuel injection system is constructed
of more precise components than the conven-
tional fuel injection pump and nozzle, so prob-
lems may occur if dirt or dust get in.
When carrying out inspection and maintenance
of the fuel system, pay more attention than usual
to prevent dirt or dust from getting in. If there is
any dirt stuck to any part, use clean fuel to wash
it off completely.
★ Precautions when replacing fuel filter cartridge
Always use a genuine Komatsu part for the fuel
filter cartridge.
The HPI type fuel injection system is constructed
of more precise components than the conven-
tional fuel injection pump and nozzle, so a spe-
cial filter with high efficiency filtering ability is
used to prevent dirt or dust from getting in.
For this reason, if any filter is used as a substi-
tute for the genuine filter, there is danger that
problems will occur with the fuel system. To pre-
vent this, never use such filters.
20-114 D375A-5
1
(5)
TESTING AND ADJUSTING MEASURING FUEL CIRCUIT PRESSURE
4) Measure the fuel pump outlet pressure at

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

voltage
speed pressure (Reference)
0.83 ± 0.14 MPa
600 rpm 1.78 ± 0.21 V
{8.45 ± 1.41 kg/cm2}
0.93 ± 0.14 MPa
700 rpm 1.94 ± 0.21 V
{9.50 ± 1.41 kg/cm2}
3) Start the engine, set the monitor panel in the 1.03 ± 0.14 MPa
800 rpm 2.10 ± 0.21 V
MONITORING MODE, and prepare for mea- {10.53 ± 1.41 kg/cm2}
suring the engine speed. 1.14 ± 0.14 MPa
900 rpm 2.26 ± 0.21 V
a For the operating method, see SPECIAL {11.60 ± 1.41 kg/cm2}
FUNCTIONS OF MONITOR PANEL 1.25 ± 0.14 MPa
1,000 rpm 2.42 ± 0.21 V
(EMMS). {12.70 ± 1.41 kg/cm2}
• Monitoring code: 99 (Engine speed) 1.34 ± 0.14 MPa
1,100 rpm 2.59 ± 0.21 V
a The engine speed is displayed on the {13.70 ± 1.41 kg/cm2}
service meter display section in 1 rpm. 1.46 ± 0.14 MPa
1,200 rpm 2.76 ± 0.21 V
{14.90 ± 1.41 kg/cm2}
a The sensor voltage shown in the above

table is the voltage measured at the
PMPR connector of the fuel pump pres-
sure sensor. It is shown for reference.
5) After finishing measurement, remove the

measuring instruments and return the re-
moved parts.
20-114-2 D375A-5
(5)
TESTING AND ADJUSTING VISUAL INSPECTION OF RETURN FUEL
VISUAL INSPECTION OF RETURN FUEL

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

★ Plug the hole of the fuel tank.
★ Keep the spill hose open and receive the fuel
with an oil pan, etc.
2. Start the engine and check that the fuel flows out
of the spill hose smoothly.
★ Spillage (Referene)
At low idling: 4 – 6 ¬/min.
At high idling: 10 – 12 ¬/min.
★ If the spillage is extremely low, check the re-
turn piping and fuel cooler for clogging.
D375A-5 20-115
4
1
TESTING AND ADJUSTING ARRANGEMENT OF CONTROL DEVICES FOR HPI
ARRANGEMENT OF CONTROL DEVICES FOR HPI

Arrangement of control devices (for troubleshooting)
20-115-1 D375A-5
(5)
TESTING AND ADJUSTING ARRANGEMENT OF CONTROL DEVICES FOR HPI
Controller pump valve

1. Engine controller
2. Fuel pump assembly
3. Control valve assembly
Sensors
4. Atmospheric pressure sensor (AAPR)
5. Boost pressure sensor (IMPR)
6. Intake air temperature sensor (IMTP)
7. Oil pressure sensor (OPS)
8. Fuel temperature sensor (FLTP)
9. Water temperature sensor (CLTP)
10. Speed sensor (SP1, SP2)
11. Fuel pump pressure sensor (PMPR)
12. Fuel rail pressure sensor (RPR)
13. Timing rail pressure sensor (TRP)
Actuator
14. Fuel pump actuator (PUMP)
15. Fuel shut-off valve (FSO+, FSO–)
16. Fuel rail actuator (RAIL)
17. Timing rail actuator (TIMG)
D375A-5 20-115-2
(5)
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
BLEEDING AIR FROM FUEL CIRCUIT
★ If the engine does not start or is difficult to start ★ Add fuel from the inlet port a (8 places). Por-
after the following operations or conditions, tion b is the outlet port after filtering (clean
bleed the air from the fuel circuit as follows. side), so never add fuel from portion b.
• When starting the engine for the first time
• After cleaning the fuel tank
• After adding fuel when the engine has stalled
• After replacing the fuel filter (only when the
air is not bled easily)
1. Open the stop valve at the fuel tank supply side,

then open the engine right side cover.
★ Check that there is ample fuel in the fuel
tank.
2. Remove fuel filter (1), fill it with fuel, then install it

again.
★ Carry out this operation only if the fuel filter
has been replaced.
★ If the fuel filter is not to be replaced, there is
danger of dirt getting in, so do not remove
the fuel filter.
20-116 D375A-5
1
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
3. Crank the engine with the starting motor, push

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

valve until it overflows.
★ Amount of fuel to add: Approx. 30 cc (ref-
erence)
3) Install air bleed plug (1).
Air bleed plug: 12.7 Nm {1.3 kgm}
4) Crank the engine with the starting motor.
D375A-5 20-117

1
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED SENSOR

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

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

monitor panel to the monitoring mode display,
and check that the engine speed is displayed
normally.
★ For details of the method of operation, see
SPECIAL FUNCTIONS OF MONITOR PAN-
EL (EMMS).
• Monitoring code: 99 (Engine speed)
2. Screw in engine speed sensor (1) until its tip

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

turns.
★ Adjust clearance a between the engine
speed sensor tip and gear tooth tip to 0.75 –
1.25 mm.
4. Hold engine speed sensor (1) and tighten lock-

nut (3).
3 Locknut:
33.9 - 47.5 Nm {3.5 - 4.8 kgm}
20-118 D375A-5
4
1
TESTING AND ADJUSTING REPLACING AND ADJUSTING FAN BELT
REPLACING AND ADJUSTING FAN BELT

Replacing Adjusting
1. Open the engine right side cover. ★ If the fan belt whines during operation, or a gap
forms between the tension pulley lever and the
2. Loosen locknut (1), then turn adjustment screw adjustment screw, adjust as follows.
(2) back fully.
1. Screw in adjustment screw (2) until the tip con-
3. Use one of the following methods to loosen the tacts tension pulley lever (3).

belt tension.

1) Insert bar (approx. 50 cm) into hole a (M12 2. From this position, tighten adjustment screw (2) a
x 1.75) in tension pulley lever (3), pull strong- further 2 turns, then secure in position with lock-
ly and keep the tension of the fan belt loos- nut (1).
ened. Locknut:
2) Remove adjustment screw (2), then screw it 245.0 - 308.7 Nm {25.0 - 31.5 kgm}
into hole b (M16 x 1.0) of bracket (4) and
loosen the tension.
★ After replacing the belts, set the adjust-
ment screw back to its original condition.
4. Remove the old fan belts and replace them with

new belts.
D375A-5 20-119

1
TESTING AND ADJUSTING ALTERNATOR, AIR CONDITIONER
TESTING AND ADJUSTING COMPRESSOR BELT TENSION
TESTING AND ADJUSTING ALTERNATOR, AIR CONDITIONER

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

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

to move alternator (3) and adjust the belt ten-

sion.
3. Tighten the 2 alternator mounting bolts and 1

lock bolt for the adjustment rod.
Alternator mounting bolt (4):
65 - 85 Nm {6.7 - 8.7 kgm}
Alternator locknut (1):
147 - 247 Nm {15 - 25 kgm}
20-120 D375A-5

1
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
1. Outline of fuel control system

• The speed signals from the fuel control dial
and decelerator pedal (decelerator potenti-
ometer) are both input to the engine control-
ler (the signal from the fuel control dial
passes through the steering controller).
The controller gives priority to the lower of
these two speed signals and sends a com-
mand to the fuel control system (HPI system)
of the engine.
• Adjustment of the engine speed is all carried
out by the linkage of the deceleration pedal.
D375A-5 20-121
1
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
2. Preparatory work 3. Adjusting deceleration pedal speed

1) Start the engine, switch the monitor panel to With the fuel control dial in the high idling posi-
the monitoring mode display, and prepare to tion, press decelerator pedal (2) until it touches
measure the engine speed. the stopper. Check that the decelerator pedal
★ For details of the method of operation, speed is normal under this condition.
see SPECIAL FUNCTIONS OF MONI- • Deceleration speed: 900 ± 50 rpm
TOR PANEL (EMMS). ★ If the deceleration speed is not correct, ad-
• Monitoring code: 99 (Engine speed) just installed dimension a of rod (1).
★ The engine speed is displayed on the • Standard installed dimension a of rod: 124
service meter display section in 1 rpm. mm (reference)
4. High idling speed

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

sition and check that the engine speed is at
least 1000 rpm.
★ If the engine speed is less than 1000
rpm, extend installation dimension a of
rod (1) to raise the speed to above 1000
rpm.
20-122 D375A-5
1
(5)
TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURE
1. Measuring torque converter inlet pressure 2. Measuring torque converter outlet pressure
(IN) (OUT)
1) Connect oil pressure gauge (1) of hydraulic 1) Connect hydraulic tester H2 to oil pressure
tester H1 to oil pressure measurement nip- measurement nipple (2).
ple (1). ★ Use a 0.98 MPa {10 kg/cm2} oil pressure
★ Use a 2.5 MPa {25 kg/cm2} oil pressure gauge.
gauge.
2) Start the engine and set all the functions of

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

4) After completing the measurement, remove the measuring equipment and set to the orig-
the measuring equipment and set to the original condition.
inal condition.
20-124 D375A-5
1
3. Measuring torque converter lock-up clutch 3) Set the parking brake lever in the FREE po-
pressure (LU) sition and turn the lock-up mode switch ON.
1) Connect oil pressure gauge 1 of hydraulic 4) Set the PCCS lever direction to F and the
tester H1 to oil pressure measurement nip- speed to the 1st, and rotate the transmission
ple (3). under no load.
★ Use a 2.5 MPa {25 kg/cm2} oil pressure 5) Gradually raise the engine speed, and mea-
gauge. sure the oil pressure when the lock-up pilot
lamp lights up.
2) Start the engine and set the monitor panel in

the "Adjustment mode" and disengage both 6) After completing the measurement, remove
steering clutches. the measuring equipment and set to the orig-
★ For the operating method, see "Special inal condition.
functions of monitor panel (EMMS)".
★ Adjustment code: Co (Disengagement of
both steering clutches)
★ The transmission speed is displayed on
the service meter display section (Unit: 1
rpm).
D375A-5 20-125
1
(5)
4. Measuring torque converter stator clutch 5. Measuring transmission main relief pressure
pressure (SC) (TM)
1) Connect oil pressure gauge 1 of hydraulic 1) Connect oil pressure gauge 1 of hydraulic
tester H1 to oil pressure measurement nip- tester H1 to oil pressure measurement nip-
ple (4). ple (5).
★ Use a 5.8 MPa {60 kg/cm2} oil pressure ★ Use a 5.8 MPa {60 kg/cm2} oil pressure
gauge. gauge.
2) Start the engine and set all the functions of 2) Start the engine and set all the functions of
the PCCS lever to neutral. the PCCS lever to neutral.
3) Measure the oil pressure with the engine at 3) Measure the oil pressure with the engine at
low idling and high idling. low idling and high idling.
4) After completing the measurement, remove 4) After completing the measurement, remove
the measuring equipment and set to the orig- the measuring equipment and set to the orig-
inal condition. inal condition.
20-126 D375A-5
1
6. Measuring transmission F clutch pressure 7. Measuring transmission R clutch pressure

(FWD) (R)
1) Connect oil pressure gauge of hydraulic 1) Connect oil pressure gauge of hydraulic
ple (6). ple (7).
gauge. gauge.
2) Start the engine and set the monitor panel in 2) Start the engine and set the monitor panel in
the "Adjustment mode" and disengage both the "Adjustment mode" and disengage both
steering clutches. steering clutches.
★ For the display on the panel, see "5. ★ For the display on the panel, see "5.
Measuring torque converter lock-up Measuring torque converter lock-up
clutch pressure (LU)". clutch pressure (LU)".
★ Adjustment code: Co (Disengagement of ★ Adjustment code: Co (Disengagement of
both steering clutches) both steering clutches)
3) Set the parking brake lever in the FREE po- 3) Set the parking brake lever in the FREE po-
sition. sition.
4) Keep pressing the brake pedal, set the 4) Keep pressing the brake pedal, set the
PCCS lever direction to F and the speed to PCCS lever direction to R and the speed to
the 3rd, and rotate the transmission under no the 3rd, and rotate the transmission under no
load. load.
5) Measure the oil pressure at low idling. 5) Measure the oil pressure at low idling.
D375A-5 20-127

1
8. Measuring transmission 1st clutch pressure 9. Measuring transmission 2nd clutch pressure
(1ST) (2ND)
ple (8). ple (9).
gauge. gauge.
2) Start the engine and set the monitor panel in 2) Start the engine and set the monitor panel in
the "Adjustment mode" and disengage both the "Adjustment mode" and disengage both
steering clutches. steering clutches.
★ For the display on the panel, see "5. ★ For the display on the panel, see "5.
Measuring torque converter lock-up Measuring torque converter lock-up
clutch pressure (LU)". clutch pressure (LU)".
★ Adjustment code: Co (Disengagement of ★ Adjustment code: Co (Disengagement of
both steering clutches) both steering clutches)
3) Set the parking brake lever in the FREE po- 3) Set the parking brake lever in the FREE po-
sition. sition.
4) Keep pressing the brake pedal, set the 4) Keep pressing the brake pedal, set the
PCCS lever direction to F and the speed to PCCS lever direction to F and the speed to
the 1st, and rotate the transmission under no the 2nd, and rotate the transmission under
load. no load.
5) Measure the oil pressure at low idling. 5) Measure the oil pressure at low idling.
20-128 D375A-5

1
10. Measuring transmission 3rd clutch pressure 11. Measuring left steering clutch pressure (LC)
(3RD) 1) Connect oil pressure gauge of hydraulic
1) Connect oil pressure gauge of hydraulic tester H1 to oil pressure measurement nip-
tester H1 to oil pressure measurement nipple (11).
gauge.
2) Start the engine and set the parking lever to

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

inal condition.

inal condition.
D375A-5 20-129

1
12. Measuring left steering brake pressure (LB) 13. Measuring right steering clutch pressure (RC)
tester H1 to oil pressure measurement nipple tester H1 to oil pressure measurement nipple
(12). (13).
gauge. gauge.
2) Start the engine and set the parking lever to 2) Start the engine and set the parking lever to
the FREE position. the FREE position.
3) Measure the oil pressure with the engine at 3) Operate the PCCS lever steering fully to the
low idling and high idling. right.
★ Check that the oil pressure becomes 0 ★ Set the direction to the neutral position.
when the PCCS lever steering is operat- 4) Measure the oil pressure with the engine at
ed fully to the left. low idling and high idling.
★ Check that the oil pressure becomes 0 ★ Check that the oil pressure becomes 0
when the brake pedal is depressed or the when the PCCS lever steering is returned
parking lever is operated to the LOCK po- to neutral.
sition.

4) After completing the measurement, remove the measuring equipment and set to the orig-
the measuring equipment and set to the original condition.
inal condition.
20-130 D375A-5
1
14. Measuring right steering brake pressure (RB) 15. Measuring transmission lubrication pressure
1) Connect oil pressure gauge 1 of hydraulic 1) Connect hydraulic tester H2 to oil pressure
tester H1 to oil pressure measurement nip- measurement nipple (15).
gauge.
2) Start the engine and measure the oil pres-

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

inal condition.

inal condition.
D375A-5 20-131
1
MEASURING POWER TRAIN OIL PRESSURE

16. Measuring output pressure of sudden stop
prevention valve
1) Connect oil pressure gauge 1 of hydraulic
tester H1 to oil pressure pickup nipples (12)
and (14).
a Use the oil pressure gauge of 5.9 MPa
{60 kg/cm2}.
• (12): For steering left brake
• (14): For steering right brake
3) Set the parking brake lever in the FREE po-

sition and set the PCCS lever in the ALL
NEUTRAL position.
4) Run the engine at low idling and measure
the oil pressure.
a If the output pressure of the sudden stop
prevention valve is as follows, it is nor-
mal.
• 1.13 – 1.57 MPa {11.5 – 16.0 kg/cm2}
2) Start the engine, set the monitor panel in the
ADJUSTMENT MODE, and set the sudden
stop prevention valve in the operation mode.
a For the operating method, see SPECIAL
FUNCTIONS OF MONITOR PANEL
(EMMS).
a Adjustment code:
b5 (Operation mode of sudden stop
prevention valve)
a The voltage of the brake pedal potenti-
ometer is displayed on the service meter
display section (in 1 mV).
5) After finishing measurement, remove the

measuring instruments and return the re-
moved parts.
20-131-1 D375A-5
(5)
ADJUSTING TRANSMISSION SPEED SENSOR
TESTING AND ADJUSTING SIMPLE PROCEDURE FOR TESTING
ADJUSTING BRAKE SPEED
TRANSMISSION PERFORMANCE
SENSOR
ADJUSTING TRANSMISSION SIMPLE PROCEDURE FOR

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

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

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

raise the engine speed to high idling. Check that
the machine does not start to move.
¤ The torque converter is stalled, so keep the
brake pedal depressed firmly during the op-
eration. For safety reasons, always keep
your right foot on the decelerator pedal until
the completion of the measurement opera-
tion.
5. After completing the adjustment, switch the mon-
itor panel to the monitoring mode display, and
check that the transmission speed is displayed
normally.
★ For details of the method of operation, see
SPECIAL FUNCTIONS OF MONITOR PAN-
EL (EMMS).
★ Monitoring code: 70 (Transmission speed)
20-132 D375A-5
4
1
TESTING AND ADJUSTING ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER
ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER

Adjusting brake pedal
Adjusting parking lever
D375A-5 20-133
1
(5)
Adjusting brake pedal 5. Initial setting of brake potentiometer

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

1) Start the engine and set the monitor panel in
the ADJUSTMENT MODE.
★ For the operating method, see SPECIAL
(EMMS).
★ Adjustment code:
bL (Brake release mode)
2) With the parking brake lever in the FREE po-
sition, press the brake pedal and check that
the brake oil pressures on both sides be-
come 0.
★ For the measuring points of the brake oil
pressure, see MEASURING POWER
TRAIN OIL PRESSURE.
20-134 D375A-5
1
(5)
ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER

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

1) Turn the starting switch ON and set the mon-
itor panel in the MONITORING MODE.
(EMMS).
• Monitoring code:
L9 (Steering controller switch input 1)
2) Set the parking brake lever in the FREE po-
sition and LOCK position and check that the
limit switch signals are input normally at the
respective positions.
D375A-5 20-134-1
(5)
TESTING AND ADJUSTING ADJUSTING POSITION OF PCCS LEVER CONSOLE
ADJUSTING POSITION OF PCCS LEVER CONSOLE
1. Set operator’s seat (1) facing the front (dozing

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

to operator’s seat (1).
★ If it is not parallel, adjust installed dimension
a of rod (3).
• Standard installed dimension a: 179 mm
★ The locknut at the rear of the turnbuckle has
a left-handed thread (reverse thread)
D375A-5 20-135

1
EMERGENCY ESCAPE METHOD WHEN THERE IS FAILURE IN POWER
TESTING AND ADJUSTING TRAIN
EMERGENCY ESCAPE METHOD WHEN THERE IS FAILURE IN

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

(using K1)
★ If a problem occurs in the electrical system of
the power train control (direction, speed,
steering) and the machine does not move,
carry out the emergency escape as follows.
★ With this procedure, it is necessary to be 3) Disconnect the neutral safety relay (NSF) in-
able to start the engine. If the engine will not side the fuse room, then connect pin and
start, see EMERGENCY ESCAPE METH- pin of the connector at the wiring harness
OD USING BRAKE RELEASE DEVICE. end directly.
1) Connect switch assembly
and resistor ★ With this operation, the neutral safety re-
to wiring harness of emergency escape lay or transmission controller will not
¤
device K1. work, so carry out this operation only if

¤
Resistor controls the drive voltage of the engine will not start electrically.
the solenoid, so connect it before con- With this method, if the engine starts, the
necting the wiring harness to the ma- neutral safety relay function will not
¤
chine. work, so before starting the engine, set
In order to prevent mistaken actuation, the parking lever to the LOCK position
set all the speed range switches of and all the PCCS lever functions to the

¤
switch assembly to the OFF position neutral position.
and the directional switch to the P posi- With this method, start the engine only
tion. when carrying out the emergency es-
cape. In all other cases when the engine
does not start, always carry out trouble-
shooting and repair the cause.
2) Open the inspection cover on the left fender

and connect wiring harness
to PL1 con-
nector (1) and PL2 connector (2).
• PL1 connector (1): Connect to male and 4) Start the engine and set the parking lever to
female ends the FREE position.
• PL2 connector (2): Connect to male end 5) Operate switch assembly and move the
★ The female end of connector PL2 re- machine to a safe place.
mains disconnected, so cover it with vi- ★ The speed switch has an electric circuit
nyl. that gives priority to operation of the low
speed switch.
20-136 D375A-5

1
EMERGENCY ESCAPE METHOD WHEN THERE IS FAILURE IN POWER
TESTING AND ADJUSTING TRAIN
4) Connect the hose at the tip of pump assem-

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

tank, then disconnect supply hose (3) of the
pin-puller solenoid valve.
D375A-5 20-137
4
1
ADJUSTING IDLER CLEARANCE
TESTING AND ADJUSTING CHECKING WEAR OF SPROCKET
ADJUSTING IDLER CHECKING WEAR OF

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

and reduce shim (2) to adjust.
• Standard clearance a on one side: 0 - 0.5
mm
• Types of shim thickness: 0.5 mm, 1.0 mm

★ When the machine is new, 10 mm thickness
of shim is installed on each side.
★ When adjusting, reduce the shim thickness
uniformly on the inside and outside.
Mounting bolt:
824 - 1030 Nm {84 - 105 kgm}
20-138 D375A-5

1
TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING TRACK SHOE TENSION

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

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

Loosen plug (3) and release some of the grease.
¤ There is danger that the plug may fly out un-
der the high internal pressure of the grease,
so never loosen the plug more than 1 turn.
3 Plug: 59 - 88 Nm {6 - 9 kgm}
D375A-5 20-139
1
TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE
2. Measuring center pump relief pressure 4) Run the engine at low idling and high idling
1) Remove work equipment small pump pres- and operate the blade lever or ripper lever to
sure sensor (10). relieve each cylinder circuit. Measure the oil
pressure at this time.
2) Install adapter Q2, nipple 1 of hydraulic

tester Q1, and pressure sensor (10), and 5) After finishing measurement, remove the
connect them to oil pressure gauge 2. measuring instruments and return the re-
★ Use the oil pressure gauge of 39.2 MPa moved parts.
{400 kg/cm2}.
3) Start the engine and reset the safety lock le-

ver.
D375A-5 20-141
1
(5)
TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE

Measuring (Measuring with monitor panel) 3) Start the engine and reset the safety lock le-
a Meaure the work equipment oil pressure under ver.
the following condition. 4) Run the engine at low idling and high idling
• Hydraulic oil temperature: 45 – 55ºC and operate the blade lever to relieve the
blade lift cylinder circuit. Measure the oil
1. Measuring front pump relief pressure pressure at this time.
1) Disconnect the blade lift cylinder hoses from
the cylinder and block the control valve side.
• Flange for blocking:
07379-01260 (4 pieces)
a Stop the cylinder side, too, with cork
stoppers, etc.
2) Start the engine, set the monitor panel in the
MONITORING MODE, and prepare for mea-
suring the oil pressure.
(EMMS).
HL (Work equipment large pump oil
pressure)
a The oil pressure is displayed on the ser-
vice meter display section in 1 kg/cm2.
20-141-1 D375A-5
(5)
2. Measuring center pump relief oil pressure Adjusting

1) Start the engine, switch the monitor panel to
the monitoring mode display, and prepare to 1. Adjusting front pump relief pressure
measure the oil pressure. a If the front pump relief pressure is not cor-
a For details of the method of operation, rect, adjust main relief valve (1) of the blade
see SPECIAL FUNCTIONS OF MONI- lift valve as follows.
TOR PANEL (EMMS).
H5 (Center pump oil pressure)
a The oil pressure is displayed on the ser-
vice meter display section in 1 kg/cm2.
1) Remove the right side cover.

2) Remove cover (2).
3) Loosen locknut (3), then turn adjustment
screw (4) to adjust.
a Turn the adjustment screw as follows.
• To INCREASE pressure, turn CLOCK-
WISE
• To DECREASE pressure, turn COUN-
TERCLOCKWISE
a Amount of adjustment for one turn of ad-
justment screw:
3 Locknut :
Approx. 2.43 MPa (approx. 24.8 kg/cm2)
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
3 Cover:
4) Install cover (2).
29.4 – 39.2 Nm {3 – 4 kgm}
2) Start the engine and reset the safety lock le-

ver.
3) Run the engine at low idling and high idling
and operate the blade lever or ripper lever to
relieve each cylinder circuit. Measure the oil
pressure at this time.
5) After completion of the adjustment, repeat

the above procedure to check the oil pres-
sure again.
D375A-5 20-141-2
(5)
2. Adjusting center pump relief pressure 5) After completion of the adjustment, repeat
★ If the center pump relief pressure are not the above procedure to check the oil pres-
correct, adjust main relief valve (5) of the sure again.
blade tilt and ripper Lo valve as follows.
1) Remove the right side cover.

★ Turn the adjustment screw as follows.
• To INCREASE pressure, turn CLOCK-
WISE
• To DECREASE pressure, turn COUN-
TERCLOCKWISE
★ Amount of adjustment for one turn of ad-
justment screw: Approx. 2.43 MPa (ap-
prox. 24.8 kg/cm2)
4) Install cover (6).
3 Cover: 29.4 - 39.2 Nm {3 - 4 kgm}
20-142 D375A-5
1
(5)
TESTING AND ADJUSTING TESTING AND ADJUSTING CONTROL CIRCUIT MAIN PRESSURE
Adjusting
★ If the control circuit main pressure is not correct,
adjust charge relief valve (2) as follows.

★ Turn the adjustment screw as follows.
• To INCREASE pressure, turn
CLOCKWISE
• To DECREASE pressure, turn
COUNTERCLOCKWISE
★ Amount of adjustment for one turn of ad-
justment screw: 0.77 MPa (7.8 kg/cm2)
3 Locknut:
54 - 74 Nm (5.5 - 7.5 kgm}
2) After completion of the adjustment, repeat

the above procedure to check the oil pres-
sure again.
20-144 D375A-5
1
(5)
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE
20-146 D375A-5
1
TESTING AND ADJUSTING ADJUSTING PLAY OF PPC VALVE
ADJUSTING PLAY OF PPC VALVE

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

the amount of play.
★ When doing this, do not make the piston
move.
3. Secure disc (3) in position and tighten locknut

(2).
3 Locknut: 98 - 127 Nm {10 - 13 kgm}
4. Install boot (1).
D375A-5 20-147
1
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND
TESTING AND ADJUSTING RIPPER
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF

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

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

Extend the tilt cylinder rod fully, then push the packing, the speed of downward
the blade against the ground to raise the movement in the above operation will
right side of the chassis. become faster for the following rea-
sons.
1) When the work equipment is set to the posture
given above, (holding pressure applied to the
bottom end), oil will leak from the bottom end to
the head end. However, the volume at the head
end is smaller than at the bottom end (by an
amount proportional to the volume of the rod), so
if the oil flows in from the bottom end, the internal
pressure at the head end will rise.
2) If the internal pressure at the head end rises, a
balance will be made in proportion to this at a
certain pressure (this differs according to the
amount of leakage). When the pressure be-
3) Ripper lift cylinder comes balanced, the speed of downward move-
Push the ripper against the ground to raise ment becomes slower.
the rear of the chassis. 3) In this condition, if the lever is operated as shown
above, the circuit at the head end is connected to
the drain circuit (the bottom end is closed by a
check valve), and the oil at the head end flows to
the drain circuit. As a result, the balance is lost
and the speed of downward movement increas-
es.)
D375A-5 20-149
1
TESTING AND ADJUSTING MEASURING LEAKAGE INSIDE WORK EQUIPMENT CYLINDER
MEASURING LEAKAGE INSIDE WORK EQUIPMENT CYLINDER

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

inder and block the hose with an oil stopper plug.
★ Remove the cover when disconnecting the
blade tilt cylinder hose.
¤ Be careful not to disconnect the hose at the
bottom end.
20-150 D375A-5
1
(5)
RELEASING REMAINING PRESSURE IN WORK EQUIPMENT CYLINDERS
TESTING AND ADJUSTING BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS
RELEASING REMAINING BLEEDING AIR FROM WORK

PRESSURE IN WORK EQUIPMENT CYLINDERS
EQUIPMENT CYLINDERS ★ After removing or installing work equipment cyl-
inders or disconnecting and connecting hydrau-
★ When disconnecting the piping between the con-
lic piping, bleed the air from the circuit as follows.
trol valve and work equipment cylinder, first re-
lease the remaining pressure inside the circuit as
1. Start the engine and run at idling for about 5 min-
follows.
utes.
1. Loosen the oil filler cap slowly to release the
2. Run the engine at low idling, and extend and re-
pressure inside the hydraulic tank.
tract the cylinders 4 - 5 times.
★ Stop the piston rod about 100 mm before the
2. Set the safety lock lever to the FREE position,
end of the stroke. Never operate it to the re-
then operate the work equipment control levers
lief position.
to the front, rear, left, and right.
★ When the levers are operated 2 - 3 times, the
3. Run the engine at high idling and repeat the pro-
pressure inside the accumulator is fully re-
cedure in Step 2.
leased.
4. Run the engine at low idling and operate the cyl-
3. Start the engine, run at low idling for approx. 5
inder to the end of the stroke to relieve the cir-
seconds, then stop the engine.
cuit.
4. Repeat the operation in Steps 2 and 3 above 2 -
3 times.
D375A-5 20-151
1
TESTING AND ADJUSTING ADJUSTING RIPPER LEVER POSITION
ADJUSTING RIPPER LEVER POSITION
★ Use the following procedure to adjust the ripper 5) Loosen nut (3).
lever to the optimum position. 6) Turn knob (4) 180°.
★ It is possible to adjust the position of the ripper le- 7) Tighten nut (3) to hold knob (4) in position.
ver within a range of ± 40 mm to the front and rear
of the center of the lever shaft.
1. Adjusting within range of 40 mm from center to

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

front
1) Loosen lock bolt (1).
2) Remove lever (2) and turn it 180°.
3) Install lever (2) to lever (5), then set it to the
optimum position.
4) Tighten lock bolt (1) to hold lever (2) in posi-
tion.
20-152 D375A-5

1
TESTING AND ADJUSTING ADJUSTING BLADE
ADJUSTING BLADE
★ If the blade has been removed or disassembled, 2) Use shims to adjust the clearance at lift por-
adjust as follows. tion (2).
1. Procedure for adjusting with shims when as- Adjust- Standard

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

spherical portion in the axial direction
is within 1 mm. Check that the ball ro-
tates smoothly.
20-154 D375A-5

1
TESTING AND ADJUSTING ADJUSTING BLADE
3) Use shims to adjust the clearance at trunnion

portion (3) (shim adjustment type).
Adjust- Standard
Standard
ment loca- Clearance shim
clearance
tion thickness
1.56±0.65mm
3 c Total clear- 12mm
ance
2. Adjusting blade tilt

1) Adjust installation dimension d of brace (4)
with the handle.
• Installation dimension d of brace (3):
1554 mm
2) Measure left and right tilt e1 and e2.
• Right tilt e1: Approx. 700 mm
• Left tilt e2: Approx. 700 mm
3) If the tilt is not the same on the left and right
sides, adjust installation dimension d of
brace (4) as follows to give the same tilt on
both sides.
• e1 > e2: Carry out fine adjustment to
make installation dimension d longer
• e1 < e2: Carry out fine adjustment to
make installation dimension d shorter
D375A-5 20-155
1
ADJUSTMENT OF PCCS LEVER POTENTIOMETERS

When adjusting the lever assembly
independently X kΩ
1. Position lever in “NEUTRAL (both forward & re-
verse, steering)”
5 V pin and signal pin. (See table 1).
(ex. For ST1, measure resistance between pins
A (5 V) and H (SIG))
signal pin and GND pin. (See table 1).
(ex. For ST1, measure between pins H (SIG) and
G (GND))
4. Adjust resistance to be X = Y (tolerance: X – Y ≤
0.04 kΩ) by slightly turning the potentiometer Y kΩ
body.
(Loosen screws (1) before adjusting)
5. Secure the potentiometer in place by tightening
screw (1).
Table 1
PIN No.
POTENTIOMETER No.
5V SIG GND
1 ST1 A H G
2 ST2 M E F
3 FR3 L K J
4 FR4 O P Q
20-155-1 D375A-5
4
D375A-5 20-155-2
4
TESTING AND ADJUSTING CHECKING THE ADJUSTMENT OF PCCS LEVER
CHECKING THE ADJUSTMENT OF PCCS LEVER

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

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

power source.
2. Screw 6. Controller
B. Wiring connection of adjustment for external
3. PCCS lever 7. Machine power source
power source.
4. Tester 8. External power source (5 V)
20-155-3 D375A-5
4
DISASSEMBLY AND ASSEMBLY OF PCCS LEVER

DISASSEMBLY
1. Open armrest and remove screws (1) (4 places/
hexagon socket head).
2. Remove armrest & box assembly.
3. Remove screws (3).
D375A-5 20-155-4
4
5. Remove screws (5) (6 places).
6. Sling cover (6) and disconnect wiring for fuel dial.
7. Peel boot, remove bolts (7) (4 places/hexagon

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

(11).
9. Loosen screw (9), then adjust voltage by turning
potentiometer (10) slightly.
ASSEMBLY
• For assembly, procedure in reverse order.
20-155-5 D375A-5
4
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Special functions are displayed Special functions control portion 1 Special functions control portion 2
portion (basic control) (switch control)
1. Speed range display portion 3. Service switch 6. Slow reverse mode switch
2. Service meter display portion 4. Buzzer cancel switch 7. SSC (Shoe Slip Control) switch
5. Economy mode switch 8. Bedrock selection switch
9. Auto shift down switch
10. Shift up switch
11. Shift down switch
★ EMMS: Equipment Management Monitoring System
20-156 D375A-5
1
(5)
OPERATION AND DISPLAY OF OPERA-

TOR MODE (OUTLINE)
★ This section gives only an outline of the operator
mode.
For details of each function and mode and the
method of operation, see the Operation and
Maintenance Manual.
1. Normal display (default)

When the condition of the machine is normal, the
monitor panel displays the following information.
Speed range display (1):
• Left side: Direction (P, N, F, R)
• Right side: Speed range (1, 2, 3)
• Bottom: Shift mode (!lamp)
• Graphics: Engine speed
Service meter display (2):
• Service meter (in units of 0.1h)
2. User code display function

If an abnormality occurs during operation and it
is necessary to inform the operator, the user
code and service meter are displayed in turn in
service meter display (2).
If the user code indicates a serious problem, the
warning lamp flashes and the alarm buzzer
sounds at the same time.
<Reference>
The user code is displayed only when a serious
problem occurs.
There are cases when an abnormality occurs
and the user code is not displayed, so if you feel
there is in the problem, always check for a ser-
vice code display on the service code display
function of the service mode.
20-158 D375A-5
1
(5)
Table of user codes
Method of displaying abnor-

User code Nature of abnormality Action recommended to operator
mality
• Only user code is displayed • Torque converter does not lock up • Automatic functions stop or some
• Blade dual tilt does not work functions stop, but operation is possi-
E01 ble
• Please contact your Komatsu distrib-
utor for repairs
• User code is displayed • Does not shift up or down • Engine stops but it is possible to start
• Warning lamp flashes • Blade pitch does not work it again and carry out operations
• Alarm buzzer sounds without limit. However, care must be
E02
taken by user
• Please contact your Komatsu distrib-
utor for repairs
• User code is displayed • Abnormality in engine water temper- • Move to a safe place
• Warning lamp flashes ature sensor • Please contact your Komatsu distrib-
• Alarm buzzer sounds • Available speed ranges are limited utor for repairs
CALL 03 • Engine does not rise to full speed
• Excessive transmission shock
• Difficult to turn (steer)
• Excessive shock when braking
• User code is displayed • Engine control impossible • Stop machine immediately
CALL • Warning lamp flashes • Travel impossible • Please contact your Komatsu distrib-
• Alarm buzzer sounds • Machine stops utor for repairs
D375A-5 20-159
1
OPERATION AND DISPLAY OF SERVICE

MODE
Method of switching to service mode
★ When using the service mode, carry out the fol-
lowing special operation to switch the screen dis-
play.
1) Special operation of switches

Set service switch (3) to the ON position, then
hold buzzer cancel switch (4) at the ON position
for at least 7 seconds.
★ The mode displayed on the panel differs ac-
cording to the selection position of the econ-
omy mode switch (see next section).
2) Selecting mode to use

After switching to the service mode, operate the
following switches to switch to the mode to be
used.
• Economy mode switch (5)
Econo- F1-R2 F2-R2

Mode
my mode lamp lamp
OFF Monitoring mode !
1 Adjustment mode ! !
2 Service code display mode
★ When switching to each mode, the shift

mode display lamp lights up or goes out to in-
dicate which mode is now being used.
★ The economy mode switch can be set to the
position to be used before switching to the
service mode.
★ The diagram on the right shows the initial
screen when the economy mode switch is
OFF and the monitoring mode has been se-
lected.
3) Finishing mode, function

When the service switch is turned OFF, the
mode or function can be finished regardless of
the mode or level being operated.
20-160 D375A-5
1
(5)
3. Monitoring mode
In the monitoring mode, it is possible to check
the condition of various parts of the machine on
the monitor panel according to the signals from
the sensors installed to various parts of the ma-
chine.
1) Selecting mode
Switch to the service mode and select the moni-
toring mode with the economy mode switch.
• Economy mode switch (5): OFF
2) Content of display
In the monitoring mode, the following information
is displayed on the monitor panel.
• Speed range display (1): Monitoring code
• Service meter display (2): Monitoring data
★ For details of the code and data, see TABLE
OF MONITORING MODES.
3) Method of selecting monitoring code

★ There are the following three methods of se-
lecting the monitoring code, so operate the
mode that is easiest to use.
i) Method of scrolling code forward or in re-
verse
The monitoring codes are in the internally
set order.
If the following switches are operated, the
codes are scrolled forward or in reverse in
the internally set order, so scroll to the code
to be selected.
• Slow reverse mode switch (6): Scroll for-
ward
• Buzzer cancel switch (4): Scroll in re-
verse
★ When the system is switched to the mon-
itoring mode, the 1st code is displayed.
★ For details of the order of the codes, see
TABLE OF MONITORING MODES.
D375A-5 20-161
1
(5)
ii) Method of block jump + scrolling forward and

in reverse
The monitoring codes are divided into 5
blocks internally according to the type of da-
ta.
screen will jump to the 1st code of each
block, so scroll forward or in reverse to select
the code from the lock.
• SSC switch (7): Go to next block
★ When the system is switched to the mon-
itoring mode, block 1 is displayed.
★ The blocks jump in the following order
(for details, see TABLE OF MONITOR-
ING CODES).
1 Steering system 38 items

2 Transmission system 27 items
3 Work equipment system 13 items
4 Engine system 9 items
5 Monitor panel system 15 items
iii) Method of inputting code

The monitoring codes are set internally as 2-
digit alphanumerical codes.
codes in the speed range display (left, right)
change, so input the code to be used.
• Bedrock selection switch (8)
Left switch: Left code changes
Right switch: Right code changes
★ The left and right codes change in the
following order according to the opera-
tion of the switches (letters which are not
used for any code are jumped).
9→A→b→C→d→E→F→H→J→L→N→
o→P→R→U→0→1→2→3→4→5→6→
7→8→9
20-162 D375A-5
1
(5)
4) Hold function for monitoring data

For data such as the engine speed, which is not
stable during monitoring, if it is difficult to read
the screen display, operate the following switch
to hold the data or cancel the hold.
The switch for holding or canceling the hold acts
as a toggle switch to switch ON or OFF.
• Auto shift down switch (9):
Switches between HOLD and CANCEL HOLD
5) When operating machine with monitoring mode

still displayed
If it is necessary to move the work equipment or
travel with the monitoring mode still displayed,
do as follows.
i) Method of operating work equipment:
Use auto shift down switch (9) to switch
the existing condition.
★ The auto shift down switch acts as both
the holder function and work equipment
operation function, so be careful when
operating it.
★ Service meter display (2) continues to
display the monitoring data, and speed
range display (1) returns to the normal
display.
★ While the machine is being operated, the
monitoring code cannot be changed, so
if it is necessary to change the code, re-
turn first to the monitoring mode.
ii) Method of returning to monitoring mode:
Operate the parking lever to the LOCK posi-
tion and hold buzzer cancel switch (4) at the
ON position for at least 1 sec.
D375A-5 20-163
1
(5)
Table of monitoring modes

Order Code Content of display Unit Controller
1 Steering system
1 99 Engine speed rpm Steering controller
2 91 Value of voltage for engine speed sensor mV Steering controller
3 7o Transmission speed rpm Steering controller
4 93 Value of voltage for transmission speed sensor mV Steering controller
5 7R Torque converter speed rpm Steering controller
6 95 Value of voltage for torque converter speed sensor mV Steering controller
7 bA Battery voltage value mV Steering controller
8 L1 Value of voltage for steering potentiometer 1 mV Steering controller
9 L2 Value of voltage for steering potentiometer 2 mV Steering controller
10 L7 Value of voltage for brake potentiometer mV Steering controller
11 A6 Tilt angle 0.001° Steering controller
12 A8 Value of voltage for tilt angle sensor mV Steering controller
13 F5 Fuel control dial command speed rpm Steering controller
14 F6 Value of voltage for fuel control dial mV Steering controller
15 d5 Deceleration potentiometer command speed rpm Steering controller
16 d6 Value of voltage for deceleration potentiometer mV Steering controller
17 A5 Value of voltage for acceleration sensor mV Steering controller
18 5U SSC command speed rpm Steering controller
19 5d Value of voltage for engine command mV Steering controller
20 L9 Steering controller switch input 1 (bit) Steering controller
21 LE Steering controller switch input 2 (bit) Steering controller
22 LL Steering controller oil pressure switch input 3 (bit) Steering controller
23 CE Steering controller HPI input 4 (bit) Steering controller
24 LF Steering controller switch input 5 (bit) Steering controller
25 LJ Steering controller switch input 6 (bit) Steering controller
26 7b Steering fill switch input (bit) Steering controller
27 P1 Value of voltage for left brake ECMV output command mA Steering controller
28 c1 Value of voltage for left brake ECMV output FB mA Steering controller
29 P2 Value of voltage for right brake ECMV output command mA Steering controller
30 c2 Value of voltage for right brake ECMV output FB mA Steering controller
31 P3 Value of voltage for left clutch ECMV output command mA Steering controller
32 c3 Value of voltage for left clutch ECMV output FB mA Steering controller
33 P4 Value of voltage for right clutch ECMV output command mA Steering controller
34 c4 Value of voltage for right clutch ECMV output FB mA Steering controller
35 58 Steering controller output (bit) Steering controller
36 d5 Value of voltage for sudden stop prevention solenoid drive mV Steering controller
37 d8 Value of voltage for engine controller relay drive mV Steering controller
38 dA Value of voltage for battery relay drive mV Steering controller
: Code for PCCS lever potentiometers.
20-164 D375A-5
(7)
1

2 Transmission system
39 3E Engine speed rpm Transmission controller
40 92 Value of voltage for engine speed sensor mV Transmission controller
41 7P Transmission speed rpm Transmission controller
42 94 Value of voltage for transmission speed sensor mV Transmission controller
43 A7 Tilt angle 0.001° Transmission controller
44 A9 Value of voltage for tilt angle sensor mV Transmission controller
45 L3 Value of voltage for directional potentiometer 1 mV Transmission controller
46 L4 Value of voltage for directional potentiometer 2 mV Transmission controller
47 L5 Transmission controller switch input 1 (bit) Transmission controller
48 L8 Transmission controller switch input 2 (bit) Transmission controller
49 7H Transmission fill switch input (bit) Transmission controller
50 P5 Value of voltage for FORWARD clutch ECMV (E-POCV) output command mA Transmission controller
51 c5 Value of voltage for FORWARD clutch ECMV (E-POCV) output FB mA Transmission controller
52 P6 Value of voltage for REVERSE clutch ECMV (E-POCV) output command mA Transmission controller
53 c6 Value of voltage for REVERSE clutch ECMV output FB mA Transmission controller
54 P7 Value of voltage for 1st clutch ECMV output command mA Transmission controller
55 c7 Value of voltage for 1st clutch ECMV output FB mA Transmission controller
56 P8 Value of voltage for 2nd clutch ECMV output command mA Transmission controller
57 c8 Value of voltage for 2nd clutch ECMV output FB mA Transmission controller
58 P9 Value of voltage for 3rd clutch ECMV output command mA Transmission controller
59 c9 Value of voltage for 3rd clutch ECMV output FB mA Transmission controller
60 Ld Transmission controller output (bit) Transmission controller
61 dL Value of voltage for lock-up solenoid drive mV Transmission controller
62 db Value of voltage for back-up alarm relay drive mV Transmission controller
63 dN Value of voltage for neutral safety relay drive mV Transmission controller
64 d1 (Not used) — —
65 d2 (Not used) — —
3 Work equipment system
66 bd Blade lever knob switch input (bit) Transmission controller
67 bH Blade lever oil pressure switch input (bit) Transmission controller
68 57 Transmission controller toggle switch input (bit) Transmission controller
2
69 HL Front pump oil pressure kg/cm Transmission controller
70 4L Value of voltage for front pump oil pressure sensor mV Transmission controller
2
71 H5 Center pump oil pressure kg/cm Transmission controller
72 45 Value of voltage for center pump oil pressure sensor mV Transmission controller
73 56 Transmission controller solenoid drive status (bit) Transmission controller
74 d3 Value of voltage for blade pitch solenoid drive mV Transmission controller
75 d4 Value of voltage for blade dual solenoid drive mV Transmission controller
: Code for PCCS lever potentiometers.
D375A-5 20-165
(7)
1

76 Fc (Not used) — —
77 FF (Not used) — —
78 R7 Ripper lever oil pressure switch input (bit) Transmission controller
4 Engine system
79 60 Deceleration pedal speed rpm Engine controller
80 61 Engine No. 2 throttle speed rpm Engine controller
81 62 Engine speed rpm Engine controller
82 63 Engine water temperature °C Engine controller
83 64 (Not used) — —
84 65 Engine oil pressure kPa Engine controller
85 66 Fuel consumption ratio 0.1¬/h Engine controller
86 67 Fuel temperature °C Engine controller
87 68 Fuel consumption amount ¬ Engine controller
5 Monitor panel system
88 U2 Monitor panel (tachometer) program No. Numeral Monitor panel (tachometer)
89 U3 Transmission controller program No. Numeral Transmission controller
90 U4 Monitor panel (caution) program No. Numeral Monitor panel (caution)
91 U5 Steering controller program No. Numeral Steering controller
92 5N S-NET communication connection status (bit) Steering controller
93 78 (Not used) — Steering controller
94 77 Torque converter oil temperature °C Steering controller
95 FL Value of voltage for fuel level sensor mV Steering controller
96 Bu Travel speed (theoretical value) m/h Steering controller
97 FR Drawbar pull (theoretical value) m(F/W) Steering controller
98 C5 Steering status code HEX Steering controller
99 CF Fill condition setting variable HEX Steering controller
100 Cb Modulation condition setting variable HEX Steering controller
101 Cc Gearshift point setting variable HEX Steering controller
102 5F Slip flag (bit) Steering controller
★ Order for scrolling forward and in reverse when selecting code:

The monitoring code is scrolled forward and in reverse in the order shown in the table.
★ Jump function when selecting code:
If the jump function is used when selecting the code, the 1st code for eachblock ((1), 2, 3, 4, 5) is dis-
played.
★ Bit for units:
The ON-OFF input signal or output signal are items displayed on the special screen display.
(For details, see Details of bit display codes.)
20-166 D375A-5
1
Details of bit display codes

Example of bit data display:
• The bit data is displayed on service meter dis-
play (2) as [-] for OFF and [o] for ON.
• 135 show the bit OFF
• 246 show the bit ON
★ The item status given in this section shows the
conditions when the bit is ON.
L9: Steering controller switch input 1

1: (Not used)
2: (Not used)
3: (Not used)
4: (Not used)
5: Parking lever switch FREE
6: Parking lever switch LOCK
LE: Steering controller switch input 2

1: Buzzer cancel switch ON (operated)
2: (Not used)
3: (Not used)
4: (Not used)
5: Service switch ON
6: (Not used)
LL: Steering controller oil pressure switch input 3

1: (Not used)
2: (Not used)
3: (Not used)
4: Ripper RAISE oil pressure switch ON (operated)
5: Ripper LOWER oil pressure switch ON (operated)
6: Ripper TILT IN oil pressure switch ON (operated)
D375A-5 20-167
1
(5)
CE: Steering controller switch HPI input 4

1: Red lamp signal ON
2: Yellow lamp signal ON
3: Orange lamp signal ON
4: (Not used)
5: Engine oil pressure signal ON
6: Fuel temperature signal ON
LF: Steering controller switch input 5

1: Starting switch ACC signal ON
2: Turbo timer signal ON
3: Engine Li command signal ON
4: Motoring switch signal ON
5: N signal 1 ON
6: N signal 2 ON
LJ: Steering controller switch input 6

1: Preheating signal ON
2: Starting switch C signal ON
3: (Not used)
4: Night lighting signal ON
5: (Not used)
6: (Not used)
7b: Steering fill switch input

1: Left brake fill switch ON
2: Left clutch fill switch ON
3: (Not used)
4: (Not used)
5: Right clutch fill switch ON
6: Right brake fill switch ON
20-168 D375A-5
1
58: Steering controller output

: (Not used)
: (Not used)
: (Not used)
: Engine controller drive relay output: Output
: Battery relay drive output: Output
: Emergency stop prevention solenoid relay drive
output: Output
L5: Transmission controller switch input 1

: Shift up switch OFF
: Shift up switch ON
: Shift down switch OFF
: Shift down switch ON
: Parking lever switch FREE
: Parking lever switch LOCK
L8: Transmission controller switch input 2

: Auto shift down switch ON
: (Not used)
: (Not used)
: (Not used)
: Service switch ON
: (Not used)
7H: Transmission fill switch input

: F clutch fill switch ON
: R clutch fill switch ON
: 1st clutch fill switch ON
: 2nd clutch fill switch ON
: 3rd clutch fill switch ON
: (Not used)
D375A-5 20-169

1
Ld: Transmission controller output

: (Not used)
: (Not used)
: (Not used)
: Backup alarm relay drive output: Output
: Neutral safety relay drive output: Output
: Lock-up solenoid drive output: Output
bd: Blade lever knob switch input

: Blade lever tilt switch: Dual
: Blade lever tilt switch: Single
: Blade lever pitch switch OFF
: Blade lever pitch switch ON
: (Not used)
: (Not used)
bH: Blade lever oil pressure switch input

: (Not used)
: (Not used)
: (Not used)
: (Not used)
: Blade tilt left oil pressure switch ON (operated)
: Blade tilt right oil pressure switch ON (operated)
57: Transmission controller toggle switch input

: Auto shift down switch ON
: (Not used)
: (Not used)
: (Not used)
: (Not used)
: (Not used)
20-170 D375A-5

1
56: Transmission controller solenoid drive status

1: Dual selection solenoid drive output: Output
2: Pitch selection solenoid drive output: Output
3: (Not used)
4: (Not used)
5: (Not used)
6: (Not used)
R7: Ripper lever oil pressure switch input

1: (Not used)
2: Ripper RAISE oil pressure switch ON (operated)
3: Ripper LOWER oil pressure switch ON
(operated)
4: Ripper TILT IN oil pressure switch ON (operated)
5: Ripper TILT BACK oil pressure switch ON
(operated)
6: (Not used)
5N: S-NET communication connection

1: (Not used)
2: Monitor panel (tachometer) connected
3: Transmission controller connected
4: Monitor panel (caution) connected
5: Steering controller connected
6: (Not used)
5F: Slip flag

1: (Not used)
2: (Not used)
3: (Not used)
4: (Not used)
5: (Not used)
6: (Not used)
D375A-5 20-171
1
4. Adjustment mode
In the adjustment mode, it is possible to check
the status and carry out adjustment of the ma-
chine controller and various equipment.
1) Selecting mode
Switch to the service mode, then use the econo-
my mode switch to select the adjustment mode.
• Economy mode switch (5): 1
2) content of display
In the adjustment mode, the following informa-
tion is displayed on the monitor panel.
• Speed range display (1): Adjustment mode
• Service meter display (2): Related data
★ For details of the code and related data, see
TABLE OF ADJUSTMENT MODES AND
ADJUSTMENT PROCEDURE.
3) Selecting adjustment mode

In the adjustment mode, there is a fixed order for
the internal settings.
When the following switch is pressed, the code
will scroll forward in the order set internally, so
the code to use is displayed.
• Slow reverse mode switch (6): Scroll forward
★ for details of the order for the adjustment
mode, see TAB LE O F ADJUSTMENT
MODES AND ADJUSTMENT PROCE-
DURE.
★ The code cannot be scrolled in reverse, so if
you go past the code to be used, it is neces-
sary to continue scrolling forward for one cy-
cle, or to switch to another mode and then
enter the adjustment mode again.
4) Switches and buzzers used in adjustment mode

• Buzzer cancel switch (4): Confirmation func-
tion
• Auto shift down switch (9): Selection function
• Shift up switch (10): Increase value (oil pres-
sure only)
• Shift down switch (11): Decrease value (oil
pressure only)
★ When the confirmation operation of the
buzzer cancel switch is recognized, the
alarm buzzer will sound once.
20-172 D375A-5
1
(5)
1 AF: Transmission manual mode

• This code is the function to set the transmission
to the manual mode and to make it possible to
travel in 2nd or 3rd.
• The service meter display shows the travel
speed (unit: 0.01 km/h).
• Method of use
When this code is displayed, set the parking le-
ver to the FREE position and operate the shift up
switch or shift down switch. When this is done,
the speed range display will switch as follows to
make it possible to travel in 2nd or 3rd.
Screen display: N1 ↔ N2 ↔ N3
★ When this code is finished, the function be-
comes ineffective.
2 CH: (Not used)
20-174 D375A-5
1
(5)
3 Co: Both steering clutches released

• This code is the function to engage the transmis-
sion clutch without allowing the machine to move
when carrying out inspection, maintenance,
troubleshooting, or Pm clinic.
• The service meter display shows the transmis-
sion speed (unit: rpm).
• Method of use
The function is effective when this code is being
displayed. Both steering clutches are disen-
gaged, so the machine does not travel even if the
PCCS lever is operated.
comes ineffective.
4 5A: Specification code comparison

(steering controller)
¤ Always carry out this adjustment code if the
steering controller has been replaced. If the ad-
justment is not carried out, service code [E0151]
may be displayed and the system may not work
normally.
• This code carries out the initial setting of the
specification code recognized by the steering
controller. It also functions to format the set val-
ue in the memory inside the controller.
• The service meter display shows the specifica-
tion code in numerals.
• Method of adjustment
1) Hold the buzzer cancel switch for at least 1
sec. at the ON position and check that the
alarm buzzer sounds.
2) Check that the specification code display
changes from [202] to [222].
★ If [222] is not displayed for the specification
code, the controller wiring harness or con-
troller itself is probably defective
★ Even when this code is finished, the setting
remains effective.
D375A-5 20-175
1
(5)
5 7A: Specification code comparison (transmis-

sion controller)
transmission controller has been replaced. If the
adjustment is not carried out, service code
[E0486] may be displayed and the system may
not work normally.
• This code carries out the initial setting of the
specification code recognized by the transmis-
sion controller. It also functions to format the set
value in the memory inside the controller.
tion code in numerals.
2) Check that the specification code display
changes from [101] to [111].
★ If [111] is not displayed for the specification
code, the controller wiring harness or con-
troller itself is probably defective.
remains effective.
6 5C: Specification code comparison (machine

specification)
steering controller or transmission controller has
been replaced. If the adjustment is not carried
out, service code [E0151] may be displayed and
the system may not work normally.
• This code is the function to make the controller
forming the system recognize the machine spec-
ification.
tion code in letters.
1) Operate the auto shift down switch to the left
and right and display the specification code to
be set.
Specification
Machine specification
code
body00 Single tilt without SSC
body01 Single tilt with SSC
body10 Dual tilt without SSC
body11 Dual tilt with SSC

remains effective.
20-176 D375A-5
1
(5)
7 NA: Tilt angle sensor standard value setting

• This code is the function to adjust the 0 point of
the tilt angle sensor and to check the installation
tolerance.
• The service meter display shows the divergence
compared with the specified amount from the
neutral position in a voltage value (unit: mV).
★ Formatting of the existing data is carried out
with adjustment code [5C].
★ Carry out the adjustment with the machine
parked on flat ground.
2) Display the divergence compared with the
specified amount from the neutral position.
remains effective.
8 bP: Brake pedal standard position set

• This code is the function to adjust the neutral po-
sition of the brake pedal.
neutral position in a voltage value (unit: mV).
remains effective.
D375A-5 20-177
1
(5)
9 bL: Brake release mode

• This code is the function to assist the adjustment
of the parking lever cable or brake pedal rod when
the brake is released with the brake ECMV.
• If the brake oil pressure is measured in this con-
dition, it is possible to check the actuation status
of the brake valve.
• The service meter display shows the voltage val-
ue (unit: mV) of the brake pedal potentiometer.
• Method of use
When this code is displayed, the function be-
comes effective. The brake ECMV releases the
brake, so measure the brake oil pressure as nec-
essary (the brake oil pressure cannot be
checked on the monitor panel).
comes ineffective.
0 b5: Sudden stop prevention valve actuation

mode
• This code is the function to check the actuation
of the sudden stop prevention valve when the
output to the clutch ECMV, brake ECMV, and
sudden stop prevention solenoid valve is set to
0.
If the brake oil pressure is measured in this con-
dition, it is possible to check the actuation status
of the sudden stop prevention valve.
• The service meter display shows the voltage val-
ue (unit: mV) of the brake pedal potentiometer.
• Method of use
When this code is displayed, the function be-
comes effective. The clutch ECMV, brake ECMV,
and sudden stop prevention solenoid valve out-
put become 0, so measure the brake oil pressure
as necessary (the brake oil pressure cannot be
checked on the monitor panel).
comes ineffective.
20-178 D375A-5
(7)
1
A No: PCCS lever neutral position set

• This code is the function to adjust the neutral po-
sition of the PCCS lever in the turn (steering) di-
rection.
neutral position of the steering potentiometer in
a voltage value (unit: mV).
1) Set the PCCS lever to the neutral position in
the steering direction.
remains effective.
B NL: PCCS lever left max. position set

• This code is the function to adjust the maximum
left position of the PCCS lever in the turn (steer-
ing) direction.
maximum left position of the steering potentiom-
eter in a voltage value (unit: mV).
1) Operate the PCCS lever to the maximum left
position in the steering direction.
specified amount from the maximum left po-
sition.
remains effective.
D375A-5 20-179
1
(5)
C NR: PCCS lever right max. position set

• This code is the function to adjust the maximum
right position of the PCCS lever in the turn
(steering) direction.
maximum left position of the steering potentiom-
eter in a voltage value (unit: mV).
1) Operate the PCCS lever to the maximum
right position in the steering direction.
specified amount from the maximum right
position.
remains effective.
D PA: Brake automatic adjustment

• This code is the function to maintain the perfor-
mance of the brake control by automatically ad-
justing any changes in the performance caused
by variation or wear in the brake parts.
• The service meter display shows the brake com-
mand oil pressure (unit: 0.01 kg/cm2).
¤ With this adjustment, the machine moves ap-
prox. 1 - 2 m forward, so carry out the adjustment
on flat ground where it is possible to ensure safe-
ty in the surrounding area.
• Method of adjustment 1 (preparatory work)
★ Check that the torque converter oil tempera-
ture is in the operating range when carrying
out this adjustment.
1) Start the engine and select this code.
2) Set the parking lever to the FREE position.
3) Set the auto shift down switch to OFF
4) Run the engine at low idling.
5) Depress the brake pedal and decelerator
pedal to hold the machine.
20-180 D375A-5
1
(5)
6) Operate the PCCS lever direction to F and

the speed to 3.
★ Keep the steering at the neutral position.
7) Gradually release the decelerator pedal and
brake pedal and check that the machine
does not move.
¤ If the machine moves, there is an abnor-
mality, so stop the adjustment immedi-
ately.
★ If it is confirmed that the machine does
not move, go on to the following Method
of adjustment 2.
• Method of adjustment 2 (adjusting left clutch)
1) Operate the PCCS lever steering fully to the
left.
2) Check that the display for the tachometer
graphic and command oil pressure changes
automatically.
★ The tachometer graphic shows the
progress of the adjustment.
3) Drive the machine forward 1 - 2 m, then stop
the machine and check that the alarm buzzer
sounds.
4) Return the PCCS lever steering to the neu-
tral position.
★ After completing the adjustment of the
left clutch, go on to the following Method
of adjustment 3.
★ It is possible to check the compensation
value for the left brake oil pressure with
adjustment code [N1]
• Method of adjustment 3 (adjusting right brake)
right.
automatically.
3) Drive the machine forward 1 - 2 m, then stop
the machine and check that the alarm buzzer
sounds.
tral position.
value for the right brake oil pressure with
remains effective.
D375A-5 20-181
1
E N1: Left brake oil pressure offset

• This code is the function to adjust the left brake
oil pressure manually.
• The service meter display shows the offset oil
pressure (unit: 0.01 kg/cm2). (If it has already
been adjusted, the value is displayed, but if it is
within the permitted range, it is possible to adjust
further.).
★ The maximum permitted range for adjust-
ment is ± 3 kg/cm2 (display: 300).
1) Operate the shift up switch or shift down
switch and set the offset oil pressure.
• Shift up switch (10): Oil pressure increas-
es
• Shift down switch (11): Oil pressure in-
creases
★ The offset oil pressure changes 0.5 kg/
cm2 (display: 50) at a time.
remains effective.
F N2: Right brake oil pressure offset

• This code is the function to adjust the right brake
oil pressure manually.
further.).
ment is ± kg/cm2 (display: 300).
es
creases
remains effective.
20-182 D375A-5
1
(5)
G PE: Steering clutch automatic adjustment

• This code is the function to maintain the perfor-
mance of the steering control by automatically
adjusting any changes in the performance
caused by variation or wear in the steering clutch
parts.
• The service meter display shows the clutch com-
mand oil pressure (unit: 0.01kg/cm2).
• Method of adjustment 1 (preparatory work)
★ Check that the torque converter oil tempera-
ture is in the operating range when carrying
out this adjustment.
2) Set the parking lever to the FREE position.
3) Set the auto shift down switch to OFF
4) Run the engine at low idling.
5) Depress the brake pedal and decelerator
pedal to hold the machine.
the speed to 3.
★ Keep the steering at the neutral position.
7) Gradually release the decelerator pedal and
brake pedal and check that the machine
does not move.
¤ If the machine moves, there is an abnor-
mality, so stop the adjustment immedi-
ately.
★ If it is confirmed that the machine does
not move, go on to the following Method
of adjustment 2.
• Method of adjustment 2 (adjusting left clutch)
left.
automatically.
3) Raise the engine speed and check that the
tral position.
★ After completing the adjustment of the
left clutch, go on to the following Method
of adjustment 3.
value for the left clutch oil pressure with
D375A-5 20-183
1
(5)
• Method of adjustment 3 (adjusting right clutch)

right.
automatically.
3) Raise the engine speed and check that the
tral position.
value for the right clutch oil pressure with
remains effective.
H N3: Left steering clutch oil pressure offset

• This code is the function to adjust the left steer-
ing clutch oil pressure manually.
further.).
es
creases
remains effective.
20-184 D375A-5
1
(5)
I N4: Right steering clutch oil pressure offset

• This code is the function to adjust the right steer-
ing clutch oil pressure manually.
pressure (unit: 0.01 kg/cm 2). (If it has already
further.).
es
creases
remains effective.
J CN: Transmission trigger compensation value

overwrite count
• This code is the function to check the transmis-
sion clutch learning control count and to format
the learning control count (all clutches).
• The service meter display shows the learning
control count (unit: No. of times)
• Method of checking
When the code is selected, the number shown in
the service meter display is the present learning
control count.
• Method of formatting
2) Check that the display for the learning con-
trol count has returned to [0].
★ Even when this code is finished, the initial
setting remains effective.
D375A-5 20-185
1
(5)
K Fx: Transmission F clutch trigger compensation value

sion F clutch learning control value and to format
the learning control value (all clutches).
• The service meter display shows control value -
control value (unit: 10 ms).
When the code is selected, the following data are
displayed for 2 seconds.
Speed range Service meter display (Engine condition)
display
Control value H1 -
F1 control value L1 Low
F2 Control value H2 - Medium (low speed)

control value L2
Control value H3 - Medium
F3 control value L3 (high speed)
Control value H4 -
F4 control value L4 High speed
• Control value Hx: Control value (unit: 10 ms)

when torque converter oil temperature is high
• Control value Lx: Control value (unit: 10 ms)
when torque converter oil temperature is low
2) Check that the display for the control value
has returned to [00].
L Rx: Transmission R clutch trigger compensation value

sion R clutch learning control value and to format
the learning control value (all clutches).
display
Control value H1 -
R1 control value L1 Low
R2 Control value H2 - Medium (low speed)

control value L2
R3 Control value H3 - Medium
control value L3 (high speed)
Control value H4 -
R4 control value L4 High speed

20-186 D375A-5
1
(5)
M 1x: Transmission 1st clutch trigger compensation value

sion 1st clutch learning control value and to for-
mat the learning control value (all clutches).
display
Control value H1 -
11 control value L1 Low
12 Control value H2 - Medium (low speed)

control value L2
13 control value L3 (high speed)
Control value H4 -
14 control value L4 High speed

N 2x: Transmission 2nd clutch trigger compensation value

sion 2nd clutch learning control value and to for-
• The service meter display shows the control val-
ue - control value (unit: 10 ms).
When the code is selected, the following data is
display
Control value H1 -
21 control value L1 Low
22 Control value H2 - Medium (low speed)

control value L2
23 Control value H3 - Medium
control value L3 (high speed)
Control value H4 -
24 control value L4 High speed

D375A-5 20-187
1
(5)
O 3x: Transmission 3rd clutch trigger compensation value

sion 3rd clutch learning control value and to for-
• The service meter display shows the control val-
ue - control value (unit: 10 ms).
When the code is selected, the following data is
display
Control value H1 -
31 Low
control value L1
Control value H2 - Medium (low speed)
32 control value L2
33 control value L3 (high speed)
Control value H4 -
34 High speed
control value L4
P Pb: Steering brake I-P

• This code is the function to measure the I-P
characteristic value of the left and right steering
brake ECMV s.
• The service meter display shows the I-P mea-
surement time (unit: 10 ms).
• Method of measurement 1 (preparatory work)
• Start the engine and select this code.
• Method of measurement 2 (measuring left brake)
1) Operate the PCCS lever steering to the left
and check that the displayed value for the I-P
measurement time increases continuously
from [0].
★ Hold the lever at the left position until the
displayed value reaches [4000].
2) After checking that the displayed value has
reached [4000], return the lever to the neu-
tral position.
• Method of measurement 3 (measuring right brake)
1) Operate the PCCS lever steering to the right
from [0].
20-188 D375A-5
(7)
1
★ Hold the lever at the right position until

the displayed value reaches [4000].
tral position.
remains effective.
Q Pc: Steering clutch I-P

characteristic value of the left and right steering
clutch ECMV s.
Start the engine and select this code.
• Method of measurement 2 (measuring left clutch)
1) Operate the PCCS lever steering to the left
from [0].
★ Hold the lever at the left position until the
tral position.
• Method of measurement 3 (measuring right clutch)
1) Operate the PCCS lever steering to the right
from [0].
★ Hold the lever at the right position until
tral position.
remains effective.
D375A-5 20-189
(7)
1
R Pd: Transmission F, R clutch I-P

characteristic value of the transmission F clutch
ECMV and transmission R clutch ECMV.
• Start the engine and select this code.
• Method of measurement 2 (measuring F clutch)
check that the displayed value for the I-P
from [0].
★ Hold the lever at the F position until the
tral position.
• Method of measurement 3 (measuring R clutch)
1) Operate the PCCS lever direction to R and
from [0].
★ Hold the lever at the R position until the
tral position.
★ Even when this code is finished, the set-
ting remains effective.
S PF: Transmission 1st, 3rd clutch I-P

• This code is the function to measure the I-P char-
acteristic value of the transmission 1st clutch
ECMV and transmission 3rd clutch ECMV.
Start the engine and select this code.
20-190 D375A-5
(7)
1
• Method of measurement 2 (measuring 1st clutch)

from [0].
★ Hold the lever at the F position until the
tral position.
• Method of measurement 3 (measuring 3rd clutch)
1) Operate the PCCS lever direction to R and
from [0].
★ Hold the lever at the R position until the
tral position.
remains effective.
T PH: Transmission 2nd clutch I-P

characteristic value of the transmission 2nd
clutch ECMV.
• Method of measurement (preparatory work and
measurement)
2) Operate the PCCS lever direction to F or R
from [0].
★ Hold the lever at the F or R position until
tral position.
remains effective.
D375A-5 20-191
(7)
1
5. Service code display mode

In the service code display mode, any problem
that has occurred inside the system can be dis-
played as a service code.
1) Selecting mode
Switch to the service mode and operate the
economy mode switch to select the service code
display mode.
• Economy mode switch (5): 2
2) Content of display
• Speed range display (1):
Order of occurrence (recorded up to a
maximum of 20 items)
• Service meter display (2):
Service code and service meter reading
for time of occurrence are displayed in
turn
★ Letter at head of service code
E: Code for problem detected at present
P: Code for problem not detected at present
★ Conditions for detecting and holding service
code
For service codes other than S-NET, if a
problem is detected, the [E] display contin-
ues until the starting switch is turned OFF. If
the starting switch is turned OFF and then
turned ON again or the engine is started, the
[P] display is held until the same problem is
detected again.
For the S-NET related service codes, even if
the starting switch is not turned OFF, the dis-
play changes to the [P] display immediately
the problem is removed.
3) Operation when multiple codes are recorded

If multiple codes are recorded, operate the fol-
lowing switch to display the codesin the order of
occurrence.
• Slow reverse mode switch (6): Scroll forward
(order of occurrence)
★ The service code cannot be scrolled in re-
verse.
4) Deleting code
Display the code to be deleted, then operate the
following switch to delete the code.
• Buzzer cancel switch (4): ON (delete)
★ Only the codes headed by [P] can be delet-
ed; the codes headed by [E] cannot be de-
leted.
20-192 D375A-5
(5)
1
TABLE OF SERVICE CODES

Service User Warning Alarm
Nature of abnormality Controller
code code lamp buzzer
E0101 Abnormality in network system (steering system) S/T CALL03 q q
E0104 Abnormality in network system (monitor panel system) MON CALL03 q q
E0105 Abnormality in network system (steering system) S/T CALL03 q q
E0111 Abnormality in steering controller power source system S/T CALL q q
E0112 Abnormality in transmission controller power source system T/M CALL q q
E0120 Short circuit in warning lamp system MON CALL03 q q
E0121 Short circuit in alarm buzzer system MON CALL03 q q
E0142 Abnormality in transmission controller 5V power source system T/M CALL03 q q
E0143 Abnormality in steering controller 5V power source system S/T CALL03 q q
E0145 Abnormality in steering controller 24V power source system S/T CALL03 q q
E0146 Abnormality in transmission controller 24V power source system T/M E01
E0151 Abnormality in steering controller specification selection S/T CALL q q
E0152 Abnormality in network system (steering controller) S/T CALL03 q q
E0160 Abnormality in transmission controller ROM T/M E01
E0161 Abnormality in steering controller ROM S/T E02 q q
E0164 Abnormality in network system (transmission controller) T/M CALL03 q q
E0176 Disconnection in battery relay system S/T
E0177 Short circuit in battery relay system S/T
E0178 Disconnection in neutral safety relay system T/M E02 q q
E0179 Short circuit in neutral safety relay system T/M E02 q q
E0211 Abnormality in torque converter oil temperature MON
E0212 Short circuit in torque converter lock-up solenoid system T/M E01
E0213 Disconnection in torque converter lock-up solenoid system T/M E01
E0221 Disconnection, short circuit in tilt angle sensor system T/M E01
E0225 Slippage of power train clutch T/M E02 q q
E0230 Simultaneous abnormality in directional potentiometer system (1) T/M CALL q q
E0233 Disconnection, short circuit in directional potentiometer 1 system T/M CALL03 q q
E0234 Disconnection, short circuit in directional potentiometer 2 system T/M CALL03 q q
E0235 Divergence of directional potentiometer system signal T/M CALL03 q q
E0236 Disconnection, short circuit in shift up switch system T/M E02 q q
E0237 Disconnection, short circuit in shift down switch system T/M E02 q q
E0238 Disconnection, short circuit in parking lever switch system T/M CALL03 q q
E0239 Mismatch in parking lever switch system signals T/M CALL03 q q
E0250 Disconnection in transmission FORWARD clutch ECMV system T/M CALL03 q q
E0251 Short circuit in transmission FORWARD clutch ECMV system T/M CALL03 q q
E0252 Disconnection in transmission REVERSE clutch ECMV system T/M CALL03 q q
D375A-5 20-193
(7)
1

E0253 Short circuit in transmission FORWARD clutch ECMV (E-POCV) system T/M CALL03 q q
E0254 Disconnection in transmission 1st clutch ECMV (E-POCV) system T/M CALL03 q q
E0255 Short circuit in transmission 1st clutch ECMV (E-POCV) system T/M CALL03 q q
E0256 Disconnection in transmission 2nd clutch ECMV (E-POCV) system T/M CALL03 q q
E0257 Short circuit in transmission 2nd clutch ECMV (E-POCV) system T/M CALL03 q q
E0258 Disconnection in transmission 3rd clutch ECMV (E-POCV) system T/M CALL03 q q
E0259 Short circuit in transmission 3rd clutch ECMV (E-POCV) system T/M CALL03 q q
E0260 Defective engagement of transmission FORWARD clutch T/M CALL03 q q
E0261 Defective disengagement of transmission FORWARD clutch T/M CALL03 q q
E0262 Defective engagement of transmission REVERSE clutch T/M CALL03 q q
E0263 Defective disengagement of transmission REVERSE clutch T/M CALL03 q q
E0264 Defective engagement of transmission 1st clutch T/M CALL03 q q
E0265 Defective disengagement of transmission 1st clutch T/M CALL03 q q
E0266 Defective engagement of transmission 2nd clutch T/M CALL03 q q
E0267 Defective disengagement of transmission 2nd clutch T/M CALL03 q q
E0268 Defective engagement of transmission 3rd clutch T/M CALL03 q q
E0269 Defective disengagement of transmission 3rd clutch T/M CALL03 q q
E0270 Multiple failure in transmission clutch T/M CALL03 q q
E0271 Multiple failure in transmission clutch T/M CALL q q
E0306 Short circuit in blade tilt right oil pressure switch system T/M E02 q q
E0307 Short circuit in blade tilt left oil pressure switch system T/M E02 q q
E0308 Short circuit in ripper RAISE oil pressure switch system S/T
E0309 Short circuit in ripper LOWER oil pressure switch system S/T
E0310 Short circuit in ripper TILT IN oil pressure switch system S/T
E0311 Disconnection, short circuit in blade pitch switch system T/M E02 q q
E0312 Disconnection, short circuit in blade tilt switch system T/M E01
E0321 Disconnection in blade dual tilt selection solenoid system T/M E01
E0322 Short circuit in blade dual tilt selection solenoid system T/M E01
E0323 Disconnection in blade pitch selection solenoid system T/M E02 q q
E0324 Short circuit in blade pitch selection solenoid system T/M E02 q q
E0329 Abnormal hydraulic oil temperature MON
E0364 Disconnection in front pump oil pressure sensor system T/M
E0365 Short circuit in front pump oil pressure sensor system T/M
E0366 Disconnection in center pump oil pressure sensor system T/M
E0367 Short circuit in center pump oil pressure sensor system T/M
E0405 Disconnection, short circuit in fuel control dial system ENG CALL03 q q
E0430 Engine oil: Abnormal oil pressure ENG CALL q
E0431 Abnormal radiator coolant level MON CALL
E0432 Radiator coolant: Overheating MON E01 q
E0486 Abnormality in transmission controller model selection T/M CALL q q
E0501 Disconnection, short circuit in acceleration sensor system S/T E01
E0610 Disconnection in backup alarm relay system T/M E01
20-194 D375A-5
(6)
1

E0611 Short circuit in back-up alarm relay system T/M E01
E0660 Disconnection in ACC signal drive relay system S/T
E0661 Short circuit in ACC signal drive relay system S/T
E0721 Disconnection, short circuit in tilt angle sensor system S/T CALL03 q q
E0730 Simultaneous abnormality in steering potentiometer system (1) S/T CALL q q
E0733 Disconnection, short circuit in steering potentiometer 1 system S/T CALL03 q q
E0734 Disconnection, short circuit in steering potentiometer 2 system S/T CALL03 q q
E0735 Divergence in steering potentiometer system signal S/T CALL03 q q
E0736 Disconnection, short circuit in brake potentiometer system S/T CALL03 q q
E0750 Disconnection in right steering clutch ECMV system S/T CALL03 q q
E0751 Short circuit in right steering clutch ECMV system S/T CALL03 q q
E0752 Disconnection in left steering clutch ECMV system S/T CALL03 q q
E0753 Short circuit in left steering clutch ECMV system S/T CALL03 q q
E0754 Disconnection in right steering brake ECMV system S/T CALL q q
E0755 Short circuit in right steering brake ECMV system S/T CALL q q
E0756 Disconnection in left steering brake ECMV system S/T CALL q q
E0757 Short circuit in left steering brake ECMV system S/T CALL q q
E0760 Defective engagement of right steering clutch S/T CALL q q
E0761 Defective disengagement of right steering clutch S/T CALL q q
E0762 Defective engagement of left steering clutch S/T CALL q q
E0763 Defective disengagement of left steering clutch S/T CALL q q
E0764 Defective engagement of right steering brake S/T CALL q q
E0765 Defective disengagement of right steering brake S/T CALL q q
E0766 Defective engagement of left steering brake S/T CALL q q
E0767 Defective disengagement of left steering brake S/T CALL q q
E0779 Disconnection in sudden stop prevention solenoid system S/T CALL q q
E0780 Short circuit in sudden stop prevention solenoid system S/T CALL q q
E0781 Disconnection, short circuit parking lever switch system S/T CALL03 q q
E0782 Mismatch of parking lever switch system signals S/T CALL03 q q
E0930 Disconnection in engine speed sensor system S/T E01
E0931 Disconnection in engine speed sensor system T/M E01
E0932 Disconnection in transmission speed sensor system S/T E01
E0933 Disconnection in transmission speed sensor system T/M E01
E1939 Abnormality in J1939 communication system S/T E01
EC111 Abnormality in engine controller memory ENG CALL q q
EC112 Abnormality in timing rail actuator ENG CALL q q
D375A-5 20-195
(7)
1

EC113 Abnormality in timing rail actuator system current ENG CALL03 q q
EC115 Abnormality in engine speed sensor 2 system ENG CALL q q
EC116 Abnormality in timing rail pressure sensor system high level ENG CALL q q
EC117 Abnormality in timing rail pressure sensor system low level ENG CALL q q
EC118 Abnormality in fuel pump pressure sensor system high level ENG CALL03 q q
EC119 Abnormality in fuel pump pressure sensor system low level ENG CALL03 q q
EC121 Abnormality in engine speed sensor 1 system ENG CALL03 q q
EC122 Abnormality in boost pressure sensor system high level ENG E01
EC123 Abnormality in boost pressure sensor system low level ENG E01
EC131 Abnormality in throttle sensor system high level ENG CALL q q
EC132 Abnormality in throttle sensor system low level ENG CALL q q
EC133 Abnormality in remote throttle sensor system high level ENG CALL q q
EC134 Abnormality in remote throttle sensor system low level ENG CALL q q
EC135 Abnormality in engine oil pressure sensor system high level ENG CALL03 q q
EC141 Abnormality in engine oil pressure sensor system low level ENG CALL03 q q
EC143 Abnormal drop in engine oil pressure ENG
EC144 Abnormality in water temperature sensor system high level ENG CALL03 q q
EC145 Abnormality in water temperature sensor system low level ENG CALL03 q q
EC151 Abnormal rise in water temperature ENG
EC153 Abnormality in intake air temperature sensor system high level ENG CALL03 q q
EC154 Abnormality in intake air temperature sensor system low level ENG CALL03 q q
EC221 Abnormality in atmospheric pressure sensor system high level ENG CALL03 q q
EC222 Abnormality in atmospheric pressure sensor system low level ENG CALL03 q q
EC234 Abnormal overspeed ENG
EC254 Abnormality in fuel shut-off valve system voltage ENG E01
EC259 Abnormality in fuel shut-off valve ENG CALL q q
EC261 Rise in fuel temperature ENG
EC263 Abnormality in fuel temperature sensor system high level ENG CALL03 q q
EC265 Abnormality in fuel temperature sensor system low level ENG CALL03 q q
EC316 Abnormality in fuel pump actuator system current ENG CALL03 q q
EC318 Abnormality in fuel pump actuator ENG CALL03 q q
EC346 Abnormal engine controller power down ENG CALL03 q q
EC384 Abnormality in preheater control system ENG CALL03 q q
EC423 In-range abnormality in timing rail pressure sensor system ENG CALL03 q q
EC441 Abnormality in battery voltage system low level ENG E01
EC442 Abnormality in battery voltage system high level ENG E01
EC451 Abnormality in fuel rail pressure sensor system high level ENG CALL q q
EC452 Abnormality in fuel rail pressure sensor system low level ENG CALL q q
20-196 D375A-5
1

EC455 Abnormality in fuel rail actuator system current ENG CALL z z
EC467 Abnormality in timing rail actuator control ENG CALL03 z z
EC468 Abnormality in fuel rail actuator control ENG CALL03 z z
EC514 Abnormality in fuel rail actuator ENG CALL z z
EC554 In-range abnormality in fuel rail pressure sensor system ENG CALL03 z z
★ Letter at head of service code
E: Code for problem detected at present
P: Code for problem not detected at present
★ The controller in the Controller column indicates the controller or monitor panel responsible for the system
check for the applicable code.
MON: Monitor panel
ENG: Engine controller
T/M: Transmission controller
S/T: Steering controller
D375A-5 20-197

1
PREPARATORY WORK WHEN TROUBLESHOOTING
TESTING AND ADJUSTING ELECTRICAL SYSTEM

ELECTRICAL SYSTEM
★ When carrying out troubleshooting of the electric 2. Engine controller
circuits related to the monitor panel, engine con- 1) Remove engine left side cover (3).
troller, transmission controller, and steering con-
troller, use the following procedure to expose the
applicable connector.
1. Monitor panel
2) Remove 2 mounting bolts, then pull monitor
panel (2) out towards the operator’s seat.
2) Insert or connect the troubleshooting T-

adapter to connector ECMA and connector
ECMB of engine controller (4).
★ The connectors are held by screws, so

loosen the screws before disconnecting.
★ When returning the connectors to their
original position, tighten the screws to
the specified torque.
Screw: 2.82 Nm {0.288 kgm}
3) Insert or connect the troubleshooting T-
adapter to connector S01, connector S02,
connector S03, connector CN1, connector
CN2, and connector CN4 of the monitor pan-
el.
20-198 D375A-5
1
TESTING AND ADJUSTING ELECTRICAL SYSTEM
3. Transmission controller 4. Steering controller

