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D375a-6r Shop Manual Sen05214-01

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This document provides a notice of revision for a bulldozer model D375A-6R. It lists pages that have been newly added, replaced, or deleted with revision numbers and marks. A total of over 200 pages are indicated as revised with page numbers ranging from 1 to 227.

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© All Rights Reserved
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D375a-6r Shop Manual Sen05214-01

Uploaded by

Syah Putra
640 views1,766 pages
This document provides a notice of revision for a bulldozer model D375A-6R. It lists pages that have been newly added, replaced, or deleted with revision numbers and marks. A total of over 200 pages are indicated as revised with page numbers ranging from 1 to 227.

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komatsu

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d375a-6r Shop Manual Sen05214-01

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This document provides a notice of revision for a bulldozer model D375A-6R. It lists pages that have been newly added, replaced, or deleted with revision numbers and marks. A total of over 200 pages are indicated as revised with page numbers ranging from 1 to 227.

Copyright:

© All Rights Reserved
Download as PDF, TXT or read online from Scribd
Download as pdf or txt
640 views1,766 pages

D375a-6r Shop Manual Sen05214-01

Uploaded by

Syah Putra
This document provides a notice of revision for a bulldozer model D375A-6R. It lists pages that have been newly added, replaced, or deleted with revision numbers and marks. A total of over 200 pages are indicated as revised with page numbers ranging from 1 to 227.

Copyright:

© All Rights Reserved
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You are on page 1/ 1766

SEN05214-01

BULLDOZER D375A -6R


SERIAL NUMBERS 65001 and up
Notice of revision

Notice of revision
1st. revision 2010/3
The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary ac-
tions must be taken to these pages according to the Q Page to be newly added Add
list below.
q Page to be replaced Replace

() Page to be deleted Discard

List of revised pages


Revision Revision Revision Revision
Mark Page Mark Page Mark Page Mark Page
number number number number
Q 1 (01) 00-23 10-4 10-45
Q 2 (01) 00-24 10-5 10-46
Q 3 (01) 00-25 10-6 10-47
Q 4 (01) 00-26 10-7 10-48
Q 5 (01) 00-27 10-8 10-49
Q 6 (01) 00-28 10-9 10-50
Q 7 (01) 00-29 10-10 10-51
Q 8 (01) 00-30 10-11 10-52
Q 9 (01) 00-31 10-12 10-53
00-1 00-32 10-13 10-54
q 00-2 (01) 00-33 10-14 10-55
q 00-3 (01) 00-34 10-15 10-56
Q 00-3-1 (01) 00-35 10-16 10-57
Q 00-3-2 (01) 00-36 10-17 10-58
Q 00-3-3 (01) 00-37 10-18 10-59
Q 00-3-4 (01) 00-38 10-19 10-60
Q 00-3-5 (01) 00-39 10-20 10-61
Q 00-3-6 (01) 00-40 10-21 10-62
Q 00-3-7 (01) 00-41 10-22 10-63
Q 00-3-8 (01) 00-42 10-23 10-64
Q 00-3-9 (01) 00-43 10-24 10-65
Q 00-3-10 (01) 00-44 10-25 10-66
q 00-4 (01) 00-45 10-26 10-67
00-5 00-46 10-27 10-68
00-6 00-47 10-28 10-69
00-7 00-48 10-29 10-70
00-8 01-1 10-30 10-71
00-9 01-2 10-31 10-72
00-10 01-3 10-32 10-73
00-11 01-4 10-33 10-74
00-12 01-5 10-34 10-75
00-13 01-6 10-35 10-76
00-14 01-7 10-36 10-77
00-15 01-8 10-37 10-78
00-16 01-9 10-38 10-79
00-17 01-10 10-39 10-80
00-18 01-11 10-40 10-81
00-19 01-12 10-41 10-82
00-20 10-1 10-42 10-83
00-21 10-2 10-43 10-84
00-22 10-3 10-44 10-85

D375A-6R 1
(01)
Notice of revision

Revision Revision Revision Revision


Mark Page Mark Page Mark Page Mark Page
number number number number
10-86 10-138 10-190 10-242
10-87 10-139 10-191 10-243
10-88 10-140 10-192 10-244
10-89 10-141 10-193 10-245
10-90 10-142 10-194 10-246
10-91 10-143 10-195 10-247
10-92 10-144 10-196 10-248
10-93 10-145 10-197 10-249
10-94 10-146 10-198 10-250
10-95 10-147 10-199 Q 20-1 (01)
10-96 10-148 10-200 Q 20-2 (01)
10-97 10-149 10-201 Q 20-3 (01)
10-98 10-150 10-202 Q 20-4 (01)
10-99 10-151 10-203 Q 20-5 (01)
10-100 10-152 10-204 Q 20-6 (01)
10-101 10-153 10-205 Q 20-7 (01)
10-102 10-154 10-206 Q 20-8 (01)
10-103 10-155 10-207 Q 20-9 (01)
10-104 10-156 10-208 Q 20-10 (01)
10-105 10-157 10-209 Q 20-11 (01)
10-106 10-158 10-210 Q 20-12 (01)
10-107 10-159 10-211 Q 30-1 (01)
10-108 10-160 10-212 Q 30-2 (01)
10-109 10-161 10-213 Q 30-3 (01)
10-110 10-162 10-214 Q 30-4 (01)
10-111 10-163 10-215 Q 30-5 (01)
10-112 10-164 10-216 Q 30-6 (01)
10-113 10-165 10-217 Q 30-7 (01)
10-114 10-166 10-218 Q 30-8 (01)
10-115 10-167 10-219 Q 30-9 (01)
10-116 10-168 10-220 Q 30-10 (01)
10-117 10-169 10-221 Q 30-11 (01)
10-118 10-170 10-222 Q 30-12 (01)
10-119 10-171 10-223 Q 30-13 (01)
10-120 10-172 10-224 Q 30-14 (01)
10-121 10-173 10-225 Q 30-15 (01)
10-122 10-174 10-226 Q 30-16 (01)
10-123 10-175 10-227 Q 30-17 (01)
10-124 10-176 10-228 Q 30-18 (01)
10-125 10-177 10-229 Q 30-19 (01)
10-126 10-178 10-230 Q 30-20 (01)
10-127 10-179 10-231 Q 30-21 (01)
10-128 10-180 10-232 Q 30-22 (01)
10-129 10-181 10-233 Q 30-23 (01)
10-130 10-182 10-234 Q 30-24 (01)
10-131 10-183 10-235 Q 30-25 (01)
10-132 10-184 10-236 Q 30-26 (01)
10-133 10-185 10-237 Q 30-27 (01)
10-134 10-186 10-238 Q 30-28 (01)
10-135 10-187 10-239 Q 30-29 (01)
10-136 10-188 10-240 Q 30-30 (01)
10-137 10-189 10-241 Q 30-31 (01)

2 D375A-6R
(01)
Notice of revision

Revision Revision Revision Revision


Mark Page Mark Page Mark Page Mark Page
number number number number
Q 30-32 (01) Q 30-84 (01) Q 30-136 (01) Q 30-188 (01)
Q 30-33 (01) Q 30-85 (01) Q 30-137 (01) Q 30-189 (01)
Q 30-34 (01) Q 30-86 (01) Q 30-138 (01) Q 30-190 (01)
Q 30-35 (01) Q 30-87 (01) Q 30-139 (01) Q 30-191 (01)
Q 30-36 (01) Q 30-88 (01) Q 30-140 (01) Q 30-192 (01)
Q 30-37 (01) Q 30-89 (01) Q 30-141 (01) Q 30-193 (01)
Q 30-38 (01) Q 30-90 (01) Q 30-142 (01) Q 30-194 (01)
Q 30-39 (01) Q 30-91 (01) Q 30-143 (01) Q 40-1 (01)
Q 30-40 (01) Q 30-92 (01) Q 30-144 (01) Q 40-2 (01)
Q 30-41 (01) Q 30-93 (01) Q 30-145 (01) Q 40-3 (01)
Q 30-42 (01) Q 30-94 (01) Q 30-146 (01) Q 40-4 (01)
Q 30-43 (01) Q 30-95 (01) Q 30-147 (01) Q 40-5 (01)
Q 30-44 (01) Q 30-96 (01) Q 30-148 (01) Q 40-6 (01)
Q 30-45 (01) Q 30-97 (01) Q 30-149 (01) Q 40-7 (01)
Q 30-46 (01) Q 30-98 (01) Q 30-150 (01) Q 40-8 (01)
Q 30-47 (01) Q 30-99 (01) Q 30-151 (01) Q 40-9 (01)
Q 30-48 (01) Q 30-100 (01) Q 30-152 (01) Q 40-10 (01)
Q 30-49 (01) Q 30-101 (01) Q 30-153 (01) Q 40-11 (01)
Q 30-50 (01) Q 30-102 (01) Q 30-154 (01) Q 40-12 (01)
Q 30-51 (01) Q 30-103 (01) Q 30-155 (01) Q 40-13 (01)
Q 30-52 (01) Q 30-104 (01) Q 30-156 (01) Q 40-14 (01)
Q 30-53 (01) Q 30-105 (01) Q 30-157 (01) Q 40-15 (01)
Q 30-54 (01) Q 30-106 (01) Q 30-158 (01) Q 40-16 (01)
Q 30-55 (01) Q 30-107 (01) Q 30-159 (01) Q 40-17 (01)
Q 30-56 (01) Q 30-108 (01) Q 30-160 (01) Q 40-18 (01)
Q 30-57 (01) Q 30-109 (01) Q 30-161 (01) Q 40-19 (01)
Q 30-58 (01) Q 30-110 (01) Q 30-162 (01) Q 40-20 (01)
Q 30-59 (01) Q 30-111 (01) Q 30-163 (01) Q 40-21 (01)
Q 30-60 (01) Q 30-112 (01) Q 30-164 (01) Q 40-22 (01)
Q 30-61 (01) Q 30-113 (01) Q 30-165 (01) Q 40-23 (01)
Q 30-62 (01) Q 30-114 (01) Q 30-166 (01) Q 40-24 (01)
Q 30-63 (01) Q 30-115 (01) Q 30-167 (01) Q 40-25 (01)
Q 30-64 (01) Q 30-116 (01) Q 30-168 (01) Q 40-26 (01)
Q 30-65 (01) Q 30-117 (01) Q 30-169 (01) Q 40-27 (01)
Q 30-66 (01) Q 30-118 (01) Q 30-170 (01) Q 40-28 (01)
Q 30-67 (01) Q 30-119 (01) Q 30-171 (01) Q 40-29 (01)
Q 30-68 (01) Q 30-120 (01) Q 30-172 (01) Q 40-30 (01)
Q 30-69 (01) Q 30-121 (01) Q 30-173 (01) Q 40-31 (01)
Q 30-70 (01) Q 30-122 (01) Q 30-174 (01) Q 40-32 (01)
Q 30-71 (01) Q 30-123 (01) Q 30-175 (01) Q 40-33 (01)
Q 30-72 (01) Q 30-124 (01) Q 30-176 (01) Q 40-34 (01)
Q 30-73 (01) Q 30-125 (01) Q 30-177 (01) Q 40-35 (01)
Q 30-74 (01) Q 30-126 (01) Q 30-178 (01) Q 40-36 (01)
Q 30-75 (01) Q 30-127 (01) Q 30-179 (01) Q 40-37 (01)
Q 30-76 (01) Q 30-128 (01) Q 30-180 (01) Q 40-38 (01)
Q 30-77 (01) Q 30-129 (01) Q 30-181 (01) Q 40-39 (01)
Q 30-78 (01) Q 30-130 (01) Q 30-182 (01) Q 40-40 (01)
Q 30-79 (01) Q 30-131 (01) Q 30-183 (01) Q 40-41 (01)
Q 30-80 (01) Q 30-132 (01) Q 30-184 (01) Q 40-42 (01)
Q 30-81 (01) Q 30-133 (01) Q 30-185 (01) Q 40-43 (01)
Q 30-82 (01) Q 30-134 (01) Q 30-186 (01) Q 40-44 (01)
Q 30-83 (01) Q 30-135 (01) Q 30-187 (01) Q 40-45 (01)

D375A-6R 3
(01)
Notice of revision

Revision Revision Revision Revision


Mark Page Mark Page Mark Page Mark Page
number number number number
Q 40-46 (01) Q 40-98 (01) Q 40-150 (01) Q 40-202 (01)
Q 40-47 (01) Q 40-99 (01) Q 40-151 (01) Q 40-203 (01)
Q 40-48 (01) Q 40-100 (01) Q 40-152 (01) Q 40-204 (01)
Q 40-49 (01) Q 40-101 (01) Q 40-153 (01) Q 40-205 (01)
Q 40-50 (01) Q 40-102 (01) Q 40-154 (01) Q 40-206 (01)
Q 40-51 (01) Q 40-103 (01) Q 40-155 (01) Q 40-207 (01)
Q 40-52 (01) Q 40-104 (01) Q 40-156 (01) Q 40-208 (01)
Q 40-53 (01) Q 40-105 (01) Q 40-157 (01) Q 40-209 (01)
Q 40-54 (01) Q 40-106 (01) Q 40-158 (01) Q 40-210 (01)
Q 40-55 (01) Q 40-107 (01) Q 40-159 (01) Q 40-211 (01)
Q 40-56 (01) Q 40-108 (01) Q 40-160 (01) Q 40-212 (01)
Q 40-57 (01) Q 40-109 (01) Q 40-161 (01) Q 40-213 (01)
Q 40-58 (01) Q 40-110 (01) Q 40-162 (01) Q 40-214 (01)
Q 40-59 (01) Q 40-111 (01) Q 40-163 (01) Q 40-215 (01)
Q 40-60 (01) Q 40-112 (01) Q 40-164 (01) Q 40-216 (01)
Q 40-61 (01) Q 40-113 (01) Q 40-165 (01) Q 40-217 (01)
Q 40-62 (01) Q 40-114 (01) Q 40-166 (01) Q 40-218 (01)
Q 40-63 (01) Q 40-115 (01) Q 40-167 (01) Q 40-219 (01)
Q 40-64 (01) Q 40-116 (01) Q 40-168 (01) Q 40-220 (01)
Q 40-65 (01) Q 40-117 (01) Q 40-169 (01) Q 40-221 (01)
Q 40-66 (01) Q 40-118 (01) Q 40-170 (01) Q 40-222 (01)
Q 40-67 (01) Q 40-119 (01) Q 40-171 (01) Q 40-223 (01)
Q 40-68 (01) Q 40-120 (01) Q 40-172 (01) Q 40-224 (01)
Q 40-69 (01) Q 40-121 (01) Q 40-173 (01) Q 40-225 (01)
Q 40-70 (01) Q 40-122 (01) Q 40-174 (01) Q 40-226 (01)
Q 40-71 (01) Q 40-123 (01) Q 40-175 (01) Q 40-227 (01)
Q 40-72 (01) Q 40-124 (01) Q 40-176 (01) Q 40-228 (01)
Q 40-73 (01) Q 40-125 (01) Q 40-177 (01) Q 40-229 (01)
Q 40-74 (01) Q 40-126 (01) Q 40-178 (01) Q 40-230 (01)
Q 40-75 (01) Q 40-127 (01) Q 40-179 (01) Q 40-231 (01)
Q 40-76 (01) Q 40-128 (01) Q 40-180 (01) Q 40-232 (01)
Q 40-77 (01) Q 40-129 (01) Q 40-181 (01) Q 40-233 (01)
Q 40-78 (01) Q 40-130 (01) Q 40-182 (01) Q 40-234 (01)
Q 40-79 (01) Q 40-131 (01) Q 40-183 (01) Q 40-235 (01)
Q 40-80 (01) Q 40-132 (01) Q 40-184 (01) Q 40-236 (01)
Q 40-81 (01) Q 40-133 (01) Q 40-185 (01) Q 40-237 (01)
Q 40-82 (01) Q 40-134 (01) Q 40-186 (01) Q 40-238 (01)
Q 40-83 (01) Q 40-135 (01) Q 40-187 (01) Q 40-239 (01)
Q 40-84 (01) Q 40-136 (01) Q 40-188 (01) Q 40-240 (01)
Q 40-85 (01) Q 40-137 (01) Q 40-189 (01) Q 40-241 (01)
Q 40-86 (01) Q 40-138 (01) Q 40-190 (01) Q 40-242 (01)
Q 40-87 (01) Q 40-139 (01) Q 40-191 (01) Q 40-243 (01)
Q 40-88 (01) Q 40-140 (01) Q 40-192 (01) Q 40-244 (01)
Q 40-89 (01) Q 40-141 (01) Q 40-193 (01) Q 40-245 (01)
Q 40-90 (01) Q 40-142 (01) Q 40-194 (01) Q 40-246 (01)
Q 40-91 (01) Q 40-143 (01) Q 40-195 (01) Q 40-247 (01)
Q 40-92 (01) Q 40-144 (01) Q 40-196 (01) Q 40-248 (01)
Q 40-93 (01) Q 40-145 (01) Q 40-197 (01) Q 40-249 (01)
Q 40-94 (01) Q 40-146 (01) Q 40-198 (01) Q 40-250 (01)
Q 40-95 (01) Q 40-147 (01) Q 40-199 (01) Q 40-251 (01)
Q 40-96 (01) Q 40-148 (01) Q 40-200 (01) Q 40-252 (01)
Q 40-97 (01) Q 40-149 (01) Q 40-201 (01) Q 40-253 (01)

4 D375A-6R
(01)
Notice of revision

Revision Revision Revision Revision


Mark Page Mark Page Mark Page Mark Page
number number number number
Q 40-254 (01) Q 40-306 (01) Q 40-358 (01) Q 40-410 (01)
Q 40-255 (01) Q 40-307 (01) Q 40-359 (01) Q 40-411 (01)
Q 40-256 (01) Q 40-308 (01) Q 40-360 (01) Q 40-412 (01)
Q 40-257 (01) Q 40-309 (01) Q 40-361 (01) Q 40-413 (01)
Q 40-258 (01) Q 40-310 (01) Q 40-362 (01) Q 40-414 (01)
Q 40-259 (01) Q 40-311 (01) Q 40-363 (01) Q 40-415 (01)
Q 40-260 (01) Q 40-312 (01) Q 40-364 (01) Q 40-416 (01)
Q 40-261 (01) Q 40-313 (01) Q 40-365 (01) Q 40-417 (01)
Q 40-262 (01) Q 40-314 (01) Q 40-366 (01) Q 40-418 (01)
Q 40-263 (01) Q 40-315 (01) Q 40-367 (01) Q 40-419 (01)
Q 40-264 (01) Q 40-316 (01) Q 40-368 (01) Q 40-420 (01)
Q 40-265 (01) Q 40-317 (01) Q 40-369 (01) Q 40-421 (01)
Q 40-266 (01) Q 40-318 (01) Q 40-370 (01) Q 40-422 (01)
Q 40-267 (01) Q 40-319 (01) Q 40-371 (01) Q 40-423 (01)
Q 40-268 (01) Q 40-320 (01) Q 40-372 (01) Q 40-424 (01)
Q 40-269 (01) Q 40-321 (01) Q 40-373 (01) Q 40-425 (01)
Q 40-270 (01) Q 40-322 (01) Q 40-374 (01) Q 40-426 (01)
Q 40-271 (01) Q 40-323 (01) Q 40-375 (01) Q 40-427 (01)
Q 40-272 (01) Q 40-324 (01) Q 40-376 (01) Q 40-428 (01)
Q 40-273 (01) Q 40-325 (01) Q 40-377 (01) Q 40-429 (01)
Q 40-274 (01) Q 40-326 (01) Q 40-378 (01) Q 40-430 (01)
Q 40-275 (01) Q 40-327 (01) Q 40-379 (01) Q 40-431 (01)
Q 40-276 (01) Q 40-328 (01) Q 40-380 (01) Q 40-432 (01)
Q 40-277 (01) Q 40-329 (01) Q 40-381 (01) Q 40-433 (01)
Q 40-278 (01) Q 40-330 (01) Q 40-382 (01) Q 40-434 (01)
Q 40-279 (01) Q 40-331 (01) Q 40-383 (01) Q 40-435 (01)
Q 40-280 (01) Q 40-332 (01) Q 40-384 (01) Q 40-436 (01)
Q 40-281 (01) Q 40-333 (01) Q 40-385 (01) Q 40-437 (01)
Q 40-282 (01) Q 40-334 (01) Q 40-386 (01) Q 40-438 (01)
Q 40-283 (01) Q 40-335 (01) Q 40-387 (01) Q 40-439 (01)
Q 40-284 (01) Q 40-336 (01) Q 40-388 (01) Q 40-440 (01)
Q 40-285 (01) Q 40-337 (01) Q 40-389 (01) Q 40-441 (01)
Q 40-286 (01) Q 40-338 (01) Q 40-390 (01) Q 40-442 (01)
Q 40-287 (01) Q 40-339 (01) Q 40-391 (01) Q 40-443 (01)
Q 40-288 (01) Q 40-340 (01) Q 40-392 (01) Q 40-444 (01)
Q 40-289 (01) Q 40-341 (01) Q 40-393 (01) Q 40-445 (01)
Q 40-290 (01) Q 40-342 (01) Q 40-394 (01) Q 40-446 (01)
Q 40-291 (01) Q 40-343 (01) Q 40-395 (01) Q 40-447 (01)
Q 40-292 (01) Q 40-344 (01) Q 40-396 (01) Q 40-448 (01)
Q 40-293 (01) Q 40-345 (01) Q 40-397 (01) Q 40-449 (01)
Q 40-294 (01) Q 40-346 (01) Q 40-398 (01) Q 40-450 (01)
Q 40-295 (01) Q 40-347 (01) Q 40-399 (01) Q 40-451 (01)
Q 40-296 (01) Q 40-348 (01) Q 40-400 (01) Q 40-452 (01)
Q 40-297 (01) Q 40-349 (01) Q 40-401 (01) Q 40-453 (01)
Q 40-298 (01) Q 40-350 (01) Q 40-402 (01) Q 40-454 (01)
Q 40-299 (01) Q 40-351 (01) Q 40-403 (01) Q 40-455 (01)
Q 40-300 (01) Q 40-352 (01) Q 40-404 (01) Q 40-456 (01)
Q 40-301 (01) Q 40-353 (01) Q 40-405 (01) Q 40-457 (01)
Q 40-302 (01) Q 40-354 (01) Q 40-406 (01) Q 40-458 (01)
Q 40-303 (01) Q 40-355 (01) Q 40-407 (01) Q 40-459 (01)
Q 40-304 (01) Q 40-356 (01) Q 40-408 (01) Q 40-460 (01)
Q 40-305 (01) Q 40-357 (01) Q 40-409 (01) Q 40-461 (01)

D375A-6R 5
(01)
Notice of revision

Revision Revision Revision Revision


Mark Page Mark Page Mark Page Mark Page
number number number number
Q 40-462 (01) Q 40-514 (01) Q 40-566 (01) Q 40-618 (01)
Q 40-463 (01) Q 40-515 (01) Q 40-567 (01) Q 40-619 (01)
Q 40-464 (01) Q 40-516 (01) Q 40-568 (01) Q 40-620 (01)
Q 40-465 (01) Q 40-517 (01) Q 40-569 (01) Q 40-621 (01)
Q 40-466 (01) Q 40-518 (01) Q 40-570 (01) Q 40-622 (01)
Q 40-467 (01) Q 40-519 (01) Q 40-571 (01) Q 40-623 (01)
Q 40-468 (01) Q 40-520 (01) Q 40-572 (01) Q 40-624 (01)
Q 40-469 (01) Q 40-521 (01) Q 40-573 (01) Q 40-625 (01)
Q 40-470 (01) Q 40-522 (01) Q 40-574 (01) Q 40-626 (01)
Q 40-471 (01) Q 40-523 (01) Q 40-575 (01) Q 40-627 (01)
Q 40-472 (01) Q 40-524 (01) Q 40-576 (01) Q 40-628 (01)
Q 40-473 (01) Q 40-525 (01) Q 40-577 (01) Q 40-629 (01)
Q 40-474 (01) Q 40-526 (01) Q 40-578 (01) Q 40-630 (01)
Q 40-475 (01) Q 40-527 (01) Q 40-579 (01) Q 40-631 (01)
Q 40-476 (01) Q 40-528 (01) Q 40-580 (01) Q 40-632 (01)
Q 40-477 (01) Q 40-529 (01) Q 40-581 (01) Q 40-633 (01)
Q 40-478 (01) Q 40-530 (01) Q 40-582 (01) Q 40-634 (01)
Q 40-479 (01) Q 40-531 (01) Q 40-583 (01) Q 40-635 (01)
Q 40-480 (01) Q 40-532 (01) Q 40-584 (01) Q 40-636 (01)
Q 40-481 (01) Q 40-533 (01) Q 40-585 (01) Q 40-637 (01)
Q 40-482 (01) Q 40-534 (01) Q 40-586 (01) Q 40-638 (01)
Q 40-483 (01) Q 40-535 (01) Q 40-587 (01) Q 40-639 (01)
Q 40-484 (01) Q 40-536 (01) Q 40-588 (01) Q 40-640 (01)
Q 40-485 (01) Q 40-537 (01) Q 40-589 (01) Q 40-641 (01)
Q 40-486 (01) Q 40-538 (01) Q 40-590 (01) Q 40-642 (01)
Q 40-487 (01) Q 40-539 (01) Q 40-591 (01) Q 40-643 (01)
Q 40-488 (01) Q 40-540 (01) Q 40-592 (01) Q 40-644 (01)
Q 40-489 (01) Q 40-541 (01) Q 40-593 (01) Q 40-645 (01)
Q 40-490 (01) Q 40-542 (01) Q 40-594 (01) Q 40-646 (01)
Q 40-491 (01) Q 40-543 (01) Q 40-595 (01) Q 40-647 (01)
Q 40-492 (01) Q 40-544 (01) Q 40-596 (01) Q 40-648 (01)
Q 40-493 (01) Q 40-545 (01) Q 40-597 (01) Q 40-649 (01)
Q 40-494 (01) Q 40-546 (01) Q 40-598 (01) Q 40-650 (01)
Q 40-495 (01) Q 40-547 (01) Q 40-599 (01) Q 40-651 (01)
Q 40-496 (01) Q 40-548 (01) Q 40-600 (01) Q 40-652 (01)
Q 40-497 (01) Q 40-549 (01) Q 40-601 (01) Q 40-653 (01)
Q 40-498 (01) Q 40-550 (01) Q 40-602 (01) Q 40-654 (01)
Q 40-499 (01) Q 40-551 (01) Q 40-603 (01) Q 40-655 (01)
Q 40-500 (01) Q 40-552 (01) Q 40-604 (01) Q 40-656 (01)
Q 40-501 (01) Q 40-553 (01) Q 40-605 (01) Q 40-657 (01)
Q 40-502 (01) Q 40-554 (01) Q 40-606 (01) Q 40-658 (01)
Q 40-503 (01) Q 40-555 (01) Q 40-607 (01) Q 40-659 (01)
Q 40-504 (01) Q 40-556 (01) Q 40-608 (01) Q 40-660 (01)
Q 40-505 (01) Q 40-557 (01) Q 40-609 (01) Q 40-661 (01)
Q 40-506 (01) Q 40-558 (01) Q 40-610 (01) Q 40-662 (01)
Q 40-507 (01) Q 40-559 (01) Q 40-611 (01) Q 40-663 (01)
Q 40-508 (01) Q 40-560 (01) Q 40-612 (01) Q 40-664 (01)
Q 40-509 (01) Q 40-561 (01) Q 40-613 (01) Q 40-665 (01)
Q 40-510 (01) Q 40-562 (01) Q 40-614 (01) Q 40-666 (01)
Q 40-511 (01) Q 40-563 (01) Q 40-615 (01) Q 40-667 (01)
Q 40-512 (01) Q 40-564 (01) Q 40-616 (01) Q 40-668 (01)
Q 40-513 (01) Q 40-565 (01) Q 40-617 (01) Q 40-669 (01)

6 D375A-6R
(01)
Notice of revision

Revision Revision Revision Revision


Mark Page Mark Page Mark Page Mark Page
number number number number
Q 40-670 (01) Q 50-24 (01) Q 50-77 (01) Q 50-129 (01)
Q 40-671 (01) Q 50-25 (01) Q 50-78 (01) Q 50-130 (01)
Q 40-672 (01) Q 50-26 (01) Q 50-79 (01) Q 50-131 (01)
Q 40-673 (01) Q 50-27 (01) Q 50-80 (01) Q 50-132 (01)
Q 40-674 (01) Q 50-28 (01) Q 50-81 (01) Q 50-133 (01)
Q 40-675 (01) Q 50-29 (01) Q 50-82 (01) Q 50-134 (01)
Q 40-676 (01) Q 50-30 (01) Q 50-83 (01) Q 50-135 (01)
Q 40-677 (01) Q 50-31 (01) Q 50-84 (01) Q 50-136 (01)
Q 40-678 (01) Q 50-33 (01) Q 50-85 (01) Q 50-137 (01)
Q 40-679 (01) Q 50-34 (01) Q 50-86 (01) Q 50-138 (01)
Q 40-680 (01) Q 50-35 (01) Q 50-87 (01) Q 50-139 (01)
Q 40-681 (01) Q 50-36 (01) Q 50-88 (01) Q 50-140 (01)
Q 40-682 (01) Q 50-37 (01) Q 50-89 (01) Q 50-141 (01)
Q 40-683 (01) Q 50-38 (01) Q 50-90 (01) Q 50-142 (01)
Q 40-684 (01) Q 50-39 (01) Q 50-91 (01) Q 50-143 (01)
Q 40-685 (01) Q 50-40 (01) Q 50-92 (01) Q 50-144 (01)
Q 40-686 (01) Q 50-41 (01) Q 50-93 (01) Q 50-145 (01)
Q 40-687 (01) Q 50-42 (01) Q 50-94 (01) Q 50-146 (01)
Q 40-688 (01) Q 50-43 (01) Q 50-95 (01) Q 50-147 (01)
Q 40-689 (01) Q 50-44 (01) Q 50-96 (01) Q 50-148 (01)
Q 40-690 (01) Q 50-45 (01) Q 50-97 (01) Q 50-149 (01)
Q 40-691 (01) Q 50-46 (01) Q 50-98 (01) Q 50-150 (01)
Q 40-692 (01) Q 50-47 (01) Q 50-99 (01) Q 50-151 (01)
Q 40-693 (01) Q 50-48 (01) Q 50-100 (01) Q 50-152 (01)
Q 40-694 (01) Q 50-49 (01) Q 50-101 (01) Q 50-153 (01)
Q 40-695 (01) Q 50-50 (01) Q 50-102 (01) Q 50-154 (01)
Q 40-696 (01) Q 50-51 (01) Q 50-103 (01) Q 50-155 (01)
Q 40-697 (01) Q 50-52 (01) Q 50-104 (01) Q 50-156 (01)
Q 40-698 (01) Q 50-53 (01) Q 50-105 (01) Q 50-157 (01)
Q 50-1 (01) Q 50-54 (01) Q 50-106 (01) Q 50-158 (01)
Q 50-2 (01) Q 50-55 (01) Q 50-107 (01) Q 50-159 (01)
Q 50-3 (01) Q 50-56 (01) Q 50-108 (01) Q 50-160 (01)
Q 50-4 (01) Q 50-57 (01) Q 50-109 (01) Q 50-161 (01)
Q 50-5 (01) Q 50-58 (01) Q 50-110 (01) Q 50-162 (01)
Q 50-6 (01) Q 50-59 (01) Q 50-111 (01) Q 50-163 (01)
Q 50-7 (01) Q 50-60 (01) Q 50-112 (01) Q 50-164 (01)
Q 50-8 (01) Q 50-61 (01) Q 50-113 (01) Q 50-165 (01)
Q 50-9 (01) Q 50-62 (01) Q 50-114 (01) Q 50-166 (01)
Q 50-10 (01) Q 50-63 (01) Q 50-115 (01) Q 50-167 (01)
Q 50-11 (01) Q 50-64 (01) Q 50-116 (01) Q 50-168 (01)
Q 50-12 (01) Q 50-65 (01) Q 50-117 (01) Q 50-169 (01)
Q 50-13 (01) Q 50-66 (01) Q 50-118 (01) Q 50-170 (01)
Q 50-14 (01) Q 50-67 (01) Q 50-119 (01) Q 50-171 (01)
Q 50-15 (01) Q 50-68 (01) Q 50-120 (01) Q 50-172 (01)
Q 50-16 (01) Q 50-69 (01) Q 50-121 (01) Q 50-173 (01)
Q 50-17 (01) Q 50-70 (01) Q 50-122 (01) Q 50-174 (01)
Q 50-18 (01) Q 50-71 (01) Q 50-123 (01) Q 50-175 (01)
Q 50-19 (01) Q 50-72 (01) Q 50-124 (01) Q 50-176 (01)
Q 50-20 (01) Q 50-73 (01) Q 50-125 (01) Q 50-177 (01)
Q 50-21 (01) Q 50-74 (01) Q 50-126 (01) Q 50-178 (01)
Q 50-22 (01) Q 50-75 (01) Q 50-127 (01) Q 50-179 (01)
Q 50-23 (01) Q 50-76 (01) Q 50-128 (01) Q 50-180 (01)

D375A-6R 7
(01)
Notice of revision

Revision Revision Revision Revision


Mark Page Mark Page Mark Page Mark Page
number number number number
Q 50-181 (01) Q 50-233 (01) Q 50-285 (01) 60-13
Q 50-182 (01) Q 50-234 (01) Q 50-286 (01) 60-14
Q 50-183 (01) Q 50-235 (01) Q 50-287 (01) 60-15
Q 50-184 (01) Q 50-236 (01) Q 50-288 (01) 60-16
Q 50-185 (01) Q 50-237 (01) Q 50-289 (01) 60-17
Q 50-186 (01) Q 50-238 (01) Q 50-290 (01) 60-18
Q 50-187 (01) Q 50-239 (01) Q 50-291 (01) 60-19
Q 50-188 (01) Q 50-240 (01) Q 50-292 (01) 60-20
Q 50-189 (01) Q 50-241 (01) Q 50-293 (01) 60-21
Q 50-190 (01) Q 50-242 (01) Q 50-294 (01) 60-22
Q 50-191 (01) Q 50-243 (01) Q 50-295 (01) 60-23
Q 50-192 (01) Q 50-244 (01) Q 50-296 (01) 60-24
Q 50-193 (01) Q 50-245 (01) Q 50-297 (01) 60-25
Q 50-194 (01) Q 50-246 (01) Q 50-298 (01) 60-26
Q 50-195 (01) Q 50-247 (01) Q 50-299 (01) 60-27
Q 50-196 (01) Q 50-248 (01) Q 50-300 (01) 60-28
Q 50-197 (01) Q 50-249 (01) Q 50-301 (01) 60-29
Q 50-198 (01) Q 50-250 (01) Q 50-302 (01) 60-30
Q 50-199 (01) Q 50-251 (01) Q 50-303 (01) 60-31
Q 50-200 (01) Q 50-252 (01) Q 50-304 (01) 60-32
Q 50-201 (01) Q 50-253 (01) Q 50-305 (01) 60-33
Q 50-202 (01) Q 50-254 (01) Q 50-306 (01) 60-34
Q 50-203 (01) Q 50-255 (01) Q 50-307 (01) 60-35
Q 50-204 (01) Q 50-256 (01) Q 50-308 (01) 60-36
Q 50-205 (01) Q 50-257 (01) Q 50-309 (01) 60-37
Q 50-206 (01) Q 50-258 (01) Q 50-310 (01) 60-38
Q 50-207 (01) Q 50-259 (01) Q 50-311 (01) 60-39
Q 50-208 (01) Q 50-260 (01) Q 50-312 (01) 60-40
Q 50-209 (01) Q 50-261 (01) Q 50-313 (01) 60-41
Q 50-210 (01) Q 50-262 (01) Q 50-314 (01) 60-42
Q 50-211 (01) Q 50-263 (01) Q 50-315 (01) 60-43
Q 50-212 (01) Q 50-264 (01) Q 50-316 (01) 60-44
Q 50-213 (01) Q 50-265 (01) Q 50-317 (01) 60-45
Q 50-214 (01) Q 50-266 (01) Q 50-318 (01) 60-46
Q 50-215 (01) Q 50-267 (01) Q 50-319 (01) 60-47
Q 50-216 (01) Q 50-268 (01) Q 50-320 (01) 60-48
Q 50-217 (01) Q 50-269 (01) Q 50-321 (01) 60-49
Q 50-218 (01) Q 50-270 (01) Q 50-322 (01) 60-50
Q 50-219 (01) Q 50-271 (01) Q 50-323 (01) 60-51
Q 50-220 (01) Q 50-272 (01) Q 50-324 (01) 60-52
Q 50-221 (01) Q 50-273 (01) 60-1 60-53
Q 50-222 (01) Q 50-274 (01) 60-2 60-54
Q 50-223 (01) Q 50-275 (01) 60-3 60-55
Q 50-224 (01) Q 50-276 (01) 60-4 60-56
Q 50-225 (01) Q 50-277 (01) 60-5 60-57
Q 50-226 (01) Q 50-278 (01) 60-6 60-58
Q 50-227 (01) Q 50-279 (01) 60-7 60-59
Q 50-228 (01) Q 50-280 (01) 60-8 60-60
Q 50-229 (01) Q 50-281 (01) 60-9 60-61
Q 50-230 (01) Q 50-282 (01) 60-10 60-62
Q 50-231 (01) Q 50-283 (01) 60-11 60-63
Q 50-232 (01) Q 50-284 (01) 60-12 60-64

8 D375A-6R
(01)
Notice of revision

Revision Revision Revision Revision


Mark Page Mark Page Mark Page Mark Page
number number number number
60-65 Q 80-11 (01) Q 80-63 (01)
60-66 Q 80-12 (01) Q 80-64 (01)
60-67 Q 80-13 (01) Q 80-65 (01)
60-68 Q 80-14 (01) Q 80-66 (01)
60-69 Q 80-15 (01) 90-1
60-70 Q 80-16 (01) 90-2
60-71 Q 80-17 (01) 90-3
60-72 Q 80-18 (01) 90-4
60-73 Q 80-19 (01) 90-5
60-74 Q 80-20 (01) 90-7
60-75 Q 80-21 (01) 90-9
60-76 Q 80-22 (01) 90-11
60-77 Q 80-23 (01) 90-12
60-78 Q 80-24 (01) 90-13
60-79 Q 80-25 (01) 90-14
60-80 Q 80-26 (01) 90-15
60-81 Q 80-27 (01) 90-17
60-82 Q 80-28 (01) 90-19
60-83 Q 80-29 (01) 90-21
60-84 Q 80-30 (01) 90-23
60-85 Q 80-31 (01) 90-25
60-86 Q 80-32 (01) 90-27
60-87 Q 80-33 (01) 90-29
60-88 Q 80-34 (01) 90-31
60-89 Q 80-35 (01) 90-33
60-90 Q 80-36 (01) 90-35
60-91 Q 80-37 (01) 90-37
60-92 Q 80-38 (01) 90-39
60-93 Q 80-39 (01) 90-41
60-94 Q 80-40 (01) q 1 (01)
60-95 Q 80-41 (01) q 2 (01)
60-96 Q 80-42 (01) Q 3 (01)
60-97 Q 80-43 (01) Q 4 (01)
60-98 Q 80-44 (01) Q 5 (01)
60-99 Q 80-45 (01) Q 6 (01)
60-100 Q 80-46 (01) Q 7 (01)
60-101 Q 80-47 (01) Q 8 (01)
60-102 Q 80-48 (01) q Colophon (01)
60-103 Q 80-49 (01)
60-104 Q 80-50 (01)
60-105 Q 80-51 (01)
60-106 Q 80-52 (01)
Q 80-1 (01) Q 80-53 (01)
Q 80-2 (01) Q 80-54 (01)
Q 80-3 (01) Q 80-55 (01)
Q 80-4 (01) Q 80-56 (01)
Q 80-5 (01) Q 80-57 (01)
Q 80-6 (01) Q 80-58 (01)
Q 80-7 (01) Q 80-59 (01)
Q 80-8 (01) Q 80-60 (01)
Q 80-9 (01) Q 80-61 (01)
Q 80-10 (01) Q 80-62 (01)

D375A-6R 9
(01)
D375A-6R
SEN0521402-00 0-1

BULLDOZER
Shop Manual 0-1

D375A-6R

Machine model Serial number


D375A-6R 65001 and up

00 Index and foreword 0 -1

D375A-6R 00-1
Shop Manual
Table of contents

Table of contents 0 -2

Notice of revision .................................................................................................................... 1

00 Index and Foreword


Table of contents .................................................................................................................... 00 - 2
Table of contents ................................................................................................................. 00 - 2
Foreword and general information .......................................................................................... 00 - 5
Safety notice ........................................................................................................................ 00 - 5
How to read the shop manual .............................................................................................. 00 - 10
Explanation of terms for maintenance standard .................................................................. 00 - 12
Handling of electric equipment and hydraulic components.................................................. 00 - 14
Handling of connectors newly used for engines .................................................................. 00 - 23
How to read electric wire code............................................................................................. 00 - 26
Precautions when carrying out work .................................................................................... 00 - 29
Method of disassembling and connecting push-pull type coupler........................................ 00 - 32
Standard tightening torque table.......................................................................................... 00 - 35
List of Abbreviation .............................................................................................................. 00 - 39
Conversion table .................................................................................................................. 00 - 43

01 Specification
Specification and technical data ............................................................................................. 01 - 3
Specification drawing ........................................................................................................... 01 - 3
Specifications....................................................................................................................... 01 - 4
Weight table ......................................................................................................................... 01 - 9
Table of fuel, coolant and lubricants .................................................................................... 01 - 11

10 Structure and function


Engine and cooling system ..................................................................................................... 10- 4
Cooling system .................................................................................................................... 10- 4
Cooling fan pump................................................................................................................. 10- 7
Cooling fan motor................................................................................................................. 10- 28
Power train.............................................................................................................................. 10- 34
Power train........................................................................................................................... 10- 34
Overall drawing of power train unit ...................................................................................... 10- 36
Power train hydraulic equipment arrangement drawing....................................................... 10- 38
Damper and universal joint .................................................................................................. 10- 40
Torque converter and PTO .................................................................................................. 10- 42
Torque converter control valve ............................................................................................ 10- 48
Main relief valve and torque converter relief valve............................................................... 10- 50
Lockup clutch ECMV and stator clutch ECMV..................................................................... 10- 52
Scavenging pump ................................................................................................................ 10- 57
Transmission control............................................................................................................ 10- 58
PCCS lever .......................................................................................................................... 10- 60
Transmission........................................................................................................................ 10- 64
Transmission ECMV ............................................................................................................ 10- 78
Transmission lubrication relief valve .................................................................................... 10- 83
Steering and brake control................................................................................................... 10- 84
Transfer unit, bevel gear shaft and steering ........................................................................ 10- 86
Steering control valve .......................................................................................................... 10- 92
Steering clutch ECMV and Steering brake ECMV ............................................................... 10- 94
Parking brake valve ............................................................................................................. 10- 102
Sudden stop prevention valve.............................................................................................. 10- 103

00-2 D375A-6R
(01)
Shop Manual
Table of contents

Final drive ............................................................................................................................ 10- 105


Undercarriage and frame ........................................................................................................ 10- 110
Track frame.......................................................................................................................... 10- 110
Idler cushion ........................................................................................................................ 10- 112
Track roller bogie ................................................................................................................. 10- 113
Main frame........................................................................................................................... 10- 114
Suspension .......................................................................................................................... 10- 116
Hydraulic system .................................................................................................................... 10- 119
Work equipment hydraulic piping diagram........................................................................... 10- 119
PPC control piping diagram ................................................................................................. 10- 123
Work equipment control....................................................................................................... 10- 124
Hydraulic tank ...................................................................................................................... 10- 126
Accumulator......................................................................................................................... 10- 128
PPC lock valve..................................................................................................................... 10- 129
PPC valve ............................................................................................................................ 10- 130
Piston valve ......................................................................................................................... 10- 142
Quick drop valve .................................................................................................................. 10- 143
Pin puller switch................................................................................................................... 10- 145
Pin puller solenoid valve ...................................................................................................... 10- 146
Blade control lever (only for the machine with dual tilt specification)................................... 10- 148
Work equipment pump......................................................................................................... 10- 150
Control valve........................................................................................................................ 10- 162
Self-pressure reducing valve ............................................................................................... 10- 187
Work equipment...................................................................................................................... 10- 194
Cylinder stay ........................................................................................................................ 10- 194
Cab ......................................................................................................................................... 10- 195
Cab mount ........................................................................................................................... 10- 195
Cab ...................................................................................................................................... 10- 196
Electrical system ..................................................................................................................... 10- 198
Engine control...................................................................................................................... 10- 198
Engine control system ......................................................................................................... 10- 199
CRI engine control system................................................................................................... 10- 208
Monitor system .................................................................................................................... 10- 210
Machine monitor .................................................................................................................. 10- 212
Lamp system ....................................................................................................................... 10- 230
Engine preheat (electrical intake air heater) control ............................................................ 10- 231
Palm command control system............................................................................................ 10- 232
Sensor ................................................................................................................................. 10- 235
Vehicle health monitoring system (VHMS) .......................................................................... 10- 241
ORBCOMM system ............................................................................................................. 10- 247

20 Standard value table


Standard service value table .................................................................................................. 20- 3
Standard value table for engine........................................................................................... 20- 3
Standard value table for machine ........................................................................................ 20- 4

30 Testing and adjusting


Tools for testing, adjusting and troubleshooting ..................................................................... 30- 4
Diagnosis equipment list...................................................................................................... 30- 4
Engine and cooling system ..................................................................................................... 30- 6
Testing engine speed .......................................................................................................... 30- 6
Testing intake air pressure (boost pressure) ....................................................................... 30- 9
Testing exhaust temperature ............................................................................................... 30- 11
Testing exhaust gas color.................................................................................................... 30- 14

D375A-6R 00-3
(01)
Shop Manual
Table of contents

Adjusting valve clearance .................................................................................................... 30- 16


Measuring compression pressure........................................................................................ 30- 18
Testing blow-by pressure..................................................................................................... 30- 21
Testing engine oil pressure.................................................................................................. 30- 23
Handling of fuel system devices .......................................................................................... 30- 24
Releasing residual pressure from fuel system ..................................................................... 30- 25
Testing fuel pressure ........................................................................................................... 30- 26
Handling of reduced cylinder mode operation ..................................................................... 30- 27
Handling of no injection cranking operation ......................................................................... 30- 28
Testing leakage from pressure limiter and return rate from injector .................................... 30- 29
Bleeding air from fuel circuit................................................................................................. 30- 32
Testing fuel circuit for leakage ............................................................................................. 30- 34
Replacing and adjusting alternator and air conditioner compressor belt ............................. 30- 35
Measuring fan speed ........................................................................................................... 30- 36
Testing fan circuit oil pressure ............................................................................................. 30- 37
Bleeding air from fan pump.................................................................................................. 30- 38
Adjusting fuel control dial and decelerator pedal ................................................................. 30- 39
Power train.............................................................................................................................. 30- 42
Testing power train oil pressure........................................................................................... 30- 42
Adjusting transmission output speed sensor ....................................................................... 30- 56
Simple test procedure for brake performance...................................................................... 30- 57
Adjusting brake pedal and parking brake lever.................................................................... 30- 58
Adjusting position of pccs lever console .............................................................................. 30- 61
Emergency escape method when there is failure in power train ......................................... 30- 62
Undercarriage and frame ........................................................................................................ 30- 64
Inspecting wear of sprocket ................................................................................................. 30- 64
Testing and adjusting track shoe tension............................................................................. 30- 65
Hydraulic system..................................................................................................................... 30- 66
Testing and adjusting work equipment oil pressure............................................................. 30- 66
Testing control circuit main pressure ................................................................................... 30- 69
Testing PPC valve output pressure ..................................................................................... 30- 70
Adjusting play of PPC valve................................................................................................. 30- 72
Testing output pressure of ripper pin-puller solenoid valve ................................................. 30- 73
Checking location of cause of hydraulic drift of blade and ripper......................................... 30- 74
Testing leakage inside work equipment cylinder ................................................................. 30- 75
Releasing remaining pressure in work equipment cylinders................................................ 30- 76
Bleeding air from work equipment cylinders ........................................................................ 30- 77
Adjusting ripper lever position.............................................................................................. 30- 78
Work equipment...................................................................................................................... 30- 80
Adjusting work equipment lock lever.................................................................................... 30- 80
Adjusting blade .................................................................................................................... 30- 81
Cab and its attachments ......................................................................................................... 30- 84
Testing and adjusting operator's cab ................................................................................... 30- 84
Electrical system ..................................................................................................................... 30- 90
Special functions of machine monitor (EMMS) .................................................................... 30- 90
Handling of voltage circuit of engine controller .................................................................... 30- 148
Adjustment method when controller has been replaced ...................................................... 30- 149
Preparation work for troubleshooting for electrical equipment system ................................ 30- 153
Inspection procedure of diode.............................................................................................. 30- 157
Handling of optional devices ................................................................................................ 30- 158
Request for opening ORBCOMM terminal........................................................................... 30- 159
Initialization procedures for VHMS controller....................................................................... 30- 161
Using method of KOMTRAX functions of ORBCOMM terminal........................................... 30- 175
Precautions for replacing VHMS controller .......................................................................... 30- 178

00-3-1 D375A-6R
(01)
Shop Manual
Table of contents

Pm Clinic................................................................................................................................. 30- 184


Pm Clinic service ................................................................................................................. 30- 184

40 Troubleshooting
General information on troubleshooting.................................................................................. 40- 10
Points to remember when troubleshooting .......................................................................... 40- 10
Sequence of events in troubleshooting................................................................................ 40- 11
Checks before troubleshooting ............................................................................................ 40- 12
Classification and procedures for troubleshooting............................................................... 40- 37
Failure codes table .............................................................................................................. 40- 40
Classification and procedures for troubleshooting numbers................................................ 40- 50
Information in troubleshooting table..................................................................................... 40- 52
Troubleshooting method for disconnecting wiring harness of pressure sensor system ...... 40- 54
Connection table for connector pin numbers ....................................................................... 40- 57
T-branch box and T-branch adapter table ........................................................................... 40- 93
Connector list and layout ..................................................................................................... 40- 96
Fuse locations table............................................................................................................. 40- 110
Troubleshooting by failurecode............................................................................................... 40- 114
Failure code [1380MW] Lock up clutch: Slip........................................................................ 40- 114
Failure code [1500L0] Transmission clutch: Abnormal........................................................ 40- 115
Failure code [15E0MW] Transmission clutch: Slip .............................................................. 40- 116
Failure code [15SAL1] Forward clutch: Fill high .................................................................. 40- 118
Failure code [15SALH] Forward clutch: Fill Low.................................................................. 40- 120
Failure code [15SBL1] Reverse clutch: Fill high .................................................................. 40- 122
Failure code [15SBLH] Reverse clutch: Fill Low.................................................................. 40- 124
Failure code [15SEL1] Speed 1st clutch: Fill high ............................................................... 40- 126
Failure code [15SELH] Speed 1st clutch: Fill Low............................................................... 40- 128
Failure code [15SFL1] Speed 2nd clutch: Fill high .............................................................. 40- 130
Failure code [15SFLH] Speed 2nd clutch: Fill Low.............................................................. 40- 132
Failure code [15SGL1] Speed 3rd clutch: Fill high .............................................................. 40- 134
Failure code [15SGLH] Speed 3rd clutch: Fill Low .............................................................. 40- 136
Failure code [15SJL1] L/U: Fill high..................................................................................... 40- 138
Failure code [15SJLH] L/U: Fill low...................................................................................... 40- 140
Failure code [1800MW] P/T clutch: Slip............................................................................... 40- 142
Failure code [2201L1] Right clutch: Fill high........................................................................ 40- 144
Failure code [2201LH] Right clutch: Fill low......................................................................... 40- 146
Failure code [2202L1] Left clutch: Fill high .......................................................................... 40- 148
Failure code [2202LH] Left clutch: Fill low ........................................................................... 40- 150
Failure code [2300NR] Brake Themal Load Abnormality .................................................... 40- 152
Failure code [2301L1] Right brake: Fill high ........................................................................ 40- 154
Failure code [2301LH] Right brake: Fill low ......................................................................... 40- 156
Failure code [2301NR] Steering Brake RH Themal Load Abnormality ................................ 40- 158
Failure code [2302L1] Left brake: Fill high........................................................................... 40- 160
Failure code [2302LH] Left brake: Fill low ........................................................................... 40- 162
Failure code [2302NR] Steering Brake LH Themal Load Abnormality ................................ 40- 164
Failure code [7RFAKA] ECM ACC CUT RELAY: Disconnection......................................... 40- 166
Failure code [7RFAKB] ECM ACC CUT RELAY: Short circuit ............................................ 40- 168
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40- 170
Failure code [AB00MA] Battery Charge Abnormal .............................................................. 40- 172
Failure code [B@BAZG] Eng Oil Press Low........................................................................ 40- 173
Failure code [B@BAZK] Eng Oil Level Low......................................................................... 40- 174
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40- 175
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40- 176
Failure code [B@CENS] T/C Oil Overheat .......................................................................... 40- 177

D375A-6R 00-3-2
(01)
Shop Manual
Table of contents

Failure code [B@HANS] Hyd Oil Overheat.......................................................................... 40- 178


Failure code [B@HAZK] Hyd Oil Level Low......................................................................... 40- 179
Failure code [CA111] ECM Critical Internal Failure ............................................................. 40- 180
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ................................................ 40- 182
Failure code [CA122] Chg Air Press Sensor High Error ...................................................... 40- 184
Failure code [CA123] Chg Air Press Sensor Low Error ....................................................... 40- 186
Failure code [CA131] Throttle Sensor High Error ................................................................ 40- 188
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40- 190
Failure code [CA135] Eng Oil Press Sensor High Error ...................................................... 40- 192
Failure code [CA141] Eng Oil Press Sensor Low Error ....................................................... 40- 194
Failure code [CA144] Coolant Temp Sens High Error ......................................................... 40- 196
Failure code [CA145] Coolant Temp Sens Low Error.......................................................... 40- 198
Failure code [CA153] Chg Air Temp Sensor High Error ...................................................... 40- 200
Failure code [CA154] Chg Air Temp Sensor Low Error ....................................................... 40- 202
Failure code [CA187] Sens Supply 2 Volt Low Error ........................................................... 40- 204
Failure code [CA212] Eng Oil Temp Sensor High Error ...................................................... 40- 206
Failure code [CA213] Eng Oil Temp Sensor Low Error ....................................................... 40- 208
Failure code [CA221] Ambient Press Sens High Error ........................................................ 40- 210
Failure code [CA222] Ambient Press Sens Low Error ......................................................... 40- 212
Failure code [CA227] Sens Supply 2 Volt High Error .......................................................... 40- 214
Failure code [CA234] Eng Overspeed ................................................................................. 40- 215
Failure code [CA238] Ne Speed Sens Supply Volt Error..................................................... 40- 216
Failure code [CA263] Fuel Temp Sensor High Error ........................................................... 40- 218
Failure code [CA265] Fuel Temp Sensor Low Error ............................................................ 40- 220
Failure code [CA271] IMV/PCV1 Short Error....................................................................... 40- 222
Failure code [CA272] IMV/PCV1 Open Error....................................................................... 40- 223
Failure code [CA273] PCV2 Short Error .............................................................................. 40- 224
Failure code [CA274] PCV2 Open Error .............................................................................. 40- 225
Failure code [CA322] Inj #1 (L#1) Open/Short Error............................................................ 40- 226
Failure code [CA323] Inj #5 (L#5) Open/Short Error............................................................ 40- 228
Failure code [CA324] Inj #3 (L#3) Open/Short Error............................................................ 40- 230
Failure code [CA325] Inj #6 (L#6) Open/Short Error............................................................ 40- 232
Failure code [CA331] Inj #2 (L#2) Open/Short Error............................................................ 40- 234
Failure code [CA332] Inj #4 (L#4) Open/Short Error............................................................ 40- 236
Failure code [CA342] Calibration Code Incompatibility........................................................ 40- 238
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40- 239
Failure code [CA352] Sens Supply 1 Volt Low Error ........................................................... 40- 240
Failure code [CA386] Sens Supply 1 Volt High Error .......................................................... 40- 242
Failure code [CA441] Battery Voltage Low Error ................................................................. 40- 243
Failure code [CA442] Battery Voltage High Error ................................................................ 40- 244
Failure code [CA449] Rail Press Very High Error ................................................................ 40- 245
Failure code [CA451] Rail Press Sensor High Error ............................................................ 40- 246
Failure code [CA452] Rail Press Sensor Low Error............................................................. 40- 248
Failure code [CA553] Rail Press High Error ........................................................................ 40- 250
Failure code [CA554] Rail Press Sensor In Range Error..................................................... 40- 251
Failure code [CA559] Rail Press Low Error ......................................................................... 40- 252
Failure code [CA689] Eng Ne Speed Sensor Error ............................................................. 40- 256
Failure code [CA731] Eng Bkup Speed Sens Phase Error.................................................. 40- 258
Failure code [CA757] All Continuous Data Lost Error.......................................................... 40- 259
Failure code [CA778] Eng Bkup Speed Sensor Error.......................................................... 40- 260
Failure code [CA1633] KOMNET Datalink Timeout Error.................................................... 40- 262
Failure code [CA2185] Throt Sens Sup Volt High Error....................................................... 40- 263
Failure code [CA2186] Throt Sens Sup Volt Low Error ....................................................... 40- 264
Failure code [CA2249] Rail Press Very Low Error............................................................... 40- 265

00-3-3 D375A-6R
(01)
Shop Manual
Table of contents

Failure code [D110KB] Battery Relay: Drive Short Circuit................................................... 40- 266
Failure code [D130KA] Neutral relay: Disconnection........................................................... 40- 268
Failure code [D130KB] Neutral relay: Short circuit .............................................................. 40- 270
Failure code [D161KA] Back-up alarm releay: Disconnection ............................................. 40- 272
Failure code [D161KB] Back-up alarm releay: Short circuit................................................. 40- 274
Failure code [D182KZ] Preheater Relay Abnormality.......................................................... 40- 276
Failure code [D190KA] ACC signal relay: Disconnection .................................................... 40- 278
Failure code [D190KB] ACC signal relay: Short circuit........................................................ 40- 280
Failure code [D1EFKA] Pre lub. motor relay: Disconnection ............................................... 40- 282
Failure code [D1EFKB] Pre lub. motor relay: Short circuit................................................... 40- 284
Failure code [DAFRKR] Monitor: Can communication lost (PT) .......................................... 40- 286
Failure code [dAFRKR] Monitor: CAN communication lost (WE) ........................................ 40- 287
Failure code [DAFRMC] CAN Discon (Monitor Detected) ................................................... 40- 288
Failure code [DB2RKR] ENG cont.: Can communication lost (PT) ..................................... 40- 294
Failure code [dB2RKR] ENG controller: CAN communication lost (WE) ............................. 40- 298
Failure code [DB90KT] WE controller: Abnormality in controller ......................................... 40- 299
Failure code [DB91KK] WE controller: Source voltage reduction........................................ 40- 300
Failure code [DB92KK] WE controller: Output voltage reduction ........................................ 40- 302
Failure code [DB97KK] WE cont.: Sensor voltage 5 V (2) reduction ................................... 40- 304
Failure code [DB99KQ] WE controller: Type select signal .................................................. 40- 306
Failure code [DB9RKR] WE controller: Can communication lost (PT) ................................ 40- 307
Failure code [DBB0KK] VHMS controller:Source voltage reduction .................................... 40- 310
Failure code [DBB0KQ] VHMS connector connection abnormality ..................................... 40- 312
Failure code [DBB3KK] VHMS controller: Source voltage reduction ................................... 40- 313
Failure code [DBB5KP] VHMS: Output sensor1 voltage reduction ..................................... 40- 316
Failure code [DBB6KP] VHMS:Output sensor2 voltage reduction ...................................... 40- 318
Failure code [DBB7KP] VHMS:Output sensor3 voltage reduction ...................................... 40- 320
Failure code [DBBQKR] PT cont.: Can communication lost (VHMS) .................................. 40- 322
Failure code [DBE0KT] PT controller: Abnormality in controller .......................................... 40- 323
Failure code [DBE1KK] PT controller: Source voltage reduction......................................... 40- 324
Failure code [DBE2KK] PT controller: Output voltage reduction ......................................... 40- 326
Failure code [DBE5KK] PT cont.: Sensor voltage 5 V (1) reduction .................................... 40- 328
Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction ........................................ 40- 330
Failure code [DBE7KK] PT cont.: Sensor voltage 5 V reduction ......................................... 40- 332
Failure code [DBE9KQ] PT controller: Type select signal ................................................... 40- 334
Failure code [DBERKR] PT controller: Can communication lost (WE) ................................ 40- 335
Failure code [DD12KA] Shift up Sw: Disconnection ............................................................ 40- 338
Failure code [DD12KB] Shift up Sw: Short circuit................................................................ 40- 340
Failure code [DD13KA] Shift down Sw: Disconnection........................................................ 40- 342
Failure code [DD13KB] Shift down Sw: Short circuit ........................................................... 40- 344
Failure code [DD14KA] Parking lever Sw: Dissconnection.................................................. 40- 346
Failure code [DD14KB] Parking lever Sw: Short circuit ....................................................... 40- 348
Failure code [DDB9L4] Reverse SW Signal disagreement ................................................. 40- 350
Failure code [DDE2KA] Pre lub. oil press sw: Disconnection.............................................. 40- 352
Failure code [DDK3L4] Forward SW Signal disagreement.................................................. 40- 354
Failure code [DDK5KA] Shift switch disconnection ............................................................. 40- 356
Failure code [DDK5KB] Shift switch short circuit ................................................................. 40- 358
Failure code [DDN2LD] Blade tilt RH pressure SW abnormality ......................................... 40- 360
Failure code [DDN3LD] Blade tilt LH pressure SW abnormality .......................................... 40- 362
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection .......................................... 40- 364
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit ............................................. 40- 366
Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection .............................................. 40- 368
Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit .................................................. 40- 370
Failure code [DDNALD] Blade lift up pressure SW abnormality .......................................... 40- 372

D375A-6R 00-3-4
(01)
Shop Manual
Table of contents

Failure code [DDNBLD] Ripper lift up pressure SW abnormality......................................... 40- 374


Failure code [DDNCLD] Ripper lift down pressure SW abnormality .................................... 40- 376
Failure code [DDNDLD] Ripper tilt in pressure SW abnormality.......................................... 40- 378
Failure code [DDNELD] Ripper tilt back pressure SW abnormality ..................................... 40- 380
Failure code [DDNFLD] Blade lift down pressure SW abnormality...................................... 40- 382
Failure code [DDNLKA] Weq lock Sw: Disconnection ......................................................... 40- 384
Failure code [DDNLKB] Weq lock Sw: Short circuit............................................................. 40- 386
Failure code [DDT5KA] Neutral switch disconnection ......................................................... 40- 388
Failure code [DDT5KB] Neutral switch short circuit ............................................................. 40- 390
Failure code [DDT5KQ] Lever SPEC selection signal disagreement .................................. 40- 392
Failure code [DDTSL1] S/C: Fill high ................................................................................... 40- 394
Failure code [DDTSLH] S/C: Fill low.................................................................................... 40- 396
Failure code [DGE5KX] Ambient temp sensor abnormality ................................................. 40- 398
Failure code [DGS1KX] Hyd oil temp: signal abnormal ....................................................... 40- 400
Failure code [DGT1KA] T/C oil temp sensor: Abnormal ...................................................... 40- 402
Failure code [DGT1KX] T/C oil temp sensor: Abnormal ...................................................... 40- 404
Failure code [DGT5KA] F exhaust temp sensor disconnection ........................................... 40- 406
Failure code [DGT5KB] F exhaust temp sensor short circuit............................................... 40- 408
Failure code [DGT6KA] R exhaust temp sensor disconnection........................................... 40- 410
Failure code [DGT6KB] R exhaust temp sensor short circuit .............................................. 40- 412
Failure code [DH21KA] Weq pressure sensor: Disconnection ............................................ 40- 414
Failure code [DH21KB] Weq pressure sensor: Short circuit ................................................ 40- 416
Failure code [DHE5KB] ENG blow-by pressure sensor disconnection................................ 40- 418
Failure code [DHE5KY] ENG blow-by pressure sensor short circuit ................................... 40- 420
Failure code [DHT3KX] T/M oil pressure sensor abnormality.............................................. 40- 422
Failure code [DHT5KA] T/C in-pressure sensor: Disconnection.......................................... 40- 424
Failure code [DHT5KB] T/C in-pressure sensor: Short circuit ............................................. 40- 426
Failure code [DHT7KA] T/C out-pressure sensor: Disconnection........................................ 40- 428
Failure code [DHT7KB] T/C out-pressure sensor: Short circuit ........................................... 40- 430
Failure code [DK10KA] Fuel control Dial: Disconnection..................................................... 40- 432
Failure code [DK10KB] Fuel control Dial: Short circuit ........................................................ 40- 434
Failure code [DK30KA] ST lever 1: Disconnection .............................................................. 40- 436
Failure code [DK30KB] ST lever 1: Short circuit .................................................................. 40- 438
Failure code [DK30KX] ST lever: Out of normal range ........................................................ 40- 440
Failure code [DK30KZ] ST lever: Disconnection or short circuit .......................................... 40- 441
Failure code [DK30L8] ST lever: Signal mismatch .............................................................. 40- 442
Failure code [DK31KA] ST lever 2: Disconnection .............................................................. 40- 444
Failure code [DK31KB] ST lever 2: Short circuit .................................................................. 40- 446
Failure code [DK40KA] Brake potentiometer: Disconnection .............................................. 40- 448
Failure code [DK40KB] Brake potentiometer: Short circuit .................................................. 40- 450
Failure code [DK55KX] FR lever: Out of normal range........................................................ 40- 452
Failure code [DK55KZ] FR lever: Disconnection or short circuit.......................................... 40- 453
Failure code [DK55L8] FR lever: Signal mismatch .............................................................. 40- 454
Failure code [DK56KA] FR lever 1: Disconnection .............................................................. 40- 456
Failure code [DK56KB] FR lever 1: Short circuit.................................................................. 40- 458
Failure code [DK57KA] FR lever 2: Disconnection .............................................................. 40- 460
Failure code [DK57KB] FR lever 2: Short circuit.................................................................. 40- 462
Failure code [DK60KA] Acceleration sensor: Disconnection ............................................... 40- 464
Failure code [DK60KB] Acceleration sensor: Short circuit................................................... 40- 466
Failure code [DKH1KA] Pitch angle sensor: Disconnection................................................. 40- 468
Failure code [DKH1KB] Pitch angle sensor: Short circuit .................................................... 40- 470
Failure code [DLF1KA] T/C out-speed sensor: Disconnection ............................................ 40- 472
Failure code [DLM3KA] Fan rev. sensor: Disconnection ..................................................... 40- 474
Failure code [DLM3MB] Fan control: Decline ...................................................................... 40- 476

00-3-5 D375A-6R
(01)
Shop Manual
Table of contents

Failure code [DLT3KA] T/M out-speed sensor: Disconnection............................................ 40- 477


Failure code [DLT3KB] T/M out-speed sensor: Abnormal ................................................... 40- 478
Failure code [DW59KA] Blade dual selector SOL disconnection ........................................ 40- 479
Failure code [DW59KB] Blade dual selector SOL short circuit ............................................ 40- 480
Failure code [DW59KY] Blade dual selector SOL hot short ................................................ 40- 482
Failure code [DW5AKA] Blade pitch selector SOL disconnection ....................................... 40- 484
Failure code [DW5AKB] Blade pitch selector SOL short circuit........................................... 40- 485
Failure code [DW5AKY] Blade pitch selector SOL Short circuit .......................................... 40- 486
Failure code [DW7BKA] Fan rev EPC: Disconnection......................................................... 40- 488
Failure code [DW7BKB] Fan rev EPC: Short circuit ............................................................ 40- 489
Failure code [DWN3KA] Ssp solenoid: Disconnection ........................................................ 40- 490
Failure code [DWN3KB] Ssp solenoid: Short circuit ............................................................ 40- 492
Failure code [DWN3KY] SSP solenoid: Short circuit ........................................................... 40- 494
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection ........................................... 40- 496
Failure code [DWN5KB] Fan pump solenoid 1: Short circuit ............................................... 40- 498
Failure code [DWN5KY] Fan pump solenoid 1: Short circuit ............................................... 40- 500
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection........................................... 40- 502
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit .............................................. 40- 504
Failure code [DWNCKY] Fan pump solenoid 2: Short circuit .............................................. 40- 506
Failure code [DXH1KA] Lock-up ECMV: Disconnection...................................................... 40- 508
Failure code [DXH1KB] Lock-up ECMV: Short circuit ......................................................... 40- 509
Failure code [DXH1KY] Lock-up ECMV: Short circuit ......................................................... 40- 510
Failure code [DXH4KA] 1st clutch ECMV: Disconnection ................................................... 40- 512
Failure code [DXH4KB] 1st clutch ECMV: Short circuit ....................................................... 40- 514
Failure code [DXH4KY] 1st clutch ECMV: Short circuit ....................................................... 40- 516
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection .................................................. 40- 518
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit...................................................... 40- 520
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit...................................................... 40- 522
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection ................................................... 40- 524
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit....................................................... 40- 526
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit....................................................... 40- 528
Failure code [DXH7KA] R clutch ECMV: Disconnection...................................................... 40- 530
Failure code [DXH7KB] R clutch ECMV: Short circuit ......................................................... 40- 532
Failure code [DXH7KY] R clutch ECMV: Short circuit ......................................................... 40- 534
Failure code [DXH8KA] F clutch ECMV: Disconnection ...................................................... 40- 536
Failure code [DXH8KB] F clutch ECMV: Short circuit.......................................................... 40- 538
Failure code [DXH8KY] F clutch ECMV: Short circuit.......................................................... 40- 540
Failure code [DXH9KA] Right clutch ECMV: Disconnection ................................................ 40- 542
Failure code [DXH9KB] Right clutch ECMV: Short circuit ................................................... 40- 544
Failure code [DXH9KY] Right clutch ECMV: Short circuit ................................................... 40- 546
Failure code [DXHAKA] Left clutch ECMV: Disconnection.................................................. 40- 548
Failure code [DXHAKB] Left clutch ECMV: Short circuit ..................................................... 40- 550
Failure code [DXHAKY] Left clutch ECMV: Short circuit ..................................................... 40- 552
Failure code [DXHBKA] Right brake ECMV: Disconnection ................................................ 40- 554
Failure code [DXHBKB] Right brake ECMV: Short circuit ................................................... 40- 556
Failure code [DXHBKY] Right brake ECMV: Short circuit ................................................... 40- 558
Failure code [DXHCKA] Left brake ECMV: Disconnection .................................................. 40- 560
Failure code [DXHCKB] Left brake ECMV: Short circuit...................................................... 40- 562
Failure code [DXHCKY] Left brake ECMV: Short circuit...................................................... 40- 564
Failure code [DXJBKA] S/C ECMV: Disconnection ............................................................. 40- 566
Failure code [DXJBKB] S/C ECMV: Short circuit................................................................. 40- 567
Failure code [DXJBKY] S/C ECMV: Short circuit................................................................. 40- 568
Failure code [DY2HKA] Pre lub. motor: Disconnection ....................................................... 40- 570
Failure code [F@BBZL] ENG blow-by pressure high level.................................................. 40- 572

D375A-6R 00-3-6
(01)
Shop Manual
Table of contents

Failure code [F@BYNR] F exhaust temp high level (2) ....................................................... 40- 573
Failure code [F@BYNS] F exhaust temp high level (1) ....................................................... 40- 574
Failure code [F@BZNR] R exhaust temp high level (2)....................................................... 40- 575
Failure code [F@BZNS] R exhaust temp high level (1) ....................................................... 40- 576
Troubleshooting of electrical system (E-mode)....................................................................... 40- 578
Information contained in troubleshooting table .................................................................... 40- 578
E-1 Engine does not start (starting motor does not turn) ..................................................... 40- 580
E-2 Preheater does not operate........................................................................................... 40- 584
E-3 When starting switch is turned ON, machine monitor displays nothing......................... 40- 588
E-4 When starting switch is turned ON (before starting engine), basic check item lights up 40- 592
E-5 Precaution item lights up while engine is running ......................................................... 40- 594
E-6 Emergency stop item lights up while engine is running................................................. 40- 596
E-7 Engine coolant temperature gauge does not indicate normally .................................... 40- 597
E-8 Fuel gauge does not indicate properly .......................................................................... 40- 598
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally ............... 40- 600
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally ..................... 40- 601
E-11 Contents of display by machine monitor are different from applicable machine ......... 40- 602
E-12 Machine monitor does not display some items ........................................................... 40- 602
E-13 Function switch does not work .................................................................................... 40- 602
E-14 Operation mode does not change ............................................................................... 40- 603
E-15 Gearshift mode does not change ................................................................................ 40- 603
E-16 Customize function does not operate normally ........................................................... 40- 604
E-17 Customize memory function does not operate normally ............................................. 40- 604
E-18 Alarm buzzer does not sound or does not stop........................................................... 40- 605
E-19 When starting switch is turned OFF, service meter is not displayed........................... 40- 605
E-20 Machine monitor cannot be set in service mode ......................................................... 40- 605
E-21 The ripper pin puller cylinder does not operate ........................................................... 40- 606
E-22 Horn does not sound or does not stop ........................................................................ 40- 608
E-23 Back-up alarm does not sound or does not stop......................................................... 40- 610
E-24 Fan does not reverse .................................................................................................. 40- 612
E-25 The head lamp and rear lamp do not light up.............................................................. 40- 613
E-26 Windshield wiper does not operate ............................................................................. 40- 622
E-27 Window washer does not operate ............................................................................... 40- 630
E-28 Electric priming pump does not operate or does not stop automatically ..................... 40- 638
E-29 Orbcomm terminal does not operate normally (Data are not transmitted) .................. 40- 640
E-30 Gear cannot be shifted ................................................................................................ 40- 642
Troubleshooting of hydraulic and mechanical system (H-mode) ............................................ 40- 644
Information in troubleshooting table..................................................................................... 40- 644
List of Failure Modes and Causes ....................................................................................... 40- 646
H-1 Machine lacks power(or drawbar pull) .......................................................................... 40- 648
H-2 Machine cannot travel (at 2nd or 3rd each speed)........................................................ 40- 650
H-3 Machine cannot travel at any gear speeds ................................................................... 40- 651
H-4 Machine travels only in one direction, forward or reverse............................................. 40- 653
H-5 Large time lag at gear shifting or directional change .................................................... 40- 654
H-6 Machine connot turn...................................................................................................... 40- 655
H-7 Machine turns only to one side ..................................................................................... 40- 656
H-8 Machine overruns at turnning........................................................................................ 40- 657
H-9 Brake does not work ..................................................................................................... 40- 658
H-10 Torque converter does not lock up.............................................................................. 40- 659
H-11 Power train oil overheats............................................................................................. 40- 660
H-12 All work equipment operates too slow or lacks power ................................................ 40- 661
H-13 All work equipment does not operate.......................................................................... 40- 662
H-14 Blade lift cylinder speed is too slow or lacks power .................................................... 40- 663
H-15 Blade tilt cylinder speed is too slow or lacks power .................................................... 40- 664

00-3-7 D375A-6R
(01)
Shop Manual
Table of contents

H-16 Ripper lift cylinder speed is too slow or lacks power................................................... 40- 665
H-17 Ripper tilt cylinder speed is too slow or lacks power................................................... 40- 666
H-18 Excessive hydraulic drift of blade lift cylinder.............................................................. 40- 667
H-19 Excessive hydraulic drift of blade tilt cylinder.............................................................. 40- 668
H-20 Excessive hydraulic drift of ripper lift cylinder ............................................................. 40- 669
H-21 Ripper pin puller cylinder does not operate (machine with giant ripper) ..................... 40- 670
H-22 Blade pitch does not work (machine with dual tilt specification) ................................. 40- 671
H-23 Abnormal noise from around work equipment pump .................................................. 40- 672
H-24 Abnormal fan rotation(noise and/or vibration are abnormally large or engine overheats)40-673
Troubleshooting of engine (S-mode) ...................................................................................... 40- 674
Method of using troubleshooting chart................................................................................. 40- 674
S-1 Engine does not start easily .......................................................................................... 40- 678
S-2 Engine does not start .................................................................................................... 40- 679
S-3 Engine does not rev up smoothly (response-up is poor)............................................... 40- 682
S-4 Engine stops during operation ...................................................................................... 40- 683
S-5 Engine does not rotate smoothly (hunting) ................................................................... 40- 684
S-6 Engine lacks power (or output shortage) ...................................................................... 40- 685
S-7 Exhaust smoke is black (Incomplete combustion) ........................................................ 40- 686
S-8 Oil is consumption is excessive(or exhaust smoke is blue) .......................................... 40- 687
S-9 Engine oil becomes contaminated quickly .................................................................... 40- 688
S-10 Fuel consumption is excessive ................................................................................... 40- 689
S-11 Oil mixes into coolant(coolant blows back or is reduced) ........................................... 40- 690
S-12 Engine pressure monitor lights up (drop in engine oil pressure)................................. 40- 691
S-13 Oil level rises (Coolant or fuel mixes into oil) .............................................................. 40- 692
S-14 Coolant temperature rises too high (overheating)....................................................... 40- 693
S-15 Abnormal noise is heard ............................................................................................. 40- 694
S-16 Vibration is excessive.................................................................................................. 40- 695
S-17 Air cannot be bled from fuel circuit (when air bleeding is performed after filter is replaced or fuel is
used up and then air is bled, engine does not start or it starts but stalls)............................ 40- 696

50 Disassembly and assembly


General information on disassembly and assembly ............................................................... 50- 4
How to read this manual ...................................................................................................... 50- 4
Coating materials list ........................................................................................................... 50- 6
Special tool list..................................................................................................................... 50- 9
Sketches of special tools ..................................................................................................... 50- 17
Engine and cooling system ..................................................................................................... 50- 25
Removal and installation of fuel supply pump assembly ..................................................... 50- 25
Removal and installation of fuel injector assembly .............................................................. 50- 30
Removal and installation of cylinder head assembly ........................................................... 50- 35
Removal and installation of radiator guard assembly .......................................................... 50- 50
Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler)50- 55
Removal and installation of radiator .................................................................................... 50- 60
Removal and installation of hydraulic oil cooler................................................................... 50- 62
Removal and installation of aftercooler................................................................................ 50- 63
Removal and installation of engine assembly...................................................................... 50- 64
Removal and installation of engine hood assembly............................................................. 50- 71
Removal and installation of engine front seal ...................................................................... 50- 74
Removal and installation of engine rear seal....................................................................... 50- 76
Removal and installation of fan drive assembly................................................................... 50- 80
Removal and installation of fan motor assembly ................................................................. 50- 82
Removal and installation of fuel tank assembly ................................................................... 50- 84
Power train.............................................................................................................................. 50- 86
Removal and installation of damper assembly .................................................................... 50- 86

D375A-6R 00-3-8
(01)
Shop Manual
Table of contents

Disassembly and assembly of damper assembly ................................................................ 50- 90


Removal and installation of power train unit assembly ........................................................ 50- 93
Disconnection and connection of power train unit assembly ............................................... 50- 99
Disassembly and assembly of PTO assembly..................................................................... 50- 108
Disassembly and assembly of torque converter assembly .................................................. 50- 114
Disassembly and assembly of TORQFLOW transmission assembly .................................. 50- 123
Disassembly and assembly of steering case assembly....................................................... 50- 150
Removal and installation of power train pump and lubrication pump assembly .................. 50- 166
Removal and installation of scavenging pump assembly .................................................... 50- 167
Removal and installation of final drive assembly ................................................................. 50- 168
Disassembly and assembly of final drive assembly............................................................. 50- 170
Undercarriage and frame ........................................................................................................ 50- 183
Removal and installation of track frame assembly............................................................... 50- 183
Removal and installation of idler assembly.......................................................................... 50- 188
Disassembly and assembly of idler assembly ..................................................................... 50- 189
Removal and installation of recoil spring assembly ............................................................. 50- 193
Disassembly and assembly of recoil spring assembly......................................................... 50- 198
Removal and installation of track roller assembly................................................................ 50- 200
Disassembly and assembly of track roller assembly ........................................................... 50- 203
Removal and installation of carrier roller assembly ............................................................. 50- 206
Disassembly and assembly of carrier roller assembly ......................................................... 50- 207
Removal and installation of bogie assembly........................................................................ 50- 211
Disassembly and assembly of bogie assembly ................................................................... 50- 216
Removal and installation of first bogie assembly ................................................................. 50- 218
Separation and connection of track shoe assembly ............................................................ 50- 223
Overall disassembly and assembly of track shoe ................................................................ 50- 227
Link press press-fitting jig dimensions ................................................................................. 50- 244
Disassembly and assembly of one link assembly in the field .............................................. 50- 245
Disassembly and assembly of master link ........................................................................... 50- 250
Removal and installation of pivot shaft assembly ................................................................ 50- 254
Removal and installation of equalizer bar ............................................................................ 50- 255
Disassembly and assembly of equalizer bar bushing .......................................................... 50- 259
Removal and installation of segment tooth .......................................................................... 50- 261
Hydraulic system..................................................................................................................... 50- 262
Removal and installation of hydraulic tank assembly .......................................................... 50- 262
Removal and installation of work equipment pump assembly ............................................. 50- 265
Removal and installation of fan pump assembly.................................................................. 50- 269
Removal and installation of control valve assembly ............................................................ 50- 271
Disassembly and assembly of control valve assembly ........................................................ 50- 273
Disassembly and assembly of blade PPC valve assembly.................................................. 50- 278
Disassembly and assembly of ripper PPC valve assembly ................................................. 50- 281
Disassembly and assembly of hydraulic cylinder assembly ................................................ 50- 283
Disassembly and assembly of ripper pin puller cylinder assembly ...................................... 50- 291
Work equipment...................................................................................................................... 50- 294
Removal and installation of blade assembly........................................................................ 50- 294
Disassembly and assembly of blade assembly ................................................................... 50- 296
Disassembly and assembly of giant ripper assembly .......................................................... 50- 300
Cab and its attachments ......................................................................................................... 50- 303
Removal and installation of ROPS guard ............................................................................ 50- 303
Removal and installation of operator's cab assembly .......................................................... 50- 304
Removal and installation of floor frame assembly ............................................................... 50- 308
Removal and installation of air conditioner unit assembly ................................................... 50- 313

00-3-9 D375A-6R
(01)
Shop Manual
Table of contents

Electrical system ..................................................................................................................... 50- 319


Removal and installation of transmission controller assembly and steering controller assembly
............................................................................................................................................. 50- 319
Removal and installation of engine controller assembly...................................................... 50- 320
Removal and installation of VHMS controller assembly ...................................................... 50- 322
Removal and installation of machine monitor assembly...................................................... 50- 323

60 Maintenance Standard
Engine and cooling system ..................................................................................................... 60- 3
Engine mount....................................................................................................................... 60- 3
Cooling fan pump................................................................................................................. 60- 5
Cooling fan motor ................................................................................................................ 60- 12
Power train.............................................................................................................................. 60- 14
Power train unit.................................................................................................................... 60- 14
Damper and universal joint .................................................................................................. 60- 16
Torque converter and PTO .................................................................................................. 60- 19
Main relief valve and torque converter relief valve .............................................................. 60- 22
Lockup clutch ECMV and stator clutch ECMV..................................................................... 60- 23
Scavenging pump ................................................................................................................ 60- 24
Transmission control............................................................................................................ 60- 25
Transmission ....................................................................................................................... 60- 26
Transmission lubricating oil relief valve ............................................................................... 60- 31
Power train and lubrication pump ........................................................................................ 60- 32
Transfer, bevel gear shaft and steering unit ........................................................................ 60- 34
Steering control valve .......................................................................................................... 60- 40
Steering clutch ECMV and steering brake ECMV ............................................................... 60- 41
Parking brake valve ............................................................................................................. 60- 42
Final drive ............................................................................................................................ 60- 43
Sprocket............................................................................................................................... 60- 46
Undercarriage and frame ........................................................................................................ 60- 48
Track frame.......................................................................................................................... 60- 48
Idler cushion cushion ........................................................................................................... 60- 50
Idler...................................................................................................................................... 60- 52
Track roller........................................................................................................................... 60- 54
Carrier roller......................................................................................................................... 60- 56
Track roller bogie ................................................................................................................. 60- 57
Track shoe ........................................................................................................................... 60- 58
Main frame........................................................................................................................... 60- 62
Suspension .......................................................................................................................... 60- 64
Hydraulic system .................................................................................................................... 60- 68
PPC valve ............................................................................................................................ 60- 68
Hydraulic cylinder ................................................................................................................ 60- 74
Quick drop valve .................................................................................................................. 60- 77
Work equipment pump......................................................................................................... 60- 78
Control valve........................................................................................................................ 60- 81
Self-pressure reducing valve ............................................................................................... 60- 94
Work equipment...................................................................................................................... 60- 97
Cylinder stay ........................................................................................................................ 60- 97
Blade.................................................................................................................................... 60- 98
Cutting edge and end bit...................................................................................................... 60- 102
Ripper .................................................................................................................................. 60- 104

80 Appendix
Air conditioner ......................................................................................................................... 80- 3

D375A-6R 00-3-10
(01)
Shop Manual
Table of contents

Precautions for refrigerant ................................................................................................... 80- 3


Air conditioner component ................................................................................................... 80- 4
Configuration and function of refrigeration cycle.................................................................. 80- 6
Outline of refrigeration cycle ................................................................................................ 80- 7
Air conditioner unit ............................................................................................................... 80- 10
Blower unit ........................................................................................................................... 80- 14
FRESH/RECIRC air changeover damper ............................................................................ 80- 15
Compressor ......................................................................................................................... 80- 16
Condenser ........................................................................................................................... 80- 17
Receiver drier....................................................................................................................... 80- 18
Air conditioner control panel ................................................................................................ 80- 20
Procedure for testing and troubleshooting ........................................................................... 80- 22
Circuit diagram and arrangement of connector pins ............................................................ 80- 24
System diagram ................................................................................................................... 80- 26
Parts and connectors layout ................................................................................................ 80- 28
Testing temperature control ................................................................................................. 80- 32
Testing FRESH/RECIC air changeover ............................................................................... 80- 33
Testing relay ........................................................................................................................ 80- 34
Troubleshooting chart 1 ....................................................................................................... 80- 36
Troubleshooting chart 2 ....................................................................................................... 80- 38
Information in troubleshooting table..................................................................................... 80- 40
Troubleshooting for power supply system (Air conditioner does not operate) ..................... 80- 42
Troubleshooting for compressor system (Air is not cooled)................................................. 80- 44
Troubleshooting for blower motor system (Air does not come out or air flow is abnormal) . 80- 48
Troubleshooting for temperature control.............................................................................. 80- 54
Troubleshooting for FRESH/RECIRC air changeover ......................................................... 80- 56
Troubleshooting with gauge pressure.................................................................................. 80- 58
Connection of service tool.................................................................................................... 80- 60
Precautions for disconnecting and connecting .................................................................... 80- 62
Handling of compressor oil .................................................................................................. 80- 64

90 Diagrams and Drawings


Hydraulic diagrams and drawings........................................................................................... 90- 3
Symbols used in hydraulic circuit diagrams ......................................................................... 90- 3
Power train hydraulic diagrams and drawings ..................................................................... 90- 5
Hydraulic circuit diagram...................................................................................................... 90- 7
Electrical diagrams and drawings ........................................................................................... 90- 11
Symbols used in electrical circuit diagrams ......................................................................... 90- 11
Electrical circuit diagram ...................................................................................................... 90- 15

Index ....................................................................................................................................... 1

00-4 D375A-6R
(01)
Forword and general information
Safety notice

Forword and general information 0 -5


Safety notice 0 -5
(Rev. 2010/02)
Important safety notice

Appropriate servicing and repair are extremely important to ensure safe operation of the machine.The
shop manuals describe the effective and safe servicing and repair methods recommended by Komat-
su.Some of the servicing and repair methods require use of special tools designed by Komatsu for
special purposes.
The symbol mark "k" is indicated for matters that require special precautions for such work.The
work indicated with the warning mark should be carried out along to the instructions with special at-
tention to the precautions.Should a hazardous situation occur or be anticipated during such work, be
sure to proceed it safe and take every necessary measure.

1. General precautions
k Inappropriate handling creates an ex- 6) Keep all tools in good condition, learn the
treme danger.Read and understand what correct way to use them, and use the proper
is described in the Operation and Mainte- ones of them. Before starting work, thor-
nance Manual before operating the ma- oughly check the tools, machine, forklift,
chine.Read and understand what is service car, etc.
described in this manual before starting 7) If welding repairs are needed, always have a
work. trained and experienced welder carry out the
1) Before carrying out any greasing or repairs, work. When carrying out welding work,
read all the safety labels stuck to the always wear welding gloves, apron, shielding
machine. For the locations of the safety goggles, cap and other clothes suited for
labels and detailed explanation of precau- welding work.
tions, see the Operation and Maintenance 8) Before starting work, warm up your body
Manual. thoroughly to start work under good condi-
2) Decide a place in the repair workshop to tion.
keep tools and removed parts. Always keep 9) Avoid continuing work for long hours and
the tools and parts in their correct places. take rests at proper intervals to keep your
Always keep the work area clean and make body in good condition.
sure that there is no dirt, water, or oil on the
floor. Smoke only in the areas provided for Safety points
smoking. Never smoke while working. 1 Good arrangement
3) When carrying out any operation, always 2 Correct work clothes
wear safety shoes and helmet. Do not wear 3 Following work standard
loose work clothes, or clothes with buttons 4 Making and checking signals
Prohibition of operation and handling by unli-
missing. 5
censed workers
q Always wear the safety glasses when hit-
6 Safety check before starting work
ting parts with a hammer Wearing protective goggles(for cleaning or grind-
q Always wear safety glasses when grind- 7 ing work)
ing parts with a grinder, etc. Wearing shielding goggles and protectors(for
8
4) When carrying out any operation with 2 or welding work)
more workers, always agree on the operating 9 Good physical condition and preparation
procedure before starting. Always inform Precautions against work which you are not used
10 to or you are used to too much
your fellow workers before starting any step
of the operation. Before starting work, hang
UNDER REPAIR warning tag in the oper-
ator's compartment.
5) Only qualified workers must carry out work
and operation which require license or quali-
fication.

D375A-6R 00-5
Forword and general information
Safety notice

2. Preparation work 6) When removing a cover which is under


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

00-6 D375A-6R
Forword and general information
Safety notice

4. Precautions for slinging work and making signals


1) Only one appointed worker must make
signals and co-workers must communicate
with each other frequently. The appointed
signaler must make specified signals clearly
at a place where he is well seen from the
operator's seat and where he can see the
working condition easily. The signaler must
always stand in front of the load and guide
the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling work.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.)
4) Measure the weight of the load by the eye 8) When installing wire ropes to an angular
and check its center of gravity. load, apply pads to protect the wire ropes. If
5) Use proper sling according to the weight of the load is slippery, apply proper material to
the load and method of slinging. If too thick prevent the wire rope from slipping.
wire ropes are used to sling a light load, the 9) Use the specified eyebolts and fix wire ropes,
load may slip and fall. chains, etc. to them with shackles, etc.
6) Do not sling a load with 1 wire rope alone. If 10)Apply wire ropes to the middle portion of the
it is slung so, It may rotate and may slip out hook.
of the rope. Install 2 or more wire ropes q Slinging near the tip of the hook may
symmetrically.
k Slinging with 1 rope may cause turn-
cause the rope to slip off the hook during
hoisting. The hook has the maximum
ing of the load during hoisting, un- strength at the middle portion.
twisting of the rope, or slipping of the
rope from its original winding position
on the load, which can result in a dan-
gerous accident.
7) Limit the hanging angle to 60 , as a rule.
Do not sling a heavy load with ropes forming
a wide hanging angle from the hook.
When hoisting a load with 2 or more ropes,
the force subjected to each rope will increase
with the hanging angle. The table below
shows the variation of allowable load in kN
{kg} when hoisting is made with 2 ropes,
each of which is allowed to sling up to 9.8 kN
{1,000 kg} vertically, at various hanging
angles. When the 2 ropes sling a load verti-
cally, up to 19.6 kN {2,000 kg} of total weight 11)Do not use twisted or kinked wire ropes.
can be suspended. This weight is reduced to 12)When lifting up a load, observe the following.
9.8 kN {1,000 kg} when the 2 ropes make a q Wind in the crane slowly until wire ropes

hanging angle of 120 . If the 2 ropes sling a are stretched. When settling the wire
19.6 kN {2,000 kg } load at a lifting angle of ropes with the hand, do not grasp them
150 , each of them is subjected to a force as but press them from above. If you grasp
large as 39.2 kN {4,000 kg}. them, your fingers may be caught.
q After the wire ropes are stretched, stop
the crane and check the condition of the
slung load, wire ropes, and pads.

D375A-6R 00-7
Forword and general information
Safety notice

qIf the load is unstable or the wire rope or 13)If the hoist stops because of a power failure,
chains are twisted, lower the load and lift turn the power switch OFF. When turning on
it up again. a switch which was turned OFF by the
q Do not lift up the load at an angle. ground fault circuit interrupter, check that the
13)When lowering a load, observe the following. devices related to that switch are not in oper-
q When lowering a load, stop it temporarily ation state.
at 30 cm above the floor, and then lower 14)If you find an obstacle around the hoist, stop
it slowly. the operation.
q Check that the load is stable, and then re- 15)After finishing the work, stop the hoist at the
move the sling. specified position and raise the hook to at
q Remove kinks and dirt from the wire least 2 mabove the floor. Do not leave the
ropes and chains used for the sling work, sling installed to the hook.
and put them in the specified place.
7. Selecting wire ropes
5. Precautions for using mobile crane 1) Select adequate ropes depending on the
a Read the Operation and Maintenance Manu- weight of parts to be hoisted, referring to the
al of the crane carefully in advance and oper- table below
ate the crane safely. Wire ropes
(Standard "Z" twist ropes without galvanizing)
6. Precautions for using overhead traveling (JIS G3525, No. 6, Type 6X37-A)
crane Nominal diameter Allowable load
k A hoist crane or similar device must be
of rope
mm kN ton
used for lifting a heavy load (25 kg or
10 8.8 0.9
more).The weight of a part that is 25 kg or 12 12.7 1.3
more is indicated with the symbol "4" in 14 17.3 1.7
"Disassembly and assembly". 16 22.6 2.3
1) Before starting work, inspect the wire ropes, 18 28.6 2.9
brake, clutch, controller, rails, over wind stop 20 35.3 3.6
device, ground fault circuit interrupter, crane 25 55.3 5.6
30 79.6 8.1
collision prevention device, and power appli-
40 141.6 14.4
cation warning lamp, and check safety. 50 221.6 22.6
2) Observe the signals for sling work. 60 318.3 32.4
3) Operate the hoist at a safe place.
a The allowable load is one-sixth of the
4) Check the direction indicator plates (east,
breaking strength of the rope used (Safe-
west, south, and north) and the directions of
ty coefficient: 6).
the control buttons without fail.
5) Do not sling a load at an angle. Do not move
the crane while the slung load is swinging.
6) Do not raise or lower a load while the crane
is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and lift
up a load to a safe height.
10)Place the control switch on a position where
it will not be an obstacle to work and
passage.
11)After operating the hoist, do not swing the
control switch.
12)Remember the position of the main switch so
that you can turn off the power immediately in
an emergency.

00-8 D375A-6R
Forword and general information
Safety notice

8. Precautions for disconnecting and a For tightening torque, see the precau-
connecting hoses and tubes in an air condi- tions for installation in each section of
tioner circuit "Disassembly and assembly".
1) Disconnection
k Although the refrigerant (refrigerant
gas: R134a) used on the machine's air
conditioner is less destructive to the
ozone layer for environmentally friend-
liness, it is not allowed to be vented
into the atmosphere as is.Whenever
disconnecting the air conditioner gas
circuit, be sure to recover the refriger-
ant gas to reuse it.
a Ask a gualified person for collecting and
filling operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to
the atmosphere.
k If the refrigerant gas gets in your eyes
or contacts your skin, you may lose
your sight or your skin may be fro-
zen.Whenever recovering or adding
refrigerant gas, you must put on safety
glasses, safety gloves and long
sleeved clothes.
The refrigerant gas must be recovered
and added by a qualified person.

2) Connection
1] When installing the air conditioner circuit
hoses and tubes, take care to prevent dirt
and water from entering into them.
2] Make sure that before installing the air
conditioner hoses or tubes the O-rings (1)
are fitted to their joints.
3] Check that each O-ring (1) is not
damaged or deteriorated.
4] When connecting the refrigerant piping,
coat the O-ring (1) with the compressor oil
(Denso: ND-OIL8 or Valeo Thermal
Systems Japan Corp.: ZXL100PG
(PAG46 or the equivalent) for the refrig-
erant (R134a).
a Example of O-ring (Fitted to every
joint of hoses and tubes)

D375A-6R 00-9
Forword and general information
How to read the shop manual

How to read the shop manual 0 -10


(Rev. 2010/02)

q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is
required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the "Chassis volume" and "Engine volume". For the engine unit, see the engine vol-
ume of the engine model mounted on the machine.

1. Composition of shop manual


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

00. Index and foreword


This section contains the index, foreword and safety and basic information.If any revision is made, the
LIST OF REVISED PAGES will be added.

01. Specification
This section explains the specifications of the machine.

10. Structure and function


This section explains the structure and function of each component.It serves not only to give an under-
standing for the structure of each component, but also serves as reference material for troubleshooting.

20. Standard value table


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

30. Testing and adjusting


This section explains measuring instruments and measuring methods for testing and adjusting, as well as
the adjusting method of each part.The standard values and judgment criteria for "Testing and adjusting"
are explained in standard value table.

40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided
by failure modes. The "S mode" of the troubleshooting related to the engine may be also explained in the
Chassis volume and Engine volume. In this case, see the Chassis volume.

50. Disassembly and assembly


This section explains the special tools and procedures for removing, installing, disassembling, and assem-
bling each component, as well as precautions for them.In addition, tightening torque, and quantity and
weight of coating material, oil, grease, and coolant necessary for the work are also explained.

60. Maintenance standard


This section gives maintenance standard values of each component. The maintenance standard sub-sec-
tion explains the criteria and remedies for disassembly and service.

80. Appendix
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not
classifiable in other sections.

90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of remanufacturing and repairing engine and replacing parts.

00-10 D375A-6R
Forword and general information
How to read the shop manual

2. Revision and distribution


Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.

3. Filing method
File the revised or added pages in the correct order of the page numbers printed in the LIST OF REVISED
PAGES.

q Revision number
When a manual is revised, revision number of each page is increased by 1.
(Example: (01), (02), (03)...)

q Revisions
The revised pages are shown in the LIST OF REVISED PAGES.

4.Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will be
used practically.

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving standards are


a Caution
necessary when performing work.

4
Weight of parts of component or parts. Caution necessary when selecting hoisting
Weight
wire, or when working posture is important, etc.

3 Tightening torque Places that require special attention for tightening torque during assembly.

2 Coat Places to be coated with adhesives, etc. during assembly.

5 Oil, coolant Places where oil, etc. must be added, and capacity.

6 Drain Places where oil, etc. must be drained, and quantity to be drained.

5. Units
In this shop manual, the units are indicated with International System of units (SI).
For reference, conventionally used Gravitational System of units is indicated in parentheses { }.

D375A-6R 00-11
Forword and general information
Explanation of terms for maintenance standard

Explanation of terms for maintenance standard 0 -12


(Rev. 2010/02)
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the ma-
chine maintenance work. The following terms are used to explain the criteria.

1. Standard dimension and tolerance


q To be accurate, the finishing size of parts is a
little different from one to another.
q To specify a finishing size of a part, a tempo-
rary standard size is set and an allowable dif-
ference from that size is indicated.
q The above size set temporarily is called the
"standard size" and the range of difference
from the standard size is called the "toler-
ance".
q The tolerance with the symbols of + or is in-
dicated on the right side of the standard size.

Example:
Standard size Tolerance
-0.022
120
-0.126
a The tolerance may be indicated in the text
and a table as [standard size (upper limit of
tolerance/lower limit of tolerance)].
Example) 120 (0.022/0.126)

q Usually, the size of a hole and the size of the


shaft to be fitted to that hole are indicated by
the same standard size and different toler-
ances of the hole and shaft. The tightness of
fit is decided by the tolerance.
q Indication of size of rotating shaft and hole
and relationship drawing of them 3. Standard interference
q When the diameter of a hole of a part shown
Example: in the given standard size and tolerance table
Tolerance
Standard size is smaller than that of the mating shaft, the
Shaft Hole
-0.030 +0.046 difference between those diameters is called
60 the "interference".
-0.076 0
q The range (A B) from the difference (A) be-
tween the minimum size of the shaft and the
2. Standard clearance and standard value maximum size of the hole to the difference
q The clearance made when new parts are as-
(B) between the maximum size of the shaft
sembled is called the "standard clearance", and the minimum size of the hole is the "stan-
which is indicated by the range from the min- dard interference".
imum clearance to the maximum clearance. q After repairing or replacing some parts, mea-
q When some parts are repaired, the clearance
sure the size of their hole and shaft and
is generally adjusted to the standard clear- check that the interference is in the standard
ance. range.
q A value of performance and function of new
products or equivalent is called the "standard
value", which is indicated by a range or a tar-
get value.
q When some parts are repaired, the value of
performance/function is set to the standard
value.

00-12 D375A-6R
Forword and general information
Explanation of terms for maintenance standard

4. Repair limit and allowable value or allowable


dimension
q The size of a part changes because of wear
and deformation while it is used. The limit of
changed size is called the "repair limit".
q If a part is worn to the repair limit, it must be
replaced or repaired.
q The performance and function of a product
lowers while it is used. A value which the
product can be used without causing a prob-
lem is called the "allowable value" or "allow-
able dimension".
q If a product deviates from the allowable val-
ue, it must be checked or repaired. However,
since most of the allowable values are esti-
mated from various tests or experiences in
most cases, it must be judged after consider-
ing the operating condition and customer's
requirement.

5. Clearance limit
q Parts can be used until the clearance be-
tween them is increased to a certain limit.
The limit at which those parts cannot be used
is called the "clearance limit".
q If the clearance between the parts exceeds
the clearance limit, they must be replaced or
repaired.

6. Interference limit
q The allowable maximum interference be-
tween the hole of a part and the shaft of an-
other part to be assembled is called the
"interference limit".
q The interference limit shows the repair limit of
the part of smaller tolerance.
q If the interference between the parts exceeds
the interference limit, they must be replaced
or repaired.

D375A-6R 00-13
Forword and general information
Handling of electric equipment and hydraulic components

Handling of electric equipment and hydraulic components 0 -14


(Rev. 2010/02)
To maintain the performance of the machine over a long period, and to prevent failures or other troubles be-
fore they occur, correct "operation", "maintenance and inspection", "troubleshooting", and "repairs" must be
carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and "Han-
dling hydraulic components" (particularly gear oil and hydraulic oil).

Points to remember when handling electric equipment 0 -14


1. Handling wiring harnesses and connectors
Wiring harnesses consist of wires connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wires.
Compared with other electrical components
fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness
1) Defective contact of connectors (defective
contact between male and female connec-
tors)
Defective contact occurs due to improper
fitting between a male and female connec-
tors, or displacement of one or both of the
connectors, or corrosion or oxidization on the
contact surfaces.When poor contact resulted
from a corroded or oxidized contact surfaces,
you can make it shiny again (normal condi-
tion is recovered) by connecting and discon-
necting the connector about 10 times.

2) Defective crimping or soldering of connectors


The pins of the male and female connectors
are connected to wires by crimping or
soldering. If excessive force is applied to the
wire, the joint is separated and causes a
defective contact or the wire is broken.

00-14 D375A-6R
Forword and general information
Handling of electric equipment and hydraulic components

3) Disconnections in wiring
If the harness is pulled to disconnect the
connector, or components are lifted with a
crane with the harness still connected, or a
heavy object hits the harness, the crimping of
the connector may separate, or the soldering
may be damaged, or the harness may be
broken.

4) High-pressure water entering connector


The connector is designed to make it difficult
for water to enter (drip-proof structure), but if
high-pressure water is sprayed directly on
the connector, water may enter the
connector, depending on the direction of the
water jet.
Accordingly, take care not to splash water
over the connector.
The connector is designed to prevent water
from entering, but at the same time, if water
does enter, it is difficult for it to be drained.
Therefore, if water should get into the
connector, the pins will be short-circuited by
the water, so if any water gets in, immediately
dry the connector or take other appropriate
action before passing electricity through it.
5) Oil or dirt stuck to connector
Since oil is not conductive, if oil or grease
adheres to the connector forms an oil film on
the mating surface of the male and female
connectors, it cause defective contact.If
adherence of oil or grease to a connector is
observed, wipe it off with a dry cloth or blow
it off with compressed air and then spray
contact restorer to the connector.
a When wiping the joint portion of the con-
nector, be careful not to apply excessive
force or deform the pins.
a If oil or water is contained in the com-
pressed air, contamination on the con-
tacts is made worse. So remove such oil
and water from the compressed air com-
pletely before starting the cleaning pro-
cess.

D375A-6R 00-15
Forword and general information
Handling of electric equipment and hydraulic components

3. Removing, installing, and drying connectors


and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when disconnecting.
When disconnecting a connector, hold
the connector.For connectors held by a
screw, loosen the screw fully, then hold
the male and female connectors in each
hand and pull them apart.For connectors
attached with a lock stopper, press down
the stopper with your thumb and pull the
connectors apart.
a Never pull with one hand.

2] When removing from clips


q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is in-
stalled.

q When removing a connector from a


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

3] Action to take after removing connectors


After removing a connector, cover it with
a vinyl bag to prevent the entry of dust,
dirt, oil, or water to the contact portion.
a If the machine is left disassembled for
a long time, it is particularly easy for
improper contact to occur, so always
cover the connector.

00-16 D375A-6R
Forword and general information
Handling of electric equipment and hydraulic components

2) Connecting connectors
1] Check the connector visually.
Check that no oil, dirt, or water is stuck to
connector pins (joint portion).
Check that connector pins are free from
deformation, defective contact, corrosion,
or damage.
Check that external surface of the
connectors is free from damage or
breakage.
a If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry
cloth.If any water has got inside the
connector, warm the inside of the con-
nector and harness with a dryer, but
be careful not to make them too hot as
this will cause short circuits.
a If there is any damage or breakage,
replace the connector.
2] Fix the connector securely.
Position the connectors correctly, and
then fit them securely. For connectors
with the lock stopper, push in the
connector until the stopper clicks into
position.
3] Correcting protrusion of the boot and
misalignment of the wiring harness
For connectors fitted with the fuel spray
prevention caps, correct any extrusion of
the caps. In addition, if the wiring harness
is moved in laying, or the clamp is out of
position, correct it to its right position.
a If the connector cannot be corrected
easily, remove the clamp and adjust
the position.
q If the connector clamp has been re-
moved, be sure to return it to its origi-
nal position. Check also that there are
no loose clamps.

D375A-6R 00-17
Forword and general information
Handling of electric equipment and hydraulic components

3) DT connector (DT 8-pole, 12-pole)


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

00-18 D375A-6R
Forword and general information
Handling of electric equipment and hydraulic components

4) Drying wiring harness


If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must
be washed in water, do not use high-pres-
sure water or steam directly on the wiring
harness. If water gets directly on the
connector, do as follows.
1] Disconnect the connector and wipe off
the water with a dry cloth.
a If the connector is to be blown dry with
compressed air, there is the risk that
oil in the air may cause defective con-
tact, remove oil and water in the air
before starting air blow.

2] Dry the inside of the connector with a


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

3] Carry out a continuity test on the


connector.
After drying, leave the wiring harness
disconnected and carry out a continuity
test to check for any short circuits
between pins caused by water.
a After completely drying the connector,
blow it with electric contact cleaner
and reassemble.

D375A-6R 00-19
Forword and general information
Handling of electric equipment and hydraulic components

4. Handling controller
1) The controller contains a microcomputer and
electronic control circuits. These control all of
the electronic circuits on the machine, so be
extremely careful when handling the
controller.
2) Do not place objects on top of the controller.
3) Cover the control connectors with tape or a
vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in a place that can be heated to a high
temperature even for a short time. (Place it
on a suitable dry stand.)
6) Precautions when carrying out arc welding
When carrying out arc welding on the
machine body, disconnect all wiring harness
connectors connected to the controller. Fit an
arc welding ground close to the welding
point.

5. Points to remember when troubleshooting


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

00-20 D375A-6R
Forword and general information
Handling of electric equipment and hydraulic components

Points to remember when handling hydraulic components 0 -21

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. Therefore, special precaution is required when adding hydraulic oil,
or when disassembling or assembling hydraulic components.

1. Be careful of the operating environment


Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.

2. Disassembly and maintenance work in the


field
If disassembly or maintenance work is carried
out on hydraulic components in the field, there is
danger of dust entering the components. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
components should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.

3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by
leaking oil so never do this. Do not simply drain
oil out onto the ground, but collect it and ask the
customer to dispose of it, or take it back with you
for disposal.

4. Preventing intrusion of foreign materials


during refilling operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil.Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers.If an oil cleaning
device is used, it is possible to filter out the dirt
that has been collected during storage, so this is
an even more effective method.

D375A-6R 00-21
Forword and general information
Handling of electric equipment and hydraulic components

5. Replacing hydraulic oil while its temperature is high


When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is still
warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain plug
in the circuit.) If any old oil is left, the contami-
nants and sludge in it will mix with the new oil
and will shorten the life of the hydraulic oil.

6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.Normally, flushing is
carried out twice. Primary flushing is carried out
by use of flushing oil and secondary flushing is
carried out by use of the specified hydraulic oil.

7. Cleaning operations
After repairing the hydraulic components (pump,
control valve, etc.) or when running the machine,
carry out oil cleaning to remove the sludge or
contaminants in the hydraulic oil circuit. The oil
cleaning components is used to remove the ultra
fine (about 3 m) particles that the filter built in the
hydraulic equipment cannot remove, so it is an
extremely effective device.

00-22 D375A-6R
Forword and general information
Handling of connectors newly used for engines

Handling of connectors newly used for engines 0 -23


(Rev. 2010/02)
a Mainly, following engines are object for following connectors.
q 95E-5
q 107E-1
q 114E-3
q 125E-5
q 140E-5
q 170E-5
q 12V140E-3

Slide-lock type 0 -23 Pull lock type (PACKARD-2) 0 -23


(FRAMATOME-3, FRAMATOME-2) q 95170, 12V140 engines
q 95170, 12V140 engines q Various temperature sensors
q Various pressure sensors and NE speed Examples)
sensor Intake air temperature sensor in intake mani-
Examples) fold: TIM
Intake air pressure sensor in intake manifold: Fuel temperature sensor: TFUEL
PIM (125, 170, 12V140 engines) Oil temperature sensor: TOIL
Oil pressure sensor: POIL (125, 170, 12V140 Coolant temperature sensor: TWTR, etc.
engines)
Oil pressure switch (95, 107, 114 engines) Disconnection 0 -23
Ne speed sensor of flywheel housing: NE Disconnect the connector by pulling lock (B) (on the
(95-170, 12V140 engines) wiring harness side) of connector (2) outward.
Ambient pressure sensor: PAMB (125, 170,
12V140 engines)

Disconnection 0 -23
1) Slide lock L1 to the right.
2) While pressing lock L2, pull out connector (1)
toward you.
a Even if lock L2 is pressed, connector (1)
cannot be pulled out toward you, if part A
does not float. In this case, float part A
with a small screwdriver while pressing
lock L2, and then pull out connector (1) to-
ward you.

Connection 0 -23
Insert the connector straight until it "clicks".

Connection 0 -23
Insert the connector straight until it "clicks".

D375A-6R 00-23
Forword and general information
Handling of connectors newly used for engines

Push lock type (1) 0 -24


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

Disconnection 0 -24
While pressing lock (C), pull out connector (3) in the
direction of the arrow.

q 114 engine

Connection 0 -24
Insert the connector straight until it "clicks".

Push lock type (2) 0 -24


q 107, 114 engines
Example) Intake air pressure/temperature
q 107 engine sensor in intake manifold (SUMITOMO-04)

Disconnection 0 -24
While pressing lock (D), pull out connector (4) in the
direction of the arrow.

a If the lock is on the underside, use flat-head


screwdriver [1] since you cannot insert your fin-
gers.

Connection 0 -24
Insert the connector straight until it "clicks".

00-24 D375A-6R
Forword and general information
Handling of connectors newly used for engines

Push lock type (3) 0 -25 Turn-housing type (Round green connector) 0 -25
q 95, 125 170, 12V140 engines q 140 engine
Example) Intake air pressure sensor in intake
Disconnection 0 -25 manifold.
While pressing lock (E) of the connector, pull out (CANNON-04): PIM, etc.
connector (5) in the direction of the arrow.
Example) Fuel pressure sensor in common rail: Disconnection 0 -25
PFUEL etc. (AMP-3) 1) Turn housing (H1) in the direction of the
arrow.
a When connector is unlocked, housing
(H1) becomes heavy to turn.
2) Pull out housing (H1) in the direction of the
arrow.
a Housing (H1) is left on the wiring harness
side.

Example) Injection pressure control valve of fuel


supply pump: PCV (SUMITOMO-2)

Connection 0 -25
1) Insert the connector to the end, while setting
its groove.
2) Turn housing (H1) in the direction of the
arrow until it "clicks".

Examples) Speed sensor of fuel supply pump: G


(SUMITOMO-3)
a Pull the connector straight up.

Connection 0 -25
Insert the connector straight until it "clicks".

D375A-6R 00-25
Forword and general information
How to read electric wire code

How to read electric wire code 0 -26


(Rev. 2010/02)
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols.
The electric wire code is helpful in understanding the electric circuit diagram.

Example: AEX 0.85 L --- Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No.
of 0.85

Indicates color of wire by color code.


Color codes are shown in Table 3.

Indicates size of wire by nominal No.


Size (Nominal No.) is shown in Table 2.

Indicates type of wire by symbol.


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

1. Type, symbol, and material


AV and AVS are different only in thickness and outside diameter of the cover.CAVS has a circular
compressed conductor. It differs from that of AV and AVS in the outside diameter and thickness of the
cover.And AEX is similar to AV in thickness and outside diameter of the cover but different from AV and
AVS in material of the cover.

(Table 1)
Using tem-
Type Symbol Material Example of use
perature
Annealed copper for electric
Low-voltage Conductor
appliance General wiring
wire for automo- AV
(nominal No. 5 and above.)
bile Insulator Soft polyvinyl chloride
Thin-cover Annealed copper for electric
Conductor
low-voltage wire appliance General wiring
AVS -30 +60
for automobile (nominal No. 3 and below.)
Insulator Soft polyvinyl chloride
(type 1)
Thin-cover Annealed copper for electric
Conductor
low-voltage wire appliance For mid- to small-size excavators
CAVS
for automobile (nominal No. 1.25 and below.)
Insulator Soft polyvinyl chloride
(type 2)
Annealed copper for electric General wiring in extremely cold
Heat-resistant Conductor
appliance district, wiring at high ambient tem-
low-voltage wire AEX -50 +110
Heat-resistant crosslinked perature place
for automobile Insulator
polyethylene For wiring in a place of high atmo-

00-26 D375A-6R
Forword and general information
How to read electric wire code

2. Dimensions

(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diame- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
ter of strand
Conduc- Sectional area
tor 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
(mm2)

d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0

AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6


Cover D

AV Standard 4.6

AEX Standard 2.0 2.2 2.7 3.0 3.1 3.8 4.6

Nominal No. 8 15 20 30 40 50 60 85 100


Number of
strands/Diame- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
ter of strand
Conduc- Sectional area
tor 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
(mm2)

d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6

AVS Standard
Cover D

AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6

AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6

Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25


Number of 7/Circular com- 11/Circular com- 16/Circular com-
strands/Diame-
ter of strand pressed pressed pressed
Conduc- Sectional area
tor 0.56 0.88 1.29
(mm2)

d (approx.) 0.9 1.1 1.4


Cover D

CAVS Standard 1.6 1.8 2.1

"f" of nominal No. denotes "flexible".

D375A-6R 00-27
Forword and general information
How to read electric wire code

3. Color codes table

(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow & Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White

Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second
color is the color of the marking.
Example: "GW" means that the background is Green and marking is White.

4. Types of circuits and color codes

(Table 4)
Type of wire AVS/AV/CAVS AEX
Charge R WG R
Ground B B
Start R R
Light RW RB RY RG RL D
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB L
Type of cir-
Br BrW BrR BrY BrB
cuit
Lg LgR LgY LgB LgW
O
Others Gr
P
Sb
Dg
Ch

00-28 D375A-6R
Forword and general information
Precautions when carrying out work

Precautions when carrying out work 0 -29


(Rev. 2010/02)
When removing, installing, disassembling or assembling a unit, be sure to follow the general precautions giv-
en below.

1. Precautions for removal work


q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising component, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any component, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal Plug (nut end) Sleeve nut (elbow end)
number
02 07376 - 70210 02789 - 20210
03 07376 - 70315 02789 - 20315
04 07376 - 70422 02789 - 20422
05 07376 - 70522 02789 - 20522
06 07376 - 70628 02789 - 20628
10 07376 - 71034 07221 - 21034
12 07376 - 71234 07221 - 21234

2) Split flange type hoses and tubes


Nominal Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379 - 00400 07378 - 10400 07371 - 30400
05 07379 - 00500 07378 - 10500 07371 - 30500

3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part No.
number D d L
06 07049 - 00608 6 5 8
08 07049 - 00811 8 6.5 11
10 07049 - 01012 10 8.5 12
12 07049 - 01215 12 10 15
14 07049 - 01418 14 11.5 18
16 07049 - 01620 16 13.5 20
18 07049 - 01822 18 15 22
20 07049 - 02025 20 17 25
22 07049 - 02228 22 18.5 28
24 07049 - 02430 24 20 30
27 07049 - 02734 27 22.5 34

D375A-6R 00-29
Forword and general information
Precautions when carrying out work

2. Precautions for installation work


q Tighten all bolts and nuts (sleeve nuts) to the specified torque (KES) .
q Install the hoses without twisting or interference and fix them with intermediate clamps, if available.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean and degrease the part, and coat the threaded portion with 2 - 3
drops of adhesive.
q When coating with liquid gasket, clean and degrease the surface, and apply it uniformly after making
sure the surface is free from dirt or damage.
q Clean all parts, and correct any damage, dents, burrs, or rust found on them.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with molybdenum disulfide lubricant (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When installing split flanges, fasten uniformly in turn to prevent excessive tightening on one side.
a When you have removed the hydraulic equipment such as hydraulic cylinder and pump for repair, be
sure to bleed air in the following manner before operating the reassembled cylinder for the first time.
1] Start the engine and run at low idle.
2] Operate the work equipment control lever to operate the hydraulic cylinder 4 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3] Next, operate the hydraulic cylinder 3 4 times to the end of its stroke.
a When using the machine for the first time after repair or long storage, follow the same procedure.

3. Precautions for completing work


1) Refilling with coolant, oil and grease
q If the coolant has been drained, close the drain valve, and add coolant to the specified level. Run
the engine to circulate the coolant through the system . Then check the coolant level again.
q If the hydraulic component has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
q When you have removed hydraulic piping or hydraulic equipment, always bleed air from the system
after reassembling the parts, by referring to "Testing and adjusting".
q Add the specified amount of grease (molybdenum disulfide grease) to the work equipment parts.

2) Checking cylinder head and manifolds for looseness


Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see "Disassembly and assembly" .

3) Checking engine piping for damage and looseness


Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and
exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leak-
age.
If any part is loosened or damaged, retighten or repair it.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage.
If any part is loosened or damaged, retighten or repair it.

00-30 D375A-6R
Forword and general information
Precautions when carrying out work

4) Checking muffler, exhaust pipe and their mounts for damage and looseness
1] Visually check the muffler, exhaust pipe and their mounts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounts for looseness.
If any part is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to "Troubleshooting" and "Disassembly and
assembly".

D375A-6R 00-31
Forword and general information
Method of disassembling and connecting push-pull type coupler

Method of disassembling and connecting push-pull type coupler 0 -32


(Rev. 2010/02)
k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.

Type 1 0 -32

1. Disconnection
1) Hold adapter (1) and push hose joint (2) into
mating adapter (3). (Fig. 1)
a The adapter can be pushed in about 3.5
mm.
a Do not hold rubber cap portion (4).
2) With hose joint (2) pushed into adapter (3),
press rubber cap portion (4) against adapter
(3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull it
out. (Fig. 3)
a Since some hydraulic oil flows out, pre-
pare an oil container.

2. Connection
1) Hold hose adapter (1) or hose (5) and insert
it in mating adapter (3), aligning them with
each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose fitting in the adapter
on the other side perfectly, pull it back to
check the connecting condition (Fig. 5)
a When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormal-
ity, however.

00-32 D375A-6R
Forword and general information
Method of disassembling and connecting push-pull type coupler

Type 2 0 -3

1. Disconnection
1) Hold the tightening portion and push body (7)
straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal
portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1) and
2), pull out whole body (7) to disconnect it.
(Fig. 8)

2. Connection
q Hold the tightening portion and push body (7)
straight until sliding prevention ring (6) con-
tacts contact surface (a) of the hexagonal
portion at the male end. (Fig. 9)

D375A-6R 00-33
Forword and general information
Method of disassembling and connecting push-pull type coupler

Type 3 0 -34

1. Disconnection
1) Hold the tightening portion and push body (9)
straight until sliding prevention ring (8)
contacts contact surface (b) of the hexagonal
portion at the male end. (Fig. 10)
2) While holding the condition of Step 1), push
cover (10) straight until it contacts contact
surface (b) of the hexagonal portion at the
male end. (Fig. 11)
3) While holding the condition of Steps 1) and
2), pull out whole body (9) to disconnect it.
(Fig. 12)

2. Connection
q Hold the tightening portion and push body (9)
straight until sliding prevention ring (8) con-
tacts contact surface (b) of the hexagonal
portion at the male end. (Fig. 13)

00-34 D375A-6R
Forword and general information
Standard tightening torque table

Standard tightening torque table 0 -35


(Rev. 2010/02)
1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below.

a The following table applies to the bolts in Fig. A.


Thread diam- Width across
Tightening torque
eter of bolt flats
mm mm Nm kgm
6 10 11.814.7 1.21.5
8 13 27 34 2.83.5
10 17 5974 6.07.5
12 19 98123 10.012.5
14 22 157 196 16 20
16 24 245 309 25 31.5
18 27 343 427 35 43.5
20 29 490 608 50 62
22 32 662 829 67.5 84.5
24 36 824 1,030 84 105
27 41 1,180 1,470 120 150
29 46 1,5201,910 155195
33 50 1,9602,450 200250
36 55 2,4503,040 250310
39 30 2,8903,630 295370

a The following table applies to the bolts in Fig. B.


Thread diam- Width across
Tightening torque
eter of bolt flats
mm mm Nm kgm
6 10 5.99.8 0.61.0
8 12 13.723.5 1.42.4
10 14 34.346.1 3.54.7
12 17 74.590.2 7.69.2

a Fig. A a Fig. B

Remarks: The width across flats by thread diameter of flanged bolts (marked with "*") in Fig. A are the
ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)

D375A-6R 00-35
Forword and general information
Standard tightening torque table

2. Table of tightening torque for split flanged bolts


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

3. Table of tightening torque for O-ring boss piping joints


a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diam- Width across
Tightening torque Nm {kgm}
Nominal No. eter flats
mm mm Range Target
02 14 3563 {3.5 6.5} 44 {4.5}
Varies
03, 04 20 84132 {8.513.5} 103 {10.5}
depending on
05, 06 24 128186 {13.019.0} 157 {16.0}
type of con-
10, 12 33 363480 {37.049.0} 422 {43.0}
nector.
14 42 7461,010 {76.0103} 883 {90.0}

4. Table of tightening torque for O-ring boss plugs


a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Thread diam- Width across
Tightening torque Nm {kgm}
Nominal No. eter flats
mm mm Range Target
08 8 14 5.888.82 {0.60.9} 7.35 {0.75}
10 10 17 9.812.74 {1.01.3} 11.27 {1.15}
12 12 19 14.719.6 {1.52.0} 17.64 {1.8}
14 14 22 19.624.5 {2.02.5} 22.54 {2.3}
16 16 24 24.534.3 {2.53.5} 29.4 {3.0}
18 18 27 34.344.1 {3.54.5} 39.2 {4.0}
20 20 29 44.153.9 {4.55.5} 49.0 {5.0}
24 24 32 58.878.4 {6.08.0} 68.6 {7.0}
30 29 32 93.1122.5 { 9.512.5} 107.8 {11.0}
33 33 107.8147.0 {11.015.0} 127.4 {13.0}
36 36 36 127.4176.4 {13.018.0} 151.9 {15.5}
42 42 181.3240.1 {18.524.5} 210.7 {21.5}
52 52 274.4367.5 {28.037.5} 323.4 {33.0}

00-36 D375A-6R
Forword and general information
Standard tightening torque table

5. Table of tightening torque for hoses (taper seal type and face seal type)
a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque
shown in the following table.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque (Nm {kgm}) Taper seal Face seal
Nominal Width Nominal No.
Thread diame-
number of across Thread size Number of
Range Target ter (mm) (Ref-
hose flats (mm) (mm) threads, type of
erence)
thread
3454 {3.5 5.5} 44 {4.5} 9/16 18UNF 14.3
02 19
3463 {3.5 6.5} 44 {4.5} 14
22 5493 {5.59.5} 74 {7.5} 11/16 16UN 17.5
03
24 5998 {6.010.0} 78 {8.0} 18
04 27 84132 {8.513.5} 103 {10.5} 22 13/16 16UN 20.6
05 32 128186 {13.019.0} 157 {16.0} 24 1 14UNS 25.4
06 36 177245 {18.025.0} 216 {22.0} 29 1-3/16 12UN 30.2
(10) 41 177245 {18.025.0} 216 {22.0} 33
(12) 46 197294 {20.030.0} 245 {25.0} 36
(14) 55 246343 {25.035.0} 294 {30.0} 42

6. Table of tightening torque for face seal joints


a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be
used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Tightening torque (Nm {kgm}) Face seal
Outer diam- Width across Nominal No.
Thread diameter
eter of pipe flats Number of
Range Target (mm)
(mm) (mm) threads, type of
(mm)(Reference)
thread
8 19 1416 {1.41.6} 15 {1.5} 9/16 18UN 14.3
10 22 2427 {2.42.7} 25.5 {2.6} 11/16 16UN 17.5
12 24 (27) 4347 {4.44.8} 45 {4.6} 13/16 16UN 20.6
15 (16) 30 (32) 6068 {6.16.8} 64 {6.5} 1 14UN 25.4
22 (20) 36 9095 {9.29.7} 92.5 {9.4} 1 3/16 12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.

D375A-6R 00-37
Forword and general information
Standard tightening torque table

7. Table of tightening torque for 102, 107 and 114 engine series (bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts used for the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 2 1.02 0.20
8 24 4 2.45 0.41
10 43 6 4.38 0.61
12 77 12 7.85 1.22
14

8. Table of tightening torque for 102, 107 and 114 engine series (eye joints)
a Unless there are special instructions, tighten the metric eye joints used for the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque
mm Nm kgm
6 82 0.81 0.20
8 10 2 1.02 0.20
10 12 2 1.22 0.20
12 24 4 2.45 0.41
14 36 5 3.67 0.51

9. Table of tightening torque for 102, 107 and 114 engine series (taper screws)
a Unless there are special instructions, tighten NPT screws used for the 102, 107 and 114 engine series
to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 2 1.53 0.20 51 0.51 0.10
1/8 20 2 2.04 0.20 15 2 1.53 0.20
1/4 25 3 2.55 0.31 20 2 2.04 0.20
3/8 35 4 3.57 0.41 25 3 2.55 0.31
1/2 55 6 5.61 0.61 35 4 3.57 0.41
3/4 75 8 7.65 0.82 45 5 4.59 0.51

00-38 D375A-6R
Forword and general information
List of Abbreviation

List of Abbreviation 0 -39


(Rev. 2010/02)
q This list of abbreviations is taken from the abbre- q Special abbreviations that appear infrequently
viations used in the text of the shop manual for are marked in the text with an *.
parts, components, and functions whose mean- q This list of abbreviations consists of two parts.
ing is not immediately clear. The spelling is given The first part is a list of abbreviations used in the
in full with an outline of the meaning. text of the manual, and the second part is a list
q Abbreviations that are used in general society of abbreviations used in circuit diagrams.
may not be included.
List of abbreviations used in the shop manual
Purpose of use (major
Abbreviatio
Full Spelling applicable machine (*), or Explanation
n
component/system)
With this function, when the tires skid (wheels stop
Travel and brake
A.B.S. Anti-skid Brake System rotating), the brakes are released, and when the
(HD, HM)
wheels start to rotate, the brakes are applied again.
Automatic Idling Setting
A.I.S.S. Engine This function automatically sets the idling speed.
System
Instead of a steering wheel, a lever is used to carry
Advanced Joystick Steer- Steering
A.J.S.S. out the steering operations as well as to shift gear
ing System (WA)
and change direction (forward or reverse).
When the machine is traveling downhill, if the
Automatic Retarder Travel and brake accelerator pedal is released, this function auto-
A.R.A.C.
Accelerator Control (HD, HM) matically applies the retarder with a constant brak-
ing force.
When the machine is traveling downhill, if the
accelerator pedal is released, this function auto-
Automatic Retarder Travel and brake
A.R.S.C. matically applies the retarder to ensure that the
Speed Control (HD, HM)
machine speed does not accelerate above the
speed set by the operator.
When the rear wheels spin on soft ground sur-
Travel and brake
A.S.R. Automatic Spin Regulator faces, this function automatically uses the optimum
(HD, HM)
braking force to drive both wheels.
A device that can be fixed onto a machine in order
ATT. Attachment Work equipment
to enable it to do different jobs.
When the retarder is not being used, this valve
Brake Cooling oil control Brake
B.C.V. bypasses part of the brake cooling oil to reduce the
Valve (HD)
load on the hydraulic pump.
Communication and elec- Communications standard standardized as
C.A.N. Controller Area Network
tronic control ISO11898.
System that can simultaneously actuate multiple
Closed-center Load
C.L.S.S. Hydraulic actuators regardless of the load (provides better
Sensing System
ease of combined operation than O.L.S.S.).
Uses engine controller to carry out electronic con-
trol of supply pump, common rail, and injector.
C.R.I. Common Rail Injection Engine
Functions to maintain optimum fuel injection
amount and fuel injection timing.
Electronic control device that uses the signals from
Electronic Control Mod-
E.C.M. Electronic control system the sensors on the machine to indicate to the actu-
ule
ators the optimum actuation. (same as ECU)
Proportional electromagnetic valve that gradually
Electronic Control Modu- Transmission
E.C.M.V. increases oil pressure to engage clutch and
lation (D, HD, WA, etc.)
reduces transmission shock.
System that ensures smooth high-speed travel by
Electronically Controlled Travel
E.C.S.S. using hydraulic spring effect of accumulator to
Suspension System (WA)
absorb vibration of machine during travel.
Electronic control device that uses the signals from
E.C.U. Electronic Control Unit Electronic control system the sensors on the machine to indicate to the actu-
ators the optimum actuation. (same as ECM)
Functions to recirculate part of exhaust gas to com-
Exhaust Gas Recircula-
E.G.R. Engine bustion chamber in order to reduce combustion
tion
temperature, controls emission of Nox.

D375A-6R 00-39
Forword and general information
List of Abbreviation

Purpose of use (major


Abbreviatio
Full Spelling applicable machine (*), or Explanation
n
component/system)
System that allows data (filter, oil replacement
Equipment Management interval, abnormalities on machine, failure code,
E.M.M.S. Machine monitor
Monitoring System and failure history) from each sensor on the
machine to be checked on monitor.
Control system that moves an actuator in propor-
Electromagnetic Propor-
E.P.C. Hydraulic tion to the amperage of an electric current passing
tional Control
through the solenoid.
F-N-R Forward-Neutral-Reverse Operation Position of the gear shift lever or switch.
System that is used to determine the current loca-
Global Positioning Sys- Communication tion on the Earth of a ship, car, machine, etc. by
G.P.S.
tem (KOMTRAX, VHMS) receiving the radio wave signals transmitted from
the navigation satellites.
Steering function that uses a combination of
Hydrostatic Steering Sys- Steering hydraulic motor and bevel shaft to control differ-
H.S.S.
tem (D) ence in travel speed of left and right tracks to turn
machine without using steering clutch.
Hydraulic transmission system that uses a combi-
Hydro Static Transmis- Transmission
H.S.T. nation of hydraulic pump and hydraulic motor to
sion (D, WA)
shift gear steplessly without using gears.
Valve installed at inlet port of pump to adjust fuel
I.M.A. Inlet Metering Actruator Engine intake amount in order to control fuel discharge
amount of supply pump. Same as IMV.
Valve installed at inlet port of pump to adjust fuel
I.M.V. Inlet Metering Valve Engine intake amount in order to control fuel discharge
amount of supply pump. Described as IMV (IMA).
Image display device made up of a large number of
L.C.D. Liquid Crystal Display Machine monitor
pixels filled with liquid crystal.
Semiconductor element that emits light when the
L.E.D. Light Emitting Diode Electronic parts voltage is applied in forward direction, positive volt-
age to anode and negative voltage to cathode.
Function that senses differential pressure of pump
L.S. Load Sensing Hydraulic
and controls discharge amount according to load.
Service that allows transmission and reception of
Multimedia Messaging
M.M.S. Communication short messages consisting of characters or voice
Service
or images between cell phones.
Device actuated to open electric or hydraulic cir-
N.C. Normally Closed Electronic and hydraulic
cuits that are normally closed if not actuated.
Device actuated to close electric or hydraulic cir-
N.O. Normally Open Electronic and hydraulic
cuits that are normally open if not actuated.
Open-center Load Sens- Hydraulic system that can operate multiple actua-
O.L.S.S. Hydraulic
ing System tors at the same time, regardless of the load.
P.C. Pressure Control Hydraulic Controlling the oil pressure.
System in which a controller instantly analyses
Palm Command Control Steering data from each lever, pedal, and dial, and carries
P.C.C.S.
System (D) out optimum electronic control of the engine and
HST.
Valve installed at inlet port of pump to adjust fuel
P.C.V. Pump Control Valve Engine intake amount in order to control fuel discharge
amount of supply pump.
Proportional Pressure Control system that moves an actuator in propor-
P.P.C. Hydraulic
Control tion to the oil pressure.
Hydraulic
P.P.M. Piston Pump and Motor Piston pump and motor.
(D, PC, etc.)
A device to take off power of the engine in order to
P.T.O. Power Take Off Power train
drive a hydraulic pump, an air compressor, etc.
Power Tilt and power Work equipment Function that carries out hydraulic control of the tilt
P.T.P.
Pitch dozer (D) and pitch of the bulldozer blade.

00-40 D375A-6R
Forword and general information
List of Abbreviation

Purpose of use (major


Abbreviatio
Full Spelling applicable machine (*), or Explanation
n
component/system)
International System of Units (abbreviated SI from
the French Le Systeme Internationale dUnites) is
the modern form of the metric system, and is the
Le System International worlds most widely used system of measurement.
S.I. Unit
d Unites Therere seven base units: meter (m), kilogram
(kg), second (s), ampere (A), kelvin (K), candela
(cd), and mole (mol). The derived units include
Pascal (Pa), Newton (N), etc.
Solenoid is a loop of wire. However, as a matter of
fact in engineering, it refers to an actuator consists
of a solenoid and an iron core that is moved by the
SOL. Solenoid Electronic
magnetic force when the solenoid is energized.
The word solenoid also often refers to a solenoid
valve.
T.W.V. Two Way Valve Hydraulic and electronic Solenoid valve that switches over direction of flow.
Communications system that transmits machine
data, such as the present position of the machine,
Monitoring and communica- daily or aggregate hours of operation, fuel con-
Vehicle Health Monitoring
V.H.M.S. tion sumption, radiator water temperature, oil or filter
System
(D, HD, PC, WA : Large size) replacement interval, to make it possible to collect
and check this data from a distant place (Devel-
oped for use on large machines used in mines).
*: Code for machine family
D: bulldozer
HD: dump truck
HM: articulate dump truck
PC: hydraulic excavator
WA: wheel loader

D375A-6R 00-41
Forword and general information
List of Abbreviation

List of abbreviations used in the circuit drawings


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

00-42 D375A-6R
Forword and general information
Conversion table

Conversion table 0 -43


(Rev. 2010/02)
Method of using the conversion table 0 -43
The conversion table in this section is provided to enable simple conversion of figures. For details of the meth-
od of using the conversion table, see the example given below.