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

adapter to connector TMCN1, connector adapter to connector NGICN1, connector
TMCN2, and connector TMCN3 of transmis- NGICN2, and connector NGICN3 of steering
sion controller (6). controller (7).
★ If it is difficult to remove or install the con- ★ If it is difficult to remove or install the con-
nectors, remove the controller from the nectors, remove the controller from the
floor frame when carrying out the opera- floor frame when carrying out the opera-
tion. tion.
★ The connectors are held by screws, so ★ The connectors are held by screws, so

loosen the screws before disconnecting. loosen the screws before disconnecting.
★ When returning the connectors to their ★ When returning the connectors to their
original position, tighten the screws to original position, tighten the screws to
the specified torque. the specified torque.
Screw: 2.82 Nm {0.288 kgm} Screw: 2.82 Nm {0.288 kgm}
D375A-5 20-199

1
TESTING AND ADJUSTING PM CLINIC SERVICE
Pm CLINIC SERVICE
Model Serial No Service meter
D375A-5 h
User name Date of clinic Serviceman
Specifications
Blade Rear attachment Shoe width
Semi-U blade Multi-shank ripper 610 mm
U-blade Variable giant ripper 710 mm
Dual tilt blade Counterweight kg 810 mm
Operating conditions
Quarry, mine Construction Type of soil (specific gravity ) Type of work
Coal Construction, Rock Dozing %
Gold civil engineering Gravel Side cutting %
Limestone Roads Sand Ripping %
Tunnels Clay Travel %
Existence of abnormalities
Oil, water level check
Engine coolant level When necessary
Engine oil level Power train Damper case
Hydraulic oil level Final drive ( )
Engine coolant temperature Max. range Power train oil temperature Max. range Ambient temperature
Max.
Min.
Height above sea level
m
Operator’s opinion
Visual check results
Service code history
E h E h
Content: Content:
E h E h
Content: Content:
D375A-5 20-201
1
Pm-clinic
TESTING AND ADJUSTING measuring points for D375A-5 (1/3)
PM CLINIC SERVICE
q 2. q 1.
q 3.
q 5.
q 4.
q1. Engine speed: Measuring engine speed (20-102 – 103 page)

Reference items of measurement procedure (Pages)
q2. Blow-by pressure: Measuring blow-by pressure (20-112 page)

q3. Engine oil pressure: Measuring engine oil pressure (20-113 page)
q4. Boost pressure: Measuring intake air pressure (boost pressure) (20-104 page)
q5. Exhaust temperature: Measuring exhaust temperature (20-105 – 106 page)
20-202 D375A-5
1
(5)
Pm-clinic
TESTING AND ADJUSTING measuring points for D375A-5 (2/3)
PM CLINIC SERVICE
q6. Items related to torque converter: Measuring power train oil pressure (20-123 – 131-1 page)
q7. Items related to transmission: Measuring power train oil pressure (20-123 – 131-1 page)
q8. Items related to steering: Measuring power train oil pressure (20-123 – 131-1 page)
D375A-5 20-203
1
(5)
203
Pm-clinic measuring points for D375A-5 (3/3)
q9. Items related to work equipment: Testing and adjusting work equipment oil pressure (20-140 – 142 page)
q10. Items related to work equipment: Testing and adjusting control circuit main pressure (20-143 – 144 page)
20-203-1 D375A-5
(5)
TESTING AND ADJUSTING Serial
PMNoCLINIC SERVICE
Pm CLINIC CHECK SHEET D375A-5
Work order No. Date Service meter Serviceman
h
Item Measurement conditions Unit Standard value for new machine Service limit value Measurement results Pass Fail
Low idling 690 - 750 690 - 750
Decel Deceleration pedal depressed 850 - 950 850 - 950
Engine speed High idling rpm 1870 - 1930 1870 - 1930
Torque converter stall 1470 - 1570 Min. 1430
Torque converter stall + work equipment relief 1240 - 1360 Min. 1160
kPa Max. 4.9 Max. 7.9
Blow-by pressure Torque converter stall
Engine
<mmAq> <Max. 500> <Max. 800>

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

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

Engine at high idling <1.5 - 2.5> <1.5 - 2.5>
F clutch pressure T/M: F3 Engine at low idling MPa 2.40 - 2.70 2.35 - 2.94
(Co mode) <kg/cm2> <24.5 - 27.5> <24.0 - 30.0>
R clutch pressure T/M: R3 2.40 - 2.70 2.35 - 2.94
Engine at low idling <24.5 - 27.5> <24.0 - 30.0>
(Co mode)
T/M: F1 2.05 - 2.45 1.96 - 2.55
1st clutch pressure (Co mode) Engine at low idling <20.0 - 26.0>
<21.0 - 25.0>
T/M: F2 2.40 - 2.70 2.35 - 2.94
2nd clutch pressure (Co mode) Engine at low idling
<24.5 - 27.5> <24.0 - 30.0>
3rd clutch pressure T/M: F3 Engine at low idling 2.40 - 2.70 2.35 - 2.94
(Co mode) <24.5 - 27.5> <24.0 - 30.0>
20-204 D375A-5
4
1
TESTING AND ADJUSTING Serial
PM No
CLINIC SERVICE
Pm CLINIC CHECK SHEET D375A-5
Work order No Date Service meter Serviceman
h
2.40 - 2.70 Min. 2.4
Left clutch pressure <24.5 - 27.5> <Min. 24.0>
Engine at low idling Min. 2.4
Left brake pressure 2.35 - 2.65
Transmission: <24.0 - 27.0> <Min. 24.0>
Steering clutch & brake
Neutral 2.55 - 2.85 Min. 2.4

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

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

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

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

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

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

mm/5 min.
Ripper lift cylinder Max. 15 Max. 30
Visual inspection of final drive drain plug Engine stopped There must be no excessive metal particles
Always fill in the record when repairing, adjusting, or replacing main parts.
Date Service meter Repair record Date Service meter Repair record
D375A-5 20-205
1
(5)
TESTING AND
PmADJUSTING
CLINIC Serial
PMNo
CLINIC SERVICE
UNDERCARRIAGE CHECK SHEET

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

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

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

Pin No. 1.4
Right track A: Clearance between links

Pin No. 1.4
20-206 D375A-5
3
1
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)
(Program form No.: SELA195001)
Y Komatsu
Undercarriage Inspection Customer name:
Address:
Model D375A-5 Serial# Equip# Work Order No

Location SMR Wet,AR,HD or Dry Wet
Soil condition Dealer Shoe width (mm)
Working condition Inspector Shoe type SINGLE
Insp.Date(yy/mm/dd) (yyyy/m/d) Wear type NORMAL
New 100% Measured Wear SMR Hours on Comments/Observation
Wear mm % New Rebuilt Parts:
LH 1121.2 1141.2
LINK PITCH
R
M L L=l/4 RH 1121.2 1141.2
LH 280.30 285.30
master pin
master l M
i 1.3 RH 280.30 285.30
LH 181.0 163.0
H
RH 181.0 163.0
LINK HEIGHT1.3
New Turned
BUSHIN d1 LH 98.5 90.0
G New Turned
d
D is the smallest d RH 98.5 90.0
ofd1,,d2 and,d3 1
GROUSER HIGHT LH 93.0 30.0
H
0 RH 93.0 30.0
CARRIER
CARRIER LH 210.0 185.0
Front
RH 210.0 185.0
D LH 210.0 185.0
Rear
1.3 RH 210.0 185.0
IDLER
IDLER LH 23.5 36.0
Front
H RH 23.5 36.0
LH 23.5 36.0
Rear
1.3 RH 23.5 36.0
1 LH 270.0 200.0
2 LH 270.0 200.0
3 LH 270.0 200.0
4 LH 270.0 200.0
5 LH 270.0 200.0
6 LH 270.0 200.0
7 LH 270.0 200.0
TRACK ROLLER 8 LH 270.0 200.0
9 LH 270.0 200.0
10 LH 270.0 200.0
D 1 RH 270.0 200.0
h1 2 RH 270.0 200.0
h2
3 RH 270.0 200.0
D=2(h1- 4 RH 270.0 200.0
5 RH 270.0 200.0
6 RH 270.0 200.0
7 RH 270.0 200.0
8 RH 270.0 200.0
9 RH 270.0 200.0
1.3 10 RH 270.0 200.0
SPROCKET h1 LH 0.0 8.0
H is the smallest of
h1,h2,h3 h3 h2
1.3 RH 0.0 8.0
Remarks:
D375A-5 20-207
(6)
1
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)
(Program form No.: SELA195001)
Y Komatsu
Undercarriage Inspection Customer name:
Address:
Model D375A-5 Serial# Equip# Work Order No

Location SMR Wet,AR,HD or Dry Wet
Soil condition Dealer Shoe width (mm)
Working condition Inspector Shoe type SINGLE
Insp.Date(yy/mm/dd) (yyyy/m/d) Wear type IMPACT
New 100% Measured Wear SMR Hours on Comments/Observation
Wear mm % New Rebuilt Parts:
LH 1121.2 1133.2
LINK PITCH
R
M L L=l/4 RH 1121.2 1133.2
LH 280.30 283.30
master pin
master l M
i 1.3 RH 280.30 283.30
LH 181.0 163.0
H
RH 181.0 163.0
LINK HEIGHT1.3
New Turned
BUSHIN d1 LH 98.5 92.5
G New Turned
d
D is the smallest d RH 98.5 92.5
ofd1,,d2 and,d3 1
GROUSER HIGHT LH 93.0 30.0
H
0 RH 93.0 30.0
CARRIER
CARRIER LH 210.0 185.0
Front
RH 210.0 185.0
D LH 210.0 185.0
Rear
1.3 RH 210.0 185.0
IDLER
IDLER LH 23.5 36.0
Front
H RH 23.5 36.0
LH 23.5 36.0
Rear
1.3 RH 23.5 36.0
1 LH 270.0 200.0
2 LH 270.0 200.0
3 LH 270.0 200.0
4 LH 270.0 200.0
5 LH 270.0 200.0
6 LH 270.0 200.0
7 LH 270.0 200.0
TRACK ROLLER 8 LH 270.0 200.0
9 LH 270.0 200.0
10 LH 270.0 200.0
D 1 RH 270.0 200.0
2 RH 270.0 200.0
h2 h1
3 RH 270.0 200.0
D=2(h1- 4 RH 270.0 200.0
5 RH 270.0 200.0
6 RH 270.0 200.0
7 RH 270.0 200.0
8 RH 270.0 200.0
9 RH 270.0 200.0
1.3 10 RH 270.0 200.0
SPROCKET h1 LH 0.0 8.0
H is the smallest of
h1,h2,h3 h3 h2
1.3 RH 0.0 8.0
Remarks:
20-208 D375A-5
(6)
1
TROUBLESHOOTING MON MODE RELATED ELECTRICAL CIRCUIT DIAGRAM
TROUBLESHOOTING
Points to remember when troubleshooting .............................................................................................. 20-302

Sequence of events in troubleshooting ................................................................................................... 20-303
Points to remember when carrying out maintenance .............................................................................. 20-304
Checks before troubleshooting ............................................................................................................. 20-307-5
Classification of and procedure for troubleshooting ................................................................................ 20-308
Connector allocation drawing and electrical circuit diagrams for each system ....................................... 20- 311
Connection table for connector pin numbers ........................................................................................... 20-330
T-Branch box and T-Branch table ............................................................................................................ 20-353
Troubleshooting when service code is displayed (Service code) ............................................................ 20-401

Troubleshooting of electrical system (E-mode) ....................................................................................... 20-601
Troubleshooting of hydraulic and mechanical system (H-mode) ............................................................. 20-701
Troubleshooting of the engine body (S-mode) ........................................................................................ 20-801
D375A-5 20-301
(7)
1
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

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

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

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

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

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

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

chine before the failure occurred?
Did the failure occur suddenly?
Had any repairs been carried out before the
TEW00189 failure?
TEW00190
D375A-5 20-303

1
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other
troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and re-
pairs must be carried out. This section deals particularly with correct repair procedures for mechatronics
and is aimed at improving the quality of repairs. For this purpose, it gives sections on “ Handling
electric equipment” and “ Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
1. POINTS TO REMEMBER WHEN HANDLING

ELECTRIC EQUIPMENT
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are more
likely to be affected by the direct effects of rain,
water, heat, or vibration. Furthermore, during
inspection and repair operations, they are fre-
quently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
TEW00191
Main failures occurring in wiring harness

1 Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.
2 Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
are in contact at the crimped terminal or
soldered portion, but if there is excessive
force brought to bear on the wiring, the plat-
ing at the joint will peel and cause improper
connection or breakage.
20-304 D375A-5
1
3 Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.
TEW00194
4 High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, depending on the direction of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
for it to be drained. Therefore, if water should
get into the connector, the pins will be short-
TEW00195
circuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing elec-
tricity through it.
5 Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con- TEW00196
tact restorer.
fl When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
fl If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before clean-
ing with compressed air.
D375A-5 20-305

1
2) Removing, installing, and drying connectors and

wiring harnesses
· Disconnecting connectors
1 Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connec-
tors held by a screw, loosen the screw fully,
then hold the male and female connectors
in each hand and pull apart. For connectors
which have a lock stopper, press down the
stopper with your thumb and pull the con-
nectors apart.
★ Never pull with one hand.
2 When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
★ If the connector is twisted up and down
or to the left or right, the housing may
break.
TBW00484
3 Action to take after removing connectors

After removing any connector, cover it with
a vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
★ If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
TEW00198
20-306 D375A-5
1
· Connecting connectors
1 Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation, de-
fective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
★ If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
★ If there is any damage or breakage, re-
place the connector.
2 Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
3 Correct any protrusion of the boot and any

TEW00200
misalignment of the wiring harness

For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the
wiring harness is misaligned, or the clamp
is out of position, adjust it to its correct po-
sition.
★ If the connector cannot be corrected eas-
ily, remove the clamp and adjust the
position.
4 If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps. TBW00487
• Since the DT 8-pole and 12-pole heavy duty wire

connectors have 2 latches respectively, push them
in until they click 2 times.
1. Mail connector, 2. Female connector
• Normal locking state (Horizontal): a, b, d
• Incomplete locking state (Diagonal): c
D375A-5 20-307

1
TROU
• Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in wa-
ter or using steam. If the connector must be
washed in water, do not use high-pressure water
or steam directly on the wiring harness.
If water gets directly on the connector, do as fol-

lows:
1 Disconnect the connector and wipe off the
water with a dry cloth.
★ If the connector is blown dry with com-
pressed air, there is the risk that oil in the
air may cause defective contact, so re-
move all oil and water from the com-
pressed air before blowing with air.
2 Dry the inside of the connector with a dryer.

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

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
★ After completely drying the connector,
blow it with contact restorer and reas-
semble.
20-307-1 D375A-5
4
3) Handling control box

1 The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
2 Do not open the cover of the control box un-
less necessary.
3 Do not place objects on top of the control

box.
4 Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with
your hand.
5 During rainy weather, do not leave the con-
trol box in a place where it is exposed to rain.
6 Do not place the control box on oil, water, or

soil, or in any hot place, even for a short time.
(Place it on a suitable dry stand)
7 Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the control box. Fit an arc weld-
ing ground close to the welding point.
4. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connecting connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
★ Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
★ If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
★ If there is any change, there is probably defective contact in that circuit.
D375A-5 20-307-2
4
5. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hy-

draulic equipment, the most common cause of fail-
ure is dirt (foreign material) in the hydraulic circuit.
When adding hydraulic oil, or when disassembling or
assembling hydraulic equipment, it is necessary to
be particularly careful.
1) Be careful of the operating environment

Avoid adding hydraulic oil, replacing filters, or re-
pairing the machine in rain or high winds, or plac-
es where there is a lot of dust.
2) Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and maintenance of hydraulic equipment
should be carried out in a specially prepared
dustproof workshop, and the performance
should be confirmed with special test equipment.
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. If the opening is left open or is blocked with
a rag, there is danger or dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this.
Do not simply drain oil out on to the ground, col-
lect it and ask the customer to dispose of it, or
take it back with you for disposal.
4) Do not let any dirt, or dust get in during refill-

ing operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil fill-
er and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning
device is used, it is possible to filter out the dirt
that has collected during storage, so this is an
even more effective method.
20-307-3 D375A-5
4
5) Change hydraulic oil when the temperature is

high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is still
warm. When changing the oil, as much as possi-
ble of the old hydraulic oil must be drained out.
(Do not drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain plug
in the circuit.) If any old oil is left, the contami-
nants and sludge in it will mix with the new oil
and will shorten the life of the hydraulic oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to re-
move the contaminants, sludge, and old oil from
the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the machine,
carry out oil cleaning to remove the sludge or
contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove the
ultrafine (about 3µ) particles that the filter built
into the hydraulic equipment cannot remove, so
it is an extremely effective device.
D375A-5 20-307-4
4
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Judgement
Item Action
Value
1. Check fuel level — Add fuel
2. Check for impurities in fuel — Clean, drain
Lubricating oil, coolant
3. Check hydraulic oil level — Add oil

Checks before starting
4. Check oil level in damper case — Add oil

5. Check power train oil level — Add oil
6. Check engine oil level (engine oil pan level) — Add oil
7. Check coolant level — Add water
8. Check dust indicator for clogging — Clean or replace
9. Check travel of brake pedal — Adjust
mechanical equipment
Electrical
10. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace
11. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace
12. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
equipment
Hydraulic,
13. Check for abnormal noise, smell — Repair

14. Check for oil leakage — Repair
15. Carry out air bleeding — Bleed air
Other check items
16. Check battery voltage (engine stopped) 20 - 30 V Replace

17. Check battery electrolyte level — Add or replace
Electrical equipment
18. Check for discolored, burnt, exposed wiring — Replace

19. Check for missing wiring clamps, hanging wire — Repair
20. Check for water leaking on wiring (pay particularly careful attention — Disconnect connector
to water leaking on connectors or terminals) and dry
21. Check for water on wiring — Replace
22. Check alternator voltage (engine running at 1/2 throttle or above) After running for Replace
several minutes:
27.5 - 29.5 V
23. Check operating sound of battery relay (starting switch ON, OFF) — Replace
20-307-5 D375A-5
4
TROUBLESHOOTING CLASSIFICATION OF AND PROCEDURE FOR TROUBLESHOOTING
CLASSIFICATION OF AND PROCEDURE FOR

TROUBLESHOOTING
Classification of troubleshooting
Mode Contents
Service code Troubleshooting when service code is displayed
E mode Troubleshooting for electric system
H mode Troubleshooting for hydraulic and mechanical systems
S mode Troubleshooting of the engine body
Procedure for troubleshooting

If a possible fault is detected in the machine, narrow the troubleshooting Nos. according to the following proce-
dure, then go to the related troubleshooting section.
1. Procedure for troubleshooting when user code is displayed on monitor panel:

If a user code is displayed on the monitor panel, display the service code in the service code display mode
of the monitor panel (EMMS).
Carry out the troubleshooting for the displayed "service code".
★ The service code becomes "E" when a fault is detected. Accurately, even if it is "P" when the starting
switch is turned ON, the fault may not have been repaired. (Some faults are detected by simply turning
the starting switch ON, however.)
★ If the service code is recorded, be sure to perform the procedure for reproducing it to see if the corre-
sponding fault has been repaired. (For the method of reproducing the service code, see the trouble-
shooting for the service code.)
2. Procedure for troubleshooting when service code is recorded:

If a user code is not displayed on the monitor panel, check the service code in the service code display mode
of the monitor panel (EMMS).
If the service code is recorded, carry out the troubleshooting for that "service code".
★ The service code becomes "E" when a fault is detected. Accurately, even if it is "P" when the starting
switch is turned ON, the fault may not have been repaired. (Some faults are detected by simply turning
the starting switch ON, however.)
★ If the service code is recorded, be sure to perform the procedure for reproducing it to see if the corre-
sponding fault has been repaired. (For the method of reproducing the service code, see the trouble-
shooting for the service code.)
3. Procedure for troubleshooting when user code is not displayed and service code is not recorded
If a service code is not recorded on the monitor panel (EMMS), the machine may have a fault in its electric,
hydraulic, or mechanical system and may not able to detect it by the self-diagnosis.
In this case, check the possible fault again and select the related faults from the table of "Possible faults and
troubleshooting Nos. for them" and carry out troubleshooting for the related items in the "E mode", "H mode"
or "S mode".
20-308 D375A-5
1
(5)
Phenomena considered to be failures and troubleshooting No.
Troubleshooting
No. Phenomena considered to be failures
Service code E mode H mode S mode
User code, service code related
1 User code is displayed on monitor panel Check service code
2 Service code is displayed in service code display mode !
Engine related
3 Engine starting is poor (always takes time to start) S-1
4 Engine does not turn E-1 S-2 1)
Engine turns but no exhaust
5 S-2 2)
Engine does not start smoke comes out
Exhaust smoke comes out but
6 S-2 3)
engine does not start
7 Engine pickup is poor (response is poor) S-3
8 Engine stops during operation S-4
9 Engine turns irregularly (hunting) S-5
10 Lack of output or no power S-6
11 Exhaust color is black (incomplete combustion) S-7
12 Oil consumption is excessive or exhaust color is blue S-8
13 Oil quickly becomes dirty S-9
14 Fuel consumption is excessive S-10
15 Oil mixed in cooling water, blows back, water level goes down S-11
16 Oil level rises S-13
17 There is abnormal noise S-15
18 Excessive vibration S-16
19 Preheating does not work E-2
Power train related
20 No power (no drawbar pull) H-1 S-6
21 Does not travel (when in 2nd or 3rd) H-2
22 Does not move off in any speed range H-3
23 Moves in only one direction (forward or reverse) H-4
Excessive time lag when shifting gear or shifting between
24 H-5
forward and reverse
25 Cannot turn (steering) H-6
26 Turns in only one direction (steering) H-7
27 Overruns when turning (steering) H-8
28 Brakes do not work H-9
29 Torque converter does not lock up H-10
30 Torque converter oil overheats H-11
Work equipment related
31 All work equipment speeds are slow H-12
32 No work equipment moves H-13
33 Blade RAISE speed is slow or lacks power H-14
34 Blade LOWER speed is slow or lacks power H-15
35 Ripper RAISE speed is slow or lacks power H-16
36 Ripper LOWER speed is slow or lacks power H-17
37 Excessive hydraulic drift of blade lift H-18
38 Excessive hydraulic drift of blade tilt H-19
39 Excessive hydraulic drift of ripper lift H-20
40 Ripper pin-puller cylinder does not work E-3 H-21
41 Blade pitch does not work H-22
42 Abnormal noise from around hydraulic pump H-23
D375A-5 20-309
1
(5)
Troubleshooting
No. Phenomena considered to be failures
Service code E mode H mode S mode
Monitor panel related (operator mode: normal screen)
Nothing lights up on monitor panel when starting switch is
43 E-4
turned ON
All lamps on monitor panel stay on and do not go out when
44 E-5
starting switch is turned ON
45 Basic check items flash when starting switch is turned ON E-6
46 Caution items flash when engine is running E-7
47 Warning items flash when engine is running E-8
48 Preheating lamp does not light up E-9
49 Engine water temperature gauge display is not normal E-10
50 Torque converter oil temperature gauge display is not normal E-11
51 Fuel gauge display is not normal E-12
52 Travel speed, engine speed, shift mode display is not normal E-13
53 Service meter display is not normal E-14
54 Switch module cannot be operated E-15
55 Warning lamp does not flash or does not go out E-16
56 Alarm buzzer does not sound or does not stop E-17
57 Alarm buzzer cannot be canceled E-18
Monitor panel related (service mode: special for function screen)
58 Does not switch to service mode E-19
Others
59 Backup alarm does not sound E-20
Panel night lighting, front lamp, working lamp, rear lamp do
60 E-21
not light up
61 Air conditioner does not work E-22
20-310 D375A-5
1
(5)
CONNECTOR ALLOCATION DRAWING AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAMS FOR EACH SYSTEM

CIRCUIT DIAGRAMS FOR EACH SYSTEM
TABLE OF CONNECTORS
Conne Address
Connecto No. of
ctor Place of use 3-dimensional
r type pins M circuit E circuit T circuit S circuit
No. drawing
101 18-14 14 Intermediate connector (Engine side connector No. VHL) F-1 H-7 G-2 I-4 I-8
1939 9 Engine controller communication connector C-1
201 DT 4 Intermediate connector C-1 J-8
202 DT 4 Intermediate connector A-4 K-8
203 DT 2 Right front lamp A-5 K-9
204 DT 2 Left front lamp D-1 K-8
205 Terminal 1 Horn B-2
206 DT 4 Intermediate connector E-1 J-7
206 Terminal – GND N-4 L-3
212 3 Buzzer cancel switch N-6 B-2 F-8
214 DT-B 12 Intermediate connector N-3 C-8 D-7
215 DT-C 12 Intermediate connector N-2 C-7 E-7
216 DT-D 12 Intermediate connector N-2 C-3 K-6 F-7 D-7
217 DT 2 Alarm buzzer P-1 B-3
218 4 Rear lamp switch N-5 B-2
219 4 Front lamp & working lamp switch N-6 B-2
221 DT 2 Left working lamp G-2 I-8
223 DT 2 Left rear lamp J-4 I-8
224 DT 2 Ripper pin-puller solenoid valve I-3
241 DT 12 Intermediate connector D-8 E-8 J-8
242 DT 2 Right working lamp A-5 E-8
243 DT 2 Right rear lamp J-9 J-9
244 DT 2 Backup alarm K-9
262 X 2 Horn switch Q-8
263 X 2 Ripper pin-puller switch R-8
264 DT 4 Intermediate connector R-8
265 Terminal 1 Horn switch
266 Terminal 1 Horn switch
351 DT 2 Air conditioner compressor Y-3
360 DT 6 Window washer motor (left rear) K-5
369 DT 6 Window washer motor (right front) J-4
375 4 Warning lamp N-5 B-3
405 DT 2 Radiator water level switch B-2 K-9
422 DT 2 Intermediate connector K-5 I-8
423 DT 2 Fuel level sensor I-4 I-8
431 DT 3 Intermediate connector K-8 J-8 G-3
452 DT 2 Hydraulic oil temperature sensor e-5 E-8
453 DT 2 Torque converter oil temperature sensor h-3 F-8
653 DT 2 Torque converter lock-up solenoid valve e-5 K-8
701 Terminal 1 Battery relay terminal BR
702 Terminal 1 Battery relay terminal M
703 Terminal 1 Battery relay terminal B
D375A-5 20-311

1
★ The address shows the approximate position in the connector 3-dimensional allocation drawing and the cir-
cuit diagrams for each system
Conne Address
Connecto No. of
No. drawing
1-pin
800 1 Spare power source N-9
connector
1-pin
801 1 Spare power source N-9
connector
AAPR 3 Atmospheric pressure sensor C-8 G-8
ADH 4 Heater switch N-4
ARC X 2 Air conditioner condenser H-3
ASD 4 Auto shift down switch N-4 F-8
BB1 5 Front lamp relay M-8 H-1
BB2 5 Front lamp relay M-7
BB3 5 Working lamp relay M-8 I-1
BKA 5 Backup alarm relay M-8 I-3
BRK DT 3 Brake potentiometer Q-1 D-8
CAN 12 Intermediate connector d-4 E-8
CAN 3 CAN Terminal resistance W-7 K-6 F-1 L-3
CB1 2 Circuit breaker M-9 I-2
CB2 2 Circuit breaker M-9 J-1
CB3 2 Circuit breaker M-9 J-1 H-1
CB4 2 Circuit breaker M-9
CB5 2 Circuit breaker M-8 J-1
CB6 2 Circuit breaker M-8 J-3 L-5 H-2 I-2
CLTP 2 Engine water temperature sensor Y-6 K-3 F-8
CN1 AMP 12 Monitor panel O-7 A-6 E-9
CN2 AMP 8 Monitor panel P-7 A-5
CN4 M 2 Monitor panel O-6 A-6
1-pin
CN-1 1 Lamp outlet connector [cab] H-9
connector
CN-2 Terminal 1 Rear right speaker [cab] H-9
CN-3 Terminal 1 Rear right speaker [cab] H-9
CN-4 4 Rear wiper motor [cab] G-9
CN-5 Terminal 1 Rear left speaker [cab] G-9
CN-6 Terminal 1 Rear left speaker [cab] G-9
CN-9 6 Front wiper motor [cab] E-8
CN-10 9 Radio [cab] I-9
CN-11 6 Left wiper switch [cab] E-9
CN-12 6 Front wiper switch [cab] E-9
CN-13 6 Right wiper switch [cab] F-9
CN-14 6 Rear wiper switch [cab] F-9
CN-15 2 Lamp switch [cab] F-9
CN-17 4 Right door wiper motor [cab] E-8
CN-18 4 Left door wiper motor [cab] I-7
CN-19 M 4 Intermediate connector G-2
CN-20 DT 1 Cab power source connector [cab] T-1
CN-21 DT 1 Cab power source connector [cab] T-1
CN-22 Terminal 2 Cigar lighter [cab] K-6
CN-23 4 Converter [cab] G-9
CN-24 2 Intermediate connector [cab] K-6
1-pin
CN-25 1 Rotating lamp outlet connector [cab] I-9
connector
20-312 D375A-5
1
Conne Address
Connecto No. of
No. drawing
CN-26 2 Rotating lamp switch [cab] F-9
CN-81 2 Room lamp [cab] E-8
DCL DT 3 Decelerator pedal potentiometer R-1 K-3
DL1 DT 6 Intermediate connector N-1 K-4 E-7
DLCO 6 Data link crossover connector d-6
DLK HD10-6 6 Intermediate connector Q-1 L-4
ECMA 40 Engine controller d-2 K-6 B-8
ECMB 40 Engine controller b-8 K-5 B-5 K-4 L-8
EG1 24-21 21 Intermediate connector (Engine side connector No. POW) d-5 F-5 J-7
EG2 24-31 31 Intermediate connector (Engine side connector No. SIG) d-5 I-5 F-5 I-4 J-6
ESD DT 3 Connector for option O-7
F1T DT 2 1st clutch ECMV (fill switch) g-7 K-6
F2T DT 2 2nd clutch ECMV (fill switch) g-7 K-5
F3T DT 2 3rd clutch ECMV (fill switch) f-6 K-5
FD1 24-23 23 Intermediate connector W-3 G-6 H-5 H-5 G-7
FD5 DT-A 12 Intermediate connector V-2 I-2 H-5 G-2 J-6
FD6 24-31 31 Intermediate connector W-4 G-5 H-4 H-4 G-6
FFT DT 2 F clutch ECMV (fill switch) I-3 K-7
FLB DT 2 Left steering brake ECMV (fill switch) I-3 K-4
FLC DT 2 Left steering clutch ECMV (fill switch) h-7 K-5
FLTP 2 Fuel temperature sensor a-7 F-8
FRB DT 2 Right steering brake ECMV (fill switch) J-7 K-3
FRC DT 2 Right steering clutch ECMV (fill switch) h-7 K-4
FRT DT 2 F clutch ECMV (fill switch) g-7 K-6
FS1 – – Fuse box 1 N-9 J-2 L-5 I-2 H-2
FS2 – – Fuse box 2 N-9 J-2
FS4 – – Fuse box 4 O-9 J-2 L-4 I-1 H-1
FSB 24-31 31 Intermediate connector S-1 G-4 K-5 H-3 G-3
FSO- Terminal 1 Fuel shut off valve Y-5 B-9
FSO+ Terminal 1 Fuel shut off valve Y-5 B-9
GND Terminal – GND C-7
GND Terminal – GND (engine) Y-3 C-9
GND Terminal – GND (engine) Y-3 C-9
GND1 Terminal – GND H-3 J-4 G-5 I-2 I-5
GND4 Terminal – GND A-2 J-8
HEAT DT 2 Intermediate connector d-5 I-6 H-8
IMPR 3 Boost pressure sensor Z-6 H-8
IMTP 2 Intake air temperature sensor Z-7 G-8
JC01 6 Junction connector d-3 K-5 C-9
JC02 8 Junction connector c-3 K-5 C-9
JC03 8 Junction connector a-2 D-9
JC04 8 Junction connector d-2 E-9
JC11 6 Junction connector b-2 E-1
JC12 6 Junction connector b-2 D-1
JC13 8 Junction connector c-2 C-1
D375A-5 20-313

1
Conne Address
Connecto No. of
No. draw ing
JC14 8 Junction connector c-3 K-7 E-1 L-4 L-9
JC15 6 Junction connector d-3 K-7 F-1 L-3
KEY M 6 Starting sw itch O-7 B-3 L-8 E-8 F-8
LINK 6 Data link crossover connector d-4 B-9
LPP DT 3 Work equipment large pump pressure sensor D-8 K-8
M26 6 Air conditioner unit O-1
NGICN1 24 Steering controller U-8 D-2 I-2 C-1 A-9
NGICN2 40 Steering controller T-9 I-2 C-1 A-7
NGICN3 40 Steering controller T-9 E-2 C-1 A-4
NSF 5 Neutral safety relay M-7 H-1 I-3
NSW DT 3 Travel lock sw itch O-9 G-2 G-1 K-2
OLPR 3 Engine oil pressure sensor Y-3 K-3 G-8
P03 DT 6 Work equipment knob sw itch Q-8 E-2
P04 DT-A 2 Intermediate connector D-8
PAS DT 4 Tilt angle sensor F-2 H-8
PL1 24-23 23 Intermediate connector W-2 E-7 H-6
PL2 24-31 31 Intermediate connector W-3 E-7 H-7 G-5
PL3 DT-B 12 Intermediate connector V-2 E-7 H-7
PMPR 3 Fuel pump pressure sensor Z-2 I-8
PPR 5 Pump pow er relay M-7
PRE DT 2 Prelube O-7 G-2 I-2
PRS DT 2 Prelube O-8
PUMP 3 Fuel pump actuator Z-2 J-8
PWR DT 1 Intermediate connector U-2 K-3 L-2 I-2 H-2
RAIL 3 Fuel rail actuator Y-3 I-1 J-8
RHR 5 Preheater relay N-7 L-4
RHT DT 3 Electrical intake air heater timer O-8
RPD DT 2 Ripper LOWER oil pressure sw itch Q-8 F-1
RPR ? 3 Fuel rail pressure sensor d-3 I-8
RPU DT 2 Ripper RAISE oil pressure sw itch R-8 E-1
RTI DT 2 Ripper tilt in oil pressure R-8 F-1
S01 AMP 12 Monitor panel P-7 A-8 D-9
S02 M 2 Monitor panel O-6 A-7
S03 AMP 16 Monitor panel P-7 A-8 D-9
S13 DT-A 12 Intermediate connector N-3 C-4 E-7 E-7
S1T DT 2 1st clutch ECMV (solenoid valve) F-6 K-6
S21 3 SSC initial setting jumper O-6 B-2
S24 Terminal 6 Service sw itch P-1 C-5 E-9
S25 X 4 Data w rite connector (steering controller) U-8 A-1
S26 X 4 Data w rite connector (transmission controller) V-8 A-1
S2T DT 2 2nd clutch ECMV (solenoid valve) g-7 K-6
S3T DT 2 3rd clutch ECMV (solenoid valve) f-6 K-5
SDR 5 Engine controller pow er relay N-7 K-1
SFT DT 2 F clutch ECMV (solenoid valve) h-3 K-7
SLB DT 2 Left steering brake ECMV (solenoid valve) J-5 K-4
20-314 D375A-5
(7)
1
Conne Address
Connecto No. of
No. drawing
SLC DT 2 Left steering clutch ECMV (solenoid valve) I-7 K-5
SOL1 DT 2 Solenoid valve for pitch B-6 K-9
SOL2 DT 2 Solenoid valve for dual C-7 K-9
SP1 2 Engine speed sensor (master) d-6 K-4 E-8
SP2 2 Engine speed sensor (backup) d-6 K-3 F-8
SPP DT 3 Work equipment small pump pressure sensor E-8 K-8
SRB DT 2 Right steering brake ECMV (solenoid valve) J-6 K-4
SRC DT 2 Right steering clutch ECMV (solenoid valve) h-7 K-5
SRT DT 2 F clutch ECMV (solenoid valve) g-6 K-7
SS3 DT 3 Acceleration sensor F-2 H-8
STB DT 2 Sudden stop valve solenoid I-7 K-3
SX8 Terminal – GND H-3
TIMG 3 Timing rail actuator a-8 K-8
TL1 24-23 23 Fuel control dial, full monolever unit S-1 D-2 C-8
TLS DT 2 Blade tilt left oil pressure switch Q-8 F-1
TM1 DT 2 Transmission outlet speed sensor J-7 K-8 K-6
TMCN1 24 Transmission controller W-5 E-2 A-9 D-1
TMCN2 40 Transmission controller V-7 E-2 J-2 A-7 E-1
TMCN3 40 Transmission controller V-8 A-4
TMV 24-23 23 Intermediate connector g-7 J-7
TPR 3 Timing rail pressure sensor d-4 I-8
TRS DT 2 Blade tilt right oil pressure sensor Q-7 F-1
USB DT 1 Intermediate connector U-1 K-2 I-1 H-2
V23 DT 3 CAN terminal resistance W-6 F-1 J-2 A-1 F-1
VHMS 2 Intermediate connector O-9
D375A-5 20-315

1
TROUBLESHOOTING CONNECTOR ARRANGEMENT DRAWING
CONNECTOR ARRANGEMENT DRAWING
20-316 D375A-5
1
D375A-5 20-317

1
20-318 D375A-5
1
D375A-5 20-319

1
20-320 D375A-5
1
D375A-5 20-321

1
TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
20-322 D375A-5
1
TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
★ This circuit diagram has been made by extracting the monitor panel system, engine preheating, starting,
and charging system, light system, and communication network system from the overall electrical circuit
diagram.
D375A-5 20-323

1
TROUBLESHOOTING CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT)
CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT)
20-324 D375A-5
1
TROUBLESHOOTING CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT)
★ This circuit diagram has been made by extracting the engine controller system from the overall electrical
circuit diagram.
D375A-5 20-325

1
TROUBLESHOOTING CIRCUIT DRAWING FOR TRANSMISSION CONTROLLER SYSTEM (T CIRCUIT)
CIRCUIT DRAWING FOR TRANSMISSION CONTROLLER SYSTEM (T CIRCUIT)
20-326 D375A-5
1
TROUBLESHOOTING CIRCUIT DRAWING FOR TRANSMISSION CONTROLLER SYSTEM (T CIRCUIT)
★ This circuit diagram has been made by extracting the transmission controller system from the overall elec-
trical circuit diagram.
D375A-5 20-327

1
TROUBLESHOOTING CIRCUIT DRAWING FOR STEERING CONTROLLER SYSTEM (S CIRCUIT)
CIRCUIT DRAWING FOR STEERING CONTROLLER SYSTEM (S CIRCUIT)
20-328 D375A-5
1
TROUBLESHOOTING CIRCUIT DRAWING FOR STEERING CONTROLLER SYSTEM (S CIRCUIT)
★ This circuit diagram has been made by extracting the steering controller system from the overall electrical
circuit diagram.
D375A-5 20-329

1
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

★ The terms male and female refer to the pins, while the terms male housing and female housing refer
to the mating portion of the housing.
X Type Connector
Number
of Pins T-adapter
Male (Female housing) Female (Male housing)
Part Number
1 Part number: 08055-00181 Part number: 08055-00191 799-601-7010
2 799-601-7020
Part number: 08055-00282 Part number: 08055-00292
3 799-601-7030
4 799-601-7040

Terminal part number: 79A-222-3370 Terminal part number: 79A-222-3390
• Wire size: 0.85 • Wire size: 0.85
— —
• Quantity: 20 pieces • Quantity: 20 pieces
• Grommet: black • Grommet: black
— —
• Grommet: red • Grommet: red
20-330 D375A-5

1
SWP Type Connector

Number
of Pins T-adapter Part
Number
6 799-601-7050
8 799-601-7060
12 799-601-7310
14 799-601-7070
D375A-5 20-331

1
SWP Type Connector

Number
of Pins T-adapter
Part Number
16 799-601-7320

Terminal part number: Terminal part number:
— —
• Grommet: black • Grommet: black
Terminal part number: Terminal part number:
— —
• Grommet: red • Grommet: red
20-332 D375A-5

1
M Type Connector
Number
Number
1 Part number: 08056-00171 Part number: 08056-00181 799-601-7080
2 799-601-7090
3 799-601-7110
4 799-601-7120
6 799-601-7130
8 799-601-7340
D375A-5 20-333
1
(5)
S Type Connector
Number
Number
8 799-601-7140
10
799-601-7150
(white)
12
799-601-7350
(white)
16
799-601-7330
(white)
20-334 D375A-5
1
S Type Connector
Number
Number
10
—
(blue)
— —
12
799-601-7160
(blue)
16
799-601-7170
(blue)
D375A-5 20-335

1
MIC Type Connector

Number
of Pins T-adapter
Part Number
Body part number: 79A-222-2640 Body part number: 79A-222-2630
7 —
(Quantity: 5 pieces) (Quantity: 5 pieces)
11 —
5 799-601-2710

9 799-601-2950

13 799-601-2720

20-336 D375A-5

1
MIC Type Connector

Number
Number
17 799-601-2730

21 799-601-2740

—
D375A-5 20-337

1
AMP040 Type Connector

Number
of Pins T-adapter
Part Number
8 799-601-7180
Housing part number: 79A-222-3430

—
(Quantity: 5 pieces)
12 799-601-7190

—
16 799-601-7210

—
20 799-601-7220

—
★ Terminal part number: 79A-222-3470 (for all numbers of pins).
20-338 D375A-5
1
AMP070 Type Connector

Number
Number
10 799-601-7510
— Part number: 7821-92-7330
12 799-601-7520
— Part number: 7821-92-7340
14 799-601-7530
— Part number: 7821-92-7350
18 799-601-7540
— Part number: 7821-92-7360
20 799-601-7550
— Part number: 7821-92-7370
D375A-5 20-339
(7)
1
2
L Type Connector
Number
of Pins T-adapter
Part Number
2 —
— —
PA Type Connector
Number
of Pins T-adapter
Part Number
9 —
— —
BENDIX (MS) Type Connector

Number
of Pins T-adapter
Part Number
10 799-601-3460
— —
20-340 D375A-5

1
KES1 Automobile Type Connector

Number
Number
2 —
Part number: 08027-10210 (Natural color) Part number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
4 —
08027-10420 (Black) 08027-10470 (Black)
6 —
08027-10620 (Black) 08027-10670 (Black)
D375A-5 20-341

1
KES1 Automobile Type Connector

Number
of Pins T-adapter
Part Number
8 —
08027-10820 (Black) 08027-10870 (Black)
20-342 D375A-5

1
F Type Connector
Number
of Pins T-adapter
Part Number
4 —
— —
Connector for relay (Socket)

Number
of Pins T-adapter
Part Number
5 799-601-7360
— —
6 799-601-7370
— —
D375A-5 20-343
(6)
1
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector
(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part Number
Pin (male terminal) Pin (female terminal)
799-601-9210
Part number: 08191-11201, 08191-11202 Part number: 08191-14101, 08191-14102

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male terminal)
799-601-9210

08191-11205, 08191-12206 08191-13105, 08191-13106
799-601-9220

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220

08191-22205, 08191-22206 08191-23105, 08191-23106
20-344 D375A-5
1
(shell
size T-adapter Part
code) Number
799-601-9230
18-20 Part number: 08191-31201, 08191-31202 Part number: 08191-34101, 08191-34102

799-601-9230

799-601-9240

799-601-9240
D375A-5 20-345
1
(shell
size T-adapter
code) Part Number
799-601-9250

799-601-9250

799-601-9260

24-23 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260

08191-62205, 08191-62206 08191-63105, 08191-63106
20-346 D375A-5
(6)
1
(shell
size T-adapter Part
code) Number
799-601-9270

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part number: 08191-81201, 08191-81202, Part number: 08191-84101, 08191-84102,

08191-81203, 08191-81204, 08191-84103, 18191-84104,
24-22 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part number: 08191-82201, 08191-82202, Part number: 08191-83101, 08191-83102,

08191-82203, 08191-82204, 08191-83103, 18191-83104,
08191-82205, 08191-82206 08191-83105, 08191-83106
D375A-5 20-347

1
(shell
size T-adapter
code) Part Number
799-601-9290

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290

08191-92205, 08191-92206 08191-93105, 08191-93106
20-348 D375A-5

1
DT Series connector
Number
Number
2 799-601-9020
Part number: 08192-12200 (normal type) Part number: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
D375A-5 20-349
1
DT Series connector
Number
Number
8GR:799-601-9060
8B :799-601-9070
8
8G :799-601-9080
8BR :799-601-9080
Part number: 08192-1820 ! (normal type) Part number: 08192-1810 ! (normal type)
08192-2820 ! (fine wire type) 08192-2810 ! (fine wire type)
12GR:799-601-9110
12B :799-601-9120
12
12G :799-601-9130
12BR :799-601-9140
Part number: 08192-1920 ! (normal type) Part number: 08192-1910 ! (normal type)
08192-2920 ! (fine wire type) 08192-2910 ! (fine wire type)
20-350 D375A-5
1
(5)
DTM Series connector
Number
Number
2 799-601-9010
DTHD Series connector

Number
Number
1 —
Part number: 08192-31200 (Contact size #12) Part number: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
D375A-5 20-351
1
DRC26 Series connector

No. of
pins T-adapter
Part No.
24 799-601-9360
— Part No.: 7821-93-3110
40
799-601-9350
(A)
— Part No.: 7821-93-3120
40
799-601-9350
(B)
— Part No.: 7821-93-3130
20-352 D375A-5
(7)
1
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
T-BRANCH BOX AND T-BRANCH TABLE

★ The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part
number of Harness Checker Ass’y.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or
Part No. No. of pins
—
part name
799-601-2600 Measurement box Econo-21P

799-601-3100 Measurement box MS-37P
799-601-3200 Measurement box MS-37P
799-601-3300 Measurement box Econo-24P
799-601-3360 Plate For MS box
799-601-3410 BENDIX (MS) 24P
799-601-3420 BENDIX (MS) 24P
799-601-3430 BENDIX (MS) 17P
799-601-3440 BENDIX (MS) 17P
799-601-3450 BENDIX (MS) 5P
799-601-3460 BENDIX (MS) 10P
799-601-3510 BENDIX (MS) 5P
799-601-3520 BENDIX (MS) 14P
799-601-3530 BENDIX (MS) 19P
799-601-2910 BENDIX (MS) 14P
799-601-3470 Case
799-601-2710 MIC 5P
799-601-2720 MIC 13P
799-601-2730 MIC 17P
799-601-2740 MIC 21P
799-601-2950 MIC 9P
799-601-2750 ECONO 2P
799-601-2760 ECONO 3P
799-601-2770 ECONO 4P
799-601-2780 ECONO 8P
799-601-2790 ECONO 12P
799-601-2810 DLI 8P
799-601-2820 DLI 12P
799-601-2830 DLI 16P
799-601-2840 Additional cable
799-601-2850 Case
799-601-7010 X 1P
799-601-7020 X 2P
799-601-7030 X 3P
799-601-7040 X 4P
799-601-7050 SWP 6P
799-601-7060 SWP 8P
799-601-7310 SWP 12P
799-601-7070 SWP 14P
799-601-7320 SWP 16P
799-601-7080 M 1P
799-601-7090 M 2P
799-601-7110 M 3P
799-601-7120 M 4P
799-601-7130 M 6P
799-601-7340 M 8P
799-601-7140 S 8P
799-601-7150 S 10P-White
D375A-5 20-353
(7)
1
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or
Part No. No. of pins
—
part name
799-601-7160 S 12P-Blue
799-601-7170 S 16P-Blue
799-601-7330 S 16P-White
799-601-7350 S 12P-White
799-601-7180 AMP040 8P
799-601-7190 AMP040 12P
799-601-7210 AMP040 16P
799-601-7220 AMP040 20P
799-601-7230 Short connector X-2
799-601-7240 Case
799-601-7270 Case
799-601-7510 070 10P
799-601-7520 070 12P
799-601-7530 070 14P
799-601-7540 070 18P
799-601-7550 070 20P
799-601-7360 Relay connector 5P
799-601-7370 Relay connector 6P
799-601-7380 JFC connector 2P
799-601-9010 DTM 2P
799-601-9020 DT 2P
799-601-9030 DT 3P
799-601-9040 DT 4P
799-601-9050 DT 6P
799-601-9060 DT 8P-Gray
799-601-9070 DT 8P-Black
799-601-9080 DT 8P-Green
799-601-9090 DT 8P-Brown
799-601-9110 DT 12P-Gray
799-601-9120 DT 12P-Black
799-601-9130 DT 12P-Green
799-601-9140 DT 12P-Brown
799-601-9210 HD30 18-8
799-601-9220 HD30 18-14
799-601-9230 HD30 18-20
799-601-9240 HD30 18-21
799-601-9250 HD30 24-9
799-601-9260 HD30 24-16
799-601-9270 HD30 24-21
799-601-9280 HD30 24-23
799-601-9290 HD30 24-31
799-601-9310 Plate For HD30
799-601-9320 Measurement box For DT, HD
799-601-9330 Case
799-601-9340 Case
799-601-9350 DRC26 40P
799-601-9360 DRC26 24P
799-601-9410 For NE, G sensor 2P
799-601-9420 For fuel, boost press. 3P
799-601-9430 PVC socket 2P
20-354 D375A-5
(7)
1
TROUBLESHOOTING 20 TROUBLESHOOTING
TROUBLESHOOTING WHEN
SERVICE CODE IS DISPLAYED
(SERVICE CODE)
Information in troubleshooting table ........................................................................................................ 20-404

Service code E0101 [Abnormality in network system (steering)] .......................................................... 20-406
Service code E0104 [Abnormality in network system (monitor panel)] ................................................. 20-408
Service code E0111 (Abnormality in steering controller power supply system) ..................................... 20- 411
Service code E0112 (Abnormality in transmission controller power supply system) ............................. 20-413
Service code E0120 (Short circuit in caution lamp system) .................................................................. 20-415
Service code E0121 (Short circuit in caution buzzer system) ............................................................... 20-416
Service code E0142 (Abnormality in transmission controller 5 V power supply system) ...................... 20-417
Service code E0143 (Abnormality in steering controller 5 V power supply system) .............................. 20-419
Service code E0145 (Abnormality in steering controller 24 V power supply system) ............................ 20-421
Service code E0146 (Abnormality in transmission controller 24 V power supply system) .................... 20-422
Service code E0151 (Abnormality in selection of steering controller specification) ............................... 20-423
Service code E0160 (Abnormality in transmission controller ROM) ...................................................... 20-425
Service code E0161 (Abnormality in steering controller ROM) ............................................................. 20-425
Service code E0164 [Abnormality in network system (transmission)] ................................................... 20-426
Service code E0176 (Disconnection in battery relay system) ............................................................... 20-428
Service code E0177 (Short circuit in battery relay system) ................................................................... 20-429
Service code E0178 (Disconnection in neutral safety relay system) ..................................................... 20-430
Service code E0179 (Short circuit in neutral safety relay system) ........................................................ 20-432
Service code E0211 (Abnormal torque converter oil temperature) ........................................................ 20-434
Service code E0212 (Short circuit in torque converter lock-up solenoid system) .................................. 20-435
Service code E0213 (Disconnection in torque converter lock-up solenoid system) .............................. 20-436
Service code E0221 (Disconnection or short circuit in pitch angle sensor system) .............................. 20-437
Service code E0225 (Slip of power train clutch) .................................................................................... 20-439
Service code E0230 [Abnormality in both forward-reverse potentiometer systems (1)] ........................ 20-439
Service code E0233 (Disconnection or short circuit in forward-reverse potentiometer 1 system) ........ 20-441
Service code E0234 (Disconnection or short circuit in forward-reverse potentiometer 2 system) ........ 20-443
Service code E0235 (Deviation of forward-reverse potentiometer system signals) .............................. 20-444
Service code E0236 (Disconnection or short circuit in shift-up switch systems) ................................... 20-445
Service code E0237 (Disconnection or short circuit in shift-down switch systems) ............................... 20-447
Service code E0238 (Disconnection or short circuit in parking brake lever switch systems) ................ 20-449
Service code E0239 (Disagreement of parking brake lever switch system signals) ............................. 20-451
Service code E0250 (Disconnection in transmission forward clutch ECMV system) ............................ 20-452
Service code E0251 (Short circuit in transmission forward clutch ECMV system) ................................ 20-453
Service code E0252 (Disconnection in transmission reverse clutch ECMV system) ............................ 20-454
Service code E0253 (Short circuit in transmission reverse clutch ECMV system) ................................ 20-455
Service code E0254 (Disconnection in transmission 1st clutch ECMV system) ................................... 20-456
Service code E0255 (Short circuit in transmission 1st clutch ECMV system) ....................................... 20-457
Service code E0256 (Disconnection in transmission 2nd clutch ECMV system) .................................. 20-458
Service code E0257 (Short circuit in transmission 2nd clutch ECMV system) ...................................... 20-459
Service code E0258 (Disconnection in transmission 3rd clutch ECMV system) ................................... 20-460
Service code E0259 (Short circuit in transmission 3rd clutch ECMV system) ....................................... 20-461
Service code E0260 (Defective engagement of transmission forward clutch) ...................................... 20-462
Service code E0261 (Defective disengagement of transmission forward clutch) .................................. 20-463
Service code E0262 (Defective engagement of transmission reverse clutch) ...................................... 20-464
Service code E0263 (Defective disengagement of transmission reverse clutch) .................................. 20-465
Service code E0264 (Defective engagement of transmission 1st clutch) .............................................. 20-466
D375A-5 20-401
(7)
1
TROUBLESHOOTING
Service code E0265 (Defective disengagement of transmission 1st clutch) .......................................... 20-467
Service code E0266 (Defective engagement of transmission 2nd clutch) ............................................. 20-468
Service code E0267 (Defective disengagement of transmission 2nd clutch) ........................................ 20-469
Service code E0268 (Defective engagement of transmission 3rd clutch) .............................................. 20-470
Service code E0269 (Defective disengagement of transmission 3rd clutch) ......................................... 20-471
Service code E0270 [Double trouble in transmission clutch (Defective engagement)] .......................... 20-472
Service code E0271 [Double trouble in transmission clutch (Defective disengagement)] ..................... 20-472
Service code E0306 (Short circuit in blade tilt right oil pressure switch system) ................................... 20-473
Service code E0307 (Short circuit in blade tilt left oil pressure switch system) ...................................... 20-474
Service code E0308 (Short circuit in ripper lift raise oil pressure switch system) .................................. 20-475
Service code E0309 (Short circuit in ripper lift lower oil pressure switch system) ................................. 20-476
Service code E0310 (Short circuit in ripper tilt-in oil pressure switch system) ....................................... 20-477
Service code E0311 (Disconnection or short circuit in blade pitch switch systems) .............................. 20-478
Service code E0312 (Disconnection or short circuit in blade tilt switch systems) .................................. 20-480
Service code E0321 (Disconnection in blade dual selector solenoid system) ....................................... 20-482
Service code E0322 (Short circuit in blade dual selector solenoid system) ........................................... 20-483
Service code E0323 (Disconnection in blade pitch selector solenoid system) ...................................... 20-484
Service code E0324 (Short circuit in blade pitch selector solenoid system) .......................................... 20-485
Service code E0329 (Abnormal hydraulic oil temperature) ................................................................. 20-485-1
Service code E0364 (Disconnection in front large pump oil pressure sensor system) .......................... 20-486
Service code E0365 (Short circuit in front large pump oil pressure sensor system) .............................. 20-487
Service code E0366 (Disconnection in center small pump oil pressure sensor system) ....................... 20-488
Service code E0367 (Short circuit in center small pump oil pressure sensor system) ........................... 20-489
Service code E0405 (Disconnection or short circuit in fuel control dial system) .................................... 20-490
Service code E0430 (Engine oil: Abnormal oil pressure) ................................................................... 20-491-1
Service code E0431 (Abnormal radiator coolant level) ...................................................................... 20-491-1
Service code E0432 (Radiator coolant: Overheating).......................................................................... 20-491-1
Service code E0486 (Abnormality in selection of transmission controller specification) ........................ 20-492
Service code E0501 (Disconnection or short circuit in acceleration sensor system) ............................. 20-493
Service code E0610 (Disconnection in back-up alarm relay system) .................................................... 20-494
Service code E0611 (Short circuit in back-up alarm relay system) ........................................................ 20-496
Service code E0660 (Disconnection in ACC signal drive relay system) ................................................ 20-498
Service code E0661 (Short circuit in ACC signal drive relay system) .................................................... 20-499
Service code E0721 (Disconnection or short circuit in pitch angle sensor system) ............................... 20-500
Service code E0730 [Abnormality in both steering potentiometer systems (1)] ..................................... 20-502
Service code E0733 (Disconnection or short circuit in steering potentiometer 1 system) ..................... 20-504
Service code E0734 (Disconnection or short circuit in steering potentiometer 2 system) ..................... 20-506
Service code E0735 (Deviation of steering potentiometer system signals) ........................................... 20-507
Service code E0736 (Disconnection or short circuit in brake potentiometer system) ............................ 20-508
Service code E0750 (Disconnection in right steering clutch ECMV system) ......................................... 20-510
Service code E0751 (Short circuit in right steering clutch ECMV system) ............................................. 20- 511
Service code E0752 (Disconnection in left steering clutch ECMV system) ........................................... 20-512
Service code E0753 (Short circuit in left steering clutch ECMV system) ............................................... 20-513
Service code E0754 (Disconnection in right steering brake ECMV system) .......................................... 20-514
Service code E0755 (Short circuit in right steering brake ECMV system) ............................................. 20-515
Service code E0756 (Disconnection in left steering brake ECMV system) ............................................ 20-516
Service code E0757 (Short circuit in left steering brake ECMV system) ............................................... 20-517
Service code E0760 (Defective engagement of right steering clutch) ................................................... 20-518
Service code E0761 (Defective disengagement of right steering clutch) ............................................... 20-519
Service code E0762 (Defective engagement of left steering clutch) ...................................................... 20-520
Service code E0763 (Defective disengagement of left steering clutch) ................................................. 20-521
Service code E0764 (Defective engagement of right steering brake) .................................................... 20-522
Service code E0765 (Defective disengagement of right steering brake) ............................................... 20-523
Service code E0766 (Defective engagement of left steering brake) ...................................................... 20-524
Service code E0767 (Defective disengagement of left steering brake) ................................................. 20-525
Service code E0779 (Disconnection in sudden stop prevention solenoid system) ................................ 20-526
Service code E0780 (Short circuit in sudden stop prevention solenoid system) .................................... 20-527
Service code E0781 (Disconnection or short circuit in parking brake lever switch systems) ................. 20-528
20-402 D375A-5
(7)
1
TROUBLESHOOTING
Service code E0782 (Disagreement of parking brake lever switch system signals) ............................. 20-530
Service code E0930 (Disconnection in engine speed sensor system) .................................................. 20-531
Service code E0931 (Disconnection in engine speed sensor system) .................................................. 20-533
Service code E0932 (Disconnection in transmission speed sensor system) ........................................ 20-535
Service code E0933 (Disconnection in transmission speed sensor system) ........................................ 20-537
Service code E1939 (Abnormality in J1939 communication system) .................................................... 20-539
Service code EC111 (Abnormality in engine controller memory) ........................................................... 20-540
Service code EC112 (Abnormality in timing rail actuator) ...................................................................... 20-540
Service code EC113 (Abnormal current in timing rail actuator system) ................................................. 20-541
Service code EC115 (Abnormality in engine speed sensor 2 systems) ................................................. 20-542
Service code EC116 (Abnormally high level in timing rail pressure sensor system) .............................. 20-544
Service code EC117 (Abnormally low level in timing rail pressure sensor system) ............................... 20-545
Service code EC118 (Abnormally high level in fuel pump pressure sensor system) ............................. 20-546
Service code EC119 (Abnormally low level in fuel pump pressure sensor system) ............................... 20-547
Service code EC121 (Abnormality in engine speed sensor 1 systems) ................................................. 20-547
Service code EC122 (Abnormally high level in boost pressure sensor system) .................................... 20-548
Service code EC123 (Abnormally low level in boost pressure sensor system) ..................................... 20-549
Service code EC131 (Abnormally high level in throttle sensor system) ................................................. 20-550
Service code EC132 (Abnormally low level in throttle sensor system) .................................................. 20-551
Service code EC133 (Abnormally high level in remote throttle sensor system) ..................................... 20-552
Service code EC134 (Abnormally low level in remote throttle sensor system) ...................................... 20-553
Service code EC135 (Abnormally high level in engine oil pressure sensor system) ............................. 20-554
Service code EC141 (Abnormally low level in engine oil pressure sensor system) ............................... 20-555
Service code EC143 (Lowering of engine oil pressure) ......................................................................... 20-555
Service code EC144 (Abnormally high level in engine coolant temperature sensor system) ................ 20-556
Service code EC145 (Abnormally low level in engine coolant temperature sensor system) ................. 20-557
Service code EC151 (Rise of engine coolant temperature) ................................................................... 20-557
Service code EC153 (Abnormally high level in air intake temperature sensor system) ......................... 20-558
Service code EC154 (Abnormally low level in air intake temperature sensor system) .......................... 20-559
Service code EC221 (Abnormally high level in atmospheric pressure sensor system) ......................... 20-560
Service code EC222 (Abnormally low level in atmospheric pressure sensor system) ........................... 20-561
Service code EC234 (Over-speed) ........................................................................................................ 20-561
Service code EC254 (Abnormal voltage of fuel shut-off valve) .............................................................. 20-562
Service code EC259 (Abnormality in fuel shut-off valve) ....................................................................... 20-563
Service code EC261 (Abnormal rise of fuel temperature) ...................................................................... 20-563
Service code EC263 (Abnormally high level in fuel temperature sensor system) .................................. 20-564
Service code EC265 (Abnormally low level in fuel temperature sensor system) ................................... 20-565
Service code EC316 (Abnormal current of fuel pump actuator) ............................................................. 20-566
Service code EC318 (Abnormality in fuel pump actuator) ..................................................................... 20-567
Service code EC346 (Abnormality in power-down unit of engine controller) ......................................... 20-568
Service code EC384 (Abnormality in preheater control system) ............................................................ 20-570
Service code EC423 (Abnormality in in-range of timing rail pressure sensor system) .......................... 20-572
Service code EC441 (Abnormally low level in battery voltage system) ................................................. 20-574
Service code EC442 (Abnormally high level in battery voltage system) ................................................ 20-574
Service code EC451 (Abnormally high level in fuel rail pressure sensor system) ................................. 20-575
Service code EC452 (Abnormally low level in fuel rail pressure sensor system) ................................... 20-576
Service code EC455 (Abnormal current of fuel rail actuator) ................................................................. 20-577
Service code EC467 (Abnormality in timing rail actuator control) .......................................................... 20-578
Service code EC468 (Abnormality in fuel rail actuator control) .............................................................. 20-578
Service code EC514 (Abnormality in fuel rail actuator) .......................................................................... 20-579
Service code EC554 (Abnormality in in-range of fuel rail pressure sensor system) .............................. 20-580
D375A-5 20-403
(6)
1
TROUBLESHOOTING INFORMATION IN TROUBLESHOOTING TABLE
INFORMATION IN TROUBLESHOOTING TABLE

★ The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before carrying out troubleshooting, understand that information fully.
User code Service code

Trouble Trouble in machine
Display on panel Display on panel
Contents of trouble Contents of trouble detected by monitor panel or controller
Action of controller Action taken by controller to protect system or devices when monitor panel or controller detects trouble
Problem that
Problem that appears on machine as result of action taken by monitor panel or controller (shown above)
appears on machine
Related information Information related to detected trouble or troubleshooting
Cause Standard value in normal state/Remarks on troubleshooting
<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1
<Troubles in harness>
• Disconnection
Connector is connected imperfectly or harness is broken.
• Short circuit with chassis ground
Harness which is not connected to chassis ground circuit is in con-
tact with chassis ground circuit.
• Short circuit with power source
2 Harness which is not connected to power source (24 V) circuit is in
contact with power source (24 V) circuit.
• Short circuit
Possible causes Possible causes of trouble Independent harnesses are in contact with each other abnormally.
and standard val- (Given numbers are refer-
ue in normal state ence numbers, which do not <Precautions for troubleshooting>
indicate priority) 1Method of indicating connector No. and handling of T-adapter
Insert or connect T-adapter as explained below for troubleshooting,
unless otherwise specified.
3 • If connector No. has no marks of “male” and “female”, disconnect
connector and insert T-adapters in both male side and female
side.
• If connector No. has marks of “male” and “female”, disconnect
connector and connect T-adapter to only male side or female side.
2Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as ex-
plained below for troubleshooting, unless otherwise specified.
4 • Connect positive (+) lead to pin No. or harness entered on front
side.
• Connect negative (–) lead to pin No. or harness entered on rear
side.
20-404 D375A-5
1
Part of electric circuit diagram related to trouble

Connector No.: Indicates (Model Number of pins) and (Color).
Arrows (⇔): Indicate rough location of connector in machine.
D375A-5 20-405
1
TROUBLESHOOTING SERVICE CODE E0101 [ABNORMALITY IN NETWORK SYSTEM (STEERING)]
SERVICE CODE E0101 [ABNORMALITY IN NETWORK SYSTEM (STEERING)]
User code Service code Abnormality in network system (steering)

Trouble
CALL03 E0101 (Monitor panel system)
Contents of trouble Monitor panel (Tachometer module) cannot recognize S-NET of steering controller.
Flashes caution lamp and turns on caution buzzer.
Action of controller
Limits operation of engine and transmission.
Monitor panel may not display normally.
Problem that
Once machine is stopped, engine speed is limited to medium (half).
appears on machine
Once machine is stopped, travel is limited to F1 and R1.
Connection state (ON·OFF) of S-NET can be checked in monitoring mode.
Related information (Code 5N: Connection state of S-NET communication)
Method of reproducing service code: Turn starting switch ON.

★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness
Wiring harness between S03 (female) 9
1 (Disconnection in wiring or Resistance Max. 1 Ω
NGICN2 (female) K
defective contact in connec-
tor) Wiring harness between S03 (female) 8
Resistance Max. 1 Ω
NGICN2 (female) U
Short circuit with chassis without turning starting switch ON.
2 ground in wiring harness Short circuit of wiring harness between S03
(Contact with ground circuit) (female) 9 S01 (female) 8 or NGICN2 (fe- Resistance Min. 1 MΩ
male) K with chassis ground
Possible causes
and standard val- ★ Prepare with starting switch OFF, then turn starting switch ON and
ue in normal state Short circuit with power carry out troubleshooting.
3 source in wiring harness Short circuit of wiring harness between S03
(Contact with 24 V circuit) (female) 9 S01 (female) 8 or NGICN2 (fe- Voltage Max. 1 V
male) K with chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Defective monitor panel carry out troubleshooting.
4
(tachometer module) S03 Voltage
Between 9 8 69V
carry out troubleshooting.
5 Defective steering controller
NGICN2 Voltage
Between K U 69V
20-406 D375A-5
1
Circuit diagram related to S-NET communication
D375A-5 20-407
1
TROUBLESHOOTING SERVICE CODE E0104 [ABNORMALITY IN NETWORK SYSTEM (MONITOR PANEL)]
SERVICE CODE E0104 [ABNORMALITY IN NETWORK SYSTEM (MONITOR PANEL)]
User code Service code Abnormality in network system (monitor panel)

Trouble
Contents of trouble Monitor panel (Tachometer module) cannot recognize S-NET of monitor panel (caution module).
Problem that
appears on machine

Disconnection in wiring har- ★ Prepare with starting switch OFF, then carry out troubleshooting
ness without turning starting switch ON.
1 (Disconnection in wiring or
defective contact in connec- Wiring harness between S03 (female) @ Resistance Max. 1 Ω
tor) CN1 (female) A

2 ground in wiring harness Short circuit of wiring harness between S03
(Contact with ground circuit) (female) @ CN1 (female) A with chassis Resistance Min. 1 MΩ
ground
Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON and
and standard val- Short circuit with power carry out troubleshooting.
ue in normal state 3 source in wiring harness Short circuit of wiring harness between S03
(Contact with 24 V circuit) (female) @ CN1 (female) A with chassis Voltage Max. 1 V
ground
4
(tachometer module) S03 Voltage
Between @ 8 69V
5
(caution module) CN1 Voltage
Between A @ 69V
20-408 D375A-5
1
TROUBLESHOOTING SERVICE CODE E0104 [ABNORMALITY IN NETWORK SYSTEM (MONITOR PANEL)]
D375A-5 20-409
1

Trouble
Contents of trouble Monitor panel (Tachometer module) cannot recognize S-NET of steering controller.
Problem that
appears on machine
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard val-
ue in normal state Carry out troubleshooting for service code [E0101].
20-410 D375A-5
1
SERVICE CODE E0111 (ABNORMALITY IN STEERING CONTROLLER POWER
TROUBLESHOOTING SUPPLY SYSTEM)
SERVICE CODE E0111 (ABNORMALITY IN STEERING CONTROLLER POWER SUPPLY

SYSTEM)
User code Service code Abnormality in steering controller power supply system
Trouble
CALL E0111 (Steering controller system)
Contents of trouble Source voltage of steering controller is below 17 V.
Limits operation of engine, transmission, and brake.
Problem that Relays and solenoids may not be driven and system may not operate normally as result.
appears on machine Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, it cannot travel any more.
Charge level (Voltage) of battery can be checked in monitoring mode.
Related information (Code dA: Battery voltage)

Defective circuit breaker If circuit breaker is turned OFF, circuit probably has short circuit with
1
(CB1) chassis ground.
If fusible link is broken, circuit probably has short circuit with chassis
2 Defective fusible link (96A)
ground.
without turning starting switch ON.
Disconnection in wiring har- Wiring harness between NGICN3 (female) 1,
ness Resistance Max. 1 Ω
A CB1 (1)
defective contact in connec- Wiring harness between CB1 (2) fusible link
tor) battery relay terminal M
Possible causes Wiring harness between NGICN3 (female) K,
and standard val- U, V, W chassis ground
ue in normal state ★ Prepare with starting switch OFF, then carry out troubleshooting
Short circuit of wiring harness between
Short circuit with chassis
NGICN3 (female) 1, A CB1 (1) with chas- Resistance Min. 1 MΩ
4 ground in wiring harness
sis ground
(Contact with ground circuit)
Short circuit of wiring harness between CB1
(2) fusible link battery relay terminal M with Resistance Min. 1 MΩ
chassis ground
NGICN3 Voltage
Between 1, A K, U, V, W 20 30 V
D375A-5 20-411
1
SERVICE CODE E0111 (ABNORMALITY IN STEERING CONTROLLER POWER
Circuit diagram related to steering controller power supply
20-412 D375A-5
1
SERVICE CODE E0112 (ABNORMALITY IN TRANSMISSION CONTROLLER POWER

SUPPLY SYSTEM)
User code Service code Abnormality in transmission controller power supply system
Trouble
CALL E0112 (Transmission controller system)
Contents of trouble Source voltage of transmission controller is below 17 V.
Problem that Relays and solenoids may not be driven and system may not operate normally as result.
Charge level (Voltage) of battery can be checked in monitoring mode.

1
2 Defective fusible link (96A)
ground.
Disconnection in wiring har- Wiring harness between TMCN3 (female) 1,
A CB3 (1)
defective contact in connec- Wiring harness between CB3 (2) fusible link
tor) battery relay terminal M
Possible causes Wiring harness between TMCN3 (female) K,
and standard val- U, V, W chassis ground
Short circuit with chassis
TMCN3 (female) 1, A CB3 (1) with chassis Resistance Min. 1 MΩ
ground
Short circuit of wiring harness between CB3
(2) fusible link battery relay terminal M with Resistance Min. 1 MΩ
chassis ground
Defective transmission con- carry out troubleshooting.
5
troller TMCN3 Voltage
Between 1, A K, U, V, W 20 30 V
D375A-5 20-413
1
Circuit diagram related to transmission controller power supply
20-414 D375A-5
1
TROUBLESHOOTING SERVICE CODE E0120 (SHORT CIRCUIT IN CAUTION LAMP SYSTEM)
SERVICE CODE E0120 (SHORT CIRCUIT IN CAUTION LAMP SYSTEM)
User code Service code Short circuit in caution lamp system

Trouble
Contents of trouble Abnormal current flowed when caution lamp circuit output GND signal.
Turns on caution buzzer.
Action of controller Stops caution lamp circuit from outputting GND signal.
Caution lamp does not light up or flash.
Problem that
appears on machine
Method of reproducing service code:
Related information
Turn starting switch ON. (Lamp lights up for 2 seconds when switch is turned ON.)

Defective caution lamp without turning starting switch ON.
1
(Internal short circuit) 375 (male) Resistance
Between 1 2 100 400 Ω
Possible causes Short circuit with power carry out troubleshooting.
and standard val- 2 source in wiring harness Short circuit of wiring harness between 375
ue in normal state (Contact with 24 V circuit) (female) 2 CN2 (female) 7 with power Voltage Max. 1 V
source
3 Defective monitor panel CN2 Caution lamp Voltage
Between 7 chassis When turned OFF 20 30 V
ground When turned ON Max. 6 V
Circuit diagram related to caution lamp
D375A-5 20-415
1
TROUBLESHOOTING SERVICE CODE E0121 (SHORT CIRCUIT IN CAUTION BUZZER SYSTEM)
SERVICE CODE E0121 (SHORT CIRCUIT IN CAUTION BUZZER SYSTEM)
User code Service code Short circuit in caution buzzer system

Trouble
Contents of trouble Abnormal current flowed when caution buzzer circuit outputted GND signal.
Turns on caution lamp.
Action of controller Stops caution buzzer circuit from outputting GND signal.
Caution buzzer does not sound.
Problem that
appears on machine
Related information
Turn starting switch ON. (Buzzer sounds for 1 second when switch is turned ON.)

Defective caution buzzer without turning starting switch ON.
1
(Internal short circuit) 217 (male) Resistance
Between 1 2 200 Ω
Short circuit with power carry out troubleshooting.
Possible causes
2 source in wiring harness Short circuit of wiring harness between 217
and standard val-
(Contact with 24 V circuit) (female) 1 CN2 (female) 8 with power Voltage Max. 1 V
ue in normal state
source
CN2 Caution buzzer Voltage
3 Defective monitor panel
When turned OFF 20 30 V
Between 8 chassis
ground When turned ON
Max. 3 V
(sounded)
Circuit diagram related to caution buzzer
20-416 D375A-5
1
SERVICE CODE E0142 (ABNORMALITY IN TRANSMISSION CONTROLLER 5 V
TROUBLESHOOTING POWER SUPPLY SYSTEM)
SERVICE CODE E0142 (ABNORMALITY IN TRANSMISSION CONTROLLER 5 V POWER

SUPPLY SYSTEM)
User code Service code Abnormality in transmission controller 5 V power supply system
Trouble
CALL03 E0142 (Transmission controller system)
Voltage of 5 V power supply circuit for sensors of transmission controller is below 4.5 V or above 5.5 V.
Contents of trouble
Abnormal current flowed in 5 V power supply circuit for sensors of transmission controller.
Action of controller Stops 5 V power supply circuit from outputting if abnormal current flows.
System may not operate normally.
Problem that
appears on machine
Related information Method of reproducing service code: Turn starting switch ON.

TL1 (male) Resistance
Defective forward-reverse Between L J 2 kΩ ± 20%
1 potentiometer Sensor 1 (FR3) Between L chassis
(Internal short circuit) Min. 1 MΩ
ground
Between O Q 2 kΩ ± 20%
Sensor 2 (FR4) Between O chassis
Min. 1 MΩ
ground
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard val- Short circuit with chassis without turning starting switch ON.
ue in normal state 2 ground in wiring harness Short circuit of wiring harness between
(Contact with ground circuit) TMCN1 (female) L TL1 (female) L or TL1 Resistance Min. 1 MΩ
(female) O with chassis ground
3 source in wiring harness Short circuit of wiring harness between
(Contact with 24 V circuit) TMCN1 (female) L TL1 (female) L or TL1 Voltage Max. 1 V
(female) O with chassis ground
4
Between L K 4.5 5.5 V
D375A-5 20-417
1
Circuit diagram related to transmission controller 5 V power supply
20-418 D375A-5
1
SERVICE CODE E0143 (ABNORMALITY IN STEERING CONTROLLER 5 V POWER

SUPPLY SYSTEM)
User code Service code Abnormality in steering controller 5 V power supply system
Trouble
CALL03 E0143 (Steering controller system)
Voltage of 5 V power supply circuit for sensors of steering controller is below 4.5 V or above 5.5 V.
Contents of trouble
Abnormal current flowed in 5 V power supply circuit for sensors of steering controller.
System may not operate normally.
Problem that
appears on machine

When connector shown at right is disconnected, if service
Defective fuel control dial code changes to P (to indicate that trouble is repaired), Fuel control
1 trouble is in system. dial
(Internal short circuit) ★ Disconnect connector with starting switch OFF, then connector
turn starting switch ON and carry out troubleshooting.
Defective brake potentiome- code changes to P (to indicate that trouble is repaired),
BRK
2 ter trouble is in system.
★ Disconnect connector with starting switch OFF, then connector
(Internal short circuit)
Defective acceleration sen- code changes to P (to indicate that trouble is repaired),
SS3
3 sor trouble is in system.
★ Disconnect connector with starting switch OFF, then connector
TL1 (male) Resistance
Defective steering potenti- Between A G 2 kΩ ± 20%
4 ometer Sensor 1 (ST1) Between A chassis
Possible causes Min. 1 MΩ
(Internal short circuit) ground
and standard val-
ue in normal state Between M F 2 kΩ ± 20%
Sensor 2 (ST2) Between M chassis
Min. 1 MΩ
ground
Short circuit with chassis Short circuit of wiring harness between
5 ground in wiring harness NGICN1 (female) L TL1 (female) A, TL1
(Contact with ground circuit) (female) M, fuel control dial connector (fe- Resistance Min. 1 MΩ
male) 1, BRK (female) C, or SS3 (female) 8
with chassis ground
Short circuit with power Short circuit of wiring harness between
6 source in wiring harness NGICN1 (female) L TL1 (female) A, TL1
(Contact with 24 V circuit) (female) M, fuel control dial connector (fe- Voltage Max. 1 V
male) 1, BRK (female) C, or SS3 (female) 8
with chassis ground
NGICN1 Voltage
Between L K 4.5 5.5 V
D375A-5 20-419
1
20-420 D375A-5
1

SUPPLY SYSTEM)
User code Service code Abnormality in steering controller 24 V power supply system
Trouble
• Voltage of 24 V power supply circuit for sensors of steering controller is below 17 V or above 30 V.
Contents of trouble
• Abnormal current flowed in 24 V power supply circuit for sensors of steering controller.
• Flashes caution lamp and turns on caution buzzer.
Action of controller • Stops 24 V power supply circuit from outputting if abnormal current flows.
• Limits operation of engine and transmission.
• System may not operate normally.
Problem that
• Once machine is stopped, engine speed is limited to medium (half).
appears on machine
• Once machine is stopped, travel is limited to F1 and R1.
Related information • Method of reproducing service code: Turn starting switch ON.

Defective machine inclina- code changes to P (to indicate that trouble is repaired),
PAS
1 tion angle sensor trouble is in system.
connector
(Internal short circuit) ★ Disconnect connector with starting switch OFF, then
ue in normal state 2 ground in wiring harness
(Contact with ground circuit) NGICN1 (female) F – PAS (female) C with Resistance Min. 1 MΩ
chassis ground
NGICN1 Voltage
Between F – K 20 – 30 V
Circuit diagram related to steering controller 24 V power supply
D375A-5 20-421
1
4
SERVICE CODE E0146 (ABNORMALITY IN TRANSMISSION CONTROLLER 24 V POWER

SUPPLY SYSTEM)
User code Service code Abnormality in transmission controller 24 V power supply system
Trouble
E01 E0146 (Transmission controller system)
Voltage of 24 V power supply circuit for sensors of transmission controller is below 17 V or above 20 V.
Contents of trouble
Abnormal current flowed in 24 V power supply circuit for sensors of transmission controller.
Problem that
Work equipment oil pressure cannot be monitored in service mode.
appears on machine

Defective work equipment
code changes to P (to indicate that trouble is repaired),
large pump oil pressure sen- LPP
1 trouble is in system.
sor connector
★ Prepare with starting switch OFF, then turn starting
switch ON and carry out troubleshooting.
Defective work equipment
code changes to P (to indicate that trouble is repaired),
small pump oil pressure sen- SPP
2 trouble is in system.
sor connector
Possible causes ★ Prepare with starting switch OFF, then turn starting
and standard val- switch ON and carry out troubleshooting.
3 ground in wiring harness Short circuit of wiring harness between
(Contact with ground circuit) TMCN1 (female) F LPP (female) B or SPP Resistance Min. 1 MΩ
(female) B with chassis ground
4
Between F K 20 30 V
20-422 D375A-5
1
SERVICE CODE E0151 (ABNORMALITY IN SELECTION OF STEERING
TROUBLESHOOTING CONTROLLER SPECIFICATION)
SERVICE CODE E0151 (ABNORMALITY IN SELECTION OF STEERING CONTROLLER

SPECIFICATION)
User code Service code Abnormality in selection of steering controller specification

Trouble
Internal setting of steering controller specification is different from specification setting signal (Steer-
Contents of trouble
ing controller cannot recognize specification setting normally).
Action of controller Stops steering controller from outputting all signals.
Machine does not move at all.
Problem that
appears on machine

After adjustment mode is executed, if service code changes to P (to
Defective adjustment of indicate that trouble is repaired), system is normal.
1
steering controller Adjustment code:
5A [Check of specification code (Steering controller)]
Possible causes ness without turning starting switch ON.
and standard val- 2 (Disconnection in wiring or
ue in normal state defective contact in connec- Wiring harness between NGICN3 (female) J Resistance Max. 1 Ω
tor) chassis ground
NGICN3 Voltage
Between J chassis ground Max. 1 V
Circuit diagram related to steering controller specification selection signal
D375A-5 20-423
1

Trouble
Contents of trouble Steering controller detected abnormality in S-NET.
Problem that Shoe slip control (SSC) function may not work.

and standard val-
ue in normal state Carry out troubleshooting for service code [E0101].
20-424 D375A-5
1
SERVICE CODE E0160 (ABNORMALITY IN TRANSMISSION CONTROLLER ROM)
TROUBLESHOOTING SERVICE
SERVICE CODECODE
E0160E0161 (ABNORMALITY
(ABNORMALITY IN STEERING CONTROLLER ROM)
IN TRANSMISSION
SERVICE CODE E0160 (ABNORMALITY IN TRANSMISSION CONTROLLER ROM)
User code Service code Abnormality in transmission controller ROM

Trouble
Contents of trouble Information in transmission controller ROM (non-volatile memory) is abnormal.
Action of controller Sets internal adjustment values to default.
Problem that
Gear shifting feeling of transmission may become bad.
appears on machine

Possible causes
and standard val- Since trouble is in system, troubleshooting cannot be carried out.
Defective transmission con-
ue in normal state 1 troller (If there is not visible trouble in machine, controller may be used as it
is.)
SERVICE CODE E0161 (ABNORMALITY IN STEERING CONTROLLER ROM)
User code Service code Abnormality in steering controller ROM

Trouble
E02 E0161 (Steering controller system)
Contents of trouble Information in steering controller ROM (non-volatile memory) is abnormal.
Sets internal adjustment values to default.
Problem that Steering performance may lower.
appears on machine Braking performance may lower.

Possible causes
and standard val- Since trouble is in system, troubleshooting cannot be carried out.
ue in normal state 1 Defective steering controller (If there is not visible trouble in machine, controller may be used as it
is.)
D375A-5 20-425
1
TROUBLESHOOTING SERVICE CODE E0164 [ABNORMALITY IN NETWORK SYSTEM (TRANSMISSION)]
SERVICE CODE E0164 [ABNORMALITY IN NETWORK SYSTEM (TRANSMISSION)]
User code Service code Abnormality in network system (transmission)

Trouble
Contents of trouble Transmission controller detected abnormality in S-NET.
Problem that Gear shifting feeling of transmission may become bad.

ness
Wiring harness between CN1 (female) B
TMCN2 (female) K
tor) Wiring harness between CN1 (female) @
TMCN2 (female) U
2 ground in wiring harness Short circuit of wiring harness between CN1
(Contact with ground circuit) (female) B TMCN2 (female) K with chassis Resistance Min. 1 MΩ
ground
Possible causes
3 source in wiring harness Short circuit of wiring harness between CN1
(Contact with 24 V circuit) (female) B TMCN2 (female) K with chassis Voltage Max. 1 V
ground
4
(caution module) CN2 Voltage
Between B @ 69V
5
Between K U 69V
20-426 D375A-5
1
TROUBLESHOOTING SERVICE CODE E0164 [ABNORMALITY IN NETWORK SYSTEM (TRANSMISSION)]
D375A-5 20-427
1
TROUBLESHOOTING SERVICE CODE E0176 (DISCONNECTION IN BATTERY RELAY SYSTEM)
SERVICE CODE E0176 (DISCONNECTION IN BATTERY RELAY SYSTEM)
User code Service code Disconnection in battery relay system

Trouble
E0176 (Steering controller system)
Contents of trouble When signal is output to battery relay circuit, current does not flow.
Action of controller Stops outputting to battery relay circuit.
Problem that
Trouble may occur in writing data in each controller ROM (non-volatile memory).
appears on machine
Outputting to battery relay (Voltage) can be checked in monitoring mode.
Related information (Code dA: Battery relay drive voltage)
Method of reproducing service code: Turn starting switch ON and OFF.

Defective battery relay without turning starting switch ON.
1
(Internal disconnection) Battery relay Continuity
Between terminals BR E There is continuity.
ness
Wiring harness between NGICN3 (female) 4
chassis ground
Possible causes defective contact in connec-
and standard val- tor) Wiring harness between battery relay terminal
ue in normal state E chassis ground
(Contact with 24 V circuit) NGICN3 (female) 4 battery relay terminal Voltage Max. 1 V
BR with chassis ground
NGICN3 (female) Continuity
Between 4 chassis ground There is continuity.
Circuit diagram related to battery relay
20-428 D375A-5
1
TROUBLESHOOTING SERVICE CODE E0177 (SHORT CIRCUIT IN BATTERY RELAY SYSTEM)
SERVICE CODE E0177 (SHORT CIRCUIT IN BATTERY RELAY SYSTEM)
User code Service code Short circuit in battery relay system

Trouble
— E0177 (Steering controller system)
Contents of trouble • When signal is output to battery relay circuit, abnormal current flowed.
Action of controller • Stops outputting to battery relay circuit.
Problem that
• Trouble may occur in writing data in each controller ROM (non-volatile memory).
appears on machine
• Outputting to battery relay (Voltage) can be checked in monitoring mode.
Related information (Code dA: Battery relay drive voltage)
• Method of reproducing service code: Turn starting switch ON and OFF.

Defective battery relay Battery relay Continuity/Resistance
1
(Internal short circuit) Between terminals BR – E There is continuity.
Between terminal BR – chassis
Min. 1 MΩ
ground
(Contact with ground circuit) NGICN3 (female) 4 – battery relay terminal Resistance Min. 1 MΩ
BR with chassis ground
3 Defective steering controller NGICN3 Starting switch Voltage
Between 4 – chassis
ON 20 – 30 V
ground
Circuit diagram related to battery relay
D375A-5 20-429
1
TROUBLESHOOTING SERVICE CODE E0178 (DISCONNECTION IN NEUTRAL SAFETY RELAY SYSTEM)
SERVICE CODE E0178 (DISCONNECTION IN NEUTRAL SAFETY RELAY SYSTEM)
User code Service code Disconnection in neutral safety relay system

Trouble
Contents of trouble • When GND signal for neutral safety relay circuit is turned off, 24 V is not generated.
• Stops outputting GND signal for neutral safety relay circuit.
Problem that
• Engine cannot be started.
appears on machine
• Outputting to neutral safety relay (Voltage) can be checked in monitoring mode.
(Code dN: Neutral safety relay drive voltage)
• Method of reproducing service code:
Related information
Turn starting switch ON and operate parking brake lever (LOCK position).
★ This service code detects abnormality on primary side (coil side) of neutral safety relay and cannot
detect abnormality on secondary side (contact side).

1
Defective neutral safety re- without turning starting switch ON.
2 lay
NSF (Male) Resistance
(Internal disconnection)
Between 1 – 2 200 – 400 Ω
ness
Wiring harness between TMCN2 (female) 8 –
NSF (female) 2
Possible causes tor) Wiring harness between NSF (female) 1 –
and standard val- CB3 (1)
4 ground in wiring harness TMCN2 (female) 8 – NSF (female) 2 with Resistance Min. 1 MΩ
(Contact with ground circuit) chassis ground
Short circuit of wiring harness between NSF
Resistance Min. 1 MΩ
(female) 1 – CB3 (1) with chassis ground
Defective transmission con- TMCN2 Parking brake lever Voltage
5
troller
Between 8 – chassis When locked Max. 1 V
ground When free 20 – 30 V
20-430 D375A-5
1
(5)
TROUBLESHOOTING SERVICE CODE E0178 (DISCONNECTION IN NEUTRAL SAFETY RELAY SYSTEM)
Circuit diagram related to neutral safety relay
D375A-5 20-431
1
TROUBLESHOOTING SERVICE CODE E0179 (SHORT CIRCUIT IN NEUTRAL SAFETY RELAY SYSTEM)
SERVICE CODE E0179 (SHORT CIRCUIT IN NEUTRAL SAFETY RELAY SYSTEM)
User code Service code Short circuit in neutral safety relay system
Trouble
Contents of trouble • When GND signal for neutral safety relay circuit is turned off, abnormal current flowed.
• Stops outputting GND signal for neutral safety relay circuit.
Problem that
• Engine cannot be started.
appears on machine
• Outputting to neutral safety relay (Voltage) can be checked in monitoring mode.
(Code dN: Neutral safety relay drive voltage)
Related information
Turn starting switch ON and operate parking brake lever (LOCK position).
★ This service code detects abnormality on primary side (coil side) of neutral safety relay and cannot

Defective neutral safety re- without turning starting switch ON.
1 lay
NSF (male) Resistance
Between 1 – 2 200 – 400 Ω
and standard val- 2 source in wiring harness Short circuit of wiring harness between
ue in normal state (Contact with 24 V circuit) TMCN2 (female) 8 – NSF (female) 2 with Voltage Max. 1 V
chassis ground
Defective transmission con- TMCN2 Parking brake lever Voltage
3
troller
Between 8 – chassis When locked Max. 1 V
ground When free 20 – 30 V
20-432 D375A-5
1
(5)
TROUBLESHOOTING SERVICE CODE E0179 (SHORT CIRCUIT IN NEUTRAL SAFETY RELAY SYSTEM)
Circuit diagram related to neutral safety relay
D375A-5 20-433
1
TROUBLESHOOTING SERVICE CODE E0211 (ABNORMAL TORQUE CONVERTER OIL TEMPERATURE)
SERVICE CODE E0211 (ABNORMAL TORQUE CONVERTER OIL TEMPERATURE)
User code Service code Abnormal torque converter oil temperature

Trouble
E0211 (Monitor panel system)
Contents of trouble Torque converter oil temperature is above about 130°C.
Flashes caution lamp and turns on caution buzzer (Caution function of torque converter oil tempera-
ture gauge).
Problem that System does not take any particular action. If machine is used without removing cause of trouble,
appears on machine however, mechanical trouble may occur.
Torque converter oil temperature can be checked in monitoring mode.
Related information (Code 77: Torque converter oil temperature)
Method of reproducing service code: Turn starting switch ON and start engine

Overheating of torque con-
Since overheating of torque converter oil is detected, check cause and
1 verter oil
damage of machine and repair.
(when system is normal)
Check torque converter oil temperature gauge. If it does not indicate
real oil temperature, carry out troubleshooting for monitor panel (E-
mode).
Lighting segment Voltage
Possible causes 7th Above 130°C
and standard val- Defective torque converter
2 oil temperature sensor and 6th Below approx. 130°C
ue in normal state
gauge system Torque converter oil 5th Below approx. 120°C
temperature gauge 4th Below approx. 116°C
3rd Below approx. 110°C
2nd Below approx. 90°C
1st Below approx. 50°C
Since trouble is in system, troubleshooting cannot be carried out.
3 Defective monitor panel (If there is not visible trouble in machine, controller may be used as it
is.)
20-434 D375A-5
1
SERVICE CODE E0212 (SHORT CIRCUIT IN TORQUE CONVERTER LOCK-UP
TROUBLESHOOTING SOLENOID SYSTEM)
SERVICE CODE E0212 (SHORT CIRCUIT IN TORQUE CONVERTER LOCK-UP SOLENOID

SYSTEM)
User code Service code Short circuit in torque converter lock-up solenoid system
Trouble
Contents of trouble Abnormal current flowed when signal is output to torque converter lock-up solenoid.
Action of controller Stops outputting to torque converter lock-up solenoid.
Problem that
Torque converter lock-up solenoid does not work.
appears on machine
Outputting to torque converter lock-up solenoid (Voltage) can be checked in monitoring mode.
(Code dL: Lock-up solenoid drive voltage)
Related information Method of reproducing service code: Start engine, turn lock-up switch ON, and drive machine.
¤ When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that ma-
chine will not start traveling.

Defective torque converter
1 lock-up solenoid 653 (male) Resistance
(Internal short circuit) Between 1 2 30 80 Ω
Between 1 chassis ground Min. 1 MΩ
(Contact with ground circuit) TMCN3 (female) \ 653 (female) 1 with Resistance Min. 1 MΩ
Possible causes
chassis ground
and standard val-
Short circuit in wiring har- without turning starting switch ON.
ness Short circuit of wiring harness between
3
(with another wiring har- TMCN3 (female) \ 653 (female) 1 with wir-
ness) Resistance Min. 1 MΩ
ing harness between TMCN3 (female) M
653 (female) 2
Defective transmission con- TMCN3 (female) Resistance
4
troller
Between \ M 30 80 Ω
Between \ chassis ground Min. 1 MΩ
Circuit diagram related to torque converter lock-up solenoid
D375A-5 20-435
1
SERVICE CODE E0213 (DISCONNECTION IN TORQUE CONVERTER LOCK-UP
SERVICE CODE E0213 (DISCONNECTION IN TORQUE CONVERTER LOCK-UP

SOLENOID SYSTEM)
User code Service code Disconnection in torque converter lock-up solenoid system
Trouble
Contents of trouble Current does not flow when signal is output to torque converter lock-up solenoid.
Action of controller Stops outputting to torque converter lock-up solenoid.
Problem that
Torque converter lock-up solenoid does not work.
appears on machine
Outputting to torque converter lock-up solenoid (Voltage) can be checked in monitoring mode.
(Code dL: Lock-up solenoid drive voltage)

Defective torque converter without turning starting switch ON.
1 lock-up solenoid
653 (male) Resistance
Between 1 2 30 80 Ω
ness
Wiring harness between TMCN3 (female) \
Possible causes 653 (female) 1
and standard val- tor) Wiring harness between TMCN3 (female) M
ue in normal state Resistance Max. 1 Ω
653 (female) 2
3 source in wiring harness
(Contact with 24 V circuit) Short circuit of TMCN3 (female) \ 653 (fe-
Voltage Max. 1 V
male) 1 with chassis ground
4
troller TMCN3 (female) Resistance
Between \ M 30 80 Ω
Circuit diagram related to torque converter lock-up solenoid
20-436 D375A-5
1
SERVICE CODE E0221 (DISCONNECTION OR SHORT CIRCUIT IN PITCH ANGLE
TROUBLESHOOTING SENSOR SYSTEM)

SENSOR SYSTEM)
User code Service code Disconnection or short circuit in pitch angle sensor system)
Trouble
Contents of trouble Signal voltage of pitch angle sensor circuit is below 0.15 V or above 4.85 V.
Action of controller Stops auto shift-down function.
appears on machine Auto shift-down function does not work.
★ Since pitch angle sensor signal is input to both transmission controller and steering controller, related
codes may be displayed simultaneously, depending on troubled part.
(Related code: E0721)
Related information
Inputting from pitch angle revolution sensor (Voltage) can be checked in monitoring mode.
(Code A8: Pitch angle sensor voltage)
When only service code [E0221] is displayed

Possible causes defective contact in connec- Wiring harness between TMCN2 (female) 1 Resistance Max. 1 Ω
and standard val- tor) circuit branch point
ue in normal state
2
Between 1 chassis ground 0.15 4.85 V
When service codes [E0221] and [E0731] are displayed simultaneously

Defective sensor 24 V power See if service code [E0145] is displayed. If it is displayed, carry out
1
supply system troubleshooting for it first.
Defective pitch angle sensor carry out troubleshooting.
2
(Internal trouble) PAS Voltage
Between B A 0.15 4.85 V
and standard val-
Wiring harness between PAS (female) B
ness
ue in normal state
circuit branching point
Wiring harness between PAS (male) C
tor) Resistance Max. 1 Ω
NGICN1 (female) F
4 ground in wiring harness Short circuit of wiring harness between PAS
(Contact with ground circuit) (female) B TMCN1 (female) 1 NGICN1 Resistance Min. 1 MΩ
(female) C with chassis ground
D375A-5 20-437
1
Circuit diagram related to pitch angle sensor
20-438 D375A-5
1
SERVICE CODE E0225 (SLIP OF POWER TRAIN CLUTCH)
SERVICE CODE E0230 [ABNORMALITY IN BOTH FORWARD-REVERSE
TROUBLESHOOTING POTENTIOMETER
SERVICE CODE E0225 (SLIP SYSTEMS
OF POWER TRAIN (1)]
CLUTCH)
SERVICE CODE E0225 (SLIP OF POWER TRAIN CLUTCH)
User code Service code Slip of power train clutch

Trouble
When torque converter is locked up, transmission speed calculated from engine speed is different
Contents of trouble
more than 200 rpm from real speed.
Action of controller Flashes caution lamp and turns on caution buzzer.
Problem that
Auto shift-down function does not work.
appears on machine
Engine speed (rpm) and transmission speed (rpm) can be checked in monitoring mode.
(Code 99: Engine speed, Code 7o: Transmission speed)
When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that ma-

Slip of power train clutch Since slip of clutch is detected, check cause and damage of machine
1
(When system is normal) and repair.
Defective engine speed sen- See if service codes [EC121], [E0930], and [E0931] are displayed. If
Possible causes 2
sor system they are displayed, carry out troubleshooting for them.
and standard val-
ue in normal state 3 Defective transmission See if service codes [E0932] and [E0933] are displayed. If they are
speed sensor system displayed, carry out troubleshooting for them.
Since trouble is in system, troubleshooting cannot be carried out.
4 (If there is not visible trouble in machine, controller may be used as it
troller
is.)

POTENTIOMETER SYSTEMS (1)]
User code Service code Abnormality in both forward-reverse potentiometer systems (1)
Trouble
Service codes [E0233] and [E0234] are displayed simultaneously for forward-reverse potentiometer
Contents of trouble
systems 1 and 2.
Problem that Once machine is stopped, engine speed is limited to medium (half).
appears on machine Once machine is stopped, it cannot travel any more.
Inputting from forward-reverse potentiometers (Voltage) can be checked in monitoring mode.
(Code L3: Voltage of forward-reverse potentiometer 1)
Related information (Code L4: Voltage of forward-reverse potentiometer 2)
Method of reproducing service code: Turn starting switch ON and operate PCCS lever (Forward-re-
verse).

and standard val-
ue in normal state Carry out troubleshooting for service codes [E0233] and [E0244].
D375A-5 20-439
1
SERVICE CODESERVICE CODE E0231
E0231 [ABNORMALITY [ABNORMALITY
IN BOTH IN BOTH
FORWARD-REVERSE FORWARD-REVERSE
TROUBLESHOOTING POTENTIOMETER
SERVICE CODE E0232 [ABNORMALITY IN BOTH FORWARD-REVERSE SYSTEMS
POTENTIOMETER SYSTEMS(2)]
(3)]

Trouble
Forward-reverse potentiometer systems 1 and 2 are normal when starting switch is turned ON, then
Contents of trouble
service code [E0235] is displayed.
verse).

and standard val-

Trouble
Either of forward-reverse potentiometers 1 and 2 is abnormal when starting switch is turned ON, then
Contents of trouble
service codes [E0233] and [E0234] are displayed simultaneously.
verse).

and standard val-
20-440 D375A-5
1
SERVICE CODE E0233 (DISCONNECTION OR SHORT CIRCUIT IN FORWARD-
TROUBLESHOOTING REVERSE POTENTIOMETER 1 SYSTEM)
SERVICE CODE E0233 (DISCONNECTION OR SHORT CIRCUIT IN FORWARD-REVERSE

POTENTIOMETER 1 SYSTEM)
User code Service code Disconnection or short circuit in forward-reverse potentiometer 1 system
Trouble
Contents of trouble Signal voltage of forward-reverse potentiometer 1 (FR3) is below 0.5 V or above 4.5 V.
Action of controller Continues controlling with signal of forward-reverse potentiometer 2 system (FR4).
appears on machine Once machine is stopped, travel is limited to F1 and R1.
Inputting from forward-reverse potentiometer 1 (FR3) (Voltage) can be checked in monitoring mode.
(Code L3: Voltage of froward-reverse potentiometer 1)
Related information
Turn starting switch ON and operate PCCS lever (Forward-Reverse travel).

1
Defective forward-reverse
potentiometer 1 TL1 (male) Resistance
Between L J
2
(Internal disconnection or 2 kΩ ± 20%
short circuit) Between K L
Between K J
ness
Wiring harness between TMCN1 (female) L
TL1 (female) L
Possible causes Wiring harness between TMCN1 (female) 2
TL1 (female) K
and standard val-
ue in normal state
(Contact with ground circuit) TMCN1 (female) 2 TL1 (female) K with Resistance Min. 1 MΩ
chassis ground
(Contact with 24 V circuit) TMCN1 (female) 2 TL1 (female) K with Voltage Max. 1 V
chassis ground
6
Between 2 K 0.5 4.5 V
D375A-5 20-441
1
Circuit diagram related to forward-reverse potentiometers
20-442 D375A-5
1
SERVICE CODE E0234 (DISCONNECTION OR SHORT CIRCUIT IN FORWARD-REVERSE

User code Service code Disconnection or short circuit in forward-reverse potentiometer 2 system
Trouble
Contents of trouble Signal voltage of forward-reverse potentiometer 2 (FR4) is below 0.5 V or above 4.5 V.
Action of controller Continues controlling with signal of forward-reverse potentiometer 1 system (FR3).
Inputting from forward-reverse potentiometer 2 (FR4) (Voltage) can be checked in monitoring mode.
Related information

1
Defective forward-reverse
potentiometer 2 TL1 (male) Resistance
Between O Q
2
short circuit) Between P O
Between P Q
ness
Wiring harness between TMCN1 (female) L
TL1 (female) O
Possible causes Wiring harness between TMCN1 (female) I
TL1 (female) P
and standard val-
ue in normal state
(Contact with ground circuit) TMCN1 (female) I TL1 (female) P with Resistance Min. 1 MΩ
chassis ground
(Contact with 24 V circuit) TMCN1 (female) I TL1 (female) P with Voltage Max. 1 V
chassis ground
6
Between I K 0.5 4.5 V
D375A-5 20-443
1
SERVICE CODE E0235 (DEVIATION OF FORWARD-REVERSE POTENTIOMETER
TROUBLESHOOTING SYSTEM SIGNALS)
Circuit diagram related to forward-reverse potentiometers
SERVICE CODE E0235 (DEVIATION OF FORWARD-REVERSE POTENTIOMETER

SYSTEM SIGNALS)
User code Service code Deviation of forward-reverse potentiometer system signals

Trouble
Total signal voltages of forward-reverse potentiometers 1 (FR3) and 2 (FR4) is below 4.41 V or above
Contents of trouble
5.59 V.
Continues controlling with normal signal of forward-reverse potentiometer 1 (FR3) system or 2 (FR4)
system.
Related information (Code L4: Voltage of froward-reverse potentiometer 2)

and standard val-
20-444 D375A-5
1
SERVICE CODE E0236 (DISCONNECTION OR SHORT CIRCUIT IN SHIFT-UP SWITCH
TROUBLESHOOTING SYSTEMS)

SYSTEMS)
User code Service code Disconnection or short circuit in shift-up switch systems
Trouble
Contents of trouble • Signals of both shift-up switch circuit systems are turned ON or OFF simultaneously.
• Assumes that switch is not pressed.
Problem that • Transmission gear cannot be shifted up.
appears on machine • Auto shift-down function does not work.
• NO and NC signals of both switch systems are for detecting operation and error respectively.
• Inputting from shift-up switch (ON·OFF) can be checked in monitoring mode.
Related information
(Code L5: Transmission controller input 1)
• Method of reproducing service code: Turn starting switch ON and operate shift-up switch.

Shift-up switch
Defective shift-up switch TL1 (male)
OFF (Pressed) ON (Released)
1 (Internal disconnection or
N–U
short circuit) Resistance between
Max. 1 Ω Min. 1 MΩ
N–B
Resistance between
Min. 1 MΩ Max. 1 Ω

Disconnection in wiring har-
TL1 (female) U
TL1 (female) B
Wiring harness between TMCN2 (female) [ –
defective contact in connec- Resistance Max. 1 Ω
tor)
@ – TL1 (female) N
Wiring harness between TMCN1 (female) 4,

Possible causes
TMCN1 (female) 6 – TL1 (female) U with
and standard val- Short circuit with chassis Short circuit of wiring harness between
ue in normal state 3 ground in wiring harness Resistance Min. 1 MΩ
chassis ground
TMCN2 (female) [ – TL1 (female) B with
chassis ground
TMCN1 (female) 6 – TL1 (female) U with

Voltage Max. 1 V
chassis ground
(Contact with 24 V circuit)
TMCN2 (female) [ – TL1 (female) B with
Voltage Max. 1 V
chassis ground
Shift-up switch
TMCN1, TMCN2
Defective transmission con- OFF (Released) ON (Pressed)
5
troller Voltage between TMCN1
Max. 1 V 5 – 11 V
6 – TMCN1 4, @
Voltage between TMCN2
5 – 11 V Max. 1 V
[ – TMCN1 4, @
D375A-5 20-445
1
(5)
TROUBLESHOOTING SYSTEMS)
Circuit diagram related to shift-up switch and shift-down switch
20-446 D375A-5
1
SERVICE CODE E0237 (DISCONNECTION OR SHORT CIRCUIT IN SHIFT-DOWN
TROUBLESHOOTING SWITCH SYSTEMS)
SERVICE CODE E0237 (DISCONNECTION OR SHORT CIRCUIT IN SHIFT-DOWN SWITCH

SYSTEMS)
User code Service code Disconnection or short circuit in shift-down switch systems
Trouble
Contents of trouble • Signals of both shift-down switch circuit systems are turned ON or OFF simultaneously.
Problem that • Transmission gear cannot be shifted down.
appears on machine • Auto shift-down function does not work.
• Inputting from shift-down switch (ON·OFF) can be checked in monitoring mode.
Related information
• Method of reproducing service code: Turn starting switch ON and operate shift-down switch.

Shift-up switch
Defective shift-down switch TL1 (male)
OFF (Pressed) ON (Released)
D–V
D–C
Resistance between

TL1 (female) V
Wiring harness between TMCN3 (female) I –
TL1 (female) C
Wiring harness between TMCN3 (female) S –
tor)
@ – TL1 (female) D

Possible causes
TMCN3 (female) I – TL1 (female) V with
and standard val- Short circuit with chassis Short circuit of wiring harness between
ue in normal state 3 ground in wiring harness Resistance Min. 1 MΩ
chassis ground
TMCN3 (female) S – TL1 (female) C with
chassis ground
TMCN3 (female) I – TL1 (female) V with

Voltage Max. 1 V
chassis ground
TMCN3 (female) S – TL1 (female) C with
Voltage Max. 1 V
chassis ground
Shift-up switch
TMCN1, TMCN3
5
troller Voltage between TMCN3
Max. 1 V 5 – 11 V
I – TMCN1 4, @
5 – 11 V Max. 1 V
S – TMCN1 4, @
D375A-5 20-447
1
(5)
SERVICE CODE E0237 (DISCONNECTION OR SHORT CIRCUIT IN SHIFT-DOWN
Circuit diagram related to shift-up switch and shift-down switch
20-448 D375A-5
1
SERVICE CODE E0238 (DISCONNECTION OR SHORT CIRCUIT IN PARKING BRAKE
TROUBLESHOOTING LEVER SWITCH SYSTEMS)

LEVER SWITCH SYSTEMS)
User code Service code Disconnection or short circuit in parking brake lever switch systems
Trouble
Contents of trouble • Signals of both parking brake lever switch circuit systems are turned ON or OFF simultaneously.
Action of controller • Assumes that parking brake lever is at FREE position.
Problem that • Once machine is stopped, engine speed is limited to medium (half).
appears on machine • Once machine is stopped, travel is limited to F1 and R1.
★ Since parking brake switch signal is used by both transmission controller and steering controller, re-
lated codes may be displayed simultaneously, depending on troubled part.
(Related codes: E0239, E0781, E0782)
Related information • NO and NC signals of both switch systems are for detecting operation and error respectively.
• Inputting from parking brake switch (ON·OFF) can be checked in monitoring mode.
• Method of reproducing service code: Turn starting switch ON and operate parking brake lever.
ness
Wiring harness between TMCN2 (female) H –
Wiring harness between TMCN2 (female) B –
Possible causes circuit branching point
ue in normal state carry out troubleshooting.
Parking brake lever
TMCN2
Defective transmission con- At FREE At LOCK
2
troller Between H – chassis
Max. 1 V 5 – 11 V
ground
Between B – chassis
5 – 11 V Max. 1 V
ground
Defective parking brake le- without turning starting switch ON.
ver switch Parking brake lever
1 NSW
Between A – B
(Internal disconnection or At FREE At LOCK
Max. 1 Ω
Between A – B
short circuit) Min. 1 MΩ
harness between NSW (female) B –

Wiring
Wiring harness between NSW (female) C –
circuit merging point
defective contact in connec- circuit merging point Resistance Max. 1 Ω
tor) Wiring harness between NSW (female) A –
Possible causes Resistance Max. 1 Ω
chassis ground
and standard val- ★ Prepare with starting switch OFF, then carry out troubleshooting
ue in normal state without turning starting switch ON.
(female) B – TMCN1 (female) H – NGICN2 Resistance Min. 1 MΩ

Short circuit with chassis Short circuit of wiring harness between NSW
(female) 5 with chassis ground
(female) C – TMCN1 (female) B – NGICN2 Resistance Min. 1 MΩ
Short circuit of wiring harness between NSW
(female) E with chassis ground

(female) B – TMCN1 (female) H – NGICN2

Short circuit with power Short circuit of wiring harness between NSW
Voltage Max. 1 V
(female) 5 with chassis ground
(female) C – TMCN1 (female) B – NGICN2
Voltage Max. 1 V
(female) E with chassis ground
D375A-5 20-449
1
(5)
Circuit diagram related to parking brake switch
20-450 D375A-5
1
SERVICE CODE E0239 (DISAGREEMENT OF PARKING BRAKE LEVER SWITCH

SYSTEM SIGNALS)
User code Service code Disagreement of parking brake lever switch system signals
Trouble
• Switch input signal of transmission controller disagrees with communication signal from steering con-
Contents of trouble
troller.
★ Since parking brake switch signal is used by both transmission controller and steering controller and
information is exchanged by S-NET communication, related codes may be displayed simultaneously,
depending on troubled part.
(Related codes: E0101, E0104, E0105, E0152, E0164, E0238, E0781, E0782)
Related information
(Code L5: Transmission controller switch input 1)

See if service codes [E0101], [E0104], [E0105], [E0152], and [E0162]
Defective S-NET communi-
1 are displayed. If they are displayed, carry out troubleshooting for them
cation system
Possible causes first.
and standard val- See if service codes [E0238] and [E0781] are displayed. If they are
ue in normal state 2 Defective parking brake le- displayed, carry out troubleshooting for them first.
ver switch signal system
(Service code [E0782] is same as [E0239].)
3 Since trouble is in system, troubleshooting cannot be carried out.
troller
D375A-5 20-451
1
SERVICE CODE E0250 (DISCONNECTION IN TRANSMISSION FORWARD CLUTCH
TROUBLESHOOTING ECMV SYSTEM)
SERVICE CODE E0250 (DISCONNECTION IN TRANSMISSION FORWARD CLUTCH

ECMV SYSTEM)
User code Service code Disconnection in transmission forward clutch ECMV system
Trouble
Contents of trouble • When signal is output to transmission forward clutch solenoid circuit, current does not flow.
Action of controller • Stops outputting to transmission forward clutch solenoid circuit.
appears on machine • Once machine is stopped, travel is limited to R1.
• Outputting to forward clutch solenoid (Current) can be checked in monitoring mode.
(Code P5, c5: Forward clutch ECMV output current)
Related information • Method of reproducing service code: Start engine and drive forward.
chine will not travel forward.

Defective forward clutch so- without turning starting switch ON.
1 lenoid
SFT (male) Resistance
Between 1 – 2 5 – 15 Ω
ness
Wiring harness between TMCN3 (female) Y –
SFT (female) 1
and standard val- tor) Wiring harness between TMCN3 (female) C –
ue in normal state SFT (female) 2
(Contact with 24 V circuit) TMCN3 (female) Y – SFT (female) 1 with Voltage Max. 1 V
chassis ground
Defective transmission con- without turning starting switch ON.
4
Between Y – C 5 – 15 Ω
Circuit diagram related to transmission forward clutch ECMV
20-452 D375A-5
(7)
1
SERVICE CODE E0251 (SHORT CIRCUIT IN TRANSMISSION FORWARD CLUTCH
SERVICE CODE E0251 (SHORT CIRCUIT IN TRANSMISSION FORWARD CLUTCH ECMV

SYSTEM)
User code Service code Short circuit in transmission forward clutch ECMV system
Trouble
Contents of trouble • When signal was output to transmission forward clutch solenoid circuit, abnormal current flowed.
Action of controller • Stops outputting to transmission forward clutch solenoid circuit.
• Outputting to forward clutch solenoid (Current) can be checked in monitoring mode.
(Code P5, c5: Forward clutch ECMV output current)
chine will not travel forward.

Defective forward clutch so-
1 lenoid SFT (male) Resistance
(Internal short circuit) Between 1 – 2 5 – 15 Ω
Between 1 – chassis ground Min. 1 MΩ
(Contact with ground circuit) TMCN3 (female) Y – SFT (female) 1 with Resistance Min. 1 MΩ
Possible causes
chassis ground
and standard val-
3
(with another wiring har- TMCN3 (female) Y – SFT (female) 1 with
wiring harness between TMCN3 (female) C –
SFT (female) 2
4
troller
Between Y – C 5 – 15 Ω
Between Y – chassis ground Min. 1 MΩ
D375A-5 20-453
(7)
1
SERVICE CODE E0252 (DISCONNECTION IN TRANSMISSION REVERSE CLUTCH
SERVICE CODE E0252 (DISCONNECTION IN TRANSMISSION REVERSE CLUTCH ECMV

SYSTEM)
User code Service code Disconnection in transmission reverse clutch ECMV system
Trouble
Contents of trouble • When signal is output to transmission reverse clutch solenoid circuit, current does not flow.
Action of controller • Stops outputting to transmission reverse clutch solenoid circuit.
appears on machine • Once machine is stopped, travel is limited to F1.
• Outputting to reverse clutch solenoid (Current) can be checked in monitoring mode.
(Code P6, c6: Reverse clutch ECMV output current)
Related information • Method of reproducing service code: Start engine and drive in reverse.
chine will not start.

Defective reverse clutch so- without turning starting switch ON.
1 lenoid
SRT (male) Resistance
Between 1 – 2 5 – 15 Ω
ness
Wiring harness between TMCN3 (female) O –
SRT (female) 1
and standard val- tor) Wiring harness between TMCN3 (female) 3 –
ue in normal state SRT (female) 2
(Contact with 24 V circuit) TMCN3 (female) O – SRT (female) 1 with Voltage Max. 1 V
chassis ground
4
Between O – 3 5 – 15 Ω
Circuit diagram related to transmission reverse clutch ECMV
20-454 D375A-5
(7)
1
SERVICE CODE E0253 (SHORT CIRCUIT IN TRANSMISSION REVERSE CLUTCH
SERVICE CODE E0253 (SHORT CIRCUIT IN TRANSMISSION REVERSE CLUTCH ECMV

SYSTEM)
User code Service code Short circuit in transmission reverse clutch ECMV system
Trouble
Contents of trouble • When signal was output to transmission reverse clutch solenoid circuit, abnormal current flowed.
Action of controller • Stops outputting to transmission reverse clutch solenoid circuit.
• Outputting to reverse clutch solenoid (Current) can be checked in monitoring mode.
(Code P6, c6: Reverse clutch ECMV output current)

Defective reverse clutch so-
1 lenoid SRT (male) Resistance
(Contact with ground circuit) TMCN3 (female) O – SRT (female) 1 with Resistance Min. 1 MΩ
Possible causes
chassis ground
and standard val-
3
(with another wiring har- TMCN3 (female) O – SRT (female) 1 with
wiring harness between TMCN3 (female) 3 –
SRT (female) 2
4
troller
Between O – 3 5 – 15 Ω
Between O – chassis ground Min. 1 MΩ
D375A-5 20-455
(7)
1
SERVICE CODE E0254 (DISCONNECTION IN TRANSMISSION 1ST CLUTCH ECMV
TROUBLESHOOTING SYSTEM)
SERVICE CODE E0254 (DISCONNECTION IN TRANSMISSION 1ST CLUTCH ECMV

SYSTEM)
User code Service code Disconnection in transmission 1st clutch ECMV system
Trouble
Contents of trouble • When signal is output to transmission 1st clutch solenoid circuit, current does not flow.
Action of controller • Stops outputting to transmission 1st clutch solenoid circuit.
• Auto shift-down function does not work.
Problem that
appears on machine
• Outputting to 1st clutch solenoid (Current) can be checked in monitoring mode.
(Code P7, c7: 1st clutch ECMV output current)
Related information • Method of reproducing service code: Start engine and drive in F1 or R1.

Defective 1st clutch solenoid without turning starting switch ON.
1
(Internal short circuit) S1T (male) Resistance
Between 1 – 2 5 – 15 Ω
ness
Wiring harness between TMCN3 (female) E –
S1T (female) 1
ue in normal state S1T (female) 2
(Contact with 24 V circuit) TMCN3 (female) E – S1T (female) 1 with Voltage Max. 1 V
chassis ground
4
Between E – C 5 – 15 Ω
Circuit diagram related to transmission 1st clutch ECMV
20-456 D375A-5
(7)
1
SERVICE CODE E0255 (SHORT CIRCUIT IN TRANSMISSION 1ST CLUTCH ECMV
SERVICE CODE E0255 (SHORT CIRCUIT IN TRANSMISSION 1ST CLUTCH ECMV

SYSTEM)
User code Service code Short circuit in transmission 1st clutch ECMV system
Trouble
Contents of trouble • When signal was output to transmission 1st clutch solenoid circuit, abnormal current flowed.
Action of controller • Stops outputting to transmission 1st clutch solenoid circuit.
Problem that
appears on machine
• Outputting to 1st clutch solenoid (Current) can be checked in monitoring mode.
(Code P7, c7: 1st clutch ECMV output current)

Defective 1st clutch solenoid S1T (male) Resistance
1
Between 1 – 2 5 – 15 Ω
Possible causes (Contact with ground circuit) TMCN3 (female) E – S1T (female) 1 with Resistance Min. 1 MΩ
chassis ground
and standard val-
3
(with another wiring har- TMCN3 (female) E – S1T (female) 1 with
ness) wiring harness between TMCN3 (female) C –
S1T (female) 2
4
troller
Between E – chassis ground Min. 1 MΩ
D375A-5 20-457
(7)
1
SERVICE CODE E0256 (DISCONNECTION IN TRANSMISSION 2ND CLUTCH ECMV
SERVICE CODE E0256 (DISCONNECTION IN TRANSMISSION 2ND CLUTCH ECMV

SYSTEM)
User code Service code Disconnection in transmission 2nd clutch ECMV system
Trouble
Contents of trouble • When signal is output to transmission 2nd clutch solenoid circuit, current does not flow.
Action of controller • Stops outputting to transmission 2nd clutch solenoid circuit.
• Outputting to 2nd clutch solenoid (Current) can be checked in monitoring mode.
(Code P8, c8: 2nd clutch ECMV output current)

Defective 2nd clutch sole- without turning starting switch ON.
1 noid
S2T (male) Resistance
Between 1 – 2 5 – 15 Ω
ness
2 (Disconnection in wiring or Wiring harness between TMCN3 (female) Z – Resistance Max. 1 Ω
S2T (female) 1
and standard val- tor) Wiring harness between TMCN3 (female) 3 –
(Contact with 24 V circuit) TMCN3 (female) Z – S2T (female) 1 with Voltage Max. 1 V
chassis ground
4
Between Z – 3 5 – 15 Ω
Circuit diagram related to transmission 2nd clutch ECMV
20-458 D375A-5
(7)
1
SERVICE CODE E0257 (SHORT CIRCUIT IN TRANSMISSION 2ND CLUTCH ECMV
SERVICE CODE E0257 (SHORT CIRCUIT IN TRANSMISSION 2ND CLUTCH ECMV

SYSTEM)
User code Service code Short circuit in transmission 2nd clutch ECMV system
Trouble
Contents of trouble • When signal was output to transmission 2nd clutch solenoid circuit, abnormal current flowed.
Action of controller • Stops outputting to transmission 2nd clutch solenoid circuit.
• Outputting to 2nd clutch solenoid (Current) can be checked in monitoring mode.
(Code P8, c8: 2nd clutch ECMV output current)

Defective 2nd clutch sole-
1 noid S2T (male) Resistance
(Contact with ground circuit) TMCN3 (female) Z – S2T (female) 1 with Resistance Min. 1 MΩ
Possible causes
chassis ground
and standard val-
3
(with another wiring har- TMCN3 (female) Z – S2T (female) 1 with
wiring harness between TMCN3 (female) 3 –
S2T (female) 2
4
troller
Between Z – 3 5 – 15 Ω
Between Z – chassis ground Min. 1 MΩ
D375A-5 20-459
(7)
1
SERVICE CODE E0258 (DISCONNECTION IN TRANSMISSION 3RD CLUTCH ECMV
SERVICE CODE E0258 (DISCONNECTION IN TRANSMISSION 3RD CLUTCH ECMV

SYSTEM)
User code Service code Disconnection in transmission 3rd clutch ECMV system
Trouble
Contents of trouble • When signal is output to transmission 3rd clutch solenoid circuit, current does not flow.
Action of controller • Stops outputting to transmission 3rd clutch solenoid circuit.
• Outputting to 3rd clutch solenoid (Current) can be checked in monitoring mode.
(Code P9, c9: 3rd clutch ECMV output current)

Defective 3rd clutch sole- without turning starting switch ON.
1 noid
S3T (male) Resistance
Between 1 – 2 5 – 15 Ω
ness
2 (Disconnection in wiring or Wiring harness between TMCN3 (female) 5 – Resistance Max. 1 Ω
S3T (female) 1
(Contact with 24 V circuit) TMCN3 (female) 5 – S3T (female) 1 with Voltage Max. 1 V
chassis ground
4
Between 5 – C 5 – 15 Ω
Circuit diagram related to transmission 3rd clutch ECMV
20-460 D375A-5
(7)
1
SERVICE CODE E0259 (SHORT CIRCUIT IN TRANSMISSION 3RD CLUTCH ECMV
SERVICE CODE E0259 (SHORT CIRCUIT IN TRANSMISSION 3RD CLUTCH ECMV

SYSTEM)
User code Service code Short circuit in transmission 3rd clutch ECMV system
Trouble
Contents of trouble • When signal was output to transmission 3rd clutch solenoid circuit, abnormal current flowed.
Action of controller • Stops outputting to transmission 3rd clutch solenoid circuit.
• Outputting to 3rd clutch solenoid (Current) can be checked in monitoring mode.
(Code P9, c9: 3rd clutch ECMV output current)

Defective 3rd clutch sole-
1 noid S3T (male) Resistance
(Contact with ground circuit) TMCN3 (female) 5 – S3T (female) 1 with Resistance Min. 1 MΩ
Possible causes
chassis ground
and standard val-
3
(with another wiring har- TMCN3 (female) 5 – S3T (female) 1 with
wiring harness between TMCN3 (female) C –
S3T (female) 2
4
troller
D375A-5 20-461
(7)
1
SERVICE CODE E0260 (DEFECTIVE ENGAGEMENT OF TRANSMISSION FORWARD
TROUBLESHOOTING CLUTCH)
SERVICE CODE E0260 (DEFECTIVE ENGAGEMENT OF TRANSMISSION FORWARD

CLUTCH)
User code Service code Defective engagement of transmission forward clutch

Trouble
• When signal is output to transmission forward clutch solenoid circuit, fill switch signal is not turned
Contents of trouble
ON.
Action of controller • Judges that transmission is in N (Neutral) when it is set in forward position.
• Inputting from forward clutch fill switch (ON·OFF) can be checked in monitoring mode.
(Code 7H: Transmission fill switch input)

★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Defective forward clutch fill
1 switch FFT (male) PCCS lever Resistance
(Internal short circuit) Between 1 – chassis N Min. 1 MΩ
ground F (Forward) Max. 1 Ω
2
and standard val- (Disconnection in wiring or de- Wiring harness between TMCN1 (female) 5 –
ue in normal state fective contact in connector) FFT (female) 1 Resistance Max. 1 Ω
troubleshooting.
Defective transmission con- TMCN1 PCCS lever Voltage
3
troller
Between 5 – chassis N 20 – 30 V
ground F (Forward) Max. 1 V
If electric system does not have abnormality, hydraulic system may
4 Defective hydraulic system
have. Carry out related troubleshooting (H-mode).
20-462 D375A-5
(7)
1
SERVICE CODE E0261 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION
TROUBLESHOOTING FORWARD CLUTCH)
SERVICE CODE E0261 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION FORWARD

CLUTCH)
User code Service code Defective disengagement of transmission forward clutch

Trouble
• When outputting of signal to transmission forward clutch solenoid circuit is stopped, fill switch signal
Contents of trouble
is not turned OFF.
Action of controller • Judges that transmission is in N (Neutral) when it is set in reverse position.
• Inputting from forward clutch fill switch (ON·OFF) can be checked in monitoring mode.
Related information • Method of reproducing service code: Start engine and set transmission in neutral.

troubleshooting.
Defective forward clutch fill
1 switch FFT (male) PCCS lever Resistance
ground F (Forward) Max. 1 Ω
Possible causes
and standard val- Max.
(Contact with ground circuit) TMCN1 (female) 5 – FFT (female) 1 with Resistance
ue in normal state 1 MΩ
chassis ground
troubleshooting.
3
troller
Between 5 – chassis N 20 – 30 V
ground F (Forward) Max. 1 V
D375A-5 20-463
(7)
1
SERVICE CODE E0262 (DEFECTIVE ENGAGEMENT OF TRANSMISSION REVERSE
SERVICE CODE E0262 (DEFECTIVE ENGAGEMENT OF TRANSMISSION REVERSE

CLUTCH)
User code Service code Defective engagement of transmission reverse clutch

Trouble
• When signal is output to transmission reverse clutch solenoid circuit, fill switch signal is not turned
Contents of trouble
ON.
Action of controller • Judges that transmission is in N (Neutral) when it is set in reverse position.
• Inputting from reverse clutch fill switch (ON·OFF) can be checked in monitoring mode.

troubleshooting.
Defective reverse clutch fill
1 switch FRT (male) PCCS lever Resistance
ground R (Reverse) Max. 1 Ω
2
and standard val- (Disconnection in wiring or de- Wiring harness between TMCN1 (female) N –
ue in normal state fective contact in connector) FRT (female) 1 Resistance Max. 1 Ω
troubleshooting.
3
troller
Between N – chassis N 20 – 30 V
ground R (Reverse) Max. 1 V
20-464 D375A-5
(7)
1
SERVICE CODE E0263 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION
TROUBLESHOOTING REVERSE CLUTCH)
SERVICE CODE E0263 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION REVERSE

CLUTCH)
User code Service code Defective disengagement of transmission reverse clutch

Trouble
• When outputting of signal to transmission reverse clutch solenoid circuit is stopped, fill switch signal
Contents of trouble
is not turned OFF.
Action of controller • Judges that transmission is in N (Neutral) when it is set in forward position.
• Inputting from reverse clutch fill switch (ON·OFF) can be checked in monitoring mode.

troubleshooting.
Defective reverse clutch fill
1 switch FRT (male) PCCS lever Resistance
ground R (Reverse) Max. 1 Ω
Possible causes
and standard val-
(Contact with ground circuit) TMCN1 (female) N – FRT (female) 1 with Resistance Max. 1 Ω
ue in normal state
chassis ground
troubleshooting.
3
troller
Between N – chassis N 20 – 30 V
ground R (Reverse) Max. 1 V
D375A-5 20-465
(7)
1
SERVICE CODE E0264 (DEFECTIVE ENGAGEMENT OF TRANSMISSION 1ST
SERVICE CODE E0264 (DEFECTIVE ENGAGEMENT OF TRANSMISSION 1ST CLUTCH)
User code Service code Defective engagement of transmission 1st clutch

Trouble
Contents of trouble • When signal is output to transmission 1st clutch solenoid circuit, fill switch signal is not turned ON.
Problem that
appears on machine
• Inputting from 1st clutch fill switch (ON·OFF) can be checked in monitoring mode.

aPrepare with starting switch OFF, then start engine and carry out
troubleshooting.
Defective 1st clutch fill
1 switch F1T (male) PCCS lever Resistance
(Internal short circuit) Between 1 – chassis Other than F1·R1 Min. 1 MΩ
ground F1·R1 Max. 1 Ω
Disconnection in wiring har- aPrepare with starting switch OFF, then carry out troubleshooting
2
and standard val- (Disconnection in wiring or de- Wiring harness between TMCN1 (female) M –
ue in normal state fective contact in connector) F1T (female) 1 Resistance Max. 1 Ω
troubleshooting.
3
troller
Between M – chassis Other than F1·R1 20 – 30 V
ground F1·R1 Max. 1 V
20-466 D375A-5
(7)
1
SERVICE CODE E0265 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION 1ST
SERVICE CODE E0265 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION 1ST

CLUTCH)
User code Service code Defective disengagement of transmission 1st clutch

Trouble
• When outputting of signal to transmission 1st clutch solenoid circuit is stopped, fill switch signal is not
Contents of trouble
turned OFF.
• Inputting from 1st clutch fill switch (ON·OFF) can be checked in monitoring mode.

troubleshooting.
Defective 1st clutch fill
aPrepare with starting switch OFF, then carry out troubleshooting
Possible causes
and standard val-
(Contact with ground circuit) TMCN1 (female) M – F1T (female) 1 with Resistance Min. 1 MΩ
ue in normal state
chassis ground
troubleshooting.
3
troller
Between M – chassis Other than F1·R1 20 – 30 V
D375A-5 20-467
(7)
1
SERVICE CODE E0266 (DEFECTIVE ENGAGEMENT OF TRANSMISSION 2ND
SERVICE CODE E0266 (DEFECTIVE ENGAGEMENT OF TRANSMISSION 2ND CLUTCH)
User code Service code Defective engagement of transmission 2nd clutch

Trouble
Contents of trouble • When signal is output to transmission 2nd clutch solenoid circuit, fill switch signal is not turned ON.
• Inputting from 2nd clutch fill switch (ON·OFF) can be checked in monitoring mode.

troubleshooting.
Defective 2nd clutch fill
2
and standard val- (Disconnection in wiring or de- Wiring harness between TMCN1 (female) G –
troubleshooting.
3
troller
Between G – chassis Other than F2·R2 20 – 30 V
20-468 D375A-5
(7)
1
SERVICE CODE E0267 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION 2ND
SERVICE CODE E0267 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION 2ND

CLUTCH)
User code Service code Defective disengagement of transmission 2nd clutch

Trouble
• When outputting of signal to transmission 2nd clutch solenoid circuit is stopped, fill switch signal is
Contents of trouble
not turned OFF.
Problem that
appears on machine
• Inputting from 2nd clutch fill switch (ON·OFF) can be checked in monitoring mode.

troubleshooting.
Defective 2nd clutch fill
Possible causes
and standard val- Max.
(Contact with ground circuit) TMCN1 (female) G – F2T (female) 1 with Resistance
ue in normal state 1 MΩ
chassis ground
troubleshooting.
3
troller
Between G – chassis Other than F2·R2 20 – 30 V
D375A-5 20-469
(7)
1
SERVICE CODE E0268 (DEFECTIVE ENGAGEMENT OF TRANSMISSION 3RD
SERVICE CODE E0268 (DEFECTIVE ENGAGEMENT OF TRANSMISSION 3RD CLUTCH)
User code Service code Defective engagement of transmission 3rd clutch

Trouble
Contents of trouble • When signal is output to transmission 3rd clutch solenoid circuit, fill switch signal is not turned ON.
• Inputting from 3rd clutch fill switch (ON·OFF) can be checked in monitoring mode.

troubleshooting.
Defective 3rd clutch fill
2
and standard val- (Disconnection in wiring or de- Wiring harness between TMCN1 (female) A –
troubleshooting.
3
troller
Between A – chassis Other than F3·R3 20 – 30 V
20-470 D375A-5
(7)
1
SERVICE CODE E0269 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION 3RD
SERVICE CODE E0269 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION 3RD

CLUTCH)
User code Service code Defective disengagement of transmission 3rd clutch

Trouble
• When outputting of signal to transmission 3rd clutch solenoid circuit is stopped, fill switch signal is not
Contents of trouble
turned OFF.
Problem that
appears on machine
• Inputting from 3rd clutch fill switch (ON·OFF) can be checked in monitoring mode.

troubleshooting.
Defective 3rd clutch fill
Possible causes
and standard val-
(Contact with ground circuit) TMCN1 (female) A – F3T (female) 1 with Resistance Max. 1 Ω
ue in normal state
chassis ground
troubleshooting.
3
troller
Between A – chassis Other than F3·R3 20 – 30 V
D375A-5 20-471
(7)
1
SERVICE CODE E0270 [DOUBLE TROUBLE IN TRANSMISSION CLUTCH (DEFECTIVE ENGAGEMENT)]
SERVICE CODE
SERVICE CODE E0270 [DOUBLE
E0271 [DOUBLE TROUBLE
TROUBLE IN TRANSMISSION
IN TRANSMISSION CLUTCH
CLUTCH (DEFECTIVE
TROUBLESHOOTING (DEFECTIVE ENGAGEMENT)]
DISENGAGEMENT)]
SERVICE CODE E0270 [DOUBLE TROUBLE IN TRANSMISSION CLUTCH (DEFECTIVE

ENGAGEMENT)]
User code Service code Double trouble in transmission clutch (Defective engagement)
Trouble
• Following service codes related to transmission clutch are displayed simultaneously.
Contents of trouble
Either of [E0254] and [E0255] and either of [E0256] and [E0257]
Problem that
appears on machine
• Method of reproducing service code: Start engine and drive machine.
Related information ¤ When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that ma-

and standard val- Carry out troubleshooting for service codes displayed simultaneously.
ue in normal state [E0254], [E0255], [E0256], [E0257]
SERVICE CODE E0271 [DOUBLE TROUBLE IN TRANSMISSION CLUTCH (DEFECTIVE

DISENGAGEMENT)]
User code Service code Double trouble in transmission clutch (Defective disengagement)
Trouble
• Following service codes related to transmission clutch are displayed simultaneously.
1Either of [E0250] and [E0251] and either of [E0252] and [E0253]
2Either of [E0258] and [E0259] and [E0270]
3[E0260] and [E0262]
Contents of trouble 4[E0261] and [E0263]
5[E0264], [E0266], and [E0268]
6[E0265] and [E0267]
7[E0265] and [E0269]
8[E0267] and [E0269]
Problem that
appears on machine
• Once machine is stopped, it cannot travel any more.
• Method of reproducing service code: Start engine and drive machine.
Related information ¤ When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that ma-

Possible causes Carry out troubleshooting for service codes displayed simultaneously.
and standard val- [E0250], [E0251], [E0252], [E0253], [E0258], [E0259],
ue in normal state [E0260], [E0261], [E0262], [E0263], [E0264], [E0265],
[E0266], [E0267], [E0268], [E0269], [E0270]
20-472 D375A-5
1
SERVICE CODE E0306 (SHORT CIRCUIT IN BLADE TILT RIGHT OIL PRESSURE
TROUBLESHOOTING SWITCH SYSTEM)
SERVICE CODE E0306 (SHORT CIRCUIT IN BLADE TILT RIGHT OIL PRESSURE SWITCH
SYSTEM)
User code Service code Short circuit in blade tilt right oil pressure switch system
Trouble
Contents of trouble • Signal of blade tilt right oil pressure switch circuit was kept turned ON for 180 seconds.
• Judges that oil pressure switch is turned OFF.
Problem that • When pitch and dump operation or right dual tilt operation is performed, right single tilt mechanism
appears on machine operates.
• Inputting from blade tilt right oil pressure switch (ON·OFF) can be checked in monitoring mode.
(Code bH: Blade lever oil pressure switch input)
Related information
Turn starting switch ON (Service code is reproduced after 180 seconds).

After reproductive operation, if service code P is still displayed (to in-
Defective operation of lever
1 dicate that trouble is repaired), lever may have been so operated that
(Electric system is normal)
error would be detected.
troubleshooting.
Defective blade tilt right oil
2 pressure switch TRS (male) Blade lever Resistance
(Internal short circuit) Neutral Min. 1 MΩ
Between 1 – 2
Possible causes Right tilt Max. 1 Ω
ue in normal state Short circuit with chassis without turning starting switch ON.
(Contact with ground circuit) TMCN2 (female) 6 – TRS (female) 1 with Max.
Resistance
1 MΩ
chassis ground
troubleshooting.
Defective transmission con- TMCN2, TMCN1 Blade lever Voltage
4
troller
Between TMCN2 6 – Neutral 5 – 11 V
TMCN1 4, @ Right tilt Max. 1 V
Circuit diagram related to blade tilt right oil pressure switch
D375A-5 20-473
1
(5)
SERVICE CODE E0307 (SHORT CIRCUIT IN BLADE TILT LEFT OIL PRESSURE
SERVICE CODE E0307 (SHORT CIRCUIT IN BLADE TILT LEFT OIL PRESSURE SWITCH
SYSTEM)
User code Service code Short circuit in blade tilt left oil pressure switch system
Trouble
Contents of trouble • Signal of blade tilt left oil pressure switch circuit was kept turned ON for 180 seconds.
• Judges that oil pressure switch is turned OFF.
Problem that • When pitch and dump operation or right dual tilt operation is performed, left single tilt mechanism op-
appears on machine erates.
• Inputting from blade tilt left oil pressure switch (ON·OFF) can be checked in monitoring mode.
(Code bH: Blade lever oil pressure switch input)
Related information

troubleshooting.
Defective blade tilt left oil
2 pressure switch TLS (male) Blade lever Resistance
Between 1 – 2
Possible causes Left tilt Max. 1 Ω
(Contact with ground circuit) TMCN2 (female) F – TLS (female) 1 with Max.
Resistance
1 MΩ
chassis ground
troubleshooting.
Defective transmission con- TMCN2, TMCN1 Blade lever Voltage
4
troller
Between TMCN2 F – Neutral 5 – 11 V
TMCN1 4, @ Left tilt Max. 1 V
Circuit diagram related to blade tilt left oil pressure switch
20-474 D375A-5
1
(5)
SERVICE CODE E0308 (SHORT CIRCUIT IN RIPPER LIFT RAISE OIL PRESSURE
SERVICE CODE E0308 (SHORT CIRCUIT IN RIPPER LIFT RAISE OIL PRESSURE
SWITCH SYSTEM)
User code Service code Short circuit in ripper lift raise oil pressure switch system
Trouble
Contents of trouble • Signal of ripper lift raise oil pressure switch circuit was kept turned ON for 60 seconds.
Action of controller • Judges that oil pressure switch is turned OFF.
Problem that
• Shoe slip control (SSC) function does not work normally.
appears on machine
• Inputting from ripper lift raise oil pressure switch (ON·OFF) can be checked in monitoring mode.
(Code R7: Ripper lever oil pressure switch input)
Related information

troubleshooting.
Defective ripper lift raise oil
2 pressure switch RPU (male) Ripper lever Resistance
Between 1 – 2
Possible causes Raise Max. 1 Ω
(Contact with ground circuit) NGICN2 (female) 3 – RPU (female) 1 with Resistance Max.
1 MΩ
chassis ground
troubleshooting.
4 Defective steering controller NGICN2, NGICN1 Ripper lever Voltage
Between NGICN2 3 Neutral 5 – 11 V
– NGICN1 4, @ Raise Max. 1 V
Circuit diagram related to ripper lift raise oil pressure switch
D375A-5 20-475
1
(5)
SERVICE CODE E0309 (SHORT CIRCUIT IN RIPPER LIFT LOWER OIL PRESSURE
SERVICE CODE E0309 (SHORT CIRCUIT IN RIPPER LIFT LOWER OIL PRESSURE
SWITCH SYSTEM)
User code Service code Short circuit in ripper lift lower oil pressure switch system
Trouble
Contents of trouble • Signal of ripper lift lower oil pressure switch circuit was kept turned ON for 60 seconds.
Problem that
appears on machine
• Inputting from ripper lift lower oil pressure switch (ON·OFF) can be checked in monitoring mode.
Related information

troubleshooting.
Defective ripper lift lower oil
2 pressure switch RPD (male) Ripper lever Resistance
Between 1 – 2
Possible causes Lower Max. 1 Ω
(Contact with ground circuit) NGICN1 (female) N – RPD (female) 1 with Resistance Max.
1 MΩ
chassis ground
troubleshooting.
4 Defective steering controller NGICN1 Ripper lever Voltage
Between NGICN1 N Neutral 5 – 11 V
– 4, @ Lower Max. 1 V
Circuit diagram related to ripper lift lower oil pressure switch
20-476 D375A-5
1
(5)
SERVICE CODE E0310 (SHORT CIRCUIT IN RIPPER TILT-IN OIL PRESSURE SWITCH
SERVICE CODE E0310 (SHORT CIRCUIT IN RIPPER TILT-IN OIL PRESSURE SWITCH
SYSTEM)
User code Service code Short circuit in ripper tilt-in oil pressure switch system
Trouble
Contents of trouble • Signal of ripper tilt-in oil pressure switch circuit was kept turned ON for 60 seconds.
Problem that
appears on machine
• Inputting from ripper tilt-in oil pressure switch (ON·OFF) can be checked in monitoring mode.
Related information

troubleshooting.
Defective ripper tilt-in oil
2 pressure switch RTI (male) Ripper lever Resistance
Between 1 – 2
Possible causes Tilt-in Max. 1 Ω
(Contact with ground circuit) NGICN1 (female) H – RTI (female) 1 with Max.
Resistance
1 MΩ
chassis ground
troubleshooting.
4 Defective steering controller NGICN1 Ripper lever Voltage
Between NGICN1 H Neutral 5 – 11 V
– 4, @ Tilt-in Max. 1 V
Circuit diagram related to ripper tilt-in oil pressure switch
D375A-5 20-477
1
(5)
SERVICE CODE E0311 (DISCONNECTION OR SHORT CIRCUIT IN BLADE PITCH

SWITCH SYSTEMS)
User code Service code Disconnection or short circuit in blade pitch switch systems
Trouble
Contents of trouble • Signals of both blade pitch switch circuit systems are turned ON or OFF simultaneously.
Problem that
• Blade does not pitch (When pitching operation is performed, blade tilts).
appears on machine
• Inputting from blade pitch switch (ON·OFF) can be checked in monitoring mode.
Related information
(Code bD: Blade lever knob switch input)
• Method of reproducing service code: Turn starting switch ON and operate blade pitch switch.

Blade pitch switch
Defective blade pitch switch P03 (male)
OFF (Released) ON (Pressed)
1–5
Resistance between
1–2
Disconnection in wiring har- Wiring harness between TMCN2 (female) E –
P03 (female) 5
tor) P03 (female) 2
@ – P03 (female) 1
Possible causes
and standard val- Short circuit with chassis
TMCN2 (female) E – P03 (female) 5 with Resistance Min. 1 MΩ
chassis ground
TMCN2 (female) 5 – P03 (female) 2 with Resistance Min. 1 MΩ
chassis ground
Short circuit with power
TMCN2 (female) E – P03 (female) 5 with Voltage Max. 1 V
chassis ground
TMCN2 (female) 5 – P03 (female) 2 with Voltage Max. 1 V
chassis ground
Blade pitch switch
TMCN1, TMCN2
5
troller
Max. 1 V 5 – 11 V
E – TMCN1 4, @
5 – 11 V Max. 1 V
5 – TMCN1 4, @
20-478 D375A-5
1
(5)
Circuit diagram related to blade tilt switch and blade pitch switch
D375A-5 20-479
1
SERVICE CODE E0312 (DISCONNECTION OR SHORT CIRCUIT IN BLADE TILT
SERVICE CODE E0312 (DISCONNECTION OR SHORT CIRCUIT IN BLADE TILT SWITCH

SYSTEMS)
User code Service code Disconnection or short circuit in blade tilt switch systems
Trouble
Contents of trouble • Signals of both blade tilt switch circuit systems are turned ON or OFF simultaneously.
• Assumes that switch is at SINGLE position.
Problem that • Blade dual tilt mechanism does not work (When dual tilt operation is performed, single tilt mechanism
appears on machine works).
• Inputting from blade tilt switch (ON·OFF) can be checked in monitoring mode.
Related information
(Code bD: Blade lever knob switch input)
• Method of reproducing service code: Turn starting switch ON and operate blade tilt switch.

Blade tilt switch
Defective blade tilt switch P03 (male)
SINGLE DUAL
3–6
Resistance between
3–4
Disconnection in wiring har- Wiring harness between TMCN2 (female) Y –
P03 (female) 6
Wiring harness between TMCN2 (female) O –
tor) P03 (female) 4
@ – P03 (female) 3
Possible causes
and standard val- Short circuit with chassis
TMCN2 (female) Y – P03 (female) 6 with Resistance Min. 1 MΩ
chassis ground
TMCN2 (female) O – P03 (female) 4 with Resistance Min. 1 MΩ
chassis ground
Short circuit with power
TMCN2 (female) Y – P03 (female) 6 with Voltage Max. 1 V
chassis ground
TMCN2 (female) O – P03 (female) 4 with Voltage Max. 1 V
chassis ground
Blade tilt switch
TMCN1, TMCN2
Defective transmission con- SINGLE DUAL
5
troller
Max. 1 V 5 – 11 V
Y – TMCN1 4, @
5 – 11 V Max. 1 V
O – TMCN1 4, @
20-480 D375A-5
1
(5)
SERVICE CODE E0312 (DISCONNECTION OR SHORT CIRCUIT IN BLADE TILT
Circuit diagram related to blade tilt switch and blade pitch switch
D375A-5 20-481
1
SERVICE CODE E0321 (DISCONNECTION IN BLADE DUAL SELECTOR SOLENOID
SERVICE CODE E0321 (DISCONNECTION IN BLADE DUAL SELECTOR SOLENOID

SYSTEM)
User code Service code Disconnection in blade dual selector solenoid system
Trouble
Contents of trouble When signal is output to blade dual selector solenoid circuit, current does not flow.
Action of controller Stops outputting to blade dual selector solenoid circuit.
Problem that Blade dual tilt mechanism does not work (When dual tilt operation is performed, single tilt mechanism
Outputting to blade dual selector solenoid (Voltage) can be checked in monitoring mode.
Related information (Code d4: Blade dual solenoid drive voltage)
Method of reproducing service code: Turn starting switch ON and perform blade dual tilt operation.

Defective blade dual selector without turning starting switch ON.
1 solenoid
SOL2 (male) Resistance
ness
Wiring harness between TMCN3 (female) G
SOL2 (female) 1
and standard val- tor) Wiring harness between SOL (female) 2
ue in normal state chassis ground
(Contact with 24 V circuit) TMCN3 (female) G SOL2 (female) 1 with Voltage Max. 1 V
chassis ground
4
Between G chassis ground 10 40 Ω
Circuit diagram related to blade dual selector solenoid
20-482 D375A-5
1
SERVICE CODE E0322 (SHORT CIRCUIT IN BLADE DUAL SELECTOR SOLENOID
SERVICE CODE E0322 (SHORT CIRCUIT IN BLADE DUAL SELECTOR SOLENOID

SYSTEM)
User code Service code Short circuit in blade dual selector solenoid system
Trouble
Contents of trouble When signal was output to blade dual selector solenoid circuit, abnormal current flowed.
Action of controller Stops outputting to blade dual selector solenoid circuit.
Problem that Blade dual tilt mechanism does not work (When dual tilt operation is performed, single tilt mechanism
Outputting to blade dual selector solenoid (Voltage) can be checked in monitoring mode.
Related information (Code d4: Blade dual solenoid drive voltage)
Method of reproducing service code: Turn starting switch ON and perform blade dual tilt operation.

Defective blade dual selector
1 solenoid SOL2 (male) Resistance
(Contact with ground circuit) TMCN3 (female) G SOL2 (female) 1 with Resistance Min. 1 MΩ
chassis ground
3
Between G chassis ground 10 40 Ω
Circuit diagram related to blade dual selector solenoid
D375A-5 20-483
1
SERVICE CODE E0323 (DISCONNECTION IN BLADE PITCH SELECTOR SOLENOID
SERVICE CODE E0323 (DISCONNECTION IN BLADE PITCH SELECTOR SOLENOID

SYSTEM)
User code Service code Disconnection in blade pitch selector solenoid system
Trouble
Contents of trouble When signal is output to blade pitch selector solenoid circuit, current does not flow.
Stops outputting to blade pitch selector solenoid circuit.
Problem that
Blade does not pitch (When pitching operation is performed, blade tilts).
appears on machine
Outputting to blade pitch selector solenoid (Voltage) can be checked in monitoring mode.
Related information (Code d3: Blade pitch solenoid drive voltage)
Method of reproducing service code: Turn starting switch ON and perform blade pitch operation.

Defective blade pitch selec- without turning starting switch ON.
1 tor solenoid
SOL1 (male) Resistance
ness
Wiring harness between TMCN3 (female) [
SOL1 (female) 1
and standard val- tor) Wiring harness between SOL1 (female) 2
ue in normal state chassis ground
(Contact with 24 V circuit) TMCN3 (female) [ SOL1 (female) 1 with Voltage Max. 1 V
chassis ground
4
Between [ chassis ground 10 40 Ω
Circuit diagram related to blade pitch selector solenoid
20-484 D375A-5
1
SERVICE CODE E0324 (SHORT CIRCUIT IN BLADE PITCH SELECTOR SOLENOID
SERVICE CODE E0324 (SHORT CIRCUIT IN BLADE PITCH SELECTOR SOLENOID

SYSTEM)
User code Service code Short circuit in blade pitch selector solenoid system
Trouble
Contents of trouble When signal was output to blade pitch selector solenoid circuit, abnormal current flowed.
Stops outputting to blade pitch selector solenoid circuit.
Problem that
Blade does not pitch (When pitching operation is performed, blade tilts).
appears on machine
Outputting to blade pitch selector solenoid (Voltage) can be checked in monitoring mode.
Related information (Code d3: Blade pitch solenoid drive voltage)
Method of reproducing service code: Turn starting switch ON and perform blade pitch operation.

Defective blade pitch selec-
1 tor solenoid SOL1 (male) Resistance
(Contact with ground circuit) TMCN3 (female) [ SOL1 (female) 1 with Resistance Min. 1 MΩ
chassis ground
3
Between [ chassis ground 10 40 Ω
Circuit diagram related to blade pitch selector solenoid
D375A-5 20-485
1
TROUBLESHOOTING SERVICE CODE E0329 (ABNORMAL HYDRAULIC OIL TEMPERATURE)
SERVICE CODE E0329 (ABNORMAL HYDRAULIC OIL TEMPERATURE)

Trouble Hydraulic oil temperature sensor: Out of input signal range
E01 E0329
Contents of trouble • The signal from the hydraulic oil temperature sensor is out of the normal range.
Action of controller • None in particular.
Problem that
• The hydraulic oil thermometer of the monitor panel may not be displayed normally.
appears on machine
Related information • Method of reproducing error code: Turn the starting switch ON or start the engine.
Defective hydraulic oil tem- ★ Prepare with starting switch OFF, then carry out troubleshooting
perature sensor without turning starting switch.
1
(Internal disconnection or 452 (male) Resistance
short circuit) Between (1) and chassis ground Min. 1 MΩ
ness without turning starting switch.
2 (Disconnection in wiring har-
Possible causes
ness or defective contact in Wiring harness between CN1 (female) (8) and Resistance Max. 1 Ω
and standard val- 452 (female) (1)
connector)
ue in normal state
Short circuit with chassis without turning starting switch.
(Contact with ground circuit) Between CN1 (female) (8) – 452 (female) (1)
wiring harness and chassis ground
(Contact with 24-V circuit) Between CN1 (female) (8) – 452 (female) (1)
Voltage Max. 1 V
wiring harness and chassis ground
Circuit diagram related to hydraulic oil temperature sensor
20-485-1 D375A-5
(6)
SERVICE CODE E0364 (DISCONNECTION IN FRONT LARGE PUMP OIL PRESSURE
SERVICE CODE E0364 (DISCONNECTION IN FRONT LARGE PUMP OIL PRESSURE

SENSOR SYSTEM)
User code Service code Disconnection in front large pump oil pressure sensor system
Trouble
E0364 (Transmission controller system)
Contents of trouble Signal voltage of front large pump oil pressure sensor circuit is below 0.5 V.
Action of controller Does not take any particular action.
Problem that
Oil pressure of front large pump cannot be monitored.
appears on machine
Outputting from front large pump oil pressure sensor (Voltage) can be checked in monitoring mode.
Related information (Code 4L: Voltage of front large pump oil pressure sensor)

1
Defective front large pump carry out troubleshooting.
2 oil pressure sensor
LPP Voltage
Between C A
(Internal trouble)
0.5 6.0 V
ness
Wiring harness between TMCN1 (female) F
LPP (female) B
Possible causes 3 (Disconnection in wiring or Resistance Max. 1 Ω
and standard val- defective contact in connec-
Wiring harness between TMCN1 (female) 9
LPP (female) C
ue in normal state tor) Resistance Max. 1 Ω

(Contact with ground circuit) TMCN1 (female) 9 LPP (female) C with Resistance Min. 1 MΩ
chassis ground
5
Circuit diagram related to front large pump oil pressure sensor
20-486 D375A-5
1
SERVICE CODE E0365 (SHORT CIRCUIT IN FRONT LARGE PUMP OIL PRESSURE
SERVICE CODE E0365 (SHORT CIRCUIT IN FRONT LARGE PUMP OIL PRESSURE
SENSOR SYSTEM)
User code Service code Short circuit in front large pump oil pressure sensor system
Trouble
Contents of trouble Signal voltage of front large pump oil pressure sensor circuit is above 6.0 V.
Problem that
Oil pressure of front large pump cannot be monitored.
appears on machine
Outputting from work equipment large pump oil pressure sensor (Voltage) can be checked in moni-
toring mode.
Related information
(Code 4L: Voltage of front large pump oil pressure sensor)

1
Defective front large pump carry out troubleshooting.
LPP Voltage
Between C A
(Internal trouble)
0.5 6.0 V
Possible causes
(Contact with 24 V circuit) TMCN1 (female) 9 LPP (female) C with Voltage Max. 1 V
chassis ground
4
Circuit diagram related to front large pump oil pressure sensor
D375A-5 20-487
1
SERVICE CODE E0366 (DISCONNECTION IN CENTER SMALL PUMP OIL PRESSURE
SERVICE CODE E0366 (DISCONNECTION IN CENTER SMALL PUMP OIL PRESSURE

SENSOR SYSTEM)
User code Service code Disconnection in center small pump oil pressure sensor system
Trouble
Contents of trouble Signal voltage of center small pump oil pressure sensor circuit is below 0.5 V.
Problem that
Oil pressure of center small pump cannot be monitored.
appears on machine
Outputting from center small pump oil pressure sensor (Voltage) can be checked in monitoring mode.
Related information (Code 45: Voltage of center small pump oil pressure sensor)

1
Defective center small pump carry out troubleshooting.
SPP Voltage
Between C A
(Internal trouble)
0.5 6.0 V
ness
Wiring harness between TMCN1 (female) F
SPP (female) B
Possible causes 3 (Disconnection in wiring or Resistance Max. 1 Ω
and standard val- defective contact in connec-
Wiring harness between TMCN1 (female) 3
SPP (female) C
ue in normal state tor) Resistance Max. 1 Ω

(Contact with ground circuit) TMCN1 (female) 3 SPP (female) C with Resistance Min. 1 MΩ
chassis ground
5
Circuit diagram related to center small pump oil pressure sensor
20-488 D375A-5
1
SERVICE CODE E0367 (SHORT CIRCUIT IN CENTER SMALL PUMP OIL PRESSURE
SERVICE CODE E0367 (SHORT CIRCUIT IN CENTER SMALL PUMP OIL PRESSURE
SENSOR SYSTEM)
User code Service code Short circuit in center small pump oil pressure sensor system
Trouble
Contents of trouble Signal voltage of center small pump oil pressure sensor circuit is above 6.0 V.
Problem that
Oil pressure of center small pump cannot be monitored.
appears on machine
Outputting from center small pump oil pressure sensor (Voltage) can be checked in monitoring mode.
Related information (Code 45: Voltage of center small pump oil pressure sensor)

1
Defective center small pump carry out troubleshooting.
SPP Voltage
Between C A
(Internal trouble)
0.5 6.0 V
Possible causes
(Contact with 24 V circuit) TMCN1 (female) 3 SPP (female) C with Voltage Max. 1 V
chassis ground
4
Circuit diagram related to center small pump oil pressure sensor
D375A-5 20-489
1
SERVICE CODE E0405 (DISCONNECTION OR SHORT CIRCUIT IN FUEL CONTROL
TROUBLESHOOTING DIAL SYSTEM)
SERVICE CODE E0405 (DISCONNECTION OR SHORT CIRCUIT IN FUEL CONTROL DIAL

SYSTEM)
User code Service code Disconnection or short circuit in fuel control dial system
Trouble
Contents of trouble Signal voltage of fuel control dial circuit is below 0.30 V or above 4.55 V.
Action of controller Continues controlling with signal of decelerator pedal potentiometer.
Inputting from fuel control dial (Voltage) can be checked in monitoring mode.
Related information (Code F6: Voltage of fuel control dial)

1
Defective fuel control dial TL1 (male) Resistance
Between R T
4.0 6.0 kΩ
Between R S
short circuit)
0.25 7.0 kΩ
Between S T 0.25 7.0 kΩ
ness
Wiring harness between NGICN1 (female) L
TL1 (female) R
TL1 (female) S
and standard val- tor) Resistance Max. 1 Ω
ue in normal state
(Contact with ground circuit) NGICN1 (female) 8 TL1 (female) S with Resistance Min. 1 MΩ
chassis ground
NGICN1 (female) 8 TL1 (female) S
(Contact with 24 V circuit) Voltage Max. 1 V
6
troller NGICN1 Voltage
Between 8 K 0.30 4.33 V
20-490 D375A-5
1
SERVICE CODE E0405 (DISCONNECTION OR SHORT CIRCUIT IN FUEL CONTROL
TROUBLESHOOTING DIAL SYSTEM)
Circuit diagram related to fuel control dial
D375A-5 20-491
1
SERVICE CODE E0430 (ENGINE OIL: ABNORMAL OIL PRESSURE)
SERVICE CODE E0431 (ABNORMAL RADIATOR COOLANT LEVEL)
TROUBLESHOOTING SERVICE CODE E0432 (RADIATOR COOLANT: OVERHEATING)
SERVICE CODE E0430 (ENGINE OIL: ABNORMAL OIL PRESSURE)

Trouble Engine oil: Abnormal oil pressure
CALL E0430
Contents of trouble • While the engine is running, the engine oil pressure caution lamp flashes.
Action of controller • Sounds the caution buzzer (Function of monitor panel).
Problem that
• If the machine is operated as it is, the engine may be damaged.
appears on machine
Related information • Method of reproducing error code: Start the engine.
Cause Standard value in normal state/Remarks on troubleshooting.

Lowering of engine oil pres-
A phenomenon seems to have caused lowering of the engine oil pres-
Possible causes 1 sure
sure. Find and stop it and repair the damaged part.
and standard val- (When system is normal)
ue in normal state Carry out troubleshooting for the engine oil pressure caution lamp
Defective engine oil pres-
2 system according to "E-8 While engine is running, emergency stop
sure caution lamp system
item flashes" in E-mode.
SERVICE CODE E0431 (ABNORMAL RADIATOR COOLANT LEVEL)

Trouble Abnormal radiator coolant level
CALL E0431
Contents of trouble • When the starting switch is turned ON, the radiator coolant level caution lamp flashes.
Problem that
appears on machine
Related information • Method of reproducing error code: Turn the starting switch ON.

Lowering of radiator coolant
A phenomenon seems to have caused lowering of the radiator coolant
Possible causes 1 level
level. Find and stop it and repair the damaged part.
ue in normal state Carry out troubleshooting for the radiator coolant level caution lamp
Defective radiator coolant
2 system according to "E-6 When starting switch is turned ON, basic
level caution lamp system
item flashes" in E-mode.
SERVICE CODE E0432 (RADIATOR COOLANT: OVERHEATING)

Trouble Radiator coolant: Overheating
E01 E0432
Contents of trouble • While the engine is running, the engine coolant temperature caution lamp flashes.
Action of controller • Sounds the caution buzzer (Function of monitor panel).
Problem that
appears on machine
Related information • Method of reproducing error code: Start the engine.

Overheating of engine cool-
A phenomenon seems to have caused overheating of the engine cool-
Possible causes 1 ant
ant. Find and stop it and repair the damaged part.
ue in normal state Defective engine coolant Carry out troubleshooting for the engine coolant temperature caution
2 temperature caution lamp lamp system according to "E-8 While engine is running, emergency
system stop item flashes" in E-mode.
20-491-1 D375A-5
(6)
SERVICE CODE E0486 (ABNORMALITY IN SELECTION OF TRANSMISSION
TROUBLESHOOTING CONTROLLER SPECIFICATION)
SERVICE CODE E0486 (ABNORMALITY IN SELECTION OF TRANSMISSION

CONTROLLER SPECIFICATION)
User code Service code Abnormality in selection of transmission controller specification

Trouble
Internal setting of transmission controller specification is different from specification setting signal
Contents of trouble
(Transmission controller cannot recognize specification setting normally).
Action of controller Stops transmission controller from outputting all signals.
Machine does not move at all.
Problem that
appears on machine

After adjustment mode is executed, if service code changes to P (to
Defective adjustment of indicate that trouble is repaired), system is normal.
1
transmission controller Adjustment code 7A: Check of specification code
(Transmission controller)
Possible causes Disconnection in wiring har- ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard val- 2 ness without turning starting switch ON.
ue in normal state (Disconnection in wiring or de- Wiring harness between TMCN3 (female) @
fective contact in connector) chassis ground Resistance Max. 1 Ω
3
Between @ chassis ground Max. 1 V
Circuit diagram related to transmission controller specification selection signal
20-492 D375A-5
1
SERVICE CODE E0501 (DISCONNECTION OR SHORT CIRCUIT IN ACCELERATION
SERVICE CODE E0501 (DISCONNECTION OR SHORT CIRCUIT IN ACCELERATION

SENSOR SYSTEM)
User code Service code Disconnection or short circuit in acceleration sensor system
Trouble
Contents of trouble • Signal voltage of acceleration sensor is below 0.3 V or above 4.7 V.
Action of controller • Stops shoe slip control (SSC) function.
Problem that
• Even if shoe slips, engine speed does not change.
appears on machine
• Inputting from acceleration sensor (Voltage) can be checked in monitoring mode.
Related information (Code A5: Voltage of acceleration sensor)
• Method of reproducing service code: Turn starting switch ON.