Example: Method of using the conversion table to convert from millimeters to inches

1. Convert 55 mm into inches.


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

2. Convert 550 mm into inches.


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

Millimeters to inches (B)


1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.017 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

D375A-6R 00-43
Forword and general information
Conversion table

Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.017 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

Liters to U.S. Gallons


1l= 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

00-44 D375A-6R
Forword and general information
Conversion table

Liters to U.K. Gallons


1l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

D375A-6R 00-45
Forword and general information
Conversion table

kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408

100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119

150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830

200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542

00-46 D375A-6R
Forword and general information
Conversion table

Temperature 0 -47

Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade
values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
C F C F C F C F
40.4 40 40.0 11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
37.2 35 31.0 11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
34.4 30 22.0 10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
31.7 25 13.0 10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
28.9 20 4.0 9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

28.3 19 2.2 8.9 16 60.8 10.6 51 123.8 30.0 86 186.8


27.8 18 0.4 8.3 47 62.6 11.1 52 125.6 30.6 87 188.6
27.2 17 1.4 7.8 18 64.4 11.7 127.4 31.1 88 190.4
26.7 16 3.2 7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
26.1 15 5.0 6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

25.6 14 6.8 6.1 21 69.8 13.3 56 132.8 32.8 91 195.8


25.0 13 8.6 5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
24.4 12 10.4 5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
23.9 11 12.2 4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
23.3 10 14.0 3.9 25 77.0 15.6 60 140.0 35.0 95 203.0

22.8 9 15.8 3.3 26 78.8 16.1 61 141.8 35.6 96 204.8


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

20.0 4 24.8 0.6 31 87.8 18.9 66 150.8 40.6 105 221.0


19.4 3 26.6 0 32 89.6 19.4 68 152.6 43.3 110 230.0
18.9 2 28.4 0.6 33 91.4 20.0 69 154.4 46.1 115 239.0
18.3 1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0


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

14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0


13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

D375A-6R 00-47
Forword and general information
Conversion table

00-48 D375A-6R
D375A-6R
SEN0521404-00 01-

BULLDOZER
Shop Manual 01-

D375A-6R

Machine model Serial number


D375A-6R 65001 and up

01 Specification 01-

D375A-6R 01-1
Contents

Contents 01-2
01 Specification
Specification and technical data ............................................................................................. 01- 3
Specification drawing ........................................................................................................... 01- 3
Specifications....................................................................................................................... 01- 4
Weight table ......................................................................................................................... 01- 9
Table of fuel, coolant and lubricants .................................................................................... 01- 11

01-2 D375A-6R
Specification and technical data
Specification drawing

Specification and technical data 01-3


Specification drawing 01-3

Sem i - U tilt dozer + Full - U tilt dozer + Giant Semi - U tilt dozer + Full - U tilt dozer +
Item Unit
Giant ripper ripper Multi - shank ripper Multi - shank ripper
Overall
A mm 10,515 10,815 10,230 10,590
length
Overall
height 4,215 4,215 4,215 4,215
B mm
(with (4,235) (4,235) (4,235) (4,235)
ROPS)
Overall
C mm 4,695 5,140 4,695 5,140
width

D375A-6R 01-3
Specification and technical data
Specifications

Specifications 01-4

Machine model D375A-6R


Serial number 65001
Machine weight
q Bare tractor 51,800
q Ditto with semi-U dozer 62,765
q Ditto with variable multi-shank ripper 69,565
Weight

q Ditto with ROPS cab, air conditioner, seat


kg 70,835
belt, perforated side cover, and SSC

q Bare tractor with full - U dozer 64,265


q Ditto with variable giant ripper 70,465

q Ditto with ROPS cab, air conditioner, seat


71,735
belt, perforated side cover, and SSC

Min. turning radius m 4.2


Gradeability deg. 29
Stability (front, rear, left, right) deg. 35
(manual gear shift mode) (automatic gear shift mode)
Transmission speed ranges Transmission speed ranges

1st 0 3.5
Forward

2nd 0 6.8
km/h
3rd (low speed) 0 8.0
3rd 0 11.8

1st 0 4.6
Reverse

2nd 0 8.9
km/h
3rd (low speed) 0 9.7
3rd 0 15.8
Forward

1st 0 3.5
2nd km/h 0 6.8
3rd 0 11.8
Performance

Reverse

1st 0 4.6
2nd km/h 0 8.7
3rd 0 14.7

q Bare tractor 103.95 {1.06}


q With semi-U dozer 131.41 {1.34}
Ground pressure (610 shoe)

q With full-U dozer 145.14 {1.48}


q With semi-U dozer and variable
148.08 {1.51}
multi-shank ripper
q Ditto with ROPS cab, air conditioner, (kPa
seat belt, perforated side cover, and {kg/cm2}) 134.35 {1.37}
SSC
q With full-U dozer and variable giant
147.10 {1.50}
ripper
q Ditto with ROPS cab, air conditioner,
seat belt, perforated side cover, and 150.04 {1.53}
SSC

01-4 D375A-6R
Specification and technical data
Specifications

Machine model D375A-6R


Serial number 65001
Bare tractor 5,905
Overall length

With semi-U dozer 7,820


With full-U dozer 8,180
mm
With semi-U dozer + variable
10,230
multi-shank ripper
With full-U dozer + variable multi-shank
10,875
Dimensions

ripper
Overall height Overall width

Bare tractor 3,240


With semi-U dozer mm 4,695
With full-U dozer 5,140

To tip of exhaust pipe 4,215


mm
To top of air intake duct 3,480
Dimensions

Track gauge 2,500


Length of track on ground 3,980
mm
Track shoe width 610
Maximum ground clearance 605
Model SAA6D170E-5
Type 4-cycle, water-cooled, in-line vertical, direct injec-
tion type with turbocharger and aftercooler
No. of cylinders bore x stroke mm 6 - 170 x 170
Piston displacement l {cc} 23.15 {23,150}
Flywheel horsepower (ISO 9249) kW {HP} /rpm 455 {610} / 1,800
Performance

Max. torque Nm {kgm} / rpm 2,730 {278} / 1,300


Engine

Max. high idle speed rpm 1,900


Min. low idle speed rpm 750
g/kWh
Min. fuel consumption ratio 207.4 {154.7}
{g/HPh}
Starting motor 24 V, 7.5 kW x 2
Alternator 24 V, 60 A
Battery 12 V, 170 Ah x 2

Radiator core type Rectangle corrugated fin


3 - element, 1 - stage, 1 - phase (with lockup
Torque converter
clutch)
Planetary gear and multiple disc clutch type,
Transmission hydraulically actuated forced lubricated, forward 3 -
speed, reverse 3 - speed
Power train

Bevel gear shaft Spiral bevel gear type, splash lubrication type
Wet, multiple disc clutch type, spring - loaded and
Steering clutch hydraulically released (lever operated), intercon-
nected with brake
Wet, multiple disc clutch type, spring - actuated,
Steering brake hydraulically released (pedal / lever operated ),
interconnected with clutch
Single reduction spur gear single reduction , plane-
Final drive
tary gear , lubricating oil splash lubrication type

D375A-6R 01-5
Specification and technical data
Specifications

Machine model D375A-6R

Serial number 65001


Suspension Rigid, equalizer bar
Undercarriage

Carrier roller 2 each side


Track roller 7 each side
Assembly type, single grouser, 40 each side
Track shoe
pitch: 280.0 mm, width: 610 mm
Power train + Lubricating oil pump (tandem) Gear type (BAL180 + 112)
Scavenging pump (tandem) Gear type (BAR63 + 277)
Variable swash plate type (LPV90 + 30)
Cooling fan pump MPa {kg/cm2} Max. delivery pressure: 18.1 {184}
l/min/rpm Theoretical delivery: 231/1,926
Fixed swash plate type (LMF 150)
Cooling fan motor
MPa {kg/cm2} Max. allowable working pressure: 18.1 {184}
Max. pressure MPa {kg/cm2} 27.5 {280}
Hydraulic
pump

Type Variable swash plate type (HPV190)


Delivery (engine speed at 1,800 rpm) l/min 366

Machines with single tilt blade and vari- 1 + 1 + 1 + 2 spool type, hydraulic assisted, PPC
able ripper type
q For ripper tilt cylinder + Ripper tilt (in, back)
q For ripper lift cylinder + Ripper lift (raise, lower)
q For blade tilt cylinder + Blade tilt
Control valve

q For blade lift cylinder + Blade lift x 2 (raise, lower)


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

q For ripper tilt cylinder + Ripper tilt (in, back)


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

Type double acting piston


Dimensions of blade lift

Cylinder bore 140


cylinder

Piston rod outside diameter 90


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

Min. between pins distance 774


Dimensions of blade tilt

Cylinder bore 200


cylinder

Piston rod outside diameter 110


Piston stroke mm 240
Max. between pins distance 1,703
Min. between pins distance 1,463

01-6 D375A-6R
Specification and technical data
Specifications

Machine model D375A-6R

Serial number 65001

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

Piston stroke (both right and


185
left) mm
Max. distance between pins
1,675
(both right and left)
Work equipment hydraulic system

Min. distance between pins


1,490
(both right and left)
Hydraulic cylinder

Cylinder bore 200


Piston rod outside diameter 110
lift cylinder

Piston stroke mm 495


Max. between pins distance 1,855

Min. between pins distance 1,360

Cylinder bore 180


Piston rod outside diameter 110
tilt cylinder

Piston stroke mm 550


Max. between pins distance 1,800

Min. between pins distance 1,250

Hydraulic tank Box type (control valve externally installed)


Hydraulic semi-U tilt dozer
Type
Hydraulic full-U tilt dozer

Single tilt
Left: Brace type
Right: Tilt cylinder type
Blade supporting method Dual tilt
Work equipment

Left: Tilt cylinder type (for single tilt/dual tilt pitch)


Right: Tilt cylinder type (for dual tilt pitch)

Max. lift above ground mm 1,642


Dimensions Performance

Max. drop below ground mm 800


Max. adjustment tilt mm 955
Semi-U dozer

Hydraulic oil tilt mm 760


Blade capacity m3 24.0 <SAE18.5>

Blade width mm 4,695


Blade height mm 2,265 (with spill guard: 2,525)
Blade cutting angle deg. 55

D375A-6R 01-7
Specification and technical data
Specifications

Machine model D375A-6R

Serial number 65001

Max. lift above ground mm 1,642


Dimensions Performance

Max. drop below ground mm 800


Max. adjustment tilt mm 1,050
Full-U dozer

Hydraulic oil tilt mm 850


Blade capacity m3 26.3 <SAE22.0>

Blade width mm 5,140


Blade height mm 2,265 (with spill guard: 2,525)
Blade cutting angle deg. 55
Full-U dozer + pitch Semi-U dozer + Pitch

Performance

Max. hydraulic oil tilt mm 1,150


Hydraulic oil tilt (single) deg. 580
Max. pitch angle deg. Forward 4.7 / Backward 5.2
Blade cutting angle deg. 55
Work equipment

Dimensions

Max. hydraulic oil tilt mm 1,280


Hydraulic oil tilt (single) deg. 635
Max. pitch angle deg. Forward 4.7 / Backward 5.2
Blade cutting angle deg. 55
Dimensions Performance Dimensions Performance

Max. digging depth mm 1,190


Multi - shank ripper

Max. lift above ground mm 1,082


Point digging angle deg. 45 (Stepless adjustment between 31.4 54.7)

Max. beam width mm 2,910


Shank positions No. of holes 3

Max. digging depth mm 1,538


Max. lift above ground mm 1,050
Giant ripper

Point digging angle deg. 45 (Stepless adjustment between 31.6 55.0)

Max. beam width mm 1,600


Shank positions No. of holes 4

01-8 D375A-6R
Specification and technical data
Weight table

Weight table 01-9

k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Machine model D375A-6R

Serial number 65001

Engine, damper assembly 3,320


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

Radiator assembly 465


Oil cooler assembly 92
Fuel tank assembly (when full) 580 (1,600)

Power train unit 4,220


q Torque converter and PTO assembly 795
q Transmission assembly 1,000
q Transmission valve assembly 13
q Steering clutch and brake assembly 1,712
q Steering valve assembly 13
Final drive assembly 2,200 x 2
Main frame assembly 5,541
Track group assembly (each side) 7,259
q Track frame 2,038
q Idler assembly 478
q Track roller assembly (each single flange x each side) 150 x 4
q Track roller assembly (each double flange x each side) 160 x 3
q Carrier roller assembly (each x each side) 71 x 2
q First bogie and track roller assembly 258
q Each of second - fourth bogie and track roller assembly 742 x 3
q Final bogie and track roller assembly -
Track shoe assembly (610 mm) 4,200 x 2
Pivot shaft 210 x 2
Equalizer bar assembly 500

Hydraulic tank assembly (excluding oil ) 236


Control valve (for single tilt) 119
Control valve (for dual tilt) 125

D375A-6R 01-9
Specification and technical data
Weight table

Unit: kg
Machine model D375A-6R

Serial number 65001

Semi-U dozer assembly (excluding oil)


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

01-10 D375A-6R
Specification and technical data
Table of fuel, coolant and lubricants

Table of fuel, coolant and lubricants 01- 1

For details of the notes (Note 1, Note 2 - - -) in the table, see Operation and Maintenance Manual.

D375A-6R 01-11
Specification and technical data
Table of fuel, coolant and lubricants

Unit: l
D375A-6R
Refilling points
Specified capacity Refill capacity

Engine oil pan 87 86

Damper case 2.1 2.1

Power train case 275 150

Final drive case


61 61
(both sides)

Hydraulic oil system


q Single tilt, without ripper 230
130
q Single tilt with variable rippers 275
q Dual tilt with variable rippers 280

Cooling system 120

Fuel tank 1,200

01-12 D375A-6R
D375A-6R
SEN0521406-00 10-1

BULLDOZER
Shop Manual 1-01

D375A-6R

Machine model Serial number


D375A-6R 65001 and up

10 Structure and function 10-1

D375A-6R 10-1
Contents

Contents 10-2
10 Structure and function
Engine and cooling system ..................................................................................................... 10- 4
Cooling system .................................................................................................................... 10- 4
Cooling fan pump................................................................................................................. 10- 7
Cooling fan motor................................................................................................................. 10- 28
Power train.............................................................................................................................. 10- 34
Power train........................................................................................................................... 10- 34
Overall drawing of power train unit ...................................................................................... 10- 36
Power train hydraulic equipment arrangement drawing....................................................... 10- 38
Damper and universal joint .................................................................................................. 10- 40
Torque converter and PTO .................................................................................................. 10- 42
Torque converter control valve ............................................................................................ 10- 48
Main relief valve and torque converter relief valve............................................................... 10- 50
Lockup clutch ECMV and stator clutch ECMV..................................................................... 10- 52
Scavenging pump ................................................................................................................ 10- 57
Transmission control............................................................................................................ 10- 58
PCCS lever .......................................................................................................................... 10- 60
Transmission........................................................................................................................ 10- 64
Transmission ECMV ............................................................................................................ 10- 78
Transmission lubrication relief valve .................................................................................... 10- 83
Steering and brake control................................................................................................... 10- 84
Transfer unit, bevel gear shaft and steering ........................................................................ 10- 86
Steering control valve .......................................................................................................... 10- 92
Steering clutch ECMV and Steering brake ECMV ............................................................... 10- 94
Parking brake valve ............................................................................................................. 10- 102
Sudden stop prevention valve.............................................................................................. 10- 103
Final drive ............................................................................................................................ 10- 105
Undercarriage and frame ........................................................................................................ 10- 110
Track frame.......................................................................................................................... 10- 110
Idler cushion......................................................................................................................... 10- 112
Track roller bogie ................................................................................................................. 10- 113
Main frame ........................................................................................................................... 10- 114
Suspension .......................................................................................................................... 10- 116
Hydraulic system..................................................................................................................... 10- 119
Work equipment hydraulic piping diagram........................................................................... 10- 119
PPC control piping diagram ................................................................................................. 10- 123
Work equipment control ....................................................................................................... 10- 124
Hydraulic tank ...................................................................................................................... 10- 126
Accumulator ......................................................................................................................... 10- 128
PPC lock valve..................................................................................................................... 10- 129
PPC valve ............................................................................................................................ 10- 130
Piston valve.......................................................................................................................... 10- 142
Quick drop valve .................................................................................................................. 10- 143
Pin puller switch ................................................................................................................... 10- 145
Pin puller solenoid valve ...................................................................................................... 10- 146
Blade control lever (only for the machine with dual tilt specification)................................... 10- 148
Work equipment pump......................................................................................................... 10- 150
Control valve ........................................................................................................................ 10- 160
Self-pressure reducing valve ............................................................................................... 10- 187
Work equipment...................................................................................................................... 10- 194
Cylinder stay ........................................................................................................................ 10- 194

10-2 D375A-6R
Contents

Cab ......................................................................................................................................... 10- 195


Cab mount ........................................................................................................................... 10- 195
Cab ...................................................................................................................................... 10- 196
Electrical system ..................................................................................................................... 10- 198
Engine control...................................................................................................................... 10- 198
Engine control system ......................................................................................................... 10- 199
CRI engine control system................................................................................................... 10- 208
Monitor system .................................................................................................................... 10- 210
Machine monitor .................................................................................................................. 10- 212
Lamp system ....................................................................................................................... 10- 230
Engine preheat (electrical intake air heater) control ............................................................ 10- 231
Palm command control system............................................................................................ 10- 232
Sensor ................................................................................................................................. 10- 235
Vehicle health monitoring system (VHMS) .......................................................................... 10- 241
ORBCOMM system ............................................................................................................. 10- 247

D375A-6R 10-3
Engine and cooling system
Cooling system

Engine and cooling system 10-4


Cooling system 10-4

10-4 D375A-6R
Engine and cooling system
Cooling system

A: Power train oil cooler inlet


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

1. Hydraulic oil cooler


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

Specification 10-5

Radiator Power train oil cooler Hydraulic oil cooler Aftercooler

Rectangle corru- Rectangle corru-


Core type PTO-OL Rectangle straight fin
gated fin gated fin

Fin pitch (mm) 8.0/2 8.0/2 8.0/2

Total heat dissipation surface


49.09 x 3 3.77 4.09 27.39 x 2
(m2)
Cracking pressure of
pressure valve 88.3 14.7

{0.9 0.15}
(kPa {kg/cm2})
Cracking pressure of vacuum
valve 04.9

{00.05}
(kPa {kg/cm2})

D375A-6R 10-5
Engine and cooling system
Cooling system

10-6 D375A-6R
Engine and cooling system
Cooling fan pump

Cooling fan pump 10-6


Type: LPV90 + 30
Appearance 10-6

1. LPV90 Hydraulic pump


2. LPV30 Hydraulic pump

D375A-6R 10-7
Engine and cooling system
Cooling fan pump

LPV90 Hydraulic pump 10-8 10-8


Appearance 10-8

10-8 D375A-6R
Engine and cooling system
Cooling fan pump

Sectional view 10-9

IM: Control current input connector 1. Shaft


PA: Pump discharge port 2. Cradle
PDI: Drain port 3. Case
PD2: Drain port (Plug) 4. Rocker cam
PDA: Breather 5. Shoe
PEN: Control pressure pickup port (Plug) 6. Piston
PEPC: EPC source pressure input port 7. Cylinder block
PS: Pump suction port 8. Valve plate
9. Spring
10. Servo piston

D375A-6R 10-9
Engine and cooling system
Cooling fan pump

Function 10-10 q The oil is sucked into and discharged from each
q The engine rotation and torque transmitted to cylinder in cylinder block (7) through valve plate
the pump shaft is converted into the hydraulic (8).
pressure and the pressurized oil corresponding
to the load is discharged.
q The delivery of this pump can be changed by
changing the swash plate angle.
Structure 10-10
q Cylinder block (7) is connected to shaft (1)
through spline (c).
q Shaft (1) is supported by the front and rear bear-
ings (9).
q The tip of piston (6) has a spherical hollow in
which shoe (5) is being held by crimping.
q Piston (6) and shoe (5) form a spherical bearing.
q Shoe (5) is kept pressed against plane (A) of
rocker cam (4) and slids circularly.
q Rocker cam (4) pivots on cylindrical face (B) of
cradle (2) witch is fixed to case (3).
q Piston (6) in each cylinder of cylinder block (7)
reciprocates in the axial direction.
q Cylinder block (7) rotates relatively against valve
plate (8), while sealing the pressurized oil.
q The hydraulic balance is maintained properly on
this face.

10-10 D375A-6R
Engine and cooling system
Cooling fan pump

Operation 10-1 q If center line (X) of rocker cam (4) matches the
Operation of pump 10-1 axis of cylinder block (7) (the swash plate angle
q Cylinder block (7) rotates together with shaft (1) = 0), the difference between volumes (E) and (F)
and shoe (5) slides on plane (A). in cylinder block (7) is 0.
q Rocker cam (4) moves along cylindrical face (B). q No oil is sucked or discharged and a pumping
As a result, angle (a) between center line (X) of action is not performed. (The swash plate angle
rocker cam (4) and the axis of cylinder block (7) is not set to 0 actually, however.)
changes.
q Angle (a) is called the swash plate angle.

q The pump delivery is in proportion of swash plate


angle (a).
q If angle (a) is made between center line (X) of
rocker cam (4) and the axis of cylinder block (7),
plane (A) works as a cam for shoe (5).
q Piston (6) reciprocates inside cylinder block (7)
and a difference is made between volumes (E)
and (F) of cylinder chamber in cylinder block (7).
q Each piston (6) sucks and discharges oil by (F)
(E).
q If cylinder block (7) rotates and the volume of
chamber (E) is decreased, the oil is discharged
from chamber (E) during this process.
q The volume of chamber (F) is increased and the
oil is sucked in chamber (F) during this process.

D375A-6R 10-11
Engine and cooling system
Cooling fan pump

Control of delivery 10-12


q If swash plate angle (a) is increased, the differ-
ence between volumes (E) and (F) is increased,
or delivery (Q) is increased.
q Swash plate angle (a) is changed with servo pis-
ton (1).
q Servo piston (1) reciprocates straight according
to the signal pressure of the PC valve.
q This straight motion is transmitted to rocker cam
(4).
q Then, rocker cam (4) supported on the cylindri-
cal surface of cradle (2) is tilted in the axial direc-
tion.
q The pressure receiving area of the top of servo
piston (1) is different from that of the bottom.
Main pump discharge pressure (self-pressure)
(PA) is kept led in the pressure chamber on the
small-diameter piston side (upper side).
q PC valve output pressure (PEN) is led in the
pressure chamber on the large-diameter piston
side (lower side).
q The movement of servo piston (1) is controlled
according to the difference between pressure
(PA) on the small-diameter piston side and pres-
sure (PEN) on the large-diameter piston side
and the ratio of the pressure receiving area of
the small-diameter piston to that of the large-di-
ameter piston.

10-12 D375A-6R
Engine and cooling system
Cooling fan pump

D375A-6R 10-13
Engine and cooling system
Cooling fan pump

PC valve, EPC valve, Servo piston 10-14

IM: Control current input connector PC valve 10-14


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

10-14 D375A-6R
Engine and cooling system
Cooling fan pump

Function 10-15
The PC valve controls the servo piston so that the
delivery (swash plate angle) is related to the current
input to the EPC valve is as shown in the figure be-
low.

D375A-6R 10-15
Engine and cooling system
Cooling fan pump

When EPC output pressure is high [When EPC current (i) is large] 10-16

10-16 D375A-6R
Engine and cooling system
Cooling fan pump

Operation 10-17
q The relationship between the EPC valve input
current (i) and EPC valve output pressure (F) is
as shown in the figure below.

q If the EPC discharge pressure rises, spool (7) is


pushed to the left because of the difference in
sectional areas between parts (S1) and (S2) of
the spool (S1 > S2).
q Port (f) is connected to port (g) and the pump dis-
charge oil at pressure (PA) flows through port (g)
to port (f). Port (f) is disconnected from the drain
circuit.
q The pump discharge oil at pressure (PA) from
port (f) of the PC valve enters chamber (X) on
the large diameter side of servo piston (1).
q Pump pressure (PA) is also constantly applied to
chamber (Y) on the small diameter side of servo
piston (1). Since a larger force is applied to the
large diameter side because of the difference in
area between both ends of servo piston (1), how-
ever, servo piston (1) moves toward the mini-
mum swash plate angle side (upper side).
q If servo piston (1) moves up, piston (4) is moved
to the right through lever (2). Accordingly, spring
(6) is compressed and spool (7) moves to the
right.
q If spool (7) moves to the right and port (f) is dis-
connected from port (g), servo piston (1) stops
moving up.
q At this time, servo piston (1) stops at a place
higher (nearer to the minimum swash plate an-
gle) than when the EPC discharge pressure is
low.

D375A-6R 10-17
Engine and cooling system
Cooling fan pump

When EPC output pressure is low [When EPC current (i) is small] 10-18

10-18 D375A-6R
Engine and cooling system
Cooling fan pump

Operation 10-19
q If EPC current (i) reduces and the EPC output
pressure lowers, spool (7) is pushed to the right
by the force of spring (6).
q Port (g) is disconnected from port (f) and at the
same time port (f) is connected to the drain cir-
cuit.
q The oil in chamber (X) on the large diameter side
of servo piston (1) flows through port (f) of the
PC valve to the drain circuit.
q Servo piston (1) is moved toward the maximum
swash plate angle side (lower side) by the pres-
sure of chamber (Y) on the small diameter side.

D375A-6R 10-19
Engine and cooling system
Cooling fan pump

LPV30 Hydraulic pump 10-20


Appearance

IM: Control current input connector 1. Piston pump


P1: Pump discharge port 2. Servo valve
PAEPC: EPC output pressure pickup port 3. Bleeder
PE: Servo piston control pressure input port 4. EPC valve
PEPC: EPC valve source pressure input port
PH: Pump discharge pressure output port
PS: Pump suction port
TO: Drain port

10-20 D375A-6R
Engine and cooling system
Cooling fan pump

Sectional view 10-21

1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
11. Ball

D375A-6R 10-21
Engine and cooling system
Cooling fan pump

Function 10-2 q The oil is sucked into and discharged from each
q The rotation and torque of the engine are trans- cylinder chamber of cylinder block (7) through
mitted to the shaft of this pump. Then, this pump valve plate (8).
converts the rotation and torque into hydraulic
energy and discharges hydraulic oil according to
the load.
q The discharge of this pump can be changed by
changing the swash plate angle in it.
Structure 10-2
q Cylinder block (7) is connected to shaft (1)
through splines (B).
q Shaft (1) is supported by the front and rear bear-
ings (12).
q The tip of piston (6) has a spherical hollow in
which shoe (5) is being held by crimping.
q Piston (6) and shoe (5) form a spherical bearing.
q Shoe (5) is kept pressed against plane (A) of
rocket cam (4) and slids circularly.
q Rocker cam (4) pivot on ball (11).
q Piston (6) in each cylinder of cylinder block (7)
reciprocates in the axial direction.
q Cylinder block (7) rotates relatively against valve
plate (8) sealing the hydraulic oil.
q The hydraulic balance on the valve plate is main-
tained properly.

10-22 D375A-6R
Engine and cooling system
Cooling fan pump

Operation 10-23
Operation of pump 10-23
q Cylinder block (7) rotates together with shaft (1) q If center line (X) of rocker cam (4) matches the
and shoe (5) slides on plane (A). axis of cylinder block (7) (the swash plate angle
q Rocker cam (4) pivots on ball (11). As a result, is 0), there is no difference between volumes (E)
angle (a) between center line (X) of rocker cam and (F) in cylinder block (7). The hydraulic oil is
(4) and the axis of cylinder block (7) changes. not sucked or discharged.
q Angle (a) is called the swash plate angle. (The swash plate angle is not set to 0 actually,
q If angle (a) is made between center line (X) of however.)
rocker cam (4) and the axis of cylinder block (7),
plane (A) works as a cam for shoe (5).
q If angle (a) is made between center line (X) of
rocker cam (4) and the axis of cylinder block (7),
plane (A) works as a cam for shoe (5).
q Each piston (6) sucks and discharges oil by (F)
(E).
q If cylinder block (7) rotates and the volume of
chamber (E) is decreased, the oil is discharged
from chamber (E).
q The volume of chamber (F) is increased and the
oil is sucked in chamber (F).

q The pump delivery is in proportion to swash plate


angle (a).

D375A-6R 10-23
Engine and cooling system
Cooling fan pump

Control of discharge 10-24


q If swash plate angle (a) is increased, the differ-
ence between volumes (E) and (F) is increased,
or delivery (Q) is increased.
q Swash plate angle (a) is changed with servo pis-
ton (10).
q Servo piston (10) reciprocates straight according
to the signal pressure of the servo valve.
q This linear motion is transmitted to rocker cam
(4).
q Then, rocker cam (4) supported on ball (11) piv-
ots on ball (11).

10-24 D375A-6R
Engine and cooling system
Cooling fan pump

Servo valve 10-25

P: EPC valve source pressure input port 1. Plug


PE: Servo piston control pressure output port 2. Lever
PH: Pump discharge pressure input port 3. Retainer
T: Drain port 4. Sheet
5. Spool
6. Piston
7. Sleeve

D375A-6R 10-25
Engine and cooling system
Cooling fan pump

A: Drain side D: EPC output pressure side


B: Pump discharge pressure input side P: EPC source pressure input side
C: EPC output pressure receiving pressure

10-26 D375A-6R
Engine and cooling system
Cooling fan pump

Function 10-27 Operation 10-27


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

D375A-6R 10-27
Engine and cooling system
Cooling fan motor

Cooling fan motor 10-28


Type: LMF180 (150)
Appearance 10-28

P: From fan pump Specifications 10-28


T: To tank through cooler Type: LMF150
TC: To tank Capacity: 150 cm3/rev
Rated speed: 1,225 rpm
Rated flow: 184 l/min
Check valve cracking pressure:
68.6 kPa {0.7 kg/cm2}

10-28 D375A-6R
Engine and cooling system
Cooling fan motor

Sectional view 10-29

1. Output shaft 7. Valve plate


2. Case 8. End cover
3. Thrust plate 9. Center spring
4. Shoe 10. Suction safety valve
5. Piston 11. ON/OFF pilot valve
6. Cylinder block 12. Reversible valve spool
13. Speed sensor

D375A-6R 10-29
Engine and cooling system
Cooling fan motor

Hydraulic motor 10-30


Function 10-30
This hydraulic motor is called a swash plate type ax-
ial piston motor. It converts the energy of the pres-
surized oil sent from the hydraulic pump into rotary
motion.
Principle of operation 10-30
q The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
This oil can flow into the cylinder chambers on
only one side (supply side) (Y - Y) line connect-
ing the top dead center and bottom dead center
of the stroke of piston (4)
q The oil sent to one side of cylinder block (5)
presses piston (4) [2 or 3 pieces] and generates
force (F1) [F1 = P x xD2 / 4].
q This force is applied to thrust plate (2). Since
thrust plate (2) is fixed at an angle of (a ) de-
grees to the output shaft (1), the force is divided
into components (F2) and (F3).
q The radial component (F3) generates torque [T
= F3 x ri] relative to the (Y - Y) line connecting the
top dead center and bottom dead center.
q The resultant of the torque [T = (F3 x ri)] rotates
cylinder block (5) through the piston.
q Since this cylinder block (5) is splined to the out-
put shaft, the output shaft rotates to transmit the
torque.

10-30 D375A-6R
Engine and cooling system
Cooling fan motor

Suction safety valve 10-31 At stop 10-31


q If the engine is stopped and the shaft speed of
Function of suction valve 10-31 the fan pump lowers to 0rpm, the pressurized oil
q When the fan pump stops rotating, the hydraulic from the pump is not supplied to port (P) any
oil does not flow into the motor. Since the motor more. As the pressurized oil is not supplied to
continues rotation by the force of inertia the pres- the (MA) side of the motor, the motor speed low-
sure at the outlet of the motor increases. ers gradually to stop.
q When the oil stops flowing in from inlet port (P), q If the motor shaft is revolved by the force of iner-
suction safety valve (1) sucks in the oil on the tia while the oil flow in the port (P) is reducing,
outlet side and supplies it to port (MA), compen- the oil in port (T) on the outlet side is sent by suc-
sating for the lack of oil on that side to prevent tion safety valve (1) to the (MA) side to prevent
cavitation. cavitation.

Operation 10-31
When pump is started 10-31
If the pressurized oil from the pump is supplied to
port (P) and the pressure on (MA) side rises and
starting torque is generated in the motor, the motor
starts revolution.The pressurized oil on the motor
outlet (MB) side of the motor returns through port (T)
to the tank.

D375A-6R 10-31
Engine and cooling system
Cooling fan motor

Function as safety valve 10-32


q The pressure in port (P) of the fan motor may
rise abnormally as in starting engine.
q Suction safety valve (1) is installed to protect the
fan system circuit in such a case.

Operation 10-32
q If the pressure in port (P) rises above the crack-
ing pressure of suction safety valve (1), valve (2)
of suction safety valve (1) opens to release the
pressurized oil into port (T).
q By this operation, generation of abnormally high
pressure in port (P) is prevented.

10-32 D375A-6R
Engine and cooling system
Cooling fan motor

Operation of reversible valve 10-3 When ON/OFF solenoid is energized 10-3


q If ON/OFF solenoid (1) is "energized", ON/OFF
When the ON/OFF solenoid is de-energized 10-3 selector valve (2) switches to allow the pressur-
q If ON/OFF solenoid (1) is "de-energized", the ized oil from the pump to flow through port (C) to
pressurized oil from the pump is blocked by spool chamber (D).
ON/OFF selector valve (2), and port (C) con- q The pressurized oil in chamber (D) pushes valve
nects to the tank circuit. spool (3) to the left against spring (4) .
q Spool (3) is pushed to the right by spring (4). q Motor port (MB) connects to port (P) and pres-
q Motor port (MA) connects to port (P) and pres- surized oil flows in to revolve the motor in re-
surized oil flows in to revolve the motor in normal verse (counterclockwise).
direction (clockwise).

D375A-6R 10-33
Power train
Power train

Power train 10-34


Power train 10-34

Outline 10-34 Transfer (15) reduces the speed of the power trans-
The power generated by engine (1) is transmitted mitted, and then the combination of the bevel pinion
through universal joint (3) to torque converter (8) and bevel gear of the bevel gear shaft unit reduces
while damper (2) reduces torsional vibration. The the speed further and divides the power at right an-
torque converter (8) that uses oil as a medium for gles to the left and right to send to the respective
power transmission transmits the power from the steering clutches (10).
engine to the input shaft (turbine shaft) of transmis- Steering clutch (10) stops transmission of the power
sion (9) in accordance with the change in load. from the bevel gear shaft unit to the final drive to
The torque converter is equipped with a lockup steer the machine. Moving the PCCS (steering) le-
clutch, and when the speed of the output shaft of the ver in the direction to which the machine turns dis-
transmission that receives the power from the engages the steering clutch on the side and the
torque converter becomes higher, the lockup clutch machine turns to the direction. The turning angle is
is automatically engaged. When this happens, the adjusted by controlling steering brake (11) installed
drive case and turbine are combined as a unit to to the outside of the steering clutch.
transmit the power from the engine directly to the Steering brake (11) is the same disc type as that for
transmission input shaft. the steering clutch. The power output from the steer-
Transmission (9) uses a combination of planetary ing clutch goes to final drive (12), where the speed
gear mechanisms and hydraulic clutches to give is reduced to drive sprocket(13).
three forward speeds and three reverse speeds. Double-reduction type final drive (12) consists of
When a gear speed is selected with the PCCS single-reduction spur gear train and single-reduc-
(gearshift) lever according to the change in load, two tion planetary gear train. The sprocket drives track
clutches are engaged to transmit the power from the shoe (14) to make the machine travel.
torque converter to transfer (15) through its output
shaft.

10-34 D375A-6R
Power train
Power train

1. Engine (SAA6D170E-5) 10. Steering clutch


2. Damper 11. Steering brake
3. Universal joint 12. Final drive
4. Cooling fan pump (LPV90 + 30) 13. Sprocket
5. Power train pump (BAL180+112) 14. Track shoe
6. PTO 15. Transfer
7. Work equipment pump (HPV190) 16. Scavenging pump (BAR63+277)
8. Torque converter 17. Cooling fan motor (LMF150)
9. Transmission 18. Bevel gear and pinion gear

D375A-6R 10-35
Power train
Overall drawing of power train unit

Overall drawing of power train unit 10-36

10-36 D375A-6R
Power train
Overall drawing of power train unit

A: Torque converter inlet oil pressure pickup port 1. Centralized pressure pickup port
(IN) 2. Oil level gauge
B: Torque converter outlet pressure pickup port 3. Oil filler pipe
(OUT) 4. Power train and lubrication pump
C: Lockup clutch pressure pickup port (LU) 5. PTO
D: Stator clutch oil pressure pickup port (SC) 6. Torque converter
E: Left steering clutch pressure pickup port (LC) 7. Torque converter control valve
F: Left steering brake pressure pickup port (LB) 8. Transmission control valve
G: Transmission 2nd clutch pressure pickup port 9. Transmission
(2ND) 10. Steering clutch and brake
H: Transmission R clutch pressure pickup port 11. Steering control valve
(REV) 12. Transmission lubricating oil filter
J: Power train lubricating oil pressure pickup port 13. Power train oil filter
(LUB) 14. Power train oil strainer
K: Transmission 3rd clutch pressure pickup port 15. Scavenging pump
(3RD) 16. Power train oil tank
L: Transmission F clutch pressure pickup port
(FWD) Outline
M: Right steering brake pressure pickup port (RB) q The power train unit consists of torque convert-
N: Right steering clutch pressure pickup port (RC) er, transmission unit, and steering unit by rough
P: Transmission 1st clutch pressure pickup port classification.
(1ST) Accordingly, after removing power train unit, it
R: Main relief pressure pickup port (TM) can be divided into torque converter, transmis-
sion unit, and steering unit.
q The steering unit consists of transfer, bevel gear
shaft, steering clutch, and steering brake.

D375A-6R 10-37
Power train
Power train hydraulic equipment arrangement drawing

Power train hydraulic equipment arrangement drawing 10-38

1. Oil cooler A: Torque converter lock-up pressure pickup port


2. Power train oil filter B: Torque converter stator clutch pressure pickup
3. Transmission lubricating oil filter port
4. Centralized pressure pickup port C: Left steering clutch pressure pickup port
5. Torque converter valve D: Left steering brake pressure pickup port
6. Transmission control valve (ECMV) E: Transmission 2nd clutch pressure pickup port
7. Steering control valve (ECMV) F: Transmission R clutch pressure pickup port
8. Power train oil tank G: Transmission 3rd clutch pressure pickup port
9. Power train oil strainer H: Transmission F clutch pressure pickup port
10. Power train pump (BAL180+112) J: Right steering brake pressure pickup port
11. Scavenging pump (BAR63+277) K: Right steering clutch pressure pickup port
12. Cooling fan pump (LPV90+30) L: Transmission 1st clutch pressure pickup port
M: Transmission 1st clutch pressure pickup port
N: Torque converter regulator pressure pickup port
P: Torque converter relief pressure pickup port
R: Main relief pressure pickup port

10-38 D375A-6R
Power train
Power train hydraulic equipment arrangement drawing

D375A-6R 10-39
Power train
Damper and universal joint

Damper and universal joint 10-39

10-40 D375A-6R
Power train
Damper and universal joint

1. Outer body
2. Engine flywheel
3. Output shaft
4. Coupling
5. Universal joint
6. Flange
7. Rubber coupling
8. Cover
9. Breather (for damper bearing case)
10. Oil fitter pipe
11. Breather (for fly wheel housing)

Outline
The damper protects the power train (such as the
torque converter and transmission) by buffering tor-
sional vibrations resulting from fluctuations in en-
gine torque or impact torque resulting from sudden
acceleration or heavy duty operation.
The rubber couplings on the damper effciently ab-
sorbs vibrations by rubber material's internal damp-
ing effects and deformation as well as frictional
damping effects of the rubber material. This ar-
rangement also helps reducing number of compo-
nents used.
Operation
The power of engine is transmitted from flywheel (2)
through outer body (1) to rubber couplings (7). After
absorption of torsional vibrations of the engine by
the rubber coupling, power is then transmitted to the
coupling (4) via output shaft (3). Then, power is fur-
ther transmitted from the coupling to the torque con-
verter input shaft through universal joint (5).

D375A-6R 10-41
Power train
Torque converter and PTO

Torque converter and PTO 10-41


a PTO: Abbreviation for Power Take Off

10-42 D375A-6R
Power train
Torque converter and PTO

D375A-6R 10-43
Power train
Torque converter and PTO

A: To transmission control valve 1. Cooling fan pump mounting location


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

10-44 D375A-6R
Power train
Torque converter and PTO

Outline 10-4 Structure 10-4


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

Conditions for lockup mode and torque converter


mode
Torque converter output shaft speed:
(rpm)
Gear speed
Torque converter
Lockup mode
mode
Min. 1,320 Min. 1,256
Forward 1st
Max. 1,830 Max. 1,830
Forward 2nd Min. 1,584 Max. 1,555
Forward 3rd Min. 1,350 Max. 1,320
Reverse 1st Min. 1,255 Max. 1,226
Reverse 2nd Min. 1,359 Max. 1,330
Reverse 3rd Min. 1,373 Max. 1,343
a While the transmission is shifting gears, the
torque converter comes into the torque convert-
er drive mode.

D375A-6R 10-45
Power train
Torque converter and PTO

Power transmitting route 10-45

When lockup clutch is "disengaged" and stator When lockup clutch is "engaged" and stator
clutch is "engaged" 10-45 clutch is "disengaged" 10-45

As drive case (4) and turbine (6) are disconnected from Drive case (4) is connected to turbine (6) and torque
each other, the torque converter works as an ordinary converter is locked up.
torque converter. Rear housing (9) and stator shaft (10) are connected to
Rear housing (9) and stator shaft (10) are connected to each other to fix stator (11).
each other to lock stator (11).
Engine power
Engine power O
O Coupling (1)
Coupling (1) O
O Input shaft (2), clutch housing (3), drive case (4) and
Input shaft (2), clutch housing (3), drive case (4) and pump (5) rotate together
pump (5) rotate together O
O Lockup clutch (9)
Oil is used as medium O
O Turbine (6) and boss (7)
Turbine (6) and boss (7) O
O Transmission input shaft (8)
Transmission input shaft (8)

10-46 D375A-6R
Power train
Torque converter and PTO

Oil flow 10-46

q The oil flows through the main relief valve and its
pressure is regulated to the set pressure or be-
low by the torque converter relief valve. It then
flows in inlet port (A), goes through the oil pas-
sages of rear housing (1) and pump shaft (2),
and flows into pump (3) .
q The oil is given centrifugal force by pump (3) and
flows in turbine (4) to transfer its energy to tur-
bine (4).
q The oil from turbine (4) is sent to stator (5) and
flows into pump (3) again.However, a part of the
oil is sent from outlet port (B) to oil cooler through
turbine (4) and stator (5).

D375A-6R 10-47
Power train
Torque converter control valve

Torque converter control valve 10-47

A: From power train pump


B: Lockup clutch oil pressure pickup port (LC)
C:Stator clutch oil pressure pickup port (SC)

1.Main relief valve and torque converter relief valve


2. Stator clutch ECMV
3. Lockup clutch ECMV
4.Torque converter inlet oil pressure sensor

10-48 D375A-6R
Power train
Torque converter control valve

Outline 10-48
q The torque converter valve is installed at the top of the rear housing of the toque converter, and consists
of the following four types of valves.
q Two types of ECMV are installed; the identifications and differences are shown in the table below.

Identification Fill switch


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

Main relief valve 10-48 Lockup clutch ECMV 10-48


The main relief valve maintains each hydraulic cir- The lockup clutch modulating valve maintains the
cuit pressure of the transmission, steering clutch, clutch pressure at the set pressure or below to pro-
steering brake and the lockup clutch and stator tect the lockup clutch circuit from abnormally high
clutch of torque converter constantly at the set pres- pressure, as well as increasing the clutch pressure
sure. gradually to the set pressure.
Set pressure : Set pressure: 1.3 MPa {13 kg/cm2}
2.63 2.92 MPa {26.8 29.8 kg/cm2}
(Engine at rated speed)

Torque converter relief valve 10-48


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

Stator clutch ECMV 10-48


The stator clutch modulating valve maintains the
clutch pressure at the set pressure or below to pro-
tect the stator clutch circuit from abnormally high
pressure, as well as increasing the clutch pressure
gradually to the set pressure.
Set pressure: 2.7 MPa {27 kg/cm2}

D375A-6R 10-49
Power train
Main relief valve and torque converter relief valve

Main relief valve and torque converter relief valve 10-49

1. Valve body
2. Torque converter relief valve
3. Main relief valve
4. Cover
5. Piston
6. Piston

10-50 D375A-6R
Power train
Main relief valve and torque converter relief valve

Operation of main relief valve 10-50 Operation of torque converter relief valve 10-50

The oil from the hydraulic pump flows through the fil- q The oil from the main relief valve flows through
ter, port (A) of the torque converter valve, and orifice port (C) to the torque converter, and at the same
(a) of torque converter relief valve (1) to chambe (B). time, also flows through orifice (b) of torque con-
verter relief valve (3) to chamber (D).
q When the oil pressure on the torque converter
exceeds the set pressure, the oil in chamber (D)
pushes piston (4), the reaction force of which
moves torque converter relief valve (3) to the
right to open port (C) and port (E).
Then the oil in port (C) is drained from port (E) to
the oil tank.

When the oil pressure in the circuit exceeds the set


pressure, the oil in chamber (B) pushes piston (2),
the reaction force of which moves spool (1) to the
left to open port (A) and port (C).
Above operation conducts the oil from port (C) to the
torque converter.

D375A-6R 10-51
Power train
Lockup clutch ECMV and stator clutch ECMV

Lockup clutch ECMV and stator clutch ECMV 10-51


a ECMV: Abbreviation for Electronic Control Modulation Valve
a Don't try to disassemble it since the adjustment for maintaining the performance will be required.

A: To clutch
P: From pump
T: Drain
DR: Drain
P1: Clutch oil pressure pickup port
P2: Pilot oil pressure pickup port

1. Fill switch connector


2. Proportional solenoid connector
3. Oil pressure detection valve
4. Fill switch
5. Proportional solenoid
6. Oil pressure control valve
7. Nameplate

10-52 D375A-6R
Power train
Lockup clutch ECMV and stator clutch ECMV

ECMV for lockup clutch 10-52 Operation 10-52


When traveling in torque converter drive mode 10-52
Outline 10-52
This valve is used to switch the clutch in addition to
regulate the clutch oil pressure to the set pressure.
It forms a modulation wave pattern, so the stator
clutch is engaged smoothly to reduce the shock
when shifting gear. In addition, it prevents genera-
tion of peak torque in the power train. As a result, it
provides a comfortable ride for the operator and
greatly increases the durability of the power train.

When changing from traveling in torque converter


drive mode to traveling in lockup drive mode

At gear shift (traveling in lockup drive mode)

When traveling in torque converter drive mode, cur-


rent does not blow to proportional solenoid (1).
Pressure control valve (3) drains the oil from clutch
port (A) through drain port (T), and lockup clutch is
"released".
Also at this time, fill switch (5) is turned "off" be-
cause oil pressure is not applied to pressure detec-
tion valve (4).

D375A-6R 10-53
Power train
Lockup clutch ECMV and stator clutch ECMV

When traveling in direct drive mode 10-53


(Traveling in torque converter drive mode to traveling in lockup drive mode)
During filling 10-53 During pressure regulation 10-53

When traveling in lockup drive mode, current flows q If current flows in proportional solenoid (1), the
in proportional solenoid (1), the oil pressure force solenoid generates thrust in proportion to the
balanced with the solenoid force is applied to cham- current. This thrust of the solenoid is balanced
ber (B) and pushes pressure control valve (3) to the with the sum of the thrust generated by the oil
left. As a result, pump port (P) and clutch port (A) pressure in clutch port and the reaction force of
open. When the clutch is filled with oil, oil pressure pressure control valve spring (2), and then the
pickup port (4) actuates and fill switch (5) is turned pressure is regulated.
"ON". q While shifting gears, the lockup clutch oil pres-
sure is reduced temporarily to reduce the shock
when shifting gear.
Oil pressure at this time is controlled so that the
lockup piston pushing force balances with the
inside pressure of torque converter.

10-54 D375A-6R
Power train
Lockup clutch ECMV and stator clutch ECMV

ECMV for stator clutch 10-54 Operation 10-54


When traveling in direct drive mode 10-54
Outline 10-54
This valve is used to switch the clutch in addition to
regulate the clutch oil pressure to the set pressure.
It forms a modulation wave pattern, so the stator
clutch is engaged smoothly to reduce the shock
when shifting gear. In addition, it prevents genera-
tion of peak torque in the power train. As a result, it
provides a comfortable ride for the operator and
greatly increases the durability of the power train.

Lockup drive mode travel to torque converter


drive mode travel

When traveling in lockup drive mode, current does


not flow to proportional solenoid (1).
Pressure control valve (3) drains the oil from clutch
port (A) through drain port (T), and stator clutch is
"released".
Also at this time, fill switch (5) is turned "off" be-
cause oil pressure is not applied to pressure detec-
tion valve (4).

D375A-6R 10-55
Power train
Lockup clutch ECMV and stator clutch ECMV

When traveling in torque converter drive mode 10-5


(Traveling in direct drive mode to traveling in torque converter drive mode)
During filling 10-5 During pressure regulation 10-5

When traveling in torque converter drive mode cur- If current flows in proportional solenoid (1), the sole-
rent flows in proportional solenoid (1), the oil pres- noid generates thrust in proportion to the current.
sure force balanced with the solenoid force is This thrust of the solenoid is balanced with the sum
applied to chamber (B) and pushes pressure control of the thrust generated by the oil pressure in clutch
valve (3) to the left. As a result, pump port (P) and port and the reaction force of pressure control valve
clutch port (A) open. When the clutch is filled with spring (2), and then the pressure is regulated.
oil, oil pressure pickup port (4) actuates and fill
switch (5) is turned "ON".

10-56 D375A-6R
Power train
Scavenging pump

Scavenging pump 10-56


Model: BAR (3) 63 + 277

A: Discharge port
B: Small pump suction port
C: Large pump suction port

1. Small pump
2. Large pump

D375A-6R 10-57
Power train
Transmission control

Transmission control 10-57


a Regarding the steering-related description in the PCCS lever operations, refer to the "Steering and brake
control".
a PCCS: Abbreviation for the Palm Command Control System

1. Brake pedal Lever positions


2. Lock lever [1]: Neutral
3. PCCS lever (Steering, forward-reverse, gearshift) [2]: Forward
3A. Upshift switch (Gear upshifts each time this [3]: Reverse
switch is pressed) [4]: OFF
3B. Downshift switch (Gear downshifts each [5]: Upshift
time this switch is pressed) [6]: Downshift
4. Transmission neutral switch [7]: Free
5. Cable [8]: Lock
6. Transmission control valve
7. Power train controller

10-58 D375A-6R
Power train
Transmission control

Outline 10-58
q The transmission is controlled with PCCS lever
(3).
The PCCS lever is used to perform steering
operation, directional changes and gear shift
operation.
q The machine has a safety mechanism that acti-
vates transmission neutral switch (4) to allow the
engine to start only when the lock lever (2) is set
to the "Lock" position.

D375A-6R 10-59
Power train
PCCS lever

PCCS lever 10-59

a Don't try disassemble PCCS lever because, adjustments will be required for the characteristics of voltage
output and operating efforts.

1. Boot 5. Screw
2. Bracket 6. Lever
3. Plate 7. Connector
4. Bolt

10-60 D375A-6R
Power train
PCCS lever

Function 10-60
Operating effort characteristics 10-60
Operation for forward and reverse travel Operation for left and right steering

q The control lever is held at 3 positions: "FOR- q Free return


WARD" , "NEUTRAL" and "REVERSE".

D375A-6R 10-61
Power train
PCCS lever

Output voltage characteristics 10-61


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

10-62 D375A-6R
Power train
PCCS lever

Gear shift of the machine 10-62


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

Gear shift operation 10-62


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

D375A-6R 10-63
Power train
Transmission

Transmission 10-63

10-64 D375A-6R
Power train
Transmission

A: 1st clutch oil pressure pickup port


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

1. Transmission control valve


2. Front case
3. Rear case
4. Lubricating oil relief valve

D375A-6R 10-65
Power train
Transmission

10-66 D375A-6R
Power train
Transmission

5. Transmission input shaft Outline 10-6


6. Front cover q The transmission is a "forward 3-speed and re-

7. Sun gear for reverse clutch (34 teeth) verse 3-speed" transmission which consists of
8. Ring gear for reverse (hub) (91 teeth) the planetary gear trains and the disc clutches.
9. Planetary pinion for reverse clutch (25 teeth) q Transmission selects and locks two clutches out

10. Ring gear for reverse clutch (84 teeth) of the five sets of planetary gear trains and disc
11. Sun gear for forward clutch (41 teeth) clutches hydraulically by using the control valve
12. Planetary pinion for forward clutch (25 teeth) to select one travel direction and one gear
13. Ring gear for forward clutch ( 91 teeth) speed.
14. Ring gear for 3rd clutch (91 teeth) q The transmission transfers the power received

15. Planetary pinion for 3rd clutch (25 teeth) by the transmission input shaft to the output
16. Sun gear for 3rd clutch (41 teeth) shaft by changing the gear speed (forward
17. Ring gear for 2nd clutch (93 teeth) 1st-3rd or reverse 1st-3rd) with any combination
18. Planetary pinion for 2nd clutch (23 teeth) of the forword or reverse clutch, and one of three
19. 2nd sun gear(47 teeth ) speed clutches.
20. 1st clutch gear
21. 1st clutch piston No. of plates and discs used
22. 1st clutch piston housing Clutch No. Number of plates Number of discs
23. Output shaft R clutch 6 6
24. Spacer F clutch 5 6
3rd clutch 4 4
25. Collar 2nd clutch 3 3
26. 1st clutch spring 1st clutch 5 6
27. 2nd carrier
28. Plate
29. Carrier for forward and 3rd clutches Combinations of clutches at respective gear speeds
30. Piston housing for forward and 3rd speed gear and reduction ratio
31. Carrier for reverse clutch Clutches
Gear speed Reduction ratio
32. Carrier for reverse clutch engaged
Forward 1st F x 1st 3.220
33. Clutch piston Forward 2nd F x 2nd 1.745
34. Clutch spring Forward 3rd F x 3rd 1.000
35. Clutch plate Neutral (*1)
36. Clutch disc Reverse 1st R x 1st 2.471
37. Washer spring Reverse 2nd R x 2nd 1.339
38. Pin Reverse 3rd R x 3rd 0.769
39. Tie bolt *1: The 1st or 2nd clutch is filled with low-pressure
oil.

D375A-6R 10-67
Power train
Transmission

Disc clutch 10-67

Structure 10-67 Operation 10-67


When clutch is "engaged" (locked) 10-67

q The disc clutch consists of piston (2), plates (3),


discs (4), pin (5), return spring (6), and washer q The oil from ECMV is routed to the back of piston
spring (7) to fix ring gear (1). (2) through oil passage of clutch housing (8) and
q Inside teeth of disc (4) are engaged with outside pushes piston (2) leftward.
teeth of ring gear (1). q Piston (2) presses plate (3) closely against disc
q Plate (3) and clutch housing (8) are assembled (4) to stop rotation of disc (4) by using friction
with pin (5). force generated between them.
q Since inside teeth of disc (4) are engaged with
outside teeth of ring gear (1), the ring gear (1) is
locked.
When clutch is "disengaged" (released) 10-67

q When the supply of oil from ECMV is shut off,


piston (2) is returned rightward by the force of re-
turn spring (6).
q This relieves the frictional force between plates
(3) and discs (4), making the ring gear (1) free.
q Washer spring (7) installed at pin portions be-
tween the plates acts to speed up the return of
the piston when the clutch is disengaged, and
also to separate the plates and discs cleanly to
prevent drag turning.

10-68 D375A-6R
Power train
Transmission

Oil circuit of speed clutch 10-68

q When the PCCS lever is in the "NEUTRAL" po-


sition , the 1st or 2nd gear speed is kept select-
ed.
q The piston chamber of the clutch corresponding
to the selected gear speed is filled with oil by
electronically controlling the oil circuit of each
clutch.
q When the PCCS lever is shifted from the "Neu-
tral" position to the "Forward" or "Reverse" posi-
tion, the pump is required to supply oil enough to
fill the piston chamber of the forward or reverse
clutch.
q When the gear speed is changed from "Forward
1st" to "Forward 2nd", the pump is required to
supply oil enough to press the plates and discs
of the 2nd clutch since the forward clutch has
been filled with the oil.
q The time lag at shifting gears is reduced by con-
trolling the oil circuit as explained above.

D375A-6R 10-69
Power train
Transmission

Power transmitting route 10-69


Forward 1st 10-69

10-70 D375A-6R
Power train
Transmission

F clutch ring gear (4) and 1st clutch gear (16) are locked hydraulically.
The power from torque converter
O
Input shaft (1)
O
F clutch sun gear (2)
O
F clutch planetary pinion (3)
O
F clutch and 3rd carrier (10)
O
3rd planetary pinion (11) o o o
O O
3rd ring gear (12)
O O
2nd carrier (13)
O O
2nd planetary pinion (14)
O O
2nd ring gear (15)
O O
1st clutch gear (16) 3rd sun gear (18)
O O
Output shaft (19) i i i

D375A-6R 10-71
Power train
Transmission

Forward 2nd 10-71

10-72 D375A-6R
Power train
Transmission

F ring gear (4) of F clutch and 2nd ring gear (15) of 2nd clutch are locked hydraulically.
The power from torque converter
O
Input shaft (1)
O
F clutch sun gear (2)
O
F clutch planetary pinion (3)
O
F clutch and 3rd clutch carrier (10)
O
3rd planetary pinion (11) o o o
O O
3rd clutch ring gear (12)
O O
2nd clutch carrier (13)
O O
2nd clutch planetary pinion (14)
O O
2nd clutch sun gear (17) 3rd clutch sun gear (18)
O O
Output shaft (19) i i i

D375A-6R 10-73
Power train
Transmission

Forward 3rd 10-73

10-74 D375A-6R
Power train
Transmission

F ring gear (4) of F clutch and 3rd ring gear (12) of 3rd clutch are locked hydraulically.
The power from torque converter
O
Input shaft (1)
O
F clutch sun gear (2)
O
F clutch planetary pinion (3)
O
F clutch and 3rd clutch carrier (10)
O
3rd clutch planetary pinion (11)
O
3rd clutch sun gear (18)
O
Output shaft (19)

D375A-6R 10-75
Power train
Transmission

Reverse 1st 10-75

10-76 D375A-6R
Power train
Transmission

R ring gear (7) of R clutch and 1st clutch gear (16) of 1st clutch are locked hydraulically.
The power from torque converter
O
Input shaft (1)
O
R clutch sun gear (5)
O
R clutch planetary pinion (6)
O
R clutch ring gear (9)
(R clutch carrier (8) is locked with R clutch ring
gear (7) = R clutch ring gear (9) rotation direc-
tion is opposite to that of input shaft (1))
O
F clutch and 3rd clutch carrier (10)
O
3rd planetary pinion (11) o o o
O O
3rd clutch ring gear (12)
O O
2nd clutch carrier (13)
O O
2nd clutch planetary pinion (14)
O O
2nd clutch ring gear (15)
O O
1st clutch gear (16) 3rd sun gear (18)
O O
Output shaft (19) i i i

D375A-6R 10-77
Power train
Transmission ECMV

Transmission ECMV 10-7


a ECMV: Abbreviation for Electronic Control Modulation Valve
a Don't try to disassemble it since adjustment for maintaining the performance will be required

10-78 D375A-6R
Power train
Transmission ECMV

A: 1st clutch oil pressure pickup port


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

1. 3rd clutch proportional solenoid


2. 1st clutch proportional solenoid
3. R clutch proportional solenoid
4. 2nd clutch proportional solenoid
5. F clutch proportional solenoid
6. 3rd clutch fill switch
7. 2nd clutch fill switch
8. 1st clutch fill switch
9. R clutch fill switch
10. F clutch fill switch
11. Connector for 1st clutch proportional solenoid
12. Connector for 3rd clutch proportional solenoid
13. Connector for R clutch proportional solenoid
14. Connector for 2nd clutch proportional solenoid
15. Connector for F clutch proportional solenoid
16. Connector for 3rd clutch fill switch
17. Connector for 2nd clutch fill switch
18. Connector for 1st clutch fill switch
19. Connector for R clutch fill switch
20. Connector for F clutch fill switch
21. Block
22. Pressure control valve
23. Pressure detection valve
24. Spring for pressure control valve

D375A-6R 10-79
Power train
Transmission ECMV

Outline of ECMV 10-79 ECMV and proportional solenoid 10-79


The ECMV consists of a pressure control valve and For each ECMV, a proportional solenoid is installed.
a fill switch. The proportional solenoid generates thrust shown
Pressure control valve below according to the command current from the
A proportional solenoid in this valve receives the controller.
current sent from the controller and this valve con- The thrust generated by the proportional solenoid is
verts it to oil pressure. applied to the pressure control valve spool to gener-
Fill switch ate oil pressure as shown in the figure below. Ac-
This switch detects that the clutch is filled with oil cordingly, controlling the command current that
and has the following functions. changes the thrust to operate the pressure control
1. Outputs a signal (a fill signal) to the controller to valve allows for controlling the oil flow and pressure
notify that filling is completed when the clutch is to the clutch.
filled with oil. Current of proportional solenoid - thrust characteris-
2. Keeps outputting signals (fill signals) to the tics
controller while oil pressure is applied to the
clutch to notify whether oil pressure is applied or
not .

Thrust of proportional solenoid - characteristics of


hydraulic pressure

ECMV and fill switch 10-79


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

10-80 D375A-6R
Power train
Transmission ECMV

Operation of ECMV 10-80 Before shifting gear [when draining] (range A in chart)
ECMV is controlled with the command current sent
from the controller to the proportional solenoid and
the fill switch output signal.
The proportional solenoid command current of EC-
MV, clutch input pressure, and fill switch output sig-
nal change with time shown below.

Under the condition where any current is not sent to


the proportional solenoid (1), pressure control valve
(3) drains the oil from clutch port (A) through drain
port (T).
Also at this time, fill switch (5) is turned "off" be-
cause oil pressure is not applied to pressure detec-
Phase A: Before shifting gear (oil is drained) tion valve (4).
Phase B: Filling phase
Phase C: Pressure build-up phase
Phase D: Filling phase (during triggering)
Point E: Start of filling
Point F: Finish of filling
a The logic is so made that the controller does not
recognize completion of filling even if the fill
switch is turned "ON" during triggering (phase
D).
When gear is shifted with gear shift switch, the
clutch discs and plates are pressed by piston. If
high pressure is suddenly applied, the piston sud-
denly engages the clutch, causing sudden start of
the machine and excessive shock.
ECMV reduces a shock at the start of the machine
by increasing the oil pressure applied to the piston
gradually to set pressure, and allows the clutch to be
smoothly "engaged". It aims to increase durability of
the components on the power transmitting route and
enhances an operator comfort.

D375A-6R 10-81
Power train
Transmission ECMV

During filling (range B in chart) Pressure regulation (range C in chart)

When current is supplied to proportional solenoid When current flows through proportional solenoid
(1) with no oil in the clutch, the force exerted by the (1), the solenoid generates thrust in proportion to
oil pressure, that is equal to the thrust of the sole- the current. The clutch circuit pressure builds up un-
noid, develops in chamber (B) and pushes pressure til the thrust of the solenoid is balanced with the sum
control valve (3) to the right. As a result, pump port of the force exerted by the oil pressure in clutch port
(P) and clutch port (A) are opened and oil starts fill- and the force of pressure control valve spring (2),
ing the clutch. When the clutch is filled with oil, pres- and then the pressure is settled.
sure detection value (4) actuates to turn "ON" fill
switch (5).

10-82 D375A-6R
Power train
Transmission lubrication relief valve

Transmission lubrication relief valve 10-82

1. Lubricating oil pressure measurement plug Function 10-82


2. Lubricating oil relief value spool The lubricating oil 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 lubricat-
ing oil.

Cracking pressure: 0.26 MPa {2.7 kg/cm2}

D375A-6R 10-83
Power train
Steering and brake control

Steering and brake control 10-83


a Regarding the transmission-related description of the operation of the PCCS lever, refer to the "Transmis-
sion control".
a PCCS: Abbreviation for the Palm Command Control System

10-84 D375A-6R
Power train
Steering and brake control

1. Brake pedal Outline 10-84


2. Lock lever q PCCS lever (3) sends electric signals to power

3. PCCS lever(steering, forward-reverse, gear shift) train controller (4). After receiving the signals,
4. Power train controller power train controller (4) sends a proportional
5. Limit switch current to the steering ECMV (6) to operate the
6. Steering ECMV steering clutch and brake.
7. Brake valve q Brake pedal (1) sends electric signals to power

8. Parking brake lever (from lock lever) train controller (4) through the potentiometer
9. Cable (11). Upon receiving those signals, power train
10. Rod (from brake pedal) controller (4) sends a proportional current to
11. Potentiometer steering ECMV (6) to operate the brake. In this
case, the right and left brakes operate at the
Lever and pedal locations same time to activate braking. Rod (10), as an
[1]: NEUTRAL emergency brake operating device, operates the
[2]: Forward straight-travel brake through brake valve (7). (only when the
[3]: Reverse straight-travel brake pedal is depressed fully)
[4]: Left clutch "OFF" q If you completely tilt PCCS lever (3) If you slight-

[5]: Left clutch "OFF", Left brake "ON" ly tilt PCCS lever (3) leftward, the left steering
[6]: Right clutch "OFF" clutch is partially disengaged, causing the ma-
[7]: Right clutch "OFF", Right brake "ON" chine to make a gradual left turn.
[8]: Brake "released" q If you completely tilt PCCS lever (3) leftward, the

[9]: Brake "ON" left steering clutch is "disengaged" completely


[10]: Free and the left steering brake is "applied" , causing
[11]: Lock the machine to make a sharp left turn.
q The lock lever (2) is connected to parking brake
lever (8) and serves as a parking brake lever.

D375A-6R 10-85
Power train
Transfer unit, bevel gear shaft and steering

Transfer unit, bevel gear shaft and steering 10-85


Machines without VHMS controller 10-85

1. Transmission 10. L.H. steering clutch ECMV


2. Input shaft 11. R.H. steering clutch ECMV
3. Steering unit 12. Sudden stop prevention valve
4. Breather
5. Parking brake valve
6. L.H. steering brake ECMV
7. R.H. steering brake ECMV
8. Transmission output shaft speed sensor
9. Filter

10-86 D375A-6R
Power train
Transfer unit, bevel gear shaft and steering

Machines equipped with VHMS controller 10-86

1. Transmission 10. L.H. steering clutch ECMV


2. Input shaft 11. R.H. steering clutch ECMV
3. Steering unit 12. Sudden stop prevention valve
4. Breather
5. Parking brake valve
6. L.H. steering brake ECMV
7. R.H. steering brake ECMV
8. Transmission output shaft speed sensor
9. Filter

D375A-6R 10-87
Power train
Transfer unit, bevel gear shaft and steering

Transfer unit and bevel pinion 10-87


Machines without VHMS controller 10-87

1. Input shaft Outline 10-87


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

10-88 D375A-6R
Power train
Transfer unit, bevel gear shaft and steering

Machines equipped with VHMS controller 10-8

1. Input shaft Outline 10-8


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

D375A-6R 10-89
Power train
Transfer unit, bevel gear shaft and steering

Bevel gear shaft, steering clutch and brake 10-89

10-90 D375A-6R
Power train
Transfer unit, bevel gear shaft and steering

1. Output shaft Outline 10-90


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

D375A-6R 10-91
Power train
Steering control valve

Steering control valve 10-91

10-92 D375A-6R
Power train
Steering control valve

A: Left clutch pressure pickup port Outline 10-92


B: Right clutch pressure pickup port q Four ECMV's are installed on the valve seat of

C: Left brake pressure pickup port the steering control valve to control the steering
D: Right brake pressure pickup port clutch and steering brake.
E: To left clutch q The steering control valve is located in the circuit

F: To left lubrication circuit between the power train pump and the pistons of
G: To left brake the steering clutch and steering brake. It con-
H: To right clutch sists of two sets of the steering clutch ECMV
J: To right lubrication circuit (L.H. and R.H.) and two sets of the steering
K: To right brake brake ECMV (L.H. and R.H.).
L: Bevel gear shaft lubricating oil inlet port q The steering control valve sends the oil from the

M: To pin puller solenoid valve power train pump to the both left and right sides
N: From pin puller solenoid valve of steering clutches and steering brakes to con-
P: From pump trol respective disc clutches and disc brakes.
q When the PCCS lever is leaned to the right or

1. Left steering clutch ECMV left, the steering clutch is disengaged. The steer-
2. Right steering clutch ECMV ing brake will operate by leaning further the
3. Sudden stop prevention valve PCCS lever.
4. Parking brake valve q The controller sends signals to each ECMV ac-

5. Left steering brake ECMV cording to the right or left travel of the PCCS le-
6. Right steering brake ECMV ver and controls the clutch and brake for the
7. Filter gradual or sharp turns.
8. Valve seat q When the brake pedal is depressed, the control-
ler sends the command current to the steering
brake ECMV according to the pedal travel to ap-
ply the L.H. and R.H. brakes to stop the ma-
chine.
q The controller that is connected electrically to
the PCCS lever and brake pedal operates the
steering clutch and steering brake by controlling
each ECMV.
q The sudden stop prevention valve is installed to
prevent the machine from stopping suddenly
when a failure occurs in the electrical system.
q When the parking brake lever is set in the "lock"
position, the parking brake valve port is switched
to drain the oil between the L.H. and R.H. steer-
ing brake ECMV and the brake piston to apply
the brake. The parking brake valve is connected
to the brake pedal by the linkage.

D375A-6R 10-93
Power train
Steering clutch ECMV and Steering brake ECMV

Steering clutch ECMV and Steering brake ECMV 10-93


a ECMV: Abbreviation for Electronic Control Modulation Valve
a Don't try to disassemble ECMV since adjustment for maintaining the performance will be required.

A : To clutch or brake *1:


P : From pump Clutch to use ECMV Stamp of the name plate
T : Drain Steering clutch, Steering brake R*******
Dr: Drain
P1: Clutch or brake oil pressure pickup port Outline 10-93
Each ECMV keeps the steering clutch pressure and
1. Fill switch connector steering brake pressure to the set pressure and
2. Proportional solenoid connector switches the circuit to the piston chamber of the
3. Pressure detection valve steering clutch and steering brake.
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate (*1)

10-94 D375A-6R
Power train
Steering clutch ECMV and Steering brake ECMV

Outline of ECMV 10-94


The ECMV consists of a pressure control valve and
a fill switch.
Pressure control valve
A proportional solenoid in this valve receives a cur-
rent sent from the steering controller and this valve
converts it to an oil pressure.
Fill switch
This is a switch to detect that a clutch or brake is
filled with oil and has the following functions.
1. At the moment when the clutch or brake is filled
with oil, the fill switch outputs the signal (fill
signal) to the controller to notify the finishing of
filling.
2. While the oil pressure is applied to the clutch or
brake, the fill switch outputs the signal (fill signal)
to the controller to notify the presence of the oil
pressure.

ECMV and proportional solenoid 10-94


Each ECMV is equipped with a proportional sole-
noid.
The solenoid generates thrust according to the com-
mand current from the controller. The thrust gener-
ated by the proportional solenoid acts on the spool
of the pressure control valve and the valve gener-
ates the oil pressure. Accordingly, controlling the
command current that changes the thrust to operate
the pressure control valve allows for controlling the
oil flow and oil pressure.

ECMV and fill switch 10-94


Each ECMV is equipped with a fill switch.
If the clutch is filled with oil, the fill switch is turned
"ON" by the pressure of the clutch. This signal al-
lows the oil pressure to build up.

Operation of ECMV 10-94


ECMV is controlled by the command current sent
from the controller to the proportional solenoid and
the fill switch output signal.

D375A-6R 10-95
Power train
Steering clutch ECMV and Steering brake ECMV

When PCCS lever is in "NEUTRAL" position, brake pedal is "RELEASED", and parking brake lever is
in "FREE" position: Straight travel 10-95
(L.H. and R.H. clutches are "engaged", L.H. and R.H. brakes are "released", and parking brake is "released".)

q When the PCCS lever is in "neutral" position and q The oil in port (Pb) of the brake ECMV flows in
the brake pedal is "released", proportional sole- port (E) and pushes valve (7) to the left to con-
noid (1) of the clutch ECMV is de-energized and nect port (Pb) to port (B) and disconnect port (B)
the sealing part by ball (2) is opened. from port (Dr). At this time, the oil flows in the
q The oil from the power train pump flows through port behind the brake piston. As the oil pressure
port (Pc) of the clutch ECMV to orifice (a), then it rises, the brake piston is pushed to the left to
is drained through the sealing part by ball (2). compress the brake spring, then the brake is re-
q Valve (3) is moved to the right by the force of leased.
spring (4) to disconnect port (Pc) from port (C), q When the parking brake lever is in "free" posi-
and connect port (C) to port (Dr). At this time, the tion, as the parking brake valve is closed, the oil
oil from the port behind the clutch piston is in the brake circuit is not drained.
drained through port (C) and the clutch is "en-
gaged" by the force of the clutch spring.
q The oil pressure in the brake circuit, etc. is main-
tained by orifice (a).
q Proportional solenoid (5) of the brake ECMV is
energized and pushes ball (6) to the left to close
the sealing part.

10-96 D375A-6R
Power train
Steering clutch ECMV and Steering brake ECMV

When PCCS lever is in "HALFWAY TO LEFT" position, brake pedal is "RELEASED", and parking brake
lever is in "FREE" position: Gradual left turn 10-96
(L.H. clutch is "disengaged", L.H. brake is "semi-released", R.H. clutch is "engaged", R.H. brake is "released",
and parking brake is "released".)

q When the PCCS lever is "operated halfway to q The oil in port (Pb) of the brake ECMV flows in
left" and the brake pedal is "released", propor- port (E) and pushes valve (7) to the left. The cir-
tional solenoid (1) of the L.H. clutch ECMV is en- cuit pressure after port (B) depends on the com-
ergized and the sealing part by ball (2) is closed. mand current output from the controller to
q The oil from the power train pump flows through proportional solenoid (5) according to the travel
port (Pc) of the clutch EMCV and orifice (a) to of the PCCS lever.
port (F) and pushes valve (3) to the left to con- q Proportional solenoid (5) generates the thrust in
nect port (Pc) to port (C) and disconnect port (C) proportion to the command current. When this
from port (Dr). At this time, the oil flows in the thrust is balanced with the sum of the force gen-
port behind the clutch piston. As the oil pressure erated by the pressure in the port behind the
rises, the clutch piston is pushed to the left to brake piston and the force of spring (8), the
compress the clutch spring, then the clutch is brake pressure that determines braking force is
"disengaged". set up.
q Proportional solenoid (5) of the brake ECMV is q Accordingly, if the travel of the PCCS lever is
energized and pushes ball (6) to the left to close short, the cricuit pressure after port (B) is set
the sealing part. high and the brake is turned from "released" to
"semi-released". If the travel of the PCCS lever
is long, the circuit pressure after port (B) is set
low and the brake is turned from "semi-released"
to "applied".

D375A-6R 10-97
Power train
Steering clutch ECMV and Steering brake ECMV

q When the parking brake lever is in "free" posi-


tion, as the parking brake valve is closed, the oil
in the brake circuit is not drained.

10-98 D375A-6R
Power train
Steering clutch ECMV and Steering brake ECMV

When PCCS lever is in "FULLY TO LEFT" position, brake pedal is "RELEASED", and parking brake
lever is in "FREE" position: Sharp left turn 10-98
(L.H. clutch is "disengaged", L.H. brake is "applied", R.H. clutch is "engaged", R.H. brake is "released", and
parking brake is "released".)

q When the PCCS lever is moved from "halfway to q The oil pressure in the clutch circuit, etc. is main-
left" to "fully to left" position, proportional sole- tained by orifice (b).
noid (5) of the L.H. brake ECMV is de-energized q When the parking brake lever is in "free" posi-
and the sealing part by ball (6) is fully opened. tion, as the parking brake valve is closed, the oil
q Since the oil in port (E) is drained through the in the brake circuit is not drained.
sealing part, valve (7) is moved to the right by the
force of spring (8) to disconnect port (Pb) from
(B) and connect port (B) to port (Dr). At this time,
the oil from the port behind the brake piston is
drained through port (B) and the brake is "ap-
plied" by the force of the brake spring.
q The oil from the power train pump flows through
port (Pb) of the brake ECMV and orifice (b), then
it is drained through sealing part by ball (6).

D375A-6R 10-99
Power train
Steering clutch ECMV and Steering brake ECMV

When PCCS lever is in "NEUTRAL" position, brake pedal is "DELPRESSED", and parking brake lever
is in "FREE" position: Stop 10-9
(L.H. and R.H. clutches are "engaged", L.H. and R.H. brakes are "applied", and parking brake is "released".)

q When the brake pedal is depressed fully, propor-


tional solenoids (5) of L.H. and R.H. brake ECM-
VS are de-energized to open the sealing part by
ball (6).
q The controller outputs the command current to
proportional solenoids (5)according to the brake
pedal travel.
q Proportional solenoid (5) generates the thrust in
proportion to the command current. When this
thrust is balanced with the sum of the thrust ex-
erted by the pressure in the port behind the
brake piston and the force of spring (8), the
brake pressure that determines the braking force
is set up.
q Since the PCCS lever is in "neutral" position,
proportional solenoid (1) of L.H. and R.H. clutch
ECMVs are de-energized and L.H. and R.H.
clutch are "engaged".
q When the brake pedal is depressed, the parking
brake valve connected to the pedal by the link-
age operates to connect the brake circuit to the
drain circuit, allowing the oil to drain.

10-100 D375A-6R
Power train
Steering clutch ECMV and Steering brake ECMV

When PCCS lever is in "NEUTRAL" position, brake pedal is "RELEASED" and parking brake lever is
in "LOCK" position: Parking 10-101
(L.H. and R.H. clutches are "engaged", L.H. and R.H. brakes are "applied", and parking brake is "applied".)

q When the parking brake lever is set to the "lock"


position, spool (1) is moved to the left to connect
ports (A) and (B) to port (C).
q The oil in the port behind the brake piston is
drained from port (C) through ports (A) and (B).
q The oil pressure in the port behind the brake pis-
ton continues to decrease, then the brake is fully
"applied" and kept applied.
q When the engine is started again, as ports (A)
and (B) are still connected to port (C), the brake
is kept applied.
q When the parking brake lever is moved to "free"
position, spool (1) moves to the right to discon-
nect port (A) and (B) from (C). Then the oil from
the brake ECMV flows to the port behind the
brake piston and the brake is "released".

D375A-6R 10-101
Power train
Parking brake valve

Parking brake valve 10-10

1. Spool Outline 10-10


2. Valve body q The parking brake valve is installed to the steer-
ing control valve, and spool (1) operates with the
parking brake lever.
q When the parking brake lever is in "lock" posi-
tion, the brake is applied by draining the pressur-
ized oil for the L.H. and R.H. steering brakes.

10-102 D375A-6R
Power train
Sudden stop prevention valve

Sudden stop prevention valve 10-102

Outline 10-102
q The sudden stop prevention valve is installed to
prevent the machine from stopping suddenly
when an abnormality takes place in the electric
system.
q Sudden stop prevention valve (1) is installed in
the drain circuit of the brake ECMV so that the
pressure of port (DR) does not drop suddenly
when brake ECMV coil (2) is de-energized, and
consequently the sudden braking can be avoid-
ed when coil (2) of brake ECMV is de-energized.
q If an abnormality takes place in the electric sys-
tem, also coil (3) of the sudden stop prevention
valve (1) is de-energized. Then, the oil in port
(DR) is drained through orifice (a) so that the
brake is applied gradually.

D375A-6R 10-103
Power train
Sudden stop prevention valve

10-104 D375A-6R
Power train
Final drive

Final drive 10-103

Outline 10-103
q The final drive uses a single stage spur gear and
single stage planetary gear reduction system.
The lubrication is of splash type using the rota-
tion of the gears.
The final drive can be removed and installed in a
single unit.
q Floating seal (1) is installed to the rotating por-
tion of the sprocket to prevent the entry of dirt or
sand and to prevent leakage of lubricating oil.

D375A-6R 10-105
Power train
Final drive

10-106 D375A-6R
Power train
Final drive

1. Floating seal
2. Sun gear
3. Carrier
4. Hub
5. Cover
6. Sprocket boss
7. Sprocket teeth
8. Floating seal guard
9. Cover
10. Planetary pinion
11. Ring gear
12. Cover
13. No.1 gear
14. No.1 gear hub
15. No.1 pinion
16. Final drive case
17. Bearing cage
18. Boss
19. Shaft
20. Wear guard
21. Pivot shaft

D375A-6R 10-107
Power train
Final drive

Path of power transmission 10-106

10-108 D375A-6R
Power train
Final drive

q The power from the bevel gear shaft and steer-


ing clutch is transmitted to 1st pinion (15) and
then to 1st gear(13) to rotate sun gear(2) being
meshed with the 1st gear.
The rotation of sun gear (2) is transmitted to
planetary pinions (10), but ring gear (11), which
is meshed with the planetary pinions, is fixed to
cover (9), so the planetary pinions rotate along
the ring gear while moving around the sun gear.
Then, the rotating force of sun gear (2) functions
as the rotating force of carrier (3) , which
supports the planetary pinions, and is trans-
mitted to sprocket hub (4).
The rotating direction of carrier (3) is the same
as that of sun gear (2).
The rotating force transmitted to sprocket hub
(4) is transmitted to sprocket teeth (7).

D375A-6R 10-109
Undercarriage and frame
Track frame

Undercarriage and frame 10-108


Track frame 10-108

1. Idler Outline 10-108


2. Recoil spring assembly q The track rollers are mounted on the K-shaped

3. Idler cushion bogies, thereby increasing the actual contact


4. Track frame area between ground and the track even on an
5. Sprocket uneven ground to increase drawbar pull.
6. Sprocket cover q Because a rubber pad is mounted on a

7. Track roller bogie K-shaped bogie, the shock from a road surface
8. Track roller is absorbed.
9. Cap
10. Idler yoke Track roller arrangement 10-108
11. Cylinder Track roller flange type
12. Guide
1st 2nd 3rd 4th 5th 6th 7th

S D S D S D S

S: Single flange type


D: Double flange type

10-110 D375A-6R
Undercarriage and frame
Track frame

D375A-6R 10-111
Undercarriage and frame
Idler cushion

Idler cushion 10-1 0

1. Yoke Outline 10-1 0


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

10-112 D375A-6R
Undercarriage and frame
Track roller bogie

Track roller bogie 10-1 1

1. Guide Outline 10-1 1


2. Cap q The track roller is mounted on the miner bogie

3. Track roller assembly (double flange type) (6) so that the track roller and track shoe can be
4. Major bogie touched constantly.
5. Rubber mount q The vibration from a road surface is absorbed by

6. Miner bogie the rubber mount (5).


7. Track roller assembly
8. Cover
9. Cartridge pin

D375A-6R 10-113
Undercarriage and frame
Main frame

Main frame 10-1 2

10-114 D375A-6R
Undercarriage and frame
Main frame

1. Main frame
2. Bracket
3. Cap
4. Cushion
5. Plate
6. Cage
7. Clamp
8. Seal
9. Cover
10. Coupling
11. Cap
12. Cushion
13. Bushing
14. Flange
15. Cushion spacer

D375A-6R 10-115
Undercarriage and frame
Suspension

Suspension 10-1 4

10-116 D375A-6R
Undercarriage and frame
Suspension

*1. Shown in the figure is the left suspension of the single tilt specification machines.
*2. Shown in the figure are the right suspension of single tilt specification machines, and
the right and left suspensions of the dual tilt specification machines.

D375A-6R 10-117
Undercarriage and frame
Suspension

1. Equalizer bar
2. Pivot shaft assembly
3. Cover
4. Thrust plate
5. Thrust plate
6. Pivot shaft
7. Seal cage cover
8. Cover
9. Seal
10. Bushing
11. Side pin
12. Center pin
13. Bushing

Outline 10-1 6
The track frame allows its front part to move up and
down on the pivot shaft (6) at the tail connected to
its rear part.
The equalizer (1) can rock on the center pin (12) and
is connected to the left and right track frames with
side pins (11).

10-118 D375A-6R
Hydraulic system
Work equipment hydraulic piping diagram

Hydraulic system 10-1 7


Work equipment hydraulic piping diagram 10-1 7

Blade system 10-1 7

Semi-U dozer + Single tilt

1. Blade tilt cylinder


2. R.H. blade lift cylinder
3. Control valve
4. Hydraulic tank
5. Work equipment pump (HPV190)
6. L.H. blade lift cylinder

D375A-6R 10-119
Hydraulic system
Work equipment hydraulic piping diagram

Full-U dozer + Dual tilt

1. Blade tilt cylinder


2. R.H. blade lift cylinder
3. Control valve
4. Hydraulic tank
5. Work equipment pump (HPV190)
6. L.H. blade lift cylinder
7. Blade pitch cylinder

10-120 D375A-6R
Hydraulic system
Work equipment hydraulic piping diagram

Ripper system 10-1 9

Variable multi-shank ripper (Figure shows a dual tilt specification machine)

1. Control valve
2. Ripper tilt cylinder
3. Ripper lift cylinder

D375A-6R 10-121
Hydraulic system
Work equipment hydraulic piping diagram

Variable giant ripper (Figure shows a dual tilt specification machine)

1. Control valve
2. Steering control valve
3. Ripper tilt cylinder
4. Ripper lift cylinder
5. Pin puller cylinder (from power train hydraulic cir-
cuit)
6. Solenoid valve (for pin-puller)

10-122 D375A-6R
Hydraulic system
PPC control piping diagram

PPC control piping diagram 10-121

Blade and ripper control 10-121


(Figure shows a dual tilt specification machine)

1. Accumulator
2. Check valve
3. Blade control PPC valve
4. Ripper control PPC valve
5. PPC lock valve
6. Cooling fan pump
7. Self-pressure reducing valve
8. Hydraulic pump

D375A-6R 10-123
Hydraulic system
Work equipment control

Work equipment control 10-12

(Figure shows a dual tilt dozer specification machine equipped with pin puller cylinder)

10-124 D375A-6R
Hydraulic system
Work equipment control

1. Work equipment lock lever


2. Blade control lever
3. Tilt/pitch selector switch (only for dual tilt dozer specification)
4. Ripper control lever (only for ripper installed machine)
5. Pin puller swith (only for giant ripper installed machine)
6. PPC lock valve
7. Work equipment lock switch

Lever positions 10-123


[1]: Blade "HOLD"
[2]: Blade "LOWER"
[3]: Blade "FLOAT"
[4]: Blade "RAISE"
[5]: Blade "LEFT TILT/*PITCH BACK"
[6]: Blade "RIGHT TILT/*PITCH DUMP"
* Activated when the pitch selector switch is turned
"ON" (dual tilt specification only)
[7]: Ripper "HOLD"
[8]: Ripper "RAISE"
[9]: Ripper "LOWER"
[10]: Ripper "TILT IN"
[11]: Ripper "TILT BACK"
[12]: FREE
[13]: LOCK
[14]: Dual tilt selector switch "OFF"
[15]: Dual tilt selector switch "ON"
[16]: Pitch selector switch "OFF" auto return
[17]: Pitch selector switch "ON"
[18]: Pin puller switch "PUSH OUT"
[19]: Pin puller switch "PUSH IN"

Outline 10-123
q The work equipment control employs a PPC sys-
tem which uses PPC valves to move respective
spools of the control valve.
q Work equipment lock lever (1) is interconnected
with PPC lock valve (6), and when it is set to the
"LOCK" position, the flow of oil in the PPC circuit
is stopped.
q Work equipment lock lever (1) is also interlocked
with work equipment lock switch (7). When work
equipment lock lever (1) is in "Lock" position,
work equipment lock switch (7) is turned OFF,
and the engine can be started..
And when work equipment lock lever (1) is in
"Free" position, work equipment lock switch (7)
is turned ON, and engine can not be started.

D375A-6R 10-125
Hydraulic system
Hydraulic tank

Hydraulic tank 10-124

10-126 D375A-6R
Hydraulic system
Hydraulic tank

1. Oil filler port cap


2. Hydraulic oil filter element
3. Spring
4. Suction valve
5. Cover
6. Cover
7. Hydraulic tank
8. Strainer (suction)
9. Sight gauge
10. Pressure valve + Breather
11. Drain valve
12. Drain plug
13. Strainer (over flow)

Specified value

Tank capacity (l) 210

Hi (l) 144
Hydrau-
lic tank Level inside
Center (l) 130
tank
Low (l) 112
Cracking pressure of
pressure valve 17 2.5
{0.17 0.025}
(kPa {kg/cm2})
Breather
Operating pressure of
vacuum valve 2 0.3
{0.02 0.003}
(kPa {kg/cm2})

Specified value
Cracking pressure 150 30
(kPa {kg/cm2}) {1.5 0.3}
Hydraulic
Mesh size (m) 30/8
oil filter
Filtering area (cm2) 17600
Filtering oil flow (l/min) 720
Strainer
Mesh size (m) 40
(over flow)
Mesh size
105
Strainer (m)
(suction) Filtration area
3,600
(cm2)

D375A-6R 10-127
Hydraulic system
Accumulator

Accumulator 10-126
For PPC valve 10-126
Function 10-126
The accumulator is installed between the self-pres-
sure reducing valve and the PPC valve. Even if the
engine is stopped with the work equipment raised,
the pressure of the nitrogen gas compressed inside
the accumulator sends the pilot pressure to the main
control valve to actuate it and enable the work
equipment to lower under its own weight.
Operation 10-126
q After the engine is stopped, when the PPC valve
is at neutral, chamber (A) inside the bladder is
compressed by the oil pressure in chamber (B).
q When the PPC valve is operated, the oil pres-
sure in chamber (B) goes below 2.9 MPa
{30 kg/cm2}, and the pressure of the nitrogen
gas in chamber (A) expands the bladder, so the
oil in chamber (B) acts the pilot pressure and ac-
tuates the main control valve.

1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port

Specification 10-126
Type of gas: Nitrogen gas
Gas volume: 300 cc
Max. working pressure: 3.1 MPa {32 kg/cm2}
Min. working pressure: 1.2 MPa {12 kg/cm2}

10-128 D375A-6R
Hydraulic system
PPC lock valve

PPC lock valve 10-127


Outline 10-127
The PPC lock valve is installed in the PPC circuit be-
tween the PPC charge valve and PPC valve. If the
work equipment lock lever is placed at the LOCK po-
sition, the PPC lock valve interlocked with the work
equipment lock lever is actuated to stop the oil in the
PPC circuit, preventing the work equipment from
moving.

1. Lever
2. End cap
3. Ball
4. Sheet
5. Valve body

D375A-6R 10-129
Hydraulic system
PPC valve

PPC valve 10-128

Blade PPC valve 10-128


Appearance 10-128

P: From self-pressure reducing valve P3: To blade tilt valve (LEFT TILT) PPC port
P1: To blade lift valve (LOWER) PPC port P4: To blade tilt valve (RIGHT TILT) PPC port
P2: To blade lift valve (RAISE) PPC port T: To hydraulic tank

10-130 D375A-6R
Hydraulic system
PPC valve

Sectional view 10-129

1. Spool 8. Plate
2. Metering spring 9. Retainer
3. Centering spring 10. Valve body
4. Piston 11. Filter
5. Disc
6. Nut (for lever connection)
7. Joint

D375A-6R 10-131
Hydraulic system
PPC valve

Operation 10-130
Neutral 10-130
For blade lift For blade tilt 10-130
Ports (A) and (B) of the blade lift valve of the control Ports (C) and (D) of the blade tilt valve of the control
valve and ports (P1) and (P2) of the PPC valve are valve and ports (P3) and (P4) of the PPC valve are
connected through fine control hole (f) of spool (1) to connected through fine control hole (f) of spool (1) to
drain chamber (D). drain chamber (D).

10-132 D375A-6R
Hydraulic system
PPC valve

When blade control lever is in fine control range10-131


(Neutal o Fine control range) 10-131
q When piston (4) is pushed by disc (5), retainer
(9) is pushed and spool (1) is also pushed by
metering spring (2), and moves down.
q Accordingly, fine control hole (f) is disconnected
from drain chamber (D) and connected to pump
pressure chamber (PP) almost simultaneously,
and then the pilot oil flows from port (P1) through
fine control hole (f) to port (B).
q When the pressure at port (P1) becomes higher,
spool (1) is pushed back and fine control hole (f)
is shut off from pump pressure chamber (PP). At
almost the same time, it is connected to drain
chamber (D) to release the pressure at port (P1).
q As a result, spool (1) moves up and down until
the force of metering spring (2) is balanced with
the force exerted by the pressure at port (P1).
q The positional relationship between spool (1)
and valve body (10) [where fine control hole (f) is
between drain chamber (D) and pump pressure
chamber (PP)] does not change until retainer (9)
comes in contact with spool (1).
q Since metering spring (2) is compressed in pro-
portion to the travel of the control lever, the pres-
sure in port (P1) rises in proportion to the travel
of the control lever.
q Accordingly, the control valve spool moves to a
position at which the pressure in port (B) [equal
to the pressure in port (P1)] is balanced with the
force of the control valve spool return spring.

D375A-6R 10-133
Hydraulic system
PPC valve

When blade control lever is in fine control range At stroke end 10-132
(When blade control lever is returned) 10-132 q When disc (5) pushes down piston (4) and re-
q When disc (5) begins to return, spool (1) is tainer (9) pushes down spool (1), fine control
pushed up by the force of centering spring (3) hole (f) is disconnected from drain chamber (D)
and the force exerted by the pressure at port and connected to pump pressure chamber (PP).
(P1). q Accordingly, the pilot oil flows through fine con-
q Because of this, fine control hole (f) is connected trol hole (f) and port (P1) into port (B) and pushes
to drain chamber (D), and the pressurized oil at the control valve spool.
port (P1) is released. q The return oil from port (A) flows through port
q When the pressure in port (P1) lowers too much, (P2) and fine control hole (f') into drain chamber
spool (1) is pushed down by metering spring (2) (D).
and fine control hole (f) is disconnected from
drain chamber (D)and connected to pump pres-
sure chamber (PP) almost simultaneously.
Then, the oil at the pump pressure is supplied
until the pressure in port (P1) is restored to the
level corresponding to the position of the lever.
q When the control valve spool returns, the oil in
drain chamber (D) flows in through fine control
hole (f') of the valve which is not operated and
then flows through port (P2) into port (A) to sup-
ply oil.

10-134 D375A-6R
Hydraulic system
PPC valve

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

D375A-6R 10-135
Hydraulic system
PPC valve

10-136 D375A-6R
Hydraulic system
PPC valve

Ripper PPC valve 10-135


Appearance 10-135

P: From self-pressure reducing valve


P1: To ripper tilt valve PPC port
P2: To ripper tilt valve PPC port
P3: To ripper lift valve PPC port
P4: To ripper lift valve PPC port
T: To tank

D375A-6R 10-137
Hydraulic system
PPC valve

Sectional view 10-136

10-138 D375A-6R
Hydraulic system
PPC valve

1. Spool
2. Piston
3. Disc
4. Nut (for lever connection)
5. Joint
6. Plate
7. Retainer
8. Valve body
9. Filter

D375A-6R 10-139
Hydraulic system
PPC valve

Operation 10-138 q As a result, spool (1) moves up and down so that


Neutral 10-138 the force of metering spring (2) is balanced with
Ports (A) and (B) of the control valve and ports (P1) the force exerted by pressure in port (P1).The
and (P2) of the PPC valve are connected to drain positional relationship between spool (1) and
chamber (D) through fine control hole (f) of spool (1) valve body (10) [where fine control hole (f) is be-
. tween drain chamber (D) and pump pressure
chamber (PP)] does not change until retainer (9)
comes in contact with spool (1).
q Since metering spring (2) is compressed in pro-
portion to the travel of the control lever, the pres-
sure in port (P1) rises in proportion to the travel
of the control lever.
q The control valve spool moves to a position
where the pressure of port (A) (same as pres-
sure at port (P1)] and the force of the return
spring of the control lever.

When ripper control lever is in fine control range10-138


(Neutal o Fine control range) 10-138
q When piston (4) is pushed by disc (5), retainer
(9) is pushed and spool (1) is also pushed down
through metering spring (2).
q Accordingly, fine control hole (f) is disconnected
from drain chamber (D) and connected to pump
pressure chamber (PP) almost simultaneously,
and then the pilot oil flows from port (P1) to port
(A) through fine control hole (f).
q When the pressure at port (P1) becomes higher,
spool (1) is pushed back. and fine control hole (f)
is shut off from pump pressure chamber (PP). At
almost the same time, it is connected to drain
chamber (D) to release the pressure at port (P1).

10-140 D375A-6R
Hydraulic system
PPC valve

When blade control lever is in fine control range10-139 At stroke end 10-139
(When control lever is returned) 10-139 q When disc (5) pushes down piston (4) and re-
q When disc (5) begins to return, spool (1) is tainer (9) pushes down spool (1), fine control
pushed up by the force of centering spring (3) hole (f) is disconnected from drain chamber (D)
and the force exerted by the pressure at port and connected to pump pressure chamber (PP).
(P1). q The pilot oil flows through fine control hole (f)
q Fine control hole (f) is connected to drain cham- and port (P1) into port (A) and pushes the control
ber (D), and the pressurized oil at port (P1) is re- valve spool.
leased. q The return oil from port (B) flows through port
q When the pressure at port (P1) goes down too (P2) and fine control hole (f') into drain chamber
far, spool (1) is pushed down by metering spring (D).
(2). Fine control hole (f) is shut off from drain
chamber (D), and almost simultaneously, it is
connected to pump pressure chamber (PP). The
oil at pump pressure is supplied until the pres-
sure at port (P1) recovers to a pressure equiva-
lent to the position of the lever.
q When the spool of the control valve returns, the
oil in drain chamber (D) flows in through fine con-
trol hole (f') in the valve on the side that is not in
operated. The oil passes through port (P2) and
enters port (B) to replenish the port with pressur-
ized oil.

D375A-6R 10-141
Hydraulic system
Piston valve

Piston valve 10-140


For blade lift cylinder 10-140
Outline 10-140
The piston valve is installed on the piston in the
blade lift cylinder. When the piston reaches its
stroke end, the valve releases the oil from the hy-
draulic pump to reduce the oil pressure being exert-
ed 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 let-
ting the oil escape from the cylinder.

Operation 10-140
Piston valve "CLOSED" 10-140
Pressurized oil from the work equipment pump acts
on piston (2) and piston valve (3).
Then, piston valve (3) is pushed to the right and con-
tacts the tapered part of piston valve seat (4) to seal
in the oil. As a result, the pressure in the cylinder ris-
es to move piston (2) to the right.

Piston valve "OPEN" 10-140


Just before piston rod (1) reaches the end of its
stroke, the tip of valve (6) contacts the cylinder bot-
tom, so valve (6) and piston valve (3) stop at that po-
sition and do not move further. Only piston (2)
moves further.
When this happens, the oil at the cylinder head,
which has been sealed in by piston valve (3), es-
capes through piston valve seats (4) and (5), and
the pressure inside the cylinder stops rising.

10-142 D375A-6R
Hydraulic system
Quick drop valve

Quick drop valve 10-141


For blade lift cylinder 10-141
Outline 10-141 Operation 10-141
The quick drop valve installed to both right and left Start of lowering 10-141
blade lift cylinders serves to increase the blade low- When the blade control lever is operated to the
ering speed and to reduce the occurrence of vacu- LOWER, the oil from the control valve flows through
um at the cylinder bottom end when the blade is port (A) to the cylinder bottom end and pushes the
lowering, thereby shortening the time lag between piston.
lever operation and start of digging. The blade low- The oil on the cylinder head end is pushed out by
ering speed, which is generally determined by the the piston into port (B), and then flows through port
pump delivery, can be made faster with the quick (C) and control valve to the hydraulic tank.
drop valve.

1. Valve body
2. Spool
3. Check valve
4. Spring

D375A-6R 10-143
Hydraulic system
Quick drop valve

While lowering 10-142


Pressurized oil from the cylinder head end flows into
port (C) through port (B).
At this time, the oil flow is restricted by orifice (A)
provided along the way, causing a differential pres-
sure accross the orifice. When the pressure of port
(B) becomes greater than the force of spring (4), it
compresses the spring and moves spool (2) and
check valve (3) to the right.
When the spool and the check valve have moved,
the circuit connecting parts (B) and (A) is made, part
of the oil flowing from the cylinder head end to port
(C) enters the passage that connects part (A) to the
cylinder bottom end, and merged with the oil from
the control valve, and flows to the cylinder bottom
end.
Thus, the blade lowering speed increases in accor-
dance with the amount of oil that flows to the bottom
of the cylinder and reduces the formation of vacuum
at the bottom end of the cylinder.

10-144 D375A-6R
Hydraulic system
Pin puller switch

Pin puller switch 10-143

1. Connector
2. Wire
3. Switch
4. Knob

Function 10-143
The pin puller solenoid valve is controlled by turning
the pin puller switch ON/OFF. This switches the oil
circuit to the pin puller cylinder and sets the shank
mounting pin to the "PUSH IN or PULL OUT posi-
tion.

D375A-6R 10-145
Hydraulic system
Pin puller solenoid valve

Pin puller solenoid valve 10-14

1. Plug A: To pin puller cylinder bottom end


2. Spring B: To pin puller cylinder head end
3. Spring retainer P: From power train pump
4. Valve body T: To steering case
5. Spool
6. Spring retainer
7. Spring
8. Push pin
9. Solenoid assembly

10-146 D375A-6R
Hydraulic system
Pin puller solenoid valve

Operation 10-145
When pin puller switch is set to "PUSH IN" posi- When pin puller switch is set to "PULL OUT" po-
tion 10-145 sition 10-145
When the pin puller switch is set to the PUSH IN po- When the pin puller switch is set to the PULL OUT
sition, no electric current flows to solenoid (9) and it position, current flows to solenoid (9) and it is ener-
is de-energized. For spool (5), ports (P) and (B) con- gized. Then, the solenoid pushes out push pin (8)
nect to ports (A) and (T) respectively, and the oil and spool (5) moves to the left. At this point, ports
from the power train pump flows from port (P) to port (P) and (B) disconnect from ports (A) and (T) re-
(A), and enters the bottom end of pin puller cylinder spectively, and ports (P) and (A) connect to ports (B)
(10). The oil in the bottom end of the cylinder ex- and (T) respectively, so the oil from the power train
tends the cylinder to push shank mounting pin (11) pump flows from port (P) to port (B) and enters the
into shank (12) when the circuit pressure builds up head end of pin puller cylinder (10). The oil in the
sufficiently. cylinder head end retracts the cylinder to pull shank
mounting pin (11) out of shank (12) when the circuit
pressure builds up sufficiently.

D375A-6R 10-147
Hydraulic system
Blade control lever (only for the machine with dual tilt specification)

Blade control lever (only for the machine with dual tilt specification) 10-146

1. Switch (Dual/single tilt selector)


2. Switch (pitch)
3. Cover
4. Connector (male)
5. Connector (female)

10-148 D375A-6R
Hydraulic system
Blade control lever (only for the machine with dual tilt specification)

Outline 10-147
q The blade is raised, lowered, and tilted to the
right or left respectively by moving the blade con-
trol lever forward and backward or to the right or
left.Dual tilt operation can be performed by mov-
ing the lever to the right and left with switch (1)
set to the "DUAL" position.Pitch operation can
also be performed by moving the lever to the
right and left with switch (2) being pressed.
q When the lever is operated with switch (2) being
pressed, the blade pitches.When the lever is
moved to the left, the blade pitches backward,
and when moved to the right, the blade pitches
forward.
q When the switch (1) is set to the "DUAL" position
and the lever is operated, the blade is dual tilt-
ed.When the lever is moved to the left, the blade
is dual tilted to the left. When the lever is moved
to the right, the blade is dual tilted to the right.
q Even when switch (1) is set to either "DUAL" or
"SINGLE" position, if the lever is moved to the
right or left with the switch (2) kept pressed, the
blade pitches.

D375A-6R 10-149
Hydraulic system
Work equipment pump

Work equipment pump 10-148


Type: HPV190
Appearance 10-148

10-150 D375A-6R
Hydraulic system
Work equipment pump

PA: Pump discharge port


PB: Pump pressure inlet port
PD1: Case drain port
PD2: Drain plug
PEN: Control pressure pickup port
PLS: Load pressure inlet port
PLSC: Load pressure pickup port
PS: Pump suction port

1. Front pump
2. LS valve

Outline 10-149
This pump consists of a variable displacement
swash plate type piston pump and LS valve.

D375A-6R 10-151
Hydraulic system
Work equipment pump

Sectional view 10-150

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

10-152 D375A-6R
Hydraulic system
Work equipment pump

Function 10-151 q Piston (6) in each cylinder of cylinder block (7)


q The pump converts the engine rotation transmit- reciprocates in the axial direction.
ted to its shaft to oil pressure and oil flow, corre- q Cylinder block (7) seals the pressurized oil
sponding to the load. against valve plate (8) and rotates relatively.
q It is possible to change the discharge amount by q This surface is designed so that the oil pressure
changing the swash plate angle. balance is maintained at a suitable level.
q The oil is sucked into and discharged from each
Structure 10-151 cylinder in cylinder block (7) through valve plate
q Cylinder block (7) is supported by shaft (1) on
(8).
splined area (12).
q Shaft (1) is supported by each bearing (13).
q The tip of piston (6) has a spherical hollow in
which shoe (5) is being held by crimping.
q Piston (6) and shoe (5) form a spherical bearing.
q Shoe (5) is kept pressed against flat surface (A)
of rocker cam (4) and slides circularly.
q Rocker cam (4) leads high pressure oil to cylin-
drical surface (B) against cradle (2) fixed to the
case, and forms a static pressure bearing, and
slides.

D375A-6R 10-153
Hydraulic system
Work equipment pump

Operation of pump 10-152


q Cylinder block (7) rotates together with shaft (1) q If center line (X) of rocker cam (4) matches the
and shoe (5) slides on plane (A). axis of cylinder block (7) (the swash plate angle
q Rocker cam (4) moves along cylindrical face (B). is 0), there is no difference between volumes (E)
As a result, angle (a) between center line (X) of and (F) in cylinder block (7). The hydraulic oil is
rocker cam (4) and the axis of cylinder block (7) not sucked or discharged.
changes. q Suction and discharge of pressurized oil is not
q Angle (a) is called the swash plate angle. carried out in this state. Namely pumping action
is not performed. (Actually, however, the swash
plate angle is not set to 0)

q If angle (a) is made between center line (X) of


rocker cam (4) and the axis of cylinder block (7),
plane (A) works as a cam for shoe (5).
q Piston (6) slides on the inside of cylinder block
(7), so a difference between volumes (E) and (F)
is created inside cylinder block (7).
q A single piston (6) sucks and discharges the oil
by the amount subtracting (E) from (F).
q If cylinder block (7) rotates and the volume of
chamber (E) is decreased, the oil is discharged
from chamber (E) during this process.
q The volume of chamber (F) is increased and the
oil is sucked in chamber (F) during this process.

10-154 D375A-6R
Hydraulic system
Work equipment pump

Control of discharge 10-153


q If swash plate angle (a) increases, the difference
between volumes (E) and (F) increases, and
pump delivery (Q) increases.
q Swash plate angle (a) is changed with servo pis-
ton (10).
q Servo piston (10) reciprocates straight according
to the signal pressure from the LS valve.
q This linear movement is transmitted to rocker
cam (4) through slider (14).
q Rocker cam (4) supported on the cylindrical sur-
face of cradle (2) slides circularly.
q The area receiving the pressure on the right and
left sides of servo piston (10) are different from
each other, and discharge pressure (self-pres-
sure) (PP) of the main pump is constantly ap-
plied to the pressure chamber of the small
diameter piston side.
q Output pressure (PEN) of the LS valve is applied
to the pressure chamber of the large diameter
piston side.
q The movement of servo piston (10) is controlled
by the relationship of pressure between small di-
ameter piston side (PP) and large diameter pis-
ton side (PEN) and by the ratio of the area
receiving the pressure of the small diameter pis-
ton and large diameter piston.

D375A-6R 10-155
Hydraulic system
Work equipment pump

LS valve 10-154

PA: Pump port 1. Sleeve


PDP: Drain port 2. Piston
PLP: LS control pressure output port 3. Spool
PLS: LS pressure input port 4. Spring
PP: Pump port 5. Sheet
PPL: Drain port 6. Sleeve
PSIG: Drain port 7. Plug
8. Lock nut

Function 10-154
q The LS (load sensing) valve detects the load and
controls the pump delivery.
q This valve controls pump delivery (Q) with the
differential pressure between pump discharge
pressure (PP) and control valve outlet pressure
(PLS) (PLS) [= (PP) - (PLS)] (called the LS dif-
ferential pressure).
q This valve receives pump discharge pressure
(PP) and pressure (PLS) (called the LS pres-
sure) coming from the control valve output.
q The relationship between LS differential pres-
sure (PLS)[=(PP)(PLS)], which is a differential
pressure between pump discharge pressure
(PP) and LS pressure (PLS), and delivery (Q) is
as shown in the figure.

10-156 D375A-6R
Hydraulic system
Work equipment pump

Operation 10-15
When control valve is in NEUTRAL position 10-15

q The LS valve is a 3-way selector valve, and pres- q The same pump discharge pressure (PP) is sup-
sure (PLS) (LS pressure) from the control valve plied to port (J) on the small diameter piston
inlet is applied to spring chamber (B) and pump side.
discharge pressure (PP) is supplied to port (H) of q According to the area difference of servo piston
sleeve (8). (10), the servo piston is moved in the direction
q The position of spool (6) is determined by the dif- which makes the swash plate angle minimum.
ference between the force caused by LS pres-
sure (PLS), the force of spring (4), and the force
caused by pump discharge pressure (self pres-
sure) (PP).
q Before the engine is started, servo piston (10) is
pushed to the right. (See right drawing)
q When engine is started, and if the control lever is
in NEUTRAL, LS pressure (PLS) is 0 MPa
{0 kg/cm2}. (The LS pressure is interconnected
to the drain circuit through the control valve
spool)
q Spool (6) is pushed to the right, and ports (C)
and (D) are connected.
q Pump discharge pressure (PP) applies to the
large diameter piston side through port (K) .

D375A-6R 10-157
Hydraulic system
Work equipment pump

Mechanism to make the pump delivery maximum 10-156

q When the difference between pump discharge


pressure (PP) and LS pressure (PLS), in other
words, LS differential pressure (PLS) decreas-
es (for example, when the control valve open
area increases and pump discharge pressure
(PP) decreases), the combined force of LS pres-
sure (PLS) and the force of spring (4) pushes
spool (6) to the left.
q As spool (6) moves, ports (D) and (E) are inter-
connected and also connected to the drain port.
q The pressure between circuits (D) and (K) be-
comes drain pressure (PT).
q The pressure on the large diameter piston side
of servo piston (10) becomes drain pressure
(PT) and pump discharge pressure (PP) is con-
stantly applied to port (J) on the small diameter
side. Accordingly, servo piston (10) is pushed to
the left and the swash plate is moved to increase
the discharge.

10-158 D375A-6R
Hydraulic system
Work equipment pump

Mechanism to make the pump delivery minimum 10-157

q When servo piston (10) moves to the right (the


direction that reduces pump delivery) and LS dif-
ferential pressure (PLS) increases (for exam-
ple, when the control valve open area decreases
and pump discharge pressure (PP) increases),
the force caused by pump discharge pressure
(PP) pushes spool (6) to the right.
q As spool (6) moves, pump discharge pressure
(PP) flows through port (C) to port (D), and fur-
ther flows through port (K) to the large diameter
piston side.
q Although pump discharge pressure (PP) is ap-
plied to port (J) on the small diameter piston
side, servo piston (10) is pushed to the right by
the area difference between the large diameter
piston side and small diameter piston side of ser-
vo piston (10).As the result, servo piston (10)
moves into the direction to make the swash plate
angle smaller.

D375A-6R 10-159
Hydraulic system
Work equipment pump

When servo piston is balanced 10-158

q The symbols (A1), (A0) and (PEN) represent the q The force of spring (4) is adjusted so that spool
area receiving the pressure on the large diame- (6) can be balanced at the specified center when
ter piston side, the area receiving the pressure (PP) - (PLS) = 1.96 MPa {20 kg/cm2}.
on the small diameter piston side, and the pres-
sure sent to the large diameter piston side, re-
spectively.
q When the force generated by pump discharge
pressure (PP) of the LS valve is balanced with
the combined force of LS pressure (PLS) and
spring (4), and the relationship becomes (A0) x
(PP) = (A1) x (PEN), servo piston (10) stops in
that position.
q The swash plate of the pump is held at interme-
diate position.[The swash plate stops at a posi-
tion where the open area between ports (D) and
(E) of spool (6) is almost equal to the open area
between ports (C) and (D).
q The relationship between the area receiving the
pressure at both ends of servo piston (10) is
(A0):(A1) = 3:5, and the pressures applied to
both ends of the piston when the piston is bal-
anced is (PP):(PEN)C 5:3.

10-160 D375A-6R
Hydraulic system
Work equipment pump

D375A-6R 10-161
Hydraulic system
Control valve

Control valve 10-159


6-spool valve for dual tilt 10-159
Appearance 10-159

10-162 D375A-6R
Hydraulic system
Control valve

A1: To blade lift cylinder head


A2: To blade lift cylinder head
A3: To blade tilt right cylinder head
A4: To blade tilt left cylinder head
A5: To ripper cylinder head
A6: To ripper tilt cylinder bottom
B1: To blade lift cylinder bottom
B2: To blade lift cylinder bottom
B3: To blade tilt right cylinder bottom
B4: To blade tilt left cylinder bottom
B5: To ripper lift cylinder bottom
B6: To ripper tilt cylinder head
LS: To work equipment pump LS valve
LSI: LS pressure pickup port
P: From work equipment pump
PA1: From blade PPC valve port P1
PA2: From blade PPC valve port P1
PA3: From blade PPC valve port P3
PA4: From blade PPC valve port P4
PA5: From ripper PPC valve port P3
PA6: From ripper PPC valve port P2
PB: PPC basic pressure
PB1: From blade PPC valve port P2
PB2: From blade PPC valve port P2
PB3: From blade PPC valve port P4
PB4: From blade PPC valve port P3
PB5: From ripper PPC valve port P4
PB6: From ripper PPC valve port P1
P1: Pump pressure pick-up port
T: Drain port

D375A-6R 10-163
Hydraulic system
Control valve

Sectional view (1/4) 10-161

1. Ripper tilt valve


2. Ripper lift valve
3. Blade left tilt valve
4. Blade right tilt valve
5. Blade lift valve
6. Blade lift spool
7. Blade lift spool
8. Blade left tilt spool
9. Blade right tilt spool
10. Ripper lift spool
11. Ripper tilt spool
12. Load check valve
13. Pressure compensation valve

10-164 D375A-6R
Hydraulic system
Control valve

(2/4) 10-162

1. LS check valve
2. Preset plug

D375A-6R 10-165
Hydraulic system
Control valve

(3/4) 10-163

1. Main relief valve


2. LS relief valve
3. Unload valve
4. Suction valve
5. Check valve (built - in to spool)

10-166 D375A-6R
Hydraulic system
Control valve

(4/4) 10-164

1. Suction safety valve


2. Check valve (built - in to spool)
3. Suction valve
4. Suction valve

D375A-6R 10-167
Hydraulic system
Control valve

5-spool valve for single tilt 10-165


Appearance 10-165

10-168 D375A-6R
Hydraulic system
Control valve

A1: To blade lift cylinder head


A2: To blade lift cylinder head
A3: To blade tilt cylinder head
A4: To ripper cylinder head
A5: To ripper tilt cylinder bottom
B1: To blade lift cylinder bottom
B2: To blade lift cylinder bottom
B3: To blade tilt cylinder bottom
B4: To ripper lift cylinder bottom
B5: To ripper tilt cylinder head
LS: To work equipment pump LS valve
LSI: LS pressure pickup port
P: From work equipment pump
PA1: From blade PPC valve port P1
PA2: From blade PPC valve port P1
PA3: From blade PPC valve port P3
PA4: From ripper PPC valve port P3
PA5: From ripper PPC valve port P2
PB: PPC basic pressure
PB1: From blade PPC valve port P2
PB2: From blade PPC valve port P2
PB3: From blade PPC valve port P4
PB4: From ripper PPC valve port P4
PB5: From ripper PPC valve port P1
P1: Pump pressure pick-up port
T: Drain port

D375A-6R 10-169
Hydraulic system
Control valve

Sectional view (1/4) 10-167

1. Ripper tilt valve


2. Ripper lift valve
3. Blade tilt valve
4. Blade lift valve
5. Blade lift spool
6. Blade lift spool
7. Blade tilt spool
8. Ripper lift spool
9. Ripper tilt spool
10. Load check valve

10-170 D375A-6R
Hydraulic system
Control valve

(2/4) 10-168

1. LS check valve
2. Preset plug

D375A-6R 10-171
Hydraulic system
Control valve

(3/4) 10-169

1. Main relief valve


2. LS relief valve
3. Unload valve
4. Suction valve
5. Check valve (built - in to spool)

10-172 D375A-6R
Hydraulic system
Control valve

(4/4) 10-170

1. Suction safety valve


2. Check valve (built - in to spool)
3. Suction valve
4. Suction valve

D375A-6R 10-173
Hydraulic system
Control valve

10-174 D375A-6R
Hydraulic system
Control valve

Operation of control valve 10-171

Function 10-171
When the main spool is at the HOLD position, it
drains the excess oil discharged by the pump, and
prevents the pressure from being formed in the cir-
cuit from rising.
Operation 10-171
When set to "HOLD" position (operation of un-
load valve) 10-171
q When the main spool is at the HOLD position,
the pump pressure passes from chamber (A)
through oriffice (4) to chamber (D). Chambers
(C) and (C') are connected to the drain circuit.
q When oil is supplied from the pump, the pressure
in chamber (D) rises, and spool (1) is pushed to
the right by pressure (FO) which is determined
by the cross-sectional area of piston (3) receiv-
ing the pressure.
q When (FO) becomes larger than set force (FS)
of spring (2), the spool moves to the right and
connects the passage between chamber (A) and
chamber (B), so the oil from the pump is drained.
q Therefore, spool (1) is balanced at a position that
matches the supply of oil from the pump.
q Actually, the amount of oil supplied from the
pump is small, so the pressure in the circuit is al-
most the same as the set force of spring (2).

D375A-6R 10-175
Hydraulic system
Control valve

Control of flow rate 10-172


Work equipment valve
Use of the CLSS circuit (Closed - Center Load
Sensing System) makes it possible to control the oil
flow by adjusting the area of opening of the spool
driven by the PPC valve, regardless of the load.

When set to "HOLD" position (blade right tilt cylinder circuit on dual tilt specification machine) 10-172

q When the spool is set to the "HOLD" position, the q When this happens, the pump pressure is acting
pump pressure is sent from chamber (A) to pres- on the left end of spool (3) of the pressure com-
sure compensation valve spool (3) through its pensation valve, so it pushes against the force of
notch, and then conducted through chamber (B) spring (4) and moves rightward to the maximum
to chamber (C). stroke position.
q The oil in chamber (G) is drained through cham- q At this condition, the area of the opening for
ber (H) to chamber (F). spool (1) of the blade tilt valve is at its minimum.

10-176 D375A-6R
Hydraulic system
Control valve

When set to "HOLD" position (blade tilt cylinder circuit on single tilt specification machine) 10-173

q When the spool is se to "HOLD" position, the


pump pressure is sent from chamber (A) through
chamber (B) to chamber (C).
q Pressure in chamber (H) is drained to chamber
(F).
q At this condition, the area of the opening for
spool (1) of the blade tilt valve is at its minimum.

D375A-6R 10-177
Hydraulic system
Control valve

When set to RIGHT TILT position (blade right tilt cylinder circuit on dual tilt specification machine) 10-174

q When the tilt lever is operated to right tilt posi- q PLS = differential pressure between ports
tion, pilot pressure (PB1) acts on the right end of (L) and (K) = 1.96 MPa {20 kg/cm2}
spool (1) through the PPC valve. q PLS'= differential pressure between ports
q when the pressure becomes greater than the set (J) and (D)
force of spring (2), the spool (1) begins to move q PLS C PLS'
leftward. It is balanced at a position correspond-
ing to PPC output pressure (PB1).

10-178 D375A-6R
Hydraulic system
Control valve

q Chamber (C) and chamber (D) are connected,


and the oil from the pump flows through ports
(A), (B), (C) and (D) to tilt cylinder (6).
q At the same time, the load pressure in chamber
(D) passes through LS orifice (5) and chamber
(H), and is sent to chamber (G). It is also sent
from the LS circuit (O) to pump servo valve (7).
q The condition of the pressure of spool (3) is
chamber (B) pressure C chamber (C) pressure,
and chamber (G) pressure C (D)chamber (D)
pressure, so spool (3) is controlled by the differ-
ential pressure of spool (1) (chamber (C) pres-
sure - chamber (D) pressure), and balances with
the force of spring (4).
q If the oil flow is too large, the differential pressure
of spool (1) becomes larger, so spool (3) moves
in the direction to throttle the oil flow.
q On the other hand, if the oil flow is too small,
spool (3) moves in the direction to increase the
oil flow.
q Pump servo valve (7) is controlled so that the dif-
ferential pressure [LS differentical pressure:
(PLS)] between pump pressure (P) and LS
pressure (LS) remains constant.
q A suitable amount of oil flows to ensure that the
loss of pressure at the control valve (PLS') is
equal to (PLS).
q The loss of pressure in the control valve is deter-
mined by the area of the opening of the main
spool, so the oil flow matches the area of the
opening of the spool.
q The return oil flow from the tilt cylinder passes
through chamber (E) and chamber (F), and is
drained.

D375A-6R 10-179
Hydraulic system
Control valve

When set to RIGHT TILT position (blade tilt cylinder circuit on single tilt specification machine) 10-176

q When the tilt lever is operated to right tilt posi- q PLS = differential pressure between ports
tion, pilot pressure (PB3) acts on the right end of (K) and (J) = 1.96 MPa {20 kg/cm2}
spool (1) through the PPC valve. q PLS'= differential pressure between ports
q when the pressure becomes greater than the set (H) and (D)
force of spring (2), the spool (1) begins to move q PLS C PLS'
leftward. It is balanced at a position correspond-
ing to PPC output pressure (PB3).

10-180 D375A-6R
Hydraulic system
Control valve

q Chamber (C) and chamber (D) are connected,


and the oil from the pump flows through ports
(A), (B), (C) and (D) to tilt cylinder (4).
q Part of the load pressure in chamber (D) is sent
through LS orifice chambers (3) and (G), and
part of it is also conducted through LS circuit (O)
to LS valve (5).
q LS valve (5) is controlled in such that the differ-
ential pressure [LS differential pressure: (PLS)]
between pump pressure (P) and LS pressure
(LS) becomes constant.
q A suitable amount of oil flows to ensure that the
loss of pressure at the control valve (PLS') is
equal to (PLS).
q The loss of pressure in the control valve is deter-
mined by the area of the opening of the main
spool, so the oil flow matches the area of the
opening of the spool.
q The return oil flow from the tilt cylinder passes
through chamber (E) and chamber (F), and is
drained.

D375A-6R 10-181
Hydraulic system
Control valve

When set to relief (blade lift, blade tilt, ripper lift, ripper tilt) 10-178
a The diagram shows the condition when work equipment LS valve (5) is relieved at blade tilt stroke end.

q P1 = P3 + P4 = Differential pressure be- q P4 = Differential pressure between ports (B)


tween ports (M) and (P) and (P)
q P2 = Differential pressure between ports (P) q LS =P1 + P2 = Differential pressure be-
and (N) tween ports (M) and (N) =1.96 MPa {20 kg/cm2}
q P3 = Differential pressure between ports (M)
and (B)

10-182 D375A-6R
Hydraulic system
Control valve

q If blade tilt valve (1) is moved, and the pressure


of tilt cylinder (8) becomes higher, work equip-
ment LS relief valve (5) will open and oil will be
drained from LS circuit (O).
(Ports (P), (F), (G), (J) and (K))
q As a result, there will be a drop in pressure in LS
passage (O) starting from LS sensing hole (F),
and (P2) will become larger.
q For the same reason, if the pressure in chamber
(I) and (H) drops, spool (2) will push against
spring (3) and move to the right, and will make
the opening between chambers (B) and (C)
smaller, so the flow between chambers (B) and
(C) will be throttled and (P4) will become larger.
q Because of the pump swash plate control, the
system circuit is balanced at a circuit pressure
which makes the pressure loss generated by the
flow at work equipment LS relief valve (5) (P1)
+ (P2) equal to LS differential pressure (LS).
q When this happens, pump LS valve (6) detects
the differential pressure generated by LS relief
valve (5), and moves the pump swash plate from
the maximum to the minimum position.
q The swash plate is balanced at a position where
the LS differential pressure is 1.96 MPa {20
kg/cm2}.
q When the pump is at the minimum swash plate
angle (minimum oil flow), if the minimum oil flow
is greater than the LS relief oil flow + leakage at
any part, the pressure resides in the pump circuit
[the pump and chambers (A) and chamber (B)]
through pressure compensation valve (7), so the
differential pressure rises.
q If this differential pressure goes above the set
pressure for unload valve (4), the unload valve is
actuated to relieve the excess oil flow and bal-
ance the circuit.

D375A-6R 10-183
Hydraulic system
Control valve

Pitch system on dual tilt specification machine 10-180


a A dual tilt specification machine is configured with the dual tilt and pitch system circuits.
When single tilt operation is carried out 10-180

q In the single tilt mode, solenoid selector valve (1) q As a result, the right tilt cylinder does not move
is in the neutral position and connected to (PA4) and only the left tilt cylinder moves to carry out
and (PB4) of the control valve as shown in the the single tilt operation.
figure.
q PPC circuits (2) and (3) are separated from out-
put circuits (4) and (5) of the PPC valve.

10-184 D375A-6R
Hydraulic system
Control valve

When dual tilt operation is carried out 10-181

q In the dual tilt mode, the position of solenoid se- q PPC circuit (3) connected to (PA3) of the control
lector valve (1) is changed as shown in the fig- valve is connected to output circuit (5) of the
ure. PPC valve.
q At this time, PPC circuit (2) connected to (PB3) q Accordingly, both tilt cylinders move in the oppo-
of the control valve is connected to output circuit site directions each other to carry out the dual tilt
(4) of the PPC valve. operation.

D375A-6R 10-185
Hydraulic system
Control valve

When pitch operation is carried out 10-182

q In the pitch mode, the position of solenoid selec- q PPC circuit (3) connected to (PA3) of the control
tor valve (1) is changed as shown in the figure. valve is connected to output circuit (4) of the
q At this time, PPC circuit (2) connected to (PB3) PPC valve.
of the control valve is connected to output circuit q Accordingly, both tilt cylinders move in the same
(5) of the PPC valve. direction to carry out the pitch operation.

10-186 D375A-6R
Hydraulic system
Self-pressure reducing valve

Self-pressure reducing valve 10-183


General view 10-183

P1: From fan pump


P2: To fan motor
PR: To PPC valve and EPC valve, etc.
T: To tank

D375A-6R 10-187
Hydraulic system
Self-pressure reducing valve

Sectional view 10-184

1. Valve (sequence valve) 6. Screw


2. Spring 7. Poppet
3. Valve (pressure reducing valve) 8. Spring (for pressure reducing valve pilot)
4. Spring (pressure reducing valve main) 9. Spring (safety valve)
5. Filter 10. Ball

10-188 D375A-6R
Hydraulic system
Self-pressure reducing valve

Function 10-185
The self-pressure reducing valves reduce the dis-
charge pressure of the fan pump and supplies it to
the PPC valve, the EPC valve, etc. as the control
pressure.

D375A-6R 10-189
Hydraulic system
Self-pressure reducing valve

Operation 10-186
When engine is stopped (When all the oil pressures in circuit are low) 10-186

q Spring (6) pushes the poppet (5) the seat, and


port (PR) is disconnected from port (T).
q Spring (7) pushes the valve (8) to the left, and
port (P1) is connected to port (PR).
q Spring (3) pushes the valve (2) to the left, and
port (P1) is disconnected from port (P2) .

10-190 D375A-6R
Hydraulic system
Self-pressure reducing valve

When load pressure (P2) is lower than output pressure (PR) of self-pressure reducing valve 10-187

q The force of spring (3) and the force of exerted q Therefore, differential pressure is developed
by the (PR) pressure 0 MPa {0 kg/cm2}] at the across hole (a) in spool (8) to move spool (8) in
time of engine stop] push valve (2) in the direc- the direction to block the opening between ports
tion to block the passage between the ports (P1) (P1) and (PR) . Thus this valve uses the area of
and (P2). When the hydraulic oil enters (P1) port, the opening to regulate pressure (P1) to a cer-
the value balances at a position where the ex- tain level (set pressure) and supplies it as pres-
pression [Force exerted by pressure (P1) C sure (PR).
Force of spring (3) + Force (area (d) x Pressure
(PR) ] holds, and the area of the opening be-
tween ports (P1) and (P2) is adjusted so that
pressure (P1) is maintained higher than pres-
sure (PR) .
q When (PR) pressure rises above set pressure,
the poppet (5) opens and the hydraulic oil flows
through the route, from (PR) port, through hole
(a) in the spool (8), through the opening of the
poppet (5) , through to the tank port (T).

D375A-6R 10-191
Hydraulic system
Self-pressure reducing valve

When load pressure (P2) is high 10-18

q When load pressure (P2) rises due to digging or q Therefore, differential pressure is developed
other operations, pump delivery increases and across hole (a) in spool (8) to move spool (8) to
pressure (P1) rises. When the expression {Force block the opening between ports (P1) and(PR) .
exerted by pressure (P1) > Force of spring (3) + Thus this valve uses the area of the opening to
Force [area (d) x pressure (PR)]} holds, and regulate pressure (P1) to a certain level (set
valve (2) moves downward to its stroke end. As pressure) and supplies it as pressure (PR).
a result, the opening between the ports (P1) and
(P2) increases, the passage resistance be-
comes smaller to reduce engine horsepower
loss.
q When the pressure (PR) rises above the set
pressure, poppet (5) opens and hydraulic oil
flows through the route, from port (PR) , through
hole (a) in spool (8), and the opening of poppet
(5) to the tank port (T).

10-192 D375A-6R
Hydraulic system
Self-pressure reducing valve

When abnormally high pressure is generated 10-189

When the (PR) pressure of the self-pressure reduc-


ing valve rises abnormally high, the ball (10) sepa-
rates from the seat against the spring (9) to allow the
oil from port (PR) to flow to port (T) so as to reduce
the pressure (PR). As a result, the equipment (PPC
valve, solenoid valve, etc.), to which the oil pressure
is supplied, is protected from the abnormal high
pressure.

D375A-6R 10-193
Work equipment
Cylinder stay

Work equipment 10-190


Cylinder stay 10-190

1. Yoke
2. Oil seal
3. Bushing
4. Bushing

10-194 D375A-6R
Cab
Cab mount

Cab 10-191
Cab mount 10-191

1. Support Outline 10-191


2. Damper mount (front) q The cab mounts are installed at two places in the

3. Damper mount (rear) front section and at two places in the rear section
of the floor frame to secure the cab to the floor
frame.
q Oil-filled cab mounts are used to absorb vibra-
tion.

D375A-6R 10-195
Cab
Cab

Cab 10-192
Cab assembly 10-192

1. Front wiper
2. Front glass
3. Rear wiper
4. Door

10-196 D375A-6R
Cab
Cab

ROPS 10-193

1. ROPS

D375A-6R 10-197
Electrical system
Engine control

Electrical system 10-194


Engine control 10-194

1. Decelerator pedal Outline 10-194


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

10-198 D375A-6R
Electrical system
Engine control system

Engine control system 10-195

Outline 10-195 q The information of the engine controller is pos-


q The engine throttle controller receives the fuel sessed jointly by the other controllers through
control dial signal of the 1st throttle, decelerator the network and used for the optimum control of
pedal signal of the 2nd throttle, and 3rd throttle the engine and power train.
signal which is the control signal from the power q The automatic deceleration is a function of low-
train controller, and then controls the fuel supply ering the engine speed temporarily when the
pump according to the command signal having travel direction is changed from F3, R3, F2 or R2
the lowest engine speed. (for protection of the transmission clutch).
The control signals of the 3rd throttle are as
follows.
1) Automatic-deceleration (F3, R3, F2, R2)
2) Neutral deceleration
3) Shoe slip control (if equipped)
q The power train controller calculates a proper
engine speed from information items (1), (2), etc.
and sends it as the 3rd throttle signal to the en-
gine throttle controller.

D375A-6R 10-199
Electrical system
Engine control system

10-200 D375A-6R
Electrical system
Engine control system

Engine controller 10-197

Outline 10-197
Mounting the engine controller on the engine 10-197
q Since the engine controller is mounted on the
engine, it is easy to be maintained.
q In order to secure the reliability of mounted en-
gine controller, engine controller cooler is in-
stalled to cool the engine controller by fuel.
q Rubber vibration isolator reduces vibration.
Unifying the specification of engine controller 10-197
The common engine controller CM850 is adopted
which is co-developed by Komatsu and Cummins.

D375A-6R 10-201
Electrical system
Engine control system

Input/output signal CN-CE01


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

10-202 D375A-6R
Electrical system
Engine control system

CN-CE02 CN-CE02
Input/outpu Input/outpu
Pin No. Signal name Pin No. Signal name
t t
1 NC (*) - Electrical intake air heater relay
42 C
return
2 NC (*) -
43 NC (*) -
3 NC (*) -
44 NC (*) -
4 NC (*) -
45 NC (*) -
5 NC (*) -
46 CAN(+) E
6 NC (*) -
47 CAN (-) E
7 NC (*) -
48 NC (*) -
8 NC (*) -
49 NC (*) -
9 Decelerator signal B
50 NC (*) -
10 NC (*) -
*: Never connect to NC, or malfunctions or failures
11 NC (*) -
will occure.
12 NC (*) -
13 NC (*) - CN-CE03
14 NC (*) - Pin No. Signal name Input/output

15 NC (*) - 1 GND C

16 NC (*) - 2 GND C

17 NC (*) - 3 Power source (+24 V constant) A

18 NC (*) - 4 Power source (+24 V constant) A

19 NC (*) - *: Never connect to NC, or malfunctions or failures


20 NC (*) - will occur.
21 NC (*) -
22 Sensor power source (5 V) A
23 GND C
24 NC (*) -
25 NC (*) -
26 NC (*) -
27 NC (*) -
28 NC (*) -
29 NC (*) -
30 NC (*) -
31 NC (*) -
32 NC (*) -
33 GND C
34 NC (*) -
35 NC (*) -
36 NC (*) -
37 CAN shield C
38 NC (*) -
39 Key switch (ACC) B
Electrical intake air heater relay
40 D
(+)
41 NC (*) -

D375A-6R 10-203
Electrical system
Engine control system

Sensors 10-20

Fuel temperature sensor 10-20


q The fuel temperature sensor senses the fuel
temperature and sends it to the engine control-
ler. The sensor unit is a thermistor the resis-
tance of which changes according to the
temperature.
q The engine controller applies voltage to the
thermistor and senses the temperature by the
voltage divided by the resistance in the comput-
er and the resistance of the thermistor.

10-204 D375A-6R
Electrical system
Engine control system

Ne speed sensor (crank shaft angle sensor) Bkup speed sensor (G sensor) 10-202
q If the signal hole made on the flywheel passes (cylinder sensor) 10-202
over the sensor, the magnetic line of force q Similarly to the NE speed sensor, this sensor uti-
changes. lizes the pulses of 0 5 generated by the change
q If the magnetic line of force changes, the output of the magnetic line crossing the sensor unit.
of the Hall element sensor changes linearly and q The disc gear installed to the central part of the
it is converted into pulse of 0 5 by the wave camshaft of the high-pressure pump has teeth
form shaping circuit in the sensor, and then out- (cut parts) around it at intervals of 60 .
put. q In addition to the above teeth, one more tooth is
installed. Accordingly, 7 pulses are generated
every 2 revolutions of the engine.
q The standard pulse of the No. 1 cylinder is rec-
ognized by the combination of the NE speed
sensor pulse and Bkup speed sensor pulse.

Ambient pressure sensor 10-202


This sensor is used to correct altitude.

Oil pressure sensor 10-202

D375A-6R 10-205
Electrical system
Engine control system

Boost temperature sensor 10-203 Coolant temperature sensor 10-203


q The boost temperature sensor senses the intake q The coolant temperature sensor senses the
air temperature (boost temperature) and sends it coolant temperature and sends it to the engine
to the engine controller. controller.
q The sensor unit is a thermistor the resistance of q The sensor unit is a thermistor the resistance of
which changes according to the temperature. which changes according to the temperature.
The engine controller applies voltage to the The engine controller applies voltage to the
thermistor and senses the temperature by the thermistor and senses the temperature by the
voltage divided by the resistance in the comput- voltage divided by the resistance in the comput-
er and the resistance of the thermistor. er and the resistance of the thermistor.

10-206 D375A-6R
Electrical system
Engine control system

Deceleration potentiometer 10-204

1. Connector Outline 10-204


2. Lever q The deceleration potentiometer is installed to the
3. Body front lower part of the operator's cab and con-
4. Potentiometer nected to the decelerator pedal by linkage.
5. Coupling
6. Shaft q When the decelerator pedal is depressed, the
7. Stopper throttle potentiometer shaft is rotated by the link-
age and the potentiometer resistance changes.
Constant voltage is applied between pins (A)
and (C) of the potentiometer and an electric
signal is sent through pin (B) to the engine
controller according to the position of the decel-
erator pedal.

D375A-6R 10-207
Electrical system
CRI engine control system

CRI engine control system 10-205


a "CRI" is an abbreviation for Common Rail Injection.
System diagram 10-205

10-208 D375A-6R
Electrical system
CRI engine control system

1. NE speed sensor System configuration 10-206


2. Engine controller q The CRI system consists of fuel supply pump

3. Injector assembly (15), common rail (14), injector (3), engine con-
3A. Orifice troller (2) which controls those components and
3B. Control chamber sensors.
3C. Hydraulic piston q The fuel supply pump generates fuel pressure in

3D. Injector the common rail.The fuel pressure is controlled


3E. Nozzle by the fuel delivery from the supply pump.The
4. Orifice (for air bleeding) delivery is controlled by turning ON and OFF the
5. Fuel tank PCV (discharge control valve) (15A) of the fuel
6. Strainer supply pump according to the electric signals
7. Pre-fuel filter (water separator) from the engine controller.
8. Priming pump The common rail receives the pressurized fuel
9. Fuel filter from the fuel supply pump and distributes it to
10. Engine throttle controller cooler the cylinders.
11. Pressure limiter The fuel pressure is sensed by the common rail
12. Flow damper fuel pressure sensor installed to the common rail
13. High pressure injection pipe and controlled by the feedback method so that
14. Common rail the actual fuel pressure corresponds to the
15. Fuel supply pump command pressure set according to the engine
15A. PCV speed and the load on the engine.
15B. High pressure pump The fuel pressure in the common rail is applied
15C. Priming pump to the nozzle (3E) side and control chamber (3B)
15D. Feed pump side of the injector through the fuel injection pipe
15E. Bkup speed sensor (G sensor) of each cylinder.
16. Overflow valve q Injector controls the fuel injection rate and fuel

17. Air bleeding valve injection timing by turning ON and OFF the TWV
(two-way solenoid valve).If the TWV is turned
Outline 10-206 ON (energized), the fuel circuit is so changed
q The signals detected by various sensors are in- that the high-pressure fuel in the control cham-
put to the engine controller. ber flows out through orifice (3A). As a result, the
q The engine controller processes input signals force exerted by the pressure of the high-pres-
and output command signals to each actuator to sure fuel on the nozzle side raises the needle
control the fuel injection rate and fuel injection valve to start fuel injection.If the TWV is turned
timing. OFF (de-energized), the fuel circuit is so
changed that the high-pressure fuel can be sup-
plied to the control chamber through the orifice.
As a result, the needle valve lowers and finishes
fuel injection.Accordingly, the fuel injection tim-
ing and fuel injection rate are electronically con-
trolled respectively by the timing to energize the
TWV and the duration of energizing the TWV.

D375A-6R 10-209
Electrical system
Monitor system

Monitor system 10-207

Outline 10-207
q The monitor system monitors the machine con- q The CPU (Central Processing Unit) in the moni-
dition with the sensors installed to various parts tor panel displays and outputs various informa-
of the machine and processes and displays the tion processed by the power train controller. The
obtained information on the monitor panel quick- display unit is LCD (Liquid Crystal Display)
ly to notify the operator of the machine condition.
The main display sections and functions of the
panel are as follows.

1. Monitor unit which turns on the alarm when the-


machine has a trouble.
2. Gauge unit which constantly displays the
machine condition (coolant temperature, torque
converter oil temperature, fuel level, etc.)
3. Function of displaying error codes.
4. Current and voltage values of the sensors and
solenoids.

10-210 D375A-6R
Electrical system
Monitor system

Processing on machine monitor (common to all specifications) 10-208

Display of machine monitoer


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

Display of monitoring condition


Contents and conditions of processing Method Flow of signals
1. The communication conditions of each sensor, each solenoid, and CAN
are displayed. Each sensor
q The item Nos. and device conditions are notified to the machine monitor CAN O
by CAN. Controller
q The machine monitor displays the items and each value. O
2. Each items is selected by using the cursor switches and confirmation Machine monitor
CAN
switch.

Other items
Contents and conditions of processing Method Flow of signals
1. Monitoring
2. Abnormality record
3. Maintenance record
4. Maintenance mode change
5. Phone number setting
6. Default
7. Adjustment
8. PM clinic
9. Cylinder cutout mode operation
10. No injection cranking
11. Fuel consumption display
12. Load memory display
13. VHMS setting
14. Snap shot
86. Setting of shoe slip control (if equipped)
87. Setting of pre-lubrication
88. Screen adjustment a
a Since this item is included in the service menu, it is not usually displayed.For details of the operating meth-
od, see "Special functions of monitor panel (EMMS)" section of Testing and adjusting.

D375A-6R 10-211
Electrical system
Machine monitor

Machine monitor 10-209

Outline 10-209 Precautions on the machine monitor display 10-209


q The machine monitor has monitor display func- q The liquid crystal display panel may have black
tion, mode selection function and switch function spots (which do not light up) or bright spots
for electrical parts etc. (which stay on). Products having 10 or less black
q The machine monitor has a CPU (Central Pro- or bright spots conform the product specification;
cessing Unit) in it to process, display, and output such the condition is quite normal.
the information. q When the engine is started, the battery voltage
q The monitor display employs an LCD (Liquid may suddenly drop depending on the tempera-
Crystal Display). The switches are flat sheet ture and the battery condition. If this happens,
switches. the display on the machine monitor may momen-
tarily go out, but this does not indicate any ab-
normality.
q Continuous operation of the machine monitor
may display blue bright spots on the screen hav-
ing a black background; it is quite normal.
The screen normally displayed on the monitor
has a blue or white background. For this reason,
blue spots will not cause any problem (since the
liquid crystal lights up red, blue, and green spots
when displaying white).

10-212 D375A-6R
Electrical system
Machine monitor

Input and output signals 10-210


CN-CM01 CN-CM03
Input/out- Input/out-
Pin No. Signal name Pin No. Signal name
put put
1 Battery power (+24 V constant) Input 1 RS232C CD for communication terminal Input
2 Battery power (+24 V constant) Input 2 RS232C RXD for communication terminal Input
3 Battery power GND 3 RS232C SG for communication terminal
4 Battery power GND 4
GND for communication terminal control

Input/out- signal
5 Wake-up 5 Communication terminal selection signal Input
put
6 Relay output Output 6 RS232C RTS for communication terminal Output
7 Chassis signal GND 7 RS232C TXD for communication terminal Output
8 Hydraulic oil pressure 8 RS232C DTR for communication terminal Output
9 Fuel level Input 9 RS232C DSR for communication terminal Input
10 NC (*) 10 RS232C CTS for communication terminal Input
11 Battery charge Input 11 RS232C RI for communication terminal Input
12 Chassis analog signal GND 12 GND for communication terminal power
13 Light switch Input Input CH1 for communication terminal sta-
13 Input
14 Key switch (ACC) Input tus
Output for communication terminal power
15 Key switch (C) Input 14 Output
control
16 Preheating Input Output CH1 for communication terminal
15 Output
17 NC (*) control
18 NC (*) Output CH2 for communication terminal
16 Output
control
*: Never connect to NC, or malfunctions or failures 17
Input CH2 for communication terminal sta-
Input
will occur. tus
18 Power supply for communication terminal Output

CN-CM02
Input/out- CN-CM04
Pin No. Signal name
put Input/out-
1 NC (*) Pin No. Signal name
put
2 NC (*) 1 NC (*)
3 Coolant level sensor Input 2 NC (*)
4 NC (*) 3 NC (*)
5 NC (*) 4 NC (*)
6 NC (*) 5 NC (*)
7 Chassis signal GND 6 NC (*)
8 CAN terminating resistance 7 NC (*)
9 COMM_CAN_H_0
Input/out- 8 NC (*)
put 9 NC (*)
Input/out-
10 COMM_CAN_L_0 10 NC (*)
put
11 NC (*) 11 NC (*)
12 NC (*) 12 NC (*)

*: Never connect to NC, or malfunctions or failures *: Never connect to NC, or malfunctions or failures
will occur. will occur.

CN-CM05
Input/out-
Pin No. Signal name
put
1 Power supply for camera Output
2 Camera NTSC signal input 1 Input
3 Camera NTSC signal input 2 Input
4 Camera NTSC signal input 3 Input
5 Electric power supply GND for camera
6 Camera signal GND1
7 Camera signal GND2
8 Camera signal GND3

D375A-6R 10-213
Electrical system
Machine monitor

Monitor control portion 10-21

1. Gearshift mode selector switch 9. Fuel level gauge


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

10-214 D375A-6R
Electrical system
Machine monitor

Machine monitor display 10-212


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

When sensor is abnormal or


Display when normal: OFF
Oil pressure when wiring harness is dis-
Display when abnormal: ON
connected

Displays when starting switch is set to


ON position and engine is running
Check

Battery charge condi-


When charge is defective Display when normal: OFF
tion
Display when abnormal: ON CAUTION
lamp flashes
Displays when starting switch is turned
Engine oil level (if Lights up at low level or to ON position with engine stopped.
equipped) below Display when abnormal: OFF Display
when normal: ON

Displays when starting switch is turned


Hydraulic oil level (if Lights up when oil level is to ON position with engine stopped.
equipped) below suction limit Display when normal: ON Display
when abnormal: OFF

D375A-6R 10-215
Electrical system
Machine monitor

Display
Symbol Display item Contents Description
category

Lights when it becomes 49.0


Oil pressure
kPa{0.5 kg/cm2} and below

Lights when it becomes 7.8


Battery charge condi-
V and below while engine is
tion
running

Lights when it becomes


Radiator coolant level
below "low" line

Engine coolant temperature


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

Torque converter oil ON position and engine is running


ment is;
temperature Display when normal: OFF
Above 120 C: Symbol ON
Display when abnormal: ON
Above 130 C: Symbol ON +
Alarm buzzer sounds
buzzer sounds

Above 100 C: Symbol ON


Hydraulic oil temper-
Above 110 C: Symbol ON +
ature
buzzer sounds

Lights up for 30 seconds


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

Lights up when -7,470 490


Air cleaner clogging Pa {-762 50 mmH2O} is
reached.

Hydraulic oil level (if Lights up when oil level is


equipped) below suction limit

Lights according to required time deter-


mined by engine controller.
It also lights up at the time of manual
Pilot

Preheating When preheating


preheat by setting the starting switch at
the preheat position (turning the switch
counterclockwise).

10-216 D375A-6R
Electrical system
Machine monitor

Display
Symbol Display item Contents Description
category

Engine coolant tem-


perature

Torque converter oil


Reads the temperature
temperature
Gauge

Hydraulic oil temper-


ature

Fuel level Reads the level

Service meter (Hours


From 0 to 99999 Progresses when the engine is running
meter)

D375A-6R 10-217
Electrical system
Machine monitor

Gauge 10-215

The gauge pointer disappears when information on coolant temperature or hydraulic oil temperature cannot
be obtained due to disconnection of CAN.
Gauge Range Temperature or volume Indicator Buzzer sounds.
A1 105 Red Q
Engine coolant tem- A2 102 Red
A3 100 Off
perature
A4 85 Off
( C)
A5 60 Off
A6 30 White
B1 130 Red Q
Power train oil temper- B2 120 Red
B3 118 Off
ature
B4 90 Off
( C)
B5 50 Off
B6 0 White
C1 110 Red Q
Hydraulic oil tempera- C2 100 Red
C3 98 Off
ture
C4 70 Off
( C)
C5 20 Off
C6 0 White
D1 1000 Off
D2 755 Off
Fuel level D3 550 Off
(l) D4 395 Off
D5 275 Off
D6 145 Red

10-218 D375A-6R
Electrical system
Machine monitor

Machine speed 10-216 Battery voltage 10-216

1. 0 km/h 3. 10 km/h 1. 0 V 4. 25 V
2. 5 km/h 4. 15 km/h 2. 17 V 5. 30 V
3. 20 V 6. 31 V

Hydraulic pump oil pressure 10-216 Engine speed 10-216

1. 0 MPa 4. 30 MPa 1. 500 rpm 4. 2000 rpm


2. 10 MPa 5. 40 MPa 2. 1000 rpm 5. 2500 rpm
3. 20 MPa 6. 50 MPa 3. 1500 rpm 6. 3000 rpm

Engine oil pressure 10-216 Drawbar pull 10-216

1. 0 MPa 4. 0.4 MPa 1. 0 W 4. 0.6 W


2. 0.2 MPa 5. 0.5 MPa 2. 0.2 W 5. 0.8 W
3. 0.3 MPa 6. 0.7 MPa 3. 0.4 W 6. 1.0 W

D375A-6R 10-219
Electrical system
Machine monitor

Guidance icon and function switch 10-217


The function of the function switches differ depending on the screen display. Each guidance icon shows the
function of the switch below it.
Switches with no guidance icon are disabled.
The functions shown by the guidance icons are as shown in the table below.

Switch
Symbol Item Function
power

F6 Enter Enters selected/set item.

F5 Return Returns to previous screen or condition.

F4 Select service meter/clock Switches service meter and clock display alternatively.

Selection of maintenance
F5 Switches to Maintenance List screen.
screen

F6 Select user mode screen Switches to Use Menu screen.

Selects item on left side (Selects right end item after left end
F3 Select item
item).

Selects item on right side (Selects left end item after right end
F4 Select item
item).

Selects item on lower side (Selects top item after bottom


F3 Select item
item)/Resets holding of monitoring.

Selects item on upper side (Selects bottom item after top


F4 Select item
item)/Holds monitoring.

Displays next page for selection (Selects top page after last
F1 Select item
page).

Displays previous page for selection (Selects last page after


F2 Select item
top page).

Returns selected item to default setting. (Used for screen


F2 Return to default setting
adjustment.)

Starts operation. (Used to start measurement of split fuel con-


F1 Start
sumption on fuel consumption display screen.)

Stops operation. (Used to stop measurement of split fuel con-


F1 Stop
sumption on fuel consumption display screen.)

F1/F2 Clear Clears selected / displayed item

F1 Set Executes setting

F2 Change of multi-gauge Changes display item for multi gauge

10-220 D375A-6R
Electrical system
Machine monitor

Service meter and clock switching function 10-218 Maintenance reminder function 10-218
Pressing F4 on the standard screen when the ser- Pressing F5 on the standard screen switches to the
vice meter is displayed in the top center of the Maintenance List screen.
screen switches the display to the clock, and doing
so when the clock is displayed switches the display
to the service meter.

F1: Displays the next page.


Displays the top page when the last page is dis-
played.
F2: Displays the previous page.
Displays the last page when the top page is dis-
played.
F3: Selects (highlights) an item one down.
F4: Selects (highlights) an item one up.
F5: Returns to the normal screen.
F6: Hold down the button to switch to the Mainte-
nance Time Reset screen.
No operation at least 30 sec.: Returns to the stan-
dard screen.
q On the Maintenance List screen, if the time re-
maining until maintenance for any item is less
than thirty hours, the remaining time display is
highlighted in yellow. If the time remaining until
maintenance becomes 0 hours, the remaining
time display is highlighted in red.
q On the Maintenance Time Reset screen, the re-
maining time for the selected item can be reset
and returned to the default.

D375A-6R 10-221
Electrical system
Machine monitor

F5: Cancels the reset to return to the Maintenance q The defailt password is 000000.
List screen. q Enabling the password lock on an attachment-
F6: Resets the remaining time and returns to the equipped machine locks the attachment setting
standard screen. screen at the same time.
No operation at least 30 sec.: Returns to the stan- a For information on changing the maintenance
dard screen. password, see "Function of changing mainte-
nance password" of "Testing and adjusting".
q The table below shows the maintenance items
and replacement intervals.
The time remaining to maintenance is reduced
as the machine is operated.
Replacement interval
No. Item
(Hours)
01 Engine oil 500
02 Engine oil filter 500
03 Fuel main filter 500
41 Fuel pre-filter 500
04 Hydraulic oil filter 2000
07 Damper case oil 2000
08 Finaldrive case oil 2000
10 Hydraulic oil 2000
19 P/L oil 1000
20 P/L oil filter 500
P/L: Power train

q The display of the maintenance monitor differs


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

q To prevent careless reset of the maintenance in-


terval, the screen is password protected.

10-222 D375A-6R
Electrical system
Machine monitor

User mode 10-2 0


q Pressing F6 on the standard screen enters the
user mode, switching to the User Menu screen.
q In user mode, you can perform setting for items
relating to the machine monitor and machine
shown below.
Utility screen select
Multi-gauge
Screen adjustment
Time adjustment
Language setting
Reverse-interlok Enabled Mode (When cam-
era is set)
Fan reverse mode
Normal 10-2 0
Skipping pre-lubrication
q The standard screen is displayed.
Load display 10-2 0
q The horizontal axis indicates the time and the
vertical axis indicates the drawbar pull. The ma-
chine should be operated with the drawbar pull
kept in the green range.
q The graph on the screen is updated and scrolled
to the left at intervals of several seconds.

Body pitch display 10-2 0


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

F3: Selects (highlights) an item one down.


F4: Selects (highlights) an item one up.
F5: Returns to the normal screen.
F6: Switches to the setting screen for the selected
item.
No operation at least 30 sec.: Returns to the stan-
dard screen.
(In user mode, no switch operation at least 30 sec.
returns to the previous screen.)

Utility screen select 10-2 0


q If Utility Screen Select is selected with switch F6,
(1) Standard Display, (2) Load Display, or (3)
Body Pitch Display can be selected.
Multi-gauge 10-2 0
q Select the desired item with switch F3 or F4 and
q On this screen, the display item assigned to the
enter that item with switch F6.
gauge at the center can be selected.

D375A-6R 10-223
Electrical system
Machine monitor

q Select desired item with switch F3 or F4 and en- F2: Returns all adjusted values to the defaults.
ter that item with switch F6. F3: Decreases the value indicated by the indicator
one graduation left.
F4: Increases the value indicated by the indicator
one graduation right.
F5: Cancels changes you made before entering
them with F6 and returns to the User Menu screen.
F6: Confirms the changes and moves to the next
item.
q For machines equipped with a camera, the
brightness, contrast, and illuminance of the cam-
era screen are also adjustable.
q Select Screen Adjustment from the User Menu
screen to switch to the screen for selecting a
camera screen you want to adjust.
q The following items can be selected.
Sellectable item for multi gauge
No. Selected item Remarks
1 PL oil temperature With caution
Hydraulic oil tempera-
2 With caution
ture
3 Vehicle speed
Hydraulic pump pres-
4
sure
5 Engine oil pressure With caution
6 Battery voltage
7 Engine speed
8 Traction force
9 Clock
Engine coolant temper-
10 For Utility Screen Select F3: Selects (highlights) an item one down.
ature
11 Fuel level For Utility Screen Select F4: Selects (highlights) an item one up.
F5: Cancels changes you made before entering
them with F6 and returns to the User Menu screen.
Screen adjustment 10-2 1 F6: Moves to the setup items of the selected (high-
q Selecting the Screen Adjustment on the User lighted) item.
Menu screen and pressing F6 switches to the q The adjustment methods for the camera screen
Screen Adjustment screen. and standard screen are the same.
q From this menu, you can adjust the brightness,
q The background when adjusting the camera
contrast, and luminance of the machine monitor screen is the No.1 camera image.
screen.
q When the light switch is set to "Night mode ON",
the night mode screen is adjustable.
q When the light switch is set to "Daytime mode
ON" or OFF, the daytime mode screen is adjust-
able.

F3: Selects (highlights) an item one down.


F4: Selects (highlights) an item one up.
F5: Cancels changes you made before entering
them with F6 and returns to the User Menu screen.
F6: Enter the changes and moves to the next item.

10-224 D375A-6R
Electrical system
Machine monitor

Clock adjustment 10-2 2 F5: Cancels change you made before


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

Language setting 10-2 2


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

D375A-6R 10-225
Electrical system
Machine monitor

Setting of camera for reverse-interlock enabled


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

q Function of the function keys


F3: Selects (highlights) an item one down.
F4: Selects (highlights) an item one up.
F5: Return to former screen.
F6: Fix the selection.

a The setting whether cameras are installed or not


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

10-226 D375A-6R
Electrical system
Machine monitor

Fan reverse mode 10-2 4


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

Precautions for using fan reverse mode 10-2 4


q The rotation direction of the fan cannnot be
changed while the engine is running.
q When running the fan in reverse, set the lock le-
ver to the LOCK position.
q While the fan is running in reverse, the machine
cannot travel.
q When canceling the reverse mode, set the start-
ing switch to OFF position to stop the engine.
q When using this mode, warm up the engine suf-
ficiently. If the engine is not warmed up, the fan
may not supply sufficient air.

D375A-6R 10-227
Electrical system
Machine monitor

Pre-lubrication skip mode (applied to machines Function of checking service meter 10-2 5
equipped with pre-lubrication 10-2 5 q If you continuously pressing working mode se-
q This mode is used for starting engine without ac- lector switch (1) and buzzer cancel switch (2) at
tivating pre-lubrication. the same time when setting the starting switch to
q Turn "ON" the starting switch, select The item on the OFF position, the service meter will appear
the screen (A) with F3 or F4 key while engine is on the screen in 3 to 5 seconds.
not started, then fix it with F6 key.
q Press F6 on screen (B) to complete pre-lubrica-
tion skip.
After setting the mode, the display returns to
user menu automatically.
q Setting the starting switch to "START" position
initiates the starter rotation and starts up the en-
gine without turning on the pre-lubrication oper-
ation.

q When these switches are released, the LCD


goes out.
a Continuous operation of the machine monitor
may display blue bright spots on this screen; it is
quite normal.

10-228 D375A-6R
Electrical system
Machine monitor

Function of checking display LCD 10-2 6


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

q Pressing any function switch returns to the pre-


vious screen.

D375A-6R 10-229
Electrical system
Lamp system

Lamp system 10-2 7


Operation 10-2 7

Related electrical circuit diagram 10-2 7

10-230 D375A-6R
Electrical system
Engine preheat (electrical intake air heater) control

Engine preheat (electrical intake air heater) control 10-2 8


Operation 10-2 8

Related electrical circuit diagram 10-2 8

D375A-6R 10-231
Electrical system
Palm command control system

Palm command control system 10-2 9

1. Machine monitor (Multi-information)


2. Gearshift mode switch
3. Engine controller
4. Power train controller
5. Engine speed sensor
6. Transmission control valve
7. Steering control valve
8. Transmission output shaft speed sensor

10-232 D375A-6R
Electrical system
Palm command control system

Gear shift mode function 10-230 6. Preset gearshift pattern(gear speed at start)
Outline 10-230 7. Mark of "Dozing 2" (which indicates manual
There are the auto gearshift mode and manual gear- gearshift mode)
shift mode in the gearshift mode. These modes are C: Shoe slip control mode (if equipped)
changed to each other each time gearshift mode 8. Gear speed used currently
switch (1) is pressed. 9. Preset gearshift pattern (gear speed at start)
1. Auto gearshift mode (Heavy duty dozing mode) 10. Mark of "Ripping" (which indicates shoe slip
q If a load is applied, the gear is shifted down control mode)
automatically. When the load is removed,
the gear is shifted up to the set maximum us-
able gear speed automatically.
q The torque converter lockup operates ac-
cording to loads and the maximum usable
gear speed is selected automatically. In this
mode, less fuel is consumed and more pro-
duction is obtained.
2. Manual gearshift mode (General dozing mode,
ripping mode)
q If a load is applied, the gear is shifted down
automatically. When the load is removed,
however, the gear is not shifted up automati-
cally.
3. Shoe slip control mode (if equipped)
q If a load is applied, the gear is shifted down
automatically. When the load is removed,
however, the gear is not shifted up automati-
cally.
q Automatic deceleration of the engine during
the ripping operation reduces operator's fa-
tigue and prevents grousers from useless
wearing caused by shoe slippage.

Gear shift operation 10-230


Select a gear speed by pressing (a) or (b) on the
PCCS lever (steering / directional / gearshift lever).
(a): Shift-up switch
(b): Shift-down switch

Screen display 10-230


The gearshift mode is displayed in the gearshift
mode display section of the monitor panel as shown
below.
A: Auto gearshift mode
1. Gear speed used currently
2. Preset gearshift pattern (gear speed at start)
or maximum usable gear speed
3. Mark of AUTO (which indicates auto gearshift
mode)
4. Mark of "Dozing 1" (which indicates automatic
gearshift mode)
B: Manual gearshift mode
5. Gear speed used currently

D375A-6R 10-233
Electrical system
Palm command control system

Setting the preset with the shift switch operation a When the starting switch is set to ON position,
in NEUTRAL 10-231 the auto gearshift mode ([F1 R1]) is set. When
Set the preset gearshift pattern (gear speed at start) the gearshift mode is changed, [F1 R1] is se-
or the maximum usable gear speed (for only the lected initially.
auto gearshift mode) by using the gearshift switches
with travel control lever in neutral. Changing gear speed with the shift switch oper-
A: Auto gearshift mode ation during travel 10-231
Setting preset gearshift pattern (gear speed at The maximum usable gear speed (in the auto gear-
start) or maximum usable gear speed shift mode) or the current gear speed (in the manual
gearshift mode) can be changed with the gearshift
switches while the machine is traveling.
A: Auto gearshift mode
Changing maximum usable gear speed
During forward travel: The maximum usable
gear speed can be set to F1 - F2.
During reverse travel: The maximum usable
gear speed can be set to R1 R3.
Shift-up switch: Each time this switch is pressed,
the maximum usable gear speed is shifted up to
the next range.
Shift-down switch: Each time this switch is
pressed, the maximum usable gear speed is
shifted down to the next range.
B: Manual gearshift mode
B: Manual gearshift mode
Setting preset gearshift pattern (gear speed at
Changing current gear speed
start)
During forward travel: The current gear speed
can be set to F1 - F2.
During reverse travel: The current gear speed
can be set to R1 - R2.
Shift-up switch: Each time this switch is pressed,
the current gear speed is shifted up to the next
range.
Shift-down switch: Each time this switch is
pressed, the current gear speed is shifted down
to the next range.
C: Shoe slip control mode(if equipped)
Changing current speed
During forward travel: The current gear speed is
fixed to F1.
C:Shoe slip control mode (if equipped) During reverse travel: The current gear speed
Setting preset gearshift pattern (gear speed at can be set to R1 - R2.
start) Shift-up switch: Each time this switch is pressed,
the current gear speed is shifted up to the next
range.
Shift-down switch: Each time this switch is
pressed, the current gear speed is shifted down
to the next range.

10-234 D375A-6R
Electrical system
Sensor

Sensor 10-232
Sensor name Type of sensor When normal When abnormal
Torque converter oil temperature
Resistive
sensor
Hydraulic oil temperature sensor Resistive

Coolant level sensor Contact ON (Closed) OFF (Open)

Fuel level sensor Resistive


Transmission output shaft R speed
Resistive
sensor
Pitch angle sensor Resistive

Acceleration sensor Resistive

Speed sensor Resistance

Engine oil level sensor Contact ON (Closed) OFF (Open)

Air cleaner clogging sensor Contact OFF (Closed) ON (Open)

Hydraulic oil level sensor Contact OFF (Closed) ON (Open)

Torque converter oil temperature sensor 10-232


Hydraulic oil temperature sensor 10-232

1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector

D375A-6R 10-235
Electrical system
Sensor

Radiator coolant level sensor 10-23

1. Float 4. Wire
2. Sensor 5. Connector
3. Tube

Fuel level sensor 10-23

1. Connector Function 10-23


2. Float The fuel level sensor is installed to the side face of
3. Arm the fuel tank. The float moves up and down accord-
4. Body ing to the fuel level. This movement of the float is
5. Spring transmitted by the arm to the variable resistor to
6. Contact change its resistance. This sends a signal to the
7. Spacer monitor panel to indicate the remaining fuel level.
When the display on the monitor panel reaches a
certain level, a warning lamp flashes.

10-236 D375A-6R
Electrical system
Sensor

Transmission output shaft speed sensor 10-234

1. Magnet
2. Terminal
3. Case
4. Boot
5. Connector

Pitch angle sensor 10-234

1. Body
2. Tube
3. Wire
4. Connector

D375A-6R 10-237
Electrical system
Sensor

Acceleration sensor 10-235

1. Sensor portion
2. Wire
3. Connector

Outline 10-235
q The acceleration sensor is installed under the
front of the operator's cab.
q The position of the ball inside the sensor chang-
es according to the acceleration.
The coil inside the sensor detects the position of
the ball. The change in the position is amplified
by the amp and is sent as a voltage change to
the power train controller.
q The input and output characteristics of the sen-
sor are shown in the figure on the right.

10-238 D375A-6R
Electrical system
Sensor

Speed sensor 10-236

1. Sensor
2. O-ring
3. Connector
4. Wire

Function 10-236
q Speed sensor, which is installed in the case of
the cooling fan motor, detects gear speed as
pulse signals from cylinder block spline inside
the motor and sends them as converted electric
signals to the controller.
q Since the clearance between the sensor and
spline is controlled to the specified dimension,
adjustment at installation is not necessary.

D375A-6R 10-239
Electrical system
Sensor

Engine oil level sensor 10-237

1. Connector 3. Float
2. Bracket 4. Switch

Air cleaner clogging sensor 10-237

1. Spring 4. Wire
2. Switch 5. Connector
3. Hose 6. GND

Hydraulic oil level sensor 10-237

1. Stopper 4. Plug
2. Float 5. Tube
3. Sensor 6. Connector

10-240 D375A-6R
Electrical system
Vehicle health monitoring system (VHMS)

Vehicle health monitoring system (VHMS) 10-238


Outline 10-238
VHMS is a system consisting of a VHMS controller If the "ORBCOMM terminal system" is installed to
and various types of sensors (some of them are the machine, it can transmit the data recorded in the
commonly used with other systems) and used for re- VHMS by satellite communication to the administra-
cording the operating state of the machine. It col- tor or the service department, allowing for remote
lects and records diverse information including the machine management .
machine's location and operation information as For use of VHMS, see "Testing and adjusting".
well as data from measuring instruments for later
use in maintenance and servicing.Confirmation of
the collected data is done after it is downloaded to a
PC.

VHMS controller 10-238

Note 1. VHMS is an abbreviation of Vehicle Health Monitoring System.

D375A-6R 10-241
Electrical system
Vehicle health monitoring system (VHMS)

Input/Output signal 10-239


CN1 [CN 1] CN2 [CN2 A, B]
Input/out Input/out
Pin No. Signal name Pin No. Signal name
put put
CN1-1 NC CN2-A1 NC

CN1-2 Sensor power supply (24 V) Output CN2-A2 NC

CN1-3 Sensor power supply (12 V) Output CN2-A3 NC

CN1-4 Sensor power supply (5 V) Output CN2-A4 NC

CN1-5 Sensor power supply (5 V) Output CN2-A5 Exhaust temperature (Rear) Input
Power supply (Constant power
CN1-6 Input CN2-A6 NC
supply) (24 V)
Power supply (Constant power CN2-A7 Exhaust temperature (Front) Input
CN1-7 Input
supply) (24 V)
CN1-8 BR power supply (24 V) Input CN2-A8 NC

CN1-9 BR power supply (24 V) Input CN2-A9 CONNECTOR SEL0 (OPEN) Input

CN1-10 NC CN2-A10 Ambient temperature Input

CN1-11 GND CN2-A11 NC

CN1-12 GND CN2-A12 Sensor GND

CN1-13 NC CN2-A13 Sensor GND

CN1-14 NC CN2-A14 NC

CN1-15 NC CN2-A15 Transmission, main oil pressure Input

CN1-16 NC CN2-A16 NC

CN1-17 Start signal Input CN2-A17 WAKE UP (Low) Input

CN1-18 NC CN2-A18 Blowby pressure Input

CN1-19 GND CN2-B1 NC

CN1-20 GND CN2-B2 NC

CN2-B3 NC

CN2-B4 NC

CN2-B5 NC

CN2-B6 WAKE UP (Hi) Input

CN2-B7 NC

CN2-B8 NC

CN2-B9 GND

CN2-B10 NC

CN2-B11 NC

CN2-B12 CONNECTOR SEL1 (GND) Input

10-242 D375A-6R
Electrical system
Vehicle health monitoring system (VHMS)

CN3 [CN3 A, B] CN4 [CN4 A, B]


Input/out Input/out
Pin No. Signal name Pin No. Signal name
put put
CN3-A1 NC CN4-A1 NC
CN3-A2 CAB out D/L Sw Input CN4-A2 NC
CN3-A3 NC CN4-A3 NC
CN3-A4 NC Input/out
CN4-A4 CAN (1) H (KOM-NET/c)
put
Model selection (See ORB connec-
CN3-A5 Input CN4-A5 CAN (0) shield (MMS)
tion)
CN3-A6 NC Input/out
CN4-A6 CAN (0) H (MMS)
put
CN3-A7 NC CN4-A7 NC
CN3-A8 NC
CN4-A8 NC
CN3-A9 CONNECTOR SEL2 (GND) Input CN4-A9 GND
CN3-A10 NC
CN4-A10 RS232C RXD (PC Tool) Input
CN3-A11 NC
CN4-A11 RS232C TXD (PC Tool) Output
CN3-A12 NC Input/out
CN4-A12 CAN (1) L (KOM-NET/c)
put
CN3-A13 NC
CN4-A13 CAN (1) SH (KOM-NET/c)
CN3-A14 NC
Input/out
CN4-A14 CAN (0) L (MMS)
CN3-A15 NC put
CN3-A16 NC CN4-B1 NC

CN3-A17 NC CN4-B2 NC

CN3-A18 NC CN4-B3 GNG (Orbcomm)

CN3-B1 NC CN4-B4 RS232C TX1 (Orbcomm) Output

CN3-B2 NC CN4-B5 NC

CN3-B3 NC CN4-B6 NC

CN3-B4 NC CN4-B7 NC

CN3-B5 NC CN4-B8 NC

CN3-B6 NC CN4-B9 GND (Orbcomm)

CN3-B7 NC CN4-B10 RS232C RX1 (Orbcomm) Input

CN3-B8 NC CN5
Input/out
CN3-B9 NC Pin No. Signal name
put
CN3-B10 NC CN5-1 LAN TX+ Output
CN3-B11 NC CN5-2 LAN TX- Output
CN3-B12 CONNECTOR SEL3 (OPEN) Input CN5-3 LAN RX+ Input
CN5-4 LAN RT3
CN5-5 LAN RT4
CN5-6 LAN RX- Input
CN5-7 LAN RT1
CN5-8 LAN RT2
CN5-9 NC
CN5-10 NC
CN5-11 PWR(LAN5 V) Output
CN5-12 GND (LAN)

D375A-6R 10-243
Electrical system
Vehicle health monitoring system (VHMS)

Sensors 10-241 Exhaust gas temperature sensor/amplifier 10-241

Engine oil temperature sensor 10-241 Specification 10-241


Specification 10-241 Rated voltage: DC24 V
Type of sensors: Thermistor Detectable temperature range: 100 1,000 C
Measuring range: 40 130 C 300 800 C
80 130 C (Assured accuracy: 10 C)
(Assured accuracy: 2 C) Output voltage characteristics
Maximum power consumption: 0.5 mW (Atmospheric temperature: 20 C)
Withstand pressure: 4.9 MPa {50 kg/cm2} Reference values
Operating temperature: -30 C - +140 C Sensed
Performance table temperature 50 100 400 700 800
Tem- ( C)
Resis- Temper- Resis- Temper- Resis- Output volt-
pera- 1.191 1.397 2.626 3.899 4.316
tance ature tance ature tance age (V)
ture
(kz) ( C) (kz) ( C) (kz)
( C) Operating temperature range: -40 +110 C
30 35.27 80 6.571 110 2.887 Current consumption: Max. 30 mA
a. Heat sensing part of sensor
40 24.28 85 5.682 115 2.544 Outside diameter of mounting part: R1/8
b. Amplifier
50 17.05 90 4.931 120 2.248
c. Connector (power supply side)
60 12.20 95 4.293 125 1.992 d. Connector (sensor side)

70 8.884 100 3.750 130 1.769 Function 10-241


The exhaust temperature sensor is a thermocouple
a. Heat sensing part of sensor type sensr and installed to the turbocharger inlet. It
Outside diameter of mounting part: R1/4 outputs the exhaust temperature data to the VHMS
controller.
Function 10-241
The engine oil temperature sensor is installed to the
engine oil filter. It inputs the change of the tempera-
ture as the change of the thermistor resistance to
the VHMS controller.

10-244 D375A-6R
Electrical system
Vehicle health monitoring system (VHMS)

Ambient temperature sensor 10-242


Specification 10-242
Power consumption: Max. 0.5 mW
Withstand pressure: 0.98 MPa {10 kg/cm2}
Detectable temperature range (ambient tempera-
ture):
-30 +120 C
Storage temperature range: -50 +140 C
Performance table
Detected
temperature -20 -10 0 10 20 50
( C)
Resis-
30.32 18.58 11.74 7.623 5.077 1.712
tance(kz)
a. Heat sensing part of sensor
Outside diameter of mounting part: 16 x 1.5

Function 10-242
The ambient temperature sensor inputs the change
of the ambient temperature as the change of the
thermistor resistance to the VHMS controller.

D375A-6R 10-245
Electrical system
Vehicle health monitoring system (VHMS)

Engine blow-by pressure sensor 10-243

1. Sensor Specification and function 10-243


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

Transmission main oil pressure sensor 10-243


1. Sensor
2. Connector

10-246 D375A-6R
Electrical system
ORBCOMM system

ORBCOMM system 10-24

Outline 10-24
q The ORBCOMM terminal system is a communi-
cation system to use the satellite communication
service of ORBCOMM Co., Ltd. (USA). If this
system is installed to the machine, the data re-
corded in the VHMS controller and various infor-
mation obtained through the network in the
machine can be transmitted by the satellite com-
munication.
q It is required to sign up for the ORBCOMM termi-
nal system before using its functions.
For details of procedures for launching the
station and others, see "Testing and adjusting".
q The ORBCOMM terminal system may or may
not be installed to the machine, depending on
the user's purchase specification.

D375A-6R 10-247
Electrical system
ORBCOMM system

ORBCOMM terminal system 10-245

1. Communication antenna connection


18 NC
2. DRC connector connection (40 poles)
19 NC
Outline 10-245
q The ORBCOMM terminal obtains various kinds 20 NC
of machine information from the network signals
21 NC
and input signal in the machine and transmits
them via the wireless communication antenna. It 22 NC
contains a CPU (Central Processing Unit) and
has wireless communication function. 23 NC
q This terminal has a LED lamp unit and a 7-seg-
ment display lamp unit used for inspection and 24 NC
troubleshooting. 25 NC
Input/Output signal 10-245
DRC conector 26 NC
1 NC 27 NC
2 NC 28 NC
3 NC 29 DOUT (GND)
4 COMM 232C RXD 30 NC
5 COMM 232C TXD 31 NC
6 NC 32 NC
7 NC 33 NC
8 NC 34 NC
9 NC 35 NC
10 NC 36 ACC Input
11 RS232C GND 37 DIS_SEL0 (GND)
12 NC 38 DIS_SEL0 (GND)
13 NC 39 Constant power supply (24 V)
14 NC 40 Constant power supply (24 V)
15 NC

16 NC

17 NC

10-248 D375A-6R
Electrical system
ORBCOMM system

Antenna 10-246

Specification 10-246
Type: Helical whip antenna (1)
Impedance: 20
Input terminal: M-P type
Length: 165 20 mm
a. Communication antenna mounting part

Function 10-246
It transmits the data collected and stored with VHMS
controller to the computer center via the communi-
cation satellite.

D375A-6R 10-249
Electrical system
ORBCOMM system

10-250 D375A-6R
20-1

BULLDOZER
D375A-6R

Machine model Serial number


D375A-6R 65001 and up

20 Standard value table 20-1

D375A-6R 20-1
(01)
Contents

Contents 20-2
20 Standard value table
Standard service value table................................................................................................... 20- 3
Standard value table for engine ........................................................................................... 20- 3
Standard value table for machine ........................................................................................ 20- 4

20-2 D375A-6R
(01)
Standard service value table
Standard value table for engine

Standard service value table 20-3


Standard value table for engine 20-3
Machine model D375A-6R

Engine SAA6D170E-5
Standard value for Service limit
Item Measurement conditions Unit
new machine value
High idle 1,900 (0/-50) 1,900 (0/-50)
Rotating speed Low idle rpm 750 50 750 50
Rated speed 1,800 1,800
kPa Min. 144 Max. 130.6
Boost pressure At rated horsepower
{mmHg} {Min. 1,080} {Max. 980}
Whole speed range (Ambient temper-
Exhaust temperature C Max. 680 Min. 700
ature: 20 C)
At sudden acceleration Max. 3.5 Min. 4.5
Exhaust gas color Bosch index
At high idle Max. 1.0 Min. 2.0
Valve clearance Intake valve 0.32
mm
(Normal temperature) Exhaust valve 0.62
Compression pressure Engine oil temperature: 40 - 60 C MPa Min. 2.94 Max. 2.1
(SAE15W-40 or SAE30 {kg/cm2} {Min. 30} {Max. 21}
oil) (Engine speed) (rpm) (210250)
Blow-by pressure At rated horsepower
kPa Max. 3.43 Min. 9.41
(SAE15W-40 or SAE30 (Coolant temperature: Within operat-
{mmH2O} {Max. 350} {Min. 960}
oil) ing range)
SAE0W30EOS, Min. 392.27 Max. 235.36
Hydraulic At high idle SAE5W40EOS, kPa {Min. 4.0} {Max. 2.4}
(Oil temperature: 90 - SAE10W30DH,
110 C) SAE15W40DH, {kg/cm2} Min. 98.07 Max. 78.45
At low idle
SAE30DH {Min. 1.0} {Max. 0.8}

Oil temperature Whole speed range (inside oil pan) C 90 110 Min. 120

Deflection when pressed with finger


Alternator belt tension mm (Auto-tension)
force of approx. 58.8 N {6 kg}
Air conditioner com- Deflection when pressed with finger
mm (Auto-tension)
pressor belt tension force of approx. 98 N {10 kg}

D375A-6R 20-3
(01)
Standard service value table
Standard value table for machine

Standard value table for machine 20-4


Machine model D375A-6R
Category

Standard value
Service limit
Item Measurement conditions Unit for new
value
machine

Decelerator pedal q Working mode: P-mode


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

q
ating range
Torque converter
q Hydraulic oil temperature: 45 55 C rpm 1,530 50 1,450
stall speed
q Decelerator pedal low speed:
Pedal depressed
q Torque converter stall speed: F3
Torque converter q Torque converter + Work equipment speed:
stall + Work equip- F3 + Ripper raise 1,500 50 1,400
ment relief speed q Measure with adjustment ID: 0530 (Stall mode)

q Engine stopped Neutral o For-


q Center of lever knob 30 5 Max. 8.0
Forward and ward
reverse Neutral o
PCCS lever

30 5 30 5
Reverse
Full stroke mm
40 5 40 5
(Neutral
(Play: Max. 3) (Play: Max. 3)
Steering Right/Left)
Until clutch is
95 95
fully disengaged
Engine stopped
Control lever/pedal stroke

q
Decelerator pedal q Center of pedal mm 45 15 45 15

q Engine at low idling


q Center of pedal Full stroke 75 5 75 5
Brake pedal mm
Until oil pressure
54 5 54 5
becomes zero
q Engine at low idling
q Hydraulic oil temperature: Neutral Raise 60 10 60 10
45 55 C
Blade lever q Center of lever knob Neutral Float mm 85 10 85 10

Neutral
53 10 53 10
Left/Right tilt
q Engine at low idling Neutral
q Hydraulic oil temperature: Raise/Lower 78 10 78 10
Ripper lever 45 55 C mm
q Center of lever knob Neutral Tilt for-
81 10 81 10
ward/back

20-4 D375A-6R
(01)
Standard service value table
Standard value table for machine

Machine model D375A-6R


Category

Standard value
Service limit
Item Measurement conditions Unit for new
value
machine
q Engine stopped Neutral o For- 56.9 6.9 56.9 6.9
q Center of lever knob ward {5.8 0.7} {5.8 0.7}
Forward and
reverse Neutral o 56.9 6.9 56.9 6.9
Control lever/pedal operating effort

Reverse {5.8 0.7} {5.8 0.7}


Until clutch is 12.8 3.9 12.8 3.9
PCCS lever

fully disengaged N {1.3 0.4} {1.3 0.4}

Left
{kg} 16.7 4.9 16.7 4.9
At stroke end
{1.7 0.5} {1.7 0.5}
Steering
Until clutch is 13.7 3.9 13.7 3.9
fully disengaged {1.4 0.4} {1.4 0.4}

Right
19.6 4.9 19.6 4.9
At stroke end
{2 0.5} {2 0.5}
q Engine stopped N 49.0 9.8 49.0 9.8
Decelerator pedal q Center of pedal {kg} {5.0 1.0} {5.0 1.0}
q Engine at low idling N 460.6 49.0 460.6 49.0
Brake pedal q Center of pedal {kg} {47.0 5.0} {47.0 5.0}
q Engine at low idling
Control lever/pedal operating effort

39.2 5.9 39.2 5.9


q Hydraulic oil temperature: Neutral o Raise {4.0 0.6} {4.0 0.6}
45 55 C
q Center of lever knob N 82.3 9.8 82.3 9.8
Blade lever Neutral o Float
{kg} {8.4 1.0} {8.4 1.0}
Neutral 28.4 4.9 28.4 4.9
Left/Right tilt {2.90.5} {2.90.5}
q Engine at low idling Neutral 21.6 4.9 21.6 4.9
q Hydraulic oil temperature: Raise/Lower {2.20.5} {2.20.5}
45 55 C N
Ripper lever
q Center of lever knob Neutral Tilt for- {kg} 20.6 4.9 20.6 4.9
ward/back {2.10.5} {2.10.5}
q Fan 100 % mode Engine at low
Min. speed q Hydraulic oil temperature: idling 350 100
Min. 40 C rpm
Engine at high
Fan

Max. speed 1,210 25 Max. 1,110


idling
Engine at high MPa 15.7 2.5 15.7 2.5
Circuit oil pressure
idling {kg/cm2} {16025} {16025}

D375A-6R 20-5
(01)
Standard service value table
Standard value table for machine

Machine model D375A-6R


Category

Standard value
Service limit
Item Measurement conditions Unit for new
value
machine
q Power train oil temperature: Engine at low 0.03 0.25 0.03 0.25
Within operating range idling {0.3 2.5} {0.3 2.5}
Torque converter
inlet pressure Engine at high 0.69 1.05 0.69 1.05
idling {7.0 10.7} {7.0 10.7}
Engine at low 0.03 0.20 0.03 0.20
Torque converter idling {0.3 2.0} {0.3 2.0}
outlet pressure Engine at high 0.44 0.70 0.44 0.70
idling MPa {4.5 7.0} {4.5 7.0}
Engine at low {kg/cm2}
Torque converter
idling
lockup clutch pres-
sure Engine at high 1.29 1.54 1.29 1.54
idling {13.2 15.7} {13.2 15.7}
Engine at low 2.25 2.87 2.25 2.87
Power train oil pressure

Torque converter idling {23.0 29.3} {23.0 29.3}


stator clutch pres-
sure Engine at high 2.55 2.87 2.55 2.87
idling {26.0 29.3} {26.0 29.3}
q Power train oil temperature: Engine at low 2.48 2.87 2.38 3.07
Within operating range idling {25.3 29.3} {24.3 31.3}
Transmission main
relief pressure Engine at high 2.68 2.87 2.58 3.07
idling {27.3 29.3} {26.3 31.3}
q Adjustment ID: Engine at low 2.25 2.84 2.06 3.13
5535 idling {23.0 29.0} {21.0 31.9}
Transmission F
Measure in (both
clutch pressure Engine at high 2.55 2.87 2.35 3.16
steering clutch
disengage modes) idling MPa {26.0 29.3} {23.9 32.2}
Engine at low {kg/cm2} 2.25 2.84 2.06 3.13
Transmission R idling {23.0 29.0} {21.0 31.9}
clutch pressure Engine at high 2.55 2.87 2.35 3.16
idling {26.0 29.3} {23.9 32.2}
Engine at low 2.06 2.35 1.86 2.55
Transmission 1st idling {21.0 24.0} {18.9 26.0}
clutch pressure Engine at high 2.06 2.35 1.86 2.55
idling {21.0 24.0} {18.9 26.0}

20-6 D375A-6R
(01)
Standard service value table
Standard value table for machine

Machine model D375A-6R


Category

Standard value
Service limit
Item Measurement conditions Unit for new
value
machine
q Adjustment ID: Engine at low 2.25 2.84 2.06 3.13
5535 idling {23.0 29.0} {21.0 31.9}
Transmission 2nd Measure in (both
clutch pressure steering clutch Engine at high 2.55 2.87 2.30 3.16
disengage modes) idling {26.0 29.3} {23.4 32.2}
Engine at low MPa 2.25 2.84 2.06 3.13
Transmission 3rd idling {kg/cm2} {23.0 29.0} {21.0 31.9}
clutch pressure Engine at high 2.55 2.87 2.30 3.16
idling {26.0 29.3} {23.4 32.2}
Transmission lubri- q Power train oil temperature: Engine at high 0.08 0.25 0.08 0.25
cating oil pressure Within operating range idling {0.8 2.5} {0.8 2.5}
q Power train oil temperature: Engine at low 2.25 2.84 2.2 3.04
Power train oil pressure

Within operating range idling {23.0 29.0} {22.4 31.0}


Steering left clutch
pressure Engine at high 2.55 2.87 2.4 3.07
idling {26.0 29.3} {24.4 31.3}
Engine at low 2.25 2.84 2.2 3.04
Steering left brake idling {23.0 29.0} {22.4 31.0}
pressure Engine at high 2.55 2.87 2.4 3.07
idling MPa {26.0 29.3} {24.4 31.3}
Engine at low {kg/cm2} 2.25 2.84 2.2 3.04
Steering right clutch idling {23.0 29.0} {22.4 31.0}
pressure Engine at high 2.55 2.87 2.4 3.07
idling {26.0 29.3} {24.4 31.3}
Engine at low 2.25 2.84 2.2 3.04
Steering right brake idling {23.0 29.0} {22.4 31.0}
pressure Engine at high 2.55 2.87 2.4 3.07
idling {26.0 29.3} {24.4 31.3}
Pin puller operating q Power train oil temperature: Engine at high MPa 2.55 0.10 Min. 2.2
Within operating range
pressure idling {kg/cm2} {26.0 1.0} {Min. 22}
q Flat ground 20.6 1.0 20.6 1.0
q Engine coolant tempera- F1
(3.50.2) (3.50.2)
ture: Within operating
range 10.6 0.6 10.6 0.6
F2
q Power train oil tempera- (6.80.3) (6.80.3)
ture: Within operating
9.0 0.4 9.0 0.4
Automatic gear shift mode

range F3L
Power train performance

(8.00.4) (8.00.4)
q Engine at high idling
q Run up distance: 10 - 30 6.1 0.3 6.1 0.3
F3
m (11.80.6) (11.80.6)
sec.
Travel speed q Measurement distance:
(km/h) 15.7 0.8 15.7 0.8
20 m R1
q ( ) indicates travel speed (4.60.2) (4.60.2)
8.1 0.4 8.1 0.4
R2
(8.90.4) (8.90.4)
7.4 0.3 7.4 0.3
R3L
(9.70.5) (9.70.5)

4.9 0.3 4.9 0.3


R3
(15.80.7) (15.80.7)

D375A-6R 20-7
(01)
Standard service value table
Standard value table for machine

Machine model D375A-6R


Category

Standard value
Service limit
Item Measurement conditions Unit for new
value
machine
q Flat ground 20.6 1.0 20.6 1.0
q Engine coolant tempera- F1
(3.50.2) (3.50.2)
ture: Within operating
range 10.6 0.6 10.6 0.6
Power train performance

Manual gear shift mode


F2
q Power train oil tempera- (6.80.3) (6.80.3)
ture: Within operating 6.1 0.3 6.1 0.3
range F3
sec (11.80.6) (11.80.6)
Travel speed q Engine at high idling
(km/h) 15.7 0.7 15.7 0.7
q Run up distance: 10 - 30 R1
m (4.60.3) (4.60.3)
q Measurement distance: 8.2 0.4 8.2 0.4
20 m R2
(8.70.4) (8.70.4)
q ( ) indicates travel speed
4.9 0.3 4.9 0.3
R3
(14.70.7) (14.70.7)
q Hydraulic oil temperature: Engine at low
45 55 C
idling
Unload pressure q Cylinder stroke end
Engine at high 2.45 (+1.37/0) 2.45 (+1.37/0)
idling {25 (+14/0)} {25 (+14/0)}
Engine at low 26.4 28.4 26.4 29.4
Blade tilt relief pres- idling {270 290} {270 300}
sure Engine at high 27.4 29.4 27.4 29.4
idling {280 300} {280 300}
Work equipment oil pressure

Engine at low 26.4 28.4 26.4 29.4


idling MPa {270 290} {270 300}
Ripper lift relief
pressure {kg/cm2}
Engine at high 27.4 29.4 27.4 29.4
idling {280 300} {280 300}
Engine at low 26.4 28.4 26.4 29.4
Ripper tilt relief idling {270 290} {270 300}
pressure Engine at high 27.4 29.4 27.4 29.4
idling {280 300} {280 300}
Engine at low 25.48 1.27 25.48 1.27
LS pressure idling {260 13} {260 13}
(Load sensing pres-
sure) Engine at high 25.48 1.27 25.48 1.27
idling {260 13} {260 13}
Control circuit oil q Hydraulic oil temperature: 45 55 C 3.43 4.12 3.43 4.12
pressure q Engine at high idling MPa {35 42} {35 42}
PPC valve output q Circuit oil pressure: Lever in neutral {kg/cm2} 3.43 4.12 Min. 3.33
pressure q Output pressure: Lever at stroke end {35 42} {Min. 34}

20-8 D375A-6R
(01)
Standard service value table
Standard value table for machine

Machine model D375A-6R


Category

Standard value
Service limit
Item Measurement conditions Unit for new
value
machine

Engine at low
7 13 20
idling

Raise
Engine at high
3.7 4.7 6
idling
Blade lift sec.
Engine at low
q Hydraulic oil tempera- 1.3 1.7 1.3 1.8
idling
ture: 45 55 C

Lower
q Apply no load to blade.
q Between ground surface Engine at high
1.3 1.7 1.3 1.8
and raised end of blade idling

Engine at low
24 6
idling
L.H. tilt

Engine at high
2.5 3.5 5
idling
Blade tilt sec.
Engine at low
q Hydraulic oil tempera- 24 6
idling
R.H. tilt

ture: 45 55 C
Work equipment speed

q Apply no load to blade. Engine at high


Work equipment

q Between left tilt end and 2.5 3.5 5


idling
right tilt end
Engine at low
46 7
idling
L.H. tilt
Dual tilt specification

Engine at high
2.5 3.5 5
idling

sec.
Engine at low
46 7
idling
R.H. tilt

q Hydraulic oil tempera-


ture: 45 55 C
q Apply no load to blade. Engine at high
2.5 3.5 5
q Between left tilt end and idling
Blade
right tilt end
dual tilt
Engine at low
24 5
idling
L.H. tilt
Single tilt specification

Engine at high
2.5 3.5 5
idling
sec.
Engine at low
q Hydraulic oil tempera- 24 5
idling
R.H. tilt

ture: 45 55 C
q Apply no load to blade. Engine at high
q Between left tilt end and 2.5 3.5 5
idling
right tilt end

D375A-6R 20-9
(01)
Standard service value table
Standard value table for machine

Machine model D375A-6R


Category

Standard value
Service limit
Item Measurement conditions Unit for new
value
machine
Engine at low
46 7

Dump
idling
Engine at high
2.5 3.5 5
idling
Engine at low
35 6
q Hydraulic oil tempera- idling
Blade pitch ture: 45 55 C sec.
q Apply no load to blade.
Between dump end and

Back
q
back end Engine at high
2.5 3.5 5
idling
Work equipment speed

Engine at low *G 46
7
idling *M 46
Raise

Engine at high *G 23
5
idling *M 2.5 3.5
Ripper lift sec.
q Hydraulic oil tempera- Engine at low
ture: 45 55 C 1.5 2.5 1.5 2.5
idling
Lower

q Apply no load to ripper.


Engine at high
q Between ground level 1.5 2.5 1.5 2.5
Work equipment

idling
and rising end of ripper
Engine at low
10 16 20
idling
Tilt in

Engine at high
4.5 5.5 7
idling
Ripper tilt Engine at low sec.
q Hydraulic oil tempera-
6 10 15
idling
Tilt back

ture: 45 55 C
q Apply no load to blade.
q Between forward tilt end Engine at high
2.8 3.8 6
and backward tilt end idling

q Hydraulic oil temperature:


45 55 C Engine at low
Max. 8 12
q Lever full stroke idling
Blade q Time required for the blade
to be lowered to the ground Engine at high
from the highest RAISE po- Max. 1.8 2.0
idling
sition and to lift the idler.
Time lag

Hydraulic oil temperature:


q sec.
45 55 C Engine at low

q Lever full stroke idling
q Start lowering operation at
Ripper
ripper max. raising position
*G Max. 1.0 *G 1.5
and measure time from Engine at high
when ripper reaches ground idling
until sprocket rises. *M Max. 1.5 *M 2
* G: Variable giant ripper specification, M: Variable multi-shank ripper specification

20-10 D375A-6R
(01)
Standard service value table
Standard value table for machine

Machine model D375A-6R


Category

Standard value
Service limit
Item Measurement conditions Unit for new
value
machine

Hydraulic drift
mm Max. 65 130
of lifted blade

q Hydraulic oil temperature: 45 55 C


q Engine stopped
q Measuring reduction of blade bottom height "h"
(for 5 minutes).

Hydraulic drift
of machine mm Max. 50 100
lifted by blade

q Hydraulic oil temperature: 45 55 C


Work equipment

Hydraulic drift

q Engine stopped
q Measure reduction of idler center height "h" (for
5 minutes).

Hydraulic drift
of machine mm Max. 50 80
tilted by blade

q Hydraulic oil temperature: 45 55 C


q Engine stopped
q Measuring reduction of track shoe bottom
height "h" (for 5 minutes).

Hydraulic drift
mm Max. 25 50
of lifted ripper

q Hydraulic oil temperature: 45 55 C


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

D375A-6R 20-11
(01)
Standard service value table
Standard value table for machine

Machine model D375A-6R


Category

Standard value
Service limit
Item Measurement conditions Unit for new
value
machine
Hydraulic drift

Hydraulic drift
of machine mm Max. 30 60
lifted by ripper
Work equipment

q Hydraulic oil temperature: 45 55 C


q Engine stopped
q Measure reduction of sprocket center height "h"
(for 5 minutes).
q Engine at high idling
Cylinder internal leakage

Blade tilt cylin- q Hydraulic oil temperature: 45 55 C Max. 3.0 12


der q Relieve cylinder and measure leakage for 1
minute.
Ripper lift cyl-
cc/min. Max. 3.6 12
inder

Ripper tilt cyl-


Max. 3.2 12
inder

20-12 D375A-6R
(01)
Shop Manual 30-1

BULLDOZER
D375A-6R

Machine model Serial number


D375A-6R 65001 and up

30 Testing and adjusting 30-1

D375A-6R 30-1
(01)
Contents

Contents 30-2
30 Testing and adjusting
Tools for testing, adjusting and troubleshooting ..................................................................... 30- 4
Diagnosis equipment list ...................................................................................................... 30- 4
Engine and cooling system ..................................................................................................... 30- 6
Testing engine speed........................................................................................................... 30- 6
Testing intake air pressure (boost pressure) ....................................................................... 30- 9
Testing exhaust temperature ............................................................................................... 30- 11
Testing exhaust gas color .................................................................................................... 30- 14
Adjusting valve clearance .................................................................................................... 30- 16
Measuring compression pressure........................................................................................ 30- 18
Testing blow-by pressure..................................................................................................... 30- 21
Testing engine oil pressure.................................................................................................. 30- 23
Handling of fuel system devices .......................................................................................... 30- 24
Releasing residual pressure from fuel system ..................................................................... 30- 25
Testing fuel pressure ........................................................................................................... 30- 26
Handling of reduced cylinder mode operation ..................................................................... 30- 27
Handling of no injection cranking operation ......................................................................... 30- 28
Testing leakage from pressure limiter and return rate from injector .................................... 30- 29
Bleeding air from fuel circuit................................................................................................. 30- 32
Testing fuel circuit for leakage ............................................................................................. 30- 34
Replacing and adjusting alternator and air conditioner compressor belt ............................. 30- 35
Measuring fan speed ........................................................................................................... 30- 36
Testing fan circuit oil pressure ............................................................................................. 30- 37
Bleeding air from fan pump.................................................................................................. 30- 38
Adjusting fuel control dial and decelerator pedal ................................................................. 30- 39
Power train.............................................................................................................................. 30- 42
Testing power train oil pressure........................................................................................... 30- 42
Adjusting transmission output speed sensor ....................................................................... 30- 56
Simple test procedure for brake performance...................................................................... 30- 57
Adjusting brake pedal and parking brake lever.................................................................... 30- 58
Adjusting position of pccs lever console .............................................................................. 30- 61
Emergency escape method when there is failure in power train ......................................... 30- 62
Undercarriage and frame ........................................................................................................ 30- 64
Inspecting wear of sprocket ................................................................................................. 30- 64
Testing and adjusting track shoe tension............................................................................. 30- 65
Hydraulic system..................................................................................................................... 30- 66
Testing and adjusting work equipment oil pressure............................................................. 30- 66
Testing control circuit main pressure ................................................................................... 30- 69
Testing PPC valve output pressure ..................................................................................... 30- 70
Adjusting play of PPC valve................................................................................................. 30- 72
Testing output pressure of ripper pin-puller solenoid valve ................................................. 30- 73
Checking location of cause of hydraulic drift of blade and ripper......................................... 30- 74
Testing leakage inside work equipment cylinder ................................................................. 30- 75
Releasing remaining pressure in work equipment cylinders................................................ 30- 76
Bleeding air from work equipment cylinders ........................................................................ 30- 77
Adjusting ripper lever position.............................................................................................. 30- 78
Work equipment...................................................................................................................... 30- 80
Adjusting work equipment lock lever.................................................................................... 30- 80
Adjusting blade .................................................................................................................... 30- 81
Cab and its attachments ......................................................................................................... 30- 84
Testing and adjusting operator's cab ................................................................................... 30- 84

30-2 D375A-6R
(01)
Contents

Electrical system ..................................................................................................................... 30- 90


Special functions of machine monitor (EMMS).................................................................... 30- 90
Handling of voltage circuit of engine controller .................................................................... 30- 148
Adjustment method when controller has been replaced...................................................... 30- 149
Preparation work for troubleshooting for electrical equipment system ................................ 30- 153
Inspection procedure of diode ............................................................................................. 30- 157
Handling of optional devices................................................................................................ 30- 158
Request for opening ORBCOMM terminal .......................................................................... 30- 159
Initialization procedures for VHMS controller....................................................................... 30- 161
Using method of KOMTRAX functions of ORBCOMM terminal .......................................... 30- 175
Precautions for replacing VHMS controller.......................................................................... 30- 178
Pm Clinic................................................................................................................................. 30- 184
Pm Clinic service ................................................................................................................. 30- 184

D375A-6R 30-3
(01)
Tools for testing, adjusting and troubleshooting
Diagnosis equipment list

Tools for testing, adjusting and troubleshooting 30-4


Diagnosis equipment list 30-4

Sym-
Testing/Adjusting item Part No. Part name Qty Remarks
bol
Testing intake air pres-
A 799-201-2202 Boost gauge kit 1 -101 200 kPa {-760 1,500 mmHg}
sure (boost pressure)
Testing exhaust temper- B 799-101-1502 Digital thermometer 1 -99.9 1,299C
ature 799-201-1150 Adapter connector 1 For Pm clinic specification
1 799-201-9001 Handy smoke checker 1
Testing exhaust gas
C Commercially Bosch index: 0 to 9
color 2 Smoke meter 1
available
Adjusting valve clear- Commercially Intake side: 0.32 mm,
D Feeler gauge 1
ance available Exhaust side: 0.62 mm
1 795-502-1590 Compression gauge 1 0 7 MPa {0 70 kg/cm2}
795-611-1220 Adapter 1
Testing compression 2
E 6261-71-6150 Gasket 1
pressure
795-799-5410 Adapter 1
3
795-799-5420 Remover 1
Testing blow-by pres-
F 799-201-1504 Blow-by checker 1
sure
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Pressure gauge: 60 MPa
Testing engine oil pres- 790-261-1204 Digital hydraulic tester 1
G {600 kg/cm2}
sure 2 799-401-2320 Gauge 1 Pressure gauge: 1.0 MPa {10 kg/cm2}
799-101-5230 Nipple 1
3
6215-81-9720 O-ring 1
799-101-5002 Hydraulic tester 1
1 *As common as G1
790-261-1204 Digital hydraulic tester 1
2 799-401-2320 Gauge 1 *As common as G2
Testing fuel pressure H
799-101-5160 Nipple 1 R 1/8
3 795-471-1450 Adapter 1 M8 x 1.25
07005-00812 Gasket 1
1 6167-11-6640 Spacer 1 Inside diameter: 10 mm
2 6206-71-1770 Joint 1 Joint diameter: 10 mm
Commercially
3 Hose 1 f 5 mm (Inside diameter) x 2 3 m
available
Testing fuel return rate Commercially
J 4 Hose 1 f 16 mm (Inside diameter) x 2 3 m
and leakage available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
799-101-5002 Hydraulic tester 1
Testing power train oil 1 *As common as G1
K 790-261-1204 Digital hydraulic tester 1
pressure
2 799-401-2320 Gauge 1 *As common as G2
19M-06-32820 Switch assembly 1
Emergency escape 1 7824-66-6430 Resistor 1
method when there is L
failure in power train 195-06-71220 Wiring harness 1
2 790-190-1601 Pump assembly 1

30-4 D375A-6R
(01)
Tools for testing, adjusting and troubleshooting
Diagnosis equipment list

Sym-
Testing/Adjusting item Part No. Part name Qty Remarks
bol
Testing and adjusting 799-101-5002 Hydraulic tester 1
work equipment oil 1 *As common as G1
790-261-1204 Digital hydraulic tester 1
pressure, Testing con- M
799-101-5220 Nipple 2 M10 x 1.25
trol circuit main pres- 2
sure 07002-11023 O-ring 2
Testing PPC valve out- 799-101-5002 Hydraulic tester 1
N 1 *As common as G1
put pressure 790-261-1204 Digital hydraulic tester 1
Testing output pressure 799-101-5002 Hydraulic tester 1
1 *As common as G1
of ripper pin-puller sole- P 790-261-1204 Digital hydraulic tester 1
noid valve 2 799-401-3200 Adapter 1 Size 03
Testing leakage inside
Commercially
work equipment cylin- Q Measuring cylinder 1
available
der
799-101-5002 Hydraulic tester 1
1 *As common as G1
790-261-1204 Digital hydraulic tester 1
Testing fan circuit oil
S 2 790-301-1330 q Flange 1 Size: 10
pressure
3 07372-21055 Bolt 4
4 07000-13035 O-ring 1
Testing operating effort 79A-264-0021 Push-pull scale 1 0 294 N {0 30 kg}
T
and depressing force 79A-264-0091 Push-pull scale 1 0 490 N {0 50 kg}
Testing stroke and Commercially
U Ruler 1
hydraulic drift available
Testing work equip- Commercially
V Stopwatch 1
ment speed available
Testing voltage and Commercially
W Multimeter 1
resistance available
1 799-608-3211 Discket 1
Initialization of VHMS
Z 2 799-608-3220 Wiring harness 1
controller Commercially Lap top type personal com- OS: Windoes98/2000/Me/XP/VISTA
3 1
available puter [With RS232C terminal]
799-601-7400 T-adapter assembly 1 AMP040 Connector
799-601-7500 T-adapter assembly 1 AMP040 Connector
799-601-9000 T-adapter assembly 1 DT, HD30 connector
799-601-9300 T-adapter assembly 1 DRC26-24, 40-pin
799-601-7360 Adapter 1 Relay (5 pins)
799-601-3450 Adapter 1 VHMS download harness
799-601-4100 T-adapter assembly 1 Connected with engine
799-799-5530 q T-adapter 1 Engine coolant, oil, fuel temperature
795-799-5540 q T-adapter 1 Boost temperature sensor
Diagnosis sensor and 799-601-4130 q T-adapter 1 Ne sensor
harness 799-601-4150 q T-adapter 1 Oil pressure sensor
799-601-4211 q T-adapter 1 Controller (50 poles)
799-601-4220 q T-adapter 1 Controller (60 poles)
799-601-4240 q Socket 1 Ambient pressure sensor
799-601-4250 q Socket 1 Boost pressure sensor
799-601-4260 q T-adapter 1 Controller (4 poles)
799-601-9020 q T-adapter 1 Injector
799-601-9420 q T-adapter 1 Common rail pressure sensor
799-601-9430 q T-adapter 1 Supply pump PCV
799-601-9030 T-adapter 1 G sensor

D375A-6R 30-5
(01)
Engine and cooling system
Testing engine speed

Engine and cooling system 30-6


Testing engine speed 30-6
3. Measuring high idle speed
k Park the machine on a level ground and low- 1) Start the engine and set the fuel control dial
er the work equipment and set firmly on the in the high idle (MAX) position.
ground, then set the parking brake lever and 2) Set the PCCS lever, blade control lever, and
work equipment lock lever to the LOCK posi- ripper control lever in neutral and measure
tion. the engine speed.
a Measure the engine speed under the following a The parking brake lever and work equip-
conditions. ment lock lever may be kept in the LOCK
q Coolant temperature: position.
Within operating range
q Power train oil temperature: 4. Measuring decelerator pedal speed
Within operating range 1) Start the engine and set the fuel control dial
q Hydraulic oil temperature: 45 55C in the high idle (MAX) position.
q Working mode: P-mode 2) Set the PCCS lever, blade control lever, and
q Gear shift mode: Manual ripper control lever in neutral, press the
decelerator pedal to the stroke end, and
1. Preparation work measure the engine speed.
Measure the engine speed with the Adjustment a The parking brake lever and work equip-
function in the service mode of the machine ment lock lever may be kept in the LOCK
monitor. position.
a For the operating method, see "Special func-
tions of machine monitor (EMMS)". 5. Measuring torque converter stall speed
q Adjustment ID: 0530 (Stall mode) 1) Start the engine and set the fuel control dial
a When stalling the torque converter for a pur- in the low idle (MIN) position.
pose other than measuring the engine 2) Operate the shift up (UP) switch of the PCCS
speed, be sure to use this adjustment code, lever and set the preset mode display section
too. to [F3-R3].
a The preset mode display section (at the
right bottom of the screen) can be set to
[F3-R3] only while the adjustment func-
tion is selected.
3) With the brake pedal depressed securely and
the parking brake lever in the free position,
set the PCCS lever in the forward position.
a Before going to the next step, check that
[F3] is displayed in the gear speed display
section (at the right bottom of the screen).
a Keep the steering unit in neutral.
4) Press the decelerator pedal and set the fuel
control dial in the high idle (MAX) position.
5) Return the decelerator pedal slowly to stall
the torque converter with the engine at high
2. Measuring low idle speed
idle.
k Keep the brake pedal securely de-
1) Start the engine and set the fuel control dial
in the low idle (MIN) position.
pressed and keep your right foot on
2) Set the PCCS lever, blade control lever, and
the decelerator pedal for safety until
ripper control lever in neutral and measure
the work is finished.
the engine speed.
6) Right after the power train oil temperature
a The parking brake lever and work equip-
gauge (T/C TEMPERATURE) indicates 118
ment lock lever may be kept in the LOCK
C, return the PCCS lever to the neutral posi-
position.
tion.

30-6 D375A-6R
(01)
Engine and cooling system
Testing engine speed

a The top of the green range of the power a The preset mode display section (at the
train oil temperature gauge indicates ap- right bottom of the screen) can be set to
proximately 118 to 120 C. [F3-R3] only while the adjustment func-
7) Repeat above steps 3) 6) 3 times. tion is selected.
8) Perform steps 3) to 5) again and measure the 3) Set the work equipment lock lever in the free
engine speed when the power train oil position and operate the ripper control lever
temperature gauge (T/C TEMPERATURE) to set the ripper lift cylinder to the raise stroke
indicates 118 C. end.
a Immediately after finishing measuring, re- 4) With the brake pedal depressed securely and
turn the PCCS lever to the neutral posi- the parking brake lever in the free position,
tion and lower the power train oil set the PCCS lever in the forward position.
temperature with the engine at high idle. a Before going to the next step, check that
[F3] is displayed in the gear speed display
6. Measuring torque converter stall speed section (at the right bottom of the screen).
(Inspection on Pm clinic screen) a Keep the steering unit in neutral.
1) Start the engine and set the fuel control dial 5) Press the decelerator pedal and set the fuel
in the low idle (MIN) position. control dial in the high idle (MAX) position.
2) Switch the machine monitor to the "Pm clinic" 6) Return the decelerator pedal slowly to stall
function display of the service mode. the torque converter with the engine at high
a For the operating method, see "Special idle.
functions of machine monitor (EMMS)". k Keep the brake pedal securely de-
pressed and keep your right foot on
the decelerator pedal for safety until
the work is finished.
7) Right after the power train oil temperature
gauge (T/C TEMPERATURE) indicates 118
C, return the PCCS lever to the neutral posi-
tion.
a The top of the green range of the power
train oil temperature gauge indicates ap-
proximately 118 to 120 C.
8) Repeat above steps 4) 7) 3 times.
9) Perform steps 4) to 6) again, operate the
ripper control lever to relieve the ripper raise
system, and measure the engine speed
3) Operate the shift up (UP) switch of the PCCS
when the power train oil temperature gauge
lever and set the preset mode display section
(T/C TEMPERATURE) indicates 118 C.
to [F2-R2].
a Immediately after finishing measuring, re-
4) With the brake pedal depressed securely and
turn the PCCS lever to the neutral posi-
the parking brake lever in the free position,
tion and lower the power train oil
set the PCCS lever in the forward position.
temperature with the engine at high idle.
5) Shift to 3rd gear by operating the shift up
(UP) switch of PCCS lever.
8. Measuring torque converter stall + Work
a Before going to the next step, check that
equipment relief speed (Full stall speed)
[F3] is displayed in the gear speed display
(Inspection on Pm clinic screen)
section (at the right bottom of the screen).
1) Start the engine and set the fuel control dial
a Keep the steering unit in neutral.
in the low idle (MIN) position.
6) Repeat the measuring process in a similar
2) Switch the machine monitor to the "Pm clinic"
way by following step 4) and later of "5.
function display of the service mode.
Measuring torque converter stall speed."
a For the operating method, see "Special
functions of machine monitor (EMMS)".
7. Measuring torque converter stall + work
equipment relief speed (Full stall speed)
1) Start the engine and set the fuel control dial
in the low idle (MIN) position.
2) Operate the shift up (UP) switch of the PCCS
lever and set the preset mode display section
to [F3-R3].

D375A-6R 30-7
(01)
Engine and cooling system
Testing engine speed

3) Operate the shift up (UP) switch of the PCCS


lever and set the preset mode display section
to [F2-R2].
4) With the brake pedal depressed securely and
the parking brake lever in the free position,
set the PCCS lever in the forward position.
5) Shift to 3rd gear by operating the shift up
(UP) switch of PCCS lever.
a Before going to the next step, check that
[F3] is displayed in the gear speed display
section (at the right bottom of the screen).
a Keep the steering unit in neutral.
6) Repeat the measuring process in a similar
way by following Step 5) and later of "7.
Measuring torque converter stall + Work
equipment relief speed (Full stall speed)".

30-8 D375A-6R
(01)
Engine and cooling system
Testing intake air pressure (boost pressure)

Testing intake air pressure (boost 2) Test the boost pressure when the torque
pressure) 30-9 converter is stalled at high idle speed.
a For the torque converter stall procedure,
see Step 3) and later in "6. Measuring
a Testing instruments of intake air pressure (boost torque converter stall speed (Inspection
pressure) on Pm clinic screen)" of "Testing engine
Symbol Part No. Part name speed".
A 799 - 201 - 2202 Boost gauge kit
2. Testing with boost gauge kit
k Park the machine on a level ground and low- 1) Open the engine left cover.
er the work equipment and set firmly on the 2) Remove boost pressure pickup plug (1) at
ground, then set the parking brake lever and the rear of the air intake manifold.
work equipment lock lever to the LOCK posi-
tion.
k When installing and removing the testing in-
strument, take care not to touch a hot part of
the engine.
a A nipple (quick coupler) is installed to the intake
air pressure (boost pressure) pickup port of the
Pm clinic specification machine.
a Measure the intake air pressure (boost pres-
sure) under the following condition.
q Coolant temperature:
Within operating range
q Power train oil temperature:
Within operating range
q Hydraulic oil temperature: 45 55C
3) Install nipple [1] of boost gauge kit A and
q Working mode: P-mode
connect gauge [2].
q Gear shift mode: Manual
a Normally, the intake air pressure (boost pres-
sure) should be tested while the engine is run-
ning at the rated output. In the field, however, an
approximate value can be obtained by stalling
the torque converter.

1. Testing using machine monitor (Pm clinic)


1) Turn starting switch to ON position and
switch machine monitor to "Pm clinic" func-
tion display of the service mode.
a For the operating method, see "Special
functions of machine monitor (EMMS)".
a The VHMS specification machine is
shown as an example in the figure.

4) Run the engine at middle or higher speed


and bleed oil from the hose.

D375A-6R 30-9
(01)
Engine and cooling system
Testing intake air pressure (boost pressure)

a Install the connecting parts of the gauge


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

5) Switch the machine monitor to the "Adjust-


ment" function display of the service mode.
q Adjustment code: 0530 (Stall mode)
a For the operating method, see "Special
functions of machine monitor (EMMS)".

6) Test the intake air pressure (boost pressure)


while the engine is running at high idle and
the torque converter is stalling.
a For the torque converter stall procedure,
see "5. Measuring torque converter stall
speed" of "Testing engine speed".

7) After completing the test remove the testing


equipment and set to the original condition.
q Remove the remaiSning liquid gasket
from the thread part of the removed plug
with a wire brush, and then apply adhe-
sive or liquid gasket and install the plug.
2 Plug: LT-2 or LG-5
3 Plug: 9.8 19.6 Nm {1.0 2.0 kgm}

30-10 D375A-6R
(01)
Engine and cooling system
Testing exhaust temperature

Testing exhaust temperature 30-1

a Checking tools for exhaust gas temperature


Sym-
Part No. Part name
bol
B 799-101-1502 Digital thermometer

a Checking tools for exhaust gas temperature (for


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

k Park the machine on a level ground and low-


er the work equipment and set firmly on the
ground, then set the parking brake lever and
work equipment lock lever to the LOCK posi-
tion.
k Remove and install the testing tools after the
exhaust manifold temperature has lowered.
a Test the exhaust temperature under the follow-
ing conditions. 4) Procedure for measuring at maximum
q Engine coolant temperature: Within operat-
temperature while troubleshooting
ing range Check the maximum exhaust gas tempera-
q Power train oil temperature:
ture during actual operations.
Within operating range a Use the digital temperature gauge in the
q Hydraulic oil temperature: 45 55 C
PEAK mode.
q Working mode: P-mode
a The exhaust gas temperature largely de-
q Gear shift mode: Manual
pends on the ambient air temperature (in-
take air temperature of engine).
1. Measuring with digital thermometer Accordingly, if any abnormal value is ob-
1) Open the engine right side cover, and tained, correct it using the following calcu-
remove the heat insulation cover. lation.
q Corrected value [C] = Measured val-
2) Remove the exhaust gas temperature ue + 2 x (20 - Ambient temperature)
inspection plug.
2. Procedure for testing periodically by preven-
3) Install sensors [1] of digital temperature tive maintenance service (Pm clinic)
gauge B and connect them to meter [2]. a If the torque converter alone has stalled, the
a Clamp the wiring harness of the digital torque converter oil will overheat before the
thermometer not to come into contact exhaust gas temperature stabilizes. There-
with any hot parts during measuring. fore, check the exhaust gas temperature ac-
cording to the following procedure.
1) Turn the starting switch to the ON position
and switch the machine monitor to the
"Adjustment" function display of the service
mode.
q Adjustment code: 0530 (Stall mode)
a For the operating method, see "Special
functions of machine monitor (EMMS)"
section.

D375A-6R 30-11
(01)
Engine and cooling system
Testing exhaust temperature

k When the power train oil temperature


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

2) Run the engine to warm it up.


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

30-12 D375A-6R
(01)
Engine and cooling system
Testing exhaust temperature

2) Run the engine to warm it up.


a The standard warm-up operation is as fol-
lows.
q Low idle: 3 minutes
q Run at a medium speed: 1 minute
q High idle: 1 minute
3) Set the fuel control dial to the low idle (MIN)
position.
4) Operate the shiftup (UP) switch of the PCCS
lever and set the preset mode display section
to [F2-R2].
5) With the brake pedal depressed securely and
the parking brake lever in the free position,
set the PCCS lever in the forward position.
6) Shift to 3rd gear by operating the shift up
(UP) switch of PCCS lever.
a Before going to the next step, check that
[F3] is displayed in the gear speed display
section (at the right bottom of the screen).
a Keep the steering unit in neutral.
7) Repeat the measuring process in the similar
way by following Step 5) and later of "2. Peri-
odic measurement procedure using the
preventive maintenance service (Pm clinic)".

D375A-6R 30-13
(01)
Engine and cooling system
Testing exhaust gas color

Testing exhaust gas color 30-14


2. Testing with C2smoke meter
a Checking tools for exhaust gas color 1) Insert probe [1] of the smoke meter C2 into
Symbol Part No. Part name the outlet of the exhaust pipe and fix it to the
1 799-201-9001 Handy smoke checker exhaust pipe using a clip.
C Commercially
2 Smoke meter
available

k Park the machine on a level ground and low-


er the work equipment and set firmly on the
ground, then set the parking brake lever and
work equipment lock lever to the LOCK posi-
tion.
k Be careful not to touch any hot part when re-
moving or installing the checking tools.
a If an air source and an electric power source are
not available in the field, use a handy smoke
checker C1. When recording official data, use a
smoke meter C2.
a Check the exhaust gas color under the following 2) Connect the probe hose, receptacle of the
condition. accelerator switch, and air hose to the smoke
q Engine coolant temperature: Within operat- meter C2.
ing range a Limit the supplied air pressure to 1.5 MPa
q Working mode: P-mode
{15 kg/cm2}.
q Gear shift mode: Manual
3) Connect the power cable to an AC recep-
tacle.
1. Testing with C1handy smoke checker
a Before connecting the cable, check that
1) Stick a sheet of filter paper to smoke checker
the power switch of the smoke meter is
C1.
turned OFF.
2) Insert the exhaust gas intake pipe into the
4) Loosen the cap nut of the suction pump and
exhaust pipe.
fit the filter paper.
3) Start the engine.
a Fit the filter paper securely so that the ex-
4) Accelerate the engine suddenly or run it at
haust gas will not leak.
high idle and operate the handle of smoke
5) Turn on the power switch of smoke meter C2.
checker C1 so that the filter paper will absorb
the exhaust gas.

5) Remove the filter paper and compare it with


the attached scale.
6) After completing the test remove the testing
equipment and set to the original condition.

30-14 D375A-6R
(01)
Engine and cooling system
Testing exhaust gas color

6) Start the engine.


7) Accelerate the engine suddenly or run at high
idle, and depress the accelerator switch of
smoke meter C2, at the same time to collect
the exhaust gas color on the filter.
8) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated
value.
9) After completing the test remove the testing
equipment and set to the original condition.

D375A-6R 30-15
(01)
Engine and cooling system
Adjusting valve clearance

Adjusting valve clearance 30-16

a Adjusting tools for valve clearance


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

k Park the machine on a level ground and low-


er the work equipment and set firmly on the
ground, then set the parking brake lever and
work equipment lock lever to the LOCK posi-
tion.

1. Remove the engine hood.

2. Remove cylinder head cover.


a Remove covers (1) and (2), bracket (3) and 6
cylinder head covers (4). For details, see
Disassembly and assembly volume, "Re-
moval and installation of cylinder head as-
sembly".

4. When the No. 1 cylinder is at the compression


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

30-16 D375A-6R
(01)
Engine and cooling system
Adjusting valve clearance

6. Rotate the crackshaft forward one turn and


adjust the valve clearance indicated by Q of the
valve layout plan.
a The adjustment method is the same as
above.

7. After finishing adjustment, return the removed-


parts.
3 Cylinder head cover mounting bolt:
{No. 1, 3, 4, 5, 6 cylinders}
9.8 1.0 Nm {1.0 0.1 kgm}
{No.2 cylinder}
58.8 73.5 Nm {6 7.5 kgm}

D375A-6R 30-17
(01)
Engine and cooling system
Measuring compression pressure

Measuring compression pressure 30-18


a Remove the terminal on the injector side and
a Testing tools for compression pressure the mounting bolt on the rocker housing side,
Sym- and remove the injector wiring harness from
Part No. Part name the injector.
bol
1 795-502-1590 Compression gauge a Loosen the 2 terminal nuts alternately.
795-611-1220 Adapter
2
E 6261-71-6150 Gasket 5. Remove injector holder (7), and remove injector
795-799-5410 Adapter (8).
3
795-799-5420 Remover

k Park the machine on a level ground and low-


er the work equipment and set firmly on the
ground, then set the parking brake lever and
work equipment lock lever to the LOCK posi-
tion.
k When testing the compression pres-sure,
take care not to burn yourself on the exhaust
manifold, muffler, etc. or get caught in a ro-
tating part.
a Measuring the compression pressure under the
following condition.
(Engine oil temperature: 40 60C)
a Insert the pin (indicated by the arrow) at the
1. Remove the engine hood.
end of the toolE3 into hole (a) of adaptor (9),
and pull out the injector by moving the weight
2. Remove cylinder head cover.
of tool E3 up and down.
a Remove covers (1) and (2), bracket (3) and
cylinder head cover (4) to test the compres-
sion pressure. For details, see Disassembly
and assembly volume, "Removal and instal-
lation of cylinder head assembly".

3. Adjust the valve clearance of the cylinder to be


inspected. For details, see "Testing and
adjusting valve clearance".

4. Disconnect fuel high-pressure tube (5) and


injector wiring harness (6).

30-18 D375A-6R
(01)
Engine and cooling system
Measuring compression pressure

6. Install adapter E2 to the injector mounting hole 2) Press injector (8) with adaptor (9) into the
and connect compression gauge E1. cylinder head by hand.
a Fit the gasket to the injector end without fail
a Fix the adapter with the injector holder.
3 Holder mounting bolt :
58.8 73.5 Nm {6 7.5 kgm}
a By coating a small amount of oil to the con-
necting portions of the adapter and gauge,
air will not leak easily.

3) Install holder (7) and tighten bolt (13) and


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

a Install the injector wiring harness according


to the following procedure
1) Assemble injector wiring harness (6) from the
8. Rotate the engine with the starting motor and inside of rocker arm housing and fix the
test the compression pressure. connector side with plate (15).
a Read the pressure gauge pointer when it is
stabilized.
9. After completing the test remove the testing
equipment and set to the original condition.
a Install the injector and fuel high-pressure
tube according to the following procedure.
1) Install gasket (10) and O-rings (11) and (12).
a Take care not to install O-ring (11) to the
groove (b).
2 O-ring: Engine oil

D375A-6R 30-19
(01)
Engine and cooling system
Measuring compression pressure

2) Fit spacer (16) and fix it with bolt (17).


3) Alternately tighten nuts (18) on the injector
side.
3 Nut:
2 0.2 Nm {0.2 0.02 kgm}

a Tighten the cylinder head cover mounting


bolt with the following torque.
3 Cylinder head cover mounting bolt:
{No. 1, 3, 4, 5, 6 cylinders}
9.8 1.0 Nm {1.0 0.1 kgm}
{No.2 cylinder}
58.8 - 73.5 Nm {6 - 7.5 kgm}

30-20 D375A-6R
(01)
Engine and cooling system
Testing blow-by pressure

Testing blow-by pressure 30-21


a Measuring tools for blow-by pressure 3) Turn the starting switch to the ON position
Sym- and switch the machine monitor to the
Part No. Part name
bol "Adjustment" function display of the service
F 799- 201-1504 Blow-by checker mode.
q Adjustment code: 0530 (Stall mode)

k Park the machine on a level ground and low- a For the operating method, see "Special
er the work equipment and set firmly on the functions of machine monitor (EMMS)".
ground, then set the parking brake lever and
work equipment lock lever to the LOCK posi-
tion.

a Measure the blow-by pressure under the follow-


ing condition.
q Engine coolant temperature: Within operat-
ing range
q Power train oil temperature:
Within operating range
q Hydraulic oil temperature: 45 55 C
q Working mode: P-mode
q Gear shift mode: Manual

4) Run the engine at high idle and test the


1. Testing with blowby kit blow-by pressure when the torque converter
1) Open the engine left side cover and pull out stalls.
blow-by hose (1). a For the torque converter stall procedure,
see "5. Measuring torque converter stall
2) Install nozzle [1] and hose [2] of blowby speed" of "Testing engine speed".
checker F to blowby hose (1) and connect a Blow-by pressure varies greatly with the
them to gauge [3]. condition of the engine. Therefore, if the
value by the test is considered unusual,
make a check for excessive oil consump-
tion, bad color of exhaust gas, early oil
deterioration, early oil contamination,
etc., which are related to improper
blow-by pressure.
5) After completing the test remove the testing
equipment and set to the original condition.

D375A-6R 30-21
(01)
Engine and cooling system
Testing blow-by pressure

2. Testing for VHMS specification


1) Turn starting switch to ON position and
switch machine monitor to "Pm clinic" func-
tion display of the service mode.
a For the operating method, see "Special
functions of machine monitor (EMMS)".

2) Test the blowby pressure when the torque


converter is stalled at high idle speed.
a For the torque converter stall procedure,
see Step 3) and later in "6. Measuring
torque converter stall speed (Inspection
on Pm clinic screen)" of "Testing engine
speed".

30-22 D375A-6R
(01)
Engine and cooling system
Testing engine oil pressure

Testing engine oil pressure 30-23


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

k Park the machine on a level ground and low-


er the work equipment and set firmly on the
ground, then set the parking brake lever and
work equipment lock lever to the LOCK posi-
tion.

a A nipple (quick coupler) is installed into the hy-


draulic oil inspection port of the engine for the 3) Install nipple G3 and connect it to gauge G2.
Pm clinic specification machine.
a Measure the engine oil pressure under the fol-
lowing condition.
q Engine oil temperature: Min. 70 C
q Engine coolant temperature: Within operat-
ing range
q Working mode: P-mode
q Gear shift mode: Manual

1. Testing using machine monitor (Pm clinic)


1) Turn starting switch to ON position and
switch machine monitor to "Pm clinic" func-
tion display of the service mode.
a For the operating method, see "Special
functions of machine monitor (EMMS)". 4) Run the engine and measure the engine oil
pressure at low idle and also at high idle.

2) Run the engine and measure the engine oil


pressure at low idle and also at high idle.
5) After completing the test remove the testing
equipment and set to the original condition.

D375A-6R 30-23
(01)
Engine and cooling system
Handling of fuel system devices

Handling of fuel system devices 30-24

a Precautions for checking and maintaining fuel


system
The common rail fuel injection system (CRI)
consists of more precise parts than the conven-
tional fuel injection pump and nozzle. If foreign
matter enters this system, it can cause a trouble.
When checking and maintaining the fuel system,
take care more than the past. If dust, etc. sticks
to any part, wash that part thoroughly with clean
fuel.
a Precautions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter
cartridge
Since the common rail fuel injection system
(CRI) consists of more precise parts than the
conventional fuel injection pump and nozzles, it
employs a high-efficiency special filter to prevent
foreign matter from entering it. If a filter other
than the genuine one is used, the fuel system
may have a trouble. Accordingly, never use such
a filter.

30-24 D375A-6R
(01)
Engine and cooling system
Releasing residual pressure from fuel system

Releasing residual pressure from


fuel system 30-25

a Pressure is generated in the low-pressure circuit


and high-pressure circuit of the fuel system while
the engine is running.
Low pressure circuit: Feed pump Fuel main
filter Fuel supply pump
High-pressure circuit: Supply pump Common
rail Injector
a The pressure in both low-pressure circuit and
high-pressure circuit lowers to a safety level au-
tomatically 30 seconds after the engine is
stopped.
a Before the fuel circuit is checked and its parts
are removed, the remaining pressure in the fuel
circuit must be released completely. According-
ly, observe the following.
k Before checking the fuel system or removing
its parts, wait at least 30 seconds after stop-
ping the engine until the residual pressure in
the fuel circuit is released. (Do not start the
work just after stopping the engine since
there is residual pressure.)

D375A-6R 30-25
(01)
Engine and cooling system
Testing fuel pressure

Testing fuel pressure 30-26


3. Install nipple H3 and connect it to gauge H2.
a Measuring tools for fuel pressure
Sym-
Part No. Part name
bol
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
2 799-401-2320 Gauge
H
799-101-5160 Nipple (R 1/8)
3 795-471-1450 Adapter (M8 x 1.25)
07005-00812 Gasket

k Park the machine on a level ground and low-


er the work equipment and set firmly on the
ground, then set the parking brake lever and
work equipment lock lever to the LOCK posi-
tion.
4. Start the engine and inspect the fuel pressure
a Test only the fuel pressure in the low-pressure with the engine running at high idle or at the
circuit from the feed pump through the engine equivalent of rated output speed (stall load).
controller cooler and fuel filter to the supply a If the fuel pressure is in the following range, it
pump. is normal.
k Since the pressure in the high-pressure cir- Engine speed Fuel pressure
cuit from the supply pump through the com- At high idle or at the 0.15 0.3 MPa
equivalent of rated out-
mon rail to the injector is very high, it cannot {1.5 3 kg/cm2}
put speed
be measured.
a Test the fuel pressure under the following condi-
tions.
q Working mode: P-mode
q Gear shift mode: Manual

1. Open the engine left cover.

2. Remove plug (1).

5. After completing the test remove the testing


equipment and set to the original condition.

30-26 D375A-6R
(01)
Engine and cooling system
Handling of reduced cylinder mode operation

Handling of reduced cylinder


mode operation 30-27

a Reduced cylinder mode operation means to run


the engine with the fuel injectors of 1 or more cyl-
inders disabled electrically to reduce the number
of effective cylinders. The purposes and effects
of this operation are as follows.

1. This operation is used to find out a cylinder


which does not output power normally (or,
combustion in it is abnormal).

2. When a cylinder is selected for the reduced


cylinder mode operation, if the engine speed and
output do not change from the normal operation
(all-cylinder operation), that cylinder has 1 or
more defects.
q Leaking at cylinder head gasket
q Defective injection
q Defective piston, piston ring and cylinder lin-
er
q Defective valve mechanism (Moving valve
system)
q Defect in electrical system

3. Since the common rail fuel injection system


controls the injector of each cylinder electroni-
cally, the operator can perform the cylinder cut
out mode operation easily with switches to find
out a defective cylinder.
a To implement reduced cylinder mode opera-
tion, see "Special functions of monitor panel
(EMMS)".
a Use the reduced cylinder mode for only the
purpose of troubleshooting.

D375A-6R 30-27
(01)
Engine and cooling system
Handling of no injection cranking operation

Handling of no injection cranking


operation 30-28

a No-injection cranking means to crank the engine


with the starting motor while all the injections are
stopped electrically. The purpose and effect of
this operation are as follows.
q When a machine or engine has been stored for
a long time, implementing the no-injection crank-
ing before starting the engine lubricates the en-
gine parts and thus prevents its seizure.
a Do not use the no-injection cranking function for
any purpose other than the above.
a To perform no-injection cranking operation, see
"Special functions of machine monitor (EMMS)".

30-28 D375A-6R
(01)
Engine and cooling system
Testing leakage from pressure limiter and return rate from injector

Testing leakage from pressure limiter and return rate from injector 30-29

a Testing instruments for fuel return rate and leak- a Test the fuel return rate and leakage under the
age following conditions.
Symbol Part No. Part name q Working mode: P-mode
1 6167-11-6640 Spacer q Gear shift mode: Manual
2 6206-71-1770 Joint
Commercially
3 Hose
available
Commercially
J 4 Hose
available
Commercially
5 Measuring cylinder
available
Commercially
6 Stopwatch
available
a Prepare an oil pan of about 20 l to receive the oil
that will flow out during the testing process..

k Park the machine on a level ground and low-


er the work equipment and set firmly on the
ground, then set the parking brake lever and
work equipment lock lever to the LOCK posi-
tion.

D375A-6R 30-29
(01)
Engine and cooling system
Testing leakage from pressure limiter and return rate from injector

1. Preparation work
1) Remove tube (3) between common rail (1)
and block (2).
2) Insert spacer J1 on block (2) side and tighten
the removed joint bolt again.
3 Joint bolt:
9.8 12.7 Nm {1.0 1.3 kgm}
a Be sure to fit the gaskets to both ends of
the spacer.

2. Testing leakage from pressure limiter


1) Route inspection hose J3 in such that it may
be free from slack and then insert its end to
the oil pan (saucer).
2) Turn the starting switch to the ON position
and switch the machine monitor to "Adjust-
ment" function display of the service mode.
q Adjustment code: 0530 (Stall mode)
a For the operating method, see "Special
3) Insert joint J2 to common rail (1) side and functions of machine monitor (EMMS)".
tighten the currently removed joint bolt again.
3 Joint bolt:
17.7 22.6 Nm {1.8 2.3 kgm}
a Be sure to fit the gaskets to both ends of
the joint.
4) Connect inspection hose J3 to the tip of joint
J2.
a Bind the connecting part of the test hose
with a wire, etc. to prevent it from coming
off.
a The above is the preparation work for
testing the leakage from the pressure lim-
iter.

3) Run the engine at high idle and stall the


torque converter. After the engine speed is
stabilized, measure the return rate in 1
minute with measuring cylinderJ5.
a For the torque converter stall procedure,
see "5. Measuring torque converter stall
speed" of "Testing engine speed".
a You may test for 20 seconds and judge by
multiplying the result by 3.
a If the leakage from the pressure limiter is
in the following range, it is normal.
Engine speed Leakage
(rpm) (cc/min)
Equivalent to rated oper-
Max. 10
ation

30-30 D375A-6R
(01)
Engine and cooling system
Testing leakage from pressure limiter and return rate from injector

3) Run the engine at high idle and stall the


torque converter. After the engine speed is
stabilized, measure the return rate in 1
minute with measuring cylinder J5.
a For the torque converter stall procedure,
see "5. Measuring torque converter stall
speed" of "Testing engine speed".
a You may test for 20 seconds and judge by
multiplying the result by 3.
a If the supply pump is not supplying fuel,
the engine speed may not rise. In this
case, record the engine speed, too, dur-
ing the test.
a If the return rate (spill) from the injector is
4) After finishing testing, stop the engine. in the following range, it is normal.
Engine speed
3. Testing return rate from injector (Equivalent to rated output Return (Spill) limit
1) Remove the hose (4) at spill outlet and operation load) (cc/min)
(rpm)
connect inspection hose J4 in stead. Then
1,600 960
insert the hose end to the oil container 1,700 1,020
(saucer). 1,800 1,080
1,900 1,140
2,000 1,200

2) Turn the starting switch to the ON position


and switch the machine monitor to "Adjust-
ment" function display of the service mode. 4) After finishing testing, stop the engine.
q Adjustment code: 0530 (Stall mode)
a For the operating method, see "Special 4. Work after finishing testing
functions of machine monitor (EMMS)". After finishing all testing, remove the testing
tools and return the removed parts.

D375A-6R 30-31
(01)
Engine and cooling system
Bleeding air from fuel circuit

Bleeding air from fuel circuit 30-32


3. Open the engine left cover.
k Park the machine on a level ground and low-
er the work equipment and set firmly on the 4. Open air bleeding valve (2).
ground, then set the parking brake lever and
work equipment lock lever to the LOCK posi-
tion.
a Bleed air from the fuel circuit in the following cas-
es according to this procedure.
q When the fuel filter is replaced
q When fuel is used up
q When the engine is started for the first time
after the fuel piping or supply pump is re-
placed
a When the fuel filter is replaced, don't feed fuel to
the filters, including both the main and pre-filter.
k While the electric priming pump is in opera-
tion, pressure is applied to the fuel circuit. Do
not loosen the air bleeding plug at this time, 5. Set electric priming pump switch (3) inside the
since the fuel may spout out. engine compartment to the "ON" position.
a Lamp (4) will start flashing and operation of
1. Set the starting switch to OFF position. the electric priming pump will be started.
2. Check that supply valve (1) of the fuel tank is in
the "OPEN" position.

30-32 D375A-6R
(01)
Engine and cooling system
Bleeding air from fuel circuit

a The built-in timer of this switch automatically 2) While the electric priming pump is operating,
starts or stops operation of the electric prim- crank the engine with the starting motor.
ing pump. (See the figure below) a If the engine does not start, wait for about
a Operation of the electric priming pump is 2 minutes and then repeat steps 1) and
stopped as long as flashing of the lamp is 2).
continued. It is not an error. a Do not rotate the starting motor for more
a Shifting the switch to OFF while the lamp is than 20 seconds continuously.
flashing turns off the lamp and stops the elec- 3) If the engine starts, run it at low idle for 5
tric priming pump, too. minutes to bleed all air from the fuel circuit.

6. After the specified time (about 7 minutes), lamp


(4) goes off automatically and the electric
priming pump stops.
a When the fuel filter alone was replaced,
above completes bleeding air..

7. When fuel is not provided in the fuel circuit such


as when run out of fuel occurred or when
replacement of the fuel pipe or supply pump was
done, set switch (3) to ON again after the elec-
tric priming pump is automatically stopped.

8. Bleeding air, in this case, completes as lamp (4)


went off.

9. Close air bleeding valve (2).

10. Start the engine with the starting motor.


a Do not rotate the starting motor for more than
20 seconds continuously.
a The air in the high-pressure circuit is bled au-
tomatically by cranking the engine.

11. If the engine starts, run it at low idle for 5 minutes


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

D375A-6R 30-33
(01)
Engine and cooling system
Testing fuel circuit for leakage

Testing fuel circuit for leakage 30-34


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

2. Start the engine, keep its speed below 1,000


rpm, and stop it when its speed stabilizes.

3. Check the fuel piping and devices for fuel


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

4. Run the engine at low idle.

5. Check the fuel piping and devices for fuel


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

6. Run the engine at high idle.

7. Check the fuel piping and devices for fuel


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

30-34 D375A-6R
(01)
Engine and cooling system
Replacing and adjusting alternator and air conditioner compressor belt

Replacing and adjusting alternator and air conditioner compressor belt30-35

k Park the machine on a level ground and low-


er the work equipment and set firmly on the
ground, then set the parking brake lever and
work equipment lock lever to the LOCK posi-
tion.

a Since the alternator and air conditioner com-


pressor belt is equipped with the auto-tensioner,
its tension does not usually need to be tested or
adjusted.
a Following describes the auto-tensioner adjust-
ment procedure at the belt replacement.

1. Open the engine left side cover.

2. Loosen lock nut (1) and tighten push bolt (2) fully
to loosen tension pulley (4).

3. Replace belt (5).

4. After replacing the belt, loosen push bolt (2) until


installed length "a" is 90 mm.

5. Tighten locknut (1).

D375A-6R 30-35
(01)
Engine and cooling system
Measuring fan speed

Measuring fan speed 30-36

k Park the machine on a level ground and low-


er the work equipment and set firmly on the
ground, then set the parking brake lever and
work equipment lock lever to the LOCK posi-
tion.
a Testing the fan motor speed under the following
condition.
q Hydraulic oil temperature: 45 55 C
q Working mode: P-mode
q Gear shift mode: Manual

1. Start the engine and switch the machine monitor


to the "Adjustment" function display of the
service mode.
q Adjustment ID: 1005 (Fan 100% mode)
a For the operating method, see "Special func-
tions of machine monitor (EMMS)".
a If this adjustment code is displayed, the fan
speed is kept at 100% speed in accordance
with the engine speed, regardless of the
state of the machine.

2. While running the engine at low idle and high


idle, measure the fan speed

3. After finishing measurement, remove the


measuring instruments and return the removed
parts.
a If the starting switch is turned to the OFF po-
sition, the fan 100% mode is reset.

30-36 D375A-6R
(01)
Engine and cooling system
Testing fan circuit oil pressure

Testing fan circuit oil pressure 30-37


4. Install nipple [2] of hydraulic tester S1 and
a Testing tools for fan circuit oil pressure connect it to oil pressure gauge [1].
Symbol Part No. Part name a For an analog oil pressure gauge, the pres-
1
799-101-5002 Hydraulic tester sure must be 40 MPa {400 kg/cm2}.
790-261-1204 Digital hydraulic tester
S 2 790-301-1330 q Flange
3 07372-21055 Bolt
4 07000-13035 O-ring

k Park the machine on a level ground and low-


er the work equipment and set firmly on the
ground, then set the parking brake lever and
work equipment lock lever to the LOCK posi-
tion.
a Test the fan circuit oil pressure under the follow-
ing condition.
q Hydraulic oil temperature: 45 55C
q Working mode: P-mode
q Gear shift mode: Manual
5. Start the engine and switch the machine monitor
1. Open the radiator mask. to the "Adjustment" function display of the
service mode.
q Adjustment ID: 1005 (Fan 100% mode)
2. Remove bolt (1) and disconnect tube (2).
a For the operating method, see "Special func-
tions of machine monitor (EMMS)".
a If this adjustment code is displayed, the fan
speed is kept at 100% speed in accordance
with the engine speed, regardless of the
state of the machine.

3. Install oil pressure testing flange S2 and then


install tube (2) again with bolt S3.
q The stem of oil pressure testing bolt S3 is 15
mm longer.

6. While running the engine at high idle, measure


the fan circuit oil pressure.

7. After completing the test remove the testing


equipment and set to the original condition.

D375A-6R 30-37
(01)
Engine and cooling system
Bleeding air from fan pump

Bleeding air from fan pump 30-38

a If the fan pump is removed and installed or its


piping is disconnected and connected, bleed air
from the pump case according to the following
procedure.
a Before bleeding air, check that the hydraulic oil
level is proper.

1. Remove the floor mat.

2. Remove the left foot rest (1).

3. Loosen air bleeders (2) and (3), and leave it for


15 minutes.

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


idle.

5. After oil flows out of air bleeder, tighten air


bleeders (2) and (3).

30-38 D375A-6R
(01)
Engine and cooling system
Adjusting fuel control dial and decelerator pedal

Adjusting fuel control dial and decelerator pedal 30-39

1. Outline of fuel control system [1] Fuel control dial (2nd throttle signal)
q The following signals are inputted as rotation [2] Engine controller
command signals to the engine controller. [3] Power train controller
q Decelerator pedal potentiometer signal [4] Decelerator pedal (1st throttle signal)
q 3rd throttle signal [5] Decelerator potentiometer
The engine controller controls the fuel control [6] Engine (CRI system)
system of the engine (CRI system) according [7] Machine control signal (3rd throttle signal)
to the lowest engine speed signal among [8] Rod
those input signals.
q Adjust the deceleration slow speed by adjust- 2. Preparation work
ing the decelerator pedal linkage. a Set the working mode to P mode and set the
gear shift mode to Manual.
1) Start the engine and switch the machine
monitor to "Adjustment" function display of
the service mode.
a For the operating method, see "Special
functions of machine monitor (EMMS)".

D375A-6R 30-39
(01)
Engine and cooling system
Adjusting fuel control dial and decelerator pedal

3. Adjusting deceleration pedal speed


With the fuel control dial in the high idle position,
press decelerator pedal (4) until it touches the
stopper. Check that the decelerator pedal speed
is normal under this condition.
q Deceleration speed: 900 50 rpm
a If the deceleration speed is not correct, ad-
just installed dimension (a) of rod (8).
q Standard installed dimension (a) of rod: 123
mm (reference)

4. Adjusting full speed


Set the fuel control dial to the high idle position
and check that the high idle speed is correct.
q High idle speed: 1,900 (0/-50) rpm
a If the high idle speed is abnormal, adjust it
according to the following procedure.
q If the engine speed is high:
To remove the play of the decelerator pedal,
use stopper bolt (9) to adjust the engine
speed to less than 1,800 rpm, then adjust to
the high idle speed.
q If the engine speed is low:
Raise the speed to the high idle speed by
adjusting stopper bolt (9).

5. After finishing all adjustment, return the removed


parts.

30-40 D375A-6R
(01)
Engine and cooling system
Adjusting fuel control dial and decelerator pedal

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

Power train 30-42


Testing power train oil pressure 30-42
a Table of pressure pick-up port positions and
a Testing tools for power train oil pressure gauges to use
Symbol Part No. Part name Gauge
799 - 101 - 5002 Hydraulic tester No. Mark Checked oil pressure
1 (MPa {kg/cm2})
K 790 - 261 - 1204 Digital hydraulic tester Torque converter inlet
2 799 - 401 - 2320 Gauge 1 IN 2.5 {25}
pressure
Torque converter outlet
2 OUT 1.0 {10}
k Stop the machine on level ground, lower the pressure
Torque converter lock-up
work equipment to the ground, stop the en- 3 LU 2.5 {25}
clutch pressure
gine, and set the parking brake lever and Torque converter stator
work equipment lock lever in the lock posi- 4 SC 6 {60}
clutch pressure
tion. Transmission main relief
5 T/M 6 {60}
a Test the power train oil pressure under the fol- pressure
lowing condition. 6 FWD
Transmission F clutch
6 {60}
q Power train oil temperature: Within operating pressure
range Transmission R clutch
7 REV 6 {60}
q Working mode: P mode
pressure
Transmission 1st clutch
q Gear shift mode: Manual 8 1ST 6 {60}
pressure
a The power train oil pressure pickup ports (cen- Transmission 2nd clutch
tralized oil pressure pickup ports) are located in- 9 2ND 6 {60}
pressure
side the inspection window cover on the left Transmission 3rd clutch
10 3RD 6 {60}
outside of the operator's cab. pressure
Left steering clutch pres-
11 LC 6 {60}
sure
Left steering brake pres-
sure
12 LB 6 {60}
Output pressure of sudden
stop prevention valve
Right steering clutch pres-
13 RC 6 {60}
sure
Right steering brake pres-
sure
14 RB 6 {60}
Output pressure of sudden
stop prevention valve
Transmission lubricating
15 LUB 1.0 {10}
oil pressure

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

1. Testring torque converter inlet pressure (IN) 2. Testing torque converter outlet pressure
(Testing with oil pressure gauge) (OUT)
1) Connect oil pressure gauge [1] of hydraulic (Testing with oil pressure gauge)
tester K1 to oil pressure test nipple (1). 1) Connect gauge K2 to oil pressure test nipple
a When using an analogue oil pressure (2).
gauge, use one of 2.5 MPa {25 kg/cm2}.

2) Start the engine and set the PCCS lever in


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

4) After completing the test remove the testing 4) After completing the test remove the testing
equipment and set to the original condition. equipment and set to the original condition.

D375A-6R 30-43
(01)
Power train
Testing power train oil pressure

3. Measuring torque converter inlet pressure 4. Measuring torque converter lockup (LU)
and outlet pressure clutch pressure
[Checking with machine monitor (Pm clinic)] 1) Connect oil pressure gauge [1] of hydraulic
1) Turn starting switch to ON position and tester K1 to oil pressure test nipple (3).
switch machine monitor to "Pm clinic" func- a For an analog oil pressure gauge, the
tion display of the service mode. pressure must be 2.5 MPa {25 kg/cm2}.
a For the operating method, see "Special
functions of machine monitor (EMMS)".

2) Start the engine and set the PCCS lever in


the fully neutral position.
a The test may be performed with the park-
ing brake lever in the LOCK position.
3) While running the engine at low idle and high
idle, measure the inlet pressure and outlet
pressure of the torque converter.

2) Start the engine, set the machine monitor to


"Adjusting" function of the service mode, and
disengage both steering clutches.
q Adjustment ID:
5535 (Both steering clutch disengage
mode)
a For the operating method, see "Special
functions of machine monitor (EMMS)".

30-44 D375A-6R
(01)
Power train
Testing power train oil pressure

3) Set the gearshift mode and preset range as 5. Testing torque converter stator clutch pres-
follows with the gearshift mode selector sure (SC)
switch and shiftup or shiftdown switch. 1) Connect oil pressure gauge [1] of hydraulic
q Gear shift mode: Automatic gear shift tester K1 to oil pressure test nipple (4).
q Preset mode: F2 and R2 a When using an analog oil pressure
4) With the brake pedal depressed, set the gauge, use one of 6 MPa {60 kg/cm2}.
PCCS lever to forward and the gear speed to
the 2nd.
5) Gradually release the brake pedal.
6) With the decelerator pedal depressed, set
the fuel control dial to the MAX position.
7) Gradually release the decelerator pedal and
raise the engine speed.
8) Test the torque converter lock-up clutch
pressure when the engine speed reaches
near the high idle.
a The test cannot be made at a low engine
speed.
9) After completing the test remove the testing
equipment and set to the original condition.
2) Start the engine and set the PCCS lever in
the fully neutral position.
a The test may be performed with the park-
ing brake lever in the LOCK position.
3) Measure the torque converter stator clutch
pressure with the engine at low idle and high
idle.

4) After completing the test remove the testing


equipment and set to the original condition.

D375A-6R 30-45
(01)
Power train
Testing power train oil pressure

6. Testing transmission main relief pressure [Checking with machine monitor (for VHMS
(T/M) specification)]
[Testing using oil pressure gauge] 1) Turn starting switch to ON position and
1) Connect oil pressure gauge [1] of hydraulic switch machine monitor to "Pm clinic" func-
tester K1 to oil pressure test nipple (5). tion display of the service mode.
a When using an analog oil pressure a For the operating method, see "Special
gauge, use one of 6 MPa {60 kg/cm2}. functions of machine monitor (EMMS)".

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

4) After completing the test remove the testing


equipment and set to the original condition.

30-46 D375A-6R
(01)
Power train
Testing power train oil pressure

7. Testing transmission F clutch pressure


(FWD)
1) Connect oil pressure gauge [1] of hydraulic
tester K1 to oil pressure pickup plug (6).
a When using an analog oil pressure
gauge, use one of 6 MPa {60 kg/cm2}.

7) After completing the test remove the testing


equipment and set to the original condition.

2) Start the engine and set the parking brake


lever in the FREE position.
3) Switch the machine monitor to the "Adjust-
ment" function display of the service mode
and disengage both steering clutches.
q Adjustment ID:
5535 (Disengage mode for both steering
clutches)
a For the operating method, see "Special
functions of machine monitor (EMMS)".

4) Set the gearshift mode and preset range as


follows with the gearshift mode selector
switch and shiftup or shiftdown switch.
q Gear shift mode: Manual gear shift
q Preset mode: F1 and R1
5) While pressing the brake pedal, set the direc-
tion of PCCS lever in the forward position.
a Keep the steering unit in neutral.
a Check that [F1] is displayed in the gear
speed display section.
6) Measure the F clutch pressure with the
engine at low idle and high idle.

D375A-6R 30-47
(01)
Power train
Testing power train oil pressure

8. Testing transmission R clutch pressure


(REV)
1) Connect oil pressure gauge [1] of hydraulic
tester K1 to nipple (7) for checking oil pres-
sure.
a When using an analog oil pressure
gauge, use one of 6 MPa {60 kg/cm2}.

7) After completing the test remove the testing


equipment and set to the original condition.

2) Start the engine and set the parking brake


lever in the FREE position.
3) Switch the machine monitor to the "Adjust-
ment" function display of the service mode
and disengage both steering clutches.
q Adjustment ID:
5535 (Disengage mode for both steering
clutches)
a For the operating method, see "Special
functions of machine monitor (EMMS)".

4) Set the gearshift mode and preset range as


follows with the gearshift mode selector
switch and shiftup or shiftdown switch.
q Gear shift mode: Manual gear shift
q Preset mode: F1 and R1
5) While pressing the brake pedal, set the
PCCS lever in the backward position.
a Keep the steering unit in neutral.
a Check that [R1] is displayed in the gear
speed display section.
6) Measure the R clutch pressure with the
engine at low idle and high idle.

30-48 D375A-6R
(01)
Power train
Testing power train oil pressure

9. Testing transmission 1st clutch pressure


(1st)
1) Connect oil pressure gauge [1] of hydraulic
tester K1 to nipple (8) for checking oil pres-
sure.
a When using an analog oil pressure
gauge, use one of 6 MPa {60 kg/cm2}.

7) After completing the test remove the testing


equipment and set to the original condition.

2) Start the engine and set the parking brake


lever in the FREE position.
3) Switch the machine monitor to the "Adjust-
ment" function display of the service mode
and disengage both steering clutches.
q Adjustment ID:
5535 (Disengage mode for both steering
clutches)
a For the operating method, see "Special
functions of machine monitor (EMMS)".

4) Set the gearshift mode and preset range as


follows with the gearshift mode selector
switch and shiftup or shiftdown switch.
q Gear shift mode: Manual gear shift
q Preset mode: F1 and R1
5) While pressing the brake pedal, set the direc-
tion of PCCS lever in the forward position.
a Keep the steering unit in neutral.
a Check that [F1] is displayed in the gear
speed display section.
6) Measure the 1st clutch pressure with the
engine at low idle and high idle.

D375A-6R 30-49
(01)
Power train
Testing power train oil pressure

10. Testing transmission 2nd clutch pressure (2nd)


1) Connect oil pressure gauge [1] of hydraulic
tester K1 to nipple (9) for checking oil pres-
sure.
a When using an analog oil pressure
gauge, use one of 6 MPa {60 kg/cm2}.

7) After completing the test remove the testing


equipment and set to the original condition.

2) Start the engine and set the parking brake


lever in the FREE position.
3) Switch the machine monitor to the "Adjust-
ment" function display of the service mode
and disengage both steering clutches.
q Adjustment ID:
5535 (Disengage mode for both steering
clutches)
a For the operating method, see "Special
functions of machine monitor (EMMS)".

4) Set the gearshift mode and preset range as


follows with the gearshift mode selector
switch and shiftup or shiftdown switch.
q Gear shift mode: Manual gear shift
q Preset mode: F1 and R1
5) While pressing the brake pedal, set the direc-
tion of PCCS lever in the forward position and
shift the gear to 2nd using the shiftup switch.
a Keep the steering unit in neutral.
a Check that [F2] is displayed in the gear
speed display section.
6) Measure the 2nd clutch pressure with the
engine at low idle and high idle.

30-50 D375A-6R
(01)
Power train
Testing power train oil pressure

11. Testing transmission 3rd clutch pressure 6) Measure the 3rd clutch pressure with the
(3rd) engine at low idle and high idle.
1) Connect oil pressure gauge [1] of hydraulic
tester K1 to nipple (10) for checking oil pres-
sure.
a When using an analog oil pressure
gauge, use one of 6 MPa {60 kg/cm2}.

7) After completing the test remove the testing


equipment and set to the original condition.

2) Start the engine and set the parking brake


lever in the FREE position.
3) Switch the machine monitor to the "Adjust-
ment" function display of the service mode
and disengage both steering clutches.
q Adjustment ID:
5535 (Disengage mode for both steering
clutches)
a For the operating method, see "Special
functions of machine monitor (EMMS)".

4) Set the gearshift mode and preset range as


follows with the gearshift mode selector
switch and shiftup or shiftdown switch.
q Gear shift mode: Manual gear shift
q Preset mode: F1 and R1
5) With the brake pedal depressed, set the
PCCS lever in the reverse position and shift
up the gear speed to the 3rd with the shiftup
switch.
a Keep the steering unit in neutral.
a Check that [F3] is displayed in the gear
speed display section.

D375A-6R 30-51
(01)
Power train
Testing power train oil pressure

12. Testing left steering clutch pressure (LC) 13. Testing left steering brake pressure (LB)
1) Connect oil pressure gauge [1] of hydraulic 1) Connect oil pressure gauge [1] of hydraulic
tester K1 to oil pressure test nipple (11). tester K1 to oil pressure test nipple (12).
a When using an analog oil pressure a When using an analog oil pressure
gauge, use one of 6 MPa {60 kg/cm2}. gauge, use one of 6 MPa {60 kg/cm2}.

2) Start the engine and set the parking brake 2) Start the engine and set the parking brake
lever in the FREE position. lever in the FREE position.
3) Operate the PCCS lever steering fully to the 3) Measure the left steering brake pressure with
left. the engine at low idle and high idle.
a Set the direction to the neutral position. a Check that the oil pressure becomes 0
4) Measure the left steering clutch pressure when the PCCS lever steering is operat-
with the engine at low idle and high idle. ed fully to the left.
a Check that the oil pressure becomes 0 a Check that the oil pressure becomes 0
when the PCCS lever steering is returned when the brake pedal is depressed fully
to neutral. or the parking brake lever is operated to
the LOCK position.

5) After completing the test remove the testing


equipment and set to the original condition. 4) After completing the test remove the testing
equipment and set to the original condition.

30-52 D375A-6R
(01)
Power train
Testing power train oil pressure

14. Testing right steering clutch pressure (RC) 15. Testing right steering brake pressure (RB)
1) Connect oil pressure gauge [1] of hydraulic 1) Connect oil pressure gauge [1] of hydraulic
tester K1 to oil pressure test nipple (13). tester K1 to oil pressure test nipple (14).
a When using an analog oil pressure a When using an analog oil pressure
gauge, use one of 6 MPa {60 kg/cm2}. gauge, use one of 6 MPa {60 kg/cm2}.

2) Start the engine and set the parking brake 2) Start the engine and set the parking brake
lever in the FREE position. lever in the FREE position.
3) Operate the PCCS lever steering fully to the 3) Measure the right steering brake pressure
right. with the engine at low idle and high idle.
a Set the direction to the neutral position. a Check that the oil pressure becomes 0
4) Measure the right steering clutch pressure when the PCCS lever steering is operat-
with the engine at low idle and high idle. ed fully to the right.
a Check that the oil pressure becomes 0 a Check that the oil pressure becomes 0
when the PCCS lever steering is returned when the brake pedal is depressed fully
to neutral. or the parking brake lever is operated to
the LOCK position.

5) After completing the test remove the testing


equipment and set to the original condition. 4) After completing the test remove the testing
equipment and set to the original condition.

D375A-6R 30-53
(01)
Power train
Testing power train oil pressure

16. Testing transmission lubrication pressure 17. Testing of output pressure of sudden stop
(LUB) prevention valve (Sudden stop prevention
1) Connect gauge K2 to oil pressure test nipple valve operation mode)
(15). 1) Connect oil pressure gauge [1] of hydraulic
tester K1 to oil pressure pickup nipples (12)
and (14).
a When using an analog oil pressure
gauge, use one of 6 MPa {60 kg/cm2}.
q (12): For steering left brake

2) Start the engine and test the transmission


lubricating pressure with the engine at high
idle.

q (14): For steering right brake

3) After completing the test remove the testing


equipment and set to the original condition.

2) Start the engine, switch the machine monitor


to "Adjusting" function of the service mode
and deactivate the sudden stop prevention
valve and right and left brake ECMV.
q Adjustment ID: 9996 (Sudden stop pre-
vention valve operation mode)
a For the operating method, see "Special
functions of machine monitor (EMMS)".

30-54 D375A-6R
(01)
Power train
Testing power train oil pressure

3) Set the parking brake lever in the FREE posi-


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

5) After completing the test remove the testing


equipment and set to the original condition.

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

Adjusting transmission output speed sensor 30-56

k Park the machine on a level ground and low- 6. Hold sensor (2) and tighten locknut (4).
er the work equipment and set firmly on the a Take care that the speed sensor is not
ground, then set the parking brake lever and dragged.
work equipment lock lever to the LOCK posi- 3 Nut: 49.0 68.6 Nm {5 7 kgm}
tion.

1. Remove cover (1) under the fuel tank.

7. After finishing adjustment, return the removed


parts.

2. Remove transmission output speed sensor (2). 8. Start the engine, set the machine monitor to
a Before adjusting, remove the sensor, and "Adjusting" function of the service mode, and
check that the tip of the sensor is not disengage both steering clutches.
scratched and that there are no iron particles q Adjustment ID:
sticking to it. 5535 (Disengage mode for both steering
clutches)
a For the operating method, see "Special func-
tions of machine monitor (EMMS)".
a Set the working mode to P mode and set the
gear shift mode to Manual.

9. Operate the PCCS lever in the direction of


forward or reverse position, and check the trans-
mission speed is displayed normally.

3. Look through the sensor mounting hole and


check that a tooth tip of gear (3) is at the center
of the hole.
a If the tooth tip is not at the center of the hole,
adjust it by starting the engine and moving
the machine forward or in reverse.

4. Screw in sensor (2) until its tip lightly touches the


tooth tip of gear (3).
2 Threads of sensor: Gasket sealant
(LG-5)

5. Return sensor (2) by 1/2 - 1 turn.


a Clearance (a) between the sensor tip and
gear tooth tip becomes 0.75 1.50 mm.

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

Simple test procedure for brake performance 30-57

k Park the machine on a level ground and low- k Since the torque converter is stalled, keep
er the work equipment and set firmly on the pressing the brake pedal securely and
ground, then set the parking brake lever and keep your right foot on the decelerator
work equipment lock lever to the LOCK posi- pedal for safety until the work is finished.
tion.
a Carry out the simple performance test of the
brake under the following condition.
q Power train oil temperature:
Within operating range

1. Set the blade and ripper in the travel posture on


a level place.

2. Start the engine and set the parking brake lever


in the FREE position.

3. Set the gearshift mode and preset range as


follows with the gearshift mode selector switch
and shiftup or shiftdown switch.
q Gear shift mode: Manual gear shift
q Preset mode: F2 and R2

4. While pressing the brake pedal, set the direction


of PCCS lever in the forward position.
k If this test is carried out in the 1st gear po-
sition, the brake will be overloaded. Ac-
cordingly, be sure to carry out in the 2nd
gear speed.
a Check that [F2] is displayed in the gear
speed display section.
a Keep the steering unit in neutral.

5. Press the decelerator pedal and set the fuel


control dial in the high idle (MAX) position.

6. Return the decelerator pedal slowly and check


that the machine does not start when the engine
speed reaches the high idle speed.

D375A-6R 30-57
(01)
Power train
Adjusting brake pedal and parking brake lever

Adjusting brake pedal and parking brake lever 30-58

Adjusting brake pedal 30-58

Adjusting parking brake lever 30-58

30-58 D375A-6R
(01)
Power train
Adjusting brake pedal and parking brake lever

Adjusting brake pedal 30-59


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

2. Adjusting installed length of brake rod


1) Keep the parking brake lever in the release
position.
2) Install brake rod (3) and release brake pedal
(1) (do not depress it).
3) Adjust installed dimensions c and d of brake 5. Checking brake oil pressure
rod (3) with turnbuckle (5) so that the spool of 1) Start the engine and switch the machine
brake valve (4) is at the OFF position. monitor to the "Adjustment" function display
a The locknut of the turnbuckle has a of the service mode.
q Adjustment ID: 9995 (Control brake re-
left-handed thread (reverse thread) at the
brake pedal end. lease mode)
q Stopper bolt installation dimension c: 32
a For the operating method, see "Special
mm functions of machine monitor (EMMS)".
q Stopper bolt installation dimension d: 14
a The function of this mode is used to can-
mm cel electrical control of brake oil pressure
3 Locknut:
and makes it possible to check the brake
34.358.8 Nm {3.56.0 kgm} oil pressure mechanically.
4) Check that clearance x between yoke (12) a Set the working mode to P mode and set
and pin (13) is approximately 1 mm. the gear shift mode to Manual.

3. Checking travel of brake pedal


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

4. Adjusting brake potentiometer


Turn the starting switch ON and set the machine
monitor to Adjusting function of the service
mode. 2) With the parking brake lever in the FREE
q Adjustment ID: 0005 position, depress the brake pedal fully and
(Brake pedal potentiometer initial correction) check that the brake oil pressure on both
a For the operating method, see "Special func- sides of left and right becomes 0.98 MPa {10
tions of machine monitor (EMMS)". kg/cm2} or less.
a Set the working mode to P mode and set the a For the checking port for the brake oil
gear shift mode to Manual. pressure, see "Testing power train oil
pressure".
a When the brake pedal is depressed, if the
brake oil pressure does not drop below
0.98 MPa {10 kg/cm2}, adjust its linkage
again.

D375A-6R 30-59
(01)
Power train
Adjusting brake pedal and parking brake lever

a If the linkage is adjusted normally, the


brake pedal potentiometer may be adjust-
ed wrongly or broken. (Adjust the poten-
tiometer only when necessary.)

Adjusting parking brake lever side 30-60


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

3. Checking brake oil pressure


Start the engine, set the parking brake lever in
the FREE position and LOCK position, and
check that the brake oil pressure becomes as
follows at the respective positions.
a For the checking port for the brake oil pres-
sure, see "Testing power train oil pressure".
2
q LOCK position: 0 MPa {0 kg/cm }, FREE po-
sition: Specified pressure

4. Checking limit switch


1) Turn the starting switch ON and set the
machine monitor to Monitoring function of the
service mode.
q Monitoring code: 40905 (P/T SW Input 3)
a For the operating method, see "Special
functions of machine monitor (EMMS)".
a Set the working mode to P mode and set
the gear shift mode to Manual.

30-60 D375A-6R
(01)
Power train
Adjusting position of pccs lever console

Adjusting position of pccs lever console 30-61

1. Set operators seat (1) facing the front (dozing


position).

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


parallel to operators seat (1).
a If it is not parallel, adjust installed dimension
(a) of rod (3).
q Standard installed dimension (a): 179 mm
a The locknut at the rear of the turnbuckle has
a left-handed thread (reverse thread)

D375A-6R 30-61
(01)
Power train
Emergency escape method when there is failure in power train

Emergency escape method when q PL2 connector (2): Connect to male end
there is failure in power train 30-62 a The female end of connector PL2 re-
mains disconnected, so cover it with vinyl.
a Tools for emergency escape a Insert switch assembly [1] inside the cab
Symbol Part No. Part name through the cab window.
19M-06-32820 Switch assembly
1 7824-66-6430 Resistor
L
195-06-71220 Wiring harness
2 790-190-1601 Pump assembly

1. Emergency escape method with switch box


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

2) Open the inspection cover on the left fender


and connect wiring harness [3] to PL1
connector (1) and PL2 connector (2). 4) Start the engine and set the parking brake
q PL1 connector (1): Connect to male and
lever in the FREE position.
female ends 5) Operate switch assembly [1] and move the
machine to a safe place.
a The gear speed switch has an electric cir-
cuit that gives priority to operation of the
low speed switch.

30-62 D375A-6R
(01)
Power train
Emergency escape method when there is failure in power train

k Take care that the L.H. and R.H. steer-


ing directions are opposite when re-
verse.

4) Connect end hose of pump assembly L2 to


the supply hose. (Use the nipple of face seal
type.)
2. Emergency escape method with brake a Block the solenoid valve side with plug.
releasing device (Use L2) Plug: 02789-00315
a If the engine cannot be started and the park- 5) Turn the starting switch ON and set the
ing brake cannot be released, carry out the parking brake lever in the FREE position.
emergency escape according to the following 6) Operate the vacuum pump to raise the brake
procedure. releasing oil pressure to the initial pressure.
1) Assemble pump assembly L2. q Initial pressure: Approx. 2.74 MPa {28

kg/cm2}
a Since an accumulator is installed in the
circuit, the handle must be operated 30 -
50 times to raise the oil pressure.
a If the oil pressure does not rise above a
certain level, the relief valve may be set to
low pressure. In this case, adjust the set
pressure of the relief valve.
7) Tow the machine to a safe place.
a The brake releasing oil pressure lowers
gradually because of internal leakage and
the brake is applied again approximately
one minute after. Therefore, work quickly.
a When the brake release oil pressure
2) Install volume pump [4] of pump assembly L2 drops to about 1.57 MPa {16 kg/cm2}, the
to the outside of the operators cab. brake is applied. In such a case, increase
the brake release oil pressure to its initial
level by operating the vacuum pump
again.

3) Remove the fuel tank undercover and


disconnect supply hose (3) of the pin puller
solenoid valve.

D375A-6R 30-63
(01)
Undercarriage and frame
Inspecting wear of sprocket

Undercarriage and frame 30-64


Inspecting wear of sprocket 30-64

a Use the "Full-scale dimensions drawing of


sprocket profile" in "Sprocket" in "maintenance
standard" as a gauge for testing wear of the
sprocket.

a Make a copy of the "Full-size drawing of sprock-


et tooth shape" on a transparent paper or sheet
and apply it directly to the sprocket to see if the
sprocket can be used.

30-64 D375A-6R
(01)
Undercarriage and frame
Testing and adjusting track shoe tension

Testing and adjusting track shoe tension 30-65


Inspection 30-65 2. If tension is too high:
1. Drive the machine forward and stop on a hori- Loosen plug (3) and release some of the grease.
zontal surface. k There is danger that the plug may fly out
a Stop the machine without using the brake. under the high internal pressure of the
grease, so never loosen the plug more
2. Put straight steel rod (1) on top of the track shoe than 1 turn.
between the idler and front carrier roller, and 3 Plug: 59 88 Nm {6 9 kgm}
check clearance (a) from the bottom of the steel
rod to the track shoe grouser. 3. If tension is too low:
q Standard clearance (a): 20 30 mm Pump in grease through grease fitting (4).
a If the track shoe is not tensed well, drive the
machine forward and in reverse slowly.
a After finishing adjustment, check the tension
again according to the above procedure.

Adjusting 30-65
a If the track shoe tension is abnormal, adjust it ac-
cording to the following procedure.

1. Remove cover (2).

D375A-6R 30-65
(01)
Hydraulic system
Testing and adjusting work equipment oil pressure

Hydraulic system 30-6


Testing and adjusting work equipment oil pressure 30-6

a Measuring and adjusting instruments for work


equipment oil pressure
Symbol Part No. Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
M
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring

k Stop the machine on level ground, lower the


work equipment to the ground, stop the en-
gine, and set the parking brake lever and
work equipment lock lever in the lock posi-
tion.
a Open the cover of the main control valve (both 3) Run the engine at high idle and set the blade
sides). control lever and ripper control lever in
neutral and measure the unload pressure.
Testing 30-6
a Measure the work equipment oil pressure under a The work equipment lock lever may be
the following condition. set in the LOCK position.
k Do not operate the work equipment
q Hydraulic oil temperature: 45 55C
q Working mode: P-mode
when analog oil pressure gauge (6
q Gear shift mode: Manual MPa {60 kg/cm2}) is installed. (To pro-
a The unload pressure, work equipment oil pres- tect the gauge from being damaged)
sure can be checked with the monitoring func-
tion of the service mode of the machine monitor
(See 3).

1. Measuring unload pressure


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

4) After completing the test remove the testing


equipment and set to the original condition.

2. Testing work equipment oil pressure


1) Remove P oil pressure pickup plug (1) and
LS oil pressure pickup plug (2) from the
control valve.
2) Mount nipple M2, and connect it to oil pres-
sure gauge [1] of hydraulic tester M1.
a When using an analog oil pressure
gauge, use one of 6 MPa {60 kg/cm2}.

30-66 D375A-6R
(01)
Hydraulic system
Testing and adjusting work equipment oil pressure

5) After completing the test remove the testing


equipment and set to the original condition.

3. Testing using machine monitor (Pm clinic)


1) Turn starting switch to ON position and
switch machine monitor to "Pm clinic" func-
tion display of the service mode.
a For the operating method, see "Special
functions of machine monitor (EMMS)".
a The VHMS specification is shown as an
example in the figure.

2) Mount nipple M2, and connect it to oil pres-


sure gauge [1] of hydraulic tester M1.
a When using analog oil pressure gauges,
use ones of 40 MPa {400 kg/cm2}.

2) Start the engine and measure each oil pres-


sure.
a The measuring condition of each oil pres-
sure is the same with 1 2 above.
a Hydraulic pressure displayed at P stamp
side of control valve can be measured,
but hydraulic pressure at LS stamp side
3) Start the engine and set the work equipment
(work equipment LS relief pressure) can-
lock lever in the free position.
not be measured.
4) Run the engine at high idle, operate the blade
control lever and ripper control lever to
relieve each cylinder at a stroke end, and
measure the work equipment relief pressure
and work equipment LS relief pressure.
a The work equipment relief oil pressure is
displayed at P stamp side (plug-1 side),
but work equipment LS relief oil pressure
is displayed at LS stamp side (plug-2
side).

D375A-6R 30-67
(01)
Hydraulic system
Testing and adjusting work equipment oil pressure

Adjustment 30-68 4) After finishing measurement, check the work


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

2. Adjusting work equipment oil pressure


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

1) While fixing adjustment nut (4), loosen


locknut (5).
2) Adjust the pressure by rotating adjustment
nut (4).
a If the adjustment nut is
q rotated to the right, the pressure is
heightened.
q rotated to the left, the pressure is low-
ered.
a Quantity of adjustment per turn of adjust-
ment nut:
Approx. 19.6 MPa {200 kg/cm2}
3) While fixing adjustment nut (4), tighten
locknut (5).
3 Locknut: 39 49 Nm {4 5 kgm}

30-68 D375A-6R
(01)
Hydraulic system
Testing control circuit main pressure

Testing control circuit main pressure 30-69


4. After completing the test remove the testing
Tools for testing control circuit main pressure equipment and set to the original condition.
Symbol Part No. Part name
M 1
799-101-5002 Hydraulic tester Adjusting 30-69
790-261-1204 Digital hydraulic tester a The self pressure reducing valve cannot be ad-
justed.
Inspection 30-69
k Stop the machine on level ground, lower the
work equipment to the ground, stop the en-
gine, and set the parking brake lever and
work equipment lock lever in the lock posi-
tion.
a Test the control circuit main pressure under the
following conditions.
q Hydraulic oil temperature: 45 55C

1. Open the cover of the main control valve (both


sides).

2. Connect oil pressure gauge [1] of hydraulic


tester M1.
a When using an analog oil pressure gauge,
use one of 6 MPa {60 kg/cm2}.
a Inspection nipple (1) is equipped.

3. Start the engine, run it at high idle, and test the


oil pressure when the blade lever and ripper
lever are placed at the HOLD position.

D375A-6R 30-69
(01)
Hydraulic system
Testing PPC valve output pressure

Testing PPC valve output pressure 30-70


4. Start the engine and set the work equipment lock
a Tools for testing PPC valve output pressure lever in the free position.
Symbol Part No. Part name
N 1
799 - 101 - 5002 Hydraulic tester 5. Run the engine at high idle, operate the control
790 - 261 - 1204 Digital hydraulic tester lever of the circuit to be tested, and test the oil
pressure.
k Stop the machine on level ground, lower the work a Operate the control lever fully when testing.
equipment to the ground, stop the engine, and set a On the side of LOWER of the blade lift con-
the parking brake lever and work equipment lock trol, operate the lever to the FLOAT position.
lever in the lock position.
a Check that the control circuit oil pressure is cor- 6. After completing the test remove the testing
rect before testing the PPC valve output pres- equipment and set to the original condition.
sure.
a Test the PPC valve output pressure under the
following conditions.
q Hydraulic oil temperature: 45 55C

1. Open the cover of the main control valve (both


sides).

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


to be tested.
a For details of the position to be tested, see
the drawing on the next page.

3. Fit nipple [1] (R1/8) of hydraulic testerN1, then


connect to oil pressure gauge [2].
a Use a 6 MPa {60 kg/cm2} oil pressure gauge.

30-70 D375A-6R
(01)
Hydraulic system
Testing PPC valve output pressure

A. Blade RAISE E. Ripper TILT (In)


B. Blade TILT (Right) F. Ripper RAISE
C. Blade LOWER G. Ripper TILT (Back)
D. Blade TILT (Left) H. Ripper LOWER

D375A-6R 30-71
(01)
Hydraulic system
Adjusting play of PPC valve

Adjusting play of PPC valve 30-72

a If there are excessive plays at the tips of the rip-


per control lever and blade control lever, adjust
the PPC valve according to the following proce-
dure.
a The diagram shows the PPC valve for the ripper.
q Standard play (a):
1 - 6 mm at the position 400 mm away from lever
rotation center
(both to front and rear, and to left and right)
q Standard play (b): 0.03 0.30 mm (full stroke)
a Exchange the joint (4) when lever end play is
longer than 24 mm at neutral position must be
joint may have damaged.

1. Remove fuel spray prevention cap (1).

2. Loosen locknut (2) and rotate disc (3) to adjust


the amount of play.
a Do not move the pistons at this time.

3. Secure disc (3) in position and tighten locknut


(2).
3 Lock nut: 69 88 Nm {7 9 Kgm}

4. Apply grease (G2-LI) to rotate area of joint (4)


and to contact area of disc and piston.
2 Rotate area of the joint: G2-L1
2 Contact area of the disc and the pis-
ton: G2-L1

5. Install fuel spray prevention cap (1).

30-72 D375A-6R
(01)
Hydraulic system
Testing output pressure of ripper pin-puller solenoid valve

Testing output pressure of ripper pin-puller solenoid valve 30-73

a Tools for testing output pressure of ripper


pin-puller solenoid valve
Sym-
Part No. Part name
bol
799 - 101 - 5002 Hydraulic tester
1
790 - 261 - 1204 Digital hydraulic tester
P
Oil pressure pickup adapter
2 799 - 401 - 3200
(03 size)

k Stop the machine on level ground, lower the


work equipment completely to the ground,
then set the parking brake lever and work
equipment lock lever to the LOCK position.
a Test the output pressure of the ripper pin puller
solenoid valve under the following conditions. 4. Start the engine, run at high idle, and test the oil
q Power train oil temperature:
pressure when the ripper pin-puller switch is
Within operating range actuated.

1. Disconnect pin-puller cylinder hoses (1) and (2).

5. After completing the test remove the testing


equipment and set to the original condition.
2. Fit adapter P2, then connect the hoses again.

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


connect to oil pressure gauge [2].
a Use a 6 MPa {60 kg/cm2} oil pressure gauge.

D375A-6R 30-73
(01)
Hydraulic system
Checking location of cause of hydraulic drift of blade and ripper

Checking location of cause of hydraulic drift of blade and ripper 30-74

a When the hydraulic drift of the blade or ripper oc-


curs, check if the cause for the drift is in the cyl-
inder packing or in the control valve according to
the following procedure.
1. Set the cylinder to be inspected to the following
posture, then stop the engine.
1) Blade lift cylinder
Raise the front of the machine by thrusting
the blade.
a Do not extend the blade lift cylinder to the
stroke end since it is equipped with the
piston valve.

2. Operate the control lever in the direction to


extend the cylinder rod, and check the move-
ment of the cylinder.
q If the lowering speed is increased at this time,
the cylinder packing is defective.
q If there is no change, the control valve is de-
fective.
a If there is no more pressure in the accumula-
tor, run the engine for approx. 10 seconds to
charge the accumulator.