1
Defective acceleration sen- carry out troubleshooting.
2 sor
SS3 Voltage
(Internal trouble)
Between 2 – 3 0.75 – 4.25 V
ness
– SS3 (female) 1
tor) Wiring harness between NGICN1 (female) 1
– SS3 (female) 2
and standard val-
(Contact with ground circuit) NGICN1 (female) 1 – SS3 (female) 2 with Resistance Min. 1 MΩ
chassis ground
(Contact with 24 V circuit) Short circuit of wiring harness between
Voltage Max. 1 V
NGICN1 (female) 1 – SS3 (female) 2
6
troller NGICN1 Voltage
Between 1 – K 0.75 – 4.25 V
Circuit diagram related to acceleration sensor
D375A-5 20-493
1
TROUBLESHOOTING SERVICE CODE E0610 (DISCONNECTION IN BACK-UP ALARM RELAY SYSTEM)
SERVICE CODE E0610 (DISCONNECTION IN BACK-UP ALARM RELAY SYSTEM)
User code Service code Disconnection in back-up alarm relay system

Trouble
Contents of trouble • When GND signal for back-up alarm relay circuit is turned off, 24 V is not generated.
Action of controller • Stops outputting to back-up alarm relay circuit.
Problem that
• Back-up alarm does not sound.
appears on machine
• Outputting to back-up alarm relay (Voltage) can be checked in monitoring mode.
(Code db: Back-up alarm relay drive voltage)
Related information • Method of reproducing service code: Turn starting switch ON and set parking brake lever in neutral.
★ This service code detects abnormality on primary side (coil side) of back-up alarm relay and cannot

1 Defective fuse FS4-1 If fuse is broken, circuit probably has short circuit with chassis ground.
Defective back-up alarm re- without turning starting switch ON.
2 lay
BKA (male) Resistance
Between 1 – 2 200 – 400 Ω
ness
Wiring harness between TMCN2 (female) H –
BKA (female) 2
tor) Wiring harness between BKA (female) 1 –
FS4-1 outlet
and standard val-
4 ground in wiring harness TMCN2 (female) H – BKA (female) 2 with Resistance Min. 1 MΩ
(Contact with ground circuit) chassis ground
Short circuit of wiring harness between BKA
(female) 1 – FS4-1 outlet with chassis ground
5
troller
Between H – chassis Neutral 20 – 30 V
ground Reverse Max. 1 V
20-494 D375A-5
1
(5)
TROUBLESHOOTING SERVICE CODE E0610 (DISCONNECTION IN BACK-UP ALARM RELAY SYSTEM)
Circuit diagram related to back-up alarm
D375A-5 20-495
1
TROUBLESHOOTING SERVICE CODE E0611 (SHORT CIRCUIT IN BACK-UP ALARM RELAY SYSTEM)
SERVICE CODE E0611 (SHORT CIRCUIT IN BACK-UP ALARM RELAY SYSTEM)
User code Service code Short circuit in back-up alarm relay system
Trouble
Contents of trouble • When GND signal for back-up alarm relay circuit was output, abnormal current flowed.
Action of controller • Stops outputting to back-up alarm relay circuit.
Problem that
• Back-up alarm does not sound.
appears on machine
• Outputting to back-up alarm relay (Voltage) can be checked in monitoring mode.
(Code db: Back-up alarm relay drive voltage)
Related information • Method of reproducing service code: Turn starting switch ON and operate PCCS lever (in reverse).
★ This service code detects abnormality on primary side (coil side) of back-up alarm relay and cannot

Defective back-up alarm re- without turning starting switch ON.
1 lay
BKA (male) Resistance
Between 1 – 2 200 – 400 Ω
and standard val- 2 source in wiring harness
ue in normal state (Contact with 24 V circuit) Short circuit of wiring harness between
Voltage Max. 1 V
TMCN2 (female) H – BKA (female) 2
3
troller
Between H – chassis Neutral 20 – 30 V
ground Reverse Max. 1 V
20-496 D375A-5
1
(5)
TROUBLESHOOTING SERVICE CODE E0611 (SHORT CIRCUIT IN BACK-UP ALARM RELAY SYSTEM)
D375A-5 20-497
1
TROUBLESHOOTING SERVICE CODE E0660 (DISCONNECTION IN ACC SIGNAL DRIVE RELAY SYSTEM)
SERVICE CODE E0660 (DISCONNECTION IN ACC SIGNAL DRIVE RELAY SYSTEM)
User code Service code Disconnection in ACC signal drive relay system
Trouble
Contents of trouble When signal is output to ACC signal drive circuit, current does not flow.
Action of controller Stops outputting to ACC signal drive relay circuit.
Problem that
Turbocharger timer function does not work (if equipped).
appears on machine
Outputting to ACC signal drive relay (Voltage) can be checked in monitoring mode.
(Code d8: Engine controller relay drive voltage)
Related information
Turn starting switch ON and OFF (when turbocharger timer is in operation).
★ This service code detects abnormality on primary side (coil side) of ACC signal drive relay and cannot

Defective ACC signal drive without turning starting switch ON.
1 relay
SDR (male) Resistance
Between 1 2 200 400 Ω
ness
Wiring harness between NGICN3 (female) H
Possible causes SDR (female) 1
and standard val- tor) Wiring harness between SDR (female) 2
ue in normal state Resistance Max. 1 Ω
chassis ground
(Contact with 24 V circuit) Short circuit of wiring harness between
Voltage Max. 1 V
NGICN3 (female) H SDR (female) 1
4
troller SGICN3 (female) Resistance
Between H chassis ground 200 400 Ω
Circuit diagram related to ACC signal drive relay
20-498 D375A-5
1
TROUBLESHOOTING SERVICE CODE E0661 (SHORT CIRCUIT IN ACC SIGNAL DRIVE RELAY SYSTEM)
SERVICE CODE E0661 (SHORT CIRCUIT IN ACC SIGNAL DRIVE RELAY SYSTEM)
User code Service code Short circuit in ACC signal drive relay system
Trouble
Contents of trouble When signal is output to ACC signal drive circuit, abnormal current flowed.
Action of controller Stops outputting to ACC signal drive relay circuit.
Problem that
Turbocharger timer function does not work (if equipped).
appears on machine
Outputting to ACC signal drive relay (Voltage) can be checked in monitoring mode.
(Code d8: Engine controller relay drive voltage)
Related information
Turn starting switch ON and OFF (when turbocharger timer is in operation).
★ This service code detects abnormality on primary side (coil side) of ACC signal drive relay and cannot

Defective ACC signal drive without turning starting switch ON.
1 relay
SDR (male) Resistance
Between 1 2 200 400 Ω
Possible causes
and standard val-
ue in normal state 2 ground in wiring harness Short circuit of wiring harness between
(Contact with ground circuit) NGICN3 (female) H SDR (male) 1 with Resistance Min. 1 MΩ
chassis ground
3
Between H chassis ground 200 400 Ω
Circuit diagram related to ACC signal drive relay
D375A-5 20-499
1

SENSOR SYSTEM)
User code Service code Disconnection or short circuit in pitch angle sensor system
Trouble
Contents of trouble Signal voltage of pitch angle sensor circuit is below 0.15 V or above 4.85 V.
Steering function and braking function may lower.
Problem that
appears on machine
★ Since pitch angle sensor signal is input to both steering controller and transmission controller, related
Related information
Inputting from pitch angle revolution sensor (Voltage) can be checked in monitoring mode.
(Code A8: Pitch angle sensor voltage)

1
Possible causes (Disconnection in wiring or de- Wiring harness between NGICN2 (female) C
fective contact in connector) circuit branching point Resistance Max. 1 Ω
and standard val-
ue in normal state ★ Prepare with starting switch OFF, then turn starting switch ON and
2
troller NGICN2 Resistance
Between C chassis ground 0.15 4.85 V

1
Defective pitch angle sensor carry out troubleshooting.
2
(Internal trouble) PAS Voltage
Between B A 0.15 4.85 V
and standard val- Disconnection in wiring har- without turning starting switch ON.
ue in normal state ness Wiring harness between PAS (female) B
3 Resistance Max. 1 Ω
(Disconnection in wiring or de- circuit branching point
fective contact in connector) Wiring harness between PAS (male) C
NGICN1 (female) F
4 ground in wiring harness Short circuit of wiring harness between PAS
(Contact with ground circuit) (female) B TMCN1 (female) C NGICN1 Resistance Min. 1 MΩ
(female) C with chassis ground
20-500 D375A-5
1
Circuit diagram related to pitch angle sensor
D375A-5 20-501
1
SERVICE
SERVICE CODECODE
E0730 E0730 [ABNORMALITY
[ABNORMALITY IN BOTH STEERING
IN BOTH STEERING POTENTIOMETER
TROUBLESHOOTING SERVICE CODE E0731 [ABNORMALITY IN BOTH STEERING POTENTIOMETER
SYSTEMS
SYSTEMS(1)]
(2)]
SERVICE CODE E0730 [ABNORMALITY IN BOTH STEERING POTENTIOMETER

SYSTEMS (1)]
User code Service code Abnormality in both steering potentiometer systems (1)
Trouble
Service codes [E0733] and [E0734] are displayed simultaneously for steering potentiometer systems
Contents of trouble
1 and 2.
Inputting from steering potentiometers (Voltage) can be checked in monitoring mode.
(Code L1: Voltage of steering potentiometer 1)
Related information
Method of reproducing service code: Turn starting switch ON and operate PCCS lever (Steering).

and standard val-

SYSTEMS (2)]
Trouble
Steering potentiometer systems 1 and 2 are normal when starting switch is turned ON, then service
Contents of trouble
code [E0735] is displayed.
Related information

and standard val-
20-502 D375A-5
1
TROUBLESHOOTING SYSTEMS (3)]

SYSTEMS (3)]
Trouble
Either of steering potentiometers 1 and 2 is abnormal when starting switch is turned ON, then service
Contents of trouble
codes [E0733] and [E0734] are displayed simultaneously.
Related information

and standard val-
D375A-5 20-503
1
SERVICE CODE E0733 (DISCONNECTION OR SHORT CIRCUIT IN STEERING
TROUBLESHOOTING POTENTIOMETER 1 SYSTEM)

User code Service code Disconnection or short circuit in steering potentiometer 1 system
Trouble
Contents of trouble Signal voltage of steering potentiometer 1 (ST1) is below 0.5 V or above 4.5 V.
Action of controller Continues controlling with signal of steering potentiometer 2 system (ST2).
Inputting from steering potentiometer 1 (ST1) (Voltage) can be checked in monitoring mode.
Related information (Code L1: Voltage of steering potentiometer 1)

1
Defective steering potenti-
ometer 1 TL1 (male) Resistance
Between A G
2
short circuit) Between H A
Between H G
ness
TL1 (female) A
Possible causes Wiring harness between NGICN1 (female) 2
TL1 (female) H
and standard val-
ue in normal state
(Contact with ground circuit) NGICN1 (female) 2 TL1 (female) H with Resistance Min. 1 MΩ
chassis ground
(Contact with 24 V circuit) NGICN1 (female) 2 TL1 (female) H with Voltage Max. 1 V
chassis ground
NGICN1 Voltage
20-504 D375A-5
1
Circuit diagram related to steering potentiometer
D375A-5 20-505
1

User code Service code Disconnection or short circuit in steering potentiometer 2 system
Trouble
Contents of trouble Signal voltage of steering potentiometer 2 (ST2) is below 0.5 V or above 4.5 V.
Action of controller Continues controlling with signal of steering potentiometer 1 system (ST1).
Inputting from steering potentiometer 2 (ST2) (Voltage) can be checked in monitoring mode.
Related information (Code L2: Voltage of steering potentiometer 2)

Defective sensor power sup- See if service code [E0143] is displayed. If it is displayed, carry out
1
ply system troubleshooting for it first.
Defective steering potenti-
ometer 2 TL1 (male) Resistance
Between M F
2
short circuit) Between E M
Between E F
ness
TL1 (female) M
Possible causes Wiring harness between NGICN1 (female) I
TL1 (female) E
and standard val-
ue in normal state
(Contact with ground circuit) NGICN1 (female) I TL1 (female) E with Resistance Min. 1 MΩ
chassis ground
(Contact with 24 V circuit) NGICN1 (female) I TL1 (female) E with Voltage Max. 1 V
chassis ground
NGICN1 Voltage
Between I K 0.5 4.5 V
20-506 D375A-5
1
SERVICE CODE E0735 (DEVIATION OF STEERING POTENTIOMETER SYSTEM
TROUBLESHOOTING SIGNALS)
Circuit diagram related to steering potentiometers
SERVICE CODE E0735 (DEVIATION OF STEERING POTENTIOMETER SYSTEM

SIGNALS)
User code Service code Deviation of steering potentiometer system signals

Trouble
Contents of trouble Total signal voltages of steering potentiometers 1 (ST1) and 2 (ST2) is below 4.41 V or above 5.59 V.
Action of controller Continues controlling with normal signal of steering potentiometer 1 (ST1) system or 2 (ST2) system.

and standard val-
D375A-5 20-507
1
SERVICE CODE E0736 (DISCONNECTION OR SHORT CIRCUIT IN BRAKE
TROUBLESHOOTING POTENTIOMETER SYSTEM)

POTENTIOMETER SYSTEM)
User code Service code Disconnection or short circuit in brake potentiometer system
Trouble
Contents of trouble Signal voltage of brake potentiometer circuit is below 0.5 V or above 4.5 V.
Action of controller Stops controlling with brake potentiometer signal.
Brake control performance of brake pedal lowers.
Problem that
appears on machine
Inputting from brake potentiometer (Voltage) can be checked in monitoring mode.
Related information (Code L7: Voltage of brake potentiometer)
Method of reproducing service code: Turn starting switch ON and operate brake pedal.

1
Defective brake potentiome-
ter BRK (male) Resistance
Between A C
2
(Internal disconnection or 4.0 6.0 kΩ
short circuit) Between A B 0.25 7.0 kΩ
Between B C 0.25 7.0 kΩ
ness
BRK (female) C
3 (Disconnection in wiring or Resistance
Possible causes Wiring harness between NGICN1 (female) 3
BRK (female) B
tor) Resistance
and standard val-
ue in normal state
(Contact with ground circuit) NGICN1 (female) 3 BRK (female) B with Resistance Min. 1 MΩ
chassis ground
(Contact with 24 V circuit) NGICN1 (female) 3 BRK (female) B with Voltage Max. 1 V
chassis ground
NGICN1 Voltage
Between 3 B 0.5 4.5 V
20-508 D375A-5
1
TROUBLESHOOTING POTENTIOMETER SYSTEM)
Circuit diagram related to brake potentiometer
D375A-5 20-509
1
SERVICE CODE E0750 (DISCONNECTION IN RIGHT STEERING CLUTCH ECMV
SERVICE CODE E0750 (DISCONNECTION IN RIGHT STEERING CLUTCH ECMV SYSTEM)
User code Service code Disconnection in right steering clutch ECMV system
Trouble
Contents of trouble • When signal is output to right steering clutch solenoid circuit, current does not flow.
Action of controller • Stops outputting to right steering clutch solenoid circuit.
• Machine cannot be steered to right.
Problem that
appears on machine
• Outputting to right steering clutch solenoid (Current) can be checked in monitoring mode.
(Code P4, c4: Right steering clutch ECMV output current)
Related information
Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to right).

Defective right steering without turning starting switch ON.
1 clutch solenoid
SRC (male) Resistance
Between 1 – 2 5 – 15 Ω
ness
2 (Disconnection in wiring or Wiring harness between NGICN3 (female) Y Resistance Max. 1 Ω
– SRC (female) 1
and standard val- tor) Wiring harness between NGICN3 (female) M
ue in normal state – SRC (female) 2
aPrepare with starting switch OFF, then turn starting switch ON and
(Contact with 24 V circuit) NGICN3 (female) Y – SRC (female) 1 with Voltage Max. 1 V
chassis ground
NGICN3 (female) Resistance
Between Y – M 5 – 15 Ω
Circuit diagram related to right steering clutch ECMV
20-510 D375A-5
(7)
1
SERVICE CODE E0751 (SHORT CIRCUIT IN RIGHT STEERING CLUTCH ECMV
SERVICE CODE E0751 (SHORT CIRCUIT IN RIGHT STEERING CLUTCH ECMV SYSTEM)
User code Service code Short circuit in right steering clutch ECMV system
Trouble
Contents of trouble • When signal was output to right steering clutch solenoid circuit, abnormal current flowed.
Action of controller • Stops outputting to right steering clutch solenoid circuit.
• Machine cannot be steered to right.
Problem that
appears on machine
• Outputting to right steering clutch solenoid (Current) can be checked in monitoring mode.
(Code P4, c4: Right steering clutch ECMV output current)
Related information
Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to right).

Defective right steering
1 clutch solenoid SRC (male) Resistance
(Contact with ground circuit) NGICN3 (female) Y – SRC (female) 1 with Resistance Min. 1 MΩ
Possible causes
chassis ground
and standard val-
ue in normal state aPrepare with starting switch OFF, then carry out troubleshooting
3
(with another wiring har- NGICN3 (female) Y – SRC (female) 1 with
wiring harness between NGICN3 (female) M
– SRC (female) 2
4 Defective steering controller NGICN3 (female) Resistance
Between Y – M 5 – 15 Ω
Between Y – chassis ground Min. 1 MΩ
Circuit diagram related to right steering clutch ECMV
D375A-5 20-511
(7)
1
SERVICE CODE E0752 (DISCONNECTION IN LEFT STEERING CLUTCH ECMV
SERVICE CODE E0752 (DISCONNECTION IN LEFT STEERING CLUTCH ECMV SYSTEM)
User code Service code Disconnection in left steering clutch ECMV system
Trouble
Contents of trouble • When signal is output to left steering clutch solenoid circuit, current does not flow.
Action of controller • Stops outputting to left steering clutch solenoid circuit.
• Machine cannot be steered to left.
Problem that
appears on machine
• Outputting to left steering clutch solenoid (Current) can be checked in monitoring mode.
(Code P3, c3: Left steering clutch ECMV output current)
Related information
Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to left).

Defective left steering clutch without turning starting switch ON.
1 solenoid
SLC (male) Resistance
Between 1 – 2 5 – 15 Ω
ness
2 (Disconnection in wiring or Wiring harness between NGICN3 (female) O Resistance Max. 1 Ω
– SLC (female) 1
and standard val- tor) Wiring harness between NGICN3 (female) M
ue in normal state – SLC (female) 2
(Contact with 24 V circuit) NGICN3 (female) O – SLC (female) 1 with Voltage Max. 1 V
chassis ground
Between O – M 5 – 15 Ω
Circuit diagram related to left steering clutch ECMV
20-512 D375A-5
(7)
1
SERVICE CODE E0753 (SHORT CIRCUIT IN LEFT STEERING CLUTCH ECMV
SERVICE CODE E0753 (SHORT CIRCUIT IN LEFT STEERING CLUTCH ECMV SYSTEM)
User code Service code Short circuit in left steering clutch ECMV system
Trouble
Contents of trouble • When signal was output to left steering clutch solenoid circuit, abnormal current flowed.
Action of controller • Stops outputting to left steering clutch solenoid circuit.
• Machine cannot be steered to left.
Problem that
appears on machine
• Outputting to left steering clutch solenoid (Current) can be checked in monitoring mode.
(Code P3, c3: Left steering clutch ECMV output current)
Related information
Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to left).

Defective left steering clutch
1 solenoid SLC (male) Resistance
(Contact with ground circuit) NGICN3 (female) O – SLC (female) 1 with Resistance Min. 1 MΩ
Possible causes
chassis ground
and standard val-
3
(with another wiring har- NGICN3 (female) O – SLC (female) 1 with
wiring harness between NGICN3 (female) M
– SLC (female) 2
Between O – M 5 – 15 Ω
Between O – chassis ground Min. 1 MΩ
Circuit diagram related to left steering clutch ECMV
D375A-5 20-513
(7)
1
SERVICE CODE E0754 (DISCONNECTION IN RIGHT STEERING BRAKE ECMV
SERVICE CODE E0754 (DISCONNECTION IN RIGHT STEERING BRAKE ECMV SYSTEM)
User code Service code Disconnection in right steering brake ECMV system
Trouble
Contents of trouble • When signal is output to right steering brake solenoid circuit, current does not flow.
Action of controller • Stops outputting to right steering brake solenoid circuit.
• Limits operation of engine, transmission, and brake.
• Brake is kept applied lightly during travel.
Problem that
appears on machine
• Outputting to right steering brake solenoid (Current) can be checked in monitoring mode.
Related information (Code P2, c2: Right steering brake ECMV output current)
• Method of reproducing service code: Turn starting switch ON and release parking brake lever.

Defective right steering without turning starting switch ON.
1 brake solenoid
SRB (male) Resistance
Between 1 – 2 5 – 15 Ω
ness
2 (Disconnection in wiring or Wiring harness between NGICN3 (female) E Resistance Max. 1 Ω
– SRB (female) 1
and standard val- tor) Wiring harness between NGICN3 (female) C
ue in normal state – SRB (female) 2
(Contact with 24 V circuit) NGICN3 (female) E – SRB (female) 1 with Voltage Max. 1 V
chassis ground
Circuit diagram related to right steering brake ECMV
20-514 D375A-5
(7)
1
SERVICE CODE E0755 (SHORT CIRCUIT IN RIGHT STEERING BRAKE ECMV
SERVICE CODE E0755 (SHORT CIRCUIT IN RIGHT STEERING BRAKE ECMV SYSTEM)
User code Service code Short circuit in right steering brake ECMV system
Trouble
Contents of trouble • When signal was output to right steering brake solenoid circuit, abnormal current flowed.
Action of controller • Stops outputting to right steering brake solenoid circuit.
• Limits operation of engine, transmission, brake.
Problem that
appears on machine
• Outputting to right steering brake solenoid (Current) can be checked in monitoring mode.
Related information (Code P2, c2: Right steering brake ECMV output current)

Defective right steering
1 brake solenoid SRB (male) Resistance
(Contact with ground circuit) NGICN3 (female) E – SRB (female) 1 with Resistance Min. 1 MΩ
Possible causes
chassis ground
and standard val-
3
(with another wiring har- NGICN3 (female) E – SRB (female) 1 with
wiring harness between NGICN3 (female) C
– SRB (female) 2
Between E – chassis ground Min. 1 MΩ
Circuit diagram related to right steering brake ECMV
D375A-5 20-515
(7)
1
SERVICE CODE E0756 (DISCONNECTION IN LEFT STEERING BRAKE ECMV
SERVICE CODE E0756 (DISCONNECTION IN LEFT STEERING BRAKE ECMV SYSTEM)
User code Service code Disconnection in left steering brake ECMV system
Trouble
Contents of trouble • When signal is output to left steering brake solenoid circuit, current does not flow.
Action of controller • Stops outputting to left steering brake solenoid circuit.
Problem that
appears on machine
• Outputting to left steering brake solenoid (Current) can be checked in monitoring mode.
Related information (Code P1, c1: Left steering brake ECMV output current)

Defective left steering brake without turning starting switch ON.
1 solenoid
SLB (male) Resistance
Between 1 – 2 5 – 15 Ω
ness
2 (Disconnection in wiring or Wiring harness between NGICN3 (female) 5 Resistance Max. 1 Ω
– SLB (female) 1
and standard val- tor) Wiring harness between NGICN3 (female) C
ue in normal state – SLB (female) 2
(Contact with 24 V circuit) NGICN3 (female) 5 – SLB (female) 1 with Voltage Max. 1 V
chassis ground
Circuit diagram related to left steering brake ECMV
20-516 D375A-5
(7)
1
SERVICE CODE E0757 (SHORT CIRCUIT IN LEFT STEERING BRAKE ECMV
SERVICE CODE E0757 (SHORT CIRCUIT IN LEFT STEERING BRAKE ECMV SYSTEM)
User code Service code Short circuit in left steering brake ECMV system
Trouble
Contents of trouble • When signal was output to left steering brake solenoid circuit, abnormal current flowed.
Action of controller • Stops outputting to left steering brake solenoid circuit.
Problem that
appears on machine
• Outputting to left steering brake solenoid (Current) can be checked in monitoring mode.
Related information (Code P1, c1: Left steering brake ECMV output current)

Defective left steering brake
1 solenoid SLB (male) Resistance
(Contact with ground circuit) NGICN3 (female) 5 – SLB (female) 1 with Resistance Min. 1 MΩ
Possible causes
chassis ground
and standard val-
3
(with another wiring har- NGICN3 (female) 5 – SLB (female) 1 with
– SLB (female) 2
Circuit diagram related to left steering brake ECMV
D375A-5 20-517
(7)
1
SERVICE CODE E0779 (DISCONNECTION IN SUDDEN STOP PREVENTION
SERVICE CODE E0779 (DISCONNECTION IN SUDDEN STOP PREVENTION SOLENOID

SYSTEM)
User code Service code Disconnection in sudden stop prevention solenoid system
Trouble
Contents of trouble • When signal is output to sudden stop prevention solenoid circuit, current does not flow.
Problem that
appears on machine
• Outputting to sudden stop prevention solenoid (Voltage) can be checked in monitoring mode.
Related information (Code d5: Sudden stop prevention solenoid drive voltage)

Defective sudden stop pre- without turning starting switch ON.
1 vention solenoid
STB (male) Resistance
Between 1 – 2 5 – 25 Ω
ness
– STB (female) 1
tor) Wiring harness between NGICN3 (female) C
and standard val- Resistance Max. 1 Ω
ue in normal state – STB (female) 2
(Contact with 24 V circuit) NGICN3 (female) 7 – STB (female) 1 with Voltage Max. 1 V
chassis ground
Circuit diagram related to sudden stop prevention solenoid
20-526 D375A-5
1
SERVICE CODE E0780 (SHORT CIRCUIT IN SUDDEN STOP PREVENTION
SERVICE CODE E0780 (SHORT CIRCUIT IN SUDDEN STOP PREVENTION SOLENOID

SYSTEM)
User code Service code Short circuit in sudden stop prevention solenoid system
Trouble
Contents of trouble • When signal is output to sudden stop prevention solenoid circuit, abnormal current flowed.
Problem that
appears on machine
• Outputting to sudden stop prevention solenoid (Voltage) can be checked in monitoring mode.
Related information (Code d5: Sudden stop prevention solenoid drive voltage)

Defective sudden stop pre-
1 vention solenoid STB (male) Resistance
(Contact with ground circuit) Short circuit of wiring harness between Resistance Max. 1 Ω
Possible causes NGICN3 (female) 7 – STB (female) 1
Short circuit in wiring har-
3
(with another wiring har- NGICN3 (female) 7 – STB (female) 1 with
ness) Resistance Max. 1 Ω
– STB (female) 2
Circuit diagram related to sudden stop prevention solenoid
D375A-5 20-527
1

LEVER SWITCH SYSTEMS)
User code Service code Disconnection or short circuit in parking brake lever switch systems
Trouble
Contents of trouble • Signals of both parking brake lever switch circuit systems are turned ON or OFF simultaneously.
Action of controller • Assumes that parking brake lever is at FREE position.
Problem that
• Travel lock does not work (Mechanical parking brake and pedal work normally.)
appears on machine
★ Since parking brake switch signal is used by both transmission controller and steering controller, re-
lated codes may be displayed simultaneously, depending on troubled part.
(Related codes: E0238, E0239, E0782)
Related information
(Code L9: Steering controller switch input 1)
ness
– circuit branching point
Wiring harness between NGICN2 (female) E
Possible causes – circuit branching point
ue in normal state carry out troubleshooting.
Parking brake lever
NGICN2
At FREE At LOCK
Between 5 – chassis
Max. 1 V 5 – 11 V
ground
Between E – chassis
5 – 11 V Max. 1 V
ground
Defective parking brake le- without turning starting switch ON.
ver switch Parking brake lever
1 NSW
Between A – B
(Internal disconnection or At FREE At LOCK
Max. 1 Ω
Between A – C
short circuit) Min. 1 MΩ
harness between NSW (female) B –

Wiring
Wiring harness between NSW (female) C –
circuit merging point
defective contact in connec- circuit merging point Resistance Max. 1 Ω
tor) Wiring harness between NSW (female) A –
chassis ground
(female) B – NGICN2 (female) 5 – TMCN1 Resistance Min. 1 MΩ

Short circuit with chassis Short circuit of wiring harness between NSW
(female) H with chassis ground
(female) C – NGICN2 (female) E – TMCN1 Resistance Min. 1 MΩ

(female) B – NGICN2 (female) 5 – TMCN1

Short circuit with power Short circuit of wiring harness between NSW
Voltage Max. 1 V
(female) H with chassis ground
(female) C – NGICN2 (female) E – TMCN1
Voltage Max. 1 V
20-528 D375A-5
1
(5)
Circuit diagram related to parking brake switch
D375A-5 20-529
1

SYSTEM SIGNALS)
User code Service code Disagreement of parking brake lever switch system signals
Trouble
Switch input signal of steering controller disagrees with communication signal from steering control-
Contents of trouble
ler.
★ Since parking brake switch signal is used by both transmission controller and steering controller and
information is exchanged by S-NET communication, related codes may be displayed simultaneously,
depending on troubled part.
Related information (Related codes: E0101, E0104, E0105, E0152, E0164, E0238, E0239, E0781)
Inputting from parking brake switch (ON·OFF) can be checked in monitoring mode.
(Code L9: Steering controller switch input 1)
Method of reproducing service code: Turn starting switch ON and operate parking brake lever.

See if service codes [E0101], [E0104], [E0105], [E0152], and [E0162]
Defective S-NET communi-
1 are displayed. If they are displayed, carry out troubleshooting for them
Possible causes cation system
first.
and standard val-
ue in normal state See if service codes [E0238] and [E0781] are displayed. If they are
Defective parking brake le-
2 displayed, carry out troubleshooting for them first.
ver switch signal system
(Service code [E0239] is same as [E0782].)
3 Defective steering controller Since trouble is in system, troubleshooting cannot be carried out.
20-530 D375A-5
1
TROUBLESHOOTING SERVICE CODE E0930 (DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM)
SERVICE CODE E0930 (DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM)
User code Service code Disconnection in engine speed sensor system

Trouble
Contents of trouble Engine speed signal is not input from engine controller.
Action of controller Cannot recognize engine speed.
Problem that Tachometer graphic section is not displayed.
appears on machine Steering performance may lower.
★ Since engine speed signal is input to both steering controller and transmission controller, related
Related information
Inputting from engine speed sensor (Voltage) can be checked in monitoring mode.
(Code 91: Engine speed sensor input signal)
Method of reproducing service code: Start engine.

ness
Wiring harness between NGICN2 (female) ^
and standard val- tor) Wiring harness between NGICN2 (female) ]
ue in normal state circuit branching point
troubleshooting.
NGICN2 Voltage
Between ^ ] Approx 3.3 V

ness
Wiring harness between ECMB (female) O
and standard val- tor) Wiring harness between EG2 (male) T cir-
ue in normal state cuit branching point
troubleshooting.
2 Defective engine controller
ECMB Voltage
Between O chassis ground
D375A-5 20-531
1
Circuit diagram related to engine speed sensor signal
20-532 D375A-5
1
SERVICE CODE E0931 (DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM)
User code Service code Disconnection in engine speed sensor system

Trouble
Contents of trouble Engine speed signal is not input from engine controller.
Action of controller Cannot recognize engine speed.
★ Since engine speed signal is input to both steering controller and transmission controller, related
Related information
Inputting from engine speed sensor (Voltage) can be checked in monitoring mode.
(Code 92: Engine speed sensor input signal)

ness
Wiring harness between TMCN2 (female) ^
and standard val- tor) Wiring harness between TMCN2 (female) ]
ue in normal state circuit branching point
Defective transmission con- troubleshooting.
2
Between ^ ] Approx 3.3 V

ness
Wiring harness between ECMB (female) O
and standard val- tor) Wiring harness between EG2 (male) T cir-
ue in normal state cuit branching point
ECMB Voltage
Between O chassis ground
D375A-5 20-533
1
Circuit diagram related to engine speed sensor signal
20-534 D375A-5
1
SERVICE CODE E0932 (DISCONNECTION IN TRANSMISSION SPEED SENSOR
SERVICE CODE E0932 (DISCONNECTION IN TRANSMISSION SPEED SENSOR SYSTEM)
User code Service code Disconnection in transmission speed sensor system

Trouble
Contents of trouble Signal is not input from transmission speed sensor
Action of controller Cannot recognize transmission output speed.
★ Since transmission speed signal is input to both steering controller and transmission controller, relat-
ed codes may be displayed simultaneously, depending on troubled part.
Inputting from transmission speed sensor (Voltage) can be checked in monitoring mode.
Related information
(Code 94: Transmission speed sensor input signal)
Method of reproducing service code: Start engine and drive machine.
¤ When troubleshooting by operating transmission, set system in adjustment mode (Code: Co) so that
machine will not start.

ness
Wiring harness between TMCN2 (female) T
Possible causes Wiring harness between TMCN2 (female) S
and standard val- circuit branching point
ue in normal state
2
troller
Between T S 500 1,000 Ω
Between T chassis ground Min. 1 MΩ

Defective transmission without turning starting switch ON.
speed sensor TM1 (male) Resistance
1
(Internal disconnection or
short circuit) Between 1 2 500 1,000 Ω
Possible causes Disconnection in wiring har- without turning starting switch ON.
and standard val- ness
Wiring harness between TM1 (female) 1
ue in normal state 2 (Disconnection in wiring or Resistance Max. 1 Ω
tor) Wiring harness between TM1 (male) 2 cir-
cuit branching point
3 ground in wiring harness Short circuit of wiring harness between TM1
(Contact with ground circuit) (female) 1 TMCN2 (female) T NGICN2 Resistance Min. 1 MΩ
(female) T with chassis ground
D375A-5 20-535
1
Circuit diagram related to transmission speed sensor
20-536 D375A-5
1
SERVICE CODE E0933 (DISCONNECTION IN TRANSMISSION SPEED SENSOR SYSTEM)
User code Service code Disconnection in transmission speed sensor system

Trouble
Contents of trouble Signal is not input from transmission speed sensor
Action of controller Cannot recognize transmission output speed.
Problem that
Steering performance may lower.
appears on machine
★ Since transmission speed signal is input to both steering controller and transmission controller, relat-
ed codes may be displayed simultaneously, depending on troubled part.
Inputting from transmission speed sensor (Voltage) can be checked in monitoring mode.
Related information
(Code 93: Transmission speed sensor input signal)
Method of reproducing service code: Start engine and drive machine.
¤ When troubleshooting by operating transmission, set system in adjustment mode (Code: Co) so that
machine will not start.

ness
Wiring harness between NGICN2 (female) T
Possible causes Wiring harness between NGICN2 (female) S
and standard val- circuit branching point
ue in normal state
Between T S 500 1,000 Ω
Between T chassis ground Min. 1 MΩ

Defective transmission without turning starting switch ON.
speed sensor TM1 (male) Resistance
1
(Internal disconnection or
short circuit) Between 1 2 500 1,000 Ω
Possible causes Disconnection in wiring har- without turning starting switch ON.
and standard val- ness
Wiring harness between TM1 (female) 1
ue in normal state 2 (Disconnection in wiring or Resistance Max. 1 Ω
tor) Wiring harness between TM1 (male) 2 cir-
cuit branching point
3 ground in wiring harness Short circuit of wiring harness between TM1
(Contact with ground circuit) (female) 1 NGICN2 (female) T TMCN2 Resistance Min. 1 MΩ
(female) T with chassis ground
D375A-5 20-537
1
Circuit diagram related to transmission speed sensor
20-538 D375A-5
1
TROUBLESHOOTING SERVICE CODE E1939 (ABNORMALITY IN J1939 COMMUNICATION SYSTEM)
SERVICE CODE E1939 (ABNORMALITY IN J1939 COMMUNICATION SYSTEM)
User code Service code Abnormality in J1939 communication system

Trouble
Contents of trouble Steering controller cannot receive communication signal of J1939 communication.
Action of controller Cannot receive communication information from engine controller.
Monitoring mode of engine controller system cannot be used.
Problem that
Service codes of engine controller system cannot be recorded.
appears on machine
Engine information cannot be displayed on monitor panel normally.
J1939 communication is communication circuit between engine controller and steering controller. Al-
Related information though transmission controller is connected to this circuit, it does not communicate.

1
(Disconnection in wiring or de- Wiring harness between NGICN2 (female) L
fective contact in connector) ECMB (female) L Resistance Max. 1 Ω
Reset according to following procedure, then check displayed service

code to see which controller is defective.
Possible causes When P (reset) is displayed: Steering controller is defective.
and standard val- When E (detection) is displayed: Engine controller is defective.
ue in normal state 1)With starting switch turned OFF, exchange steering controller and
Defective steering controller transmission controller.
2 2)Turn starting switch ON.
or engine controller
3)Set monitor panel in adjustment mode (service mode) and execute
adjustment codes [5A] and [7A].
4)Turn starting switch OFF and ON.
5)Set monitor panel in service code display mode and check dis-
played code.
★ After checking, return controllers to original states.
Circuit diagram related to J1939 communication
D375A-5 20-539
1
SERVICE CODE EC111 (ABNORMALITY IN ENGINE CONTROLLER MEMORY)
SERVICE CODE (ABNORMALITY
CODE EC111 EC112 (ABNORMALITY IN TIMING
IN ENGINE RAIL ACTUATOR)
CONTROLLER MEMORY)
SERVICE CODE -+ (ABNORMALITY IN ENGINE CONTROLLER MEMORY)
User code Service code Abnormality in engine controller memory

Trouble
CALL EC111 (Engine controller system)
Contents of trouble Memory in controller has trouble or processor in controller has communication trouble.
Problem that
Engine cannot be started.
appears on machine

Reset according to following procedure. If service code E is displayed
Possible causes
at this time, engine controller is defective.
and standard val-
ue in normal state 1 Defective engine controller 1)Keep starting switch at OFF position for 5 seconds.
2)Run engine at low idling.
3)Check service code.
SERVICE CODE -+ (ABNORMALITY IN TIMING RAIL ACTUATOR)
User code Service code Abnormality in timing rail actuator

Trouble
Displayed fuel value of timing rail is excessively different from actual timing fuel.
Contents of trouble Judgment value (for reference):
Error is above 400 mm3/st or below 750 mm3/st (When water temperature is below 0°C).
Limits engine speed to 1,500 rpm.
Problem that
Engine speed lowers.
appears on machine
Related information Method of reproducing service code: Start engine.

Check displayed service codes. If code related to engine controller is
1 Defective related systems
displayed, carry out troubleshooting for it first.
Clogging, looseness, break-
Check fuel filter/piping directly for clogging, looseness, breakage, and
2 age, or leakage of fuel filter/
Possible causes leakage.
piping
and standard val-
3 Defective timing rail actuator Check timing rail actuator directly for defective operation.
ue in normal state
Clogging of timing rail actua-
4 Check timing rail actuator screen directly for clogging.
tor screen
5 Breakage of injector O-ring Check injector O-ring directly for breakage.
If causes 1 5 are not detected, engine controller may be defective.
(Since trouble is in system, troubleshooting cannot be carried out.)
20-540 D375A-5
1
SERVICE CODE EC113 (ABNORMAL CURRENT IN TIMING RAIL ACTUATOR
SERVICE CODE EC113 (ABNORMAL CURRENT IN TIMING RAIL ACTUATOR SYSTEM)
User code Service code Abnormal current in timing rail actuator system
Trouble
CALL03 EC113 (Engine controller system)
• Current in timing rail actuator is out of normal range.
Contents of trouble
• Normal range (for reference): 0.40 ± 0.35 A (When engine is stopped)
Action of controller • Flashes caution lamp and turns on caution buzzer.
Problem that • Engine output lowers.
appears on machine • Exhaust gas becomes white.
• Special cable (795-799-5460) is necessary for troubleshooting for timing rail actuator.
Related information
• Method of reproducing service code: Turn starting switch ON (or start engine).

Defective timing rail actuator TIMG (male) Resistance
1
Between A – C
(Internal trouble)
7–9Ω
Between A, C – chassis ground Min. 100 kΩ
ness
Wiring harness between ECMA (female) 1 –
TIMG (female) A
Wiring harness between ECMA (female) J –
TIMG (female) C
Possible causes
Short circuit in wiring har- Short circuit of wiring harness between ECMA
ness (female) 1 – TIMG (female) A with wiring Resistance Min. 1 MΩ
3
(with another wiring har- harness around it
ness) Short circuit of wiring harness between ECMA
(female) J – TIMG (female) C with wiring Resistance Min. 1 MΩ
harness around it
ECMA (female) Resistance
Between 1 – J 7–9Ω
Wiring harness between 1, J –
Min. 1 MΩ
wiring harness around it
Circuit diagram related to timing rail actuator
D375A-5 20-541
(7)
1
TROUBLESHOOTING SERVICE CODE EC115 (ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEMS)
SERVICE CODE EC115 (ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEMS)
User code Service code Abnormality in engine speed sensor 2 systems

Trouble
Contents of trouble • Signal is not input to either of engine speed sensor circuit 2 systems.
• Outputs speed signal of 0 rpm.
Problem that
• Engine stops.
appears on machine
• Inputting from engine speed sensor (rpm) can be checked in monitoring mode.
(Code 62: Engine speed)
Related information
• Special cable (795-799-5520) is necessary for troubleshooting for engine speed sensor.
• Method of reproducing service code: Start engine.

SP1 (male), SP2 (male) Resistance
Between A – B
Defective engine speed sen-
1 sor 1 k – 2 kΩ
(Internal trouble) Between A – A Max. 10 Ω
Between B – B Max. 10 Ω
Between A – chassis ground Min. 10 MΩ
Damage of engine speed
2 Check engine speed sensor directly.
sensor
SP1 (female) A
Wiring harness between ECMA (female) Q –
Disconnection in wiring har- Resistance Max. 10 Ω
ness
SP1 (female) B
3 (Disconnection in wiring or Wiring harness between ECMA (female) R –
SP2 (female) A
tor) Wiring harness between ECMA (female) [ –
SP2 (female) B
Wiring harness between ECMA (female) \ –
and standard val-
(female) Q – SP1 (female) A with wiring har- Resistance Min. 1 MΩ

Short circuit of wiring harness between ECMA
ness around it
(female) R – SP1 (female) B with wiring har- Resistance Min. 1 MΩ
ness
4
(with another wiring harness around it
ness)
(female) [ – SP2 (female) A with wiring har- Resistance Min. 1 MΩ
ness around it
(female) \ – SP2 (female) B with wiring har- Resistance Min. 1 MΩ

ness around it
troubleshooting.
5 Defective engine controller Between Q – R 1 k – 2 kΩ
Between Q, R – chassis ground Min. 1 MΩ
Between [ – \ 1 k – 2 kΩ
Between [, \ – chassis ground Min. 1 MΩ
20-542 D375A-5
1
Circuit diagram related to engine speed sensor
D375A-5 20-543
1
SERVICE CODE EC116 (ABNORMALLY HIGH LEVEL IN TIMING RAIL PRESSURE
SERVICE CODE EC116 (ABNORMALLY HIGH LEVEL IN TIMING RAIL PRESSURE

SENSOR SYSTEM)
User code Service code Abnormally high level in timing rail pressure sensor system
Trouble
Contents of trouble • Signal voltage of timing rail pressure sensor circuit is above 4.78 V.
Action of controller • Opens and controls timing rail.
• Limits engine speed to 1,500 rpm.
Problem that • Engine makes abnormal combustion sound or discharges white smoke, then its speed is set to
appears on machine 1,500 rpm.
• Special cable (795-799-5480) is necessary for troubleshooting for timing rail pressure sensor.
Related information

Defective timing rail pres-
1 sure sensor TPR Voltage
(Internal trouble) Between A – B 4.75 – 5.25 V
Between C – B 0.42 – 0.58 V
TPR (female) A
TPR (female) B
defective contact in connec- Wiring harness between ECMA (female) H –
tor)
TPR (female) C
Wiring harness between ECMA (female) W –
Possible causes
(female) 5 – TPR (female) A with wiring har- Resistance Min. 1 MΩ

Short circuit in wiring harness around it
ness
3
(female) H – TPR (female) B with wiring har- Resistance Min. 1 MΩ
(with another wiring har- Short circuit of wiring harness between ECMA
ness)
ness around it
(female) W – TPR (female) C with wiring har- Resistance Min. 1 MΩ

ness around it
4 Defective engine controller ECMA Voltage
Between 5 – H 4.75 – 5.25 V
Between W – H 0.42 – 0.58 V
Circuit diagram related to engine speed sensor
20-544 D375A-5
(7)
1
SERVICE CODE EC117 (ABNORMALLY LOW LEVEL IN TIMING RAIL PRESSURE
SERVICE CODE EC117 (ABNORMALLY LOW LEVEL IN TIMING RAIL PRESSURE

SENSOR SYSTEM)
User code Service code Abnormally low level in timing rail pressure sensor system
Trouble
Contents of trouble • Signal voltage of timing rail pressure sensor circuit is below 0.30 V.
Action of controller • Opens and controls timing rail.
• Limits engine speed to 1,500 rpm.
Problem that • Engine makes abnormal combustion sound or discharges white smoke, then its speed is set to
appears on machine 1,500 rpm.
Related information • Method of reproducing service code: Start engine.

and standard val-
ue in normal state Carry out troubleshooting for service code [EC116].
D375A-5 20-545
1
SERVICE CODE EC118 (ABNORMALLY HIGH LEVEL IN FUEL PUMP PRESSURE
SERVICE CODE EC118 (ABNORMALLY HIGH LEVEL IN FUEL PUMP PRESSURE

SENSOR SYSTEM)
User code Service code Abnormally high level in fuel pump pressure sensor system
Trouble
Contents of trouble • Signal voltage of fuel pump pressure sensor circuit is above 4.78 V.
• Opens and controls fuel pump.
Problem that
appears on machine
• Special cable (795-799-5480) is necessary for troubleshooting for fuel pump pressure sensor.
Related information

Defective fuel pump pres-
1 sure sensor PMPR (male) Voltage
Between C – B 0.42 – 0.58 V
PMPR (female) A
PMPR (female) B
defective contact in connec- Wiring harness between ECMA (female) H –
tor)
PMPR (female) C
Wiring harness between ECMA (female) V –
Possible causes
(female) 5 – PMPR (female) A with wiring Resistance Min. 1 MΩ

harness around it
ness
3
(female) H – PMPR (female) B with wiring Resistance Min. 1 MΩ
ness)
harness around it
(female) V – PMPR (female) C with wiring Resistance Min. 1 MΩ

harness around it
4 Defective engine controller ECMA (female) Resistance
Between 5 – H 4.75 – 5.25 V
Between V – H 0.42 – 0.58 V
Circuit diagram related to fuel pump pressure sensor
20-546 D375A-5
(7)
1
SERVICE CODE EC119 (ABNORMALLY LOW LEVEL IN FUEL PUMP PRESSURE
SERVICE CODE EC119 (ABNORMALLY LOW LEVEL IN FUELSENSOR SYSTEM)
PUMP PRESSURE
SENSOR SYSTEM)
SERVICE CODE EC119 (ABNORMALLY LOW LEVEL IN FUEL PUMP PRESSURE

SENSOR SYSTEM)
User code Service code Abnormally low level in fuel pump pressure sensor system
Trouble
Contents of trouble • Signal voltage of fuel pump pressure sensor circuit is below 0.30 V.
• Opens and controls fuel pump.
Problem that
appears on machine

and standard val-
SERVICE CODE EC121 (ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEMS)
User code Service code Abnormality in engine speed sensor 1 systems

Trouble
Contents of trouble • Signal is not input to both of engine speed sensor circuit 2 systems.
Problem that
appears on machine
• Inputting from engine speed sensor (rpm) can be checked in monitoring mode.
Related information (Code 62: Engine speed)

and standard val-
D375A-5 20-547
1
SERVICE CODE EC122 (ABNORMALLY HIGH LEVEL IN BOOST PRESSURE
SERVICE CODE EC122 (ABNORMALLY HIGH LEVEL IN BOOST PRESSURE SENSOR

SYSTEM)
User code Service code Abnormally high level in boost pressure sensor system
Trouble
E01 EC122 (Engine controller system)
Contents of trouble • Signal voltage of boost pressure sensor circuit is above 4.72 V.
Problem that • When machine is accelerated sharply, exhaust gas color is bad.
appears on machine • Engine output rises.
• Special cable (795-799-5480) is necessary for troubleshooting for boost pressure sensor.
Related information

Defective boost pressure
1 sensor IMPR (male) Voltage
Between C – B 0.42 – 0.58 V
IMPR (female) A
IMPR (female) B
defective contact in connec- Wiring harness between ECMA (female) G –
tor)
IMPR (female) C
Wiring harness between ECMA (female) Y –
Possible causes
(female) 6 – IMPR (female) A with wiring

Short circuit in wiring har- Resistance Min. 1 MΩ
harness around it
ness
3
(female) G – IMPR (female) B with wiring
harness around it
(female) Y – IMPR (female) C with wiring

harness around it
Between 6 – G 4.75 – 5.25 V
Between Y – G 0.42 – 0.58 V
Circuit diagram related to boost pressure sensor
20-548 D375A-5
(7)
1
SERVICE CODE EC123 (ABNORMALLY LOW LEVEL IN BOOST PRESSURE SENSOR
SERVICE CODE -+ ! (ABNORMALLY LOW LEVEL IN BOOST PRESSURE SENSOR

SYSTEM)
User code Service code Abnormally low level in boost pressure sensor system
Trouble
Contents of trouble Signal voltage of boost pressure sensor circuit is below 0.30 V.
Problem that
Engine output lowers.
appears on machine

and standard val-
D375A-5 20-549
1
SERVICE CODE EC131 (ABNORMALLY HIGH LEVEL IN THROTTLE SENSOR
SERVICE CODE -+! (ABNORMALLY HIGH LEVEL IN THROTTLE SENSOR SYSTEM)
User code Service code Abnormally high level in throttle sensor system
Trouble
Contents of trouble Signal voltage of throttle sensor (deceleration potentiometer) circuit is above 4.80 V.
Keeps engine speed at constant level.
Problem that
Engine output and speed rise suddenly.
appears on machine
Inputting from deceleration potentiometer to steering controller (Voltage) can be checked in monitor-
ing mode.
Related information
(Code d6: Deceleration potentiometer voltage)

Defective deceleration po- DCL (male) Resistance
Between A C
1 tentiometer
4.0 6.0 kΩ
Between A B
(Internal trouble)
0.25 7.0 kΩ
Between B C 0.25 7.0 kΩ
Wiring harness between ECMB (female) P
DCL (female) A
Wiring harness between ECMB (female) A
DCL (female) C
tor)
Possible causes Wiring harness between ECMB (female) S
DCL (female) B
and standard val- Resistance Max. 10 Ω
Short circuit of wiring harness between ECMB
Short circuit in wiring har- (female) P DCL (female) A with wiring har- Resistance Min. 1 MΩ
ness around it
ness
3 Short circuit of wiring harness between ECMB
(female) A DCL (female) C with wiring har- Resistance Min. 1 MΩ
(with another wiring har-
ness)
ness around it
(female) S DCL (female) B with wiring har- Resistance Min. 1 MΩ
ness around it
ECMB Voltage
Between S A 0.30 4.80 V
Circuit diagram related to deceleration potentiometer
20-550 D375A-5
1
SERVICE CODE EC132 (ABNORMALLY LOW LEVEL IN THROTTLE SENSOR
SERVICE CODE -+! (ABNORMALLY LOW LEVEL IN THROTTLE SENSOR SYSTEM)
User code Service code Abnormally low level in throttle sensor system
Trouble
Contents of trouble Signal voltage of throttle sensor (deceleration potentiometer) circuit is below 0.30 V.
Problem that
Engine speed and output lower suddenly.
appears on machine
Inputting from deceleration potentiometer to steering controller (Voltage) can be checked in monitor-
ing mode.
Related information
(Code d6: Deceleration potentiometer voltage)

and standard val-
D375A-5 20-551
1
SERVICE CODE EC133 (ABNORMALLY HIGH LEVEL IN REMOTE THROTTLE
SERVICE CODE -+!! (ABNORMALLY HIGH LEVEL IN REMOTE THROTTLE SENSOR

SYSTEM)
User code Service code Abnormally high level in remote throttle sensor system
Trouble
Contents of trouble Signal voltage of remote throttle sensor (SSC command) circuit is above 4.80 V.
Problem that
Engine speed rises suddenly.
appears on machine
Outputting of SSC command to steering controller (Voltage) can be checked in monitoring mode.
Related information (Code 5U: Engine command voltage)

1
(Disconnection in wiring or de- Wiring harness between ECMB (female) T
fective contact in connector) NGICN2 (female) A Resistance Max. 10 Ω

ness
2 Short circuit of wiring harness between ECMB
ness) (female) T NGICN2 (female) A with wiring Resistance Min. 1 MΩ
harness around it
Possible causes
and standard val- Reset according to following procedure, then check displayed service
ue in normal state code to see which controller is defective.
When P (reset) is displayed: Steering controller is defective.
When E (detection) is displayed: Engine controller is defective.
1)With starting switch turned OFF, exchange steering controller and
Defective engine controller transmission controller.
3 2)Turn starting switch ON.
or steering controller
3)Set monitor panel in adjustment mode (service mode) and execute
adjustment codes [5A] and [7A].
4)Turn starting switch OFF and ON.
5)Set monitor panel in service code display mode and check dis-
played code.
★ After checking, return controllers to original states.
Circuit diagram related to SSC command
20-552 D375A-5
1
SERVICE CODE EC134 (ABNORMALLY LOW LEVEL IN REMOTE THROTTLE
SERVICE CODE -+!" (ABNORMALLY LOW LEVEL IN REMOTE THROTTLE SENSOR

SYSTEM)
User code Service code Abnormally low level in remote throttle sensor system
Trouble
Contents of trouble Signal voltage of remote throttle sensor (SSC command) circuit is below 0.30 V.
Problem that
Engine speed lowers suddenly.
appears on machine
Outputting of SSC command to steering controller (Voltage) can be checked in monitoring mode.
Related information (Code 5U: Engine command voltage)

and standard val-
D375A-5 20-553
1
SERVICE CODE EC135 (ABNORMALLY HIGH LEVEL IN ENGINE OIL PRESSURE
SERVICE CODE -+!# (ABNORMALLY HIGH LEVEL IN ENGINE OIL PRESSURE

SENSOR SYSTEM)
User code Service code Abnormally high level in engine oil pressure sensor system
Trouble
Contents of trouble Signal voltage of engine oil pressure sensor circuit is above 4.88 V.
Problem that
appears on machine
Special cable (795-799-5470) is necessary for troubleshooting for engine oil pressure sensor.
Related information

Defective engine oil pres-
1 sure sensor OLPR Voltage
(Internal trouble) Between A B 4.75 5.25 V
Between C B 0.42 0.58 V
Wiring harness between ECMA (female) 6
OLPR (female) A
Wiring harness between ECMA (female) G
OLPR (female) B
tor)
Wiring harness between ECMA (female) N
OLPR (female) C
Possible causes
Short circuit in wiring har- (female) 6 OLPR (female) A with wiring Resistance Min. 1 MΩ
harness around it
ness
3 Short circuit of wiring harness between ECMA
(female) G OLPR (female) B with wiring
harness around it
(female) N OLPR (female) C with wiring Resistance Min. 1 MΩ
harness around it
Between 6 G 4.75 5.25 V
Between N G 0.42 0.58 V
Circuit diagram related to engine oil pressure sensor
20-554 D375A-5
1
SERVICE CODE EC141 (ABNORMALLY LOW LEVEL IN ENGINE OIL PRESSURE
SENSOR
SERVICE CODE EC141 (ABNORMALLY LOW LEVEL IN ENGINE SYSTEM)
OIL PRESSURE
TROUBLESHOOTING SERVICE CODE EC143 (LOWERING OF ENGINE OIL PRESSURE)
SENSOR SYSTEM)
SERVICE CODE EC141 (ABNORMALLY LOW LEVEL IN ENGINE OIL PRESSURE

SENSOR SYSTEM)
User code Service code Abnormally low level in engine oil pressure sensor system
Trouble
Contents of trouble • Signal voltage of engine oil pressure sensor circuit is below 0.31 V.
Problem that
appears on machine

and standard val-
SERVICE CODE EC143 (LOWERING OF ENGINE OIL PRESSURE)
User code Service code Lowering of engine oil pressure

Trouble
— EC143 (Engine controller system)
• Engine oil pressure sensor detected pressure lower than pressure set in controller.
• Criterion (for reference): Max. 0.05 MPa {0.5 kg/cm2} at 600 rpm
Max. 0.09 MPa {0.9 kg/cm2} at 1,000 rpm
Contents of trouble
Action of controller • Limits fuel injection rate to 50% after 10 seconds.
Problem that
appears on machine

Possible causes 1 Defective related systems
and standard val-
ue in normal state 2 Defective engine oil pres- Carry out troubleshooting for service codes [EC135] and [EC141].
sure sensor system
3 Defective engine See S mode.
D375A-5 20-555
1
(5)
SERVICE CODE EC144 (ABNORMALLY HIGH LEVEL IN ENGINE COOLANT
TROUBLESHOOTING TEMPERATURE SENSOR SYSTEM)
SERVICE CODE EC144 (ABNORMALLY HIGH LEVEL IN ENGINE COOLANT

TEMPERATURE SENSOR SYSTEM)
User code Service code Abnormally high level in engine coolant temperature sensor system
Trouble
Contents of trouble • Signal voltage of engine coolant temperature sensor circuit is above 4.95 V.
Problem that
appears on machine
• Special cable (795-799-5530) is necessary for troubleshooting for engine coolant temperature sen-
Related information sor.

Defective engine coolant without turning starting switch ON.
1 temperature sensor
CLTP Resistance
Between A – B
(Internal trouble)
600 – 36 kΩ
ness
Wiring harness between ECMA (female) L –
CLTP (female) A
Wiring harness between ECMA (female) G –
CLTP (female) B
Possible causes
(female) L – CLTP (female) A with wiring

ness Resistance Min. 1 MΩ
3
ness)
(female) G – CLTP (female) B with wiring
harness around it
Between N – G 600 – 36 kΩ
Circuit diagram related to engine coolant temperature sensor
20-556 D375A-5
1
SERVICE CODE EC145 (ABNORMALLY LOW LEVEL IN ENGINE COOLANT
SERVICE CODE EC145 (ABNORMALLYTEMPERATURE SENSORCOOLANT
LOW LEVEL IN ENGINE SYSTEM)
TROUBLESHOOTING SERVICE CODE EC151 (RISE OF ENGINE COOLANT
TEMPERATURE TEMPERATURE)
SENSOR SYSTEM)
SERVICE CODE EC145 (ABNORMALLY LOW LEVEL IN ENGINE COOLANT

TEMPERATURE SENSOR SYSTEM)
User code Service code Abnormally low level in engine coolant temperature sensor system
Trouble
Contents of trouble • Signal voltage of engine coolant temperature sensor circuit is below 0.21 V.
Problem that
appears on machine

and standard val-
SERVICE CODE EC151 (RISE OF ENGINE COOLANT TEMPERATURE)
User code Service code Rise of engine coolant temperature

Trouble
• Engine coolant temperature sensor detected temperature higher than temperature set in controller.
Contents of trouble
• Criterion (for reference): Min. 105°C
Action of controller • Limits fuel injection rate to 50% after 10 seconds.
Problem that
appears on machine

and standard val-
ue in normal state 2 Defective engine coolant Carry out troubleshooting for service codes [EC144] and [EC145].
temperature sensor system
D375A-5 20-557
1
(5)
SERVICE CODE EC153 (ABNORMALLY HIGH LEVEL IN AIR INTAKE TEMPERATURE
SERVICE CODE EC153 (ABNORMALLY HIGH LEVEL IN AIR INTAKE TEMPERATURE

SENSOR SYSTEM)
User code Service code Abnormally high level in air intake temperature sensor system
Trouble
Contents of trouble • Signal voltage of air intake temperature sensor circuit is above 4.88 V.
Problem that
appears on machine
• Special cable (795-799-5540) is necessary for troubleshooting for air intake temperature sensor.
Related information

Defective air intake tempera- without turning starting switch ON.
1 ture sensor
IMTP (female) Resistance
Between A – B
(Internal trouble)
36 – 600 Ω
ness
Wiring harness between ECMA (female) M –
IMTP (female) A
IMTP (female) B
Possible causes
(female) M – IMTP (female) A with wiring har- Resistance Min. 1 MΩ

ness
3
ness)
(female) G – IMTP (female) B with wiring har- Resistance Min. 1 MΩ
ness around it
Between M – G 36 – 600 Ω
Circuit diagram related to air intake temperature sensor
20-558 D375A-5
1
SERVICE CODE EC154 (ABNORMALLY LOW LEVEL IN AIR INTAKE TEMPERATURE
SERVICE CODE -+#" (ABNORMALLY LOW LEVEL IN AIR INTAKE TEMPERATURE

SENSOR SYSTEM)
User code Service code Abnormally low level in air intake temperature sensor system
Trouble
Contents of trouble Signal voltage of air intake temperature sensor circuit is below 0.08 V.
Problem that
appears on machine

and standard val-
D375A-5 20-559
1
SERVICE CODE EC221 (ABNORMALLY HIGH LEVEL IN ATMOSPHERIC PRESSURE
SERVICE CODE -+ (ABNORMALLY HIGH LEVEL IN ATMOSPHERIC PRESSURE

SENSOR SYSTEM)
User code Service code Abnormally high level in atmospheric pressure sensor system
Trouble
Contents of trouble Signal voltage of atmospheric pressure sensor circuit is above 4.78 V.
Problem that
appears on machine
Special cable (795-799-5460) is necessary for troubleshooting for atmospheric pressure sensor.
Related information

Defective atmospheric pres-
1 sure sensor AAPR Voltage
AAPR (female) A
Wiring harness between ECMA (female) G
AAPR (female) B
tor)
Wiring harness between ECMA (female) X
AAPR (female) C
Possible causes
Short circuit in wiring har- (female) 6 AAPR (female) A with wiring Resistance Min. 1 MΩ
harness around it
ness
(female) G AAPR (female) B with wiring
harness around it
(female) X AAPR (female) C with wiring Resistance Min. 1 MΩ
harness around it
Between 6 G 4.75 5.25 V
Between X G 0.42 0.58 V
Circuit diagram related to atmospheric pressure sensor
20-560 D375A-5
1
SERVICE CODE EC222 (ABNORMALLY LOW LEVEL IN ATMOSPHERIC PRESSURE
SENSOR
SERVICE CODE EC222 (ABNORMALLY LOW LEVEL IN ATMOSPHERIC SYSTEM)
PRESSURE
TROUBLESHOOTING SERVICE CODE EC234 (OVER-SPEED)
SENSOR SYSTEM)
SERVICE CODE EC222 (ABNORMALLY LOW LEVEL IN ATMOSPHERIC PRESSURE

SENSOR SYSTEM)
User code Service code Abnormally low level in atmospheric pressure sensor system
Trouble
Contents of trouble • Signal voltage of atmospheric pressure sensor circuit is below 0.20 V.
Problem that
appears on machine

and standard val-
SERVICE CODE EC234 (OVER-SPEED)
User code Service code Over-speed

Trouble
• Engine speed sensor detected speed higher than speed set in controller.
Contents of trouble
• Criterion (for reference): Min. 2,400 rpm
Action of controller • Closes fuel rail actuator fully (Cuts out fuel).
Problem that
appears on machine

Possible causes
and standard val- 1 Defective related systems
ue in normal state
D375A-5 20-561
1
(5)
TROUBLESHOOTING SERVICE CODE EC254 (ABNORMAL VOLTAGE OF FUEL SHUT-OFF VALVE)
SERVICE CODE EC254 (ABNORMAL VOLTAGE OF FUEL SHUT-OFF VALVE)
User code Service code Abnormal voltage of fuel shut-off valve

Trouble
Contents of trouble • Voltage (Resistance) of fuel shut-off valve circuit is above 6.0 V (below 20 Ω).
Action of controller • Turns off power for fuel shut-off valve.
Problem that
• Engine stops.
appears on machine

Defective fuel shut-off valve FSO (Valve side) Resistance
1
(Internal trouble)
Between (+) – (–) 23 – 40 Ω
Between (+) – chassis ground 100 kΩ
ness
Wiring harness between ECMA (female) T –
FSO (wiring harness side) (+)
tor) Wiring harness between FSO (wiring harness
and standard val- side) (–) – chassis ground
ness (female) T – FSO (wiring harness side) (+) Resistance Min. 1 MΩ
3
(with another wiring har- with wiring harness around it
ness) Short circuit of wiring harness between FSO
(wiring harness side) (–) – chassis ground Resistance Min. 1 MΩ
with wiring harness around it
ECMA Resistance
Between T – chassis ground 23 – 40 Ω
Circuit diagram related to fuel shut-off valve
20-562 D375A-5
1
SERVICE CODE EC259 (ABNORMALITY IN FUEL SHUT-OFF VALVE)
SERVICECODE
CODE EC261
EC259 (ABNORMAL RISEINOF
(ABNORMALITY FUEL
FUEL TEMPERATURE)
SHUT-OFF VALVE)
SERVICE CODE EC259 (ABNORMALITY IN FUEL SHUT-OFF VALVE)
User code Service code Abnormality in fuel shut-off valve

Trouble
Contents of trouble • Fuel shut-off valve cannot be closed (Engine does not stop when electric power is turned off).
• Turns off power for fuel shut-off valve.
Problem that
• Engine cannot be stopped.
appears on machine

2 Trouble in fuel shut-off valve Check inside of fuel shut-off valve directly.
Possible causes
and standard val- Clogging, looseness, break-
ue in normal state 3 age, or leakage of fuel filter/
leakage.
piping
4 Trouble in injector Check inside of injector directly.
If causes 1 – 4 are not detected, engine controller may be defective.
SERVICE CODE EC261 (ABNORMAL RISE OF FUEL TEMPERATURE)
User code Service code Abnormal rise of fuel temperature

Trouble
• Fuel temperature sensor detected temperature lower than temperature set in controller.
Contents of trouble
• Criterion (for reference): Min. 76°C
Action of controller • Limits engine speed to 800 rpm after 30 seconds.
Problem that
appears on machine

and standard val-
ue in normal state 2 Defective fuel temperature Carry out troubleshooting for service codes [EC263] and [EC264].
sensor system
D375A-5 20-563
1
(5)
SERVICE CODE EC263 (ABNORMALLY HIGH LEVEL IN FUEL TEMPERATURE
SERVICE CODE EC263 (ABNORMALLY HIGH LEVEL IN FUEL TEMPERATURE SENSOR

SYSTEM)
User code Service code Abnormally high level in fuel temperature sensor system
Trouble
Contents of trouble • Signal voltage of fuel temperature sensor circuit is above 4.95 V.
Problem that
appears on machine
• Special cable (795-799-5530) is necessary for troubleshooting for fuel temperature sensor.
Related information

Defective fuel temperature without turning starting switch ON.
1 sensor
FLTP (female) Resistance
Between A – B
(Internal trouble)
600 – 36 kΩ
ness
Wiring harness between ECMA (female) P –
FLTP (female) A
FLTP (female) B
Possible causes
(female) P – FLTP (female) A with wiring har- Resistance Min. 1 MΩ

ness
3
ness)
(female) G – FLTP (female) B with wiring har- Resistance Min. 1 MΩ
ness around it
Between P – G 600 – 36 kΩ
Circuit diagram related to fuel temperature sensor
20-564 D375A-5
1
SERVICE CODE EC265 (ABNORMALLY LOW LEVEL IN FUEL TEMPERATURE
SERVICE CODE -+ $# (ABNORMALLY LOW LEVEL IN FUEL TEMPERATURE SENSOR

SYSTEM)
User code Service code Abnormally low level in fuel temperature sensor system
Trouble
Contents of trouble Signal voltage of fuel temperature sensor circuit is below 0.21 V.
Problem that
appears on machine

and standard val-
D375A-5 20-565
1
TROUBLESHOOTING SERVICE CODE EC316 (ABNORMAL CURRENT OF FUEL PUMP ACTUATOR)
SERVICE CODE -+!$ (ABNORMAL CURRENT OF FUEL PUMP ACTUATOR)
User code Service code Abnormal current of fuel pump actuator

Trouble
Current of fuel pump actuator circuit is out of normal range.
Contents of trouble
Normal range (for reference): 0.40 ± 0.35 A (When engine is stopped)
Problem that
appears on machine
Special cable (795-799-5470) is necessary for troubleshooting for fuel pump actuator.
Related information

Defective fuel pump actuator PUMP (male) Resistance
1
Between A C
(Internal trouble)
79Ω
Between A, C chassis ground Min. 100 kΩ
ness
Wiring harness between ECMA (female) A
PUMP (female) A
Wiring harness between ECMA (female) ^
PUMP (female) C
Possible causes
ness (female) A PUMP (female) A with wiring Resistance Min. 1 MΩ
3
(female) ^ PUMP (female) C with wiring Resistance Min. 1 MΩ
harness around it
Between A ^ 79Ω
Between A, ^ another wiring
Min. 1 MΩ
harness
Circuit diagram related to fuel pump actuator
20-566 D375A-5
1
TROUBLESHOOTING SERVICE CODE EC318 (ABNORMALITY IN FUEL PUMP ACTUATOR)
SERVICE CODE EC318 (ABNORMALITY IN FUEL PUMP ACTUATOR)
User code Service code Abnormality in fuel pump actuator

Trouble
• Displayed pressure of fuel pump is excessively different from actual value.
Contents of trouble
• Criteria for difference (for reference): ±0.21 MPa {2.1 kg/cm2} (when water temperature is 38°C)
Problem that
• Engine speed is unstable.
appears on machine

leakage.
piping
Suction of air caused by low Air may be sucked because of lowering of fuel level in tank. If fuel level
3
fuel level in tank gauge is in red range, supply fuel.
Suction resistance of fuel filter may be large. Check fuel filter directly.
Possible causes
When new Max. –13.6 kPa
and standard val- Large suction resistance of
4 Fuel pump Engine high filter is used {Max. –102 mmHg}
ue in normal state fuel filter
inlet pressure idling Normal Max. –27.1 kPa
condition {Max. –203 mmHg}
Trouble in fuel pump actua-
5 Fuel pump actuator may malfunction. Check it directly.
tor
Defective electric system of
6 Carry out troubleshooting for service codes [EC118] and [EC119].
fuel pump pressure sensor
7 Trouble in injector Inside of injector may be defective. Check it directly.
If causes 1 – 6 are not detected, engine controller may be defective.
D375A-5 20-567
1
(5)
SERVICE CODE EC346 (ABNORMALITY IN POWER-DOWN UNIT OF ENGINE
TROUBLESHOOTING CONTROLLER)

CONTROLLER)
User code Service code Abnormality in power-down unit of engine controller

Trouble
Contents of trouble • Data recorded in power-down unit of engine controller has error.
Problem that • Power-down data (maintenance information, current controller information, engine operating hours,
appears on machine etc.) are lost.
• Charge level of battery (Voltage) can be checked in monitoring mode.

1 Defective fusible link (34 A)
ground.
Defective fuse
2 If fuse is broken, circuit probably has short circuit with chassis ground.
(FS1-1, FS1-4)
Disconnection in wiring har- Wiring harness between ECMB (female) 3 –
FS1-3 outlet
Wiring harness between ECMA (female) 4,
tor) 5 – FS1-4 outlet
Wiring harness between FS1 inlet – fusible
link – battery relay terminal B
and standard val- without turning starting switch ON.
ue in normal state
(female) 3 – FS1-3 outlet with wiring harness Resistance Min. 1 MΩ
Short circuit in wiring har- around it
ness
ness) (female) 4, 5 – FS1-4 outlet with wiring har- Resistance Min. 1 MΩ
ness around it
Wiring harness between FS1 inlet – fusible
link – battery relay terminal B with wiring har- Resistance Min. 1 MΩ
ness around it
5 Defective engine controller ECMA, ECMB Voltage
Between ECMB 3, 4, 5 –
17.3 – 34.7 V
ECMA 7, 8
20-568 D375A-5
1
TROUBLESHOOTING CONTROLLER)
Circuit diagram related to engine controller power supply
D375A-5 20-569
1
TROUBLESHOOTING SERVICE CODE EC384 (ABNORMALITY IN PREHEATER CONTROL SYSTEM)
SERVICE CODE -+!&" (ABNORMALITY IN PREHEATER CONTROL SYSTEM)
User code Service code Abnormality in preheater control system

Trouble
Contents of trouble Disconnection or short circuit was detected in preheater control circuit.
Problem that
appears on machine

Defective preheater relay without turning starting switch ON.
1
(Internal trouble) RHR (male) Resistance
Between 1 2 200 400 Ω
ness
RHR (female) 1
tor) Wiring harness between RHR (female) 2
chassis ground
and standard val- without turning starting switch ON.
ue in normal state
ness (female) 2 RHR (female) 1 with wiring har- Resistance Min. 1 MΩ
3
ness) Short circuit of wiring harness between RHR
(female) 2 chassis ground with wiring har- Resistance Min. 1 MΩ
ness around it
Between 2 chassis ground 200 400 Ω
Between 2 another wiring
Min. 1 MΩ
harness
20-570 D375A-5
1
TROUBLESHOOTING SERVICE CODE EC384 (ABNORMALITY IN PREHEATER CONTROL SYSTEM)
Circuit diagram related to preheater control
D375A-5 20-571
1
SERVICE CODE EC423 (ABNORMALITY IN IN-RANGE OF TIMING RAIL PRESSURE

SENSOR SYSTEM)
User code Service code Abnormality in in-range of timing rail pressure sensor system
Trouble
• Timing rail pressure sensor detected abnormal pressure.
Contents of trouble
• Criterion (for reference): Min. 2.42 MPa {24.65 kg/cm2} when starting switch is turned on
• Limits high idling speed to 1,500 rpm.
Problem that
appears on machine
• Special cable (799-795-5460) is necessary for troubleshooting for timing rail pressure sensor.
Related information

Defective timing rail pres-
1 sure sensor TIMG (male) Voltage
Between C – B 0.42 – 0.58 V
Disconnection in wiring har- Wiring harness between ECMA (female) 5 –
TPR (female) A
Wiring harness between ECMA (female) H –
TPR (female) B
tor)
Wiring harness between ECMA (female) W –
TPR (female) C

Possible causes
(female) 5 – TPR (female) A with wiring har- Resistance Min. 1 MΩ
and standard val-
ue in normal state Short circuit in wiring harness around it
ness
3
(female) H – TPR (female) B with wiring har- Resistance Min. 1 MΩ
ness)
ness around it
(female) W – TPR (female) C with wiring har- Resistance Min. 1 MΩ

ness around it
When new Max. –13.6 kPa
Large suction resistance of
4 Fuel pump Engine high filter is used {Max. –102 mmHg}
fuel filter
inlet pressure idling Normal Max. –27.1 kPa
condition {Max. –203 mmHg}
5 Defective engine controller ECMA (female) Resistance
Between 5 – H 4.75 – 5.25 V
Between W – H 0.42 – 0.58 V
20-572 D375A-5
1
(5)
Circuit diagram related to timing rail pressure sensor
D375A-5 20-573
1
SERVICE
SERVICE CODE
CODE EC441
EC441 (ABNORMALLY
(ABNORMALLY LOW LEVEL
LOW LEVEL IN BATTERY
IN BATTERY VOLTAGE
VOLTAGE SYSTEM)
TROUBLESHOOTING SERVICE CODE EC442 (ABNORMALLY HIGH LEVEL IN BATTERY VOLTAGESYSTEM)
SYSTEM)
SERVICE CODE -+"" (ABNORMALLY LOW LEVEL IN BATTERY VOLTAGE SYSTEM)
User code Service code Abnormally low level in battery voltage system
Trouble
Contents of trouble Voltage of controller power supply circuit is below 12 V.
Problem that
appears on machine

and standard val-
SERVICE CODE -+"" (ABNORMALLY HIGH LEVEL IN BATTERY VOLTAGE SYSTEM)
User code Service code Abnormally high level in battery voltage system
Trouble
Contents of trouble Voltage of controller power supply circuit is below 38 V.
Problem that
appears on machine

and standard val-
20-574 D375A-5
1
SERVICE CODE EC451 (ABNORMALLY HIGH LEVEL IN FUEL RAIL PRESSURE
SERVICE CODE -+"# (ABNORMALLY HIGH LEVEL IN FUEL RAIL PRESSURE SENSOR
SYSTEM)
User code Service code Abnormally high level in fuel rail pressure sensor system
Trouble
Contents of trouble Signal voltage of fuel rail pressure sensor circuit is above 4.78 V.
Opens and controls fuel rail.
Problem that
appears on machine
Special cable (795-799-5460) is necessary for troubleshooting for fuel rail pressure sensor.
Related information

Defective fuel rail pressure
1 sensor RPR Voltage
RPR (female) A
Wiring harness between ECMA (female) H
RPR (female) B
tor)
Wiring harness between ECMA (female) U
RPR (female) C
Possible causes
Short circuit in wiring har- (female) 5 RPR (female) A with wiring har- Resistance Min. 1 MΩ
ness around it
ness
(female) H RPR (female) B with wiring har- Resistance Min. 1 MΩ
ness)
ness around it
(female) U RPR (female) C with wiring har- Resistance Min. 1 MΩ
ness around it
Between 5 H 4.75 5.25 V
Between U H 0.42 0.58 V
Circuit diagram related to fuel rail pressure sensor
D375A-5 20-575
1
SERVICE CODE EC452 (ABNORMALLY LOW LEVEL IN FUEL RAIL PRESSURE
SERVICE CODE -+"# (ABNORMALLY LOW LEVEL IN FUEL RAIL PRESSURE SENSOR
SYSTEM)
User code Service code Abnormally low level in fuel rail pressure sensor system
Trouble
Contents of trouble Signal voltage of fuel rail pressure sensor circuit is below 0.15 V.
Reduces current for fuel rail actuator to 0 A.
Problem that
appears on machine

and standard val-
20-576 D375A-5
1
TROUBLESHOOTING SERVICE CODE EC455 (ABNORMAL CURRENT OF FUEL RAIL ACTUATOR)
SERVICE CODE -+"## (ABNORMAL CURRENT OF FUEL RAIL ACTUATOR)
User code Service code Abnormal current of fuel rail actuator

Trouble
Current of fuel rail actuator circuit is out of normal range.
Contents of trouble
Normal range (for reference): 0.40 ± 0.35 A (When engine is stopped)
Problem that
appears on machine
Special cable (795-799-5470) is necessary for troubleshooting for fuel rail actuator.
Related information
Method of reproducing service code: Turn starting switch ON or start engine.

Defective fuel rail actuator RAIL (male) Resistance
1
Between A C
(Internal trouble)
79Ω
Between A, C chassis ground Min. 100 kΩ
ness
RAIL (female) A
Wiring harness between ECMA (female) @
RAIL (female) C
Possible causes
ness (female) 3 RAIL (female) A with wiring har- Resistance Min. 1 MΩ
3
(female) @ RAIL (female) C with wiring har- Resistance Min. 1 MΩ
ness around it
Between 3 @ 79Ω
Between 3, @ another wiring
Min. 1 MΩ
harness
Circuit diagram related to fuel rail actuator
D375A-5 20-577
1
SERVICE CODE EC467 (ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL)
SERVICE CODEEC467
CODE EC468(ABNORMALITY
(ABNORMALITY
ININ FUEL RAIL ACTUATOR CONTROL)
TIMING
SERVICE CODE -+"$% (ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL)
User code Service code Abnormality in timing rail actuator control

Trouble
Displayed timing rail fuel value is so different from quantity of actual timing fuel that target value can-
Contents of trouble
not be obtained.
Problem that
appears on machine

and standard val-
SERVICE CODE -+"$& (ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL)
User code Service code Abnormality in fuel rail actuator control

Trouble
Displayed injection rate of fuel rail is so different from actual injection rate that target value cannot be
Contents of trouble
obtained.
Limits maximum injection rate to 217 mm3/st.
Problem that
appears on machine

Possible causes leakage.
piping
and standard val-
3 Trouble in fuel rail actuator Fuel pump actuator may have trouble in it. Check it directly.
ue in normal state
Clogging of fuel rail actuator
4 Fuel rail actuator screen may be clogged. Check it directly.
screen
5 Breakage of injector O-ring Injector O-ring may be broken. Check it directly.
If causes 1 5 are not detected, engine controller may be defective.
20-578 D375A-5
1
TROUBLESHOOTING SERVICE CODE EC514 (ABNORMALITY IN FUEL RAIL ACTUATOR)
SERVICE CODE -+#" (ABNORMALITY IN FUEL RAIL ACTUATOR)
User code Service code Abnormality in fuel rail actuator

Trouble
Displayed injection rate of fuel rail is excessively different from actual injection rate.
Contents of trouble
Criterion (for reference): Difference is ±600 mm3/st for ±50 msec or ±250 mm3/st for ±200 msec.
Problem that
appears on machine

and standard val-
D375A-5 20-579
1
SERVICE CODE EC554 (ABNORMALITY IN IN-RANGE OF FUEL RAIL PRESSURE
SERVICE CODE -+##" (ABNORMALITY IN IN-RANGE OF FUEL RAIL PRESSURE

SENSOR SYSTEM)
User code Service code Abnormality in in-range of fuel rail pressure sensor system
Trouble
Fuel rail pressure sensor detected abnormal pressure.
Contents of trouble
Criterion (for reference): Min. 0.17 MPa {1.76 kg/cm2} when starting switch is turned on
Problem that
appears on machine
Special cable (799-795-5460) is necessary for troubleshooting for fuel rail pressure sensor.
Related information

Defective fuel rail pressure
1 sensor RPR Voltage
Disconnection in wiring har- Wiring harness between ECMA (female) 5
RPR (female) A
Wiring harness between ECMA (female) H
RPR (female) B
tor)
Wiring harness between ECMA (female) U
RPR (female) C

Possible causes without turning starting switch ON.
and standard val- Short circuit of wiring harness between ECMA
ue in normal state (female) 5 RPR (female) A with wiring har- Resistance Min. 1 MΩ
Short circuit in wiring harness around it
ness
(female) H RPR (female) B with wiring har- Resistance Min. 1 MΩ
ness)
ness around it
(female) U RPR (female) C with wiring har- Resistance Min. 1 MΩ
ness around it
Large suction resistance of
4 Negative suction pressure
fuel filter 27 kPa {203 mmHg}
(Tank side)
Between 5 H 4.75 5.25 V
Between U H 0.42 0.58 V
20-580 D375A-5
1
SERVICE CODE EC554 (ABNORMALITY IN IN-RANGE OF FUEL RAIL PRESSURE
Circuit diagram related to fuel rail pressure sensor
D375A-5 20-581
1
TROUBLESHOOTING OF ELECTRICAL SYSTEM

(E-MODE)
Information in troubleshooting table ......................................................................................................... 20-602

E-1 The engine does not start ................................................................................................................ 20-603
E-2 Preheat does not operate (Manual preheating function) .................................................................. 20-605
E-3 The ripper pin puller cylinder does not operate ................................................................................ 20-607
E-4 When the starting switch is on, none of the monitor panels come on .............................................. 20-608
E-5 When the starting switch is on, all the monitor panels are kept coming on and do not come out ............ 20- 609
E-6 When the starting switch is on, the basic check item flashes .......................................................... 20-610
E-7 When the engine is operating, the caution item flashes .................................................................. 20-611
E-8 When the engine is operating, the emergency alarm item flashes .................................................. 20-613
E-9 The preheating lamp does not come on .......................................................................................... 20-616
E-10 The display of the engine water temperature gauge is not normal ................................................ 20-617
E-11 The display of the torque converter oil temperature gauge is not normal ...................................... 20-618
E-12 The display of the fuel gauge is not normal ................................................................................... 20-619
E-13 The display of the gear speed/engine speed/shift mode is not normal .......................................... 20-620
E-14 The display of the service meter is not normal .............................................................................. 20-620
E-15 The switch module cannot be operated ......................................................................................... 20-622
E-16 The alarm lamp does not flash or come out ................................................................................... 20-623
E-17 The alarm buzzer does not sound or stop ..................................................................................... 20-624
E-18 The alarm buzzer cannot be cancelled .......................................................................................... 20-625
E-19 The service mode cannot be selected ........................................................................................... 20-626
E-20 Back-up alarm does not sound ...................................................................................................... 20-627
E-21 Instrument panel night lamp, headlamp, working lamp and rear lamp do not come on ................. 20-628
E-22 Air conditioner does not operate .................................................................................................... 20-632
D375A-5 20-601
1

Standard value in normal state to judge possible causes
Remarks on judgment
1
<Troubles in harness>
Disconnection
Connector is connected imperfectly or harness is broken.
Short circuit with chassis ground
Harness which is not connected to chassis ground circuit is in con-
tact with chassis ground circuit.
Short circuit with power source
2 Harness which is not connected to power source (24 V) circuit is in
contact with power source (24 V) circuit.
Short circuit
Possible causes of trouble Independent harnesses are in contact with each other abnormally.
Possible causes (Given numbers are refer-
and standard val- ence numbers, which do not <Precautions for troubleshooting>
ue in normal state indicate priority) 1Method of indicating connector No. and handling of T-adapter
Insert or connect T-adapter as explained below for troubleshooting,
unless otherwise specified.
3 If connector No. has no marks of male and female, disconnect
connector and insert T-adapters in both male side and female
side.
If connector No. has marks of male and female, disconnect
connector and connect T-adapter to only male side or female side.
2Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative () lead of tester as ex-
plained below for troubleshooting, unless otherwise specified.
4 Connect positive (+) lead to pin No. or harness entered on front
side.
Connect negative () lead to pin No. or harness entered on rear
side.
Part of electric circuit diagram related to trouble

Connector No.: Indicates (Model Number of pins) and (Color).
Arrows (⇔): Indicate rough location of connector in machine.
20-602 D375A-5
1
TROUBLESHOOTING E-1 THE ENGINE DOES NOT START
E-1 THE ENGINE DOES NOT START

Trouble The engine does not start.
Because the neutral safety function is provided in the engine starting circuit, the engine can be started
only when the parking lever is in the lock position.
Related information
If the Monitor panel does not come on or the Operating sound of the battery relay is not heard when
the starting switch is ON, a main power system abnormality is assumed. So inspect it.

Battery voltage Battery specific gravity
1 Insufficient battery capacity
Min. 24 V Min. 1.26
★ Prepare the engine with the starting switch OFF and diagnose it
with the starting switch OFF as is.
Starting switch failure
2 Key (male) Switch position Resistance value
OFF Min. 1 MΩ
Between 5 and 3
START Max. 1 Ω
with the engine start.
Neutral safety relay failure
3 If the engine is started by the engine starting operation by replacing
this relay with another relay with the starting switch OFF, the neutral
safety relay (NSF) is faulty.
Diode failure with the starting switch OFF as is.
4
(Internal short circuit) D03 (female) Resistance value
Between 1 and 2 Min. 1 MΩ
Diode failure with the starting switch ON.
5
(Internal short circuit) Alternator Voltage
Between R terminal and ground Max. 1 V
Possible causes
and standard val- Starter Voltage
ue in normal state Power: Between B terminal
20 30 V
and ground
Starter failure
6 Charge: Between R terminal
(Internal fault) Max. 1 V
and ground
Start: Between C terminal
20 30 V
and ground
If each voltage of power, charge, or start is normal and the starter is
not turned, the starter is faulty.
Harness disconnection fail- with the starting switch OFF as is.
ure Between the harnesses between key (female) Resistance
7 Max. 1 Ω
(Disconnection/connector 3 and NSF (female) 3 value
contact failure) Between harnesses between NSF (female) 5 Resistance
Max. 1 Ω
and top and bottom starter C terminal value
with the starting switch ON.
Between alternator R terminal and top and
bottom starter C terminal, between alternator
Harness hot short-circuiting R terminal and D03 (female) 2, between al-
8 failure ternator R terminal and S03 (female) 4, be-
(24 V circuit and contact) tween alternator R terminal and CN1 (female) Voltage Max. 1 V
4, and between harness and ground
(Note: If hot short-circuiting occurs, the charge
level lamp comes on when the starting switch
is ON.)
D375A-5 20-603
1
TROUBLESHOOTING E-1 THE ENGINE DOES NOT START
Engine start/charge-related circuit diagram
20-604 D375A-5
1
TROUBLESHOOTING E-2 PREHEAT DOES NOT OPERATE (MANUAL PREHEATING FUNCTION)
E-2 PREHEAT DOES NOT OPERATE (MANUAL PREHEATING FUNCTION)

Trouble Preheat does not operate.
★ This troubleshooting describes the procedures when the electrical intake air heater mounting unit is
not heated (if only the preheating lamp does not come on, execute the diagnosis indicating that the
Preheating lamp does not come on.)
Related information Preheat includes the Automatic preheating function and the Manual preheating function. Even if
which function is operated, the preheating lamp comes on.
If the Monitor panel does not come on or No operating sound of the battery relay is heard when
the starting switch is ON, a main power system abnormality is assumed. So inspect it.