[Reference:]If the cause of the hydraulic drift is


2) Blade tilt cylinder in the packing, the blade lowering speed in the
Extend the tilt cylinder rod fully, then push the above operation becomes faster for the following
blade against the ground to raise the right reasons.
side of the chassis. 1) When the work equipment is set to the
posture given above, (holding pressure
applied to the bottom end), oil will leak from
the bottom end to the head end. However,
the volume at the head end is smaller than at
the bottom end (by an amount proportional to
the volume of the rod), so if the oil flows in
from the bottom end, the internal pressure at
the head end will rise.
2) As the internal pressure on the head side
increases, both pressures come to balance
at a certain level of pressure (depending on
leakage), and the lowering speed becomes
slow.
3) In this condition, if the lever is operated as
shown above, the circuit at the head end is
3) Ripper lift cylinder
connected to the drain circuit (the bottom end
Push the ripper against the ground to raise
is closed by a check valve), and the oil at the
the rear of the chassis.
head end flows to the drain circuit. As a
result, the balance is lost and the speed of
downward movement increases.)

30-74 D375A-6R
(01)
Hydraulic system
Testing leakage inside work equipment cylinder

Testing leakage inside work 3. Run the engine at high idle and apply the relief
equipment cylinder 30-75 pressure to the bottom end of the cylinder.
q Blade tilt cylinder: Extract the cylinder to be
tested.
a Tools for testing leakage from work equipment q Ripper lift cylinder: Lower ripper
cylinder q Ripper tilt cylinder: Tilt ripper to front
Symbol Part No. Part name
Commercially 4. After thirty seconds elapse, measure the amount
Q Measuring cylinder
available of leakage for the following one minute.

a Test for oil leakage inside the hydraulic cylinder 5. After finishing testing, return the machine status
under the following conditions. as it was.
q Hydraulic oil temperature: 45 55C
a The blade lift cylinder has a built-in piston valve,
so the internal leakage cannot be tested.

1. Fully extend the cylinder to be tested, and set to


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

2. Disconnect hose on the cylinder head side and


block the hose side with a plug.
a Remove the hose cover of the blade tilt cylin-
der.
k Take care not to disconnect the hose on
the bottom side.

D375A-6R 30-75
(01)
Hydraulic system
Releasing remaining pressure in work equipment cylinders

Releasing remaining pressure in


work equipment cylinders 30-76

a When disconnecting the piping between the con-


trol valve and work equipment cylinder, release
the residual pressure in the circuit according to
the following procedure.

1. Start the engine and lower the blade and ripper


to the ground.

2. Stop the engine.

3. Loosen the hydraulic tank cap gradually to


release the residual pressure in the tank.

4. Set the work equipment lock lever in the FREE


position, and move the work equipment control
lever back and forth and around.
a After the levers are operated 2 3 times, the
residual pressure in the accumulator is fully
released.

5. Tighten the oil filler cap of the hydraulic tank.

30-76 D375A-6R
(01)
Hydraulic system
Bleeding air from work equipment cylinders

Bleeding air from work equipment


cylinders 30-7

a If the work equipment cylinder was removed and


installed or its piping was disconnected and con-
nected, bleed air from its circuit according to the
following procedure.

1. Run the engine at low idle for about five minutes.

2. Running the engine at low idle, extend and


retract the cylinder to be bled 4 5 times.
a Stop the piston about 100 mm before the
ends of the stroke. Never operate it to the re-
lief position.

3. Running the engine at high idle and carry out the


operation in 2.

4. Running the engine at low idle, move the


cylinder to the stroke end to relieve the oil.

D375A-6R 30-77
(01)
Hydraulic system
Adjusting ripper lever position

Adjusting ripper lever position 30-78

a Use the following procedure to adjust the ripper


lever to the optimum position.
a It is possible to adjust the position of the ripper
lever within a range of 40 mm to the front and
rear of the center of the lever shaft.

1. Adjusting within range of 40 mm from center


to rear
1) Loosen lock bolt (1).
2) Set lever (2) to the optimum position.
3) Tighten lock bolt (1) to hold lever (2) in posi-
tion.

2. Adjusting within range of 40 mm from center


to front
1) Loosen lock bolt (1).
2) Remove lever (2) and turn it 180 .
3) Install lever (2) to lever (5), then set it to the
optimum position.
4) Tighten lock bolt (1) to hold lever (2) in posi-
tion.
5) Loosen nut (3).
6) Turn knob (4) 180 .
7) Tighten nut (3) to hold knob (4) in position.

30-78 D375A-6R
(01)
Hydraulic system
Adjusting ripper lever position

D375A-6R 30-79
(01)
Work equipment
Adjusting work equipment lock lever

Work equipment 30-80


Adjusting work equipment lock lever 30-80

k Stop the machine on level ground, lower the a Set the working mode to P mode and set the
work equipment to the ground, stop the en- gear shift mode to Manual.
gine, and set the parking brake lever and
work equipment lock lever in the lock posi-
tion.
a Tighten the locknut of the rod securely and bend
the cotter pin securely.
a Remove the control valve cover.

1. Set work equipment lock lever (1) in the LOCK


position.

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


(a) of lever (3).
a Just set the roller of the limit switch to the
sliding surface. Do not move it.
3. Set work equipment lock lever (1) in the FREE
5. Check that the limit switch signal is input
position and check that limit switch (2) operates
normally when work equipment lock lever (1) is
normally.
set in the FREE position and LOCK position.
q Stroke of limit switch: 2.5 3 mm
q Free position:
Work equipment lock NC OFF, Work equip-
4. Turn the starting switch ON and set the machine
ment lock NO ON
monitor to Monitoring function of the service
q LOCK position:
mode.
Work equipment lock NC ON, Work equip-
a Monitoring code:
ment lock NO OFF
70300 (Blade Sw Input)
a For the operating method, see "Special func-
tions of machine monitor (EMMS)".

30-80 D375A-6R
(01)
Work equipment
Adjusting blade

Adjusting blade 30-81

a If the blade is removed and installed, or disas-


sembled and assembled, adjust the various
places of the blade according to the following
procedure.

1. Procedure for adjusting with shims when


assembling
1) Use shims to adjust the clearance at center
portion (1) and (2).
Adjust- Standard
Adjusted Standard
ment shim thick-
clearance clearance
location ness
1 a
See Note 4.5 mm
2 b
Note: Adjust so that the play of the ball at the
spherical portion in the axial direction is
within 1 mm. Check that the ball rotates
smoothly.

D375A-6R 30-81
(01)
Work equipment
Adjusting blade

2) Use shims to adjust the clearance at trunnion


portion (3).
Adjust- Standard
Adjusted Standard clear-
ment shim thick-
clearance ance
location ness
1.56 0.65 mm
3 c 12 mm
Total clearance

2. Adjusting blade tilt


(only for single tilt specification machine)
1) Adjust installation dimension (d) of brace (4)
with the handle.
q Dimension (d) of installed brace: 1,587
mm
2) Test left and right tilt (e1) and (e2).
[Semi-U dozer]
q Right tilt (e1): Approx. 770 mm
q Left tilt (e2): Approx. 770 mm
[Full-U dozer]
q Right tilt (el): Approx. 840 mm
q Left tilt (el): Approx. 840 mm
3) If the tilt is not the same on the left and right
sides, adjust installation dimension (d) of
brace (4) as follows to give the same tilt on
both sides.
q (e1) > (e2): Carry out fine adjustment to
make installation dimension d longer
q (e1) < (e2): Carry out fine adjustment to
make installation dimension d shorter

30-82 D375A-6R
(01)
Work equipment
Adjusting blade

D375A-6R 30-83
(01)
Cab and its attachments
Testing and adjusting operator's cab

Cab and its attachments 30-84


Testing and adjusting operator's cab 30-84

Check after installing cab assembly 30-84


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

6) Seal the mounting holes of lock lever (1) with


2) Prepare a transparent vinyl hose.
tape (2).
q Outside diameter: 10 mm,
Length: 3000 mm
3) Secure the end of the hose inside the cab to
the top of the backrest with tape.
4) Pour water in the hose up to approsimately
half of the length.
5) Remove slide glass lever lock (1) and insert
the other end of vinyl hose [1].

30-84 D375A-6R
(01)
Cab and its attachments
Testing and adjusting operator's cab

7) Set the coolant level in the vinyl hose out of


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

2. Check of sealing performance


1) Close the all openings of the cab.
2) Throw water onto the area near the cab
(hatched area) at a rate of about 19 l/min for
10 minutes.
q At this time, it is not necessary to splash
pressurized coolant.
3) Splash coolant horizontally from a hose over
sealing surface (3).
4) Check around the dashboard carefully.
a If coolant leaks, caulk the leaking part and
check again.

D375A-6R 30-85
(01)
Cab and its attachments
Testing and adjusting operator's cab

3. Testing and adjusting door lock 2) Check the relationship between the door
Close the door and check the relationship latch and striker (on both sides).
between the operator's cab and door. If there is q Close door (5) and check the engaging
any fault, repair it. condition of latch (6) and striker (7).
1) Check the installed height of damper rubbers q Normal:
(4). (Check 4 pieces on each side.) Deviation (a) is 0.5 mm or less.
(Check 4 locks on each side.) a Check deviation (a) of latch center (y) and
q Stick adhesive tape [1] to the contact face striker center (x) from each other from the
of damper rubber (4), open and close the direction of (A).
door 2 3 times. Then, check the contact
face of adhesive tape [1] against the op-
erator's cab.
Normal:
When the door is closed, the damper
rubbers come in contact lightly.
Abnormal:
When the door is closed, the damper
rubbers do not come in contact or come in
contact so strongly that the adhesive
tapes are removed.

30-86 D375A-6R
(01)
Cab and its attachments
Testing and adjusting operator's cab

3) Adjusting height of damper rubber


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

a Open the door and check the engag-


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

4) Adjusting height of latch and striker


1] Loosely tighten the mounting bolts of
striker (7), open and close the door two to
three times in order to align latch (6) with
striker (7).
2] Check the engaging condition of latch (6)
and striker (7).
3] Tighten the mounting bolts of striker (7) to
the specified torque.
4] Open and close the door and check that it
is locked and unlocked smoothly. If the
door is not locked and unlocked smoothly
(if the knob is heavy), perform the adjust-
ment procedure from the first.
a Operating effort of door unlock lever:
68.6 19.6 N {7 2 kg}
5) Apply grease (G2-LI) to latch (6).
a If latch (6) is not sufficiently greased, the
knob becomes heavy.

4. Testing open lock


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

D375A-6R 30-87
(01)
Cab and its attachments
Testing and adjusting operator's cab

2) Adjust 2] Adjusting installed height of stopper


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

30-88 D375A-6R
(01)
Cab and its attachments
Testing and adjusting operator's cab

D375A-6R 30-89
(01)
Electrical system
Special functions of machine monitor (EMMS)

Electrical system 30-90


Special functions of machine monitor (EMMS) 30-90

30-90 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

Upper section of machine monitor (Display section)


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

Upper section of machine monitor (Switch section)


[F1]: F1 function switch
[F2]: F2 function switch
[F3]: F3 function switch
[F4]: F4 function switch
[F5]: F5 function switch
[F6]: F6 function switch
a The function of each function switch is indicated
by graphic mark in the multi-display (a) above
that function switch.
a If the graphic mark of a function switch is not dis-
played, that function switch is not working.

Lower section of machine monitor (Switch section)


[1]: Numeral 1 input switch/Operation mode selector
switch
[2]: Numeral 2 input switch/Gearshift mode selector
switch
[3]: Numeral 3 input switch/Customize switch
[4]: Numeral 4 input switch/Buzzer cancel switch
[5]: Numeral 5 input switch
[6]: Numeral 6 input switch/Customize memory
switch
[7]: Numeral 7 input switch
[8]: Numeral 8 input switch
[9]: Numeral 9 input switch
[0]: Numeral 0 input switch
Switch having no numerals: Unused
a Each switch has the function indicated by graph-
ic mark and the function of inputting a numeral.
a The machine monitor automatically judges
which function of each switch is currently effec-
tive, according to the display condition of
multi-display (a).

D375A-6R 30-91
(01)
Electrical system
Special functions of machine monitor (EMMS)

t Ordinary functions and special functions of machine monitor 30-92


The machine monitor has the ordinary function and special functions and displays information of various types
on the multi-display.
Some items are displayed automatically according to the internal setting of the machine monitor and the oth-
ers are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The items in this mode are displayed ordinarily. The operator can display and set them by operating the
switches (Display and setting of some items need special operations of the switches).
2. Special functions: Service mode
The items in this mode are not displayed ordinarily. Each serviceman can display them by operating the
switches specially.
This mode is used for special setting, testing, adjusting, or troubleshooting.
Page Page
Operator mode (Outline) Service mode
30-93 30-102
A Display of KOMATSU logo 30-93 01 Monitoring 30-103
Mechanical system "Abnor-
A Display of check before starting 30-93 30-108
02 Abnormality mality Record"
Display of warning after check before start- Record Electrical system "Abnormal-
A 30-94 30-109
ing ity Record"
A Display of ending of maintenance interval 30-94 03 Maintenance Record 30-111
A Display of check of preset 30-94 04 Maintenance Mode Change 30-112
A Display of ordinary screen 30-95 05 Phone Number Entry 30-113
A Display of end screen 30-95 Key-on Mode 30-115
B Selection of operation mode 30-95 Unit 30-116
Setting of maintenance pass-
B Selection of gearshift mode 30-95 06 Default 30-117
OSpecial operations

word
B Customizing operation 30-96 Setting of camera 30-118
B Operation of customize memory 30-96 Setting of ECO display 30-119
B Operation to cancel alarm buzzer 30-96 07 Adjustment 30-120
Selection of dual tilt
B 30-96 08 PM clinic 30-140
(Dual tilt specification)
Operation to display camera mode (if cam-
B 30-96 09 Cylinder Cut-Out 30-142
era is installed)
B Operation to display clock and service meter 30-97 10 No Injection 30-143
B Check of maintenance information 30-97 11 Fuel Consumption 30-145
B Setting and display of user mode 30-97 12 Display of saved load 30-146
C Display of caution monitor 30-98 13 Setting of VHMS 30-147
Display function of action code and failure
C 30-98 14 Snap shot (Machine equipped with VHMS) 30-147
code
O (Special operation)
Function of checking display of LCD (Liquid
D 30-100
Crystal Display)
D Function of checking service meter 30-100
Function of changing maintenance pass- 30-101
D
word

a Classification of operator mode


A: Screen display and function from time when starting switch is turned to ON position to time when screen
changes to standard screen and screen display after starting switch is turned to OFF position
B:Display/Function when switch of machine monitor is operated
C:Display/Function when certain condition is satisfied
D:Display/Function which needs special operation of switch

30-92 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

t Operator mode (Outline) 30-93 Display of KOMATSU logo 30-93


a Only outline of the operator mode is described in When starting switch is turned ON, KOMATSU logo
this section. is displayed for 2 seconds.
For details of contents/operation of each func- After the KOMATSU logo is displayed for two sec-
tion/display, see "the Structure, function and onds, the screen changes to "Password input (if
maintenance standard, or Operation and Main- password is set)" screen , or "Check before starting"
tenance Manual". screen.
a The following are the displays or functions of the
operator mode explained in this section (includ-
ing some items which need special operations).
Display
pattern
a b c d
Display of KOMATSU logo 1 1 1 1
Display of check before starting 2 2 2 2
Display of warning after check
- - 3 -
before starting
Display of ending of maintenance
- - - 3
interval
Display of check of preset 3 3 4 4
Display of ordinary screen 4 4 5 5
Display of end screen
Selection of operation mode Check before starting screen
Selection of gearshift mode When the screen changes to the check-before-start-
Customizing operation ing screen, the check before starting is carried out
Operation of customize memory for 2 seconds.
Operation to cancel alarm buzzer a If any abnormality is detected by the check be-
Selection of dual tilt (Dual tilt specification) fore starting, the screen changes to "Display of
Operation to display camera mode (if camera is
warning after check before starting" or "Display
installed)
Operation to display clock and service meter of ending of maintenance interval".
Check of maintenance information a If no abnormality is detected by the check before
Setting and display of user mode starting, the screen changes to "Display of check
Display of caution monitor of preset".
Display function of action code and failure code a The monitors (3 pieces) displayed on the screen
O (Special operation) are the items under the check before starting.
Function of checking display of LCD (Liquid Crystal
Display)
Function of checking service meter
Function of changing maintenance password
a Display pattern of operator mode
The contents of display from the time when
starting switch is turned ON to time when screen
changes to ordinary screen depends on the
setting and condition of the machine.
a: When engine start lock is enabled
b: When engine start lock is disabled
c: When a check-before-starting item is unusual
d: When maintenance of maintenance item is
near specified time or overdue

D375A-6R 30-93
(01)
Electrical system
Special functions of machine monitor (EMMS)

Warning after check before starting screen Display of overdue maintenance


If any abnormality is detected by the check before When the check before starting is carried out, if a
starting, the warning monitor is displayed on the maintenance item is near or after the end of the set
screen. interval, the maintenance monitor is displayed for 30
a The following figure shows that the radiator cool- seconds to urge the operator to maintenance.
ant level monitor (a) is warning of low radiator a This screen is displayed only when the mainte-
coolant level. nance function is effective. The color of the
maintenance monitor (yellow or red) indicates
the length of the time after the maintenance in-
terval.
a Set or change the maintenance function in the
service mode.

Display of check of preset


If the check before starting is finished normally, the
screen to check the preset (gear speed at start) is
displayed for 2 seconds.
a After the display of check of preset is finished,
the screen changes to "display of ordinary
screen".

30-94 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

Display of ordinary screen Selection of operation mode


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

Selection of gearshift mode


While the ordinary screen is displayed, press the
gearshift mode selector switch, and the gearshift
mode monitor (a) in the gear speed display section
changes.
a Each time the switch is pressed, the gearshift
Display of end screen mode changes among [Automatic gearshift],
When starting switch is turned OFF, the end screen [Manual gearshift] and [Shoe slip control] (if
is displayed for 5 seconds. equipped) in order.
a If the automatic gearshift mode is selected, "AU-
TO" symbol (b) is displayed in the gear speed
display section. If the manual gearshift mode or
shoe slip control mode is selected, "MAN" sym-
bol is displayed.

D375A-6R 30-95
(01)
Electrical system
Special functions of machine monitor (EMMS)

Customizing operation Selection of dual tilt (Dual tilt specification)


While the ordinary screen is displayed, press the The selection of the blade dual tilt mode is made by
customize switch, and you can change the setting of changing the blade control lever knob switch while
the machine. the ordinary screen is displayed.
a If the customize memory switch is operated a If the dual tilt mode is turned ON, dual tilt mode
while the above screen is displayed, up to 5 set- monitor (a) is displayed. If the former is turned
tings can be saved. OFF, the latter is put out.

Operation of customize memory Operation to display camera mode (if camera is in-
While the ordinary screen is displayed, press the stalled)
customize memory switch, and you can select the When a camera is installed, if [F3] is pressed, the
recorded setting of customization. multi-display changes to the camera image.
a Set the connection of the camera in the service
mode.

Operation to cancel alarm buzzer


While the alarm buzzer is sounding, if the buzzer
cancel switch is pressed, the alarm buzzer stops. a Up to 3 cameras can be connected. If the cam-
a Even if the buzzer cancel switch is pressed, the era mode is selected, however, only the image of
display on the screen does not change. camera 1 is always displayed.

30-96 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

a If a caution is generated in the camera mode, the Check of maintenance information


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

Setting and display of user mode


While the ordinary screen is displayed, press [F6],
and the user menu screen is displayed.

a Display of clock

D375A-6R 30-97
(01)
Electrical system
Special functions of machine monitor (EMMS)

a There are following items in the user menu. Display function of action code and failure code
If an abnormality which displays an action code and
Utility screen select a failure code occurs on the ordinary screen or cam-
Multi-gauge era mode screen, all the information of the abnor-
mality is displayed.
Screen adjustment (a): Action code (3 digits)
(b): Failure code (5 or 6 digits)
Clock adjustment
(c): Telephone mark
Language setting (d): Telephone No.
a This screen is displayed only when an abnormal-
Reverse interlock selection mode ity (failure code) for which a user code is set oc-
curs.
Fan reverse mode
a The telephone mark and telephone number are
Skipping pre-lubrication displayed only when the telephone number is
registered in the service mode.
a If multiple abnormalities occur simultaneously,
all the codes are displayed repeatedly in order.
a Since the information of the displayed failure
Code is recorded in "Abnormality Record" in the
service mode, check the details in the service
mode.

Display of caution monitor


If an abnormality which displays a caution monitor
occurs on the ordinary screen or camera mode
screen, the caution monitor is displayed large for a
moment and then displayed at (a) in the screen.
a On the camera mode screen, the caution moni-
tor flashes at the left upper of the screen when
the caution is generated.

30-98 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

a Remedies given by displayed action codes to operator to take are as follows (Excerpt from the Operation
and Maintenance Manual).
Action
Method of indicating trouble Examples of trouble Remedy given to operator to take
code
q Although all or a part of automatic
q The backup alarm does not
function stops, machine can be op-
q Action code and failure sound
E01 erated.
code are displayed. q The fan speed is always set to
q Contact your Komatsu distributor for
the maximum.
repair.
q If operator stops and restarts en-
q Gear is not shifted up or down. gine, machine can be operated with-
q Action code and failure q Engine boost pressure is ab- out any functions being limited.
E02 code are displayed. normal. However, operator has to pay atten-
q Alarm buzzer sounds. q Exhaust gas color is bad when tion.
temperature is low. q Contact your Komatsu distributor for
repair.
q Engine coolant temperature
sensor is abnormal.
q Action code and failure
q Usable gear speeds are limited.
code are displayed. q Move machine to safe place.
q Engine speed does not rise ful-
E03 q Telephone number is dis- q Contact your Komatsu distributor for
ly.
played (if registered). repair.
q Gear shift shock is large.
q Alarm buzzer sounds.
q Steering performance lowers.
q Braking shock is increased.
q Action code and failure
code are displayed. q Engine cannot be controlled. q Stop machine immediately.
E04 q Telephone number is dis- q Machine cannot travel. q Contact your Komatsu distributor for
played (if registered). q Machine stops. repair.
q Alarm buzzer sounds.

D375A-6R 30-99
(01)
Electrical system
Special functions of machine monitor (EMMS)

Function of checking display of LCD (Liquid Crystal Function of checking service meter
Display) To check the service meter while the starting switch
While the ordinary screen is displayed, if the follow- is turned OFF, operate the numeral input switches
ing numeral input switch and function switch are op- as follows. At this time, only the service meter sec-
erated as follows, all the LCD (Liquid Crystal tion displays.
Display) lights up in white. q Operation of switches (simultaneous): [4] + [1]
q Operation of switches (simultaneous): [4] + [F2] a Since there is some time lag in start of the LCD,
a When finishing the operation of the switches, re- hold down the switches until the LCD displays
lease [F2] first. normally.
a If there is a display error in the LCD, only that a Continuous operation of the machine monitor
part is indicated in black. may display blue bright spots (spots which do
a The LCD panel sometimes has black points not go off) on the screen; it is quite normal.
(points which are not lighted) and bright points
(points which do not go off) for the reason of its
characteristics.
If the number of the bright points and black
points does not exceed 10, those points are not
a failure or a defect.
a To return to the former screen, press the function
switch.

30-100 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

Function for changing maintenance password 30-101 (If it has only 3 or less digits or has 7 or more
When changing the maintenance password used for digits, it is not accepted).
the maintenance setting function, follow these pro- q [F5]: Reset input numeral/Return to ordinary
cedures. screen
q [F6]: Confirm input numeral
1. While the ordinary screen is displayed, perform
the following operation with the numeral input
switches.
q Operation of switches (While pressing [4],
perform the operation in order):
[4 ]+ [5]o [5] o [5]
a This operation of the switches is not accept-
ed until 10 minutes pass after the starting
switch is turned on.

4. After the "New Password" screen is displayed


again, input a new password again by using the
numeral input switches and confirm it by using
the function switch.
q [F5]: Reset input numeral/Return to ordinary
screen
q [F6]: Confirm input numeral
a If a password different from the password in-
put before is input, the message to input
2. After the "Password" screen is displayed, input again is displayed.
the current password by using the numeral input
switches and confirm it by using the function
switch.
q [F5]: Reset input numeral/Return to ordinary
screen
q [F6]: Confirm input numeral
a Default password: [000000]
a If the input password is correct, the screen
changes to the next screen.
a If the input password is incorrect, the mes-
sage to request inputting the password again
is displayed.

5. If the screen to notify completion of setting is


displayed and then the ordinary screen is
displayed, the password is changed successfully

3. After the "New password" screen is displayed,


input a new password with the numeral input
switches and confirm it with the function switch.
a Set a new password of 4 6 digits

D375A-6R 30-101
(01)
Electrical system
Special functions of machine monitor (EMMS)

t Service mode 30-102 a The items which can be selected in the ser-
To change the operator mode to the service mode, vice menu are as follows.
perform the following operation. 01 Monitoring
This operation is always required when you use the Mechanical system Abnor-
service mode. 02 Abnormality mality Record
Record Electrical system "Abnormal-
1. Check of display of screen and operation of ity Record"
switches 03 Maintenance Record
04 Maintenance Mode Change
While the ordinary screen is displayed, perform
05 Phone Number Entry
the following operation with the numeral input Key-on Mode
switches. Setting of unit
q Operation of switches (While pressing [4], Setting of maintenance pass-
06 Default
perform the operation in order): word
[4]+[1]o[2]o[3] Setting of camera
a This operation of the switches is accepted Setting of ECO display
07 Adjustment
only while the ordinary screen is displayed.
08 PM clinic
09 Cylinder Cut-Out
10 No Injection
11 Fuel Consumption
12 Display of saved load
13 Setting of VHMS
14 Snap shot (Machine equipped with VHMS)
a Items with 2-digit codes are the menus dis-
played on the Service menu screen. The
items on their right are the menus on the next
hierarchy.

2. Selection of the service menu


When the "Service Menu" screen is displayed,
the service mode is selected. Select a service
menu you use by using the function switches or
numeral input switches.
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to standard screen (operator
mode)
q [F6]: Confirm selection
a You may enter a 2-digit code with the numer-
al input switches to select the menu of that
code and confirm it with [F6].

30-102 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

Monitoring
The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed to
many parts of the machine and the information from
the controllers which are controlling switches, etc.

1. Selection of menu
Select "01 Monitoring" on the "Service Menu"
screen.

3. Deciding monitoring items


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

D375A-6R 30-103
(01)
Electrical system
Special functions of machine monitor (EMMS)

4. Executing monitoring 6. Changing machine setting mode


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

5. Holding monitoring information


The monitoring information can be held and
reset with the function switches.
q [F3]: Reset holding
q [F4]:Hold information (displayed data)
q [F5]:Return to monitoring selection menu
screen

30-104 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

Monitoring items list


Code Unit (Default: SI) Component
Monitoring item (displayed on screen) Remarks
No. SI Metric Imperial in charge
50300 S/T Lever 1 Potentio mV mV mV P/T
50301 S/T Lever 2 Potentio mV mV mV P/T
50400 Brake Pedal Potentio mV mV mV P/T
31619 Brake LH ECMV(F/B) mA mA mA P/T
31618 Brake RH ECMV(F/B) mA mA mA P/T
90600 S/T Clutch LH ECMV(F/B) mA mA mA P/T
90601 S/T Clutch RH ECMV(F/B) mA mA mA P/T
31628 S.S.P Solenoid mA mA mA P/T
32900 Pitch Angle P/T
60100 Pitch Angle Sensor mV mV mV P/T
60600 BR Hold Relay mV mV mV P/T
03001 Fuel Dial Throttle % % % P/T
03000 Fuel Dial Sensor mV mV mV P/T
S/T Clutch LH Fill Sw ON OFF P/T
S/T Brake LH Fill Sw ON OFF P/T
31521 S/T Fill Sw Input
S/T Clutch RH Fill Sw ON OFF P/T
S/T Brake RH Fill Sw ON OFF P/T
50200 T/M Lever 1 Potentio mV mV mV P/T
50201 T/M Lever 2 Potentio mV mV mV P/T
31622 T/M Clutch F ECMV(F/B) mA mA mA P/T
31616 T/M Clutch R ECMV(F/B) mA mA mA P/T
31612 T/M Clutch 1st ECMV(F/B) mA mA mA P/T
31613 T/M Clutch 2nd ECMV(F/B) mA mA mA P/T
31614 T/M Clutch 3rd ECMV(F/B) mA mA mA P/T
30100 T/C Oil Temperature C C F P/T
31400 T/M Out Speed r/min rpm rpm P/T
32601 T/C In Pressure MPa kg/cm2 psi P/T
32602 T/C In Pressure Sensor mV mV mV P/T
32603 T/C Out Pressure MPa kg/cm2 psi P/T
32604 T/C Out Pressure Sensor mV mV mV P/T
31642 L/U ECMV(F/B) mA mA mA P/T
90700 S/C ECMV(F/B) mA mA mA P/T
40001 Vehicle speed km/h km/h MPH P/T
60000 Traction W W W P/T
70200 T/M Out Speed Sensor mV mV mV P/T
31624 Fan Pump Solenoid(F/B) mA mA mA P/T
10000 Fan Speed r/min rpm rpm P/T
SUNC ON OFF P/T
SUNO ON OFF P/T
SDNC ON OFF P/T
40905 P/T SW Input 3
SDNO ON OFF P/T
PNC ON OFF P/T
PNO ON OFF P/T
F ON OFF P/T
R ON OFF P/T
40906 T/M Fill Sw Input 1 1st ON OFF P/T
2nd ON OFF P/T
3rd ON OFF P/T
L/U ON OFF P/T
31520 T/M Fill Sw Input 2
S/C ON OFF P/T
Back-up alarm ON OFF P/T
N-safty ON OFF P/T
40909 P/T SW Output
Pre-lub Motor ON OFF P/T
Pre-heater ON OFF P/T
70700 Hydraulic Pump Pressure 1 MPa kg/cm2 psi W/E
70701 Hydraulic Pressure Sensor 1 mV mV mV W/E
60200 Acceleration Sensor Voltage mV mV mV P/T
60300 SSC Command Speed r/min rpm rpm P/T
31200 Torque Converter Output Speed r/min rpm rpm P/T
43001 T/M Main Oil Pressure MPa kg/cm2 psi VHMS
40910 P/T SW Input 2 ON OFF P/T

D375A-6R 30-105
(01)
Electrical system
Special functions of machine monitor (EMMS)

Code Unit (Default: SI) Component


Monitoring item (displayed on screen) Remarks
No. SI Metric Imperial in charge
W/E Lock Switch (NO) ON OFF W/E
W/E Lock SW (NC) ON OFF W/E
W/E Knob Upper SW
ON OFF W/E
(NO)
W/E Knob Upper SW
70300 Blade Sw Input ON OFF W/E
(NC)
W/E Knob Lower SW
ON OFF W/E
(NO)
W/E Knob Lower SW
ON OFF W/E
(NC)
Blade Lift Raise
Blade Lever Oil Blade Lift Lower
90802 ON OFF W/E
Press. Switch Blade Left Tilt
Blade Right Tilt
31634 Fan Pump Solenoid 2 (F/B) mA mA mA W/E
10007 Fan Speed r/min rpm rpm W/E
Ripper Lift Raise
Ripper Lever Oil Ripper Lift Lower
40982 ON OFF W/E
Press. Switch Ripper Tilt in
Ripper Tilt Out
01501 LS Solenoid (F/B) mA mA mA W/E
HYD. Oil Level
ENG Low Idle
40981 W/E SW Input C-sig ON OFF W/E
R-sig
Acc
ENG Hold
40983 W/E SW Output Fan Reverse Solenoid ON OFF W/E
ENG Shut Down
37501 Ambient Temperature C C F VHMS
42610 Exhaust Temperature, front C C F VHMS
42611 Exhaust Temperature, rear C C F VHMS
42612 Exhaust Temp. sensor, front V V V VHMS
42613 Exhaust Temp. sensor, rear V V V VHMS
42801 Blow-by Pressure KPa kg/cm2 psi VHMS
20300 VHMS LED Monitor - VHMS
Orbcomm Con. Power
Orbcomm Commu-
99003 Satellite Condition ON OFF VHMS
nication Status
Data Transmission
20227 Monitor Ass'y P/N - MON
20402 Monitor serial No - MON
20228 Monitor Prog P/N - MON
20242 P/T Con Ass'y P/N - P/T
20404 P/T Con Serial No - P/T
20243 P/T Con Prog P/N - P/T
20244 W/E Con Ass'y P/N - W/E
20405 W/E Con Serial No - W/E
20245 W/E Con Prog P/N - W/E
04200 Fuel Level Sensor Volt V V V MON
04300 Battery charge volt V V V MON
04401 Hyd Oil Temperature C C F MON
04402 Hyd Temp Sens Volt V V V MON
18900 ECM Internal Temp C C F ENG
37200 Engine Oil Pressure KPa kg/cm2 psi ENG
00201 Machine ID - ENG
20216 ECM Build Version - ENG
20217 ECM Calibration Data Ver - ENG
20400 ECM Serial No - ENG
01002 Engine Speed r/min rpm rpm ENG
36700 Engine Torque Ratio % % % ENG
31701 Decel Pedal Position % % % ENG
31703 Decel Pedal Pos Sens Volt mV mV mV ENG
17500 Engine Power Mode - ENG

30-106 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

Code Unit (Default: SI) Component


Monitoring item (displayed on screen) Remarks
No. SI Metric Imperial in charge
36400 Rail Pressure MPa kg/cm2 psi ENG
36401 Rail Pressure Sens Volt V V V ENG
36200 Rail Press Command MPa kg/cm2 psi ENG
36300 Injection Timing Command CA CA CA ENG
04107 Coolant Temperature C C F ENG
04105 Coolant Temp Sens Volt V V V ENG
37400 Ambient Pressure kPa kg/cm2 psi ENG
37401 Ambient Press Sens Volt V V V ENG
Indicated in abso-
lute pressure
36500 Charge Pressure-Abs KPa kg/cm2 psi ENG
(including ambi-
ent pressure)
36501 Charge Press Sens Volt V V V ENG
03203 Battery Power Supply V V V ENG
37300 Fuel Rate l/h l/h gal/h ENG
31706 Final Throttle Position % % % ENG
18500 Charge Temperature C C F ENG
18501 Charge Temp Sens Volt V V V ENG
18600 Inject Fueling Command mg/st mg/st mg/st ENG
17201 PCV Close Timing CA CA CA ENG
18700 Engine Output Torque Nm kgm lbft ENG
37201 Eng Oil Press Sens Volt V V V ENG
14200 Fuel Temperature C C F ENG
14201 Fuel Temp Sens Volt V V V ENG
42700 ENG Oil Temperature C C F ENG
42701 ENG Oil Temp. sensor mV mV mV ENG
Acc ON OFF P/T
40912 P/T SW Input 1 R-sig ON OFF P/T
C-sig ON OFF P/T

a Entry order of monitoring items in table


The monitoring items are entered in the order of display on the "Monitoring" screen for item selection.
a Unit
The display unit can be set to SI, Metric, or Imperial unit freely (use "Unit" menu of "Default" in the service menu to
select the unit.).
"CA" in the display unit is an abbreviation for crankshaft angle.
"mg/st" in the display unit is an abbreviation for milligram/stroke.
a Component in charge
MON: The machine monitor is in charge of detection of the monitoring information.
ENG: The engine controller is in charge of detection of the monitoring information.
P/T: The power train controller is in charge of detection of the monitoring information.
W/E: The work equipment controller is in charge of detection of the monitoring information.
VHMS: The VHMS controller is in charge of detection of the monitoring Information.

D375A-6R 30-107
(01)
Electrical system
Special functions of machine monitor (EMMS)

Abnormality Record (Mechanical Systems) 3. Information displayed on "Abnormality Record"


The machine monitor classifies and records the ab- screen
normalities which occurred in the past or which are On the "Mechanical Systems" screen, the
occurring at present into the mechanical system and following information is displayed.
electrical system. (a): Occurrence order of abnormalities from
To check the mechanical system failure history, per- latest one/Total number of records
form the following procedures. (b): Failure code
1. Selection of menu (c): Detail of failure
Select "02 Abnormality Record" on the "Service (d): Occurrence number
Menu" screen. (e): Service meter reading at first occurrence
(f): Service meter reading at last occurrence
q [F1]: Move to next page (screen) (if dis-
played)
q [F2]: Move to previous page (screen) (if dis-
played)
q [F5]: Return to Abnormality record screen
a If no "Abnormality Record" is recorded, "No
Abnormality Record" is displayed.
a If the number of occurrence time is 1 (first oc-
currence), the service meter reading at the
first occurrence and that at the last occur-
rence are the same.
a If [E] is displayed on the left of a failure code,
the abnormality is still occurring or resetting
2. Selecting sub menu
of it has not been confirmed.
After the "Abnormality Record" screen is
a For all the failure codes that the machine
displayed, select "01 Mechanical Systems" with
monitor can record, see Troubleshooting,
the function switches or numeral input switches.
"Failure codes table".
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to Service menu screen
q [F6]: Confirm selection
a You may enter a 2-digit code with the numer-
al input switches to select the item of that
code and confirm it with [F6].

4. Deleting "Abnormality Record"


A contents of the mechanical system failure
history cannot be reset.

30-108 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

"Abnormality Record" (Electrical system "Abnormali- 3. Information displayed on "Abnormality Record"


ty Record") 30-109 screen
The machine monitor classifies and records the ab- On the "Electrical Systems" screen, the following
normalities which occurred in the past or which are information is displayed.
occurring at present into the mechanical system and (a): Occurrence order of abnormalities from
electrical system. latest one/Total number of records
To check the electrical system abnormality record, (b): Failure code
perform the following procedures. (c): Detail of failure
1. Selection of menu (d): Occurrence number
Select "02 Abnormality Record" on the "Service (e): Service meter reading at first occurrence
Menu" screen. (f): Service meter reading at last occurrence
q [F1]: Move to next page (screen) (if dis-
played)
q [F2]: Move to previous page (screen) (if dis-
played)
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to Abnormality record screen
a If no "Abnormality Record" is recorded, "No
Abnormality Record" is displayed.
a If the number of occurrence time is 1 (first oc-
currence), the service meter reading at the
first occurrence and that at the last occur-
rence are the same.
a If [E] is displayed on the left of a failure code,
2. Selecting sub menu
the abnormality is still occurring or resetting
After the "Abnormality Record" screen is
of it has not been confirmed.
displayed, select "02 Electrical Systems" with
a For all the failure codes that the machine
the function switches or numeral input switches.
monitor can record, see Troubleshooting,
q [F3]: Move to lower item
"Failure codes table".
q [F4]: Move to upper item
q [F5]: Return to Service menu screen
q [F6]: Confirm selection
a You may enter a 2-digit code with the numer-
al input switches to select the item of that
code and confirm it with [F6].

4. Deleting "Abnormality Record"


1) While the "Electrical Systems" screen is
displayed, perform the following operation
with the numeral input switches.
q Operation of switches (While pressing [4],
perform the operation in order):
[4]+[1]o[2]o[3]
a Operate the switches similarly to the pro-
cedure for changing the ordinary display
to the service mode.

D375A-6R 30-109
(01)
Electrical system
Special functions of machine monitor (EMMS)

2) Check that the screen is set in the reset 4) If the screen to notify completion of reset is
mode, and then reset the items one by one or displayed and then the "Electrical Systems"
together with the function switches. (reset mode) screen is displayed, the reset of
a If the screen is set in the delete mode, the abnormality record is completed.
[CLEAR] graphic mark is indicated at a After a while, the screen returns to the
[F2]. "Electrical Sys. Error Reset" screen.
q [F2]: Delete all items
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to Abnormality record screen
q [F6]: Reset selected item
a To reset items one by one: Select the item
to be reset with [F3] or [F4] and press
[F6].
a To reset all items together: Press [F2],
and all the items are reset, regardless of
selection of the items.
a If [E] is displayed on the left of a failure
code, the deleting operation is accepted
but the information is not deleted.

3) After the "Electrical Sys. Error Reset" screen


is displayed, operate the function switches.
q [F5]: Return to Electrical systems screen
(Reset mode)
q [F6]: Perform reset
a The following figure shows the screen
displayed when the items are reset one
by one (which is a little different from the
screen displayed when all the items are
reset together).

30-110 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

Maintenance Record a The following items can be selected in the


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

41 Change of fuel pre-filter


1. Selection of menu
Select "03 Maintenance Record" on the "Service 04 Hyd Oil Filter Change
Menu" screen.
06 Corrosion Resistor Change (*)

07 Damper case service

08 Replacement interval of final drive case oil

10 Hydraulic oil change

19 Replacement of power train oil

20 Replacement of power train oil filter

*: The menu is displayed on the screen, but the


corrosion resistor is not installed.
3. Items displayed on Maintenance Record screen.
The following items are displayed.
2. Selecting maintenance record item (a): Maintenance items
After the "Maintenance Record" screen is (b): Number of times of replacement up to now
displayed, select an item to be checked by using (c): Service meter reading (SMR) at previous
the function switches or numeral input switches. replacement
q [F1]: Move to next page (screen)
q [F2]: Move to previous page (screen)
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to Service menu screen
a You may enter a 2-digit code with the numer-
al input switches to select the item of that
code.

D375A-6R 30-111
(01)
Electrical system
Special functions of machine monitor (EMMS)

Maintenance Mode Change


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

41 Change interval of fuel pre-filter


1. Selection of menu
Select "04 Maintenance Mode Change" on the 04 Hyd Oil Filter Change Int
"Service Menu" screen. 07 Check and replacement interval of damper case
oil
08 Replacement interval of final drive case oil

10 Replacement interval of hydraulic oil

19 Replacement interval of power train oil

20 Replacement interval of power train oil filter

99 Use Default Value

3. Details of setting of use or non-use of mainte-


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

a The following items can be selected on the 4. Contents of setting of each maintenance item
change of maintenance mode screen. After selecting each maintenance item, if the
screen is displayed, set the item with the function
switches.

30-112 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

q Initial value: Maintenance interval set in ma- a If this operation is executed, the set values of
chine monitor (Recommended by manufac- all the maintenance items are set to default
turer and not changeable). values.
q Set value: Maintenance interval which can be q [F5]: Return to Maintenance Mode Change
set freely. Maintenance reminder function screen
works according to this set time in operator q [F6]: Perform initialization
mode (which is set in increments of 25 a A while after [F6] is pressed, the initialization
hours). completion screen is displayed. Then, if the
q ON:Maintenance function of this item is set "Maintenance Mode Change" screen is dis-
effective in operator mode. played, initialization is completed.
q OFF:Maintenance function of this item is set
ineffective in operator mode.
q [F3]:Select Reduce set value (Upper) or OFF
(Lower).
q [F4]:Select Increase set value (Upper) or ON
(Lower).
q [F5]:Cancel setting before confirmation and
return to Maintenance Mode Change
screen.
q [F6]: Confirm setting of upper or lower line
a After the setting of the upper and lower lines
is confirmed with [F6] and the screen chang-
es to the Maintenance mode change screen
with [F5], the setting is effective. Phone Number Entry
The telephone No. displayed when the user
code/failure code is displayed in the operator mode
can be input and changed according to the following
procedure.
If a telephone No. is not input with this function, no
telephone No. is displayed in the operator mode.

1. Selection of menu
Select "05 Phone Number Entry" on the "Service
Menu" screen.

5. Function of All Default Value


After selecting "99 Use Default Value", if the
screen is displayed, set with the function
switches.

D375A-6R 30-113
(01)
Electrical system
Special functions of machine monitor (EMMS)

2. Registering and changing telephone number


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

a Up to 14 digits can be input from the left. In-


put nothing in the surplus positions.
a If an input numeral is wrong, move the cursor
(orange background) to that digit and over-
write it with the correct numeral.
a If [F6] is pressed without inputting a digit,
there is not information of phone No. Accord-
ingly, no phone No. is displayed in the oper-
ator mode.

30-114 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

Default (Key-on Mode) q Default (ALL OFF): Default setting of all


Check and change various settings related to the modes (Power: P, other 3 items: OFF) is dis-
machine monitor and the machine with the "De- played when starting switch is turned to ON
fault". position
The function of Key-on Mode is used to set the initial q [F3]: Move to lower item
mode displayed on the machine monitor when the q [F4]: Move to upper item
starting switch is turned ON. q [F5]: Cancel selection and return to Default
screen
1. Selection of menu q [F6]: Confirm selection and return to Default
Select "06 Default" on the "Service Menu" screen
screen. a When the machine is delivered, Mode at Pre-
vious key-off.

2. Selecting sub menu


After the "Default" screen is displayed, select "01
Key-on Mode" by using the function switches or
numeral input switches.
a Select this item similarly to an item on the
"Service Menu" screen.
a This function sets the following 4 mode items
(which are the items set with the customize
switch in the operator mode).
q Power: P/E
q Reverse slow mode: ON/OFF
q Work equipment fine control: ON/OFF
q Blade slow down: ON/OFF

3. Selecting mode
After the "Key-on Mode" screen is displayed,
select the mode to be set by using the function
switches.
q Mode at previous key-OFF: Final modes in
previous operation are displayed when start-
ing switch is turned to ON position

D375A-6R 30-115
(01)
Electrical system
Special functions of machine monitor (EMMS)

Default (Unit)
Check and change various settings related to the
machine monitor and the machine with the "De-
fault".
The unit selecting function is used to select the unit
of the data displayed for monitoring, etc.

1. Selection of menu
Select "06 Default" on the "Service Menu"
screen.

2. Selecting sub menu


After the "Default" screen is displayed, select "02
Unit" by using the function switches or numeral
input switches.
a Select this item similarly to an item on the
"Service Menu" screen.

3. Selecting unit
After the "Unit" screen is displayed, select the
unit to be set by using the function switches.
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Cancel selection and return to Default
screen
q [F6]: Confirm selection and return to Default
screen
a When the machine is delivered, the SI unit
system is set.

30-116 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

Default (Setting of maintenance password)


Check and change various settings related to the
machine monitor and the machine with the "De-
fault".
The function of the setting of the maintenance pass-
word is used to set the display of the password
screen when the functions related to the mainte-
nance are used in the operator mode.

1. Selection of menu
Select "06 Default" on the "Service Menu"
screen.

4. Display of maintenance password screen


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

5. Change of maintenance password


The password can be changed with the special
switch operatin in the operator mode.
2. Selecting sub menu a See "Function of changing maintenance
After the "Default" screen is displayed, select "03 password" in the operator mode.
Maintenance Password" by using the function a Default password: [000000]
switches or numeral input switches. a If the password setting is changed from "En-
a Select this item similarly to an item on the able" to "Disable", the password is reset to
"Service Menu" screen. the default.
a When "Enable" is set again, be sure to set a
new password.
a The maintenance password is different from
the engine start lock password.

3. Selecting Enable/Disable
After the "Maintenance Password" screen is
displayed, select the setting by using the func-
tion switches.
q Disable: Password screen is not displayed
q Enable: Password screen is displayed
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Cancel selection and return to Default
screen
q [F6]: Confirm selection and return to Default
screen

D375A-6R 30-117
(01)
Electrical system
Special functions of machine monitor (EMMS)

Default (Camera) a After "Camera" screen is displayed, camera


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

2. Selecting sub menu


After the "Default" screen is displayed, select "04
Camera" by using the function switches or
numeral input switches.
a Select this item similarly to an item on the
"Service Menu" screen.

3. Selecting camera setting


After the "Camera" setting screen is displayed,
select the setting by using the function switches.
q OFF: Camera is not used
q Original image: Image from connected cam-
era is displayed in original position.
(as in mirror, used as back monitor)
q Reverse Image: Image of connected camera
is displayed in reverse position (as seen di-
rectly, used as front or side monitor)
q [F3]: Move to left item
q [F4]: Move to right item
q [F5]: Cancel settings before confirmation and
return to Default setting screen
q [F6]: Confirm selection in each line

30-118 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

Default (ECO Display)


Check and change various settings related to the
machine monitor and the machine with the "De-
fault".
The ECO display setting function is used to set the
display of the ECO gauge.

1. Selection of menu
Select "06 Default" on the "Service Menu"
screen.

a Display of ECO gauge (a)

2. Selecting sub menu


After the "Default" screen is displayed, select "05
ECO Display" by using the function switches or
numeral input switches.
a Select this item similarly to an item on the
"Service Menu" screen.

3. Selecting display setting


After the "ECO Display" screen is displayed,
select the setting by using the function switches.
q ON: Display ECO
q OFF: Do not display ECO
q [F3]: Move to left item
q [F4]: Move to right item
q [F5]: Cancel selection and return to Default
screen
q [F6]: Confirm selection and return to Default
screen
a If ECO display is turned ON, ECO is dis-
played when the screen changes to the ordi-
nary screen.

D375A-6R 30-119
(01)
Electrical system
Special functions of machine monitor (EMMS)

Adjusting
You can adjust various items related to the machine
with the machine monitor.
When using an adjustment item, select it according
to the following procedure.

1. Selection of menu
Select "07 Adjustment" in the "Service menu"
screen.

3. Displaying adjustment screen


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

a lf the input adjustment ID is incorrect, the


message of "Not Available" is displayed and
the ID input screen does not change (another
ID can be input again with the numeral input
switches while this screen is displayed).

30-120 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

Adjustment items table


Adjustm
Adjustment item Remarks
ent ID
0002 Power train controller initialization
0004 Work equipment specification setting
0005 Brake pedal potentiometer initial correction
0007 Engine decelerator cutting Resetting auto-decelerating function
0009 Pitch angle sensor initial correction
0010 Fan 70% mode
0031 Work equipment controller initialization
0036 Shoe slip control specification code setting
0041 Travel lever code setting Setting and resetting uni-direction lever
Recommended mode of torque converter
0530 Stall mode
stall
1005 Fan 100 % mode
1012 Steering lever neutral position adjustment
1013 Steering lever leftmost position adjustment
1014 Steering lever rightmost position adjustment
1015 Right brake oil pressure offset
1016 Left brake oil pressure offset
2021 Power train controller voltage check mode
2022 Work equipment controller voltage check mode
5535 Both steering clutch disengage mode
5537 Left steering clutch oil pressure offset
5538 Right steering clutch oil pressure offset
6001 R1 reverse slow set speed Fine adjustment of reverse slow mode
6002 R2 reverse slow set speed Fine adjustment of reverse slow mode
6003 R3 reverse slow set speed Fine adjustment of reverse slow mode
7842 Transmission clutch IP and fill time automatic initial correction
7843 Transmission clutch IP manual initial correction
7845 Transmission clutch IP learning display
7847 Transmission clutch fill time manual initial correction
Control brake: Brake ECMV (Right and
9995 Control brake release mode
left)
9996 Sudden stop prevent valve operation mode
9997 High idle cut mode
9998 Max. gear speed setting mode

D375A-6R 30-121
(01)
Electrical system
Special functions of machine monitor (EMMS)

Adjustment ID: 0002 (Initialization of power train Adjustment ID: 0004(Work equipment specifica-
controller) tion setting)

q This adjustment code is used to initialize the q This adjustment code is used to make the
specification code recognized by the power work equipment controller recognize the type
train controller and the set values of the of the work equipment.
memory in the controller. a After the work equipment controller or the
a After the power train controller is replaced, work equipment is replaced, be sure to carry
be sure to perform this adjustment once. out this adjustment once.

q Functions of function switches q Functions of function switches


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

q Operating method: q Operating method:


1] Press [F6] and check that the alarm 1] Press [F3] or [F4] to select the specifica-
buzzer sounds. tion value [CODE] of the work equipment
2] Check that the displayed specification concerned.
code [CODE] has changed from [1x1] to CODE Type of work equipment
[111]. 0 Dual tiltdozer
a If specification code [111] is not dis- 1 Single tiltdozer
played, the controller unit may be defec- 2] Press [F6] and check that the alarm
tive. buzzer sounds.
a Even if this adjustment code is turned off, k If the specification of the work equipment
the setting is effective. is different from the setting in the control-
ler, the work equipment may move unex-
pectedly or an error may be made.
Accordingly, be sure to match the con-
troller to the work equipment.
a Even if this adjustment code is turned off, the
setting is effective.

30-122 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

Adjustment ID: 0005 (Brake pedal potentiometer Adjustment ID: 0007 (Engine decelerator cutting)
initial correction)

q This adjustment code is used to stop the au-


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

q Functions of function switches q Functions of function switches


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

q Operating method: q Operating method:


1] Check that the brake pedal is in the When this adjustment code is displayed, its
neutral position (it is not depressed) and function is effective and the auto-decelera-
keep it in that position. tion function is stopped.
2] Press [F6] and check that the alarm a After this adjustment code is turned OFF,
buzzer sounds. its function is ineffective.
a Even if the adjustment is carried out, the
displayed value does not change.
a Even if this adjustment code is turned off,
the correction is effective.
a This adjustment code is used to make the
controller recognize the zero point of the
potentiometer. It is not used to adjust the
braking force.

D375A-6R 30-123
(01)
Electrical system
Special functions of machine monitor (EMMS)

Adjustment ID: 0009 (Pitch angle sensor initial Adjustment ID: 0010 (Fan 70% mode)
correction)

q This adjustment code is used to forcibly set


q This adjustment code is used to make the the cooling fan speed to about 70%.
power train controller recognize the zero a Use this adjustment code for testing, adjust-
point of the pitch angle sensor and to correct ing, or troubleshooting when necessary.
the installation error.
a After the power train controller is replaced or q Functions of function switches
the inclination angle sensor is removed and [F3]: To increase adjustment value [FAN 70
installed or replaced, be sure to perform this % SPEED MODE]
adjustment once. [F4]: To decrease adjustment value [FAN 70
% SPEED MODE]
q Functions of function switches [F5]: To return to adjustment item selection
[F3]: Unused screen (ID input screen)
[F4]: Unused [F6]: Unused
[F5]: To return to adjustment item selection
screen (ID input screen) q Operating method:
[F6]: To save corrected value The function is effective at the time when this
adjustment is displayed and the cooling fan
q Operating method: speed is controlled to about 70% of the
1] Check that the machine is level. maximum speed.
2] Press [F6] and check that the alarm a After this adjustment code is turned OFF,
buzzer sounds. its function is ineffective.
a If the adjustment is performed, displayed
item [BODY PITCH ANGLE] changes to
[0.0] (No other displayed item changes).
a Even if this adjustment code is turned off,
the correction is effective.

30-124 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

Adjustment ID: 0031 (Work equipment controller Adjustment ID: 0036 (Shoe slip control specifica-
initialization) tion code setting)

q This adjustment code is used to initialize the q This adjustment code is used to change the
specification code recognized by the work rocky terrain specification setting when the
equipment controller and the set values of shoe slip control is used.
the memory in the controller.
a After the work equipment controller is re- a When the shoe slip control operates, if shoe
placed, be sure to carry out this adjustment slip is not restrained even if the rocky terrain
once. specification is set to "5", change the set val-
ue.
q Functions of function switches
[F3]: Unused q Functions of function switches
[F4]: Unused [F3]:To return
[F5]: To return to adjustment item selection [F4]: To go
screen (ID input screen) [F5]: To return to adjustment item selection
[F6]: To save setting screen (ID input screen)
[F6]: Confirm selection
q Operating method:
1] Press [F6] and check that the alarm q Operating method:
buzzer sounds. 1] Change the setting from [SSC SPEC H]
2] Check that the displayed specification to [SSC SPEC L] by pressing [F3] or [F4].
code [CODE] has changed from [2x2] to 2] Press [F6] to confirm the selection.
[222]. a At this time, check that alarm buzzer
a If specification code [222] is not dis- sounds.
played, the controller wiring harness or a Even if this adjustment code is turned off,
the controller unit may be defective. the setting is effective.
a Even if this adjustment code is turned off,
the setting is effective.

D375A-6R 30-125
(01)
Electrical system
Special functions of machine monitor (EMMS)

Adjustment ID:0041 (Travel lever code setting) Adjustment ID: 0530 (Stall mode)

q This adjustment code is used to correct the q This adjustment code is used to set the fan
set value of the travel lever code recognized speed in the 100% mode automatically and
by the power train controller when it is differ- make it possible to set the preset (gear speed
ent from the lever that is actually installed. at start) to [F3-R3] to stall the torque convert-
a If the power train controller is replaced while er.
a non-standard travel lever (for example, a a The preset (gear speed at start) can be set to
uni-direction lever) is installed, be sure to [F3-R3] only when this adjustment code is
perform this adjustment once. selected.
q Functions of function switches a Use this adjustment code for testing, adjust-
[F3]: Unused ing, or troubleshooting when necessary.
[F4]: Unused q Functions of function switches
[F5]: To return to adjustment item selection [F3]: Unused
screen (ID input screen) [F4]: Unused
[F6]: To save setting [F5]: To return to adjustment item selection
screen (ID input screen)
q Operating method: [F6]: Unused
1] Perform adjustment ID "0002" (Initializa-
tion of power train controller) and "0031" q Mode setting information within screen
(Initialization of work equipment [P-AUTO SFT MODE]: Automatic gearshift in
controller". P mode
a After the above operation has been [E-AUTO SFT MODE]: Automatic gearshift in
carried out, an error is displayed. E mode
2] Enter adjustment ID "0041". [P-MANUAL SFT MODE]: Manual gearshift
3] Press [F6] and check that the alarm in P mode
buzzer sounds. [E-MANUAL SFT MODE]: Manual gearshift
4] Check that the displayed specification in E mode
code [CODE] has changed from [1x1] to a When using this adjustment code, be sure to
[111]. select "P-MANUAL SFT MODE".
a If specification code [111] is not dis- q Operating method:
played, the controller unit may be de- when this adjustment code is displayed, its
fective. function is effective and the preset (gear
a Even if this adjustment code is turned speed at start) is set to [F3-R3].
off, the setting is effective. k This adjustment code does not stall the
torque converter automatically. Accord-
ingly, operate the levers and pedals se-
curely when stalling the torque converter
(For the procedure for stalling the torque
converter, see Measuring engine speed).
a When using this adjustment code, be sure to
keep the hydraulic oil temperature above
45C.(If the hydraulic oil temperature drops
below 40C, the fan speed fluctuates)
a After this adjustment code is turned OFF, its
function is ineffective.

30-126 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

Adjustment ID: 1005(Fan 100% mode) Adjustment ID: 1012 (Steering lever neutral posi-
tion adjustment)

q This adjustment code is used to set the cool-


ing fan speed to about 100% forcibly. q This adjustment code is used to make the
It can also set the adjustment value of the power train controller recognize the neutral
maximum speed. position of the steering potentiometer of the
a Use this adjustment code for testing, adjust- PCCS lever.
ing, or troubleshooting when necessary. a After the power train controller or PCCS lever
a Functions of function switches is replaced, be sure to perform this adjust-
[F3]: To increase adjustment value [FAN 100 ment once.
% SPEED MODE]
[F4]: To decrease adjustment value [FAN q Functions of function switches
100 % SPEED MODE] [F3]: Unused
[F5]: To return to adjustment item selection [F4]: Unused
screen (ID input screen) [F5]: To return to adjustment item selection
[F6]: To save adjustment value screen (ID input screen)
[F6]: To save adjustment value
q Operating method:
a When this adjustment code is displayed, q Operating method:
its function is effective and the cooling fan 1] Check that the PCCS lever is in the
speed is controlled to about 100% of the neutral position of the steering direction
maximum speed. and keep it in that position.
1] increase Or decrease the adjustment 2] Press [F6] and check that the alarm
value by pressing [F3] or [F4]. buzzer sounds.
2] when confirming the adjustment value, a Even if the adjustment is carried out, the
press [F6] and check that the alarm displayed value does not change.
buzzer sounds. a Even if this adjustment code is turned off,
a When using this adjustment code, be the adjustment is effective.
sure to keep the hydraulic oil temperature a This adjustment code is used to make the
above 45C.(If the hydraulic oil tempera- controller recognize the neutral position
ture drops below 40C, the fan speed of the potentiometer. It is not used to ad-
fluctuates) just the steering force.
a After this adjustment code is turned OFF,
its function is ineffective but the set ad-
justment value is effective.

D375A-6R 30-127
(01)
Electrical system
Special functions of machine monitor (EMMS)

Adjustment ID: 1013 (Steering lever leftmost Adjustment ID: 1014 (Steering lever rightmost
position adjustment) position adjustment)

q This adjustment code is used to make the q This adjustment code is used to make the
power train controller recognize the leftmost power train controller recognize the rightmost
position of the steering potentiometer of the position of the steering potentiometer of the
PCCS lever. PCCS lever.
a After the power train controller or PCCS lever a After the power train controller or PCCS lever
is replaced, be sure to perform this adjust- is replaced, be sure to perform this adjust-
ment once. ment once.

q Functions of function switches q Functions of function switches


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

q Operating method: q Operating method:


1] Operate the PCCS lever in the steering 1] Operate the PCCS lever in the steering
direction to the left stroke end and keep it direction to the right stroke end and keep
there. it there.
2] Press [F6] and check that the alarm 2] Press [F6] and check that the alarm
buzzer sounds. buzzer sounds.
a Even if the adjustment is carried out, the a Even if the adjustment is carried out, the
displayed value does not change. displayed value does not change.
a Even if this adjustment code is turned off, a Even if this adjustment code is turned off,
the adjustment is effective. the adjustment is effective.
a This adjustment code is used to make the a This adjustment code is used to make the
controller recognize the leftmost position controller recognize the rightmost posi-
of the potentiometer. It is not used to ad- tion of the potentiometer. It is not used to
just the steering force. adjust the steering force.

30-128 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

Adjustment ID: 1015 (Right brake oil pressure Adjustment ID: 1016 (Left brake oil pressure
offset) offset)

q This adjustment code is used to adjust the q This adjustment code is used to adjust the
right brake oil pressure manually. left brake oil pressure manually.
a Use this adjustment code for work when nec- a Use this adjustment code for work when nec-
essary. essary.

q Functions of function switches q Functions of function switches


[F3]: To increase adjustment value [F3]: To increase adjustment value
[F4]: To decrease adjustment value [F4]: To decrease adjustment value
[F5]: To return to adjustment item selection [F5]: To return to adjustment item selection
screen (ID input screen) screen (ID input screen)
[F6]: To save adjustment value [F6]: To save adjustment value

q Information displayed on screen q Information displayed on screen


The offset oil pressure is displayed and the The offset oil pressure is displayed and the
adjustment value is increased or decreased adjustment value is increased or decreased
by 0.0098 MPa {0.1 kg/cm2} (The value by 0.0098 MPa {0.1 kg/cm2} (The value
displayed on the screen is multiplied by 100). displayed on the screen is multiplied by 100).
a The default adjustment value is 0 MPa {0 a The default adjustment value is 0 MPa {0
kg/cm2}. kg/cm2}.
a The adjustment range is -0.294 0.294 a The adjustment range is -0.294 0.294
MPa {-3 3 kg/cm2}. MPa {-3 3 kg/cm2}.

q Operating method: q Operating method:


1] Increase or decrease the adjustment 1] Increase or decrease the adjustment
value by pressing [F3] or [F4]. value by pressing [F3] or [F4].
2] Press [F6] and check that the alarm 2] Press [F6] and check that the alarm
buzzer sounds. buzzer sounds.
a If an adjustment has been performed, the a It is not necessary to operate the brake
adjustment value is displayed. It can be during adjustment. After finishing adjust-
adjusted again within the allowable ment, however, operate the brake and
range. check that there is not a problem in the
a It is not necessary to operate the brake actual brake performance.
during adjustment. After finishing adjust- a If an adjustment has been performed, the
ment, however, operate the brake and adjustment value is displayed. It can be
check that there is not a problem in the adjusted again within the allowable
actual brake performance. range.
a Even if this adjustment code is turned off, a Even if this adjustment code is turned off,
the adjustment is effective. the adjustment is effective.

D375A-6R 30-129
(01)
Electrical system
Special functions of machine monitor (EMMS)

Adjustment ID: 2021 (Power train controller Adjustment ID: 2022 (Work equipment controller
voltage check mode) voltage check mode)

q This adjustment code is used to check the q This adjustment code is used to check the
unswitched power supply voltage and acces- unswitched power supply voltage and acces-
sory power supply voltage applied to the sory power supply voltage applied to the
power train controller. work equipment controller.
a Use this adjustment code for testing, adjust- a Use this adjustment code for testing, adjust-
ing, or troubleshooting when necessary. ing, or troubleshooting when necessary.

q Functions of function switches q Functions of function switches


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

q Information displayed on screen q Information displayed on screen


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

q Operating method: q Operating method:


When this adjustment code is displayed, its When this adjustment code is displayed, its
function is effective and the unswitched function is effective and the unswitched
power supply voltage and accessory power power supply voltage and accessory power
supply voltage are displayed simultaneously. supply voltage are displayed simultaneously.
a After this adjustment code is turned OFF, a After this adjustment code is turned OFF,
its function is ineffective. its function is ineffective.

30-130 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

Adjustment ID: 5535 (Both steering clutch disen-


gage mode)

q This adjustment code is used to disengage


both steering clutches with the parking brake
ON.

a Used to check the torque converter lockup


operation, lockup operating pressure and
transmission clutch operating pressure.

q Functions of function switches


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

q Operating method:
When this adjustment code is displayed, its
function is effective and both steering
clutches are disengaged.
a After this adjustment code is turned OFF,
its function is ineffective.

D375A-6R 30-131
(01)
Electrical system
Special functions of machine monitor (EMMS)

Adjustment ID: 5537 (Left steering clutch oil pres- a It is not necessary to steer the machine
sure offset) during adjustment. After finishing adjust-
ment, however, steer the machine and
check that there is no problem in the ac-
tual steering performance.
a Even if this adjustment code is turned off,
the adjustment is effective.

q This adjustment code is used to manually ad-


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

q Functions of function switches


[F3]: To increase adjustment value
[F4]: To decrease adjustment value
[F5]: To return to adjustment item selection
screen (ID input screen)
[F6]: To save adjustment value

q Information displayed on screen


The offset oil pressure is displayed and the
adjustment value is increased or decreased
by 0.0098 MPa {0.1 kg/cm2} (The value
displayed on the screen is multiplied by 100).
a The default adjustment value is 0 MPa {0
kg/cm2}.
a The adjustment range is -0.294 0.294
MPa {-3 3 kg/cm2}.

q Operating method:
1] Increase or decrease the adjustment
value by pressing [F3] or [F4].
2] Press [F6] and check that the alarm
buzzer sounds.
a If an adjustment has been performed, the
adjustment value is displayed. It can be
adjusted again within the allowable
range.

30-132 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

Adjustment ID: 5538 (Right steering clutch oil a It is not necessary to steer the machine
pressure offset) during adjustment. After finishing adjust-
ment, however, steer the machine and
check that there is no problem in the ac-
tual steering performance.
a Even if this adjustment code is turned off,
the adjustment is effective.

q This adjustment code is used to manually ad-


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

q Functions of function switches


[F3]: To increase adjustment value
[F4]: To decrease adjustment value
[F5]: To return to adjustment item selection
screen (ID input screen)
[F6]: To save adjustment value

q Information displayed on screen


The offset oil pressure is displayed and the
adjustment value is increased or decreased
by 0.0098 MPa {0.1 kg/cm2} (The value
displayed on the screen is multiplied by 100).
a The default adjustment value is 0 MPa {0
kg/cm2}.
a The adjustment range is -0.294 0.294
MPa {-3 3 kg/cm2}.

q Operating method:
1] Increase or decrease the adjustment
value by pressing [F3] or [F4].
2] Press [F6] and check that the alarm
buzzer sounds.
a If an adjustment has been performed, the
adjustment value is displayed. It can be
adjusted again within the allowable
range.

D375A-6R 30-133
(01)
Electrical system
Special functions of machine monitor (EMMS)

Adjustment ID: 6001 (R1 reverse slow set speed) Adjustment ID: 6002 (R2 reverse slow set speed)

q This adjustment code is used to adjust the q This adjustment code is used to adjust the
engine speed applied to travel at gear speed engine speed applied to travel at gear speed
R1 with the reverse slow mode ON. R2 with the reverse slow mode ON.
a Use this adjustment code for work when nec- a Use this adjustment code for work when nec-
essary. essary.

q Functions of function switches q Functions of function switches


[F3]: To increase adjustment value [F3]: To increase adjustment value
[F4]: To decrease adjustment value [F4]: To decrease adjustment value
[F5]: To return to adjustment item selection [F5]: To return to adjustment item selection
screen (ID input screen) screen (ID input screen)
[F6]: To save adjustment value [F6]: To save adjustment value

q Information displayed on screen q Information displayed on screen


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

q Operating method: q Operating method:


1] Increase or decrease the adjustment 1] Increase or decrease the adjustment
value by pressing [F3] or [F4]. value by pressing [F3] or [F4].
2] Press [F6] and check that the alarm 2] Press [F6] and check that the alarm
buzzer sounds. buzzer sounds.
a If an adjustment has been performed, the a If an adjustment has been performed, the
adjustment value is displayed. It can be adjustment value is displayed. It can be
adjusted again within the allowable adjusted again within the allowable
range. range.
a It is not necessary to drive the machine a It is not necessary to drive the machine
during adjustment. After finishing adjust- during adjustment. After finishing adjust-
ment, however, drive the machine at R1 ment, however, drive the machine at R2
with the reverse slow mode ON and with the reverse slow mode ON and
check that there is not a problem in the check that there is not a problem in the
actual travel speed. actual travel speed.
a Even if this adjustment code is turned off, a Even if this adjustment code is turned off,
the adjustment is effective. the adjustment is effective.

30-134 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

Adjustment ID: 6003 (R3 reverse slow set Adjustment ID: 7842 (Transmission clutch IP and
speed) fill time automatic initial correction)

q This adjustment code is used to adjust the q This adjustment code is used to make the
engine speed applied to travel at gear speed power train controller recognize the mechan-
R3 with the reverse slow mode ON. ical condition of the transmission.
a Use this adjustment code for work when nec- a After the power train controller or PCCS lever
essary. is replaced, be sure to perform this adjust-
ment once.
q Functions of function switches
[F3]: To increase adjustment value q Functions of function switches
[F4]: To decrease adjustment value [F3]: Unused
[F5]: To return to adjustment item selection [F4]: Unused
screen (ID input screen) [F5]: To return to adjustment item selection
[F6]: To save adjustment value screen (ID input screen)
[F6]: To start automatic correction
q Information displayed on screen
The lower speed (reduced from the high idle q Conditions for correction work
speed of 1,900 rpm) is displayed and the 1] [ENGINE SPEED]: 1,7001,950 rpm
adjustment value is increased or decreased 2] [T/C TEMPERATURE]: 6585C
in 50 rpm units. 3] Parking brake lever:Lock position
a The factory default of the adjustment val- 4] PCCS lever: Neutral position
ue is 300 rpm (Display: 30). a When using this adjustment code, keep
(Factory default: 1,900 - 300 = 1,600 rpm) the above conditions (In particular, in-
crease the power train oil temperature
q Operating method: sufficiently before starting adjustment).
1] Increase or decrease the adjustment
value by pressing [F3] or [F4]. q Operating method:
2] Press [F6] and check that the alarm 1] Stall the torque converter so that the
buzzer sounds. torque converter oil temperature will be
a If an adjustment has been performed, the stabilized in the range of 65 85C.
adjustment value is displayed. It can be 2] Fix the engine speed in the range of 1,700
adjusted again within the allowable 1,900 rpm.
range. 3] Set the PCCS lever in the neutral position
a It is not necessary to drive the machine and set the parking brake lever in the lock
during adjustment. After finishing adjust- position.
ment, however, drive the machine at R2 4] Input adjustment ID [7842] directly with
with the reverse slow mode ON and the numeral input switches and press
check that there is not a problem in the [F6].
actual travel speed. 5] Press [F6] again.
a Even if this adjustment code is turned off, a IP correction is started automatically.
the adjustment is effective. a Which clutch is being adjusted is dis-
played in section "a".

D375A-6R 30-135
(01)
Electrical system
Special functions of machine monitor (EMMS)

6] If [End of teaching. Press F6] is displayed Adjustment ID: 7843 (Transmission clutch IP
in section "a", press [F6] again. manual initial correction)
a The buzzer sounds and the adjusted
value is stored.
a This work takes 3 - 5 minutes to com-
plete.

q Use this adjustment to perform the correction


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

q Functions of function switches


[F3]: To increase adjustment value
[F4]: To decrease adjustment value
[F5]: To return to adjustment item selection
screen (ID input screen)
[F6]: To save adjustment value
a If [F2] is pressed while [F1] is pressed, all
the correction values are set to 0.

q Functions of shift up/down switches


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

q Conditions for correction work


Same as the conditions for IP automatic
correction (Adjustment ID: 7842).

q Operating method:
1] Start the engine and keep its speed in the
specified range of condition with the fuel
control dial.
2] Select a clutch to be corrected manually
with the shift-up or shift-down switches.
3] Increase or decrease the adjustment
value by pressing [F3] or [F4].
4] Press [F6] and check that the alarm
buzzer sounds.
a The machine does not move during the
correction work.
a Even if this adjustment code is turned off,
the adjustment is effective.

30-136 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

Adjustment ID: 7845 (Transmission clutch IP Adjustment ID: 7847 (Transmission clutch fill
learning display) time manual initial correction)

q This adjustment code is used to check the in- q This adjustment code is used to carry out cor-
formation of correction made by the IP auto- rection manually when the correction is not
matic correction (Adjustment ID: 7842) or IP carried out normally by the operation of fill
manual correction (Adjustment ID: 7843). time automatic correction (Adjustment ID:
a Use this adjustment code for testing, adjust- 7842).
ing, or troubleshooting when necessary. a Use at the fill time correction work, if neces-
q Functions of function switches sary.
[F3]: To change display q Functions of function switches
[F4]: To change display [F3]: To increase adjustment value
[F5]: To return to adjustment item selection [F4]: To decrease adjustment value
screen (ID input screen) [F5]: To return to adjustment item selection
[F6]: Unused screen (ID input screen)
[F6]: To save adjustment value
q Operating method: a If [F2] is pressed while [F1] is pressed, all the
When this adjustment code is displayed, its correction values are set to 0.
function is effective and the correction infor- q Functions of shift up/down switches
mation is displayed. You can select a clutch to be corrected
a After this adjustment code is turned OFF, manually with the shift-up and shift-down
its function is ineffective. switches.
a The value displayed when the clutch is se-
lected is correction information set automati-
cally or manually before.
q Conditions for correction work
Same as the conditions for fill time automatic
correction (Adjustment ID: 7842).

q Operating method:
1] Start the engine and keep its speed in the
specified range of condition with the fuel
control dial.
2] Select a clutch to be corrected manually
with the shift-up or shift-down switches.
3] Increase or decrease the adjustment
value by pressing [F3] or [F4].
4] Press [F6] and check that the alarm
buzzer sounds.
a The machine does not move during the
correction work.
a Even if this adjustment code is turned off,
the adjustment is effective.

D375A-6R 30-137
(01)
Electrical system
Special functions of machine monitor (EMMS)

Adjustment ID: 9995 (Control brake release Adjustment ID: 9996 (Sudden stop prevention
mode) valve operation mode)

q This adjustment code is used to release the q This adjustment code is used to stop the sud-
control brake (right and left brake ECMV) to den stop prevent solenoid valve and right
check the operation of the backup brake and left brake ECMV to check the operation
(brake pedal solenoid valve). of the sudden stop prevent valve.
a Use this adjustment code for testing, adjust- a Use this adjustment code for testing, adjust-
ing, or troubleshooting when necessary. ing, or troubleshooting when necessary.

q Functions of function switches q Functions of function switches


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

q Operating method: q Operating method:


When this adjustment code is displayed, its When this adjustment code is displayed, its
function is effective and the control brake function is effective and the sudden stop
(right and left brake ECMV) is kept released. prevent solenoid valve and right and left
a After this adjustment code is turned OFF, brake ECMV are kept stopped.
its function is ineffective. a After this adjustment code is turned OFF,
its function is ineffective.

30-138 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

Adjustment ID: 9997 (High idle cut mode) Adjustment ID: 9998 (Max. gear speed setting
mode)

q This adjustment code is used to limit the high


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

D375A-6R 30-139
(01)
Electrical system
Special functions of machine monitor (EMMS)

PM clinic q 3rd screen


The machine monitor can check the condition of
the machine without connecting testing tools to
assist the Pm Clinic and other periodic inspec-
tions.

1) Selection of menu
Select "08 PM CLINIC" on the "Service
Menu" screen.

q 4th screen (The figure shows VHMS in-


stallation specification)

2) Information displayed on Pm Clinic screen


The Pm Clinic function displays the following
information on 6 pages.
q 1st screen

q 5th screen

q 2nd screen (The figure shows VHMS in-


stallation specification)

30-140 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

q 6th screen (The figure shows VHMS in-


stallation specification)

q [F1]: To switch screen


q [F2]: To switch screen
q [F3]: Reset holding
q [F4]:Hold information (displayed data)
q [F5]: Return to Service menu screen

3) Holding displayed information


The displayed information can be held and
released with [F3] and [F4].

D375A-6R 30-141
(01)
Electrical system
Special functions of machine monitor (EMMS)

Cylinder Cut-Out
The operator can perform Cylinder Cut-Out
operation with the machine monitor.
Reduced cylinder mode operation means to run
the engine with 1 or more fuel injectors disabled
electrically to reduce the number of effective
cylinders. This operation is used to find out a
cylinder which does not output power normally
(combustion in it is abnormal).

1) Selection of menu
Select "09 Cylinder Cutout" on the "Service
Menu" screen.
3) Resetting disabled cylinder
When changing a cylinder to be disabled or
when reduced cylinder mode operation is
finished, select a disabled cylinder to be
reset with the function switches.
a This operation may be performed while
the engine is running.
a When [F6] is pressed, if background (a) of
the selected cylinder No. becomes light
blue, the cylinder is reset.
a If the machine monitor resets a cutout cyl-
inder but the engine controller cannot re-
set that cutout cylinder, the background
2) Selecting cylinder to be disabled (a) of the cylinder No. becomes red.
After the "Cylinder Cutout" screen is a The reduced cylinder mode operation is
displayed, select a cylinder to be Cut out by not automatically reset after the screen
using the function switches. returns to the operator mode. According-
q [F1]: Move selection mark (R) to left ly, be sure to perform the resetting opera-
q [F2]: Move selection mark (R) to right tion after the reduced cylinder mode
q [F3]: Reset holding operation is finished.
q [F4]: Hold
q [F5]: Return to Service menu screen 4) Function of holding displayed information
q [F6]: Confirm selection If [F4] is pressed during the reduced cylinder
a This operation may be performed while mode operation, the displayed information is
the engine is running. newly held (c) (The real-time information is
a When [F6] is pressed, if background (a) of kept displayed on the left side).
the selected cylinder No. becomes white, a If [F3] is pressed with the condition of
the cylinder is disabled. hold, the holding function is canceled.
a If the machine monitor resets a cutout cyl- a The holding function is effective, regard-
inder but the engine controller cannot re- less of setting or canceling the cylinder
set that cutout cylinder, the background cutout mode operation.
(a) of the cylinder No. becomes yellow.
a One or more cylinders can be disabled.

30-142 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

[Reference] No injection cranking


q If a normally operating cylinder is dis- The machine monitor is equipped with the func-
abled, the following phenomena occur. tion capable of lubricating the engine through no
1) Lowering of engine speed injection cranking. When a machine has been
2) Increase of final injection rate stored for a long time, this function is used to
command (quantity) lubricate the engine prior to its restart in order to
q If the engine is running near the high idle, prevent its wear or damage due to a lack of lubu-
however, the engine speed may not lower rication oil.
for the reason of engine control. Set the no-injection cranking while the engine is
q In this case, lower the engine speed with stopped.
the fuel control dial and judge by increase
of the injection rate command. 1) Selection of menu
Select "10 No Injection" on the "Service
Menu" screen.

2) Preparation for no injection cranking


When the No injection screen is displayed,
the machine monitor checks automatically if
no injection cranking can be performed.
If no injection cranking can be performed, the
screen changes to the next screen automati-
cally.
a If no injection cranking cannot be per-
formed because the engine is running or
the communication is abnormal, the
screen does not change from the follow-
ing screen. In this case, depress [F5] to
return to the "Service Menu" screen and
solvethe problem.

D375A-6R 30-143
(01)
Electrical system
Special functions of machine monitor (EMMS)

3) Display of confirmation screen 5) Finishing no injection cranking


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

6) Prohibiting no injection cranking


If the operator tries to perform the no injection
4) Starting no injection cranking cranking while the engine is running, the
If no injection cranking (Fuel injection in no message that the engine is running is
cylinders) becomes effective, that is displayed and the no injection cranking is not
displayed on the screen. Under this condi- set effective.
tion, crank the engine with the starting motor. a Press [F5] to return to the "Service Menu"
a While the screen is changing to the fol- screen, stop the engine, and select no in-
lowing screen, the screen of "Being pre- jection cranking again.
pared" is displayed.
a Limit the cranking time to 20 seconds to
protect the starting motor.

30-144 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

Fuel Consumption 3) Display and function during measurement


This function calculates the hourly fuel Clock mark (a) flashes during measurement.
consumption from the actual fuel consumption in a While the fuel consumption is being mea-
a measuring period and indicates it. sured, the operator can work with the op-
erator mode and other functions.
1) Selection of menu Measurement is not finished until this
Select "11 Fuel Consumption" on the screen is displayed again and [F1] is
"Service Menu" screen. pressed (Even if the starting switch is
turned OFF, this function is kept effective,
although fuel consumption is measured
only while the engine is running).

2) Starting measurement
After the screen of "Fuel Consumption" is
displayed, start measurement by using the
function switches. 4) Finishing measurement
q [F1]: Start Press [F1], and measurement is finished and
q [F2]: Clear the data are displayed on the finishing date
q [F5]: Return to Service menu screen and time side.
a When the screen of "Fuel Consumption"
is displayed, if a data is indicated, it is the 5) Displaying fuel consumption
data of the previous measurement. This If the measurement is finished, the hourly
data is not an obstacle to new measure- fuel consumption calculated from the fuel
ment and can be deleted by pressing consumption calculated by the engine
[F2]. controller and the elapsed time are
a If [F1] is pressed, the data is displayed on displayed.
the starting date and time side and mea-
surement starts.
a The display unit of the fuel changes ac-
cording to the unit set with the initializa-
tion (unit setting) function.
SI and meter: l/h, inch: gal/h

D375A-6R 30-145
(01)
Electrical system
Special functions of machine monitor (EMMS)

Display of load record q [F1]: To switch screen


This function displays the data accumulated q [F2]: To switch screen
since the machine started operation. q [F5]: Return to Service menu screen
(It displays the data saved in the controller.) q 2nd screen
1] F1 travel distance
1) Selection of menu The cumulative travel distance in F1
Select "12 Display of saved load" on the (theoretical value) is displayed.
"Service Menu" screen. 2] F2 travel distance
The cumulative travel distance in F2
(theoretical value) is displayed
3] F3 travel distance
The cumulative travel distance in F3
(theoretical value) is displayed.
4] R1 travel distance
The cumulative travel distance in R1
(theoretical value) is displayed.
5] R2 travel distance
The cumulative travel distance in R2
(theoretical value) is displayed.
6] R3 travel distance
The cumulative travel distance in R3
(theoretical value) is displayed.
2) Information displayed on Display of saved
load screen
The following Information is displayed 2
screens of the "Display of saved load"
screen.

q 1st screen
1] 1000 RPM service meter
The number of cumulative operation
hours at engine speed higher than 1,000
rpm is displayed.
2] Forward travel distance
The cumulative forward travel distance
(theoretical value) is displayed.
3] Reverse travel distance
The cumulative reverse travel distance
(theoretical value) is displayed.

30-146 D375A-6R
(01)
Electrical system
Special functions of machine monitor (EMMS)

Setting of VHMS Snap shot (VHMS specification)


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

1) Selection of menu
Select "14 Snap shot" on the "Service Menu"
screen.

2) Setting of installation of VHMS


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

q [F3]: To select "ON"


q [F4]: To select "OFF"
q [F5]: Return to Service menu screen
q [F6]: Confirm selection

q [F1]: To start measurement


q [F5]: Return to Service menu screen

D375A-6R 30-147
(01)
Electrical system
Handling of voltage circuit of engine controller

Handling of voltage circuit of engine controller 30-148

1. When disconnecting or connecting a connector


between engine controller and engine, be sure
to turn off the starting switch.
k Before connecting the harness connec-
tor, be sure to completely remove sand,
dust, water, etc., from inside of controller
side connector.

2. Do not start the engine with T-adapter inserted in


or connected to a connector between engine
controller and engine for troubleshooting
a You may turn the starting switch to the OFF
or ON position but must not turn it to the
START position.

30-148 D375A-6R
(01)
Electrical system
Adjustment method when controller has been replaced

Adjustment method when controller has been replaced 30-149


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

D375A-6R 30-149
(01)
Electrical system
Adjustment method when controller has been replaced

9) Press [F5] to return to the adjustment ID input


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

3) Press [F3] to select "ON" and press [F6] to


enter the selection.

12)Press [F5] to return to the adjustment ID input


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

1) Set the machine monitor in the service mode.


2) Select "13 VHMS Setting" in the "Service
menu" screen.

30-150 D375A-6R
(01)
Electrical system
Adjustment method when controller has been replaced

4. Prelube setting
a Set this item after the machine monitor was
replaced, too.
1) Input "87" with the numeral input switches
and press [F6] in the "Service menu" screen.
2) Press [F3] to select "ON" and press [F6] to
enter the selection.

4) Check to see if there is any failure code being


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

5. Turning power on again a Precautions after replacing controller:


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

3) Press [F3] or [F4] to select "02 Electrical


system abnormality recrd" and press [F6] to
enter the selection.

D375A-6R 30-151
(01)
Electrical system
Adjustment method when controller has been replaced

7. Work equipment specification selection a For details, see "Special functions of monitor
1) Select "07 Adjustment" in the "Service menu" panel (EMMS)", "Adjustment" function.
screen. q Adjustment ID: 7845

12. Trigger teaching value check


a For details, see "Special functions of monitor
panel (EMMS)", "Adjustment" function.
q Adjustment ID: 7847

13. Steering lever neutral position adjustment


a For details, see "Special functions of monitor
panel (EMMS)", "Adjustment" function.
q Adjustment ID: 1012

14. Steering lever leftmost position adjustment


a For details, see "Special functions of monitor
panel (EMMS)", "Adjustment" function.
q Adjustment ID: 1013
2) Input adjustment ID [0004] directly with the
numeral input switches and press [F6].
15. Steering lever rightmost position adjustment
3) Press [F3] or [F4] to select Dual tilt or Single
a For details, see "Special functions of monitor
tilt.
panel (EMMS)", "Adjustment" function.
4) Press [F6] to enter the selection.
q Adjustment ID: 1014
a The buzzer sounds and the work equip-
ment specification is stored.
16. Shoe slip control specification setting
a For details, see "Special functions of monitor
panel (EMMS)", "Adjustment" function.
q Adjustment ID: 0036

17. Setting of travel control lever codes


(Only for the machine with travel control
lever different from the standard one)
a For details, see "Special functions of monitor
panel (EMMS)", "Adjustment" function.
q Adjustment ID: 0041

8. Brake pedal potentiometer initial correction


a For details, see "Special functions of monitor
panel (EMMS)", "Adjustment" function.
q Adjustment ID: 0005

9. Pitch angle sensor standard setting


a For details, see "Special functions of monitor
panel (EMMS)", "Adjustment" function.
q Adjustment ID: 0009

10. IP automatic correction and trigger auto-


matic initial teaching
a For details, see "Special functions of monitor
panel (EMMS)", "Adjustment" function.
q Adjustment ID: 7842

11. IP correction value check (Check of correc-


tion value of electric current)

30-152 D375A-6R
(01)
Electrical system
Preparation work for troubleshooting for electrical equipment system

Preparation work for troubleshooting for electrical equipment system 30-153

a When performing troubleshooting for an electri- 3) Insert or connect test T-adapters into or to
cal circuit related to the machine monitor, engine connectors CM01 and CM02 on the back
controller, work equipment controller, power side of the machine monitor.
train controller, VHMS controller, or ORBCOMM
terminal, expose the related connectors accord-
ing to the following procedure.

1. Machine monitor
1) Remove cover (1).

2. Engine controller
1) Open covers (4) and (5) on the left side of the
engine.

2) Remove 4 mounting bolts (2) and pull out


machine monitor (3) toward this side.

D375A-6R 30-153
(01)
Electrical system
Preparation work for troubleshooting for electrical equipment system

2) Remove engine controller covers (6) and (7).

3) Insert or connect the diagnostic T-adapter in


or to the connector (ENG, EGC2, EGC3) of
engine controller (8).
a Since the connectors are secured with
screws, loosen those screws before dis-
connecting.
a When returning the connector to the pre-
vious condition, tighten the screw to the
following torque.
3 Screw:3 1 Nm {0.3 0.1 kgm}

k In order to prevent malfunction and mis-


taken system error warning, be sure to
completely remove foreign object (b)
such as sand, dust, water, etc., from in-
side of controller side connector (a) with
air blow etc., before connecting to har-
ness connector.

30-154 D375A-6R
(01)
Electrical system
Preparation work for troubleshooting for electrical equipment system

3. Work equipment controller 4. Power train controller


1) Slide the operator's seat to the front end and 1) Slide the operator's seat to the front end and
fold the seat back forward. fold the seat back forward.
2) Remove cover (9). 2) Remove cover (9).

3) Remove the mounting bolts of work equip- 3) Remove the mounting bolts of power train
ment controller (10). controller (11).

4) Insert or connect test T-adapters into or to 4) Insert or connect test T-adapters into or to
connectors WECN1, WECN2 and WECN3. connectors PTCN1, PTCN2 and PTCN3.
a Since the connectors are secured with a Since the connectors are secured with
screws, loosen those screws before dis- screws, loosen those screws before dis-
connecting. connecting.
a When returning the connector to the pre- a When returning the connector to the pre-
vious condition, tighten the screw to the vious condition, tighten the screw to the
following torque. following torque.
3 Screw:3 1 Nm {0.3 0.1 kgm} 3 Screw:3 1 Nm {0.3 0.1 kgm}

D375A-6R 30-155
(01)
Electrical system
Preparation work for troubleshooting for electrical equipment system

5. VHMS controller (VHMS specification) 2) Remove the mounting bolts of ORBCOMM


1) Open the cover on the left side of the floor terminal (16) and pull out the terminal.
and remove cover (12).
2) Insert or connect troubleshooting T-adapters
in or to connectors V1, V2A, V2B, V3A, V3B,
V4A, V4B of VHMS controller (13).
a If it is difficult to remove and install the
connectors, remove the controller for the
ease of work.

3) Insert or connect test T-adapter into or to


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

30-156 D375A-6R
(01)
Electrical system
Inspection procedure of diode

Inspection procedure of diode 30-157


2. When using an analog multimeter
a The direction of continuity of diode is marked on 1) Set the tester in the resistance range.
the surface of the diode. 2) Apply the leads of the tester as explained
below and check the movement of the
pointer.
1] Set red (+) test lead to diode anode (P)
side and black () test lead to cathode (N)
side.
2] Set red (+) test lead to diode cathode (N)
side and black () test lead to anode (P)
side.
3) Judge the condition of the diode by the move-
ment of the pointer.
q Needle does not deflect with connection i)
but deflects with connection ii): Normal.
(However deflection range (resistance
value) varies depending on the type of
1. When using a digital multimeter tester and testing range.)
1) Set the tester in the diode range and check q Needle deflects with both connection i)
the indicated value. and ii): Defective (internal short circuit)
a When an ordinary circuit tester is used, q Needle does not deflect with either con-
the voltage of the internal battery is indi- nection 1] or 2]: Defective (internal dis-
cated. connection)
2) Put the red probe (+) of the test lead to the
anode (P) of and the black probe () to the
cathode (N) of diode, and confirm the indi-
cated value.
3) Judge the condition of the diode by the indi-
cated value.
q Indicated value remains unchanged:
Conduction is absent (Failure)
q The indicated value changes: The diode
has conductivity (Normal) (See a below.)
Note: In the case of a silicon diode, a value in
the range from 460 to 600 mV is indicated.
q Displayed value becomes 0 or near 0 :
Short-circuiting of diode internal part (de-
fect)

D375A-6R 30-157
(01)
Electrical system
Handling of optional devices

Handling of optional devices 30-158


4. Connecting C signal of starting switch
a D375A-6R is equipped with the connectors in If the C signal (starting signal) of the starting
the fuse box for optional equipment to be in- switch is necessary for an optional device such
stalled. Use these connectors to obtain the nec- as the pre-lubricator, take the signal out of the
essary signals or power for the equipment following connector pin.
without remodeling the machine wiring harness. q CN-PRS (2-pole heavy duty wire connector)
a For the locations of the connectors, see Trouble- a Remove the connector installed when the
shooting, "Connector list and layout". machine is shipped, and connect pin (1) to
the starting signal to be finally output by the
1. Connecting the ACC signal of starting switch pre-lubricator and connect pin (2) to the input
If the ACC signal (ON signal) of the starting signal from the starting switch.
switch is necessary for a optional device such as
the turbocharger timer, connect it through the 5. Connecting external power source
following connector pin. If an external power source is necessary,
q Pin (B) of CN-ESD (3-pole heavy duty wire connect it through the following connectors.
connector) q CN-800 (Plug connector):
a A 20A fuse is installed on the upstream side Used for device in cab
of this connector pin. q CN-810 (Plug connector):
Used for device out of cab
2. Input of engine stop signal a A 20A fuse is installed on the upstream side
If the engine needs to be stopped with the of these connectors.
starting switch in the ON position for an optional
device such as the engine emergency stop
system, use the circuit of the following connector
pin.
q Pin [A] of CN-ESD (3-pole heavy duty wire
connector)
a Before using this circuit, be sure to notify your
Komatsu distributor.

3. Inputting engine low-idle command


If it is required to keep the engine speed at low
idle for an optional device such as the engine
protector, use the circuit of the following
connector pin.
q Pin (C) of CN-ESD (3-pole heavy duty wire
connector)
a Before using this circuit, be sure to notify your
Komatsu distributor.

30-158 D375A-6R
(01)
Electrical system
Request for opening ORBCOMM terminal

Request for opening ORBCOMM terminal 30-159


30-159
a If the machine is equipped with ORBCOMM, fill
in the "Request for opening VHMS ORBCOMM
terminal" and send it by fax or mail to "KOMAT-
SU KOMTRAX SUPPORT CENTER" before ini-
tializing the VHMS controller.
a Initialize the VHMS controller after the opening
notification is received from "KOMATSU
KOMTRAX SUPPORT CENTER".
a If the ORBCOMM antenna is installed and the
starting switch is turned to the ON position be-
fore the opening notification is received, the OR-
BCOMM terminal transmits radio waves and
ORBCOMM CO. LTD. sends out the stop signal
automatically. In this case, complicated proce-
dures and some time are required to open the
ORBCOMM terminal service again.

D375A-6R 30-159
(01)
Electrical system
Request for opening ORBCOMM terminal

30-160 D375A-6R
(01)
Electrical system
Initialization procedures for VHMS controller

Initialization procedures for VHMS controller 30-161


1. Check of machine information, engine infor-
a Initialization tools for VHMS controller mation and controller information
Sym- Part name a This step is a work performed on the whole
Part No. machine.
bol
1 799-608-3211 Discket Check and record the machine information,
2 799-608-3220 Wiring harness engine information, VHMS controller infor-
Notebook type personal com- mation and ORBCOMM terminal information.
Z
Commercially puter: Windows NO Information to be checked
3
available 98/2000/Me/XP/VISTA (*) [With 1 Model name
RS232C terminal] 2 Machine serial No.
*: VHMS setting tool: Ver. 3.06.00.03 or later, VHMS 3 Current service meter reading
analysis tool: Ver. 3.05.00.00 or later. 4 Engine serial No.
5 Transmission serial No.
6 VHMS controller serial No.
a Before starting full operation after completion of ORBCOMM terminal serial No.
local assembly or before resuming operation af- 7
[Only for machines equipped with ORBCOM]
ter storage for a long period, initialize the VHMS
controller according to the following procedure.
a Machine data collected with the VHMS controller a VHMS controller (1) is in the control box on
are stored and managed in WebCARE data- the left side of the floor and ORBCOMM ter-
base. To process the data smoothly on the We- minal (2) is in the control box on the right side
bCARE, it is necessary to set the VHMS of the floor.
controller consistently. If it is not set correctly,
data will not be taken into the WebCARE and
data in the VHMS controller may not be utilized.
Accordingly, be sure to carry out the initializa-
tion.
a For the method of installing the VHMS Initializa-
tion Program to the personal computer, refer to
the Operation and Maintenance Manual con-
tained in the package of diskette Z1.
a Since the service menu of the machine monitor
will be used in the following procedure, read
"Special functions of machine monitor (EMMS)"
and understand the operating procedure in ad-
vance.
a The initial setting procedure is described in the
ORBCOM installation specification and the OR-
BCOM-less specification. When using the ORB-
COM installation specification, implement the
procedures needed for VHMS alone, bypassing
those prepared only for ORBCOM installation
specification.
a During the initialization work, confirm each work
according to the "VHMS Initialization Work
Checklist".

D375A-6R 30-161
(01)
Electrical system
Initialization procedures for VHMS controller

2. Connection of personal computer


1) Make sure that starting switch is in OFF posi-
tion.
k When connecting and disconnecting
the PC, be sure to turn the starting
switch to the OFF position.
2) Connect PC Z3 and download connectors
(VDW) and (DL1) with wiring harness Z2.
a The download connectors are installed to
the following places.
q VDW: At bottom of left rear of operator
seat
q DL1: Right rear of machine (Side of
backup lamp)
a Connect it to RS232C terminal on the PC.
3. Check of operation and satellite capturing
condition of VHMS controller
a This step is a work performed in the opera-
tor's cab.
a Check of satellite capturing condition is nec-
essary o only [ORBCOMM specification].

[Method of checking with monitoring func-


tion](Monitoring code: 99003)
1) Turn the starting switch to ON position.
2) Set the machine monitor to display the
service menu.
a For the operating method, see "Special
functions of machine monitor (EMMS)".

a Execute initialization of VHMS from the 3) Select "01 Monitoring".


connector in the cab.
a Use the ground download connector for
only downloading.

30-162 D375A-6R
(01)
Electrical system
Initialization procedures for VHMS controller

4) Input monitoring code 99003 directly with the 2) At least 3 minutes after the starting switch is
numeral input switches. turned to the ON position, check the commu-
a The communication condition of the OR- nication condition of the ORBCOMM terminal
BCOMM terminal is displayed. by the display condition of the decimal point
(indicated with the arrow) of the machine
monitor.

[Method of checking with monitoring func-


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

[Method of checking with VHMS controller]


1) Turn the starting switch to ON position.
2) The 7-segment LED (indicated with the
arrow) of the VHMS controller flashes and
rotates, and then counts up.

D375A-6R 30-163
(01)
Electrical system
Initialization procedures for VHMS controller

3) Confirm that the ORBCOMM terminal has


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

4. Start-up of VHMS initialization tool


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

3) When [Date/Time] information is not appro-


priate, correct it in the following procedure.

30-164 D375A-6R
(01)
Electrical system
Initialization procedures for VHMS controller

1] Press [Edit] button (1) on the right lower


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

4) If information in the [Machine information]


box is not correct, change it according to the
following procedures:
1] Press the [Edit] button (2) on the lower
right portion of the [Machine information]
box to display the correction screen.
2] Correct the information and press the
[OK] button.

5) After checking/changing all the data in


[Machine information], press [Apply] button
(3) to enter the setting.
a If the [Apply] button(3) is pressed, the
screen for checking the setting appears.
Check the setting again and press the
[OK] button if the setting is correct.
a In case of the ORBCOMM Specification,
execute [Communication Setting] first
and then settle the setting.

D375A-6R 30-165
(01)
Electrical system
Initialization procedures for VHMS controller

[Communication Setting] 9) To change setting in [SHORT TREND ANAL-


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

8) To change the setting in [SHORT FAULT


HISTRY], follow the procedure below: 10)To change the setting of [Satellite Setting],
1] Select [SHORT FAULT HISTRY] on the follow the procedure below.
screen and press [Edit] button (5) on the 1] Press the [Edit] button in the [Satellite
left lower part of the [File Transfer Setting] Setting] block to display the setting
block to display the setting screen. screen.
2] Change the setting and then press the 2] Set the GCC Code to the applicable area
[OK] button. and then press the [OK] button.
a At initialization, select [Occurrence] at
[Timing] and set the function to [ON].

30-166 D375A-6R
(01)
Electrical system
Initialization procedures for VHMS controller

GCC
Area Remarks
Code
N.America
*1: Except U.S. Territories in
(*1)
1 Micronesia and Midway
C.S.Americas
Island
Faroe Islands
Europe (*2)
Middle East
*2 Except Faroe Islands
120 Asia (*3)
*3 Except Japan
Africa
Oceania CIS
130 Japan
a If the combination of the country name
and code in the list box displayed by the
setting tool is different from the above ta-
ble, select the GCC code in the table or
input the value through the keyboard. 6. Initialization of VHMS controller (Ver. 3.5.2.1
11)After checking/changing all the data in or after)
[Communication Setting], press [Apply] a This step is a work performed in the opera-
button to enter the setting. tor's cab (on the personal computer).
a If the [Apply] button is pressed, the a When initializing, do not change the data of
screen for checking the setting appears. service meter [SMR].
Check the setting again and press the 1) Select [VHMS Setting] and press the "Next"
[OK] button if the setting is correct. button.

2) Select [Set up & All clear] and press the


"Next" button.

12)After checking/changing the data of [Machine


Information] and [Communication Setting],
press the [Exit] button at the lower right
portion of the screen to finish [VHMS Initial
setting Tool].

D375A-6R 30-167
(01)
Electrical system
Initialization procedures for VHMS controller

3) Check the machine information. If it does not 4) Select the time zone.
need to be corrected, press the "Next" 5) Input the local time.
button. 6) If the DST (Daylight Saving Time) is used
now, select it and press the "Next" button.
a If the DST is selected, the clock is ad-
vanced 1 hour automatically, thus the
time must be corrected again.

a If the VHMS was installed additionally,


the information of [Serial No.] etc. must
be input.

7) Set the GCC Code to the applicable area and


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

30-168 D375A-6R
(01)
Electrical system
Initialization procedures for VHMS controller

8) The contents of the setting are displayed 7. Downloading of set data


finally. If there is not a problem, press the 1) Connect PC Z3 and download connectors
"Apply" button. (VDW) in the cab or ground download
connector (DL1) with wiring harness Z2.

a Download connector (VDW) in the cab is


9) The system asks you if you save the data
installed to the left rear lower part of the
before changing the setting. If you do not
operator's seat.
need to save, select "NO".

a The ground download connector DL1 is


installed to the side of the backup lamp at
the rear right of the machine.
10)After finishing the work of changing the
contents of initialization, press the "OK"
button to finish the program.

D375A-6R 30-169
(01)
Electrical system
Initialization procedures for VHMS controller

2) When using download connector (VDW) in 8. Check of downloaded data


the cab, set the starting switch in the ON a This step is a work performed in the opera-
position. tor's cab (on the personal computer).
3) When using ground download connector 1) Check the setting data by using [View] func-
(DL1), turn switch (3) ON. tion.
a The green LED lights up. a For the operation procedures, refer to the
Operation and Maintenance Manual for
4) Click the icon of [VHMS Analysis Tool] on the VHMS Technical Analysis Tool.
PC to start the VHMS analysis tool. a Make sure that the [MFA0] code at the
time when the snapshot was operated is
displayed in [Fault History].
a Make sure that the snap shot data are re-
corded.

a Input [User Name] and [Password].


a For the operation procedures, refer to the
Operation and Maintenance Manual for
VHMS Technical Analysis Tool.
2) After checking the set data, terminate [VHMS
Technical Analysis Tool].

9. Disconnection of Personal Computer


1) Make sure that starting switch is in OFF posi-
tion.
k When connecting and disconnecting
the PC, be sure to turn the starting
switch to the OFF position.
2) End the OS of the PC and then turn the PC
OFF.

5) Using the [Download] function, download the


data currently recorded in the VHMS
controller to the personal computer.
a For the operation procedures, refer to the
Operation and Maintenance Manual for
VHMS Technical Analysis Tool.
a Make sure that downloading has complet-
ed before proceeding to the next step.

30-170 D375A-6R
(01)
Electrical system
Initialization procedures for VHMS controller

3) If the data was downloaded in the cab, 10. Report to Komatsu


disconnect wiring harness Z2 from download After completing steps 1 to 9 successfully, send
connector (VDW). the "VHMS/WebCARE setting notification form"
prepared at the end of this section to
VHMS/WebCARE Support Center of Komatsu,
Tokyo.
a Since Komatsu has to set the receiving side
of the satellite communication, be sure to in-
form Komatsu of the completion of the set-
ting.
a Send the first downloaded data of VHMS via
e-mail to the following address along with the
"VHMS/WebCARE setting notification form",
a When using the KOMTRAX functions on the
machine equipped with the ORBCOMM,
complete the radio station establishment on
the machine side and apply a checkmark to
4) If the data was downloaded on the ground, the column "Do you use KOMTRAX servic-
turn switch (3) OFF and disconnect wiring es?" in the "VHMS/WebCARE setting notifi-
harness Z2 from download connector (DL1). cation form."

Komatsu VHMS/WebCARE Support Center

2-3-6, Akasaka Minato-ku Tokyo, Japan

FAX: 81-3-5561-4766 (from outside of Japan)

E-mail: webcare@komatsu.co.jp

D375A-6R 30-171
(01)
Electrical system
Initialization procedures for VHMS controller

Date of setting:
DB/branch
[For storage] name:
VHMS initial setting work check sheet Data entered by:

Setting step Check item Result

Model name
Serial No.
Check of nameplates of chassis and
1 Engine serial No.
components
Transmission controller serial No.
VHMS controller serial No.

2 Connection of PC with VHMS controller Is connection made securely? yes no

Is operation normal?
3 Check of operation VHMS controller (Displays decimal counting in ascending-order succeeding yes no
to rotation)

4 Starting of VHMS initialization Tool Is setting tool set in "Data Clear and Set up" mode? yes no

Is model name correct? yes no


Initialization of VHMS controller Is machine serial No. input correctly? yes no
(Setting of machine information) Is engine serial No. input correctly? yes no
5
Set basic information of machine to Is today's date displayed? yes no
VHMS controller in this step. Does clock indicate present time? yes no
Is SMR input correctly? yes no

6 Saving of set items Is LED (7-segment) turned OFF? yes no

7 Check of VHMS function Does LED operate normally? yes no

Are service mode "SNAPSHOT" selected and is switch


8 Performing Quick Pm Clinic yes no
pressed?

9 Saving operation of VHMS Is LED (7-segment) turned OFF? yes no

10 Downloading Does LED operate normally? yes no

Are all files downloaded? yes no


Hour, min-
The time downloaded (Reference wrist watch)
ute:
11 Check of downloaded data [Check of data]
Is there MFA0 error in Fault History? yes no
Are SMR and time in Fault History matched to set values? yes no
Are all data of Snap Shot prepared? yes no

12 Saving operation of VHMS Is LED (7-segment) turned OFF? yes no

30-172 D375A-6R
(01)
Electrical system
Initialization procedures for VHMS controller

[For keeping] Date of setting:


DB/branch name:
ORBCOMM Station Establishment Check
Sheet Data entered by:

Setting step Check item Result

Model name
Serial No.
Check of nameplates of chassis Engine serial No.
1
and components Transmission serial No.
VHMS controller serial No.
ORBCOMM controller serial No.

Connection of PC with VHMS con-


2 Is connection made securely? yes no
troller

Check of operation VHMS control- Is operation normal?


3 yes no
ler (Displays counting in ascending-order succeeding to rotation)

4 Starting of VHMS initialization Tool Is setting tool set in "Set up" mode? yes no

Enter set value of S.Fault History.


Execution of communication On Off
Number of communication (Default: 8) hrs
Initialization of VHMS controller Enter set value of S. Trend Analysis.
1. Setting of communication Execution of communication On Off
(Machine information and PLM Interval (Default: 20H) hrs
5
have been set) Enter set value of S. Payload data (If PLM is installed).
Execution of communication On Off
Time to start collection
Collection interval (Number of days) day
2. Setting of start of communica-
Is GCC code set? (130 for Japan) yes no
tion

6 Saving of set items Is LED (7-segment) turned OFF after saving operation? yes no

Check of operation of ORBCOMM How is display of decimal point on VHMS monitor (7-segment)?
7 yes no
controller (Off, On, long/short blinking)

D375A-6R 30-173
(01)
Electrical system
Initialization procedures for VHMS controller

30-174 D375A-6R
(01)
Electrical system
Using method of KOMTRAX functions of ORBCOMM terminal

Using method of KOMTRAX functions of ORBCOMM terminal 30-175

a The KOMTRAX functions are added to the OR- a The ORBCOMM terminal executes the
BCOMM terminal of this machine. sign-up test and judges the result by it-
a The ORBCOMM terminal equipped with the self. The criterion is as follows.
KOMTRAX function can display the machine on q The starting switch is in the ON position.
the control screen of the KOMTRAX system. q The VHMS controller can communicate
a When using the KOMTRAX functions, perform with the ORBCOMM terminal (They are
the following procedure. connected normally).
1. Make the request for opening the ORBCOMM q A valid GCC code is set to the VHMS con-
terminal and receive the opening notification. troller.
a See "Request for opening ORBCOMM termi- q The ORBCOMM terminal is receiving the
nal". signals from the ORBCOMM communica-
tion satellite. (The ORBCOMM antenna is
2. Initialize the VHMS controller and set the GCC connected.)
code of the machine location. q Positioning of the machine with the is
a See "Initialization procedure for VHMS con- completed (The GPS antenna is connect-
troller". ed.)
4) Check that LED1 is lighting.
3. Perform the sign-up test on the machine side. a At this time, the sign-up test is completed.
a Perform the sign-up test in an open outdoor a Once the sign-up test is completed, the
place. ORBCOMM terminal cannot be returned
a If the sign-up test is performed in an indoor to the original state.
place where the satellite radio waves are
blocked, it may not be completed.
a It may take time to complete the sign-up test,
depending on the condition of receiving sig-
nals from the ORBCOMM communication
satellite and GPS satellite.
1) Check that the VHMS controller, ORBCOMM
terminal, ORBCOMM antenna and JPS
antenna are connected to the wiring harness
of the machine.
2) Turn the starting switch to the ON position.
3) Wait until LED1 lights up.
a LED1 keeps flashing until the sign-up test
is completed.

D375A-6R 30-175
(01)
Electrical system
Using method of KOMTRAX functions of ORBCOMM terminal

[LED display] [State]


(1) LED-Green KOMTRAX state Waiting for server trigger: Lighting
Normal operating state: Turning off
(2) LED-Red ORBCOMM satellite capture Satellite not captured: Lighting
Satellite captured (No transmission data):Quick flashing
Satellite captured (There is transmission data): Slow flashing
Power OFF: Turning off
(3) LED Yellow VHMS start recognition VHMS start recognized: Lighting
VHMS stop recognized: Turning off
(4) LED Green ORBCOMM MODEM power ON: Lighting
OFF: Turning off
(5) LED Red Unused Kept Turning off
(6) LED Red Unused Kept Turning off
(7) 7 segment Number of mails waiting to be sent (Max. of 9)
(8) Dot GPS satellite capture state Satellite not captured: Turning off
Satellite captured: Lighting

* Flashing inter-
val
Quick flashing: Cycle of 1 sec (Lighting for 0.5 sec and Turning off for 0.5 sec repeatedly)
Slow flashing: Cycle of 4 sec (Lighting for 0.5 sec and Turning off for 1.5 sec repeatedly)

30-176 D375A-6R
(01)
Electrical system
Using method of KOMTRAX functions of ORBCOMM terminal

4. Apply for starting to use.


1) Notify the VHMS/WebCARE operations
administrator of the following information of
the machine which has completed the station
set-up check.
q Model, model No. and serial No. of ma-
chine
q Part No. and serial No. of ORBCOMM ter-
minal
q Reading of service meter when sign-up
test was completed (0.1 h unit)
2) Fill in the "VHMS/WebCARE setting notifica-
tion form" and apply a checkmark to the
column of "Do you use KOMTRAX
services?" in the form.
3) Send the "VHMS/WebCARE setting notifica-
tion form" to VHMS/WebCARE Support
Center in Komatsu Head Office.

Komatsu VHMS/WebCARE Support Center

2-3-6, Akasaka Minato-ku Tokyo, Japan

FAX: 81-3-5561-4766 (from outside of Japan)

E-mail: webcare@komatsu.co.jp

4) The KOMTRAX operations administrator


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

D375A-6R 30-177
(01)
Electrical system
Precautions for replacing VHMS controller

Precautions for replacing VHMS controller 30-178


2. Check, saving and writing of information set
a Tools for replacing VHMS controller in VHMS controller (Before Ver. 3.5.2.1)
Sym- a This step is a work performed in the opera-
Part No. Part name tor's cab (on the personal computer).
bol
1 799-608-3211 Discket a Transfer the set data of the VHMS controller
2 799-608-3220 Wiring harness to be replaced to the personal computer and
Notebook type personal com- then write it in the newly installed VHMS con-
Z
Commercially puter: Windows troller.
3
available 98/2000/Me/XP/VISTA (*) [With
RS232C terminal]
2-1. Check and saving of information set in
*: VHMS setting tool Ver. 3.06.00.03 or later, VHMS VHMS controller to be replaced.
analysis tool Ver.3.05.00.00 or later 1) Connect the PC and start the VHMS initial
a When the VHMS controller needs to be re- setting tool.
placed, set it before removing it and the installed a See "Initialization procedures for VHMS
new VHMS controller according to the following controller".
procedure. 2) Select "Save/Load" and press the "OK"
a Machine data collected with the VHMS controller button.
are stored and managed in WebCARE data-
base. To process the data smoothly on the We-
bCARE, it is necessary to set the VHMS
controller consistently. If it is not set correctly,
data will not be taken into the WebCARE and
data in the VHMS controller may not be utilized.
Accordingly, be sure to carry out the initializa-
tion.
a During the initialization work, confirm each work
according to the "VHMS Initialization Work
Checklist".

[Work before replacing VHMS controller] 30-178


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

30-178 D375A-6R
(01)
Electrical system
Precautions for replacing VHMS controller

2-2. Writing of set information in new VHMS


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

5) Check the information again and press the


"OK" button to save it.

3) Select [Load] from [File] in the menu.


6) Select [Exit] from [File] in the menu to finish
the VHMS setting tool.
7) Disconnect the PC.
a See "9. Disconnection Personal Comput-
er" in "Initialization procedure for VHMS
controller".
8) Turn the PC OFF.
9) Replace the VHMS controller.

D375A-6R 30-179
(01)
Electrical system
Precautions for replacing VHMS controller

4) The saved information is displayed. Press 7) After setting the time, press the "OK" button.
the "OK" button.

8) Press [Apply] button to display contents of


the setting. Check the setting again and, if it
is acceptable, press [OK] button.

5) The saved information is displayed on


another screen.
6) Press the [Edit] button to set the time.

30-180 D375A-6R
(01)
Electrical system
Precautions for replacing VHMS controller

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

3-1. Check and saving of information set in


VHMS controller to be replaced.
1) Connect the PC and start the VHMS initial
setting tool.
a See "Initialization procedures for VHMS
controller".
2) Select [When VHMS needs to be replaced]
and press the "Next" button.

10)Select [Exit] from [File] in the menu to finish


the VHMS setting tool.

3) Select [Save Current Setting before replace-


ment of VHMS controller] and press the
"Next" button.

D375A-6R 30-181
(01)
Electrical system
Precautions for replacing VHMS controller

4) Check all the information before replacing 3) Select [Use Previous setting after replace-
the VHMS controller and press the "Save" ment of VHMS controller] and press the
button. "Next" button.

5) Select [Exit] from [File] in the menu to finish 4) The saved information is displayed. Press
the VHMS setting tool. the "Next" button.
6) Disconnect the PC.
a See "9. Disconnection Personal Comput-
er" in "Initialization procedure for VHMS
controller".
7) Turn the PC OFF.
8) Replace the VHMS controller.

3-2. Writing of set information in new VHMS


controller
1) Connect the personal computer again and
start the VHMS technical analysis tool.
a See "Initialization procedures for VHMS
controller".
2) Select [When VHMS needs to be replaced]
and press the "Next" button.
5) Set the time and press the "Apply" button.

30-182 D375A-6R
(01)
Electrical system
Precautions for replacing VHMS controller

6) The system asks you if you will save the [Work after replacing VHMS controller] 30-183
previous data. Press the "NO" button. a Download the data referring to "7. Downloading
a Usually, you do not need to save the pre- of set data" in "Initialization procedures for
vious data. VHMS ".
a After completing the setting after the replace-
ment, send the check sheet to VHMS/Web-
CARE Support Center of Komatsu, Tokyo.
a Send the data downloaded before and after re-
placing the VHMS controller to the following ad-
dress via e-mail.

Komatsu VHMS/WebCARE Support Center

2-3-6, Akasaka Minato-ku Tokyo, Japan

FAX: 81-3-5561-4766 (from outside of Japan)

E-mail: webcare@komatsu.co.jp

7) The above completes modification of the


setting. Press [OK] button to end the VHMS
initial setting tool.

D375A-6R 30-183
(01)
Pm Clinic
Pm Clinic service

Pm Clinic 30-184
Pm Clinic service 30-184
Model Serial No. Service meter reading
D375A-6R #65001- h

User name Date of clinic Inspector


/ /

Specifications
Blade Blade tilt Attachment Shoe width
Semi U blade Single tilt blade Multishank ripper 610 mm
U blade Dual tilt blade Variable giant ripper 710 mm
Counter weight ( kg) 810 mm
Others ( ) Other

Operating conditions
Construction Type of soil (specific gravity) Type of work
Quarry, mine
Construction, civil engi- Rock Dozing %
Coal
neering Gravel Side cutting %
Gold
Roads Sand Ripping %
Limestone
Tunnels Clay Travel %

Existence of abnormalities
Oil, coolant level check
Engine coolant level When necessary
Engine oil level Power train Damper case
Hydraulic oil level Final drive ( )

Ambient temperature Height above sea level


Max.
C m
Min.

Operator's opinion

Visual check results

Failure code history


[ ] h [ ] h
Content: Content:
[ ] h [ ] h
Content: Content:
Operating mode
q Working mode: P- or E-mode
q Gear shift mode: Auto or Manual
q Preset: F or R

Comment

30-184 D375A-6R
(01)
Pm Clinic
Pm Clinic service

Measurement item for Pm Clinic of D375A-6R 30-185

Measuring methods:
Q: Measurement with machine monitor
E: Measurement by gauge. (sensor or quick copuler)
x: Need installation sensor or quick copuler

Engine
Specifica-
Engine speed Engine oil pressure Exhaust temperature Blowby pressure Boost pressure
tions
STD Q Q x x Q
Pm clinic Q Q E x Q
VHMS Q Q Q Q Q

Power train oil circuit


Torque con- Torque con- Torque con-
Specifica- Steering pres- Brake pres-
verter inlet verter outlet verter stator L/U
tions sure sure
pressure pressure clutch pressure
STD Q Q E E E E
Pm clinic Q Q E E E E
VHMS Q Q E E E E

Power train oil circuit


Transmission Transmission
Specifica-
main relief 1st 2nd 3rd F R lubricating oil
tions
pressure pressure
STD E E E E E E E
Pm clinic E E E E E E E
VHMS Q E E E E E E

Work equipment circuit Fan circuit


Specifica-
Control source pressure Pump pressure Rotating speed
tions
STD E E Q
Pm clinic E Q Q
VHMS E Q Q

D375A-6R 30-185
(01)
Pm Clinic
Pm Clinic service

Testing points for Pm clinic (1/3) 30-186

For the measurement procedures, see the following pages.


*1. Enging speed:"Testing engine speed"
*2. Blow-by pressure: "Testing blow-by pressure"
*3. Engine oil pressure: "Testing engine oil pressure"
*4. Boost pressure: "Testing intake air pressure (boost pressure)"
*5. Exhaust gas temperature: "Testing exhaust temperature"

30-186 D375A-6R
(01)
Pm Clinic
Pm Clinic service

Testing points for Pm clinic (2/3) 30-187

For the measurement procedures, see the following pages.


*6. Measurement related to torque converter: "Testing power train oil pressure"
*7. Measurement related to transmission: "Testing power train oil pressure"
*8. Measurement related to steering brake "Testing power train oil pressure"

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

Testing points for Pm clinic (3/3) 30-18

For the measurement procedures, see the following pages.


*9. Hydraulic pressure of work equipment: "Testing and adjusting work equipment oil pressure"
*10. Source pressure of control circuit: "Testing control circuit main pressure"
*11. Fan speed: "Measuring fan speed"

30-188 D375A-6R
(01)
Pm Clinic
Pm Clinic service

Pm Clinic check sheet D375A-6R Serial No.

Work order No. Date of clinic Service meter reading Inspector


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

SAE0W30E0S Min. 98.07 Max. 78.45


Low idle SAE5W40E0S {Min. 1.0} {Max. 0.8}
SAE10W30DH kPa
Engine oil pressure
SAE15W40DH {kg/cm2} Min. 343.23 Max. 205.94
High idle Oil temperature: {Min.3.5} {Max. 2.1}
Min.70C
kPa Min. 131 Max. 117
Boost pressure At torque converter stall
{mmHg} {Min. 980} {Max. 880}
Torque converter stall + No. 1, 2 , 3 cylinder
Exhaust temperature C Max. 670 Min. 700
Work equipment relief No. 4, 5, 6 cylinder

k For torque converter lockup clutch pressure, set both of the steering clutches to the disengage mode on the machine mon-
itor and check the pressure.
Standard
Service limit Test Rem-
Item Test conditions Unit value for new OK NG
value results arks
machine
0.03 0.25 i
Inlet oil pressure
{0.3 2.5} i
0.03 0.20 i
Outlet oil pressure
{0.3 2.0} i
Engine at low idling
Lockup clutch pres- 00 i
sure {0 0} i
Torque converter

Stator clutch oil pres- 2.25 2.87 i


sure {23.0 29.3} i
Transmission: Neutral MPa 0.69 1.05 i
Inlet oil pressure
{kg/cm2} {7.0 10.7} i
0.44 0.70 i
Outlet oil pressure
{4.5 7.0} i
Engine at high idling
Lockup clutch pres- 00 i
sure {0 0} i
Stator clutch oil pres- 2.55 2.87 i
sure {26.0 29.3} i
Lockup clutch pres- Transmission: F2 1.29 1.54 i
Engine at high idling
sure (Adjustment ID: 5535) {13.2 15.7} i
k For each of the transmission clutch pressures, set both of the steering clutches to the disengage mode on the machine
monitor and check the pressures only in low idle for safety.
Standard Service limit Test Rem-
Item Test conditions Unit OK NG
value for new value results arks
2.48 2.87 2.38 3.07
Engine at low idling
{25.3 29.3} {24.3 31.3}
Main relief pressure
2.68 2.87 2.58 3.07
Transmission: Neutral Engine at high idling
{27.3 29.3} {26.3 31.3}
Lubricating oil pres- 0.08 0.25 i
Engine at high idling
sure {0.8 2.5} i
Transmission

Transmission: F1 2.25 2.84 2.06 3.13


F clutch pressure Engine at low idling MPa
(Adjustment ID: 5535) {23.0 29.0} {21.0 31.9}
R clutch pressure
Transmission: R1
Engine at low idling {kg/cm2} 2.25 2.84 2.06 3.13
(Adjustment ID: 5535) {23.0 29.0} {21.0 31.9}
Transmission: F1 2.06 2.35 1.86 2.55
1st clutch pressure Engine at low idling
(Adjustment ID: 5535) {21.0 24.0} {18.9 26.0}
Transmission: F2 2.25 2.84 2.06 3.13
2nd clutch pressure Engine at low idling
(Adjustment ID: 5535) {23.0 29.0} {21.0 31.9}
Transmission: F3 2.25 2.84 2.06 3.13
3rd clutch pressure Engine at low idling
(Adjustment ID: 5535) {23.0 29.0} {21.0 31.9}

D375A-6R 30-189
(01)
Pm Clinic
Pm Clinic service

Pm Clinic check sheet D375A-6R Serial No.

Work order No. Date of clinic Service meter reading Inspector


/ / h

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

Left clutch pressure


Engine at high {26.0 29.3} {24.4 31.3}
idling 2.55 2.87 2.4 3.07
Left brake pressure MPa {26.0 29.3} {24.4 31.3}
Right clutch pressure {kg/cm2} 2.25 2.84 2.2 3.04
Engine at low {23.0 29.0} {22.4 31.0}
idling 2.25 2.84 2.2 3.04
Right brake pressure
{23.0 29.0} {22.4 31.0}
Transmission: Neutral
2.55 2.87 2.4 3.07
Right clutch pressure
Engine at high {26.0 29.3} {24.4 31.3}
idling 2.55 2.87 2.4 3.07
Right brake pressure
{26.0 29.3} {24.4 31.3}
Brake performance Engine at high idle, F2, brake actuated Machine must not move

Standard value
Service limit Test
Item Test conditions Unit for new OK NG Remarks
value results
machine
Work equipment
Control lever in NEU- Engine at high 2.45 3.82 2.45 3.82
pump
Hydraulic system

TRAL position idling {25 39} {25 39}


(Unload pressure)
Engine at low MPa 27.5 29.4 Min. 26.5
Work equipment Ripper lift relief or idling {280 300} {Min. 270}
pump blade tilt relief {kg/cm2} 27.5 29.4 Min. 26.5
Engine at high {280 300} {Min. 270}
Control circuit source Control lever in NEU- idling 3.43 4.12 Min. 3.1
pressure TRAL position {35 42} {Min. 32}

Standard value
Service limit Test
Item Test conditions Unit for new OK NG Remarks
value results
machine
Engine at low
Min. speed 250 - 450
idling
Fan

Fan 100 % mode rpm


Engine at high
Max. speed 1,185 1,235 Max. 1,110
idling

Standard value
Service limit Test
Item Test conditions Unit for new OK NG Remarks
value results
machine
Engine at low
7 13 20
idling
Blade RAISE
Engine at high
3.7 - 4.7 6
idling
Engine at low
24 6
Blade tilt (left and right tilt) idling
[Single tilt model] Engine at high
2.5 3.5 5
idling
Work equipment speed

Engine at low
46 7
Blade tilt (left and right tilt) idling
[Dual tilt model, Dual setting] Engine at high
2.5 3.5 5
idling
sec.
Engine at low
46 7
Blade dump idling
[Dual tilt specification] Engine at high
2.5 3.5 5
idling
Engine at low
24 5
Blade tilt (left and right tilt) idling
[Dual tilt model, Single setting] Engine at high
2.5 3.5 5
idling
Engine at low
6 10 15
idling
Ripper tilt (ino out)
Engine at high
2.8 3.8 6
idling

30-190 D375A-6R
(01)
Pm Clinic
Pm Clinic service

Pm Clinic check sheet D375A-6R Serial No.