Starting switch failure
1 Key (male) Switch position Resistance value
OFF Min. 1 MΩ
Between 5 and 2
HEAT Max. 1 Ω
If the fuse is damaged by fire, the possibility of a ground fault having
2 Fuse (FS4-4) failure
occurred in the circuit is great.
Preheater relay failure with HEAT.
3
(Internal disconnection) If the engine is preheated by the heat operation by replacing this relay
with the starting switch OFF, the preheater relay (RHR) is faulty.
with HEAT.
Preheater Voltage
Power: Between power sup-
Heater relay failure ply terminal and 20 30 V
4
(Internal fault) ground
Signal: Between signal termi-
Possible causes 20 30 V
and standard val- nal and ground
ue in normal state If each voltage of power and signal is normal and no operation sound
is heard, the heater relay is faulty.
Electrical intake air heater with the starting switch OFF as is.
5 failure
Electrical intake air heater Continuity
(Internal fault)
Between terminals Continue
Between harnesses between FS4-5 exit and Resistance
Max. 1 Ω
Harness disconnection fail- RHR (female) 5 value
ure Between RHR (female) 3 and key (female)
6 Resistance
(Disconnection/connector 2, and between harnesses RHR (female) 3 Max. 1 Ω
value
contact failure) and heater relay
Between harnesses between battery relay M
Resistance
terminal and starter and between the batter Max. 1 Ω
value
relay M terminal and heater relay
Harness ground fault with the starting switch OFF as is.
7
(GND circuit and contact) Between FS4-5 (exit side)-related harnesses Resistance
Min. 1 MΩ
and between grounds value
D375A-5 20-605
1
TROUBLESHOOTING E-2 PREHEAT DOES NOT OPERATE (MANUAL PREHEATING FUNCTION)
Engine preheat-related circuit diagram
20-606 D375A-5
1
TROUBLESHOOTING E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE
E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE

Trouble The ripper pin puller cylinder does not operates.
Related information

If the fuse is damaged by fire, the possibility of a ground fault having
1 Fuse (FS4-1) failure
occurred in the circuit is great.
Pin puller switch failure with the starting switch OFF as is.
2 (Internal disconnection/short 263 (male) Switch Resistance value
circuit) Draw-in Max. 1 Ω
Between 1 and 2
Pull-in Min. 1 MΩ
Pin puller solenoid failure with the starting switch OFF as is.
3 (Internal disconnection/short 224 (male) Resistance value
circuit) Between 1 and 2 10 80 Ω
Between 1 and groud Min. 1 MΩ
Possible causes with the starting switch Off as is.
and standard val- Between harnesses between FS4-1 exit and Resistance
Harness disconnection fail-
ue in normal state Max. 1 Ω
ure 263 (female) 1 value
4
(Disconnection/connector Between harnesses between 263 (female) 2 Resistance
contact failure) Max. 1 Ω
and 224 (female) 1 value
Between harnesses between 224 (female) 2 Resistance
Max. 1 Ω
and ground value
Harness ground fault Between FS4-1 (exit side)-related harnesses Resistance
5 Min. 1 MΩ
(GND circuit and contact) and between grounds value
Between harness and ground between 263 Resistance
Min. 1 MΩ
(female) 2 and 224 (female) 1 value
Harness hot short-circuiting
6 failure
Between harness and ground between 263
(24 V circuit and contact) Voltage Max. 1 V
(female) 2 and 224 (female) 1
Ripper pin puller solenoid-related circuit diagram
D375A-5 20-607
1
E-4 WHEN THE STARTING SWITCH IS ON, NONE OF THE MONITOR PANELS
TROUBLESHOOTING COME ON
E-4 WHEN THE STARTING SWITCH IS ON, NONE OF THE MONITOR PANELS COME ON
Trouble (1) The caution module (gauge portion/lamp portion) does not come on.
Related information When the starting switch is ON, all the monitor panels come on for three seconds.

If the circuit breaker is disconnected, the possibility of a ground fault
1 Circuit breaker (CB2) failure
having occurred in the circuit is great.
ure Between harnesses between CN1 (female) 1 Resistance
2 Max. 1 Ω
(Disconnection/connection and CB2 exit value
Possible causes contact failure) Between harnesses between CN1 2 and Resistance
Max. 1 Ω
and standard val- ground value
ue in normal state ★ Prepare the engine with the starting switch OFF and diagnose it
3
(GND circuit and contact) Between CB2 (exit side)-related harnesses Resistance
Min. 1 MΩ
Monitor panel failure with the starting switch ON.
4
(Caution module) CN1 Voltage
Between 1 and 2 20 30 V
Trouble (2) The tachometer module (tachometer portion/service meter portion) does not come on.
Related information When the starting switch is ON, all the monitor panels come on for three seconds.

Circuit breaker (CB2, CB6) If the circuit breaker is disconnected, the possibility of a ground fault
1
failure having occurred in the circuit is great.
Harness disconnection fail- Between harnesses between S03 (female) 1 Resistance
Max. 1 Ω
ure and CB2 exit value
2
(Disconnection/connector Between harnesses between S03 (female) 7 Resistance
Max. 1 Ω
contact failure) and CB6 exit value
Between harnesses between S03 (female) 2 Resistance
Possible causes Max. 1 Ω
and ground value
and standard val-
ue in normal state
Harness fault ground Between CB2 (exit side)-related harnesses Resistance
3 Min. 1 MΩ
(GND circuit and contact) and between grounds value
Between CB6 (exit side)-related harnesses Resistance
Min. 1 MΩ
Monitor panel failure CN1 Voltage
4
(Tachometer module)
20-608 D375A-5
1
E-5 WHEN THE STARTING SWITCH IS ON, ALL THE MONITOR PANELS ARE
TROUBLESHOOTING KEPT COMING ON AND DO NOT COME OUT
Monitor panel power supply-related circuit diagram
E-5 WHEN THE STARTING SWITCH IS ON, ALL THE MONITOR PANELS ARE KEPT COMING
ON AND DO NOT COME OUT
Trouble (1) The caution module (gauge portion/lamp portion) does not come out.
Related information When the starting switch is ON, all the monitor panels come on for three seconds, they come out.

and standard val- Monitor panel failure
ue in normal state 1 (Caution module) Because the monitor panel is internally faulty, it cannot be diagnosed.
Trouble (2) The tachometer module (tachometer portion/service meter portion) does not come out.
Related information When the starting switch is ON, all the monitor panels come on for three seconds, they come out.

1 Because the monitor panel is internally faulty, it cannot be diagnosed.
ue in normal state (Tachometer module)
D375A-5 20-609
1
TROUBLESHOOTING E-6 WHEN THE STARTING SWITCH IS ON, THE BASIC CHECK ITEM FLASHES
E-6 WHEN THE STARTING SWITCH IS ON, THE BASIC CHECK ITEM FLASHES
Trouble The radiator water level lamp flashes.
Related information The basic check item flashes when an abnormality is detected before the engine starts.

Radiator water level de-
Because the radiator water level decrease is detected, inspect the ra-
1 crease
diator water level (the lamp flashes below the specified level).
(When system is normal)
Radiator water level failure
2 405 (male) Radiator water level Resistance value
At normal time Max. 1 Ω
Between 1 and 2
At decreased time Min. 1 MΩ
Possible causes
and standard val-
ue in normal state
3 Max. 1 Ω
(Disconnection/connector and 405 (female) 1 value
contact failure) Between harnesses between 405 (female) 2 Resistance
Max. 1 Ω
and ground value
Monitor panel failure
4 CN1 Radiator water level Voltage
(Caution module)
At normal time Max. 1 V
Between 1 and 2
At decreased time 20 20 V
Radiator water level sensor-related circuit diagram
20-610 D375A-5
1
TROUBLESHOOTING E-7 WHEN THE ENGINE IS OPERATING, THE CAUTION ITEM FLASHES
E-7 WHEN THE ENGINE IS OPERATING, THE CAUTION ITEM FLASHES

Trouble The charge level lamp flashes.
Related information The caution item flashes if an abnormality is detected when the engine is operating.

Alternator failure starting the engine.
1 (Insufficient power genera- Alternator Engine speed Voltage
tion) Between R terminal Above intermediate
20 30 V
and ground speed (half)
Harness disconnection fail- ★ Prepare the engine with the starting switch OFF and diagnose it
ure with the starting switch OFF as is.
2
(Disconnection/connector Between harnesses between CN1 (female) 4 Resistance
Max. 1 Ω
contact failure) and alternator R terminal value
Possible causes ★ Prepare the engine with the starting switch OFF and diagnose it
and standard val- with the starting switch OFF as is.
ue in normal state Between CN1 4 and S03 (female) 4, Be-
Harness ground fault tween CN1 (female) and alternator R terminal,
3 between CN1 (female) 4 and top and bottom
(GND circuit and contact) Resistance
starter R terminal, between CN1 (female) 4 Min. 1 MΩ
value
and NGICN3 (female), between harness and
ground between CN1 (female) 4 and battery
relay BR terminal
4 CN1 Engine speed Voltage
(Caution module)
Between 4 and Above intermediate
20 30 V
ground speed (half)
D375A-5 20-611
1
TROUBLESHOOTING E-7 WHEN THE ENGINE IS OPERATING, THE CAUTION ITEM FLASHES
20-612 D375A-5
1
E-8 WHEN THE ENGINE IS OPERATING, THE EMERGENCY ALARM ITEM
TROUBLESHOOTING FLASHES
E-8 WHEN THE ENGINE IS OPERATING, THE EMERGENCY ALARM ITEM FLASHES
Trouble (1) The fuel temperature lamp flashes.
The emergency alarm item flashes if an abnormality is detected when the engine is operating and
Related information
sounds the alarm buzzer.

Fuel temperature rises ab- Inspect the fuel temperature since abnormal increase of fuel temper-
1 normally ature has been detected. (When fuel temperature exceeds the speci-
(When system is normal) fied temperature: Lamp flashes.)
Possible causes
Fuel temperature sensor
and standard val-
ue in normal state 2 system failure Execute the service codes [EC261], [EC263] and [EC265].
(Engine controller system)
If there is an abnormality in Causes 1 and 2, a monitor panel failure is
3 assumed (because the monitor panel is internally faulty, it cannot be
(Caution module)
diagnosed).
Trouble (2) Engine oil pressure lamp flashes.

Related information

Engine oil pressure de-
Because the engine oil pressure decrease is detected, inspect the en-
1 crease
gine oil pressure (below specified pressure: Lamp flashes).
(When system is normal)
Possible causes
and standard val- Engine oil pressure sensor
2 system failure Execute the service codes [EC135] [EC141], and [EC143].
ue in normal state
(engine controller system)
If there is an abnormality in Causes 1 and 2, a monitor panel failure is
(Caution module)
diagnosed).
Trouble (3) The engine water temperature lamp flashes.

Related information
The engine water temperature lamp flashes/comes out being linked with the display of the engine wa-
ter temperature gauge.

Engine water temperature Because the engine water temperature overheat is detected, inspect
1 overheat the engine oil pressure (above water temperature of 108°C; Lamp
(When system is normal) flashes)
Check the display of the engine water temperature gauge. If the dis-
play is not normal, execute the diagnosis indicating that the Display
of the engine water temperature gauge is not normal.
Engine water Water temperature
Gauge segment
temperature lamp
Possible causes
and standard val- Engine water temperature 7th stage 108°C Flashes
2 system failure 6th stage Approx. 108°C
ue in normal state
(engine controller system)
5th stage Approx. 102°C
Comes out
3rd stage Approx. 94°C
2nd stage Approx. 83°C
1st stage Approx. 70°C
If there is no abnormality in Causes 1 and 2, a monitor panel failure is
(Caution module)
diagnosed).
D375A-5 20-613
1
Trouble (4) The torque converter oil temperature lamp flashes.

Related information
The torque converter oil temperature lamp flashes/comes out being linked with the display of the
torque converter oil temperature gauge.

Torque converter oil temper- Because the torque converter overheat is detected, inspect the torque
1 ature overheat converter oil temperature (above water temperature of 130°C; Lamp
(When system is normal) flashes)
Check the display of the torque converter oil temperature gauge. If the
display is not normal, execute the diagnosis indicating that the Dis-
play of the torque converter oil temperature gauge is not normal.
Gauge segment Oil temperature lamp
temperature
Possible causes
and standard val- Torque converter oil temper- 7th stage 130°C Flashes
2 6th stage Approx. 130°C
ue in normal state ature system failure
Comes out
3rd stage Approx. 110°C
2nd stage Approx. 90°C
1st stage Approx. 50°C
If there is no abnormality in Causes 1 and 2, a monitor panel failure is
(Caution module)
diagnosed).
20-614 D375A-5
1
Trouble (5) The hydraulic oil temperature lamp flashes.

Related information

Abnormal hydraulic oil tem- Because the abnormal hydraulic oil temperature rise is detected, in-
1 perature rise spect the hydraulic oil temperature
(When system is normal) (Above specified temperature: Lamp flashes)
Hydraulic oil temperature Hydraulic oil
2 sensor failure 452 (male) Continuity
temperature
Between 1 and Max. 105°C No continuity
Possible causes ground Min. 105°C Continue
and standard val-
3
(GND circuit and contact) Between harness and ground between CN1 Resistance
Min. 1 MΩ
Monitor panel failure Hydraulic oil
4 CN1 Voltage
(Caution module) temperature
Between 8 and Max. 105°C 20 30 V
ground Min. 105°C Max. 1 V
Hydraulic oil temperature sensor-related circuit diagram
D375A-5 20-615
1
TROUBLESHOOTING E-9 THE PREHEATING LAMP DOES NOT COME ON
E-9 THE PREHEATING LAMP DOES NOT COME ON

Trouble The preheating lamp does not come on.
★ This troubleshooting describes the procedures when the preheating lamp does not come on (if the
electrical intake air heater mounting portion is not heated, execute the diagnosis indicating that the
Related information Preheat lamp does not operate.
Preheat includes the Automatic preheat function and the Manual preheat function. Even if which
function operates, the preheating lamp comes on.

1
Max. 1 Ω
contact failure) and heater relay terminal value
Possible causes with the starting switch OFF as is.
Harness ground fault
and standard val- 2 (GND circuit and contact)
Between harness and ground between CN2 Resistance
ue in normal state Min. 1 MΩ
(female) 5 and heater relay terminal value
3 CN2 Starting switch Voltage
(Caution module)
Between 5 and ON Max. 1 V
ground HEAT 20 30 V
Engine preheat-related circuit diagram
20-616 D375A-5
1
E-10 THE DISPLAY OF THE ENGINE WATER TEMPERATURE GAUGE IS NOT
TROUBLESHOOTING NORMAL
E-10 THE DISPLAY OF THE ENGINE WATER TEMPERATURE GAUGE IS NOT NORMAL
Trouble The display of the engine water temperature gauge is nor normal.
The signal of the engine water temperature gauge is received by the communication from the engine
Related information
controller.

Engine water temperature
Possible causes 1 system failure Execute the diagnosis of the service codes [EC144] and [EC145].
and standard val- (Engine controller system)
ue in normal state If there is an abnormality in Cause 1, a monitor panel abnormality is
(Caution module)
diagnosed).
D375A-5 20-617
1
E-11 THE DISPLAY OF THE TORQUE CONVERTER OIL TEMPERATURE
TROUBLESHOOTING GAUGE IS NOT NORMAL
E-11 THE DISPLAY OF THE TORQUE CONVERTER OIL TEMPERATURE GAUGE IS NOT
NORMAL
Trouble The display of the torque converter oil temperature gauge is not normal.
Related information

Torque converter oil temper- Torque converter oil
453 (male) Resistance value
ature sensor failure temperature
1
(Internal disconnection/short Approx. 80 k
Between 1 and 2
circuit) approx. 3.8 kΩ
10 100°C
Between 1 and
Min. 1 MΩ
ground
2 Max. 1 Ω
Possible causes contact failure) Between harnesses between 453 (female) 2 Resistance
Max. 1 Ω
and standard val- and ground value
3
(GND circuit and contact) Between harness and ground between CN2 Resistance
Min. 1 MΩ
4 failure
Between harness and ground beytween CN2
(24 V circuit and contact) Voltage Max. 1 V
Monitor panel failure Torque converter oil
5 CN2 (female) Resistance value
(Caution module) temperature
Between 2 and Approx. 80 k
10 100°C
ground approx. 3.8 kΩ
Torque converter oil temperature-related circuit diagram
20-618 D375A-5
1
TROUBLESHOOTING E-12 THE DISPLAY OF THE FUEL GAUGE IS NOT NORMAL
E-12 THE DISPLAY OF THE FUEL GAUGE IS NOT NORMAL

Trouble The display of the fuel gauge is not normal.
Related information

Fuel level sensor failure with the starting switch OFF as is.
1 (Internal disconnection/short 423 (male) Remaining fuel level Resistance value
circuit) Between 1 and 2 Full Max. approx. 12 Ω
(ground) Empty Approx. 85 110 Ω
2
and 423 (female) 1 value
Possible causes ★ Prepare the engine with the starting switch OFF and diagnose it
and standard val- Harness ground fault with the starting switch OFF as is.
ue in normal state 3 (GND circuit and contact) Between harness and ground between CN2 Resistance
Min. 1 MΩ
4 failure
(24 V circuit and contact) Between harness and ground between CN2
Voltage Max. 1 V
5 CN2 (female) Remaining fuel level Resistance value
(Caution module)
Between 3 and Full Max. approx. 12 Ω
ground Empty Approx. 85 110 Ω
Fuel level sensor-related circuit diagram
D375A-5 20-619
1
E-13 THE DISPLAY OF THE GEAR SPEED/ENGINE SPEED/SHIFT
E-13 THE DISPLAY OF THE GEAR SPEED/ENGINEMODE IS NOT NORMAL
SPEED/SHIFT MODE IS
TROUBLESHOOTING E-14 THE DISPLAY OF THE SERVICE METER IS NOT NORMAL
E-13 THE DISPLAY OF THE GEAR SPEED/ENGINE SPEED/SHIFT MODE IS NOT NORMAL
Trouble The display of the gear speed/engine speed/shift mode is not normal.
The signal of the gear speed/engine speed/shift mode is received by the communication from the
Related information
transmission controller and steering copntroller.

E-14 THE DISPLAY OF THE SERVICE METER IS NOT NORMAL

Trouble (1) When the engine is operating, the time of the service meter does not run too fast.
Clock the time of the service meter using an engine operating signal (alternator voltage/engine oil
Related information
pressure).

If the charge level lamp flashes when the engine is operating, execute
1 Alternator system failure the diagnosis indicating that the Caution item flashes when the en-
gine is operating.
Engine oil pressure sensor If the engine oil pressure lamp flashes when the engine is operating,
2 system failure execute the diagnosis indicating that the Emergency alarm item
(Engine controller system) flashes when the engine is operating.
Possible causes
and standard val- with the starting switch OFF as is.
ure
ue in normal state 3
(Disconnection/connector Between harnesses between S03 (female) 3 Resistance
Max. 1 Ω
contact failure) and circuit merging point value
4 S03 Engine speed Voltage
(Tachometer module)
Between 4 and Above intermediate
20 30 V
ground speed (half)
Trouble (2) The service meter is not displayed fully.

Related information

20-620 D375A-5
1
TROUBLESHOOTING E-14 THE DISPLAY OF THE SERVICE METER IS NOT NORMAL
D375A-5 20-621
1
TROUBLESHOOTING E-15 THE SWITCH MODULE CANNOT BE OPERATED
E-15 THE SWITCH MODULE CANNOT BE OPERATED

Trouble (1) Even if the switch is operated, the lamp is not switched.
Related information

ue in normal state 1 (Switch module) Because the monitor panel is internally faulty, it cannot be diagnosed.
Trouble (2) Even if the switch is operated, the system setting is not switched.
Related information The signal of the switch module is sent to each controller by communication.

1
Possible causes (Disconnection/connector Between harnesses between S013 (female) Resistance
Max. 1 Ω
and standard val- contact failure) 8 and circuit merging point value
Monitor panel failure with the engine start.
2
(Switch module) S01 Voltage
Between 8 and ground 69V
S-NET communication-related circuit diagram
20-622 D375A-5
1
TROUBLESHOOTING E-16 THE ALARM LAMP DOES NOT FLASH OR COME OUT
E-16 THE ALARM LAMP DOES NOT FLASH OR COME OUT

Trouble The alarm lamp does not flash or come out.
If a short circuit occurs in the alarm lamp system, a service code is displayed. In other failures, any
Related information
service code cannot be displayed.

Alarm lamp failure with the starting switch OFF as is.
circuit) Between 1 and 2 100 400 Ω
Between 1 and ground Min. 1 MΩ
Possible causes ure Between harnesses between CN2 (female) 7 Resistance
3 Max. 1 Ω
and standard val- (Disconnection/connector and 375 (female) 2 value
ue in normal state contact failure) Between harnesses between 375 (female) 1 Resistance
Max. 1 Ω
and CB2 exit value
4
Min. 1 MΩ
and grounds value
5 CN2 Alarm lamp Voltage
(Caution module)
Between 7 and Coming out 20 30 V
ground Coming on Max. 6 V
Alarm lamp-related circuit diagram
D375A-5 20-623
1
TROUBLESHOOTING E-17 THE ALARM BUZZER DOES NOT SOUND OR STOP
E-17 THE ALARM BUZZER DOES NOT SOUND OR STOP

Trouble The alarm buzzer does not sound or stop.
If a short circuit occurs in the alarm lamp system, a service code is displayed. In other failures, any
Related information
service code cannot be displayed.

Alarm lamp failure with the starting switch OFF as is.
circuit) Between 1 and 2 200 Ω
Between 2 and ground Min. 1 MΩ
Possible causes 3 Max. 1 Ω
and standard val-
contact failure) Between harnesses between 217 (female) 2 Resistance
ue in normal state Max. 1 Ω
and CB2 exit value
4
Min. 1 MΩ
and grounds value
Monitor panel failure CN2 Alarm buzzer Voltage
5
(Caution module) At stoppage time 20 30 V
Between 8 and
At operating
ground Max. 3 V
(sounding) time
Alarm buzzer-related circuit diagram
20-624 D375A-5
1
TROUBLESHOOTING E-18 THE ALARM BUZZER CANNOT BE CANCELLED
E-18 THE ALARM BUZZER CANNOT BE CANCELLED
Trouble • The alarm buzzer cannot be cancelled.

Related information

Buzzer cancel switch failure
1 212 (male) Buzzer cancel switch Resistance value
Between 1 and 2 OFF Min. 1 MΩ
Between 1 and 3 ON Max. 1 Ω
Harness disconnection fail- Between harnesses between NGICN2 Z and Resistance
Max. 1 Ω
ure 212 (female) 1 value
2
Possible causes (Disconnection/connector Between harnesses between 212 (female) 2 Resistance
and standard val- and ground value
ue in normal state Between harnesses between 212 (female) 3 Resistance
Max. 1 Ω
and ground value
3
(GND circuit and contact) Between harness and ground between Resistance
Min. 1 MΩ
NGICN Z and 212 (female) 1 value
4 Steering controller failure NGICN2 Buzzer cancel switch Voltage
Between Z and OFF 20 – 30 V
ground ON Max. 1 V
Buzzer cancel switch-related circuit diagram
D375A-5 20-625
1
TROUBLESHOOTING E-19 THE SERVICE MODE CANNOT BE SELECTED
E-19 THE SERVICE MODE CANNOT BE SELECTED
Trouble • The service mode cannot be selected.

Related information

★ Set the starting switch to OFF for preparation and troubleshoot
while keeping the switch OFF.
Defective service switch
1 S24 Switch Resistance value
Between 1 and 3 OFF Min. 1 MΩ
Between 4 and 6 ON Max. 1 Ω
while keeping the switch OFF.
Resistance
Harness between S03 (female) 5 and S24 3 Max. 1 Ω
value
Disconnection of harness
Resistance
2 (Disconnection, defective Harness between S24 1 and ground Max. 1 Ω
value
contact of connector)
Harness between NG1CN1 (female) 6 and Resistance
Possible causes Max. 1 Ω
S24 6 value
and standard val-
Resistance
ue in normal state Harness between S24 5 and ground Max. 1 Ω
value
★ Set the starting switch to OFF for preparation and set the switch to
ON for troubleshooting.
Defective monitor panel
3 S03 Service switch Voltage
(Tachometer module)
Between 5 and OFF 20 – 30 V
ground ON Max. 1 V
★ Set the starting switch to OFF for preparation and set the switch to
ON for troubleshooting.
4 Defective steering controller NGICN1 Service switch Voltage
Between 6 and OFF 20 – 30 V
ground ON Max. 1 V
The buzzer cancel switch The buzzer cancel switch system is supposed to be defective. Execute
5
system is defective the troubleshooting of “Alarm buzzer cannot be cancelled.”
Circuit diagram related to service switch
20-626 D375A-5
1
(5)
TROUBLESHOOTING E-20 BACK-UP ALARM DOES NOT SOUND
E-20 BACK-UP ALARM DOES NOT SOUND

Trouble The back-up alarm does not sound.
When a failure occurs on the primary side (coil side) of the back-up alarm relay, a service code is dis-
Related information played, but in case of a failure on the secondary side (contact side), no service code cannot be dis-
played.

When the fuse is blown, there is a high possibility that the circuit was
1 Defective fuse (FS4-1)
short-circuited with ground.
★ Set the starting switch to OFF for preparation and set to ON for trou-
bleshooting.
Defective back alarm relay
2 Replace this relay with another relay while the starting switch is set to
OFF, set the starting switch to ON and reverse this machine. If the
back-up alarm sounds, the back-up alarm relay (BKA) is defective.
while keeping it to OFF.
Harness between FS4-1 outlet and BKA (fe- Resistance
Possible causes Disconnection of harness Max. 1 Ω
male) 3 value
and standard val- 3 (Disconnection, defective
ue in normal state contact of connector) Harness between BKA (female) 5 and 244 Resistance
Max. 1 Ω
(female) 2 value
Resistance
Harness between 244 (female) 1 and ground Max. 1 Ω
value
Ground fault of harness Between harness (between FS4-1 outlet and Resistance
4 Min. 1 MΩ
(contact with GND circuit) BKA (female) 3) and ground value
Between harness (between BKA (female) 5 Resistance
Min. 1 MΩ
and 244 (female) 2) and ground value
Defective back-up alarm When Causes 1 to 4 are not applicable, the back-up alarm is sup-
5
(internal defect) posed to be defective.
D375A-5 20-627
1
E-21 INSTRUMENT PANEL NIGHT LAMP, HEADLAMP, WORKING LAMP AND
TROUBLESHOOTING REAR LAMP DO NOT COME ON
E-21 INSTRUMENT PANEL NIGHT LAMP, HEADLAMP, WORKING LAMP AND REAR
LAMP DO NOT COME ON
Trouble (1) Any of the instrument panel night lamp, headlamp, working lamp and rear lamp do not come on.
Related information

2 (Disconnection, defective
Harness between FS2-5 (outlet side) and cir- Resistance
contact of connector) Max. 1 Ω
cuit branched portion value
Possible causes while keeping it to OFF.
and standard val- Between harness related to FS2-5 (outlet Resistance
Min. 1 MΩ
ue in normal state side) and ground value
Between harnesses (between 219 (female) 3
Ground fault of harness and CN4 (female) 1, between 219 (female)
3 3 and S03 (female) 1, between 219 (female) Resistance
(contact with GND circuit) Min. 1 MΩ
3 and S02 (female) 1, between 219 (female) value
3 and S01 (female) @ and between 219 (fe-
male) 3 and BB1 (female) 1) and ground
Between harnesses (between 218 (female) 3
Resistance
and 223 (female) 1 and between 218 (fe- Min. 1 MΩ
value
male) 3 and 243 (female) 1) and ground
Trouble (2) Any of the instrument panel night lamp, headlamp, working lamp and rear lamp do not come on.
Related information

Headlamp and working lamp while keeping it to OFF.
1 switches 219 (male) Switch Resistance value
(Internal disconnection) OFF Min. 1 MΩ
Between 2 and 3
ON Max. 1 Ω
Possible causes ★ Set the starting switch to OFF for preparation and troubleshoot
and standard val- while keeping it to OFF.
ue in normal state Harness between 219 (female) 2 and circuit Resistance
Max. 1 Ω
branched portion value
Harnesses between 219 (female) 3 and BB1
2 (Disconnection, defective Resistance
(female) 1 and between 219 (female) 3 and Max. 1 Ω
contact of connector) value
BB3 (female) 1
Harnesses between BB1 (female) 2 and
Resistance
ground and between BB3 (female) 2 and Max. 1 Ω
value
ground
20-628 D375A-5
1
Trouble (3) Only the instrument panel night lamp does not come on.
Related information

Defective night lamp The night lamp is supposed to be defective. Check if the light bulb is
1
(Burnt bulb) burned out.
★ Set the starting switch to OFF for preparation Resistance
Max. 1 Ω
and troubleshoot while keeping it to OFF. value
Harness between S01 (female) 8 and circuit Resistance
Max. 1 Ω
Max. 1 Ω
2 (Disconnection, defective Resistance
Harness between S02 (female) 2 and ground Max. 1 Ω
value
contact of connector)
Max. 1 Ω
Possible causes branched portion value
and standard val- Harness between CN4 (female) 1 and circuit Resistance
Max. 1 Ω
ue in normal state branched portion value
Resistance
Harness between S04 (female) 2 and ground Max. 1 Ω
value
★ Set the starting switch to OFF for preparation and set it to ON for
Defective monitor panel troubleshooting.
3
(Switch module) Between S01 @ and 2
Light switch ON 20 30 V
Between S01 1 and 2
4
(Tachometer module)
Between S03 6 and 2 Light switch ON 20 30 V
5
(Caution module)
Between CN4 1 and 2 Light switch ON 20 30 V
Trouble (4) Only the headlamp does not come on.

Related information

Defective headlamp The headlamp is supposed to be defective. Check if the light bulb is
1
Defective circuit breaker When the circuit breaker is cut off, there is a high possibility that the
2
(CB5) circuit was short-circuited with ground.
troubleshooting.
Defective headlamp relay
3 When the starting switch is set to OFF, replace the relay with another
relay. Set the starting switch to ON and set the light switch to ON. If
the headlamp comes on, the headlamp relay (BB1) is defective.
Possible causes ★ Set the starting switch to OFF for preparation and troubleshoot
and standard val-
ue in normal state Disconnection of harness Harness between CB5 outlet and BB1 (fe- Resistance
Max. 1 Ω
4 (Disconnection, defective male) 3 value
contact of connector) Harnesses between BB1 (female) 5 and 203
Resistance
(female) 1 and between BB1 (female) 5 and Max. 1 Ω
value
204 (female) 1
Ground fault of harness Between harness related to CB5 (outlet side) Resistance
Min. 1 MΩ
5 and ground value
(contact with GND circuit)
Between harnesses (between BB1 (female)
Resistance
5 and 203 (female) 1, between BB1 (female) Min. 1 MΩ
value
5 and 204 (female) 1) and ground
D375A-5 20-629
1
Trouble (5) Only the working lamp does not come on. (Both right and left, or one side only)
Related information

Defective working lamp The working lamp is supposed to be defective. Check if the light bulb
1
(Burnt bulb) is burned out.
troubleshooting.
Defective working lamp relay
3 When the starting switch is set to OFF, replace the relay with another
relay. Set the starting switch to ON and set the light switch to ON. If
the working lamp comes on, the working lamp relay (BB3) is defective.
Possible causes
and standard val-
ue in normal state Disconnection of harness Harness between FS2-4 outlet and BB3 (fe- Resistance
Max. 1 Ω
4 (Disconnection, defective male) 3 value
contact of connector) Harnesses between BB3 (female) 5 and 221
Resistance
(female) 1 and between BB3 (female) 5 and Max. 1 Ω
value
241 (female) 1
Between harness related to FS2-4 (outlet Resistance
Ground fault of harness Min. 1 MΩ
5 side) and ground value
(contact with GND circuit)
Between harnesses (between BB3 (female)
Resistance
5 and 221 (female) 1, between BB3 (female) Min. 1 MΩ
value
5 and 241 (female) 1) and ground
Trouble (6) Only the rear lamp does not come on. (Both right and left, or one side only)
Related information

Defective rear lamp The rear lamp is supposed to be defective. Check if the light bulb is
1
troubleshooting.
Defective rear lamp switch
2 218 (male) Switch Resistance value
Possible causes OFF Min. 1 MΩ
Between 2 and 3
and standard val- ON Max. 1 Ω
ue in normal state ★ Set the starting switch to OFF for preparation and troubleshoot
Disconnection of harness Harness between 18 (female) 2 and circuit Resistance
Max. 1 Ω
3 (Disconnection, defective branched portion value
contact of connector) Harnesses between 218 (female) 3 and 223
Resistance
(female) 1 and between 218 (female) 3 and Max. 1 Ω
value
243 (female) 1
20-630 D375A-5
1
Circuit diagram related to instrument panel night lamp, headlamp, working lamp and rear lamp
D375A-5 20-631
1
TROUBLESHOOTING E-22 AIR CONDITIONER DOES NOT OPERATE
E-22 AIR CONDITIONER DOES NOT OPERATE

Trouble (1) No airflow occurs
Related information

Defective circuit breaker When the circuit breaker is cut off, there is a high possibility that the
1
(CB4) circuit was short-circuited with ground.
Defective blower main relay while keeping it to OFF.
2
(coil side) CN-R1 (male) Resistance value
Between (1) and (2) 240 ± 40 Ω
Defective blower main relay troubleshooting.
3
(contact side) CN-R1 Voltage
Between (6C) and ground 20 30 V
Defective blower Hi relay while keeping it to OFF.
4
Between (1) and (2) 240 ± 40 Ω
Defective blower Hi relay troubleshooting.
5
(contact side) Set the starting switch to ON and set the blower Hi switch to ON. If the
motor rotates, the relay is normal.
Defective blower Mi relay while keeping it to OFF.
6
Between (1) and (2) 240 ± 40 Ω
Defective blower Mi relay troubleshooting.
7
(contact side) Set the starting switch to ON and set the blower Mi switch to ON. If the
Possible causes
and standard val- troubleshooting.
ue in normal state 8 Defective blower motor
Set the starting switch to ON and set the blower Lo switch to ON. If the
Harness between CR-R3 (female) (0B), CN-
Resistance
AC1 (female) (0C), CN-R (female) (0D) or Max. 1 Ω
value
CCN-R2 (female) (0E) and ground
Harness between CN-B (female) (10A) and Resistance
Max. 1 Ω
CN-R (female) (10B) value
Harnesses between CN-B (female) (11A) and
Resistance
CN-R2 (female) (11B) and between CN-B (fe- Max. 1 Ω
value
male) (11A) and CN-R (female) (11C)
Disconnection of harness Harnesses between CB4 outlet and CNAC1
9 (Disconnection, defective (female) (13C), between CB4 outlet and CN-
Resistance
contact of connector) R1 (female) (13D), between CB4 outlet and Max. 1 Ω
value
CN-R2 (female) (13E) and between CB4 out-
let and CN-R3 (female) (13H)
Harness between CN-R1 (female) (14A) and Resistance
Max. 1 Ω
CN-AC1 (female) (14B) value
Max. 1 Ω
Max. 1 Ω
When cases 1 to 9 are not applicable, the control panel is supposed to be
10 Defective control panel
defective.
Mistake of failure phenome- When any specific cause cannot be determined, failure phenomena might
11
non have been mistaken. Execute the troubleshooting of No cooling.
20-632 D375A-5
1
Trouble (2) No cooling

Related information

troubleshooting.
1 Defective pressure switch CN-P Blower switch Voltage
Between (26A) and
ON 20 30 V
ground
Defective compressor clutch while keeping it to OFF.
2 relay
CN-R4 (male) Resistance value
(coil side)
Between (1) and (2) 240 ± 40 Ω
Defective compressor clutch troubleshooting.
3 relay
CN-R4 Voltage
(contact side)
Between (9B) and ground 20 30 V
Condenser relay troubleshooting.
4
(contact side) CN-R5 Voltage
Between (7B) and ground 20 30 V
5 Defective thermistor
CN-AC1 (male) Resistance value
Between (15B) and (16C) Max. 3,500 Ω
Defective condenser blower while keeping it to OFF.
6
resistor Condenser blower resistor Resistance value
Possible causes Between terminals 2.8 Ω ± 5%
and standard val- ★ Set the starting switch to ON for troubleshooting.
ue in normal state 7 Defective condenser motor Set the air conditioner switch to ON. If the motor rotates, it is normal.
★ Start the engine for troubleshooting.
Defective compressor mag-
8 The compressor magnet clutch is supposed to be defective. Check it
net clutch
directly.
9 Defective compressor
The compressor is supposed to be defective. Check it directly.
Harnesses between CB4 outlet and CN-R5
Resistance
(female) (6B) and between CB4 outlet and Max. 1 Ω
value
CN-R4 (female) (6D)
Harness between CN-R5 (female) (7B) and Resistance
Max. 1 Ω
ARC (female) 2 value
Harness between CN-R4 (female) (9B) and Resistance
Max. 1 Ω
Disconnection of harness 351 (female) 1 value
10 (Disconnection, defective Harnesses between CB4 outlet and CN-R4 Resistance
Max. 1 Ω
contact of connector) (female) (131) value
Harness between CN-T (female) (15A) and Resistance
Max. 1 Ω
Harness between CN-P (female) (19A) and Resistance
Max. 1 Ω
CN-R4 (female) (19C) value
Harness between CN-P (female) (26A) and Resistance
Max. 1 Ω
Harness between ARC (female) 1 and Resistance
Max. 1 Ω
ground value
When cases 1 to 10 are not applicable, the control panel is supposed
11 Defective control panel
to be defective.
D375A-5 20-633
1
Circuit diagram related to air conditioner
20-634 D375A-5
1
TROUBLESHOOTING OF
HYDRAULIC AND MECHANICAL SYSTEM
(H-MODE)
Information in troubleshooting table ......................................................................................................... 20-702

H-1 No force (No drawbar pull) ............................................................................................................... 20-703
H-2 No travel (At 2nd or 3rd speed) ........................................................................................................ 20-704
H-3 No travel at all gear speeds ............................................................................................................. 20-705
H-4 Large time lag at gear speed shifting or forward-reverse shifting .................................................... 20-706
H-5 Large time lag at gear speed shifting or forward-reverse shifting .................................................... 20-707
H-6 Steering is not possible .................................................................................................................... 20-708
H-7 Steering is possible only on one side .............................................................................................. 20-708
H-8 Steering overrun occurs ................................................................................................................... 20-709
H-9 Brake does not work ........................................................................................................................ 20-709
H-10 Torque converter is not lock-up ...................................................................................................... 20-710
H-11 Torque converter oil is overheated ................................................................................................. 20-710
H-12 All work equipment operates slowly ............................................................................................... 20-711
H-13 All work equipment does not operate ............................................................................................ 20-712
H-14 Blade lift raising speed is slow or the blade lift has no power ........................................................ 20-713
H-15 Blade tilt raising speed is slow or the blade tilt has no power ........................................................ 20-713
H-16 Ripper lift raising speed is slow or the ripper lift has no power ...................................................... 20-714
H-17 Ripper tilting speed is slow or the blade tilt has no power ............................................................. 20-714
H-18 Hydraulic drift of blade lift is large .................................................................................................. 20-715
H-19 Hydraulic drift of blade tilt is large .................................................................................................. 20-715
H-20 Hydraulic drift of ripper lift is large ................................................................................................. 20-716
H-21 Ripper pin puller cylinder does not operate ................................................................................... 20-716
H-22 Blade pitch does not operate ......................................................................................................... 20-717
H-23 Abnormal noise occurs around the work equipment pump ............................................................ 20-717
D375A-5 20-701
1

2
Possible causes Possible causes of trouble
and standard val- (Given numbers are refer-
ue in normal state Standard value in normal state to judge possible causes
ence numbers, which do not
Remarks on judgment
indicate priority)
3
20-702 D375A-5
1
TROUBLESHOOTING H-1 NO FORCE (NO DRAWBAR PULL)
H-1 NO FORCE (NO DRAWBAR PULL)
Trouble • No force (No drawbar pull)

Related information • Before troubleshooting, check that the power train oil level is normal.

1 Defective power train pump The power train pump is supposed to be defective. Check it directly.
★ Set the starting switch to OFF for preparation and idle the engine at
a high speed for troubleshooting (after checking that the transmis-
sion main relief pressure is normal).
Internal defect of torque con-
2 Torque converter Torque converter
verter PCCS lever
inlet pressure outlet pressure
0.8 – 1.0 MPa 39.2 – 63.7 MPa
Full neutral
{8.0 – 10.0 kg/cm2} {4.0 – 6.5 kg/cm2}
Incorrect pressure set to a high speed for troubleshooting.
3 transmission main relief
PCCS lever Transmission main relief pressure
valve
Full neutral 2.45 – 2.94 MPa {25.0 – 30.0 kg/cm2}
Defective operation of trans- while keeping it to OFF.
4
mission main relief valve Check it directly that the spring free length (120.3 mm) is normal and
that the spool moves smoothly.
a low speed for troubleshooting (after checking that the transmis-
Transmission clutch Clutch pressure
Defective operation of trans- FWD 2.35 – 2.94 MPa {24.0 – 30.0 kg/cm2}
5
mission valve (ECMV)
REV 2.35 – 2.94 MPa {24.0 – 30.0 kg/cm2}
1ST 1.96 – 2.55 MPa {20.0 – 26.0 kg/cm2}
Possible causes
2ND 2.35 – 2.94 MPa {24.0 – 30.0 kg/cm2}
and standard val-
ue in normal state 3RD 2.35 – 2.94 MPa {24.0 – 30.0 kg/cm2}
a high speed for troubleshooting.
Internal defect of transmis- Measuring conditions Engine speed
6
sion
F3 stall 1,430 rpm
F3 stall + Work equipment relief 1,160 rpm
★ Move the machine to a flat ground and start the engine for trouble-
shooting.
Defective operation (drag-
7 Idle the engine at a low speed and operate F2. Unless the machine
ging) of brake
moves, the brake is being dragged. (Execute the troubleshooting of
“Brake does not work.”)
PCCS lever Left stroke end Right stroke end
Min. 2.4 MPa 0
Left clutch pressure
{Min. 24 kg/cm2} {0}
0 Min. 2.4 MPa
8 Defective steering clutch Right clutch pressure
{0} {Min. 24 kg/cm2}
0 Min. 2.4 MPa
Left brake pressure
{0} {Min. 24 kg/cm2}
Min. 2.4 MPa 0
Right brake pressure
{Min. 24 kg/cm2} {0}
When the oil pressure is abnormal, execute the troubleshooting of
“Steering is not possible.”
D375A-5 20-703
1
4
TROUBLESHOOTING H-2 NO TRAVEL (AT 2ND OR 3RD SPEED)
H-2 NO TRAVEL (AT 2ND OR 3RD SPEED)
Trouble • No travel (at 2nd or 3rd speed)

• Before troubleshooting, check that the power train oil level is normal.
Related information
• Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.)

Internal defect of torque con- Torque converter Torque converter
1 PCCS lever
verter inlet pressure outlet pressure
0.8 – 1.0 MPa 39.2 – 63.7 MPa
Full neutral
{8.0 – 10.0 kg/cm2} {4.0 – 6.5 kg/cm2}
a low speed for troubleshooting.
Defective operation of trans-
2 Transmission clutch Clutch pressure
2ND 2.35 – 2.94 MPa {24.0 – 30.0 kg/cm2}
3RD 2.35 – 2.94 MPa {24.0 – 30.0 kg/cm2}
Internal defect of transmis- The inside of transmission clutch (2nd speed, 3rd speed) is supposed
3
sion clutch to be defective. Check it directly.
4 Defective operation (dragging) is supposed, check linkage valves.
ging) of parking brake
Possible causes
and standard val- ★ Move the machine to a flat ground and start the engine for trouble-
ue in normal state shooting.
ging) of brake
“Brake does not work.”)
Min. 2.4 MPa 0
{Min. 24 kg/cm2} {0}
0 Min. 2.4 MPa
Defective steering clutch, Right clutch pressure
6 {0} {Min. 24 kg/cm2}
brake
0 Min. 2.4 MPa
Left brake pressure
{0} {Min. 24 kg/cm2}
Min. 2.4 MPa 0
{Min. 24 kg/cm2} {0}
When the oil pressure is abnormal, execute the troubleshooting of
“Steering is not possible.”
20-704 D375A-5
1
4
TROUBLESHOOTING H-3 NO TRAVEL AT ALL GEAR SPEEDS
H-3 NO TRAVEL AT ALL GEAR SPEEDS
Trouble • No travel at all gear speeds

Related information • Before troubleshooting, check that the power train oil level is normal.

Incorrect pressure set to a high speed for troubleshooting.
PCCS lever Transmission main relief pressure
valve
Full neutral 2.45 – 2.94 MPa {25.0 – 30.0 kg/cm2}
3
Defective operation of trans- FWD 2.35 – 2.94 MPa {24.0 – 30.0 kg/cm2}
4
REV 2.35 – 2.94 MPa {24.0 – 30.0 kg/cm2}
1ST 1.96 – 2.55 MPa {20.0 – 26.0 kg/cm2}
2ND 2.35 – 2.94 MPa {24.0 – 30.0 kg/cm2}
3RD 2.35 – 2.94 MPa {24.0 – 30.0 kg/cm2}
Possible causes Internal defect of transmis- The inside of transmission clutch (2nd speed, 3rd speed) is supposed
and standard val- 5 sion clutch to be defective. Check it directly.
ue in normal state
★ Move the machine to a flat ground and idle the engine at a high
speed for troubleshooting (after checking that the transmission main
relief pressure is normal).
6 Defective operation of brake Brake pedal Brake oil pressure (right and left)
Release Min. 2.4 MPa {Min. 24 kg/cm2}
Step on 0 {0}
Min. 2.4 MPa 0
Defective seal of steering {Min. 24 kg/cm2} {0}
7
clutch 0 Min. 2.4 MPa
Right clutch pressure
{0} {Min. 24 kg/cm2}
0 Min. 2.4 MPa
Left brake pressure
{0} {Min. 24 kg/cm2}
Min. 2.4 MPa 0
{Min. 24 kg/cm2} {0}
Internal defect of steering The inside of the steering clutch is supposed to be defective, check it
8
clutch directly.
D375A-5 20-705
1
4
H-4 LARGE TIME LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE
TROUBLESHOOTING SHIFTING
H-4 LARGE TIME LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE SHIFTING

Trouble Large time lag at gear speed shifting or forward-reverse shifting
Related information Before troubleshooting, check that the power train oil level is normal.

Incorrect pressure set to PCCS lever Transmission main relief pressure
valve Full neutral 2.45 2.94 MPa {25.0 30.0 kg/cm2}
When the oil pressure is abnormal, clean the valve and then check the
oil pressure again.
3
Possible causes sion main relief pressure is normal).
and standard val-
ue in normal state Defective operation of trans-
4 FWD 2.35 2.94 MPa {24.0 30.0 kg/cm2}
REV 2.35 2.94 MPa {24.0 30.0 kg/cm2}
1ST 1.96 2.55 MPa {20.0 26.0 kg/cm2}
2ND 2.35 2.94 MPa {24.0 30.0 kg/cm2}
3RD 2.35 2.94 MPa {24.0 30.0 kg/cm2}
Defective seal of transmis- When the cause 4 is not applicable, the clutch seal is supposed to be
5
sion clutch defective. Check it directly.
Internal defect of transmis- The inside of the transmission clutch is supposed to be defective,
6
sion clutch check it directly.
shooting.
ging) of brake
Brake does not work.)
20-706 D375A-5
1
H-5 LARGE TIME LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE
TROUBLESHOOTING SHIFTING
H-5 LARGE TIME LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE SHIFTING

Trouble Large time lag at gear speed shifting or forward-reverse shifting
Related information Before troubleshooting, check that the power train oil level is normal.

Defective operation of trans- PCCS lever Transmission main relief pressure
2
mission main relief valve Full neutral 2.45 2.94 MPa {25.0 30.0 kg/cm2}
When the oil pressure is abnormal, clean the valve and then check the
oil pressure again.
Possible causes Defective operation of trans- FWD 2.35 2.94 MPa {24.0 30.0 kg/cm2}
and standard val- 3 mission valve (ECMV)
ue in normal state REV 2.35 2.94 MPa {24.0 30.0 kg/cm2}
1ST 1.96 2.55 MPa {20.0 26.0 kg/cm2}
2ND 2.35 2.94 MPa {24.0 30.0 kg/cm2}
3RD 2.35 2.94 MPa {24.0 30.0 kg/cm2}
Defective seal of transmis- When the cause 3 is not applicable, the clutch seal is supposed to be
4
sion clutch defective. Check it directly.
Internal defect of transmis- The inside of the transmission clutch is supposed to be defective,
5
sion clutch check it directly.
shooting.
ging) of brake
D375A-5 20-707
1
H-6 STEERING IS NOT POSSIBLE
TROUBLESHOOTING H-7 STEERING H-6
IS POSSIBLE
STEERINGONLY ONPOSSIBLE
IS NOT ONE SIDE
H-6 STEERING IS NOT POSSIBLE
Trouble • Steering is not possible.

Related information

★ Start the engine for preparation and idle it at a low speed for trou-
bleshooting.
1 Defective operation of brake Lift the machine with the blade and the ripper and steer the wheel for
F3 travel (or R3 travel). If the track shoe stops, the brake is defective.
(Execute the troubleshooting of “Brake does not work.”)
Possible causes Min. 2.4 MPa 0
and standard val- {Min. 24 kg/cm2} {0}
Defective operation of steer-
ue in normal state 2 0 Min. 2.4 MPa
ing clutch valve (ECMV) Right clutch pressure
{0} {Min. 24 kg/cm2}
0 Min. 2.4 MPa
Left brake pressure
{0} {Min. 24 kg/cm2}
Min. 2.4 MPa 0
{Min. 24 kg/cm2} {0}
Defective seal of steering When the cause 2 is not applicable, the clutch seal is supposed to be
3
clutch defective. Check it directly.
4
clutch directly.
H-7 STEERING IS POSSIBLE ONLY ON ONE SIDE
Trouble • Steering is possible only on one side.

Related information

Min. 2.4 MPa 0
{Min. 24 kg/cm2} {0}
1 0 Min. 2.4 MPa
Possible causes ing clutch valve (ECMV) Right clutch pressure
{0} {Min. 24 kg/cm2}
and standard val-
ue in normal state 0 Min. 2.4 MPa
Left brake pressure
{0} {Min. 24 kg/cm2}
Min. 2.4 MPa 0
{Min. 24 kg/cm2} {0}
Defective seal of steering When the cause 1 is not applicable, the clutch seal is supposed to be
2
clutch defective. Check it directly.
3
clutch directly.
20-708 D375A-5
1
4
H-8 STEERING OVERRUN OCCURS
TROUBLESHOOTING H-9 BRAKE
H-8 STEERING DOES NOT
OVERRUN WORK
OCCURS
H-8 STEERING OVERRUN OCCURS
Trouble • Steering overrun occurs.

Related information

★ Start the engine for preparation and idle it at a low speed for trou-
bleshooting.
Possible causes 1 Defective operation of brake Lift the machine with the blade and the ripper and steer the wheel for
and standard val- F3 travel (or R3 travel). If the track shoe stops, the brake is defective.
ue in normal state (Execute the troubleshooting of “Brake does not work.”)
When the track shoe does not stop in the troubleshooting of the cause
2 1, the steering clutch is defective. (Execute the troubleshooting of
ing clutch
“Steering is not possible.”)
H-9 BRAKE DOES NOT WORK
Trouble • Brake does not work.

Related information

1 Degradation of brake Step on the brake pedal, shift the gear to F2 and idle the engine at a
high speed. When the machine moves, the brake performance is de-
graded.
Defective operation of brake The brake pedal and the brake valve are supposed not to work nor-
2
pedal mally. Check them directly.
Possible causes PCCS lever Left stroke end Right stroke end
and standard val- Min. 2.4 MPa 0
ue in normal state Left clutch pressure
{Min. 24 kg/cm2} {0}
3 0 Min. 2.4 MPa
ing brake valve (ECMV) Right clutch pressure
{0} {Min. 24 kg/cm2}
0 Min. 2.4 MPa
Left brake pressure
{0} {Min. 24 kg/cm2}
Min. 2.4 MPa 0
{Min. 24 kg/cm2} {0}
When the brake seal is not normal in the troubleshooting of the cause
4 Defective brake seal
3, the brake seal is supposed to be defective. Check it directly.
5 Internal defect of brake The inside of the brake is supposed to be defective. Check it directly.
D375A-5 20-709
1
4
H-10 TORQUE CONVERTER IS NOT LOCK-UP
TROUBLESHOOTING H-11H-10
TORQUE CONVERTER
TORQUE OIL IS OVERHEATED
CONVERTER NOT LOCK-UP
H-10 TORQUE CONVERTER IS NOT LOCK-UP

Trouble The torque converter is not lock-up.
Before troubleshooting, check that the power train oil level is normal.
Related information
Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.)

Defective operation of a high speed for troubleshooting.
2 torque converter lock-up Torque converter Clutch pressure
valve Min. 1.27 1.47 MPa
At lock-up time
{Min. 13.0 15.0 kg/cm2}
Possible causes
Defective seal of lock-up When the troubleshooting of the case 2 is not normal, the lock-up
and standard val- 3
clutch clutch seal is supposed to be defective. Check it directly.
ue in normal state
Internal defect of lock-up The inside of the lock-up clutch is supposed to be defective. Check it
4
clutch directly.
Internal defect of torque con- Measuring conditions Engine speed
5
verter
F3 stall 1,430 rpm
F3 stall + Work equipment relief 1,160 rpm
H-11 TORQUE CONVERTER OIL IS OVERHEATED

Trouble The torque converter oil is overheated.
Before troubleshooting, check that the power train oil level is normal.
Before troubleshooting, check that the indication of the torque converter oil temperature gauge agrees
with actual temperature of the torque converter oil. (When the indication does not agree with actual
Related information
temperature, execute the troubleshooting of The indication of torque converter oil temperature gauge
is abnormal.)
Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.)

Engine output is supposed to have increased abnormally. Trouble-
1 Rise of engine output
shoot referring to the shop manual for engine.
Defective power train pump The power train pump is supposed to be defective, or air is supposed
2
or air entry in suction circuit to have entered from the suction circuit. Check them directly.
Internal defect of torque con- Torque converter Torque converter
3 PCCS lever
Possible causes verter inlet pressure outlet pressure
and standard val- 0.8 1.0 MPa 39.2 63.7 MPa
ue in normal state Full neutral
{8.0 10.0 kg/cm2} {4.0 6.5 kg/cm2}
Defective operation (slide) of The inside of the transmission clutch is supposed to be defective (the
4
transmission clutch clutch slides). Check it directly.
Defective operation (drag- Idle the engine at a low speed and operate F2. Unless the machine
5
ging) of brake moves, the brake is being dragged. (Execute the troubleshooting of
Defective operation (slide) of The inside of the steering clutch is supposed to be defective (the
6
steering clutch clutch slides). Check it directly.
20-710 D375A-5
1
TROUBLESHOOTING H-12 ALL WORK EQUIPMENT OPERATES SLOWLY
H-12 ALL WORK EQUIPMENT OPERATES SLOWLY

Trouble All work equipment operates slowly.
Related information Before troubleshooting, check that the hydraulic tank oil level is normal.

Defective PTO (work equip- The work equipment pump drive of the PTO is supposed to be defec-
1
ment pump drive) tive. Check it directly.
Defective work equipment The work equipment large pump is supposed to be defective. Check
2
large pump it directly.
Defective work equipment The work equipment small pump is supposed to be defective. Check
3
small pump it directly.
4 Defective PPC charge pump The PPC charge pump is supposed to be defective. Check it directly.
Improper pressure set to a high speed for troubleshooting.
5 main relief valve for blade lift
Blade lever Main relief pressure
valve
Raise Min. 19.6 MPa {Min. 200 kg/cm2}
Internal defect of main relief The inside of the main relief valve for blade lift valve is supposed to be
Possible causes 6
valve for blade lift valve defective. Check it directly.
and standard val-
ue in normal state ★ Set the starting switch to OFF for preparation and idle the engine at
7 main relief valve for blade tilt
ripper Lo valve
Internal defect of main relief
The inside of the main relief valve for blade tilt ripper Lo valve is sup-
8 valve for blade tilt ripper Lo
posed to be defective. Check it directly.
valve
9
charge relief valve Work equipment lever Control relief pressure
Full neutral Min. 3.9 MPa {Min. 40.0 kg/cm2}
Internal defect of charge re- The inside of the charge relief valve is supposed to be defective.
10
lief valve Check it directly.
11 Internal leak of PPC valve Internal leak of PPC valve is supposed. Check it directly.
D375A-5 20-711
1
TROUBLESHOOTING H-13 ALL WORK EQUIPMENT DOES NOT OPERATE
H-13 ALL WORK EQUIPMENT DOES NOT OPERATE

Trouble All work equipment does not operate.
Related information Before troubleshooting, check that the hydraulic tank oil level is normal.

Defective PTO (work equip- The work equipment pump drive of the PTO is supposed to be defec-
1
ment pump drive) tive. Check it directly.
Defective work equipment The work equipment large pump is supposed to be defective. Check
2
large pump it directly.
Defective work equipment The work equipment small pump is supposed to be defective. Check
3
small pump it directly.
4 Defective PPC charge pump The PPC charge pump is supposed to be defective. Check it directly.
5 main relief valve for blade lift
valve
Internal defect of main relief The inside of the main relief valve for blade lift valve is supposed to be
6
Possible causes valve for blade lift valve defective. Check it directly.
and standard val- ★ Set the starting switch to OFF for preparation and idle the engine at
ue in normal state Improper pressure set to a high speed for troubleshooting.
7 main relief valve for blade tilt
ripper Lo valve
Internal defect of main relief
The inside of the main relief valve for blade tilt ripper Lo valve is sup-
8 valve for blade tilt ripper Lo
posed to be defective. Check it directly.
valve
9
charge relief valve Work equipment lever Control relief pressure
Full neutral Min. 3.9 MPa {Min. 40.0 kg/cm2}
Internal defect of charge re- The inside of the charge relief valve is supposed to be defective.
10
lief valve Check it directly.
Defective operation of PPC The PPC lock valve is supposed to operate abnormally. Check the le-
11
lock valve ver linkage or the lock valve directly.
20-712 D375A-5
1
H-14 BLADE
H-14 LIFT RAISING
BLADE SPEED IS
LIFT RAISING SLOWIS
SPEED OR THE OR
SLOW BLADE
THELIFT HASLIFT
BLADE NO HAS
POWER
NO
TROUBLESHOOTING H-15 BLADE TILT RAISING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER
H-14 BLADE LIFT RAISING SPEED IS SLOW OR THE BLADE LIFT HAS NO POWER
Trouble Blade lift raising speed is slow or the blade lift has no power.
Before troubleshooting, check that the hydraulic tank oil level is normal.
Check if the blade has been modified.
Related information
In case of large hydraulic drift of the blade lift, execute the troubleshooting of Hydraulic drift of blade
lift is large.

Defective operation of PPC a high speed for troubleshooting.
1
valve Blade lever PPC valve output pressure
Raising stroke end Min. 3.9 MPa {Min. 40 kg/cm2}
Possible causes Defective operation of blade The spool of the blade lift control valve is suppose to operate abnor-
2
and standard val- lift control valve (spool) mally. Check it directly.
ue in normal state The suction valve of the blade lift control valve is suppose to operate
Defective operation of blade abnormally. Check it directly.
3 lift control valve ★ It is also acceptable to replace the suction valve on the head side
(suction valve) with the one on the bottom side to check change of the phenome-
non as another method.
Air is supposed to enter the blade lift cylinder. Bleed air and check the
4 Air entry in blade lift cylinder
change of phenomenon.
H-15 BLADE TILT RAISING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER
Trouble Blade tilt raising speed is slow or the blade tilt has no power.
Related information
lift is large.

1
Possible causes valve Blade lever PPC valve output pressure
and standard val- Tilt stroke end Min. 3.9 MPa {Min. 40 kg/cm2}
ue in normal state Defective operation of blade The spool of the blade tilt control valve is suppose to operate abnor-
2
tilt control valve (spool) mally. Check it directly.
Air is supposed to enter the blade tilt cylinder. Bleed air and check the
3 Air entry in blade tilt cylinder
D375A-5 20-713
1
H-16 RIPPER
H-16 LIFT RAISING
RIPPER SPEED IS
LIFT RAISING SLOWIS
SPEED OR THE OR
SLOW RIPPER
THE LIFT HASLIFT
RIPPER NO HAS
POWER
NO
TROUBLESHOOTING H-17 RIPPER TILTING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER
H-16 RIPPER LIFT RAISING SPEED IS SLOW OR THE RIPPER LIFT HAS NO POWER
Trouble Ripper lift raising speed is slow or the ripper lift has no power.
Check if the ripper has been modified.
Related information
lift is large.

1
valve Ripper lever PPC valve output pressure
Raising stroke end Min. 3.9 MPa {Min. 40 kg/cm2}
Possible causes Defective operation of ripper The spool of the ripper lift control valve (Lo, Hi) is suppose to operate
2
and standard val- lift control valve (spool) abnormally. Check it directly.
ue in normal state The constant differential pressure valve of the ripper lift control valve
Defective operation of ripper
(Hi) is suppose to operate abnormally. Check it directly.
lift control valve
3 ★ It is also acceptable to replace the constant differential pressure
(constant differential pres-
valve on the head side with the one on the bottom side to check
sure valve)
change of the phenomenon as another method.
Air is supposed to enter the ripper lift cylinder. Bleed air and check the
4 Air entry in ripper lift cylinder
H-17 RIPPER TILTING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER
Trouble Ripper tilting speed is slow or the ripper has no power.
Related information

1
valve Ripper lever PPC valve output pressure
Tilt end Min. 3.9 MPa {Min. 40 kg/cm2}
Possible causes Defective operation of ripper The spool of the ripper tilt control valve (Lo, Hi) is suppose to operate
2
and standard val- tilt control valve (spool) abnormally. Check it directly.
ue in normal state The constant differential pressure valve of the ripper tilt control valve
Defective operation of ripper
(Hi) is suppose to operate abnormally. Check it directly.
tilt control valve
3 ★ It is also acceptable to replace the constant differential pressure
(constant differential pres-
valve on the head side with the one on the bottom side to check
sure valve)
change of the phenomenon as another method.
Air is supposed to enter the ripper tilt cylinder. Bleed air and check the
4 Air entry in ripper tilt cylinder
20-714 D375A-5
1
H-18 HYDRAULIC DRIFT OF BLADE LIFT IS LARGE
TROUBLESHOOTING H-19 HYDRAULIC DRIFT OF BLADE LIFT
H-18 TILT IS LARGE
H-18 HYDRAULIC DRIFT OF BLADE LIFT IS LARGE

Trouble Hydraulic drift of the blade lift is large
Related information
Before troubleshooting, check that no oil leaks from the work equipment circuit.

★ Start the engine for preparation and stop it for troubleshooting.
Follow the procedures below for the troubleshooting. When the hy-
draulic drift speed becomes fast, the spool seal of the blade lift control
valve is defective:
Possible causes Defective seal of blade lift
1 1)Stretch the blade lift on the ground and push up the front of the ma-
and standard val- control valve (spool)
ue in normal state chine.
2)Stop the engine and release the safety lock lever.
3)Move the blade lever to the lift lowering side, and check the phe-
nomenon.
Defective seal of blade lift The seal of the blade lift cylinder is supposed to be defective. Check
2
cylinder it directly.
H-19 HYDRAULIC DRIFT OF BLADE TILT IS LARGE

Trouble Hydraulic drift of the blade tilt is large
Related information

draulic drift speed becomes fast, the spool seal of the blade tilt control
Defective seal of blade tilt valve is defective:
1
Possible causes control valve (spool) 1)Stretch the blade tilt on the ground and push up the right side of the
and standard val- machine.
ue in normal state 2)Stop the engine and release the safety lock lever.
3)Move the blade tilt to the right tilt side, and check the phenomenon.
Defective seal of blade tilt a high speed for troubleshooting.
2
cylinder Blade tilt cylinder Leakage from cylinder
Right tilt stroke end 12 cc/min
D375A-5 20-715
1
H-20 HYDRAULIC DRIFT OF RIPPER LIFT IS LARGE
TROUBLESHOOTING H-21 RIPPER PIN PULLERDRIFT
H-20 HYDRAULIC CYLINDER DOES NOT
OF RIPPER LIFT OPERATE
IS LARGE
H-20 HYDRAULIC DRIFT OF RIPPER LIFT IS LARGE

Trouble Hydraulic drift of the ripper lift is large
Related information

draulic drift speed becomes fast, the spool seal of the ripper lift control
valve (Hi) is defective:
Defective seal of blade lift
1 1)Stretch the ripper lift on the ground and push up the rear of the ma-
Possible causes control valve (spool)
chine.
and standard val- 2)Stop the engine and release the safety lock lever.
ue in normal state
3)Move the ripper lever to the lift lowering side, and check the phe-
nomenon.
Defective seal of ripper lift a high speed for troubleshooting.
2
cylinder Ripper lift cylinder Leakage from cylinder
Lowering stroke end 12 cc/min
H-21 RIPPER PIN PULLER CYLINDER DOES NOT OPERATE

Trouble Ripper pin puller cylinder does not operate.
Related information Before troubleshooting, check that transmission main relief pressure is normal.

Possible causes Defective operation of pin Pin puller operating
1 Pin puller switch Measuring position
and standard val- puller solenoid pressure
ue in normal state Push-in Cylinder bottom side Min. 2.4 MPa
Pull-in Cylinder head side {Min. 24 kg/cm2}
Internal defect of pin puller The inside of the pin puller cylinder is supposed to be defective. Check
2
cylinder it directly.
20-716 D375A-5
1
H-22 BLADE PITCH DOES NOT OPERATE
TROUBLESHOOTING H-23 ABNORMAL NOISE OCCURSH-22
AROUND THE
BLADE WORK
PITCH EQUIPMENT
DOES PUMP
NOT OPERATE
H-22 BLADE PITCH DOES NOT OPERATE

Trouble Blade pitch does not operate.
Related information

Defective operation of blade Operate both the blade pitch and the blade tilt. When only the pitch op-
Possible causes 1 pitch selection solenoid eration is not possible, the pitch selection solenoid valve is operating
and standard val- valve abnormally.
ue in normal state Operate both the blade pitch and the blade tilt. When both the pitch
Defective operation of blade
2 operation and the tilt operation are not possible, the pitch cylinder (tilt
pitch cylinder
cylinder) is operating abnormally.
H-23 ABNORMAL NOISE OCCURS AROUND THE WORK EQUIPMENT PUMP

Trouble Abnormal noise occurs around the work equipment pump.
Related information Before troubleshooting, check that the oil level in the hydraulic tank is normal.

1 Improper oil is used Improper oil is supposed to be used. Check it directly.
Clogging of hydraulic tank The hydraulic tank strainer is supposed to be clogged. Check it direct-
Possible causes 2
strainer ly.
and standard val-
ue in normal state 3 Air entry in suction circuit Air is supposed to have entered the suction circuit of the work equip-
ment pump. Check the piping directly.
Internal defect of work The inside of the work equipment pump is supposed to be defective.
4
equipment pump Check it directly.
D375A-5 20-717
1
TROUBLESHOOTING OF THE ENGINE BODY

(S-MODE)
Points to remember when troubleshooting .............................................................................................. 20-802

Method of using troubleshooting charts ................................................................................................... 20-803
S-1 Starting performance is poor (starting always takes time) ............................................................. 20-806
S-2 Engine does not start ..................................................................................................................... 20-809
1) Engine does not turn ................................................................................................................ 20-809
2) Engine turns but no exhaust smoke comes out (fuel is not being injected) ............................. 20-810
3) Exhaust smoke comes out but engine does not start (fuel is being injected) ........................... 20-812
S-3 Engine does not pick up smoothly (follow-up is poor) .................................................................... 20-814
S-4 Engine stops during operations ...................................................................................................... 20-816
S-5 Engine does not rotate smoothly (hunting) ..................................................................................... 20-818
S-6 Engine lacks output (or lacks power) .............................................................................................. 20-820
S-7 Exhaust smoke is black (incomplete combustion) .......................................................................... 20-822
S-8 Oil consumption is excessive (or exhaust smoke is blue) .............................................................. 20-824
S-9 Oil becomes contaminated quickly ................................................................................................. 20-825
S-10 Fuel consumption is excessive ....................................................................................................... 20-826
S-11 Oil is in cooling water, or water spurts back, or water level goes down .......................................... 20-827
S-12 Oil pressure caution lamp lights up (drop in oil pressure) .............................................................. 20-828
S-13 Oil level rises .................................................................................................................................. 20-829
S-14 Water temperature becomes too high (overheating) ...................................................................... 20-830
S-15 Abnormal noise is made ................................................................................................................. 20-831
S-16 Vibration is excessive ..................................................................................................................... 20-832
D375A-5 20-801
(5)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

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

hurry to disassemble the components 1) Is there any sign of abnormality in the ma-
If components are disassembled immediately chine or engine?
any failure occurs: 2) Always carry out the Checks before starting.
• Parts that have no connection with the failure 3) Carry out other checks if necessary.
or other unnecessary parts will be disassem- 4) Other maintenance items can be checked
bled. externally, so check any item that is consid-
• It will become impossible to find the cause of ered to be necessary.
the failure. 5) Check for any error display on the controller.
It will also cause a waste of man-hours, parts, or
oil or grease, and at the same time, will also lose 4. Confirming failure
the confidence of the user or operator. Confirm the extent of the failure yourself, and
For this reason, when carrying out troubleshoot- judge whether to handle it as a real failure or as
ing, it is necessary to carry out thorough prior in- a problem with the method of operation, etc.
vestigation and to carry out troubleshooting in a When operating the machine to re-enact the
accordance with the fixed procedure. troubleshooting symptoms, do not carry out
any investigation or measurement that may
2. Points to ask user or operator make the problem worse.
1) Have any other problems occurred apart
from the problem that has been reported? 5. Troubleshooting
2) Was there anything strange about the ma- Use the results of the investigation and inspec-
chine before the failure occurred? tion in Items 2 – 4 to narrow down the causes of
3) Did the failure occur suddenly, or were there failure, then use the troubleshooting matrix or
problems with the machine condition before flowchart to locate the position of the failure ex-
this? actly.
4) Under what conditions did the failure occur? a The basic procedure for troubleshooting is
5) Had any repairs been carried out before the as follows.
failure? When were these repairs carried 1) Start from the simple points.
out? 2) Start from the most likely points.
6) Has the same kind of failure occurred be- 3) Investigate other related parts or informa-
fore? tion.
6. Measures to remove root cause of failure

Even if the failure is repaired, if the root cause of
the failure is not repaired, the same failure will
occur again.
To prevent this, always investigate why the prob-
lem occurred. Then, remove the root cause.
20-802 D375A-5
(5)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make fi-
nal confirmation.
[Questions]
Sections A + B in the chart on the right corre-
sponds to the items where answers can be ob-
tained from the user. The items in B are items
that can be obtained from the user, depending
on the user’s level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under C in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information A that he has obtained from the
user and the results of C that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with Q, and of these, causes that have a high prob-
ability are marked with w.
Check each of the [Questions] and [Check items]
in turn, and marked the Q or w in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is the
most probable cause, so start troubleshooting for
that item to make final confirmation of the cause.
As a rule, do not use it when calculating the points
for locating the cause, but it can be included if nec-
essary to determine the order for troubleshooting.
Use the E in the Cause column as reference for
[Degree of use (Operated for long period)] in the
[Questions] section as reference.
D375A-5 20-803
(5)
• Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms
have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became weak-
er], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)

General causes why exhaust smoke is black
• Insufficient intake of air
• Defective condition of fuel injection
• Excessive injection of fuel
20-804 D375A-5
(5)
Five causes
Step 1
Clarify the relationship between the three symptoms in

the [Questions] and [Check items] section and the five
Cause items in the vertical column.
Three symptoms
Step 2
Add up the total of and marks where the horizontal
limes for the three symptoms and the vertical columns for
the causes intersect.
(1) Clogged air cleaner element:
(2) Defective contact of valve, valve seat:
(3) Leakage of air between turbocharger
and head:
(4) Worn piston ring, cylinder liner:
(5) Defective timing rail pressure sensor:
Step 3
The calculation in Step 2 show that the closest
relationship is with [Worn piston ring, cylinder liner].
Follow this column down to the troubleshooting area and
carry out the troubleshooting item marked .
The Remedy is given as [Clean], so carry out cleaning,
and the exhaust gas color should return to normal.
D375A-5 20-805
(5)
TROUBLESHOOTING S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)
General causes why starting performance is poor Causes

• Defective electrical system
Defective preheating circuit (when starting in low temperatures)

• Insufficient supply of fuel
• Improper selection of fuel
• Defective HPI sensor
• Defective HPI actuator
Defective contact of valve, valve seat
Clogged timing rail actuator screen

Loose piping, fuel filter, entry of air
Defective or deteriorated battery

Worn piston ring, cylinder liner
Defective alternator regulator

Clogged air cleaner element
Defective injector check ball

Clogged fuel filter, strainer
Cut, worn injector O-ring

Defective shut-off valve
Clogged fuel tank cap
Defective fuel pump
Defective alternator
Defective injector
Confirm recent repair history
Degree of use of machine Operated for long period
Starting performance became worse gradually
Engine starts easily when warm
Questions
Non-specified fuel is being used

Replacement of filters has not been carried out according to Operation Manual
Engine oil must be added more frequently
Charge caution lamp lights up
When preheating, preheating indicator lamp does not light up
Dust indicator is red
Air breather hole in fuel tank cap is clogged
Starting motor cranks engine slowly
When engine is Little fuel comes out even when injection pump sleeve nut is loosened
cranked with
starting motor, Little fuel comes out even when fuel filter air bleed plug is loosened
Check items
When exhaust manifold is touched immediately after starting engine, temperature

of some cylinders is low
Engine does not pick up smoothly, and combustion is irregular
There is hunting from engine (rotation is irregular)
Blow-by gas is excessive
Difficult to stop engine
Inspect air cleaner element directly

When compression pressure is measured, it is found to be low
Inspect fuel filter, strainer directly
When negative pressure at inlet port of fuel pump is measured, it is found to be high
When pressure at outlet port of fuel pump is measured, it is found to vary
When pressure at outlet port of fuel pump is measured, it is found to be low
Inspect fuel pump directly
Troubleshooting
Inspect fuel shut-off valve directly

Inspect timing rail actuator screen directly
When temperature of exhaust gas of each cylinder is measured, there are some
cylinders that are low
Inspect injector directly
When specific gravity of electrolyte and voltage of battery are measured, one of
them is low
When starting switch is turned to HEAT, heater mount does not become warm
Is voltage 26 - 30V between alternator terminal B and terminal E with Yes
engine at low idling? No
Inspect sensor directly (Output voltage and resistance)
Inspect actuator directly (Resistance and filter for clogging)
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
20-806 D375A-5
(5)
TROUBLESHOOTING S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)
Causes 1. If the following service codes are displayed, carry out

the troubleshooting in “Service code”. (If any of the fol-
lowing service codes is not displayed, they are not
probably the cause of the trouble. In this case, inspect
Defective intake manifold temperature sensor the other devices for the cause.)
[EC514]: Abnormality in fuel rail actuator
1)
1) [EC112]: Abnormality in timing rail actuator
1)
Defective atmospheric pressure sensor
Defective fuel pump actuator (Marked

Defective timing rail actuator (Marked
Defective fuel pump pressure sensor
Defective timing rail pressure sensor
Defective water temperature sensor
[EC318]: Abnormality in fuel pump actuator

Defective fuel rail actuator (Marked
Defective fuel rail pressure sensor
Defective boost pressure sensor
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
D375A-5 20-807
(5)
TROUBLESHOOTING S-2 ENGINE DOES NOT START
S-2 ENGINE DOES NOT START
1) Engine does not turn Causes
General causes why engine does not turn

• Internal parts of engine seized
a See Troubleshooting S-4.
• Defective electrical system
• Problem in power train (troubleshooting in chassis volume)
Defective safety relay or safety switch

Defective battery terminal connection
Defective starting circuit wiring

Broken flywheel ring gear
Defective starting switch
Defective starting motor

Defective battery relay
Questions
Condition of horn when starting Horn does not sound

switch is turned ON Horn volume is low
Battery electrolyte is low
Battery terminal is loose
When starting switch is turned to ON, there is no clicking sound from battery relay
When starting switch is turned to START, starting pinion does not move out
Check items
Speed of rotation is low

When starting switch is turned Makes grating noise
to START, starting pinion moves
out, but Soon disengages again
Makes rattling noise and does not turn
Inspect flywheel ring gear directly

Troubleshooting
When specific gravity of electrolyte and voltage of battery are measured, one of them is low
When terminal B and terminal C of starting switch are connected, engine starts
Turn starting switch
There is no 24V between battery relay terminal B and terminal E
OFF, connect cord,
and carry out When terminal B and terminal C of starting motor are connected, engine starts
troubleshooting at When terminal B and terminal C of safety relay are connected, engine starts
1.
ON
When terminal of safety switch and terminal B of starting motor are connected, engine starts
Replace
Replace
Replace
Replace
Replace
Replace
Correct
—
Remedy
1. Carry out troubleshooting in chassis volume
D375A-5 20-809
(5)
2) Engine turns but no exhaust smoke comes out (fuel is not being injected) Causes
General causes why engine turns but no exhaust smoke comes out
• Fuel is not being supplied
• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter)

Defective fuel shut-off valve wiring

Clogged timing actuator screen
Broken fuel pump drive shaft
Defective fuel shut-off valve
Insufficient fuel in tank
Questions
Exhaust smoke suddenly stopped coming out (when starting again)

Starts when engine is warm
When fuel tank is inspected, it is found to be empty
Rust and water are found when fuel tank is drained
When fuel filter is drained, fuel does not come out
Check items
There is leakage from fuel piping

Wiring of fuel shut-off valve is loose
Cylinder block ground wiring is loose
When engine is cranked with Fuel pump outlet port coupler is pushed, almost no fuel comes out
starting motor, and Fuel pump outlet port coupler is pushed, air comes out together with fuel
Troubleshooting
Inspect fuel pump drive shaft directly

Inspect fuel shut-off valve directly
When starting switch is turned to START, voltage [24V] is not generated between fuel shut-off valve connector
pins
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
Add
20-810 D375A-5
(5)
Causes
1. If the following service codes are displayed, carry out
the other devices for the cause.)
Defective intake manifold temperature sensor

1)
1)
[EC112]: Abnormality in timing rail actuator
1)


Defective water temperature sensor

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
D375A-5 20-811
(5)
3) Exhaust smoke comes out but engine does not start (fuel is being Causes
injected)
Defective dynamic valve system (valve, rocker arm, etc.)

General causes why exhaust smoke comes out but engine does not start
• Lack of rotating force due to defective electrical system
• Improper selection of fuel and oil
Defective preheating heater circuit


Clogged timing actuator screen

Defective fuel pump
Defective injector
Suddenly failed to start
Questions
Starts when engine is warm

When preheating, preheating indicator lamp does not light up
When fuel filter is drained, no fuel comes out
Check items

Starting motor cranks engine slowly
When engine is cranked, abnormal noise is generated around cylinder head
When engine is Fuel pump outlet port coupler is pushed, almost no fuel comes out
cranked with starting
motor, and Fuel pump outlet port coupler is pushed, air comes out together with fuel

Inspect dynamic valve system directly
Troubleshooting
When fuel filter, strainer directly

When temperature of exhaust gas of each cylinder is measured, there are some cylinders that are low
When specific gravity of electrolyte and voltage of battery are measured, one of them is low
When starting switch is at HEAT, heater mount does not become warm
Inspect fuel rail actuator directly
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Remedy
20-812 D375A-5
(5)
Replace Defective atmospheric pressure sensor
Replace Defective boost pressure sensor
Replace Defective fuel rail pressure sensor
D375A-5
Replace Defective timing rail pressure sensor
Replace Defective fuel pump pressure sensor
Replace Defective water temperature sensor
Causes
Replace Defective intake manifold temperature sensor

Replace Defective fuel rail actuator (Marked 1)
TROUBLESHOOTING
Replace Defective timing rail actuator (Marked 1)

Replace Defective fuel pump actuator (Marked 1)
Replace Clogged fuel rail actuator

(5)
20-813
S-2 ENGINE DOES NOT START
TROUBLESHOOTING S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)
General causes why engine does not pick up smoothly Causes

• Defective condition of fuel spray
• Improper fuel used
• Abnormality in fuel control system
Defective contact of valve and valve seat


• Normal output is not applied
Failure boost pressure sensor

o See Troubleshooting S-6

Improper valve clearance

Seized turbocharger
Defective fuel pump

Defective injector
Engine pick-up suddenly became worse
Questions

Rust and water are found when fuel is drained
When engine is cranked Fuel pump outlet port coupler is pushed, almost no fuel comes out
with starting motor, and Fuel pump outlet port coupler is pushed, air comes out together with fuel
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Check items
Blue under light load

Color of exhaust gas
Black
Clanging sound is heard from around cylinder head
Noise of interference is heard from around turbocharger
High idling speed under no load is normal, but speed suddenly drops when load is applied

When turbocharger is rotated by hand, it is found to be heavy
Inspect valve clearance directly
Troubleshooting

When temperature of injector of each cylinder is measured, there are some cylinders that are low
When intake air pressure (boost pressure) is measured, it is found to be normal
Inspect for air leakage
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Clean
Remedy
20-814 D375A-5
(5)
TROUBLESHOOTING S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)
Causes
Air leakage from piping between turbocharger and cylinder head lowing service codes is not displayed, they are not
1)
1)

1)


Replace
Replace
Replace
Replace
Replace
D375A-5 20-815
(5)
TROUBLESHOOTING S-4 ENGINE STOPS DURING OPERATIONS
S-4 ENGINE STOPS DURING OPERATIONS
General causes why engine stops during operations Causes

• Seized parts inside engine
Failure in power train (troubleshooting in chassis volume)

• There is overheating
Broken dynamic valve system (valve, rocker arm, etc.)
Broken, seized main bearing, connecting rod bearing
Broken auxiliary equipment (pump, compressor, etc.)

• Problem in power train (troubleshooting in chassis volume)

Broken, seized piston, connecting rod
Broken fuel pump drive shaft

Broken, seized gear train
Defective injector
Abnormal noise was heard and engine stopped suddenly
Engine overheated and stopped
Condition when engine stopped
Engine stopped slowly
Questions
There was hunting and engine stopped

Fuel level caution lamp lights up
Metal particles are found when oil is drained
Does not turn at all
When it is attempted
Check items
Turns in opposite direction

to turn by hand using
barring tool Moves amount of gear backlash
Fuel pump shaft does not turn
Engine turns, but stops when load is applied to machine

Inspect piston, connecting rod directly
Inspect main bearing, connecting rod directly
Inspect gear train directly
Troubleshooting

Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed
1.