Work order No. Date of clinic Service meter reading Inspector


/ / h

Standard
value for Service Test
Item Test conditions Unit OK NG Remarks
new limit value results
machine
Hydraulic drift

Blade lift cylinder Max. 65 i


Engine stopped
Hydraulic oil temperature: mm/5min.
Ripper lift cylinder 45 55 C Max. 25 i

Standard
value for Service Test
Item Test conditions Unit OK NG Remarks
new limit value results
machine
Visual check of final There must be no exces-
Engine stopped -
drive drain plug sive metal particles
Always fill in the record when repairing, adjusting, or replacing main parts.
Date Service meter reading Repair record Date Service meter reading Repair record

D375A-6R 30-191
(01)
Pm Clinic
Pm Clinic service

30-192 D375A-6R
(01)
Pm Clinic
Pm Clinic service

D375A-6R 30-193
(01)
Pm Clinic
Pm Clinic service

30-194 D375A-6R
(01)
SEN0521412-00 40-1

D375A-6R

BULLDOZER
Shop Manual 40-1

D375A-6R

Machine model Serial number


D375A-6R 65001 and up

40 Troubleshooting 40-1

D375A-6R 40-1
(01)
Contents

Contents 40-2
40 Troubleshooting
General information on troubleshooting .................................................................................. 40- 10
Points to remember when troubleshooting .......................................................................... 40- 10
Sequence of events in troubleshooting................................................................................ 40- 11
Checks before troubleshooting ............................................................................................ 40- 12
Classification and procedures for troubleshooting ............................................................... 40- 37
Failure codes table............................................................................................................... 40- 40
Classification and procedures for troubleshooting numbers ................................................ 40- 50
Information in troubleshooting table..................................................................................... 40- 52
Troubleshooting method for disconnecting wiring harness of pressure sensor system....... 40- 54
Connection table for connector pin numbers ....................................................................... 40- 57
T-branch box and T-branch adapter table ........................................................................... 40- 93
Connector list and layout ..................................................................................................... 40- 96
Fuse locations table ............................................................................................................. 40- 110
Troubleshooting by failurecode ............................................................................................... 40- 114
Failure code [1380MW] Lock up clutch: Slip........................................................................ 40- 114
Failure code [1500L0] Transmission clutch: Abnormal ........................................................ 40- 115
Failure code [15E0MW] Transmission clutch: Slip............................................................... 40- 116
Failure code [15SAL1] Forward clutch: Fill high .................................................................. 40- 118
Failure code [15SALH] Forward clutch: Fill Low .................................................................. 40- 120
Failure code [15SBL1] Reverse clutch: Fill high .................................................................. 40- 122
Failure code [15SBLH] Reverse clutch: Fill Low.................................................................. 40- 124
Failure code [15SEL1] Speed 1st clutch: Fill high ............................................................... 40- 126
Failure code [15SELH] Speed 1st clutch: Fill Low ............................................................... 40- 128
Failure code [15SFL1] Speed 2nd clutch: Fill high .............................................................. 40- 130
Failure code [15SFLH] Speed 2nd clutch: Fill Low .............................................................. 40- 132
Failure code [15SGL1] Speed 3rd clutch: Fill high............................................................... 40- 134
Failure code [15SGLH] Speed 3rd clutch: Fill Low .............................................................. 40- 136
Failure code [15SJL1] L/U: Fill high ..................................................................................... 40- 138
Failure code [15SJLH] L/U: Fill low...................................................................................... 40- 140
Failure code [1800MW] P/T clutch: Slip............................................................................... 40- 142
Failure code [2201L1] Right clutch: Fill high ........................................................................ 40- 144
Failure code [2201LH] Right clutch: Fill low......................................................................... 40- 146
Failure code [2202L1] Left clutch: Fill high .......................................................................... 40- 148
Failure code [2202LH] Left clutch: Fill low ........................................................................... 40- 150
Failure code [2300NR] Brake Themal Load Abnormality..................................................... 40- 152
Failure code [2301L1] Right brake: Fill high ........................................................................ 40- 154
Failure code [2301LH] Right brake: Fill low ......................................................................... 40- 156
Failure code [2301NR] Steering Brake RH Themal Load Abnormality ................................ 40- 158
Failure code [2302L1] Left brake: Fill high........................................................................... 40- 160
Failure code [2302LH] Left brake: Fill low............................................................................ 40- 162
Failure code [2302NR] Steering Brake LH Themal Load Abnormality................................. 40- 164
Failure code [7RFAKA] ECM ACC CUT RELAY: Disconnection......................................... 40- 166
Failure code [7RFAKB] ECM ACC CUT RELAY: Short circuit ............................................ 40- 168
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40- 170
Failure code [AB00MA] Battery Charge Abnormal .............................................................. 40- 172
Failure code [B@BAZG] Eng Oil Press Low........................................................................ 40- 173
Failure code [B@BAZK] Eng Oil Level Low......................................................................... 40- 174
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40- 175
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40- 176
Failure code [B@CENS] T/C Oil Overheat .......................................................................... 40- 177

40-2 D375A-6R
(01)
Contents

Failure code [B@HANS] Hyd Oil Overheat ......................................................................... 40- 178


Failure code [B@HAZK] Hyd Oil Level Low ........................................................................ 40- 179
Failure code [CA111] ECM Critical Internal Failure ............................................................. 40- 180
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ................................................ 40- 182
Failure code [CA122] Chg Air Press Sensor High Error ...................................................... 40- 184
Failure code [CA123] Chg Air Press Sensor Low Error ....................................................... 40- 186
Failure code [CA131] Throttle Sensor High Error ................................................................ 40- 188
Failure code [CA132] Throttle Sensor Low Error................................................................. 40- 190
Failure code [CA135] Eng Oil Press Sensor High Error ...................................................... 40- 192
Failure code [CA141] Eng Oil Press Sensor Low Error ....................................................... 40- 194
Failure code [CA144] Coolant Temp Sens High Error......................................................... 40- 196
Failure code [CA145] Coolant Temp Sens Low Error.......................................................... 40- 198
Failure code [CA153] Chg Air Temp Sensor High Error ...................................................... 40- 200
Failure code [CA154] Chg Air Temp Sensor Low Error ....................................................... 40- 202
Failure code [CA187] Sens Supply 2 Volt Low Error ........................................................... 40- 204
Failure code [CA212] Eng Oil Temp Sensor High Error ...................................................... 40- 206
Failure code [CA213] Eng Oil Temp Sensor Low Error ....................................................... 40- 208
Failure code [CA221] Ambient Press Sens High Error ........................................................ 40- 210
Failure code [CA222] Ambient Press Sens Low Error......................................................... 40- 212
Failure code [CA227] Sens Supply 2 Volt High Error .......................................................... 40- 214
Failure code [CA234] Eng Overspeed ................................................................................. 40- 215
Failure code [CA238] Ne Speed Sens Supply Volt Error..................................................... 40- 216
Failure code [CA263] Fuel Temp Sensor High Error ........................................................... 40- 218
Failure code [CA265] Fuel Temp Sensor Low Error............................................................ 40- 220
Failure code [CA271] IMV/PCV1 Short Error....................................................................... 40- 222
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40- 223
Failure code [CA273] PCV2 Short Error .............................................................................. 40- 224
Failure code [CA274] PCV2 Open Error.............................................................................. 40- 225
Failure code [CA322] Inj #1 (L#1) Open/Short Error ........................................................... 40- 226
Failure code [CA323] Inj #5 (L#5) Open/Short Error ........................................................... 40- 228
Failure code [CA324] Inj #3 (L#3) Open/Short Error ........................................................... 40- 230
Failure code [CA325] Inj #6 (L#6) Open/Short Error ........................................................... 40- 232
Failure code [CA331] Inj #2 (L#2) Open/Short Error ........................................................... 40- 234
Failure code [CA332] Inj #4 (L#4) Open/Short Error ........................................................... 40- 236
Failure code [CA342] Calibration Code Incompatibility ....................................................... 40- 238
Failure code [CA351] Injectors Drive Circuit Error............................................................... 40- 239
Failure code [CA352] Sens Supply 1 Volt Low Error ........................................................... 40- 240
Failure code [CA386] Sens Supply 1 Volt High Error .......................................................... 40- 242
Failure code [CA441] Battery Voltage Low Error................................................................. 40- 243
Failure code [CA442] Battery Voltage High Error ................................................................ 40- 244
Failure code [CA449] Rail Press Very High Error................................................................ 40- 245
Failure code [CA451] Rail Press Sensor High Error............................................................ 40- 246
Failure code [CA452] Rail Press Sensor Low Error............................................................. 40- 248
Failure code [CA553] Rail Press High Error ........................................................................ 40- 250
Failure code [CA554] Rail Press Sensor In Range Error..................................................... 40- 251
Failure code [CA559] Rail Press Low Error ......................................................................... 40- 252
Failure code [CA689] Eng Ne Speed Sensor Error ............................................................. 40- 256
Failure code [CA731] Eng Bkup Speed Sens Phase Error.................................................. 40- 258
Failure code [CA757] All Continuous Data Lost Error ......................................................... 40- 259
Failure code [CA778] Eng Bkup Speed Sensor Error.......................................................... 40- 260
Failure code [CA1633] KOMNET Datalink Timeout Error.................................................... 40- 262
Failure code [CA2185] Throt Sens Sup Volt High Error ...................................................... 40- 263
Failure code [CA2186] Throt Sens Sup Volt Low Error ....................................................... 40- 264
Failure code [CA2249] Rail Press Very Low Error............................................................... 40- 265

D375A-6R 40-3
(01)
Contents

Failure code [D110KB] Battery Relay: Drive Short Circuit ................................................... 40- 266
Failure code [D130KA] Neutral relay: Disconnection........................................................... 40- 268
Failure code [D130KB] Neutral relay: Short circuit .............................................................. 40- 270
Failure code [D161KA] Back-up alarm releay: Disconnection ............................................. 40- 272
Failure code [D161KB] Back-up alarm releay: Short circuit................................................. 40- 274
Failure code [D182KZ] Preheater Relay Abnormality .......................................................... 40- 276
Failure code [D190KA] ACC signal relay: Disconnection .................................................... 40- 278
Failure code [D190KB] ACC signal relay: Short circuit ........................................................ 40- 280
Failure code [D1EFKA] Pre lub. motor relay: Disconnection ............................................... 40- 282
Failure code [D1EFKB] Pre lub. motor relay: Short circuit................................................... 40- 284
Failure code [DAFRKR] Monitor: Can communication lost (PT) .......................................... 40- 286
Failure code [dAFRKR] Monitor: CAN communication lost (WE) ........................................ 40- 287
Failure code [DAFRMC] CAN Discon (Monitor Detected) ................................................... 40- 288
Failure code [DB2RKR] ENG cont.: Can communication lost (PT)...................................... 40- 294
Failure code [dB2RKR] ENG controller: CAN communication lost (WE) ............................. 40- 298
Failure code [DB90KT] WE controller: Abnormality in controller ......................................... 40- 299
Failure code [DB91KK] WE controller: Source voltage reduction ........................................ 40- 300
Failure code [DB92KK] WE controller: Output voltage reduction......................................... 40- 302
Failure code [DB97KK] WE cont.: Sensor voltage 5 V (2) reduction ................................... 40- 304
Failure code [DB99KQ] WE controller: Type select signal................................................... 40- 306
Failure code [DB9RKR] WE controller: Can communication lost (PT)................................. 40- 307
Failure code [DBB0KK] VHMS controller:Source voltage reduction .................................... 40- 310
Failure code [DBB0KQ] VHMS connector connection abnormality ..................................... 40- 312
Failure code [DBB3KK] VHMS controller: Source voltage reduction ................................... 40- 313
Failure code [DBB5KP] VHMS: Output sensor1 voltage reduction...................................... 40- 316
Failure code [DBB6KP] VHMS:Output sensor2 voltage reduction....................................... 40- 318
Failure code [DBB7KP] VHMS:Output sensor3 voltage reduction....................................... 40- 320
Failure code [DBBQKR] PT cont.: Can communication lost (VHMS) .................................. 40- 322
Failure code [DBE0KT] PT controller: Abnormality in controller .......................................... 40- 323
Failure code [DBE1KK] PT controller: Source voltage reduction......................................... 40- 324
Failure code [DBE2KK] PT controller: Output voltage reduction ......................................... 40- 326
Failure code [DBE5KK] PT cont.: Sensor voltage 5 V (1) reduction .................................... 40- 328
Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction ........................................ 40- 330
Failure code [DBE7KK] PT cont.: Sensor voltage 5 V reduction ......................................... 40- 332
Failure code [DBE9KQ] PT controller: Type select signal ................................................... 40- 334
Failure code [DBERKR] PT controller: Can communication lost (WE) ................................ 40- 335
Failure code [DD12KA] Shift up Sw: Disconnection ............................................................ 40- 338
Failure code [DD12KB] Shift up Sw: Short circuit ................................................................ 40- 340
Failure code [DD13KA] Shift down Sw: Disconnection........................................................ 40- 342
Failure code [DD13KB] Shift down Sw: Short circuit ........................................................... 40- 344
Failure code [DD14KA] Parking lever Sw: Dissconnection.................................................. 40- 346
Failure code [DD14KB] Parking lever Sw: Short circuit ....................................................... 40- 348
Failure code [DDB9L4] Reverse SW Signal disagreement.................................................. 40- 350
Failure code [DDE2KA] Pre lub. oil press sw: Disconnection .............................................. 40- 352
Failure code [DDK3L4] Forward SW Signal disagreement.................................................. 40- 354
Failure code [DDK5KA] Shift switch disconnection.............................................................. 40- 356
Failure code [DDK5KB] Shift switch short circuit ................................................................. 40- 358
Failure code [DDN2LD] Blade tilt RH pressure SW abnormality ......................................... 40- 360
Failure code [DDN3LD] Blade tilt LH pressure SW abnormality .......................................... 40- 362
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection .......................................... 40- 364
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit.............................................. 40- 366
Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection............................................... 40- 368
Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit .................................................. 40- 370
Failure code [DDNALD] Blade lift up pressure SW abnormality .......................................... 40- 372

40-4 D375A-6R
(01)
Contents

Failure code [DDNBLD] Ripper lift up pressure SW abnormality......................................... 40- 374


Failure code [DDNCLD] Ripper lift down pressure SW abnormality .................................... 40- 376
Failure code [DDNDLD] Ripper tilt in pressure SW abnormality.......................................... 40- 378
Failure code [DDNELD] Ripper tilt back pressure SW abnormality ..................................... 40- 380
Failure code [DDNFLD] Blade lift down pressure SW abnormality...................................... 40- 382
Failure code [DDNLKA] Weq lock Sw: Disconnection ......................................................... 40- 384
Failure code [DDNLKB] Weq lock Sw: Short circuit............................................................. 40- 386
Failure code [DDT5KA] Neutral switch disconnection ......................................................... 40- 388
Failure code [DDT5KB] Neutral switch short circuit............................................................. 40- 390
Failure code [DDT5KQ] Lever SPEC selection signal disagreement .................................. 40- 392
Failure code [DDTSL1] S/C: Fill high................................................................................... 40- 394
Failure code [DDTSLH] S/C: Fill low.................................................................................... 40- 396
Failure code [DGE5KX] Ambient temp sensor abnormality ................................................. 40- 398
Failure code [DGS1KX] Hyd oil temp: signal abnormal ....................................................... 40- 400
Failure code [DGT1KA] T/C oil temp sensor: Abnormal ...................................................... 40- 402
Failure code [DGT1KX] T/C oil temp sensor: Abnormal ...................................................... 40- 404
Failure code [DGT5KA] F exhaust temp sensor disconnection ........................................... 40- 406
Failure code [DGT5KB] F exhaust temp sensor short circuit............................................... 40- 408
Failure code [DGT6KA] R exhaust temp sensor disconnection........................................... 40- 410
Failure code [DGT6KB] R exhaust temp sensor short circuit .............................................. 40- 412
Failure code [DH21KA] Weq pressure sensor: Disconnection ............................................ 40- 414
Failure code [DH21KB] Weq pressure sensor: Short circuit................................................ 40- 416
Failure code [DHE5KB] ENG blow-by pressure sensor disconnection................................ 40- 418
Failure code [DHE5KY] ENG blow-by pressure sensor short circuit ................................... 40- 420
Failure code [DHT3KX] T/M oil pressure sensor abnormality.............................................. 40- 422
Failure code [DHT5KA] T/C in-pressure sensor: Disconnection.......................................... 40- 424
Failure code [DHT5KB] T/C in-pressure sensor: Short circuit ............................................. 40- 426
Failure code [DHT7KA] T/C out-pressure sensor: Disconnection ....................................... 40- 428
Failure code [DHT7KB] T/C out-pressure sensor: Short circuit ........................................... 40- 430
Failure code [DK10KA] Fuel control Dial: Disconnection..................................................... 40- 432
Failure code [DK10KB] Fuel control Dial: Short circuit ........................................................ 40- 434
Failure code [DK30KA] ST lever 1: Disconnection .............................................................. 40- 436
Failure code [DK30KB] ST lever 1: Short circuit.................................................................. 40- 438
Failure code [DK30KX] ST lever: Out of normal range........................................................ 40- 440
Failure code [DK30KZ] ST lever: Disconnection or short circuit .......................................... 40- 441
Failure code [DK30L8] ST lever: Signal mismatch .............................................................. 40- 442
Failure code [DK31KA] ST lever 2: Disconnection .............................................................. 40- 444
Failure code [DK31KB] ST lever 2: Short circuit.................................................................. 40- 446
Failure code [DK40KA] Brake potentiometer: Disconnection .............................................. 40- 448
Failure code [DK40KB] Brake potentiometer: Short circuit.................................................. 40- 450
Failure code [DK55KX] FR lever: Out of normal range........................................................ 40- 452
Failure code [DK55KZ] FR lever: Disconnection or short circuit.......................................... 40- 453
Failure code [DK55L8] FR lever: Signal mismatch .............................................................. 40- 454
Failure code [DK56KA] FR lever 1: Disconnection .............................................................. 40- 456
Failure code [DK56KB] FR lever 1: Short circuit.................................................................. 40- 458
Failure code [DK57KA] FR lever 2: Disconnection .............................................................. 40- 460
Failure code [DK57KB] FR lever 2: Short circuit.................................................................. 40- 462
Failure code [DK60KA] Acceleration sensor: Disconnection ............................................... 40- 464
Failure code [DK60KB] Acceleration sensor: Short circuit................................................... 40- 466
Failure code [DKH1KA] Pitch angle sensor: Disconnection ................................................ 40- 468
Failure code [DKH1KB] Pitch angle sensor: Short circuit .................................................... 40- 470
Failure code [DLF1KA] T/C out-speed sensor: Disconnection ............................................ 40- 472
Failure code [DLM3KA] Fan rev. sensor: Disconnection ..................................................... 40- 474
Failure code [DLM3MB] Fan control: Decline ...................................................................... 40- 476

D375A-6R 40-5
(01)
Contents

Failure code [DLT3KA] T/M out-speed sensor: Disconnection ............................................ 40- 477
Failure code [DLT3KB] T/M out-speed sensor: Abnormal ................................................... 40- 478
Failure code [DW59KA] Blade dual selector SOL disconnection......................................... 40- 479
Failure code [DW59KB] Blade dual selector SOL short circuit ............................................ 40- 480
Failure code [DW59KY] Blade dual selector SOL hot short................................................. 40- 482
Failure code [DW5AKA] Blade pitch selector SOL disconnection ....................................... 40- 484
Failure code [DW5AKB] Blade pitch selector SOL short circuit ........................................... 40- 485
Failure code [DW5AKY] Blade pitch selector SOL Short circuit .......................................... 40- 486
Failure code [DW7BKA] Fan rev EPC: Disconnection......................................................... 40- 488
Failure code [DW7BKB] Fan rev EPC: Short circuit ............................................................ 40- 489
Failure code [DWN3KA] Ssp solenoid: Disconnection......................................................... 40- 490
Failure code [DWN3KB] Ssp solenoid: Short circuit ............................................................ 40- 492
Failure code [DWN3KY] SSP solenoid: Short circuit ........................................................... 40- 494
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection............................................ 40- 496
Failure code [DWN5KB] Fan pump solenoid 1: Short circuit ............................................... 40- 498
Failure code [DWN5KY] Fan pump solenoid 1: Short circuit ............................................... 40- 500
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection ........................................... 40- 502
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit............................................... 40- 504
Failure code [DWNCKY] Fan pump solenoid 2: Short circuit............................................... 40- 506
Failure code [DXH1KA] Lock-up ECMV: Disconnection ...................................................... 40- 508
Failure code [DXH1KB] Lock-up ECMV: Short circuit.......................................................... 40- 509
Failure code [DXH1KY] Lock-up ECMV: Short circuit.......................................................... 40- 510
Failure code [DXH4KA] 1st clutch ECMV: Disconnection.................................................... 40- 512
Failure code [DXH4KB] 1st clutch ECMV: Short circuit ....................................................... 40- 514
Failure code [DXH4KY] 1st clutch ECMV: Short circuit ....................................................... 40- 516
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection .................................................. 40- 518
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit ...................................................... 40- 520
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit ...................................................... 40- 522
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection ................................................... 40- 524
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit....................................................... 40- 526
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit....................................................... 40- 528
Failure code [DXH7KA] R clutch ECMV: Disconnection...................................................... 40- 530
Failure code [DXH7KB] R clutch ECMV: Short circuit ......................................................... 40- 532
Failure code [DXH7KY] R clutch ECMV: Short circuit ......................................................... 40- 534
Failure code [DXH8KA] F clutch ECMV: Disconnection ...................................................... 40- 536
Failure code [DXH8KB] F clutch ECMV: Short circuit.......................................................... 40- 538
Failure code [DXH8KY] F clutch ECMV: Short circuit.......................................................... 40- 540
Failure code [DXH9KA] Right clutch ECMV: Disconnection ................................................ 40- 542
Failure code [DXH9KB] Right clutch ECMV: Short circuit.................................................... 40- 544
Failure code [DXH9KY] Right clutch ECMV: Short circuit.................................................... 40- 546
Failure code [DXHAKA] Left clutch ECMV: Disconnection .................................................. 40- 548
Failure code [DXHAKB] Left clutch ECMV: Short circuit...................................................... 40- 550
Failure code [DXHAKY] Left clutch ECMV: Short circuit...................................................... 40- 552
Failure code [DXHBKA] Right brake ECMV: Disconnection ................................................ 40- 554
Failure code [DXHBKB] Right brake ECMV: Short circuit.................................................... 40- 556
Failure code [DXHBKY] Right brake ECMV: Short circuit.................................................... 40- 558
Failure code [DXHCKA] Left brake ECMV: Disconnection .................................................. 40- 560
Failure code [DXHCKB] Left brake ECMV: Short circuit...................................................... 40- 562
Failure code [DXHCKY] Left brake ECMV: Short circuit...................................................... 40- 564
Failure code [DXJBKA] S/C ECMV: Disconnection ............................................................. 40- 566
Failure code [DXJBKB] S/C ECMV: Short circuit................................................................. 40- 567
Failure code [DXJBKY] S/C ECMV: Short circuit................................................................. 40- 568
Failure code [DY2HKA] Pre lub. motor: Disconnection........................................................ 40- 570
Failure code [F@BBZL] ENG blow-by pressure high level .................................................. 40- 572

40-6 D375A-6R
(01)
Contents

Failure code [F@BYNR] F exhaust temp high level (2)....................................................... 40- 573
Failure code [F@BYNS] F exhaust temp high level (1) ....................................................... 40- 574
Failure code [F@BZNR] R exhaust temp high level (2)....................................................... 40- 575
Failure code [F@BZNS] R exhaust temp high level (1)....................................................... 40- 576
Troubleshooting of electrical system (E-mode)....................................................................... 40- 578
Information contained in troubleshooting table .................................................................... 40- 578
E-1 Engine does not start (starting motor does not turn)..................................................... 40- 580
E-2 Preheater does not operate .......................................................................................... 40- 584
E-3 When starting switch is turned ON, machine monitor displays nothing ........................ 40- 588
E-4 When starting switch is turned ON (before starting engine), basic check item lights up 40- 592
E-5 Precaution item lights up while engine is running ......................................................... 40- 594
E-6 Emergency stop item lights up while engine is running ................................................ 40- 596
E-7 Engine coolant temperature gauge does not indicate normally .................................... 40- 597
E-8 Fuel gauge does not indicate properly .......................................................................... 40- 598
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally ............... 40- 600
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally..................... 40- 601
E-11 Contents of display by machine monitor are different from applicable machine ......... 40- 602
E-12 Machine monitor does not display some items ........................................................... 40- 602
E-13 Function switch does not work .................................................................................... 40- 602
E-14 Operation mode does not change............................................................................... 40- 603
E-15 Gearshift mode does not change ................................................................................ 40- 603
E-16 Customize function does not operate normally ........................................................... 40- 604
E-17 Customize memory function does not operate normally ............................................. 40- 604
E-18 Alarm buzzer does not sound or does not stop........................................................... 40- 605
E-19 When starting switch is turned OFF, service meter is not displayed........................... 40- 605
E-20 Machine monitor cannot be set in service mode......................................................... 40- 605
E-21 The ripper pin puller cylinder does not operate........................................................... 40- 606
E-22 Horn does not sound or does not stop ........................................................................ 40- 608
E-23 Back-up alarm does not sound or does not stop......................................................... 40- 610
E-24 Fan does not reverse .................................................................................................. 40- 612
E-25 The head lamp and rear lamp do not light up ............................................................. 40- 613
E-26 Windshield wiper does not operate ............................................................................. 40- 622
E-27 Window washer does not operate............................................................................... 40- 630
E-28 Electric priming pump does not operate or does not stop automatically..................... 40- 638
E-29 Orbcomm terminal does not operate normally (Data are not transmitted) .................. 40- 640
E-30 Gear cannot be shifted................................................................................................ 40- 642
Troubleshooting of hydraulic and mechanical system (H-mode) ............................................ 40- 644
Information in troubleshooting table..................................................................................... 40- 644
List of Failure Modes and Causes ....................................................................................... 40- 646
H-1 Machine lacks power(or drawbar pull) .......................................................................... 40- 648
H-2 Machine cannot travel (at 2nd or 3rd each speed) ....................................................... 40- 650
H-3 Machine cannot travel at any gear speeds ................................................................... 40- 651
H-4 Machine travels only in one direction, forward or reverse............................................. 40- 653
H-5 Large time lag at gear shifting or directional change .................................................... 40- 654
H-6 Machine connot turn ..................................................................................................... 40- 655
H-7 Machine turns only to one side ..................................................................................... 40- 656
H-8 Machine overruns at turnning ....................................................................................... 40- 657
H-9 Brake does not work ..................................................................................................... 40- 658
H-10 Torque converter does not lock up ............................................................................. 40- 659
H-11 Power train oil overheats ............................................................................................ 40- 660
H-12 All work equipment operates too slow or lacks power ................................................ 40- 661
H-13 All work equipment does not operate.......................................................................... 40- 662
H-14 Blade lift cylinder speed is too slow or lacks power .................................................... 40- 663
H-15 Blade tilt cylinder speed is too slow or lacks power .................................................... 40- 664

D375A-6R 40-7
(01)
Contents

H-16 Ripper lift cylinder speed is too slow or lacks power................................................... 40- 665
H-17 Ripper tilt cylinder speed is too slow or lacks power................................................... 40- 666
H-18 Excessive hydraulic drift of blade lift cylinder.............................................................. 40- 667
H-19 Excessive hydraulic drift of blade tilt cylinder.............................................................. 40- 668
H-20 Excessive hydraulic drift of ripper lift cylinder ............................................................. 40- 669
H-21 Ripper pin puller cylinder does not operate (machine with giant ripper) ..................... 40- 670
H-22 Blade pitch does not work (machine with dual tilt specification) ................................. 40- 671
H-23 Abnormal noise from around work equipment pump .................................................. 40- 672
H-24 Abnormal fan rotation(noise and/or vibration are abnormally large or engine overheats)40-673
Troubleshooting of engine (S-mode) ...................................................................................... 40- 674
Method of using troubleshooting chart................................................................................. 40- 674
S-1 Engine does not start easily .......................................................................................... 40- 678
S-2 Engine does not start .................................................................................................... 40- 679
S-3 Engine does not rev up smoothly (response-up is poor)............................................... 40- 682
S-4 Engine stops during operation....................................................................................... 40- 683
S-5 Engine does not rotate smoothly (hunting).................................................................... 40- 684
S-6 Engine lacks power (or output shortage)....................................................................... 40- 685
S-7 Exhaust smoke is black (Incomplete combustion) ........................................................ 40- 686
S-8 Oil is consumption is excessive(or exhaust smoke is blue) .......................................... 40- 687
S-9 Engine oil becomes contaminated quickly .................................................................... 40- 688
S-10 Fuel consumption is excessive.................................................................................... 40- 689
S-11 Oil mixes into coolant(coolant blows back or is reduced)............................................ 40- 690
S-12 Engine pressure monitor lights up (drop in engine oil pressure) ................................. 40- 691
S-13 Oil level rises (Coolant or fuel mixes into oil) .............................................................. 40- 692
S-14 Coolant temperature rises too high (overheating) ....................................................... 40- 693
S-15 Abnormal noise is heard.............................................................................................. 40- 694
S-16 Vibration is excessive.................................................................................................. 40- 695
S-17 Air cannot be bled from fuel circuit (when air bleeding is performed after filter is replaced or fuel is
used up and then air is bled, engine does not start or it starts but stalls) ............................ 40- 696

40-8 D375A-6R
(01)
Contents

D375A-6R 40-9
(01)
General information on troubleshooting
Points to remember when troubleshooting

General information on troubleshooting 40-10


Points to remember when troubleshooting 40-10
k Stop the machine in a level place, and check that the lock pin, blocks, and parking brake are se-
curely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative () terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air, al-
ways release the internal pressure first. When installing measuring equipment, be sure to connect
it properly.

The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
ventreoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
standthe structure and function. However, a short cut to effective troubleshooting is to ask the operatorvarious
questions to form some idea of possible causes of the failure that would produce the reported symptoms.

1. When carrying out troubleshooting, do not hurry 4) Check maintenance items can be checked
to disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
after any failure occurs:
q Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or as
q It will become impossible to find the cause of a problem with the method of operation, etc.
the failure. a When operating the machine to reenact the
It will also cause a waste of manhours, parts, or troubleshooting symptoms, do not perform
oil or grease, and at the same time, will also lose any inspection or measurement that may
the confidence of the user or operator. make the problem worse.
For this reason, when carrying out trouble-
shooting, it is necessary to carry out thorough 5. Troubleshooting
prior investigation and to carry out trouble- Use the results of the investigation and inspec-
shooting in accordance with the fixed procedure. tion in Items 2 4 to narrow down the causes of
failure, then use the troubleshooting table or
2. Points to ask the user or operator troubleshooting flowchart to locate the position
1) Have any other problems occurred apart of the failure exactly.
from the problem that has been reported? a The basic procedures for troubleshooting is
2) Was there anything strange about the as follows.
machine before the failure occurred? 1] Start from the simple points.
3) Did the failure occur suddenly, or were there 2] Start from the most likely points.
problems with the machine condition before 3] Investigate other related parts or informa-
the failure? tion.
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the 6. Measures to remove root cause of failure
failure? When were these repairs carried Even if the failure is repaired as a short term
out? fixing, if the root cause of the failure is not
6) Has the same kind of failure occurred removed, the same failure will occur again. In
before? order to prevent this, always investigate why the
problem occurred. Then, remove the root cause.
3. Checks before troubleshooting
1) Is there any sign of irregularities of the
machine?
2) Make checks before starting day's work.
3) Make checks of other items.

40-10 D375A-6R
(01)
General information on troubleshooting
Sequence of events in troubleshooting

Sequence of events in troubleshooting 40-1


(Rev. 2007. 12)

D375A-6R 40-11
(01)
General information on troubleshooting
Checks before troubleshooting

Checks before troubleshooting 40-12


No. Item Criterion Remedy

1 Check for abnormal sounds and smells Repair

2 Check for dirt around engine Remove

3 Check for water leakage around engine Repair

4 Check for oil leakage around engine Repair


a: Engine, lubricating oil and coolant

5 Check for leakage from fuel line Repair

6 Check of radiator for clogging Remove

7 Check of level and type of fuel Refilling with oil

8 Check for foreign matter in fuel Clean and drain

9 Check of fuel pre filter Replace

10 Check of fuel filter Replace

11 Check of level (in oil pan) and type of engine oil Between H L Refilling with oil

12 Check of coolant level (in sub tank) Between H L Refilling with coolant

No clogging indi-
13 Check of air cleaner for clogging Clean or replace
cation on monitor

1 Check for abnormal sounds and smells Repair

2 Check for oil leakage Repair

3 Check of hydraulic oil Between H L Refilling with oil


b: Hydraulic and mechanical equipment

4 Check of hydraulic oil strainer Clean and drain

5 Check of hydraulic oil filter Replace

6 Check of power train case oil level Between H L Refilling with oil

7 Check of power train pump strainer Clean and drain

8 Check of transmission oil filter and torque converter oil filter Clean and drain

9 Check of damper case oil level Between H L Refilling with oil

10 Check of final drive case oil level Between H L Refilling with oil

11 Execution of air bleeding operation Air bleeding

40-12 D375A-6R
(01)
General information on troubleshooting
Checks before troubleshooting

No. Item Criterion Remedy

1 Check of battery terminals for looseness and corrosion Retighten or replace

2 Check of alternator terminals for looseness and corrosion Retighten or replace

3 Check of starting motor terminals for looseness and corrosion Retighten or replace

4 Check of battery voltage (with engine stopped) 20 30 V Charge or replace

5 Check of battery electrolyte level Between H L Add or replace

Check of wiring harness for discoloration, burnt areas and cover


6 Repair or replace
peeling
Check for removal of wiring harness clamp and sagging of wiring
7 Repair
harness
c: Electrical equipment

8 Check of grounding Repair

9 Check for loose connector and damaged lock Repair or replace

10 Check of connector pin for corrosion, bends and deformation Repair or replace

11 Check for water and foreign matter in connector Dry, clean or replace

12 Check of wiring harness for open and short circuit Repair or replace

13 Check of fuse for breakage and corrosion Replace

14 Check of circuit breaker Push in reset button


After several
Check of alternator voltage (When engine speed is medium or minutes opera-
15 Replace
higher) tion: 27.5 29.5
V
Check of battery relay operation sound (When the starting switch is
16 Replace
turned to ON or OFF position)
e. Interior parts d. Exterior parts

1 Check of undercarriage Repair

2 Check of handrails and steps Repair

3 Check of mirrors Clean or repair

1 Check of gauges and monitors Clean or replace

2 Check of seat belt Repair

D375A-6R 40-13
(01)
General information on troubleshooting
Checks before troubleshooting

Testing procedure before troubleshooting 40-14


Walk-around check 40-14

Before starting the engine, look around and under the machine to check for any loose nuts or bolts, leakage
of oil, fuel or coolant, and check the condition of the work equipment and hydraulic system.
Check the connectors for looseness, the wiring harnesses for play, and the hot parts for accumulated dust.

k Accumulated combustibles around hot engine parts such as the engine muffler, turbocharger, etc.
and leaking fuel and oil may cause a machine fire. Be sure to check thoroughly and repair any ab-
normalities.

a1. and b1. Check for abnormal sounds and b3. Check of hydraulic equipment, hydraulic
smells tank, hoses and joints for oil leakage
Check for abnormal sounds and smells. Check and repair any oil leaks.
Some causes of abnormal sounds and smells
can damage the machine if they are left as they c1. Check around battery and dirt removal
are. Therefore, stop the machine immediately Check and remove any accumulated dirt and
when you find any abnormality. combustibles (dead leaves, twigs, etc.) around
the battery.
a2. Check around engine and dirt removal
Check and remove any accumulated dirt around d1. Check of undercarriage (track, sprocket,
the engine and any combustibles (dead leaves, idler and guard) for abnormalities, wear, loose
twigs, etc.) on hot engine parts such as the en- bolts and oil leakage from roller
gine muffler, turbocharger, etc.. Repair any abnormalities.

a3. Check for water leakage around engine d2. Check of handrails and steps for abnormali-
a4. Check for oil leakage around engine ties and loose bolts
Check any oil leaks from the engine and any wa- Repair any abnormalities and retighten any
ter leaks from the coolant system. If any of them loose bolts.
is abnormal, carry out a repair.
d3. Check and cleaning of rear view mirrors
a5. Check for leakage from fuel line Check and repair any abnormalities and break-
Check any fuel leaks and damaged hoses and age of the rear view mirrors.
tubes. If any of them is abnormal, carry out a re- Clean the mirror surfaces and adjust their angles
pair. so that the operator can see the area behind him
at the operator's seat.
a6. Check of radiator and dirt removal
Check and remove any accumulated dirt and e1. Check of gauges and monitors for abnormal-
combustibles (dead leaves, twigs, etc.) around ities
the radiator. Check the gauges and monitors inside the oper-
For removal of dirt from the radiator, see the ator cab. If any of them is abnormal, replace it.
Operation and Maintenance Manual, "Cleaning Clean up the surfaces.
and testing of radiator fins, oil cooler fins, after-
cooler fins, fuel cooler fins and air conditioner e2. Check of seat belt and mounting hardware
condenser fins (machine with the air condi- Check the hooks, locks and hook fittings for
tioner)". damage. If any of them has a problem, repair the
damage.
b2. Check of work equipment, cylinders, linkage
and hoses for breakage, wear and clearance
Check the work equipment, cylinders, linkage
and hoses for cracks and excessive wear, check
that each clearance is within the normal range,
and then repair any abnormalities.

40-14 D375A-6R
(01)
General information on troubleshooting
Checks before troubleshooting

Testing according to testing procedure 40-15 a8. Check for contaminants in fuel
a. Engine lubricating oil and coolant 40-15 1. Open the cover on the rear side of the machine.
2. Put a container under drain hose (1) to receive
a7. Check of level and type of fuel the drained fuel.
k Fuel is flammable and dangerous. Do not 3. Turn drain valve (2) to the "OPEN" position (O)
bring any open flame near fuel. to discharge the sediment and water in the
k When adding fuel, take care not to let it over- bottom together with the fuel.
flow. 4. When only the clean fuel flows out, turn drain
k Wipe off any spilt fuel. If fuel has spilt over valve (2) to the "CLOSE" position (S).
dirt and sand, remove the dirt and sand, too. 5. Close the cover.
1. Turn the starting switch to the ON position and
check the fuel level with fuel level gauge (G) in
the monitor panel.
After checking, return the switch to the OFF posi-
tion.

a9. Check for fuel pre-filter (water separator)


k Immediately after the engine is stopped, its
parts and oil will still be very hot may burn
your hands on contact. Therefore, wait until
they have cooled down before starting the
2. If the fuel level is low, open oil filler cap (F) of the work.
fuel tank and add fuel through the oil filler port to k High pressure is generated in the engine fuel
the necessary level. piping system while the engine is running.
q If the filter of breather (1) is clogged, the pres- Wait for at least 30 seconds after stopping
sure in the tank decreases and fuel may not the engine until the internal pressure de-
be supplied. To prevent this, clean the filter. creases, and then replace the filter.

k Do not bring any open flame near the filter.


a Komatsu genuine fuel prefilter cartridges use a
special filter with a high filtration efficiency.
When replacing, be sure to use a Komatsu gen-
uine cartridges.

a The common rail fuel injection system of this ma-


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

a When testing and servicing the fuel system, be


extremely careful that no foreign matter enters. If
any dirt sticks, remove it completely by using fu-
el.
q Prepare an oil receiving container.
q Prepare the filter wrench.

D375A-6R 40-15
(01)
General information on troubleshooting
Checks before troubleshooting

1. Turn supply valve (1) of the fuel tank to the


"CLOSE" (S) position.

2. Open the engine hood.


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

9. Clean the filter bracket and apply oil lightly to the


packing surface of the filter cartridge.
a Do not pour fuel into the filter cartridge.
10. Remove cap (A) at the center of the filter
cartridge and install the cartridge in the filter
bracket.

6. Clean transparent cup (3), and remove seal (4).


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

40-16 D375A-6R
(01)
General information on troubleshooting
Checks before troubleshooting

a10. Check of fuel filter


k Immediately after the engine is stopped, its
parts and oil will still be very hot may burn
your hands on contact. Therefore, wait until
they have cooled down before starting the
work.
k High pressure is generated in the engine fuel
piping system while the engine is running.
Wait for at least 30 seconds after stopping
the engine until the internal pressure de-
creases, and then replace the filter.

k Do not bring any open flame near the filter.


a Komatsu genuine fuel filter cartridges use a spe- 4. Place the oil receiving container under filter
cial filter with a high filtration efficiency. When re- cartridge (3).
placing, be sure to use a Komatsu genuine 5. Using the filter wrench, rotate filter cartridge (3)
cartridges. to the left to remove.

a The common rail fuel injection system of this ma-


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

a When testing and servicing the fuel system, be


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

2. Open the engine hood.


3. Open air bleeding valve (2).

D375A-6R 40-17
(01)
General information on troubleshooting
Checks before troubleshooting

8. Install the filter cartridge.


a When installing the filter cartridge, tighten it
by 3/4 turns after its O-ring has been securely
placed on the sealing surface of the filter
head.
a If the filter cartridge is over tightened, the
O-ring is damaged to cause fuel leak. If the
filter cartridge is not tightened sufficiently,
fuel also leaks through the clearance at the
packing. Therefore, observe the tightening
angle.
9. Turn valve (1) at the fuel tank bottom to the
"OPEN" (O) position.
10. Bleed air. For details, see Testing and adjusting, 6. If the oil level is above H
"Bleeding air from fuel circuit". 1) Remove the cover from the machine bottom
11. Close air bleeding valve (2). and place a oil container under it.

a11. Check of level (in oil pan) and type of en-


gine oil
k Immediately after the engine is stopped, its
parts and oil will still be very hot may burn
your hands on contact. Therefore, wait until
they have cooled down before starting the
work.
a If the engine has been operated, wait for at least
15 minutes after stopping it, and check the oil
level.
a When checking, set the machine in a horizontal
position.
1. Stop the engine. 2) Remove drain plug (1).
2. Open the engine hood. 3) Loosen drain valve (2) slowly so that the oil
3. Remove oil level gauge (G) and wipe gauge oil will not spurt over you, and drain the exces-
off with a cloth. sive oil.
4. Insert oil level gauge (G) fully and pull it out. a Take care not to deform the stopper pin in
drain valve (2) by overloosening it.
3 Drain plug (1):
68.6 9.81 Nm {7 1 kgm}
3 Drain valve (2):
63.7 14.7 Nm {6.5 1.5 kgm}

5. Check the oil level on the "ENGINE STOPPED"


stamp side of oil level gauge (G). If it is between
the stamps of H and L, it is at the correct level.
If the oil level is below L, add oil through oil filler
4) Check the oil level again.
port (F).
7. If the oil is at the correct level, tighten the oil filler
cap securely and close the engine hood.

40-18 D375A-6R
(01)
General information on troubleshooting
Checks before troubleshooting

a12. Check of coolant level (in sub tank)


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

D375A-6R 40-19
(01)
General information on troubleshooting
Checks before troubleshooting

a13. Check of air cleaner for clogging Cleaning of outer element


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

2. Hold and pull out outer element (4) while


swinging it up, down and laterally and rotating
element to the right and left.
a Never remove inner element (5). If it is re-
moved, dirt will enter and can damage the
engine..
a Do not use a screwdriver or another tool.
a After removing outer element (4), check that
the inner element has not come off or slant-
ed. If the inner element is slanting, push it in
straight with the hand.
3. After removing outer element (4), cover the inner
element (5) with a clean cloth or tape to prevent
dirt from sticking to it.

a Do not clean the element until the yellow piston


of dust indicator (1) enters outer red zone (A).
If the element is cleaned frequently before the
yellow piston of dust indicator (1) enters outer
red zone (A), the true performance of the air
cleaner will not be realized and the cleaning
effect will decrease.
a If the outer element is checked or cleaned while
the engine is running, the dirt sticking to it will fall
into the inner element side more frequently and
enter and damage the engine. Be sure to stop
the engine before cleaning.

40-20 D375A-6R
(01)
General information on troubleshooting
Checks before troubleshooting

4. Remove any dirt sticking to the inside of air 6. Next, blow air along the outside pleats, and blow
cleaner body (6) and cover (3) with a clean cloth, again along the inside pleats.
brush, etc.
a When cleaning the element, do not tap it or
bump it against other objects.

a After cleaning, light up the inside of the ele-


ment to check it. If the element has a small
hole or a thin component, replace it.

5. Blow dry compressed air (Max. 196 kPa {2


kg/cm2}) along the inside pleats of the outer 7. Remove the cloth or tape covering inner element
element. (6).
8. Check and remove any dirt, oil, etc. sticking to
the sealing surface of the cleaned or new
element.
a If the element or O-ring used for more than 1
year is cleaned and reused, it can cause a
trouble. Therefore, do not reuse it.
a Do not use the element if its pleats, gasket or
seal is damaged.

D375A-6R 40-21
(01)
General information on troubleshooting
Checks before troubleshooting

9. Push the outer element straight into the air


cleaner body while swinging it up, down and
laterally.
a Install the air cleaner elements so that their
bottoms (ends with no holes) (B) and (C) will
be on cover (3) side.
If the air cleaner element is installed in
reverse, it may be broken and the engine
may be damaged seriously.

10. Install cover (3) according to the following proce-


dure.
1) Set cover (3) to the element.

2) Hitch the tips of hooks (2) to the projection of


the air cleaner body to lock.
a Hitch hooks (2) diagonally (top and bot-
tom, or right and left) to lock.
a After installing cover (3), check for clear-
ance between air cleaner body and cover
(3). If there is any clearance, remove and
install cover (3) correctly.

40-22 D375A-6R
(01)
General information on troubleshooting
Checks before troubleshooting

Replacement of element 4. Replace O-ring (7) of cover (3) with a new one.
1. Remove outer element (4). For details, see
"Cleaning of outer element".
2. Remove inner element (5) and install new inner
element (5) quickly to air cleaner body (6).
a Do not clean or reuse the inner element.
When replacing the outer element, also re-
place the inner element.

5. Install cover (3). For details, see "Cleaning of


outer element".
6. Replace the seal of cover (3) with a new one.

a Install the air cleaner element so that its bot-


tom (end with no hole) (B) will be on cover (3)
side.
If the air cleaner element is installed in
reverse, it may be broken and the engine
may be damaged seriously.
a If the outer element and cover are installed
while the inner element is not installed se-
curely, the outer element may be broken. In-
stall the inner element securely.

3. Push the outer element straight into the air


cleaner body while swinging it up, down and
laterally.
a Install the air cleaner element so that its bot-
tom (end with no hole) (C) will be on cover (3)
side.
If the air cleaner element is installed in
reverse, it may be broken and the engine
may be damaged seriously.

D375A-6R 40-23
(01)
General information on troubleshooting
Checks before troubleshooting

b. Hydraulic and mechanical equipment 40-24 Since the oil level fluctuates according to the oil
temperature, note the following when checking
b3. Check of hydraulic oil level it.
k Immediately after the engine is stopped, its q Before operation (oil temperature: 10 to 30
parts and oil will still be very hot may burn C), the oil level should be at the center be-
your hands on contact. Therefore, wait until tween lines H and L.
they have cooled down before starting the q During operation (oil temperature: 50 to 80
work. C), the oil level should be near line H.
k If the oil filler cap is removed quickly, the oil b4. Check of hydraulic oil strainer
may spurt out. Therefore rotate the oil filler k Immediately after the engine is stopped, its
cap slowly to release the internal pressure parts and oil will still be very hot may burn
and then remove it. your hands on contact. Therefore, wait until
1. Lower the work equipment to the ground and they have cooled down before starting the
stop the engine. Check the oil level and add new work.
oil if necessary. k If the oil filler cap is removed quickly, the oil
2. Turn the starting switch to the ON position within may spurt out. Therefore rotate the oil filler
15 seconds after stopping the engine and cap slowly to release the internal pressure
operate each control lever (work equipment and and then remove it.
travel) to the stroke end in each direction to 1. Stop the engine and remove oil filler cap (F) of
release the internal pressure. the hydraulic tank to release the internal pres-
3. Open the cover on the right side of the machine sure.
and check sight gauge (G). If the oil level is 2. Remove bolts (5) to remove cover (6).
between lines H and L, it is at the correct level. When removing the bolts, keep pressing down
a If the oil level is below line L, add oil through on cover (6) since it may be flung toward you by
oil filter port (F). the internal spring.
a Do not add oil to above line H. If too much is 3. Pull out the rod and remove the strainer.
added, it may damage the hydraulic circuit 4. Remove dirt from the strainer and clean it using
and spurt out. cleaning oil. If the strainer is broken, replace it
a If the oil level is above line H, stop the engine with a new one.
and wait until the hydraulic oil cools down. 5. Insert and set the strainer.
Then, loosen drain valve (1) at the hydraulic 6. While pressing down the spring with the projec-
tank bottom to drain excessive oil through tion at the bottom of cover (1), install the bolts.
drain plug (P) into a container. 7. Tighten the mounting bolts.

40-24 D375A-6R
(01)
General information on troubleshooting
Checks before troubleshooting

b5. Check of hydraulic oil filter


k Immediately after the engine is stopped, its
parts and oil will still be very hot may burn
your hands on contact. Therefore, wait until
they have cooled down before starting the
work.
k If the oil filler cap is removed quickly, the oil
may spurt out. Therefore rotate the oil filler
cap slowly to release the internal pressure
and then remove it.
1. On a level and firm surface, lower the work
equipment to the ground and stop the engine.
2. Remove oil filler cap (F) of the hydraulic tank to
release the internal pressure. 7. Clean the inside of the case and the removed
parts, and install the new element.
8. Set cover (1) and install it with the mounting bolts
while pressing it with your hand.
9. Tighten the mounting bolts.
10. Install oil filler cap (F).
11. Run the engine at a low idling speed for 10
minutes to bleed air.
12. Stop the engine.

3. Prepare a container to receive the drained oil.


4. Remove drain plug (1) at the tank bottom and
loosen drain valve (2) to drain the oil.
a When loosening drain plug (1), take care that
the oil does not splash over you.

5. After draining the oil, tighten drain plug (1) and


drain valve (2).
6. Remove bolts (3), and then remove cover (4)
and pull out the element.
a Check the bottom of the filter case and re-
move dirt if there is. At this time, take extreme
care that dirt does not enter the hydraulic
tank.

D375A-6R 40-25
(01)
General information on troubleshooting
Checks before troubleshooting

b6. Check of power train case oil level 6. If the oil level is above H, open the undercover
k Since the undercover is heavy, do not open and drain the oil according to the following
or close it from beneath. When removing procedure.
bolts (5), stand on the rear side just under the 1) Remove two bolts (4) on the front side of the
cover so that you can move away quickly in machine.
case of an emergency. 2) Gradually remove two bolts (5) on the rear
q When checking, set the machine in a hori- side of the machine, while supporting cover
zontal position. (3).
q While the engine is stopped, the oil level can- 3) Since the front of cover (3) is equipped with
not be accurately checked since the oil level the hinge pin, lower cover (3) gradually.
increases. When checking while the engine
is running or after the engine is started, check
with the COLD side of gauge (G) in the idle
state.
1. Start the engine, set the fuel control dial to low
idle (MIN) position, and keep running the engine
at a low idling speed for 3 to 5 minutes.
q Perform the following procedure without
stopping the engine.
2. Remove oil level gauge (G) and wipe gauge oil
off with a cloth.
3. Insert oil level gauge (G) fully into the guide.
4. Pull out oil level gauge (G) and check the oil
level. If the oil level is between (H) and (L) on the (F): Front of machine
"COLD IDLE" stamp side of oil level gauge (G),
it is the correct level.
5. If the oil level is below (L) on the "COLD IDLE"
stamp side of oil level gauge (G), remove oil filter
cap (F) and add oil. When adding oil, remove oil
level gauge (G).

4) Remove hose (1) to change its position as


(A) and loosen drain valve (2) to drain exces-
sive oil.
q When draining the oil, put a container under
hose (1) to drain the oil into.

7. After checking the oil level and adding oil, install


oil level gauge (G) and oil filler cap (F).

40-26 D375A-6R
(01)
General information on troubleshooting
Checks before troubleshooting

b7. Check of power train pump strainer


1. Remove cover (1) at the rear of the left side
cover and cover (2) on the left fender.

2. Loosen bolts (3) to remove case (4).

7. Add oil through oil filler port (F) up to the speci-


fied level.
8. After adding oil, check the oil level, referring to
"Check of power train case oil level".

3. Remove strainer (5) and magnet (6).


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

D375A-6R 40-27
(01)
General information on troubleshooting
Checks before troubleshooting

b8. Check of transmission oil filter and torque 2. Remove bolts (1) of transmission oil filter (B) and
converter oil filter torque converter oil filter (C). Pull up cover (2)
k If pressure remains in the filter, oil may spurt and take out element (3).
out. To prevent this, depress the brake pedal 3. Clean the inside of the case and the removed
several times and lock it before opening the parts.
filter case. 4. Install cover (A) on the right fender.
1. Remove cover (A) on the right fender.
(B): Transmission oil filter
(C): Torque converter oil filter

40-28 D375A-6R
(01)
General information on troubleshooting
Checks before troubleshooting

b9. Check of damper case oil level b10. Check of final drive case oil level
q Check the oil level while the engine is stopped. k Since the oil may spurt out due to internal
q When checking, park the machine on a level pressure, rotate the plug gradually from its
ground. side to release the internal pressure and then
1. Pull out oil level gauge (G) and wipe off the oil remove it carefully.
with a cloth. 1. Park the machine on a level place.
2. Insert oil level gauge (G) again fully into the oil 2. Remove oil level plug (G) and check the oil level.
level gauge pipe and pull it out. If the oil level is near the plug hole bottom, it is at
the correct level.

3. If the oil level is between stamps H and L of oil


level gauge (G), it is at the correct level. If the oil 3. If the oil level is low, add power train oil through
level is below L, add oil through the oil level oil filler plug hole (F).
gauge holder. a Remove all dirt and sand around oil filler plug
(F) and take care that dirt and sand will not
enter the plug hole when adding oil.

4. If the oil level is above H, open the undercover,


referring to step 6. of b.6 "Check of power train
case oil level".
5. Prepare an oil pan, remove the drain plug to b11. Performing air bleeding operation
drain excessive oil, and check the oil level again. q For the procedure for bleeding air from the fuel
system, see Testing and adjusting, "Bleeding air
from fuel circuit".
q For the procedure for bleeding air from the hy-
draulic equipment, see Testing and adjusting,
"Bleeding air from each part".

D375A-6R 40-29
(01)
General information on troubleshooting
Checks before troubleshooting

c. Electrical equipment 40-30 c3. Check of starting motor terminals for loose-
ness and corrosion
c1. Check of battery terminals for looseness and Open the engine hood and check starting motor
corrosion (ST-L) terminals B and C for breakage, looseness
Open cover (1) at the left front of the machine and and corrosion.
check the cable terminals for battery (A) for loose- Check starting motor (ST-U) similarly, too.
ness and corrosion.

c2. Check of alternator terminals for looseness c4. Testing of battery voltage (when engine
and corrosion stops)
Open the engine hood and check alternator termi- Test the battery voltage by using the battery tester
nals B and R for breakage, looseness and corro- while the engine is stopped.
sion.

40-30 D375A-6R
(01)
General information on troubleshooting
Checks before troubleshooting

c5. Check of battery electrolyte level


Check before operating the machine.
k Do not use the battery while its electrolyte
level is below LOWER LEVEL. If it is used un-
der that condition, its inside will deteriorate,
its service life will be shortened and it may
lead to an explosion.
k Since the battery produces combustible gas
that can explode, do not bring any open
flame near it.
k Battery electrolyte is dangerous. Take care
that it does not come in contact with your
eyes or skin. If it does, wash it away with wa-
ter and contact your doctor. a If you have added refined water above the
a Do not add battery electrolyte beyond the UP- U.L. line, take some of it out using a syringe
PER LEVEL mark. Excessive addition can dam- or similar tool. Neutralize the liquid that has
age the painted surface and corrode the parts. been taken out with sodium bicarbonate or
a As refined water (Example: Commercially avail- other suitable liquid, and wash it out with a
able battery fluid) added to the battery may large amount of water.
freeze, add it before starting work for the day so q When electrolyte level cannot be checked
that it will not freeze. through the side face of the battery
q When checking the electrolyte level through the 1. Remove cap (2) on the top of the battery.
side face of the battery (Described previously)
1. Clean around the electrolyte level lines with a 2. Look into electrolyte level opening (3) to check
cloth dampened with water and check that the the electrolyte level. If the electrolyte level is
electrolyte level is between UPPER LEVEL below sleeve (4), be sure to add refined water
(U.L.) and LOWER LEVEL (L.L.) (Example: Commercially available battery fluid)
a Do not clean the battery with a dry cloth since up to the sleeve bottom (U.L. line).
static electricity may cause an explosion. q (A) Correct level: Since the electrolyte level
reaches to the sleeve bottom, the shape of
the electrode plates will appear distorted due
to the surface tension.
q (B) Low: Since the electrolyte level does not
reach the sleeve bottom, the shape of the
electrode plates will appear straight.
3. After adding the refined water, tighten cap (2).

2. If the electrolyte level is below the center


between the U.L. and L.L. lines, remove cap (2)
and add refined water (Example: Commercially
available battery fluid) to the U.L. line immedi-
ately.
3. After adding the refined water, tighten the cap
securely.
a If you have added refined water above the
U.L. line, take some of it out using a syringe
or similar tool. Neutralize the liquid that has
been taken out with sodium bicarbonate or
other suitable liquid, and wash it out with a
large amount of water.

D375A-6R 40-31
(01)
General information on troubleshooting
Checks before troubleshooting

c6. Check of wiring harness for discoloration, c9. Check for loose connectors and damaged
burnt areas and cover peeling locks
q Check the wiring harness and cables for discol- q Pull the male and female parts of the connector
oration and burn. by the hand to check the condition of their con-
a Discoloration and burnt areas indicate the possi- nection.
bility of a short circuit or a circuit ground fault. q If the connecting condition is abnormal, connect
q Check the wiring harnesses and cables for dam- it securely.
age and peeling of the covers.
q If any fault are discovered, repair or replace the
wiring harness or cable.

c7. Check for removal of wiring harness clamps


and sagging of the wiring harness
q Check the wiring harnesses for sagging and play
caused by removal of a clamp.
a In particular, carefully check around the hot and
movable parts.
q If any part is off the clamp, resecure it with
clamp.

q Check the connector to see whether it is un-


locked and check its lock portion and housing for
cracks.
q Check lock screws (L) of controller (CNT) for
looseness.
a Use a hexagonal wrench with 4 mm width
across flats.

c8. Check of grounding


a Check the ground terminal for looseness and
rusting in particular.
q Check the connection of ground strap (1) of en-
gine controller (EC).

q Open the cover at the front of the fuel tank on the


left side of the machine and check the connec-
tion of the floor ground strap.

40-32 D375A-6R
(01)
General information on troubleshooting
Checks before troubleshooting

c10. Check of connector pin for corrosion, q Remove foreign matter in the connector using a
bends and deformation cloth or other material, and blow compressed air
q Disconnect the connector and check the pins for against the inside of the connector.
corrosion, bending and retraction. Check that
the female pins have not expanded.
q If any pin is found to be damaged, repair or re-
place it.
a If the pins are not shiny, apply contact restorer to
them and connect and disconnect several times
to shine them. (If the pins do not become shiny,
connect and disconnect the connector 10 times)

c11. Check for water and foreign matter in the


connector
q Disconnect the connector and check whether
there is water, dirt, sand, etc. in it.

a If there is sand or foreign matter in the connec-


tor, check the seal for damage.
q If the seal is defective, repair or replace it.
q Dry the moisture in the connector using a drier.

D375A-6R 40-33
(01)
General information on troubleshooting
Checks before troubleshooting

c12. Check of wiring harness for open and short Open inspection cover (A), and fuse boxes (1) to (3)
circuiting are seen.
q Check the connections (crimped parts) between
each connector pin and wiring harness.
q If there is any open circuit in wiring harness or
connector as illustrated in (A), repair or replace
them.

q Check whether any pins are touching any adja-


cent pins due to peeling of the wire cover, defec-
tive crimping of the pin, etc.

c13. Check of fuse for breakage and corrosion


a When replacing a fuse, be sure to turn off the
power (turn the starting switch to the OFF posi- Fuse box (4) is located overhead.
tion).
q The fuse holders are installed to the left front
lower part of operator's seat and to the overhead
section.
q If a fuse is corroded and coated with white pow-
der, or there is any play between the fuse and
fuse holder, replace the fuse.
q Replace each fuse with the one of the same ca-
pacity.

40-34 D375A-6R
(01)
General information on troubleshooting
Checks before troubleshooting

c14. Check of circuit breaker q Check of circuit breaker of main power supply
k Do not keep pressing the reset button of the 1. Turn starting switch to OFF position.
circuit breaker. (Doing so can cause a fire.) 2. Open the inspection cover at the front of the fuel
q The circuit breaker breaks the electrical circuit to tank on the left side of the machine. Check circuit
protect the electrical equipment and wiring when breakers (A) to (E).
an overcurrent flows through it. It can be used re-
peatedly.

q Check of circuit breaker in each circuit


If the circuit breaker works, reset button (1)
comes out.
q Check all the circuit breakers to see whether any
of reset buttons (1) have come out.
q To return the broken electrical circuit to normal
condition, push in reset button (1) that has come
out.
a If reset button (1) comes out again soon after it
is pushed in and the starting switch is turned to
the ON position, the overcurrent is still flowing. 3. Push reset buttons (A) to (E) of the circuit
Check the electrical circuit in this case. breakers in order.
a If the electrical circuit is broken, the operating ef-
fort of the reset button is heavier compared with
the case when the circuit is operating normal.
a The height of the reset button does not change
when the circuit is broken or normal.

D375A-6R 40-35
(01)
General information on troubleshooting
Checks before troubleshooting

c15. Check of alternator voltage (when engine c16. Check of battery relay operation sound
speed is medium or higher) 1. Open the battery cover.
1. Open the engine hood. 2. Check whether the battery relay operation sound
2. Connect the positive (+) line of the tester to alter- is heard when starting switch is turned to
nator terminal (B) and connect the negative (-) ON/OFF position.
line to the chassis ground. q If the operation sound is not heard, check the
3. Start and warm up the engine and measure the related circuits, referring to E-1 in the E
voltage while running the engine at a medium or mode.
a higher speed. q If the related circuits are free from abnormal-
q If the voltage is abnormal, repair or replace ities, replace the battery relay.
the alternator.

40-36 D375A-6R
(01)
General information on troubleshooting
Classification and procedures for troubleshooting

Classification and procedures for troubleshooting 40-37

Classification of troubleshooting 40-37


Mode Contents
Display of code Troubleshooting by failure code
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine

Procedure for troubleshooting 40-37


If a phenomenon which appears a source of a trouble occurs on the machine, select a proper troubleshooting
No. according to the following procedure, and then go to the corresponding troubleshooting section.

1. Procedure for troubleshooting when user code and failure code are displayed on machine
monitor:
If a user code and a failure code are displayed on the standard screen of themachine monitor, perform the
troubleshooting for the corresponding "Display of code" according to the displayed failure code.
a If multiple failure codes are displayed simultaneously, all the codes are displayed repeatedly in order.
Note down all the codes.

2. Procedure for troubleshooting when a user code and a failure code are not displayed on machine
monitor:
Check a mechanical system failure code and an electrical system failure code with the failure record func-
tion of the machine monitor. (See [*1].)
1) If a failure code is displayed, perform troubleshooting for the corresponding "Display of code"
according to the failure code.
a If an electrical system failure code is dispayed after having noted down all the codes, delete all the
codes and reproduce them, and then see if the trouble is still detected. (See [*2].)
a A failure code of the mechanical system cannot be deleted.
2) If no failure code is found in the abnormality record, a trouble that the machine cannot find out by itself
may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon which is assumed to show a trouble again and select the same
phenomenon from the list on the next page, and then perform troubleshooting corresponding to that
phenomenon in the "E-mode", "H-mode", or "S-mode".

3. Action to take after failure is eliminated


Clear all the failure codes in the electrical system abnormality record, referring to the next page.

D375A-6R 40-37
(01)
General information on troubleshooting
Classification and procedures for troubleshooting

[*1], [*2] 4. Press [F6] switch ( ) on the panel switch to


1. While pressing numerical key [4] on the panel confirm and go to "Mechanical system Abnor-
switch at the normal screen, press [1], [2] and [3] mality Record" screen.
in order.

5. Press the [F3] switch (R) on the panel switch to


see if the next failure code is displayed and note
down all the failure codes.
a A failure code of the mechanical system can-
not be deleted.
6. Press [F5] switch (RETURN) on the panel switch
to return to the "Failure history" screen.
7. Enter the "Electrical system abnormality record"
similarly to steps 2 and 3.
8. Press the [F3] switch (R) on the panel switch to
see if the next failure code is displayed and note
down all of the failure codes.
a "E" on the left of a failure code indicates that
the failure code is "active" (the failure re-
mains or restoration to normal has not been
2. On the service menu screen, press [F3] switch checked). A failure code having no "E" on its
(R) on the panel switch once to select "02 left is a "non-active" one. Since it disappears
Abnormality Record". at the following clear step, be sure to note it
3. Press [F6] switch ( ) on the panel switch to down.
confirm and go to "Abnormality Record" screen. 9. While pressing numerical key [4] on the panel
switch, press [1], [2] and [3] in this order to enter
the "Clear mode". (Same as 1)
10. Press [F2] switch(CLEAR) on the panel switch.
11. Press [F6] switch ( ) on the panel switch to clear
all the failure codes temporarily.
12. Press [F5] switch (RETURN) on the panel switch
to return to the "Electrical system failure record"
screen. See if any failure code is still displayed
and note down the displayed ones.

40-38 D375A-6R
(01)
General information on troubleshooting
Classification and procedures for troubleshooting

13. Press [F5] switch (RETURN) on the panel switch


to return to the "Failure history" screen.

D375A-6R 40-39
(01)
General information on troubleshooting
Failure codes table

Failure codes table 40-40


Reference
Failure Component Category of
Failure (Displayed on screen) Action code document
code in charge record
page
Electrical
1380MW Lock up clutch:Slip P/T 40-114
system
Electrical
1500L0 Transmission clutch:Abnormal P/T E03 40-115
system
Electrical
15E0MW Transmission clutch:Slip P/T 40-116
system
Electrical
15SAL1 Forward clutch:Fill high P/T E03 40-118
system
Electrical
15SALH Forward clutch:Fill low P/T E03 40-120
system
Electrical
15SBL1 Reverse clutch:Fill high P/T E03 40-122
system
Electrical
15SBLH Reverse clutch:Fill low P/T E03 40-124
system
Electrical
15SEL1 Speed 1st clutch:Fill high P/T E03 40-126
system
Electrical
15SELH Speed 1st clutch:Fill low P/T E03 40-128
system
Electrical
15SFL1 Speed 2nd clutch:Fill high P/T E03 40-130
system
Electrical
15SFLH Speed 2nd clutch:Fill low P/T E03 40-132
system
Electrical
15SGL1 Speed 3rd clutch:Fill high P/T E03 40-134
system
Electrical
15SGLH Speed 3rd clutch:Fill low P/T E03 40-136
system
Electrical
15SJL1 L/U :Fill high P/T E02 40-138
system
Electrical
15SJLH L/U :Fill low P/T E02 40-140
system
Electrical
1800MW P/T clutch:Slip P/T E02 40-142
system
Electrical
2201L1 Right clutch:Fill high P/T E04 40-144
system
Electrical
2201LH Right clutch:Fill low P/T E04 40-146
system
Electrical
2202L1 Left clutch:Fill high P/T E04 40-148
system
Electrical
2202LH Left cluth:Fill low P/T E04 40-150
system
Mechanical
2300NR Brake Thermal Load Abnormality P/T 40-152
system
Electrical
2301L1 Right brake:Fill high P/T E04 40-154
system
Electrical
2301LH Right brake:Fill low P/T E04 40-156
system
Mechanical
2301NR Steering Brake RH Thermal Load Abnormality P/T 40-158
system
Electrical
2302L1 Left brake:Fill high P/T E04 40-160
system
Electrical
2302LH Left brake:Fill low P/T E04 40-162
system
Mechanical
2302NR Steering Brake LH Thermal Load Abnormality P/T 40-164
system
Electrical
7RFAKA ECM ACC CUT RELAY:Disconnection W/E 40-166
system
Electrical
7RFAKB ECM ACC CUT RELAY:Short circuit W/E 40-168
system

40-40 D375A-6R
(01)
General information on troubleshooting
Failure codes table

Reference
Failure Component Category of
Failure (Displayed on screen) Action code document
code in charge record
page
Mechanical
AA10NX Air Cleaner Clogging MON 40-170
system
Mechanical
AB00MA Battery Charge Abnormal MON 40-172
system
Mechanical
B@BAZG Eng Oil Press Low ENG 40-173
system
Mechanical
B@BAZK Eng oil level low MON 40-174
system
Mechanical
B@BCNS Eng Water Overheat ENG 40-175
system
Mechanical
B@BCZK Eng water level low MON 40-176
system
Mechanical
B@CENS T/C Oil Overheat P/T 40-177
system
Mechanical
B@HANS Hyd Oil Overheat P/T 40-178
system
Mechanical
B@HAZK Hyd Oil Level Low W/E 40-179
system
Electrical
CA111 ECM Critical Internal Failure ENG E03 40-180
system
Electrical
CA115 Eng Ne and Bkup Speed Sens Error ENG E03 40-182
system
Electrical
CA122 Chg Air Press Sensor High Error ENG E03 40-184
system
Electrical
CA123 Chg Air Press Sensor Low Error ENG E03 40-186
system
Electrical
CA131 Throttle Sensor High Error ENG E03 40-188
system
Electrical
CA132 Throttle Sensor Low Error ENG E03 40-190
system
Electrical
CA135 Eng Oil Press Sensor High Error ENG E02 40-192
system
Electrical
CA141 Eng Oil Press Sensor Low Error ENG E01 40-194
system
Electrical
CA144 Coolant Temp Sens High Error ENG E01 40-196
system
Electrical
CA145 Coolant Temp Sens Low Error ENG E01 40-198
system
Electrical
CA153 Chg Air Temp Sensor High Error ENG E01 40-200
system
Electrical
CA154 Chg Air Temp Sensor Low Error ENG E01 40-202
system
Electrical
CA187 Sens Supply 2 Volt Low Error ENG E03 40-204
system
Electrical
CA212 Eng Oil Temp Sensor Low Error ENG E01 40-206
system
Electrical
CA213 Eng Oil Temp Sensor Low Error ENG E01 40-208
system
Electrical
CA221 Ambient Press Sens High Error ENG E01 40-210
system
Electrical
CA222 Ambient Press Sens Low Error ENG E01 40-212
system
Electrical
CA227 Sens Supply 2 Volt High Error ENG E03 40-214
system
Electrical
CA234 Engine Overspeed ENG E02 40-215
system
Electrical
CA238 Ne Speed Sens Supply Volt Error ENG E03 40-216
system
Electrical
CA263 Fuel Temp Sensor High Error ENG E01 40-218
system

D375A-6R 40-41
(01)
General information on troubleshooting
Failure codes table

Reference
Failure Component Category of
Failure (Displayed on screen) Action code document
code in charge record
page
Electrical
CA265 Fuel Temp Sensor Low Error ENG E01 40-220
system
Electrical
CA271 IMV/PCV1 Short Error ENG E03 40-222
system
Electrical
CA272 IMV/PCV1 Open Error ENG E03 40-223
system
Electrical
CA273 PCV2 Short Error ENG E03 40-224
system
Electrical
CA274 PCV2 Open Error ENG E03 40-225
system
Electrical
CA322 Inj #1(L#1) Open/Short Error ENG E03 40-226
system
Electrical
CA323 Inj #5(L#5) Open/Short Error ENG E03 40-228
system
Electrical
CA324 Inj #3(L#3) Open/Short Error ENG E03 40-230
system
Electrical
CA325 Inj #6(L#6) Open/Short Error ENG E03 40-232
system
Electrical
CA331 Inj #2(L#2) Open/Short Error ENG E03 40-234
system
Electrical
CA332 Inj #4(L#4) Open/Short Error ENG E03 40-236
system
Electrical
CA342 Calibration Code Incompatibility ENG E03 40-238
system
Electrical
CA351 Injectors Drive Circuit Error ENG E03 40-239
system
Electrical
CA352 Sens Supply 1 Volt Low Error ENG E03 40-240
system
Electrical
CA386 Sens Supply 1 Volt High Error ENG E03 40-242
system
Electrical
CA441 Battery Voltage Low Error ENG E03 40-243
system
Electrical
CA442 Battery Voltage High Error ENG E03 40-244
system
Electrical
CA449 Rail Press Very High Error ENG E03 40-245
system
Electrical
CA451 Rail Press Sensor High Error ENG E03 40-246
system
Electrical
CA452 Rail Press Sensor Low Error ENG E03 40-248
system
Electrical
CA553 Rail Press High Error ENG E03 40-250
system
Electrical
CA554 Rail Press Sensor In Range Error ENG E03 40-251
system
Electrical
CA559 Rail Press Low Error ENG E03 40-252
system
Electrical
CA689 Eng Ne Speed Sensor Error ENG E03 40-256
system
Electrical
CA731 Eng Bkup Speed Sens Phase Error ENG E03 40-258
system
Electrical
CA757 All Continuous Data Lost Error ENG E03 40-259
system
Electrical
CA778 Eng Bkup Speed Sensor Error ENG E03 40-260
system
Electrical
CA1633 KOMNET Datalink Timeout Error ENG E03 40-262
system
Electrical
CA2185 Throt Sens Sup Volt High Error ENG E03 40-263
system
Electrical
CA2186 Throt Sens Sup Volt Low Error ENG E03 40-264
system

40-42 D375A-6R
(01)
General information on troubleshooting
Failure codes table

Reference
Failure Component Category of
Failure (Displayed on screen) Action code document
code in charge record
page
Electrical
CA2249 Rail Press Very Low Error ENG E03 40-265
system
Electrical
D110KB Battery Relay:Drive Short Circuit W/E 40-266
system
Electrical
D130KA Neutral relay:Disconnection P/T E02 40-268
system
Electrical
D130KB Neutral relay:Short circuit P/T E02 40-270
system
Electrical
D161KA Back-up alarm releay:Disconnection P/T E01 40-272
system
Electrical
D161KB Back-up alarm releay:Short circuit P/T E01 40-274
system
Electrical
D182KZ Preheater Relay Abnormality P/T E01 40-276
system
Electrical
D190KA ACC signal relay:Disconnection W/E 40-278
system
Electrical
D190KB ACC signal relay:Short circuit W/E 40-280
system
Electrical
D1EFKA Pre lub. motor relay:Disconnection P/T E02 40-282
system
Electrical
D1EFKB Pre lub. motor relay:Short circuit P/T E02 40-284
system
Electrical
DAFRKR Monitor:Can communication lost(PT) P/T E03 40-286
system
Electrical
dAFRKR Monitor:Can communication lost(WE) W/E E03 40-287
system
Electrical
DAFRMC CAN Discon (Monitor Detected) MON E03 40-288
system
Electrical
DB2RKR ENG cont.:Can communication lost(PT) P/T E03 40-294
system
Electrical
dB2RKR ENG controller:Can communication lost(WE) W/E E03 40-298
system
Electrical
DB90KT WE controller:Abnormality in controller W/E E01 40-299
system
Electrical
DB91KK WE controller:Source voltage reduction W/E E04 40-300
system
Electrical
DB92KK WE controller:Output voltage reduction W/E E04 40-302
system
Electrical
DB97KK WE cont.:Sensor voltage 5V (2) reduction W/E 40-304
system
Electrical
DB99KQ WE controller:Type select signal W/E E04 40-306
system
Electrical
DB9RKR WE controller:CAN communication error (PT) P/T E03 40-307
system
Electrical
DBB0KK VHMS controller:Source voltage reduction VHMS 40-310
system
Electrical
DBB0KQ VHMS Connector Connection Abnormality VHMS 40-312
system
Electrical
DBB3KK VHMS controller:Source voltage reduction VHMS 40-313
system
Electrical
DBB5KP VHMS:Output sensor1 voltage reduction VHMS 40-316
system
Electrical
DBB6KP VHMS:Output sensor2 voltage reduction VHMS 40-318
system
Electrical
DBB7KP VHMS:Output sensor3 voltage reduction VHMS 40-320
system
Electrical
DBBQKR PT controller:CAN communication lost (VHMS) VHMS 40-322
system
Electrical
DBE0KT PT controller:Abnormality in controller P/T E01 40-323
system

D375A-6R 40-43
(01)
General information on troubleshooting
Failure codes table

Reference
Failure Component Category of
Failure (Displayed on screen) Action code document
code in charge record
page
Electrical
DBE1KK PT controller:Source voltage reduction P/T E04 40-324
system
Electrical
DBE2KK PT controller:Output voltage reduction P/T E04 40-326
system
Electrical
DBE5KK PT cont.:Sensor voltage5V (1) reduction P/T E03 40-328
system
Electrical
DBE6KK PT cont.:Sensor voltage 24V reduction P/T E03 40-330
system
Electrical
DBE7KK PT cont.:Sensor voltage 5V (2) reduction P/T E01 40-332
system
Electrical
DBE9KQ PT controller:Type select signal P/T E04 40-334
system
Electrical
DBERKR PT controller: CAN communication lost (WE) W/E E03 40-335
system
Electrical
DD12KA Shift up Sw:Disconnection P/T E02 40-338
system
Electrical
DD12KB Shift up Sw:Short circuit P/T E02 40-340
system
Electrical
DD13KA Shift down Sw:Disconnection P/T E02 40-342
system
Electrical
DD13KB Shift down Sw:Short circuit P/T E02 40-344
system
Electrical
DD14KA Parking lever Sw:Dissconnection P/T E03 40-346
system
Electrical
DD14KB Parking lever Sw:Short circuit P/T E03 40-348
system
Electrical
DDB9L4 Reverse SW Signal disagreement P/T E03 40-350
system
Electrical
DDE2KA Pre lub. oil press sw:Disconnection P/T E02 40-352
system
Electrical
DDK3L4 Forward SW Signal disagreement P/T E03 40-354
system
Electrical
DDK5KA Shift switch disconnection P/T E02 40-356
system
Electrical
DDK5KB Shift switch short circuit P/T E02 40-358
system
Electrical
DDN2LD Blade tilt RH pressure SW abnormality W/E 40-360
system
Electrical
DDN3LD Blade tilt LH pressure SW abnormality W/E 40-362
system
Electrical
DDN7KA WEQ Knob Sw(down):Disconnection W/E E02 40-364
system
Electrical
DDN7KB WEQ Knob Sw(down):Short circuit W/E E02 40-366
system
Electrical
DDN9KA WEQ Knob Sw(up):Disconnection W/E E01 40-368
system
Electrical
DDN9KB WEQ Knob Sw(up):Short circuit W/E E01 40-370
system
Electrical
DDNALD Blade lift up pressure SW abnormality W/E 40-372
system
Electrical
DDNBLD Ripper lift up pressure SW abnormality W/E 40-374
system
Electrical
DDNCLD Ripper lift down pressure SW abnormality W/E 40-376
system
Electrical
DDNDLD Ripper tilt in pressure SW abnormality W/E 40-378
system
Electrical
DDNELD Ripper tilt back pressure SW abnormality W/E 40-380
system
Electrical
DDNFLD Blade lift down pressure SW abnormality W/E 40-382
system

40-44 D375A-6R
(01)
General information on troubleshooting
Failure codes table

Reference
Failure Component Category of
Failure (Displayed on screen) Action code document
code in charge record
page
Electrical
DDNLKA Weq lock Sw:Disconnection W/E E03 40-384
system
Electrical
DDNLKB Weq lock Sw:Short circuit W/E E03 40-386
system
Electrical
DDT5KA Neutral switch disconnection P/T E04 40-388
system
Electrical
DDT5KB Neutral switch short circuit P/T E04 40-390
system
Electrical
DDT5KQ Lever SPEC selection signal disagreement P/T E04 40-392
system
Electrical
DDTSL1 S/C :Fill high P/T E02 40-394
system
Electrical
DDTSLH S/C :Fill low P/T E02 40-396
system
Electrical
DGE5KX Ambient temp sensor abnormality VHMS 40-398
system
Electrical
DGS1KX Hyd oil temp:signal abnormal P/T E01 40-400
system
Electrical
DGT1KA T/C oil temp sensor:Abnormal W/E E01 40-402
system
Electrical
DGT1KX T/C oil temp sensor:Abnormal W/E E01 40-404
system
Electrical
DGT5KA F exhaust temp sensor disconnection VHMS 40-406
system
Electrical
DGT5KB F exhaust temp sensor short circuit VHMS 40-408
system
Electrical
DGT6KA R exhaust temp sensor disconnection VHMS 40-410
system
Electrical
DGT6KB R exhaust temp sensor short circuit VHMS 40-412
system
Electrical
DH21KA Weq pressure sensor:Disconnection W/E E01 40-414
system
Electrical
DH21KB Weq pressure sensor:Short circuit W/E E01 40-416
system
Electrical
DHE5KB ENG blow-by pressure sensor disconnection VHMS 40-418
system
Electrical
DHE5KY ENG blow-by pressure sensor short circuit VHMS 40-420
system
Electrical
DHT3KX T/M oil pressure sensor abnormality VHMS 40-422
system
Electrical
DHT5KA T/C in-pressure sensor:Disconnection P/T E02 40-424
system
Electrical
DHT5KB T/C in-pressure sensor:Short circuit P/T E02 40-426
system
Electrical
DHT7KA T/C out-pressure sensor:Disconnection P/T E02 40-428
system
Electrical
DHT7KB T/C out-pressure sensor:Short circuit P/T E02 40-430
system
Electrical
DK10KA Fuel control Dial:Disconnection P/T E03 40-432
system
Electrical
DK10KB Fuel control Dial:Short circuit P/T E03 40-434
system
Electrical
DK30KA ST lever1:Disconnection P/T E03 40-436
system
Electrical
DK30KB ST lever1:Short circuit P/T E03 40-438
system
Electrical
DK30KX ST lever:Out of normal range P/T E04 40-440
system
Electrical
DK30KZ ST lever:Disconnection or short circuit P/T E04 40-441
system

D375A-6R 40-45
(01)
General information on troubleshooting
Failure codes table

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

40-46 D375A-6R
(01)
General information on troubleshooting
Failure codes table

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

D375A-6R 40-47
(01)
General information on troubleshooting
Failure codes table

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

40-48 D375A-6R
(01)
General information on troubleshooting
Failure codes table

a The items in this table are arranged in the order of the failure codes.
a A component in charge is a controller or the machine monitor in charge of the system check.
MON : Monitor panel
ENG : Engine controller
P/T : Power train controller
W/E : Work equipment controller
VHMS : VHMS controller
a The failure codes having no numbers in respective action code columns are not displayed on the standard
screen even when a failure related to them occurs. The failures are simply recorded in the abnormality
record (electrical equipment system or mechanical equipment system abnormality record) of the service
menu.
a The history classification column shows in which system each failure is classified, the electrical equipment
system or mechanical equipment system, when it is recorded in the failure history.
Since the failure codes of VHMS are special to the VHMS specification and saved only in the VHMS
controller, however, they are not recorded in the fault history
The 4-letter codes in [ ] among the VHMS codes are the failure codes displayed on the 7-segment LED of
the VHMS controller (They are divided into 2 2-letter codes).
a Blinking and lighting of failure code
q Blinking:The trouble has not been repaired.
q Lighting:The trouble has been repaired.

D375A-6R 40-49
(01)
General information on troubleshooting
Classification and procedures for troubleshooting numbers

Classification and procedures for troubleshooting numbers 40-50


Phenomena looking like troubles and troubleshooting Nos.
Troubleshooting
No. Phenomena supposed to show troubles Reference document
Index
page
Action code and failure code
The action code and failure code are displayed on the machine moni-
1
tor.
When abnormality record is checked, failure code is shown in
2 Take actions by following the failure code.
mechanical system abnormality record
When abnormality record is checked, failure code is shown in electri-
3
cal system abnormality record

Troubleshooting
No. Phenomena supposed to show troubles Index Reference document
page
Phenomena related to engine
4 Starting performance is poor S-1 40-678
5 Engine does not start E-1,S-2,-17 40-580,40-679,40-696
6 Engine does not pick up smoothly S-3 40-682
7 Engine stops during operations S-4 40-683
8 Engine does not rotate smoothly (such as hunting) S-5 40-684
9 Engine lack output (or lacks power) S-6 40-685
10 Exhaust smoke is black (incomplete combustion) S-7 40-686
11 Oil consumption is excessive (or exhaust smoke is blue) S-8 40-687
12 Oil contaminates quickly S-9 40-688
13 Fuel consumption is excessive S-10 40-689
14 Oil is in coolant (or coolant spurts back or coolant level goes down) S-11 40-690
15 Oil pressure drops S-12 40-691
16 Oil level rises (Entry of coolant/fuel) S-13 40-692
17 Coolant temperature becomes too high (overheating) S-14 40-693
18 Abnormal noise is heard S-15 40-694
19 Vibration is excessive S-16 40-695
20 The preheater does not operate. E-2 40-584
21 Electric priming pump does not operate or does not stop automatically. E-28 40-638
Phenomena related to power train
22 Power is low (Insufficient drawbar pull) H-1 40-648
23 The machine does not travel (at 2nd or 3rd) H-2 40-650
24 Machine does not start at all gear speeds H-3 40-651
25 The machine can travel in forward or reverse only H-4 40-653
26 Large time lag at gear speed shifting or forward-reverse shifting H-5 40-654
27 Steering does not turn H-6 40-655
28 Steering turns only in one direction (left or right) H-7 40-656
29 The machine oversteered H-8 40-657
30 The brake does not work. H-9 40-658
31 Torque converter lockup is not turned on H-10 40-659
32 The torque converter oil temperature is heated abnormally high H-11 40-660
Phenomena related to work equipment
33 All work equipment operates slowly or lacks power. H-12 40-661
34 All work equipment does not operate. H-13 40-662
35 The blade liftting speed is slow, or the lifting force is not enough. H-14 40-663
Tilting blade speed is slow to be raised or the tilting force is not
36 H-15 40-664
enough.
37 Ripper lift is slow to raise, or lifting force is not enough H-16 40-665
38 Ripper tilt is slow to raise, or tilting force is not enough H-17 40-666
39 The hydraulic drift of the blade is large. H-18 40-667

40-50 D375A-6R
(01)
General information on troubleshooting
Classification and procedures for troubleshooting numbers

Troubleshooting
No. Phenomena supposed to show troubles Reference document
Index
page
40 Hydraulic drift of tilted blade is large. H-19 40-668
41 Excessive hydraulic drift of ripper lift. H-20 40-669
42 The ripper pin puller cylinder does not work. E-21, H-21 40-606,40-670
43 The blade pitch does not work. H-22 40-671
44 Abnormal noise is heard from around the work equipment pump H-23 40-672
The fan speed is abnormal (excessive noise from or vibration of fan, or
45 H-24 40-673
overheating).
Phenomena related to machine monitor
46 When starting switch turned ON, machine monitor displays nothing E-3 40-588
When starting switch is turned to ON position (with engine stopped),
47 E-4 40-592
basic check item (radiator coolant level) lamp lights.
48 Precaution lights up while engine is running E-5 40-594
49 Emergency stop item lights up while engine is running E-6 40-596
50 Engine coolant temperature gauge does not indicate normally E-7 40-597
51 Fuel gauge does not operate normally E-8 40-598
The power train oil temperature gauge (multi-gauge) does not indicate
52 E-9 40-600
properly.
Hydraulic oil temperature gauge (multi-gauge) does not operate nor-
53 E-10 40-601
mally
Contents of display by machine monitor are different from applicable
54 E-11 40-602
model.
55 Machine monitor does not display some items E-12 40-602
56 The function switch does not work. E-13 40-602
57 Operation mode does not change E-14 40-603
58 Gear shift mode does not change E-15 40-603
59 Customize function does not operate normally E-16 40-604
60 Customize memory function does not operate normally E-17 40-604
61 Alarm buzzer cannot be stopped E-18 40-605
62 When starting switch is turned OFF, service meter is not displayed. E-19 40-605
63 Machine monitor cannot be set in service mode E-20 40-605
64 The horn does not sound or does not stop sounding. E-22 40-608
65 The backup alarm does not sound or does not stop sounding E-23 40-610
66 The fan does not rotate in reverse. E-24 40-612
67 Headlamp, back-up lamp, and/or ripper point lamp does not light E-25 40-613
68 Windshield wiper does not operate. E-26 40-622
69 Window washer does not operate. E-27 40-630
The ORBCOMM terminal does not operate normally (Data are not
70 E-29 40-640
transmitted).
71 Gear cannot be shifted E-30 40-642

D375A-6R 40-51
(01)
General information on troubleshooting
Information in troubleshooting table

Information in troubleshooting table 40-52


a Troubleshooting Table and Circuit Diagram Related collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.
Action code Failure code
Display on Description of problem that appears on machine monitor as: abnormal-
Display on Failure
machine mon- ity record
machine monitor
itor
Failure Description of the failure detected by the machine monitor or controller
description
Action of
machine mon- Action taken by machine monitor or controller to protect system or devices when machine monitor or
itor or control- controller detects failure
ler
Problem on Problem that appears on machine as result of action taken by machine monitor or controller (shown
machine above)
Related infor-
Information related to detected trouble or troubleshooting
mation
Cause Procedure, measuring location, criteria and remarks
<Information described>
q Procedure
q Measuring location
Probable causes a Between A - B" means "Measure voltage or resistance and so on between A
and B".
q Standard value in normal condition to evalute assumed cause if it is good condi-
tion or not.
q Remarks required to evaluate the cause is correct
<How to use the troubleshooting sheet>
1 - Defective q Perform troubleshoot in following procedure in numerical order.
q If the testing result shows abnormality, the cause described on the left column
conforms.
q If it shows normal, and unless otherwise specified particularly, proceed to the
next step (cause).
Open circuit in wiring harness
q Check that the failure is fixed after a failure was found and repaired.
(Open circuit in wiring or
2 <Phenomenon of defective wiring harness>
defective contact in connec-
q Disconnection in wiring
tor)
The connector connection is defective or the wiring harness is disconnected.
q Ground fault
A harness not connected to ground (earth) circuit contacts the ground(earth) or
machine.
Ground fault in wiring harness q Hot short circuit
3
(Contact with ground circuit) A harness not connected to the power (24 V) circuit contacts the power (24
V)circuit.
q Short circuit
An independent wire in the harness abnormally contacts another wire.
(Poor insulation of connector or others)
Hot short circuit <Notes on troubleshooting>
4
(Contact with 24 V circuit) (1)How to indicate connector number and handle T-branch
For troubleshooting, insert or connect T-branch adapter as shown below unless
especially specified.
q When "male" or "female" is not indicated with a connector number, discon-
nect the connector, and insert T-branch adapter in both male and female.
q When "male" or "female" is indicated with a connector number, disconnectthe
5 Short circuit in wiring harness
connector, and connect T-branch adapter only to either male or femae end.
(2)Description sequence of pin number and handling of tester lead
Connect positive (+) lead and negative (-) lead of tester as explained below for
troubleshooting, unless otherwise specified.
q Connect positive (+) lead to pin No. or wiring harness entered on front side.
q Connect the minus () lead to a pin or harness indicated in the rear.
6 Defective controller

40-52 D375A-6R
(01)
General information on troubleshooting
Information in troubleshooting table

Related circuit diagram 40-53

This drawing is a part of the circuit diagram related to trou-


bleshooting.
q (-) Connector No.: Indicates (Model - Number of pins)
and (Color).
q "Connector No. and pin No." from each branching/merg-
ing point:
Shows the ends of branch or source of merging within
the parts of the same wiring harness.
q Arrow (io): Roughly shows the location on the ma-
chine.
q NO: Normally Open
q NC: Normally Closed

D375A-6R 40-53
(01)
General information on troubleshooting
Troubleshooting method for disconnecting wiring harness of pressure sensor system

Troubleshooting method for disconnecting wiring harness of pressure


sensor system 40-54

a Since pressure sensor consists not only of resistors but also electronic circuits such as amplifiers, it may
have the deferences among the registances measured and its own polarities. So troubleshoting must be
performed carefully.

Failure codes applicable to this diagnosis


q CA123: Charge air pressure sensor low error
q CA222: Ambient pressure sensor low error

Procedure
1. Measure and record resistance of pressure sensor unit.
1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor.
2) Measure resistances R1 and R2 between pins.
a If tester probes polarities to apply are reversed, measured values may change. Therefore, when
measuring resistances, apply the same tester probe polarities to the pressure sensor in steps 1 and
2.
a If measured value is infinite, take measurements with tester probes polarities exchanged each oth-
er and record the finite value obtained as a measured value.
a Since measured values may be diferent from each other, take several measurements. Cause of the
diferences appears to be that the sensor may be charged by the tester. Take several measurement
in both steps 1 and 2. Take the fact into consideration this diferences when determining whether
the wiring harness is disconnected in step 3.

2. Measure and record resistance with wiring harness between pressure sensor and engine controller
connected
1) Since 5 V power supply to pressure sensor is supplied to other sensors, disconnect the other sensor
connectors first.(*)
2) Connect the pressure sensor to be measured, disconnect connector (3) on engine controller side, and
connect T-adapter (4) to wiring harness side.
3) Connect T-box (5) to T-adapter (4) and measure respective pins for resistances R1' and R2'.

3. Judging open circuit


If there is an "apparent difference" between resistances R1 and R2 measured in step 1 and resistances
R1' and R2' measured in step 2, "wiring harness is disconnected".
a "Apparent difference" means a difference of 10 or more times.

40-54 D375A-6R
(01)
General information on troubleshooting
Troubleshooting method for disconnecting wiring harness of pressure sensor system

List of pressure sensor measuring locations and reference values


Internal resistance of measured
Measuring location at
Sensor sensor Remarks
sensor pin
(Reference value)
Charge pressure R2: Between (1) and (3) Approx. 2.9k Sensor is common to engine mod-
sensor R1: Between (2) and (3) Approx. 4.3k els 125, 170 and 12V140
Sensor is common to engine mod-
R2: Between (1) and (3) Approx. 3.2k
els 95, 125, 170 and 12V140
Ambient pressure R1: Between (2) (+) and
Approx. 4.6k
sensor (1) (-) If polarities are reversed, resis-
R1: Between (1) (+) and tance value changes.
Approx. 2.9k
(2) (-)

*: When measuring R2', disconnect the following connectors.(See circuit diagram related to each code)
q When measuring R2' of charge pressure sensor
(CA123)
Connectors of resistance RES, engine oil pressure sensor, ambient pressure sensor, and G sensor
q When measuring R2' of ambient pressure sen-
sor (CA222)
Connectors of charge pressure sensor, resistance RES, engine oil pressure sensor, and G sensor

D375A-6R 40-55
(01)
General information on troubleshooting
Troubleshooting method for disconnecting wiring harness of pressure sensor system

Measurement record (For measuring locations, see circuit diagram related to each code)
Sensor + Wiring harness
Sensor unit (Measuring
(Measuring location on
Sensor location on sensor pin Measured value Measured value
wiring harness side of
side)
engine controller)
R1: Between (1) (+) and
R2: Between (1) and (3)
Charge pressure (2) (-)
sensor R1': Between (44) and
R1: Between (2) and (3)
(47)
R2': Between (37) and
R2: Between (1) and (3)
(38) (*)
Ambient pressure R1: Between (2) (+) and R1': Between (3) (+)
sensor (1) (-) and (38) (-)
R1: Between (1) (+) and R1': Between (38) (+)
(2) (-) and (3) (-)

40-56 D375A-6R
(01)
General information on troubleshooting
Connection table for connector pin numbers

Connection table for connector pin numbers 40-57


(Rev. 2009. 04)
a The terms of male and female refer to the pins, while the terms of male housing and female housing refer
to the mating portion of the housing.

D375A-6R 40-57
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-58 D375A-6R
(01)
General information on troubleshooting
Connection table for connector pin numbers

D375A-6R 40-59
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-60 D375A-6R
(01)
General information on troubleshooting
Connection table for connector pin numbers

D375A-6R 40-61
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-62 D375A-6R
(01)
General information on troubleshooting
Connection table for connector pin numbers

D375A-6R 40-63
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-64 D375A-6R
(01)
General information on troubleshooting
Connection table for connector pin numbers

D375A-6R 40-65
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-66 D375A-6R
(01)
General information on troubleshooting
Connection table for connector pin numbers

D375A-6R 40-67
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-68 D375A-6R
(01)
General information on troubleshooting
Connection table for connector pin numbers

D375A-6R 40-69
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-70 D375A-6R
(01)
General information on troubleshooting
Connection table for connector pin numbers

D375A-6R 40-71
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-72 D375A-6R
(01)
General information on troubleshooting
Connection table for connector pin numbers

D375A-6R 40-73
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-74 D375A-6R
(01)
General information on troubleshooting
Connection table for connector pin numbers

D375A-6R 40-75
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-76 D375A-6R
(01)
General information on troubleshooting
Connection table for connector pin numbers

D375A-6R 40-77
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-78 D375A-6R
(01)
General information on troubleshooting
Connection table for connector pin numbers

D375A-6R 40-79
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-80 D375A-6R
(01)
General information on troubleshooting
Connection table for connector pin numbers

D375A-6R 40-81
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-82 D375A-6R
(01)
General information on troubleshooting
Connection table for connector pin numbers

D375A-6R 40-83
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-84 D375A-6R
(01)
General information on troubleshooting
Connection table for connector pin numbers

D375A-6R 40-85
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-86 D375A-6R
(01)
General information on troubleshooting
Connection table for connector pin numbers

D375A-6R 40-87
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-88 D375A-6R
(01)
General information on troubleshooting
Connection table for connector pin numbers

D375A-6R 40-89
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-90 D375A-6R
(01)
General information on troubleshooting
Connection table for connector pin numbers

D375A-6R 40-91
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-92 D375A-6R
(01)
General information on troubleshooting
T-branch box and T-branch adapter table

T-branch box and T-branch adapter table 40-93


(Rev. 2009. 03)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal col-
umn indicates a part number of harness checker assembly.

T-adapter kit

Number of pins

799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identificati
Part number Part name
on symbol

799-601-2600 T-box(for ECONO) 21 q q q q q


799-601-3100 T-box(for MS) 37 q
799-601-3200 T-box(for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3420 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3430 Adapter for BENDIX (MS) 17 MS-17P q
799-601-3440 Adapter for BENDIX (MS) 17 MS-17P q
799-601-3450 Adapter for BENDIX (MS) 5 MS-5P q
799-601-3460 Adapter for BENDIX (MS) 10 MS-10P q
799-601-3510 Adapter for BENDIX (MS) 5 MS-5S q
799-601-3520 Adapter for BENDIX (MS) 17 MS-17P q
799-601-3530 Adapter for BENDIX (MS) 19 MS-19P q
799-601-2910 Adapter for BENDIX (MS) 14 MS-14P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2760 Adapter for ECONO 3 ECONO3P q q
799-601-2770 Adapter for ECONO 4 ECONO4P q q
799-601-2780 Adapter for ECONO 8 ECONO8P q q
ECONO12
799-601-2790 Adapter for ECONO 12
P
q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2820 Adapter for DLI 12 DLI-12P q q
799-601-2830 Adapter for DLI 16 DLI-16P q q
ECONO12
799-601-2840 Extension cable (ECONO type) 12
P
q q q
799-601-2850 Case q
799-601-4350 T-box(for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7030 Adapter for X 3 X3P q q q q
799-601-7040 Adapter for X 4 X4P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 - q q
799-601-7090 Adapter for M 2 M2P q q q q
799-601-7110 Adapter for M 3 M3P q q q q
799-601-7120 Adapter for M 4 M4P q q q q
799-601-7130 Adapter for M 6 M6P q q q q
799-601-7340 Adapter for M 8 M8P q

D375A-6R 40-93
(01)
General information on troubleshooting
T-branch box and T-branch adapter table

T-adapter kit

Number of pins

799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identificati
Part number Part name
on symbol

799-601-7140 Adapter for M 8 S8P q q q q


799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 - q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 - q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9220 Adapter for HD30-18 14 D18-14 q q
799-601-9230 Adapter for HD30-18 20 D18-20 q q
799-601-9240 Adapter for HD30-18 21 D18-21 q q
799-601-9250 Adapter for HD30-24 9 D24-9 q q
799-601-9260 Adapter for HD30-24 16 D24-16 q q
799-601-9270 Adapter for HD30-24 21 D24-21 q q
799-601-9280 Adapter for HD30-24 23 D24-23 q q
799-601-9290 Adapter for HD30-24 31 D24-31 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box(for ECONO) 24 q q q
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430*
Socket for engine(CRI-T3) PCV
2 P q q

40-94 D375A-6R
(01)
General information on troubleshooting
T-branch box and T-branch adapter table

T-adapter kit

Number of pins

799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identificati
Part number Part name
on symbol

799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q


795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540*
Socket for engine(CRI-T3) TIM
2 A q q
795-799-5460 Cable for engine (HPI-T2) 3 - q
795-799-5470 Cable for engine (HPI-T2) 3 - q
795-799-5480 Cable for engine (HPI-T2) 3 - q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE,CAM 3 FCIN q q
Adapter for engine (CRI-T3)
799-601-4140
Atomosphere pressure
3 FCIG q q
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
Adapter for engine (CRI-T3)
799-601-4160
Oil pressure switch
2 4160 q q
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
Socket for engine (CRI-T3)
799-601-4190*
Common rail pressure
3 1,2,3L q q
Socket for engine (CRI-T3)
799-601-4230*
Air intake pressure/temperature
4 1,2,3,4C q q
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
Socket for engine (CRI-T3)
799-601-4340*
Pump actuator
2 2,PA q q
Socket for engine (CRI-T3)(95)
799-601-4380*
Air intake pressure/temperature
4 1,2,3,4T q
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 - q
799-601-4280* Box for controller (PUMP) 121 - q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
799-601-9890 Multi-adapter for DT2 4 andDTM2 3, - q
4
"*" Shows not T-adapter but socket.

D375A-6R 40-95
(01)
General information on troubleshooting
Connector list and layout

Connector list and layout 40-96

Connector Connector Number Connector Connector Number


Location Address Location Address
No. type of pins No. type of pins
Intermediate Additional
19 DT 4 F-1
connector ADH2 Relay 5 power supply W-7
Intermediate 2 relay
20 DTHD 1 X-8
connector Intermediate
ADHA DT 4 U-4
Intermediate connector
21 DTHD 1 X-8
connector Air cleaner
Intermediate AF1 DT 2 clogging C-1
241 DT 6 B-7
connector switch
Intermediate Alternator B
241 DT 6 - ALB Terminal 1 AG-1
connector terminal
Starting Alternator R
ALR Terminal 1 AG-1
250 Terminal 1 switch B ter- N-2 terminal
minal Air suspen-
Starting ASUS DT 2 sion seat (if U-6
255 Terminal 1 switch R1 ter- N-1 equipped)
minal AT11 - 1 GPS antenna -
Starting Circuit
256 Terminal 1 switch R2 ter- N-1 B105L Terminal 1 breaker L-5
minal (105A)
Starting Circuit
260 Terminal 1 N-1
switch BR B105S Terminal 1 breaker L-4
Starting (105A)
270 Terminal 1 switch ACC N-2 Circuit
B30L Terminal 1 K-5
terminal breaker (30A)
Starting Circuit
B30S Terminal 1 K-4
280 Terminal 1 switchC ter- N-2 breaker (30A)
minal Circuit
B7L Terminal 1 K-5
Power train breaker (30A)
453 DT 2 oil tempera- AB-3 Circuit
B7S Terminal 1 J-4
ture sensor breaker (30A)
Standby elec- Circuit
800 Plug 1 tric power U-8 BH1L Terminal 1 breaker K-5
supply (105A)
Standby elec- Circuit
810 Plug 1 tric power X-9 BH2S Terminal 1 breaker K-4
supply (105A)
12S1 YAZAKI 2 12 V socket 1 U-5 Backup alarm
BKA Relay 5 U-7
relay
12S2 YAZAKI 2 12 V socket 2 U-5 BKAL DT 2 Backup alarm J-8
Intermediate Blade
12VS DT 3 X-9
connector LOWER oil
BLD DT 2 P-9
Air condi- pressure
AC1 MIC 17 N-4
tioner unit switch
Air condi- Blade RAISE
AC2 AMP 16 tioner control N-5 BLU DT 2 oil pressure P-9
panel switch
Air condi- Battery relay
BRB Terminal 1 J-2
AC3 AMP 12 tioner control N-5 1
panel Battery relay
BRB Terminal 1 L-3
Diode 2
ACS DT 2 AH-1
(surge-killer) Battery relay
BRC Terminal 1 K-3
ACC cutout 1
ACT Relay 5 V-6
relay Battery relay
BRC Terminal 1 L-3
Additional 2
ADH SWP 6 heater switch O-6 Battery relay
BRE Terminal 1 J-1
(if equipped) 1
Additional Battery relay
BRE Terminal 1 L-1
ADH1 Relay 5 power supply W-7 2
1 relay

40-96 D375A-6R
(01)
General information on troubleshooting
Connector list and layout

Connector Connector Number Connector Connector Number


Location Address Location Address
No. type of pins No. type of pins
Brake potenti- Right door
BRK DT 3 Q-1 CN-17 - 4 E-9
ometer wiper motor
Intermediate Left door
CN-18 - 4 F-9
connector wiper motor
BSW DT 3 (one-way - Washer sys-
CN-19 - 4 F-1
type model) tem harness
(if equipped) CN2 DT 2 Injector #2 AF-4
Circuit Rear speaker
CB1 - 1 W-6 CN-2 - 1 C-9
breaker (20A) (right)
Circuit ACC power
CN-20 - 1 X-8
CB105 - 1 breaker L-4 supply
(105A) Battery power
CN-21 - 1 X-8
Circuit supply
CB2 - 1 W-5 Cigarette
breaker (20A)
Circuit CN-22 - 2 lighter power I-9
CB3 - 1 W-5
breaker (20A) port
Circuit Front lamp
CB30 - 1 K-4 CN-23 - 2 switch (if B-9
breaker (30A)
Circuit equipped)
CB4 - 1 W-5 Revolving
breaker (20A)
Circuit CN-25 - 2 warning lamp B-9
CB40 - 1 breaker (40A) - (if equipped)
(if equipped) Revolving
Circuit warning lamp
CB5 - 1 W-5 CN-26 - 2 B-9
breaker (20A) switch (if
Circuit equipped)
CB6 - 1 W-5
breaker (20A) CN3 DT 2 Injector #3 AG-5
Circuit Rear speaker
CB7 - 1 J-4 CN-3 - 1 C-9
breaker (30A) (right)
Circuit Glass heat-
CN-34 - 4 -
CBH1 - 1 breaker K-5 ing wire relay
(105A) CN4 DT 2 Injector #4 AH-5
Machine Rear window
CM01 070 18 N-6 CN-4 - 4 C-9
monitor wiper motor
Machine CN5 DT 2 Injector #5 AI-5
CM02 070 12 N-5 Rear speaker
monitor CN-5 - 1 C-8
Machine (left)
CM03 070 18 - CN6 DT 2 Injector #6 AI-5
monitor
Machine Rear speaker
CM04 070 12 - CN-6 - 1 C-8
monitor (left)
Machine Glass with
CM05 MITSUMI 8 - heating wire
monitor CN-6_1 - 1 -
CN1 DT 2 Injector #1 AF-4 (machin with
Additional EU spec.)
CN-1 - 1 light (if B-9 Glass with
equipped) heating wire
CN-6_2 - 1 -
CN-10 - 9 Radio G-9 (machin with
Left wiper EU spec.)
CN-11 - 6 A-9
switch CN-81 - 2 Room lamp E-9
Front wiper Front wiper
CN-12 - 6 A-9 CN-9 - 6 D-8
switch motor
12 V power Headlamp
CN-12V - 3 - CN-AL1 - 2 -
supply (left)
12 V power Headlamp
CN-12VS - 3 X-9 CN-AL2 - 2 -
supply (right)
Right wiper Headlamp
CN-13 - 6 A-9 CN-AL3 - 2 -
switch (left rear)
Rear wiper Headlamp
CN-14 - 6 A-9 CN-AL4 - 2 -
switch (right rear)
Rear lamp Back-up lamp
CN-AL5 - 2 -
CN-15 - 2 switch (if B-9 (left)
equipped)

D375A-6R 40-97
(01)
General information on troubleshooting
Connector list and layout

Connector Connector Number Connector Connector Number


Location Address Location Address
No. type of pins No. type of pins
Back-up lamp Engine con-
CN-AL6 - 2 - ENG DRC26-60 60 AJ-2
(right) troller
CN-SM1 - 5 - EPP DT 6 (Spare) C-1
CONV DT 6 Converter S-1 Intermediate
CAN termi- ES2 DT 2 connector E-9
CT2 DT 3 nating resis- AJ-2 (male)
tor Service con-
ESD DT 3 T-2
CAN termi- nector
CTV DT 3 nating resis- W-2 Exhaust gas
tor temperature
EXAF DT 3 X-3
Deceleration sensor, front
DEC DT 3 Q-1
potentiometer amp
Fuel control Exhaust gas
DIAL M 3 S-8
dial temperature
EXAR DT 3 V-3
VHMS down- sensor, rear
DL1 BENDIX 5 load connec- K-9 amp
tor Exhaust gas
Download EXHF DT 2 temperature AE-8
DLSW Terminal 4 K-8
switch sensor (front)
VHMS down- Exhaust gas
DLT DT 2 K-9
load light EXHR DT 2 temperature AF-9
Emergency sensor (rear)
evacuation Exhaust gas
DPNL - 2 system cir- AC-1 temperature
EXTF DT 2 X-3
cuit (C/B sensor, front
model) amp
Intermediate Exhaust gas
DS1 DT-B 12 N-4
connector temperature
Intermediate EXTR DT 2 V-2
DS2 DT-C 12 N-3 sensor, rear
connector amp
Intermediate 1st clutch
DS3 DT-A 12 N-4
connector F1T DT 2 ECMV (fill Z-9
Intermediate switch)
DS4 DT-D 12 N-3
connector 2nd clutch
Intermediate F2T DT 2 ECMV (fill Y-8
DS5 DT-B 12 N-3
connector switch)
Alternator E 3rd clutch
E Terminal 1 AG-1
terminal F3T DT 2 ECMV (fill Y-8
Intermediate switch)
E22 DT-A 12 AJ-2
connector Intermediate
Electric prim- F40 DTHD 1 connector (if -
EFP DT 2 AI-1
ing pump equipped)
Intermediate Fan pump
EG1 DTP04-2P 2 AJ-3
connector FA1 DT 2 (LPV90) sole- Y-5
Intermediate noid valve
EG2 DT-B 12 AJ-3
connector Fan pump
Intermediate FA2 DT 2 (LPV30) sole- AA-7
EG3 DT 4 AJ-3
connector noid valve
Intermediate Fan reverse
EG4 DT-A 12 C-7
connector FAR2 DT 2 solenoid A-3
Intermediate valve
EG5 DT 4 C-8
connector Intermediate
Intermediate FD1 24-31 31 J-5
EG6 DT 6 C-7 connector
connector Intermediate
DRC26-50S Engine con- FD1 24-31 31 -
EGC2 50 AJ-3 connector
04 troller Intermediate
Engine con- FD2 DT-A 12 K-7
EGC3 DTP06-4S 4 AJ-2 connector
troller Intermediate
Engine hold- FD5 DT-B 12 T-2
EHL Relay 5 W-7 connector
ing relay Air condi-
Blow-by pres- FEN DT 2 tioner com- AH-1
ENBP DT 3 AI-1
sure sensor pressor

40-98 D375A-6R
(01)
General information on troubleshooting
Connector list and layout

Connector Connector Number Connector Connector Number


Location Address Location Address
No. type of pins No. type of pins
Forward Ground
GND05 Terminal 1 H-2
FFT DT 2 clutch ECMV AA-9 (fender)
(fill switch) GND06 Terminal 1 Ground (floor) S-1
Fuel level GND07 Terminal 1 Ground A-5
FGS DT 2 K-6
gauge Ground
GND0A Terminal 1 A-6
Left steering (lamp)
FLB DT 2 brake ECMV AD-5 Ground
GND0B Terminal 1 H-2
(fill switch) (fender)
Left steering GND1 Terminal 1 Ground (cab) B-8
FLC DT 2 clutch ECMV AB-8 Ground
GND11 Terminal 1 AJ-2
(fill switch) (engine)
Front lamp GND2 Terminal 1 Ground (cab) B-8
FLSW SWP 6 O-7 Additional
switch H01 - 1 R-8
Torque con- heater PW1
verter lockup Additional
H02 - 1 R-8
FLUC DT 2 clutch right Y-4 heater PW2
ECMV (fill Hydraulic oil
switch) HDT DT 2 temperature AA-7
Right steer- sensor
ing brake Hydraulic oil
FRB DT 2 AD-6 HHP DT 3 pump pres- D-8
ECMV (fill
switch) sure sensor
Right steer- Intermediate
ing clutch HLS DT 2 connector E-9
FRC DT 2 AB-7 (female)
ECMV (fill
switch) Hydraulic oil
Reverse HLS DT 2 level sensor C-2
FRT DT 2 clutch ECMV Z-9 (if equipped)
(fill switch) HNSW DT 2 Horn switch Q-8
FR lever (if HRN - Horn A-3
FRTS Terminal 6 - Preheater
equipped) HT Terminal 1 C-8
Fan reverse relay
FRV DT 2 A-3 Preheater
sensor HT/A Terminal 1 E-1
Fuse box relay
FS11 - 5 V-9 Preheater
(inlet) HT/B Terminal 1 E-1
Fuse box relay
FS12 - 5 V-9 Diode
(outlet) HTD DT 2 I-3
Fuse box (surge-killer)
FS21 - 5 V-9 Intermediate
(inlet)
Fuse box connector
FS22 - 5 V-9 INJ DT 12 AJ-5
(outlet) (Injectors #1 -
Fuse box #6)
FS31 - 5 W-9 Intake tem-
(inlet)
Fuse box INT DT 2 perature sen- B-2
FS32 - 5 W-9 sor
(outlet)
Intermediate Service con-
FSB 24-31 31 M-8 J1939 DT 3 nector AG-5
connector
Torque con- (engine)
verter stator JB1 - - Junction box AF-4
FSTC DT 2 clutch left Y-5 Starting
KEY DT 6 N-6
ECMV (fill switch
switch) Communica-
KOM1 DRC26-40A 40 P-7
Intermediate tion terminal
FTS - 3 connector (if R-1 KOM2 - 1 GPS antenna Q-8
equipped) Communica-
Engine Bkup KOM3 - 1 tion terminal Q-8
G DT 3 speed (G) AJ-4 antenna
sensor Intermediate
LHD DT 4 A-3
GND - 1 Ground E-1 connector
GND01 - 1 Ground N-7 Left head-
LHDL DT 2 A-2
GND02 - 1 Ground N-7 lamp
GND03 - 1 Ground N-7

D375A-6R 40-99
(01)
General information on troubleshooting
Connector list and layout

Connector Connector Number Connector Connector Number


Location Address Location Address
No. type of pins No. type of pins
Left head- Engine com-
lamp (addi- partment
OPT Relay 5 W-7
tional lamp relay (if
LHDL1 DT 2 -
headlamp equipped)
model) (if Intermediate
P03 DT 6 P-7
equipped) connector
Right head- Ambient pres-
LHDR DT 2 A-5 PAMB AMP 3 AJ-3
lamp sure sensor
Right head- SUMI- Supply pump
PCV1 2 AJ-4
lamp (addi- TOMO #1
tional SUMI- Supply pump
LHDR1 DT 2 - PCV2 2 AJ-4
headlamp TOMO #2
model) (if Common rail
equipped) PFUEL AMP 3 pressure sen- AH-5
Diode sor
LMD1 DT 2 O-1 Preheater
(surge-killer) PHR Relay 5 X-7
Diode relay
LMD2 DT 2 O-1 SUMI- Boost pres-
(surge-killer) PIM 3 AJ-4
Left head- TOMO sure sensor
LMFL Relay 5 U-8 Intermediate
lamp relay PL1 24-23 23 AD-6
Right head- connector
LMFR Relay 5 V-6 Emergency
lamp relay
Back-up lamp evacuation
LMRE Relay 5 W-6
relay PL1F 24-23 23 system cir- AD-1
Working lamp cuit (C/B
LMW Relay 5 X-8
relay model)
Left back-up Emergency
LREL DT 2 K-6
lamp (70W) evacuation
Right back-up PL1M 24-23 23 system cir- AD-1
LRER DT 2 F-9
lamp (70W) cuit (C/B
Ripper point model)
LRP DT 2 lamp (70W) (if - Intermediate
PL2 24-31 31 AD-7
equipped) connector
Intermediate Emergency
LRR DT 3 H-9
connector evacuation
Left working PL2 24-31 31 system cir- AD-1
LWKL DT 2 F-1
lamp (70W) cuit (C/B
Right work- model)
LWKR DT 2 ing lamp A-6 Intermediate
PL3 24-31 31 A-6
(70W) connector
Air condi- Intermediate
tioner control- connector
M26 DT 6 P-1 PLB DT 2 C-1
ler (cab (pre-lubrica-
model) tion system)
Intermediate Diode
PLS DT 2 I-3
connector (surge-killer)
MMS DT-C 12 W-4
(MMS device Pin puller
PLSW DT 2 Q-8
(if equipeed)) switch
FRAMA- Engine Ne Pre-lubrica-
NE 3 AJ-3 PLUB Relay 5 U-7
TONE speed sensor tion relay
Neutral safety Pre-lubrica-
NSF Relay 5 X-8
relay PM1 Terminal 1 tion motor (if -
Parking brake equipped)
NSW DT 3 T-2
lever switch Emergency
Intermediate evacuation
OBC DT-A 12 R-8
connector PNL 24-31 31 system cir- AB-3
Engine oil cuit (C/B
OLV DT 2 level switch (if AI-1 model)
equipped) Engine oil
Option switch FRAMA-
POIL 3 pressure sen- AI-1
OPSW SWP 6 O-6 TONE
(if equipped) sor

40-100 D375A-6R
(01)
General information on troubleshooting
Connector list and layout

Connector Connector Number Connector Connector Number


Location Address Location Address
No. type of pins No. type of pins
Pre-lubrica- Ripper tilt in
tion oil pres- RTI DT 2 oil pressure P-8
POP Terminal 1 AH-1
sure switch (if switch
equipped) Intermediate
Pin puller RTS - 3 connector (if R-1
PPL DT 2 solenoid I-9 equipped)
valve 1st clutch
Pre-lubrica- S1T DT 2 ECMV (sole- Y-9
PR1 Terminal 1 tion relay (if - noid valve)
equipped) 2nd clutch
Pre-lubrica- S2T DT 2 ECMV (sole- Y-7
PR2 Terminal 1 tion relay (if - noid valve)
equipped) 3rd clutch
Pre-lubrica- S3T DT 2 ECMV (sole- Y-8
PR3 Terminal 1 tion relay (if - noid valve)
equipped) Forward
Pre-lubrica- clutch ECMV
SFT DT 2 Z-7
PR4 Terminal 1 tion relay (if - (solenoid
equipped) valve)
Pre-lubrica- Shift down
SFTD - 3 R-1
PRE DT 2 tion connec- D-8 switch
tor Shift down
SFTU - 3 R-1
Intermediate switch
PRT1 DT-A 12 M-2
connector Left steering
Intermediate brake ECMV
PRT2 DT 4 D-1 SLB DT 2 AD-5
connector (solenoid
Intermediate valve)
PRT3 DT 2 M-2
connector Left steering
Pitch angle clutch ECMV
PT1 DT 3 D-1 SLC DT 2 AB-8
sensor (solenoid
Power train valve)
PTCN1 DRC26-24A 24 U-6
controller Torque con-
Power train verter lockup
PTCN2 DRC26-40A 40 U-6
controller SLUC DT 2 clutch right Y-4
Power train ECMV (sole-
PTCN3 DRC26-40B 40 T-7
controller noid valve)
Intermediate BG shift
PWR DTHD 1 U-3
connector switch
Intermediate SNC DT 6 (one-way S-7
RB1 DT 6 D-8
connector type model)
Intermediate (if equipped)
RDG DT-B 12 A-5
connector Solenoid
RES DT 2 Resistor AI-1 SOL1 DT 2 valve for D-8
Rear lamp pitching
RLSW SWP 6 O-7
switch Dual-tilt sys-
Ripper lower SOL2 DT 2 tem solenoid D-8
RPD DT 2 oil pressure O-8 valve
switch Right steer-
Emergency ing brake
evacuation SRB DT 2 AD-5
ECMV (sole-
RPNL - 2 system cir- AD-3 noid valve)
cuit (C/B Right steer-
model) ing clutch
Ripper raise SRC DT 2 AB-8
ECMV (sole-
RPU DT 2 oil pressure P-8 noid valve)
switch Reverse
Diode (BR clutch ECMV
RSD DT 2 hold J-4 SRT DT 2 Y-8
(solenoid
(backup)) valve)
Ripper tilt KOMNET ser-
RTB DT 2 back oil pres- P-8 SRV DT-A 12 vice connec- P-1
sure switch tor

D375A-6R 40-101
(01)
General information on troubleshooting
Connector list and layout

Connector Connector Number Connector Connector Number


Location Address Location Address
No. type of pins No. type of pins
Acceleration Data writing
sensor (dedi- connector
SSA DT 4 E-1
cate SSC TMF X 4 (work equip- T-7
model option) ment control-
Torque con- ler)
verter stator Transmission
SSTC DT 2 clutch left Y-5 main oil pres-
ECMV (sole- sure sensor
TMMD DT 3 Z-7
noid valve) (VHMS instal-
Starting motor lation model
ST/B1 Terminal 1 AE-6
A only)
Starting motor Intermediate
ST/B2 Terminal 1 AE-5 TMV 24-23 23 AA-7
B connector
Starting motor Engine oil
ST1 DT 2 AG-5
A (top) TOIL PACKARD 2 temperature AJ-2
Starting motor sensor
ST2 DT 2 AG-5
B (bottom) Torque con-
Sudden stop verter outlet
TOP DT 3 AB-3
prevention pressure sen-
STB DT 2 AC-8
solenoid sor
valve Main power
Data writing TR1L - 1 K-3
terminal
connector Main power
STF X 4 T-7 TR1S - 1 K-3
(S/T control- terminal
ler) Main power
TR2L - 1 -
Battery relay terminal 2
SW Terminal 1 K-1
1 Main power
TR2L - 1 K-3
Battery relay terminal
SW Terminal 1 L-1
2 Main power
TR2S - 1 -
Ground terminal 2
SX-8 Terminal 1 F-1
(fender) Right oil pres-
Torque con- sure switch
TRS DT 2 P-9
TC1 DT 2 verter output AC-7 for tilting
speed sensor blade
Fuel tempera- Coolant tem-
TFUEL PACKARD 2 AG-1
ture sensor TWTR PACKARD 2 perature sen- AE-7
Boost tem- sor
TIM PACKARD 2 perature sen- AI-5 Intermediate
USB DTHD 1 U-3
sor connector
Torque con- VHMS con-
V1 070 20 V-2
verter inlet troller
TIP DT 3 Y-6
pressure sen- VHMS con-
V2A 070 18 W-2
sor troller
Intermediate VHMS con-
TL1 24-31 31 M-9,U-5 V2B 070 12 X-2
connector troller
Intermediate VHMS con-
TL2 DT-B 8 T-7 V3A 070 18 W-2
connector troller
Intermediate VHMS con-
TL3 DT 6 T-7 V3B 070 12 W-2
connector troller
(one-way VHMS con-
V4A 070 14 X-2
TL3 DT 6 type model) T-7 troller
(if equipped) VHMS con-
V4B 070 10 W-2
Left oil pres- troller
sure switch Intermediate
TLS DT 2 P-9 VDA DT-D 12 L-9
for tilting connector
blade Intermediate
VDB DT-B 12 K-7
Transmission connector
outlet shaft Intermediate
VDC DT-D 12 I-3
speed sensor connector
TM1 DT 2 AD-7 VHMS down-
(VHMS instal-
lation model VDW BENDIX 5 load connec- S-2
only) tor

40-102 D375A-6R
(01)
General information on troubleshooting
Connector list and layout

Connector Connector Number


Location Address
No. type of pins
Intermediate
VED DT-C 12 K-6
connector
Intermediate
VEG DT-C 12 AJ-3
connector
Intermediate
VF1 DT-B 12 V-3
connector
Intermediate
VF2 24-31 31 U-4,V-2
connector
Work equip-
WECN1 DRC26-24A 24 ment control- T-7
ler
Work equip-
WECN2 DRC26-40A 40 ment control- S-8
ler
Work equip-
WECN3 DRC26-40B 40 ment control- S-8
ler
WE lock
WELK DT 3 P-7
switch
Coolant level
WLD DT 2 A-3
sensor
Washer tank
WSFR YAZAKI 2 J-5
(front)
Washer tank
WSLH YAZAKI 2 J-5
(left)
Washer tank
WSRH YAZAKI 2 J-4
(right)
Washer tank
WSRR YAZAKI 2 J-5
(rear)
Rear view
TAJIMI camera (if -
equipped)

D375A-6R 40-103
(01)
General information on troubleshooting
Connector list and layout

40-104 D375A-6R
(01)
General information on troubleshooting
Connector list and layout

D375A-6R 40-105
(01)
General information on troubleshooting
Connector list and layout

40-106 D375A-6R
(01)
General information on troubleshooting
Connector list and layout

D375A-6R 40-107
(01)
General information on troubleshooting
Connector list and layout

40-108 D375A-6R
(01)
General information on troubleshooting
Connector list and layout

D375A-6R 40-109
(01)
General information on troubleshooting
Fuse locations table

Fuse locations table 40-1 0


Connection table of circuit breakers and fuse boxes 40-1 0
a This connection table shows the devices to which each power supply of the circuit breakers and fuse box
supplies power (An accessory power supply is a device which supplies power while the starting switch is
in ON position and an unswitched power supply is a device which supplies power while the starting switch
is in OFF and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the circuit breakers
and fuses to see if the power is supplied normally.

Mounting location of circuit breakers (1) - (4) 40-1 0

Mounting location of circuit breakers (5) to (10) 40-1 0

40-110 D375A-6R
(01)
General information on troubleshooting
Fuse locations table

Circuit breakers CB1CB7, CB30, CB105 and CBH1


Power breaker Circuit
Capacity (A) Destination of power
(Power supply type) breaker No.
1 (Main power supply) 105 CB105 Main power supply
2 (Unswitched power supply) 30 CB30 Unswitched power supply
3 (Main power supply) 105 CBH1 Preheater relay
Engine controller unswitched power supply
4 (Unswitched power supply) 30 CB7
Power supply of electric priming pump timer
CB105
5 20 CB1 Power train controller
(Main power supply)
Starting switch
6 20 CB2 Machine monitor (ACC)
(ACC)
7 20 CB3 Work equipment controller
CB105
8 20 CB4 Air conditioner
(Main power supply)
9 20 CB5 Headlamp
CB30
10 20 CB6 Unswitched power supply of starting switch
(Unswitched power supply)
a Resetting circuit breakers (1) (4)
Turn starting switch to OFF position, and press RESET button 5 - 10 minutes after power-off. If electrical
circuit is open, the RESET button is heavy to operate when compared with normal operation. The RESET
button has the same height when electrical circuit is open and when breakers are reset. Therefore, you
can determine the condition by checking the return force.
Do not hold down the RESET button too long.
a Resetting circuit breakers (5) (10)
Turn starting switch to OFF position, and press protruded RESET button (11). If RESET button is
protruded again, perform troubleshooting and repair defect.

D375A-6R 40-111
(01)
General information on troubleshooting
Fuse locations table

Mounting location of fuse boxes FS11 to FS31 40-1 2

Mounting location of fuse box (Cab top end) 40-1 2

40-112 D375A-6R
(01)
General information on troubleshooting
Fuse locations table

Fuse box FS11


Power breaker Fuse capacity
Destination of power
(Power supply type) (A)
1 CB105 (Main power supply) 20 VHMS controller power supply
Unswitched power supply of VHMS, power train, and work
2 20
CB30 (Unswitched power equipment controllers
3 supply) 20 Unswitched power supply of cab
4 10 12V converter unswitched power supply
5 CB105 (Main power supply) 20 12V converter power supply
Fuse box FS21
Power breaker Fuse capacity
Destination of power
(Power supply type) (A)
1 5 Backup alarm
2 20 Pin puller, preheater, air suspension seats
3 CB105 (Main power supply) 20 Additional heater
4 20 Working lamp
5 20 Rear lamp
Fuse box FS31
Power breaker Fuse capacity
Destination of power
(Power supply type) (A)
1 Starting switch (ACC) 5 ACC for engine controller
2 5 Horn
3 CB105 (Main power supply) 20 Spare power supply (1)
4 20 Spare power supply (2)
5 Starting switch (ACC) 20 Spare ACC signal
Fuse box (Cab top end)
Power breaker Fuse capacity
Destination of power
(Power supply type) (A)
1 10 Radio, cigarette lighter, room lamp
2 10 Rear wiper
3 15 Rear wiper
4 10 Front wiper
5 CB105 (Main power supply) 15 Left wiper
6 20 Additional back-up lamp
7 20 Additional headlamp, revolving warning lamp
8 20 Glass with heating wire
9 - Spare
CB30 (Unswitched power
10 10 Radio memory
supply)

D375A-6R 40-113
(01)
Troubleshooting by failurecode
Failure code [1380MW] Lock up clutch: Slip

Troubleshooting by failurecode 40-1 4


Failure code [1380MW] Lock up clutch: Slip 40-1 4
Action code Failure code Lockup clutch slip
Failure
(Power train controller system)
1380MW
q When torque converter is locked up, sensed engine speed does not match with sensed torque con-
Detail of failure
verter output speed.
Action of con-
q None in particular.
troller
Problem on
q None in particular.
machine
q Engine speed and torque converter speed can be checked with monitoring function.
Related infor- Code: 01002 Engine speed
mation (Code 31200: Transmission input speed (Torque converter output speed))
q Method of reproducing failure code: Start engine, turn lockup clutch ON and drive machine.

Cause Procedure, measuring location, criteria and remarks


Lockup clutch slip(When system is
1 Check for cause of lockup clutch slip and damage of machine.
normal)
Defective engine speed sensor
2 If failure code[CA689] or [CA778] is displayed, carry out troubleshooting for it.
system
Defective torque converter speed
3 If failure code [DLF1KA] is displayed, carry out troubleshooting for it.
sensor

4 Defective power train controller Since failure is in it, troubleshooting cannot be carried out.

40-114 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [1500L0] Transmission clutch: Abnormal

Failure code [1500L0] Transmission clutch: Abnormal 40-1 5


Action code Failure code Transmission clutch: Abnormal
Failure
(Power train controller system)
E03 1500L0
q Among failure codes related to transmission clutch, following codes occurred at the same time
(Gear speed limit).
(1) Either of [DXH4KA] and [DXH4KB], and either of [DXH5KA] and [DXH5KB].
q Among failure codes related to transmission clutch, following codes occurred at the same time
(Travel trouble).
(2) Either of [DXH8KA] and [DXH8KB] , and either of [DXH7KA] and [DXH7KB].
(3) Either of [DXH6KA] and [DXH6KB], and either of [DXH5KA] and [DXH5KB], and either of
Detail of failure
[DXH4KA] and [DXH4KB]
(4)[15SALH] and [15SBLH]
(5) Either of [15SAL1] and [DXH8KY], and either of [15SBL1] and [DXH7KY]
(6) [15SELH] and [15SFLH] and [15SGLH]
(7) Either of [15SEL1] and [DXH4KY], and either of [15SFL1] and [DXH5KY]
(8) Either of [15SEL1] and [DXH4KY], and either of [15SGL1] and [DXH6KY]
(9) Either of [15SFL1] and [DXH5KY], and either of [15SGL1] and [DXH6KY]

Action of controller q Limits operation of engine and transmission.

q The auto shift down function does not start.


Problem on machine q Once machine is stopped, engine speed is limited to medium (half) speed.
q Once machine is stopped, it can travel only by the minimum gear speed which can operate.
Related information q Method of reproducing failure code: Engine start + Run

Cause Procedure, measuring location, criteria and remarks


If another failure code is displayed, carry out troubleshooting for it.
[15SAL1], [15SALH], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1], [15SFLH], [15SGL1], [15SGLH]
[DXH4KA], [DXH4KB], [DXH5KA], [DXH5KB], [DXH6KA], [DXH6KB], [DXH7KA], [DXH7KB], [DXH8KA], [DXH8KB],
[DXH4KY], [DXH5KY], [DXH6KY], [DXH7KY], [DXH8KY]

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

Failure code [15E0MW] Transmission clutch: Slip 40-1 6


Action code Failure code Transmission clutch slip
Failure
(Power train controller system)
15E0MW
Detail of failure q Sensed torque converter output speed does not match with sensed transmission output speed.
Action of con-
q None in particular.
troller
Problem on
q None in particular.
machine
q Torque converter speed and transmission speed can be checked with monitoring function.
Related infor- (Code 31200: Transmission input speed (Torque converter output speed))
mation (Code 31400: Transmission output speed)
q Method of reproducing failure code: Start engine and drive machine.

Cause Procedure, measuring location, criteria and remarks


Transmission clutch slip (When
1 Check for cause of transmission clutch slip and damage of machine.
system is normal)
Defective torque converter speed Check if failure code [DLF1KA] is displayed
2
sensor Carry out troubleshooting for it.
Defective transmission speed sen- Check if failure code [DLT3KA], [DLT3KB] is displayed
3
sor Carry out troubleshooting for it.
4 Defective power train controller Since failure is in it, troubleshooting cannot be carried out.

40-116 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [15E0MW] Transmission clutch: Slip

D375A-6R 40-117
(01)
Troubleshooting by failurecode
Failure code [15SAL1] Forward clutch: Fill high

Failure code [15SAL1] Forward clutch: Fill high 40-1 8


Action code Failure code Forward clutch fill dwitch signal is ON.
Failure
(Power train controller system)
E03 15SAL1
q Nevertheless controller does not output command current to transmission F clutch ECMV solenoid
Detail of failure
circuit, fill switch signal is ON.
q Sets transmission to neutral when operator sets it to reverse position (Prevention of double en-
Action of con-
gagement).
troller
q Limits operation of engine and transmission.
q Once machine is stopped, engine speed is limited to medium (half) speed.
Problem on
q Once machine is stopped, travel is limited to F1.
machine
q Automatic gear shifting function does not operate.
q State (ON/OFF) of F clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 40906 T/M Fill Sw Input 1)
q Method of reproducing failure code: Start engine and set PCCS lever in neutral position.
Related infor-
q Remove seat (approx. 50 kg) and seat bottom cover.
mation
q First, check power train oil filter for clogging etc.
q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power
train oil pressure".

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective F clutch ECMV fill 2. Disconnect connector FFT and connect T-adapter to male side.
1
switch (Internal short circuit) Between FFT (female) (1) and ground
Resistance Min. 1 Mz
(Fill switch OFF)
1. Turn starting switch to OFF position.
2. Disconnect connector FFT.
Ground fault in wiring harness or 3. Start engine.
2
defective power train controller If failure code [15SAL1] is still displayed, there is ground fault in wiring harness
or power train controller is defective.
(If failure code [15SAL1] is not displayed, F clutch fill switch is defective)
a If cause 2 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors PTCN2 and FFT, and connect T-adapter to female
3 side of either of them.
(Contact with ground circuit)
Between PTCN2 (female) (5) or FFT (female)
Resistance Min. 1 Mz
(1) and ground
If "check result of cause 2 is abnormal" and "check result of cause 3 is normal",
power train controller is defective.
q Reference; the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
3. Start engine.
4 Defective power train controller a Keep PCCS lever in N position.
Between PTCN2 (5) and ground Voltage 711 V
1 3 are same as above.
4. While depressing brake pedal, operate PCCS lever (to select gear speed)
and perform troubleshooting.
Between PTCN2 (5) and
F1/F2/F3 Voltage Max. 1 V
ground

40-118 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [15SAL1] Forward clutch: Fill high

Circuit diagram related to forward clutch ECMV 40-1 9

D375A-6R 40-119
(01)
Troubleshooting by failurecode
Failure code [15SALH] Forward clutch: Fill Low

Failure code [15SALH] Forward clutch: Fill Low 40-120


Action code Failure code Forward clutch fill switch signal is OFF.
Failure
(Power train controller system)
E03 15SALH
q Nevertheless controller outputs command current to transmission F clutch ECMV solenoid circuit,
Detail of failure
fill switch signal is turned OFF.
q Sets transmission to neutral when operator sets it to forward position (Prevention of defective en-
Action of con-
gagement).
troller
q Limits operation of engine and transmission.
q Once machine is stopped, engine speed is limited to medium (half) speed.
Problem on
q Once machine is stopped, travel is limited to R1.
machine
q Automatic gear shifting function does not operate.
q State (ON/OFF) of F clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 40906 T/M Fill Sw Input 1)
q Method of reproducing failure code: Start engine and set PCCS lever in forward position.
Related infor-
q Remove seat (approx. 50 kg) and seat bottom cover.
mation
q First, check power train oil filter for clogging etc.
q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power
train oil pressure".

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector FFT and connect T-adapter to male side.
3. Start engine.
a Keep PCCS lever in N position.
Defective F clutch ECMV fill Between FFT (male) (1) and ground Resistance Min. 1 Mz
1
switch (It does not turn ON) 1 3 are same as above.
4. While depressing brake pedal, operate PCCS lever (gear speed) and per-
form troubleshooting.
Between FFT (male) (1) and
F1/F2/F3 Resistance Max. 1 z
ground
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN2 and FFT, and connect T-adapters to female
Open circuit in wiring harness
2 side of them.
(open circuit or defective contact)
Between PTCN2 (female) (5) and FFT
Resistance Max. 1 z
(female) (1)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
3. Start engine.
a Keep PCCS lever in N position.

3 Defective power train controller Between PTCN2 (5) and ground Voltage 711 V
1 3 are same as above.
4. While depressing brake pedal, operate PCCS lever (gear speed) and per-
form troubleshooting.
Between PTCN2 (5) and
F1/F2/F3 Voltage Max. 1 V
ground

40-120 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [15SALH] Forward clutch: Fill Low

Circuit diagram related to forward clutch ECMV 40-121

D375A-6R 40-121
(01)
Troubleshooting by failurecode
Failure code [15SBL1] Reverse clutch: Fill high

Failure code [15SBL1] Reverse clutch: Fill high 40-12


Action code Failure code Reverse clutch fill switch signal is ON.
Failure
(Power train controller system)
E03 15SBL1
q Nevertheless controller does not output command current to transmission R clutch ECMV solenoid
Detail of failure
circuit, fill switch signal is turned ON.
q Sets transmission to neutral when operator sets it to forward position (Prevention of double en-
Action of con-
gagement).
troller
q Limits operation of engine and transmission.
q Once machine is stopped, engine speed is limited to medium (half) speed.
Problem on
q Once machine is stopped, travel is limited to R1.
machine
q Automatic gear shifting function does not operate.
q State (ON/OFF) of R clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 40906 T/M Fill Sw Input 1)
q Method of reproducing failure code: Start engine and set PCCS lever in neutral position.
Related infor-
q Remove seat (approx. 50 kg) and seat bottom cover.
mation
q First, check power train oil filter for clogging etc.
q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power
train oil pressure".

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective R clutch ECMV fill 2. Disconnect connector FRT and connect T-adapter to male side.
1
switch (Internal short circuit) Between FRT (female) (1) and ground
Resistance Min. 1 Mz
(Fill switch OFF)
1. Turn starting switch to OFF position.
2. Disconnect connector FRT.
Ground fault in wiring harness or 3. Start engine.
2
defective power train controller If failure code [15SBL1] is still displayed, there is ground fault in wiring harness
or power train controller is defective.
(If failure code [15SBL1] is not displayed, R clutch fill switch is defective.)
a If cause 2 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors PTCN2 and FRT and connect T-adapter to female
3
(Contact with ground circuit) side of either of them.
Between PTCN2 (female) (36) or FRT
Resistance Min. 1 Mz
(female) (1) and ground
If "check result of cause 2 is abnormal" and "check result of cause 3 is normal",
power train controller is defective.
q Reference; the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
3. Start engine.
4 Defective power train controller a Keep PCCS lever in N position.
Between PTCN2 (36) and ground Voltage 711 V
1 3 are same as above.
4. While depressing brake pedal, operate PCCS lever (to select gear speed)
and perform troubleshooting.
Between PTCN2 (36) and
R1/R2/R3 Voltage Max. 1 V
ground

40-122 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [15SBL1] Reverse clutch: Fill high

Circuit diagram related to reverse clutch ECMV 40-123

D375A-6R 40-123
(01)
Troubleshooting by failurecode
Failure code [15SBLH] Reverse clutch: Fill Low

Failure code [15SBLH] Reverse clutch: Fill Low 40-124


Action code Failure code Reverse clutch fill switch signal is OFF.
Failure
(Power train controller system)
E03 15SBLH
q Nevertheless controller outputs command current to transmission R clutch ECMV solenoid circuit,
Detail of failure
fill switch signal is turned OFF.
q Sets transmission to neutral when operator sets it to reverse position (Prevention of defective en-
Action of con-
gagement).
troller
q Limits operation of engine and transmission.
q Once machine is stopped, engine speed is limited to medium (half) speed.
Problem on
q Once machine is stopped, travel is limited to F1.
machine
q Automatic gear shifting function does not operate.
q State (ON/OFF) of R clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 40906 T/M Fill Sw Input 1)
q Method of reproducing failure code: Start engine and set PCCS lever in reverse position.
Related infor-
q Remove seat (approx. 50 kg) and seat bottom cover.
mation
q First, check power train oil filter for clogging etc.
q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power
train oil pressure".
Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector FRT and connect T-adapter to male side.
3. Start engine.
a Keep PCCS lever in N position.
Defective R clutch ECMV fill Between FRT (male) (1) and ground Resistance Min. 1 Mz
1
switch (It does not turn ON) 1 3 are same as above.
4. While depressing brake pedal, operate PCCS lever (gear speed) and per-
form troubleshooting.
Between FRT (male) (1) and
R1/R2/R3 Resistance Max. 1 z
ground
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN2 and FRT, and connect T-adapters to female
Open circuit in wiring harness
2 side of them.
(open circuit or defective contact)
Between PTCN2 (female) (36) and FRT
Resistance Max. 1 z
(female) (1)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
3. Start engine.
a Keep PCCS lever in N position.

3 Defective power train controller Between PTCN2 (36) and ground Voltage 711 V
1 3 are same as above.
4. While depressing brake pedal, operate PCCS lever (gear speed) and per-
form troubleshooting.
Between PTCN2 (36) and
R1/R2/R3 Voltage Max. 1 V
ground

40-124 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [15SBLH] Reverse clutch: Fill Low

Circuit diagram related to reverse clutch ECMV 40-125

D375A-6R 40-125
(01)
Troubleshooting by failurecode
Failure code [15SEL1] Speed 1st clutch: Fill high

Failure code [15SEL1] Speed 1st clutch: Fill high 40-126


Action code Failure code Speed 1st clutch: fill switch signal is ON.
Failure
(Power train controller system)
E03 15SEL1
q Nevertheless controller does not output command current to transmission 1st clutch ECMV sole-
Detail of failure
noid circuit, fill switch signal is turned ON.
Action of con-
q Limits operation of engine and transmission.
troller
q Once machine is stopped, engine speed is limited to medium (half) speed.
Problem on
q Once machine is stopped, travel is limited to F1 and R1.
machine
q Automatic gear shifting function does not operate.
q State (ON/OFF) of 1st clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 40906 T/M Fill Sw Input 1)
q Method of reproducing failure code: Start engine and set PCCS lever in neutral position.
Related infor-
q Remove seat (approx. 50 kg) and seat bottom cover.
mation
q First, check power train oil filter for clogging etc.
q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power
train oil pressure".

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective 1st clutch ECMV fill 2. Disconnect connector F1T and connect T-adapter to male side.
1
switch (Internal short circuit) Between F1T (female) (1) and ground
Resistance Min. 1 Mz
(Fill switch OFF)
1. Turn starting switch to OFF position.
2. Disconnect connector F1T.
Ground fault in wiring harness or 3. Start engine.
2
defective power train controller If failure code [15SEL1] is still displayed, there is ground fault in wiring harness
or power train controller is defective.
(If failure code [15SEL1] is not displayed, 1st clutch fill switch is defective)
a If cause 2 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors PTCN2 and F1T and connect T-adapter to female
3
(Contact with ground circuit) side of either of them.
Between PTCN2 (female) (35) or F1T
Resistance Min. 1 Mz
(female) (1) and ground
If "check result of cause 2 is abnormal" and "check result of cause 3 is normal",
power train controller is defective.
q Reference; the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
3. Start engine.
4 Defective power train controller a Keep PCCS lever in N position.
Between PTCN2 (35) and ground Voltage 711 V
1. 3. are same as above.
4. While depressing brake pedal, operate PCCS lever (to select gear speed)
and perform troubleshooting.
Between PTCN2 (35) and
F1/R1 Voltage Max. 1 V
ground

40-126 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [15SEL1] Speed 1st clutch: Fill high

Circuit diagram related to 1st clutch ECMV 40-127

D375A-6R 40-127
(01)
Troubleshooting by failurecode
Failure code [15SELH] Speed 1st clutch: Fill Low

Failure code [15SELH] Speed 1st clutch: Fill Low 40-128


Action code Failure code Speed 1st clutch fill switch signal is OFF.
Failure
(Power train controller system)
E03 15SELH
q Nevertheless controller outputs command current to transmission 1st clutch ECMV solenoid circuit,
Detail of failure
fill switch signal is turned OFF.
Action of con-
q Limits operation of engine and transmission.
troller
q Once machine is stopped, engine speed is limited to medium (half) speed.
Problem on
q Once machine is stopped, travel is limited to F2 and R2.
machine
q Automatic gear shifting function does not operate.
q State (ON/OFF) of 1st clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 40906 T/M Fill Sw Input 1)
q Method of reproducing failure code: Start engine and set PCCS lever in F1 or R1 position.
Related infor-
q Remove seat (approx. 50 kg) and cover under seat.
mation
q First, check power train oil filter for clogging etc.
q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train
oil pressure".

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
3. Start engine.
a Keep PCCS lever in N position.
Defective 1st clutch ECMV fill Between F1T (male) (1) and ground Resistance Min. 1 Mz
1
switch (It does not turn ON) 1 3 are same as above.
4. While depressing brake pedal, operate PCCS lever (gear speed) and per-
form troubleshooting.
Between F1T (male) (1) and
F1/R1 Resistance Max. 1 z
ground
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN2 and F1T, and connect T-adapters to female
Open circuit in wiring harness
2 side of them.
(open circuit or defective contact)
Between PTCN2 (female) (35) and F1T
Resistance Max. 1 z
(female) (1)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
3. Start engine.
a Keep PCCS lever in N position.

3 Defective power train controller Between PTCN2 (35) and ground Voltage 711 V
1 3 are same as above.
4. While depressing brake pedal, operate PCCS lever (gear speed) and per-
form troubleshooting.
Between PTCN2 (35) and
F1/R1 Voltage Max. 1 V
ground

40-128 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [15SELH] Speed 1st clutch: Fill Low

Circuit diagram related to 1st clutch ECMV 40-129

D375A-6R 40-129
(01)
Troubleshooting by failurecode
Failure code [15SFL1] Speed 2nd clutch: Fill high

Failure code [15SFL1] Speed 2nd clutch: Fill high 40-130


Action code Failure code 2nd clutch oil pressure 1
Failure
(Power train controller system)
E03 15SFL1
q Nevertheless controller does not output command current to transmission 2nd clutch ECMV sole-
Detail of failure
noid circuit, fill switch signal is turned ON.
Action of con-
q Limits operation of engine and transmission.
troller
q Once machine is stopped, engine speed is limited to medium (half) speed.
Problem on
q Once machine is stopped, travel is limited to F2 and R2.
machine
q Automatic gear shifting function does not operate.
q The condition (ON/OFF) of the 2nd clutch ECMV fill switch signal can be checked with the monitor-
ing function.
(Code: 40906 T/M Fill Sw Input 1)
Related infor- q Method of reproducing failure code: Start engine and set PCCS lever in neutral position.
mation q Remove seat (approx. 50 kg) and seat bottom cover.
q First, check power train oil filter for clogging etc.
q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power train
oil pressure".

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective 2nd clutch ECMV fill 2. Disconnect connector F2T and connect T-adapter to male side.
1
switch (internal short circuit) Between F2T (female) (1) and ground
Resistance Min. 1 Mz
(Fill switch OFF)
1. Turn starting switch to OFF position.
2. Disconnect connector F2T.
Ground fault in wiring harness or 3. Start engine.
2
defective power train controller If failure code [15SFL1] is still displayed, there is ground fault in wiring harness
or power train controller is defective.
(If failure code [15SFL1] is not displayed, 2nd clutch fill switch is defective)
a If cause 2 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors PTCN2 and F2T, and connect T-adapter to female
3
(Contact with ground circuit) side of either of them.
Between PTCN2 (female) (25) or F2T
Resistance Min. 1 Mz
(female) (1) and ground
If "check result of cause 2 is abnormal" and "check result of cause 3 is normal",
power train controller is defective.
q Reference; the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
3. Start engine.
4 Defective power train controller a Keep PCCS lever in N position.
Between PTCN2 (25) and ground Voltage 711 V
1 3 are same as above.
4. While depressing brake pedal, operate PCCS lever (to select gear speed)
and perform troubleshooting.
Between PTCN2 (25) and
F2/R2 Voltage Max. 1 V
ground

40-130 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [15SFL1] Speed 2nd clutch: Fill high

Circuit diagram related to 2st clutch ECMV 40-131

D375A-6R 40-131
(01)
Troubleshooting by failurecode
Failure code [15SFLH] Speed 2nd clutch: Fill Low

Failure code [15SFLH] Speed 2nd clutch: Fill Low 40-132


Action code Failure code 2nd clutch oil pressure 2
Failure
(Power train controller system)
E03 15SFLH
q Nevertheless controller outputs command current to transmission 2nd clutch ECMV solenoid cir-
Detail of failure
cuit, fill switch signal is turned OFF.
Action of con-
q Restricts operation of engine and transmission.
troller
q Once machine is stopped, engine speed is limited to half of full speed.
Problem on
q Once machine stops, travel is restricted to F1 and R1.
machine
q Automatic gear shifting function does not operate.
q The condition (ON/OFF) of the 2nd clutch ECMV fill switch signal can be checked with the monitor-
ing function.
(Code: 40906 T/M Fill Sw Input 1)
Related infor- q Method of reproducing failure code: Start engine and PCCS lever in F2 or R2 position.
mation q Remove seat (approx. 50 kg) and seat bottom cover.
q First, check power train oil filter for clogging etc.
q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power
train oil pressure".