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Remedy
Add
20-816 D375A-5
(5)
TROUBLESHOOTING S-4 ENGINE STOPS DURING OPERATIONS

1)
1)

1)


Defective fuel shut-off valve

Clogged fuel inlet circuit
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
D375A-5 20-817
(5)
TROUBLESHOOTING S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
General causes why engine does not rotate smoothly Causes

• Air in fuel system
• Defective governor mechanism
High resistance, clogged fuel return circuit

Defective actuation of timing rail actuator
Defective actuation of fuel rail actuator

Defective injector check ball


Defective fuel pump
Defective injector
Questions
Occurs at a certain speed range

Occurs at low idling
Condition of hunting
Occurs even when speed is raised
Occurs on slopes
Rust, water are found when fuel tank is drained
Leakage from fuel piping
Check items
Engine speed sometimes rises too far
Engine is difficult to stop

Troubleshooting

When flow of spill fuel is checked visually, it is found to be low
Inspect fuel rail actuator screen directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
20-818 D375A-5
(5)
Replace Defective atmospheric pressure sensor
Replace Defective boost pressure sensor
Replace Defective fuel rail pressure sensor
D375A-5
Replace Defective timing rail pressure sensor
Replace Defective fuel pump pressure sensor
Replace Defective fuel pump actuator (Marked 1)
Causes
— Defective in throttle sensor

Replace Defective in speed sensor
TROUBLESHOOTING
Replace Clogged fuel rail actuator screen

Replace Clogged timing rail actuator screen
inspect the other devices for the cause.)
troubleshooting in “Service code”. (If it is not displayed,
it is not probably the cause of the trouble. In this case,
1. If the following service code is displayed, carry out the
(5)
20-819
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
TROUBLESHOOTING S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)
a Measure the engine speed and judge if the problem is in the engine Causes
or on the machine.
General causes why engine lacks output

(if non-specified fuel is used, output drops)
Improper adjustment of valve clearance

• There is overheating

Seized turbocharger, interference


Defective fuel pump

Defective injector
Suddenly
Power was lost
Questions
Gradually
Dust indicator lamp is red
Black
Check items

Engine pickup is poor and combustion is irregular
High idling speed of engine is low

Troubleshooting

Check part No. of controller calibration data
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Remedy
20-820 D375A-5
(5)
TROUBLESHOOTING S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)

1)
1)

1)

High resistance or clogged fuel circuit
Defective controller calibration data [EC318]: Abnormality in fuel pump actuator

Defective throttle sensor

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
—
—
D375A-5 20-821
(5)
TROUBLESHOOTING S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)
General causes why exhaust smoke is black Causes

Leakage of air between turbocharger and cylinder head

1)
Improper adjustment of valve clearance

Failure timing rail pressure sensor

Seized turbocharger, interference

Crushed, clogged muffler

Defective fuel pump
Defective injector
Suddenly became black
Color of exhaust gas Gradually became black
Questions

Suddenly
Power was lost
Gradually
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
Check items

Exhaust noise is abnormal
Engine pickup is poor and combustion is irregular
Inspect air cleaner directly

Troubleshooting

When muffler is removed, exhaust sound improves
Inspect between turbocharger and cylinder head directly
Abnormality in timing rail pressure sensor system is indicated ( 2)
Inspect sensor directly (Output voltage)
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Remedy
20-822 D375A-5
(5)
TROUBLESHOOTING S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)

2. If a service code of the timing rail pressure sensor sys-
tem is displayed, carry out the troubleshooting in “Ser-
vice code”.
D375A-5 20-823
(5)
TROUBLESHOOTING S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)
a To prevent the oil from leaking up or down in the turbocharger, Causes

do not run the engine at idling for more than 20 minutes contin-
uously (both low and high idling).
General causes why oil consumption is excessive
Worn seal at turbine end

Worn seal at blower end
• Abnormal combustion of oil
• External leakage of oil
Worn, damaged valve (stem, guide, seal)

• Wear of parts in lubrication system
Leakage from oil pan or cylinder head

Clogged breather or breather hose
Dust sucked in from intake system
Leakage from oil filter or oil cooler

Leakage from oil drain plug

Too much engine oil added
Worn, broken rear oil seal
Leakage from oil piping

Broken piston ring
Broken oil cooler

Turbocharger
Questions

Oil consumption suddenly increased
Engine oil becomes contaminated quickly
Oil level is above H level on gauge
Outside of engine is dirty with oil
There are loose piping clamps in intake system
Inside of turbocharger intake pipe is dirty with oil
Check items
Inside of exhaust pipe is dirty with oil

There is oil in engine cooling water
Oil level in clutch chamber or damper chamber rises
Exhaust smoke is blue under light load
Excessive
Amount of blow-by gas
None
When intake manifold is removed, dust is found inside

Excessive play of turbocharger shaft
Troubleshooting
When intake manifold is removed, inside is found to be dirty with oil

Inspect breather element directly
Inspect rear oil seal directly
There is external leakage of oil from engine
Pressure-tightness test of oil cooler shows there is leakage
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
20-824 D375A-5
(5)
TROUBLESHOOTING S-9 OIL BECOMES CONTAMINATED QUICKLY
S-9 OIL BECOMES CONTAMINATED QUICKLY
General causes why oil becomes contaminated quickly Causes

• Entry of exhaust gas into oil due to internal wear
• Clogging of lubrication passage
• Defective combustion
• Operation under excessive load
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
• Oil change interval is too long
Clogged breather, breather tube

Worn valve (stem, guide, seal)
Defective oil filter safety valve

Too much engine oil added
Exhaust smoke is black

Clogged oil cooler
Clogged oil filter
Questions

Non-specified oil is being used
Oil level is above H level on gauge
When oil filter is inspected, metal particles are found
When exhaust pipe is removed, inside is found to be dirty with oil
Even when engine oil temperature rises, oil filter caution lamp lights up (machines equipped with caution lamp)
Check items
Engine oil temperature rises quickly

Black
Excessive
Amount of blow-by gas
None
Inspect turbocharger lubrication drain tube directly
Troubleshooting S-7
Troubleshooting
Excessive play of turbocharger shaft

Inspect breather element directly
Carry out
Inspect oil cooler directly
Inspect oil filter directly
Inspect safety valve directly
Replace
Replace
Replace
Replace
Correct
eplace
Clean
Clean
Clean
—
Remedy
D375A-5 20-825
(5)
TROUBLESHOOTING S-10 FUEL CONSUMPTION IS EXCESSIVE
S-10 FUEL CONSUMPTION IS EXCESSIVE
General causes why fuel consumption is excessive Causes

• Leakage of fuel
High resistance, clogged fuel return circuit

Failure timing rail pressure sensor
Leakage of fuel inside head cover

Failure fuel rail pressure sensor

Defective fuel pump
Defective injector
Questions
More than for other machines of same model

Condition of fuel consumption Gradually increased
Suddenly increased
There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Check items
Black
Exhaust smoke color
White
Inspect inside of head cover directly

Troubleshooting

Abnormality in fuel rail pressure sensor system is indicated ( 1)
Abnormality in timing rail pressure sensor system is indicated ( 1)
When flow of return fuel is checked visually, it is found to be low
Inspect sensor directly (Output voltage)
Replace
Replace
Replace
Replace
Replace
Replace
Replace
1. If a service code of the fuel rail pressure sensor system or timing rail pressure sensor
Correct
Clean
Clean
system is displayed, carry out the troubleshooting in "Service code". Remedy
20-826 D375A-5
(5)
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER
TROUBLESHOOTING LEVEL GOES DOWN
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN
General causes why oil is in cooling water Causes

• Internal leakage in lubrication system
Broken power train oil cooler (troubleshooting in chassis volume)

• Internal leakage in cooling system
Damaged cylinder liner O-ring, holes caused by pitting

Insufficient protrusion of cylinder liner
Broken cylinder head, head gasket
Internal cracks in cylinder block
Broken oil cooler core, O-ring

Broken water pump seal
Questions
Suddenly increased
Oil level
Gradually increased
Hard water is being used as cooling water (or corrosion resistor valve is closed)
Excessive air bubbles inside radiator, spurts back
Check items
Engine oil level has risen, oil is cloudy white

Hydraulic oil, transmission oil on machine side is cloudy white
When hydraulic oil, transmission oil on machine side is drained, water is found
Troubleshooting
Carry out pressure-tightness test of cylinder head

Inspect cylinder block, liner directly
Inspect cylinder liner directly
Carry out pressure-tightness test of oil cooler
Inspect water pump directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
D375A-5 20-827
(5)
TROUBLESHOOTING S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)
General causes why oil pressure caution lamp lights up Causes

• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
• Improper selection of fuel (insufficient viscosity)
• Deterioration of oil due to overheating
Clogged, broken oil pump suction pipe

Broken oil pump suction pipe brazing
Leaking, crushed hydraulic piping

Clogged oil pan suction strainer
Defective oil pump relief valve
Defective oil pressure sensor

Defective oil level sensor
Worn crankshaft journal
Lack of oil in oil pan
Defective oil pump
Clogged oil cooler

Clogged oil filter
Water, fuel in oil

Questions
Non-specified oil is being used

Engine oil pressure caution lamp lights up
Lights up at low idling
Lights up at low, high idling
Condition when oil pressure lamp lights up
Lights up on slopes
Sometimes lights up
Oil level caution lamp lights up (machines equipped with caution lamp)
Check items
There is crushing, external leakage from hydraulic piping

Oil level in oil pan is low
Oil is cloudy white or smells of diesel oil
When oil is drained, metal particles are found
When oil filter is inspected, metal particles are found
Carry out Troubleshooting
Inspect suction strainer, pipe directly
Troubleshooting
Oil pump rotation is heavy, there is play

Inspect relief valve, regulator valve directly
When engine oil level sensor is replaced, oil pressure lamp goes out
(machines equipped with oil level sensor)
S-13
When oil pressure is measured, it is found to be normal

Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Adjust
Clean
Clean
Clean
Clean

Add
20-828 D375A-5
(5)
TROUBLESHOOTING S-13 OIL LEVEL RISES
S-13 OIL LEVEL RISES
a If there is oil in the cooling water, carry out Troubleshooting S-11. Causes
General causes why oil level rises
Clogged water pump drain hole (breather hole), defective seal
Defective auxiliary equipment (pump, compressor) seal

• Cooling water in oil (milky white)

• Fuel in oil (diluted, and smells of diesel fuel)
• Entry of water or oil from other component
Defective cylinder head injector sleeve

Broken, broken rear oil seal face

Broken oil cooler core, O-ring
Cracks inside cylinder block
Defective thermostat seal

Broken aftercooler core
Worn fuel pump seal

Questions

Fuel must be added more frequently
Engine oil smells of diesel fuel
There is oil in cooling water
When engine is first started, drops of water come from muffler
When radiator cap is removed and engine is run at low idling, an abnormal number of bubbles
appear, or water spurts back
Check items
Exhaust smoke is white

Water pump drain hole (breather hole) is clogged
When water pump drain hole (breather hole) is cleaned, water comes out
Oil level goes down in clutch or damper chamber
Oil level goes down in hydraulic tank
Carry out pressure-tightness test of aftercooler
Troubleshooting
Inspect rear oil seal directly

Carry out pressure-tightness test of oil cooler
Inspect water pump directly
Inspect thermostat directly
Inspect injector directly
Inspect pump auxiliary equipment (pump, compressor) directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
D375A-5 20-829
(5)
TROUBLESHOOTING S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
General causes why water temperature becomes too high Causes

• Lack of cooling air (deformation, damage of fan)
Rise in power train oil temperature (troubleshooting in chassis volume)

• Drop in heat dissipation efficiency
• Rise in oil temperature in power train

(troubleshooting in chassis volume)
Defective radiator cap (pressure valve)
Defective water temperature gauge

Defective operation of thermostat

Fan belt slipping, worn fan pulley
Clogged, crushed radiator fins
Cracks inside cylinder block
Clogged, broken oil cooler
Clogged radiator core

Lack of cooling water
Broken water pump

Questions
Suddenly overheated
Condition of overheating
Always tends to overheat
Rises quickly
Water temperature gauge
Does not go down from red range
Radiator water level caution lamp lights up (machines equipped with caution lamp)
Engine oil level has risen, oil is cloudy white
Cloudy white oil is floating on cooling water
Excessive air bubbles inside radiator, water spurts back
When light bulb is held behind radiator, no light passes through
Radiator shroud, inside of underguard are clogged with dirt or mud
Check items
Water is leaking because of cracks in hose or loose clamps

When belt tension is inspected, it is found to be loose
Fan belt whines under sudden load
Cooling water flows out from overflow hose
Power train oil temperature enters red range faster than engine water temperature

Inspect oil cooler directly
Troubleshooting
Inspect radiator core directly

When temperature difference between top and bottom radiator tanks is measured, it is found to
be slight
Carry out function test on radiator cap (cracking pressure)
When temperature difference between top and bottom radiator tanks is measured, it is found to
be excessive
Carry out function test on thermostat (cracking temperature)
1.
When water temperature is measured, it is found to be normal

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Add
20-830 D375A-5
(5)
TROUBLESHOOTING S-15 ABNORMAL NOISE IS MADE
S-15 ABNORMAL NOISE IS MADE
a Judge if the noise is an internal noise or an external noise. Causes

General causes why abnormal noise is made
Air leakage from auxiliary equipment (pump, compressor)

• Abnormality due to defective parts
Broken dynamic valve system (valve, rocker arm, etc.)
Defect inside muffler (dividing board out of position)

• Abnormal combustion noise
• Air sucked in from intake system
Leakage of air between turbocharger and head
Excessive wear of piston ring, cylinder liner
Deformed cooling fan, fan belt interference

Seized turbocharger, internal interference
Defective adjustment of valve clearance
Missing, seized gear bushing

Improper gear train backlash
Seized crankshaft bearing
Defective injector
Gradually occurred
Questions
Condition of abnormal noise

Suddenly occurred
Seal on injection pump has come off
Metal particles are found in oil filter
Leakage of air between turbocharger and head, loose clamp
Vibrating noise is heard from around muffler
Check items
Black
Engine pickup is poor and combustion is abnormal
Abnormal noise is loud when accelerating engine
Troubleshooting
When muffler is removed, abnormal noise disappears

Inspect crankshaft bearing directly
Inspect front gear and rear gear directly
Inspect cooling fan, belt directly
When temperature of exhaust gas of each cylinder is measured, there are some cylinders that are low
Inspect piping of pump auxiliary equipment (pump, compressor, etc.) directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Adjust
D375A-5 20-831
(5)
TROUBLESHOOTING S-16 VIBRATION IS EXCESSIVE
S-16 VIBRATION IS EXCESSIVE
a If there is abnormal noise together with the vibration, carry out Trouble- Causes
shooting S-15 also.
Defective dynamic valve system (valve, rocker arm, etc. stuck)

General causes why vibration is excessive
Internal damage in clutch chamber or damper chamber

• Defective parts (abnormal wear, breakage)
• Improper alignment between engine and chassis
Loose engine mounting bolts, broken cushion

• Abnormal combustion
Worn front support spigot joint portion

Worn main bearing, connecting rod
(troubleshooting for machine)

Improper gear train backlash
Defective vibration damper
Worn cam bushing
Clogged injector
Questions
Suddenly increased
Condition of vibration
Gradually increased
Seal on injection pump has come off
Metal particles are found in oil filter
Metal particles are found when oil is drained
Check items
Oil pressure is low at low idling

Vibration occurs at mid-range speed
Vibration follows engine speed
Exhaust smoke is black

Inspect main bearing, connecting rod directly
Troubleshooting
Inspect cam bushing directly

Inspect front gear train and rear gear train directly
Inspect vibration damper directly
Injection pump test shows that injection amount is incorrect
Inspect front support spigot joint directly
Inspect engine mounting bolts, cushions directly
Inspect clutch chamber or damper chamber directly (troubleshooting for machine)
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Remedy
20-832 D375A-5
(5)
30 DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY
30 DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL ................. 30- 5 REMOVAL AND INSTALLATION OF

Removal and installation of assemblies 30- 5 DAMPER ASSEMBLY ................................. 30- 29
Disassembly and assembly of Special tools .......................................... 30- 29
assemblies ........................................... 30- 6 Removal ................................................ 30- 29
PRECAUTIONS WHEN CARRYING Installation ............................................. 30- 31
OUT OPERATION ...................................... 30- 7 DISASSEMBLY AND ASSEMBLY OF
SPECIAL TOOL LIST ................................. 30- 8-1 DAMPER ..................................................... 30- 33
SKETCHES OF SPECIAL TOOLS ............ 30-8-10 Disassembly of damper assembly ........ 30- 33
REMOVAL AND INSTALLATION OF Disassembly of damper cover assembly 30- 33
FUEL PUMP ASSEMBLY ........................... 30- 9 Assembly of damper assembly ............. 30- 34
Removal ............................................... 30- 9 Assembly of damper cover assembly ... 30- 35
Installation ............................................. 30- 9 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF POWER TRAIN UNIT ASSEMBLY ............. 30- 36
ENGINE FRONT SEAL .............................. 30- 10 Removal ................................................ 30- 36
Special tools ......................................... 30- 10 Installation ............................................. 30- 39
Removal ............................................... 30- 10 DISCONNECTION OF
Installation ............................................. 30- 10 POWER TRAIN UNIT ASSEMBLY ............. 30- 40
REMOVAL AND INSTALLATION OF CONNECTION OF POWER TRAIN UNIT
ENGINE REAR SEAL ................................. 30- 12 ASSEMBLY ................................................. 30- 45
Special tools ......................................... 30- 12 DISASSEMBLY AND ASSEMBLY OF
Removal ............................................... 30- 12 PTO ASSEMBLY ....................................... 30- 47
Installation ............................................ 30- 12 Disassembly .......................................... 30- 47
REMOVAL AND INSTALLATION OF Assembly .............................................. 30- 50
CYLINDER HEAD ASSEMBLY .................. 30- 14 DISASSEMBLY AND ASSEMBLY OF
Special tools ......................................... 30- 14 TORQUE CONVERTER ASSEMBLY ......... 30- 54
Removal ............................................... 30- 14 Special tools .......................................... 30- 54
Installation ............................................ 30- 17 Disassembly .......................................... 30- 54
REMOVAL AND INSTALLATION OF Assembly .............................................. 30- 58
FUEL TANK ASSEMBLY ............................ 30- 19 DISASSEMBLY AND ASSEMBLY OF
Removal ............................................... 30- 19 TORQFLOW TRANSMISSION
Installation ............................................ 30- 19 ASSEMBLY ................................................. 30- 64
REMOVAL AND INSTALLATION OF Special tools .......................................... 30- 64
RADIATOR ASSEMBLY ............................ 30- 20 Disassembly .......................................... 30- 64
Removal ............................................... 30- 20 Assembly .............................................. 30- 79
Installation ............................................ 30- 21 DISASSEMBLY AND ASSEMBLY OF
REMOVAL AND INSTALLATION OF STEERING CASE ASSEMBLY .................. 30- 96
RADIATOR GUARD ASSEMBLY ............... 30- 22 Disassembly .......................................... 30- 96
Special tools ......................................... 30- 22 Assembly .............................................. 30-102
Removal ............................................... 30- 22 REMOVAL AND INSTALLATION OF
Installation ............................................ 30- 24 POWER TRAIN, LUBRICATION
REMOVAL AND INSTALLATION OF PUMP ASSEMBLY ..................................... 30- 113
ENGINE ASSEMBLY .................................. 30- 25 Removal ................................................ 30- 113
Special tools ......................................... 30- 25 Installation ............................................. 30- 113
Removal ............................................... 30- 25
Installation ............................................. 30- 28
D375A-5 30-1
2(7)c
REMOVAL AND INSTALLATION OF DISASSEMBLY AND ASSEMBLY OF

SCAVENGING PUMP ASSEMBLY ............. 30-114 BOGIE ASSEMBLY ..................................... 30-159
Removal ................................................ 30-114 Special tools .......................................... 30-159
Installation ............................................. 30-114 Disassembly .......................................... 30-159
REMOVAL AND INSTALLATION OF Assembly ............................................... 30-160
FINAL DRIVE ASSEMBLY .......................... 30-115 REMOVAL AND INSTALLATION OF
Special tools .......................................... 30-115 1ST BOGIE ASSEMBLY ............................. 30-161
Installation ............................................. 30-115 Removal ................................................ 30-161
DISASSEMBLY AND ASSEMBLY OF Installation ............................................. 30-163
FINAL DRIVE ASSEMBLY .......................... 30-116 Sketch of special tool ............................ 30-166
Special tools .......................................... 30-116 EXPANDING AND ASSEMBLY TRACK
Disassembly .......................................... 30-116 SHOE INSTALLATION ................................. 30-167
Assembly .............................................. 30-122 Check before expanding track
REMOVAL AND INSTALLATION OF shoe assembly ...................................... 30-167
TRACK FRAME ASSEMBLY ...................... 30-131 Expanding track shoe assembly ............ 30-168
Removal ................................................ 30-131 Expanding track shoe assembly ............ 30-168
Installation ............................................. 30-132 Installation of track shoe assembly ........ 30-169
REMOVAL AND INSTALLATION OF WHOLE DISASSEMBLY AND ASSEMBLY
IDLER ASSEMBLY ..................................... 30-133 OF TRACK SHOE ....................................... 30-170
Installation ............................................. 30-133 Whole disassembly ............................... 30-171
DISASSEMBLY AND ASSEMBLY OF Whole assembly .................................... 30-173
IDLER ASSEMBLY .................................... 30-134 1. When recycling for lubricated
Special tools .......................................... 30-134 track ................................................. 30-173
Disassembly .......................................... 30-134 2. When recycling for grease-
Assembly .............................................. 30-135 filled track ........................................ 30-182
Sketch of special tool ............................ 30-138 DIMENSIONS TABLE OF FITTING
REMOVAL AND INSTALLATION OF JIG OF LINK PRESS ................................... 30-187
RECOIL SPRING ASSEMBLY .................... 30-139 DISASSEMBLY AND ASSEMBLY OF
Special tools .......................................... 30-139 1 LINK IN THE FIELD .................................. 30-188
Installation ............................................. 30-142 Disassembly .......................................... 30-188
DISASSEMBLY AND ASSEMBLY OF Assembly ............................................... 30-190
RECOIL SPRING ASSEMBLY ................... 30-143 DISASSEMBLY AND ASSEMBLY OF
Special tools .......................................... 30-143 MASTER LINK ............................................. 30-192
Disassembly .......................................... 30-143 Special tools .......................................... 30-192
Assembly .............................................. 30-144 Disassembly .......................................... 30-193
REMOVAL AND INSTALLATION Assembly ............................................... 30-194
TRACK ROLLER ASSEMBLY ..................... 30-145 REMOVAL AND INSTALLATION OF
Special tools .......................................... 30-145 PIVOT SHAFT ASSEMBLY ......................... 30-197
Installation ............................................. 30-146 Removal ................................................ 30-197
Sketch of special tool ............................ 30-148 Installation ............................................. 30-197
DISASSEMBLY AND ASSEMBLY OF Sketch of special tool ............................ 30-198
TRACK ROLLER ASSEMBLY .................... 30-149 REMOVAL AND INSTALLATION OF
Special tools .......................................... 30-149 EQUALIZER BAR ........................................ 30-199
Disassembly .......................................... 30-149 Special tools .......................................... 30-199
Assembly .............................................. 30-150 Removal ................................................ 30-199
Sketch of special tool ............................ 30-152 Installation ............................................. 30-201
BOGIE ASSEMBLY .................................... 30-153 EQUALIZER BAR BUSHING ...................... 30-202
Special tools .......................................... 30-153 Special tools .......................................... 30-202
Removal ................................................ 30-153 Disassembly .......................................... 30-202
Installation ............................................. 30-155 Assembly ............................................... 30-203
Sketch of special tool ............................ 30-158 Sketch of special tool ............................ 30-204
30-2 D375A-5
" 2 "

SEGMENT TOOTH .................................... 30-205 GIANT RIPPER ASSEMBLY ...................... 30-237
Removal ............................................... 30-205 Disassembly .......................................... 30-237
Installation ............................................ 30-205 Assembly .............................................. 30-238
REMOVAL AND INSTALLATION OF REMOVAL AND INSTALLATION OF
HYDRAULIC TANK ASSEMBLY ................ 30-206 ROPS GUARD ............................................ 30-240
Removal ............................................... 30-206 Removal ................................................ 30-240
Installation ............................................ 30-208 Installation ............................................. 30-240
REMOVAL AND INSTALLATION OF REMOVAL AND INSTALLATION OF
WORK EQUIPMENT AND PPC OPERATOR'S CAB ASSEMBLY ................ 30-241
PUMP ASSEMBLY ..................................... 30-209 Removal ................................................ 30-241
Removal ............................................... 30-209 Installation ............................................. 30-242
Installation ............................................ 30-209 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF FLOOR FRAME .......................................... 30-243
BLADE LIFT VALVE ASSEMBLY ............... 30-210 Special tools .......................................... 30-243
Removal ............................................... 30-210 Removal ................................................ 30-243
Installation ............................................ 30-211 Installation ............................................. 30-246
DISASSEMBLY AND ASSEMBLY OF REMOVAL AND INSTALLATION OF
BLADE LIFT VALVE ASSEMBLY ............... 30-212 DASHBOARD ASSEMBLY ......................... 30-248
Assembly .............................................. 30-212 Special tools .......................................... 30-248
DISASSEMBLY AND ASSEMBLY OF Removal ................................................ 30-248
BLADE TILT AND RIPPER LOW Installation ............................................. 30-249
VALVE ASSEMBLY .................................... 30-214 REMOVAL AND INSTALLATION OF
Assembly .............................................. 30-215 MONITOR PANEL ASSEMBLY ................... 30-250
DISASSEMBLY AND ASSEMBLY OF Removal ................................................ 30-250
RIPPER HIGH VALVE ASSEMBLY ........... 30-216 Installation ............................................. 30-250
Assembly .............................................. 30-217 REMOVAL AND INSTALLATION OF
DISASSEMBLY AND ASSEMBLY OF AIR CONDITIONER UNIT ASSEMBLY ...... 30-251
PPC CHARGE VALVE ASSEMBLY ........... 30-218 Removal ................................................ 30-251
Assembly .............................................. 30-218 Installation ............................................. 30-253
DISASSEMBLY AND ASSEMBLY OF
BLADE PPC VALVE ASSEMBLY ............... 30-219
Assembly .............................................. 30-219
RIPPER PPC VALVE ASSEMBLY ............. 30-221
Assembly .............................................. 30-221
HYDRAULIC CYLINDER ASSEMBLY ....... 30-222
Special tools ......................................... 30-222
Disassembly ......................................... 30-222
Assembly .............................................. 30-225
RIPPER PIN PULLER CYLINDER
ASSEMBLY ................................................ 30-228
Special tools ......................................... 30-228
Disassembly ......................................... 30-228
Assembly .............................................. 30-229
REMOVAL AND INSTALLATION OF
BLADE ASSEMBLY .................................... 30-231
Removal ............................................... 30-231
Installation ............................................ 30-232
BLADE ASSEMBLY .................................... 30-233
Disassembly ......................................... 30-233
Assembly .............................................. 30-235
D375A-5 30-3
2 " "
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
HOW TO READ THIS MANUAL

ASSEMBLIES
Special tools Installation of parts

• Special tools that are deemed necessary for re- • Except where otherwise instructed, install parts
moval or installation of parts are listed. is the reverse order of removal.
• List of the special tools contains the following • Instructions and precautions for installing parts
kind of information. are shown with q 1 mark in the INSTALLATION
1) Necessity Section, identifying which step the instructions
": Special tools which cannot be substitut- are intended for.
ed, should always be used. • Marks shown in the INSTALLATION Section
# Special tools which are very useful if stand for the following.
available, can be substituted with com- ¤ This mark indicates safety-related pre-
mercially available tools. cautions which must be followed when
2) Distinction of new and existing special tools doing the work.
N: Tools with new part numbers, newly ★ This mark gives guidance or precau-
developed for this model. tions when doing the procedure.
R: Tools with upgraded part numbers, re- 2 This mark stands for a specific coating
modeled from already available tools agent to be used.
for other models. 3 This mark indicates the specified
Blanks: Tools already available for other torque.
models, used without any modifica-
tion. 5 This mark indicates an amount of oil or
3) Circle mark (!) in sketch column: water to be added.
A circle mark means that a sketch of the spe-
cial tool is presented in the section of Sketch- Sketches of special tools
es for Special Tools.
• Various special tools are illustrated for the con-
★ Part No. of special tools starting with 79*T
venience of local manufacture.
means that they are locally made parts and as
such not interchangeable with those made by
Komatsu in Japan e.g. 79*T---xxx---xxxx.
Removal of parts
• The REMOVAL Section contains procedures,
precautions and the amount of oil or water to be
drained.
• Various symbols used in the REMOVAL Section
are explained and listed below.
¤ This mark indicates safety-related pre-
cautions which must be followed when
doing the work.
★ This mark gives guidance or precautions
when doing the procedure.
q1 This mark shows that there are instruc-
tions or precautions for installing parts.
6 This mark shows oil or water to be
drained.
4 Mass of a part or component.
D375A-5 30-5
2 !
4 !
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL

ASSEMBLIES
Special tools Assembly

• Special tools which are deemed ncessary for • Section titled ASSEMBLY contain procedures,
disassembly and assembly are listed in this sec- precautions and the know-how for the work, as
tion. well as the amount of oil or water to be added.
• List of the special tools contains the following • Various symbols used in the ASSEMBLY Section
kind of information. are explained and listed below.
1) Neccessity ¤ This mark indicates safety-related pre-
": Special tools which cannot be substitut- cautions which must be followed when
ed, should always be used. doing the work.
# Special tools which are very useful if ★ This mark gives guidance or precau-
available, can be substituted with com- tions when doing the procedure.
mercially available tools. 2 This mark stands for a specific coating
2) Distinction of new and existing special tools agent to be used.
N: Tools with new part numbers, newly 3 This mark indicates the specified
developed for this model. torque.
R: Tools with upgraded part numbers, re-
modeled from already available tools 5 This mark indicates an amount of oil or
for other models. water to be added.
Blanks: Tools already available for other
models, used without any modifica- Sketches of special tools
tion.
• Various special tools are illustrated for the con-
3) Circle mark (!) in sketch column:
venience of local manufacture.
A circle mark means that a sketch of the spe-
cial tool is presented in the section of Sketch-
es for Special Tools.
★ Part No. of special tools starting with 79*T
means that they are locally made parts and as
such not interchangeable with those made by
Komatsu in Japan e.g. 79*T---xxx---xxxx.
Disassembly
• The DISASSEMBLY Section contains proce-
dures, precautions and the amount of oil or water
to be drained.
• Various symbols used in the DISASSEMBLY
Section are explained and listed below.
¤ This mark indicates safety-related pre-
cautions which must be followed when
doing the work.
★ This mark gives guidance or precautions
when doing the procedure.
q1 This mark shows that there are instruc-
tions or precautions for installing parts.
6 This mark shows oil or water to be
drained.
4 Mass of a part or component.
30-6 D375A-5
! 2 !
4
PRECAUTIONS WHEN CARRYING
DISASSEMBLY AND ASSEMBLY OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general pre-
cautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
• If the coolant contains antifreeze dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number of thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering
after removal.
★ Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Nut (elbow end)
number
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
2) Split flange type hoses and tubes
Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions (mm)
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
D375A-5 30-7
2 !
4 !
PRECAUTIONS WHEN CARRYING
DISASSEMBLY AND ASSEMBLY OUT OPERATION
2. Precautions when carrying out installation work

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

• If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the water level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment has been removed, always bleed the air from the system after reassem-
bling the parts. For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
30-8 D375A-5
" 2 "
DISA
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

★ Tools with part number 79!T-!!!-!!!! cannot be supplied (they are items to be locally manufac-
tured).
★ Necessity: ": Cannot be substituted, should always be installed (used).
#: Extremely useful if available, can be substituted with commercially available part.
★ New/remodel: N: Tools with new part numbers, newly developed for this model.
R: Tools with upgraded part numbers, remodeled from items already available for other mod-
els.
Blank: Tools already available for other models, used without any modification.
★ Tools marked ! in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPE-
CIAL TOOLS).
Component Symbol Part No. Part name Nature work remarks
795-902-1410 Sleeve " 1

1
01050-32240 Bolt " 3 Removal, installation of engine front
795-902-1430 Push tool " 1 seal
3
01050-32235 Bolt " 3
795-902-1420 Sleeve " 1
2 795-902-1450 Bolt " 2
Removal, installation of engine rear
A 01582-02016 Nut " 2
seal
Engine assembly 795-902-1440 Push tool " 1
4
01050-32050 Bolt " 4
5 790-331-1110 Wrench " 1 Tightening of cylinder head bolt
791-451-1000 Remover " 1
Removal, installation of radiator
6 790-101-2102 Puller (294 kN {30 ton}) " 1
guard assembly
790-101-1102 Pump " 1
795-799-5410 Adapter " 1 Removal, installation of injector as-
A
795-799-5420 Remover " 1 sembly
Torque converter 790-413-1010 Bracket " 1 Disassembly, assembly of torque

C
assembly 790-501-5000 Repair stand (100 V) " 1 converter assembly
790-415-1011 Bracket " 1 Disassembly, assembly of torquflow

1
750-501-5000 Repair stand (100 V) " 1 transmission assembly
2 791-615-1130 Push tool " 1 Removal, installation of snap ring

791-615-1200 Ring assembly " 1
• 791-615-1210 • Ring 1
3 • 135-A90-1150 • Bolt 1 Installation of No. 3 ring gear
Torquflow transmission • 01580-01008 • Nut 1

D
assembly • 01641-51032 • Washer 2
791-615-1101 Ring assembly " 1
• 791-615-1111 • Ring 1
4 • 135-A90-1150 • Bolt 1 Installation of No. 1 ring gear
• 01580-01008 • Nut 1
• 01641-51032 • Washer 2
5 799-301-1600 Oil leak tester " 1 Operation check of clutch piston
D375A-5 30-8-1
4
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Component Symbol Part No. Part name Nature work remarks
1 791T-650-2330 Sleeve " 1 N !

2 791T-650-2340 Plate " 1 N !
3 790-201-3310 Bolt " 2
4 790-101-2510 Block " 1
Removal, installation of pivot shaft
Pivot shaft assembly P 5 790-101-2570 Washer " 2
assembly
6 01580-01613 Nut " 2
7 01643-31645 Washer " 2
8 790-105-2300 Jack assembly " 1
9 790-101-1102 Pump " 1
791-650-1300 Remover # 1
• 791-735-1123 • Sleeve 1
• 790-434-1050 • Screw 1
Removal, installation of equalizer
Equalizer bar N 1 • 01580-02419 • Nut 1
bar
• 01643-32460 • Washer
790-101-2102 Puller (294 kN {30 ton}) # 1
790-101-1102 Pump # 1
1 791T-650-2410 Bracket " 1 N !
2 791T-650-2420 Bracket " 1 N !
3 790-438-1110 Screw " 1
Disassembly, assembly of equalizer
Equalizer bar bushing N 2 4 791-112-1180 Nut " 2
bar for bushing
5 790-101-2540 Washer " 2
6 790-101-2102 Puller (294 kN {30 ton}) " 1
7 791-101-1102 Pump " 1
Cylinder Disassembly, assembly of hydraulic
1 790-502-1003 # 1
Repair stand cylinder assembly
790-201-1702 Push tool KIT " 1
• 790-201-1841 • Push tool 1
2 • 790-201-1861 • Push tool 1 Press fitting of bushing
• 790-101-5021 • Clip 1
• 01010-50816 • Bolt 1
790-201-1500 Push tool KIT " 1
• 790-201-1650 • Plate 1
3 • 790-201-1670 • Plate 1 Press fitting of seal
• 790-101-5021 • Clip 1
Hydraulic cylinder
U • 01010-50816 • Bolt 1
assembly
4 790-720-1000 Expander " 1
796-720-1680 Ring " 1
07281-01589 Clamp " 1
796-720-1720 Ring " 1 Installation of piston ring
5
07281-02429 Clamp " 1
796-720-1690 Ring " 1
07281-02169 Clamp " 1
790-102-2302 Wrench
or " 1
6 790-330-1100 Multi wrench Tightening of cylinder head
790-101-1102 Pump " 1
30-8-8 D375A-5
4
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

Note: komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
L1 Plate
L8 Plate
30-8-10 D375A-5
(7)
4
L10 Push tool
L13 Plate
D375A-5 30-8-11
(7)
4
L17 Guide
L21 Sling tool
30-8-12 D375A-5
(7)
4
L21 Tube
L21 Plate
D375A-5 30-8-13
(7)
4
P1 Sleeve
P2 Plate
30-8-14 D375A-5
(7)
4
N2-1 Bracket
N2-2 Bracket
D375A-5 30-8-15
(7)
4
DISASSEMBLY AND ASSEMBLY FUEL PUMP ASSEMBLY
REMOVAL AND
INSTALLATION OF
FUEL PUMP ASSEMBLY
REMOVAL INSTALLATION
1. Close fuel supply valve. • Carry out installation in the reverse order to re-
moval.
2. Remove engine left side covers (1) and (2).
★ Bleed air from fuel circuit.
1) Remove air bleed valve (1).
2) Fill with clean fuel through hole in valve until
it overflows.
★ Amount of fuel: Approx. 300 cc (refer-
ence)
3) Install air bleed valve (1).
3 Air bleed valve:
12.7 Nm {1.3 kgm}
4) Crank engine with starting motor.
3. Disconnect fuel tubes (3) and (4).

4. Remove fuel hose (5).
5. Disconnect wiring connector (6).
6. Remove clamps (7) and (8).
7. Loosen fuel pump mounting bolt (9) and remove
fuel pump assembly (10).
D375A-5 30-9
2 " "
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY OF ENGINE FRONT SEAL
REMOVAL AND
INSTALLATION
OF ENGINE FRONT SEAL
SPECIAL TOOLS INSTALLATION
Sym- Ne- Q'ty New/Re- Sketch • Carry out installation in the reverse order to re-
Part No. Part name
bol cessity model moval.
795-902-1410 Sleeve 1 q1
1
01050-32240 Bolt 3 a Align the crankshaft pulley with the dowel pin
A
795-902-1430 Push tool 1 when installing.
3
01050-32235 Bolt 3 a Tighten the mounting bolts in the order
3 Crankshaft pulley mounting bolt:

shown in the diagram below.
REMOVAL 1st step:

1. Remove radiator guard assembly. For details, 73.5 ± 19.6Nm {7.5 ± 2kgm}
see REMOVAL OF RADIATOR GUARD AS- 2nd step:
SEMBLY. 245 ± 19.6Nm {25 ± 2kgm}
q1
3rd step:
2. Remove crankshaft pulley (1). 637 ± 19.6Nm {65 ± 2kgm}
q2
q2
3. Remove front seal (2).
• Procedure for assembling standard seal
a Fill the lip portion with approx. 5 cc of lithium
grease (G2-LI).
a Using tool A3, press fit front seal (2) to front
cover (3).
a After press fitting, check installation dimen-
sion a.
Front seal installation dimension a:
66 mm (standard)
30-10 D375A-5
(7)
2 c
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY OF ENGINE FRONT SEAL
• Procedure of assembling front seal with sleeve

(for repair)
1) Using tool A1, guide bolt 1 , and nut 2 ,
press fit sleeve (4) to crankshaft (5).
★ Tighten 3 nuts 2 uniformly.
★ Press fit until tool A1 contacts the end
face of the crankshaft.
★ After press fitting, check that sleeve in-
stallation dimension b is the specified di-
mension.
Sleeve installation dimension b:
68 ± 0.1mm
2) Using tool A3, press fit front seal (6) to front

cover (3).
a Fill the lip portion with approx. 5 cc lithi-
um grease (G2-LI).
a After press fitting, check installation di-
mension c.
Front seal installation dimension c:
66 mm (standard)
D375A-5 30-11
(7) c
2
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
REMOVAL AND
INSTALLATION OF
ENGINE REAR SEAL
SPECIAL TOOLS 5. Remove rear seal (2).
Sym- Part No. Part name Ne- Q'ty New/Re- Sketch
bol cessity model
795-902-1420 Sleeve 1
2 795-902-1450 Bolt 2
A 01582-02016 Nut 2
795-902-1440 Push tool 1
4
01050-32050 Bolt 4
REMOVAL
1. Remove damper assembly. For details, see RE-
MOVAL OF DAMPER ASSEMBLY.
2. Remove 1 mounting bolt of flywheel (1) and in-
stall guide bolt 1 . INSTALLATION
3. Using eyebolts 2 , sling flywheel (1), then re- q1
move remaining mounting bolts. q1 ★ Coat the thread and seat of the flywheel
mounting bolts with anti-friction compound
4. Move flywheel towards you, then lift off.
(LM-P).
¤ The spigot portion of the flywheel is shallow
★ Secure the flywheel and the housing with
and it may suddenly fall, so be careful not to
q2
stopper 3 , then tighten the mounting bolts.
get your fingers caught.
4 Flywheel: 45kg
30-12 D375A-5
c 2 c
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
a Tighten the flywheel mounting bolts in the order q2
3 Flywheel mounting bolt:

shown in the diagram below. • Procedure for assembling standard seal.
a Using tool A4, press fit the rear seal (2) until
1st step: 98 ± 19.6Nm {10 ± 2kgm} it contacts the flywheel housing.
2nd step: 294 ± 19.6Nm {30 ± 2kgm}
3rd step: 539 ± 19.6Nm {55 ± 2kgm} • Assembly procedure for seal with sleeve (for
maintenance)
1) Using tool A2, guide bolt 5 , and nut 6 ,
press fit sleeve (3) to crankshaft (4).
a Tighten 2 nuts 6 uniformly.
a Press fit until tool A2 contacts the crank.
a After press fitting, check that mounting
dimension a of sleeve is the specified di-
mension.
Sleeve mounting dimension a:27 ± 1mm
a After installing the flywheel, use dial gauge 4 to

measure the radial and face runout of the fly-
wheel.
• Face runout: Max. 0.15 mm
• Radial runout: Max. 0.20 mm
2) Using tool A4, press fit rear seal (5) until it

contacts flywheel housing (6).
D375A-5 30-13
(7) c
2
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
REMOVAL AND
INSTALLATION OF
CYLINDER HEAD ASSEMBLY
SPECIAL TOOLS 5. Disconnect water tube (3).
Sym- Ne- Q'ty New/Re- Sketch 6. Remove wiring (4) and wiring clamp.
Part No. Part name
bol cessity model
795-799-5410 Adapter " 1
A
795-799-5420 Remover " 1
A5 790-331-1110 Wrench " 1
REMOVAL
¤ Disconnect the cable from the negative (–) termi-
nal of the battery.
1. Drain coolant.
2. Remove hood assembly. For details, see RE-
MOVAL OF HOOD ASSEMBLY.
3. Remove engine right side cover (1). 7. Remove air cleaner dust discharge tube, hose,
and clamp (5).
8. Remove dust indicator hose (6).
9. Remove suction tube (7).
10. Remove left and right air cleaner assembly
mounting bolts (8).
11. Remove hose (9) and tube (10) between turbo-
charger and aftercooler.
12. Lift off air cleaner assembly (11).
4 Air cleaner assembly: 45 kg
4. Remove engine left side cover (2).
30-14 D375A-5
! 2 !
4
13. Remove alternator (12). 21. Remove adiabatic cover (24).

14. Remove U-bolt, and disconnect bracket (13) and
water tube (14).
15. Remove tube (15).
22. Lift off muffler assembly (25).
16. Remove fuel tube (16), fuel hose (17), and fuel
filter assembly (18).
17. Disconnect corrosion hose (19), and remove
corrosion resistor assembly (20).
18. Disconnect electrical intake air heater wiring
(21).
19. Disconnect fuel tube (22). q1
20. Lift off aftercooler assembly (23). q2
23. Disconnect turbocharger inlet lubrication tube

(26) and outlet tube (27), then disconnect ex-
haust temperature wiring.
D375A-5 30-15
2 !
4 !
24. Sling turbocharger assembly and exhaust mani- 29. Remove crosshead (34) and push rod (35).
fold (28) as one unit, then loosen mounting bolts q6
and remove. q3
30. Using tool A, remove injector assembly (36).
4 Turbocharger, q7
exhaust manifold assembly: 60kg
31. Remove mounting bolts, then remove rocker arm

25. Remove air cleaner bracket and wiring clamp. housing (37). q8
26. Remove spill hose (30).

27. Remove cylinder head cover (32). q4
32. Loosen cylinder head mounting bolts (38), then

using eyebolts, remove cylinder head assembly
(39). q9
28. Remove rocker arm assembly (33). q5 4 Cylinder head assembly: 60kg
★ Loosen the locknut, then loosen the adjust-
ment screws 2 or 3 turns.
30-16 D375A-5
! 2 !
4
INSTALLATION q4
• Carry out installation in the reverse order to re- 3 Cylinder head cover mounting bolt:
moval. 31.85 ± 2.45Nm {3.25 ± 0.25kgm}
q1 q5
3 Delivery tube sleeve nut: ★ Clean the hole of the mounting bolts and install.
92.5 ± 2.5Nm {9.45 ± 0.25kgm} ★ Check that the ball portion of the adjustment
screw is fitted securely in the socket portion of
q2 the push rod.
★ Tighten the aftercooler mounting bolts in the or- 3 Rocker arm mounting bolt:
der shown in the diagram below. 98 ± 4.9Nm {10 ± 0.5kgm}
3 Mounting bolt: 3 Locknut: 67.62 ± 9.8Nm {6.9 ± 1kgm}
66.15 ± 7.35Nm {6.75 ± 0.75kgm}
q6
★ Adjust the crosshead as follows.
1) Loosen the locknut, then turn back the ad-
justment screw.
2) Hold down the top surface of the crosshead
lightly, and screw in the adjustment screw.
3) After the adjustment screw contacts the
valve stem, screw it in a further 20°.
4) Tighten the locknut to hold the adjustment
screw in position.
3 Locknut: 58.8 ± 5.88Nm {6 ± 0.6kgm}
q7
q3 3 Injector mounting bolt:
★ Tighten the turbocharger and exhaust manifold 1st step : 29.4 ± 4.9Nm {3 ± 0.5kgm}
mounting bolts in the order shown in the diagram 2nd step : Tighten 90 - 120°
below.
3 Turbocharger, exhaust manifold assem- q8
bly mounting bolt: 3 Rocker arm housing mounting bolt:
110.35 ± 12.25Nm {11.25 ± 1.25kgm} 98 ± 4.9Nm {10 ± 0.5kgm}
D375A-5 30-17
2 !
4 !
q9 ★ After tightening, make one punch mark a on the

★ Check that there is no dirt or dust on the cylinder main bolt head (if the bolt is new, do not make
head mounting surface or inside the cylinder. any punch mark).
★ Check that the grommet does not come out
when installing the gasket.
★ Tighten the cylinder head mounting bolts in the
order shown in the diagram.
2 Mounting bolt:
Anti-friction compound (LM-P)
3 Cylinder head mounting bolts (1 - 7 ):
1st step:
245 ± 9.8Nm {25 ± 1kgm}
2nd step:
382.5 ± 9.8Nm {39 ± 1kgm}
3rd step:
Make marks with paint on bolt
and head, then tighten a fur- • Refilling with water
ther 90 - 120°° . Add water through water filler to the specified
(The mounting bolts may be level. Run the engine to circulate the water
tightened to the above angle through the system. Then check the water level
with tool A5.) again.
3 Mounting bolts (8 - 9 )
98.1 ± 4.9Nm {10 ± 0.5kgm}
30-18 D375A-5
! 2 !
4
DISASSEMBLY AND ASSEMBLY FUEL TANK ASSEMBLY
REMOVAL AND
INSTALLATION OF
FUEL TANK ASSEMBLY
REMOVAL 5. Disconnect fuel return hose (7) and hose clamp
¤ Disconnect the cable from the negative (–) termi- (8).
nal of the battery.
1. Remove covers (1) and (2).
6. Lift off fuel tank assembly (9).

4 Fuel tank assembly:
2. Disconnect wiring connector (CN-422) (3). Approx. 500 kg (when empty)

Approx. 1350 kg (when full)
3. Close fuel supply valve and disconnect fuel sup-
ply hose (4).
4. Disconnect brackets (5) and (6).
INSTALLATION
• Carry out installation in the reverse order to re-
moval.
3 Fuel tank mounting bolt:
927 ± 98Nm {94.5 ± 10kgm}
D375A-5 30-19
2 " "
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY
REMOVAL AND
INSTALLATION OF
RADIATOR ASSEMBLY
REMOVAL 8. Disconnect sub tank hose (7).
¤ Disconnect the cable from the negative (–) termi- 9. Disconnect radiator water level sensor connector
nal of the battery. (CN-405) (8).
1. Drain coolant. 10. Remove windbreaker plate (9).
2. Remove inspection cover (17). 11. Using eyebolts, sling radiator assembly, then re-
move 2 each of left and right top mount bolts
3. Disconnect front lamp connector (CN-202) (1).
(10).
4. Using eyebolts, lift off radiator top cover (2).
4 Radiator top cover: 76kg
12. Remove 2 covers (11).

13. Open guard (12).
5. Disconnect radiator inlet hose (3) and aeration
hose (4).
6. Remove ground wiring (CN-GND4) (5).
7. Disconnect wiring clamps (6) (4 places), and
move wiring towards left side of radiator.
30-20 D375A-5
" 2 "
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY
14. Remove windbreaker plate (13). INSTALLATION

moval.
3 Radiator inlet hose clamp:
882 ± 98Ncm {90 ± 10kgcm}
3 Aeration hose clamp:
333.2 ± 49Ncm {34 ± 5kgcm}
Refilling with water

Add water through water filler to the specified level.
Run the engine to circulate the water through the
system. Then check the water level again.
15. Disconnect radiator outlet tube (14).

16. Remove bottom mount bolt (15).
17. Lift off radiator assembly (16).

4 Radiator assembly: 390kg
D375A-5 30-21
2 " "
REMOVAL AND INSTALLATION OF RADIATOR
DISASSEMBLY AND ASSEMBLY GUARD ASSEMBLY
REMOVAL AND
INSTALLATION OF RADIATOR
GUARD ASSEMBLY
SPECIAL TOOLS 2. Disconnect hose (2).
Sym- Ne- Q'ty New/Re- Sketch
¤ Release the remaining pressure in the hy-
Part No. Part name draulic circuit. For details, see TESTING
bol cessity model
791-451-1000 Remover # 1 AND ADJUSTING, Releasing remaining
Puller pressure in hydraulic circuit.
A 6 790-101-2102 # 1
(294kN {30ton}) ★ Fit a blind plug to prevent any dirt or dust
790-101-1102 Pump # 1 from entering.
REMOVAL
1. Remove cap (1) of blade lift cylinder.
★ Check the number and thickness of the
shims, and keep in a safe place.
¤ Start the engine, and retract the piston rod,
then tie the piston rod with wire to prevent it
from coming out.
3. Sling blade lift cylinder assembly (3), then fit cyl-

inder holder and secure to radiator guard.
4. Drain coolant.
30-22 D375A-5
" 2 "
6. Disconnect radiator inlet hose (4). 10. Open engine underguard.

★ Disconnect at the radiator end and move it 11. Remove right undercover of radiator guard, then
towards the engine. remove radiator outlet tube (11).
7. Disconnect aeration hose (5) and hose (6) from ★ Loosen the clamp at the hose portion, then
reserve tank. remove the tube.
★ Disconnect at the radiator end, then remove
2 clamps and move towards the engine.
12. Disconnect wiring connector (12) (CN-21), and

remove cover (13).
8. Disconnect PPC oil cooler piping (7) and (8).
13. Disconnect blade piping (14) and (15).
9. Disconnect fuel cooler piping (9) and (10).
D375A-5 30-23
2 " "
14. Loosen tension of tension pulley (16) and re- 17. Lift off radiator guard assembly (20).
move fan belt (17). ¤ Be careful not to damage the wiring and pip-
ing when removing.
4 Radiator guard assembly: 2,700kg
15. Sling radiator and guard assembly, remove lock

bolt, then using tool A6, push rear pin (18) to in-
side radiator guard, and remove.
INSTALLATION
16. Remove lock plate, and using tool A6, pull front
pin (19) to outside of radiator guard, and remove. • Carry out installation in the reverse order to re-
moval.
★ Standard shim thickness: 4mm

882 ± 98Ncm {90 ± 10kgcm}
333.2 ± 49Ncm {34 ± 5kgcm}
3Radiator outlet hose clamp:
882 ± 98Ncm {90 ± 10kgcm}

30-24 D375A-5
" 2 "
DISASSEMBLY AND ASSEMBLY ENGINE ASSEMBLY
REMOVAL AND
INSTALLATION OF
ENGINE ASSEMBLY
SPECIAL TOOLS 5. Remove air cleaner dust discharge tube hose
clamp (3).
Sym- Part No. Part name Ne- Q'ty New/Re- Sketch
bol cessity model 6. Remove air cleaner band (4).
799-703-1200 Service tool kit 1
7. Remove air supply tube clamp (5), then remove
799-703-1100 Vacuum pump 1
air supply tube (6).
799-703-1110 Vacuum pump 1
X
799-703-1120 Vacuum pump 1 8. Disconnect dust indicator hose (7).
Gas leak 9. Lift off air cleaner assembly (8).
4 Air cleaner assembly: 22kg
799-703-1401 1
detecter
REMOVAL
nal of the battery.1.
1. Drain coolant.
2. Remove engine hood assembly.
3. Remove engine right side cover (1).
10. Disconnect ground connection wiring (9).

11. Disconnect starting motor wiring (10).
12. Close heater valve (11), and move engine to
rear.
4. Remove engine left side cover (2).
D375A-5 30-25
(7) c
2
13. Remove torque converter oil cooler connector 16. Disconnect fuel supply hose (18).
(12). 17. Disconnect fuel return hose (19) and remove
14. Disconnect radiator outlet tube (13). hose clamp.
15. Disconnect air conditioner hoses (16) and (17). 18. Disconnect wiring connectors (CN-101) (20),
a Collect air conditioner gas (R134a) completely (CU-EG1) (21), and (CU-EG2) (22).
before disconnecting the hoses.
a Fit blind plugs to prevent dirt, dust, or mois-
ture from getting inside the hoses.
a Disconnect all clamps of hoses (16) and
(17).
19. Disconnect radiator inlet hose (23).

Disconnect aeration hose (24).
30-26 D375A-5
(7)
2 c
20. Remove fan net (22). 26. Lift off bracket assembly (32).
21. Loosen tension of tension pulley (23) and re- 4 Bracket assembly: 170kg
move fan belt (24).
27. Remove damper case oil level gauge (33).

22. Remove right covers (25) and (26).
28. Remove bracket (34).
23. Remove left covers (27) and (28).
29. Sling universal joint (35), remove mounting bolts,

then lift off.
25. Disconnect wiring connectors (CN206) (30) and
(CN-201) (31).
D375A-5 30-27
2 " "
30. Remove front mount bolt (36) and rear mount INSTALLATION
bolt (37). ★ Be careful to prevent the entry of moisture, dust
31. Raise engine assembly (38), and remove right or dirt into the air conditioner circuit hoses when
rear mount cap (39). installing.
4 Engine assembly: 3,200kg ★ Check that there are O-rings at the portion of the
air conditioner hoses connecting to the piping,
then tighten. Coat the O-rings thoroughly with
compressor oil (Showa-Shell Suniso 4G or 5G).
32. Move engine assembly (38) to above chassis

and operate chain block to raise front of engine
3 Air conditioner gas piping tightening

assembly and set assembly at an angle.
33. Pass chassis parts through front and rear of en- torque
gine assembly (38), then rotate engine assembly
(38) 90° to right of chassis and remove. Thread size Tightening torque
★ When removing, be careful not to damage
the wiring and hoses. 16 × 1.5 13.23 ± 1.47Nm {1.35 ± 0.15kgm}
22 × 1.5 22.05 ± 2.45Nm {2.25 ± 0.25kgm}
24 × 1.5 31.85 ± 2.45Nm {3.25 ± 0.25kgm}
M6 bolt
5.39 ± 1.47Nm {0.55 ± 0.15kgm}
(receiver portion)
M6 bolt
9.8 ± 1.96Nm {1.0 ± 0.2kgm}
(compressor portion)

882 ± 98Ncm {90 ± 10kgcm}
333.2 ± 49Ncm {34 ± 5kgcm}
3 Universal joint mounting bolt:
176.4 ± 19.6Nm {18 ± 2kgm}
3 Engine mount bolt:
926.1 ± 102.9Nm {94.5 ± 1kgm}

Charging air conditioner with gas

Using tool X, charge the air conditioner circuit with
air conditioner gas (R134a).
30-28 D375A-5
" 2 "
DISASSEMBLY AND ASSEMBLY DAMPER ASSEMBLY
REMOVAL AND
INSTALLATION OF
DAMPER ASSEMBLY
SPECIAL TOOLS 5. Remove right covers (5) and (6).
Sym- Ne- Q'ty New/Re- Sketch 6. Remove left covers (7) and (8).
Part No. Part name
bol cessity model
799-7.3-1200 Service tool kit 1
799-703-1100 Vacuum pump 1
799-703-1110 Vacuum pump 1
X
799-703-1120 Vacuum pump 1
Gas leak de-
799-703-1401 1
tector
REMOVAL
nal of the battery.
2. Disconnect ground connection wiring (1). 8. Disconnect wiring connector (CN-206) (10).
3. Disconnect starting motor wiring (2).
4. Close heater valve, then remove heater hose
clamp, and disconnect heater hoses (3) and (4).
q1
D375A-5 30-29
(7) c
2
9. Disconnect air conditioner hoses (11) and (12). 13. Open power train underguard (front).
a Collect air conditioner gas (R134a) completely 14. Sling universal joint (27), then remove mounting
q2
before disconnecting the hoses. bolts, and lift off.D
4 Universal joint: 45kg
a Fit blind plugs to prevent dirt, dust, or mois-
ture from getting inside the hoses.
10. Lift off bracket (13).
4 Bracket assembly: 170kg
15. Remove drain plug and drain oil from damper

case.
6 Damper case: Approx. 2.1¬
11. Remove damper case oil level gauge (25).
16. Remove holder (28) and coupling (29). q3
17. Remove retainer (30).
30-30 D375A-5
(7)
2 c
18. Using eyebolts 1 , sling damper cover (31), then INSTALLATION

use forcing screws to remove. q4
¤ To prevent the damper cover from coming moval.
out suddenly, set guide bolt 2 (¬=200mm). q1
4 Damper cover: 75kg ★ Install the hoses without twisting or interfer-
ence.
19. Using eyebolts 3 , remove damper assembly
q5
★ Be careful to prevent the entry of moisture,
(32). dust or dirt into the air conditioner circuit hos-
¤ To prevent the damper assembly from comes when installing.
i n g o u t s u d d e n l y, s e t g u i d e b o l t 4 ★ Check that there are O-rings at the portion of
(¬=200mm). the air conditioner hoses connecting to the
4 Damper assembly: 70kg piping, then tighten.
Coat the O-rings thoroughly with compres-
sor oil (Showa-Shell Suniso 4G or 5G).
20. Remove bearing (33) from flywheel.

q6
3 Air conditioner gas piping tightening
torque
Thread size Tightening torque
16 × 1.5 13.23 ± 1.47Nm {1.35 ± 0.15kgm}
22 × 1.5 22.05 ± 2.45Nm {2.25 ± 0.25kgm}
24 × 1.5 31.85 ± 2.45Nm {3.25 ± 0.25kgm}
q2
176.4 ± 19.6Nm {18 ± 2kgm}
q3
2 Holder mounting bolt thread portion:
Thread tightener (LT-2)
276.85 ± 31.85Nm {28.25 ± 3.25kgm}
D375A-5 30-31
2 " "
q4
★ Using guide bolt 2 (¬=200 mm), dtermine
the position of the damper cover.
q5
★ Using guide bolt 4 (¬=200 mm), dtermine
the position of the damper assembly.
q6
★ Fill approx.50% (approx. 11 g) of the hatched
portion a in the diagram with grease (G2-LI).
• Refilling with oil

★ Fill with oil to the specified level.
• Charging air conditioner with gas

★ Using tool X, charge the air conditioner cir-
cuit with air conditioner gas (R134a).
30-32 D375A-5
" 2 "
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF DAMPER
DISASSEMBLY AND
ASSEMBLY OF DAMPER
DISASSEMBLY OF DAMPER ASSEMBLY 6. Remove seal (7) from flanges (2) and (5).
1. Set damper assembly to block 1 .
2. Remove mounting nut (1), then using forcing
screws 2 , remove flange (2).
DISASSEMBLY OF DAMPER COVER

ASSEMBLY
7. Remove bearing (8) and oil seal (9) from cover
3. Remove shaft (3). (10).
4. Remove rubber (4). 8. Remove oil seal (11) from retainer (12).
5. Using forcing screws 2 , remove flange (5) from

body (6).
D375A-5 30-33
2 " "
ASSEMBLY OF DAMPER ASSEMBLY 3. Set flange and body assembly to block, then set
1. Install seals (7) to flanges (2) and (5). shaft (3) in position.
★ Install the seal with the lip facing the inside 4. Assemble rubber (4).
as shown in the diagram. ★ When assembling the rubber, coat the whole
surface of the rubber, the outside circumfer-
ence of the shaft, and the inside circumfer-
ence of the body with grease (G2-LI).
★ After assembling to the rubber, fill approx.
30% of the clearance (16 places) between
the flange and body with grease (G2-LI).
2. Align bolt holes with body (6) and install flange

(5).
2 Mating surface of flange:
Gasket sealant (LG-4)
★ Check that there are no dents, rust, oil or
grease, or water on the mating surface, then 5. Install flange (2).
2 Mating surface of flange:
coat both faces of the flange and body with
gasket sealant.
★ Check that there are no dents, rust, oil or
grease, or water on the mating surface, then
coat both faces of the flange and body with
gasket sealant.
6. Set bolt in position, and tighten mounting nut (1).
30-34 D375A-5
" 2 "
ASSEMBLY OF DAMPER COVER ASSEM- 9. Using push tool 5 , press fit oil seal (9) to cover
BLY (10).
7. Using push tool 3 , press fit oil seal (11) to re- 2 Oil seal press-fitting surface:
tainer (12). Gasket sealant (LG-1)
2 Oil seal press-fitting surface: ★ Coat the inside surface of the retainer thinly
Gasket sealant (LG-1) with gasket sealant and wipe off any sealant
that is squeezed out.
2 Lip of oil seal: Grease (G2-LI)
★ Coat the inside surface of the retainer thinly
with gasket sealant and wipe off any sealant
that is squeezed out.
8. Using push tool 4 , press fit bearing (8) to cover

(10).
D375A-5 30-35
2 " "
REMOVAL AND INSTALLATION OF POWER
DISASSEMBLY AND ASSEMBLY TRAIN UNIT ASSEMBLY
REMOVAL AND
INSTALLATION OF POWER
TRAIN UNIT ASSEMBLY
REMOVAL 9. Disconnect wiring connectors (CN-PL1) (7),
1. Drain oil from hydraulic tank and power train (CN-PL2) (8), and (CN-PL3)(9).
case. 10. Loosen locknut and remove from bracket.
6 ¬
Hydraulic tank: Approx. 120¬
6 ¬
Power train case: 150¬
2. Remove floor frame assembly. For details, see
REMOVAL OF FLOOR FRAME ASSEMBLY.
3. Remove fuel tank. For details, see REMOVAL
OF FUEL TANK ASSEMBLY.
4. Remove 2 clamps (1) of hydraulic and PPC
pump inlet tube coupling.
★ Move the coupling towards the power train
unit and disconnect the tube.
5. Disconnect PPC drain hose (2).
11. Disconnect torque converter oil cooler hose (10).
★ Disconnect at the pump inlet tube end, and
move it to the right side of the chassis.
6. Disconnect 2 PPC oil cooler hoses (3), then dis-
connect clamps (2 places).
★ Move the 2 hoses together to the outside of
the oil level gauge, then move them to the
right side of the chassis.
7. Disconnect hydraulic and PPC pump outlet hose
(4).
★ Disconnect at the pump end.
8. Disconnect wiring connectors (CN-241) (5) and
(CN-404) (6), then disconnect clamps (2 places).
12. Disconnect right rear lamp connector (CN-243)

(11), then disconnect clamps at top of frame (3
places) and at bottom of frame (1 place).
13. Remove frame (12).
30-36 D375A-5
" 2 "
14. Disconnect torque converter oil cooler hose (13), 18. Disconnect universal joint (18) at torque convert-
then disconnect bracket at frame end. er end.
★ Move the hose towards the front of the chas- ★ After disconnecting, move it towards the
sis. damper end.
15. Disconnect ripper low valve hose (14), then dis-
connect bracket (1 place) on top of steering
case.
★ Move the hose towards the power train unit
end.
16. Disconnect 2 pin puller solenoid hoses (15), then
disconnect clamp.
★ Disconnect the hose at the steering case
end, and move it towards the ripper end.
19. Remove cover (19), then using eyebolts, pull out

left and right drive shaft (30).
★ If the shaft does not come out, push up the
shoe grouser from the ground surface with a
jack and move the sprocket backwards or
forwards to adjust to a position where the
shaft can be removed, then pull the shaft out.
★ Pull the shaft out to a point where it contacts
the sprocket.
17. Disconnect clamps (16) and (17) and remove

bracket.
★ Move the hose towards the right side of the
chassis.
D375A-5 30-37
2 " "
20. Remove right floor frame rear mount (21). 22. Remove left and right rear mount caps (24).
★ Remove at this point because the right floor
frame rear mount will interfere when the
power train unit is raised.
23. Loosen left and right rear coupling clamps (25).

★ Move the clamps towards the main frame,
open the joint of the coupling, then move the
21. Remove left floor frame mount (22) and right seal towards the main frame.
floor frame mount (23).
★ The front mount of the power train unit is
tightened together with the front mount of the
floor frame.
4 Left floor frame mount: 38kg
Right floor frame mount: 37kg
30-38 D375A-5
" 2 "
24. Lift off power train unit assembly (26). • Refilling with oil (power train case, hydraulic
★ Check that all the wiring and piping has been tank)
disconnected before removing the power ★ Add oil through oil filler to the specified level.
train unit assembly. Run the engine to circulate the oil through
4 Power train unit assembly: 4,200kg the system. Then check the oil level again.
5 ¬
Power train case: Approx.150¬
¬
Hydraulic tank: Approx.120¬
INSTALLATION
moval.

176.4 ± 19.6Nm {18 ± 2kgm}
★ If the shaft does not go in, push up the shoe

grouser from the ground surface with a jack
and move the sprocket backwards or for-
wards to adjust to a position where the shaft
meshes, then assemble the shaft.
3 Rear mount cap mounting bolt:

367.5 ± 61.25Nm {43.75 ± 6.25kgm}
3 Rear coupling clamp mounting bolt:
6.85 ± 1.96Nm {0.7 ± 0.2kgm}
★ When installing the power train unit assem-

bly, pay attention to the mating surface of the
coupling and be careful not to damage the
coupling seal at the rear mount.
D375A-5 30-39
2 " "
DISCONNECTION OF POWER
TRAIN UNIT ASSEMBLY
1. Draining oil 6. Disconnect 14 pressure detection hoses (5) and
Before setting power train unit assembly in posi- remove central pressure detection bracket (6) as
tion, drain oil from oil pan. one unit.
2. Raise power train unit assembly (1) and set to ★ Before removing, mark all the hoses with
block 1 . tags to prevent mistakes in the mounting po-
★ Set blocks under the front of the oil pan, un- sition when installing.
der the transmission rear case, and under
the steering case.
7. Remove oil level gauge (7).

8. Remove oil filler pipe (8).
3. Remove brake rod (2).
4. Remove parking brake cable (3).
★ Measure the dimension of the mounting
bracket portion.
5. Remove control cable and bracket assembly (4).
★ Disconnect the directional control cable and
speed control cable together with the lever at
the control valve end.
30-40 D375A-5
" 2 "
9. Lift off filter assembly (9) together with bracket. 12. Lift off scavenging pump assembly (12).
4 Filter assembly: 120kg 4 Scavenging pump assembly: 41kg
10. Lift off strainer assembly (10) together with suc-

tion tube.
4 Strainer assembly:50kg
13. Lift off front mount (13).

4 Front mount: 150kg
11. Lift off power train and lubrication pump assem-

bly (11).
4 Power train, lubrication pump assembly:
50kg
14. Remove outlet hose of hydraulic and PPC pump.

15. Lift off hydraulic and PPC pump assembly (14)
together with inlet tube.
4 Work equipment, PPC pump assembly:
65kg
D375A-5 30-41
2 " "
16. Disconnect hydraulic hoses (35) and (36) of ser- 20. Remove block from under oil pan, and sling oil
vo valve (34). pan (17).
17. Disconnect bolts (37) and (38). 21. Remove mounting bolts, then remove oil pan
(17).
18. Remove 3 bolts (39), then remove servo valve
★ In addition to the mounting bolts at the front,
(34).
rear, left, and right, there are also bolts in-
stalled inside the holes at 4 places under the
oil pan.
4 Oil pan: 110kg
19. Disconnect steering control rod (15) at control

valve end, and remove together with lever as-
sembly (16).
22. Remove bearing cage (18) together with torque

converter speed sensor.
23. Remove case (19).
30-42 D375A-5
" 2 "
24. Remove shaft (20). 28. Set PTO, torque converter, and transmission as-
sembly (22) with PTO side at top, then set on
block 3 .
25. Set block 2 under PTO.

26. Sling steering case assembly (21), and remove
block from under steering case. 29. Remove coupling (23).
30. Remove retainer (24).
27. Remove mounting bolts, then remove steering

case assembly (21).
4 Steering case assembly: 1,750kg
31. Remove snap ring (25), then remove spacer
(26).
D375A-5 30-43
2 " "
32. Using eyebolts, lift off PTO assembly (27).

4 PTO assembly: 290kg
33. Lift off torque converter assembly (28).

4 Torque converter assembly: 550kg
30-44 D375A-5
" 2 "
DISASSEMBLY AND ASSEMBLY CONNECTION OF POWER TRAIN UNIT ASSEMBLY
CONNECTION OF POWER
TRAIN UNIT ASSEMBLY
• Carry out connection in the reverse order to dis- ★ Check that the tip of shaft (20) is fitted securely
connection. in drum (31) of bearing cage (18).
★ Bend the cotter pin securely.

★ Set the installation dimension of the bracket to
the dimension measured when removing.
★ Adjust the limit switch and the lever of the direc-
tional control linkage as follows.
1) Set lever (29) to N position and insert.
2) Set up and down lever (29) at a height where
roller of up and down limit switch (30) con-
tacts groove in lever (29), then tighten tem-
porarily.
3) Move lever (29) to F and R positions and
check that roller is pushed in securely [F: top
limit switch], [R: bottom limit switch], then ★ Check that shaft (20) is fitted securely in boss
tighten lever (29) fully. (32) at the tip of the transmission input shaft.
★ Bend the cotter pin securely.
D375A-5 30-45
2 " "
DISASSEMBLY AND ASSEMBLY CONNECTION OF POWER TRAIN UNIT ASSEMBLY
3 Steering case mounting bolt: 3) Select shim thickness.

276.85 ± 31.85Nm {28.25 ± 3.25kgm} Shim thickness = a + 0 - 0.05 mm
Types of shim thickness = 0.15 mm, 0.2 mm,
★ Adjust the retainer shim as follows. 0.5 mm
1) Without fitting shim, install retainer (24) and 4) Assemble selected shim thickness and tight-
tighten 6 mounting bolts to following torque. en mounting bolts of retainer (24) to speci-
2 Oil seal: Grease (G2-LI)
fied torque.
3 Mounting bolt:
3 Mounting bolt: 9.8Nm {1kgm}
66.15 ± 7.35Nm {6.75 ± 0.75kgm}
2) Using clearance gauge, measure clearance ★ Check that the number and thickness of
a between retainer (24) and PTO housing the shims is the same on both the left
(33). and right sides.
★ Assemble the shims (34) as shown in the
diagram below so that they do not block
the forcing screw tap H hole in the retain-
er.
★ Measure clearance a at 4 places (A, B, C, D)

around the circumference and calculate the av-
erage.
★ Coat portion P of the PTO shaft with anti-friction

compound (LM-P) and the spline portion Q with
grease (G2-LI).
30-46 D375A-5
" 2 "
DISASSEMBLY AND ASSEMBLY PTO ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF
PTO ASSEMBLY
DISASSEMBLY 3) Using puller 2 , remove bearings (5) and (6)
1. PTO lubrication tube from gear (7).
Sling PTO assembly and remove lubrication tube
(1).
★ Remove 3 lubrication tubes on the opposite
side, then set the torque converter side at the
bottom and lower the assembly.
3. Power train pump gear assembly

1) Using forcing screws 1 , pull out cover as-
sembly (8) and remove.
2) Using puller, remove gear assembly (10)
from cover (9).
2. Hydraulic, PPC pump gear assembly
1) Using forcing screws 1 , pull out cover as-
sembly (2) and lift off.
2) Using puller 2 , remove gear assembly (3)
from cover (4).
D375A-5 30-47
2 " "
3) Using puller 2 , remove bearings (11) and 5. Idler gear assembly

(12) from gear (13). 1) Remove plate (17).
4) Turn over PTO case, and remove cover (14). 2) Turn over PTO case, then using forcing
screws 1 , remove shaft assembly (18).
4. Scavenging pump gear
★ The bearing outer race and gear assem-
1) Remove snap ring (15) at bottom of PTO
bly will come out from the bottom of the
case, then remove gear (16).
PTO case, so set a wooden block and
take care not to cause damage.
3) Remove plug (19), then using forcing
screws, push out bearing inner race (20).
★ After removing the bearing, install the
plug.
30-48 D375A-5
" 2 "
4) Remove bearing outer races (21) and (22) 3) Remove bearing outer race (29).
from gear (23). 4) Remove sleeve (30).
6. PTO race 7. Bearing

1) Remove race assembly (24) and bearing Remove snap ring (31), then remove bearing
outer race (25) as one unit. (32).
2) Remove bearing inner races (26) and (27)

from race (28).
D375A-5 30-49
2 " "
ASSEMBLY 3) Using push tool, press fit bearing inner races

★ Wash all parts clean and check that there are no (27) and (26) to race (28).
scratches or dirt before assembling.
★ Check that the snap ring is fitted securely in the
groove.
1. Bearing
1) Using push tool, press fit bearing (32) to
case.
★ Drop approx. 6 cc of engine oil
(SAE10W-CD or SAE30-CD) on the
bearing, and rotate it 10 times.
2) Install snap ring (31).
4) Install race assembly (24).

2 Inside surface of race:
5) Using push tool, press fit bearing outer race
(25).
2. PTO case
1) Install sleeve (30) to case.
★ Install the sleeve with the chamfered por-
tion on the inside circumference facing
down.
★ Expand fit the sleeve.
2) Using push tool, press fit bearing outer race
(29).
30-50 D375A-5
" 2 "
3. Idler gear 4) Turn over PTO case and install gear assem-
1) Using push tool 3 , press fit bearing outer bly (33).
races (22) and (21) to gear (23). 5) Press fit bearing spacer (34) and bearing in-
ner race (35).
2) Using push tool 4 , press fit bearing inner

race (20) to shaft.
3) Fit O-ring and install shaft assembly (18).
6) Install plate (17).

2 Mounting bolt:
3 Mounting bolt:
110.35 ± 12.25Nm {11.25 ± 1.25kgm}
4. Scavenging pump gear

1) Install gear (16).
2 Spline portion: Grease (G2-LI)
D375A-5 30-51
2 " "
2) nstall snap ring (15) from bottom of PTO 3) Using push tool 6 , press fit gear assembly
case. (10) to cover (9).
5. Power train pump gear assembly 2 Gear spline portion:
1) Fit O-ring and install cover (14). Grease (G2-LI)
4) Fit O-ring, then raise cover assembly (8) and
install to case.
★ If the cover assembly is stiff and it is dif-
ficult to insert into the case, tap uniformly
around the circumference with a plastic
hammer to install.
2) Using push tool 5 , install bearings (11) and

(12) to gear (13).
6. Hydraulic, PPC pump gear assembly

1) Using push tool 5 , press fit bearings (5) and
(6) to gear (7).
30-52 D375A-5
" 2 "
2) Using push tool 6 , press fit gear assembly 7. Lubrication tube

(3) to cover (4). Sling PTO assembly, and install lubrication tube
★ At one end, the end face of the bearing is (1).
level with the end face of the gear. Install ★ Install the 3 lubrication tubes on the opposite
so that this end is facing the cover. side also.
2 Gear spline portion:
Grease (G2-LI)
3) Fit O-ring, then raise cover assembly (2) and
install to case.
★ If the cover assembly is stiff and it is dif-
ficult to insert into the case, tap uniformly
around the circumference with a plastic
hammer to install.
D375A-5 30-53
2 " "
DISASSEMBLY AND ASSEMBLY OF TORQUE
DISASSEMBLY AND ASSEMBLY CONVERTER ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF TORQUE
CONVERTER ASSEMBLY
SPECIAL TOOLS 1. Torque converter valve assembly
Remove torque converter valve assembly (1).
Sym- Part No. Part name
Ne- Q'ty New/Re- Sketch
bol cessity model 2. Draining oil
790-413-1010 Bracket # 1 Remove 2 drain plugs (2) and drain oil from
C Repair pump case.
790-501-5000 stand # 1 ★ After draining the oil, tighten the plugs.
(100V)
3. Lock-up clutch, drive case assembly
1) Leaving 2 mounting bolts (3), remove other
DISASSEMBLY
mounting bolts, then set with input shaft at
• Preparatory work top and remove remaining 2 mounting bolts.
Set torque converter assembly (56) to tool C.
2) Using eyebolts 1 , remove lock-up clutch

and drive case assembly (4).
3) Disassemble lock-up clutch and drive case
assembly as follows.
i) Remove 2 seal rings (5).
ii) Using forcing screws 2 , remove input
shaft (6).
30-54 D375A-5
" 2 "
iii) Remove snap ring (7), then remove plate vii) Remove seal ring (13) from piston.
(8). viii) Remove seal ring (14) from housing.
iv) Set with clutch housing at bottom, then
using forcing screws 3 , remove turbine
(9).
ix) Using push tool 5 , remove bearing (15)

from housing.
v) Set with clutch housing at top, then using

eyebolts 4 , remove housing and piston
assembly (10).
★ When the assembly is removed, the
piston will come out, so support it by
hand when removing.
vi) Remove piston (11) from housing (12).
x) Remove 2 discs (16) and 1 plate (17)

from drive case (18).
★ Store the discs and plates in a flat
place to prevent them from becom-
ing deformed.
D375A-5 30-55
2 " "
4. Stator assembly 5. Pump assembly

1) Remove snap ring (19), then remove stator 1) Remove snap ring (25).
assembly (20). 2) Remove pump assembly (26).
2) Disassemble stator assembly as follows. 3) Disassemble pump assembly as follows.
i) Remove snap ring (21), then remove i) Remove retainer (27).
race (22) from stator (23). ii) Remove bearing and guide assembly
(28) from pump (29).
ii) Remove snap ring (24) from stator (23).

iii) Remove bearing outer race (30) from
guide (31).
6. Stator clutch housing
Set with stator clutch housing side at top, then
remove stator clutch housing (32).
30-56 D375A-5
" 2 "
7. Spring 2) Remove seal ring (42) from piston.

Remove spring (33). 3) Remove seal ring (43) from case.
8. Spring, discs, plate
Remove spring (34), 2 discs (35), and 1 plate
(36).
★ Store the discs and plates in a flat place to
prevent them from becoming deformed.
12. Stator shaft assembly

1) Tap stator shaft assembly (44) with plastic
hammer to remove from case (45).
2) Disassemble stator shaft assembly as fol-
lows.
i) Using push tool 6 , remove shaft as-
9. Pin
sembly (45) from stator shaft assembly.
Remove pin (37).
10. Inner gear
Remove snap ring (38), then remove inner gear
(39).
11. Piston
1) Remove piston (40) from case (41).
D375A-5 30-57
2 " "
ii) Remove snap ring (47), then remove ASSEMBLY

bearing inner race (48), bushing (49), ★ Wash all parts clean and check that there are no
and seal shaft (50) from shaft. scratches or dirt before assembling.
iii) Remove seal ring (51), then remove ★ Check that the snap ring is fitted securely in the
plate (54). groove.
iv) Remove snap ring (35), then remove
plate (54). • Preparatory work
Set case (41) to tool C.
v) Using push tool 7 , remove bearing (55).

1. Stator shaft assembly
1) Assemble stator shaft assembly as follows.
i) Using push tool, press fit bearing (55) to
stator shaft (52).
ii) Install plate (54) and secure with snap
ring (53).
iii) Install seal ring (51).
★ After installing the seal ring, coat
with grease (G2-LI) and fit securely
to shaft.
30-58 D375A-5
" 2 "
iv) Install seal ring (50) to shaft. 2) Tap stator shaft (52) with plastic hammer to
★ After installing the seal ring, coat press fit bearing portion to case.
with grease (G2-LI) and fit securely 3) Set shaft (46) to stator shaft, then using push
to the shaft. tool, press fit bearing portion.
v) Using push tool 9 , press fit bushing 4) Turn over case, and tighten mounting bolts of
(49). shaft from case end.
★ Be careful not to deform the bushing 2 Outer circumference of seal ring:
when press fitting. Grease (G2-LI)
3 Mounting bolt:
66.15 ± 7.35Nm {6.75 ± 0.75kgm}
vi) Using push tool 0, press fit bearing in-

ner race (48).
vii) Install snap ring (47) and secure bearing
inner race. 2. Piston
1) Install seal ring (43) to case.
2 Outer circumference of seal ring:
Grease (G2-LI)
★ The seal ring must be installed facing in
the correct direction. Assemble as
shown in the diagram.
2) Install seal ring (42) to piston.
2 Outer circumference of seal ring:
Grease (G2-LI)
D375A-5 30-59
2 " "
★ The seal ring must be installed facing in 7. Stator clutch housing

the correct direction. Assemble as Install stator clutch housing (32).
shown in the diagram. ★ Check that the spring is fitted securely in the
piston and housing holes.
2 Mounting bolt:
3 Mounting bolt:
110.35 ± 12.25Nm {11.25 ± 1.25kgm}
8. Pump assembly
1) Assemble pump assembly as follows.
i) Using push tool, press fit bearing outer
race (30) to guide (31).
★ Drop approx.6 cc of engine oil (SAE10W-
CD or SAE30-CD) on the bearing, and
rotate it 10 times.
3) Install piston (40) to case (41).
2 Mating surface of seal ring:
Grease (G2-LI)
3. Inner gear
Install inner gear (39), and secure with snap ring
(38).
4. Pin
Install pin (37).
5. Plate, discs, spring
Install 1 plate (36), 2 discs (35), and spring (34).
6. Spring
Install spring (33).
30-60 D375A-5
" 2 "
9. Stator assembly
ii) Set bearing and guide assembly (28) to 1) Assemble stator assembly as follows.
pump (29), then tap with plastic hammer i) Install snap ring (24) to stator (23).
to press fit bearing portion.
iii) Install retainer (27).
2 Mounting bolt:
3 Mounting bolt: 66.15 ± 7.35Nm
{6.75 ± 0.75kgm}
2) Install pump assembly (26).
★ When installing the pump, be careful not
to damage the seal ring assembled to
the shaft.
ii)Assemble race (22) in stator (23), then

secure with snap ring (21).
2) Install stator assembly (20) to stator shaft,
then secure with snap ring (19).
D375A-5 30-61
2 " "
10. Lock-up clutch, drive case assembly iii) Install seal ring (14) to housing.
1) Assemble lock-up clutch and drive case as- 2 Outer circumference of seal
sembly as follows. ring: Grease (G2-LI)
i) Set turbine (9) to block A , then set drive
iv) Install seal ring (13) to piston.
2 Outer circumference of seal
case (18) to turbine.
ring: Grease (G2-LI)
ii) Install 2 discs (16) and 1 plate (17).
v) Install piston (11) to housing (12).