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector F2T and connect T-adapter to male side.
3. Start engine.
a Keep PCCS lever in N position.
Defective 2nd clutch ECMV fill Between F2T (male) (1) and ground Resistance Min. 1 Mz
1
switch (It does not turn ON) 1. 3. are same as above.
4. While depressing brake pedal, operate PCCS lever (gear speed) and per-
form troubleshooting.
Between F2T (male) (1) and
F2/R2 Resistance Max. 1 z
ground
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN2 and F2T and connect T-adapters to female
Open circuit in wiring harness
2 side of them.
(open circuit or defective contact)
Between PTCN2 (female) (25) and F2T
Resistance Max. 1 z
(female) (1)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
3. Start engine.
a Keep PCCS lever in N position.

3 Defective power train controller Between PTCN2 (25) and ground Voltage 711 V
1. 3. are same as above.
4. While depressing brake pedal, operate PCCS lever (gear speed) and per-
form troubleshooting.
Between PTCN2 (25) and
F2/R2 Voltage Max. 1 V
ground

40-132 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [15SFLH] Speed 2nd clutch: Fill Low

Circuit diagram related to 2st clutch ECMV 40-13

D375A-6R 40-133
(01)
Troubleshooting by failurecode
Failure code [15SGL1] Speed 3rd clutch: Fill high

Failure code [15SGL1] Speed 3rd clutch: Fill high 40-134


Action code Failure code 3rd clutch oil pressure 1
Failure
(Power train controller system)
E03 15SGL1
q Nevertheless controller does not output command current to transmission 3rd clutch ECMV sole-
Detail of failure
noid circuit, fill switch signal is turned ON.
Action of con-
q Restricts operation of engine and transmission.
troller
q Once machine is stopped, engine speed is limited to half of full speed.
Problem on
q Once machine is stopped, travel is restricted to F3 and R3.
machine
q Automatic gear shifting function does not operate.
q Signal (ON/OFF) from 3rd clutch ECMV fill switch can be checked by using monitoring function.
(Code: 40906 T/M Fill Sw Input 1)
q Method of reproducing failure code: Start engine and set PCCS lever in neutral position.
Related infor-
q Remove seat (approx. 50 kg) and seat bottom cover.
mation
q First, check power train oil filter for clogging etc.
q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power
train oil pressure".

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective 3rd clutch ECMV fill 2. Disconnect connector F3T and connect T-adapter to male side.
1
switch (internal short circuit) Between F3T (female) (1) and ground
Resistance Min. 1 Mz
(Fill switch OFF)
1. Turn starting switch to OFF position.
2. Disconnect connector F3T.
Ground fault in wiring harness or 3. Start engine.
2
defective power train controller If failure code[15SGL1] is still displayed, there is ground fault in wiring har-
ness or power train controller is defective.
(If failure code[15SGL1] is not displayed, 3rd clutch fill switch is defective)
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors PTCN2 and F3T, and connect T-adapter to female
3
(Contact with ground circuit) side of either of them.
Between PTCN2 (female) (15) or F3T
Resistance Min. 1 Mz
(female) (1) and ground
If "check result of cause 2 is abnormal" and "check result of cause 3 is normal",
power train controller is defective.
q Reference; the followings are criteria in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
3. Start engine.
4 Defective power train controller a Keep PCCS lever in N position.
Between PTCN2 (15) and ground Voltage 711 V
1. 3. are same as above.
4. While depressing brake pedal, operate PCCS lever (gear speed) and per-
form troubleshooting.
Between PTCN2 (15) and
F3/R3 Voltage Max. 1 V
ground

40-134 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [15SGL1] Speed 3rd clutch: Fill high

Circuit diagram related to 3rd clutch ECMV 40-135

D375A-6R 40-135
(01)
Troubleshooting by failurecode
Failure code [15SGLH] Speed 3rd clutch: Fill Low

Failure code [15SGLH] Speed 3rd clutch: Fill Low 40-136


Action code Failure code 3rd clutch oil pressure 2
Failure
(Power train controller system)
E03 15SGLH
q Nevertheless controller outputs command current to transmission 3rd clutch ECMV solenoid circuit,
Detail of failure
fill switch signal is turned OFF.
Action of con-
q Limits operation of engine and transmission.
troller
q Once machine is stopped, engine speed is limited to medium (half) speed.
Problem on
q Once machine is stopped, travel is limited to F1 and R1.
machine
q Automatic gear shifting function does not operate.
q Condition (sending/shutting off) of 3rd clutch ECMV fill switch signal can be checked with monitor-
ing function.
(Code: 40906 T/M Fill Sw Input 1)
Related infor- q Method of reproducing failure code: Start engine and PCCS lever in F3 or R3 position.
mation q Remove seat (approx. 50 kg) and seat bottom cover.
q First, check power train oil filter for clogging etc.
q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power
train oil pressure".

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector F3T and connect T-adapter to male side.
3. Start engine.
a Keep PCCS lever in N position.
Defective 3rd clutch ECMV fill Between F3T (male) (1) and ground Resistance Min. 1 Mz
1
switch (It is not turned ON.) 1 3 are same as above.
4. While depressing brake pedal, operate PCCS lever (to select gear speed)
and perform troubleshooting.
Between F3T (male) (1) and
F3/R3 Resistance Max. 1 z
ground
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN2 and F3T and, connect T-adapters to female
Open circuit in wiring harness
2 side of them.
(open circuit or defective contact)
Between PTCN2 (female) (15) and F3T
Resistance Max. 1 z
(female) (1)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
3. Start engine.
a Keep PCCS lever in N position.

3 Defective power train controller Between PTCN2 (15) and ground Voltage 7 11 V
1 3 are same as above.
4. While depressing brake pedal, operate PCCS lever (to select gear speed)
and perform troubleshooting.
Between PTCN2 (15) and
F3/R3 Voltage Max. 1 V
ground

40-136 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [15SGLH] Speed 3rd clutch: Fill Low

Circuit diagram related to 3rd clutch ECMV 40-137

D375A-6R 40-137
(01)
Troubleshooting by failurecode
Failure code [15SJL1] L/U: Fill high

Failure code [15SJL1] L/U: Fill high 40-138


Action code Failure code Lockup clutch fill switch signal is ON.
Failure
(Power train controller system)
E02 15SJL1
q Nevertheless controller does not output command current to torque converter lockup clutch ECMV
Detail of failure
solenoid circuit, fill switch signal is turned ON.
Action of con-
q Prohibits lockup.
troller
Problem on
q Engine may stall during travel.
machine
q State of lockup clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 31520 T/M Fill Sw Input 2)
q Method of reproducing failure code: Start engine and set PCCS lever in R (reverse) position (in au-
Related infor- tomatic gearshift mode).
mation q Remove seat (approx. 50 kg) and seat bottom cover.
q First, check power train oil filter for clogging etc.
q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power
train oil pressure".

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective lockup clutch ECMV fill 2. Disconnect connector FLUC, and connect T-adapter to male side.
1
switch (Internal short circuit) Between FLUC (female) (1) and ground
Resistance Min. 1 Mz
(Fill switch OFF)
1. Turn starting switch to OFF position.
2. Disconnect connector FLUC.
3. Start engine.
Ground fault in wiring harness or a Keep PCCS lever in N position.
2
defective power train controller
If failure code [15SJL1] is still displayed, there is ground fault in wiring har-
ness or power train controller is defective.
(If failure code [15SJL1] is not displayed, lockup clutch fill switch is defective)
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors PTCN2 and FLUC, and connect T-adapter to female
3 side of either of them.
(Contact with ground circuit)
Between PTCN2 (female) (38) or FLUC
Resistance Min. 1 Mz
(female) (1) and ground
If "check result of cause 2 is abnormal" and "check result of cause 3 is normal",
power train controller is defective.
q Reference; the followings are criteria in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
3. Start engine.
a Keep PCCS lever in N position.
Between PTCN2 (38) and ground Voltage 711 V
4 Defective power train controller
1. 3. are same as above.
4. Raise tracks off the ground.
5. Travel in R1 (Reverse) (Automatic gear shift mode) and troubleshoot with
clutch locked up.
a See Testing and adjusting, "Testing power train oil pressure", 4. Testing
torque converter lockup clutch pressure (LU).
Between PTCN2 (38) and
R1 Voltage Max. 1 V
ground

40-138 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [15SJL1] L/U: Fill high

Circuit diagram related to lockup clutch ECMV 40-139

D375A-6R 40-139
(01)
Troubleshooting by failurecode
Failure code [15SJLH] L/U: Fill low

Failure code [15SJLH] L/U: Fill low 40-140


Action code Failure code Lockup clutch fill switch is OFF.
Failure
(Power train controller system)
E02 15SJLH
q Nevertheless controller outputs command current to torque converter lockup clutch ECMV solenoid
Detail of failure
circuit, fill switch signal is turned OFF.
Action of con-
q Prohibits lockup.
troller
Problem on
q It is impossible to lockup.
machine
q State of lockup clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 31520 T/M Fill Sw Input 2)
q Method of reproducing failure code: Start engine and set PCCS lever in R (reverse) position (in au-
Related infor- tomatic gearshift mode).
mation q Remove seat (approx. 50 kg) and seat bottom cover.
q First, check power train oil filter for clogging etc.
q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power
train oil pressure".

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector FLUC, and connect T-adapter to male side.
3. Start engine.
4. Raise tracks off the ground.
Defective lockup clutch ECMV fill 5. Travel machine in R1 (automatic gearshift mode), and troubleshoot with
1 lockup in operation.
switch (It does not turn ON)
a See Testing and adjusting, "Testing power train oil pressure", 4. Testing
torque converter lockup clutch pressure (LU).
Between FLUC (female) (1) and ground
Resistance Max. 1 z
(Fill switch: ON)
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN2 and FLUC and connect T-adapters to
Open circuit in wiring harness
2 female side of them.
(open circuit or defective contact)
Between PTCN2 (female) (38) and FLUC
Resistance Max. 1 z
(female) (1)
If cause is not found by the above checks, power train controller is defective.
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
3. Start engine.
a Keep PCCS lever in N position.
Between PTCN2 (38) and ground Voltage 711 V
3 Defective power train controller 1. 3. are same as above.
4. Raise tracks off the ground.
5. Travel machine in R1 (automatic gearshift mode), and troubleshoot with
lockup in operation.
a See Testing and adjusting, "Testing power train oil pressure", 4. Testing
torque converter lockup clutch pressure (LU).
Between PTCN2 (38) and
R1 Voltage Max. 1 V
ground

40-140 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [15SJLH] L/U: Fill low

Circuit diagram related to lockup clutch ECMV 40-141

D375A-6R 40-141
(01)
Troubleshooting by failurecode
Failure code [1800MW] P/T clutch: Slip

Failure code [1800MW] P/T clutch: Slip 40-142


Action code Failure code Power train clutch slip
Failure
(Power train controller system)
E02 1800MW

Detail of failure q When torque converter is locked up, engine speed does not match sensed transmission output.

Action of con-
q None in particular.
troller
Problem on
machine
q Engine state (speed) and torque converter state (speed) can be checked with monitoring funtion.
Related infor-
Code 01002: Engine speed, Code 31200: Transmission input speed (Torque converter speed)
mation
q Method of reproducing failure code: Engine start + Turn lockup clutch ON + Drive machine.

Cause Procedure, measuring location, criteria and remarks


Power train clutch slip (When the a Clutch slip was detected; check the cause and machine damage state, then
1
system is normal) repair the machine.
Check whether failure codes [CA689] and [CA778] are displayed. If they are
2 Defective engine rotation sensor
displayed, carry out the troubleshooting.
Defective transmission speed sen- Check whether failure codes [DLT3KA] or [DLT3KB] is displayed. If it is dis-
3
sor played, carry out the troubleshooting.

4 Defective power train controller Since this is internal failure, troubleshooting cannot be performed.

40-142 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [1800MW] P/T clutch: Slip

D375A-6R 40-143
(01)
Troubleshooting by failurecode
Failure code [2201L1] Right clutch: Fill high

Failure code [2201L1] Right clutch: Fill high 40-14


Action code Failure code Right clutch fill switch signal is ON.
Failure
(Power train controller system)
E04 2201L1
q Nevertheless controller does not output command current to right steering clutch ECMV solenoid
Detail of failure
circuit, fill switch signal is turned ON.
Action of con-
q Restricts operations of engine, transmission, and brake.
troller
Problem on q Once machine is stopped, engine speed is limited to medium (half) speed.
machine q Once machine is stopped, it cannot travel any more.
q State (ON/OFF) of right steering clutch ECMV fill switch signal can be checked with monitoring
function.
(Code: 31521 Steering Fill Sw Input)
Related infor- q Method of reproducing failure code: Start engine.
mation q Remove seat (approx. 50 kg) and seat bottom cover.
q First, check power train oil filter for clogging etc.
q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power
train oil pressure".

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective right steering clutch 2. Disconnect connector FRC and connect T-adapter to male side.
1 ECMV fill switch (Internal short cir-
cuit) Between FRC (female) (1) and ground
Resistance Min. 1 Mz
(Fill switch OFF)
1. Turn starting switch to OFF position.
2. Disconnect connector FRC.
3. Start engine.
Ground fault in wiring harness or
2 If failure code [2201L1] is still displayed, there is ground fault in wiring harness
defective power train controller
or power train controller is defective.
(If failure code [2201L1] is not displayed, right steering clutch fill switch is
defective.)
a If cause 2 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors PTCN2 and FRC and connect T-adapter to female
3
(Contact with ground circuit) side of either of them.
Between PTCN2 (female) (16) or FRC
Resistance Min. 1 Mz
(female) (1) and ground
If "check result of cause 2 is abnormal" and "check result of cause 3 is normal",
power train controller is defective.
q Reference; the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
3. Start engine.
4 Defective power train controller a Keep PCCS lever in N position.
Between PTCN2 (16) and ground Voltage 7 11 V
1 3 are same as above.
4.While depressing brake pedal, operate PCCS lever (steering) and perform
troubleshooting.
Between PTCN2 (16) and
Left Max. Voltage Max. 1 V
ground

40-144 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [2201L1] Right clutch: Fill high

Circuit diagram related to right clutch ECMV 40-145

D375A-6R 40-145
(01)
Troubleshooting by failurecode
Failure code [2201LH] Right clutch: Fill low

Failure code [2201LH] Right clutch: Fill low 40-146


Action code Failure code Right steering clutch fill switch signal is OFF.
Failure
(Power train controller system)
E04 2201LH
q Nevertheless controller outputs command current to right steering clutch ECMV solenoid circuit, fill
Detail of failure
switch signal is turned OFF.
Action of con-
q Restricts operations of engine, transmission, and brake.
troller
Problem on q Once machine is stopped, engine speed is limited to medium (half) speed.
machine q Once machine is stopped, it cannot travel any more.
q State (ON/OFF) of right steering clutch ECMV fill switch signal can be checked with monitoring
function.
(Code: 31521 Steering Fill Sw Input)
q Method of reproducing failure code: Start engine and release parking brake lever and operate
Related infor-
PCCS lever (right steering).
mation
q Remove seat (approx. 50 kg) and seat bottom cover.
q First, check power train oil filter for clogging etc.
q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power
train oil pressure".

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector FRC and connect T-adapter to male side.
3. Start engine.
a Keep PCCS lever in N position.
Defective right steering clutch
1 ECMV fill switch (It does not turn Between FRC (male) (1) and ground Resistance Min. 1 Mz
ON) 1 3 are same as above.
4.While depressing brake pedal, operate PCCS lever (steering) and perform
troubleshooting.
Between FRC (male) (1) and
Left Max. Resistance Max. 1 z
ground
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN2 and FRC, and connect T-adapters to female
Open circuit in wiring harness
2 side of them.
(open circuit or defective contact)
Between PTCN2 (female) (16) and FRC
Resistance Max. 1 z
(female) (1)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
3. Start engine.
a Keep PCCS lever in N position.

3 Defective power train controller Between PTCN2 (16) and ground Voltage 7 11 V
1. 3. are same as above.
4.While depressing brake pedal, operate PCCS lever (steering) and perform
troubleshooting.
Between PTCN2 (16) and
Left Max. Voltage Max. 1 V
ground

40-146 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [2201LH] Right clutch: Fill low

Circuit diagram related to right clutch ECMV 40-147

D375A-6R 40-147
(01)
Troubleshooting by failurecode
Failure code [2202L1] Left clutch: Fill high

Failure code [2202L1] Left clutch: Fill high 40-148


Action code Failure code Speed Left clutch fill switch signal is ON.
Failure
(Power train controller system)
E04 2202L1
q Nevertheless controller does not output command current to left steering ECMV solenoid circuit, fill
Detail of failure
switch signal is turned ON.
Action of con-
q Restricts operations of engine, transmission, and brake.
troller
Problem on q Once machine is stopped, engine speed is limited to medium (half) speed.
machine q Once machine is stopped, it cannot travel any more.
q State (ON/OFF) of left steering ECMV fill switch signal can be checked with monitoring function.
(Code: 31521 Steering Fill Sw Input)
q Method of reproducing failure code: Start engine.
Related infor-
q Remove seat (approx. 50 kg) and seat bottom cover.
mation
q First, check power train oil filter for clogging etc.
q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power
train oil pressure".

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective left steering ECMV fill 2. Disconnect connector FLC and connect T-adapter to male side.
1
switch (Internal short circuit) Between FLC (female) (1) and ground
Resistance Min. 1 Mz
(Fill switch OFF)
1. Turn starting switch to OFF position.
2. Disconnect connector FLC.
Ground fault in wiring harness or 3. Start engine.
2
defective power train controller If failure code [2202L1] is still displayed, there is ground fault in wiring harness
or power train controller is defective.
(If failure code [2202L1] is not displayed, left steering fill switch is defective)
a If cause 2 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors PTCN2 and FLC, and connect T-adapter to female
3
(Contact with ground circuit) side of either of them.
Between PTCN2 (female) (26) or FLC
Resistance Min. 1 Mz
(female) (1) and ground
If "check result of cause 2 is abnormal" and "check result of cause 3 is normal",
power train controller is defective.
q Reference; the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
3. Start engine.
4 Defective power train controller a Keep PCCS lever in N position.
Between PTCN2 (26) and ground Voltage 7 11 V
1. 3. are same as above.
4.While depressing brake pedal, operate PCCS lever (steering) and perform
troubleshooting.
Between PTCN2 (26) and
Left Max. Voltage Max. 1 V
ground

40-148 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [2202L1] Left clutch: Fill high

Circuit diagram related to left clutch ECMV 40-149

D375A-6R 40-149
(01)
Troubleshooting by failurecode
Failure code [2202LH] Left clutch: Fill low

Failure code [2202LH] Left clutch: Fill low 40-150


Action code Failure code Left cluth fill switch is OFF.
Failure
(Power train controller system)
E04 2202LH
q Nevertheless controller outputs command current to left steering ECMV solenoid circuit, fill switch
Detail of failure
signal is turned OFF.
Action of con-
q Restricts operations of engine, transmission, and brake.
troller
Problem on q Once machine is stopped, engine speed is limited to medium (half) speed.
machine q Once machine is stopped, it cannot travel any more.
q State (ON/OFF) of left steering ECMV fill switch signal can be checked with monitoring function.
(Code: 31521 Steering Fill Sw Input)
q Method of reproducing failure code: Engine start and release parking brake lever and operate
Related infor- PCCS lever. (left steering).
mation q Remove seat (approx. 50 kg) and seat bottom cover.
q First, check power train oil filter for clogging etc.
q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power
train oil pressure".

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector FLC and connect T-adapter to male side.
3. Start engine.
a Keep PCCS lever in N position.
Defective left steering ECMV fill Between FLC (male) (1) and ground Resistance Min. 1 Mz
1
switch (It does not turn ON) 1 2 are same as above.
4.While depressing brake pedal, operate PCCS lever (steering) and perform
troubleshooting.
Between FLC (male) (1) and
Left Max. Resistance Max. 1 z
ground
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN2 and FLC and connect T-adapters to female
Open circuit in wiring harness
2 side of them.
(open circuit or defective contact)
Between PTCN2 (female) (26) and FLC
Resistance Max. 1 z
(female) (1)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
3. Start engine.
a Keep PCCS lever in N position.

3 Defective power train controller Between PTCN2 (26) and ground Voltage 711 V
1. 3. are same as above.
4.While depressing brake pedal, operate PCCS lever (steering) and perform
troubleshooting.
Between PTCN2 (26) and
Left Max. Voltage Max. 1 V
ground

40-150 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [2202LH] Left clutch: Fill low

Circuit diagram related to left clutch ECMV 40-151

D375A-6R 40-151
(01)
Troubleshooting by failurecode
Failure code [2300NR] Brake Themal Load Abnormality

Failure code [2300NR] Brake Themal Load Abnormality 40-152


Action code Failure code Brake thermal load abnormality
Failure
(Power train controller system)
2300NR
q The power train controller judged from the angle of inclination, travel speed, continuous operating
Detail of failure
time of the brake pedal, etc. that the brake was heating abnormally.
Action of con-
q None in particular.
troller
Problem on

machine
Related infor-

mation

Cause Procedure, measuring location, criteria and remarks


1 Improper braking during downhill travel (Machine traveled down a slope with brake pedal pressed)

2 Defective power train controller When the operation in cause 1 is not performed

40-152 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [2300NR] Brake Themal Load Abnormality

D375A-6R 40-153
(01)
Troubleshooting by failurecode
Failure code [2301L1] Right brake: Fill high

Failure code [2301L1] Right brake: Fill high 40-154


Action code Failure code Speed right brake fill switch signal is ON.
Failure
(Power train controller system)
E04 2301L1
q Nevertheless controller does not output command current to right steering brake ECMV solenoid
Detail of failure
circuit, fill switch signal is turned ON.
Action of con-
q Restricts operations of engine, transmission, and brake.
troller
Problem on q Once machine is stopped, engine speed is limited to medium (half) speed.
machine q Once machine is stopped, it cannot travel any more.
q State (ON/OFF) of right steering brake ECMV fill switch signal can be checked with monitoring func-
tion.
(Code: 31521 Steering Fill Sw Input)
Related infor- q Method of reproducing failure code: Start engine.
mation q Remove seat (approx. 50 kg) and seat bottom cover.
q First, check power train oil filter for clogging etc.
q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power
train oil pressure".

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective right steering brake 2. Disconnect connector FRB and connect T-adapter to male side.
1 ECMV fill switch (Internal short cir-
cuit) Between FRB(female) (1) and ground
Resistance Min. 1 Mz
(Fill switch OFF)
1. Turn starting switch to OFF position.
2. Disconnect connector FRB.
3. Start engine.
Ground fault in wiring harness or
2 If failure code [2301L1] is still displayed, there is ground fault in wiring harness
defective power train controller
or power train controller is defective.
(If failure code [2301L1] is not displayed, right steering brake fill switch is
defective.)
a If cause 2 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors PTCN2 and FRB, and connect T-adapter to female
3
(Contact with ground circuit) side of either of them.
Between PTCN2(female )(37) or FRB
Resistance Min. 1 Mz
(female) (1) and ground
If "check result of cause 2 is abnormal" and "check result of cause 3 is normal",
power train controller is defective.
q Reference; the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
3. Start engine.
4 Defective power train controller 4. Release the parking brake.
a Keep PCCS lever in N position.
Between PTCN2 (37) and ground Voltage Max. 1 V
1 4 are same as above.
5. While depressing the brake and perform troubleshooting.
Between PTCN2 (37) and ground Voltage 7 11 V

40-154 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [2301L1] Right brake: Fill high

Circuit diagram related to right brake ECMV 40-15

D375A-6R 40-155
(01)
Troubleshooting by failurecode
Failure code [2301LH] Right brake: Fill low

Failure code [2301LH] Right brake: Fill low 40-156


Action code Failure code Right brake fill switch signal is OFF.
Failure
(Power train controller system)
E04 2301LH
q Nevertheless controller outputs command current to right steering brake ECMV solenoid circuit, fill
Detail of failure
switch signal is turned OFF.
Action of con-
q Restricts operations of engine, transmission, and brake.
troller
Problem on q Once machine is stopped, engine speed is limited to medium (half) speed.
machine q Once machine is stopped, it cannot travel any more.
q State (ON/OFF) of right steering brake ECMV fill switch signal can be checked with monitoring func-
tion.
(Code: 31521 Steering Fill Sw Input)
Related infor- q Method of reproducing failure code:Start engine and release the parking brake.
mation q Remove seat (approx. 50 kg) and seat bottom cover.
q First, check power train oil filter for clogging etc.
q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power
train oil pressure".

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector FRB and connect T-adapter to male side.
Between FRB (male) (1) and ground Resistance Min. 1 Mz
Defective right steering brake
1 ECMV fill switch (It does not turn 1 2 are same as above.
ON) 3. Start the engine.
a Keep PCCS lever in N position.
4. Release parking brake and perform troubleshooting.
Between FRB (male) (1) and ground Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN2 and FRB, and connect T-adapters to female
Open circuit in wiring harness
2 side of them.
(open circuit or defective contact)
Between PTCN2 (female) (37) and FRB
Resistance Max. 1 z
(female) (1)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
3. Start engine.
4. Release the parking brake.
a Keep PCCS lever in N position.
3 Defective power train controller
Between PTCN2 (37) and ground Voltage Max. 1 V
1 4 are same as above.
5. While depressing the brake and perform troubleshooting.
Between PTCN2 (37) and ground Voltage 7 11 V

40-156 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [2301LH] Right brake: Fill low

Circuit diagram related to right brake ECMV 40-157

D375A-6R 40-157
(01)
Troubleshooting by failurecode
Failure code [2301NR] Steering Brake RH Themal Load Abnormality

Failure code [2301NR] Steering Brake RH Themal Load Abnormality 40-158


Action code Failure code Right steering brake thermal load abnormality
Failure
(Power train controller system)
2301NR
q The power train controller judged from the angle of inclination and continuous operating time of the
Detail of failure
right steering that the steering brake was heating abnormally.
Action of con-
q None in particular.
troller
Problem on

machine
Related infor-

mation

Cause Procedure, measuring location, criteria and remarks


1 Improper steering during downhill travel (Machine traveled down a slope and was steered to right continuously)

2 Defective power train controller When the operation in cause 1 is not performed

40-158 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [2301NR] Steering Brake RH Themal Load Abnormality

D375A-6R 40-159
(01)
Troubleshooting by failurecode
Failure code [2302L1] Left brake: Fill high

Failure code [2302L1] Left brake: Fill high 40-160


Action code Failure code Left brake fill switch signal is ON.
Failure
(Power train controller system)
E04 2302L1
q Nevertheless controller does not output command current to left steering brake clutch ECMV sole-
Detail of failure
noid circuit, fill switch signal is turned ON.
Action of con-
q Restricts operations of engine, transmission, and brake.
troller
Problem on q Once machine is stopped, engine speed is limited to medium (half) speed.
machine q Once machine is stopped, it cannot travel any more.
q State (ON/OFF) of left steering brake cluth ECMV fill switch signal can be checked with monitoring
function.
(Code: 31521 Steering Fill Sw Input)
Related infor- q Method of reproducing failure code: Start engine.
mation q Remove seat (approx. 50 kg) and seat bottom cover.
q First, check power train oil filter for clogging etc.
q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power
train oil pressure".

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective left steering brake clutch 2. Disconnect connector FLB and connect T-adapter to male side.
1 ECMV fill switch (Internal short cir-
cuit)) Between FLB(female) (1) and ground
Resistance Min. 1 Mz
(Fill switch OFF)
1. Turn starting switch to OFF position.
2. Disconnect connector FLB.
3. Start engine.
Ground fault in wiring harness or
2 If failure code [2302L1] is still displayed, there is ground fault in wiring harness
defective power train controller
or power train controller is defective.
(If failure code [2302L1] is not displayed, left steering brake clutch fill switch is
defective.)
a If cause 2 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors PTCN2 and FLB and connect T-adapter to female
3
(Contact with ground circuit) side of either of them.
Between PTCN2(female) (6) or FLB(female)
Resistance Min. 1 Mz
(1) and ground
If "check result of cause 2 is abnormal" and "check result of cause 3 is normal",
power train controller is defective.
q Reference; the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
3. Start engine.
4 Defective power train controller 4. Release the parking brake.
a Keep PCCS lever in N position.
Between PTCN2 (6) and ground Voltage Max. 1 V
1 4 are same as above.
5. While depressing the brake and perform troubleshooting.
Between PTCN2 (6) and ground Voltage 7 11 V

40-160 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [2302L1] Left brake: Fill high

Circuit diagram related to left brake ECMV 40-161

D375A-6R 40-161
(01)
Troubleshooting by failurecode
Failure code [2302LH] Left brake: Fill low

Failure code [2302LH] Left brake: Fill low 40-162


Action code Failure code Left brake fill switch signal is OFF.
Failure
(Power train controller system)
E04 2302LH
q Nevertheless controller outputs command current to left steering brake clutch ECMV solenoid cir-
Detail of failure
cuit, fill switch signal is turned OFF.
Action of con-
q Restricts operations of engine, transmission, and brake.
troller
Problem on q Once machine is stopped, engine speed is limited to medium (half) speed.
machine q Once machine is stopped, it cannot travel any more.
q State (ON/OFF) of left steering brake cluth ECMV fill switch signal can be checked with monitoring
function.
(Code: 31521 Steering Fill Sw Input)
Related infor- q Method of reproducing failure code: Engine start and release parking bake lever.
mation q Remove seat (approx. 50 kg) and seat bottom cover.
q First, check power train oil filter for clogging etc.
q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power
train oil pressure".

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector FLB and connect T-adapter to male side.
Between FLB(male) (1) and ground Resistance Min. 1 Mz
Defective left steering brake clutch
1 ECMV fill switch (It does not turn 1 2 are same as above.
ON) 3. Starting engine
a Keep PCCS lever in N position.
4. Release the parking brake and carry out troubleshooting.
Between FLB (male) (1) and ground Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN2 and FLB, and connect T-adapters to female
Open circuit in wiring harness
2 side of them.
(open circuit or defective contact)
Between PTCN2 (female) (6) and
Resistance Max. 1 z
FLB(female) (1)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
3. Start engine.
4. Release the parking brake.
a Keep PCCS lever in N position.
3 Defective power train controller
Between PTCN2 (6) and ground Voltage Max. 1 V
1 4 are same as above.
5. While depressing the brake and perform troubleshooting.
Between PTCN2 (6) and ground Voltage 7 11 V

40-162 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [2302LH] Left brake: Fill low

Circuit diagram related to left brake ECMV 40-163

D375A-6R 40-163
(01)
Troubleshooting by failurecode
Failure code [2302NR] Steering Brake LH Themal Load Abnormality

Failure code [2302NR] Steering Brake LH Themal Load Abnormality 40-164


Action code Failure code Left steering brake thermal load abnormality
Failure
(Power train controller system)
2302NR
q Power train controller judged from the angle of inclination, travel speed and continuous operating
Detail of failure
time of the left steering that the steering brake was heating abnormally.
Action of con-
q None in particular.
troller
Indication of
problem on
machine
Related infor-

mation

Cause Procedure, measuring location, criteria and remarks


1 Improper steering during downhill travel (Machine traveled down a slope and was steered to left continuously)

2 Defective power train controller When the operation in cause 1 is not performed

40-164 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [2302NR] Steering Brake LH Themal Load Abnormality

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

Failure code [7RFAKA] ECM ACC CUT RELAY: Disconnection 40-16


Action code Failure code Open circuit in engine controller ACC cut relay
Failure
(Work equipment controller system)
- 7RFAKA
q No voltage is applied to engine controller ACC cut relay primary (coil side) circuit when no ground-
Detail of failure
ing.
Action of con-
q Stops grounding to engine controller ACC cut relay primary (coil side) circuit.
troller
q Engine does not start.
Problem on
q If engine ACC cutoff mechanism is mounted, the engine cannot be stopped by ACC cutoff. (The
machine
engine cannot be stopped by engine ACC cutoff mechanism.)
q Output to engine controller ACC cut relay primary (coil side) circuit can be checked with monitoring
function (Code: 40983 W/E controller SW output).
Related infor- q Method of reproducing failure code: Turn the starting switch to ON position.
mation q This failure code detects failure on primary side (coil side) of engine controller ACC cut relay, but
not on secondary side (contact side).
q If pin WECN2 (8) has ground fault, engine cannot be started.

Cause Procedure, measuring location, criteria and remarks


Defective engine con- 1. Turn starting switch to OFF position.
troller ACC cut relay 2. Disconnect connector ACT and connect T-adapter to male side.
1
(Internal open or short
circuit) Between ACT (male) (1) and (2) Resistance 200 400 z
1. Turn starting switch to OFF position.
2. Disconnect connectors WECN2 and KEY, and connect T-adapters to female side of
Open or short circuit in them.
2 a If resistance is 1 Mz or above, wiring harness has disconnection. If resistance is 1 z or
wiring harness
below, wiring harness has short circuit.
Between KEY (female) (1) and WECN2 (female) (8) Resistance 200 400 z
a If cause 2 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring
2. Disconnect connectors WECN2, ACT and KEY, and connect T-adapters to female side
harness
3 of them.
(open circuit or defec-
tive contact) Between WECN2 (female) (8) and ACT (female) (2) Resistance Max. 1 z
Between KEY (female) (1) and ACT (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring
2. Disconnect connectors WECN2 and ACT, and connect T-adapters to female side of
harness
4 them.
(Contact with ground
Between ACT (female) (2) or WECN2 (female) (8) and
circuit) Resistance Min. 1 Mz
ground
If cause is not found by the above checks, work equipment controller is defective.
q Reference: the followings are standard values in normal condition.

Defective work equip- 1. Turn starting switch to OFF position.


5 2. Insert T-adapter into connector WECN2.
ment controller
3. Turn starting switch to ON position.
Between WECN2 (8) and ground Voltage Max. 1 V

40-166 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [7RFAKA] ECM ACC CUT RELAY: Disconnection

Circuit diagram related to engine controller shut down 40-167

D375A-6R 40-167
(01)
Troubleshooting by failurecode
Failure code [7RFAKB] ECM ACC CUT RELAY: Short circuit

Failure code [7RFAKB] ECM ACC CUT RELAY: Short circuit 40-168
Action code Failure code Engine controller ACC cut relay disconnection
Failure
(Work equipment controller system)
7RFAKB
q Abnormal current flows when grounding to engine controller ACC cut relay primary (coil side) circuit
Detail of failure
.
Action of con-
q Stops grounding to engine controller ACC cut relay primary (coil side) circuit.
troller
Problem on
q Engine does not start.
machine
q Output to engine controller ACC cut relay primary (coil side) circuit can be checked with monitoring
function (Code: 40983 W/E controller SW output).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation
q This failure code detects failure on primary side (coil side) of engine controller ACC cut relay, but
not on secondary side (contact side).

Cause Procedure, measuring location, criteria and remarks


Defective engine con- 1. Turn starting switch to OFF position.
troller ACC cut relay 2. Disconnect connector ACT and connect T-adapter to male side.
1
(Internal open or short
circuit) Between ACT (male) (1) and (2) Resistance 200 400 z
1. Turn starting switch to OFF position.
2. Disconnect connectors WECN2 and KEY and connect T-adapters to female side of
Open or short circuit in them.
2 a If resistance is above 1 Mz, wiring harness has disconnection. If resistance is below
wiring harness
1 z, wiring harness has short circuit.
Between KEY (female) (1) and WECN2 (female) (8) Resistance 200 400 z
1. Turn starting switch to OFF position.
Hot short circuit in wir- 2. Disconnect connectors WECN2 and ACT, and connect T-adapter to female side of
ing harness WECN2.
3
(Contact with 24 V cir- 3. Turn starting switch to ON position.
cuit)
Between WECN2 (female) (8) and ground Voltage Max. 1 V
If cause is not found by the above checks, work equipment controller is defective.
Reference: the followings are criteria in normal condition.
q

Defective work equip- 1. Turn starting switch to OFF position.


4 2. Insert T-adapter into connector WECN2.
ment controller
3. Turn starting switch to ON position.
Between WECN2 (8) and ground Voltage Max. 1 V

40-168 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [7RFAKB] ECM ACC CUT RELAY: Short circuit

Circuit diagram related to engine controller shut down 40-169

D375A-6R 40-169
(01)
Troubleshooting by failurecode
Failure code [AA10NX] Air Cleaner Clogging

Failure code [AA10NX] Air Cleaner Clogging 40-170


Action code Failure code Air cleaner clogging
Failure
(Machine monitor system)
AA10NX
q Air cleaner clogging switch signal voltage was not 1 V or less while engine was running, and ma-
Detail of failure
chine monitor detected clogging of air cleaner (open of switch contacts).
Action of con-
q None in particular
troller
Problem on
q If the machine is operated under such a condition, engine may be damaged.
machine
Related infor-
q Method of reproducing failure code: Start engine.
mation

Cause Procedure, measuring location, criteria and remarks


Air cleaner clogging Air cleaner may be clogged. Check it for clogging and then clean or replace if
1
(When system is normal) clogged.
1. Turn starting switch to OFF position.
2. Disconnect connector AF1 and connect T-adapter to male side.
3. Start engine.
Defective air cleaner clogging When air
2 cleaner is nor- Resistance Max. 1 z
switch (Internal disconnection)
Between AF1 (male) (1) and mal *1
(2) When air
cleaner is Resistance Min. 1 Mz
clogged *2
1. Turn starting switch to OFF position.
2. Disconnect connectors CM01, CM02 and AF1, and connect T-adapters to
Open circuit in wiring harness female side of them.
3 (Open circuit in wiring or defective Between CM02 (female) (4) and AF1 (female)
Resistance Max. 1 z
contact in connector) (1)
Between CM01 (female) (7) and AF1 (female)
Resistance Max. 1 z
(2)
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors CM01 and CM02.
3. Start engine.
When air
4 Defective power train controller
cleaner is nor- Voltage Max. 1 V
Between CM02 (4) and mal
CM01 (7)
Air cleaner is
Voltage 7 11 V
clogged

q Air cleaner suction resistance


*1: Max. -3,430 Pa {-350 mmH2O}
*2: -7,470 490 Pa {-762 50 mmH2O}

40-170 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [AA10NX] Air Cleaner Clogging

Circuit diagram related to air cleaner 40-171

D375A-6R 40-171
(01)
Troubleshooting by failurecode
Failure code [AB00MA] Battery Charge Abnormal

Failure code [AB00MA] Battery Charge Abnormal 40-172


Action code Failure code Battery Charge Abnormal
Failure
(Machine monitor system)
AB00MA
q While engine was running, voltage from alternator lowered, and machine monitor detected that bat-
Detail of failure
tery charge voltage was low.
Action of con-
q Displays charge level monitor red on machine monitor.
troller
Problem on
q If machine is used as it is, battery may not be charged.
machine
q Battery voltage can be checked with monitoring function.
Related infor-
(Code: 04300 Charge voltage)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks


Defective charge by alternator It is suspected that malfunction of battery charge is occurring at present or
1
(When system is normal) occurred in past. Investigate cause and damage condition, and correct it.

Defective charge level monitor If cause 1 is not detected, charge level monitor system may be defective. Per-
2
system form E-5 Caution item lights up while engine is running in E mode.

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

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


Action code Failure code Eng Oil Press Low
Failure
(Engine controller system)
B@BAZG
q While engine was running, signal voltage from engine oil pressure sensor dropped, and engine
Detail of failure
controller detected engine oil pressure too low.
Action of con-
q Displays engine oil pressure monitor red on machine monitor.
troller
Problem on
q If machine is used as it is, engine may be seized.
machine
q Engine oil pressure sensor signal is input to engine controller and then transmitted to machine mon-
itor through communication system.
Related infor-
q Engine oil pressure can be checked with monitoring function.
mation
(Code: 37200 Engine Oil Pressure Sensor)
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks


Lowering of engine oil pressure
1 Engine oil pressure may be low. Check it and remove cause if it is low.
(When system is normal)
If cause 1 is not the cause for the trouble, engine oil pressure sensor system
Defective engine oil pressure cau-
2 may be defective. Perform troubleshooting for failure codes [CA135] and
tion lamp circuit
[CA141].

D375A-6R 40-173
(01)
Troubleshooting by failurecode
Failure code [B@BAZK] Eng Oil Level Low

Failure code [B@BAZK] Eng Oil Level Low 40-174


Action code Failure code Eng oil level low
Failure
(Machine monitor system)
B@BAZK
q While engine was running, signal voltage from engine oil level switch was not 1 V or less, machine
Detail of failure
monitor detected that engine oil level was low (oil level switch was open).
Action of con-
q Displays radiator coolant level monitor red on machine monitor.
troller
Problem on
q If machine is used as it is, engine may be seized.
machine
Related infor-
q Method of reproducing failure code:Start engine
mation

Cause Procedure, measuring location, criteria and remarks


Engine oil level low
1 Check engine oil level. If it is low, remove cause.
(When system is normal)
1. Turn starting switch to OFF position.
Defective engine oil level sensor 2. Disconnect connector OLV.
2 3. Turn starting switch to ON position.
(Internal defect)
Between OLV (male) (1) and ground Resistance Max. 1 z
1. Turn starting switch to OFF position.
Disconnection in wiring harness
2. Disconnect connector CM02 and connect T-adapter to female side.
3 (Open circuit in wiring or defective
contact in connector) Between CM02 (female) (2) and OLV(female)
Resistance Max. 1 z
(1)
If cause is not found by above checks, machine monitor is defective.
q Reference: the followings are criteria in normal condition.
1. Turn starting switch to OFF position.
4 Defective machine monitor 2. Insert T-adapter into connector CM02.
3. Turn starting switch to ON position.
Between CM02 (female) (2) and ground Voltage Max. 1 V

Circuit diagram related to engine oil level 40-174

40-174 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [B@BCNS] Eng Water Overheat

Failure code [B@BCNS] Eng Water Overheat 40-175


Action code Failure code Eng Coolant Overheat
Failure
(Engine controller system)
B@BCNS
q While engine was running, voltage from engine coolant temperature sensor dropped, and engine
Detail of failure
controller detected that engine coolant was overheated.
Action of con-
q Displays engine coolant temperature monitor red on machine monitor.
troller
Problem on
q If machine is used as it is, engine may be seized.
machine
q Engine controller inputs voltage of engine coolant temperature sensor signal and then transmits the
data to machine monitor through CAN communication system.
Related infor-
q Engine coolant temperature can be checked with monitoring function
mation
(Code: 04107 Engine coolant temperature)
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks


Overheated engine coolant (when
1 Check engine coolant for overheating. If it is overheated, remove cause.
system is normal)
Defective engine coolant tempera- If cause 1 is not detected, engine coolant temperature sensor may be defec-
2
ture sensor system tive. Perform troubleshooting for failure codes [CA144] and [CA145].

D375A-6R 40-175
(01)
Troubleshooting by failurecode
Failure code [B@BCZK] Eng Water Level Low

Failure code [B@BCZK] Eng Water Level Low 40-176


Action code Failure code Eng coolant level low
Failure
(Machine monitor system)
B@BCZK
q While starting switch was ON (and engine was stopped) or engine was running, radiator coolant
Detail of failure level switch signal was not 1 V or less, machine monitor detected that radiator coolant level was
low (sensor contact was open).
Action of con-
q Displays radiator coolant level monitor red on machine monitor.
troller
Problem on
q If machine is used as it is, engine may be overheated.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks


Coolant level low Check radiator sub tank for lowering of coolant level. If coolant level is low, add
1
(When system is normal) coolant.
If cause 1 is not detected, radiator coolant level monitor may be defective.
Defective radiator coolant level
2 Carry out "E-4 Caution item lights up while starting switch is ON (and engine is
monitor system
stopped)" in E mode.

40-176 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [B@CENS] T/C Oil Overheat

Failure code [B@CENS] T/C Oil Overheat 40-17


Action code Failure code Torque converter overheating
Failure
(Power train controller system)
B@CENS
q While engine was running, voltage from torque converter oil temperature sensor dropped, and pow-
Detail of failure
er train controller detected that power train oil was overheated.
Action of con-
q Displays power train oil temperature monitor red on machine monitor.
troller
Problem on
q If machine is used as it is, power train components may be damaged.
machine
q Work equipment controller inputs the signal voltage of torque converter oil temperature sensor, and
transmits this information to the machine monitor through power train controller on CAN communi-
Related infor- cation system.
mation q Torque converter oil temperature can be checked with monitoring function.
(Code: 30100 T/C Oil Temperature)
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks


Overheating of torque converter
1 Torque converter oil may be overheated. If it is overheated, remove cause.
oil (When system is normal)
If cause 1 is not detected, torque converter oil temperature sensor system may
Defective torque converter oil
2 be defective. Perform troubleshooting for failure code [DGT1KA] or [DGT1KX]
temperature sensor system
.

D375A-6R 40-177
(01)
Troubleshooting by failurecode
Failure code [B@HANS] Hyd Oil Overheat

Failure code [B@HANS] Hyd Oil Overheat 40-178


Action code Failure code Hydraulic Oil overheating
Failure
(Power train controller system)
B@HANS
q While engine was running, hydraulic oil temperature sensor voltage dropped, and power train con-
Detail fo failure
troller detected hydraulic oil overheat by data sent from machine monitor by CAN communication.
Action of con-
q Displays hydraulic oil temperature monitor red on machine monitor.
troller
Problem on
q If machine is operated as it is, work equipment circuit units may be damaged.
machine
q Signal voltage of hydraulic oil temperature sensor is input in machine monitor, and then the data is
transmitted to power train controller through CAN communication system.
Related infor-
q Hydraulic oil temperature can be checked with monitoring function
mation
(Code: 04401 Hyd Oil Temperature)
q Method of reproducing failure code:Start engine

Cause Procedure, measuring location, criteria and remarks


Hyd Oil Overheat Hydraulic oil may be overheating. Check it and remove cause if it is overheat-
1
(When system is normal) ing.
If cause 1 is not the cause for the trouble, hydraulic oil temperature gauge sys-
Defective hydraulic oil tempera- tem may be defective. Perform troubleshooting for failure code [DGS1KX] or
2
ture gauge system "E-10 Hydraulic oil temperature gauge (Multi-gauge) does not display nor-
mally" in E-mode.

40-178 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [B@HAZK] Hyd Oil Level Low

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


Action code Failure code Hyd Oil Level Low
Failure
(Work equipment controller system)
B@HAZK
q Signal voltage from or hydraulic oil lever switch open oil level switch was not 1 V or less while en-
Detail of failure gine was running, and work equipment controller detected low hydraulic oil level or oil lever switch
open.
Action of con-
q None in particular.
troller
Problem on
q If machine is operated as it is, work equipment circuit units may be damaged.
machine
q Signal of hydraulic oil level switch is input to work equipment controller and then the data is trans-
mitted to machine monitor through CAN communication system.
Related infor-
q Hydraulic oil level switch can be checked with monitoring function.
mation
(Code: 40981 W/E controller SW input)
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks


Hydraulic oil level low (during nor-
1 Hydraulic oil may be low. Check it and add oil if necessary.
mal system operation)
1. Turn starting switch to OFF position.
Defective hydraulic oil level switch 2. Disconnect connector HLS and connect T-adapter to male side.
2 3. Turn starting switch to ON position.
(internal failure)
Between HLS (male) (1) and (2) Resistance Max. 1 z
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors WECN1 and WECN2, and connect T-adapters to
3 (Open circuit in wiring or defective female side of them.
contact in connector) Between WECN2 (female) (28) and WECN1
Resistance Max. 1 z
(female) (4)
If cause is not found by above checks, work equipment controller is defective.
q Reference: the followings are standard values in normal condition.
Defective work equipment control- 1. Turn starting switch to OFF position.
4 2. Insert T-adapter into connectors WECN1 and WECN2
ler
3. Turn starting switch to ON position.
Between WECN2 (28) and WECN1 (4) Voltage Max. 1 V

Circuit diagram related to hydraulic oil level switch 40-179

D375A-6R 40-179
(01)
Troubleshooting by failurecode
Failure code [CA111] ECM Critical Internal Failure

Failure code [CA111] ECM Critical Internal Failure 40-180


Action code Failure code Abnormality in engine controller
Failure
(Engine controller system)
E03 CA111
Detail of failure q Trouble occurred in engine controller.
Action of con-
q None in particular.
troller
Problem on
q Engine continues running, but it may stop during operations or may not restart once it is in stopped.
machine
q Power supply voltage of engine controller can be checked with moniitoring funtion.
Related infor-
(Code: 03203 Battery voltage)
mation
q Method of reproducing failure code: Turn starting switch to ON position

Cause Procedure, measuring location, criteria and remarks


1 Loose or corroded battery terminal Battery cable terminal may be loose or corroded. Check it directly.
1. Turn starting switch to OFF position.
Loosened terminal or partial dis-
2 Check terminals of alternator, battery relay, ground (GND11) etc. for loose-
connection at terminal
ness.
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
3 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position, then carry out troubleshooting.
2. Perform troubleshooting when engine is cranked.
4 Improper battery voltage
Between battery terminal
Voltage 20 30 V
(+) and (-).
1. Turn starting switch to OFF position.
2. Insert T-adapter between male and female side of connector E22.
5 Defective alternator 3. Start engine (Engine speed: Middle or faster).
Between E22 (3) and
Voltage 26 30.5 V
ground
If no abnormality is found by above checks, engine controller is defective.
(Since failure is in it, troubleshooting cannot be performed.)
q Reference: The followings are standard values in normal condition.
1. Turn starting switch to OFF position and disconnect ground strap.
2. Insert T-adapter between male and female sides of EGC3.
3. Connect the ground cable.
6 Defective engine controller
4. Measure voltage with starting switch at OFF position and when starting
engine.
Between EGC3 (3) and
Voltage 20 30 V
(1)
Between EGC3 (4) and
Voltage 20 30 V
(2)

40-180 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA111] ECM Critical Internal Failure

Circuit diagram related to engine controller power supply 40-181

D375A-6R 40-181
(01)
Troubleshooting by failurecode
Failure code [CA115] Eng Ne and Bkup Speed Sens Error

Failure code [CA115] Eng Ne and Bkup Speed Sens Error 40-182
Action code Failure code Abnormality in engine Ne/Bkup speed sensor
Failure
(Engine controller system)
E03 CA115
Detail of failure q Abnormality occurred in the signal of Ne and Bkup speed sensor circuits at the same time.
Action of con-
q Stops the engine.
troller
Problem on q The engine does not start. (if engine has been stopped.)
machine q Engine stops. (if engine has been running.)
Related infor-
q Method of reproducing failure code: Start engine.
mation

Cause Procedure, measuring location, criteria and remarks


1 Defective Ne speed sensor system Carry out troubleshooting for failure code [CA689].
2 Defective Bkup speed sensor system Carry out troubleshooting for failure code [CA778].
If cause is not found by above checks,, engine controller may be
3 Defective engine controller defective. (Since failure is in it, troubleshooting cannot be per-
formed.)

40-182 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA115] Eng Ne and Bkup Speed Sens Error

D375A-6R 40-183
(01)
Troubleshooting by failurecode
Failure code [CA122] Chg Air Press Sensor High Error

Failure code [CA122] Chg Air Press Sensor High Error 40-184
Action code Failure code Charge pressure sensor too high
Failure
(Engine controller system)
E03 CA122
Detail of failure q High voltage occurred in charge pressure sensor (boost pressure sensor) signal circuit.
Action of con-
troller q Takes it that boost pressure is at fixed value (400 kPa {4.1 kg/cm2}), and allows engine to run.

Problem on
q Engine does not accelerate smoothly.
machine
q The signal (voltage) from the charge pressure sensor (boost pressure sensor) can be checked with
the monitoring function (Code: 36501 (V)).
q Pressure (Boost pressure) sensed by charge pressure sensor (boost pressure sensor) can be
Related infor-
checked with monitoring function (Code: 36500 (kPa)).
mation
q Method of reproducing failure code: Turn starting switch to ON position.
q If sensor connector is disconnected, code [CA123] for "Low Error" is displayed, even in normal con-
dition.

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
Defective sensor power supply If failure code [CA187] or [CA227] is displayed at the same time, carry out
2
system troubleshooting for that first.
1. Turn starting switch to OFF position.
2. Disconnect connector PIM.
Defective charge pressure (boost 3. Turn starting switch to ON position.
3
pressure) sensor
If failure code changes from [CA122] to [CA123], charge pressure (boost pres-
sure) sensor is defective.
1. Turn starting switch to OFF position, then carry out troubleshooting.
2. Disconnect connectors ENG and PIM, and connect T-adapter to female
4 Short circuit in wiring harness side of ENG.
Between ENG (female)
Resistance Min. 1 Mz
(37) - (44)
1. Turn starting switch to OFF position.
2. Disconnect connector PIM, and insert T-adapter into connector ENG.
Hot short circuit in wiring harness
5 3. Turn starting switch to ON position (with connector PIM disconnected).
(Short circuit with 24 V circuit)
Between ENG (44) and
Voltage Max. 1V
(47)
If no abnormality is found by above checks, engine controller is defective.
6 Defective engine controller
(Since failure is in it, troubleshooting cannot be performed.)

40-184 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA122] Chg Air Press Sensor High Error

Circuit diagram related to charge pressure sensor 40-185

D375A-6R 40-185
(01)
Troubleshooting by failurecode
Failure code [CA123] Chg Air Press Sensor Low Error

Failure code [CA123] Chg Air Press Sensor Low Error 40-186
Action code Failure code Charge pressure sensor too low
Failure
(Engine controller system)
E03 CA123
Detail of failure q Low voltage occurred in charge pressure sensor (boost pressure sensor) signal circuit.
Action of con-
troller q Takes it that boost pressure is at fixed value (400 kPa {4.1 kg/cm2}), and allows engine to run.

Problem on
q Engine does not accelerate smoothly.
machine
q The signal (voltage) from the charge pressure sensor (boost pressure sensor) can be checked with
the monitoring function (Code: 36501 (V)).
q Pressure (Boost pressure) sensed by charge pressure sensor (boost pressure sensor) can be
checked with monitoring function (Code: 36500 (kPa)).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation
q Because troubleshooting "socket" for this sensor features female connector alone, it is not usable
for checking open circuit in wiring harness and voltage at sensor connector (not designed as a
T-adapter).
q If sensor connector is disconnected, this code is displayed.

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
Defective power supply system of
If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
2 charge pressure sensor (boost
for it first.
pressure sensor)
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and PIM.
3 Short circuit in wiring harness 3. Connect T-adapter to female side of ENG.
Between ENG (female)
Resistance Min. 1 Mz
(44) and (47)
1. Turn starting switch to OFF position, then carry out troubleshooting.
2. Disconnect connectors ENG and PIM, and connect T-adapter to female
Ground fault in wiring harness side of ENG.
4
(Contact with ground circuit)
Between ENG (female)
Resistance Min. 1 Mz
(44) and ground
If cause is not found by the above checks, there may be open circuit in wiring
5 Open circuit in wiring harness
harness. (*)
a If causes 1 - 5 are not the cause for the trouble and check result of cause 6
is abnormal, sensor is defective.
1. Turn starting switch to OFF position.
Defective charge pressure (boost 2. Connect T-adapter to connector ENG.
pressure) sensor 3. Turn starting switch to ON position.
6
(Improper input voltage to engine Between
controller) ENG
Sensor out-
(female) Voltage 0.3 4.7 V
put
(44) and
(47)
If no abnormality is found by above checks, engine controller is defective.
7 Defective engine controller
(Since failure is in it, troubleshooting cannot be performed.)

*: See "Troubleshooting method for disconnected wiring harness of pressure sensor system" of "Related trou-
bleshooting information".

40-186 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA123] Chg Air Press Sensor Low Error

Circuit diagram related to charge pressure sensor 40-187

D375A-6R 40-187
(01)
Troubleshooting by failurecode
Failure code [CA131] Throttle Sensor High Error

Failure code [CA131] Throttle Sensor High Error 40-18


Action code Failure code Throttle sensor too high
Failure
(Engine controller system)
E03 CA131
Detail of failure q High voltage occurred in decelerator pedal potentiometer signal circuit.
Action of con-
q Operate the decelerator pedal at a fixed value.
troller
Problem on
q The engine does not reach full throttle.
machine
q Signal of decelerator potentiometer voltage can be checked with monitoring function (Code:
31703).
Related infor-
q Signal state of decelerator potentiometer (decelerator opening) can be checked with monitoring
mation
function (Code: 31701).
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
Defective throttle sensor power
2 If failure code [CA2185] is displayed, troubleshoot it first.
supply system
1. Turn starting switch to OFF position.
2. Disconnect connector DEC and connect T-adapter to male side.
Defective decelerator pedal (throt- Between DEC (male) (B) and (C) Resistance 4.06.0 kz
3
tle sensor)
Between DEC (male) (A) and (C) Resistance 0.25.0 kz
Between DEC (male) (B) and (A) Resistance 0.25.0 kz
1. Turn starting switch to OFF position.
2. Disconnect connector EGC2 and connect T-adapter to female side.
Open or short circuit in wiring har-
4
ness Between EGC2 (female) (22) and (23) Resistance 4.06.0 kz
Between EGC2 (female) (9) and (23) Resistance 0.25.0 kz
a If no abnormality is found in checks on cause 4, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors EGC2 and DEC, and connect T-adapter to female
5 Short circuit in wiring harness side of either of them.
Between EGC2 (female) (9) and (22), or
Resistance Min. 1 Mz
between DEC (female) (A) and (B)
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector DEC and connect T-adapter to female side.
6 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between DEC (female) (B) and ground Voltage Max. 1 V
If no abnormality is found by the above checks, the engine controller is defec-
tive. (Since the faliure is in it, troubleshooting cannot be performed.)
q Reference; the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter between male and female sides of EGC2.
3. Turn starting switch to ON position.
7 Defective engine controller 4. Operate decelerator pedal, and troubleshoot.
Between
EGC2 (22) Power supply Voltage 4.75 5.25 V
and (23)
Between Depress decelerator pedal. Voltage Approx. 4.7 V
EGC2 (9)
and (23) Release decelerator pedal. Voltage Approx. 0.4 V

40-188 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA131] Throttle Sensor High Error

Circuit diagram related to decelerator pedal 40-189

D375A-6R 40-189
(01)
Troubleshooting by failurecode
Failure code [CA132] Throttle Sensor Low Error

Failure code [CA132] Throttle Sensor Low Error 40-190


Action code Failure code Throttle sensor too low
Failure
(Engine controller system)
E03 CA132
Detail of failure q Decelerator potentiometer signal circuit of throttle sensor detected abnormally low voltage.
Action of con-
q Operate the decelerator pedal at a fixed value.
troller
Problem on
q The engine does not reach full speed.
machine
q Signal of decelerator potentiometer voltage can be checked with monitoring function (Code:
31703).
Related infor-
q Signal state of decelerator potentiometer (decelerator opening) can be checked with monitoring
mation
function (Code: 31701).
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
Defective throttle sensor power
2 If failure code [CA2186] is also indicated, perform troubleshooting for it first.
supply system
1. Turn starting switch to OFF position.
2. Disconnect connector DEC and connect T-adapter to male side.
Defective decelerator pedal (throt- Between DEC (male) (B) and (C) Resistance 4.06.0 kz
3
tle sensor)
Between DEC (male) (A) and (C) Resistance 0.25.0 kz
Between DEC (male) (B) and (A) Resistance 0.25.0 kz
1. Turn starting switch to OFF position.
2. Disconnect connector EGC2 and connect T-adapter to female side.
Open or short circuit in wiring har-
4
ness Between EGC2 (female) (22) and (23) Resistance 4.06.0 kz
Between EGC2 (female) (9) and (23) Resistance 0.25.0 kz
a If no abnormality is found in checks on cause 4, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector EGC2 and DEC and connect T-adapter to each
female side.
Open circuit in wiring harness
Between EGC2 (female) (22) and DEC
5 (Open circuit in wiring or defective Resistance Max. 1 z
(female) (A)
contact in connector)
Between EGC2 (female) (9) and DEC
Resistance Max. 1 z
(female) (B)
Between EGC2 (female) (23) and DEC
Resistance Max. 1 z
(female) (C)
a If no abnormality is found in checks on cause 4, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors EGC2 and DEC, and connect T-adapter to female
6 Short circuit in wiring harness side of either of them.
Between EGC2 (female) (9) and (23), or
Resistance Min. 1 Mz
between DEC (female) (B) and (C)
1. Turn starting switch to OFF position.
2. Disconnect connectors EGC2 and DEC, and connect T-adapter to female
Ground fault in wiring harness side of either of them.
7
(Contact with ground circuit)
Between EGC2 (female) (9) or DEC (female)
Resistance Min. 1 Mz
(B) and ground

40-190 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA132] Throttle Sensor Low Error

Cause Procedure, measuring location, criteria and remarks


If no abnormality is found by above checks, engine controller is defective. (Since fail-
ure is in it, troubleshooting cannot be performed.)
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter between male and female sides of EGC2.
3. Turn starting switch to ON position.
4. Operate decelerator pedal, and troubleshoot.
8 Defective engine controller
Between EGC2 (22) and
Power supply Voltage 4.75 5.25 V
(23)
Depress decelerator
Voltage Approx. 4.7 V
pedal.
Between EGC2 (9) and (23)
Release decelerator
Voltage Approx. 0.4 V
pedal.

Circuit diagram related to decelerator pedal 40-191

D375A-6R 40-191
(01)
Troubleshooting by failurecode
Failure code [CA135] Eng Oil Press Sensor High Error

Failure code [CA135] Eng Oil Press Sensor High Error 40-192
Action code Failure code Eng Oil Press Sensor High Error
Failure
(Engine controller system)
E02 CA135
Detail of failure q High voltage was detected in engine oil pressure sensor signal circuit.
Action of con-
troller q Takes it that engine oil pressure is default (250 kPa {2.5 kg/cm2}), and allows engine to run.

Problem on
machine
q Signal voltage from the engine oil pressure sensor can be checked with the monitoring function
(Code: 37201 (V)).
Related infor-
q Oil pressure sensed by engine oil pressure sensor can be checked with monitoring function (Code:
mation
37200 (kPa)).
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
Defective power supply system of If failure code [CA187] or [CA227] indicated, carry out troubleshooting for
2
engine oil pressure sensor itfirst.
1. Turn starting switch to OFF position.
Defective engine oil pressure sen- 2. Disconnect connector POIL.
3 3. Turn starting switch to ON position.
sor
If failure code changes from [CA135] to [CA141],sensor is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and POIL, and connect T-adapter to female
4 Short circuit in wiring harness side of either one of them.
Between ENG (female) (13) and (37), or
Resistance Min. 1 Mz
between POIL (female) (1) and (3)
1. Turn starting switch to OFF position.
2. Disconnect connector POIL.
3. Connect T-adapter to female side of connector POIL or connect T-adapter
Hot short circuit in wiring harness to connector ENG.
5
(Short circuit with 24 V circuit) 4. Turn starting switch to ON position (with connector POIL disconnected).
Between ENG (female) (13) and (47), or
Voltage Max. 1 V
between POIL (female) (3) and (2)
If no abnormality is found by above checks, engine controller is defective.
6 Defective engine controller
(Since failure is in it, troubleshooting cannot be performed.)

40-192 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA135] Eng Oil Press Sensor High Error

Circuit diagram related to engine oil pressure sensor 40-193

D375A-6R 40-193
(01)
Troubleshooting by failurecode
Failure code [CA141] Eng Oil Press Sensor Low Error

Failure code [CA141] Eng Oil Press Sensor Low Error 40-194
Action code Failure code Eng Oil Press Sensor Low Error
Failure
(Engine controller system)
E02 CA141
Detail of failure q Low voltage was detected in engine oil pressure sensor signal circuit.
Action of con-
troller q Takes it that engine oil pressure is default (250 kPa {2.5 kg/cm2}), and allows engine to run.

Problem on
machine
q Signal voltage from the engine oil pressure sensor can be checked with the monitoring function
(Code: 37201 (V)).
Related infor-
q Oil pressure sensed by engine oil pressure sensor can be checked with monitoring function (Code:
mation
37200 (kPa)).
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
for it first.
1. Turn starting switch to OFF position.
Defective power supply system of 2. Disconnect connector POIL and connect T-adapter to each female side of
2
engine oil pressure sensor them.
3. Turn starting switch to ON position.
Between POIL(female)(1) Power supply
Voltage 4.75 5.25 V
and (2) input
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and POIL and connect T-adapter to female
side.
a If power supply input in checks on cause
2 is normal, this check is not required.
Resistance Max. 1 z
Open circuit in wiring harness Between ENG (female) (37) and POIL
3 (Open circuit in wiring or defective (female) (1)
contact in connector) a If power supply input in checks on cause
2 is normal, this check is not required.
Resistance Max. 1 z
Between ENG (female) (47) and POIL
(female) (2)
Between ENG (female) (13) and POIL
Resistance Max. 1 z
(female) (3) (Sensor output)
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and POIL, and connect T-adapter to female
Ground fault in wiring harness side of either one of them.
4
(Contact with ground circuit)
Between ENG (female) (13) or POIL (female)
Resistance Min. 1 Mz
(3) and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and POIL, and connect T-adapter to female
5 Short circuit in wiring harness side of either one of them.
Between ENG (female) (13) and (47), or
Resistance Min. 1 Mz
between POIL (female) (2) and (3)
a If cause items 1 - 5 are not the cause for the trouble and check result of
Defective engine oil pressure sen- cause 6 is abnormal, sensor is defective.
sor (Improper input voltage to 1. Turn starting switch to OFF position.
6 2. Insert T-adapter into connector ENG.
engine controller)
3. Turn starting switch to ON position.
Between ENG (13) and (47) Sensor output Voltage 0.3 4.7 V
If no abnormality is found by above checks, engine controller is defective.
7 Defective engine controller
(Since failure is in it, troubleshooting cannot be performed.)

40-194 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA141] Eng Oil Press Sensor Low Error

Circuit diagram related to engine oil pressure sensor 40-195

D375A-6R 40-195
(01)
Troubleshooting by failurecode
Failure code [CA144] Coolant Temp Sens High Error

Failure code [CA144] Coolant Temp Sens High Error 40-196


Action code Failure code Coolant Temp Sens High Error
Failure
(Engine controller system)
E02 CA144
Detail of failure q High voltage was detected in engine coolant temperature sensor signal circuit.
Action of con-
q Sets coolant temperature to fixed temperature (90 C),and allows for operation.
troller
Problem on q Engine does not start easily at low temperature.
machine q Overheat prevention function does not work.
q Signal voltage from engine coolant temperature sensor can be checked with monitoring function
(Code: 04105 (V)).
q Temperature sensed by engine coolant temperature sensor can be checked by using monitoring
function. (Code: 04107 (C))
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation
q This failure code is displayed if temperature sensor connector is disconnected.
q Because troubleshooting "socket" for this sensor features female connector alone, it is not connect-
able to female connector of sensor wiring harness, and thus not usable for checking open circuit
(not designed as a T-adapter).

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector TWTR and connect socket to male side of connector.
a If coolant temperature sensor has resistance of 700 z - 37 kz with coolant
temperature above 0 C, regard coolant temperature sensor as normal.
Between 0 C Resistance 30 37 kz
TWTR
(male) (A) 25 C Resistance 9.3 10.7 kz
Defective coolant temperature
2 and (B)
sensor 50 C Resistance 3.2 3.8 kz
a Coolant
temper- 80 C Resistance 1.0 1.3 kz
ature
-Resis-
taure 95 C Resistance 700 800 z
charac-
teristics
1. Turn starting switch to OFF position.
2. Disconnect connector ENG and connect T-adapter to female side.
Open or short circuit in wiring har- Between ENG (female) (15) and (38) (Cool-
3 ant temperature: Min. 0 C)
ness
a Use coolant temperature -Resistance Resistance 700 z 37 kz
characteristics table shown above as re-
sistance criteria.
If no abnormality is found by above checks, engine controller is defective.
4 Defective engine controller
(Since failure is in it, troubleshooting cannot be performed.)

40-196 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA144] Coolant Temp Sens High Error

Circuit diagram related to coolant temperature sensor 40-197

D375A-6R 40-197
(01)
Troubleshooting by failurecode
Failure code [CA145] Coolant Temp Sens Low Error

Failure code [CA145] Coolant Temp Sens Low Error 40-198


Action code Failure code Coolant Temp Sens Low Error
Failure
(Engine controller system)
E02 CA145
Detail of failure q Low voltage was detected in engine coolant temperature sensor signal circuit.
Action of con-
q Sets coolant temperature to fixed temperature (90 C),and allows for operation.
troller
Problem on q Engine does not start easily at low temperature.
machine q Overheat prevention function does not work.
q Signal voltage from engine coolant temperature sensor can be checked with monitoring function
(Code: 04105 (V)).
q Temperature sensed by engine coolant temperature sensor can be checked by using monitoring
Related infor-
function. (Code: 04107 ( C))
mation
q Method of reproducing failure code: Turn starting switch to ON position.
q If temperature sensor connector is disconnected, this failure code is not displayed but failure code
[CA144] for "High Error" is displayed.

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector TWTR and connect socket to male side of connector.
a If coolant temperature sensor has resistance of 700 z - 37 kz with coolant
temperature above 0 C, regard coolant temperature sensor as normal.
Between 0 C Resistance 30 37 kz
TWTR
(male) (A) 25 C Resistance 9.3 10.7 kz
and (B) 50 C Resistance 3.2 3.8 kz
Defective coolant temperature a Coolant
2
sensor temper- 80 C Resistance 1.0 1.3 kz
ature
-Resis-
taure 95 C Resistance 700 800 z
charac-
teristics
Between
All coolant tem-
(B) and Resistance Min. 1 Mz
perature range
ground
1. Turn starting switch to OFF position.
2. Disconnect connector ENG and connect T-adapter to female side.
Between ENG (female) (15) and (38) (Cool-
3 Short circuit in wiring harness ant temperature: Min. 0 C)
a Use coolant temperature -Resistance Resistance 700 z 37 kz
characteristics table shown above as re-
sistance criteria.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ENG and TWTR, and connect T-adapter to female
4 side of ENG.
(Contact with ground circuit)
Between ENG (female) (15) and ground Resistance Min. 1 Mz
If no abnormality is found by above checks, engine controller is defective.
5 Defective engine controller
(Since failure is in it, troubleshooting cannot be performed.)

40-198 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA145] Coolant Temp Sens Low Error

Circuit diagram related to coolant temperature sensor 40-19

D375A-6R 40-199
(01)
Troubleshooting by failurecode
Failure code [CA153] Chg Air Temp Sensor High Error

Failure code [CA153] Chg Air Temp Sensor High Error 40-20
Action code Failure code Charge (Boost) temperature sensor signal voltage is too high.
Failure
(Engine controller system)
E01 CA153
Detail of failure q High voltage was detected in charge (boost) temperature sensor signal circuit.
Action of con-
q Set charge temperature to fixed temperature (70 C) ,and allow for operation.
troller
Problem on
q Engine does not start easily at low temperature.
machine
q Signal voltage from charge temperature sensor (boost temperature sensor) can be checked with
monitoring function (Code: 18501 (V)).
q Temperature sensed by charge temperature sensor (boost temperature sensor) can be checked
by using monitoring function. (Code: 18500 ( C))
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation
q Because troubleshooting "socket" for this sensor features female connector alone, it is not connect-
able to female connector of sensor wiring harness, and thus not usable for checking open circuit
(not designed as a T-adapter).
q This failure code is displayed if temperature sensor connector is disconnected.

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector TIM and connect socket to male side of connector.
a If temperature sensor has resistance of 280 z 382 kz, regard charge tem-
perature sensor as normal.
Between -40 C Resistance 291 382 kz
TIM (male)
-20 C Resistance 85 109 kz
Defective charge temperature (A) and (B)
2 a Charge Resistance
sensor 0 C 29 36 kz
temper-
ature 30 C Resistance 7.3 8.8 kz
-Resis- Resistance
60 C 2.3 2.7 kz
tance
chari- 90 C Resistance 860 970 z
acteris- Resistance
130 C 280 320 z
tic
1. Turn starting switch to OFF position.
2. Disconnect connector ENG and connect T-adapter to female side.
Open or short circuit in wiring har- Between ENG (female) (23) and (47)
3
ness a Use "charge temperature-Resistance 280 z
Resistance
characteristics" table shown above as re- 382 kz
sistance criteria.
If no abnormality is found by above checks, engine controller is defective.
4 Defective engine controller
(Since failure is in it, troubleshooting cannot be performed.)

40-200 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA153] Chg Air Temp Sensor High Error

Circuit diagram related to charge temperature sensor 40-201

D375A-6R 40-201
(01)
Troubleshooting by failurecode
Failure code [CA154] Chg Air Temp Sensor Low Error

Failure code [CA154] Chg Air Temp Sensor Low Error 40-202
Action code Failure code Charge (Boost) temperature sensor signal volatge too low
Failure
(Engine controller system)
E01 CA154
Detail of failure q Low voltage was detected in charge (boost) temperature sensor signal circuit.
Action of con-
q Set charge temperature to fixed temperature (70 C) ,and allow for operation.
troller
Problem on
q Engine does not start easily at low temperature.
machine
q Signal voltage from charge temperature sensor (boost temperature sensor) can be checked with
monitoring function (Code: 18501 (V)).
q Temperature sensed by charge temperature sensor (boost temperature sensor) can be checked
Related infor-
by using monitoring function. (Code: 18500 ( C))
mation
q Method of reproducing failure code: Turn starting switch to ON position.
q If temperature sensor connector is disconnected, this failure code is not displayed but failure code
[CA153] for "High Error" is displayed.

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector TIM and connect socket to male side of connector.
a If temperature sensor has resistance of 280 z - 382 kz, regard charge tem-
perature sensor as normal.
Between -40 C Resistance 291 382 kz
TIM (male)
(A) and (B) -20 C Resistance 85 109 kz
Defective charge temperature
2 a Charge
sensor 0 C Resistance 29 36 kz
temper-
ature 30 C Resistance 7.3 8.8 kz
-Resis-
60 C Resistance 2.3 2.7 kz
tance
chari- 90 C Resistance 860 970 z
acteris-
tic 130 C Resistance 280 320 z
1. Turn starting switch to OFF position.
2. Disconnect connector ENG and connect T-adapter to female side.
3 Short circuit in wiring harness Between ENG (female) (23) and (47)
a Use "charge temperature-Resistance 280 z
Resistance
characteristics" table shown above as re- 382 kz
sistance criteria.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ENG and TIM and connect T-adapter to female side
4 of ENG.
(Contact with ground circuit)
Between ENG (female) (23) and ground Resistance Min. 1 Mz
If no abnormality is found by above checks, engine controller is defective.
5 Defective engine controller
(Since failure is in it, troubleshooting cannot be performed.)

40-202 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA154] Chg Air Temp Sensor Low Error

Circuit diagram related to charge temperature sensor 40-203

D375A-6R 40-203
(01)
Troubleshooting by failurecode
Failure code [CA187] Sens Supply 2 Volt Low Error

Failure code [CA187] Sens Supply 2 Volt Low Error 40-204


Action code Failure code Sens Supply 2 Volt Low Error
Failure
(Engine controller system)
E03 CA187
Detail of failure q Low voltage appears in sensor power supply 2 (5 V) circuit.
q Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor signals.
q Ignores signals from engine oil pressure sensor, takes it that engine oil pressure is default value
(250 kPa {2.5 kg/cm2}), and allows engine to run.
Action of con- q Ignores signals from ambient pressure sensor, takes it that ambient pressure is default value (52.44
troller
kPa {0.53 kg/cm2}), and allows engine to run.
q Ignores signals from boost pressure sensor, takes it that boost pressure is at fixed value (400 kPa
{4.1 kg/cm2}), and allows engine to run.
Problem on
q Engine output drops.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect following connectors sequentially one by one and turn starting
switch to ON position each time.
3. After troubleshooting, return to 1.
If this failure code is not displayed when a connector is disconnected, that sen-
sor or engine wiring harness is defective.
a Other failure codes are displayed, too. This is because the connector is dis-
connected. Ignore failure codes other than [CA187].
2 Defective sensor or wiring harness Sensor, harness Connector
Bkup speed sensor G connector
Oil pressure sensor POIL connector
Charge (boost) pressure
PIM connector
sensor
Ambient pressure sensor PAMB connector
Engine harness ENG

3 Defect in related system If another failure code is displayed, perform troubleshooting for it.

1. Turn starting switch to OFF position.


2. Disconnect connector ENG and connect T-adapter to male side.
4 Defective engine controller 3. Turn starting switch to ON position with engine wiring harness discon-
nected.
Between ENG (male) (37) and (47) Voltage 4.75 5.25 V

40-204 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA187] Sens Supply 2 Volt Low Error

Circuit diagram related to sensor power supply 2 40-205

D375A-6R 40-205
(01)
Troubleshooting by failurecode
Failure code [CA212] Eng Oil Temp Sensor High Error

Failure code [CA212] Eng Oil Temp Sensor High Error 40-206
Action code Failure code Eng Oil Temp Sensor Low Error
Failure
(Engine controller system)
E01 CA212
Detail of failure q High voltage was detected engine oil temperature sensor signal circuit
Action of con-
q Sets engine oil temperature to fixed value (100 C), and allows engine to run.l
troller
Problem on
machine
q Signal voltage from engine oil temperature sensor can be checked with monitoring function (Code:
42701 (V)).
q Temperature sensed by engine oil temperature sensor can be checked with monitoring function
(Code: 42700 (C)).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation
q This failure code is displayed if temperature sensor connector is disconnected.
q Because troubleshooting "socket" for this sensor features female connector alone, it is not connect-
able to female connector of sensor wiring harness, and thus not usable for checking open circuit
(not designed as a T-adapter).

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connectors TOIL and connect socket to male side of connector.
a If oil temperature sensor resistance is 700 z - 37 kz with oil temperature is
above0 C, regard oil temperature sensor as normal.
0 C Resistance 30 37 kz
2 Defective oil temperature sensor Between TOIL (male)
25 C Resistance 9.3 10.7 kz
(A) and (B)
a Oil temperature -Re- 50 C Resistance 3.2 3.8 kz
sistance characteris-
80 C Resistance 1.0 1.3 kz
tics
95 C Resistance 700 800 z
1. Turn starting switch to OFF position.
2. Disconnect connector ENG and connect T-adapter to female side.
Open or short circuit in wiring har- Between ENG (female) (17) and (47) (Oil temper-
3
ness ature: Min. 0 C)
Resistance 700 z 37 kz
a UseOil temperature -Resistance charactenis
table shown above as resistance criteria.
If no abnormality is found by above checks, engine controller is defective.
4 Defective engine controller
(Since failure is in it, troubleshooting cannot be performed.)

40-206 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA212] Eng Oil Temp Sensor High Error

Circuit diagram related to engine oil temperature sensor 40-207

D375A-6R 40-207
(01)
Troubleshooting by failurecode
Failure code [CA213] Eng Oil Temp Sensor Low Error

Failure code [CA213] Eng Oil Temp Sensor Low Error 40-208
Action code Failure code Eng Oil Temp Sensor Low Error
Failure
(Engine controller system)
E01 CA213
Detail of failure q Low voltage was detected in engine oil temperature sensor signal circuit.
Action of con-
q Sets engine oil temperature to fixed value (100 C), and allows engine to run.l
troller
Problem on
machine
q Signal voltage from engine oil temperature sensor can be checked with monitoring function (Code:
42701 (V)).
q Temperature sensed by engine oil temperature sensor can be checked with monitoring function
Related infor-
(Code: 42700 (C)).
mation
q Method of reproducing failure code: Turn starting switch to ON position.
q If temperature sensor connector is disconnected, this failure code is not displayed but failure code
[CA212] for "High Error" is displayed.

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connectors TOIL and connect socket to male side of connector.
a If oil temperature sensor resistance is 700 z 37 kz with oil temperature is
above 0 C, regard oil temperature sensor as normal.
0 C Resistance 30 37 kz
Between TOIL (male) (A)
25 C Resistance 9.3 10.7 kz
2 Defective oil temperature sensor and (B)
a Oil temperature -Re- 50 C Resistance 3.2 3.8 kz
sistance characteris-
80 C Resistance 1.0 1.3 kz
tics
95 C Resistance 700 800 z
All oil tem-
Between (B) and ground perature Resistance Min. 1 Mz
range
1. Turn starting switch to OFF position.
2. Disconnect connector ENG and connect T-adapter to female side.
3 Short circuit in wiring harness Between ENG (female) (17) and (47) (Oil tempera-
ture: Min. 0 C) Resis- 700 z
a UseOil temperature -Resistance charactenis tance 37 kz
table shown above as resistance criteria.
1. Turn starting switch to OFF position.
2. Disconnect connector ENG and connect T-adapter to female side.
Ground fault in wiring harness 1. Turn starting switch to OFF position.
4 2. Disconnect connectors ENG and TOIL, and connect T-adapter to female
(Contact with ground circuit)
side of ENG.
Resis-
Between ENG (female) (17) and ground Min. 1 Mz
tance
If no abnormality is found by above checks, engine controller is defective.
5 Defective engine controller
(Since failure is in it, troubleshooting cannot be performed.)

40-208 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA213] Eng Oil Temp Sensor Low Error

Circuit diagram related to engine oil temperature sensor 40-209

D375A-6R 40-209
(01)
Troubleshooting by failurecode
Failure code [CA221] Ambient Press Sens High Error

Failure code [CA221] Ambient Press Sens High Error 40-210


Action code Failure code Ambient Press Sens High Error
Failure
(Engine controller system)
E03 CA221
Detail of failure q High voltage was detected in ambient pressure sensor signal circuit .
Action of con- q Takes it that ambient pressure value is default value (52.44 kPa {0.53 kg/cm2}), and allows engine
troller to run.
Problem on
q Engine output drops.
machine
q Signal voltage from ambient pressure sensor can be checked with monitoring function (Code:
37401 (V)).
Related infor-
q Ambient pressure sensed by the ambient pressure sensor can be checked with monitoring function
mation
(Code: 37400 (kPa)).
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
Defective power supply line of If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
2
ambient pressure sensor for it first.
1. Turn starting switch to OFF position.
Defective ambient pressure sen- 2. Disconnect connector PAMB.
3 3. Turn starting switch to ON position.
sor
If failure code changes from [CA221] to [CA222] ,sensor is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector ENG and PAMB, and connect T-adapter to female
4 Short circuit in wiring harness side of ENG.
Between ENG (female) (37) and (3) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector PAMB.
Hot short circuit in wiring harness 3. Insert T-adapter into connector ENG.
5
(Contact with 24 V circuit) 4. Turn starting switch to ON position (with connector PAMB disconnected).
Between ENG (3) and (38) Voltage Max. 1 V
If no abnormality is found by above checks, engine controller is defective.
6 Defective engine controller
(Since failure is in it, troubleshooting cannot be performed.)

40-210 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA221] Ambient Press Sens High Error

Circuit diagram related to ambient pressure sensor 40-21

D375A-6R 40-211
(01)
Troubleshooting by failurecode
Failure code [CA222] Ambient Press Sens Low Error

Failure code [CA222] Ambient Press Sens Low Error 40-212


Action code Failure code Ambient Press Sens Low Error
Failure
(Engine controller system)
E03 CA222
Detail of failure q Low voltage was detected ambient pressure sensor signal circuit .
Action of con- q Takes it that ambient pressure value is default value(52.44 kPa {0.53 kg/cm2}), and allows engine
troller to run.
Problem on
q Engine output drops.
machine
q Signal voltage from ambient pressure sensor can be checked with monitoring function (Code:
37401 (V)).
q Ambient pressure sensed by the ambient pressure sensor can be checked with monitoring function
(Code: 37400 (kPa)).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation
q Because troubleshooting "socket" for this sensor features female connector alone, it is not usable
for checking open circuit in wiring harness and voltage at sensor connector (not designed as a
T-adapter).
q If sensor connector is disconnected, this code is displayed.

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
Defective power supply line of If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
2
ambient pressure sensor for it first.
1. Turn starting switch to OFF position.
2. Disconnect connectors PAMB and ENG.
3 Short circuit in wiring harness 3. Connect T-adapter to female side of ENG.
Between ENG (female) (3) and (38) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors PAMB and ENG and connect T-adapter to female
4 side of ENG.
(Contact with ground circuit)
Between ENG (female) (3) and ground Resistance Min. 1 Mz
If cause is not found by the above checks, there may be open circuit in wiring
5 Open circuit in wiring harness
harness. (*)
a If causes 1 - 5 are not the cause for the trouble and check result of cause 6
is abnormal, sensor is defective.
Defective ambient pressure sen-
1. Turn starting switch to OFF position.
sor
6 2. Insert T-adapter into connector ENG.
(Improper input voltage to engine
3. Turn starting switch to ON position.
controller)
Sensor out-
Between ENG (3) and (38) Voltage 0.3 - 4.7 V
put
If no abnormality is found by above checks, the engine controller is defective.
7 Defective engine controller
(Since failure is in it, troubleshooting cannot be performed.)

*: See "Troubleshooting method for disconnected wiring harness of pressure sensor system" of "Related trou-
bleshooting information".

40-212 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA222] Ambient Press Sens Low Error

Circuit diagram related to ambient pressure sensor 40-213

D375A-6R 40-213
(01)
Troubleshooting by failurecode
Failure code [CA227] Sens Supply 2 Volt High Error

Failure code [CA227] Sens Supply 2 Volt High Error 40-214


Action code Failure code Sensor power supply circuit valtage is too high
Failure
(Engine controller system)
E03 CA227
Detail of failure q High voltage appears in sensor power supply 2 (5 V) circuit.
q Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor signals.
q Ignores signals from engine oil pressure sensor, takes it that engine oil pressure is default value
(250 kPa {2.5 kg/cm2}), and allows engine to run.
Action of con- q Ignores signals from ambient pressure sensor, takes it that ambient pressure is default value (52.44
troller
kPa {0.53 kg/cm2}), and allows engine to run.
q Ignores signals from boost pressure sensor, takes it that boost pressure is at fixed value (400 kPa
{4.1 kg/cm2}), and allows engine to run.
Problem on
q Engine output drops.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks


Perform troubleshooting for failure code [CA187].

40-214 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA234] Eng Overspeed

Failure code [CA234] Eng Overspeed 40-215


Action code Failure code Engine overspeed
Failure
(Engine controller defective)
CA234
Detail of failure q Engine speed exceeded operating range.

Action of con-
q Reduce fuel injection rate until engine speed lowers in operating range.
troller
Problem on
q Engine speed fluctuates.
machine
Related infor- q Engine speed can be checked by using monitoring function. (Code: 01002 (rpm))
mation q Method of reproducing failure code: Start engine and keep it running at high idle.

Cause Procedure, measuring location, criteria and remarks


1 Use of improper fuel Improper fuel may be used. Check it directly.

2 Defect in related system If another failure code is displayed, perform troubleshooting for it.

The method of using machine may be improper, so instruct the operator on


3 Usage is improper
how to use machine properly.
If causes 1 and 2 are not cause of failure, engine controller may be defective.
4 Defective engine controller
(Since failure is in it , troubleshooting cannot be performed.)

D375A-6R 40-215
(01)
Troubleshooting by failurecode
Failure code [CA238] Ne Speed Sens Supply Volt Error

Failure code [CA238] Ne Speed Sens Supply Volt Error 40-216


Action code Failure code Ne Speed Sens Supply Volt Error
Failure
(Engine controller system)
E03 CA238
Detail of failure q Abnormality occurred in Ne speed sensor power supply (5 V) circuit.
Action of con- q Controls engine by using signals from Bkup speed sensor.
troller q Limits engine output and continues operation.
q Engine output drops.
Problem on
q Engine stops during operation (When engine Bkup speed sensor is also defective).
machine
q Engine cannot be started if it is stopped. (When engine Bkup speed sensor is also defective)
Related infor-
q Method of reproducing failure code: Turn the starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. After troubleshooting, return to 1.
If this failure code is not displayed when a connector is disconnected, that sen-
sor or engine wiring harness is defective.
2 Defective sensor or wiring harness a Other failure codes are displayed, too. This is because the connector is dis-
connected. Ignore failure codes other than [CA238].
Sensor, harness Connector
Ne speed sensor NE
Engine harness ENG
1. Turn starting switch to OFF position.
2. Disconnect connector ENG and connect T-adapter to male side.
3. Turn starting switch to ON position with engine wiring harness discon-
3 Defective engine controller nected.

Between ENG(male)(16) and (48) Voltage 4.75 to 5.25 V

Circuit diagram related to Ne speed sensor 40-216

40-216 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA238] Ne Speed Sens Supply Volt Error

D375A-6R 40-217
(01)
Troubleshooting by failurecode
Failure code [CA263] Fuel Temp Sensor High Error

Failure code [CA263] Fuel Temp Sensor High Error 40-218


Action code Failure code Fuel temperature sensor signal voltage is too high
Failure
(Engine controller system)
E01 CA263
Detail of failure q High voltage was detected in fuel temperature sensor signal circuit .
q Uses signals from coolant temperature sensor to perform fuel injection rate correction based on fuel
Action of con-
temperature.
troller
q Sets fuel temperature value to fixed value (95 C) and allows engine to run.
Problem on

machine
q Signal voltage from the fuel temperature sensor can be checked with the monitoring function (Code:
14201 (V)).
q Temperature sensed by fuel temperature sensor can be checked by using monitoring function.
(Code: 14200 ( C))
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation
q This failure code is displayed if temperature sensor connector is disconnected.
q Because troubleshooting "socket" for this sensor features female connector alone, it is not connect-
able to female connector of sensor wiring harness, and thus not usable for checking open circuit
(not designed as a T-adapter).

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshooting",
tor
and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector TFUEL and connect socket to male side of connector.
a If coolant temperature sensor resistance is 700 z 37 kz with coolant tem-
perature is above 0 C, regard coolant temperature sensor as normal.
Between TFUEL 0 C Resistance 30 37 kz
2 Defective fuel temperature sensor (male)
25 C Resistance 9.3 10.7 kz
(A) and (B)
a Fuel tempera- 50 C Resistance 3.2 3.8 kz
ture -Resis-
80 C Resistance 1.0 1.3 kz
tance
characteristic 95 C Resistance 700 800 z
1. Turn starting switch to OFF position.
2. Disconnect connector ENG and connect T-adapter to female side.
Open or short circuit in wiring har- Between ENG (female) (30) and (47) (Fuel tem-
3 perature: Min. 0 C)
ness 700 z
a Use Fuel temperature - Resistance charac- Resistance
37 kz
teristics table shown above as resistance cri-
taeria.
If no abnormality is found by above checks, engine controller is defective.
4 Defective engine controller
(Since failure is in it, troubleshooting cannot be performed.)

40-218 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA263] Fuel Temp Sensor High Error

Circuit diagram related to fuel temperature sensor 40-219

D375A-6R 40-219
(01)
Troubleshooting by failurecode
Failure code [CA265] Fuel Temp Sensor Low Error

Failure code [CA265] Fuel Temp Sensor Low Error 40-2 0


Action code Failure code Fuel Temp Sensor Low Erro
Failure
(Engine controller system)
E01 CA265
Detail of failure q Low voltage was detected in fuel temperature sensor signal circuit.
q Uses signals from coolant temperature sensor to perform fuel injection rate correction based on fuel
Action of con-
temperature.
troller
Sets fuel temperature value to fixed value (95 C) and allows engine to run.
Problem on
machine
q Signal voltage from fuel temperature sensor can be checked by using monitoring function. (Code:
14201 (V))
q Temperature sensed by fuel temperature sensor can be checked by using monitoring function.
Related infor-
(Code: 14200 ( C))
mation
q Method of reproducing failure code: Turn starting switch to ON position.
q If temperature sensor connector is disconnected, this failure code is not displayed but failure code
[CA263] for "High Error" is displayed.

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshooting",
tor
and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector TFUEL and connect socket to male side of connector.
a If coolant temperature sensor resistance is 700 z 37 kz with coolant tem-
perature is above 0 C, regard coolant temperature sensor as normal.
Between TFUEL 0 C Resistance 30 37 kz
(male)
25 C Resistance 9.3 10.7 kz
2 Defective fuel temperature sensor (A) and (B)
a Fuel tempera- 50 C Resistance 3.2 3.8 kz
ture -Resis-
80 C Resistance 1.0 1.3 kz
tance
characteristic 95 C Resistance 700 800 z
All fuel tem-
Between (B) and
perature Resistance Min. 1 Mz
ground
range
1. Turn starting switch to OFF position.
2. Disconnect connector ENG and connect T-adapter to female side.
Between ENG (female) (15) and (38) (fuel tem-
3 Short circuit in wiring harness perature: Min. 0 C)
700 z
a Use Fuel temperature - Resistance charac- Resistance
37 kz
teristics table shown above as resistance cri-
taeria.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connector TFUEL, and connect T-adapter to female side of
4 ENG.
(Contact with ground circuit)
Between ENG (female) (30) and ground Resistance Min. 1 Mz
If no abnormality is found by above checks, engine controller is defective.
5 Defective engine controller
(Since failure is in it, troubleshooting cannot be performed.)

40-220 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA265] Fuel Temp Sensor Low Error

Circuit diagram related to fuel temperature sensor 40-2 1

D375A-6R 40-221
(01)
Troubleshooting by failurecode
Failure code [CA271] IMV/PCV1 Short Error

Failure code [CA271] IMV/PCV1 Short Error 40-2 2


Action code Failure code IMV/PCV1 Short Error
Failure
(Engine controller system)
E03 CA271
Detail of failure q Short circuit was detected in supply pump PCV1 circuit.
Action of con-
troller
Problem on
q Engine output drops.
machine
Related infor- q Under normal conditions, pulse voltage of approx. 24 V is applied to PCV1 (1) while engine is run-
mation ning. However, it cannnot be measured with multimeter since it is pulse voltage.

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector PCV1.
Defective supply pump PCV1
2 3. Turn starting switch to ON position.
(internal short circuit)
If failure code changes from [CA271] to [CA272], supply pump PCV1 is defec-
tive.
1. Turn starting switch to OFF position.
2. Disconnect connector ENG and connect T-adapter to female side.
3 Short circuit in wiring harness
Between ENG (female) (4) and (5) (PCV1 resis-
Resistance 2.3 5.3 z
tance)
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connector ENG and PCV1, and connect Tadapter to female
4 side of ENG.
(Contact with ground circuit)
Between ENG (female) (4) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector PCV1.
Hot short circuit in wiring harness 3. Insert T-adapter into connector ENG.
5
(Contact with 24 V circuit) 4. Turn starting switch to ON position (with connector PCV1 disconnected).
Between ENG (4) and (5) Voltage Max. 3 V
If no abnormality is found by above checks, engine controller is defective.
6 Defective engine controller
(Since failure is in it troubleshooting cannot be performed.)

Circuit diagram related to PCV1 40-2 2

40-222 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA272] IMV/PCV1 Open Error

Failure code [CA272] IMV/PCV1 Open Error 40-2 3


Action code Failure code IMV/PCV1 Open Error
Failure
(Engine controller system)
E03 CA272
Detail of failure q Disconnection was detected in supply pump PCV1 circuit.
Action of con-
troller
Problem on
q Engine output drops.
machine
q Method of reproducing failure code: Turn the starting switch to ON position.
q Under normal conditions, pulse voltage of approx. 24 V is applied to PCV (1) while engine is running
Related infor- . However it cannot be measured with multimeter since it is pulse voltage.
mation q Because troubleshooting "socket" for PCV1 features female connector alone, it is not connectable
to female connector of sensor wiring harness, and thus not usable for checking open circuit (not
designed as a T-adapter).

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
Defective supply pump PCV1 2. Disconnect connectors PCV1 and connect socket to male side.
2
(Internal disconnection)
Between PCV1 (male) (1) and (2) Resistance 2.3 5.3 z
1. Turn starting switch to OFF position.
Open or short circuit in wiring har- 2. Disconnect connector ENG and connect T-adapter to female side.
3
ness Between ENG (female) (4) and (5) (PCV1 resis-
Resistance 2.3 5.3 z
tance)
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ENG and PCV1.
4 3. Connect T-adapter to female side of connector ENG.
(Contact with ground circuit)
Between ENG (4) and (5) Resistance Min. 1 Mz
If no abnormality is found by above checks, engine controller is defective.
5 Defective engine controller
(Since failure is in it, troubleshooting cannot be performed.)

Circuit diagram related to PCV1 40-2 3

D375A-6R 40-223
(01)
Troubleshooting by failurecode
Failure code [CA273] PCV2 Short Error

Failure code [CA273] PCV2 Short Error 40-2 4


Action code Failure code PCV2 short circuit error
Failure
(Engine controller system)
E03 CA273
Detail of failure q Short circuit was detected in supply pump PCV2 circuit.
Action of con-
troller
Problem on
q Engine output drops.
machine
q Method of reproducing failure code: Turn starting switch to ON position.
Related infor-
q While engine is running normally, approximately 24 V of pulse voltage is applied to PCV2 (1). But
mation
it is pulse voltage and cannot be measured by using multimeter.

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector PCV2.
Defective supply pump PCV2
2 3. Turn starting switch to ON position.
(Internal short)
If failure code changes from [CA273] to [CA274], supply pump PCV2 is defec-
tive.
1. Turn starting switch to OFF position.
2. Disconnect connector ENG and connect T-adapter to female side.
3 Short circuit in wiring harness
Between ENG (female) (9) and (10) (PCV2 resis-
Resistance 2.3 5.3 z
tance)
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connector ENG and PCV2, and connect Tadapter to female
4 side of ENG.
(Contact with ground circuit)
Between ENG (female) (9) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector PCV2.
Hot short circuit in wiring harness 3. Insert T-adapter into connector ENG.
5
(Contact with 24 V circuit) 4. Turn starting switch to ON position (with connector PCV2 disconnected).
Between ENG (9) and (10) Voltage Max. 3 V
If no abnormality is found by above checks, engine controller is defective.
6 Defective engine controller (Since failure is in it, troubleshooting cannot be performed.)

Circuit diagram related to PCV2 40-2 4

40-224 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA274] PCV2 Open Error

Failure code [CA274] PCV2 Open Error 40-2 5


Action code Failure code PCV2 disconnection
Failure
(Engine controller system)
E03 CA274
Detail of failure q Disconnection was detected in supply pump PCV2 circuit.
Action of con-
troller
Problem on
q Engine output drops.
machine
q Method of reproducing failure code: Turn starting switch to ON position.
Related infor-
q While engine is running normally, approximately 24 V of pulse voltage is applied to PCV2 (1). But
mation
it is pulse voltage and cannot be measured by using multimeter.

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
Defective supply pump PCV2 2. Disconnect connector PCV2 and connect socket to male side.
2
(internal open circuit)
Between PCV2 (male) (1) and (2) Resistance 2.3 5.3 z
1. Turn starting switch to OFF position.
Open or short circuit in wiring har- 2. Disconnect connector ENG and connect T-adapter to female side.
3
ness Between ENG (female) (9) and (10) (PCV2 resis-
Resistance 2.3 5.3 z
tance)
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connector ENG and PCV2.
4 3. Connect T-adapter to female side of connector ENG.
(Contact with ground circuit)
Between ENG (9) and (10) Resistance Min. 1 Mz
If no abnormality is found by above checks, engine controller is defective.
5 Defective engine controller
(Since the failure is in it, troubleshooting cannot be performed.)

Circuit diagram related to PCV2 40-2 5

D375A-6R 40-225
(01)
Troubleshooting by failurecode
Failure code [CA322] Inj #1 (L#1) Open/Short Error

Failure code [CA322] Inj #1 (L#1) Open/Short Error 40-2 6


Action code Failure code Injector #1(L#1) open/short circuit error
Failure
(Engine controller system)
E03 CA322
Detail of failure q Disconnection or short circuit was detected in injector #1 circuit.
Action of con-
troller
Problem on q Engine output drops.
machine q Engien speed does not stabilize
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, approximately 65 V of pulse voltage is applied to injector (posi-
mation
tive) side. But it is pulse voltage and cannot be measured by using multimeter.

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector CN1 and connect T-adapter to male side.
2 Defective injector #1
Between CN1 (male) (1) and (2) Resistance 0.4 1.1 z
Between CN1 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector ENG and connect T-adapter to female side.
Open circuit or ground fault of wir-
3
ing harness Between ENG (female) (45) and (53) Resistance 0.4 1.1 z
Between ENG (female) (45) and ground Resistance Min. 1 Mz
a If no abnormality is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ENG and CN1, and connect T-adapters to each
4 (Open circuit in wiring or defective female side.
contact in connector) Between ENG (female) (45) and CN1 (female) (1) Resistance Max. 1 z
Between ENG (female) (53) and CN1 (female) (2) Resistance Max. 1 z
a If no abnormality is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ENG and CN1, and connect T-adapter to female
5
(Contact with ground circuit) side of either one of them.
Between ENG (female) (45) or CN1 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and CN1, and connect T-adapter to female
side of ENG.
a Check with circuit tester in continuity mode.
6 Short circuit in wiring harness Between ENG (female) (45) and each pin other than No continuity
(45) (No sound is heard)
Between ENG (female) (53) and each pin other than No continuity
(53) (No sound is heard)
Defective other cylinder injectors If the failure codes for other injectors are displayed, perform troubleshooting of
7
or wiring harness them, too.
If no abnormality is found by above checks, engine controller is defective.
8 Defective engine controller
(Since failure is in it , troubleshooting cannot be performed.)

40-226 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA322] Inj #1 (L#1) Open/Short Error

Circuit diagram related to injector #1 40-2 7

D375A-6R 40-227
(01)
Troubleshooting by failurecode
Failure code [CA323] Inj #5 (L#5) Open/Short Error

Failure code [CA323] Inj #5 (L#5) Open/Short Error 40-2 8


Action code Failure code Injector #5(L#5) open/short circuit error
Failure
(Engine controller system)
E03 CA323
Detail of failure q Disconnection or short circuit was detected in injector #5 circuit.
Action of con-
troller
Problem on q Engine output drops.
machine q Engine speed does not stabilize.
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, approximately 65 V of pulse voltage is applied to injector (posi-
mation
tive) side. But it is pulse voltage and cannot be measured by using multimeter.

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector CN5 and connect T-adapter to male side.
2 Defective injector #5
Between CN5 (male) (1) and (2) Resistance 0.4 1.1 z
Between CN5 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector ENG and connect T-adapter to female side.
Open circuit or ground fault of wir-
3
ing harness Between ENG (female) (46) and (60) Resistance 0.4 - 1.1 z
Between ENG (female) (46) and ground Resistance Min. 1 Mz
a If no abnormality is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ENG and CN5, and connect T-adapters to each
4 (Open circuit in wiring or defective female side.
contact in connector) Between ENG (female) (46) and CN5 (female) (1) Resistance Max. 1 z
Between ENG (female) (60) and CN5 (female) (2) Resistance Max. 1 z
a If no abnormality is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ENG and CN5, and connect T-adapter to female
5
(Contact with ground circuit) side of either one of them.
Between ENG (female) (46) or CN5 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and CN5, and connect T-adapter to female
side of ENG.
a Check with circuit tester in continuity mode.
6 Short circuit in wiring harness Between ENG (female) (46) and each pin other than No continuity
(46) (No sound is heard)
Between ENG (female) (60) and each pin other than No continuity
(60) (No sound is heard)
Defective other cylinder injectors If failure codes for other injectors are displayed, perform troubleshooting for
7
or wiring harness them, too.
If no abnormality is found by above checks, engine controller is defective.
8 Defective engine controller
(Since failure is in it, troubleshooting cannot be performed.)

40-228 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA323] Inj #5 (L#5) Open/Short Error

Circuit diagram related to injector #5 40-2 9

D375A-6R 40-229
(01)
Troubleshooting by failurecode
Failure code [CA324] Inj #3 (L#3) Open/Short Error

Failure code [CA324] Inj #3 (L#3) Open/Short Error 40-230


Action code Failure code Injector #3(L#3) open /short circuit error
Failure
(Engine controller system)
E03 CA324
Detail of failure q Disconnection or short circuit was detected in injector #3 circuit.
Action of con-
troller
Problem on q Engine output drops.
machine q Engine speed does not stabilize.
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, approximately 65 V of pulse voltage is applied to injector (posi-
mation
tive) side. But it is pulse voltage and cannot be measured by using multimeter.

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector CN3 and connect T-adapter to male side.
2 Defective injector #3
Between CN3 (male) (1) and (2) Resistance 0.4 1.1 z
Between CN3 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector ENG and connect T-adapter to female side.
Open circuit or ground fault of wir-
3
ing harness Between ENG (female) (55) and (52) Resistance 0.4 1.1 z
Between ENG (female) (55) and ground Resistance Min. 1 Mz
a If no abnormality is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ENG and CN3, and connect T-adapters to each
4 (Open circuit in wiring or defective female side.
contact in connector) Between ENG (female) (55) and CN3 (female) (1) Resistance Max. 1 z
Between ENG (female) (52) and CN3 (female) (2) Resistance Max. 1 z
a If no abnormality is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ENG and CN3, and connect T-adapter to female
5
(Contact with ground circuit) side of either one of them.
Between ENG (female) (55) or CN3 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and CN3, and connect T-adapter to female
side of ENG.
a Check with circuit tester in continuity mode.
6 Short circuit in wiring harness Between ENG (female) (55) and each pin other than No continuity
(55) (No sound is heard)
Between ENG (female) (52) and each pin other than No continuity
(52) (No sound is heard)
Defective other cylinder injectors If failure codes for other injectors are displayed, perform troubleshooting for
7
or wiring harness them, too.
If no abnormality is found by above checks, engine controller is defective.
8 Defective engine controller
(Since failure is in it, troubleshooting cannot be performed.)

40-230 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA324] Inj #3 (L#3) Open/Short Error

Circuit diagram related to injector #3 40-231

D375A-6R 40-231
(01)
Troubleshooting by failurecode
Failure code [CA325] Inj #6 (L#6) Open/Short Error

Failure code [CA325] Inj #6 (L#6) Open/Short Error 40-232


Action code Failure code Injector #6 (L#6) open / short circuit error
Failure
(Engine controller system)
E03 CA325
Detail of failure q Opening or short circuit was detected in drive circuit of No. 6 injector.
Action of con-
troller
Problem on q Engine output drops.
machine q Engine speed does not stabilize.
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, approximately 65 V of pulse voltage is applied to injector (posi-
mation
tive) side. But it is pulse voltage and cannot be measured by using multimeter.

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector CN6 and connect T-adapter to male side.
2 Defective injector #6
Between CN6 (male) (1) and (2) Resistance 0.4 1.1 z
Between CN6 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector ENG and connect T-adapter to female side.
Open circuit or ground fault of wir-
3
ing harness Between ENG (female) (57) and (59) Resistance 0.4 1.1 z
Between ENG (female) (57) and ground Resistance Min. 1 Mz
a If no abnormality is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ENG and CN6, and connect T-adapters to each
4 (Open circuit in wiring or defective female side.
contact in connector) Between ENG (female) (57) and CN6 (female) (1) Resistance Max. 1 z
Between ENG (female) (59) and CN6 (female) (2) Resistance Max. 1 z
a If no abnormality is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ENG and CN6, and connect T-adapter to female
5
(Contact with ground circuit) side of either one of them.
Between ENG (female) (57) or CN6 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and CN6, and connect T-adapter to female
side of ENG.
a Check with circuit tester in continuity mode.
6 Short circuit in wiring harness Between ENG1 (female) (57) and each pin other No continuity
than (57) (No sound is heard)
Between ENG1 (female) (59) and each pin other No continuity
than (59) (No sound is heard)
Defective injector or wiring har- If the failure codes for other injectors are displayed, perform troubleshooting
7
ness of another cylinder for them, too.
If no abnormality is found by above checks, engine controller is defective.
8 Defective engine controller
(Since failure is in it, troubleshooting cannot be performed.)

40-232 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA325] Inj #6 (L#6) Open/Short Error

Circuit diagram related to injector #6 40-23

D375A-6R 40-233
(01)
Troubleshooting by failurecode
Failure code [CA331] Inj #2 (L#2) Open/Short Error

Failure code [CA331] Inj #2 (L#2) Open/Short Error 40-234


Action code Failure code Injector #2 Open/Short circuit error
Failure
(Engine controller system)
E03 CA331
Detail of failure q Disconnection or short circuit was detected in injector #2 circuit.
Action of con-
troller
Problem on q Engine output drops.
machine q Engine speed does not stabilize.
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, approximately 65 V of pulse voltage is applied to injector (posi-
mation
tive) side. But it is pulse voltage and cannot be measured by using multimeter.

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector CN2 and connect T-adapter to male side.
2 Defective injector #2
Between CN2 (male) (1) and (2) Resistance 0.4 1.1 z
Between CN2 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector ENG and connect T-adapter to female side.
Open circuit or ground fault of wir-
3
ing harness Between ENG (female) (54) and (51) Resistance 0.4 1.1 z
Between ENG (female) (54) and ground Resistance Min. 1 Mz
a If no abnormality is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ENG and CN2, and connect T-adapters to each
4 (Open circuit in wiring or defective female side.
contact in connector) Between ENG (female) (54) and CN2 (female) (1) Resistance Max. 1 z
Between ENG (female) (51) and CN2 (female) (2) Resistance Max. 1 z
a If no abnormality is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ENG and CN2, and connect T-adapter to female
5
(Contact with ground circuit) side of either one of them.
Between ENG (female) (54) or CN2 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and CN, and connect T-adapter to female side
of ENG.
a Check with circuit tester in continuity mode.
6 Short circuit in wiring harness Between ENG (female) (54) and each pin other than No continuity
(54) (No sound is heard)
Between ENG (female) (51) and each pin other than No continuity
(51) (No sound is heard)
Defective other cylinder injectors If failure codes for other injectors are displayed, perform troubleshooting for
7
or wiring harness them, too.
If no abnormality is found by above checks, engine controller is defective.
8 Defective engine controller
(Since failure is in it, troubleshooting cannot be performed.)

40-234 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA331] Inj #2 (L#2) Open/Short Error

Circuit diagram related to injector #2 40-235

D375A-6R 40-235
(01)
Troubleshooting by failurecode
Failure code [CA332] Inj #4 (L#4) Open/Short Error

Failure code [CA332] Inj #4 (L#4) Open/Short Error 40-236


Action code Failure code Injector #4 (L#4) open / short circuit error
Failure
(Engine controller system)
E03 CA332
Detail of failure q Disconnection or short circuit was detected in injector #4 circuit.
Action of con-
troller
Problem on q Engine output drops.
machine q Engine speed does not stabilize.
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, approximately 65 V of pulse voltage is applied to injector (posi-
mation
tive) side. But it is pulse voltage and cannot be measured by using multimeter.

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector CN4 and connect T-adapter to male side.
2 Defective injector #4
Between CN4 (male) (1) and (2) Resistance 0.4 1.1 z
Between CN4 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector ENG and connect T-adapter to female side.
Open circuit or ground fault of wir-
3
ing harness Between ENG (female) (56) and (58) Resistance 0.4 1.1 z
Between ENG (female) (56) and ground Resistance Min. 1 Mz
a If no abnormality is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ENG and CN4, and connect T-adapters to each
4 (Open circuit in wiring or defective female side.
contact in connector) Between ENG (female) (56) and CN4 (female) (1) Resistance Max. 1 z
Between ENG (female) (58) and CN4 (female) (2) Resistance Max. 1 z
a If no abnormality is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ENG and CN4, and connect T-adapter to female
5
(Contact with ground circuit) side of either one of them.
Between ENG (female) (56) or CN4 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and CN4, and connect T-adapter to female
side of ENG.
a Check with circuit tester in continuity mode.
6 Short circuit in wiring harness Between ENG (female) (56) and each pin other than No continuity
(56) (No sound is heard)
Between ENG (female) (58) and each pin other than No continuity
(58) (No sound is heard)
Defective other cylinder injectors If failure codes for other injectors are displayed, perform troubleshooting for
7
or wiring harness them, too.
If no abnormality is found by above checks, engine controller is defective.
8 Defective engine controller
(Since failure is in it, troubleshooting cannot be performed.)

40-236 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA332] Inj #4 (L#4) Open/Short Error

Circuit diagram related to injector #4 40-237

D375A-6R 40-237
(01)
Troubleshooting by failurecode
Failure code [CA342] Calibration Code Incompatibility

Failure code [CA342] Calibration Code Incompatibility 40-238


Action code Failure code Engine controller data inconsistency
Failure
(Engine controller system)
E04 CA342
Detail of failure q Data inconsistency occurres in engine controller.
Action of con-
troller
Problem on q Engine continues running ordinarily, but it may stop during operation or may not restart once it is
machine stopped.
Related infor-
q Method of reproducing failure code: Turn the starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks


Preform troubleshooting for failure code [CA111].

40-238 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA351] Injectors Drive Circuit Error

Failure code [CA351] Injectors Drive Circuit Error 40-239


Action code Failure code Injectors drive circuit error
Failure
(Engine controller system)
E03 CA351
Detail of failure q Abnormality has occurred in injector drive circuit.
Action of con-
q Limits engine output for travel (Limits common rail pressure) and allows engine to run
troller
Problem on
q Engine output drops.
machine
Related infor-
q Method of reproducing failure code: Start engine.
mation

Cause Procedure, measuring location, criteria and remarks


Check whether other failure code (failure code related to injector system ) are
1 Defect in related system
displayed together. If another code is displayed, perform troubleshooting for it.
Perform troubleshooting for failure code [ CA111]

D375A-6R 40-239
(01)
Troubleshooting by failurecode
Failure code [CA352] Sens Supply 1 Volt Low Error

Failure code [CA352] Sens Supply 1 Volt Low Error 40-240


Action code Failure code Sensor power supply 1voltage is too low
Failure
(Engine controller system)
E03 CA352
Detail of failure q Low voltage appears in sensor power supply 1 (5 V) circuit.
Action of con-
q Limits engine output (limits common rail pressure) and allows engine to run.
troller
Problem on
q Engine output drops.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshooting",
tor
and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. After each troubleshooting, turn starting swith to OFF position.
If this failure code is not displayed when sensor connector is disconnected, that
sensor or engine wiring harness is defective.
Defective sensor or wiring harness a Other failure code(s) is(are) displayed at the same time. This is because the
2
sensor connector is disconnected. Therefore, ignore failure codes other
than [CA352].
Sensor, harness Connector
Common rail pressure sensor PFUEL
Engine harness ENG

3 Defect in related system If another failure code is displayed, perform troubleshooting for it.

1. Turn starting switch to OFF position.


2. Disconnect connector ENG and connect T-adapter to male side.
4 Defective engine controller 3. Turn starting switch to ON position with engine wiring harness disconnected.
Between ENG (male) (33) and (47) Voltage 4.75 5.25 V

40-240 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA352] Sens Supply 1 Volt Low Error

Circuit diagram related to sensor power supply 1 circuit 40-241

D375A-6R 40-241
(01)
Troubleshooting by failurecode
Failure code [CA386] Sens Supply 1 Volt High Error

Failure code [CA386] Sens Supply 1 Volt High Error 40-242


Action code Failure code Sensor power supply 1 voltage is too high
Failure
(Engine controller system)
E03 CA386
Detail of failure q High voltage is detected in sensor power supply 1 (5 V) circuit.
Action of con-
q Limits engine output (limits common rail pressure) and allows engine to run
troller
Problem on
q Engine output drops.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks


Perform troubleshooting for failure code[CA352]

40-242 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA441] Battery Voltage Low Error

Failure code [CA441] Battery Voltage Low Error 40-243


Action code Failure code Battery power circuit voltage is to low
Failure
(Engine controller system)
E04 CA441
Contents of
q Low voltage (5.7 V or below) is detected in power supply circuit.
trouble
Action of con-
troller
Problem on q Engine contionues running ordinarily, but it may stop during operation or may not restart once it is
machine stopped.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks


Perform troubleshooting for failure code [CA111].

D375A-6R 40-243
(01)
Troubleshooting by failurecode
Failure code [CA442] Battery Voltage High Error

Failure code [CA442] Battery Voltage High Error 40-24


Action code Failure code Battery Voltage High Error
Failure
(Engine controller system)
E04 CA442
Detail of fail-
q High voltage (36 V or higher) appears in power supply circuit.
ure
Action of con-
troller
Problem on
q Engine continues running, but it may stop during operations or may not restart once it is in stopped.
machine
q Method of reproducing failure code: Turn starting switch to ON position.
Related infor-
q Power supply voltage of engine controller can be checked by using monitoring function. (Code: 03203
mation
(V))

Cause Procedure, measuring location, criteria and remarks


Preform troubleshooting for failure code [CA111].

40-244 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA449] Rail Press Very High Error

Failure code [CA449] Rail Press Very High Error 40-245


Action code Failure code Rail Press Very High Error
Failure
(Engine controller system)
E03 CA449
q Common rail pressure sensor circuit detects abnormally high pressure (pressure exceeding set
Detail of failure
maximum level).
Action of con-
q Limits engine output (limits common rail pressure) and allows engine to run.
troller
Problem on
q Engine output drops.
machine
q Signal voltage from common rail pressure sensor can be checked with monitoring function (Code:
36401 (V)).
Related infor-
q Common rail pressure sensed by common rail pressure sensor can be checked with monitoring
mation
function (Code: 36400 (MPa)).
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


Perform troubleshooting for failure code [CA553].

D375A-6R 40-245
(01)
Troubleshooting by failurecode
Failure code [CA451] Rail Press Sensor High Error

Failure code [CA451] Rail Press Sensor High Error 40-246


Action code Failure code Rail Press Sensor High Error
Failure
(Engine controller system)
E03 CA451
Detail of failure q High voltage was detected in signal circuit of common rail pressure sensor.
Action of con-
q Limits engine output (limits common rail pressure) and allows engine to run.
troller
Problem on
q Engine output drops.
machine
q Signal voltage from common rail pressure sensor can be checked with monitoring function (Code:
36401 (V)).
Related infor- q Common rail pressure sensed by common rail pressure sensor can be checked with monitoring
mation function (Code: 36400 (MPa)).
q This failure code is displayed if common rail pressure sensor connector is disconnected.
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshooting",
tor
and check them directly.
a If failure code [CA352] (Ground fault in sensor power supply line) or [CA386]
is displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective common rail pressure
2 2. Disconnect connector PFUEL and connect T-adapter to female side.
sensor power supply line
3. Turn starting switch to ON position.
Power sup-
Between PFUEL (female) (1) and (3) Voltage 4.75 5.25 V
ply input
1. Turn starting switch to OFF position.
2. Disconnect connectors PFUEL and ENG and connect T-adapters to each
female side.
a If power supply input in checks on cause 2 is nor-
mal, this check is not required. Resistance Max. 1 z
Open circuit in wiring harness
Between ENG(female) (33) and PFUEL(female) (1)
3 (Open circuit in wiring or defective
a If power supply input in checks on cause 2 is nor-
contact in connector)
mal, this check is not required.
Resistance Max. 1 z
Between ENG (female) (47) and PFUEL (female)
(3)
Between ENG (female) (25) and PFUEL (female)
Resistance Max. 1 z
(2) (Sensor output)
1. Turn starting switch to OFF position.
Short circuit in wiring harness 2. Disconnect connectors PFUEL and ENG
4 3. Connect T-adapter to female side of ENG.
Between ENG (female) (25) and (33) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors PFUEL and insert T-adapter into connector ECM.
Hot short circuit in wiring harness 3. Turn starting switch to ON position (with connector PFUEL disconnected).
5 a ENG (25) pin is connected to 5 V power supply through resistor in engine
(Contact with 24 V circuit)
controller.
Between ENG (25) and (47) Voltage Approx. 5 V
a If causes 1 5 are not cause of failure and check result of cause 6 is abnor-
mal, sensor is defective.
Defective common rail pressure
1. Turn starting switch to OFF position.
sensor
6 2. Insert T-adapter into connector ENG.
(Improper input voltage to engine
3. Turn starting switch to ON position.
controller)
Sensor out-
Between ENG (25) and (47) Voltage 0.2 4.6 V
put
If no abnormality is found by above checks, engine controller is defective.
7 Defective engine controller
(Since failure is in it, troubleshooting cannot be performed.)

40-246 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA451] Rail Press Sensor High Error

Circuit diagram related to common rail pressure 40-247

D375A-6R 40-247
(01)
Troubleshooting by failurecode
Failure code [CA452] Rail Press Sensor Low Error

Failure code [CA452] Rail Press Sensor Low Error 40-248


Action code Failure code Rail Press Sensor Low Error
Failure
(Engine controller system)
E03 CA452
Detail of failure q Low voltage was detected in signal circuit of common rail pressure sensor.
Action of con-
q Limits engine output (limits common rail pressure) and allows engine to run.
troller
Problem on
q Engine output drops.
machine
q Signal voltage from common rail pressure sensor can be checked with monitoring function (Code:
36401 (V)).
q Common rail pressure sensed by common rail pressure sensor can be checked with monitoring
Related infor-
function (Code: 36400 (MPa)).
mation
q Method of reproducing failure code: Turn starting switch to ON position.
q Even under normal conditions, if sensor connector is disconnected, this failure code is not displayed
but other failure code for High Error, namely , [CA451], appears.

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
a If failure code [CA352] (Ground fault in sensor power supply line) or [CA386]
is displayed, perform troubleshooting for it first.

Defective common rail pressure 1. Turn starting switch to OFF position.


2 2. Disconnect connector PFUEL and connect T-adapter to female side.
sensor power supply line
3. Turn starting switch to ON position.
Power sup-
Between PFUEL (female) (1) and (3) Voltage 4.75 5.25 V
ply input
1. Turn starting switch to OFF position.
Defective common rail pressure 2. Disconnect connector PFUEL
3 3. Turn starting switch to ON position.
sensor
If failure code changes from [CA452] to [CA451] , sensor is defective.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ENG and PFUEL , and connect T-adapter to female
4 side of ENG
(Contact with ground circuit)
Between ENG (female) (25) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and PFUEL , and connect T-adapter to female
5 Short circuit in wiring harness side of ENG
Between ENG (25) and (47) Resistance Min. 1 Mz
If no abnormality is found by above checks, engine controller is defective.
6 Defective engine controller
(Since failure is in it, troubleshooting cannot be performed.)

40-248 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA452] Rail Press Sensor Low Error

Circuit diagram related to common rail pressure 40-249

D375A-6R 40-249
(01)
Troubleshooting by failurecode
Failure code [CA553] Rail Press High Error

Failure code [CA553] Rail Press High Error 40-250


Action code Failure code Common rail pressure is high
Failure
(Engine controller system)
E02 CA553
q Abnormal high pressure (higher than set pressure) was detected more than 10 seconds in the sig-
Detail of failure
nal circuit of common rail pressure sensor.
Action of con-
troller
Problem on
machine
q Signal voltage from common rail pressure sensor can be checked with monitoring function (Code:
36401 (V)).
Related infor-
q Common rail pressure sensed by common rail pressure sensor can be checked with monitoring
mation
function (Code: 36400 (MPa)).
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1 Defect in related system If another failure code is displayed, perform troubleshooting for it.

2 Use of improper fuel Check fuel used directly (for high viscosity).
Defective electrical system of Electrical system of common rail pressure sensor may be defective. Perform
3
common rail pressure sensor troubleshooting for failure codes [CA451] and [CA452].
Defective mechanical system of
4 Check mechanical system of common rail pressure sensor directly.
common rail pressure sensor

5 Defective overflow valve Check overflow valve directly for broken spring, worn seat, and stuck ball.

6 Clogging of overflow piping Check overflow piping directly for clogging.


A mechanical defect of the pressure limiter may exist, check the limiter
7 Defective pressure limiter
directly.

40-250 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA554] Rail Press Sensor In Range Error

Failure code [CA554] Rail Press Sensor In Range Error 40-251


Action code Failure code Common rail pressure sensor signal voltage is beyond input range
Failure
(Engine controller system)
E03 CA554
Detail of failure q Signal voltage of common rail pressure sensor is beyond input range.
Action of con-
q Limits engine output (limits common rail pressure) and allows engine to run.
troller
Problem on
q Engine output drops.
machine
q Signal voltage from common rail pressure sensor can be checked with monitoring function (Code:
36401 (V)).
Related infor-
q Common rail pressure sensed by common rail pressure sensor can be checked with monitoring
mation
function (Code: 36400 (MPa)).
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


Perform troubleshooting for failure code [CA451], [CA452]

D375A-6R 40-251
(01)
Troubleshooting by failurecode
Failure code [CA559] Rail Press Low Error

Failure code [CA559] Rail Press Low Error 40-252


Action code Failure code Rail Press Low Error
Failure
(Engine controller system)
E02 CA559
Detail of failure q Supply pump does not pressure feed fuel (level1).
Action of con-
q Limits common rail pressure.
troller
Problem on
q Engine output drops.
machine
q Common rail pressure sensed by common rail pressure sensor can be checked with monitoring
Related infor-
function (Code: 36400 (MPa)).
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks


1 Defect in related system If another failure code is displayed, perform troubleshooting for it first.
2 Use of improper fuel Fuel used may be improper. Check it directly.
a For more information on troubleshooting, see Note 1. For check of fuel pres-
sure in fuel low-pressure circuit, see Testing and adjusting, "Testing fuel
pressure".
3 Defect in low pressure circuit parts
Fuel pressure in low-pressure circuit 0.15 0.3 MPa
(At high idle or under load equivalent
to rated output operation) {1.53.0 kg/cm2}
4 Clogged fuel filter,or strainer a For more information on troubleshooting, see Note 2.
Defective electrical system of sup- Electrical system of supply pump PCV may be defective. Perform trouble-
5
ply pump PCV shooting for failure code [CA271], [CA272], [CA273], or [CA274].
Defective common rail pressure Common rail pressure sensor may be defective. Check wiring harness for
6
sensor damage.
a For check of leakage from pressure limiter, see Testing and adjusting,
"Checking fuel return rate and leakage".
7 Defective pressure limiter Leakage from pressure limiter
(Rated output operation or equiralent Max. 10 cc/min
(load at stalling))
a For check of limit return rate (spill) from injector, see Testing and adjusting,
"Checking fuel return rate and leakage".
Engine speed during rated output
Injector return
operation or equivalent
(spill) limit
(load at stalling)
8 Defective injector 1,600 rpm 960 cc/min
1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
9 Defective supply pump If causes 1 8 are not detected, supply pump may be defective.

<How to use check sheet>


Perform the above troubleshooting and use the attached "Check sheet for no-pressure feed",to note the check
resuets.

40-252 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA559] Rail Press Low Error

Note 1: To determine if low-pressure circuit parts is defective, check following items.


1) Fuel level
2) Clogging of fuel tank breather
3) Seizure and wear of feed pump and clogging of filter
4) Leakage or clogging of low-pressure fuel piping
5) Defective operation of bypass valve and installation of wrong part (See Fig. 1)
6) Clogged fuel filter
7) Fuel in oil pan (Fuel leakage inside head cover)

Fig. 1: Locations of overflow valve (1) , bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1):Spring is visible through both holes.
q Bypass valve (2): Spring is visible through nut side hole.
q Fuel inlet joint (3): Gauze filter is visible through both holes

Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the problem is not solved by performing 1) and 2) above, replace the fuel filter.

D375A-6R 40-253
(01)
Troubleshooting by failurecode
Failure code [CA559] Rail Press Low Error

Check sheet for no-pressure feed


Model D375A-6R Work No.
Machine serial No. # Date of check / /
Engine SAA6D170E-5 Service meter reading h
Engine serial No. # Worker's name
A. Visual check Good NG
1 Fuel leakage to outside
2 Clogging of fuel tank breather
B. Inspection with machine monitor (02 = Abnormality record; 01 = Monitoring; 09 = Cylinder cutout mode
Good NG
operation
3 Checking failure code / / / /
Check of monitoring information
Standard value Measured
Code Display item Checking condition SI unit Good NG
(Reference value) value
Low idle r/min 700 800
01002 Engine speed High idle r/min 1,850 1,900
At torque converter stall r/min 1,490 1,580
Low idle % 0
31701 Decel pedal position
High idle % 100
Inject fueling com-
4 18600 At torque converter stall mg/st - - -
mand
36200 Rail press command At torque converter stall MPa -
36400 Reil pressure At torque converter stall MPa -
Low idle CA - - -
Injection timing com-
36300 High idle CA - - -
mand
At torque converter stall CA - - -
36500 Charge pressure -Abs At torque converter stall kPa - - -
04107 Coolant temperature Low idle C - - -
14200 Fuel temperature Low idle C - - -
Cylinder cut out mode operation (Engine speed)
Standard value Measured
Function Cut out cylinder Checking condition Unit Good NG
(Reference value) value
No. 1 cylinder Low idle r/min - - -
5 No. 2 cylinder Low idle r/min - - -
Set by No. 3 cylinder Low idle r/min - - -
cylinder No. 4 cylinder Low idle r/min - - -
No. 5 cylinder Low idle r/min - - -
No. 6 cylinder Low idle r/min - - -
Standard value Measured
C.Check of fuel circuit pressure Checking condition Unit Good NG
(Reference value) value
High idling or under load MPa
Fuel low-pressure circuit pres- 0.15 0.3
6 equivalent to rated output
sure
operation(stalling) {kg/cm2} {1.5 3.0}

D. Check of strainers and filters Good NG


7 Visual inspection of strainer
8 Visual inspection of gauze filter
9 Visual check of fuel filter
E. Check of leakage and fuel return Standard value Measured
Checking condition Unit Good NG
rate (Reference value) value
Under load equivalent to
10 Leakage from pressure limiter rated output operation(stall- cc/min Max. 10
ing)
Torque converter stall at Speed:
cc/min 960
1,600 rpm
Torque converter stall at
cc/min 1,020
1,700 rpm Return
Torque converter stall at rate:
11 Return rate from injector cc/min 1,080
1,800 rpm
Torque converter stall at
cc/min 1,140
1,900 rpm
Torque converter stall at
cc/min 1,200
2,000 rpm

40-254 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA559] Rail Press Low Error

D375A-6R 40-255
(01)
Troubleshooting by failurecode
Failure code [CA689] Eng Ne Speed Sensor Error

Failure code [CA689] Eng Ne Speed Sensor Error 40-256


Action code Failure code Eng Ne Speed Sensor Error
Failure
(Engine controller system)
E03 CA689
Detail of failure q Abnormal signal appear in engine Ne speed sensor circuit.
Action of con-
q Controls engine by using signals from engine Bkup speed sensor.
troller
Problem on q Engine stops during operation (When engine Bkup speed sensor is also defective).
machine q Engine cannot be started if it is stopped. (When engine Bkup speed sensor is also defective)
q Method of reproducing failure code: Start engine.
q Since inside of speed sensor is not composed of coil but Hall sensor and electronic circuit, speed
Related infor- sensor cannot be determined to be normal by measuring its resistance with circuit tester.
mation q Since speed sensor outputs 5 V pulse voltage during normal operation, it cannot be measured with
multimeter.
q Speed sensor calculates engine speed by detecting holes made in the flywheel.
Cause Procedure, measuring location, criteria and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshooting",
tor
and check them directly.
Defective Ne speed sensor power
2 If failure code [CA238] is also displayed, perform troubleshooting for it first.
supply line
Breakage or improper installation
Engine Ne speed sensor may be damaged or improperly installed (loose).
3 (looseness) of engine Ne speed
Check sensor directly.
sensor
1. Turn starting switch to OFF position.
2. Disconnect connector NE and connect T-adapter to female side.
4 Defective Ne speed sensor power 3. Turn starting switch to ON position.
supply input Power sup-
Between NE (female) (1) and (2) Voltage 4.75 5.25 V
ply input
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and NE.
If no abnormality is found in checks on cause 4, this
Open circuit in wiring harness check is not required. Resistance Max. 1 z
5 (Open circuit in wiring or defective Between ENG (female) (16) and NE (female) (1)
contact in connector) If no abnormality is found in checks on cause 4, this
check is not required. Resistance Max. 1 z
Between ENG (female) (48) and NE (female) (2)
Between ENG (female) (27) and NE (female) (3) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and NE.
6 Short circuit in wiring harness Between ENG (female) (16) and (27), or between
Resistance Min. 1 Mz
NE (female) (1) and (3)
Between ENG (female) (27) and (48), or between
Resistance Min. 1 Mz
NE (female) (2) and (3)
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ENG and NE.
7
(Contact with ground circuit) Between ENG (female) (27) or NE (female) (3) and
Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector NE.
8 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between NE (female) (3) and ground Voltage Max. 1 V
If failure is not found by above checks, engine Ne speed sensor may be defec-
9 Defective engine Ne speed sensor
tive. (Since failure is in it, troubleshooting cannot be performed.)
If cause is not found by above checks,, engine controller may be defective.
10 Defective engine controller
(Since failure is in it, troubleshooting cannot be performed.)

40-256 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA689] Eng Ne Speed Sensor Error

Circuit diagrams related to engine Ne speed sensor 40-257

q Ne speed sensor detects part (A) of flywheel (1), where hole (H) is not made to recognize one turn of fly-
wheal, and the engine controller calculates the engine speed and phase.

D375A-6R 40-257
(01)
Troubleshooting by failurecode
Failure code [CA731] Eng Bkup Speed Sens Phase Error

Failure code [CA731] Eng Bkup Speed Sens Phase Error 40-258
Action code Failure code Engine Bkup speed sensor phase error
Failure
(Engine controller system)
E03 CA731
q Engine Bkup speed sensor circuit detects phase error.
Detail of failure
(Bkup speed sensor signal is out of phase with Ne speed sensor signal.)
Action of con-
q Controls the engine by using signals from engine Ne speed sensor.
troller
Engine stops during operation (when Ne speed sensor is also defective at the same time).
q
Problem on
Engine cannot be started once it is stopped (when Ne speed sensor is also defective at the same
q
machine
time).
q Method of reproducing failure code: Start engine.
Related infor-
a To replace Bkup speed sensor, fuel supply pump must be replaced as a unit. (See Disassembly
mation
and assembly, "Removal and installation of fuel supply pump".)

Cause Procedure, measuring location, criteria and remarks


Defective engine Ne speed sensor Engine Ne speed sensor may be defective. Perform troubleshooting for failure
1
system code [CA689]
Defective engine Bkup speed sen- Engine Bkup speed sensor may be defective. Perform troubleshooting for fail-
2
sor system ure code [CA778]

40-258 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA757] All Continuous Data Lost Error

Failure code [CA757] All Continuous Data Lost Error 40-259


Action code Failure code All engine controller data lost error
Failure
(Engine controller system)
E03 CA757
Detail of failure q All data in engine controller are lost.
Action of con-
troller
Problem on
q Engine continues running, but it may stop during operations or may not restart once it is in stopped.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks


Perform troubleshooting for failure code [CA111].

D375A-6R 40-259
(01)
Troubleshooting by failurecode
Failure code [CA778] Eng Bkup Speed Sensor Error

Failure code [CA778] Eng Bkup Speed Sensor Error 40-260


Action code Failure code Eng Bkup Speed Sensor Error
Failure
(Engine controller system)
E03 CA778
Detail of failure q Abnormality has occurred in engine Bkup speed sensor circuit.
Action of con-
q Controls engine by using Ne speed sensor signal.
troller
q Engine stops during operation (when Ne speed sensor is also defective at the same time).
Problem on
q Engine cannot be started once it is stopped (when Ne speed sensor is also defective at the same
machine
time).
q Method of reproducing failure code: Start engine.
a If engine Bkup speed sensor is replaced, fuel supply pump must be replaced.
(See Disassembly and assembly, "Removal and installation of fuel supply pump".)
Related infor-
q Since inside of speed sensor is not composed of coil but electronic circuit, speed sensor cannot be
mation
determined to be normal by measuring its resistance with circuit tester.
q Since speed sensor outputs 5 V pulse voltage during normal operation, it cannot be measured with
multimeter.

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
Defective sensor power supply
2 If failure code [CA187] or [CA227] is also displayed, troubleshoot it first.
system
Damage or improper installation
Engine Bkup speed (G) sensor may be damaged or improperly installed
3 (loose) of engine Bkup speed (G)
(loose). Check sensor directly.
sensor
1. Turn starting switch to OFF position.
4 Defective resistor (RES) 2. Disconnect connector RES and connect T-adapter to male side.
Between RES (male) (1) and (2) Resistance 620 z
1. Turn starting switch to OFF position.
2. Disconnect connector G and connect T-adapter to female side.
Defective engine Bkup speed sen- 3. Turn starting switch to ON position.
5
sor power supply input
Power sup- 4.75 -
Between G (female) (A) and (B) Voltage
ply input 5.25V
1. Turn starting switch to OFF position.
Open or short circuit in wiring har- 2. Disconnect connectors ENG and G, and connect T-adapter to female side
6 ness of ENG.
(Resistor RES line) Between ENG (female) (37) and (26) Resistance 620 z
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG, G and RES, and connect T-adapters to
female side of each one of them.
a If check result on cause 5 shows normal power
Open circuit in wiring harness supply voltage, this check is not required. Be- Resistance Max. 1 z
7 (Open circuit in wiring or defective tween ENG (female) (37) and G (female) (A)
contact in connector)
a If check result on cause 5 shows normal power
supply voltage, this check is not required. Be- Resistance Max. 1 z
tween ENG (female) (47) and G (female) (B)
Between ENG (female) (26) and G (female) (C) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors ENG, G and RES, and connect T-adapter to female
side of ENG or G.
8 Short circuit in wiring harness Between ENG (female) (26) and (37), or between G
Resistance Min. 1 Mz
(female) (A) and (C)
Between ENG (female) (26) and (47), or between G
Resistance Min. 1 Mz
(female) (B) and (C)

40-260 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA778] Eng Bkup Speed Sensor Error

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors ENG and G and connect T-adapter to female side
Ground fault in wiring harness of either of them.
9
(contact with ground circuit)
Between ENG (female) (26) or G (female) (C) and
Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
Hot short in wiring harness (Con- 2. Disconnect connectors G and RES, and connect T-adapter to female side.
10 3. Turn starting switch to ON position.
tact with 24 V circuit)
Between G (female) (C) and ground Voltage Max. 1 V
Defective engine Ne speed sen- If engine failure is not found by above checks, engine Bkup speed sensor may
11
sor be defective. (Since failure is in it, troubleshooting cannot be performed.)
If engine failure is not found by above checks, engine controller may be defec-
12 Defective engine controller
tive. (Since failure is in it, troubleshooting cannot be performed.)

Circuit diagram related to engine Bkup speed sensor 40-261

D375A-6R 40-261
(01)
Troubleshooting by failurecode
Failure code [CA1633] KOMNET Datalink Timeout Error

Failure code [CA1633] KOMNET Datalink Timeout Error 40-262


Action code Failure code CAN (KOMNET) communication disconnection
Failure
(Engine controller system)
E03 CA1633
q Engine controller detected communication error in CAN (KOMNET) communication circuit between
Detail of failure
engine controller and power train controller ,work equipment controller or machine monitor.
Action of con- q Controls engine in default mode, and holds state at the time of abnormally.
troller q If cause of failure disappears, machine becomes normal by itself.
q Information may not be transmitted normally through CAN (KOMNET) communication and machine
Problem on
may not operate normally.
machine
(Trouble phenomenon depends on failed section.)
Related infor-
q Method of reproducing failure code: Start engine.
mation

Cause Procedure, measuring location, criteria and remarks


Perform troubleshooting for failure code [DB2RKR].

40-262 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA2185] Throt Sens Sup Volt High Error

Failure code [CA2185] Throt Sens Sup Volt High Error 40-263
Action code Failure code Throt Sens Sup Volt High Error
Failure
(Engine controller system)
E03 CA2185
Detail of failure q High voltage (approx. 5.25 V) was detected in throttle sensor power supply circuit.
Action of con-
q Operate the decelerator pedal at a fixed value.
troller
Problem on
q Engine speed cannot be controlled with decelerator pedal.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks
Defective wiring har-
1 before troubleshooting" of "General information on troubleshooting", and check them
ness connector
directly.
1. Turn starting switch to OFF position.
2. Disconnect connector DEC and turn starting switch to ON position.
Defective throttle sen-
2
sor (decelerator pedal) If this failure code is not displayed, throttle sensor is defective.
a Other failure codes are displayed, too. This is because the connector is disconnected.
Ignore failure codes other than [CA2185].
1. Turn starting switch to OFF position.
2. Disconnect connectors EGC2, EGC3 and DEC, and connect T-adapters to female side
Short circuit in wiring of EGC2 and EGC3.
3
harness Between EGC2 (female) (22) and each pin other than
Resistance Min. 1 Mz
EGC2 (female) (22)
Between EGC2 (female) (22) and EGC3 (female) (3) Resistance Min. 1 Mz
Hot short circuit in wir- 1. Turn starting switch to OFF position.
ing harness 2. Disconnect connector DEC and connect T-adapter to female side.
4
(Contact with 24 V cir- 3. Turn starting switch to ON position.
cuit) Between DEC (female) (A) and ground Voltage 4.75 5.25 V
1. Turn starting switch to OFF position.
Defective engine con- 2. Disconnect connector EGC2 and connect T-adapter to male side.
5
troller 3. Turn starting switch to ON position.
Between EGC2 (male) (22) and (23) Voltage 4.75 5.25 V

Circuit diagram related to decelerator pedal 40-263

D375A-6R 40-263
(01)
Troubleshooting by failurecode
Failure code [CA2186] Throt Sens Sup Volt Low Error

Failure code [CA2186] Throt Sens Sup Volt Low Error 40-264
Action code Failure code Throt Sens Sup Volt High Error
Failure
E03 CA2186 (Engine controller system)
Detail of failure q Low voltage was detected in throttle sensor power supply circuit.
Action of controller q Operate the decelerator pedal at a fixed value.
Problem on
q Engine speed cannot be controlled with decelerator pedal.
machine
Related information q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


See descriptions of wiring harness and connectors in "c: Electrical equipment" in
Defective wiring harness
1 "Checks before troubleshooting" of "General information on troubleshooting", and
connector
check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector DEC and turn starting switch to ON position.
Defective throttle sensor
2 If this failure code is not displayed, throttle sensor is defective.
(decelerator pedal)
a Other failure code is displayed together. This is because that the sensor connector
is disconnected. Ignored except the failure code other than [CA2186].
1. Turn starting switch to OFF position.
Ground fault in wiring
2. Disconnect connector EGC2 and DEC and connect T-adapter to female side of
harness
3 either one of them.
(Contact with ground cir-
Between EGC2 (female) (22) or DEC (female) (A) and
cuit) Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector EGC2 and DEC and connect T-adapter to female side of
Short circuit in wiring har- EGC2.
4 3. Turn starting switch to ON position.
ness
Between EGC2 (female) (22) and each pin other than
Resistance Min. 1 Mz
EGC2 (female) (22)
1. Turn starting switch to OFF position.
2. Disconnect connector EGC2 and connect T-adapter to male side.
Defective engine control- 3. Turn starting switch to ON position with connecting engine wiring harness discon-
5
ler nected.
Between EGC2 (male) (22) and (23) Voltage 4.75 5.25 V

Circuit diagram related to decelerator pedal 40-264

40-264 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [CA2249] Rail Press Very Low Error

Failure code [CA2249] Rail Press Very Low Error 40-265


Action code Failure code Supply pump no-pressure feed error 2
Failure
(Engine controller system)
E03 CA2249
Detail of failure q No-pressure feed error (level 2) in supply pump was detected.
Action of con-
q Limits common rail pressure.
troller
Problem on
q Engine output drops.
machine
q The signal voltage from the common rail pressure sensor can be checked with the monitoring func-
tion (Code: 36401 (V)).
Related infor-
q Common rail pressure sensed by common rail pressure sensor can be checked with monitoring
mation
function (Code: 36400 (MPa)).
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks


Perform troubleshooting for failure code [CA559] .

D375A-6R 40-265
(01)
Troubleshooting by failurecode
Failure code [D110KB] Battery Relay: Drive Short Circuit

Failure code [D110KB] Battery Relay: Drive Short Circuit 40-26


Action code Failure code Short circuit in battery relay drive circuit
Failure
(Work equipment controller system)
D110KB
Detail of failure q Abnormal current flowed when outputting 24 V to battery relay primary circuit (coil side).
Action of con-
q Stops 24 V output to battery relay primary circuit (coil side).
troller
Problem on
q Problem may occur in data writing to ROM (nonvolatile memory) of each controller.
machine
q Output condition (voltage) to battery relay primary circuit (coil side) can be checked with monitoring
Related infor- function.
mation (Code: 60600: Battery relay drive voltage)
q Method of reproducing failure code: Turn starting switch from ON to OFF.

Cause Procedure, measuring location, criteria and remarks

Defective battery relay 1. Turn starting switch to OFF position.


1
(Internal short circuit) Between terminals SW and BRE Continuity
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect negative battery cable (in order not to make short circuit).
2 3. Disconnect cable from terminal BRE and disconnect connector WECN3.
(Contact with ground circuit)
Between terminal SW and ground Resistance Min. 1 Mz
If cause is not found by the above checks, work equipment controller is defec-
tive.
q Reference: the following is standard value in normal condition.
Defective work equipment control- 1. Turn starting switch to OFF position.
3
ler 2. Insert T-adapter into connector WECN3.
3. Turn starting switch to ON position.
Between WECN3 (4) and ground Voltage 20 30 V

40-266 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [D110KB] Battery Relay: Drive Short Circuit

Circuit diagram related to battery relay 40-267

D375A-6R 40-267
(01)
Troubleshooting by failurecode
Failure code [D130KA] Neutral relay: Disconnection

Failure code [D130KA] Neutral relay: Disconnection 40-268


Action code Failure code Open cricuit in neutral safety relay
Failure
(Power train controller system)
E02 D130KA
q No voltage is applied to neutral safety relay primary circuit (coil side) when controller stopped
Detail of failure
grounding.
Action of con-
q Stops grounding to neutral safety relay primary circuit (coil side).
troller
Problem on
q Engine does not start.
machine
q Output to neutral safety relay primary circuit (coil side) can be checked with monitoring function.
(Code: 40909 P/T controller SW output)
q Method of reproducing failure code:Turn the starting switch to ON position, and operate parking
Related infor-
brake lever (FREE).
mation
q This failure code detects failure on primary side (coil side) of neutral safety relay, but not on sec-
ondary side (contact side).
q If PTCN2 (8) has ground fault, engine can start even if PCCS lever is not set to NEUTRAL position.

Cause Procedure, measuring location, criteria and remarks


Defective neutral 1. Turn starting switch to OFF position.
safety relay 2. Disconnect connector NSF and connect T-adapter to male side.
1
(internal open circuit or
short circuit) Between NSF (male) (1) and (2) Resistance 200 400 z
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN2 and KEY, and connect T-adapters to female side of
Open or short circuit in them.
2 a If resistance is above 1 Mz, wiring harness is broken. If resistance is below 1 z, wiring
wiring harness
harness has short circuit.
Between KEY (female) (1) and PTCN2 (female) (8) Resistance 200 400 z
a If cause 2 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring
2. Disconnect connectors PTCN2, NSF and KEY, and connect T-adapters to female side
harness
3 of them.
(open circuit or defec-
tive contact) Between PTCN2 (female) (8) and NSF (female) (2) Resistance Max. 1 z
Between KEY (female) (1) and NSF (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring
2. Disconnect connectors PTCN2 and NSF, and connect T-adapters to female side of
harness
4 them.
(Contact with ground
Between NSF (female) (2) or PTCN2 (female) (8) and
circuit) Resistance Min. 1 Mz
ground
If cause is not found by the above checks, power train controller is defective.
q Reference: The following are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
Defective power train
5 3. Turn starting switch to ON position.
controller
4. Operate parking brake lever and troubleshoot.
Lever: FREE Voltage 20 30 V
Between PTCN2 (8) and ground
Lever: LOCK Voltage Max. 1 V

40-268 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [D130KA] Neutral relay: Disconnection

Circuit diagram related to neutral safety relay 40-269

D375A-6R 40-269
(01)
Troubleshooting by failurecode
Failure code [D130KB] Neutral relay: Short circuit

Failure code [D130KB] Neutral relay: Short circuit 40-270


Action code Failure code Short circuit in neutral safety relay
Failure
(Power train controller system)
E02 D130KB
q Abnormal current flowed in neutral safety relay primary circuit (coil side) when controller grounded
Detail of failure
neutral safety relay.
Action of con-
q Stops grounding to neutral safety relay primary circuit (coil side).
troller
Problem on
q Engine does not start.
machine
q Output to neutral safety relay primary circuit (coil side) can be checked with monitoring function.
(Code: 40909 P/T controller SW output)
Related infor- q Method of reproducing failure code:Turn the starting switch to ON position, and operate parking
mation brake lever (LOCK).
q This failure code detects failure on primary side (coil side) of neutral safety relay, but not on sec-
ondary side (contact side).

Cause Procedure, measuring location, criteria and remarks


Defective neutral 1. Turn starting switch to OFF position.
safety relay 2. Disconnect connector NSF and connect T-adapter to male side.
1
(internal open circuit or
short circuit) Between NSF (male) (1) and (2) Resistance 200 400 z
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN2 and KEY, and connect T-adapters to female side of
Open or short circuit in them.
2 a If resistance is above 1 Mz, wiring harness is broken. If resistance is below 1 z, wiring
wiring harness
harness has short circuit.
Between KEY (female) (1) and PTCN2 (female) (8) Resistance 200 400 z
1. Turn starting switch to OFF position.
Hot short circuit in wir- 2. Disconnect connectors PTCN2 and NSF, and connect T-adapter to female side of
ing harness PTCN2.
3
(Contact with 24 V cir- 3. Turn starting switch to ON position.
cuit)
Between PTCN2 (female) (8) and ground Voltage Max. 1 V
If cause is not found by the above checks, power train controller is defective.
q Reference: the following are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
Defective power train
4 3. Turn starting switch to ON position.
controller
4. Operate parking brake lever and troubleshoot.
Lever: FREE Voltage 20 30 V
Between PTCN2 (8) and ground
Lever: LOCK Voltage Max. 1 V

40-270 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [D130KB] Neutral relay: Short circuit

Circuit diagram related to neutral safety relay 40-271

D375A-6R 40-271
(01)
Troubleshooting by failurecode
Failure code [D161KA] Back-up alarm releay: Disconnection

Failure code [D161KA] Back-up alarm releay: Disconnection 40-272


Action code Failure code Backup alarm releay:Disconnection
Failure
(Power train controller system)
E01 D161KA
q No voltage is applied to backup alarm relay primary circuit (coil side) when controller stopped
Detail of failure
grounding.
Action of con-
q Stops grounding to backup alarm relay primary circuit.
troller
Problem on
q The backup alarm does not sound
machine
q Output condition to backup alarm relay primary circuit (coil side) can be checked with monitoring
function.
(Code: 40909 P/T controller SW output)
Related infor- q Method of reproducing failure code:Turn starting switch to ON position and move PCCS lever (to
mation NEUTRAL).
q This failure code detects failure on primary side (coil side) of backup alarm relay, but not on sec-
ondary side (contact side).
q If pin PTCN2(18) has ground fault, backup alarm keeps sounding.

Cause Procedure, measuring location, criteria and remarks


If fuse FS22-5 is broken, circuit probably has ground fault. In this case, per-
1 Defective fuse FS22-5
form troubleshooting for cause 5 first.

Defective backup alarm relay 1. Turn starting switch to OFF position.


2 (internal open circuit or short cir- 2. Disconnect connector BKA and connect T-adapter to male side.
cuit) Between BKA (male) (1) and (2) Resistance 200 400 z
1. Turn starting switch to OFF position.
2. Disconnect fuse FS22-5.
Open or short circuit in wiring har- 3. Disconnect connector PTCN2 and connect T-adapter to female side.
3 a If resistance is above 1 Mz, wiring harness has disconnection. If resistance
ness
is below 1 z, wiring harness has short circuit.
Between PTCN2 (female) (18) and FS22-5 Resistance 200 400 z
a If cause 3 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN2 and BKA, and connect T-adapters to female
Open circuit in wiring harness
4 side of them.
(open circuit or defective contact)
Between PTCN2 (female) (18) and BKA (female) (2) Resistance Max. 1 z
Between FS22-5 and BKA (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect fuse FS22-5.
Ground fault in wiring harness 3. Disconnect connector PTCN2 and connect T-adapter to female side.
5
(Contact with ground circuit) Between BKA (female) (1) and ground Resistance Min. 1 Mz
Between BKA (female) (2) or PTCN2 (female) (18)
Resistance Min. 1 Mz
and ground
If cause is not found by the above checks, power train controller is defective.
q Reference: the following are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
6 Defective power train controller 3. Turn starting switch to ON position.
4. Operate PCCS lever and perform troubleshooting.
Between PTCN2 (18) N Voltage 20 30 V
and ground R(Reverse) Voltage Max. 1 V

40-272 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [D161KA] Back-up alarm releay: Disconnection

Circuit diagram related to backup alarm relay 40-273

D375A-6R 40-273
(01)
Troubleshooting by failurecode
Failure code [D161KB] Back-up alarm releay: Short circuit

Failure code [D161KB] Back-up alarm releay: Short circuit 40-274


Action code Failure code Short circuit in backup alarm relay
Failure
(Power train controller system)
E01 D161KB
q Abnormal current flowed in backup alarm relay circuit when controller grounded backup alarm re-
Detail of failure
lay.
Action of con-
q Stops grounding to backup alarm relay primary circuit.
troller
Problem on
q The backup alarm does not sound
machine
q Output condition to backup alarm relay can be checked by monitoring function.
(Code: 40909 P/T controller SW output)
Related infor- q Method of reproducing failure code:Turn starting switch to ON position and operate PCCS lever to
mation reverse.
q This failure code detects failure on primary side (coil side) of backup alarm relay, but not on sec-
ondary side (contact side).

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective backup alarm relay 2. Disconnect connector BKA and connect T-adapter to male side.
1 (internal open circuit or short cir-
cuit) Between BKA (male) (1) and (2) Resistance 300600 z

1. Turn starting switch to OFF position.


2. Disconnect fuse FS22-5.
3. Disconnect connector PTCN2 and connect T-adapter to female side.
Open or short circuit in wiring har- a If resistance is above1 Mz, wiring harness is broken. If resistance is
2
ness below1 z, wiring harness has short circuit.

Between PTCN2 (female) (18) and FS22-5 Resistance 300600 z

1. Turn starting switch to OFF position.


2. Disconnect connector PTCN2 and BKA , and connect T-adapter to female
Hot short in wiring harness (Con- side of PTCN2.
3
tact with 24 V circuit) 3. Turn starting switch to ON position.
Between PTCN2 (female) (18) and ground Voltage Max. 1 V
If cause is not found by the above checks, power train controller is defective.
q Reference: the following are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
4 Defective power train controller 3. Turn starting switch to ON position.
4. Operate PCCS lever and perform troubleshooting.
N Voltage 2030 V
Between PTCN2 (18) and ground
R(Reverse) Voltage Max. 1 V

40-274 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [D161KB] Back-up alarm releay: Short circuit

Circuit diagram related to back-up alarm relay 40-275

D375A-6R 40-275
(01)
Troubleshooting by failurecode
Failure code [D182KZ] Preheater Relay Abnormality

Failure code [D182KZ] Preheater Relay Abnormality 40-276


Action code Failure code Preheater relay open or short circuit
Failure
(Power train controller system)
E01 D182KZ
q Abnormal current flowed when preheater relay primary is grounded circuit (coil side) or no voltage
Detail of failure
is applied when it is not grounded.
Action of con-
q Stops grounding to preheater relay primary circuit (coil side).
troller
Problem on q Auto preheater does not operate (or continues to preheat).
machine q Preheater operates when it is turned ON manually.
q Output to preheater relay primary circuit (coil side) can be checked with monitoring function.
(Code: 40909 P/T controller SW Output)
Related infor- q Method of reproducing failure code:Turn the starting switch to ON position, and operate parking
mation brake lever (FREE).
q This failure code detects failure on primary side (coil side) of preheater relay, but not on secondary
side (contact side).

Cause Procedure, measuring location, criteria and remarks


Defective preheater 1. Turn starting switch to OFF position.
relay 2. Disconnect connector PHR and connect T-adapter to male side.
1
(internal open circuit or
short circuit) Between PHR (male) (1) and (2) Resistance 200 400 z
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN2 and KEY, and connect T-adapters to female side of
Open or short circuit in them.
2 a If resistance is above 1 Mz, wiring harness is broken. If resistance is below 1 z, wiring
wiring harness
harness has short circuit.
Between KEY (female) (1) and PTCN2 (female) (19) Resistance 200 400 z
a If cause 2 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring
2. Disconnect connectors PTCN2, PHR and KEY, and connect T-adapters to female side
harness
3 of them.
(open circuit or defec-
tive contact) Between PTCN2 (female) (19) and PHR (female) (2) Resistance Max. 1 z
Between KEY (female) (1) and PHR (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring
2. Disconnect connectors PTCN2 and PHR, and connect T-adapters to female side of
harness
4 them.
(Contact with ground
Between PHR (female) (2) or PTCN2 (female) (19) and
circuit) Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
Hot short circuit in wir- 2. Disconnect connectors PTCN2 and PHR, and connect T-adapter to PTCN2 female
ing harness connector.
5
(Contact with 24 V cir- 3. Turn starting switch to ON position.
cuit)
Between PTCN2 (female) (19) and ground Voltage Max. 1 V
If cause is not found by the above checks, power train controller is defective.
q Reference: The following are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
Defective power train 3. Turn starting switch to ON position.
6
controller Auto preheater
Voltage 20 30 V
not operated
Between PTCN2 (19) and ground
Auto preheater
Voltage Max. 1 V
operated

40-276 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [D182KZ] Preheater Relay Abnormality

Circuit diagram related to preheater relay 40-27

D375A-6R 40-277
(01)
Troubleshooting by failurecode
Failure code [D190KA] ACC signal relay: Disconnection

Failure code [D190KA] ACC signal relay: Disconnection 40-278


Action code Failure code ACC signal drive relay disconnection
Failure
(Work equipment controller system)
E00 D190KA
Detail of failure q No voltage is applied to engine holding relay (EHL) primary circuit (coil side) when no grounding.
Action of con-
q Stops grounding to engine holding relay (EHL) primary circuit (coil side).
troller
Problem on q Turbocharger timer does not function (if the turbocharger timer is installed).
machine q Machine is not affected (if turbocharger timer is not installed).
q Output to engine holding relay primary circuit (coil side) can be checked with monitoring function.
(Code: 40983 W/E controller SW Output)
q Method of reproducing failure code: Turn starting switch to ON position.
Related infor-
q This failure code detects failure on primary side (coil side) of engine holding relay (EHL), but not on
mation
secondary side (contact side).
q If WECN2 (18) has ground fault, engine keeps running even if starting switch is turned to OFF po-
sition.

Cause Procedure, measuring location, criteria and remarks


Defective engine hold- 1. Turn starting switch to OFF position.
ing relay (Internal dis- 2. Disconnect connector EHL and connect T-adapter to male side.
1
connection or short
circuit) Between EHL (male) (1) and (2) Resistance 200 400 z
1. Turn starting switch to OFF position.
2. Disconnect connectors WECN2 and KEY, and connect T-adapters to female side of
Open or short circuit in them.
2 a If resistance is above 1 Mz, wiring harness has disconnection. If resistance is below
wiring harness
1 z, wiring harness has short circuit.
Between KEY (female) (1) and WECN2 (female) (18) Resistance 200 400 z
a If cause 2 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring
2. Disconnect connectors WECN2, EHL and KEY, and connect T-adapters to female side
harness
3 of them.
(open circuit or defec-
tive contact) Between WECN2 (female) (8) and EHL (female) (2) Resistance Max. 1 z
Between KEY (female) (1) and EHL (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring
2. Disconnect connectors WECN2 and EHL, and connect T-adapters to female side of
harness
4 them.
(Contact with ground
Between EHL (female) (2) or WECN2 (female) (18) and
circuit) Resistance Min. 1 Mz
ground
Defective work equip-
5 If cause is not found by the above checks, work equipment controller is defective.
ment controller

40-278 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [D190KA] ACC signal relay: Disconnection

Circuit diagram related to ACC signal drive relay 40-279

D375A-6R 40-279
(01)
Troubleshooting by failurecode
Failure code [D190KB] ACC signal relay: Short circuit

Failure code [D190KB] ACC signal relay: Short circuit 40-280


Action code Failure code ACC signal drive relay short circuit
Failure
(Work equipment controller system)
E00 D190KB
q No current flows when grounding to engine holding relay (EHL) primary circuit (coil side) or no volt-
Detail of failure
age is applied when no grounding.
Action of con-
q Stops grounding to engine holding relay (EHL) primary circuit (coil side).
troller
Problem on q Turbocharger timer does not function (if the turbocharger timer is installed).
machine q Machine is not affected (if turbocharger timer is not installed).
q Output to engine shutoff delay relay (EHL) primary circuit (coil side) can be checked by monitoring
function.
Related infor- (Code: 40983 W/E control SW Output)
mation q Method of reproducing failure code: Turn starting switch to ON position.
q This failure code detects failure on primary side (coil side) of engine shutoff delay relay (EHL), but
not on secondary side (contact side).

Cause Procedure, measuring location, criteria and remarks


Defective engine hold- 1. Turn starting switch to OFF position.
ing relay (Internal dis- 2. Disconnect connector EHL and connect T-adapter to male side.
1
connection or short
circuit) Between EHL (male) (1) and (2) Resistance 200 400 z
1. Turn starting switch to OFF position.
2. Disconnect connectors WECN2 and KEY, and connect T-adapters to female side of
Open or short circuit in them.
2 a If resistance is above 1 Mz, wiring harness is broken. If resistance is below 1 z, wiring
wiring harness
harness has short circuit.
Between KEY (female) (1) and WECN2 (female) (18) Resistance 200 400 z
1. Turn starting switch to OFF position.
Hot short circuit in wir- 2. Disconnect connectors WECN2 and EHL, and connect T-adapter to female side of
ing harness WECN2.
3
(Contact with 24 V cir- 3. Turn starting switch to ON position.
cuit)
Between WECN2 (female) (18) and ground Voltage Max. 1 V
Defective work equip-
4 If cause is not found by the above checks, work equipment controller is defective.
ment controller

40-280 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [D190KB] ACC signal relay: Short circuit

Circuit diagram related to ACC signal drive relay 40-281

D375A-6R 40-281
(01)
Troubleshooting by failurecode
Failure code [D1EFKA] Pre lub. motor relay: Disconnection

Failure code [D1EFKA] Pre lub. motor relay: Disconnection 40-282


Action code Failure code Pre-lubricating motor relay open circuit
Failure
(Power train controller system)
E02 D1EFKA
q No voltage is applied to pre-lubricating motor relay primary (coil side) circuit when grounding is cut
Detail of failure
off.
Action of con-
q Stops grounding to pre-lubricating motor relay primary circuit (coil side).
troller
Problem on q The pre-lubricating motor does not operate.
machine q The engine does not start (engine starts if pre-lubrication is skipped).
q Output to pre-lubricating motor relay primary circuit (coil side) can be checked with monitoring func-
tion. (Code: 40909 P/T controller SW Output)
Related infor- q Method of reproducing failure code: Turn starting switch to ON position.
mation q This failure code detects failure on primary side (coil side) of pre-lubricating motor relay, but not on
secondary side (contact side).
q If pin PTCN2 (23) has ground fault, pre-lubricating motor keeps running.

Cause Procedure, measuring location, criteria and remarks


Defective pre-lubricat- 1. Turn starting switch to OFF position.
ing motor relay 2. Disconnect connector PLUB and connect T-adapter to male side.
1
(internal open circuit or
short circuit) Between PLUB (male) (1) and (2) Resistance 200 400 z
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN2 and KEY, and connect T-adapters to female side of
Open or short circuit in them.
2 a If resistance is above 1 Mz, wiring harness is broken. If resistance is below 1 z, wiring
wiring harness
harness has short circuit.
Between KEY (female) (1) and PTCN2 (female) (9) Resistance 200 400 z
a If cause item 2 is not the cause for the trouble, this check is not required.
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors PTCN2, PLUB and KEY, and connect T-adapters to female side
3 (Wire breakage or of them.
defective contact of Between PTCN2 (female) (9) and PLUB (female) (2) Resistance Max. 1 z
connector)
Between KEY (female) (1) and PLUB (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring
2. Disconnect connectors PTCN2 and PLUB, and connect T-adapter to female side of
harness
4 them.
(Contact with ground
Between PLUB (female) (2) or PTCN2 (female) (9) and
circuit) Resistance Min. 1 Mz
ground
If cause is not found by the above checks, power train controller is defective.
q Reference: The following are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
3. Turn starting switch to ON position.
Defective power train
5 When pre-lubri-
controller
cation has
Voltage 20 30 V
been com-
Between PTCN2 (9) and ground
pleted
Pre-lubrication
Voltage Max. 1 V
is in operation.

40-282 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [D1EFKA] Pre lub. motor relay: Disconnection

Circuit diagram related to pre-lubricating motor relay 40-283

D375A-6R 40-283
(01)
Troubleshooting by failurecode
Failure code [D1EFKB] Pre lub. motor relay: Short circuit

Failure code [D1EFKB] Pre lub. motor relay: Short circuit 40-284
Action code Failure code Pre-lubricating motor short circuit
Failure
(Power train controller system)
E02 D1EFKB
q When the pre-lubricating motor relay primary (coil side) circuit was grounded extraordinary current
Detail of failure
flowed.
Action of con-
q Stops grounding to pre-lubricating motor relay primary circuit (coil side).
troller
Problem on q The pre-lubricating motor does not operate.
machine q Engine does not start (engine starts if pre-lubrication is skipped).
q Output to pre-lubricating motor relay primary circuit (coil side) can be checked with monitoring func-
tion. (Code: 40909 P/T controller SW Output)
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation
q This failure code detects failure on primary side (coil side) of pre-lubricating motor relay, but not on
secondary side (contact side).

Cause Procedure, measuring location, criteria and remarks


Defective pre-lubricat- 1. Turn starting switch to OFF position.
ing motor relay 2. Disconnect connector PLUB and connect T-adapter to male side.
1
(internal open circuit or
short circuit) Between PLUB (male) (1) and (2) Resistance 200 400 z
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN2 and KEY, and connect T-adapters to female side of
Open or short circuit in them.
2 a If resistance is above 1 Mz, wiring harness is broken. If resistance is below 1 z, wiring
wiring harness
harness has short circuit.
Between KEY (female) (1) and PTCN2 (female) (9) Resistance 200 400 z
1. Turn starting switch to OFF position.
Hot short circuit in wir- 2. Disconnect connectors PTCN2 and PLUB, and connect T-adapter to female side of
ing harness PTCN2.
3
(Contact with 24 V cir- 3. Turn starting switch to ON position.
cuit)
Between PTCN2 (female) (9) and ground Voltage Max. 1 V
If cause is not found by the above checks, power train controller is defective.
q Reference: The following are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
3. Turn starting switch to ON position.
Defective power train
4 When pre-lubri-
controller
cation has
Voltage 20 30 V
been com-
Between PTCN2 (9) and ground
pleted
Pre-lubrication
Voltage Max. 1 V
is in operation.

40-284 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [D1EFKB] Pre lub. motor relay: Short circuit

Circuit diagram related to pre-lubricating motor relay 40-285

D375A-6R 40-285
(01)
Troubleshooting by failurecode
Failure code [DAFRKR] Monitor: Can communication lost (PT)

Failure code [DAFRKR] Monitor: Can communication lost (PT) 40-286


Action code Failure code CAN communication with machine monitor is impossible
Failure (detected by power train controller)
E03 DAFRKR (Power train controller system)

Detail of failure q Power train controller cannot recognize machine monitor with CAN communication circuit.
Action of con-
q Limits operation of engine and transmission.
troller
q System may not operate properly.
Problem on
q Once machine is stopped, engine speed is limited to medium (half) speed.
machine
q Once machine is stopped, travel is limited to F1 and R1.
q Method of reproducing failure code: Turn starting switch to ON position.
q Start of CAN communication is notified to each controller by ACC signal from starting switch.
q Failure code is displayed on machine monitor by CAN communication. Accordingly, if CAN com-
Related infor- munication of machine monitor fails, code [DAFRKR] is not displayed on machine monitor and it
mation can be observed only through KOMTRAX system.
q Since each controller and machine monitor receive power from battery directly, they are kept ON
even while starting switch is OFF.
q Since CAN communication signal is pulse voltage, it cannot be measured with multimeter.

Cause Procedure, measuring location, criteria and remarks


Defective power sup-
1 Perform troubleshooting for E mode, "E-3".
ply to machine monitor
Defective CAN com-
2 Perform troubleshooting for failure code [DAFRMC], cause 10 and after.
munication

40-286 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [dAFRKR] Monitor: CAN communication lost (WE)

Failure code [dAFRKR] Monitor: CAN communication lost (WE) 40-287


Action code Failure code CAN communication with machine monitor is impossible
Failure (detected by work equipment controller)
E03 dAFRKR (Work equipment controller system)

Detail of failure q Work equipment controller cannot recognize machine monitor with CAN communication circuit.
Action of con-
q Limits operation of engine and transmission.
troller
q System may not operate properly.
Problem on
q Once machine is stopped, engine speed is limited to medium (half) speed.
machine
q Once machine is stopped, travel is limited to F1 and R1.
q Method of reproducing failure code: Turn starting switch to ON position.
q Start of CAN communication is notified to each controller by ACC signal from starting switch.
q Failure code is displayed on machine monitor by CAN communication. Accordingly, if CAN com-
Related infor- munication of machine monitor fails, code [dAFRKR] is not displayed on machine monitor and it
mation can be observed only through KOMTRAX system.
q Since each controller and machine monitor receive power from battery directly, they are kept ON
even while starting switch is OFF.
q Since CAN communication signal is pulse voltage, it cannot be measured with multimeter.

Cause Procedure, measuring location, criteria and remarks


Defective power sup-
1 Perform troubleshooting for E mode, "E-3".
ply to machine monitor
Defective CAN com-
2 Perform troubleshooting for failure code [DAFRMC], cause 10 and after.
munication

D375A-6R 40-287
(01)
Troubleshooting by failurecode
Failure code [DAFRMC] CAN Discon (Monitor Detected)

Failure code [DAFRMC] CAN Discon (Monitor Detected) 40-28


Action code Failure code CAN communication is impossible (Machine monitor Detected)
Failure
E03 DAFRMC (Mechane monitor power train control system)

q Machine monitor cannot recognize power train controller, work equipment controller or VHMS con-
Detail of failure
troller in CAN communication.
Action of con- q Restricts operation of engine and transmission.
troller q If cause of failure disappears, machine monitor returns to normal status.
q System may not operate properly.
Problem on
q Once machine is stopped, engine speed is limited to half of full speed.
machine
q Once machine stops, travel is restricted to F1 and R1.
q Method of reproducing failure code: Turn starting switch to ON position.
q Start of CAN communication is notified to each controller by ACC signal from starting switch.
q Failure code is sent to machine monitor by CAN communication. Accordingly, if other CAN-related
failure code such as [DB2RKR] is displayed on machine monitor, there can not be ground fault,
short circuit and hot short circuit in wiring harness (CAN communication line).
Related infor-
q If failurecode [DB2RKR] is also displayed, problem with engine controller, cause items 1 to 6, will
mation
be the most probable cause of the failure.
q Since each controller and machine monitor receive power from battery directly, they are kept ON
even while starting switch is OFF.
q The CAN communication line signal in operation is pulse voltage, so it cannot be measured by us-
ing multimeter.

Cause Procedure, measuring location, criteria and remarks


Defective engine con-
1 troller circuit breaker If circuit breaker is turned OFF, controller probably has short circuit in it.
(CB7)
a If circuit breaker has tripped, this check is not required.
1. Turn starting switch to OFF position.
Defective engine con- 2. Disconnect connectors EGC3 and connect T-adapter to male side.
2 troller (Internal short a Measured value: Approx. 9 -20 kz
circuit) a If measured value is below 10 z, engine controller is defective (internal short circuit).
Between EGC3 (male) (3) and (1) Resistance Max. 10 z
1. Turn starting switch to OFF position.
2. Disconnect connectors EGC3 and connect T-adapter to female side.
3. If circuit breaker has tripped, reset it.
Defective power sup-
3 a If result is abnormal, perform troubleshooting for [CA111].
ply to engine controller
Between EGC3 (female) (3) and (1) or ground Voltage 20 30 V
Between EGC3 (female) (4) and (2) or ground Voltage 20 30 V
1. Turn starting switch to OFF position.
Broken engine control- 2. Remove the fuse in fuse box FS32-5.
4
ler ACC fuse If fuse has blown out, the circuit probably has ground fault. In this case, perform trouble-
shooting for cause 14 first.
Defective ACC cutout
If failure code [7RFAKA] or [7RFAKB] is also displayed, perform troubleshooting for it
5 relay (for engine con-
first.
troller) drive

40-288 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DAFRMC] CAN Discon (Monitor Detected)

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective ACC cutout 2. Replace ACC cutout relay (connector ACT) with another relay (backup alarm relay;
relay (for engine con- connector BKA, etc.)
6 troller) (Internal dis- 3. Turn starting switch to ON position.
connection or short
circuit) If this failure code goes off, original ACC cutout relay (for engine controller) is defective.

Defective power sup-


If failure code [DBERKR] or [DBBQKR] is also displayed, perform troubleshooting for fail-
7 ply to power train con-
ure code [DBE1KK] or [DBE2KK] first.
troller
Defective power sup-
If failure code [DB9RKR] is also displayed, perform troubleshooting for failure code
8 ply to work equipment
[DB91KK] and [DB92KK] first.
controller
Defective power sup-
9 Perform troubleshooting for failure codes [DBB0KK] and [DBB3KK].
ply to VHMS controller
1. Turn starting switch to OFF position.
Defective CAN termi-
2. Disconnect connectors CT2 and CM02 and connect T-adapters to male side of them.
nating resistor
10
(internal open circuit Between CT2 (male) (A) and (B) Resistance 120 12 z
or short circuit)
Between CM02 (male) (8) and (10) Resistance 120 12 z
q CAN communication line
a There is 120 z CAN terminating resistor inside machine monitor, too. Since120 z re-
sistor is connected in parallel, if resistance measured at connector of controller other
than machine monitor is 60 z which is combined resistance, there is no open circuit in
writing harness.
1. Turn starting switch to OFF position and disconnect ground cable.
2. Disconnect one of following connectors EGC2, PTCN2, WECN2, V4A, CT2 and CM02
and connect T-adapter to female side of that connector.
a If connector has short circuit (Resistance between terminals is1 z or less), disconnect
Open or short circuit in all of EGC2, PTCN2, WECN2, V4A and CM02 and check again to see if there is short
11 circuit between wiring harnesses or in controller.
wiring harness
Between EGC2 (female) (46) and (47) Resistance Approx. 60 z
Between PTCN2 (female) (32) and (22) Resistance Approx. 60 z
Between WECN2 (female) (32) and (22) Resistance Approx. 60 z
Between V4A (female) (12) and (4) Resistance Approx. 60 z
Between CT2 (female) (A) and (B) Resistance Approx. 120 z
Between CM02 (female) (9) and (10) Resistance Approx. 120 z

D375A-6R 40-289
(01)
Troubleshooting by failurecode
Failure code [DAFRMC] CAN Discon (Monitor Detected)

Cause Procedure, measuring location, criteria and remarks


a If check result of cause item 11 is normal, this check is not required.
1. Turn starting switch to OFF position and disconnect ground strap.
2. Disconnect connectors EGC2, PTCN2, WECN2, V4A, CT2 and CM02 and connect
T-adapters to female side of them.
Between PTCN2 (female) (32) and CM02 (female)
Resistance Max. 1 z
(9)/(8)
Between PTCN2 (female) (22) and CM02 (female) (10) Resistance Max. 1 z

Open circuit in wiring Between PTCN2 (female) (32) and EGC2 (female) (46) Resistance Max. 1 z
harness Between PTCN2 (female) (22) and EGC2 (female) (47) Resistance Max. 1 z
12 (Open circuit in wiring
or defective contact in Between PTCN2 (female) (32) and WECN2 (female)
Resistance Max. 1 z
connector) (32)
Between PTCN2 (female) (22) and WECN2 (female)
Resistance Max. 1 z
(22)
Between PTCN2 (female) (32) and V4A (female) (4) Resistance Max. 1 z
Between PTCN2 (female) (22) and V4A (female) (12) Resistance Max. 1 z
Between EGC2 (female) (46) and CT2 (female) (A) Resistance Max. 1 z
Between EGC2 (female) (47) and CT2 (female) (B) Resistance Max. 1 z
q ACC signal from starting switch
1. Turn starting switch to OFF position and disconnect ground strap.
2. Insert T-adapters into connectors PTCN3, WECN3, V1, CM01, ACT and EGC2.
3. Connect the ground cable and turn the starting switch to ON position.
Open circuit in wiring Between PTCN3 (14) or (24) and (31) Voltage 20 30 V
harness
13 (Open circuit in wiring Between WECN3 (14) or (24) and (31) Voltage 20 30 V
or defective contact in Between V1 (17) and (19) Voltage 20 30 V
connector)
Between CM01 (14) and (3) Voltage 20 30 V
Between ACT(1), (3) and ground Voltage 20 30 V
Between EGC2 (39) and ground Voltage 20 30 V
q CAN communication line
a If another failure code related to CAN communication such as [DB2RKR] is displayed
on machine monitor, this check is not required.
a If check result of cause item 11 is normal (there is open cricuit), measure at only 1
place.
1. Turn starting switch to OFF position and disconnect ground strap.
2. Disconnect connectors PTCN2, WECN2, V4A, CM02 and EGC2, and connect
T-adapter to female side of one of them.
Between PTCN2 (female) (32), WECN2 (female) (32),
V4A (female) (4), CM02 (female) (8), (9) or EGC2 Resistance Min. 1 Mz
Ground fault in wiring (female) (46) and ground
harness Between PTCN2 (female) (22) , WECN2 (female) (22),
14
(Contact with ground V4A (female) (12), CM02 (female) (10) or EGC2 Resistance Min. 1 Mz
circuit) (female) (47) and ground
q ACC signal from starting switch
1. Turn starting switch to OFF position and disconnect ground strap.
2. Disconnect connectors PTCN3, WECN3, V1, CM01 and ACT, and connect T-adapter
to female side of one of them.
3. Disconnect connectors EGC2 and connect T-adapter to female side.
Between PTCN3 (female) (14), (24), WECN3 (female)
(14), (24), V1 (female) (17) or CM01 (female) (14) and Resistance Min. 1 Mz
ground
Between EGC2 (female) (39) and ground Resistance Min. 1 Mz

40-290 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DAFRMC] CAN Discon (Monitor Detected)

Cause Procedure, measuring location, criteria and remarks

a If another failure code related to CAN communication such as [DB2RKR] is displayed


on machine monitor, this check is not required.
a If check result of cause item 11 is normal (there is no disconnection), measure at only
1 place each.
1. Turn starting switch to OFF position and disconnect ground strap.
Short circuit or hot 2. Insert T-adapter into connector PTCN2, WECN2, V4A, CM02 or EGC2.
short circuit in wiring 3. Connect ground strap.
15 harness 4. Turn starting switch to ON position.
(Contact with 24 V cir- a Since voltages of CAN H and CAN L are 2.5 1 V even while communication is con-
cuit) tinued, they are judged to be normal if they are 1 - 4 V.
Between PTCN2 (32), WECN2 (32), V4A (4), CM02 (8),
Voltage 14V
(9) or EGC2(46) and ground
Between PTCN2 (22), WECN2 (22), V4A(12),
Voltage 14V
CM02( 10), or EGC2 (47) and ground
If cause is not found by above checks and another failure code related to CAN communi-
cation such as [DB2RKR] is not displayed, identify which controller is defective according
to following procedure.
q Step 1
1. Turn starting switch to OFF position and disconnect ground strap.
2. Disconnect engine controller (connector EGC2).
3. Connect the ground cable and turn the starting switch to ON position.
Defective
NO power train
controller
Is failure code [DB2RKR] displayed?
Defective
YES engine control-
ler
Defective work
NO equipment
Defective engine con- Is failure code [dB2RKR] displayed? controller
troller, power train Defective
16 controller, work equip- YES engine control-
ment controller and ler
VHMS controller q Step 2
1. Turn starting switch to OFF position and disconnect ground strap.
2. Disconnect power train controller (connector PTCN2).
3. Connect the ground cable and turn the starting switch to ON position.
Defective work
NO equipment
controller
Is failure code [DBERKR] displayed?
Defective
YES power train
controller
Defective
NO VHMS control-
ler
Is failure code [DBBQKR] displayed?
Defective
YES power train
controller
Defective machine If Failure is not found by above checks, machine monitor is defective.
17
monitor (Since trouble is in system, troubleshooting cannot be performed.)

D375A-6R 40-291
(01)
Troubleshooting by failurecode
Failure code [DAFRMC] CAN Discon (Monitor Detected)

Circuit diagram related to CAN 40-292

40-292 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DAFRMC] CAN Discon (Monitor Detected)

D375A-6R 40-293
(01)
Troubleshooting by failurecode
Failure code [DB2RKR] ENG cont.: Can communication lost (PT)

Failure code [DB2RKR] ENG cont.: Can communication lost (PT) 40-294
Action code Failure code CAN communication with engine controller is impossible.
Failure (detected by power train controller)
E03 DB2RKR (Power train controller system)

Detail of failure q Power train controller cannot recognize engine controller in CAN communication.
Action of con-
q Limits operation of engine and transmission.
troller
q System may not operate properly.
Problem on
q Once machine stops, engine speed is limited to half of full speed.
machine
q Once machine is stopped, travel is limited to F1 and R1.
q Method of reproducing failure code: Turn starting switch to ON position.
q Start of CAN communication is notified to each controller by ACC signal from starting switch.
q Failure code is sent to machine monitor by CAN communication. Accordingly, if failure code
[DB2RKR] is displayed on the machine monitor, CAN communication between power train control-
ler and machine monitor is normal.
Related infor-
That is, there cannot be short circuit, ground fault or hot short circuit in CAN communication line.
mation
q If failure code [DAFRMC] is also displayed, cause of this failure is probably engine controller prob-
lem in cause1 and 2.
q Since each controller and machine monitor receive power from battery directly, they have power
even while starting switch is OFF.
q Since CAN communication line signal is pulse voltage, it cannot be measured with multimeter.

Cause Procedure, measuring location, criteria and remarks


Defective engine con-
1 troller circuit breaker If circuit breaker is turned OFF, controller probably has short circuit in it.
(CB7)
a If circuit breaker has tripped, this check is not required.
1. Turn starting switch to OFF position.
Defective engine con- 2. Disconnect connectors EGC3 and connect T-adapter to male side.
2 troller (Internal short a Measured value: approximately 9-20 kz
circuit) a If measured value is below 10 z, engine controller is defective (internal short circuit).
Between EGC3 (male) (3) and (1) Resistance Max. 10 z
1. Turn starting switch to OFF position.
2. Disconnect connectors EGC3 and connect T-adapter to female side.
3. If circuit breaker has tripped, reset it.
Defective power sup-
3 a If result is abnormal, perform troubleshooting for [CA111].
ply to engine controller
Between EGC3 (female) (3) and (1) or ground Voltage 20 30 V
Between EGC3 (female) (4) and (2) or ground Voltage 20 30 V
1. Turn starting switch to OFF position.
Broken engine control- 2. Remove the fuse in fuse box FS32-5.
4
ler ACC fuse If fuse has blown out, the circuit probably has ground fault. In this case, perform trouble-
shooting for cause item 11 first.
Defective ACC cutout
If failure code [7RFAKA] or [7RFAKB] is also displayed, perform troubleshooting for it
5 relay (for engine con-
first.
troller) drive
1. Turn starting switch to OFF position.
Defective ACC cutout 2. Replace ACC cutout relay (connector ACT) with another relay (backup alarm relay;
relay (for engine con- connector BKA, etc.)
6 troller) 3. Turn starting switch to ON position .
(internal open circuit or
short circuit) If this failure code goes off, original ACC cutout relay (for engine controller) is defective.

40-294 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DB2RKR] ENG cont.: Can communication lost (PT)

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective CAN termi-
2. Disconnect connectors CT2 and CM02 and connect T-adapters to male side of them.
nating resistor (Inter-
7
nal open or short Between CT2 (male) (A) and (B) Resistance 120 12 z
circuit)
Between CM02 (male) (8) and (10) Resistance 120 12 z
q CAN communication line
a There is 120 z CAN terminating resistor inside machine monitor, too. Since120 z re-
sistor is connected in parallel, if resistance measured at connector of controller other
than machine monitor is 60 z which is combined resistance, there is no open circuit in
writing harness.
1. Turn starting switch to OFF position and disconnect ground cable.
2. Disconnect one of following connectors EGC2, PTCN2, WECN2, V4A, CT2 and CM02
and connect T-adapter to female side of that connector.
a If connector has short circuit (Resistance between terminals is1 z or less), disconnect
Open or short circuit in all of EGC2, PTCN2, WECN2, V4A and CM02 and check again to see if there is short
8 circuit between wiring harnesses or in controller.
wiring harness
Between EGC2 (female) (46) and (47) Resistance Approx. 60 z
Between PTCN2 (female) (32) and (22) Resistance Approx. 60 z
Between WECN2 (female) (32) and (22) Resistance Approx. 60 z
Between V4A (female) (12) and (4) Resistance Approx. 60 z
Between CT2 (female) (A) and (B) Resistance Approx. 120 z
Between CM02 (female) (9) and (10) Resistance Approx. 120 z
a If check result of cause item 8 is normal, this check is not required.
1. Turn starting switch to OFF position and disconnect ground strap.
2. Disconnect connectors EGC2, PTCN2, WECN2, V4A, CT2 and CM02 and connect
T-adapters to female side of them.
Between PTCN2 (female) (32) and CM02 (female) (9)/(8) Resistance Max. 1 z
Between PTCN2 (female) (22) and CM02 (female) (10) Resistance Max. 1 z

Identifying open circuit Between PTCN2 (female) (32) and EGC2 (female) (46) Resistance Max. 1 z
in wiring harness (Wire Between PTCN2 (female) (22) and EGC2 (female) (47) Resistance Max. 1 z
9
breakage or defective
contact of connector) Between PTCN2 (female) (32) and WECN2 (female) (32) Resistance Max. 1 z
Between PTCN2 (female) (22) and WECN2 (female) (22) Resistance Max. 1 z
Between PTCN2 (female) (32) and V4A (female) (4) Resistance Max. 1 z
Between PTCN2 (female) (22) and V4A (female) (12) Resistance Max. 1 z
Between EGC2 (female) (46) and CT2 (female) (A) Resistance Max. 1 z
Between EGC2 (female) (47) and CT2 (female) (B) Resistance Max. 1 z

D375A-6R 40-295
(01)
Troubleshooting by failurecode
Failure code [DB2RKR] ENG cont.: Can communication lost (PT)

Cause Procedure, measuring location, criteria and remarks


q ACC signal from starting switch
1. Turn starting switch to OFF position and disconnect ground strap.
2. Insert T-adapters into connectors PTCN3, WECN3, V1, CM01, ACT and EGC2.
3. Connect the ground cable and turn the starting switch to ON position.
Open circuit in wiring Between PTCN3 (14) or (24) and (31) Voltage 20 30 V
harness
10 (Open circuit in wiring Between WECN3 (14) or (24) and (31) Voltage 20 30 V
or defective contact in Between V1 (17) and (19) Voltage 20 30 V
connector)
Between CM01 (14) and (3) Voltage 20 30 V
Between ACT(1), (3) and ground Voltage 20 30 V
Between EGC2 (39) and ground Voltage 20 30 V
q ACC signal from starting switch
1. Turn starting switch to OFF position and disconnect ground strap.
2. Disconnect connectors PTCN3, WECN3, V1, CM01 and ACT, and connect T-adapter
Ground fault in wiring to female side of one of them.
11 harness (Contact with 3. Disconnect connectors EGC2 and connect T-adapter to female side.
ground circuit) Between PTCN3 (female) (14), (24), WECN3 (female)
(14), (24), V1 (female) (17) or CM01 (female) (14) and Resistance Min. 1 Mz
ground
Between EGC2 (female) (39) and ground Resistance Min. 1 Mz
If cause is not found by above checks and failure code [DAFRMC] is displayed, engine
Defective engine con-
12 controller is defective.
troller
(Since trouble is in system, troubleshooting cannot be performed.)
Defective power train If cause is not found by the above checks, power train controller is defective.
13
controller (Since trouble is in system, troubleshooting cannot be performed.)

40-296 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DB2RKR] ENG cont.: Can communication lost (PT)

Circuit diagram related to CAN 40-297

D375A-6R 40-297
(01)
Troubleshooting by failurecode
Failure code [dB2RKR] ENG controller: CAN communication lost (WE)

Failure code [dB2RKR] ENG controller: CAN communication lost (WE) 40-298
Action code Failure code CAN communication with engine controller is impossible
Failure (detected by work equipment controller)
E03 dB2RKR (Work equipment controller system)

Detail of failure q Work equipment controller cannot recognize engine controller in CAN communication circuit.
Action of con-
q Limits operation of engine, transmission, and fan.
troller
q System may not operate properly.
Problem on
q Once machine is stopped, engine speed is limited to medium (half) speed.
machine
q Once machine is stopped, travel is limited to F1 and R1.
q Method of reproducing failure code: Turn starting switch ON.
q Start of CAN communication is notified to each controller by ACC signal from starting switch.
q Failure code is sent to machine monitor by CAN communication. Accordingly, if failure code
[dB2RKR] is displayed on machine monitor, CAN communication between work equipment con-
troller and machine monitor is normal.
Related infor-
That is, there cannot be short circuit, ground fault or hot short circuit in CAN communication line.
mation
q If failure code [DAFRMC] is also displayed, cause of this failure is probably engine controller prob-
lem.
q Since each controller and machine monitor receive power from battery directly, they are kept ON
even while starting switch is OFF.
q Since CAN communication signal is pulse voltage, it cannot be measured with multimeter.

Cause Procedure, measuring location, criteria and remarks


Perform troubleshooting for failure code [DB2RKR].

40-298 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DB90KT] WE controller: Abnormality in controller

Failure code [DB90KT] WE controller: Abnormality in controller 40-29


Action code Failure code Data recorded in work equipment controller are abnormal
Failure
(Work equipment controller system)
E01 DB90KT
Detail of failure q Information in ROM (non-volatile memory) in work equipment controller is abnormal.
Action of con-
q Reset internal adjustment values to default values.
troller
Problem on q Operating feel of work equipment may become bad.
machine q Adjusting function by machine monitor may not operate properly.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks


Use Adjustment function in service mode, and perform operation of reproduc-
Defective adjustment of work
1 ing trouble. If "E" of failure code disappears at this time, system is normal.
equipment controller
q Adjustment code: 0031 (Initialization of work equipment controller)
Defective work equipment control- Troubleshooting cannot be carried out since defect is in work equipment con-
2
ler troller. (If there is no visible trouble in machine, controller may be used as it is.)

D375A-6R 40-299
(01)
Troubleshooting by failurecode
Failure code [DB91KK] WE controller: Source voltage reduction

Failure code [DB91KK] WE controller: Source voltage reduction 40-30


Action code Failure code Battery direct voltage drop of work equipment controller
Failure
(Work equipment controller system)
E04 DB91KK
Detail of failure q The battery direct power supply voltage for work equipment controller is below 17 V.
Action of con-
q Limits operation of engine, transmission, brake and work equipment.
troller
q Machine monitor may not display properly.
Problem on q Relay and solenoid may not be actuated and therefore, system may not operate properly.
machine q Once machine is stopped, engine speed is limited to medium (half) speed.
q Once machine is stopped, it cannot travel any more.
q Main power source voltage for work equipment controller can be checked in adjusting function.
Related infor-
(Code: 2022 Work equipment controller voltage check mode)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


Trip of circuit breaker If circuit breaker has tripped, circuit probably has ground fault. In this case, perform trou-
1
(CB30) bleshooting for cause 7 first.
If fuse FS12-4 is blown out, circuit probably has ground fault. In this case, perform trouble-
2 Defective fuse FS12-4
shooting for cause 7 first.

Loose terminal or dis- 1. Turn starting switch to OFF position.


3
connection at terminal Check terminals of battery, battery relay, etc.

Improper battery volt- 1. Perform troubleshooting with starting switch at OFF and when starting engine.
4
age Between battery (+) and (-) Voltage 20 30 V
1. Turn starting switch to OFF position.
2. Disconnect the ground cable.
3. Disconnect connector WECN3 and connect T-adapter to female side.
Open circuit or ground 4. Connect the ground cable.
5
fault of wiring harness a If voltage is 0 V, wiring harness has open cricuit or ground fault.
Between WECN3 (female) (1) and (21)/(31) Voltage 20 30 V
Between WECN3 (female) (11) and (32)/(33) Voltage 20 30 V
a If cause item 4 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect the ground cable.
Open circuit in wiring 3. If the fuse is blown, replace it.
harness 4. If circuit breaker has tripped, reset it.
6
(open circuit or defec- 5. Disconnect connector WECN3 and connect T-adapter to female side.
tive contact) Between WECN3 (female) (21), (31), (32) or (33) and
ground Resistance Max. 1 z
a Check terminal GND01 for looseness and rust.
Between WECN3 (female) (1) or (11) and battery (+) Resistance Max. 1 z

40-300 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DB91KK] WE controller: Source voltage reduction

Cause Procedure, measuring location, criteria and remarks


a If cause 4 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect ground strap.
Ground fault in wiring
3. If fuse is blown out, replace it.
harness
7 4. If circuit breaker has tripped, reset it.
(Contact with ground
5. Disconnect connector WECN3 and connect T-adapter to female side.
circuit)
Between WECN3 (female) (1) and (21)/(31) Resistance Min. 1 Mz
Between WECN3 (female) (11) and (32)/(33) Resistance Min. 1 Mz
If cause is not found by above checks, work equipment controller is defective.
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Disconnect ground strap.
Defective work equip-
8 3. Insert T-adapter into connector WECN3.
ment controller
4. Connect ground strap.
Between WECN3 (1) and (21)/(31) Voltage 20 30 V
Between WECN3 (11) and (32)/(33) Voltage 20 30 V

Circuit diagram related to power supply for work equipment controller 40-301

D375A-6R 40-301
(01)
Troubleshooting by failurecode
Failure code [DB92KK] WE controller: Output voltage reduction

Failure code [DB92KK] WE controller: Output voltage reduction 40-302


Action code Failure code Voltage drop in power supply for work equipment control-
Failure ler-related actuators
E04 DB92KK (Work equipment controller system)

q Power supply (battery relay output) voltage for the actuators related to work equipment controller
Detail of failure
(relay, solenoid or others) is below 17 V.
Action of con-
q Limits operation of engine, transmission, brake and work equipment.
troller
q Relay and solenoid may not be actuated and therefore, system may not operate properly.
Problem on
q Once machine is stopped, engine speed is limited to medium (half) speed.
machine
q Once machine is stopped, it cannot travel any more.
q Power source voltage of work equipment controller can be checked in adjusting function.
Related infor-
(Code: 2022 Work equipment controller voltage check mode)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


Trip of circuit breaker If CB3 or CB105 circuit breaker has tripped, circuit probably has ground fault. In this case,
1
CB3 or CB105 perform troubleshooting for cause 6 first.

Loose terminal or dis- 1. Turn starting switch to OFF position.


2
connection at terminal Check terminals of battery, battery relay, etc.

Improper battery volt- 1. Perform troubleshooting with starting switch at OFF and when starting engine.
3
age Between battery (+) and (-) Voltage 20 30 V
1. Turn starting switch to OFF position.
2. Disconnect the ground cable.
3. Insert T-adapter into connector WECN3.
Defective wiring har- 4. Connect the ground cable.
4 ness or power train 5. Turn starting switch to ON position.
controller Between WECN3 (2) and (21) Voltage 20 30 V
Between WECN3 (12) and (31) Voltage 20 30 V
Between WECN3 (22) and (32) Voltage 20 30 V
a If cause item 4 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect ground strap (in order not to make short circuit).
Open circuit in wiring
3. Disconnect connector WECN3 and connect T-adapter to female side.
harness
5
(open circuit or defec- Between ground and WECN3 (female) (21)/(31)/(32)/
tive contact) (33) respectively Resistance Max. 1 z
a Check terminal GND01 for looseness and rust.
Between terminal BRC and WECN3 (female)
Resistance Max. 1 z
(2)/(12)/(22) respectively
a If cause 4 is not the cause for the trouble, this check is not required.
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect ground strap (in orde not to make short circuit).
6
(Contact with ground 3. If circuit breaker has tripped, reset it.
circuit) 4. Disconnect connector WECN3.
Between terminal BRC and ground Resistance Min. 1 Mz
Defective work equip-
7 If cause is not found by above checks, work equipment controller is defective.
ment controller

40-302 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DB92KK] WE controller: Output voltage reduction

Circuit diagram related to power supply for work equipment controller 40-303

D375A-6R 40-303
(01)
Troubleshooting by failurecode
Failure code [DB97KK] WE cont.: Sensor voltage 5 V (2) reduction

Failure code [DB97KK] WE cont.: Sensor voltage 5 V (2) reduction 40-304


Action code Failure code Work equipment sensor 5 V power supply abnormality
Failure
(Work equipment controller system)
DB97KK
q Voltage of 5 V power supply circuit for work equipment controller sensor is below 4.5 V or above
Detail of failure 5.5 V.
q Abnormal current flowed in 5 V power supply circuit for work equipment controller sensor.
Action of con-
q Stops output to 5 V power supply circuit if abnormal voltage flows.
troller
Problem on q Hydraulic pressure of work equipment pump cannot be monitored correctly (but machine opera-
machine tions are not affected).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector HHP.
3. Turn starting switch to ON position.
Defective hydraulic pump pres-
1 q If this code is not displayed when hydraulic pump pressure sensor is discon-
sure sensor (Internal defect)
nected, that sensor is defective.
a Other failure codes are displayed, too. This is because the connector is dis-
connected. Ignore failure codes other than [DB97KK].
1. Turn starting switch to OFF position.
2. Disconnect connectors WECN3 and HHP, and connect T-adapter to female
Ground fault in wiring harness
2 side of either of them.
(Contact with ground circuit)
WECN3 (female) (34) or HHP (female) (B) and
Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector HHP and connect T-adapter to female side.
3 Short circuit in wiring harness 3. Turn starting switch to ON position.
Between HHP (female) (B) and (A) Voltage 4.5 5.5 V
If cause is not found by the above checks, work equipment controller is defec-
tive.
q Reference: The following are standard values in normal condition.
1. Turn starting switch to OFF position.
Defective work equipment control- 2. Insert T-adapters into connectors WECN1 and WECN3.
4
ler 3. Turn starting switch to ON position.
a Since 24 V power is supplied to connector WECN3, 5 V output cannot be
checked with connector WECN3 disconnected.
Between WECN3 (34) and WECN1 (21) Voltage 4.5 5.5 V

40-304 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DB97KK] WE cont.: Sensor voltage 5 V (2) reduction

Circuit diagram related to work equipment controller sensors 5 V power supply 40-305

D375A-6R 40-305
(01)
Troubleshooting by failurecode
Failure code [DB99KQ] WE controller: Type select signal

Failure code [DB99KQ] WE controller: Type select signal 40-306


Action code Failure code Machine model selection error on work equipment
Failure
(Work equipment controller system)
E04 DB99KQ
q Specification setting in work equipment controller does not match specification setting memory (Ini-
Detail of failure
tial setting of work equipment controller has not yet been performed).
Action of con- q Turns all outputs from work equipment controller OFF.
troller q Limits operation of engine, transmission, brake and work equipment.
q Machine does not move at all.
Problem on
q Once machine is stopped, engine speed is limited to half of full speed.
machine
q Once machine stops, it cannot travel at all.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks


Use adjustment function in service mode, and perform operation of reproduc-
Defective adjustment of work ing trouble. If E of failure code disappears at this time, system function is
1
equipment controller proper.
q Adjustment code: 0031 (Initialization of work equipment controller)

40-306 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DB9RKR] WE controller: Can communication lost (PT)

Failure code [DB9RKR] WE controller: Can communication lost (PT) 40-307


Action code Failure code CAN communication with work equipment controller (detected
Failure power train controller)
E03 DB9RKR (Power train controller system)

Detail of failure q Power train controller cannot recognize work equipment controller in CAN communication circuit.
Action of con-
q Limits operation of engine and transmission.
troller
q System may not operate properly.
Problem on
q Once machine is stopped, engine speed is limited to medium (half) speed.
machine
q Once machine is stopped, travel is limited to F1 and R1.
q Method of reproducing failure code: Turn starting switch to ON position.
q Start of CAN communication is notified to each controller by ACC signal from starting switch.
q Failure code is sent to machine monitor by CAN communication. Accordingly, if failure code
[DB9RKR] is displayed on the machine monitor, CAN communication between power train control-
Related infor-
ler and machine monitor is normal. That is, there can not be short circuit, ground fault or hot short
mation
circuit in CAN communication line.
q Since each controller and machine monitor receive power from battery directly, they are kept ON
even while starting switch is OFF.
q Since CAN communication signal is pulse voltage, it cannot be measured with multimeter.

Cause Procedure, measuring location, criteria and remarks


Defective power supply to work If failure code [DAFRMC] is also displayed, perform troubleshooting for failure
1
equipment controller code [DB91KK] and [DB92KK] first.
1. Turn starting switch to OFF position.
Defective CAN terminating resis- 2. Disconnect connectors CT2 and CM02 and connect T-adapters to male
tor side of them.
2
(internal open circuit or short cir- Between CT2 (male) (A) and (B) Resistance 120 12 z
cuit)
Between CM02 (male) (8) and (10) Resistance 120 12 z
q CAN communication line
a There is 120 z CAN terminating resistor inside machine monitor, too. Since
120 z resistor is connected in parallel, if resistance measured at connector
of controller other than machine monitor is 60 z which is combined resis-
tance, there is no open circuit in writing harness.
1. Turn starting switch to OFF position and disconnect ground strap.
2. Disconnect one of following connectors EGC2, PTCN2, WECN2, V4A, CT2
and CM02 and connect T-adapter to female side of that connector.
a If connector has short circuit (Resistance between terminals is1 z or less),
Open or short circuit in wiring har- disconnect all of EGC2, PTCN2, WECN2, V4A and CM02 and check again
3
ness to see if there is short circuit between wiring harnesses or in controller.
Between EGC2 (female) (46) and (47) Resistance Approx. 60 z
Between PTCN2 (female) (32) and (22) Resistance Approx. 60 z
Between WECN2 (female) (32) and (22) Resistance Approx. 60 z
Between V4A (female) (12) and (4) Resistance Approx. 60 z
Between CT2 (female) (A) and (B) Resistance Approx. 120 z
Between CM02 (female ) (9) and (10) Resistance Approx. 120 z

D375A-6R 40-307
(01)
Troubleshooting by failurecode
Failure code [DB9RKR] WE controller: Can communication lost (PT)

Cause Procedure, measuring location, criteria and remarks


a If check result of cause 3 is normal, this check is not required.
1. Turn starting switch to OFF position and disconnect ground strap.
2. Disconnect connectors EGC2, PTCN2, WECN2, V4A, CT2 and CM02 and
connect T-adapters to female side of them.
Between PTCN2 (female) (32) and CM02
Resistance Max. 1 z
(female) (9)/(8)
Between PTCN2 (female) (22) and CM02
Resistance Max. 1 z
(female) (10)
Between PTCN2 (female) (32) and EGC2
Resistance Max. 1 z
(female) (46)
Between PTCN2 (female) (22) and EGC2
Open circuit in wiring harness Resistance Max. 1 z
(female) (47)
4 (Open circuit in wiring or defective
Between PTCN2 (female) (32) and WECN2
contact in connector) Resistance Max. 1 z
(female) (32)
Between PTCN2 (female) (22) and WECN2
Resistance Max. 1 z
(female) (22)
Between PTCN2 (female) (32) and V4A
Resistance Max. 1 z
(female) (4)
Between PTCN2 (female) (22) and V4A
Resistance Max. 1 z
(female) (12)
Between EGC2 (female) (46) and CT2
Resistance Max. 1 z
(female) (A)
Between EGC2 (female) (47) and CT2
Resistance Max. 1 z
(female) (B)
q ACC signal from starting switch
1. Turn starting switch to OFF position and disconnect ground strap.
2. Insert T-adapters into connectors PTCN3, WECN3, V1, CM01, ACT and
EGC2.
3. Connect the ground cable and turn the starting switch to ON position.
Open circuit in wiring harness Between PTCN3 (14) or (24) and (31) Voltage 20 30 V
5 (Open circuit in wiring or defective Between WECN3 (14) or (24) and (31) Voltage 20 30 V
contact in connector)
Between V1 (17) and (19) Voltage 20 30 V
Between CM01 (14) and (3) Voltage 20 30 V
Between ACT(1), (3) and ground Voltage 20 30 V
Between EGC2 (39) and ground Voltage 20 30 V
q ACC signal from starting switch
1. Turn starting switch to OFF position and disconnect ground strap.
2. Disconnect connectors PTCN3, WECN3, V1, CM01 and ACT, and connect
T-adapter to female side of one of them.
Ground fault in wiring harness 3. Disconnect connectors EGC2 and connect T-adapter to female side.
6
(Contact with ground circuit) Between PTCN3 (female) (14), (24), WECN3
(female) (14), (24), V1 (female) (17) or CM01 Resistance Min. 1 Mz
(female) (14) and ground
Between EGC2 (female) (39) and ground Resistance Min. 1 Mz
If cause is not found by above checks and failure code [DAFRMC] is dis-
Defective work equipment control-
7 played, work equipment controller is defective.
ler
(Since trouble is in system, troubleshooting cannot be performed.)
If cause is not found by the above checks, power train controller is defective.
8 Defective power train controller
(Since trouble is in system, troubleshooting cannot be performed.)

40-308 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DB9RKR] WE controller: Can communication lost (PT)

Circuit diagram related to CAN 40-309

D375A-6R 40-309
(01)
Troubleshooting by failurecode
Failure code [DBB0KK] VHMS controller:Source voltage reduction

Failure code [DBB0KK] VHMS controller:Source voltage reduction 40-310


Action code Failure code Voltage drop in power supply to VHMS controller
Failure
( VHMS controller system)
DBB0KK
q When engine was running, the switch power voltage from battery relay to VHMS controller dropped
Detail of failure
below 19.5 V.
Action of con-
q None in particular
troller
Problem on
q System may not operate properly.
machine
Related infor-
q VHMS controller LED displays "n9" o "C01".
mation

Cause Procedure, measuring location, criteria and remarks


If circuit breaker trips, circuit probably has ground fault. In this case, perform
1 Trip of circuit breaker (CB105)
troubleshooting for cause 7 first.
If fuse FS12-5 is blown out, circuit probably has ground fault. In this case, per-
2 Defective fuse FS12-5
form troubleshooting for cause 7 first.

Loose terminal or disconnection at 1. Turn starting switch to OFF position.


3
terminal Check terminals of battery, battery relay, TR1S, TR2L, etc.
1. Turn starting switch to OFF position.
4 Improper battery voltage 2. Perform troubleshooting when engine is cranked.
Between battery (+) and (-) Voltage 20 30 V
1. Turn starting switch to OFF position.
2. Disconnect the ground cable.
3. Disconnect connector V1 and connect T-adapter to female side.
4. If the fuse is blown, replace it.
5. If circuit breaker trips, reset it.
Open circuit or ground fault of wir-
5 6. Connect the ground cable.
ing harness
7. Turn starting switch to ON position.
a If voltage is 0 V, wiring harness is open-cricuited or ground fault.
Between V1 (female) (8) and (11), (12) Voltage 20 30 V
Between V1 (female) (9) and (19), (20) Voltage 20 30 V
a If cause 4 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect the ground cable.
3. If the fuse is blown, replace it.
4. If circuit breaker trips, reset it.
Open circuit in wiring harness 5. Disconnect connector V1 and connect T-adapter to female side.
6
(open circuit or defective contact) Between ground and V1 (female) (11) or (12) or (19)
or (20)
Resistance Max. 1 z
a Check terminal GND01 for looseness and rust-
ing.
Between V1 (female) (8), (9) and battery relay BRC
Resistance Max. 1 z
terminal
a If cause 4 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect the ground cable.
Ground fault in wiring harness 3. If the fuse is blown, replace it.
7
(Contact with ground circuit) 4. If circuit breaker trips, reset it.
5. Disconnect connector V1 and connect T-adapter to female side.
Between V1 (female) (8) and (11), (20) Resistance Min. 1 Mz
Between V1 (female) (9) and ground Resistance Min. 1 Mz

40-310 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DBB0KK] VHMS controller:Source voltage reduction

Cause Procedure, measuring location, criteria and remarks


If cause is not found by the above checks, power train controller is defective.
q Reference; the followings are criteria in normal condition.
1. Turn starting switch to OFF position.
2. Disconnect ground strap.
3. Connect T-adapter to connector V1.
8 Defective VHMS controller
4. Connect ground strap.
5. Turn starting switch to ON position.
Between V1 (8) and (11), (12) Voltage 20 30 V
Between V1 (9) and (19), (20) Voltage 20 30 V

Circuit diagram related to power supply for VHMS controller 40-31

D375A-6R 40-311
(01)
Troubleshooting by failurecode
Failure code [DBB0KQ] VHMS connector connection abnormality

Failure code [DBB0KQ] VHMS connector connection abnormality 40-312


Action code Failure code VHMS connector connection abnormality
Failure
(VHMS controller system)
DBB0KQ
Detail of failure q Incorrect connection of connector V2A, V2B, V3A or V3B of VHMS controller
Action of con-
q None in particular
troller
Problem on
q Sensor signal value may not be indicated properly.
machine
Related infor-
q VHMS controller LED displays "n9" o "05".
mation

Cause Procedure, measuring location, criteria and remarks


Check if connectors "V2A" and "V3A" as well as connectors "V2B" and "V3B"
1 Wrong connector connection
of VHMS controller are connected incorrectly.

40-312 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DBB3KK] VHMS controller: Source voltage reduction

Failure code [DBB3KK] VHMS controller: Source voltage reduction 40-313


Action code Failure code Voltage drop in unswithed power supply to VHMS controller
Failure
(VHMS controller system)
DBB3KK
Detail of failure q 24 V power supply voltage from battery to VHMS controller is below 12.5 V.
Action of con-
q None in particular
troller
Problem on
q VHMS does not operate.
machine
Related infor-
mation

Cause Procedure, measuring location, criteria and remarks


If circuit breaker trips, circuit probably has ground fault. In this case, perform
1 Trip of circuit breaker (CB30)
troubleshooting for cause 7 first.
If fuse FS12-4 is blown out, circuit probably has ground fault. In this case, per-
2 Defective fuse FS12-4
form troubleshooting for cause 7 first.

Loose terminal 1. Turn starting switch to OFF position.


3
or disconnection at terminal Check terminals of battery, battery relay, etc.
1. Turn starting switch to OFF position, then carry out troubleshooting.
4 Improper battery voltage 2. Perform troubleshooting when engine is cranked.
Between battery (+) and (-) Voltage 20 30 V
1. Turn starting switch to OFF position.
2. Disconnect the ground cable.
3. Disconnect connector V1 and connect T-adapter to female side.
4. If the fuse is blown, replace it.
Open circuit or ground fault of wir- 5. If circuit breaker trips, reset it.
5
ing harness 6. Connect the ground cable.
a If voltage is 0 V, wiring harness is open-cricuited or ground fault.
Between V1 (female) (6) and (11), (12) Voltage 20 30 V
Between V1 (female) (7) and (19), (20) Voltage 20 30 V
a If cause 5 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect the ground cable.
3. If the fuse is blown, replace it.
Open circuit in wiring harness 4. If circuit breaker trips, reset it.
6
(open circuit or defective contact) 5. Disconnect connector V1 and connect T-adapter to female side.
Between ground and V1 (female) (11) or (12) or (19)
or (20) Resistance Max. 1 z
a Check terminal GND0I for looseness and rust.
Between each of V1 (female) (6), (7) and battery (+) Resistance Max. 1 z

D375A-6R 40-313
(01)
Troubleshooting by failurecode
Failure code [DBB3KK] VHMS controller: Source voltage reduction

Cause Procedure, measuring location, criteria and remarks


a If cause 5 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect ground strap.
3. If fuse is blown out, replace it.
Ground fault in wiring harness
7 4. If circuit breaker trips, reset it.
(Contact with ground circuit)
5. Disconnect connector V1 and connect T-adapter to female side.
Between V1 (female) (6) and (11), (20) Voltage Min. 1 Mz
Between V1 (female) (7) and ground Voltage Min. 1 Mz
If cause is not found by the above checks, VHMS controller is defective.
q Reference; the followings are criteria in normal condition.
1. Turn starting switch to OFF position.
2. Disconnect ground strap.
8 Defective VHMS controller 3. Connect T-adapter to connector V1.
4. Connect ground strap.
Between V1 (6) and (11), (12) Voltage 20 30 V
Between V1 (7) and (19), (20) Voltage 20 30 V

40-314 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DBB3KK] VHMS controller: Source voltage reduction

Circuit diagram related to power supply for VHMS controller 40-315

D375A-6R 40-315
(01)
Troubleshooting by failurecode
Failure code [DBB5KP] VHMS: Output sensor1 voltage reduction

Failure code [DBB5KP] VHMS: Output sensor1 voltage reduction 40-316


Action code Failure code VHMS sensor 5 V power supply abnormality
Failure
(VHMS controller system)
E00 DBB5KP
q Voltage of 5 V power supply circuit from VHMS controller to sensors is below 4.5 V or above 5.5 V.
Detail of failure
q Abnormal current flowed in 5 V power supply circuit for VHMS controller sensor.
Action of con-
q None in particular
troller
Problem on
q A part of VHMS does not operate.
machine
Related infor-
q VHMS controller LED displays "N9" o "04".
mation

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector ENBP.
Defective blowby pressure sensor 3. Turn starting switch to ON position.
1
(Internal defect) q If this code is not displayed, blowby pressure sensor is defective.
a Other failure codes are displayed, too. This is because the connector is dis-
connected. Ignore failure codes other than [DBB5KP].
1. Turn starting switch to OFF position.
2. Disconnect connectors V1 and ENBP, and connect T-adapter to female
Ground fault in wiring harness
2 side of either of them.
(Contact with ground circuit)
Between V1 (female) (4) or ENBP (female) (B) and
Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
Hot short in wiring harness (Con- 2. Disconnect connectors ENBP and connect T-adapter to female side.
3 3. Turn starting switch to ON position.
tact with 24 V circuit)
Between ENBP (female) (B) and (A) Voltage 4.5 5.5 V
If cause is not found by the above checks, VHMS controller is defective.
q Reference: The following are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector V1 and V2A.
3. Turn starting switch to ON position.
4 Defective VHMS controller
a Since 24 V power is supplied to connector V1, 5 V output cannot be
checked with connector V1 disconnected.
Between V1 (4) and V2A (12) Voltage 4.5 5.5 V
Between V1(5) and V2A(12) Voltage 4.5 5.5 V

40-316 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DBB5KP] VHMS: Output sensor1 voltage reduction

Circuit diagram related to power supply for VHMS controller sensors 5V 40-317

D375A-6R 40-317
(01)
Troubleshooting by failurecode
Failure code [DBB6KP] VHMS:Output sensor2 voltage reduction

Failure code [DBB6KP] VHMS:Output sensor2 voltage reduction 40-318


Action code Failure code VHMS sensor 24 V power supply abnormality
Failure
(VHMS controller system)
DBB6KP
q 24 V power supply circuit voltage from VHMS controller to sensors is above normal range (20 V -
Detail of failure 30 V).
q Abnormal current flowed in 24 V sensor power supply circuit to VHMS controller.
Action of con-
q None in particular
troller
Problem on
q Sensor input value to controller may not be obtained correctly.
machine
Related infor-
q VHMS controller LED displays "n9" o "02".
mation

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect following connectors one by one and turn starting switch to ON position
Defective transmis- each time.
sion main oil pressure 3. After troubleshooting, return to 1.
sensor, front (cylinder q If this code is not displayed when a sensor or a device is disconnected, that sensor or
Nos. 1 - 3) exhaust device is defective.
temperature sensor, a Other failure codes are displayed, too. This is because the connector is disconnected.
rear (cylinder Nos. 4 - Ignore failure codes other than [DBB6KP].
1 6) exhaust tempera- Device or sensor Connector
ture sensor, front
exhaust temperature Transmission main oil pressure sensor TMMD
sensor amplifier or Front (cylinder Nos. 1 - 3) exhaust temperature sensor EXHF
rear exhaust tempera-
ture sensor amplifier Rear (cylinder No. 4 - 6) exhaust temperature sensor EXHR
(Internal defect) Front exhaust temperature sensor amplifier EXAF
Rear exhaust temperature sensor amplifier EXAR
1. Turn starting switch to OFF position.
2. Disconnect connectors EXHF, EXHR, EXTF, EXTR, EXAF, EXAR, TMMD, V1 and
V2A, and connect T-adapter to female side of them or to male side of EXTF.
Between EXHF (female) (1) or EXTF (male) (1) and
Resistance Min. 1 Mz
ground
Ground fault in wiring Between EXHF (female) (1) and (2), or between EXTF
harness Resistance Min. 1 Mz
2 (male) (1) and (2)
(Contact with ground Between EXHR (female) (1) or EXTR (male) (1) and
circuit) Resistance Min. 1 Mz
ground
Between EXHR (female) (1) and (2), or between EXTR
Resistance Min. 1 Mz
(male) (1) and (2)
Between V1 (female) (2) and ground Resistance Min. 1 Mz
Between V1 (female) (2) and V2A (female) (12)/(13) Resistance Min. 1 Mz
If cause is not found by the above checks, VHMS controller is defective.
q Reference: Following shows standard values in normal condition.
1. Turn starting switch to OFF position.
Defective VHMS con- 2. Insert T-adapter into connectors V1 and V2A.
3 3. Turn starting switch to ON position.
troller
a Since 24 V power is supplied to connector V1, 24 V output cannot be checked with con-
nector V1 disconnected.
Between V1 (2) and V2A (12)/(13) Voltage 20 30 V

40-318 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DBB6KP] VHMS:Output sensor2 voltage reduction

Circuit diagram related to VHMS controller sensor 24V power supply 40-319

D375A-6R 40-319
(01)
Troubleshooting by failurecode
Failure code [DBB7KP] VHMS:Output sensor3 voltage reduction

Failure code [DBB7KP] VHMS:Output sensor3 voltage reduction 40-320


Action code Failure code VHMS sensor 12 V power supply abnormality
Failure
(VHMS controller system)
DBB7KP
q Voltage of 12 V power supply circuit from VHMS controller to sensors is below 11.5 V or above 12.5
Detail of failure V.
q Abnormal current flowed in 12 V sensor power supply circuit to VHMS controller.
Action of con-
q None in particular
troller
Problem on
q When downloading from VHMS controller, LED (Download light) does not light up.
machine
Related infor-
q VHMS controller LED displays "N9" o "03".
mation

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector DLT.
Defective download LED (Internal 3. Turn starting switch to ON position.
1
defect) q If this code is not displayed, download LED is defective.
a Other failure codes are displayed, too. This is because the connector is dis-
connected. Ignore failure codes other than [DBB7KP].
1. Turn starting switch to OFF position.
2. Disconnect connectors V1 and DLT, and connect T-adapter to female side
Ground fault in wiring harness
2 of either of them.
(Contact with ground circuit)
Between V1 (female) (3) or DLT (female) (1) and
Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector DLT and connect T-adapter to female side.
Hot short in wiring harness (Con- 3. Turn starting switch to ON position.
3
tact with 24 V circuit)
Between DLT (female) (1) and (2) Voltage 11.512.5V

If cause is not found by the above checks, VHMS controller is defective.


q Reference: The following are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Connect T-adapter to connector V1.
4 Defective VHMS controller 3. Turn starting switch to ON position.
a Since 24 V power is supplied to connector V1, 12 V output cannot be
checked with connector V1 disconnected.

Between V1 (3) and (12) Voltage 11.512.5V

40-320 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DBB7KP] VHMS:Output sensor3 voltage reduction

Circuit diagram related to VHMS controller sensor 24 V power supply 40-321

D375A-6R 40-321
(01)
Troubleshooting by failurecode
Failure code [DBBQKR] PT cont.: Can communication lost (VHMS)

Failure code [DBBQKR] PT cont.: Can communication lost (VHMS) 40-32


Action code Failure code CAN communication with power train controller is impossible
Failure (detected by VHMS controller)
E00 DBBQKR (VHMS controller system)

q VHMS controller cannot recognize engine controller, power train controller, work equipment con-
Detail of failure
troller, and machine monitor in CAN communication.
Action of con-
q None in particular
troller
Problem on
q VHMS function to collect information from other controllers does not work.
machine
Related infor-
q VHMS controller LED panel displays "n8" o "02".
mation

Cause Procedure, measuring location, criteria and remarks


Perform troubleshooting for failure code [DBERKR].

40-322 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DBE0KT] PT controller: Abnormality in controller

Failure code [DBE0KT] PT controller: Abnormality in controller 40-323


Action code Failure code Data recorded in power train controller are abnormal
Failure
(Power train controller system)
E01 DBE0KT
Detail of failure q Information in ROM (non-volatile memory) in power train controller is abnormal.
Action of con-
q Resets internal adjustment values to default values.
troller
Problem on q Transmission gear shift feel may become bad.
machine q Adjusting function by power train controller may not operate properly.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks


Use adjustment function in service mode, and perform operation of reproduc-
Defective adjustment of power ing trouble. If "E" of failure code disappears at this time, system function is
1
train controller proper.
q Adjustment code: 0002 (Initialization of power train controller)
Troubleshooting cannot be performed since defect is in power train controller.
2 Defective power train controller
(If there is no any visible trouble in machine, controller may be used as it is.)

D375A-6R 40-323
(01)
Troubleshooting by failurecode
Failure code [DBE1KK] PT controller: Source voltage reduction

Failure code [DBE1KK] PT controller: Source voltage reduction 40-324


Action code Failure code Battery direct power supply voltage drop for power train controller
Failure
(Power train controller system)
E04 DBE1KK
Detail of failure q The voltage of battery direct power supply to power train controller is below 17 V.
Action of con-
q Restricts operations of engine, transmission, and brake.
troller
q Machine monitor may not display correctly.
Problem on q Relay and solenoid may not be actuated and therefore, system may not operate properly.
machine q Once machine is stopped, engine speed is limited to half of full speed.
q Once machine is stopped, it cannot travel any more.
q Power source voltage of power train controller can be checked by adjusting function.
Related infor-
(Code: 2021: Power train controller voltage check mode)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


Trip of circuit breaker If circuit breaker has tripped, circuit probably has ground fault. In this case, perform trou-
1
(CB30) bleshooting for cause 7 first.
If fuse FS12-4 is blown out, circuit probably has ground fault. In this case, perform trouble-
2 Defective fuse FS12-4
shooting for cause 7 first.
Loose terminal, 1. Turn starting switch to OFF position.
3 or disconnection at ter-
minal Check terminals of battery, battery relay, etc.

Improper battery volt- 1. Perform troubleshooting with starting switch at OFF and when starting engine.
4
age Between battery (+) and (-) Voltage 20 30 V
1. Turn starting switch to OFF position.
2. Disconnect ground strap.
3. Disconnect connector PTCN3 and connect T-adapter to female side.
Open circuit or ground 4. Connect ground strap.
5
fault in wiring harness a If voltage is 0 V, wiring harness is open-cricuited or ground fault.
Between PTCN3 (female) (1) and (21), (31) Voltage 20 30 V
Between PTCN3 (female) (11) and (32), (33) Voltage 20 30 V
a If cause 4 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect ground strap.
Open circuit in wiring 3. If fuse has blown out, replace it.
harness 4. If circuit breaker has tripped, reset it.
6
(open circuit or defec- 5. Disconnect connector PTCN3 and connect T-adapter to female side.
tive contact) Between PTCN3 (female) (21)/(31)/(32)/(33) and ground
Resistance Max. 1 z
a Check terminal GND01 for looseness and rust.
Between PTCN3(female) (1), (2) and battery (+) Resistance Max. 1 z

40-324 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DBE1KK] PT controller: Source voltage reduction

Cause Procedure, measuring location, criteria and remarks


a If cause 4 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect ground strap.
Ground fault in wiring
3. If fuse is blown out, replace it.
harness
7 4. If circuit breaker has tripped, reset it.
(Contact with ground
5. Disconnect connector PTCN3 and connect T-adapter to female side.
circuit)
Between PTCN3 (female) (1) and (21)/(31) Resistance Min. 1 Mz
Between PTCN3 (female) (11) and (32)/(33) Resistance Min. 1 Mz
If cause is not found by the above checks, power train controller is defective.
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Disconnect ground strap.
Defective power train
8 3. Insert T-adapter into connector PTCN3.
controller
4. Connect ground strap.
Between PTCN3 (1) and (21)/(31) Voltage 20 30 V
Between PTCN3 (11) and (32)/(33) Voltage 20 30 V

Related circuit diagram 40-325

D375A-6R 40-325
(01)
Troubleshooting by failurecode
Failure code [DBE2KK] PT controller: Output voltage reduction

Failure code [DBE2KK] PT controller: Output voltage reduction 40-326


Action code Failure code Voltage drop in power supply for power train controller-related
Failure actuators
E04 DBE2KK (Power train controller system)

q Power supply (battery relay output) voltage for the actuators related to power train controller (relay,
Detail of failure
solenoid or others) is below 17 V.
Action of con-
q Restricts operations of engine, transmission, and brake.
troller
q Relay and solenoid may not drive be actuated and therefore, system may not operate properly.
Problem on
q Once machine is stopped, engine speed is limited to half of full speed.
machine
q Once machine is stopped, it cannot travel any more.
q Main power source voltage of power train controller can be checked by adjusting function.
Related infor- (Code: 2021: Power train controller voltage check mode)
mation q If the battery relay is not turned ON, see E-mode, E-1.
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


Trip of circuit breaker If CB1 or CB105 circuit breaker has tripped circuit probably has ground fault. In this case,
1
CB1 or CB105 perform troubleshooting for cause 6 first.
Loose terminal, 1. Turn starting switch to OFF position.
2 or disconnection at ter-
minal Check terminals of battery, battery relay, etc.

Improper battery volt- 1. Perform troubleshooting with starting switch at OFF and when starting engine.
3
age Between battery (+) and (-) Voltage 20 30 V
1. Turn starting switch to OFF position.
2. Disconnect ground strap.
3. Insert T-adapter into connector PTCN3.
Defective wiring har- 4. Connect ground strap.
4 ness or power train 5. Turn starting switch to ON position.
controller Between PTCN3 (2) and (21) Voltage 20 30 V
Between PTCN3 (12) and (31) Voltage 20 30 V
Between PTCN3 (22) and (32) Voltage 20 30 V
a If cause 4 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Disconnect ground strap (in order not to make short circuit).
harness 3. Disconnect connector PTCN3 and connect T-adapter to female side.
5
(open circuit or defec- Between PTCN3 (female) (21)/(31)/(32)/(33) and ground
tive contact) Resistance Max. 1 z
a Check terminal GND01 for looseness and rust.
Between PTCN3 (female) (2), (12) or (22) and BRC Resistance Max. 1 z
a If cause 4 is not the cause for the trouble, this check is not required.
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect ground strap (in order not to make short circuit).
6 3. If circuit breaker has tripped, reset it.
(Contact with ground
circuit) 4. Disconnect connector PTCN3.
Between terminal BRC and ground Resistance Min. 1 Mz
Defective power train
7 If cause is not found by the above checks, power train controller is defective.
controller

40-326 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DBE2KK] PT controller: Output voltage reduction

Related circuit diagram 40-327

D375A-6R 40-327
(01)
Troubleshooting by failurecode
Failure code [DBE5KK] PT cont.: Sensor voltage 5 V (1) reduction

Failure code [DBE5KK] PT cont.: Sensor voltage 5 V (1) reduction 40-328


Action code Failure code Power train controller 5 V power supply (1) abnormality
Failure
(Power train controller system)
E03 DBE5KK
q Voltage of 5 V power supply (1) circuit from power train controller to sensors is below 4.5 V or
Detail of failure above 5.5 V.
q Abnormal current flowed in 5 V power supply (1) circuit for power train controller sensors.
Action of con- q Stops output to 5 V power supply (1) circuit, if abnormal current flows.
troller q Restricts operation of engine and transmission.
q System may not operate properly.
Problem on
q Once machine is stopped, engine speed is limited to half of full speed.
machine
q Once machine is stopped, travel is limited to F1 and R1.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.


2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. After troubleshooting, return to 1.
q If this code is not displayed when a sensor is disconnected, that sensor is
defective.
Defective fuel control dial, brake
a Other failure codes are displayed at the same time. This is because the
1 pedal or PCCS lever (Internal
connector is disconnected. Ignore failure codes other than [DBE5KK].
defect)
Device Connector
Fuel control dial DIAL
PCCS lever TL2
Brake pedal BRK
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN1 and connect T-adapter to female side.
2 Defective power train controller 3. Turn starting switch to ON position.
Between PTCN1 (female) (22) and (21) Voltage 4.5 5.5 V
1. Turn starting switch to OFF position.
2. Disconnect all of connectors PTCN1, DIAL, and TL2, and connect
Ground fault in wiring harness T-adapter to female side of either of them.
3
(Contact with ground circuit)
Between ground and PTCN1 (female) (22), TL2
Resistance Min. 1 Mz
(female) (4) and (5), BRK (C) or DIAL (female) (1)
1. Turn starting switch to OFF position.
2. Disconnect all of connectors DIAL, TL2, and BRK, and connect T-adapter
to female side of either of them.
Hot short circuit in wiring harness 3. Turn starting switch ON.
4
(Contact with 24 V circuit)
Between TL2 (female) (4) and (1) or between
(female) (5) and (8) or between BRK (C) and (A), or Voltage 4.5 5.5 V
between DIAL (female) (1) and (3)

40-328 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DBE5KK] PT cont.: Sensor voltage 5 V (1) reduction

Related circuit diagram 40-329

D375A-6R 40-329
(01)
Troubleshooting by failurecode
Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction

Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction 40-3 0


Action code Failure code Power train controller sensor 24 V power supply abnormality
Failure
(Power train controller system)
E03 DBE6KK
q Voltage of 24 V power supply circuit from power train controller to sensors is below 17 V or above
Detail of failure 30 V.
q Abnormal current flowed in 24 V power supply circuit for power train controller sensors.
Action of con- q Stops output to 24 V power source circuit if abnormal voltage flows.
troller q Limits operation of engine and transmission.
q System may not operate properly.
Problem on
q Once machine is stopped, engine speed is limited to half of full speed.
machine
q Once machine stops, travel is limited to F1 and R1.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. After troubleshooting, return to 1).
q If this code is not displayed when a sensor is disconnected, that sensor is
Defective inclination angle sen- defective.
sor, torque converter inlet pres- a Other failure codes are displayed, too. This is because the connector is dis-
1 sure sensor or torque converter connected. Ignore failure codes other than [DBE6KK].
outlet pressure sensor (Internal
Sensor Connector
defect)
Pitch angle sensor PT1
Torque converter inlet pressure sensor TIP
Torque converter outlet pressure sen-
TOP
sor
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN1 and connect T-adapter to female side.
2 Defective power train controller 3. Turn starting switch to ON position.
Between PTCN1 (female) (16) and (21) Voltage 20 30 V
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1, PT1, TIP, and TOP, and connect T-adapter
Ground fault in wiring harness to female side of either of them.
3
(Contact with ground circuit)
Between ground and PTCN1 (female) (16) or TIP
Resistance Min. 1 Mz
(B) or TOP (B) or PT1 (female) (C)
1. Turn starting switch to OFF position.
2. Disconnect connectors PT1, TIP, and TOP, and connect T-adapter to
female side of either of them.
4 Short circuit in wiring harness 3. Turn starting switch to ON position.
Between TIP (B) and (A) or between TOP (B) and
Voltage 20 30 V
(A) or between PT1 (female) (C) and (A)

40-330 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction

Related circuit diagram 40-3 1

D375A-6R 40-331
(01)
Troubleshooting by failurecode
Failure code [DBE7KK] PT cont.: Sensor voltage 5 V reduction

Failure code [DBE7KK] PT cont.: Sensor voltage 5 V reduction 40-3 2


Action code Failure code Power train controller sensor 5 V power supply (2) abnormality
Failure
(Power train controller system)
E01 DBE7KK
q Voltage of 5 V power supply (2) circuit from power train controller to sensors is below 4.5 V or above
Detail of failure 5.5 V.
q Abnormal current flowed in 5 V power supply (2) circuit for power train controller sensor.
Action of con-
q Stops output to 5 V power supply (2) circuit, if abnormal current flows.
troller
Problem on
q Shoe slip control function may not operate properly (only for machine with shoe slip control).
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector SSA.
Defective acceleration sensor 3. Turn starting switch to ON position.
1
(Internal defect) q If this code is not displayed, acceleration sensor is defective.
a Other failure codes are displayed, too. This is because the connector is dis-
connected. Ignore failure codes other than [DBE7KK].
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SSA and connect T-adapter to female
Ground fault in wiring harness
2 side of either of them.
(Contact with ground circuit)
Between PTCN3 (female) (34) or SSA (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector SSA and connect T-adapter to female side.
3 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between SSA(female)(1) and (3) Voltage 4.5 5.5 V
If cause is not found by the above checks, power train controller is defective.
q Reference: The following are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN3.
4 Defective power train controller 3. Turn starting switch to ON position.
a Since 24 V power is supplied to connector PTCN3, 5 V output cannot be
checked with connector PTCN3 disconnected.
Between PTCN3 (34) and ground Voltage 4.5 5.5 V

40-332 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DBE7KK] PT cont.: Sensor voltage 5 V reduction

Circuit diagram related to power train controller sensor 5 V (2) power supply 40-3 3

D375A-6R 40-333
(01)
Troubleshooting by failurecode
Failure code [DBE9KQ] PT controller: Type select signal

Failure code [DBE9KQ] PT controller: Type select signal 40-3 4


Action code Failure code Power train controller: Type select signal
Failure
(Power train controller system)
E04 DBE9KQ
q The specification set in power train controller does not agree with the specification set in memory
Detail of failure
(Initialization of the power train controller is not performed).
Action of con- q Turns all outputs of power train controller to OFF position.
troller q Limits operation of engine and transmission.
q Machine does not move at all.
Problem on
q Once machine is stopped, engine speed is limited to medium (half) speed.
machine
q Once machine stops, it cannot travel at all.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks


Display adjustment function in service mode and perform operation of repro-
Defective adjustment of power
1 ducing trouble. If E of failure code disappears at this time, system is normal.
train controller
q Adjustment code: 0002 (Initialization of power train controller)

40-334 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DBERKR] PT controller: Can communication lost (WE)

Failure code [DBERKR] PT controller: Can communication lost (WE) 40-3 5


Action code Failure code CAN communication with power train controller is impossible.
Failure (detected by work equipment controller )
E03 DBERKR (Work equipment controller system)

Detail of failure q Work equipment controller cannot recognize power train controller in CAN communication.
Action of con-
q Limits operation of engine and transmission.
troller
q System may not operate normally.
Problem on
q Once machine is stopped, engine speed is limited to medium (half) speed.
machine
q Once machine is stopped, travel is limited to F1 and R1.
q Method of reproducing failure code: Turn starting switch to ON position.
q Start of CAN communication is notified to each controller by ACC signal of starting switch.
q Failure code is sent to machine monitor by CAN communication. Accordingly, if failure code
[DBERKR] is displayed on the machine monitor, CAN communication between work equipment
Related infor- controller and machine monitor is normal. That is, there can not be short circuit, ground fault or hot
mation short circuit in CAN communication line.
q Since each controller and machine monitor receive power from battery directly, they are kept ON
even while starting switch is OFF.
q The CAN communication line signal in operation is pulse voltage, so it cannot be measured by us-
ing multimeter.

Cause Procedure, measuring location, criteria and remarks


Defective power supply to power If failure code [DBBQKR] is also displayed, perform troubleshooting for failure
1
train controller code [DBE1KK] and [DBE2KK] first.
1. Turn starting switch to OFF position.
Defective CAN terminating resis- 2. Disconnect connectors CT2 and CM02 and connect T-adapters to male
tor side of them.
2
(internal open circuit or short cir- Between CT2 (male) (A) and (B) Resistance 120 12 z
cuit)
Between CM02 (male) (8) and (10) Resistance 120 12 z
q CAN communication line
a There is 120 z CAN terminating resistor inside machine monitor, too. Since
120 z resistor is connected in parallel, if resistance measured at connector
of controller other than machine monitor is 60 z which is combined resis-
tance, there is no open circuit in wiring harness.
1. Turn starting switch to OFF position and disconnect ground strap.
2. Disconnect one of following connectors EGC2, PTCN2, WECN2, V4A, CT2
and CM02 and connect T-adapter to female side of that connector.
a If connector has short circuit (Resistance between terminals is 1 z or less),
Open or short circuit in wiring har- disconnect all of EGC2, PTCN2, WECN2, V4A and CM02 and check again
3 to see if there is short circuit between wiring harnesses or in controller.
ness
Between EGC2 (female) (46) and (47) Resistance Approx. 60 z
Between PTCN2 (female) (32) and (22) Resistance Approx. 60 z
Between WECN2 (female) (32) and (22) Resistance Approx. 60 z
Between V4A (female) (12) and (4) Resistance Approx. 60 z
Between CT2 (female) (A) and (B) Resistance Approx. 120 z
Between CM02 (female) (9) and (10) Resistance Approx. 120 z

D375A-6R 40-335
(01)
Troubleshooting by failurecode
Failure code [DBERKR] PT controller: Can communication lost (WE)

Cause Procedure, measuring location, criteria and remarks


a If check result of cause 3 is normal, this check is not required.
1. Turn starting switch to OFF position and disconnect ground strap.
2. Disconnect connectors EGC2, PTCN2, WECN2, V4A, CT2 and CM02 and
connect T-adapters to female side of them.
Between PTCN2 (female) (32) and CM02
Resistance Max. 1 z
(female) (9)/(8)
Between PTCN2 (female) (22) and CM02
Resistance Max. 1 z
(female) (10)
Between PTCN2 (female) (32) and EGC2
Resistance Max. 1 z
(female) (46)
Open circuit in wiring harness Between PTCN2 (female) (22) and EGC2
Resistance Max. 1 z
4 (Open circuit in wiring or defective (female) (47)
contact in connector) Between PTCN2 (female) (32) and WECN2
Resistance Max. 1 z
(female) (32)
Between PTCN2 (female) (22) and WECN2
Resistance Max. 1 z
(female) (22)
Between PTCN2 (female) (32) and V4A
Resistance Max. 1 z
(female) (4)
Between PTCN2 (female) (22) and V4A
Resistance Max. 1 z
(female) (12)
Between EGC2 (female) (46) and CT2
Resistance Max. 1 z
(female) (A)
Between EGC2 (female) (47) and CT2
Resistance Max. 1 z
(female) (B)
q ACC signal from starting switch
1. Turn starting switch to OFF position and disconnect ground strap.
2. Insert T-adapters into connectors PTCN3, WECN3, V1, CM01, ACT and
EGC2.
3. Connect the ground cable and turn the starting switch to ON position.
Open circuit in wiring harness Between PTCN3 (14) or (24) and (31) Voltage 20 30 V
5 (Open circuit in wiring or defective Between WECN3 (14) or (24) and (31) Voltage 20 30 V
contact in connector)
Between V1 (17) and (19) Voltage 20 30 V
Between CM01 (14) and (3) Voltage 20 30 V
Between ACT(1), (3) and ground Voltage 20 30 V
Between EGC2 (39) and ground Voltage 20 30 V
q ACC signal from starting switch
1. Turn starting switch to OFF position and disconnect ground strap.
2. Disconnect connectors PTCN3, WECN3, V1, CM01 and ACT, and connect
T-adapter to female side of one of them.
Ground fault in wiring harness 3. Disconnect connectors EGC2 and connect T-adapter to female side.
6
(Contact with ground circuit) Between PTCN3 (female) (14), (24), WECN3
(female) (14), (24), V1 (female) (17) or CM01 Resistance Min. 1 Mz
(female) (14) and ground
Between EGC2 (female) (39) and ground Resistance Min. 1 Mz
If cause is not found by above checks and failure code [DAFRMC] is dis-
7 Defective power train controller played, power train controller is defective.
(Since trouble is in system, troubleshooting cannot be performed.)
Defective work equipment control- If cause is not found by above checks, work equipment controller is defective.
8
ler (Since trouble is in system, troubleshooting cannot be performed.)

40-336 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DBERKR] PT controller: Can communication lost (WE)

Circuit diagram related to CAN 40-3 7

D375A-6R 40-337
(01)
Troubleshooting by failurecode
Failure code [DD12KA] Shift up Sw: Disconnection

Failure code [DD12KA] Shift up Sw: Disconnection 40-3 8


Action code Failure code Shift up switch: Disconnection
Failure
(Power train controller system)
E02 DD12KA
Detail of failure q Both lines of NO* and NC* for shift up switch circuit are OPEN (switch: OFF) at the same time.
Action of con-
q Recognizes that the shift up switch is not pressed.
troller
Problem on
q Transmission gear cannot be shifted up.
machine
q "NO*" line is used for sensing operation and "NC*" line is used for detecting error.
q Condition of shift up switch signal can be checked with monitoring function.
Related infor-
(Code: 40905 Power train control switch Input 3)
mation
q Method of reproducing failure code: Turning on the starting switch and operating the shift up switch
q Connector SFTU has no T-adapters, don't carry out troubleshooting in female side.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector SFTU.
3. Turn shift up switch to ON or OFF position and troubleshoot.
a "Switch OFF": Release, "Switch ON": Press
Defective shift up switch Switch: OFF Resistance Max. 1 z
1 Between SFTU (male)
(Internal disconnection)
(3) and (2) Switch: ON Resistance Min. 1 Mz

Between SFTU (male) Switch: OFF Resistance Min. 1 Mz


(1) and (2) Switch: ON Resistance Max. 1 z
1.Turn starting switch to OFF position.
2.Disconnect connector SFTU.
3.Insert T-adapter into connector TL3.
4.Turn starting switch ON position.
a When voltage is 0V, it shows open circuit, and when voltage is 24 V, it
Disconnection or hot short in wir-
2 shows hot short circuit in wiring harness.
ing harness
a Voltage of approx. 9 V is applied to signal lines of "NO" and "NC" through
resistor in power train controller.
Between TL3 (1) and (2) Voltage 711 V
Between TL3 (3) and (2) Voltage 711 V
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 and PTCN3, and connect T-adapters to
female side of them.
3. Turn shift up switch to ON or OFF position and troubleshoot.
Disconnection in wiring harness
3
(open circuit or defective contact) Between PTCN3 (female) (29) and Switch: OFF Resistance Max. 1 z
PTCN1 (female) (10)
Between PTCN3 (female) (39) and
Switch: ON Resistance Max. 1 z
PTCN1 (female) (10)

40-338 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DD12KA] Shift up Sw: Disconnection

Cause Procedure, measuring location, criteria and remarks


If cause is not found by the above checks, power train controller is defective.
q Reference; the followings are criteria in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors PTCN1 and PTCN3.
3. Turn starting switch to ON position.
4. Turn shift down switch to ON or OFF position and troubleshoot.
a Voltage of apporximately 9 V is applied to PTCN3 pin (29) and PTCN3 pin
4 Defective power train controller
(39) through resistor in power train controller.
Between PTCN3 (29) Switch: OFF Voltage Max. 1 V
and PTCN1 (10) Switch: ON Voltage 711 V

Between PTCN3 (39) Switch: OFF Voltage 711 V


and PTCN1 (10) Switch: ON Voltage Max. 1 V

*NO: Normally Open


*NC: Normally Closed

Circuit diagram related to shift up switch 40-3 9

D375A-6R 40-339
(01)
Troubleshooting by failurecode
Failure code [DD12KB] Shift up Sw: Short circuit

Failure code [DD12KB] Shift up Sw: Short circuit 40-340


Action code Failure code Shift up switch: Short circuit
Failure
(Power train controller system)
E02 DD12KB
Detail of failure q Both lines of NO* and NC* for shift up switch circuit are 0 V (switch: ON) at the same time.
Action of con-
q Recognizes that the shift up switch is not pressed.
troller
Problem on
q Transmission gear cannot be shifted up.
machine
q "NO*" line is used for sensing operation and "NC*" line is used for detecting error.
q Condition of shift up switch signal can be checked with monitoring function.
Related infor- (Code: 40905 Power train control switch Input 3)
mation q Method of reproducing failure code: Turn starting switch to ON position (and operate shift up
switch).
q Connector SFTU has no T-adapters, don't carry out troubleshooting in female side.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector SFTU.
3. Turn shift switch to ON or OFF position and troubleshoot.
a "Switch OFF": Release, "Switch ON": Press
Defective shift up switch Switch: OFF Resistance Max. 1 z
1 Between SFTU (male)
(Internal open circuit in wiring)
(3) and (2) Switch: ON Resistance Min. 1 Mz

Between SFTU (male) Switch: OFF Resistance Min. 1 Mz


(1) and (2) Switch: ON Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SFTU and connect T-adapter to female
Ground fault in wiring harness side of PTCN3.
2
(Contact with ground circuit) Between PTCN3 (female) (39) and ground Resistance Min. 1 Mz
Between PTCN3 (female) (29) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SFTU and connect T-adapter to female
side of PTCN3.
a Check with multimeter in continuity mode.
3 Short circuit in wiring harness
Between PTCN3 (female) (29) and each pin other No continuity
than (29) (No sound is heard)
Between PTCN3 (female) (39) and each pin other No continuity
than (39) (No sound is heard)
If cause is not found by the above checks, power train controller is defective.
q Reference; the followings are criteria in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors PTCN1 and PTCN3.
3. Turn starting switch to ON position.
4. Turn shift switch to ON or OFF position and troubleshoot.
4 Defective power train controller
a Voltage of apporx.9 V is applied to PTCN3 pin (29) and PTCN3 pin (39)
through resistor in power train controller.
Between PTCN3 (29) Switch: OFF Voltage Max. 1 V
and PTCN1 (10) Switch: ON Voltage 711 V
Between PTCN3 (39) Switch: OFF Voltage 711 V
and PTCN1 (10) Switch: ON Voltage Max. 1 V
*NO: Normally Open
*NC: Normally Closed

40-340 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DD12KB] Shift up Sw: Short circuit

Circuit diagram related to shift up switch 40-341

D375A-6R 40-341
(01)
Troubleshooting by failurecode
Failure code [DD13KA] Shift down Sw: Disconnection

Failure code [DD13KA] Shift down Sw: Disconnection 40-342


Action code Failure code Shift-down switch Disconnection
Failure
(Power train controller system)
E02 DD13KA
Detail of failure q Both linens of NO* and NC* for shift down switch circuit are OPEN (switch: OFF) at the same time.
Action of con-
q Recognizes that the shift up switch is not pressed.
troller
Problem on
q Shift down is not possible.
machine
q NO* line is used for sensing operation and NC* line is used for detecting error.
q Condition of shift up switch signal can be checked with moniitoring function.
Related infor-
(Code: 40905 Power train control switch Input 3)
mation
q Method of reproducing failure code: Turn starting switch ON (and operate shift up switch)
q Connector SFTD has no T-adapters, don't perform troubleshooting in female side.

Cause Procedure, measuring location, criteria and remarks


1.Turn starting switch to OFF position.
2.Disconnect connector SFTD.
3.Insert T-adapter into connector TL3.
4.Turn starting switch ON position.
a When voltage is 0 V, it shows open circuit, and when voltage is 24 V, it
Disconnection or hot short in wir-
1 shows hot short circuit in wiring harness.
ing harness
a Voltage of apporximately 9 V is applied to signal lines of "NO" and "NC"
through resistor in power train controller.
Between TL3 (4) and (5) Voltage 711 V
Between TL3 (6) and (5) Voltage 711 V
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN1, PTCN3 and SFTD, and connect T-adapters
to female side of them.
Disconnection in wiring harness
2 Between PTCN3 (female) (19) and SFTD (male) (1) Resistance Max. 1 z
(open circuit or defective contact)
Between PTCN1 (female) (10) and SFTD (male) (2) Resistance Max. 1 z
Between PTCN3 (female) (9) and SFTD (male) (3) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors TL3 and connect T-adapters to female side.
3. Turn shift up switch to ON or OFF position and troubleshoot.
a Switch OFF: Release, Switch ON: Press
Defective shift down switch Switch: OFF Resistance Max. 1 z
3 Between TL3 (male) (5)
(Internal disconnection)
and (6) Switch: ON. Resistance Min. 1 Mz

Between TL3 (male) (4) Switch: OFF Resistance Min. 1 Mz


and (5) Switch:ON Resistance Max. 1 z

40-342 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DD13KA] Shift down Sw: Disconnection

Cause Procedure, measuring location, criteria and remarks


If cause is not found by the above checks, power train controller is defective.
q Reference; the followings are criteria in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors PTCN1 and PTCN3.
3. Turn starting switch to ON position.
4. Turn shift down switch to ON or OFF position and troubleshoot.
a Voltage of apporximately 9 V is applied to PTCN3 pin (19) and pin (9)
4 Defective power train controller
through resistor in power train controller.
Between PTCN3 (19) Switch: OFF Voltage 711 V
and PTCN1 (10) Switch: ON Voltage Max. 1 V

Between PTCN3 (9) and Switch: OFF Voltage Max. 1 V


PTCN1 (10) Switch: ON Voltage 711 V

*NO: Normally Open


*NC: Normally Closed

Circuit diagram related to shift up switch 40-343

D375A-6R 40-343
(01)
Troubleshooting by failurecode
Failure code [DD13KB] Shift down Sw: Short circuit

Failure code [DD13KB] Shift down Sw: Short circuit 40-34


Action code Failure code Shiftdown switch: short circuit
Failure
(Power train controller system)
E02 DD13KB
Detail of failure q Both lines of NO* and NC* for shift down switch circuit are 0 V (switch: ON) at the same time.
Action of con-
q Recognizes that the shift up switch is not pressed.
troller
Problem on
q Shift down is not possible.
machine
q NO* line is used for sensing operation and NC* line is used for detecting error.
q Condition of shift up switch signal can be checked with moniitoring function.
Related infor-
(Code: 40905 Power train control switch Input 3)
mation
q Method of reproducing failure code: Turn starting switch ON (and operate shift down switch).
q Connector SFTD has no T-adapters, don't perform troubleshooting in female side.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SFTD and connect T-adapter to female
Ground fault of wiring harness side of PTCN3.
1
(Contact with GND circuit) Between PTCN3 (female) (9) and ground Resistance Min. 1 Mz
Between PTCN3 (female) (19) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SFTD and connect T-adapter to female
side of PTCN3.
a Check with multimeter in continuity mode.
2 Short circuit in wiring harness Between PTCN3 (female) (9) and each pin other No continuity
than (9) (No sound is heard)
Between PTCN3 (female) (19) and each pin other No continuity
than (19) (No sound is heard)
1. Turn starting switch to OFF position.
2. Disconnect connectors TL3 and connect T-adapters to female side.
3. Turn shift down switch to ON or OFF position and troubleshoot.
Defective shift down switch a Switch OFF: Release, Switch ON: Press
3
(Internal disconnection) Between TL3 (male) (5) Switch: OFF Resistance Max. 1 z
and (6) Switch: ON Resistance Min. 1 Mz
Between TL3 (male) (4) Switch: OFF Resistance Min. 1 Mz
and (5) Switch: ON Resistance Max. 1 z
If cause is not found by the above checks, power train controller is defective.
q Reference; the followings are cirteria in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors PTCN1 and PTCN3.
3. Turn starting switch to ON position.
4. Turn shift down switch to ONor OFF position and troubleshoot.
4 Defective transmission controller
a Voltage of apporx.9 V is applied to PTCN3 pin (19) and pin (9) through re-
sistor in power train controller.
Between PTCN3 (19) Switch: OFF Voltage 711 V
and PTCN1 (10) Switch: ON Voltage Max. 1 V
Between PTCN3 (9) and Switch: OFF Voltage Max. 1 V
PTCN1 (10) Switch: ON Voltage 711 V
*NO: Normally Open
*NC: Normally Closed

40-344 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DD13KB] Shift down Sw: Short circuit

Circuit diagram related to shift down switch 40-345

D375A-6R 40-345
(01)
Troubleshooting by failurecode
Failure code [DD14KA] Parking lever Sw: Dissconnection

Failure code [DD14KA] Parking lever Sw: Dissconnection 40-346


Action code Failure code Parking lever switch: Disconnection
Failure
(Power train controller system)
E03 DD14KA
q Both lines of NO* and NC* for parking brake lever switch circuit are OPEN (switch: OFF) at the
Detail of failure
same time.
Action of con- q Recognizes parking brake lever is in Free position.
troller q Limits operation of engine and transmission.
q Once machine is stopped, engine speed is limited to medium (half) speed.
Problem on
q Once machine is stopped, travel is limited to F1 and R1.
machine
q Engine cannot start.
q NC* line is used for sensing operation and NO* line is used for detecting error.
q Condition of parking brake lever switch signal can be checked with monitoring function.
Related infor- (Code: 40905 Power train control switch Input 3)
mation q Method of reproducing failure code:Turn starting switch to ON position and operate parking brake
lever.
q When parking brake lever is in free position, parking brake lever switch is turned to ON position.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector NSW and connect T-adapter to male side.
3. Operate parking brake lever and troubleshoot.

1
Defective parking brake lever Between NSW (male) (A) Lever: LOCK Resistance Min. 1 Mz
switch (Internal disconnection) and (B) Lever: FREE Resistance Max. 1 z

Between NSW (male) (A) Lever: LOCK Resistance Max. 1 z


and (C) Lever: FREE Resistance Min. 1 Mz
1.
Turn starting switch to OFF position.
2.
Disconnect connector NSW and connect T-adapter to female side.
3.
Turn starting switch to ON position.
a
If voltage is 0 V, it shows open circuit, and if voltage is 24 V, it shows hot
Open circuit or hot short circuit in short circuit in wiring harness.
2
wiring harness a Voltage of approximately 9 V is applied to signal lines of "NO" and "NC"
through resistor in power train controller.
Between NSW (female) (B) and (A) Voltage 711 V
Between NSW (female) (C) and (A) Voltage 711 V
a If cause 2 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 and NSW, and connect T-adapters to
female side of them.
Open circuit in wiring harness Between PTCN1 (female) (12) and NSW (female)
3 Resistance Max. 1 z
(open circuit or defective contact) (C)
Between PTCN1 (female) (18) and NSW (female)
Resistance Max. 1 z
(B)
Between NSW (female) (A) and ground Resistance Max. 1 z

40-346 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DD14KA] Parking lever Sw: Dissconnection

Cause Procedure, measuring location, criteria and remarks


If cause is not found by the above checks, power train controller is defective.
q Reference; the followings are criteria in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN1.
3. Turn starting switch to ON position.
4. Operate shiftup switch and troubleshoot.
a The voltage of approximately 9 V is applied to PTCN1 pin (12) and pin (18)
4 Defective power train controller
through the resistor in the power train controller.
Between PTCN1 (18) Lever: LOCK Voltage 711 V
and ground Lever: FREE Voltage Max. 1 V

Between PTCN1 (12) Lever: LOCK Voltage Max. 1 V


and ground Lever: FREE Voltage 711 V

*NO: Normally Open


*NC: Normally Closed

Circuit diagram related to parking brake lever switch 40-347

D375A-6R 40-347
(01)
Troubleshooting by failurecode
Failure code [DD14KB] Parking lever Sw: Short circuit

Failure code [DD14KB] Parking lever Sw: Short circuit 40-348


Action code Failure code Parking lever switch: Short circuit
Failure
(Power train controller system)
E03 DD14KB
q Both lines of NO* and NC* for parking brake lever switch circuit are 0 V (switch: ON) at the same
Detail of failure
time.
Action of con- q Recognizes parking brake lever is in FREE position.
troller q Limits operation of engine and transmission.
q Once machine is stopped, engine speed is limited to medium (half) speed.
Problem on
q Once machine is stopped, travel is limited to F1 and R1.
machine
q Engine cannot start.
q NC* line is used for sensing opration and NO* line is used for detecting error.
q Condition of parking brake lever switch signal can be checked with monitoring function.
Related infor- (Code: 40905 Power train control Input 3)
mation q Method of reproducing failure code: Turn starting switch to ON position and operate parking brake
lever.
q When parking brake lever is FREE, parking brake lever switch becomes ON.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector NSW and connect T-adapter to male side.
3. Operate parking brake lever and troubleshoot.
Defective parking brake lever
1 Between NSW (male) (A) Lever: LOCK Resistance Min. 1 Mz
switch (Internal disconnection)
and (B) Lever: FREE Resistance Max. 1 z
Between NSW (male) (A) Lever: LOCK Resistance Max. 1 z
and (C) Lever: FREE Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 and NSW, and connect T-adapter to female
side of either of them.
Ground fault in wiring harness
2 Between NSW (female) (B) or PTCN1 (female) (18)
(Contact with ground circuit) Resistance Min. 1 Mz
and ground
Between NSW (female) (C) or PTCN1 (female) (12)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 and NSW, and connect T-adapter to female
side of either of PTCN1.
a Check with multimeter continuity mode.
3 Short circuit in wiring harness Between PTCN1 (female ) (12) and each pin other No continuity
than (12) (No sound is heard)
Between PTCN1 (female ) (18) and each pin other No continuity
than (18) (No sound is heard)
If cause is not found by the above checks, power train controller is defective.
q Reference; the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN1.
3. Turn starting switch to ON position.
4. Operate shiftup switch and troubleshoot.
4 Defective power train controller
a The voltage of approximately 9 V is applied to PTCN1 pin (12) and pin (18)
through the resistor in the power train controller.
Between PTCN1 (18) Lever: LOCK Voltage 711 V
and ground Lever: FREE Voltage Max. 1 V
Between PTCN1 (12) Lever: LOCK Voltage Max. 1 V
and ground Lever: FREE Voltage 711 V
*NO: Normally Open
*NC: Normally Closed

40-348 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DD14KB] Parking lever Sw: Short circuit

Circuit diagram related to parking brake lever switch 40-349

D375A-6R 40-349
(01)
Troubleshooting by failurecode
Failure code [DDB9L4] Reverse SW Signal disagreement

Failure code [DDB9L4] Reverse SW Signal disagreement 40-350


Action code Failure code Inconsistent reverse switch signal
Failure
(Power train controller system)
E03 DDB9L4
Detail of failure q There is inconsistency in line 2 of NO* for reverse switch circuit.
Action of con-
q Recognizes that reverser switch is not pressed.
troller
Problem on q Once machine is stopped, engine speed is limited to medium (half) speed.
machine q Once machine is stopped, travel is limited to F1.
q Condition of reverse switch signal can be checked with monitoring function.
(Code: 40905 Power train control switch Input 3)
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position (and operate reverse
mation
switch).
q Since T-adapter is not prepared for connector RTS, female side check is not required.

Cause Procedure, measuring location, criteria and remarks


Wrong selection of travel lever
1 If failure code [DDT5KQ] is displayed, carry out troubleshooting for it.
type
1.
Turn starting switch to OFF position.
2.
Disconnect connector RTS.
3.
Insert T-adapter into connector TL3.
4.
Turn starting switch to ON position.
a
If voltage is 0 V, it shows open circuit in wiring harness, and if voltage is 24
Open circuit or hot short circuit in
2 V, it shows hot short circuit in wiring harness.
wiring harness
a Voltage of approximately 9 V is applied to two signal lines of "NO" through
resistor in power train controller.
Between TL3 (4) and (2) Voltage 711 V
Between TL3 (6) and (5) Voltage 711 V
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1, PTCN3, TL3, and RTS, and connect
T-adapters to female side of PTCN1, PTCN3, and PL3.
Open circuit in wiring harness Between PTCN3 (female) (19) and RTS (male) (1) Resistance Max. 1 z
3
(open circuit or defective contact) Between PTCN1 (female) (10) and TL3 (female) (2) Resistance Max. 1 z
Between PTCN1 (female) (10) and RTS (male) (2) Resistance Max. 1 z

Between PTCN3 (female) (9) and RTS (male) (3) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and RTS, and connect T-adapter to female
Ground fault in wiring harness side of PTCN3.
4
(Contact with ground circuit) Between PTCN3 (female) (9) and ground Resistance Min. 1 Mz
Between PTCN3 (female) (19) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and RTS, and connect T-adapter to female
side of PTCN3.
a Check with multimeter in continuity mode.
5 Short circuit in wiring harness Between PTCN3 (female) (9) and each pin other No continuity
than (9) (No sound is heard)
Between PTCN3 (female) (19) and each pin other No continuity
than (19) (No sound is heard)

40-350 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DDB9L4] Reverse SW Signal disagreement

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors TL3 and connect T-adapters to female side.
3. Disconnect connector FTS.
4. Turn reverse switch ON/OFF, and troubleshoot.
a Switch OFF: Release, Switch ON: Press
Defective reverse switch
6 Switch: OFF Resistance Min. 1 Mz
(Internal disconnection) Between TL3 (male) (5)
and (6) Switch: ON Resistance Max. 1 z

Between TL3 (male) (4) Switch: OFF Resistance Min. 1 Mz


and FTS (female) (2) Switch: ON Resistance Max. 1 z
If cause is not found by the above checks, power train controller is defective.
q Reference; the followings are criteria in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors PTCN1 and PTCN3.
3. Turn starting switch to ON position.
4. Turn reverse switch ON/OFF, and troubleshoot.
a Voltage of approximately 9 V is applied to PTCN3 pin (19) and pin (9)
7 Defective power train controller
through resistor in power train controller.
Between PTCN3 (19) Switch: OFF Voltage 711 V
and PTCN1 (10) Switch: ON Voltage Max. 1 V

Between PTCN3 (9) and Switch: OFF Voltage 711 V


PTCN1 (10) Switch: ON Voltage Max. 1 V

*NO: Normally Open

Circuit diagram related to reverse switch 40-351

a Exclusive for single-direction lever

D375A-6R 40-351
(01)
Troubleshooting by failurecode
Failure code [DDE2KA] Pre lub. oil press sw: Disconnection

Failure code [DDE2KA] Pre lub. oil press sw: Disconnection 40-352
Action code Failure code Pre-lubricating oil pressure switch open circuit
Failure
(Power train controller)
E02 DDE2KA
q Power train controller has started pre-lubrication, pre-lubricating motor is operating, and voltage is
Detail of failure detected at pre-lubricating motor. However, pre-lubricating oil pressure switch is not turned to OFF
position.
Action of con-
q None in particular
troller
Problem on
q Engine does not run (It runs in skip mode, however).
machine
q Pre-lubricating oil pressure switch is turned to ON position when oil pressure is not applied.
q Whether pre-lubricating oil pressure switch is turned to ON position can be checked with monitoring
Related infor- function.
mation (Code: 40910 PT controller SW Input 2)
q Whether pre-lubricating motor is in operation can be checked with monitoring function.
(Code: 40909 P/T controller SW Output)

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect terminal POP.
Defective pre-lubricating oil pres- 3. Turn starting switch to ON position.
1
sure switch a During pre-lubrication
Between terminal POP (on pre-lubricating oil pres- Not conductive
sure switch side) and ground
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connector PTCN2 and connect T-adapter to female side.
2
(open circuit or defective contact)
Between PTCN2 (female) (13) and ground Resistance Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connector PTCN2 and connect T-adapter to female side.
3 3. Disconnect terminal POP.
(Contact with ground circuit)
Between PTCN2 (female) (13) and ground Resistance Min. 1 Mz
If cause is not found by above checks, power train controller is defective.
q Reference: Following shows criteria in normal condition.
1. Turn starting switch to OFF position.
4 Defective power train controller 2. Insert T-adapter into connector PTCN2.
3. Turn starting switch to ON position.
a Between PTCN2 (13) and (29) during pre-lubri-
Voltage 711 V
cation

Circuit diagram related to pre-lubricating oil pressure switch 40-352

40-352 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DDE2KA] Pre lub. oil press sw: Disconnection

D375A-6R 40-353
(01)
Troubleshooting by failurecode
Failure code [DDK3L4] Forward SW Signal disagreement

Failure code [DDK3L4] Forward SW Signal disagreement 40-354


Action code Failure code Inconsistent forward switch signal
Failure
(Power train controller system)
E03 DDK3L4
Detail of failure q There is inconsistency in line 2 of NO* for forward switch circuit.
Action of con-
q Recognizes that forward switch is not pressed.
troller
Problem on q Once machine is stopped, engine speed is limited to medium (half) speed.
machine q Once machine is stopped, travel is limited to R1.
q Condition of forward switch signal can be checked with monitoring function.
Related infor- (Code: 40905 Power train control switch Input 3)
mation q Method of reproducing failure code: Turn starting switch to ON position (and operate forward
switch).

Cause Procedure, measuring location, criteria and remarks


Wrong selection of travel lever
1 If failure code [DDT5KQ] is displayed, carry out troubleshooting for it.
type
1. Turn starting switch to OFF position.
2. Disconnect connector FTS.
3. Disconnect connectors TL3 and connect T-adapters to female side.
4. Turn shift up switch to ON or OFF position and troubleshoot.
a "Switch OFF": Release, "Switch ON": Press
Defective forward switch
2 Switch: OFF Resistance Min. 1 Mz
(Internal open circuit in wiring) Between FTS (male) (3)
and TL3 (male) (5) Switch: ON Resistance Max. 1 z

Between FTS (male) (1) Switch: OFF Resistance Min. 1 Mz


and (2) Switch: ON Resistance Max. 1 z
1.
Turn starting switch to OFF position.
2.
Disconnect connector FTS.
3.
Insert T-adapter into connector TL3.
4.
Turn starting switch to ON position.
a
If voltage is 0 V, it shows open circuit in wiring harness, and if voltage is 24
Open circuit or hot short circuit in
3 V, it shows hot short circuit in wiring harness.
wiring harness
a Voltage of about 9 V is applied to signal lines of NO and NC through re-
sistor in power train controller.
Between TL3 (1) and (2) Voltage 711 V
Between TL3 (3) and (5) Voltage 711 V
a If cause 2 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN1, PTCN3 and TL3, and connect T-adapters to
female side of them.
3. Disconnect connector RTS.
Open circuit in wiring harness
4 Max. 1 z
(open circuit or defective contact) Between PTCN3 (female) (39) and TL3 (female) (1) Resistance
Between PTCN1 (female) (10) and TL3 (female) (2) Resistance Max. 1 z
Between PTCN3 (female) (29) and TL3 (female) (3) Resistance Max. 1 z
Between PTCN1 (female) (10) and RTS (male) (2) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and FTS, and connect T-adapter to female
Ground fault in wiring harness side of PTCN3.
5
(Contact with ground circuit) Between PTCN3 (female) (39) and ground Resistance Min. 1 Mz
Between PTCN3 (female) (29) and ground Resistance Min. 1 Mz

40-354 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DDK3L4] Forward SW Signal disagreement

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and FTS, and connect T-adapter to female
side of PTCN3.
a Check with multimeter in continuity mode.
6 Short circuit in wiring harness Between PTCN3 (female) (29) and each pin other No continuity
than (29) (No sound is heard)
Between PTCN3 (female) (39) and each pin other No continuity
than (39) (No sound is heard)
If cause is not found by the above checks, power train controller is defective.
q Reference; the followings are criteria in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors PTCN1 and PTCN3.
3. Turn starting switch to ON position.
4. Turn shift up switch to ON or OFF position and troubleshoot.
a The voltage of approximately 9 V is applied to PTCN3 pin (29) and pin (39)
7 Defective power train controller
through the resistor in power train controller.
Between PTCN3 (29) Switch: OFF Voltage 711 V
and PTCN1 (10) Switch: ON Voltage Max. 1 V

Between PTCN3 (39) Switch: OFF Voltage 711 V


and PTCN1 (10) Switch: ON Voltage Max. 1 V

*NO: Normally Open

Circuit diagram related to forward switch 40-35

a Exclusive for single-direction lever

D375A-6R 40-355
(01)
Troubleshooting by failurecode
Failure code [DDK5KA] Shift switch disconnection

Failure code [DDK5KA] Shift switch disconnection 40-356


Action code Failure code Shift switch disconnection
Failure
(Transmission controller system)
E02 DDK5KA
q Both lines of NO: Normally Open and NC: Normally Closed for shift up switch circuit are OPEN
Detail of failure
(switch: OFF) at the same time.
Action of con-
q Recognizes that switch is not pressed.
troller
Problem on
q Gear cannot be shifted up and down (1st io2nd).
machine
q NO: Normally Open line is used for sensing operation and NC: line is used for detecting error.
Related infor- q Condition of shift up switch signal can be checked with monitoring function.
mation (Code: 40905 Power train control switch Input 3)
q Method of reproducing failure code: Turning on the starting switch and operating the shift up switch

Cause Procedure, measuring location, criteria and remarks


Wrong selection of travel lever
1 If failure code [DDT5KQ] is displayed, carry out troubleshooting for it.
type
1. Turn starting switch to OFF position.
2. Disconnect connector SNC and connect T-adapter to male side.
3. Turn shift switch to ON or OFF position and troubleshoot.
a Switch OFF: Release, Switch ON: Press
Defective shift switch Switch: OFF Resistance Max. 1 z
2 Between SNC (male) (1) and
(Internal open circuit in wiring)
(3) Switch: ON Resistance Min. 1 Mz

Between SNC (male) (1) and Switch: OFF Resistance Min. 1 Mz


(2) Switch: ON Resistance Max. 1 z
1.
Turn starting switch to OFF position.
2.
Disconnect connector SNC and connect T-adapter to female side.
3.
Turn starting switch to ON position.
a
If voltage is 0 V, it shows open circuit in wiring harness, and if voltage is 24
Open circuit or hot short circuit in V, it shows hot short circuit in wiring harness.
3
wiring harness a Voltage of about 9 V is applied to signal lines of NO and NC through re-
sistor in power train controller.
Between SNC (female) (2) and (1) Voltage 711 V
Between SNC (female) (3) and (1) Voltage 711 V
a If cause 2 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1, PTCN2 and SNC, and connect T-adapter
to female side of them.
Open circuit in wiring harness Between PTCN1 (female) (10) and SNC
4 Resistance Max. 1 z
(open circuit or defective contact) (female) (1)
Between PTCN2 (female) (7) and SNC
Resistance Max. 1 z
(female) (2)
Between PTCN1 (female) (6) and SNC
Resistance Max. 1 z
(female) (3)

40-356 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DDK5KA] Shift switch disconnection

Cause Procedure, measuring location, criteria and remarks


If cause is not found by the above checks, power train controller is defective.
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors PTCN1 and PTCN2.
3. Turn starting switch to ON position.
4. Turn shift down switch to ON or OFF position and troubleshoot.
a Voltage of about 9 V is applied to PTCN1 pin (6) and PTCN2 pin (7) through
5 Defective power train controller
resistor in power train controller.
Between PTCN2 (7) and Switch: OFF Voltage 711 V
PTCN1(10) Switch: ON Voltage Max. 1 V

Between PTCN1 (6) and Switch: OFF Voltage Max. 1 V


PTCN1(10) Switch: ON Voltage 711 V

Circuit diagram related to shift switch 40-357

a Exclusive for single-direction lever

D375A-6R 40-357
(01)
Troubleshooting by failurecode
Failure code [DDK5KB] Shift switch short circuit

Failure code [DDK5KB] Shift switch short circuit 40-358


Action code Failure code Shift switch short circuit
Failure
(Power train controller system)
E02 DDK5KB
q Both lines of NO: Normally Open and NC: Normally Closed for shift up switch circuit are 0 V (switch:
Detail of failure
ON) at the same time.
Action of con-
q Recognizes that switch is not pressed.
troller
Problem on
q Gear cannot be shifted up and down (1st io2nd).
machine
q NO: Normally Open line is used for sensing operation and NC: line is used for detecting error.
Related infor- q Condition of shift up switch signal can be checked with monitoring function.
mation (Code: 40905 Power train control Input 3)
q Method of reproducing failure code: Turning on the starting switch and operating the shift up switch

Cause Procedure, measuring location, criteria and remarks


Wrong selection of travel lever
1 If failure code [DDT5KQ] is displayed, carry out troubleshooting for it.
type
1. Turn starting switch to OFF position.
2. Disconnect connector SNC and connect T-adapter to male side.
3. Turn shift up switch to ON or OFF position and troubleshoot.
a Switch OFF: Release, Switch ON: Press
Defective shift up switch Max. 1 z
2 Between SNC (male) (1) and Switch: OFF Resistance
(Internal disconnection)
(3) Switch: ON Resistance Min. 1 Mz

Between SNC (male) (1) and Switch:OFF Resistance Min. 1 Mz


(2) Switch: ON Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors STC1, STC3 and SNC and connect T-adapter to
female side of one of them.
3. Turn starting switch to ON position.
Ground fault of wiring harness
3 Between SNC (female) (2) and ground , or
(Contact with rround circuit) Resistance Min. 1 Mz
between PTCN2(female) (7) and ground
Between SNC (female) (3) and ground , or
Resistance Min. 1 Mz
between PTCN1 (female) (6) and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1, PTCN2 and SNC and connect T-adapters
to female side of PTCN1 and PTCN2.
a Check with multimeter in continuity mode.
4 Short circuit in wiring harness
Between PTCN1 (female) (6) and each pin No continuity (No sound is
other than (6) heard)
Between PTCN2 (female) (7) and each pin No continuity (No sound is
other than (7) heard)

40-358 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DDK5KB] Shift switch short circuit

Cause Procedure, measuring location, criteria and remarks


If cause is not found by the above checks, power train controller is defective.
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors PTCN1 and PTCN2.
3. Turn starting switch to ON position.
4. Turn shift down switch to ON or OFF position and troubleshoot.
a Voltage of about 9 V is applied to PTCN1 pin (6) and PTCN2 pin (7) through
5 Defective power train controller
resistor in power train controller.
Between PTCN2 (7) and Switch: OFF Voltage 711 V
PTCN1(10) Switch: ON Voltage Max. 1 V

Between PTCN1 (6) and Switch: OFF Voltage Max. 1 V


PTCN1(10) Switch: ON Voltage 711 V

Circuit diagram related to shift switch 40-359

D375A-6R 40-359
(01)
Troubleshooting by failurecode
Failure code [DDN2LD] Blade tilt RH pressure SW abnormality

Failure code [DDN2LD] Blade tilt RH pressure SW abnormality 40-360


Action code Failure code Blade tilt right hand oil pressure switch is pressed for long time
Failure
(Work equipment controller system)
DDN2LD
Detail of failure q The signal of the blade tilt right oil pressure switch circuit is kept turned 0 V (ON) for 60 seconds.
Action of con-
q Recognizes that the oil pressure switch is turned to OFF position.
troller
Problem on
q Data communication of VHMS may be abnormal
machine
q The input state (ON/OFF) from the blade tilt right hand oil pressure switch can be checked monii-
toring funtion. (Code 90802: Blade oil pressure switch input state)
q Method of reproducing failure code: Turn the starting switch to ON position (Error is reproduced
Related infor-
after 60 seconds).
mation
q First, check power train oil filter for clogging etc.
q Next, check that hydraulic pressure of work equipment is normal by referring to Testing and adjust-
ing, "Testing work equipment hydraulic pressure".

Cause Procedure, measuring location, criteria and remarks


Wrong operation of lever If failure code (reset indication) is displayed even after reset operation, incor-
1
(When electrical system is normal) rect shift lever operation might be made.
1. Turn starting switch to OFF position.
Defective blade tilt right hand oil 2. Disconnect connector TRS and connect T-adapter to male side.
2 pressure switch (Internal short cir-
cuit) Between TRS (female) (1) and ground
Resistance Min. 1 Mz
(Oil pressure switch is OFF position.)
1. Turn starting switch to OFF position.
2. Disconnect connector TRS.
Ground fault of wiring harness or 3. Turn starting switch to ON position (and wait for longer than 60 sec.).
3 defective work equipment control- If failure code [DDN2LD] is still displayed, there is ground fault of wiring har-
ler ness or work equipment controller is defective.
(If failure code [DDN2LD] is not displayed, blade tilt right oil pressure switch is
defective.)
a If cause 3 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connector WECN2 and TRS, and connect T-adapter to female
4
(Contact with ground circuit) side of either of them.
Between WECN2 (female) (7) or TRS (female) (1)
Resistance Min. 1 Mz
and ground
If check result of cause 3 is abnormal and check result of cause 4 is normal,
power train controller is defective.
q Reference; the followings are criteria in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors WECN1 and WECN2.
3. Start engine.
Defective work equipment control- a Keep PCCS lever in N position.
5
ler Between WECN2 (7) and WECN1 (4) Voltage 711 V
1. 3. are same as above.
4. While depressing brake pedal, operate blade lever and perform trouble-
shooting.
Between WECN2 (7) and
R.H. tilt Voltage Max. 1 V
WECN1 (4)

40-360 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DDN2LD] Blade tilt RH pressure SW abnormality

Circuit diagram related to Blade tilt right hand oil pressure switch 40-361

D375A-6R 40-361
(01)
Troubleshooting by failurecode
Failure code [DDN3LD] Blade tilt LH pressure SW abnormality

Failure code [DDN3LD] Blade tilt LH pressure SW abnormality 40-362


Action code Failure code Blade tilt left hand oil pressure switch is pressing for long time
Failure
(Work equipment controller system)
- DDN3LD
Detail of failure q The signal of the blade tilt left oil pressure switch circuit is kept turned ON (0 V) for 60 seconds.
Action of con-
q Recognizes that oil pressure switch is turned to OFF position.
troller
Problem on
q Data communication of VHMS may become abnormal.
machine
q The input state (ON/OFF) from the blade tilt left hand oil pressure switch can be checked moniitor-
ing funtion. (Code 90802: Blade oil pressure switch input state)
q Method of reproducing failure code: Turn the starting switch to ON position (Error is reproduced
Related infor-
after 60 seconds).
mation
q First, check power train oil filter for clogging etc.
q Next, check that hydraulic pressure of work equipment is normal by referring to Testing and adjust-
ing, "Testing work equipment hydraulic pressure".