2 Mating surface of seal ring:
Grease (G2-LI)
★ When installing, be careful not to
damage the seal ring.
vi) Using eyebolts 4 , install housing and
piston assembly (10).
2 Mounting bolt:
3 Mounting bolt:
110.35 ± 12.25Nm
{11.25 ± 1.25kgm}
30-62 D375A-5
" 2 "
vii) Using push tool, press fit bearing (15). 3) Tighten mounting bolts (3).
viii) Install plate (8) and secure with snap ring ★ Check that drain plug (2) has been tight-
(7). ened.
ix) Install input shaft (6). 3 Mounting bolt:
2 Mounting bolt: 53.9 ± 4.9Nm {5.5 ± 0.5kgm}
Thread tightener (LT-2) 3 Drain plug:
3 Mounting bolt: 11.25 ± 1.45Nm {1.15 ± 0.15kgm}
277.0 ± 31.9Nm
{28.5 ± 3.25kgm} 11. Torque converter valve assembly
x) Install 2 seal rings (5). Install torque converter valve assembly (1).
★ Tighten the mounting bolts equally to prevent
unbalanced tightening.
3 Mounting bolt:
49.0 ± 4.9Nm {5.0 ± 0.5kgm}
2) Using eyebolts 1 , install lock-up clutch and

drive case assembly (4).
★ Align the tturbine oil groove (marked a)
and drain plug (2) when installing.
D375A-5 30-63
2 " "
DISASSEMBLY AND ASSEMBLY OF TORQFLOW
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF TORQFLOW
TRANSMISSION ASSEMBLY
SPECIAL TOOLS 2. Control valve assembly
1) Remove tube.
Sym- Ne- New/Re-
Part No. Part name Q'ty Sketch 2) Remove cover (2), then remove sleeve in-
bol cessity model
790-415-1011 Bracket # 1 side.
Repair
1
750-501-5000 stand # 1
(100V)
2 791-615-1130 Push tool # 1
Ring as-
791-615-1200 # 1
sembly
791-615-1210 Ring 1
3
135-A90-1150 Bolt 1
D 01580-01008 Nut 1
01641-51032 Washer 2
Ring as-
791-615-1101 # 1
sembly
791-615-1111 Ring 1
4
135-A90-1150 Bolt 1
01580-01008 Nut 1
4) Remove control valve assembly (4) as one
01641-51032 Washer 2
unit with seat.
Oil leak
5 799-301-1600
tester
# 1 ★ Remove the 4 mounting bolts marked *.
Do not remove any other bolts.
DISASSEMBLY
1. Preparatory work
Set transmission assembly (1) to tool D1.
3. Lubrication valve assembly

Remove lubrication valve assembly (5).
30-64 D375A-5
" 2 "
4. Front case 3) Using eyebolts 2 , lift off input shaft and No.
1) Set input shaft end at top and stand trans- 1 carrier assembly (8).
mission assembly. 4) Turn over input shaft and No. 1 carrier as-
2) Using eyebolts, remove front case (6). sembly, and remove seal ring (9).
5) Disassemble input shaft and No. 1 carrier as-

5. Input shaft, No. 1 carrier assembly sembly as follows.
1) Remove 17 tie bolts (7). i) Remove snap ring (10), then remove No.
2) Using forcing screws 1 , disconnect input 2 sun gear (11).
shaft and No. 1 carrier assembly (8). ii) Remove spacer and bearing assembly
★ Tighten the forcing screws uniformly, and (12).
be careful not to twist the input shaft and
No. 1 carrier assembly.
D375A-5 30-65
2 " "
iii) Using push tool, remove ball bearings vi) Using eyebolts 3 , sling housing and No.
(13) and (14) from spacer (15). 1 carrier assembly (18) and set on block.
★ Put the tip of the input shaft in con-
tact with the ground and separate the
housing and No. 1 carrier assembly
from the block by approx. 20 mm.
vii) Remove snap ring (19).
iv) Remove No. 1 sun gear (16).

v) Remove spacer (17).
viii) Tap housing with plastic hammer and

drop housing and No. 1 carrier assembly
(20) on block to remove input shaft as-
sembly (21).
ix) Using press, remove ball bearing (22)
from input shaft (23).
30-66 D375A-5
" 2 "
x) Remove snap ring (24) from housing and xiv) Using push tool 5 , remove ball bearing
No. 1 carrier assembly (20). (28) from housing.
xi) Set housing and No. 1 carrier assembly xv) Remove spacer (29) from No. 1 carrier
on block, then using push tool 4 , re- assembly (26).
move housing (25) from No. 1 carrier as-
sembly (26).
xvi) Turn over No. 1 carrier assembly, remove

snap ring (30), then remove collar (31).
xii) Remove snap ring (27) from housing xvii) Turn over No. 1 carrier assembly, pull out
(25). shaft (33) partially from carrier (32), re-
xiii) Turn over housing and set on block, then move ball (34), then remove shaft (33).
remove seal ring (146). ★ Keep the ball in a safe place and be
careful not to lose it.
D375A-5 30-67
2 " "
xviii) Remove gear (34) and thrust washer 7. No. 1 clutch ring gear
(35) from carrier. Remove No. 1 clutch ring gear (41).
xix) Remove needle bearing (36) from gear
(34).
8. No. 1 housing
1) Using eyebolts 5 , remove No. 1 housing as-
6. No. 1 discs, plates, springs sembly (42).
1) Remove 12 springs (37).
2) Remove 6 discs (38), 6 springs (40), and 5
plates (39) in turn, then remove guide plate.
★ Store the discs and plates in a flat place
to prevent them from becoming de-
formed.
30-68 D375A-5
" 2 "
2) Disassemble No. 1 housing assembly as fol- 9. No. 2 discs, plates, springs

lows. 1) Remove 12 springs (47).
i) Remove piston (43) from housing (44). 2) Remove 6 discs (48), 5 plates (49), and 6
springs (50) in turn.
formed.
ii) Remove seal ring (45) from piston (43).

iii) Remove seal ring (46) from housing (44).
3) Remove 17 sleeves (51).
D375A-5 30-69
2 " "
4) Remove seal ring (52) from No. 2 and No. 3 2) Disassemble No. 1 ring gear and No. 2, No.
carrier. 3 carrier assembly as follows.
5) Remove 6 torque pins (53). i) Remove seal rings (57) and (58).
6) Remove 12 guide pins (54). ii) Remove ring (59).
10. No. 1 ring gear, No. 2, No. 3 carrier assembly iii) Pull out shaft (61) partially from carrier
1) Using eyebolts 6 , lift off No. 1 ring gear and (60), remove ball (62), then remove shaft
No. 2, No. 3 carrier assembly (55). (61).
★ Keep the ball in a safe place and be
careful not to lose it.
30-70 D375A-5
" 2 "
iv) Remove gear (63) and thrust washer 12. No. 2, No. 3 housing assembly
(64) from carrier. 1) Using eyebolts 7 , remove No. 2 and No. 3
v) Remove needle bearing (65) from gear housing assemblies (68) as one unit with top
(63). and bottom pistons.
★ No. 2, No. 3 carrier (60) and No. 1 ★ Tie the bottom piston with wire to prevent
ring gear (66) are secured by an in- it from falling out.
ternal embedded ring, so they can-
not be disassembled.
2) Disassemble No. 2 and No. 3 housing as-

semblies as follows.
11. No. 2 ring gear i) Remove pistons (69) and (70) from
Remove No. 2 ring gear (67). housing (71).
D375A-5 30-71
2 " "
ii) Remove seal ring (72) from piston (69). 13. No. 3 discs, plates, springs
iii) Remove seal ring (73) from piston (70). 1) Remove guide plate, then remove 12 springs
(76).
2) Remove 4 discs (77), 4 springs (79), and 3
plates (78) in turn.
formed.
iv) Remove seal rings (74) and (75) from

housing (71).
14. No. 3, No. 4 clutch plate

Using eyebolts 8 , remove plate (80).
30-72 D375A-5
" 2 "
15. No. 4 discs, plates, springs 2) Disassemble No. 4 housing assembly as fol-
1) Remove 3 discs (81), 3 springs (83), and 2 lows.
plates (82) in turn, then remove guide plate i) Remove piston (86) from housing (87).
(147).
formed.
2) Remove 6 torque pins (84).
ii) Remove seal ring (88) from piston (86).

iii) Remove seal ring (89) from housing (87).
16. No. 4 housing assembly

1) Using eyebolts 9 , remove housing assem-
bly (85) as one unit with piston.
D375A-5 30-73
2 " "
17. No. 3 ring gear, No. 4 carrier, No. 5 clutch as- 5) Set No. 4 carrier end at top and stand trans-
sembly mission assembly.
1) Rotate tool D1, and set transmission facing 6) Using eyebolts 0 , sling No. 3 ring gear and
sideways. No. 4 carrier, No. 5 clutch assembly (95),
2) Remove plate (90). then tap bottom part of output shaft with a
3) Remove snap ring (91), then remove plate copper hammer and remove.
(92).
7) Disassemble No. 3 ring gear and No. 4 carri-

4) Remove snap ring (93), then remove spacer er, No. 5 clutch assembly as follows.
(94). i) Remove 2 seal rings (56) from housing.
ii) Remove seal ring (118) from input shaft.
30-74 D375A-5
" 2 "
iii) Remove snap ring (96), then remove No. vi) Using eyebolts A , remove No. 3 ring
3 sun gear (97). gear and No. 4 carrier assembly (101) as
iv) Remove collar and bearing assembly one unit with No. 4 sun gear.
(98). vii) Remove No. 4 sun gear (102) from No. 3
ring gear and No. 4 carrier assembly
(101).
v) Using push tool, remove ball bearing

(99) from collar (100).
viii) Turn over No. 3 ring gear and No. 4 car-
rier assembly and remove hub (103).
ix) Remove seal rings (104) and (105) from
hub (103).
D375A-5 30-75
2 " "
x) Remove snap ring (106), then remove xv) Turn over carrier (109) and remove snap
collar (107) from No. 3 ring gear and No. ring (115).
4 carrier assembly (101). xvi) Turn over carrier, then using push tool,
xi) Remove seal ring (108) from collar (107). remove ball bearing (116).
★ No. 3 ring gear (117) and No. 4 carri-
er (109) are secured by an internal
embedded ring, so they cannot be
disassembled.
xii) Pull out shaft (110) partially from carrier

(109), remove ball (111), then remove
shaft (110).
★ Keep the ball in a safe place and be
careful not to lose it. xvii) Set output end of output shaft at top, and
xiii) Remove gear (112) and thrust washer put output shaft and housing assembly
(113) from carrier. (118) on top of block.
xiv) Remove needle bearing (114) from gear xviii) Using forcing screws, disconnect input
(112). shaft and housing assembly (118), then
use eyebolts B to remove.
★ Tighten the forcing screws uniformly
and disconnect the output shaft and
housing.
30-76 D375A-5
" 2 "
xix) Remove 6 discs (119), 6 springs (121), xxi) Set housing assembly (123) to press,
and 5 plates (120) from housing (122) in then using tool D2, tighten spring, and
turn. remove snap ring (125).
★ Store the discs and plates in a flat ★ Operate the press slowly and push
place to prevent them from becom- up the springs uniformly.
ing deformed. xxii) Remove retainer (126) and spring (127)
from housing (128).
xx) Set output shaft and housing assembly

to press, then using push tool C , re- xxiii) Remove piston (129) from housing, then
move housing assembly (123) from out- remove seal ring (130) from piston (129).
put shaft assembly (124).
★ To prevent the housing assembly
from falling out, set block D under
the housing assembly.
D375A-5 30-77
2 " "
xxiv)Remove seal ring (131) from housing 18. Rear case assembly
(128). 1) Remove collar (138) from rear case (139).
xxv) Remove snap ring (132) from housing.
xxvi)Using push tool, remove ball bearing
(133) from housing.
2) Remove seal ring (140) from collar (138).
xxvii) Remove snap ring (134), then remove

needle bearing (135) from input shaft
(124).
xxviii)Turn over output shaft, remove snap ring
(136), then remove roller bearing (137)
from output shaft.
3) Turn over rear case, remove snap ring (141),

then remove ball bearing (142).
30-78 D375A-5
" 2 "
ASSEMBLY 2) Turn over rear case (139) and install to collar

★ Wash all parts clean, dry them (especially the oil (138).
holes), check that there are no scratches or dirt, ★ Be careful not to get the seal ring caught.
then coat the sliding parts with engine oil before
assembling.
★ Coat each spline portion with grease (G2-LI).
1. Preparatory work
Set rear case (139) to tool D1.
3. Output shaft assembly

1) Using push tool, press fit needle bearing
(135) to output shaft (124), then secure with
snap ring (134).
2) Using push tool, press fit ball bearing (142)

2. Rear case assembly to output shaft.
1) Install seal ring (149) to collar (138).
★ Install the seal ring in the direction
2 Seal ring: Grease (G2-LI)
D375A-5 30-79
2 " "
3) Install spacer (94) and secure with snap ring 8) Install plate (92) and secure with snap ring
(93). (91).
2 Mounting bolt:
3 Mounting bolt:
66.15 ± 7.35Nm {6.75 ± 0.75kgm}
5) Install seal ring (118).
4. No. 3 ring gear, No. 4 carrier, No. 5 clutch as-

sembly
1) Assemble No. 3 ring gear, No. 4 carrier, and
No. 5 clutch assembly as follows.
• When No. 3 ring gear, No. 4 carrier is
supplied as an individual part.
Using tool D3, compress ring (143), then
set No. 3 ring gear (117) on top of No. 4
carrier (109), and tap No. 3 ring gear
6) Turn over rear case (139) and set output (117) with a plastic hammer to assemble.
shaft assembly (124) in position, then using ★ Check that the ring is fitted securely
push tool, press fit bearing portion. in the groove.
30-80 D375A-5
" 2 "
i) Using push tool, press fit ball bearing v) Install seal ring (108) to collar (107).
(116) to carrier (109), and secure with 2 Seal ring: Grease (G2-LI)
snap ring (115).
vi) Align collar (107) with dowel pin, then in-
stall No. 3 ring gear and No. 4 carrier as-
sembly (101) and secure with snap ring
(106).
★ Knock in the dowel pin portion with a
plastic hammer until there is no
clearance at the mating surface.
ii) Turn over carrier.

iii) Assemble needle bearing (114) to gear
(112), then fit thrust washers (113) to
both ends and set carrier in position.
iv) Fit ball (111) and install shaft (110) to
carrier.
★ Check that the gear rotates smooth-
ly. vii) Install seal rings (105) and (104) to hub
(103).
viii) Install hub (103) to No. 3 ring gear and
No. 4 carrier assembly (101).
★ Be careful not to get the seal ring
caught.
D375A-5 30-81
2 " "
ix) Using eyebolts E , install housing (122) xi) Using push tool, press fit ball bearing
to No. 3 ring gear and No. 4 carrier as- (133) to housing (128), and secure with
sembly. snap ring (132).
x) Install 6 discs (119), 6 springs (121), and xii) Install seal ring (131) to housing.
5 plates (120) in turn. ★ Install the seal ring in the direction
2 Seal ring:
Grease (G2-LI)
30-82 D375A-5
" 2 "
xiii) Install seal ring (130) to piston (129). xvii) Using eyebolts F , install housing as-
★ Install the seal ring in the direction sembly (123).
shown in the diagram below. 2 Mounting bolt:
2 Seal ring: Grease (G2-LI) Thread tightener (LT-2)
xiv) Install piston (129) to housing (128). 3 Mounting bolt:
★ Be careful not to get the seal ring
176.4 ± 19.6Nm {18 ± 2kgm}
caught.
xviii) Install 2 seal rings (56) to housing.
xv) Set spring (127) and retainer (126) to

housing.
★ Set the 3 springs as shown in the di- 2) Turn over rear case (139), and No. 3 ring
agram below. gear, No. 4 carrier, and No. 5 clutch assem-
xvi) Set housing assembly (123) to press, bly (95).
and using tool D2, compress spring, then 3) Using eyebolts 0 , set No. 3 ring gear, No. 4
install snap ring (125). carrier assembly, and No. 5 clutch assembly
★ Spring installed load: (95) to rear case and output shaft.
2,175N {222kg} ★ Be careful not to get the seal ring caught.
D375A-5 30-83
2 " "
4) Using push tool G , press fit bearing portion 6. No. 3 sun gear
of No. 3 ring gear, No. 4 carrier, and No. 5 1) Using push tool, press fit ball bearing (99) to
clutch assembly (95) to output shaft. collar (100).
5. No. 4 sun gear 2) Install collar and bearing assembly (98).

Install No. 4 sun gear (102). ★ Install with the flanged side of the collar
at the top.
3) Install No. 3 sun gear (97) and secure with
snap ring (96).
30-84 D375A-5
" 2 "
7. No. 4 housing assembly 4) Using eyebolts 9 , align dowel pin and install
1) Install seal ring (89) to housing (87). No. 4 housing assembly (85).
★ Install the seal ring in the direction ★ Knock in the dowel pin portion with a
shown in the diagram below. plastic hammer until there is no clear-
2 Seal ring: Grease (G2-LI) ance at the mating surface.
2) Install seal ring (88) to piston (86).
8. No. 4 discs, plates, springs

1) Install 6 torque pins (84).
★ Length of torque pin: 162mm
2) Fit guide plate (147), and install 3 discs (81),
3 springs (83), and 2 plates (82) in turn.
3) Install piston (86) to housing (87).
★ Be careful not to get the seal ring caught.
D375A-5 30-85
2 " "
9. No. 3, No. 4 clutch plate 11. No. 1 ring gear, No. 3 housing assembly
Using eyebolts 8 , align plate (80) with dowel pin 1) Install seal rings (74) and (75) to housing
and install. (71).
★ Knock in the dowel pin portion with a plastic ★ Install the seal ring in the direction
hammer until there is no clearance at the shown in the diagram below.
mating surface. 2 Seal ring: Grease (G2-LI)

1) Install 4 discs (77), 3 springs (79), and 3
2) Install 12 guide pins (54).
★ Length of guide pin: 360mm
3) Fit 12 springs (76) and install guide plate. 3) Install seal ring (72) to piston (69).
★ Free length of spring: 97mm ★ Install the seal ring in the direction
30-86 D375A-5
" 2 "
4) Install pistons (70) and (69) to housing (71). 12. No. 2 ring gear
★ Be careful not to get the seal ring caught. Install ring gear (67).
★ Tie piston (70) with thin wire to prevent it
from falling out when the housing is
raised.
13. No. 1 ring gear, No. 2, No. 3 carrier assembly

1) Assemble No. 1 ring gear and No. 2, No. 3
carrier assembly as follows.
5) Align dowel pin and install housing assembly • When No. 1 ring gear and No. 2, No. 3
(68). carrier is supplied as an individual part.
★ Knock in the dowel pin portion with a Using tool D4, compress ring (144), then
plastic hammer until there is no clear- set No. 1 ring gear (66) on top of No. 2,
ance at the mating surface. No. 3 carrier (60), and tap No. 1 ring gear
(66) with a plastic hammer to assemble.
★ Check that the ring is fitted securely
in the groove.
D375A-5 30-87
2 " "
i) Assemble needle bearing (65) to gear iii) Install ring (59) to carrier.
(63), then fit thrust washers (64) to both ★ Check that the ring is fitted securely
sides and set to carrier (60). in the groove.
iv) Install seal rings (58) and (57) to carrier.
★ Center seal ring (58) with the carrier
and secure in position with grease
(G2-LI).
ii) Fit ball (62) and install shaft (61) to carri-

er.
★ Check that the gear rotates smooth-
ly.
2) Using eyebolts 6 , install No. 1 ring gear and

No. 2, No. 3 carrier assembly (55).
30-88 D375A-5
" 2 "
3) Using push tool H , press fit bearing portion 3) Install 17 sleeves (51).
of No. 1 ring gear and No. 2, No. 3 carrier as-
sembly (55).
and install it in the bolt hole marked q.

★ Set the sleeve with the slit at the bottom

1) Install 6 torque pins (53).
★ Length of torque pin:199mm
2) Install seal ring (52) to No. 2, No. 3 carrier.
4) Install 12 springs (47).

★ Free length of spring: 70mm
5) Install 6 discs (48), 6 springs (50), and 5
★ Align the notches in the oil groover on the
outside circumference of the discs.
D375A-5 30-89
2 " "
15. No. 1 housing assembly 4) Using eyebolts 5 , align dowel pin and install
1) Install seal ring (46) to housing (44). housing (42).
★ Install the seal ring in the direction ★ Check that the spring is fitted securely in
shown in the diagram below. the hole in the housing.
2 Seal ring: Grease (G2-LI) ★ Knock in the dowel pin portion with a
plastic hammer until there is no clear-
ance at the mating surface.
16. No. 1 clutch ring gear

Install No. 1 clutch ring gear (41).
3) Install piston (43) to housing (44).

30-90 D375A-5
" 2 "
17. No. 1 discs, plates, springs ii) Fit ball (34) and install shaft (33) to carri-
1) Fit guide plate and install 12 springs (37). er.
★ Free length of spring: 66mm iii) Install collar (31) to carrier and secure
2) Install 6 discs (38), 6 springs (40), and 5 with snap ring (30).
iv) Using push tool I , press fit ball bearing

18. Input shaft, No. 1 carrier assembly (28) to plate (25), then secure with snap
1) Assemble input shaft and No. 1 carrier as- ring (27).
sembly as follows.
i) Assemble needle bearing (36) to gear
(34), then fit thrust washers (35) to both
ends and set to carrier (32).
D375A-5 30-91
2 " "
v) Turn over plate and install seal ring viii) Using press, install ball bearing (22) to
(146). input shaft assembly (23).
★ Align the center of the plate and use ix) Set housing and No. 1 carrier assembly
grease (G2-LI) to hold the seal ring in (20) to block.
position. x) Using eyebolts 3 , install input shaft as-
vi) Install spacer (29) to No. 1 carrier assembly (18) to housing and No. 1 carrier
sembly (26). assembly.
vii) Set plate (25) to No. 1 carrier (26), then xi) Install snap ring (19).
using push tool J , press fit bearing por-
tion and secure with snap ring (24).
30-92 D375A-5
" 2 "
xii) Set input shaft and No. 1 carrier assem- xv) Install spacer and bearing assembly
bly facing sideways, and install spacer (12).
(17). ★ Install the small diameter bearing
xiii) Install No. 1 sun gear (16). facing the No. 1 sun gear.
xvi) Install No. 2 sun gear (11) and secure
with snap ring (10).
xiv) Using push tool, press fit ball bearings

(13) and (14) to spacer (15).
xvii) Install seal ring (9) to No. 1 carrier.
★ Align with the center of the carrier
and use grease (G2-LI) to hold the
seal ring in position.
2) Turn over input shaft and No. 1 carrier as-
sembly (8), then using eyebolts 2 , set to
No. 1 housing.
★ Check that the tip of the input shaft does
not interfere with the output shaft bear-
ing, and lower slowly.
D375A-5 30-93
2 " "
3) Tighten 4 tie bolts (12) uniformly on diago- 20. Front case

nally opposite sides. Fit O-ring and use eyebolts to install front case
4) Tighten remaining bolts (12). (6).
3 Tie bolt: ★ Check that the front case does not interfere
259.7 ± 14.7Nm {26.5 ± 1.5kgm} and lower gradually.
21. Output shaft bearing

19. Air check
1) Set output shaft end at top and stand trans-
Using tool D5, check stroke of each clutch pis-
mission assembly.
ton.
2) Using push tool, press fit roller bearing (137)
★ Air pressure: 490-588KPa {5-6kg/cm2}
to output shaft, and secure with snap ring
★ Standard stroke of piston
(136).
★ Be careful not to hit or damage the bear-
Piston No. 1 No. 2 No. 3 No. 4 No. 5
ing cage or roller.
Stroke (mm) 6.7 7.0 5.6 4.7 7.0 Use a push tool of a size that pushes
only the outer race.
30-94 D375A-5
" 2 "
22. Lubrication valve assembly 2) Install cover (3).

Install lubrication valve assembly (5). ★ Remove plug (145) and check that the
linkage pin on the inside of the cover is
meshed with the yoke of the control valve
spool.
After checking, install plug (145).
3) Fit O-ring and install sleeve, then install cov-
er (2).
4) Install tube.
23. Control valve assembly

1) Install control valve assembly (4) as one unit
with seat.
3 Mounting bolt:
49.0 ± 4.9Nm {5.0 ± 0.5kgm}
D375A-5 30-95
2 " "
DISASSEMBLY AND ASSEMBLY OF STEERING
DISASSEMBLY AND ASSEMBLY CASE ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF STEERING
CASE ASSEMBLY
DISASSEMBLY iii) Using forcing screws 1 , remove sleeve
1. Steering control valve assembly (7).
1) Remove steering control valve assembly (1). iv) Using puller 2 , pull out bearing inner
4
race (8) from sleeve.
Steering control valve assembly:
25kg
2) Remove seat (2).
2. Clutch, brake assembly

1) Using eyebolts, sling clutch and brake as-
sembly, then remove mounting bolts, and re-
move clutch and brake assembly (3).
★ Remove the clutch and brake assembly
on the opposite side in the same way.
★ When pulling out the clutch and brake
assembly, be careful not to damage the
discs and plates.
v) Turn over clutch and brake assembly,

then using eyebolts 3 , disconnect
clutch assembly (9) and brake assembly
(10).
2) Disconnect clutch and brake assembly as

follows.
i) Remove plate (4), then remove collar (5).
ii) Remove plate (6).
30-96 D375A-5
" 2 "
3) Disassemble clutch assembly as follows. vi) Remove outer race (18) from plate.
i) Remove stopper (11). vii) Remove bearing and cage assembly
ii) Remove discs (12), springs (13), and (19).
ing deformed.
viii) Remove plate (21) and nut (22) from

cage (20).
ix) Remove bearing and inner race (23),
spacers (24) and (25), and bearing outer
iii) Remove torque pin (15). race (26).
iv) Using eyebolts, remove clutch hub (16).
v) Using forcing screws 4 , remove plate
(17).
D375A-5 30-97
2 " "
x) Using eyebolts, remove clutch cage (27). xvi) Using eyebolts 6 , remove brake hub
xi) Remove seal ring (28) from clutch cage. (33).
xii) Remove piston (29). xvii) Remove bearing (34) from brake hub.
xiii) Remove seal ring (30) from piston.
4) Disassemble brake assembly as follows.

xiv) Remove bearing outer race (31) from i) Remove stopper (35).
clutch cage. ii) Remove discs (36), springs (37), and
xv) Remove belleville spring (32). plates (38) in turn.
ing deformed.
30-98 D375A-5
" 2 "
iii) Using eyebolts 7 , remove brake cage 3. Shafts

(39). Remove left and right shafts (46).
iv) Remove bearing outer race (40) and seal 4. Lubrication tube
ring (41) from brake cage. Remove lubrication tube (47).
v) Remove torque pin (42).

5. Pipes
vi) Remove piston (43).
1) Remove left and right pipes (48).
vii) Remove seal ring (44) from piston.
2) Remove pipe (49).
viii) Remove belleville spring (45).
D375A-5 30-99
2 " "
6. Transfer, gear housing assembly v) Using puller 0 , remove both bearing in-
1) Fit guide bolt 8 , raise with eyebolts 9 , then ner races (55).
remove housing assembly (50). vi) Remove lubrication tube (56).
2) Disassemble transfer gear housing assem-
bly as follows.
i) Set transfer gear housing assembly on
block.
ii) Remove lubrication tube (51).
vii) Using eyebolts A , remove pinion hous-

ing assembly (57).
★ Check the number and thickness of
the shims, and keep in a safe place.
viii) Using forcing screws, remove cover (58).
iii) Using push tool, remove bearing (53). ix) Remove holder (59).
iv) Remove drive gear (54).
30-100 D375A-5
" 2 "
x) Push pinion shaft with press, then pull xv) Remove bearing (70) from case.
out pinion gear (60). xvi) Remove bearing (71) from case.
xi) Remove holder, then using puller B , re-
move bearing inner race (61) from pinion
gear (60).
xii) Remove cage and bearing assembly
(62).
7. Right cage
1) Turn over steering case so that right cage is
at top.
2) Remove cage and bearing assembly (72).
xiii) Remove collar (63) from gear (64). shims, and keep in a safe place.
xiv) Using push tool C , remove bearing out- 3) Remove bearing outer race from cage and
er races (65) and (69), bearing inner rac- bearing assembly.
es (66) and (67), and collar (68). 4) Using eyebolts D , remove cage (73).
D375A-5 30-101
2 " "
8. Bevel gear, shaft assembly 2) Remove bearing outer race (80) from cage
1) Using eyebolts, remove bevel gear and shaft and bearing assembly.
assembly.
2) Disassemble bevel gear and shaft assembly
as follows.
i) Pull out reamer bolt, then remove bevel
gear (75) from shaft (76).
ASSEMBLY
★ Wash all parts clean and check that there are no
scratches or dirt before assembling.
★ Coat the rotating portion of the bearing with en-
ii) Using puller E , remove bearing inner gine oil and rotate it several times.
races (77) and (78) from shaft. ★ Coat the sliding parts with engine oil, then as-
semble.
9. Left cage ★ Check that the snap ring is fitted securely in the
1) Turn over steering case so that left side of groove.
steering case is at top, then remove cage
and bearing assembly (79). 1. Left cage
★ Check the number and thickness of the 1) Using push tool, press fit bearing outer race
shims, and keep in a safe place. (80).
2) Assemble shims, and install cage and bear-
ing assembly (79).
★ Standard shim thickness: 2mm
3 Cage, bearing assembly mounting
bolt: 176.4 ± 19.6Nm {18 ± 2kgm}
30-102 D375A-5
" 2 "
2. Bevel gear, shaft assembly 2) Assemble shim and install cage and bearing
1) Assemble bevel gear and shaft assembly as assembly (72).
follows. ★ Standard shim thickness: 2mm
i) Using push tool F , press fit bearing in- 3 Cage, bearing assembly mounting
ner races (78) and (77). bolt:
ii) ii) Set bevel gear (75) to shaft (76) and 176.4 ± 19.6Nm {18 ± 2kgm}
tighten reamer bolt.
3 Reamer bolt:
274.4 ± 29.4Nm {28 ± 3kgm}
2) Using eyebolts, install bevel gear and shaft
assembly (74).
4. Adjusting preload
Adjust shim thickness at cage to adjust rotating
force of bevel gear shaft.
★ Rotate the bevel gear 2 - 3 times and put the
push-pull scale in contact with the tip of the
3. Right cage tooth.
1) Using eyebolts D , install cage (73). ★ Rotating force (with bevel gear not meshed):
4.9 - 5.88 N {0.5 - 0.6 kg}
(Rotating torque: 23.52 - 28.42 Nm
{2.4 - 2.9 kgm})
D375A-5 30-103
2 " "
5. Transfer, gear housing assembly vi) Using push tool H , press fit inner race
1) Assemble transfer and gear housing assem- (61) to pinion gear (60).
bly as follows. vii) Install holder.
i) Using push tool F , press fit transfer 3 Holder mounting bolt:
gear bearing (71) to case. 276.85 ± 31.85Nm {28.25 ± 3.25kgm}
ii) Using push tool G , press fit pinion bear-
viii) Install gear (64) and collar (63) to pinion
ing (70) to case.
gear.
iii) Using push tool, press fit bearing outer

race (69) to cage. ix) Using push tool I , press fit cage and
iv) Assemble bearing inner races (67) and bearing assembly (62).
x) Install holder (59).
(66) and collar (68).
v) Using push tool, press fit bearing outer
race (65). 276.85 ± 31.85Nm {28.25 ± 3.25kgm}
30-104 D375A-5
" 2 "
xi) Tighten mounting bolts of cover (58) in xiii) Tighten mounting bolts of cover (58) in
the order given in diagram and to tighten- order given in diagram.
ing torque given below, and temporarily 3 Mounting bolt:
assemble cover (58).
3 Mounting bolt: 49Nm {5kgm}
66.15 ± 7.35Nm {6.75 ± 0.75kgm}
xiv) Assemble shims to pinion housing as-

xii) Check clearance A between cover and sembly (57), then use eyebolts A to in-
cage, and check that it is as given below. stall.
★ Clearance A : 0.48 ± 0.27mm ★ Standard shim thickness: 2mm
★ Check that the variation around the xv) Install lubrication tube (56).
whole circumference is less than
0.05 mm and that the bearing is
completely press fitted and is not at
an angle.
D375A-5 30-105
2 " "
xvi) Using push tool J , press fit bearing in- 2) Fit guide bolt 8 to steering case, then using
ner race (55) to both sides of drive gear. eyebolts 9 , install transfer and gear housing
xvii) Set drive gear (54) to case. assembly (50).
3 Mounting bolt:
276.85 ± 31.85Nm
{28.25 ± 3.25kgm}
6. Lubrication tube
Install lubrication tube (47).
xviii) Using push tool K , press fit bearing

(53).
xix) Install bearing assembly (52) to case.
xx) Install lubrication tube (51) as one unit
with block.
7. Adjusting backlash, tooth contact

1) Adjusting backlash
Testing
Put the probe of dial gauge L in contact with
the tooth face at the tip of the bevel gear, fix
the bevel pinion in position, and read the
scale when the bevel gear is moved back-
ward and forward.
★ Standard value of backlash:
0.3-0.4mm
★ Measure at 3 places on diametrically op-
posite sides.
30-106 D375A-5
" 2 "
Adjusting 2) Adjusting tooth contact

If the result of the measurement shows that Testing
the backlash is not correct, adjust as follows. i) Coat the tooth face of the bevel pinion
i) When backlash is too small: lightly with red lead (minium), then rotate
Adjust the shim thickness at the bevel the bevel gear forward and backward
pinion end and move the bevel pinion in and inspect the pattern left on the teeth.
direction A.
Or, adjust the shim thickness at the bear-
ing cage of the bevel gear shaft and
move the bevel gear in direction B.
ii)
The standard value for the tooth contact
is as follows
(from small end of pinion)
a) Width of tooth contact: 30 - 75 %
ii)
When backlash is too large: b) Center of tooth contact: 25 - 50 %
Adjust the shim thickness at the bevel c) Position of tooth contact: 25 - 50 %
pinion end and move the bevel pinion in ★ When preload is applied to the taper roll-
direction C. er bearing supporting the bevel gear, it
Or, adjust the shim thickness at the bear- should be within the standard value with
ing cage of the bevel gear shaft and only the bevel pinion meshed and under
move the bevel gear in direction D. no load.
★ When adjusting the shim thickness at the ★ The tooth contact should be at the center
bearing cage of the bevel gear shaft, do of the tooth height and there should be
not change the preload of the bearing. no strong contact at the root of the gear
Adjust by moving shims from one side to tooth.
the opposite side. Always keep the In addition, the contact should be more
same total thickness of shims. or less the same for forward and reverse.
D375A-5 30-107
2 " "
Adjusting ii)
When bevel pinion is too close to center
If the result of the inspection shows that the of bevel gear:
correct tooth contact is not being obtained, Contact is at the big end of the convex
adjust again as follows. tooth face of the bevel gear and the small
i) When bevel pinion is too far from center end of the concave tooth face.
line of bevel gear: [Adjusting]
Contact is at the small end of the convex Follow the same procedure as in Step i)
tooth face of the bevel gear and at the big but move the bevel pinion in direction A
end of the concave tooth face. and the bevel gear in direction B.
[Adjusting] ★ When adjusting the movement in and out
Adjust the shim thickness at the bevel of the bevel gear, do not change the pre-
pinion end and move the bevel pinion in load of the bearing. Adjust by moving
direction A. shims from one side to the opposite side.
Or, adjust the shim thickness at the bear- Always keep the same total thickness of
ing cage of the bevel gear shaft and shims.
move the bevel gear in direction B.
After adjusting, check the tooth contact
pattern and backlash again.
8. Pipes
1) Install pipe (49).
2) Install left and right pipes (48).
30-108 D375A-5
" 2 "
9. Clutch, brake assembly vi) Using eyebolts 7 install brake cage (39).
1) Assemble brake assembly as follows. 3 Mounting bolt:
i) Install belleville spring (45). 110.25 ± 12.25Nm {11.25 ± 1.25kgm}
★ Install the belleville springs back to
vii) Install plates (38), springs (37), and
back.
discs (36).
ii) Install seal ring (44) to piston (43).
★ Check that there is no dirt or damage
to the mating faces of the discs and
plates, and coat thinly with engine oil
before assembling.
iii) Install piston (43).

iv) Install torque pin (42).
v) Using push tool, install seal ring (41) and
bearing outer race (40) to brake cage.
viii) Install stopper (35).
3 Mounting bolt:
276.85 ± 31.85Nm {28.25 ± 3.25kgm}
2) Assemble clutch assembly as follows.
i) Using push tool, install bearing (34) to
brake hub.
D375A-5 30-109
2 " "
ii) Using eyebolts 6 , install brake hub (33) ix) Install bearing inner race (26), spacers
to clutch housing. (25) and (24), and bearing inner race
iii) Install belleville spring (32). (23) to cage (20).
★ Install the belleville springs back to x) Tighten nut (22), and install plate (21).
back. ★ Use a push tool, hold the cage in a
press, and use a hook wrench to
tighten the nut.
iv) Install outer race (31) to clutch cage.

v) Install seal ring (30) to piston.
vi) Install piston (29).
vii) Install seal ring (28) to clutch cage.

viii) Using eyebolts, install clutch cage (27) to
housing.
30-110 D375A-5
" 2 "
xi) Install bearing and cage assembly (19). xvii) Install plates (14), springs (13), and
xii) Using push tool, install outer race (18) to discs (12) in turn.
plate. ★ Check that there is no dirt or damage
to the mating faces of the discs and
plates, and coat thinly with engine oil
before assembling.
xviii) Install stopper (11).
3 Mounting bolt:
276.85 ± 31.85Nm
{28.25 ± 3.25kgm}
xiii) Install plate (17).

3 Mounting bolt:
110.25 ± 12.25Nm {11.25 ± 1.2kgm}
xiv) Set guide bolt to housing.
xv) Using eyebolts, install clutch hub (16).
★ Check that the rotating force of the
housing is less than 29.4N {3 kg} and
that it rotates smoothly. 3) Connect clutch and brake assembly as fol-
xvi) Install torque pin (15). lows.
i) Using eyebolts C , install brake assem-
bly (10) to clutch assembly (9).
ii) Using push tool D , press fit bearing in-
ner race (8) to sleeve.
D375A-5 30-111
2 " "
iii) Set sleeve (7) to clutch and brake as- 10. Shafts
sembly. Install left and right shafts (46).
★ If the bevel gear is locked in position and it is
difficult to insert the shaft, release the steer-
ing brake before inserting.
Remove plug (81), then remove mounting
bolt (82), and screw the mounting bolt into
the plug hole to compress the clutch spring
and release the brake.
iv) Install plate (6).

3 Mounting bolt:
110.25 ± 12.25Nm
{11.25 ± 1.25kgm}
v) Fit collar (5) and install plate (4).
4) Using eyebolts, install clutch and brake as-
sembly.
1) Install seat (2).
{28.25 ± 3.25kgm} 2) Raise steering control valve assembly (1)
and install.
{5.0 ± 0.5kgm}
30-112 D375A-5
" 2 "
REMOVAL AND INSTALLATION OF POWER TRAIN,
DISASSEMBLY AND ASSEMBLY LUBRICATION PUMP ASSEMBLY
REMOVAL AND
INSTALLATION OF POWER
TRAIN, LUBRICATION PUMP
ASSEMBLY
REMOVAL
1. Remove power train underguard (front).
4 Power train underguard (front): 280kg
3. Disconnect tube (2).

4. Lift off power train and lubrication pump assem-
bly (3).
4 Power train, lubrication pump assembly:
50kg
INSTALLATION
moval.
D375A-5 30-113
2 " "
REMOVAL AND INSTALLATION OF SCAVENGING
DISASSEMBLY AND ASSEMBLY PUMP ASSEMBLY
REMOVAL AND INSTALLA-

TION OF SCAVENGING PUMP
ASSEMBLY
REMOVAL
1. Remove power train underguard (front).
4 Power train underguard (front): 280kg
2. Disconnect inlet tube (1).
★ The oil in the piping will leak out, so use a
container to catch it.
3. Disconnect outlet tube (2).
4. Remove scavenging pump assembly (3).
INSTALLATION
moval.
• Refilling with oil (power train case)

Add oil through oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.
30-114 D375A-5
" 2 "
REMOVAL AND INSTALLATION OF FINAL DRIVE
DISASSEMBLY AND ASSEMBLY ASSEMBLY
REMOVAL AND
INSTALLATION OF FINAL
DRIVE ASSEMBLY
SPECIAL TOOLS 5. Remove 3 bolts of final drive, and install tool J1.
6. Sling final drive assembly (5), then remove
q2
bol cessity model mounting bolts and lift off.
4
J 1 790-337-1001 Lifting tool # 1
Final drive assembly: 2,300kg
REMOVAL
1. Remove track shoe assembly. For details, see
REMOVAL OF TRACK SHOE ASSEMBLY.
2. Raise chassis with jack or ripper, then set stand
1 under frame.
3. Remove covers (1) and (2).
INSTALLATION
moval.
q1
★ If the shaft does not go in, push up the shoe
grouser from the ground surface with a jack
and move the sprocket backwards or for-
wards to adjust to a position where the shaft
4. Remove cover (3), then using eyebolts, pull out
q1
meshes, then assemble the shaft.
q2
drive shaft (4).
2 Final drive assembly mounting bolt:

★ If the shaft does not come out, push up the
shoe grouser from the ground surface with a
jack and move the sprocket backwards or Thread tightener (LT-2)
forwards to adjust to a position where the 3 Final drive assembly mounting bolt:
shaft can be removed, then pull the shaft out. 1,720 ± 190Nm {175 ± 20kgm}
★ Pull the shaft out to a point where it contacts
the sprocket.
• Refilling with oil (final drive case)
5 ¬ (SAE 30CD)
Final drive case: 65¬
D375A-5 30-115
2 " "
DISASSEMBLY AND ASSEMBLY OF FINAL
DISASSEMBLY AND ASSEMBLY DRIVE ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF FINAL
DRIVE ASSEMBLY
SPECIAL TOOLS DISASSEMBLY
Sym- Ne- Q'ty New/Re- Sketch 1. Draining oil
Part No. Part name
bol cessity model Remove drain plug and drain oil from final drive
791-580-3200 Remover " 1 case.
6 ¬
Puller
2 790-101-2102 (294 kN " 1
Final drive case: Approx.61¬
{30 ton})
2. Sprocket
790-101-1102 Pump " 1
1) Set final drive assembly to block (height: ap-
791-580-3300 Installer " 1
prox. 50 mm).
Puller 2) Remove sprocket (1).
3 790-101-2102 (294 kN " 1
{30 ton})
790-101-1102 Pump " 1
4 790-431-1071 Installer " 1 N
791-580-3400 Remover " 1
Puller
5 790-101-2102 (294 kN " 1
J
{30 ton})
790-101-1102 Pump " 1
791-580-3500 Installer " 1
Puller
6 790-101-2102 (294 kN " 1
{30 ton})
790-101-1102 Pump " 1
Remover
790-431-1230 " 1
& installer 3. Cover
7
Puller Using eyebolts 1 , remove cover (2).
790-101-2102 (294 kN " 1
{30 ton})
790-101-1102 Pump " 1
8 790-431-1250 Guide " 1
30-116 D375A-5
! 2 !
4
4. Hub 2) Using tool J2, disconnect sprocket hub as-

1) Remove plate (3). sembly (6) and bearing (7).
2) Using eyebolts 2 , lift off hub (4). 3) Using eyebolts 3 , remove sprocket hub as-
sembly (6).
5. Sprocket hub assembly

1) Remove holder (5).
4) Remove bearing inner race (8) from sprocket

hub assembly.
D375A-5 30-117
2 " "
5) Turn over sprocket hub assembly, and re- 2) Disassemble cover assembly as follows.
move floating seal cover (9) and bearing out- i) Remove floating seal cover (15).
er races (10) and (11). ii) Remove floating seal (16) from floating
6) Remove floating seal (12) from floating seal seal cover.
cover. ★ Be careful not to damage the floating
★ Be careful not to damage the floating seal and keep it in a safe place.
seal and keep it in a safe place.
iii) Remove spacer (17) and bearing inner

6. Wear guard race (18).
Lift off wear guard (13).
7. Cover assembly
1) Using eyebolts 4 , lift off cover assembly
(14).
30-118 D375A-5
" 2 "
iv) Remove plate, then remove ring gear iv) Remove planetary gear (23), bearing in-
(19). ner races (24A) and (24B), and spacer
8. Carrier assembly (24C).
1) Using eyebolts 5 , remove carrier assembly
(20).
v) Remove bearing outer race (24D).
2) Disassemble carrier assembly as follows.

i) Set carrier assembly to block (approx.
100mm).
ii) Remove holder (21).
iii) Using tool J7, remove planetary gear
shaft (22).
9. Sun gear
1) Remove plate (25), button (26), and sun gear
(27).
D375A-5 30-119
2 " "
10. Hub, shaft assembly 3) Disassemble hub assembly as follows.

1) Remove plate (28). i) Remove gear (32) from hub (33).
ii) Remove hub (33) from boss (34).
iii) Using puller, remove bearing outer race
(35) from boss (34).
2) Using tool J5, pull out hub assembly (29) and

bearing inner race (30) from shaft assembly
(31).
4) Using eyebolts 6 , pull out shaft assembly
(31) from case.
5) Disassemble shaft assembly as follows.
i) Remove collar (36).
ii) Remove bearing inner race (37) and col-
lar (38).
30-120 D375A-5
" 2 "
11. Cage assembly 12. Gear assembly

1) Using eyebolts 7 , remove cage assembly 1) Remove gear assembly (44).
(39). 2) Using puller 9 , remove bearing inner races
2) Remove shims (40). (45) and (46) from gear.
13. Outer race, oil seals

1) Using puller 0 , remove bearing outer race
3) Disassemble cage assembly as follows. (48).
i) Using puller 8 , remove bearing outer 2) Remove oil seals (49) and (50) from case.
race (41).
ii) Remove oil seals (42) and (43).
D375A-5 30-121
2 " "
ASSEMBLY 2) Using push tool C , press fit bearing outer

★ Wash all parts clean, check that there are no race (48).
dents or dirt, then coat the sliding parts with en-
gine oil before assembling.
1. Oil seals, bearing outer race
1) Using push tools A and B , install oil seals
(50) and (49).
★ Install the bottom seal with the side re-
ceiving the pressure at the bottom and
the top seal with the side receiving the
pressure at the top.
2 Press-fitting surface of oil seal:
★ Coat the inside surface of the case thinly 2. Gear assembly
with gasket sealant and wipe off any 1) Using push tool D , press fit bearing inner
sealant that is squeezed out. races (46) and (45) to gear.
2) Set tool J8 to case, and install gear assem-
bly (44).
★ Leave tool J8 in position. (Remove it af-
ter installing the cage.)
30-122 D375A-5
" 2 "
3. Cage assembly ii) Using push tool E , press fit bearing out-
1) Assemble cage assembly as follows. er race (41).
i) Using push tools A and B , install oil
seals (43) and (42).
★ Install the bottom seal with the side
receiving the pressure at the bottom
and the top seal with the side receiv-
ing the pressure at the top.
2 Lip of oil seal:
Grease (G2-LI)
2 Press-fitting surface of oil seal:
★ Coat the inside surface of the case
thinly with gasket sealant and wipe
off any sealant that is squeezed out.
2) Using eyebolts 7 , set cage assembly (39)
to case, then tighten portions C and D uni-
formly with mounting bolts.
3 Mounting bolt: 14.7Nm {1.5kgm}
D375A-5 30-123
2 " "
3) In this condition, use thickness gauge F as a + b [mm] No. of shims to use

shown in the diagram below and measure Total shim
Less thickness
clearances a and b between cage A and From t = 0.1 t = 0.5 t = 1.0
than c [mm]
case B.
4) Use table to set thickness c of shim to insert. 1.6 1.8 1 1.0
5) Assemble shims selected in Step 4), then
1.8 2.0 1 1 1.1
tighten 4 cage mounting bolts.
3 Mounting bolt:
2.0 2.2 2 1 1.2
227.3 ± 80.85Nm
{23.25 ± 8.25kgm} 2.2 2.4 3 1 1.3
★ Rotate the gear and tighten uniformly, 2.4 2.6 4 1 1.4
then remove tool J8. 2.6 2.8 1 1 1.5
2.8 3.0 1 1 1 1.6
3.0 3.2 2 1 1 1.7
3.2 3.4 3 1 1 1.8
3.4 3.6 4 1 1 1.9
3.6 3.8 2 2.0
3.8 4.0 1 2 2.1
4.0 4.2 2 2 2.3
4.2 4.4 3 2 2.3
4.4 4.6 4 2 2.4
4.6 4.8 1 2 2.5
4.8 5.0 1 1 2 2.6
5.0 5.2 2 1 2 2.7
5.2 5.4 3 1 2 2.8
5.4 5.6 4 1 2 2.9
5.6 5.8 5 1 2 3.0
30-124 D375A-5
" 2 "
4. Hub, shaft assembly ii) Set boss (34) to hub (33).

1) Assemble shaft assembly as follows. 4) Set shaft assembly (31) and hub assembly
i) Install collar (38). (29) in position, then using tool J6, press fit
ii) Using push tool (17), press fit bearing in- bearing portion (30).
ner race (37).
iii) Install collar (38).
5) Tighten mounting bolts of hub assembly

(29).
2) Using eyebolts 6 , install shaft assembly 3 Mounting bolt:
(31) to case. 276.85 ± 31.85Nm
3) Assemble hub assembly as follows. {28.25 ± 3.25kgm}
i) Using push tool, press fit bearing outer
2 Mounting bolt:
race (35) to boss (34).

3 Mounting bolt:
548.8 ± 58.8Nm {56 ± 6kgm}
7) Install gear (32).
3 Mounting bolt:
539 ± 49Nm {55 ± 5kgm}
D375A-5 30-125
2 " "
5. Sun gear i) Install ring and spacer to planetary gear,

1) Install sun gear (27) to hub assembly. then using push tool H , press fit top and
2) Install button (26) and plate (25). bottom bearing outer races (24D).
6. Carrier assembly ii) Assemble spacer (24C) and bearing in-

1) Assemble carrier assembly as follows. ner races (24B) and (24A) to planetary
★ The bearing for the planetary gear con- gear (23), and set to carrier.
sists of a set, so match the distinguishing
marks on the inner race, outer race, and
q1.Distinguishing mark for bearing

spacer when assembling.
q2.Distinguishing mark for bearing

spacer
30-126 D375A-5
" 2 "
iii) Using tool J7, press fit planetary gear ii) Using tool J3, press fit bearing inner race
shaft (22). (18).
★ Align the bearing and spacer hole, iii) Install spacer (17).
then gradually press fit the shaft.
iv) Install holder (21).
3 Mounting bolt:
548.8 ± 58.8Nm {56 ± 6kgm}
★ After tightening the bolts, check that
the gear rotates smoothly.
iv) Using tool J4, press fit floating seal (16)

to floating seal cover.
★ Remove all oil and grease from the
O-ring and O-ring contact surface,
and dry before installing.
★ After installing the floating seal,
check that the angle of the seal is
2) Using eyebolts 5 , install carrier assembly less than 1 mm.
(20).
7. Cover assembly
1) Assemble cover assembly as follows.
i) Fit ring gear (19), and install plate.
★ Install the plate so that the cham-
fered side is at the top.
D375A-5 30-127
2 " "
v) Install floating seal cover (15). 2) Using eyebolts 4 , raise cover assembly
★ Fit a cork plug in the forcing tap. (14) and install.
★ Coat the mating faces with Three Bond
1216.
8. Wear guard
Raise wear guard (13) and install.
★ Install the floating seal cover with the

notch facing down as shown in the
diagram below.
9. Sprocket hub assembly

1) Using tool J4, install floating seal (12) to
floating seal cover.
★ Remove all oil and grease from the O-
ring and O-ring contact surface, and dry
before installing.
★ After installing the floating seal, check
that the angle of the seal is less than 1
mm.
30-128 D375A-5
" 2 "
2) Using push tool, press fit bearing outer races 5) Using eyebolts 3 , sling sprocket hub as-
(11) and (10). sembly (6) and set to cover.
3) Install floating seal cover (9). ★ Check that there is no dirt on the sliding
surface of the floating seal, then coat
thinly with engine oil.
4) Set bearing (8) to sprocket hub assembly.
6) Using tool J3, press fit bearing portion (7).

★ Rotate the sprocket hub assembly while
press fitting.
D375A-5 30-129
2 " "
7) Install holder (5). 11. Cover

2 Mounting bolt: Using eyebolts 1 , install cover (2).
3 Mounting bolt:
276.85 ± 31.85Nm
{28.25 ± 3.25kgm}
12. Sprocket
Install sprocket (1).
2 Mounting bolt:
10. Hub 3 Mounting bolt:
1) Using eyebolts 2 , lift off hub (4). 1,813 ± 98Nm {185 ± 10kgm}
13. Refilling with oil
Tighten drain plug and add engine oil through oil
filler to the specified level.
5 Final drive case: Approx. 61¬ ¬
★ Carry out the final check of the oil level after
installing the final drive assembly to the
chassis, and check that the oil is at the spec-
ified level.
30-130 D375A-5
! 2 !
4
REMOVAL AND INSTALLATION OF TRACK
DISASSEMBLY AND ASSEMBLY FRAME ASSEMBLY
REMOVAL AND
INSTALLATION OF TRACK
FRAME ASSEMBLY
REMOVAL 6. Remove covers (3) and (4).
1. Expand the track shoe assembly. For details, 7. Remove cover (5).
see EXPANDING TRACK SHOE ASSEMBLY.
2. Raise the machine body with a jack or the ripper
and set stands 1 under the frame to float the
rear part of the machine body.
3. Set hydraulic jack 2 under the center of the
equalizer bar to float the front part of the ma-
chine body.
4. Sling the track frame assembly temporarily.
8. Apply a pad to pin (6) from rear and drive out the
pin with a hammer.
★ If the equalizer bar hole and track frame hole
are not aligned, the pin cannot be removed
easily. Adjust the hanging height of the track
frame properly.
5. Loosen front bolt (1) and rear bolt (2).
9. Remove the mounting bolts and cover (7) from

the track frame.
D375A-5 30-131
2 " "
REMOVAL AND INSTALLATION OF TRACK
DISASSEMBLY AND ASSEMBLY FRAME ASSEMBLY
10. Remove cover (8). INSTALLATION

★ For the right track frame, disconnect the 4 • Carry out installation in the reverse order to re-
hoses for the blade tilt cylinder from the cov- moval.
er.
11. Remove seal (9) and washer (10) together. 2 Inside surface of bushing : Grease (G2-LI)
★ Perform this procedure for only the right track
frame. ★ Before installing the pin, adjust the height of the
track frame and align the center of the equalizer
12. Remove washer (11) and spacer (12). bar hole and track frame hole.
★ Set the pin with the grease hole facing the out-
side of the machine.
★ Fit pin (4) and bushing (3), install cover (2), then
install the cover and cushion.
★ After removing the grease from the press fitting
surface of the seal, coat with gasket sealant (LG-
6).
★ Be careful not to install with the seal displaced in
the direction of twisting.
★ Be careful not to install the track frame with seal
(14) displaced in the direction of twisting.
• Refilling with oil (pivot case)

5
13. Lift off track frame assembly (13).
★ Receive the oil flowing out of the pivot case Pivot case : 18 ¬ (SAE30)
with an oil pan, etc.
6 Pivot case: 18 ¬
4 Track frame: 7,260 kg
30-132 D375A-5
" 2 "
DISASSEMBLY AND ASSEMBLY IDLER ASSEMBLY
REMOVAL AND
INSTALLATION OF
IDLER ASSEMBLY
1. Remove track shoe assembly. For details, see • Carry out installation in the reverse order to re-
REMOVAL OF TRACK SHOE ASSEMBLY moval.
¤ To prevent danger, never stand in front of the
idler yoke assembly. ★ For both the left and right idler assemblies,
install with the oil filler plug facing the left
2. Remove scraper (1). side of the machine.
★ Remove the inside scraper also. ★ Tighten the idler cap mounting bolts in the
3. Remove cover (2). following order.
★ Remove the inside cover also. Tightening order: 1) 2 bolts at a
2) 2 bolts at b
3) 2 bolts at a
4) Tighten all bolts to
specified torque.
2 Mounting bolt:
3 Mounting bolt :
1641.5 ± 171.5 Nm
{167.5 ± 17.5 kgm}
★ After tightening the idler cap mounting bolts,
check that clearance c between the bottom
of the idler cap and the yoke is 0.
4. Sling idler assembly and remove idler cap (3).

★ For both the left and right idler assemblies,
there is a ball assembled to the left idler cap,
so keep it in a safe place and be careful not
to lose it.
5. Lift off idler assembly (4).
4 Idler assembly : 478 kg
D375A-5 30-133
2 " "
DISASSEMBLY AND
ASSEMBLY OF
IDLER ASSEMBLY
SPECIAL TOOLS 4. Turn over idler assembly (1).
Sym- Ne- Q'ty New/Re- Sketch 5. Remove mounting bolts, then using eyebolts 3 ,
Part No. Part name
bol cessity model remove shaft (5) as one unit with retainer.
791T-630-2210 Plate # 1 "
6. Using puller 4 , remove seal guides (2) and (6),
792-530-1630 Stud # 2
and plate (8).
790-101-2510 Block # 1
790-101-2570 Washer # 2
1 01580-01613 Nut # 2
01643-31645 Washer # 2
L
Puller
790-101-2102 (294kN # 1
{30ton})
790-101-1102 Pump # 1
2 791-515-1520 Installer # 1
3 791-685-8310 Push tool # 1
4 791-601-1000 Oil pump 1
DISASSEMBLY
1. Remove oil filler plug and drain oil. 7. Remove seal guides (2) and (6) from retainers
6 Idler: 0.95 - 1.05 ¬ (3) and (7).
2. Set idler assembly (1) on blocks 1 .

3. Remove mounting bolts, then using forcing
screws 2 , remove seal guide (2) as one unit
with retainer (3) and plate (4).
30-134 D375A-5
" 2 "
8. Remove floating seal (9) from seal guides (2) ASSEMBLY

and (6). ★ Wash all parts clean and check that there are no
★ Be careful not to damage the floating seal scratches or dirt before assembling.
and keep it in a safe place.
1. Set bushing (11) and tool L1 to idler (12), and
9. Remove floating seal (10) from seal guides (3)
press fit bushing (11).
and (7).
★ First, use a plastic hammer to center the
★ Be careful not to damage the floating seal
bushing, then press fit it with a puller.
and keep it in a safe place.
★ Press fit the bushing so that press-fitting di-
mension a from the end face of the idler to
the top face of the bushing is the dimension
below.
• Press-fitting dimension a: 17 ± 0.5 mm
10. Remove bushing (11) from idler (12).
2. Using tool L2, install floating seal (10) to retain-

ers (3) and (6).
3. Fit O-ring and install retainer (3) and plate (4) to
idler.
★ Check that the plate rotates smoothly by
hand.
D375A-5 30-135
2 " "
4. Using eyebolts 3 , set idler (12) to shaft (5). 8. Set seal guide (2) to shaft, then using tool L3,
★ Set block (approx. 140 mm) under the idler. press fit seal guide (2).
5. Turn over idler assembly. ★ Press-fitting force of seal guide:
★ Tie the shaft with wire to prevent it from fall- 43 - 71 kN {4.4 - 7.2 ton})
ing out.
6. Fit O-ring and install retainer (7) and plate (8) to
idler.
★ Press fit the seal guide so that press-fitting

dimension b from the end face of the shaft to
the top face of the seal guide is the dimen-
7. Using tool L2, install floating seal (8) to seal sion below.
guides (2) and (6). • Press-fitting dimension b: 102 ± 0.2 mm
★ Turn over the idler assembly and repeat the
procedure above to press fit seal guide (6)
on the opposite side.
30-136 D375A-5
" 2 "
9. Using tool L4, charge with specified amount of

oil, then tighten oil filler plug.
6 Idler: 0.95 - 1.05 ¬
3 Oil filler plug:
206 ± 49 Nm {21 ± 5 kgm}
D375A-5 30-137
2 " "
SKETCH OF SPECIAL TOOL

Note: We will not be liable for any result caused by a special tool made according to this drawing.
L1 Plate
30-138 D375A-5
" 2 "
REMOVAL AND INSTALLATION OF RECOIL
DISASSEMBLY AND ASSEMBLY SPRING ASSEMBLY
REMOVAL AND
INSTALLATION OF RECOIL
SPRING ASSEMBLY
SPECIAL TOOLS 6. Remove covers (4).
★ Remove both the inside and outside covers.
bol cessity model
791-730-1110 Bolt # 4
M 1
01580-12722 Nut # 4
REMOVAL
1. Remove track shoe assembly. For details, see
REMOVAL OF TRACK SHOE ASSEMBLY.
¤ To prevent danger, never stand in front of the
idler yoke assembly.
2. Drain oil from recoil cylinder chamber using oil
pump.
6 Recoil cylinder chamber : Approx. 50 ¬
7. Using tool M1, remove pins (5).
3. Using eyebolt 1 , remove cover (1). ★ Remove both the inside and outside pins.
4 Cover : 40 kg
8. Lift off idler and recoil spring assembly (6).

★ Using a lever block, keep the assembly hori-
4. Remove cover (2). zontal, and be careful not to damage the oil
5. Lift off trunnion (3). seal at the track frame end.
4 Trunnion : 75 kg 4 Idler, recoil spring assembly : 2,180 kg
D375A-5 30-139
2 " "
9. Disconnect recoil cylinder assembly (8) from

idler yoke assembly (7) as follows.
1) Pit idler yoke assembly (7) in contact with
ground, then raise recoil cylinder assembly
(8).
★ When doing this, check that there is no
damage to the weld of recoil cylinder as-
sembly (7).
★ Wrap cloth around the chrome plated
bushing to protect it.
3) When the bolts are loosened, the torque will

suddenly drop. Check that the installed load
of the recoil spring is not applying any push-
ing force on the mounting bolts, then remove
all bolts.
★ If the torque increases (the installed load
of the recoil spring is applied) during the
loosening operation, stop the loosening
operation and disassemble as follows.
¤ If the torque does not drop during steps
2) Loosen idler yoke mounting bolts (9) gradu- 2) and 3) described above, and the
ally in turn on diagonally opposite sides. torque when the bolts are loosened re-
¤ To prevent danger, never stand in front of mains large, there is probably damage to
the idler yoke assembly. recoil spring set bolts (10), or nut (11) at
the tip of the shaft has fallen off, so there
¤ The recoil spring inside the recoil cylin-
is danger that the idler yoke assembly
der is applying a pushing force of approx.
may fly off to the front. For this reason,
500 kN (approx. 51 tons) on the idler
disassemble as follows.
yoke, so be careful not to loosen the
mounting bolts suddenly. Loosen the ¤ When disconnecting the idler yoke as-
mounting bolts gradually until clearance sembly and recoil cylinder assembly, do
a between the flange of the recoil cylin- not stand in front of the idler yoke assem-
der and idler yoke is 8 – 12 mm. bly or behind the recoil cylinder assem-
bly until safety has been confirmed and
the recoil spring assembly has been re-
moved.
30-140 D375A-5
" 2 "
i) Prepare the following parts. v) When recoil spring is fully extended and
• Bolt 1 (×6) : 791-730-1110 torque has completely dropped in loos-
• Nut 2 (×6) : 01580-12722 ening direction of nut 2 , remove bolt 1 .
• Washer 3 (×6) : 01643-32780 (use ★ When clearance b is approx. 230
again) mm, the spring is fully extended.
ii) Remove 6 bolts marked q, then install 10. Remove ring (12).
bolts 1 , nuts 2 , and washers 3 .
★ Check that dimension L is less than
30 mm.
★ Screw in bolts 1 until they contact
the bottom of the yoke thread.
marked q).
iii) Remove remaining 12 bolts (those not
iv) Hold bolts 1 with a wrench to prevent

them from turning, and loosen 2 nuts 2
simultaneously on diagonally opposite
sides.
★ Be careful not to let the road bear on
only one bolt.
11. Pump in grease through lubricator (13), and re-

move cylinder (14) and piston assembly (15).
D375A-5 30-141
2 " "
12. Disassemble piston assembly (15) as follows. INSTALLATION

1) Remove wear ring (16) from piston. • Carry out installation in the reverse order to re-
2) Remove snap ring (17), then remove pack- moval.
3 Cover mounting bolt:
ing (18).
277 ± 32 Nm {28.25 ± 3.25 kgm}
★ Before installing the pin, align the center of the

hole in the track frame and the dowel pin at the
recoil cylinder end with a bar.
★ Using a lever block, keep horizontal and be care-
ful not to damage the oil seal at the track frame
end when installing.
★ Adjust the clearance. For details, see TESTING
AND ADJUSTING, Adjusting clearance of idler.
★ If the recoil spring set bolt is broken or the nut at
the tip of the shaft has fallen off, see ASSEMBLY
OF RECOIL SPRING ASSEMBLY when assem-
13. Remove recoil spring assembly (19). bling.
4 Recoil spring assembly : 550 kg 2 Idler yoke assembly mounting bolt :
3 Idler yoke assembly mounting bolt :
1641.5 ± 171.5 Nm {167.5 ± 17.5 kgm}
★ To prevent air from accumulating inside the cylin-

der, fill with grease as follows.
1) Fill the inside of the cylinder with approx. 1.3
¬ of grease.
2) Set with the cylinder drain hole facing up,
then loosen the lubricator.
3) Push the piston until it contacts the stopper.
This will push out the air and any extra
grease.
14. Remove holder (20) from recoil spring assembly.
30-142 D375A-5
" 2 "
DISASSEMBLY AND ASSEMBLY OF RECOIL
DISASSEMBLY AND
ASSEMBLY OF RECOIL
SPRING ASSEMBLY
SPECIAL TOOLS 2. Apply hydraulic pressure slowly to compress
spring, then remove lock plate (2) and remove
bol cessity model nut (3).
Compres- 3. Release hydraulic pressure gradually and relieve
791-685-8501 # 1
sor
tension of spring.
Cylinder
M 2 790-101-1600 (686kN # 1
{70ton})
790-101-1102 Pump # 1
791-635-3160 Extension # 1
DISASSEMBLY
1. Remove recoil spring assembly (1) with tool M2.
¤ The spring is under high installed load, so be
careful to set it correctly.
★ Installed load of spring:
Approx. 500 kN {approx. 51 ton}
4. Remove rear pilot (5), spacer (6), bolt (7), and

front pilot (8) from spring (4).
D375A-5 30-143
2 " "
DISASSEMBLY AND ASSEMBLY OF RECOIL
ASSEMBLY 2. Apply hydraulic pressure slowly to compress

1. Assemble front pilot (8), bolt (7), spacer (6), and spring, and set so that installed length of spring
rear pilot (5) to spring (4), then set in tool M2. is specified value.
★ Installed length a of spring : 1,230.5 mm
★ Installed load of spring :
Approx. 500 kN {approx. 51 ton}
¤ The spring is under high installed load, so be

careful to set all parts correctly.
3. Fit nut (3), then install lock plate (2).
★ Make clearance b of 0 - 10 mm between the
nut and lock plate to prevent the nut from
protruding from the end face of bolt (7).
★ Bring lock plate (2) and bolt (7) into tight con-
tact, and secure in position.
2 Lock plate mounting bolt :
4. Gradually release hydraulic pressure to com-

pletely relieve tension of spring, then remove re-
coil spring assembly (1) from tool M2.
30-144 D375A-5
" 2 "
REMOVAL AND INSTALLATION TRACK
DISASSEMBLY AND ASSEMBLY ROLLER ASSEMBLY
REMOVAL AND
INSTALLATION TRACK
ROLLER ASSEMBLY
SPECIAL TOOLS 4. Set steel plate 1 on track shoe, and operate
blade and ripper to lower chassis to a point
bol cessity model where track roller assembly contacts steel plate.
790-401-1700 Lifting tool # 1 ★ Run the engine at low idling and operate the
790-401-1761 Adapter # 1
blade and ripper slowly.
12
790-401-1540 Shackle # 2
L 790-401-1770 T-Bolt # 2
791T-630-2320 Plate # 3 N "
13 01011-62700 Bolt # 6
01673-32780 Washer # 6
REMOVAL
1. Loosen track shoe tension. For details, see RE-
MOVAL OF TRACK SHOE ASSEMBLY.
2. Install tool L13 and secure bogie assembly (1).
q1
3. Operate blade and ripper, and jack up chassis to
5. Remove mounting bolts, and leave track roller
a point where track roller assembly (2) comes up
assembly (2) on steel plate 1 .
from track shoe.
6. Operate blade and ripper, and jack up chassis to
a point where track roller assembly (2) separates
from bogie.
D375A-5 30-145
2 " "
7. Using a crane and bar, pull out track roller as- INSTALLATION
sembly (2) from steel plate to outside of body. • Carry out installation in the reverse order to re-
4 Track roller assembly: moval.
150 kg (single flange)
160 kg (double flange) q1
After removing tool L3, replace mounting bolts of
cover (3) with normal parts.
927 ± 103 Nm {94.5 ± 10.5 kgm}
★ Note that the installation location differs for

the single flange track roller assembly and
double flange track roller assembly.
S: Single flange
D: Double flange
★ Install the track roller assembly with the oil
filler plug on the outside.
30-146 D375A-5
" 2 "
★ After fitting the track shoe assembly tempo-

rarily, align the position of dowel pin (4).
3 Track roller assembly mounting bolt:
1,325 ± 145 Nm {135 ± 15 kgm}
• When using assembly tool

Set tool L12 to bottom of track roller assembly,
then raise track roller assembly (2) and set to
track frame.
D375A-5 30-147
2 " "

L13 Plate
30-148 D375A-5
" 2 "
DISASSEMBLY AND ASSEMBLY OF TRACK
★ Press-fitting force of seal guide:

36 - 63 kN {3.7 - 6.4 ton})
★ Press fit the seal guide so that press-fitting
dimension b from the end face of the shaft to
the top face of the seal guide is the dimen-
sion below.
★ Press-fitting dimension b: 77 ± 0.2 mm
7. Using tool L11, charge with specified amount of

oil, then tighten oil filler plug.
5 Track roller: 1.4 - 1.5 ¬ (SAE140)

3 Oil filler plug:
206 ± 49 Nm {21 ± 5 kgm}
D375A-5 30-151
2 " "
DISASSEMBLY AND ASSEMBLY OF TRACK

L8 Plate
L10 Push tool
30-152 D375A-5
" 2 "
DISASSEMBLY AND ASSEMBLY BOGIE ASSEMBLY
3. Operate the blade and ripper to raise the ma-

chine body until the track roller is floated above
the track link.
¤ Set a block between the track roller and track
link so that the machine body will not lower.
4. Set block 1 out of the track shoe according to
the height of the track link.
5. Set steel plate 2 on the track shoe and block 1 .
6. Operate the blade and ripper to lower the ma-
chine body until the track roller of the bogie as-
sembly (1) comes in contact with steel plate 2 .
★ Operate the blade and ripper slowly with the 3) Remove floating seals (5) from the ends of
engine at low idling speed. rings (4) and (7).
★ Keep the floating seals so that they will
not be damaged.
4) Set tool L15.

5) Pull out spacer (6) and rings (7) and (8).
★ Pulling out force:
205.8 - 382.2 kN {21 - 39 tons}
8. Remove the shaft and ring.

1) Set tool L14.
2) Push shaft (3) and ring (4) simultaneously to
the opposite side.
★ Pushing force:
137.2 - 274.4 kN {14 - 28 tons}
30-154 D375A-5
" 2 "
6) Remove spacer (6). INSTALLATION

7) Remove spacer (9) and floating seal (10) be- 1. Assemble the pin assembly.
tween rings (7) and (8). 1) Using tool L18, install floating seals (5) to
★ Keep the floating seals so that they will rings (4) and (7) and install floating seal (10)
not be damaged. to the opposite side of ring (7) and ring (8).
8) Remove the shaft and rings from the bogie ★ When installing the floating seals, thor-
on the opposite side according to steps 1) - oughly degrease the O-rings and the O-
7) above. ring contact surfaces of the mating parts.
★ Check that the slant of each floating seal
is within 1mm.
9. Remove tool L13.

10. Place bogie assembly (1) on steel plate 2 .
2) Press fit shaft (3) to ring (8).
11. Operate the blade and ripper to raise the ma-
3) Install spacer (9).
chine body until the bogie assembly can be
4) Press fit ring (7) to shaft (3).
pulled out.
¤ Set a block between the track roller and track 6) Press fit ring (4) to shaft (3).
2 Apply Anti-friction compound (LM-
link so that the machine body will not lower.
12. Sling bogie assembly (1) and slide it out on steel P) to parts "a" (about 10 mm) of
plate 2 and remove it. rings (8) and (4).
4 Bogie assembly: 720 kg
D375A-5 30-155
2 " "
2. Apply lever block 3 between the guard of bogie 2) Press fit pin assembly.
assembly (1) and that of the bogie assembly on ★ Insert the pin assembly with arrow "a" on
the opposite side and slide bogie assembly (1) its end face up (in the mounting state on
on the steel plate to the mounting position. the machine body).
★ Push in the pin assembly with cover (2).
★ Press fit the pin assembly to machined
surface "b" of the bogie.
2 Apply Anti-friction compound (LM-
P) to the all outside surface of the
pin.
★ Total press fitting force for pin assembly:
245 - 441 kN {25 - 45 tons}
3. Align the pin holes of the track frame and bogie

and set guide tool L17.

Using tool L19, supply the specified quantity of
oil.
★ Oil supply pressure: 0.49 MPa {5 kg/cm2}
5 Pin assembly: 95 - 115 cc (GO-140)
4. Press fit the pin assembly.

1) Set tool L16 and cover (2).
30-156 D375A-5
" 2 "
6. Press fit the pin assembly on the opposite side

according to steps 3 - 4 above.
7. Tighten the mounting bolts of pin assembly cov-
ers (2). (Install 2 covers, outside and inside
ones.)
927 ± 103 Nm {94.5 ± 10.5 kgm}
8. Adjust the track shoe tension. For details, see

TESTING AND ADJUSTING, Testing and ad-
justing track shoe tension.
D375A-5 30-157
2 " "

L13 Plate
L17 Guide
30-158 D375A-5
" 2 "
ASSEMBLY 4. Refilling with oil

1. Assembly of pin assembly Using tool L19, supply the specified quantity of
Assemble the pin assembly according to the pro- oil.
cedure in Installation of bogie assembly. ★ Oil supply pressure: 0.49 MPa {5 kg/cm2}
(Steps 3 - 5) 5 Pin assembly: 90 - 115 cc (GO-140)
2. Set inner bogie (4) to outer bogie (5).
3. Press fitting of pin assembly
2) Press fit the pin assembly.
★ Insert the pin assembly with arrow "a" on
its end face up (in the mounting state on
the machine body).
surface "b" of the bogie and secure level
difference "b" of 5 mm between the bo-
gie and pin assembly.
2 Anti-friction compound (LM-P) to
the all outside surface of the pin. 5. Press fit the pin assembly on the opposite side
★ Total press fitting force for pin assembly: according to steps 3 - 4 above.
245 - 441 kN {25 - 45 tons} ★ After press fitting the pin assembly, rock the
smaller bogie.
6. Tighten the mounting bolts of pin assembly cov-
ers (3).
(Install 2 covers, outside and inside ones.)
824 - 1,030 Nm {84 - 105 kgm}
7. Track roller assembly

Sling 2 track roller assemblies (2) and install
them to bogie assembly (1).
2 Track roller mounting bolt:
3 Track roller mounting bolt:
1,180 - 1,470 Nm {120 - 150 kgm}
30-160 D375A-5
" 2 "
REMOVAL AND INSTALLATION OF 1ST
7. Using tool L20, sling and hold 1st bogie (5). 3) Remove floating seals (9) from the end faces
of rings (8) and (12).
8. Remove cover (6). ★ Keep the floating seals so that they will
not be damaged.
9. Pull out the shaft and ring.

1) Set tool L14. 4) Set tool L15.
2) Push shaft (7) and ring (8) simultaneously to
the opposite side.
★ Pushing force:
137.3 - 274.6 kN {14 - 28 tons}
★ When the ring is pushed out, it interferes
with the idler. To prevent this, supply
grease to the track tension adjuster in
advance to push out the idler cushion as-
sembly forward.
30-162 D375A-5
" 2 "
5) Pull out spacer (11) and rings (12) and (13). INSTALLATION
★ Pulling out force:
1. Assemble the pin assembly.
205.8 - 382.2 kN {21 - 37 tons}
1) Using tool L18, install floating seals (9) to
6) Remove spacer (11).
rings (8) and (12) and install floating seal
7) Remove spacer (14) and floating seal (10)
(10) to the opposite side of ring (12) and ring
between rings (12) and (13).
(13).
★ Keep the floating seals so that they will
★ When installing the floating seals, thor-
not be damaged.
oughly degrease the O-rings and the O-
ring contact surfaces of the mating parts.
★ Check that the slant of each floating seal
is within 1mm.
10. Lower bogie (5) on the steel plate and pull it out.
4 Bogie assembly: 110 kg
2) Press fit shaft (7) to ring (13).
2 Apply Anti-friction compound
(LM-P) to parts "a" (about 10 mm)
of rings (13) and (8).
D375A-5 30-163
2 " "
2. Place bogie assembly (5) on steel plate 1 and 2) Press fit pin assembly .
slide it to the center. ★ Insert the pin assembly with arrow "a" on
its end face up (in the mounting state on
3. Using tool L20, set the bogie in position.
the machine body).
surface "b" of the bogie and secure level
difference "b" of 5 mm between the bo-
gie and pin assembly.
2 Apply Anti-friction compound
(LM-P) to the all outside surface of
the pin.
★ Total press fitting force for pin assembly:
245 - 441 kN {25 - 45 tons}
4. Align the pin holes of the track frame and bogie

and set guide tool L17.

Using tool L19, supply the specified quantity of
oil.
★ Oil supply pressure: 0.49 MPa {5 kg/cm2}
5. Press fit the pin assembly. 5 Pin assembly: 95 - 115 cc (GO-140)
30-164 D375A-5
" 2 "
7. Press fit the pin assembly on the opposite side

according to steps 5 - 6 above.
8. Install covers (6).
(Install 2 covers, outside and inside ones.)
9. Install eyebolts to the pad mounting bolts (M12 x
2 pieces) of bogie (5) and pull up and hold the
bogie.
13. Adjust the track shoe tension. For details, see

testing and adjusting, TESTING AND ADJUST-
ING TRACK SHOE TENSION.
10. Using tool L21, insert the shaft in track roller as-
sembly (4), then sling and set it on the track
shoe, balancing it.
4 Track roller assembly: 150 kg
11. Lower the machine body slowly. When the clear-

ance between bogie (5) and shaft (3) becomes
about 20 mm, install cap (15) and secure it with
bolt (2) temporarily.
12. Align the dowel pin hole and tighten bolt (2) se-
curely.
2 Cap mounting bolt:
3 Cap mounting bolt:

1,180 - 1,470 Nm {120 - 150 kgm}
D375A-5 30-165
2 " "

L17 Guide
L21 Tube
30-166 D375A-5
! 2 !
4
L21 Plate
D375A-5 30-166-1
4
EXPANDING AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY TRACK SHOE INSTALLATION

TRACK SHOE INSTALLATION
CHECK BEFORE EXPANDING TRACK 1. Sling the end of the master link and move the
SHOE ASSEMBLY machine slowly in reverse to expand track shoe
assembly (4).
¤ Since it may be very dangerous to expand the
★ Length of track shoe: Approx. 12.5 m
track shoe assembly, check the following items in
advance.
¤ Do not loosen the lubricator more than 1 turn.
• Loosen lubricator (1) of the adjustment cylin-
der to discharge the grease and move the
machine in reverse a little and check that the
track shoe is loosened.
★ After the shoe is loosened, perform EX-
PANDING TRACK SHOE ASSEMBLY
(NORMAL).
• If the track shoe is not loosened by the above
work, the track frame may have an internal
trouble (damage of the recoil spring or recoil
spring set bolt, fall of the shaft end nut, etc.)
★ If the track shoe is not loosened, perform
EXPANDING TRACK SHOE ASSEM-
BLY (WHEN TRACK FRAME HAS IN-
TERNAL TROUBLE).
D375A-5 30-167
2 " "
EXPANDING TRACK SHOE ASSEMBLY EXPANDING TRACK SHOE ASSEMBLY

(When track frame has internal trouble). (Normal)
★ If any abnormality is detected by CHECK BE- ★ If any abnormality is not detected by CHECK BE-
FORE EXPANDING TRACK SHOE ASSEMBLY, FORE EXPANDING TRACK SHOE ASSEMBLY,
perform the following procedure. perform the following procedure.
¤ If the track shoe is removed while the track frame 1. Set the master link in position.
has an internal trouble, it may spring back. Even ★ Set the master link above the idler (a little af-
if the track shoe is removed, the idler may jump ter the idler center).
out, and that can cause a serious result. Accord- ★ Set a block (1) and (2) between the front side
ingly, expand the track shoe according to the fol- of the idler and carrier roller so that the mat-
lowing procedure. ing part of the master link will not open until
1. Remove the work equipment. For details, see the master bolt is pulled out.
REMOVAL OF WORK EQUIPMENT ASSEM-
BLY.
2. Loosen lubricator (1) and move the machine for-
ward and in reverse to discharge the grease.
¤ Do not loosen lubricator (1) more than 1 turn.
★ Check that the all grease has been dis-
charged.
2. Loosen the track shoe.

¤ Do not loosen lubricator (1) more than 1 turn.
★ Loosen all of them by 1 - 2 turns first until
they are turned lightly, then pull them out. Do
not loosen and pull out the bolts 1 by 1.
★ If the bolts are turned forcibly before they be-
come light, the threads of them and master
link may be damaged.
30-168 D375A-5
" 2 "
3. Move the machine slowly forward against large INSTALLATION OF TRACK SHOE
block 1 or a wall (or the blade of another ma- ASSEMBLY
chine of the similar size of the machine to be re-
• Carry out installation in the reverse order to EX-
paired, if available) to press the track shoe on the
PANDING.
q1
idler side. When the recoil spring is distorted,
stop and apply the brake.
★ Adjust the track shoe tension. For details,
At this time, set the master link between the idler
see testing and adjusting, TESTING AND
and front carrier roller.
ADJUSTING TRACK SHOE TENSION.
For safe work, apply a lever block between the
★ Tighten the all 4 bolts with fingers until the
carrier roller support and link.
master link mating faces are fitted.
4. Remove track shoe (5) and disconnect master ★ If the bolts are tightened forcibly before the
link (6). master link mating faces are fitted, the
5. Move the machine slowly in reverse to expand threads of the bolts and master link may be
track shoe assembly. damaged.
q2
★ Tighten the shoe mounting bolts for the mas-
ter link in the following order.
2 Shoe mounting bolt:
Anti-seizure agent (Maruzen
MOLYMAX No. 2 or equivalent)
3 Shoe mounting bolt:
1st time:
686 ± 68.6 Nm {70 ± 7 kgm}
2nd time:
Retighten by 180°° ± 10°°
D375A-5 30-169
2 ! !
WHOLE DISASSEMBLY AND
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRACK SHOE
WHOLE DISASSEMBLY
★ When disassembling the track shoe, see "Parts
judgment guide, Undercarriage, Lubricated
track" and "Parts judgment guide, Undercar-
riage, Reversing procedure for pin bushing".
1. Removal of shoe
Sling the shoe assembly and set it with the shoe
up on the floor and remove the shoe by using a
shoe bolt impact wrench.
★ If a shoe bolt is not loosened after it is un-
screwed by 1 turn (If its torque is not reduced
to 0), loosen the other bolts first, and it will be
removed smoothly.
★ If a shoe bolt is turned forcibly while its
torque is not 0, it and link will adhere to each
other and they will need to be repaired.
★ When moving the shoe assembly, take care
not to damage the master link.
★ If it is obliged to cut a shoe nut with gas, keep
the seal temperature below 80°C to prevent
thermal deterioration of the seal and take
measures to prevent the spatters from enter-
ing through the clearances among the links.
2) Operate the left cylinder to pull out the pin

and bushing from the left link simultaneously.
★ Check the pulling out force of the pin and
bushing which will be reversed and as-
sembled again, then pull out them simul-
taneously.
★ The wedge link is broken with a bang.
This sound does not indicate abnormali-
ty.
2. Disassembly of link
1) Set the link assembly on a link press and hit
it with a hammer so that the bushing will be
fitted to the jaw.
★ If the link tread, outside of the bushing,
etc. are worn, adjust the height of the jaw
or guide plate and align the pin and
bushing with the disassembly jig so that
the link hole will not be damaged during
disassembly work.
★ If the pin and bushing are not aligned
well, the link hole may be damaged and
the pin and bushing may be broken dur-
ing disassembly work.
★ Using tool R1, drive the small plug of the
pin inward after the disassembly work so
that the workplace will not become dirty.
D375A-5 30-171
2 " "
3) Return the left cylinder and operate the right 2) Measure the outside diameter of the press
cylinder to pull out the pin and bushing from fitting parts of the pin and bushing and the in-
the right link simultaneously. side diameter of the pin and bushing fitting
parts of the link with a micrometer and a cyl-
inder gauge to see if the allowable fitting al-
lowance is obtained. When using the pin,
bushing, and link for a lubricated track, how-
ever, secure the standard fitting allowance
between the pin and link.
★ If the allowable fitting allowance is not
obtained, replace the parts with new
one.
★ For the dimensional criteria, see MAIN-
TENANCE STANDARD.
4) Return the right cylinder and take out the

links, pins, bushings, and spacers on both
sides and feed the next 1 set of the link as-
sembly to the jaw.
★ If the bushing ends and sealing surfaces
are damaged, oil will leak. Accordingly,
handle them carefully.
★ Since the broken wedge link has sharp
edges, take care not to cut your hands
with them.
3. Inspection
Check the parts for the following items to see if
they can be used for a lubricated track or a
grease-filled track, then examine them generally
and determine to use them for a lubricated track
or grease-filled track.
★ For judgment of reuse of the parts, see
"Parts judgment guide, Undercarriage, Lu-
bricated track".
1) Check the parts visually for damage. If a
part seems to be damaged, check it by dye
penetrant test or magnaflux inspection. If it
has any crack, it cannot be used again. Dis-
card it.
30-172 D375A-5
" 2 "
2) When reusing the pin, chamfer its end cor-

ners smoothly with a grinder. Remove the
nodules sticking to the press fitting parts with
the grinder, too.
★ If the ends are worn and sharpened, they
may scuff the press fitting parts and
cause oil leakage.
3) If the link, pin, bushing, and spacer are dirty,
clean them. Remove the nodules sticking to
the link and bushing with the grinder, too.
★ Since these parts rust easily, clean them
just before assembling them.
★ Do not polish the bushing ends. If they
are polished, oil may leak.
★ Precautions for storage
1) Store the seal without removing it from the
link so that the counterbore portion will not
be rusted and take care not to damage the
seal lip.
2) Apply rust-preventive oil to the pin and bush-
ing fitting parts, shoe mating surface, and
master link mating surface of the link.
3) When storing, apply rust-preventive oil to the
all surfaces of the pin, bushing, and spacer.
Take care not to damage the ends of the
bushing in particular.
WHOLE ASSEMBLY
★ For the whole assembly of the track shoe, see
"Parts judgment guide, Undercarriage, Revers-
ing procedure for pin bushing".
1. WHEN RECYCLING FOR LUBRICATED

TRACK
1. Preparation work
1) Cleaning seal assembly
Remove the seal assembly from the link and
divide it into the seal ling and load ring, then
clean them.
★ Since the seal ring and load ring are de-
teriorated easily by the cleaning liquid
(trichloroethylene etc.), clean them
quickly. After cleaning them, wipe off the
cleaning agent from them.
D375A-5 30-173
2 " "
4) If the large plug was pulled out, drive it in by 5) Installation of seal assembly
using tool R3. Clean the counterbore portion of the link
In this case, clean the pin hole in advance by carefully and push in the seal to the bottom
using tool R2. by using tool R6.
i) Insert the plug through the plug insertion ★ If oil is sticking to the counterbore portion
window into the guide hole. of the link or seal assembly, the seal will
ii) Push the bar with the hand until the plug turn and its sealing performance will low-
stops. er. Accordingly, do not apply any oil.
iii) Push the plug with the bar to press the When inserting the seal in the counter-
guide against the pin. bore portion, take care that oil not stick to
iv) Drive in the bar with a hammer. the seal and counterbore portion.
★ Driving distance "a" from pin end:
11 ± 2 mm
★ If the chamfered part of the pin hole
has been worn, chamfer it with a
small-sized grinder (grindstone tip
angle: 45°- 60°) so that the plug will
not be damaged.
★ Coat the plug with GO90 and drive it
with the small diameter end ahead.
30-174 D375A-5
" 2 "
6) Adjust the dimensions of the press fitting jig 7) Adjust the relief pressure of the link press so
of the link press to keep the projection of the that the pressing force of the press will not
pin and bushing constant and keep the in- exceed the standard value.
stalled dimensions of the seal within the ★ If the pressing force is too strong, the
standard range. spacer will be pressed forcibly against
★ For the standard dimensions, see DI- the bushing. As a result, the spacer may
MENSIONS TABLE OF FITTING JIG OF be broken and it and bushing may be
LINK. worn abnormally.
★ If the pin end (part P) or link sides (parts ★ Pushing force of pin and bushing: 980 kN
Q and R) are worn, add the dimensions {170 tons}
of the worn parts when adjusting the Pushing force = 1.8 x Average pressure
standard dimensions so that the projec- (Adjust the relief pressure of the link
tions of the pins and bushings on both press to set the pushing force.)
sides will be even.
2. Assembly of link
1) Apply oil (GO90) to the mating surfaces of
the pin and bushing with a clean brush and
assemble them, then set them before the jaw
of the link press.
★ When reusing (reversing) the bushing,
set the worn outside surface of the bush-
ing on the shoe fitting side of the link (set
the bushing with the worn outside sur-
face up on the link press).
D375A-5 30-175
2 " "
2) Press fit the master links on both bushing 4) Turn over the master links and check that
sides to the bushing with the shoe fitting fac- they are press fitted in parallel.
es up. 5) Measure the projections of the bushing on
★ At this time, use the master links on the both sides with a depth gauge.
pin side as supports. ★ Adjust the press fitting jig of the link
★ Press fitting force for bushing: press so that the projections on both
196 - 343 kN {20 - 35 tons} sides will be even.
3) Using the shoe bolt hole pitch gauge, press 6) Send the master links and set the next pin
fit the master links until the distance between and bushing.
the shoe bolt holes of both links is the stan- ★ When reusing a pin, install it so that its
dard value. side hole will be the link tread side simi-
★ Remove the all steel chips caused by larly to a new one. If it is not installed so,
press fitting of the bushing with com- its strength may be lowered. According-
pressed air. ly, indicate the direction of the side hole
on the end face to prevent a mistake.
30-176 D375A-5
" 2 "
7) Apply gasket sealant (198-32-19890) to the 9) Set the right jig on the receiving side and the
pin fitting hole of the links to prevent oil from left one on the pushing side and press fit the
oozing out of the scuffed parts of the pin fit- pin and bushing simultaneously.
ting parts. ★ If the pin and bushing have play when
they are press fitted, the seal may come
off the link. To prevent this, press fit
smoothly. If the seal comes off the link,
stop press fitting and set the seal to the
link correctly, then star t press fitting
again.
★ Press fitting force for pin and bushing:
392 - 686 kN {40 - 70 tons}
8) Set the right link and install the spacer to the

pin.
★ Check that the seal surface and bushing
end are free from dir t and apply oil
(GO90) to them with a clean cloth or
brush.
★ When installing the spacer, wipe it with a
clean cloth.
10) Using the spacer for fine adjustment, press
fit the pin and bushing until the pin end is fit-
ted to the bottom of the receiving jig.
★ Adjust the depth of the receiving jig hole
so that the projections of the pin on both
sides will be even.
D375A-5 30-177
2 " "
11) Set the left link and install the spacer to the 13) Press fit until the link, spacer, and bushing
pin. are fitted together.
★ Apply oil similarly to the right link. ★ Actually, you cannot see from outside if
the above parts are fitted.
Accordingly, control the hydraulic pres-
sure of the link press. Set the relief pres-
sure to a proper level and heighten the
hydraulic pressure to that level.
For setting of the relief pressure, see
PREPARATION WORK.
★ Check that adjacent 2 links can turn
around each other.
12) Set the left jig on the receiving side and the
right one on the pushing side and press fit
the left link.
★ When press fitting, take care that both
seals and spacers will not come off.
★ Press fitting force for link:
392 - 686 kN {40 - 70 tons}
14) Using a shoe bolt hole pitch gauge, measure

the distance between the shoe bolt holes
and check that the result is within the stan-
dard range.
★ If the distance between the shoe bolt
holes is longer than the standard range,
disassemble and check for abnormality,
then press fit again.
★ If the distance between the shoe bolt
holes is shorter than the standard range
and the shoe cannot be installed, the
spacer or bushing end may be worn
more than the allowable limit. In this
case, disassemble and replace the
parts.
30-178 D375A-5
" 2 "
15) Install the ring to jig R8. 18) Using jig R10, push in the ring.
★ Pushing force for ring:
294 - 372 kN {30 - 38 tons}
16) Match the jig to the pin hole and push it in un-
til the ring is inserted in the pin groove.
★ A sound is made when the ring is insert-
19) After each link is assembled, bleed air from
ed in the pin groove.
the pin by using tool R4 and check the seal-
ing performance.
★ Keep the degree of vacuum inside the
pin at 86.7 - 93.3 kPa {650 - 700 mmHg}
for 5 seconds and check that the pres-
sure does not change.
If the pressure changes, disassemble
and check the seal. If the seal is free
from abnormality, assemble again.
17) Using jig R9, insert the ring in the pin groove
on the opposite side similarly.
D375A-5 30-179
2 " "
20) Using tool R4, supply oil (G090) until the oil 21) After supplying oil, drive in the small plug to
supply pressure rises to 196.1 - 294.2 kPa {2 the specified position, using tool R4.
- 3 kg/cm2}. ★ Apply G090 around the small plug.
★ Drive in the plug to the following depth.
Driving depth from end face: 7.5 ± 1 mm
★ In a cold or very cold district, supply Ko-

matsu genuine oil (150-09-19270 or 195-
32-61990) having better low-tempera- 22) Assemble the master link on the pin side at
ture characteristics instead of G090. last.
★ If the oil pressure is heightened too ★ Check that the master links on both sides
much, it has bad effects on the seal. are press fitted in parallel.
Take care.
★ Supply oil so that depth L of the hollow of
the pin hole will be in the following range
when the link is left with the small plug
side up (when the link assembly is
placed on its side) for 30 minutes.
Dimension L: 40 - 70 mm
30-180 D375A-5
" 2 "
3. Installation of shoe 2) When installing a double track, place the as-

1) Set the link assembly on the bed and install sembled double shoes on a level place in 1
the shoe with a shoe bolt impact wrench and line with the shoe side up. Pull pin-side mas-
a torque wrench. ter link (1) and bushing-side master link (2)
3 Shoe bolt (Regular link) together and set them to each other by the
Initial torque: mating faces. Place shoe (3) on the links
1,372 ± 137.2 Nm {140 ± 14 kgm} and check that shoe bolt (4) can be tightened
Retightening angle: 120°° ± 10°° easily until the mating faces of the links are
2 Shoe bolt:
fitted together, then connect the links with
the master bolts.
2 Shoe bolt:

3 Shoe bolt (Master link)
Initial torque:
686 ± 68.6 Nm {70 ± 7 kgm}
Retightening angle: 180°° ± 10°°
★ Tighten the bolts in the order of 1 - 4 .
D375A-5 30-181
2 " "
2. WHEN RECYCLING FOR GREASE- 3) Drive in the large and small plugs by using
FILLED TRACK tools R3 and R5.
i) Insert each plug through the plug inser-
1. Preparation work
tion window into the guide hole (Apply oil
1) Cleaning seal assembly
to the plug).
• Remove the seal assembly from the link
ii) Push the bar with the hand until the plug
and divide it into the seal ling and load
stops.
ring, then clean them.
iii) Push the plug with the bar to press the
★ Since the seal ring and load ring are
guide against the pin.
deteriorated easily by the cleaning
iv) Drive in the bar with a hammer.
liquid, clean them quickly. After
★ Driving distance "a" from pin end:
cleaning them, wipe off the cleaning
Small plug: 7.5 ± 1 mm
agent from them.
Large plug: 11 ± 2 mm
★ If the plugs were not pulled out when
the shoe was disassembled, reuse
them as they are.
2) When reusing the pin, chamfer its end cor-

ners carefully with a grinder so that it will be
press fitted smoothly.
30-182 D375A-5
" 2 "
4) If the outside of the pin, surfaces of the spac- 2. Assembly of link

er, and ends and inside of the bushing are 1) Apply lithium grease (G2-LI) to the mating
dirty, clean them. surfaces of the pin and bushing and assem-
5) Apply grease to the outside of the pin and ble them, then set them before the jaw of the
surfaces of the spacer. link press.
6) Installation of seal assembly ★ When reusing (reversing) the bushing,
• Clean the counterbore portion of the link set the worn outside surface of the bush-
carefully and push in the seal to the bot- ing on the shoe fitting side of the link (set
tom by using tool R6. the bushing with the worn outside sur-
★ If grease is sticking to the counter- face up on the link press).
bore portion of the link or seal as-
sembly, the seal will turn and its
sealing performance will lower. Ac-
cordingly, do not apply any oil.
2) Press fit the master links on both bushing

sides to the bushing with the shoe fitting fac-
es up.
★ At this time, use the master links on the
7) Adjust the dimensions of the press fitting jig pin side as supports.
of the link press to keep the projection of the ★ Press fitting force for bushing:
pin and bushing constant and keep the in- 196 - 343 kN {20 - 35 tons}
stalled dimensions of the seal within the
standard range.
★ For the standard dimensions, see DI-
MENSIONS TABLE OF FITTING JIG OF
LINK PRESS.
★ If the pin end (part P) or link sides (parts
Q and R) are worn, add the dimensions
of the worn parts when adjusting the
standard dimensions so that the projec-
tions of the pins and bushings on both
sides will be even.
D375A-5 30-183
2 " "
3) Using the shoe bolt hole pitch gauge, press ★ If the outside of the pin is worn, install it
fit the master links until the distance between so that the un-worn surface will be on the
the shoe bolt holes of both links is the stan- traction side. In this case, install the pin
dard value. so that its side hole will be the link tread
★ Remove the all steel chips caused by side, too.
press fitting of the bushing with com-
pressed air.
4) Turn over the master links and check that
they are press fitted in parallel.
7) Set both links and operate both pushing jigs

to press fit the pin and bushing simulta-
neously.
★ If the pin and bushing have play when
5) Measure the amount of protrusion of the left they are press fitted, the seal may come
and right bushing with a depth gauge. off the link. To prevent this, press fit
★ Adjust the press fitting jig of the link smoothly. If the seal comes off the link,
press so that the projections on both stop press fitting and set the seal to the
sides will be even. link correctly, then star t press fitting
again.
★ Pushing force of pin and bushing: 980 kN
{100 tons}
Pushing force ≈ 1.8 x Average pressure
★ (Adjust the relief pressure of the link
press to set the pushing force.)
6) Send the master links and set the next pin

and bushing.
★ When reusing a pin, install it so that its
side hole will be the link tread side simi-
larly to a new one. If it is not installed so,
its strength may be lowered. According-
ly, indicate the direction of the side hole
on the end face to prevent a mistake.
30-184 D375A-5
" 2 "
8) Using a shoe bolt hole pitch gauge, measure 11) Using jig R10, push in the ring.
the distance between the shoe bolt holes. ★ Pushing force for ring:
When the distance is in the standard range, 294 - 372 kN {30 - 38 tons}
stop press fitting.
12) Assemble the master link on the pin side at

9) Install the ring to jig R8. last.
★ Check that the master links on both sides
are press fitted in parallel.
3. Shoe (regular link portion)
Set the link assembly on the bed and install the
shoe with a shoe bolt impact wrench and a
torque wrench.
2 Shoe bolt :
Lubricant containing molybdenum
disulfide (LM-P)
3 Shoe bolt (Regular link):
Initial torque: 1,372 ± 137.2 Nm
{140 ± 14 kgm}
10) Match the jig to the pin hole and push it in un-
til the ring is inserted in the pin groove.
Using jig R9, install the ring on the opposite
side similarly.
★ A sound is made when the ring is insert-
ed in the pin groove.
D375A-5 30-185
2 " "
4. Assembly of 1/2 track

Place the assembled 2 shoes on a level place in
1 line with the shoe side up. Pull pin-side master
link (1) and bushing-side master link (2) together
and set them to each other by the mating faces.
Place shoe (3) on the links and check that shoe
bolt (4) can be tightened easily until the mating
faces of the links are fitted together, then con-
nect the links with the master bolts.
2 Shoe bolt:
Lubricant containing molybdenum
disulfide (LM-P)
Initial torque:
686 ± 68.6 Nm {70 ± 7 kgm}
★ Tighten the bolts in the order of 1 - 4 .
30-186 D375A-5
" 2 "
DIMENSIONS TABLE OF FITTING
DISASSEMBLY AND ASSEMBLY JIG OF LINK PRESS
DIMENSIONS TABLE OF FITTING JIG OF LINK PRESS
Unit: mm
Dimensions of jig
a 4.2
b 2.0
c 52.1
Precaution
The link receiving faces of the jaw (1) must be verti-
cal.
Replaceable wear plate (2) type shown below is de-
sirable.
D375A-5 30-187
2 " "
DISASSEMBLY AND ASSEMBLY 1 LINK IN THE FIELD
DISASSEMBLY AND
ASSEMBLY OF
1 LINK IN THE FIELD
SPECIAL TOOLS
Ne- Q'ty New/Re- Sketch Ne- Q'ty New/Re- Sketch
Symbol Part No. Part name Symbol Part No. Part name
cessity model cessity model
1 791-646-7351 Push tool # 1 21 • 791-680-5551 • Guide 1
2 791-660-7460 Pin Brush # 1 22 • 791-680-9630 • Adapter 1
Push tool 23 • 791-632-1160 • Guide 1
3 791-646-7900 # 1
(L burash) 24 195-32-61210 Bolt 2
791-701-3000 Seal Cylinder
checker #
4 # 2 R 7 25 790-101-4300 (1,470kN 1
{150ton})
791-601-1000 Oil pump
26 790-101-1102 Pump # 1
Push tool
5 791-932-1110 # 1 Cylinder
(S burash)
27 790-101-4200 (294kN # 1
6 791-632-1021 Installer # 1
{30ton})
Remover 28 791-680-1630 Spacer # 1 N "
1 791-632-1100 and installer # 1
assembly
2 • 791-632-1130 • Adapter 1
DISASSEMBLY
3 • 790-434-1610 • Guide 1
4 • 01010-51440 • Bolt 2 1. Install tool R7-2 to link (1) with tool R7-24 and in-
5 • 791-685-9510 • Frame 1
stall tool R7-3 with tool R7-4.
R
★ Use the shoe bolts for tool R7-24.
6 • 791-685-9530 • Rod 1
7 • 791-685-9520 • Frame 1
8 • 791-685-9550 • Nut 3
9 • 04530-12030 • Eye bolt 1
7 10 • 791-685-9560 • Bolt 4
11 • 791-126-0150 • Adapter 1
12 • 791-685-9540 • Rod 1
13 • 791-632-1140 • Adapter 1
14 • 791-680-5520 • Guide 1
15 • 01010-51030 • Bolt 1
16 • 791-632-1150 • Pusher 1
17 • 791-685-9620 • Extention 1
18 • 791-632-1180 • Adapter 1
19 • 791-680-5543 • Adapter 1
20 • 791-632-1170 • Guide 1
30-188 D375A-5
" 2 "
2. Assemble tools R7-25 and R7-5 - R7-11, then ★ If the cylinder reaches the stroke end, con-
sling and set them on the shoe. nect tool R7-17 and repeat the work.
3. Insert tool R7-12 from the cylinder side and in- 5. Set tools R7-27 and R7-28 to the center on the
stall it with 2 tools R7-8. roller tread side of the link to be disassembled
and connect tool R7-26. Apply hydraulic pres-
sure to open the link by 5 - 6 mm and disconnect
it.
4. Set tools R7-13 - R7-16 and connect them by

tool R7-26. Apply hydraulic pressure and pull
out pin (2).
6. Repeat steps 1 - 4 to pull out pin (3) on the op-
posite side.
D375A-5 30-189
2 " "
7. Repeat step 5 to remove link (4). 2) Set tool R7-19 to the pin-side end of the link
and press fit pin (7).
★ Set the pin with its side hole on the link
tread side.
★ Press fitting force of pin:
206 - 323 kN {21 - 33 tons}
ASSEMBLY
1. Assemble the link sub-assembly according to
the following procedure.
1) Set tool R7-18 to the bushing-side end of link
(5) and press fit bushing (6).
★ Press fitting force of bushing: 2. Set link sub-assembly (8) to the link to be con-
196 - 294 kN {20 - 35 tons} nected.
3. Set link (9) on the opposite side and support it

with tool R7-20.
30-190 D375A-5
" 2 "
4. Similarly to the disassembly procedure, set tools 7. Set link (11) to be connected to link (10) and con-
R7-25, R7-5 - R7-12, and R7-17 to the link. nect them with tool R7-23, then remove tools R7-
5. Use R7-19 and R7-21 to press fit the pin. Use 27 and R7-28.
tools R7-22, R7-18, and R7-21 to press fit the
bushing. Press fit the pin and bushing alternate-
ly.
★ Press fit the pin first. After the bushing is en-
gaged with the link, remove tool R7-20 in-
stalled in step 3, then press fit the bushing.
206 - 323 kN {21 - 33 tons}
★ Press fitting force of bushing:
196 - 294 kN {20 - 30 tons}
8. Similarly to the disassembly procedure, set tools

R7-2 - R7-12 and press fit pin (12) to the link.
2 Pin fitting hole of link:
Gasket sealant (198-32-19890)
★ Set the pin with its side hole on the link tread
side.
412 - 646 kN {42 - 66 tons}
★ If the cylinder reaches the stroke end, insert
tools R7-17 and R7-14 - R7-16 and repeat
6. Similarly to the disassembly procedure, push the work.
open link (10) to be connected by using tools R7-
27 and R7-28.
D375A-5 30-191
2 " "
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF MASTER LINK
DISASSEMBLY • Master link type

1) Cutting and removal of master link on bush-
★ For the method of using tool R7, see DISAS-
ing side with gas
SEMBLY OF 1 LINK IN THE FIELD.
Cut the parts marked with gas and re-
1. Removal of track shoe assembly move the parts marked . Move master
Remove the track shoe assembly from the track links (5) and (6) in the direction of and to
frame. For details, see EXPANDING TRACK pull them out. Then, push pins (8) and (9)
SHOE ASSEMBLY. out of regular link (7) in the directions of
2. Disassembly of shoe and with a press.
Disconnect the all master links and divide the • Necessary special tools:
shoes into 4 parts. 1. Gas cutting machine
2. Tool R7
3. Removal of master link
• Master pin type
1) Cutting of regular link with gas
move the parts marked .
• Necessary special tool: Gas cutting ma-
chine
2) Removal of master link on pin side

move the parts marked . Push pin (10)
out of link (11) in the direction of with a
press. Then, pull pin (10) and link (12) to-
gether out of bushing (13).
• Necessary special tools:
2) Removal of regular link 1. Gas cutting machine
Push pin (1) in the direction of with a press 2. Tool R7
to remove it from link (2), then pull pin (1) and
link (3) together out of bushing (4).
D375A-5 30-193
2 " "
ASSEMBLY 2. Installation of link at bushing end

★ For the method of using tool R7, see DISAS- 1) Expand the center of the link tread with tool
SEMBLY of 1 link in the field. R7 as shown in the figure. (Expand the link
end by 10 mm.)
1. Assembly of link at bushing end
1) Press fit bushing-side master link (1) at
bushing end to bushing (2) with a press.
★ When press fitting both master links,
take care that they will be in parallel with
each other.
★ Do not damage the mating surfaces of
the master links and end faces of the
bushing.
Unit: mm
L1 184 ± 0.7
L2 253.4 ± 0.7
D1 Drill 33 in diameter 2) Set spacer (3) and seal assembly (4) to the
counterbore of the link of the connecting
D2 30 × 2.0 part.
3) Match the pin hole and bushing hole to each

other and connect the pin and bushing with
guide pin 1 .
30-194 D375A-5
" 2 "
4) Press fit pin (5) with tool R7 and install at ★ Adjust the end play of the connecting
bushing end master link (1). part (the thrust play between the links
2 Apply gasket sealant (198-32- before and after the pin) to 0 - 0.13 mm.
19890) to the pin hole of the link. ★ Take care that dirt and sand will not stick
to the seal, spacer, end of bushing, and
★ Set the pin with its side hole on the link
tap-hole mating face of the master link.
tread side.
5) Using tools R7, R8, R9, and R10, install the 3. Assembly of at pin end link
ring. 1) Set spacer (3) and seal assembly (4) to the
counterbore of the master link.
6) Install the shoe to the link of the connecting

part. 2) Pass pin (9) through bushing (8) and set and
7) Drive large plug (6) with tool R3 and supply press fit pin-side master links (10) at pin end
oil with tool R4, then drive small plug (7) with from both sides with tool R7.
tool R5. 3) Using tools R7, R8, R9, and R10, install the
ring.
4) Drive large plug (11) with tool R3 and supply
oil with tool R4, then drive small plug (12)
with tool R5.
★ When press fitting both master links,

take care that they will be in parallel with
each other (Bushing side and pin side).
★ Do not damage the mating surfaces of
the master links and end faces of the
bushing.
D375A-5 30-195
2 " "
4. Connection of master links

Place the assembled 2 shoes on a level place in
1 line with the shoe side up. Pull master link (13)
at pin end and bushing-side master link (14) to-
gether and set them to each other by the mating
faces. Place the shoe on the links and check that
the shoe bolt can be tightened easily until the
mating faces of the links are fitted together, then
connect the links with the master bolts.
Initial torque:
686 ± 68.6 Nm {70 ± 7 kgm}
30-196 D375A-5
" 2 "
DISASSEMBLY AND ASSEMBLY PIVOT SHAFT ASSEMBLY
REMOVAL AND
INSTALLATION OF
PIVOT SHAFT ASSEMBLY
SPECIAL TOOLS 3. Remove seal (2) and cover (3). q2

bol cessity model
1 791T-650-2330 Sleeve # 1 N "
2 791T-650-2340 Plate # 1 N "
3 790-201-3310 Bolt # 2
4 790-101-2510 Block # 1
5 790-101-2570 Washer # 2
P
6 01580-01613 Nut # 2
7 01643-31645 Washer # 2
Jack
8 790-105-2300 # 1
assembly
9 790-101-1102 Pump # 1
1. Track frame assembly • Carry out installation in the reverse order to re-
★ Remove the track frame assembly. For de- moval.
q1
tails, see REMOVAL OF TRACK FRAME
2 Press fitting face of pivot shaft:

ASSEMBLY.
2. Sling pivot shaft assembly (1) temporarily and
q2
remove the mounting bolts. Using forcing screw
1 , pull out the pivot shaft assembly. q1
4 Pivot shaft assembly: 390 kg ★ Using tool P, press fit seal (2) to the pivot
shaft.
2 Press fitting face of seal:
★ Check that press fitting dimension "a" of the
seal from the shaft end is in the standard
range.
• Press fitting dimension "a":
655 ± 1.0 mm
D375A-5 30-197
2 " "
DISASSEMBLY AND ASSEMBLY PIVOT SHAFT ASSEMBLY

P1 Sleeve
P2 Plate
30-198 D375A-5
" 2 "
DISASSEMBLY AND ASSEMBLY EQUALIZER BAR
REMOVAL AND
INSTALLATION OF
EQUALIZER BAR
SPECIAL TOOLS 3. Remove seal (2) and washer (3) together. q 1
★ Perform this procedure for only the right track
bol cessity model frame.
791-650-1300 Remover ! 1 4. Remove washer (4) and spacer (5).
• 791-735-1123 • Sleeve 1 ★ Receive the oil flowing out of the pivot case
• 790-434-1050 • Screw 1 with an oil pan, etc.
• 01580-02419 • Nut 1 6 Pivot case: 18 ¬
N 1
• 01643-32460 • Washer
Puller 5. Set hydraulic jack 1 (490 kN (50 tons}) under
790-101-2102 (294kN ! 1 the radiator guard.
{ton})
790-101-1102 Pump ! 1
REMOVAL
1. Remove the engine underguard and power train
underguard (front).
4 Engine underguard: 290 kg
Power train underguard (front): 280 kg

★ For the right track frame, disconnect the 4
hoses for the blade tilt cylinder.
★ Since the whole machine body will be raised
by using the blade, plug the hoses on the tilt 6. Remove cover (6).
cylinder side securely.
7. Remove cover (7) and loosen bolt (8).
D375A-5 30-199
2 " "
8. Loosen clamping bolt (9) of the rear equalizer 12. Disconnect lubrication tube (12).
q4
bar side pin. 13. Remove 2 lock plates (13).
q2 q3
q5
9. Remove side pin (10). 14. Using tool N1, remove center pin (14).
★ If the equalizer bar hole is not aligned with ★ If the equalizer bar hole is not aligned with
the track frame hole, the pin cannot be pulled the main frame hole, the pin cannot be pulled
out easily. Accordingly, adjust the height of out easily. Accordingly, adjust the height of
the equalizer bar with hydraulic jack 1 . the main frame with hydraulic jack 1 .
10. Repeat steps 6 - 9 and remove the side pin on

the opposite side.
11. Operate hydraulic jack 1 slowly to lower the ma-
chine body until the equalizer bar touches both
track frames.
30-200 D375A-5
" 2 "
15. Operate the blade to raise the front part of the INSTALLATION
machine body and set stand 3 under the radia- • Carry out installation in the reverse order to re-
tor guard. moval.
q1
★ After removing the grease from the pressfit-
ting surface of the seal, coat with gasket
sealant (LG-6).
★ Be careful not to install with the seal dis-
placed in the direction of twisting.
q2
2 Inside surface of bushing :
Grease (G2-LI)
★ Before installing the pin, operate hydraulic
jack 1 to adjust the height of the main frame
and align the center of the equalizer bar hole
16. Sling equalizer bar (15) and remove it over the and track frame hole.
main frame and track frame. ★ Set the pin with the grease hole facing the
¤ After removing the equalizer bar, do not low- outside of the machine.
er the machine body. q3
4 Equalizer bar assembly: 500 kg ★ Fit pin and bushing, install cover, then install
the cover and cushion.
★ Tighten bolt (8), then tighten cover mounting
bolt.
q4
3 Lock plate mounting bolt :
549 ± 59 Nm {56 ± 6 kgm}
q5
2 Equalizer bar bushing and main frame
bushing : Grease (G2-LI)
★ Before installing the pin, operate the crane to
align the center of the main frame hole and
the equalizer bar hole.
• Refilling with oil (pivot case)

5 Pivot case : 18 ¬ (SAE30)
D375A-5 30-201
2 " "
DISASSEMBLY AND ASSEMBLY OF EQUALIZER
DISASSEMBLY AND ASSEMBLY BAR BUSHING
DISASSEMBLY AND
ASSEMBLY OF EQUALIZER
BAR BUSHING
SPECIAL TOOLS 2. Guide bushing
1) Remove seal (2).
Symbol Part No. Part name 2) Remove snap ring (3).
cessity model
1 791T-650-2410 Bracket # 1 N "
2 791T-650-2420 Bracket # 1 N "
3 790-438-1110 Screw # 1
4 791-112-1180 Nut # 2
N 2 #
5 790-101-2540 Washer 2
Puller
6 790-101-2102 (294kN # 1
{30ton})
7 790-101-1102 Pump # 1
DISASSEMBLY
1. Center bushing
1) Remove center bushing (1). 3) Set tool N2 and remove side bushing (4)
from equalizer bar (5).
30-202 D375A-5
" 2 "
ASSEMBLY 2) Install snap ring (3).

1. Side bushing ★ After installing the snap ring, fill parts "c"
1) Set side bushing (4) and tool N2 and press fit before and after the side bushing with
grease (G2-LI).
2 Amount of grease to be supplied to
side bushing (4) to equalizer bar (5).
2 Outside of side bushing:
side bushing: 0.3 ¬
3) Using a press, press fit seal (2).
★ Press fit the side bushing in the direction
★ Press fitting force for seal:
shown below.
9.8 - 29.4 kN {1 - 3 tons}
★ Press fit the seal so that its metallic part
will not be projected from the equalizer
bar end.
2 Seal lip: Grease (G2-LI)
i)Set split (mating) face "a" of the outer

bushing on the level.
ii) Set grease holes "b" of the inner
bushing and outer bushing diagonally.
★ Press fitting force for side bushing:
34.3 - 73.5 kN {3.5 - 7.5 tons} 2. Center bushing
Using the press, press fit bushing (1).
2 Outside of center bushing:
★ Press fitting force for center bushing:
4.9 - 186.2 kN {5 - 19 tons}
D375A-5 30-203
2 " "

N2-1 Bracket
N2-2 Bracket
30-204 D375A-5
" 2 "
DISASSEMBLY AND ASSEMBLY SEGMENT TOOTH
REMOVAL AND
INSTALLATION OF
SEGMENT TOOTH
1. Stop the machine in a position where the seg- • Carry out installation in the reverse order to re-
ment tooth can be removed (between the chute moval.
and track frame).
2. Remove covers (1) and (2). 2 Seat of segment tooth mounting nut:
3 Segment tooth mounting nut:
1,813 ± 98 Nm {185 ± 10 kgm}
3. Remove the mounting bolts and segment tooth

(3).
★ Before removing the all mounting bolts, in-
sert bar 1 in the upper mounting bolt hole
and move and remove the segment tooth
outward.
4 Segment tooth: 35 kg
D375A-5 30-205
2 " "
REMOVAL AND INSTALLATION OF HYDRAULIC
DISASSEMBLY AND ASSEMBLY TANK ASSEMBLY
REMOVAL AND
INSTALLATION OF
HYDRAULIC
TANK ASSEMBLY
REMOVAL 5. Disconnect the 2 PPC hoses and 3 main hoses
¤ Lower the work equipment to the ground and re- (5) from the blade lift valve.
★ The PPC hoses are classified by the color
q1
lease the residual pressure from the piping, re-
fe r r i n g t o T E S T I N G A N D A D J U S T I N G , bands.
Releasing residual pressure from hydraulic cir-
cuit. Then, loosen the hydraulic oil filler cap to
release the internal pressure of the hydraulic
tank.
1. Drain the oil from the hydraulic tank.
6 Hydraulic tank: 230 ¬
2. Remove operator's cab right cover (1).
6. Open hydraulic tank front cover (6) and discon-

nect hoses (7) and (8) from the blade lift valve.
★ Move the disconnected hoses toward the op-
erator's cab.
3. Disconnect PPC charge valve (2) from the hy-

draulic tank.
★ Move the PPC charge valve toward the floor
frame.
30-206 D375A-5
" 2 "
7. Disconnect 6 PPC hoses (9), 4 rear main hoses 10. Lift off hydraulic tank assembly (16).
(10), and 4 front main hoses/tubes (11) from the 4 Hydraulic tank assembly: 380 kg q3
blade tilt and ripper Lo valve.
bands. q2
8. Disconnect return hose (12) and suction tube
(13) from the hydraulic tank.
9. Remove hydraulic tank front cover (14) and dis-

connect return hose (15).
D375A-5 30-207
2 " "
INSTALLATION 3 Hydraulic tank mounting bolt:

• Carry out installation in the reverse order to re- 151.9 ± 24.5 Nm {15.5 ± 2.5 kgm}
moval. q3
q1 q2
• Refilling with oil (Hydraulic tank)
Add oil through the oil filler to the specified level.
★ The connecting positions of the PPC hoses Run the engine to circulate the oil through the
are indicated by the band colors on their system. Then, check the oil level again.
quick couplers. When connecting them,
confirm them by the band colors. • Bleeding air
Bleeding the air from the piping.
For details, see TESTING AND ADJUSTING,
Bleeding air from hydraulic cylinder.
Distinguishing color bands

(View from operator’s cad)
A. Transparent
B. Red/White
C. Black/Blue
D. Brown
E. Black
F. Green
G. White
H. Yellow
30-208 D375A-5
" 2 "
REMOVAL AND INSTALLATION OF WORK
DISASSEMBLY AND ASSEMBLY EQUIPMENT AND PPC PUMP ASSEMBLY
REMOVAL AND
INSTALLATION OF WORK
EQUIPMENT
AND PPC PUMP ASSEMBLY
REMOVAL 7. Sling work equipment pump assembly (5) tem-
¤ Lower the work equipment to the ground and re- porarily and remove the mounting bolts, then re-
lease the residual pressure from the piping, remove the work equipment pump assembly.
fe r r i n g t o T E S T I N G A N D A D J U S T I N G , 4 Work equipment and PPC pump
Releasing residual pressure from hydraulic cir- assembly: 45 kg
tank.
nal of the battery.
2. Remove the floor frame assembly. For details,
see REMOVAL OF FLOOR FRAME ASSEM-
BLY.
3. Disconnect hydraulic oil temperature sensor
connector (CN-452) (1).
INSTALLATION
4. Disconnect 2 hoses (2).
5. Disconnect 4 delivery hoses (3). moval.
6. Disconnect suction tube (4).
★ Remove the 2 clamps and move the coupling 3 Suction tube clamp bolt:
toward the pump to disconnect the suction 26.95 ± 2.45 Nm {2.75 ± 0.25 kgm}
tube.
system. Then, check the oil level again.
D375A-5 30-209
2 " "
REMOVAL AND INSTALLATION OF BLADE
DISASSEMBLY AND ASSEMBLY LIFT VALVE ASSEMBLY
REMOVAL AND
INSTALLATION OF BLADE
LIFT VALVE ASSEMBLY
REMOVAL 4. Open hydraulic tank front cover (4) and discon-
¤ Lower the work equipment to the ground and re- nect hoses (5) and (6).
lease the residual pressure from the piping, re-
fe r r i n g t o T E S T I N G A N D A D J U S T I N G ,
Releasing residual pressure from hydraulic cir-
tank.
2. Remove operator's cab right cover (1).
5. Sling work blade lift valve (7) temporarily and re-

move the mounting bolts. Then, remove the
blade lift valve assembly.
4 Blade lift valve assembly: 60 kg
3. Disconnect 2 PPC hoses (2) and 3 main hoses

(3).
bands. q1
30-210 D375A-5
" 2 "
REMOVAL AND INSTALLATION OF BLADE
DISASSEMBLY AND ASSEMBLY LIFT VALVE ASSEMBLY
INSTALLATION
moval.
q1
★ The connecting positions of the PPC hoses
are indicated by the band colors on their
confirm them by the band colors.

A. Transparent
B. Red/White

• Bleeding air
Bleed air from the piping. For details, see TEST-
ING AND ADJUSTING, Bleeding air from hy-
draulic cylinders.
D375A-5 30-211
2 " "
DISASSEMBLY AND ASSEMBLY BLADE LIFT VALVE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF BLADE LIFT VALVE

ASSEMBLY
★ This chapter deals only with precautions to be 4. Assembly of main relief and shuttle valve as-
followed when reassembling the Blade Lift Valve sembly
Assembly. Fit the O-ring and main relief and shuttle valve
assembly (18).
ASSEMBLY ★ Tighten the mounting bolts in the order of 1
-4.
3 Mounting bolt:
★ Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with engine
oil before installing. 1st time:
34.3 ± 4.9 Nm {3.5 ± 0.5 kgm}
1. Assembly of shuttle valve assembly
2nd time:
Install ball (31) and fit the O-ring and plug (30).
3 Plug:
66.15 ± 7.35 {6.75 ± 0.75 kgm}
34.3 ± 4.9 Nm {3.5 ± 0.5 kgm}
2. Assembly of check valve assembly

Install valve (29) and spring (28) and fit the O-
ring and plug (27).
3 Plug:367.5 ± 24.5 Nm {37.5 ± 2.5 kgm}
3. Assembly of suction valve assembly

Install valve (26) and spring (25) and fit the O-
ring and plug (24).
3 Plug:514.5 ± 24.5 Nm {52.5 ± 2.5 kgm}
30-212 D375A-5
" 2 "
DISASSEMBLY AND ASSEMBLY BLADE LIFT VALVE ASSEMBLY
★ If the main relief valve was disassembled,

adjust it after installing the valve assembly to
the machine body, referring to TESTING
AND ADJUSTING, Measuring and adjusting
work equipment oil pressure.
5. Assembly of demand valve assembly
1) Install seal (17), spool (16), O-ring, and case
(15).
3 Mounting bolt:
186.2 ± 9.8 Nm {19 ± 1 kgm}
2) Install spring (14) and case (13).
3 Mounting bolt:
186.2 ± 9.8 Nm {19 ± 1 kgm}
6. Assembly of main spool assembly

1) Install spool (12), O-ring, and case (11).
2) Install retainer (10), spring (9), O-ring, and
case (8).
3) Install retainer (7), spacer (6), spring (5), re-
tainer (4), and washer (3) and tighten bolts
(2).
3 Mounting bolt:
110.25 ± 12.25 Nm
{11.25 ± 1.25 kgm}
★ Tighten the bolts with the spool installed
in the body.
4) Install the O-ring and case (1).
D375A-5 30-213
2 " "
DISASSEMBLY AND ASSEMBLY OF BLADE TILT
DISASSEMBLY AND ASSEMBLY AND RIPPER LOW VALVE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF BLADE TILT AND RIPPER

LOW VALVE ASSEMBLY
30-214 D375A-5
" 2 "
DISASSEMBLY AND ASSEMBLY OF BLADE TILT
DISASSEMBLY AND ASSEMBLY AND RIPPER LOW VALVE ASSEMBLY
★ This chapter deals only with precautions to be

followed when reassembling the Blade Tilt and
Ripper Low Valve Assembly.
ASSEMBLY
oil before installing.
1. Assembly of shuttle valve assembly
1) Install ball (20) and seat (19) to plug (18).
2) Install the O-ring and plug (18).
3 Plug:
34.3 ± 4.9 Nm {3.5 ± 0.5 kgm}
2. Assembly of check valve assembly

1) Install valve (17) and spring (16).
2) Install the O-ring, seat (15), and bar (14) and
tighten bolts (13).
3. Assembly of main relief valve assembly
Install the O-ring and main relief valve assembly
(12).
3 Main relief valve assembly:
83.3 ± 14.7 Nm {8.5 ± 1.5 kgm}
★ If the main relief valve was disassembled,
adjust it after installing the valve assembly to
the machine body, referring to TESTING
AND ADJUSTING, Measuring and adjusting
work equipment oil pressure.
4. Assembly of spool assembly
1) Install spool (10) to body (11).
2) Set retainer (9), spacers (8) and (7), spring
(6), retainer (5), and washer (4) and tighten
bolts (3).
★ Tighten the bolts with the spool installed
in the body.
3 Mounting bolt:
34.3 ± 4.9 Nm {3.5 ± 0.5 kgm}
D375A-5 30-215
2 " "
DISASSEMBLY AND ASSEMBLY RIPPER HIGH VALVE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF RIPPER HIGH VALVE

ASSEMBLY
30-216 D375A-5
" 2 "
DISASSEMBLY AND ASSEMBLY RIPPER HIGH VALVE ASSEMBLY
★ This chapter deals only with precautions to be 5. Assembly of constant-differential pressure

followed when reassembling the Ripper High valve assembly
Valve Assembly. 1) Install spool (9).
2) Set retainer (8), spring (7), and retainer (6) to
ASSEMBLY the spool and install plug (5).
★ Be sure to tighten the plug with the spool in-
stalled in the valve.
oil before installing.
6. Install ball (4), O-ring, and plug (3).
1. Install valve (23), spring (22), seat (21), O-ring, 3 Plug: 34.3 ± 4.9 Nm {3.5 ± 0.5 kgm}
and plug (20).
3 Plug: 7. Install the O-ring and blocks (2) and (1).
514.5 ± 24.5 Nm {52.5 ± 2.5 kgm}
2. Install check valve (19), spring (18), O-ring, and
plug (17).
3 Plug: 127.4 ± 19.6 Nm {13 ± 2 kgm}
3. Assembly of ripper lift high valve assembly
1) Install spool (16).
2) Set retainer (15) and spring (14) to the spool
and install the O-ring and plug (13).
3 Plug:
66.15 ± 7.35 {6.75 ± 0.75 kgm}
3) Set retainer (12) and spring (11) to the spool
and install the O-ring and plug (10).
3 Plug:
66.15 ± 7.35 {6.75 ± 0.75 kgm}
★ Be sure to tighten the plugs with the
spool installed in the valve.
4. Assembly of ripper tilt high valve assembly

Assemble the ripper tilt high valve assembly ac-
cording to the assembly procedure for the ripper
lift high valve assembly.
D375A-5 30-217
2 " "
DISASSEMBLY AND ASSEMBLY OF PPC CHARGE
DISASSEMBLY AND ASSEMBLY VALVE ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF PPC CHARGE
VALVE ASSEMBLY
followed when reassembling the PPC Charge
Valve Assembly.
ASSEMBLY
★ Check the all parts for dirt or damage. Coat their
sliding surfaces with engine oil before installing.
1. Install plugs (13) and (12).
2. Install poppet (11) and spring (10) to valve body
(1), then tighten plug (9).
★ When installing the spring, check its free
length.
Free length of spring: 25.3 mm
3. Install poppet (8) and spring (7) to valve body (1),
then tighten plug (6).
★ When installing the spring, check its free
length.
Free length of spring: 20.6 mm
4. Install strainer (5) and plug (4).
★ Tighten the strainer to the following torque
and caulk it by 2 places.
3 Strainer:
7.35 ± 0.49 Nm {0.75 ± 0.05 kgm}
5. Tighten relief valve (3) into valve body (1).

3 Relief valve:
53.9 ± 4.9 Nm {5.5 ± 0.5 kgm}
6. Install accumulator (2) to valve body (1).
30-218 D375A-5
" 2 "
DISASSEMBLY AND ASSEMBLY OF BLADE PPC
DISASSEMBLY AND
ASSEMBLY OF BLADE PPC
VALVE ASSEMBLY
followed when reassembling the Blade PPC
Valve Assembly.
ASSEMBLY
1. Install the blade RAISE valve
1) Install the blade RAISE valve
2) Install the blade RAISE valve
★ Install spring (37) with its small seat di-
ameter (inside diameter) end on the
shim (38) side.
3) Install spring (36), retainer (35), piston (34),
spring (33), and piston (32).
★ When installing piston (34), apply grease
(G2-LI) to the outside of the piston and
the inside of the body hole.
(G2-LI) to the inside of the body hole.
2. Install the blade LOWER valve.
1) Install valve (31) to body (18).
2) Install shim (30) and spring (29) to valve
(31).
shim (30) side.
3) Install spring (28), retainer (27), piston (26),
shim (25), retainer (24), ball (23), collar (22),
spring (21), spacer (20), and piston (19).
3. Install the blade tilt valve.
1) Install valve (17) to body (18).
2) Install shim (16) and spring (15) to valve
(17).
shim (16) side.
D375A-5 30-219
2 " "
DISASSEMBLY AND ASSEMBLY OF BLADE PPC
3) Install spring (14), retainer (13), and pistons

(12) and (11).
4. Install orifice (10).
3 Orifice:
11.8-14.7 Nm {1.2-1.5 kgm}
5. Install the O-ring and plate (9).

6. Install the O-ring and body (8).
7. Install the O-ring to collar (7) and install them to
body (8), then install seal (6).
8. Install plate (5).
3 Mounting bolt:
11.8-14.7 Nm {1.2-1.5 kgm}
9. Install joint (4).

★ When installing the joint, apply adhesive (LT-
2) to the female threads hole of body (8).
3 Joint:
44.1 ± 4.9 Nm {3.5 ± 0.5 kgm}
★ Apply grease (G2-LI) to the rocking part of
the joint.
10. Install boot (3) and disc (2) and secure them with
nut (1).
★ Apply grease (G2-LI) to the contact surfaces
of disc (2) and pistons (32), (19), and (11).
3 Nut:
112.7 ± 14.7 Nm {11.5 ± 1.5 kgm}
★ After installing the disc, adjust its height, re-
ferring to TESTING AND ADJUSTING, Ad-
justing PPC valve.
30-220 D375A-5
" 2 "
DISASSEMBLY AND ASSEMBLY OF RIPPER
DISASSEMBLY AND ASSEMBLY PPC VALVE ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF RIPPER
PPC VALVE ASSEMBLY
followed when reassembling the Ripper PPC
Valve Assembly.
ASSEMBLY
1. Install valve (13) to body (14).
2. Install shim (12) and spring (11) to valve (13).
★ Install spring (11) with its small seat diameter
(inside diameter) end on the shim (12) side.
3. Install spring (10), retainer (9), and piston (8).
★ Springs (10) having different number of turns
are used for the following hydraulic ports.
Take care when installing them.
Port Total number of turns
P1, P2 9
P3, P4 10.5
★ Each port position is stamped on the under-

side of the valve body.
2 Piston: Grease (G2-LI)
★ When installing piston (8), apply grease to
the outside of the piston and the inside of the
body hole.
4. Install the O-ring to collar (7) and install them to
body (14), then install seal (6).
5. Install plate (5).
3 Mounting bolt:
13.72 ± 1.96 Nm {1.4 ± 0.2 kgm}
6. Install joint (4).
2 Rocking part of joint: Grease (G2-LI)
2 Joint: Thread tightener (LT-2)
3 Joint: 44.1 ± 5 Nm {4.5 ± 0.5 kgm}
★ Observe the tightening torque for the joint.
7. Install boot (3) and disc (2) and secure them with
nut (1).
3 Nut: 112.7 ± 14.7 Nm {11.5 ± 1.5 kgm}
★ After installing the disc, adjust its height, re-
ferring to TESTING AND ADJUSTING, Ad-
justing PPC valve.
D375A-5 30-221
2 " "
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC
DISASSEMBLY AND ASSEMBLY CYLINDER ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
Sym- Ne- Q'ty New/Re- Sketch 1. Cylinder tube
Part No. Part name
bol cessity model Remove the cylinder tube.
Cylinder re-
1 790-502-1003 ! 1 2. Quick drop valve assembly
pair stand
Push tool ★ Perform this procedure for only the blade lift
790-201-1702 # 1
kit cylinder.
• 790-201-1841 • Push tool 1 1) Remove quick drop valve assembly (1).
2
• 790-201-1861 • Push tool 1
• 790-101-5021 • Clip 1
• 01010-50816 • Bolt 1
Push tool
790-201-1500 # 1
kit
• 790-201-1650 • Plate 1
3
• 790-201-1670 • Plate 1
• 790-101-5021 • Clip 1
U
• 01010-50816 • Bolt 1
4 790-720-1000 Expander # 1
796-720-1680 Ring # 1
07281-01589 Clamp # 1
796-720-1720 Ring # 1
5
07281-02429 Clamp # 1 2) Disassemble the quick drop valve assembly
796-720-1690 Ring # 1 according to the following procedure.
07281-02169 Clamp # 1
i) Remove elbow (2).
ii) Remove spring (3), washer (4), and
790-102-2302 Wrench
valves (5) and (6), then pull out collar (7).
# 1
6 790-330-1100 Multi-
wrench
790-101-1102 Pump # 1
30-222 D375A-5
" 2 "
3. Piston rod assembly 2) Remove spacer (11).

1) Set cylinder assembly (8) to tool U1. 3) Remove the piston assembly.
2) Remove head assembly (9). 4) Remove backup rings (13) and (14) and O-
3) Pull out piston rod assembly (10). ring (15).
★ Put an oil pan under the cylinder to re- 5) Remove retainer (16).
ceive the oil.
6) Disassemble the piston assembly according

4. Piston assembly to the following procedure.
1) Set piston rod assembly (10) to tool U1. i) Remove wear ring (17).
ii) Remove piston ring (18).
D375A-5 30-223
2 " "
5. Cylinder head assembly ii) Remove snap ring (22) and tool (23).
1) Remove cylinder head assembly (19) from iii) Remove packing (24) and bushing (25).
the piston rod.
2) Disassemble the cylinder head assembly ac-

cording to the following procedure.
i) Remove O-ring (20) and backup ring
(21).
30-224 D375A-5
" 2 "
ASSEMBLY v) Install backup ring (21) and O-ring (20).

★ Apply engine oil to the sliding surfaces of each
part and install the packings, dust seals, and O-
rings, taking care not to damage them.
1. Cylinder head assembly
1) Assemble the cylinder head assembly ac-
2) Install cylinder head assembly (19) to the

piston rod.
i) Using tool U2, press fit bushing (25) to

the head.
ii) Install packing (24).
iii) Using tool U3, press fit seal (23).
iv) Install snap ring (22).
D375A-5 30-225
2 " "
2. Piston assembly 2) Install retainer (16).

1) Assemble the piston assembly according to 3) Install the O-ring and backup rings (14) and
the following procedure. (13).
i) Using tool U4, expand piston ring (18). ★ Apply grease to the O-ring and backup
★ Set the piston ring to the tool and rings so that the backup rings will not
turn the handle of the tool by 8 - 10 open.
turns to expand the piston ring. 4) Install piston assembly (12).
ii) Remove piston ring (18) from tool U4 5) Install spacer (11) and tighten the mounting
and install it to the piston. bolts.
2 Mounting bolt:
3 Mounting bolt:
Blade lift:
66.5 ± 7.5 Nm {6.75 ± 0.75 kgm}
Blade tilt, ripper lift, ripper tilt:
176.5 ± 19.5 Nm {18 ± 2 kgm}
iii) Set tool U5 and shrink piston ring (18).

iv) Install wear ring (17) to the piston.
3. Piston rod assembly

1) Set cylinder (8) to tool U1.
30-226 D375A-5
" 2 "
2) Install piston rod (10) to cylinder (8). 2) Install quick drop valve assembly (1).
★ Apply grease to the sealing part of the
piston. 5. Cylinder tube
★ Push in the piston rod fully. Install the cylinder tube.
3) Push head assembly (9) in the cylinder and
tighten the mounting bolts.
★ Apply grease to the backup rings.
4. Quick drop valve assembly

★ Perform this procedure for only the blade lift
cylinder.
1) Assemble the quick drop valve assembly ac-
i) Install collar (7), valves (6) and (5), wash-
er (4), and spring (3).
D375A-5 30-227
2 " "
DISASSEMBLY AND ASSEMBLY OF RIPPER PIN
DISASSEMBLY AND ASSEMBLY PULLER CYLINDER ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF RIPPER PIN
PULLER
CYLINDER ASSEMBLY
Sym- Ne- Q'ty New/Re- Sketch 1. Cylinder assembly
Part No. Part name
bol cessity model 1) Set pin puller cylinder assembly (1) to tool
Cylinder re- U1.
1 790-502-1003 ! 1
pair stand
2) Using tool U6, remove cylinder head assem-
Push tool bly (2).
790-201-1702 # 1
kit
3) Remove piston rod (3) and cylinder head as-
2 • 790-201-1721 • Push tool 1
sembly (2) together.
• 790-101-5021 • Clip 1
★ Put an oil pan under the cylinder to re-
• 01010-50816 • Bolt 1 ceive the oil.
Push tool
790-201-1500 # 1
kit
3 • 790-201-1530 • Plate 1
U
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
4 790-720-1000 Expander # 1
796-720-1630 Ring # 1
5
07281-00709 Clamp # 1
Wrench
790-102-2302
# 1
6 790-330-1100 Multi-
wrench
790-101-1102 Pump
2. Cylinder head assembly

1) Remove cylinder head assembly (2) from
piston rod (3).
30-228 D375A-5
" 2 "
2) Remove O-ring (5) and backup ring (6). ASSEMBLY

3) Remove O-ring (7). ★ Apply engine oil to the sliding surfaces of each
4) Remove snap ring (8) and dust seal (9). part and install the packings, dust seals, and O-
5) Remove rod packing (10) and bushing (11). rings, taking care not to damage them.
1) Using tool U4, expand piston ring (12).
★ Set the piston ring to the tool and turn the
handle of the tool by 8 - 10 turns to expand
the piston ring.
2) Remove piston ring (12) from the tool and in-
stall it to piston rod (3).
3) Using tool U5, shrink piston ring (12).

Remove piston ring (12) from piston rod (3).
D375A-5 30-229
2 " "
2. Cylinder head assembly 6) Install cylinder head assembly (2) to piston

1) Using tool U2, press fit bushing (11) to cylin- rod (3).
der head (4).
3. Cylinder assembly
2) Using tool U3, press fit dust seal (9) to cylin- 1) Set the cylinder to tool U1 and support it with
der head (4). block 1 .
2) Install piston rod (3) and cylinder head as-
sembly (2) together.
★ Apply grease to the sealing part of the
piston.
★ Apply grease to the backup ring.
★ Push in the piston fully.
3) Using tool U6, tighten cylinder head assem-
bly (2).
3 Cylinder head assembly:
441 ± 44.1 Nm {45 ± 4.5 kgm}
3) Install snap ring (8) and rod packing (10).

4) Install O-ring (7).
5) Install backup ring (6) and O-ring (4).
30-230 D375A-5
" 2 "
DISASSEMBLY AND ASSEMBLY BLADE ASSEMBLY
REMOVAL AND
INSTALLATION OF
BLADE ASSEMBLY
REMOVAL
¤ Lower the work equipment to a level place and
set blocks 1 under both straight frames (6) se-
curely.
1. Remove cap (1) from the lift cylinder. q1
★ Check the quantity and thickness of the in-
serted shims.
3. Remove both covers (3).

4. Disconnect hose (4).
★ Plug the openings so that dirt will not enter
the piping.
5. Remove both trunnion caps (5).
6. Remove blade assembly (6). q2
★ Start the engine and move the machine in re-
verse slowly to disconnect the blade assem-
bly from the trunnion.
2. Sling lift cylinder assembly (2) temporarily. Start

the engine and retract the piston rod fully. Install
the cylinder fixing tool and fix the cylinder to the
radiator guard.
★ Bind the piston rod with wires so that it will
not come out.
★ Similarly, disconnect the cylinder on the op-
posite side from the blade.
¤ Release the residual pressure from the piping,
referring to TESTING AND ADJUSTING, Re-
leasing residual pressure from hydraulic circuit.
Then, loosen the hydraulic oil filler cap to release
the internal pressure of the hydraulic tank.
D375A-5 30-231
2 " "
INSTALLATION
moval.
q1
★ Referring to TESTING AND ADJUSTING,
Adjusting semi-U tiltdozer, adjust the shims.
q2
★ Adjust height "b" and width "c" of both
straight frames to the following values with
block 1 , etc.
• Trunnion height "b": Approx. 863 mm
• Frame width "c": Approx. 3,484 mm

30-232 D375A-5
" 2 "
DISASSEMBLY AND
ASSEMBLY OF
BLADE ASSEMBLY
DISASSEMBLY 3. Sling tilt cylinder assembly (4) temporarily and
¤ Set blocks 1 and stands 2 securely under both remove the lock plate and pin (5).
straight frames and blade to stabilize the blade. 4. Remove the lock plate and pin (6) and lift off tilt
cylinder assembly (4).
4 Tilt cylinder assembly: 380 kg
1. Remove right frame covers (1) and (2).

2. Disconnect tilt cylinder hose (3).
5. Set block 3 under right center brace (7) and re-
move the mounting bolts of cap (8) on the center
frame side.
★ Check the quantity and thickness of the
shims inserted under the cap.
D375A-5 30-233
2 " "
6. Sling right straight frame (9) temporarily and dis- 11. Sling center brace (15) temporarily and remove
connect right center brace (7). the mounting bolts and cap (16) and lift off both
7. Remove the lock plate and pin (10) and lift off center braces (15) and (7).
right straight frame (9). ★ Check the quantity and thickness of the
4
shims inserted under the cap.
4
Straight frame: 1,150 kg
Center brace: 220 kg
8. Sling tilt brace (11) temporarily and remove the

12. Sling blade (17) and bring down the blade.
lock plate and pin (12).
4 Blade: 4,900 kg
9. Remove the lock plate and pin (13) and lift off tilt
brace (11).
4 Tilt brace: 200 kg
10. Disconnect the left center brace and remove left
straight frame (14) similarly to steps 5 - 7 above.
30-234 D375A-5
" 2 "
ASSEMBLY 3. Sling right straight frame (9) and install pin (10)
★ Check the thickness and quantity of the shims and secure it with the lock plate.
removed from each part during disassembly and 4 Straight frame: 220 kg
insert those shims to their original position.
★ For adjustment of the shims, see TESTING AND 4. Sling right straight frame (9) temporarily and set
ADJUSTING, Adjusting blade. the ball of right center brace (7) to right straight
frame (9).
1. Sling blade (17) and put a block, stand, etc. un-
der it securely to stabilize it.
4 Blade: 4,900 kg
5. Insert the shims under cap (8) of right center

brace (7) and tighten the mounting bolts.
★ Standard shim thickness: 4.5 mm
2. Sling center brace (15) and set the shims and
tighten the mounting bolts of cap (16).
★ Set a block under the center brace according
to the height of the straight frame.
★ Standard shim thickness: 4.5 mm
4 Center brace: 220 kg
★ Install center brace (7) on the opposite side
similarly.
D375A-5 30-235
2 !
4 !
6. Sling tilt cylinder assembly (4) and install pin (6) 10. Install left straight frame (14) similarly to steps 3
and secure it with the lock plate. - 5 above and connect the left center brace.
4 Tilt cylinder assembly: 380 kg 11. Sling tilt brace (11) and install pin (13) and se-
cure it with the lock plate.
4
7. Install pin (5) and secure it with the lock plate.
Tilt brace: 200 kg
12. Install pin (12) and secure it with the lock plate.
8. Connect tilt cylinder hose (3).

9. Install right frame covers (2) and (1).
13. Supplying grease
After finishing the assembly work, supply suffi-
cient amount of grease to the parts shown in the
following figure.
2 Each part of work equipment:
Grease (G2-LI)
30-236 D375A-5
" 2 "
DISASSEMBLY AND ASSEMBLY OF GIANT
DISASSEMBLY AND ASSEMBLY RIPPER ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF GIANT
RIPPER ASSEMBLY
DISASSEMBLY ★ Start the engine and retract the piston rod
1. Drive the machine over block 1 and lower the fully and lower it onto the lift cylinder.
blade to the ground. ¤ After stopping the engine, release the resid-
ual pressure from the piping, referring to
¤ Lock the brake securely.
TESTING AND ADJUSTING, Releasing re-
2. Sling the shank temporarily and operate the pin sidual pressure from hydraulic circuit. Then,
puller switch to pull out the shank pin. loosen the hydraulic oil filler cap to release
the internal pressure of the hydraulic tank.
3. Raise the ripper fully and lower and remove
shank (1) slowly. 7. Disconnect 4 lift cylinder hoses (4), 4 tilt cylinder
4 Shank: 470 kg hoses (5), and 2 pin puller cylinder hoses (6).
4. Set stand 2 between the arm and beam.
8. Sling tilt cylinder assembly (7) temporarily and

remove pin (8) and lift off tilt cylinder assembly
5. Sling the lift cylinder assembly and remove pin (7).
4
(2).
Tilt cylinder assembly: 270 kg
★ Start the engine and retract the piston rod
fully and lower it onto the arm.
6. Sling the tilt cylinder assembly and remove pin
(3).
D375A-5 30-237
2 " "
9. Sling lift cylinder assembly (9) temporarily and ASSEMBLY

remove pin (10) and lift off lift cylinder assembly 1. Sling and set arm (13) in position and install both
(9). pins (14) and secure them with the lock plates.
4
4
Lift cylinder assembly: 350 kg
Arm: 1,000 kg
★ Set a stand under the arm.
10. Sling beam (11) temporarily and remove both

pins (12) and lift off beam (11).
2. Sling and set beam (11) in position and install
4 Beam: 2,000 kg both pins (12) and secure them with the lock
plates.
4 Beam: 2,000 kg
★ Set a stand under the beam.
11. Sling arm (13) temporarily and remove both pins

(14) and lift off arm (13).
4 Arm: 1,000 kg
30-238 D375A-5
" 2 "
3. Sling and set lift cylinder assembly (9) in position 6. Sling the tilt cylinder assembly temporarily. Start
and install pin (10) and secure it with the lock the engine and extend the piston rod to align it
plate. with the pin hole. Install pin (3) and secure it with
4 Lift cylinder assembly: 350 kg the lock plate.
7. Sling the lift cylinder assembly temporarily. Start
the engine and extend the piston rod to align it
with the pin hole. Install pin (2) and secure it with
the lock plate.
8. Drive the machine over block 1 and lower the
blade to the ground.
¤ Lock the brake securely.
4. Sling and set tilt cylinder assembly (7) in position

and install pin (8) and secure it with the lock
plate.
4 Tilt cylinder assembly: 270 kg
9. Raise the ripper a little and remove stand 2 .

10. Raise the ripper fully. Pass a wire through the
shank holder and raise shank (1) slowly to align
it with the pin hole. Operate the pin puller switch
to insert the shank pin.
11. Raise the blade and lower the machine body
from block 1 .
12. Bleed air from the cylinders. For details, see
TESTING AND ADJUSTING, Bleeding air from
hydraulic cylinders.
5. Connect 2 pin puller cylinder hoses (6), 4 tilt cyl-
inder hoses (5), and 4 lift cylinder hoses (4).
D375A-5 30-239
2 " "
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF ROPS GUARD
REMOVAL AND
INSTALLATION OF ROPS
GUARD
REMOVAL
1. Sling ROPS guard (1) and remove 12 mounting
bolts (2). q1
2. Lift off ROPS guard (1). q2
4 ROPS guard: 766 kg
INSTALLATION
moval.
q1
3 ROPS guard mounting bolt:
1,715 ± 196 Nm {175 ± 20 kgm}
q2
★ Install the ROPS guard so that the fire extin-
guisher seats (3 pieces) will be on the right
of the machine body.
30-240 D375A-5
! 2 !
4
REMOVAL AND INSTALLATION OF OPERATOR'S
DISASSEMBLY AND ASSEMBLY CAB ASSEMBLY
REMOVAL AND
INSTALLATION OF
OPERATOR'S CAB
ASSEMBLY
REMOVAL 6. Remove garnishes (7), (8), and (9).
nal of the battery.
1. Remove the ROPS guard. For details, see Re-
moval of ROPS guard.
2. Remove the operator's cab left cover.
3. Disconnect wiring connectors (CN-19) (2) and
(CN-20, CN-21) (3).
★ Pull out the wires from inside of the opera-
tor's cab.
4. Disconnect 4 window washer hoses (4). q1
★ Pull out the hoses from inside of the opera-
tor's cab.
7. Remove covers (10) on both sides and covers
(12) and (13).
5. Remove steps (5) and covers (6).

8. Remove angle (14) and in-cab angle (15).
D375A-5 30-241
2 !
4 !
9. Remove 19 mounting bolts and lift off operator's INSTALLATION

cab assembly (16). ★ Before installing the cab, loosen the mounting
4 Operator's cab assembly: 420 kg bolts of angle bar (14) and in-cab angle bar (15).
1. Seal
1) Fit seal (17) to guide plate (18) of the air con-
ditioner box.
2 Part A on outside of seal
(Sealing face against cab):
Grease (G2-LI)
2) Sling operator's cab assembly (16) and stick

seal (19) to the mating face of the former.
30-242 D375A-5
! 2 !
4
DISA
2. Operator’s cab assembly ★ Check that clearance a between cab-

1) Lower the operator’s cab assembly to the side air conditioner duct (22) and monitor
floor slowly. (23) is the same on both sides.
★ Take care not to shift or damage the seal. Furthermore, check that seals (25) of
★ Check that the air conditioner duct seal cab-side air conditioner ducts (22-1) are
on the cab side is fitted to the air condi- fitted to both faces C of dashboard-side
tioner duct on the dashboard side and no air conditioner duct (26) and are not
clearance is made. shifted laterally.
★ Lower the cab carefully, since the clear-
ance between the air conditioner duct on
the cab side and the monitor is little.
2) Tighten the mounting bolts temporarily.
★ Note that the bolt length and washer at
the door inlet are different.
★ Check that the seal between air condi-
tioner bracket (20) and cab (21) is fitted
securely.
★ Check the joint B of the seal and floor
frame for gap.
If there is a clearance, remove the cab,
and then install it correctly. If the clear-
ance is little, fill it with sealant, however.
D375A-5 30-242-1
4
★ If the clearance between cab-side air

conditioner duct (22-1) and monitor (23)
is not the same on both sides, loosen
mounting screws (27) of the cab-side air
conditioner duct and adjust the duct so
that the clearance will be the same on
both sides.
If cab-side air conditioner duct and dash-
board-side air conditioner duct are shift-
ed laterally, adjust their positions
similarly to the above.
3) Securely tighten the mounting bolts tight-

ened temporarily in step 2).
4) Securely tighten the mounting bolts of angle
bar (14) and in-cab angle bar (15).
★ After the above work, carry out installation from

step 7 in reverse order to removal.
q1
★ When connecting the window washer hoses,
match the colors of their bands.
30-242-2 D375A-5
4
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF FLOOR FRAME
8. Disconnect blade PPC hoses (15), (16), (17), 12. Remove window washer hose clamp (33).
(18), and (19). q2
★ Move the hoses together toward the floor
frame.
9. Disconnect ripper PPC hoses (20), (21), (22),
(23), and (24). q3
★ Move the hoses together toward the floor
frame.
10. Disconnect PPC hose (25).
13. Disconnect parking brake cable (34) from the le-

ver and remove it from the bracket.
★ Before disconnecting the cable, check its in-
stalled length. q4
14. Disconnect brake pedal linkage (35) from the
turnbuckle. q5
★ Before disconnecting the linkage, check the
installed length of the brake rod.
★ The turnbuckle has opposite threads.
11. Remove wiring connectors CN-FD5 (26), CN-
BWR (27), CN-USB (28), CN-FSB (29), CN-TL1
(30), CN-19 (31), and CN-SX8 (32).
★ Disconnect CN-TL1 from inside of the floor.
30-244 D375A-5
" 2 "
15. Remove armrest (36). 19. Disconnect ground wire (40).

16. Remove right console (37). 20. Remove 4 left front mounting bolts (41). q7
q8
★ Disconnect wiring connectors (CN-262, CN-
21. Remove 4 right front mounting bolts (42).
263) inside the console.
★ Before removing the console, remove the le-
ver boot from the console.
17. Remove left console cover (38).
22. Lift off floor frame assembly (45).

4 Floor frame assembly: 600 kg
★ Using a chain block, sling the floor frame as-
sembly slowly, balancing it carefully.
18. Remove 4 rear mounting bolts (39) from each
q6
★ After removing the floor frame assembly, re-
side.
move the spacers on the right front floor
mount.
D375A-5 30-245
2 " "
INSTALLATION q2 q3
• Carry out installation in the reverse order to re- ★ The connecting positions of the PPC hoses
moval. are indicated by the band colors on their
q1
confirm them by the band colors.
★ Connect the hoses so carefully that they will
not be twisted.
★ When installing the air conditioner circuit
hoses, take care that dirt, dust, or water will
not enter them.
★ When connecting the air conditioner hoses,
check that the O-rings are fitted to their
adapters.
Apply sufficient amount of compressor oil
(Showa-Shell Suniso 4G or 5G) to the O-
rings.

A. Transparent
B. Red/White
C. Black/Blue
D. Brown
E. Black
F. Green
G. White
H. Yellow
3 Tightening torque for air conditioner

refrigerant piping
16 × 1.5 12.23 ± 1.47Nm {1.35 ± 0.15kgm}
22 × 1.5 22.05 ± 2.45Nm {2.25 ± 0.25kgm}
24 × 1.5 31.85 ± 2.45Nm {3.25 ± 0.25kgm}
M6 bolt (for receiver) 5.39 ± 1.47Nm {0.55 ± 0.15kgm}
M6 bolt
9.8 ± 1.96Nm {1.0 ± 0.2kgm}
(for compressor)
30-246 D375A-5
" 2 "
q4
★ Adjust the parking brake lever linkage. For
details, see TESTING AND ADJUSTING,
Adjusting PCCS (Steering, Forward/Reverse
travel, Gear shifting), parking brake lever
linkage.
q5
★ Adjust the brake pedal linkage. For details,
see TESTING AND ADJUSTING, Adjusting
brake pedal linkage.
3 Brake pedal linkage turnbuckle:
45.56 ± 12.25 Nm
{4.76 ± 1.25 kgm}
q6 q7
3 Rear mounting bolt:
338.1 ± 39.2 Nm {34.5 ± 4kgm}
3 Front mounting bolt:
338.1 ± 39.2 Nm {34.5 ± 4kgm}
q8
• Charging air conditioner with refrigerant
gas
Using tool X, charge the air conditioner cir-
cuit with refrigerant (R134a).
• Refilling with water
Add water through the water filler to the
specified level. Run the engine to circulate
the water through the system. Then, check
the water level again.
D375A-5 30-247
2 " "
DISASSEMBLY AND ASSEMBLY DASHBOARD ASSEMBLY
7. Lift off dashboard assembly (9). 3 Tightening torque for air conditioner
4 Dashboard assembly: 95 kg refrigerant piping
16 × 1.5 12.23 ± 1.47Nm {1.35 ± 0.15kgm}
22 × 1.5 22.05 ± 2.45Nm {2.25 ± 0.25kgm}
24 × 1.5 31.85 ± 2.45Nm {3.25 ± 0.25kgm}
M6 bolt
9.8 ± 1.96Nm {1.0 ± 0.2kgm}
(for compressor)
• Charging air conditioner with refrigerant gas

Using tool X, charge the air conditioner circuit
INSTALLATION with refrigerant (R134a).
• Carry out installation in the reverse order to re- Add water through the water filler to the specified
moval. level. Run the engine to circulate the water
q1
through the system. Then, check the water level
again.
★ Connect the hoses so carefully that they will
not be twisted.
★ When installing the air conditioner circuit
hoses, take care that dirt, dust, or water will
not enter them.
adapters.
(Showa-Shell Suniso 4G or 5G) to the O-
rings.
D375A-5 30-249
2 " "
REMOVAL AND INSTALLATION OF MONITOR
DISASSEMBLY AND ASSEMBLY PANEL ASSEMBLY
REMOVAL AND
INSTALLATION OF MONITOR
PANEL ASSEMBLY
REMOVAL
nal of the battery.
1. Remove mounting bolts, then open monitor pan-
el assembly (1).
2. Disconnect connectors (CN-1, CN-2, CN-3, CN-

4, CN-5, CN-S01, CN-S02) (2).
3. Remove monitor panel assembly.
INSTALLATION
moval.
30-250 D375A-5
" 2 "
REMOVAL AND INSTALLATION OF AIR
DISASSEMBLY AND ASSEMBLY CONDITIONER UNIT ASSEMBLY
9. Remove ducts (17) and (18). 12. Disconnect bracket (22) and clamp (23).
10. Remove monitor (19) and cover (20). 13. Disconnect relays (CN-R1) (24), (CN-R2) (25),
and (CN-R3) (26) in the right part of the dash-
board and connector (CN-M26) (27).
11. Remove inside filter (21).
14. Remove air conditioner unit (28).

15. Remove blower motor (29).
30-252 D375A-5
" 2 "
REMOVAL AND INSTALLATION OF AIR
DISASSEMBLY AND ASSEMBLY CONDITIONER UNIT ASSEMBLY
INSTALLATION • Charging air conditioner with refrigerant gas

• Carry out installation in the reverse order to re- Using tool X, charge the air conditioner circuit
moval. with refrigerant (R134a).
q1
★ Connect the hoses so carefully that they will Add water through the water filler to the specified
not be twisted. level. Run the engine to circulate the water
★ When installing the air conditioner circuit through the system. Then, check the water level
hoses, take care that dirt, dust, or water will again.
not enter them.
adapters.
(Showa-Shell Sniso 4G or 5G) to the O-
rings.
3 Tightening torque for air conditioner

refrigerant piping
16 × 1.5 12.23 ± 1.47Nm {1.35 ± 0.15kgm}
22 × 1.5 22.05 ± 2.45Nm {2.25 ± 0.25kgm}
24 × 1.5 31.85 ± 2.45Nm {3.25 ± 0.25kgm}
M6 bolt
9.8 ± 1.96Nm {1.0 ± 0.2kgm}
(for compressor)
D375A-5 30-253
2 " "
90 OTHERS
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM ................................................................................... 90- 2

POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM ................................................................................... 90- 3
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (TILTDOZER) ................................................... 90- 4
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (TILTDOZER) ................................................... 90- 5
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (DUAL TILTDOZER) ......................................... 90- 6
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (DUAL TILTDOZER) ......................................... 90- 7
ELECTRICAL CIRCUIT DIAGRAM 1/5 ..................................................................................................... 90- 9
ELECTRICAL CIRCUIT DIAGRAM 2/5 ..................................................................................................... 90-11
DIAGRAM FOR ELECTRICAL CIRCUIT OF AIR CONDITIONER ........................................................... 90-19
ELECTRIC CIRCUIT DIAGRAM OF INSIDE CAB .................................................................................... 90-20
D375A-5 90-1
4
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
1. Oil tank 37. R.H steering clutch

2. Power train oil strainer 38. R.H steering brake
3. Power train pump (BAL180) 39. L.H steering brake
4. Power train oil filter 40. L.H steering clutch
Set pressure: 0.29 MPa {3.0 kg/cm2} 41. Brake prevention valve
5. Transmission lubrication pump (BAL112) 42. Transmission lubrication valve
6. Power train lubricating oil filter Set pressure: 0.26 MPa {2.7 kg/cm2}
7. Main relief valve 43. Transmission lubrication
Set pressure: 2.65 ± 0.1 MPa {27.0 ± 1.0 kg/cm2} 44. PTO lubrication
8. Modulating relief valve (ECMV) for R clutch 45. Scavenging pump (BAR63 + 277)
9. Modulating relief valve (ECMV) for F clutch 46. Solenoid valve (for ripper pin puller)
10. Modulating relief valve (ECMV) for 3rd clutch 47. Pin puller cylinder
11. Modulating relief valve (ECMV) for 2nd clutch 48. Steering case
12. Modulating relief valve (ECMV) for 1st clutch A. Torque converter lockup pressure pick-up port
13. Fill switch B. Torque converter stator clutch pressure pick-up
Operating pressure: 0.26 MPa {2.7 kg/cm2} port
14. 1st clutch C. L.H steering clutch operating pressure pick-up
15. 2nd clutch port
16. 3rd clutch D. L.H steering brake operating pressure pick-up
17. R clutch port
18. F clutch E. Transmission 2nd clutch operating pressure pick-
up port
19. Pilot filter
F. Transmission R clutch operating pressure pick-up
20. Torque converter relief valve
port
Set pressure: 0.88 ± 0.1 MPa {9.0 ± 1.0 kg/cm2}
G. Transmission 3rd clutch operating pressure pick-
21. Torque converter
up port
Set pressure: 1.3 +0.1 +1 2
0 MPa {13 0 kg/cm }
H. Transmission F clutch operating pressure pick-up
22. Oil cooler
port
23. Steering clutch/brake lubrication
J. R.H steering brake operating pressure pick-up
24. Torque converter case port
25. Torque converter lockup valve K. R.H steering clutch operating pressure pick-up
26. Lockup clutch modulating valve port
Set pressure: 1.3 +0.1 MPa {13 +1 kg/cm2} L. Transmission 1st clutch operating pressure pick-
0 0
27. Torque converter lockup solenoid valve up port
28. Torque converter lockup clutch M. Transmission main relief pressure pick-up port
29. Stator clutch modulating valve N. Torque converter regulator pressure pick-up port
Set pressure: 2.65 ± 0.1 MPa {27.0 ± 1.0 kg/cm2} P. Torque converter relief pressure pick-up port
30. Stator clutch lubrication
31. Stator clutch
32. Parking brake valve
33. R.H steering ECMV
34. R.H brake ECMV
35. L.H brake ECMV
36. L.H steering ECMV
90-2 D375A-5
90
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
D375A-5 90-3
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (TILTDOZER)
TILTDOZER
1. Hydraulic tank 13E. Ripper lift constant differential pressure
1A. Oil filler cap valve
2. Strainer 13F. Shuttle valve
3. PPC charge pump (SAR(1) 022) 13G. Shuttle valve
4. PPC charge valve 13H. Suction valve (for ripper lift)
Set pressure: 4.46 MPa {45.5 kg/cm2} 13J. Ripper tilt HI valve
5. Accumulator 13K. Ripper tilt constant differential pressure
6. Oil cooler (for PPC) valve
7. PPC lock valve 13L. Ripper tilt constant differential valve
8. Blade control PPC valve 13M. Shuttle valve
8A. For blade lift 13N. Shuttle valve
8B. For blade tilt 14. Quick drop valve
9. Ripper control PPC valve 15. R.H blade lift cylinder
9A. For ripper lift 16. L.H blade lift cylinder
9B. For ripper tilt 17. Blade tilt cylinder
10. Work equipment pump (SAR(4) 140 + (3) 071) 18. R.H ripper tilt cylinder
11. Blade control valve 19. R.H ripper lift cylinder
11A. Demand valve 20. L.H ripper lift cylinder
11B. Main relief valve 21. L.H ripper tilt cylinder
Set pressure: 20.6 MPa {210 kg/cm2} 22. Hydraulic oil filter
11C. Shuttle valve Set pressure: 0.15 MPa {1.5 kg/cm2}
11D. Check valve
11E. Check valve
11F. Blade lift valve
11G. Suction valve (for blade lift)
11H. Shuttle valve
12. Blade tilt, ripper LO valve
12A. Main relief valve
Set pressure: 20.6 MPa {210 kg/cm2}
12B. Check valve
12C. Blade tilt valve
12D. Check valve
12E. Ripper tilt valve
12F. Check valve
12G. Ripper lift valve
12H. Shuttle valve
13. Ripper HI valve
13A. Check valve
13B. Check valve
13C. Ripper lift (HI) valve
13D. Ripper lift constant differential pressure
valve
90-4 D375A-5
4
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
TILTDOZER
★ For details of the pin puller cylinder, see POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM.
D375A-5 90-5
4
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (DUAL TILTDOZER)
DUAL TILTDOZER
1. Hydraulic tank 13E. Ripper lift constant differential pressure
1A. Oil filler cap valve
2. Strainer 13F. Shuttle valve
3. PPC charge pump (SAR(1) 022) 13G. Shuttle valve
4. PPC charge valve 13H. Suction valve (for ripper lift)
Set pressure: 4.46 MPa {45.5 kg/cm2} 13J. Ripper tilt HI valve
5. Accumulator 13K. Ripper tilt constant differential pressure
6. Oil cooler (for PPC) valve
7. PPC lock valve 13L. Ripper tilt constant differential pressure
valve
8. Blade control PPC valve
13M. Shuttle valve
8A. For blade lift
13N. Shuttle valve
8B. For blade tilt
14. Quick drop valve
9. Ripper control PPC valve
15. R.H blade lift cylinder
9A. For ripper lift
16. L.H blade lift cylinder
9B. For ripper tilt
17. Pitch selector solenoid valve
10. Work equipment pump (SAR(4) 140 + (3) 071)
18. Dual tilt selector solenoid valve
11. Blade lift control valve
19. Blade tilt cylinder
11A. Demand valve
20. Blade pitch cylinder
11B. Main relief valve
Set pressure: 20.6 MPa {210 kg/cm2} 21. R.H ripper tilt cylinder
11C. Shuttle valve 22. R.H ripper lift cylinder
11D. Check valve 23. L.H ripper lift cylinder
11E. Check valve 24. L.H ripper tilt cylinder
11F. Blade lift valve 25. Hydraulic oil filter
Set pressure: 0.15 MPa {1.5 kg/cm2}
11G. Suction valve (for blade lift)
11H. Shuttle valve
12. Blade tilt, ripper LO valve
12A. Main relief valve
Set pressure: 20.6 MPa {210 kg/cm2}
12B. Check valve
12C. Blade valve
12D. Check valve
12E. Ripper tilt valve
12F. Check valve
12G. Ripper lift valve
12H. Shuttle valve
13. Ripper HI valve
13A. Check valve
13B. Check valve
13C. Ripper lift (HI) valve
13D. Ripper lift constant differential pressure
valve
90-6 D375A-5
4
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
DUAL TILTDOZER
★ For details of the pin puller cylinder, see POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM.
D375A-5 90-7
4
ELECTRICAL CIRCUIT DIAGRAM 1/5
D375A-5 90-9
4
D375A-5 90-11
4
D375A-5 90-13
4
D375A-5 90-15
4
D375A-5 90-17
4
DIAGRAM FOR ELECTRICAL CIRCUIT OF AIR CONDITIONER
D375A-5 90-19
ELECTRIC CIRCUIT DIAGRAM OF INSIDE CAB
90-20 D375A-5

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GENERAL

SPECIFICATION DRAWING ..................................................................................................................... 01- 2

Machine model D375A-5

Serial number 18001 and up

Minimum turning radius m 4.2

1st speed 0  3.8

1st speed 0  5.1

Bare tractor 103.16 {1.06}

Bare tractor 5,770

Bare tractor 3,220

To top of exhaust pipe 4,035

Machine model D375A-5

Serial number 18001 and up

Track gauge 2,500

Type of engine 4-cycle, water-cooled, in-line vertical type, direct injec-

Number of cylinders  Bore × Stroke mm 6  170 × 170

Flywheel horsepower kw {HP}/rpm 391 {525}/1,800

Min. fuel consumption ratio g/kw.h 209 {156}

Starting motor 24 V, 7.5 kW × 2

Radiator core type Type D

Torque converter 3-element, 1-stage, 1-phase (with lockup clutch)

Planetary gear type, multiple disc clutch type, hydraulic

Wet type, multiple disc clutch type, spring-boosted

Wet type, multiple disc clutch type, spring-boosted

Spur gear 1-stage, planetary gear 1-stage deceleration

Machine model D375A-5

Serial number 18001 and up

Suspension Rigid, balancing beam type

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

Scavenging pump (tandem) Gear type (BAR 63 + 277)

PPC charge pump

Maximum pressure MPa {kg/cm2} 20.6 {210}

Type Gear type, double type (SAR(4) 140 + (3) 071)

Delivery ¬/min 405

Type Double acting piston type

Cylinder bore 150

Cylinder bore 225

Machine model D375A-5

Serial number 18001 and up

Cylinder bore Left cylinder: 225, Right cylinder: 250

Cylinder bore 225

Cylinder bore 200

Control valve assembly type

Hydraulic semi U-tilt dozer,

Blade support method Brace type

Max. lifting height mm 1,660

Blade width mm 4,695

Machine model D375A-5

Serial number 18001 and up

Max. lifting height mm 1,660

Blade width mm 5,140

Max. tilt mm 1,150

Max. tilt mm 1,260

Max. digging depth mm 1,075

Max. beam width mm 2,854

Max. digging depth mm 1,435

Max. beam width mm 1,367

Machine model D375A-5

Serial number 18001 and up

Engine and damper assemblies 3,080

Radiator assembly 390

Power train unit

Final drive assembly 2,200 × 2

1st speed 0 3.8

1st speed 0 5.1

Number of cylinders Bore × Stroke mm 6 170 × 170

Clearance between the flywheel 0.022 +0.110 0.022

Oil set to within 0.90 MPa {9 kg/cm2} by

Clearance between torque 0.035 +0.016

Clearance between stator clutch 0.035 +0.013

Clearance between lock-up 0.020 +0.013

The lock-up ON/OFF operation is carried out