Cause Procedure, measuring location, criteria and remarks


If failure code lamp still lights up (resetting is still urged) after the resetting
Wrong operation of lever
1 operation is performed, it is suspected that the lever was operated to cause an
(When electrical system is normal)
error.
1. Turn starting switch to OFF position.
Defective blade tilt left hand oil 2. Disconnect connector TLS and connect T-adapter to male side.
2 pressure switch (Internal short cir-
cuit) Between TLS (female) (1) and ground
Resistance Min. 1 Mz
(Oil pressure switch is OFF position.)
1. Turn starting switch to OFF position.
2. Disconnect connector TLS.
Ground fault in wiring harness or 3. Turn starting switch to ON position (and wait for longer than 60 sec.).
3 defective work equipment control- If failure code [DDN3LD] is still displayed, there is ground fault in wiring har-
ler ness or work equipment controller is defective.
(If failure code [DDN3LD] is not displayed, blade tilt left oil pressure switch is
defective.)
a If cause 3 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connector WECN2 and TLS, and connect T-adapter to female
4
(Contact with ground circuit) side of either of them.
Between WECN2 (female) (17) or TLS (female) (1)
Resistance Min. 1 Mz
and ground
If "check result of cause 3 is abnormal" and "check result of cause 4 is normal",
power train controller is defective.
q Reference; the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors WECN1 and WECN2.
3. Start engine.
Defective work equipment control- a Keep PCCS lever in N position.
5
ler
Between WECN2 (17) and WECN1 (4) Voltage 7 11 V
1. 3. are same as above.
4.While depressing brake pedal, operate blade lever and perform trouble-
shooting.
Between WECN2 (17)
L.H. tilt Voltage Max. 1 V
and WECN1 (4)

40-362 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DDN3LD] Blade tilt LH pressure SW abnormality

Circuit diagram related to blade tilt left hand oil pressure switch 40-363

D375A-6R 40-363
(01)
Troubleshooting by failurecode
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection

Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection 40-364


Action code Failure code Work equipment knob switch (lower): Disconnection
Failure
(Work equipment controller system)
E02 DDN7KA
q Both lines of NO: Normally Open and NC: Normally Closed for blade knob lower switch circuit are
Detail of failure
OPEN (switch: OFF) at the same time.
Action of con-
q Recognizes that blade knob switch lower is not pressed.
troller
Problem on
q Blade knob switch lower does not work.
machine
q NO: Normally Open line is used for sensing operation and NC: Normally Closed line is used for de-
tecting error.
q Condition of blade knob switch lower signal can be checked with monitoring function.
Related infor-
(Code: 70300 Blade Knob Sw Input)
mation
q Method of reproducing failure code: Turn the starting switch to ON position and (operate blade pitch
switch).
q Connector WNBL has no T-adapters, don't perform troubleshooting in female side.

Cause Procedure, measuring location, criteria and remarks


1.
Turn starting switch to OFF position.
2.
Disconnect connector WNBL.
3.
Insert T-adapter into connector P03.
4.
Turn starting switch to ON position.
a
If voltage is 0 V, it shows open circuit in wiring harness, and if voltage is 24
Open circuit or hot short circuit in
1 V, it shows hot short circuit in wiring harness.
wiring harness
a Voltage of approx.9 V is applied to signal lines of NO and NC through
resistor in work equipment controller.
Between P03 (female) (2) and (1) Voltage 7 11 V
Between P03 (female) (5) and (1) Voltage 7 11 V
a If cause 2 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors WECN1, WECN2 and WNBL, and connect
T-adapters to female side of them.
Open circuit in wiring harness Between WECN2 (female) (26) and WNBL (female)
2 Resistance Max. 1 z
(open circuit or defective contact) (1)
Between WECN1 (female) (4) and WNBL (female)
Resistance Max. 1 z
(2)
Between WECN2 (female) (36) and WNBL (female)
Resistance Max. 1 z
(3)
1. Turn starting switch to OFF position.
2. Disconnect connector P03 and connect T-adapter to male side.
3. Turn blade knob lower switch to ON or OFF position and troubleshoot.
a Switch OFF: Release, Switch ON: Press
Defective knob switch for blade Switch: OFF Resistance Max. 1 z
3 Between P03 (female)
down (internal disconnection)
(5) and (1) Switch: ON Resistance Min. 1 Mz

Between P03 (female) Switch: OFF Resistance Min. 1 Mz


(1) and (2) Switch: ON Resistance Max. 1 z

40-364 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection

Cause Procedure, measuring location, criteria and remarks


If cause is not found by above checks, work equipment controller is defective.
q Reference; the followings are criteria in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors WECN1 and WECN2.
3. Turn starting switch to ON position.
4. Turn shift down switch to ON or OFF position and troubleshoot.
Defective work equipment control- a Voltage of approx.9 V is applied to WECN2 pin (26) and pin (36) through
4
ler resistor in work equipment controller.
Between WECN2 (36) Switch: OFF Voltage Max. 1 V
and WECN1 (4) Switch: ON Voltage 7 11 V

Between WECN2 (26) Switch: OFF Voltage 7 11 V


and WECN1 (4) Switch: ON Voltage Max. 1 V

Circuit diagram related to work equipment knob switch 40-365

D375A-6R 40-365
(01)
Troubleshooting by failurecode
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit

Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit 40-36


Action code Failure code Work equipment knob switch (Lower): Short circuit
Failure
(Work equipment controller system)
E02 DDN7KB
q Both lines of NO: Normally Open and NC: Normally Closed for blade knob switch lower circuit are
Detail of failure
0 V (switch: ON) at the same time.
Action of con-
q Recognizes that blade knob lower switch is not pressed.
troller
Problem on
q Blade knob switch (lower) does not work.
machine
q NO: Normally Open line is used for sensing operation and NC: Normally Closed line is used for de-
tecting error.
q Condition of blade knob switch lower signal can be checked with monitoring function.
Related infor-
(Code: 70300 Blade Knob Sw Input)
mation
q Method of reproducing failure code: Turn the starting switch to ON position and (operate blade pitch
switch).
q Connector WNBL has no T-adapters, don't perform troubleshooting in female side.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors WECN2 and WNBL, and connect T-adapter to
Ground fault of wiring harness female side of WECN2.
1
(Contact with GND circuit) Between WECN2 (female) (26) and ground Resistance Min. 1 Mz
Between WECN2 (female) (36) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors WECN2 and WNBL, and connect T-adapter to
female side of WECN2.
a Check with tester in continuity mode.
2 Short circuit in wiring harness Between WECN2 (female) (26) and each pin other No continuity
than (26) (No sound is heard)
Between WECN2 (female) (36) and each pin other No continuity
than (36) (No sound is heard)
1. Turn starting switch to OFF position.
2. Disconnect connector P03 and connect T-adapter to male side.
3. Turn blade knob switch (lower) to ON or OFF position and troubleshoot.
a Switch OFF: Release, Switch ON: Press
Defective blade knob switch lower Switch: OFF Resistance Max. 1 z
3 Between P03 (female)
(Internal disconnection)
(5) and (1) Switch: ON Resistance Min. 1 Mz

Between P03 (female) Switch: OFF Resistance Min. 1 Mz


(1) and (2) Switch: ON Resistance Max. 1 z
If cause is not found by the above checks, work equipment controller is defec-
tive.
q Reference; the followings are criteria in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors WECN1 and WECN2.
3. Turn starting switch to ON position.
4. Turn blade knob lower switch (lower) to ON or OFF position and trouble-
Defective work equipment control- shoot.
4
ler a Voltage of approx.9 V is applied to WECN2 pin (26) and pin (36) through
resistor in work equipment controller.
Between WECN (36) and Switch: OFF Voltage Max. 1 V
WECN (4) Switch: ON Voltage 7 11 V

Between WECN (26) and Switch: OFF Voltage 7 11 V


WECN (4) Switch: ON Voltage Max. 1 V

40-366 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit

Circuit diagram related to work equipment knob switch 40-367

D375A-6R 40-367
(01)
Troubleshooting by failurecode
Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection

Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection 40-368


Action code Failure code Work equipment knob switch (raise): Disconnection
Failure
(Work equipment controller system)
E01 DDN9KA
q Both lines of NO: Normally Open and NC : Normally Closed for blade knob upper switch circuit are
Detail of failure
OPEN (switch: OFF) at the same time.
Action of con-
q Recognizes that blade knob upper switch is not pressed.
troller
Problem on
q Blade knob switch (raise) does not work.
machine
q NO: Normally Open line is used for sensing operation and NC: Normally Closed line is used for de-
tecting error.
q Condition of blade knob switch signal can be checked with monitoring function.
Related infor-
(Code: 70300 Blade Knob Sw Input)
mation
q Method of reproducing failure code: Turn starting switch to ON position and operate blade knob
switch (raise).
q Connector WNBU has no T-adapters, don't perform troubleshooting in female side.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector WNBU.
3. Turn blade upper knob switch (raise) to ON or OFF position and trouble-
shoot.
a Switch OFF: Release, Switch ON: Press
Defective blade knob switch raise
1 Max. 1 z
(Internal disconnection) Between WNBU (female) Switch: OFF Resistance
(3) and (2) Switch: ON Resistance Min. 1 Mz

Between WNBU (female) Switch: OFF Resistance Min. 1 Mz


(1) and (2) Switch:ON Resistance Max. 1 z
1.Turn starting switch to OFF position.
2.Disconnect connector WNBU.
3.Insert T-adapter into connector P03.
4.Turn starting switch to ON position.
a If voltage is 0 V, it shows disconnection in wiring harness, and if voltage is
Disconnection or hot short in wir-
2 24 V, it shows hot short in wiring harness.
ing harness
a Voltage of apporx.9 V is applied to signal lines of NO and NC through
resistor in work equipment controller.
Between P03 (female) (4) and (3) Voltage 7 11 V
Between P03 (female) (6) and (3) Voltage 7 11 V
1. Turn starting switch to OFF position.
2. Disconnect connectors WECN1 and WECN2, and connect T-adapters to
female side of them.
Disconnection in wiring harness 3. Turn blade knob switch (raise) to ON or OFF position and troubleshoot.
3
(open circuit or defective contact) Between WECN2 (female) (15) and
Switch: OFF Resistance Max. 1 z
WECN1 (female) (4)
Between WECN2 (female) (5) and
Switch: ON Resistance Max. 1 z
WECN1 (female) (4)

40-368 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection

Cause Procedure, measuring location, criteria and remarks


If cause is not found by above checks, work equipment controller is defective.
q Reference; the followings are criteria in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors WECN1 and WECN2.
3. Turn starting switch to ON position.
4. Turn blade knob switch (raise) to ON or OFF position and troubleshoot.
Defective work equipment control- a Voltage of apporx.9 V is applied to WECN2 pin (5) and pin (15) through re-
4
ler sistor in work equipment controller.
Between WECN2 (5) and Switch: OFF Voltage 7 11 V
WECN1 (4) Switch: ON Voltage Max. 1 V

Between WECN2 (15) Switch: OFF Voltage Max. 1 V


and WECN1 (4) Switch: ON Voltage 7 11 V

Circuit diagram related to work equipment knob switch 40-369

D375A-6R 40-369
(01)
Troubleshooting by failurecode
Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit

Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit 40-370


Action code Failure code Work equipment knob switch (raise): Disconnection
Failure
(Work equipment controller system)
E01 DDN9KB
q Both lines of NO: Normally Open and NC : Normally Closed for blade knob switch raise circuit are
Detail of failure
0 V (switch: ON) at the same time.
Action of con-
q Recognizes that blade knob upper switch is not pressed.
troller
Problem on
q Blade knob switch (raise) does not work.
machine
q NO: Normally Open line is used for sensing operation and NC: line is used for detecting error.
q Condition of blade knob switch signal can be checked with monitoring function.
Related infor- (Code: 70300 Blade Knob Sw Input)
mation q Method of reproducing failure code: Turn starting switch to ON position and operate blade knob
switch (raise).
q Connector WNBU has no T-adapters, don't perform troubleshooting in female side.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector WNBU and connect T-adapter to male side.
3. Turn blade knob switch (raise) to ON or OFF position and troubleshoot.
a Switch OFF: Release, Switch ON: Press
Defective blade knob switch raise Switch: OFF Resistance Max. 1 z
1 Between WNBU (male)
(Internal disconnection)
(3) and (2) Switch: ON Resistance Min. 1 Mz

Between WNBU (male) Switch: OFF Resistance Min. 1 Mz


(1) and (2) Switch: ON Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors WECN1, WECN2 and WNBU and connect
Ground fault of wiring harness T-adapter to female side of either of them.
2
(Contact with groung circuit) Between WECN1 (female) (5) and ground Resistance Min. 1 Mz
Between WECN1 (female) (15) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors WECN2 and WNBU, and connect T-adapter to
female side of WECN2.
a Check with multimeter in continuity mode.
3 Short circuit in wiring harness Between WECN2 (female) (5) and each pin other No continuity
than (5) (No sound is heard)
Between WECN2 (female) (15) and each pin other No continuity
than (15) (No sound is heard)

40-370 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit

Cause Procedure, measuring location, criteria and remarks


If cause is not found by above checks, work equipment controller is defective.
q Reference; the followings are criteria in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors WECN1 and WECN2.
3. Turn starting switch to ON position.
4. Turn blade knob switch (raise) to ON or OFF position and troubleshoot.
Defective work equipment control- a Voltage of apporx.9 V is applied to WECN2 pin (5) and pin (15) through re-
4
ler sistor in work equipment controller.
Between WECN2 (5) and Switch: OFF Voltage 7 11 V
WECN1 (4) Switch: ON Voltage Max. 1 V

Between WECN2 (15) Switch: OFF Voltage Max. 1 V


and WECN1 (4) Switch: ON Voltage 7 11 V

Circuit diagram related to work equipment knob switch 40-371

D375A-6R 40-371
(01)
Troubleshooting by failurecode
Failure code [DDNALD] Blade lift up pressure SW abnormality

Failure code [DDNALD] Blade lift up pressure SW abnormality 40-372


Action code Failure code Blade lift raise oil pressure switch is pressed for long time
Failure
(Work equipment controller system)
- DDNALD
q The signal of blade lift raise (full stroke) oil pressure switch circuit is kept turned to ON position for
Detail of failure
60 seconds.
Action of con-
q Recognizes that oil pressure switch is turned to OFF position.
troller
Problem on
q Data of the VHMS may become abnormal.
machine
q Input state (ON/OFF) from blade raise (full stroke) oil pressure switch can be checked with moni-
toring function. (Code: 90802 Blade oil pressure switch input)
q Method of reproducing failure code: Turn the starting switch to ON position (Error is reproduced
Related infor-
after 60 seconds).
mation
q First, check power train oil filter for clogging etc.
q Next, check that hydraulic pressure of work equipment is normal by referring to Testing and adjust-
ing, "Testing work equipment hydraulic pressure".

Cause Procedure, measuring location, criteria and remarks


Wrong operation of lever If failure code (reset indication) is displayed even after reset operation, incor-
1
(When electrical system is normal) rect lever operation might be made.
1. Turn starting switch to OFF position.
Defective blade raise oil pressure 2. Disconnect connector BLU and connect T-adapter to male side.
2
switch (Internal short circuit) Between BLU (female) (1) and ground
Resistance Min. 1 Mz
(Oil pressure switch: OFF)
1. Turn starting switch to OFF position.
2. Disconnect connector BLU.
Ground fault in wiring harness or 3. Turn starting switch to ON position (and wait for longer than 60 sec.).
3 defective work equipment control- If failure code [DDNALD] is still displayed, there is ground fault in wiring har-
ler ness or work equipment controller is defective.
(If failure code [DDNALD] is not displayed, blade raise oil pressure switch is
defective.)
a If cause 3 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connector WECN2 and BLU, and connect T-adapter to female
4
(Contact with ground circuit) side of either of them.
Between WECN2 (female) (16) or BLU (female) (1)
Resistance Min. 1 Mz
and ground
If "check result of cause 3 is abnormal" and "check result of cause 4 is normal",
work equipment controller is defective.
q Reference; the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors WECN1 and WECN2.
3. Start engine.
Defective work equipment control-
5 a Keep the blade control lever in the neutral position.
ler
Between WECN2 (16) and WECN1 (4) Voltage 7 11 V
1. 3. are same as above.
4. Operate blade lever and perform troubleshooting.
Between WECN2 (16)
Blade lever: Raise Voltage Max. 1 V
and WECN1 (4)

40-372 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DDNALD] Blade lift up pressure SW abnormality

Circuit diagram related to blade raise oil pressure switch 40-373

D375A-6R 40-373
(01)
Troubleshooting by failurecode
Failure code [DDNBLD] Ripper lift up pressure SW abnormality

Failure code [DDNBLD] Ripper lift up pressure SW abnormality 40-374


Action code Failure code Ripper lift raise oil pressure switch is pressed for long time
Failure
(Work equipment controller system)
DDNBLD
Detail of failure q The signal of the ripper raise oil pressure switch circuit is kept turned to ON position for 60 seconds.
Action of con-
q Recognizes that oil pressure switch is turned to OFF position.
troller
Problem on q Shoe slip control (SSC) function does not activate normally.
machine q VHMS data may become abnormal.
q Input state (ON/OFF) from the ripper raise oil pressure switch can be checked moniitoring fun-
tion.(Code 40982: Ripper oil pressure switch input )
q Method of reproducing failure code: Turn the starting switch to ON position (Error is reproduced
Related infor-
after 60 seconds).
mation
q First, check power train oil filter for clogging etc.
q Next, check that hydraulic pressure of work equipment is normal by referring to Testing and adjust-
ing, "Testing work equipment hydraulic pressure".

Cause Procedure, measuring location, criteria and remarks


If failure code lamp still lights up (resetting is still urged) after the resetting
Wrong operation of lever
1 operation is performed, it is suspected that the lever was operated to cause an
(When electrical system is normal)
error.
1. Turn starting switch to OFF position.
Defective ripper raise oil pressure 2. Disconnect connector RPU and connect T-adapter to male side.
2
switch (Internal short circuit) Between RPU (female) (1) and ground
Resistance Min. 1 Mz
(Oil pressure switch: OFF.)
1. Turn starting switch to OFF position.
2. Disconnect connector RPU.
Ground fault of wiring harness or 3. Turn starting switch to ON position (and wait for longer than 60 sec.).
3 defective work equipment control- If failure code [DDNBLD] is still displayed, there is ground fault of wiring har-
ler ness or work equipment controller is defective.
(If failure code [DDNBLD] is not displayed, ripper raise oil pressure switch is
defective)
a If cause 3 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
Ground fault of wiring harness 2. Disconnect connector WECN2 and RPU, and connect T-adapter to female
4
(Contact with GND circuit) side of either of them.
Between WECN2 (female) (13) or RPU (female) (1)
Resistance Min. 1 Mz
and ground
If check result of cause 3 is abnormal and check result of cause 4 is normal,
power train controller is defective.
q Reference; the followings are criteria in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors WECN1 and WECN2.
3. Start engine.
Defective work equipment control-
5 a Keep ripper lever in neutral position.
ler
Between WECN2 (13) and WECN1 (4) Voltage 7 11 V
1. 3. are same as above.
4.Operate ripper lever and perform troubleshooting.
Between WECN2 (13)
Ripper lever: Raise Voltage Max. 1 V
and WECN1 (4)

40-374 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DDNBLD] Ripper lift up pressure SW abnormality

Circuit diagram related to ripper raise oil pressure switch 40-375

D375A-6R 40-375
(01)
Troubleshooting by failurecode
Failure code [DDNCLD] Ripper lift down pressure SW abnormality

Failure code [DDNCLD] Ripper lift down pressure SW abnormality 40-376


Action code Failure code Ripper lower oil pressure switch is pressed for long time
Failure
(Work equipment controller system)
- DDNCLD
Detail of failure q Signal of ripper lift lower oil pressure switch circuit is kept turned to ON position for 60 seconds.
Action of con-
q Recognizes that oil pressure switch is turned to OFF position.
troller
Problem on q Shoe slip control (SSC) function does not activate normally.
machine q Data of the VHMS may become abnormal.
q Input state (ON/OFF) from ripper lower oil pressure switch can be checked in the real-time monii-
toring mode. (Code 40982: Ripper oil pressure switch input signal)
q Method of reproducing failure code: Turn the starting switch to ON position (Error is reproduced
Related infor-
after 60 seconds).
mation
q First, check power train oil filter for clogging etc.
q Next, check that hydraulic pressure of work equipment is normal by referring to Testing and adjust-
ing, "Testing work equipment hydraulic pressure".

Cause Procedure, measuring location, criteria and remarks


Wrong operation of lever If failure code (reset indication) is displayed even after reset operation, incor-
1
(When electrical system is normal) rect lever operation might be made.
1. Turn starting switch to OFF position.
Defective ripper lower oil pres- 2. Disconnect connector RPD and connect T-adapter to male side.
2
sure switch (Internal short circuit) Between RPD (female) (1) and ground
Resistance Min. 1 Mz
(Oil pressure switch is OFF position.)
1. Turn starting switch to OFF position.
2. Disconnect connector RPD.
Ground fault in wiring harness or 3. Turn starting switch to ON position (and wait for longer than 60 sec.).
3 defective work equipment control- If failure code [DDNCLD] is still displayed, there is ground fault in wiring har-
ler ness or work equipment controller is defective.
(If failure code [DDNCLD] is not displayed, ripper lift lower oil pressure switch
is defective.)
a If cause 3 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connector WECN2 and RPD, and connect T-adapter to female
4
(Contact with ground circuit) side of either of them.
Between WECN2 (female) (3) or RPD (female) (1)
Resistance Min. 1 Mz
and ground
If "check result of cause 3 is abnormal" and "check result of cause 4 is normal",
power train controller is defective.
q Reference; the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors WECN1 and WECN2.
3. Start engine.
Defective work equipment control-
5 a Keep ripper lever in neutral position.
ler
Between WECN2 (3) and WECN1 (4) Voltage 7 11 V
1. 3. are same as above.
4. Operate ripper lever and perform troubleshooting.
Between WECN2 (3) and
Ripper lever: Lower Voltage Max. 1 V
WECN1 (4)

40-376 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DDNCLD] Ripper lift down pressure SW abnormality

Circuit diagram related to ripper lower oil pressure switch 40-37

D375A-6R 40-377
(01)
Troubleshooting by failurecode
Failure code [DDNDLD] Ripper tilt in pressure SW abnormality

Failure code [DDNDLD] Ripper tilt in pressure SW abnormality 40-378


Action code Failure code Ripper tilt in oil pressure switch is pressed for long time
Failure
(Work equipment controller system)
- DDNDLD
Detail of failure q Signal of ripper tilt in oil pressure switch circuit is kept turned to ON position for 60 seconds.
Action of con-
q Recognizes that oil pressure switch is turned to OFF position.
troller
Problem on q Shoe slip control (SSC) function does not activate normally.
machine q Data of the VHMS may become abnormal.
q Input state (ON/OFF) from ripper tilt in oil pressure switch can be checked with monitoring function.
(Code 40982: Ripper oil pressure switch input state)
q Method of reproducing failure code: Turn the starting switch to ON position (Error is reproduced
Related infor-
after 60 seconds).
mation
q First, check power train oil filter for clogging etc.
q Next, check that hydraulic pressure of work equipment is normal by referring to Testing and adjust-
ing, "Testing work equipment hydraulic pressure".

Cause Procedure, measuring location, criteria and remarks


Wrong operation of lever If failure code (reset indication) is displayed even after reset operation, incor-
1
(When electrical system is normal) rect lever operation might be made.
1. Turn starting switch to OFF position.
Defective ripper tilt in oil pressure 2. Disconnect connector RTI and connect T-adapter to male side.
2
switch (Internal short circuit) Between RTI (female) (1) and ground
Resistance Min. 1 Mz
(Oil pressure switch: OFF.)
1. Turn starting switch to OFF position.
2. Disconnect connector RTI.
Ground fault in wiring harness or 3. Turn starting switch to ON position (and wait for longer than 60 sec.).
3 defective work equipment control- If failure code [DDNDLD] is still displayed, there is ground fault in wiring har-
ler ness or work equipment controller is defective.
(If failure code [DDNDLD] is not displayed, ripper tilt in oil pressure switch is
defective.)
a If cause 3 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connector WECN2 and RTI, and connect T-adapter to female
4
(Contact with ground circuit) side of either of them.
Between WECN2 (female) (2) or RTI (female) (1)
Resistance Min. 1 Mz
and ground
If "check result of cause 3 is abnormal" and "check result of cause 4 is normal",
work equipment controller is defective.
q Reference; the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors WECN1 and WECN2.
3. Start engine.
Defective work equipment control-
5 a Keep ripper lever in neutral position.
ler
Between WECN2 (2) and WECN1 (4) Voltage 7 11 V
1. 3. are same as above.
4. Operate ripper lever and perform troubleshooting.
Between WECN2 (2) and Ripper lever:
Voltage Max. 1 V
WECN1 (4) Tilt in

40-378 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DDNDLD] Ripper tilt in pressure SW abnormality

Circuit diagram related to ripper tilt in oil pressure switch 40-379

D375A-6R 40-379
(01)
Troubleshooting by failurecode
Failure code [DDNELD] Ripper tilt back pressure SW abnormality

Failure code [DDNELD] Ripper tilt back pressure SW abnormality 40-380


Action code Failure code Ripper tilt back oil pressure switch is pressed for long time
Failure
(Work equipment controller system)
DDNELD
Detail of failure q Signal of the ripper tilt back oil pressure switch circuit is kept turned to ON position for 60 seconds.
Action of con-
q Recognizes that the oil pressure switch is turned OFF.
troller
Problem on q Shoe slip control (SSC) function does not activate normally.
machine q VHMS data may become abnormal.
q Input state (ON/OFF) from the ripper tilt back oil pressure switch can be checked moniitoring fun-
tion. (Code 40982: Ripper oil pressure switch input )
q Method of reproducing failure code: Turn the starting switch to ON position (Error is reproduced
Related infor-
after 60 seconds).
mation
q First, check the power train oil filter for clogging etc.
q Next, check that hydraulic pressure of work equipment is normal by referring to Testing and adjust-
ing, "Testing work equipment hydraulic pressure".

Cause Procedure, measuring location, criteria and remarks


If failure code lamp still lights up (resetting is still urged) after the resetting
Wrong operation of lever
1 operation is performed, it is suspected that lever was operated to cause an
(When electrical system is normal)
error.
1. Turn starting switch to OFF position.
Defective ripper tilt back oil pres- 2. Disconnect connector RTB and connect T-adapter to male side.
2
sure switch (Internal short circuit) Between RTB (female) (1) and ground
Resistance Min. 1 Mz
(Oil pressure switch: OFF)
1. Turn starting switch to OFF position.
2. Disconnect connector RTB.
Ground fault of wiring harness or 3. Turn starting switch to ON position (and wait for longer than 60 sec.).
3 defective work equipment control- If failure code [DDNELD] is still displayed, there is ground fault of wiring har-
ler ness or work equipment controller is defective.
(If failure code [DDNELD] is not displayed, ripper tilt back oil pressure switch is
defective)
a If cause 3 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
Ground fault of wiring harness 2. Disconnect connector WECN2 and RTB, and connect T-adapter to female
4
(Contact with ground circuit) side of either of them.
Between WECN2 (female) (38) or RTB (female) (1)
Resistance Min. 1 Mz
and ground
If check result of cause 2 is abnormal and check result of cause 3 is normal,
power train controller is defective.
q Reference; the followings are criteria in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors WECN1 and WECN2.
3. Start engine.
Defective work equipment control-
5 a Keep ripper lever in neutral position.
ler
Between WECN2 (38) and WECN1 (4) Voltage 7 11 V
1. 3. are same as above.
4.Operate ripper lever and perform troubleshooting.
Between WECN2 (38)
Ripper lever: Tilt back Voltage Max. 1 V
and WECN1 (4)

40-380 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DDNELD] Ripper tilt back pressure SW abnormality

Circuit diagram related to ripper tilt back oil pressure switch 40-381

D375A-6R 40-381
(01)
Troubleshooting by failurecode
Failure code [DDNFLD] Blade lift down pressure SW abnormality

Failure code [DDNFLD] Blade lift down pressure SW abnormality 40-382


Action code Failure code Blade lift lower oil pressure switch is pressed for long time
Failure
(Work equipment controller system)
DDNFLD
q Signal of blade lower (full stroke) oil pressure switch circuit is kept turned to ON position for 60 sec-
Detail of failure
onds.
Action of con-
q Recognizes that oil pressure switch is turned to OFF position.
troller
Indication of
problem on q Data of the VHMS may become abnormal.
machine
q Input state (ON/OFF) from blade lower (full stroke) oil pressure switch can be checked with moni-
toring function. (Code 90802: Blade oil pressure switch input state)
q Method of reproducing failure code: Turn starting switch to ON position (and wait for longer than
Related infor-
180 sec.).
mation
q First, check power train oil filter for clogging etc.
q Next, check that hydraulic pressure of work equipment is normal by referring to Testing and adjust-
ing, "Testing work equipment hydraulic pressure".

Cause Procedure, measuring location, criteria and remarks


Wrong operation of lever If failure code (reset indication) is displayed even after reset operation, incor-
1
(When electrical system is normal) rect lever operation might be made.
1. Turn starting switch to OFF position.
Defective blade lower oil pressure 2. Disconnect connector BLD and connect T-adapter to male side.
2
switch (Internal short circuit) Between BLD (female) (1) and ground
Resistance Min. 1 Mz
(Oil pressure switch is OFF position.)
1. Turn starting switch to OFF position.
2. Disconnect connector BLD.
Ground fault in wiring harness or 3. Turn starting switch to ON position (and wait for longer than 60 sec.).
3 defective work equipment control- If failure code [DDNFLD] is still displayed, there is ground fault in wiring har-
ler ness or work equipment controller is defective.
(If failure code [DDNFLD] is not displayed, blade lower oil pressure switch is
defective.)
a If cause 3 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connector WECN2 and BLD, and connect T-adapter to female
4
(Contact with ground circuit) side of either of them.
Between WECN2 (female) (6) or BLD (female) (1)
Resistance Min. 1 Mz
and ground
If check result of cause 3 is abnormal and check result of cause 4 is normal,
power train controller is defective.
q Reference; the followings are criteria in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors WECN1 and WECN2.
3. Start engine.
Defective work equipment control-
5 a Keep blade lever in neutral position.
ler
Between WECN2 (6) and WECN1 (4) Voltage 7 11 V
1. 3. are same as above.
4. Operate lever and troubleshoot.
Between WECN2 (6) and
Blade lever: Lower Voltage Max. 1 V
WECN1 (4)

40-382 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DDNFLD] Blade lift down pressure SW abnormality

Circuit diagram related to blade lower oil pressure switch 40-383

D375A-6R 40-383
(01)
Troubleshooting by failurecode
Failure code [DDNLKA] Weq lock Sw: Disconnection

Failure code [DDNLKA] Weq lock Sw: Disconnection 40-384


Action code Failure code Work equipment lock switch: Disconnection
Failure
(Work equipment controller system)
E03 DDNLKA
q Both lines of NO* and NC* for work equipment lock lever switch circuit are OPEN (switch: OFF) at
Detail of failure
the same time.
Action of con- q Recognizes that work equipment lock lever is in LOCk position.
troller q Limits operation of engine and transmission.
q Once machine is stopped, engine speed is limited to medium (half).
Problem on q Once machine is stopped, travel is limited to F1 and R1.
machine q Work equipment operation is impossible.
q Engine does not run.
q "NO*" line is used for sensing operation and "NC*" line is used for detecting error.
q Condition of work equipment lock lever switch signal can be checked with monitoring function.
(Code: 70300 Blade knob switch Input)
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position and operate work eqiup-
mation
ment lock lever.
q When work equipment lock lever is free, work equipment lock lever switch becomes "ON".
(Lever is locked in illustration.)

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector WELK and connect T-adapter to male side.
3. Operate work equipment lock lever and troubleshoot.
Defective work equipment lock Lever: FREE Resistance Min. 1 Mz
1 lever switch (Internal disconnec- Between WELK (male)
tion) (A) and (B) Lever: LOCK Resistance Max. 1 z

Between WELK (male) Lever: FREE Resistance Max. 1 z


(A) and (C) Lever: LOCK Resistance Min. 1 Mz
1.
Turn starting switch to OFF position.
2.
Disconnect connector WELK and connect T-adapter to female side.
3.
Turn starting switch to ON position.
a
If voltage is 0 V, it shows open circuit in wiring harness, and if voltage is 24
Open circuit or hot short circuit in V, it shows hot short circuit in wiring harness.
2
wiring harness a Voltage of about 9 V is applied to signal lines of NO and NC through re-
sistor in power train controller.
Between WELK (female) (A) and (B) Voltage 7 11 V
Between WELK (female) (A) and (C) Voltage 7 11 V
a If cause 2 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors WECN1, WECN2, and WELK and connect
T-adapters to female side of them.
Open circuit in wiring harness Between WECN1 (female) (10) and WELK (female)
3 Resistance Max. 1 z
(open circuit or defective contact) (A)
Between WECN2 (female) (35) and WELK (female)
Resistance Max. 1 z
(B)
Between WECN2 (female) (25) and WELK (female)
Resistance Max. 1 z
(C)

40-384 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DDNLKA] Weq lock Sw: Disconnection

Cause Procedure, measuring location, criteria and remarks


If cause is not found by the above checks, power train controller is defective.
q Reference; the followings are criteria in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors WECN1 and WECN2.
3. Turn starting switch to ON position.
4. Operate work equipment lock lever switch and troubleshoot.
Defective work equipment control- a Voltage of approximately 9 V is applied to WECN2 pin (25) and pin (35)
4
ler through resistor in power train controller.
Between WECN2 (25) Lever: FREE Voltage 7 11 V
and WECN1 (10) Lever: LOCK Voltage Max. 1 V

Between WECN2 (35) Lever: FREE Voltage Max. 1 V


and WECN1 (10) Lever: LOCK Voltage 7 11 V

*NO: Normally Open


*NC: Normally Closed

Circuit diagram related to equipment lock switch 40-385

D375A-6R 40-385
(01)
Troubleshooting by failurecode
Failure code [DDNLKB] Weq lock Sw: Short circuit

Failure code [DDNLKB] Weq lock Sw: Short circuit 40-386


Action code Failure code Work equipment lock switch: Short circuit
Failure
(Power train controller systerm)
E03 DDNLKB
q Both lines of NO* and NC* for work equipment lock lever switch circuit are 0 V (switch: ON) at the
Detail of failure
same time.
Action of con- q Recognizes that work equipment lock lever is in Lock position.
troller q Limits operation of engine and transmission.
q Once machine is stopped, engine speed is limited to medium (half) speed.
Problem on q Once machine is stopped, travel is limited to F1 and R1.
machine q Work equipment operation is impossible.
q Engine does not run.
q NO* line is used for sensing operation and NC line is used for detecting error.
q Condition of work equipment lock lever switch signal can be checked with monitoring function.
(Code: 70300 Blade knob switch Input)
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position and operate work equip-
mation
ment lock lever.
q When work equipment lock lever is free, work equipment lock lever switch becomes "ON".
(Lever is locked in illustration.)

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector WELK and connect T-adapter to male side.
3. Operate work equipment lock lever and troubleshoot.
Defective work equipment lock Lever: FREE Resistance Min. 1 Mz
1 lever switch (Internal disconnec- Between WELK (male)
tion) (A) and (B) Lever: LOCK Resistance Max. 1 z

Between WELK (male) Lever: FREE Resistance Max. 1 z


(A) and (C) Lever: LOCK Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors WECN1, WECN2 and WELK and connect
T-adapter to female side of one of them.
Ground fault in wiring harness Between WELK (female) (B) and ground or between
2 Resistance Min. 1 Mz
(Contact with ground circuit) WECN2 (female) (35) and ground.
Between WELK (female) (C) and ground or
Resistance Min. 1 Mz
between WECN2 (female) (25) and ground.
1. Turn starting switch to OFF position.
2. Disconnect connectors WECN2 and WELK, and connect T-adapter to
female side of WECN2.
a Check with circuit tester in continuity mode.
3 Short circuit in wiring harness Between WECN2 (female) (25) and each pin other No continuity
than (25) (No sound is heard)
Between WECN2 (female) (35) and each pin other No continuity
than (35) (No sound is heard)

40-386 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DDNLKB] Weq lock Sw: Short circuit

Cause Procedure, measuring location, criteria and remarks


If cause is not found by above checks, work equipment controller is defective.
q Reference; the followings are criteria in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors WECN1 and WECN2.
3. Turn starting switch to ON position.
4. Operate work equipment lock lever switch and troubleshoot.
Defective work equipment control- a Voltage of apporx.9 V is applied to WECN2 pin (25) and pin (35) through
4
ler resistor in power train controller.
Between WECN2 (25) Lever: FREE Voltage 7 11 V
and WECN1 (10) Lever: LOCK Voltage Max. 1 V

Between WECN2 (35) Lever: FREE Voltage Max. 1 V


and WECN1 (10) Lever: LOCK Voltage 7 11 V

*NO: Normally Open


*NC: Normally Closed

Circuit diagram related to work equipment lock switch 40-387

D375A-6R 40-387
(01)
Troubleshooting by failurecode
Failure code [DDT5KA] Neutral switch disconnection

Failure code [DDT5KA] Neutral switch disconnection 40-38


Action code Failure code Neutral switch disconnection
Failure
(Power train controller system)
E04 DDT5KA
q Both lines of NO: Normally Open and NC: Normally Closed for neutral switch circuit are OPEN
Detail of failure
(switch: OFF) at the same time.
Action of con-
q Recognizes that neutral switch is not pressed.
troller
Problem on q Once machine is stopped, engine speed is limited to medium (half).
machine q Once machine is stopped, it cannot travel any more.
q Method of reproducing failure code: Turn starting switch to ON position and operate neutral switch.
Related infor- q First, check the power train oil filter for clogging etc.
mation q Next, check that hydraulic pressure of work equipment is normal by referring to Testing and adjust-
ing, "Testing work equipment hydraulic pressure".

Cause Procedure, measuring location, standard (value) and remarks


Wrong selection of travel lever
1 If failure code [DDT5KQ] is displayed, carry out troubleshooting for it.
type
1. Turn starting switch to OFF position.
2. Disconnect connector SNC and connect T-adapter to male side.
3. Turn neutral switch to ON or OFF position and troubleshoot.
a Switch OFF: Release, Switch ON: Press
Defective neutral switch (Internal Switch: OFF Resistance Max. 1 z
2 Between SNC (female)
disconnection)
(4) and (6) Switch: ON Resistance Min. 1 Mz

Between SNC (female) Switch: OFF Resistance Min. 1 Mz


(4) and (5) Switch: ON Resistance Max. 1 z
1.Turn starting switch to OFF position.
2.Disconnect connector SNC and connect T-adapter to female side.
3.Turn starting switch ON position.
a If voltage is 0 V, it shows disconnection in wiring harness, and if voltage is
Disconnection or hot short in wir- 24 V, it shows hot short in wiring harness.
3
ing harness a Voltage of apporx.9 V is applied to signal lines of NO and NC through
resistor in power train controller.
Between SNC (female) (5) and (4) Voltage 711 V
Between SNC (female) (6) and (4) Voltage 711 V
a If cause 3 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1, PTCN2 and SNC, and connect T-adapter
to female side of them.
Disconnection in wiring harness Between PTCN1 (female) (10) and SNC (female)
4 Resistance Max. 1 z
(open circuit or defective contact) (4)
Between PTCN2 (female) (17) and SNC (female)
Resistance Max. 1 z
(5)
Between PTCN2 (female) (27) and SNC (female)
Resistance Max. 1 z
(6)

40-388 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DDT5KA] Neutral switch disconnection

Cause Procedure, measuring location, criteria and remarks


If cause is not found by the above checks, power train controller is defective.
q Reference; the followings are criteria in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors PTCN1 and PTCN2.
3. Turn starting switch to ON position.
4. Turn neutral switch to ON or OFF position and troubleshoot.
a Voltage of apporx.9 V is applied to PTCN2 pin (17) and PTCN2 pin (27)
5 Defective power train controller
through resistor in power train controller.
Between PTCN2 (27) Switch: OFF Voltage Max. 1 V
and PTCN1 (10) Switch: ON Voltage 7 11 V

Between PTCN2 (17) Switch: OFF Voltage 7 11 V


and PTCN1 (10) Switch: ON Voltage Max. 1 V

Circuit diagram related to neutral switch 40-389

D375A-6R 40-389
(01)
Troubleshooting by failurecode
Failure code [DDT5KB] Neutral switch short circuit

Failure code [DDT5KB] Neutral switch short circuit 40-390


Action code Failure code Neutral switch short circuit
Failure
(Power train controller systerm)
E04 DDT5KB
q Both lines of NO: Normally Open and NC : Normally Closed for neutral switch circuit are 0 V(switch:
Detail of failure
ON) at the same time.
Action of con-
q Recognizes that neutral switch is not pressed.
troller
Problem on q Once machine is stopped, engine speed is limited to medium (half).
machine q Once machine is stopped, it cannot travel any more.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position and operate neutral switch.
mation

Cause Procedure, measuring location, standard (value) and remarks


Wrong selection of travel lever
1 If failure code [DDT5KQ] is displayed, carry out troubleshooting for it.
type
1. Turn starting switch to OFF position.
2. Disconnect connector SNC and connect T-adapter to male side.
3. Turn neutral switch to ON or OFF position and troubleshoot.
a Switch OFF: Release, Switch ON: Press
Defective neutral switch Switch: OFF Resistance Max. 1 z
2 Between SNC (male) (4)
(Internal disconnection)
and (6) Switch: ON Resistance Min. 1 Mz

Between SNC (male) (4) Switch: OFF Resistance Min. 1 Mz


and (5) Switch: ON Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1, PTCN2 and SNC and connect T-adapters
to female side of them.
Ground fault of wiring harness
3 Between SNC (female) (5) or PTCN2 (female) (17)
(Contact with ground circuit) Resistance Min. 1 Mz
and ground
Between SNC (female) (6) and PTCN2 (female)
Resistance Min. 1 Mz
(27) and groud
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1, PTCN2 and SNC and connect T-adapters
to female side of PTCN2.
a Check with tester in continuity mode.
4 Short circuit in wiring harness Between PTCN2 (female) (17) and No continuity
each pin other than (17) (No sound is heard)
Between PTCN2 (female) (27) and No continuity
each pin other than (27) (No sound is heard)
If cause is not found by the above checks, power train controller is defective.
q Reference; the followings are criteria in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors PTCN1 and PTCN2.
3. Turn starting switch ON position.
4. Turn shift up switch to ON or OFF position and troubleshoot.
a Voltage of apporx.9 V is applied to PTCN2 pin (27) and PTCN2 pin (17)
5 Defective power train controller
through resistor in power train controller.
Between PTCN2 (27) Switch: OFF Voltage Max. 1 V
and PTCN1 (10) Switch: ON Voltage 711 V

Between PTCN2 (17) Switch: OFF Voltage 711 V


and PTCN1 (10) Switch: ON Voltage Max.1 V

40-390 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DDT5KB] Neutral switch short circuit

Circuit diagram related to meutral switch 40-391

D375A-6R 40-391
(01)
Troubleshooting by failurecode
Failure code [DDT5KQ] Lever SPEC selection signal disagreement

Failure code [DDT5KQ] Lever SPEC selection signal disagreement 40-392


Action code Failure code Lever specification selection signal disagreement
Failure
(Power train controller systerm)
E04 DDT5KQ
Detail of failure q While optional travel lever is installed, optional travel lever device is not set.
Action of con-
troller
Problem on q Once machine is stopped, engine speed is limited to medium (half).
machine q Once machine is stopped, it cannot travel any more.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks


Check type of travel lever in
1 Wrong selection of travel lever Select optional travel lever.
adjustment mode: 0041.
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN2 and SNC and connect T-adapters to female
side of them.
Ground fault in wiring harness Between PTCN2 (female)(17) and ground or
2 Resistance Min. 1 Mz
(Contact with ground circuit) between SNC (female) (5) and ground
Between PTCN2 (female)(27) and ground or
Resistance Min. 1 Mz
between SNC (female) (6) and ground
If causes 1 and 2 are not detected, power train controller may be defective.
3 Defective power train controller
(Since failure is in it, troubleshooting cannot be carried out.)

Circuit diagram related to lever specification selection 40-392

40-392 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DDT5KQ] Lever SPEC selection signal disagreement

D375A-6R 40-393
(01)
Troubleshooting by failurecode
Failure code [DDTSL1] S/C: Fill high

Failure code [DDTSL1] S/C: Fill high 40-394


Action code Failure code Stator clutch oil pressure 1
Failure
(Power train controller system)
E02 DDTSL1
q Nevertheless controller does not output to torque converter stator clutch ECMV solenoid circuit, fill
Detail of failure
switch signal is turned to ON position.
Action of con-
q None in particular
troller
Problem on
q Sufficient traveling torque may not be obtained
machine
q Stator clutch ECMV fill switch signal status (ON/OFF) can be checked by using the monitoring func-
tion.
(Code: 31520 T/M fill SW Input 2)
Related infor- q Method of reproducing failure code: Start engine.
mation q Remove seat (approx. 50 kg) and seat bottom cover.
q First, check power train oil filter for clogging etc.
q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power
train oil pressure".

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective stator clutch ECMV fill 2. Disconnect connector FSTC and connect T-adapter to male side.
1
switch (internal short circuit) Between FSTC (female) (1) and ground
Resistance Min. 1 Mz
(Fill switch OFF)
1. Turn starting switch to OFF position.
2. Disconnect connector FSTC.
3. Start engine.
Ground fault in wiring harness or a Keep PPC lever in N position.
2
defective power train controller
If failure code [DDTSL1] is still displayed, there is ground fault in wiring har-
ness or power train controller is defective.
(If failure code [DDTSL1] is not displayed, stator clutch fill switch is defective.)
a If cause 2 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors PTCN2 and FSTC, and connect T-adapter to female
3
(Contact with ground circuit) side of either of them.
Between PTCN2 (female) (2) and ground or
Resistance Min. 1 Mz
between FSTC (female) (1) and ground
If "check result of cause 2 is abnormal" and "check result of cause 3 is normal",
power train controller is defective.
q Reference; the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
4 Defective power train controller Between PTCN2 (2) and ground Voltage 7 11 V
1. 2. are same as above.
3. Starting engine
a Keep PCCS lever in N position.
Between PTCN2 (2) and ground Voltage Max. 1 V

40-394 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DDTSL1] S/C: Fill high

Circuit diagram related to stator clutch oil pressure 40-395

D375A-6R 40-395
(01)
Troubleshooting by failurecode
Failure code [DDTSLH] S/C: Fill low

Failure code [DDTSLH] S/C: Fill low 40-396


Action code Failure code Stator clutch oil pressure 2
Failure
(Power train controller system)
E02 DDTSLH
q Nevertheless controller does not output to torque converter stator clutch ECMV solenoid circuit, fill
Detail of failure
switch signal is turned OFF.
Action of con-
q None in particular
troller
Problem on
q Sufficient traveling torque may not be obtained
machine
q Stator clutch ECMV fill switch signal status (ON/OFF) can be checked by using the monitoring func-
tion.
(Code: 31520 T/M fill SW Input 2)
Related infor- q Method of reproducing failure code: Start engine.
mation q Remove seat (approx. 50 kg) and seat bottom cover.
q First, check power train oil filter for clogging etc.
q Next, check that clutch pressure is normal by referring to Testing and adjusting, "Testing power
train oil pressure".

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective stator clutch ECMV fill 2. Disconnect connector FSTC and connect T-adapter to male side.
1 switch (Fill switch dose not turn to 3. Start engine.
ON position) Between FSTC (female) (1) and ground
Resistance Max. 1 z
(Fill switch: ON)
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors PTCN2 and FSTC and connect T-adapter to female
2 (Open circuit in wiring or defective side of either of them.
contact) Between PTCN2 (female) (2) and FSTC
Resistance Max. 1 z
(female) (1)
If no abnormality is found by the above checks, power train controller is defec-
tive.
q Reference; the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PTCN2.
3 Defective power train controller Between PTCN2 (2) and ground Voltage 7 11 V
12 are same as above.
3. Starting engine
a Keep PCCS lever in N position.
Between PTCN2 (2) and ground Voltage Max. 1 V

40-396 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DDTSLH] S/C: Fill low

Circuit diagram related to stator clutch oil pressure 40-397

D375A-6R 40-397
(01)
Troubleshooting by failurecode
Failure code [DGE5KX] Ambient temp sensor abnormality

Failure code [DGE5KX] Ambient temp sensor abnormality 40-398


Action code Failure code Ambient temp sensor abnormality
Failure
(VHMS controller system)
DGE5KX
q Input signal voltage from the atmospheric temperature sensor reads 4.9 V and above or 0.3 V or
Detail of failure
less.
Action of con-
q None in particular.
troller
Problem on
q Monitoring function fails to monitor the atmospheric temperature.
machine
q The LED of the VHMS controller displays "n4"o"01".
Related infor- q Under normal conditions, input (temperature) from ambient temperature sensor can be checked by
mation using monitoring function. (Code: 37501 ATR TEMP)
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector INT and connect T-adapter to male side.
a If ambient temperature sensor resistance is 2.2 kz - 34 kz, regard ambient
temperature sensor as normal.
INT (male) Ambient temperature Resistance
Defective atmospheric tempera-
1
ture sensor -20 C 27 - 34 kz

Between (1) 0 C 10 - 13 kz
and (2) 25 C 3.8 - 4.6 kz
40 C 2.2 - 2.6 kz
1. Turn starting switch to OFF position.
2. Disconnect connector V2A and connect T-adapter to female side.
Open or short circuit in wiring har- Between V2A (female) (10) and (12)
2
ness a Resistance accords with ambient temper-
Resistance 2.2 - 34 kz
ature - resistance characteristics table of
ambient temperature sensor in cause 2.
a If cause 2 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors V2A and INT and connect T-adapters to female side
Open circuit in wiring harness
of them.
3 (Open circuit in wiring or defective
Between V2A (female) (10) and INT (female)
contact in connector) Resistance Max. 1 z
(1)
Between V2A (female) (12) and INT (female)
Resistance Max. 1 z
(2)
1. Turn starting switch to OFF position.
2. Disconnect connectors INT and V2A and connect T-adapter to female side
Ground fault in wiring harness
4 of either of them.
(Contact with ground circuit)
Between INT (female) (1) and ground or
Resistance Min. 1 Mz
between V2A (female) ( 10) and ground
1. Turn starting switch to OFF position.
Hot short circuit or short circuit in 2. Disconnect connectors INT and connect T-adapter to female side.
5 3. Turn starting switch to ON position.
wiring harness
Between INT (female) (1) and (2) Voltage Approx. 5 V
If cause is not found by above checks, the VHMS controller is defective.
6 Defective VHMS controller
(Since trouble is in system, troubleshooting cannot be performed.)

40-398 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DGE5KX] Ambient temp sensor abnormality

Circuit diagram related to ambient temperature sensor 40-39

D375A-6R 40-399
(01)
Troubleshooting by failurecode
Failure code [DGS1KX] Hyd oil temp: signal abnormal

Failure code [DGS1KX] Hyd oil temp: signal abnormal 40-40


Action code Failure code Hydraulic oil temperature sensor: Abnormal
Failure
(Machine monitor power train control system)
E01 DGS1KX
Detail of failure q Hydraulic oil temperature sensor signal is out of normal range.
Action of con-
q None in particular.
troller
Problem on q Hydraulic oil temperature on monitor panel is not displayed normally.
machine q Fan speed is limited to half.
q Signal voltage of hydraulic oil temperature sensor is input to machine monitor, and then the data is
transmitted to power train controller.
Related infor-
q Hydraulic oil temperature can be checked in monitoring mode.
mation
(Code: 04401 Hydraulic oil temperature)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, crit and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector HDT and connect T-adapter to male side.
Approx.
Defective hydraulic oil tempera- 10 C Resistance
90 kz
ture sensor Between HDT (male) (1)
1 Approx.
(internal open circuit or short cir- and (2) 30 C Resistance
35 kz
cuit) a Temperature charac-
Approx.
teristics of oil temper- 80 C Resistance
6.5 kz
ature sensor
Approx.
100 C Resistance
3.5 kz
1. Turn starting switch to OFF position.
2. Disconnect connector HDT and connect T-adapter to female side.
3. Turn starting switch ON position.
Disconnection, short circuit or hot a If voltage is 0 V, wiring harness has disconnection, ground fault or short cir-
2 short in or ground fault of wiring cuit, and if voltage is 24 V, wiring harness has hot short.
harness a Voltage of approximately 3.3 V is applied to temperature sensor signal lines
through resistor in machine monitor.
Between HDT (female) (1) and (2) Voltage Approx. 5 V
a
If cause 2 is not the cause for the trouble, this check is not required.
1.
Turn starting switch to OFF position.
2.
Disconnect connector CM01 and connect T-adapter to female side.
Disconnection or short circuit in a
Resistance accords with temperature characteristics table in cause 1.
3
wiring harness a
If resistance is above1 Mz, wiring harness has disconnection. If resistance
is below 1 z, wiring harness has short circuit.
Approx.3.5
Between CM01 (female) (8) and (12) Resistance
90 kz
a If neither of causes 2 and 3 is the cause for the trouble, this check is not re-
quired.
1. Turn starting switch to OFF position.
2. Disconnect connectors CM01 and HDT, and connect T-adapters to female
Disconnection in wiring harness
4 side of them.
(open circuit or defective contact)
Between CM01 (female) (8) and HDT
Resistance Max. 1 z
(female) (1)
Between CM01 (female) (12) and HDT
Resistance Max. 1 z
(female) (2)
a If cause 2 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
Ground fault of wiring harness 2. Disconnect connectors CM01 and HDT, and connect T-adapter to female
5 side of either of them.
(Contact with ground circuit)
Between CM01 (female) (8) and (3), or
Resistance Min. 1 Mz
between HDT (female) (1) and ground

40-400 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DGS1KX] Hyd oil temp: signal abnormal

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors CM01 and HDT, and connect T-adapter to female
side of CM01.
6 Short circuit in wiring harness
a Check with multimeter in continuity mode.
Between CM01 (female) (8) and each
No continuity (No sound is heard.)
pin other than (8)
7 Defective machine monitor If cause is not found by above checks, machine monitor is defective.

Circuit diagram related to hydraulic oil temperature sensor 40-401

D375A-6R 40-401
(01)
Troubleshooting by failurecode
Failure code [DGT1KA] T/C oil temp sensor: Abnormal

Failure code [DGT1KA] T/C oil temp sensor: Abnormal 40-402


Action code Failure code Torque converter oil temperature sensor: Disconnection
Failure
(Work equipment controller system)
E01 DGT1KA
Detail of failure q Torque converter oil temperature sensor signal is out of normal range.
Action of con-
q None in particular.
troller
q Power train oil temperature gauge may not indicate normally.
Problem on
q The fan speed is limited to a half.
machine
q Gear shift shock of transmission increases.
q Torque converter oil temperature is considered to be power train oil temperature.
Related infor- q Torque converter oil temperature can be checked with monitoring function.
mation (Code: 30100 T/C oil temperature)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector 453 and connect T-adapter to male side.
Defective torque converter oil tem-
Between 453 (male) (1) and 25 C Resistance Approx. 42 kz
perature sensor
1 (2)
(Internal open or short circuit in 30 C Resistance Approx. 35 kz
wiring) a Temperature character-
istics of oil temperature 80 C Resistance Approx. 6.5 kz
sensor 100 C Resistance Approx. 3.5 kz
1.Turn starting switch to OFF position.
2.Disconnect connectors 453 and connect T-adapter to female side.
3.Turn starting switch to ON position.
Open circuit or short circuit or a If voltage is 0 V, wiring harness has open circuit or ground fault or short cir-
2 ground fault or hot short circuit in cuit, and if voltage is 24 V, wiring harness has hot short circuit.
wiring harness a Voltage of apporx.5 V is applied to temperature sensor signal lines through
resistor in power train controller.
Between 453 (female) (1) and (2) Voltage Approx. 5 V
a If cause 2 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors WECN1 and connect T-adapter to female side.
Open or short circuit in wiring har- a Resistance accords with temperature characteristics table in cause 1.
3
ness a If resistance is above 1 Mz, wiring harness has disconnection. If resistance
is below 1 z, wiring harness has short circuit.
Approx. 3.5
Between WECN1 (female) (20) and (21) Resistance
90 kz
a If neither of causes 2 and 3 is the cause for the trouble, this check is not re-
quired.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors WECN1 and 453, and connect T-adapters to female
4 (Open circuit in wiring or defective side of them.
contact)
Between (female) (20) and 453 (female) (1) Resistance Max. 1 z
Between WECN1 (female) (21) and 453
Resistance Max. 1 z
(female) (2)
1. Turn starting switch to OFF position.
2. Disconnect connectors WECN1 and 453, and connect T-adapter to female
side of WECN1.
5 Short circuit in wiring harness
a Check with multimeter in continuity mode.
Between WECN1 (female) (20) and each pin No continuity (No sound is
other than (20) heard.)
Defective work equipment control-
6 If cause is not found by above checks, work equipment controller is defective.
ler

40-402 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DGT1KA] T/C oil temp sensor: Abnormal

Related circuit diagram 40-403

D375A-6R 40-403
(01)
Troubleshooting by failurecode
Failure code [DGT1KX] T/C oil temp sensor: Abnormal

Failure code [DGT1KX] T/C oil temp sensor: Abnormal 40-404


Action code Failure code Torque converter oil temperature sensor: Short circuit
Failure
(Work equipment controller system)
E01 DGT1KX
Detail of failure q Torque converter oil temperature sensor signal is out of normal range.
Action of con-
q No particular action
troller
q Power train oil temperature gauge may not indicate normally.
Problem on
q Fan speed is limited to half speed.
machine
q Shock at gear shift is hard.
q Torque converter oil temperature is considered to be power train oil temperature.
Related infor- q For temperature characteristics table of oil temperature sensor, see [DGT1KA].
mation q If the sensor connector is disconnected in the normal condition and turn starting switch to ON po-
sition, failure code [DGT1KA] is displayde.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector 453.
Defective torque converter oil tem- 3. Turn starting switch ON position.
perature sensor
1
(internal open circuit or short cir- If failure code[DGT1KX] goes off and disconnection code [DGT1KA] is dis-
cuit) played, torque converter oil temperature sensor is defective.
(If failure code [DGT1KX] is still displayed, it shows that wiring harness or
power train controller is defective.)
1. Turn starting switch to OFF position.
2. Disconnect connectors WECN1 and 453, and connect T-adapter to female
Ground fault of wiring harness
2 side of either of them.
(Contact with ground circuit)
Between WECN1 (female) (20) and ground
Resistance Min. 1 Mz
or between 453 (female) (1) and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors WECN1 and 453, and connect T-adapter to female
side of WECN1.
3 Short circuit in wiring harness
a Check with multimeter in continuity mode.
Between WECN1 (female) (20) and each pin No continuity (No sound is
other than (20) heard)
Defective work equipment control- If no failure is detected by the above checks, work equipment controller is
4
ler defective.

40-404 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DGT1KX] T/C oil temp sensor: Abnormal

Related circuit diagram 40-405

D375A-6R 40-405
(01)
Troubleshooting by failurecode
Failure code [DGT5KA] F exhaust temp sensor disconnection

Failure code [DGT5KA] F exhaust temp sensor disconnection 40-406


Action code Failure code F exhaust temp sensor disconnection
Failure
(VHMS controller system)
DGT5KA
q Input signal voltage from the exhaust gas temperature sensor on the engine front side is below 0.5
Detail of failure
V.
Action of con-
q None in particular.
troller
Problem on
q Monitoring function fails to monitor the exhaust gas temperature on the engine front side
machine
q The LED of the VHMS controller displays n3" o "12".
Related infor- q Under normal conditions, input (temperature) from front exhaust temperature sensor can be
mation checked by using monitoring function. (Code: 42610 EXHAUST TEMP FRONT)
q Method of reproducing failure code: Turn the starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


If failure code [DBB6KP] is displayed, troubleshoot it first.
1. Turn starting switch to OFF position.
Defective sensor power supply 2. Disconnect connector EXAF and connect T-adapter to female side.
1 3. Turn starting switch to ON position.
system
a If power supply voltage is abnormal, go to cause 4 or after.
Power sup-
Between EXAF (A) and (C) Voltage 20 30 V
ply
a Check that failure code [DGT6KA] is not displayed.
1. Turn starting switch to OFF position.
Defective front (cylinder Nos. 1 - 2. Replace connector EXHF with EXHR.
2 3. Turn starting switch to ON position.
3) exhaust temperature sensor
If failure code [DGT5KA] changes to [DGT6KA], original front (cylinder Nos. 1
- 3) exhaust temperature sensor is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors EXTF, EXHF, V1 and V2A, and connect T-adapters
to female side of them or male side of EXTF.
a If cause 1 is not the cause for the trouble, this
check is not required. Resistance Max. 1 z
Open circuit in wiring harness Between V1 (female) (2) and EXAF (female) (A)
3 (Open circuit in wiring or defective Between V2A (female) (7) and EXAF (female) (B) Resistance Max. 1 z
contact in connector) a If cause 1 is not the cause for the trouble, this
check is not required. Resistance Max. 1 z
Between V2A (female) (13) and EXAF (female) (C)
Between EXHF (female) (1) and EXTF (male) (1) Resistance Max. 1 z
Between EXHF (female) (2) and EXTF (male) (2) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors EXHF, EXTF,EXAF, V1 and V2A, and connect
T-adapters to female side of them or male side of EXTF.
Between EXHF (female) (1) or EXTF (male) (1) and
Resistance Min. 1 Mz
Ground fault in wiring harness ground
4
(Contact with ground circuit) Between EXHF (female) (1) and (2), or between
Resistance Min. 1 Mz
EXTF (male) (1) and (2)
Between V2A (female) (7) and ground Resistance Min. 1 Mz
Between V2A (female) (7) and (13) Resistance Min. 1 Mz

40-406 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DGT5KA] F exhaust temp sensor disconnection

Cause Procedure, measuring location, criteria and remarks


a Check that failure code [DGT6KA] is not displayed.
1. Turn starting switch to OFF position.
Defective front (cylinder Nos. 1 - 2. Replace connector EXAF with EXAR.
5 3) exhaust temperature sensor 3. Turn starting switch to ON position.
amplifier
If failure code [DGT5KA] changes to [DGT6KA], original front (cylinder Nos. 1
- 3) exhaust temperature sensor amplifier is defective.
If cause is not found by above checks, VHMS controller may be defective.
(Since failure is in it, troubleshooting cannot be performed.)
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector V1 and V2A.
3. Turn starting switch to ON position.
100 C - 200 C Voltage 1.4 1.8 V
6 Defective VHMS controller 200 C - 300 C Voltage 1.8 2.2 V
Between V2A (7) and 300 C - 400 C Voltage 2.2 2.6 V
(13)
400 C - 500 C Voltage 2.6 3.0 V
a Exhaust temperature
characteristics 500 C - 600 C Voltage 3.0 3.4 V
600 C - 700 C Voltage 3.4 3.9 V
700 C - 800 C Voltage 3.9 4.3 V

Circuit diagram related to exhaust temperature sensor 40-407

D375A-6R 40-407
(01)
Troubleshooting by failurecode
Failure code [DGT5KB] F exhaust temp sensor short circuit

Failure code [DGT5KB] F exhaust temp sensor short circuit 40-408


Action code Failure code F exhaust temp sensor short circuit
Failure
(VHMS controller system)
DGT5KB
q Input signal voltage from the exhaust gas temperature sensor on the engine front side is above 4.9
Detail of failure
V.
Action of con-
q None in particular.
troller
Problem on
q Monitoring function fails to monitor the exhaust gas temperature on the engine front side
machine
q The machine monitor does not display any failure code (the relevant failure code can be checked
by downloading data stored in the VHMS controller).
Related infor- q The LED of the VHMS controller displays n3" o "11".
mation q Under normal conditions, input (temperature) from front exhaust temperature sensor can be
checked by using monitoring function. (Code: 42610 EXHAUST TEMP FRONT)
q Method of reproducing failure code: Turn the starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


Defective sensor power supply
1 If failure code [DBB6KP] is displayed, troubleshoot it first.
system
a Check that failure code [DGT6KB] is not displayed.
1. Turn starting switch to OFF position.
Defective front (cylinder Nos. 1 - 2. Replace connector EXHF with EXHR.
2 3. Turn starting switch to ON position.
3) exhaust temperature sensor
If failure code [DGT5KB] changes to [DGT6KB], original front (cylinder Nos. 1
- 3) exhaust temperature sensor is defective.
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect all connectors EXAF and connect T-adapter to female side.
3 3. Turn starting switch to ON position.
(Short circuit with 24 V circuit)
Between EXAF (female) (B) and (C) Voltage Max. 1 V
a Check that failure code [DGT6KB] is not displayed.
1. Turn starting switch to OFF position.
Defective front (cylinder Nos. 1 - 2. Replace connector EXAF with EXAR.
4 3) exhaust temperature sensor 3. Turn starting switch to ON position.
amplifier
If failure code [DGT5KB] changes to [DGT6KB], original front (cylinder Nos. 1
- 3) exhaust temperature sensor amplifier is defective.
If cause is not found by above checks, VHMS controller may be defective.
(Since failure is in it, troubleshooting cannot be performed.)
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector V1 and V2A.
3. Turn starting switch to ON position.
100 C - 200 C Voltage 1.4 1.8 V
5 Defective VHMS controller 200 C - 300 C Voltage 1.8 2.2 V
Between V2A (7) and 300 C - 400 C Voltage 2.2 2.6 V
(13)
400 C - 500 C Voltage 2.6 3.0 V
a Exhaust temperature
characteristics 500 C - 600 C Voltage 3.0 3.4 V
600 C - 700 C Voltage 3.4 3.9 V
700 C - 800 C Voltage 3.9 4.3 V

40-408 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DGT5KB] F exhaust temp sensor short circuit

Circuit diagram related to exhaust temperature sensor 40-409

D375A-6R 40-409
(01)
Troubleshooting by failurecode
Failure code [DGT6KA] R exhaust temp sensor disconnection

Failure code [DGT6KA] R exhaust temp sensor disconnection 40-410


Action code Failure code R exhaust temp sensor disconnection
Failure
(VHMS controller system)
DGT6KA
Detail of failure q Input signal voltage from exhaust temperature sensor on the engine rear side is below 0.5 V.
Action of con-
q None in particular.
troller
Problem on
q Monitoring function fails to monitor the exhaust gas temperature on the engine rear side
machine
q The LED of the VHMS controller displays n3 o 22.
Related infor- q Under normal conditions, input (temperature) from rear exhaust temperature sensor can be
mation checked by using monitoring function. (Code: 42611 EXHAUST TEMP REAR)
q Method of reproducing failure code: Turn the starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


If failure code [DBB6KP] is displayed, troubleshoot it first.
1. Turn starting switch to OFF position.
Defective sensor power supply 2. Disconnect connector EXAR and connect T-adapter to female side.
1 3. Turn starting switch to ON position.
system
a If power supply voltage is abnormal, go to cause 4 or after.
Power sup-
Between EXAR (A) and (C) Voltage 20 30 V
ply
a Check that failure code [DGT5KA ]is not displayed.
1. Turn starting switch to OFF position.
Defective rear (cylinder Nos. 4 - 6) 2. Replace connector EXHF with EXHR.
2 3. Turn starting switch to ON position.
exhaust temperature sensor
If failure code [DGT5KA] changes to [DGT6KA], original rear (cylinder Nos,
4-6) exhaust temperature sensor is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors EXTR, EXHR, V1 and V2A, and connect T-adapters
to female side of them or male side of EXTR.
a If cause 1 is not the cause for the trouble, this
check is not required. Resistance Max. 1 z
Open circuit in wiring harness Between V1 (female) (2) and EXAR (female) (A)
3 (Open circuit in wiring or defective Between V2A (female) (5) and EXAR (female) (B) Resistance Max. 1 z
contact in connector) a If cause 1 is not the cause for the trouble, this
check is not required. Resistance Max. 1 z
Between V2A (female) (13) and EXAR (male) (C)
Between EXHR (female) (1) and EXTR (male) (1) Resistance Max. 1 z
Between EXHR (female) (2) and EXTR (male) (2) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors EXHR, EXTR, EXAR, V1 and V2A, and connect
T-adapters to female side of them or male side of EXTR.
Between EXHR (female) (1) or EXTR (male) (1) and
Resistance Min. 1 Mz
Ground fault in wiring harness ground
4
(Contact with ground circuit) Between EXHR (female) (1) and (2), or between
Resistance Min. 1 Mz
EXTR (male) (1) and (2)
V2A (female) (5) and ground Resistance Min. 1 Mz
V2A (female) (5) and (13) Resistance Min. 1 Mz

40-410 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DGT6KA] R exhaust temp sensor disconnection

Cause Procedure, measuring location, criteria and remarks


a Check that failure code [DGT5KA ]is not displayed.
1. Turn starting switch to OFF position.
Defective rear (cylinder Nos. 4 - 6) 2. Replace connector EXAF with EXAR.
5 exhaust temperature sensor 3. Turn starting switch to ON position.
amplifier
If failure code [DGT6KA] changes to [DGT5KA], original rear (cylinder Nos. 4 -
6) exhaust temperature sensor amplifier is defective.
If cause is not found by above checks, VHMS controller may be defective.
(Since failure is in it, troubleshooting cannot be performed.)
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector V1 and V2A.
3. Turn starting switch to ON position.
100 C - 200 C Voltage 1.4 1.8 V
6 Defective VHMS controller 200 C - 300 C Voltage 1.8 2.2 V
300 C - 400 C Voltage 2.2 2.6 V
Between V2A(5) and (13)
a Exhaust temperature 400 C - 500 C Voltage 2.6 3.0 V
characteristics
500 C - 600 C Voltage 3.0 3.4 V
600 C - 700 C Voltage 3.4 3.9 V
700 C - 800 C Voltage 3.9 4.3 V

Circuit diagram related to exhaust temperature sensor 40-41

D375A-6R 40-411
(01)
Troubleshooting by failurecode
Failure code [DGT6KB] R exhaust temp sensor short circuit

Failure code [DGT6KB] R exhaust temp sensor short circuit 40-412


Action code Failure code Rear exhaust gas temperature sensor (R): Short circuit
Failure
(VHMS controller system)
DGT6KB
Detail of failure q Input signal voltage from rear exhaust temperature sensor is above 4.9 V.
Action of con-
q None in particular.
troller
Problem on
q Monitoring function fails to monitor the exhaust gas temperature on the engine rear side
machine
q The LED of the VHMS controller displays "n3 o "21".
Related infor- q Under normal conditions, input (temperature) from rear exhaust temperature sensor can be
mation checked by using monitoring function. (Code: 42611 EXHAUST TEMP REAR)
q Method of reproducing failure code: Turn the starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


Defective sensor power supply
1 If failure code [DBB6KP] is displayed, troubleshoot it first.
system
a Check that failure code [DGT5KB] is not displayed.
1. Turn starting switch to OFF position.
Defective rear (cylinder Nos. 4 - 6) 2. Replace connector EXHF with EXHR.
2 3. Turn starting switch to ON position.
exhaust temperature sensor
If failure code [DGT6KB] changes to [DGT5KB], original rear (cylinder Nos. 4 -
6) exhaust temperature sensor is defective.
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector EXAR and connect T-adapter to female side.
3 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between EXAR (female) (B) and (C) Voltage Max. 1 V
a Check that failure code [DGT5KB] is not displayed.
1. Turn starting switch to OFF position.
Defective rear (cylinder Nos. 4 - 6) 2. Replace connector EXAF with EXAR.
4 exhaust temperature sensor 3. Turn starting switch to ON position.
amplifier
If failure code [DGT6KB] changes to [DGT5KB], original rear (cylinder Nos. 4 -
6) exhaust temperature sensor amplifier is defective.
If cause is not found by above checks, VHMS controller may be defective.
(Since failure is in it, troubleshooting cannot be performed.)
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector V1 and V2A.
3. Turn starting switch to ON position.
100 C - 200 C Voltage 1.4 1.8 V
5 Defective VHMS controller 200 C - 300 C Voltage 1.8 2.2 V
300 C - 400 C Voltage 2.2 2.6 V
Between V2A(5) and (13)
a Exhaust temperature 400 C - 500 C Voltage 2.6 3.0 V
characteristics
500 C - 600 C Voltage 3.0 3.4 V
600 C - 700 C Voltage 3.4 3.9 V
700 C - 800 C Voltage 3.9 4.3 V

40-412 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DGT6KB] R exhaust temp sensor short circuit

Circuit diagram related to exhaust temperature sensor 40-413

D375A-6R 40-413
(01)
Troubleshooting by failurecode
Failure code [DH21KA] Weq pressure sensor: Disconnection

Failure code [DH21KA] Weq pressure sensor: Disconnection 40-414


Action code Failure code Work equipment pump oil pressure sensor : Disconnection
Failure
(Work equipment controller system)
E01 DH21KA
Detail of failure q Signal voltage of work equipment pump oil pressure sensor is below 0.2 V.
Action of con-
q None in particular
troller
Problem on
q Oil pressure of work equipment pump cannot be monitored.
machine
q Signal voltage of work equipment pump oil pressure sensor can be checked with monitoring func-
Related infor- tion.
mation (Code: 70701 Hydraulic Pressure Sensor 1)
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


If failure code [DB97KK] is also displayed, troubleshoot it first.
1. Turn starting switch to OFF position.
Defective sensor 5 V power suplly 2. Disconnect connector HHP and connect T-adapter to female side.
1 3. Turn starting switch to ON position.
system
a If power supply voltage is abnormal, go to cause 3 or after.
Between HHP (female) (B)
Power supply Voltage 4.5 5.5 V
and (A)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector HHP.
3. Turn starting switch to ON position.
a If power supply voltage is normal and sensor output voltage is abnormal
Defective work equipment pump (below 0.5 V), internal disconnection and ground fault cannot be identified.
2 oil pressure sensor (Internal dis- In this case, go to cause 4.
connection) or ground fault If check result of cause 4 is normal, work equipment pump oil pressure
sensor is defective.
Between HHP (female) (C)
Sensor output Voltage 0.5 4.5 V
and (A)
1. Turn starting switch to OFF position.
2. Disconnect connectors WECN1, WECN3 and HHP, and connect
T-adapters to female side of them.)
a If power supply voltage in checks 1 is nor-
mal, this check is not required.
Resistance Max. 1 z
Open circuit in wiring harness Between WECN1 (female) (21) and HHP
3 (Open circuit in wiring or defective (female) (A)
contact in connector) a If power supply voltage in checks 1 is nor-
mal, this check is not required.
Resistance Max. 1 z
Between WECN3 (female) (34) and HHP
(female) (B)
Between WECN1 (female) (9) and HHP
Resistance Max. 1 z
(female) (C)
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors STC1 and HHP, and connect T-adapter to female
side of either of them.
Ground fault in wiring harness
4 Between WECN1 (female) (9) and (21), or
(Contact with ground circuit) Resistance Min. 1 Mz
between HHP (female) (C) and (A)
Between WECN1 (female) (9) and ground, or
Resistance Min. 1 Mz
between HHP (female) (C) and ground

40-414 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DH21KA] Weq pressure sensor: Disconnection

Cause Procedure, measuring location, criteria and remarks


If cause is not found by above checks, work equipment controller is defective.
q Reference: the followings are standard values in normal condition.

Defective work equipment control- 1. Turn starting switch to OFF position.


5 2. Insert T-adapter into connector WECN1
ler
3. Turn starting switch to ON position.
Between WECN1 (9) and (21) Voltage 0.5 4.5 V

Circuit diagram related to work equipment pump oil pressure 40-415

D375A-6R 40-415
(01)
Troubleshooting by failurecode
Failure code [DH21KB] Weq pressure sensor: Short circuit

Failure code [DH21KB] Weq pressure sensor: Short circuit 40-416


Action code Failure code Work equipment pump oil pressure sensor: Disconnection
Failure
(Work equipment controller system)
E01 DH21KB
Detail of failure q Signal voltage of work equipment pump oil pressure sensor is above 4.8 V.
Action of con-
q None in particular
troller
Problem on
q Oil pressure of work equipment pump cannot be monitored.
machine
q Signal voltage of work equipment pump oil pressure sensor can be checked with monitoring func-
tion.
Related infor- (Code: 70701 Hydraulic Pressure Sensor 1)
mation q Method of reproducing failure code: Turn starting switch to ON position.
q If the sensor connector is disconnected in the normal condition and turn starting switch to ON po-
sition, failure code [DH21KA] is displayed.

Cause Procedure, measuring location, criteria and remarks


If failure code [DB97KK] is also displayed, troubleshoot it first.
1. Turn starting switch to OFF position.
Defective sensor 5 V power sup- 2. Disconnect connector HHP and connect T-adapter to female side.
1 3. Turn starting switch to ON position.
ply system
a If power supply voltage is abnormal, go to cause 3 or after.
Between HHP (female) (B)
Power supply Voltage 4.5 5.5 V
and (A)
1. Turn starting switch to OFF position.
2. Disconnect connector HHP
Defective work equipment pump 3. Turn starting switch to ON position.
2 oil pressure sensor (Internal dis- If failure code [DH21KB] is not displayed but [DH21KA] of disconnection is dis-
connection) or ground fault played, work equipment pump oil pressure sensor is defective. (If failure code
[DH21KB] is still displayed, it shows that wiring harness or power train control-
ler is defective.)
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector HHP and connect T-adapter to female side.
3 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between HHP (female) (C) and (A) or ground Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connectors WECN1 and HHP, and connect T-adapter to female
side of WECN1.
4 Short circuit in wiring harness
a Check with circuit tester in continuity mode.
Between WECN1 (female) (9) and each pin No continuity (No sound is
other than (9) heard)
If cause is not found by above checks, work equipment controller is defective.
q Reference: the followings are standard values in normal condition.

Defective work equipment control- 1. Turn starting switch to OFF position.


5 2. Insert T-adapter into connector WECN1
ler
3. Turn starting switch to ON position.
Between WECN1 (9) and (21) Voltage 0.5 4.5 V

40-416 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DH21KB] Weq pressure sensor: Short circuit

Circuit diagram related to work equipment pump oil pressure 40-417

D375A-6R 40-417
(01)
Troubleshooting by failurecode
Failure code [DHE5KB] ENG blow-by pressure sensor disconnection

Failure code [DHE5KB] ENG blow-by pressure sensor disconnection 40-418


Action code Failure code Engine blow-by pressure sensor: Disconnection
Failure
(VHMS controller system)
DHE5KB
Detail of failure q Input signal voltage from the blow-by pressure sensor is below 0.1 V.
Action of con-
q None in particular
troller
Problem on
q Monitoring function fails to monitor the blow-by pressure
machine
q The LED of the VHMS controller displays "n3"o"32".
Related infor- q The input state (pressure) from the blowby pressure sensor can be checked with the monitoring
mation function (Code: 42801 BLOWBY PRESS).
q Method of reproducing failure code: Start engine and performs troubleshooting

Cause Procedure, measuring location, criteria and remarks


If failure code [DBB5KP] is displayed, troubleshoot it first.
1. Turn starting switch to OFF position.
Defective sensor 5 V power sup- 2. Disconnect connectors ENBP and connect T-adapter to female side.
1
ply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to cause 4 or after.
Between ENBP (B) and (A) Power supply Voltage 4.85 5.15 V
1. Turn starting switch to OFF position.
2. Disconnect connectors ENBP, V1 and V2A, and connect T-adapters to
female side of one of them.
Ground fault in wiring harness Between ENBP (female) (C) and (A), or
2 Resistance Min. 1 Mz
(Contact with ground circuit) between V2A (female) (18) and (12)
Between ENBP (female) (C) or V2A (female)
Resistance Min. 1 Mz
(18) and ground
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector ENBP.
3. Turn starting switch to ON position, start engine, and then perform trouble-
shooting.
Defective blow-by pressure sen- Between Sensor output (Normal) Voltage 0.5 4.5 V
3 sor ENBP (C)
and (A) At high idle Voltage 0.5 0.9 V
(Internal short circuit)
1. Turn starting switch to OFF position.
2. Disconnect connectors ENBP and connect T-adapter to male side.
Between ENBP (female) (A), (B), (C) and
Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
2. Disconnect connectors ENBP, V1 and V2A and connect T-adapters to
female side of them.
a If power supply voltage in cause 1 is nor-
mal, this check is not required.
Open circuit in wiring harness Resistance Max. 1 z
Between V1 , V2A (female) (12) and ENBP
(Open circuit in wiring or defective
4 (female) (A)
contact in connector)
a If power supply voltage in cause 1 is nor-
mal, this check is not required.
Resistance Max. 1 z
Between V1 (female) (4) and ENBP (female)
(B)
Between V2A (female) (18) and ENBP
Resistance Max. 1 z
(female) (C)

40-418 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DHE5KB] ENG blow-by pressure sensor disconnection

Cause Procedure, measuring location, criteria and remarks


If cause is not found by above checks, VHMS controller may be defective.
(Since trouble is in system, troubleshooting cannot be performed.)
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector V1 and V2A.
5 Defective VHMS controller 3. Turn starting switch to ON position, start engine, and then perform trouble-
shooting.
Between V1 (4) and V2A
Power supply Voltage 4.85 5.15 V
(12)
Between Sensor output (Normal) Voltage 0.5 4.7 V
V2A (18)
and (12) At high idle Voltage 0.5 0.9 V

Circuit diagram related to engine blow-by pressure sensor 40-419

D375A-6R 40-419
(01)
Troubleshooting by failurecode
Failure code [DHE5KY] ENG blow-by pressure sensor short circuit

Failure code [DHE5KY] ENG blow-by pressure sensor short circuit 40-420
Action code Failure code Engine blow-by pressure sensor: Short circuit
Failure
(VHMS controller system)
DHE5KY
Detail of failure q Input signal voltage from the blow-by pressure sensor is above 4.7 V.
Action of con-
q None in particular
troller
Problem on
q Monitoring function fails to monitor the blow-by pressure
machine
q The LED of the VHMS controller displays "n3" o "31".
Related infor- q The input state (pressure) from the blowby pressure sensor can be checked with the monitoring
mation function (Code: 42801 BLOWBY PRESS).
q Method of reproducing failure code: Start engine and performs troubleshooting

Cause Procedure, measuring location, criteria and remarks

If failure code [DBB5KP] is displayed, troubleshoot it first.

Defective sensor 5 V power sup- 1. Turn starting switch to OFF position.


1
ply system 2. Disconnect connectors ENBP and connect T-adapter to female side.
3. Turn starting switch to ON position.
Between ENBP (B) and (A) Power supply Voltage 4.85 5.15 V
1. Turn starting switch to OFF position.
2. Disconnect connectors ENBP, V1 and V2A and connect T-adapter to
Hot short circuit in wiring harness female side of one of them.
2 3. Turn starting switch to ON position.
(Contact with 24V circuit)
Between ENBP (female) (C) and (A) , or
Voltage Max. 1 V
between V2A (female) (18) and (12)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector ENBP.
3. Turn starting switch to ON position, start engine, and then perform trouble-
shooting.
Defective blow-by pressure sen- Between Sensor output (Normal) Voltage 0.5 4.5 V
3 sor ENBP (C)
and (A) At high idle Voltage 0.5 0.9 V
(Internal short circuit)
1. Turn starting switch to OFF position.
2. Disconnect connectors ENBP and connect T-adapter to male side.
Between ENBP (male) (A), (B),( C) and
Resistance Min. 1 Mz
ground
If cause is not found by above checks, VHMS controller may be defective.
(Since failure is in it, troubleshooting cannot be performed.)
q Reference: The following shows standard values in the normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector V1 and V2A.
4 Defective VHMS controller 3. Turn starting switch to ON position, start engine, and then perform trouble-
shooting.
Between V1 (4) and V2A
Power supply Voltage 4.85 5.15 V
(12)
Between Sensor output (Normal) Voltage 0.5 4.7 V
V2A (18)
and (12) At high idle Voltage 0.5 0.9 V

40-420 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DHE5KY] ENG blow-by pressure sensor short circuit

Circuit diagram related to engine blow-by pressure sensor 40-421

D375A-6R 40-421
(01)
Troubleshooting by failurecode
Failure code [DHT3KX] T/M oil pressure sensor abnormality

Failure code [DHT3KX] T/M oil pressure sensor abnormality 40-42


Action code Failure code
Failure Transmission oil pressure sensor input signal out of range
DHT3KX
Detail of failure q Signal voltage of transmission oil pressure sensor is abnormal (below 0.3 V or above 4.9 V).
Action of con-
q None in particular
troller
Problem on
q System may not operate normally.
machine
Related infor-
q LED displays "n6" o "14".
mation

Cause Procedure, measuring location, criteria and remarks


If failure code [DBB6KP] is displayed, troubleshoot it first.
1. Turn starting switch to OFF position.
Defective sensor power supply 2. Disconnect connectors TMMD and connect T-adapter to female side.
1
system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to cause 3 or after.
Between TMMD (B) and (C) Power supply Voltage 20 30 V
1. Turn starting switch to OFF position.
Defective transmission main oil 2. Disconnect connectors TMMD and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
pressure sensor
Between TMMD (A) and (C) Voltage 15V
1. Turn starting switch to OFF position.
2. Disconnect connectors TMMD,V1 and V2A and connect T-adapters to
female side of them.
a If cause 1 is not the cause for the failure,
this check is not required.
Open circuit in wiring harness Resistance Max. 1 z
Between V1 (female) (2) and TMMD (female)
(Open circuit in wiring or defective
3 (B)
contact in connector)
a If cause 1 is not the cause for the failure,
this check is not required.
Resistance Max. 1 z
Between V2A (female) (12) and TMMD
(female) (C)
Between V2A (female) (15) and TMMD
Resistance Max. 1 z
(female) (A)
1. Turn starting switch to OFF position.
2. Disconnect connectors TMMD,V1 and V2A and connect T-adapter to
female side of one of them.
Ground fault in wiring harness Between V2A (female) (15) or TMMD
4 Resistance Min. 1 Mz
(Contact with ground circuit) (female) (A) and ground
Between V2A (female) (15) and (12) , or
Resistance Min. 1 Mz
between TMMD (female) (A) and (C)
1. Turn starting switch to OFF position.
Hot short circuit or short circuit in 2. Disconnect connectors TMMD and connect T-adapter to female side.
5 3. Turn starting switch to ON position.
wiring harness
Between TMMD (female) (A) and (C) Voltage Max. 1 V
If cause is not found by above checks, VHMS controller is defective.
q Reference: Following shows standard values in normal condition.
1. Turn starting switch to OFF position.
6 Defective VHMS controller 2. Insert T-adapter into connector V2A.
3. Turn starting switch to ON position.
Between V2A (15) and (12) Voltage 15V

40-422 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DHT3KX] T/M oil pressure sensor abnormality

Circuit diagram related to transmission oil pressure sensor 40-423

D375A-6R 40-423
(01)
Troubleshooting by failurecode
Failure code [DHT5KA] T/C in-pressure sensor: Disconnection

Failure code [DHT5KA] T/C in-pressure sensor: Disconnection 40-424


Action code Failure code Torque converter inlet pressure sensor: Disconnection
Failure
(Power train controller system)
E02 DHT5KA
Detail of failure q Signal voltage of torque converter inlet pressure sensor is below 0.2 V.
Action of con-
q None in particular.
troller
Problem on q No hydraulic pressure can be monitored at torque converter inlet.
machine q Gear shift shock of transmission increases.
q Signal voltage of torque converter inlet pressure sensor can be checked with monitoring function.
Related infor-
(Code 32602: Torque converter inlet pressure sensor voltage)
mation
q Method of reproducing failure code: Turn the starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

If failure code [DBE6KK] is also displayed, troubleshoot it first.

1. Turn starting switch to OFF position.


Defective sensor 5 V power sup- 2. Disconnect connector TIP and connect T-adapter to female side.
1
ply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to cause 3 or after.
Between TIP (female) (B)
Power supply Voltage 20 30 V
and (A)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TIP.
3. Turn starting switch to ON position.
Defective torque converter inlet a If power supply voltage is normal and sensor output voltage is abnormal
2 pressure sensor (internal failure) (below 0.5 V), internal disconnection and ground fault cannot be identified.
or ground fault In this case, go to cause 4. If check result of cause 4 is normal, torque con-
verter inlet pressure sensor is defective.
Between TIP (female) (C)
Sensor output Voltage 0.5 6.0 V
and (A)
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 and TIP, and connect T-adapters to female
side of them.
a If power supply voltage in cause 1 is nor-
mal, this check is not required.
Open circuit in wiring harness Resistance Max. 1 z
Between PTCN1 (female) (16) and TIP
(Disconnection or defective con-
3 (female) (B)
tact in connector)
a If power supply voltage in cause 1 is nor-
mal, this check is not required.
Resistance Max. 1 z
Between PTCN1 (female) (21) and TIP
(female) (A)
Between PTCN1 (female) (13) and TIP
Resistance Max. 1 z
(female) (C)
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 and TIP, and connect T-adapter to female
side of either of them.
Ground fault in wiring harness
4 Between PTCN1 (female) (13) and (21), or
(Contact with ground circuit) Resistance Min. 1 Mz
between TIP (female) (C) and (A)
Between PTCN1 (female) (13) and ground,
Resistance Min. 1 Mz
or between TIP (female) (C) and ground

40-424 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DHT5KA] T/C in-pressure sensor: Disconnection

Cause Procedure, measuring location, criteria and remarks


If cause is not found by the above checks, power train controller is defective.
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
5 Defective power train controller 2. Insert T-adapter into connector PTCN1.
3. Turn starting switch to ON position.
Between PTCN1 (13) and (21) Voltage 0.5 6.0 V

Related circuit diagram 40-425

D375A-6R 40-425
(01)
Troubleshooting by failurecode
Failure code [DHT5KB] T/C in-pressure sensor: Short circuit

Failure code [DHT5KB] T/C in-pressure sensor: Short circuit 40-426


Action code Failure code Torque converter inlet pressure sensor: short circuit
Failure
(Power train controller system)
E02 DHT5KB
Detail of failure q Signal voltage of torque converter inlet pressure sensor is above 4.7 V.
Action of con-
q None in particular.
troller
Problem on q No hydraulic pressure can be monitored at torque converter inlet.
machine q Gear shift shock of transmission increases.
q Signal voltage of torque converter inlet pressure sensor can be checked with monitoring function.
(Code 32602: Torque converter inlet pressure sensor voltage)
Related infor-
q Method of reproducing failure code: Turn the starting switch to ON position.
mation
q If the sensor connector is disconnected in the normal condition and turn starting switch to ON po-
sition, failure code [DHT5KA] is displayed.

Cause Procedure, measuring location, criteria and remarks

If failure code [DBE6KK] is also displayed, troubleshoot it first.

1. Turn starting switch to OFF position.


Defective sensor 5 V power sup- 2. Disconnect connector TIP and connect T-adapter to female side.
1
ply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to cause 3 or after.
Between TIP (female) (B)
Power supply Voltage 20 30 V
and (A)
1. Turn starting switch to OFF position.
2. Disconnect connector TIP.
Defective torque converter inlet 3. Turn starting switch to ON position.
2 pressure sensor (internal failure)
or ground fault If failure code [DHT5KB] is not displayed, torque converter inlet pressure sen-
sor is defective. (If failure code [DHT5KB] is still displayed, it shows that wiring
harness or power train controller is defective.)
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector TIP and connect T-adapter to female side.
3 (Contact with 24 V circuit) 3. Turn starting switch to ON position.
Between TIP (female) (C) and (A) or ground Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 and TIP, and connect T-adapter to female
side of PTCN1.
4 Short circuit in wiring harness
a Check with multimeter in continuity mode.
Between PTCN1 (female ) (13) and each pin No continuity (No sound is
other than (13) heard.)
If cause is not found by the above checks, power train controller is defective.
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
5 Defective power train controller 2. Insert T-adapter into connector PTCN1.
3. Turn starting switch to ON position.
Between PTCN1 (13) and (21) Voltage 0.5 6.0 V

40-426 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DHT5KB] T/C in-pressure sensor: Short circuit

Related circuit diagram 40-427

D375A-6R 40-427
(01)
Troubleshooting by failurecode
Failure code [DHT7KA] T/C out-pressure sensor: Disconnection

Failure code [DHT7KA] T/C out-pressure sensor: Disconnection 40-428


Action code Failure code Torque converter outlet pressure sensor: Disconnection
Failure
(Power train controller system)
E02 DHT7KA
Detail of failure q Signal voltage of torque converter outlet pressure sensor is below 0.2 V.
Action of con-
q None in particular
troller
Problem on q No hydraulic pressure can be monitored at torque converter outlet.
machine q Gear shift shock of transmission increases.
q Signal voltage of torque converter outlet pressure sensor can be checked with monitoring function.
Related infor-
(Code: 32604: Torque converter outlet pressure sensor voltage)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


If failure code [DBE6KK] is also displayed, troubleshoot it first.
1. Turn starting switch to OFF position.
Defective sensor 5 V power sup- 2. Disconnect connector TOP and connect T-adapter to female side.
1 3. Turn starting switch ON position.
ply system
a If power supply voltage is abnormal, go to cause 3 or after.
Between TOP (female) (B)
Power supply Voltage 20 30 V
and (A)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TOP.
3. Turn starting switch ON position.
Defective torque converter outlet a If power supply voltage is normal and sensor output voltage is abnormal
2 pressure sensor (internal failure) (below 0.5 V), internal disconnection and ground fault cannot be identified.
or ground fault In this case, go to cause 4. If check result of cause 4 is normal, torque con-
verter outlet pressure sensor is defective.
Between TOP (female) (C)
Sensor output Voltage 0.5 4.5 V
and (A)
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 and TOP, and connect T-adapters to female
side of them.
a If power supply voltage in checks on
cause 1 is normal, this check is not re-
quired. Resistance Max. 1 z
Open circuit in wiring harness
Between PTCN1 (female) (16) and TOP
(Open circuit in wiring or defective
3 (female) (B)
contact in connector)
a If power supply voltage in checks on
cause 1 is normal, this check is not re-
quired. Resistance Max. 1 z
Between PTCN1 (female) (21) and TOP
(female) (A)
Between PTCN1 (female) (7) and TOP
Resistance Max. 1 z
(female) (C)
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 and TOP, and connect T-adapter to female
side of either of them.
Ground fault in wiring harness
4 Between PTCN1 (female) (7) and (21), or
(Contact with ground circuit) Resistance Min. 1 Mz
between TOP (female) (C) and (A)
Between PTCN1 (female) (7) and ground, or
Resistance Min. 1 Mz
between TOP (female) (C) and ground

40-428 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DHT7KA] T/C out-pressure sensor: Disconnection

Cause Procedure, measuring location, criteria and remarks


If cause is not found by the above checks, power train controller is defective.
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
5 Defective power train controller 2. Insert T-adapter into connector PTCN1.
3. Turn starting switch to ON position.
Between PTCN1 (7) and (21) Voltage 0.5 6.0 V

Circuit diagram related to torque converter outlet pressure sensor 40-429

D375A-6R 40-429
(01)
Troubleshooting by failurecode
Failure code [DHT7KB] T/C out-pressure sensor: Short circuit

Failure code [DHT7KB] T/C out-pressure sensor: Short circuit 40-430


Action code Failure code Torque converter outlet pressure sensor: short circuit
Failure
(Power train controller system)
E02 DHT7KB
Detail of failure q Signal voltage of torque converter outlet pressure sensor is above 4.7 V.
Action of con-
q None in particular
troller
Problem on q No hydraulic pressure can be monitored at torque converter outlet.
machine q Gear shift shock of transmission increases.
q Signal voltage of torque converter outlet pressure sensor can be checked with monitoring function.
(Code: 32604: Torque converter outlet pressure sensor voltage)
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation
q If the sensor connector is disconnected in the normal condition and turn starting switch to ON po-
sition,failure code [DHT7KA ] is displayed.

Cause Procedure, measuring location, criteria and remarks

If failure code [DBE6KK] is also displayed, troubleshoot it first.

1. Turn starting switch to OFF position.


Defective sensor 5 V power sup- 2. Disconnect connector TOP and connect T-adapter to female side.
1
ply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to cause 3 or after.
Between TOP (female) (B)
Power supply Voltage 20 30 V
and (A)
1. Turn starting switch to OFF position.
2. Disconnect connector TOP.
Defective torque converter outlet 3. Turn starting switch to ON position.
2 pressure sensor (internal failure)
or ground fault If failure code [DHT7KB] is not displayed, torque converter outlet pressure
sensor is defective.(If failure code [DHT7KB] is still displayed, it shows that
wiring harness or power train controller is defective.)
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector TOP and connect T-adapter to female side.
3 (Contact with 24 V circuit) 3. Turn starting switch to ON position.
Between TOP (female) (C) and (A) or ground Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 and TOP, and connect T-adapter to female
side of PTCN1.
4 Short circuit in wiring harness
a Check with circuit tester in continuity mode.
Between PTCN 1 (female) (7) and each pin No continuity (No sound is
other than (7) heard)
If cause is not found by the above checks, power train controller is defective.
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
5 Defective power train controller 2. Insert T-adapter into connector PTCN1
3. Turn starting switch to ON position.
Between PTCN1 (7) and (21) Voltage 0.5 6.0 V

40-430 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DHT7KB] T/C out-pressure sensor: Short circuit

Related circuit diagram 40-431

D375A-6R 40-431
(01)
Troubleshooting by failurecode
Failure code [DK10KA] Fuel control Dial: Disconnection

Failure code [DK10KA] Fuel control Dial: Disconnection 40-432


Action code Failure code Fuel control Dial: Disconnection
Failure
(Power train controller system)
E03 DK10KA
Detail of failure q Signal voltage of fuel control dial is below 0.5 V.
Action of con- q Continues control with signal of decelerator pedal potentiometer.
troller q Limits operation of engine and transmission.
Problem on q Once machine is stopped, engine speed is limited to medium (half) speed.
machine q Once machine is stopped, travel is limited to F1 and R1.
q Signal voltage of fuel control dial signal can be checked with monitoring function.
Related infor-
(Code 03000: Fuel Dial Sensor)
mation
q Method of reproducing failure code:Turn the starting switch to ON position)

Cause Procedure, measuring location, criteria and remarks

If failure code [DBE5KK] is also displayed, troubleshoot it first.

1. Turn starting switch to OFF position.


Defective sensor 5 V power sup- 2. Disconnect connector DIAL and connect T-adapter to female side.
1
ply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to cause 3 or after.
Between DIAL (female) Power
Voltage 4.5 5.5 V
(1) and (3) supply
1. Turn starting switch to OFF position.
2. Disconnect connector DIAL and connect T-adapter to male side.
3. Turn starting switch to ON position.
4. Rotate fuel control dial and troubleshoot.
Defective fuel dial
2 (internal open circuit or ground Between DIAL (male) (1) and (3) Resistance Approx. 5 z
fault) Between DIAL (male) (2) and (3) Resistance 0.5 - 4.5 kz
Between DIAL (male) (1) and (2) Resistance 0.5 - 4.5 kz
Between DIAL(male) (2) and
Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1, TL1 and BRK, and connect T-adapter to
female side of PTCN1
a Resistance is same as table in cause 2.
Open or short circuit in wiring har- a If resistance is above 1 Mz, wiring harness has disconnection. If resistance
3
ness is below 1 z, wiring harness has short circuit.
Between PTCN1 (female) (22)
Resistance Approx. 5 z
and (21)
Between PTCN1 (female) (8) and
Resistance 0.5 - 4.5 kz
(21)

40-432 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DK10KA] Fuel control Dial: Disconnection

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 and DIAL, and connect T-adapters to
female side of them.
a If power supply voltage in
cause 1 or check result of
cause 3 is normal, this check is
Resistance Max. 1 z
not required.
Between PTCN1 (female) (22)
and DIAL(female) (1)
Open circuit in wiring harness a If power supply voltage in
4
(open circuit or defective contact) cause 1 or check result of
cause 3 is normal, this check is
Resistance Max. 1 z
not required.
Between PTCN1 (female) (21)
and DIAL (female) (3)
a If check result of cause 3 is
normal, this check is not re-
quired. Resistance Max. 1 z
Between PTCN1 (female) (8) and
DIAL (female) (2)
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 and DIAL, and connect T-adapter to female
side of either of them.
Ground fault in wiring harness
5 PTCN1 (female) (8) and (21), or
(Contact with ground circuit) Resistance Min. 1 Mz
between DIAL (female) (2) and (3)
PTCN1 (female) (8) and ground ,
or between DIAL (female) (2) and Resistance Min. 1 Mz
ground
If cause is not found by the above checks, power train controller is defective.
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
6 Defective power train controller 2. Insert T-adapter into connector PTCN1.
3. Turn starting switch to ON position.
4. Rotate fuel control dial and troubleshoot.
PTCN1 (8) and (21) Voltage 0.5 4.5 V

Circuit diagram related to fuel control dial 40-43

D375A-6R 40-433
(01)
Troubleshooting by failurecode
Failure code [DK10KB] Fuel control Dial: Short circuit

Failure code [DK10KB] Fuel control Dial: Short circuit 40-434


Action code Failure code Fuel control Dial: Short circuit
Failure
(Power train controller system)
E03 DK10KB
Detail of failure q Signal voltage of fuel control dial is above 4.5 V.
Action of con- q Continues control with signal of decelerator pedal potentiometer..
troller q Limits operation of engine and transmission.
Problem on q Once machine is stopped, engine speed is limited to medium (half) speed.
machine q Once machine is stopped, travel is limited to F1 and R1.
q Signal voltage of fuel control dial signal can be checked with monitoring function.
Related infor-
(Code 03000: Fuel Dial Sensor)
mation
q Method of reproducing failure code:Turn the starting switch to ON position)

Cause Procedure, measuring location, criteria and remarks

If failure code [DBE5KK] is also displayed, troubleshoot it first.

1. Turn starting switch to OFF position.


Defective sensor 5 V power sup- 2. Disconnect connector DIAL and connect T-adapter to female side.
1
ply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to cause 3 or after.
Between DIAL (female) Power
Voltage 4.5 5.5 V
(1) and (3) supply
1. Turn starting switch to OFF position.
2. Disconnect connector DIAL and connect T-adapter to male side.
3. Turn starting switch to ON position.
Defective fuel dial 4. Rotate fuel control dial and troubleshoot.
2 (internal open circuit or short cir-
Between DIAL (male) (1) and (3) Resistance Approx. 5 z
cuit)
Between DIAL (male) (2) and (3) Resistance 0.5 - 4.5 kz
Between DIAL (male) (1) and (2) Resistance 0.5 - 4.5 kz
1. Turn starting switch to OFF position.
2. Disconnect connector DIAL and connect T-adapter to male side.
Hot short circuit in wiring harness 3. Turn starting switch to ON position.
3
(Contact with 24 V circuit)
Between DIAL (female) (2) and (3)
Voltage Max. 1 V
or ground
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 and DIAL, and connect T-adapter to female
side of PTCN1.
4 Short circuit in wiring harness a Check with circuit tester in continuity mode.
Between PTCN1 (female) (8) and
No continuity (No sound is heard)
each pin other than (8)
If cause is not found by the above checks, power train controller is defective.
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
5 Defective power train controller 2. Insert T-adapter into connector PTCN1.
3. Turn starting switch to ON position.
4. Rotate fuel control dial and troubleshoot.
PTCN1 (8) and (21) Voltage 0.5 4.5 V

40-434 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DK10KB] Fuel control Dial: Short circuit

Circuit diagram related to fuel control dial 40-435

D375A-6R 40-435
(01)
Troubleshooting by failurecode
Failure code [DK30KA] ST lever 1: Disconnection

Failure code [DK30KA] ST lever 1: Disconnection 40-436


Action code Failure code Steering potentiometer 1: Disconnection
Failure
(Power train controller system)
E03 DK30KA
Detail of failure q Signal voltage of PCCS lever steering potentiometer 1 (ST lever POT ) is below 0.5 V.
Action of con- q Continues control with signal of PCCS lever steering potentiometer 2 (ST lever POT 2).
troller q Limits operation of engine and transmission.
Problem on q Once machine is stopped, engine speed is limited to medium (half) speed.
machine q Once machine is stopped, travel is limited to F1 and R1.
q Signal voltage of PCCS lever steering potentiometer 1 can be checked with monitoring function.
Related infor- (Code: 50300 S/T Lever 1 Potentio)
mation q Method of reproducing failure code:Turn starting switch to ON position and Operate PCCS lever (in
steering direction)

Cause Procedure, measuring location, criteria and remarks

If failure code [DBE5KK] is also displayed, troubleshoot it first.

1. Turn starting switch to OFF position.


Defective sensor 5 V power sup- 2. Disconnect connector TL2 and connect T-adapter to female side.
1
ply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to cause 3 or after.
Between TL2 (female) Power
Voltage 4.5 5.5 V
(5) and (8) supply
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TL2.
3. Turn starting switch to ON position.
4. Operate PCCS lever (steering) and troubleshoot.
Defective PCCS lever steering a If power supply voltage is normal and sensor output voltage is abnormal
2 potentiometer 1 (Internal discon- (0.5 V or below), internal disconnection and ground fault cannot be identi-
nection) or ground fault fied. In this case, go to cause 4.
If check result of cause 4 is normal, PCCS lever steering potentiometer 1 is
defective.
Between TL2 (female) Sensor
Voltage 0.964.04 V
(7) and (8) output
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 and TL2, and connect T-adapters to female
side of them.
a If power supply voltage in
cause 1 is normal, this check is
not required. Resistance Max. 1 z
Between PTCN1 (female) (22)
Open circuit in wiring harness and TL2 (female) (5)
3
(open circuit or defective contact) a If power supply voltage in
cause 1 is normal, this check is
not required. Resistance Max. 1 z
Between PTCN1 (female) (21)
and TL2 (female) (8)
Between PTCN1 (female) (2) and
Resistance Max. 1 z
TL2 (female) (7)
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 and TL2, and connect T-adapter to female
side of either of them.
Ground fault in wiring harness Between PTCN1 (female) (2) and
4
(Contact with ground circuit) (21), or between TL2 (female) (7) Resistance Min. 1 Mz
ground (8)
Between PTCN1 (female) (2) and
ground, or between TL2 (female) Resistance Min. 1 Mz
(7) and ground

40-436 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DK30KA] ST lever 1: Disconnection

Cause Procedure, measuring location, criteria and remarks


If cause is not found by the above checks, power train controller is defective.
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
5 Defective power train controller 2. Insert T-adapter into connector PTCN1.
3. Turn starting switch to ON position.
4. Operate PCCS lever (steering) and troubleshoot.
Between PTCN1 (2) and (21) Voltage 0.964.04 V

Circuit diagram related to steering potentiometer 40-437

D375A-6R 40-437
(01)
Troubleshooting by failurecode
Failure code [DK30KB] ST lever 1: Short circuit

Failure code [DK30KB] ST lever 1: Short circuit 40-438


Action code Failure code Steering potentiometer 1: Short circuit
Failure
(Power train controller system)
E03 DK30KB
Detail of failure q Signal voltage of PCCS lever steering potentiometer 1 (ST lever POT) is above 4.5 V.
Action of con- q Continues control with signal of PCCS lever steering potentiometer 2 (ST lever POT 2).
troller q Limits operation of engine and transmission.
problem on q Once machine stops, engine speed is limited to medium (half).
machine q Once machine stops, travel is limited to F1 and R1.
q Signal voltage of PCCS lever steering potentiometer 1 can be checked with monitoring function.
Related infor- (Code: 50300 S/T Lever 1 Potentio)
mation q Method of reproducing failure code:Turn starting switch to ON position and Operate PCCS lever (in
steering direction)

Cause Procedure, measuring location, criteria and remarks


Defective sensor 5 V power sup-
1 If failure code [DBE5KK] is also displayed, troubleshoot it first.
ply system
1. Turn starting switch to OFF position.
2. Disconnect connector TL2.
3. Turn starting switch to ON position.
Defective PCCS lever steering
4. Operate PCCS lever (steering) and troubleshoot.
potentiometer 1 (Internal discon-
2 If failure code [DK30KB] is not displayed, PCCS lever steering potentiometer
nection) or ground fault
is defective. (If failure code [DK30KB] is still displayed, wiring harness or
power train controller is defective.)
a Since connector TL2is disconnected, many failure codes are displayed. Ig-
nore all displayed failure codes other than [DK30KB].
1. Turn starting switch to OFF position.
2. Disconnect connector TL2 and connect T-adapter to female side.
Hot short in wiring harness (Con- 3. Turn starting switch to ON position.
3
tact with 24 V circuit)
Between TL2 (female) (7) and (8)
Voltage Max. 1 V
or ground
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 and TL2, and connect T-adapter to female
side of PTCN1.
4 Short circuit in wiring harness a Check with tester in continuity mode.
Between PTCN1 (female) (2) and
No continuity (No sound is heard)
each pin other than (2)
If cause is not found by the above checks, power train controller is defective.
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
5 Defective power train controller 2. Insert T-adapter into connector PTCN1.
3. Turn starting switch to ON position.
4. Operate PCCS lever (steering) and troubleshoot.
Between PTCN1 (2) and (21) Voltage 0.964.04 V

40-438 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DK30KB] ST lever 1: Short circuit

Circuit diagram related to steering potentiometer 40-439

D375A-6R 40-439
(01)
Troubleshooting by failurecode
Failure code [DK30KX] ST lever: Out of normal range

Failure code [DK30KX] ST lever: Out of normal range 40-4 0


Action code Failure code Steering potentiometers 1 and 2: Out of normal range
Failure
(Power train controller system)
E04 DK30KX
q In PCCS lever steering potentiometer 1 (ST lever POT) and 2 (ST lever POT 2), either of failure
Detail of failure codes [DK30KA] and [DK30KB] and either of failure codes [DK31KA] and [DK31KB] occurred at
the same time.
Action of con-
q Limits operation of engine and transmission.
troller
Problem on q Once machine stops, engine speed is limited to medium (half).
machine q Once machine stops, it cannot travel at all.
q Signal voltage of PCCS lever steering potentiometer 1 and 2 can be checked with monitoring func-
tion.
Related infor- (Code: 50300 S/T Lever 1 Potentio)
mation (Code: 50301 S/T Lever 2 Potentio)
q Method of reproducing failure code:Turn starting switch to ON position and Operate PCCS lever (in
steering direction)

Cause Procedure, measuring location, criteria and remarks


Perform troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA] and [DK31KB].

40-440 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DK30KZ] ST lever: Disconnection or short circuit

Failure code [DK30KZ] ST lever: Disconnection or short circuit 40-4 1


Action code Failure code Steering potentiometer: Abnormal at key ON
Failure
E04 DK30KZ (Power train controller system)
q In PCCS lever steering potentiometer 1 (ST lever POT) and 2 (ST lever POT 2), when starting
Detail of failure switch is turned ON, only either side is abnormal and then either of failure codes[DK30KA] and
[DK30KB] and either of failure codes [DK31KA] and [DK31KB] occurred at the same time.
Action of con-
q Limits operation of engine and transmission.
troller
Problem on q Once machine stops, engine speed is limited to medium (half).
machine q Once machine is stopped, it cannot travel at all.
q Signal voltage of PCCS lever steering potentiometer 1 and 2 can be checked with monitoring func-
tion.
Related infor- (Code: 50300 S/T Lever 1 Potentio)
mation (Code: 50301 S/T Lever 2 Potentio)
q Method of reproducing failure code: Turn starting switch to ON position and operate PCCS lever
(in steering direction).

Cause Procedure, measuring location, criteria and remarks


Perform troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA]and [DK31KB].

D375A-6R 40-441
(01)
Troubleshooting by failurecode
Failure code [DK30L8] ST lever: Signal mismatch

Failure code [DK30L8] ST lever: Signal mismatch 40-4 2


Action code Failure code Steering potentiometer: Signal mismatch
Failure
(Power train controller system)
E03 DK30L8
q In PCCS lever steering potentiometer 1 (ST lever POT)and 2 (ST lever POT 2), total of both signal
Detail of failure
voltages is below 4.41 V or above 5.59 V.
q Continues control with signal of normal one of PCCS lever steering potentiometer 1 (ST lever
Action of con-
POT)or 2 (ST lever POT 2).
troller
q Limits operation of engine and transmission.
Problem on q Once machine stops, engine speed is limited to medium (half).
machine q Once machine stops, travel is limited to F1 and R1.
q Signal voltage of PCCS lever steering potentiometer can be checked with monitoring function.
(Code: 50300 S/T Lever 1 Potentio)
Related infor-
(Code: 50301 S/T Lever 2 Potentio)
mation
q Method of reproducing failure code:Turn starting switch to ON position and Operate PCCS lever (in
steering direction))

Cause Procedure, measuring location, criteria and remarks


Perform troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA] and [DK31KB].

40-442 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DK30L8] ST lever: Signal mismatch

D375A-6R 40-443
(01)
Troubleshooting by failurecode
Failure code [DK31KA] ST lever 2: Disconnection

Failure code [DK31KA] ST lever 2: Disconnection 40-4 4


Action code Failure code Steering potentiometer 2: Disconnection
Failure
(Power train controller system)
E03 DK31KA
Detail of failure q Signal voltage of PCCS lever steering potentiometer 2 (ST lever POT 2) is below 0.5 V.
Action of con- q Continues control with signal of PCCS lever steering potentiometer 1 (ST lever POT).
troller q Limits operation of engine and transmission.
Problem on q Once machine stops, engine speed is limited to medium (half).
machine q Once machine stops, travel is limited to F1 and R1.
q Signal voltage of PCCS lever steering potentiometer 2 can be checked with monitoring function.
Related infor- (Code: 50301 S/T Lever 2 Potentio)
mation q Method of reproducing failure code:Turn starting switch to ON position and Operate PCCS lever (in
steering direction))
Cause Procedure, measuring location, criteria and remarks

If failure code [DBE5KK] is also displayed, troubleshoot it first.

1. Turn starting switch to OFF position.


Defective sensor 5 V power sup- 2. Disconnect connector TL2 and connect T-adapter to female side.
1
ply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to cause 3 or after.
Between TL2 (female) Power
Voltage 4.5 5.5 V
(5) and (8) supply
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TL2.
3. Turn starting switch to ON position.
4. Operate PCCS lever (steering) and troubleshoot.
Defective PCCS lever steering a If power supply voltage is normal and sensor output voltage is abnormal
2 potentiometer 2 (Internal discon- (below 0.5 V), internal disconnection and ground fault cannot be identified.
nection) or ground fault In this case, go to cause 4.
If check result of cause 4 is normal, PCCS lever steering potentiometer 2 is
defective.
Between TL2 (female) Sensor
Voltage 0.964.04 V
(6) and (8) output
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 and TL2, and connect T-adapters to female
side of them.
a If power supply voltage in
cause 1 is normal, this check is
not required. Resistance Max. 1 z
Between PTCN1 (female) (22)
Disconnection in wiring harness and TL2 (female) (5)
3
(open circuit or defective contact) a If power supply voltage in
cause 1 is normal, this check is
not required. Resistance Max. 1 z
Between PTCN1 (female) (21)
and TL2 (female)(8)
Between PTCN1 (female) (19)
Resistance Max. 1 z
and TL2 (female) (6)
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 andTL2, and connect T-adapter to female
side of either of them.
Ground fault of wiring harness Between PTCN1 (female) (19)
4
(Contact with ground circuit) and (21) , or between TL2 Resistance Min. 1 Mz
(female) (6) and (8)
Between PTCN1 (female) (19)
and ground , or between TL2 Resistance Min. 1 Mz
(female) (6) and ground

40-444 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DK31KA] ST lever 2: Disconnection

Cause Procedure, measuring location, criteria and remarks


If cause is not found by the above checks, power train controller is defective.
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
5 Defective power train controller 2. Insert T-adapter into connector PTCN1.
3. Turn starting switch to ON position.
4. Operate PCCS lever (steering) and troubleshoot.
Between PTCN1(19) and (21) Voltage 0.964.04 V

Circuit diagram related to steering potentiometer 40-4 5

D375A-6R 40-445
(01)
Troubleshooting by failurecode
Failure code [DK31KB] ST lever 2: Short circuit

Failure code [DK31KB] ST lever 2: Short circuit 40-4 6


Action code Failure code Steering potentiometer 2: Short circuit
Failure
(Power train controller system)
E03 DK31KB
Detail of failure q Signal voltage of PCCS lever steering potentiometer 2 (ST lever POT 2) is above 4.5 V.
Action of con- q Continues control with signal of PCCS lever steering potentiometer 1 (ST lever POT).
troller q Limits operation of engine and transmission.
Problem on q Once machine stops, engine speed is limited to medium (half).
machine q Once machine stops, travel is limited to F1 and R1.
q Signal voltage of PCCS lever steering potentiometer 2 can be checked with monitoring function.
Related infor- (Code: 50301 S/T Lever 2 Potentio)
mation q Method of reproducing failure code:Turn starting switch to ON position and Operate PCCS lever (in
steering direction))

Cause Procedure, measuring location, criteria and remarks


Defective sensor 5 V power sup-
1 If failure code [DBE5KK] is also displayed, troubleshoot it first.
ply system
1. Turn starting switch to OFF position.
2. Disconnect connector TL2.
3. Turn starting switch to ON position.
Defective PCCS lever steering 4. Operate PCCS lever (steering) and troubleshoot.
2 potentiometer 2 (Internal discon- If failure code [DK31KB] is not displayed, PCCS lever steering potentiometer
nection) or ground fault is defective.( If failure code [DK31KB] is still displayed, wiring harness or
power train controller is defective.)
a Since connector TL2 is disconnected, many failure codes are displayed.Ig-
nore all displayed failure codes other than [DK31KB]
1. Turn starting switch to OFF position.
2. Disconnect connectors TL2 and connect T-adapter to female side.
Hot short of wiring harness (Con- 3. Turn starting switch to ON position.
3
tact with 24 V circuit)
Between TL2 (female) (6) and (8)
Voltage Max. 1 V
or ground
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 and TL2, and connect T-adapter to female
side of PTCN1.
4 Short circuit in wiring harness a Check with tester in continuity mode.
Between PTCN1 (female) (19)
No continuity (No sound is heard)
and each pin other than (19)
If cause is not found by the above checks, power train controller is defective.
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
5 Defective power train controller 2. Insert T-adapter into connector PTCN1
3. Turn starting switch to ON position.
4. Operate PCCS lever (steering) and troubleshoot.
Between PTCN1 (19) and (21) Voltage 0.964.04 V

40-446 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DK31KB] ST lever 2: Short circuit

Circuit diagram related to steering potentiometer 40-4 7

D375A-6R 40-447
(01)
Troubleshooting by failurecode
Failure code [DK40KA] Brake potentiometer: Disconnection

Failure code [DK40KA] Brake potentiometer: Disconnection 40-4 8


Action code Failure code Brake potentiometer: Disconnection
Failure
(Power train controller system)
E03 DK40KA
Detail of failure q Signal voltage of brake pedal potentiometer is below 0.5 V.
Action of con-
q Restricts operation of engine and transmission.
troller
Problem on q travel is limited to F1 and R1.
machine q Once machine stops, engine speed is limited to medium (half).
q Signal voltage of brake pedal potentiometer can be checked with monitoring function.
Related infor-
(Code: 50400 Brake Pedal Potentio)
mation
q Method of reproducing failure code:Turn starting switch to ON position and operate brake pedal.

Cause Procedure, measuring location, criteria and remarks

If failure code [DBE5KK]is also displayed, troubleshoot it first.

1. Turn starting switch to OFF position.


Defective sensor 5 V power sup- 2. Disconnect connector BRK and connect T-adapter to female side.
1
ply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to cause 3 or after.
Between BRK (female) Power
Voltage 4.5 5.5 V
(C) and (A) supply
1. Turn starting switch to OFF position.
2. Disconnect connector BRK and connect T-adapter to male side.
3. Turn starting switch to ON position.
Defective brake pedal potentiome- 4. Depress brake pedal and troubleshoot.
ter Between BRK (male) (C) and (A) Resistance Approx. 5 kz
2
(Internal disconnection or ground
fault) Between BRK (male) (A) and (B) Resistance 0.25 - 7.0 kz
Between BRK (male) (B) and (C) Resistance 0.25 - 7.0 kz
Between BRK (male) B)and
Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
2. Disconnect connectors PCTN1 and TL1, and connect T-adapters to female
side of them PTCN1.
a Resistance is same as table in cause 2.
Disconnection or short circuit in a If resistance is above 1 Mz, wiring harness has disconnection. If resistance
3
wiring harness is below 1 z, wiring harness has short circuit.
Between PTCN1 (female) (22)
Resistance Approx. 2 kz
and (21)
Between PTCN1 (female) (3) and
Resistance 0.2 - 1.8 kz
(21)

40-448 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DK40KA] Brake potentiometer: Disconnection

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 and BRK, and connect T-adapters to female
side of them.
a If power supply voltage in
cause 1 or check result of
cause 3 is normal, this check is
Resistance Max. 1 z
not required.
Between PTCN1 (female) (21)
and BRK (female) (A)
Open circuit in wiring harness a If power supply voltage in
4
(open circuit or defective contact) cause 1 or check result of
cause 3 is normal, this check is
Resistance Max. 1 z
not required.
Between PTCN1 (female) (22)
and BRK (female) (C)
a If check result of cause 3 is
normal, this check is not re-
quired. Resistance Max. 1 z
Between PTCN1 (female) (3) and
BRK (female) (B)

Circuit diagram related to brake potentiometer 40-4 9

D375A-6R 40-449
(01)
Troubleshooting by failurecode
Failure code [DK40KB] Brake potentiometer: Short circuit

Failure code [DK40KB] Brake potentiometer: Short circuit 40-450


Action code Failure code Brake potentiometer: Short circuit
Failure
(Power train controller system)
E03 DK40KB
Detail of failure q Signal voltage of brake pedal potentiometer is above 4.8 V.
Action of con-
q Restricts operation of engine and transmission.
troller
Problem on q travel is limited to F1 and R1.
machine q Once machine stops, engine speed is limited to medium (half).
q Signal voltage of brake pedal potentiometer can be checked with monitoring function.
Related infor-
(Code: 50400 Brake Pedal Potentio)
mation
q Method of reproducing failure code:Turn starting switch to ON position and operate brake pedal.

Cause Procedure, measuring location, criteria and remarks

If failure code [DBE5KK]is also displayed, troubleshoot it first.

1. Turn starting switch to OFF position.


Defective sensor 5 V power sup- 2. Disconnect connector BRK and connect T-adapter to female side.
1
ply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to cause 3 or after.
Between BRK (female) Power
Voltage 4.5 5.5 V
(C) and (A) supply
1. Turn starting switch to OFF position.
2. Disconnect connector BRK and connect T-adapter to male side.
3. Turn starting switch to ON position.
Defective brake pedal potentiome- 4. Depress brake pedal and troubleshoot.
ter Between BRK (female) (C) and
2 Resistance Approx. 5 kz
(Internal disconnection or short (A)
circuit) Between BRK (female) (A) and
Resistance 0.25 - 7.0 kz
(B)
Between BRK (female) (B) and
Resistance 0.25 - 7.0 kz
(C)
1. Turn starting switch to OFF position.
2. Disconnect connector BRK and connect T-adapter to male side.
Hot short in wiring harness (Con- 3. Turn starting switch ON position.
3
tact with 24 V circuit)
Between BRK (female) (B) and
Voltage Max. 1 V
(A) or ground
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN1 and BRK , and connect T-adapter to female
side of PTCN1.
4 Short circuit in wiring harness a Check with tester in continuity mode.
Between PTCN1 (female) (3) and
No continuity (No sound is heard)
each pin other than (3)
If cause is not found by the above checks, power train controller is defective.
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
5 Defective power train controller 2. Insert T-adapter into connector PTCN1.
3. Turn starting switch to ON position.
4. Depress brake pedal and troubleshoot.
Between PTCN1(3) and (21) Voltage 0.5 4.5 V

40-450 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DK40KB] Brake potentiometer: Short circuit

Circuit diagram related to brake potentiometer 40-451

D375A-6R 40-451
(01)
Troubleshooting by failurecode
Failure code [DK55KX] FR lever: Out of normal range

Failure code [DK55KX] FR lever: Out of normal range 40-452


Action code Failure code Front/Rear potentiometers 1 and 2: Out of normal range
Failure
(Power train controller system)
E04 DK55KX
q In PCCS lever F-R potentiometer 1 (F/R lever 3) and 2 (F/R lever 4), either of failure codes
Detail of failure [DK56KA] and [DK56KB] and either of failure codes [DK57KA] and [DK57KB]occurred at the
same time.
Action of con-
q Limits operation of engine and transmission.
troller
Problem on q Once machine stops, engine speed is limited to medium (half).
machine q Once machine is stopped, it cannot travel at all.
q Signal voltage of PCCS lever F-R potentiometer can be checked with monitoring function.
(Code: 50200 T/M Lever 1 Potentio)
Related infor-
(Code: 50201 T/M Lever 2 Potentio)
mation
q Method of reproducing failure code:Turn starting switch to ON position and operate PCCS lever (in
F-R direction).

Cause Procedure, measuring location, criteria and remarks


Perform troubleshooting for failure codes [DK56KA], [DK56KB], [DK57KA] and [DK57KB].

40-452 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DK55KZ] FR lever: Disconnection or short circuit

Failure code [DK55KZ] FR lever: Disconnection or short circuit 40-453


Action code Failure code Front/Rear potentiometer: Abnormal at key ON
Failure
(Power train controller system)
E04 DK55KZ
q In PCCS lever F-R potentiometer 1 (F/R lever 3) and 2 (F/R lever 4), when starting switch is turned
Detail of failure to ON position, only either side is abnormal and then either of failure codes [DK56KA] and
[DK56KB]and either of failure codes [DK57KA] and [DK57KB] occurred at the same time.
Action of con-
q Limits operation of engine and transmission.
troller
Problem on q Once machine stops, engine speed is limited to medium (half).
machine q Once machine stops, it cannot travel at all.
q Signal voltage of PCCS lever F-R potentiometer can be checked with monitoring function.
(Code: 50200 T/M Lever 1 Potentio)
Related infor-
(Code: 50201 T/M Lever 2 Potentio)
mation
q Method of reproducing failure code:Turn starting switch to ON position and operate PCCS lever (in
F-R direction).

Cause Procedure, measuring location, criteria and remarks


Perform troubleshooting for failure codes [DK56KA], [DK56KB], [DK57KA] and [DK57KB].

D375A-6R 40-453
(01)
Troubleshooting by failurecode
Failure code [DK55L8] FR lever: Signal mismatch

Failure code [DK55L8] FR lever: Signal mismatch 40-454


Action code Failure code Front/Rear potentiometer: Signal mismatch
Failure
(Power train controller system)
E03 DK55L8
q In PCCS lever F-R potentiometer 1 (F/R lever 3) and 2 (F/R lever 4), total of both signal voltages is
Detail of failure
below 4.41 V or above 5.59 V.

Action of con- q Continues control with signal of normal one of PCCS lever F-R potentiometer 1 or 2.
troller q Limits operation of engine and transmission.

Problem on q Once machine stops, engine speed is limited to medium (half).


machine q Once machine stops, travel is limited to F1 and R1.
q Signal voltage of PCCS lever F-R potentiometer can be checked with monitoring function.
(Code: 50200 T/M Lever 1 Potentio)
Related infor-
(Code: 50201 T/M Lever 2 Potentio)
mation
q Method of reproducing failure code:Turn starting switch to ON position and operate PCCS lever (in
F-R direction).

Cause Procedure, measuring location, criteria and remarks


Perform troubleshooting for failure codes [DK56KA], [DK56KB],[DK57KA] and [DK57KB].

40-454 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DK55L8] FR lever: Signal mismatch

D375A-6R 40-455
(01)
Troubleshooting by failurecode
Failure code [DK56KA] FR lever 1: Disconnection

Failure code [DK56KA] FR lever 1: Disconnection 40-456


Action code Failure code Front/Rear potentiometer 1: Disconnection
Failure
(Power train controller system)
E03 DK56KA
Detail of failure q Signal voltage of PCCS lever F-R potentiometer 1 (F/R lever 3) is below 0.5 V
Action of con- q Continues control with signal of PCCS lever F-R potentiometer 2 (F/R lever 4).
troller q Limits operation of engine and transmission.
Problem on q Once machine stops, engine speed is limited to medium (half).
machine q Once machine stops, travel is limited to F1 and R1.
q Signal voltage of PCCS lever F-R potentiometer 1 can be checked with monitoring function.
Related infor- (Code: 50200 T/M Lever 1 Potentio)
mation q Method of reproducing failure code:Turn starting switch to ON position and operate PCCS lever (in
F-R direction).
Cause Procedure, measuring location, criteria and remarks

If failure code [DBE5KK] is also displayed, troubleshoot it first.

1. Turn starting switch to OFF position.


Defective sensor 5 V power sup- 2. Disconnect connector TL2 and connect T-adapter to female side.
1
ply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to cause 3 or after.
Between TL2 (female) Power
Voltage 4.5 5.5 V
(4) and (1) supply
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TL2.
3. Turn starting switch ON position.
4. Operate PCCS lever (F-R) and troubleshoot.
Defective PCCS lever F-R potenti- a If power supply voltage is normal and sensor output voltage is abnormal
ometer 1 (Internal disconnection) (below 0.5 V), internal disconnection and ground fault cannot be identified.
2
or ground fault In this case, go to cause 4.
If check result of cause 4 is normal, PCCS lever F-R potentiometer 1 is
defective.
Between TL2 (3) and Sensor
Voltage 1.393.61 V
(1) output
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 and TL2, and connect T-adapters to female
side of them.
a If power supply voltage in
cause 1 is normal, this check is
not required. Resistance Max. 1 z
Between PTCN1 (female) (22)
Disconnection in wiring harness and TL2 (female) (4)
3
(open circuit or defective contact) a If power supply voltage in
cause 1 is normal, this check is
not required. Resistance Max. 1 z
Between PTCN1 (female) (21)
and TL2 (female) (1)
Between PTCN1 (female) (20)
Resistance Max. 1 z
and TL2 (female) (3)
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 and TL2, and connect T-adapter to female
side of either of them.
Ground fault of wiring harness Between PTCN1 (female) (20)
4
(Contact with ground circuit) and (21), or between Resistance Min. 1 Mz
TL2(female)(3) and (1)
Between PTCN1 (female) (20)
and ground, or between TL2 Resistance Min. 1 Mz
(female) (3) and ground

40-456 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DK56KA] FR lever 1: Disconnection

Cause Procedure, measuring location, criteria and remarks


If cause is not found by the above checks, power train controller is defective.
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
5 Defective power train controller 2. Insert T-adapter into connector PTCN1.
3. Turn starting switch to ON position.
4. Operate PCCS lever (F-R) and troubleshoot.
Between PTCN1 (20) and (21) Voltage 1.393.61 V

Circuit diagram related to forward-reverse potentiometer 40-457

D375A-6R 40-457
(01)
Troubleshooting by failurecode
Failure code [DK56KB] FR lever 1: Short circuit

Failure code [DK56KB] FR lever 1: Short circuit 40-458


Action code Failure code Front/Rear potentiometer 1: Short circuit
Failure
(Power train controller system)
E03 DK56KB
Detail of failure q Signal voltage of PCCS lever F-R potentiometer 1 (F/R lever 3) is above 4.5 V.
Action of con- q Continues control with signal of PCCS lever F-R potentiometer 2 (F/R lever 4).
troller q Limits operation of engine and transmission.
Problem on q Once machine stops, engine speed is limited to medium (half).
machine q Once machine stops, travel is limited to F1 and R1.
q Signal voltage of PCCS lever F-R potentiometer 1 can be checked with monitoring function.
Related infor- (Code: 50200 T/M Lever 1 Potentio)
mation q Method of reproducing failure code:Turn starting switch to ON position and operate PCCS lever (in
F-R direction).

Cause Procedure, measuring location, criteria and remarks


Defective sensor 5 V power sup-
1 If failure code [DBE5KK] is also displayed, troubleshoot it first.
ply system
1. Turn starting switch to OFF position.
2. Disconnect connectors TL2.
3. Turn starting switch to ON position.
Defective PCCS lever F-R potenti-
4. Operate PCCS lever (F-R) and troubleshoot.
ometer 1
2
(Internal disconnection) or ground If failure code [DK56KB] is not displayed, PCCS lever steering potentiometer
fault is defective. (This failure code is still displayed, wiring harness or power train
controller is defective.)
a Since connector TL2 is disconnected, many failure codes are displayed. Ig-
nore all displayed failure codes other than [DK56KB].
1. Turn starting switch to OFF position.
2. Disconnect connectors TL2, and connect T-adapter to female side.
Hot short of wiring harness (Con- 3. Turn starting switch ON position.
3
tact with 24 V circuit)
Between TL2 (female) (3) and (1)
Voltage Max. 1 V
or ground
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 and TL2, and connect T-adapter to female
side of PTCN1.
4 Short circuit in wiring harness a Check with tester in continuity mode.
Between PTCN1 (female) (20)
No continuity (No sound is heard)
and each pin other than (20)
If cause is not found by the above checks, power train controller is defective.
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
5 Defective power train controller 2. Insert T-adapter into connector PTCN1.
3. Turn starting switch to ON position.
4. Operate PCCS lever (F-R) and troubleshoot.
Between PTCN1 (20) and (21) Voltage 1.393.61 V

40-458 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DK56KB] FR lever 1: Short circuit

Circuit diagram related to forward-reverse potentiometer 40-459

D375A-6R 40-459
(01)
Troubleshooting by failurecode
Failure code [DK57KA] FR lever 2: Disconnection

Failure code [DK57KA] FR lever 2: Disconnection 40-460


Action code Failure code Front/Rear potentiometer 2: Disconnection
Failure
(Power train controller system)
E03 DK57KA
Detail of failure q Signal voltage of PCCS lever F-R potentiometer 2 (F/R lever 4) is below 0.5 V.
Action of con- q Continues control with signal of PCCS lever F-R potentiometer 1 (F/R lever 3).
troller q Limits operation of engine and transmission.
Problem on q Once machine stops, engine speed is limited to medium (half).
machine q Once machine stops, travel is limited to F1 and R1.
q Signal voltage of PCCS lever F-R potentiometer 2 can be checked with monitoring function.
Related infor- (Code: 50201 T/M Lever 2 Potentio)
mation q Method of reproducing failure code:Turn starting switch to ON position and operate PCCS lever (in
F-R direction).

Cause Procedure, measuring location, criteria and remarks

If failure code [DBE5KK] is also displayed, troubleshoot it first.

1. Turn starting switch to OFF position.


Defective sensor 5 V power sup- 2. Disconnect connector TL2 and connect T-adapter to female side.
1
ply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to cause 3 or after.
Between TL2 (female) Power
Voltage 4.5 5.5 V
(4) and (1) supply
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TL2.
3. Turn starting switch ON position.
4. Operate PCCS lever (F-R) and troubleshoot.
Defective PCCS lever F-R potenti- a If power supply voltage is normal and sensor output voltage is abnormal
ometer 2 (Internal disconnection) (below 0.5 V), internal disconnection and ground fault cannot be identified.
2
or ground fault In this case, go to cause 4.
If check result of cause 4 is normal, PCCS lever F-R potentiometer 2 is
defective.
Between TL2 (2) and Sensor
Voltage 1.39 3.61 V
(1) output
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 and TL2, and connect T-adapters to female
side of them.
a If power supply voltage in
cause 1 is normal, this check is
not required. Resistance Max. 1 z
Between PTCN1 (female) (22)
Disconnection in wiring harness and TL2 (female) (4)
3
(open circuit or defective contact) a If power supply voltage on
cause 1 is normal, this check is
not required. Resistance Max. 1 z
Between PTCN1(female) (21) and
TL2 (female) (1)
Between PTCN1(female) (14) and
Resistance Max. 1 z
TL2 (female) (2)
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 and TL2, and connect T-adapter to female
side of either of them.
Ground fault of wiring harness Between PTCN1 (female) (14)
4
(Contact with ground circuit) and (21), or between TL2 (female) Resistance Min. 1 Mz
(2) and (1)
Between (female) (14) and ground
, or between TL2 (female) (2) and Resistance Min. 1 Mz
ground

40-460 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DK57KA] FR lever 2: Disconnection

Cause Procedure, measuring location, criteria and remarks


If cause is not found by the above checks, power train controller is defective.
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
5 Defective power train controller 2. Insert T-adapter into connector PTCN1.
3. Turn starting switch to ON position.
4. Operate PCCS lever (F-R) and troubleshoot.
Between PTCN1 (14) and (21) Voltage 1.39 3.61 V

Circuit diagram related to Front/Rear potentiometer 40-461

D375A-6R 40-461
(01)
Troubleshooting by failurecode
Failure code [DK57KB] FR lever 2: Short circuit

Failure code [DK57KB] FR lever 2: Short circuit 40-462


Action code Failure code Front/Rear potentiometer 2: Short circuit
Failure
(Power train controller system)
E03 DK57KB
Detail of failure q Signal voltage of PCCS lever F-R potentiometer 2 (F/R lever 4) is above 4.5 V.
Action of con- q Continues control with signal of PCCS lever F-R potentiometer 1 (F/R lever 3).
troller q Limits operation of engine and transmission.
Problem on q Once machine stops, engine speed is limited to medium (half).
machine q Once machine stops, travel is limited to F1 and R1.
q Signal voltage of PCCS lever F-R potentiometer 2 can be checked with monitoring function.
Related infor- (Code: 50201 T/M Lever 2 Potentio)
mation q Method of reproducing failure code:Turn starting switch to ON position and operate PCCS lever (in
F-R direction).

Cause Procedure, measuring location, criteria and remarks


Defective sensor 5 V power sup-
1 If failure code [DBE5KK] is also displayed, troubleshoot it first.
ply system
1. Turn starting switch to OFF position.
2. Disconnect connector TL2.
3. Turn starting switch to ON position.
Defective PCCS lever F-R potenti-
4. Operate PCCS lever (F-R) and troubleshoot.
ometer 2 (Internal disconnection)
2 If failure code [DK57KB]is not displayed, PCCS lever F-R potentiometer is
or ground fault
defective. (If failure code [DK57KB] is still displayed, wiring harness or power
train controller is defective.)
a Since connector TL2 is disconnected, many failure codes are displayed. Ig-
nore all displayed failure codes other than [DK57KB].
1. Turn starting switch to OFF position.
2. Disconnect connector TL2 and connect T-adapter to female side.
Hot short of wiring harness (Con- 3. Turn starting switch to ON position.
3
tact with 24 V circuit)
Between TL2 (female) (2) and (1)
Voltage Max. 1 V
or ground
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 and TL2, and connect T-adapter to female
side of PTCN1.
4 Short circuit in wiring harness a Check with tester in continuity mode.
Between PTCN1 (female) (14)
No continuity (No sound is heard)
and each pin other than (14)
If cause is not found by the above checks, power train controller is defective.
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
5 Defective power train controller 2. Insert T-adapter into connector PTCN1.
3. Turn starting switch to ON position.
4. Operate PCCS lever (F-R) and troubleshoot.
Between PTCN1 (14) and (21) Voltage 1.393.61 V

40-462 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DK57KB] FR lever 2: Short circuit

Circuit diagram related to forward-reverse potentiometer 40-463

D375A-6R 40-463
(01)
Troubleshooting by failurecode
Failure code [DK60KA] Acceleration sensor: Disconnection

Failure code [DK60KA] Acceleration sensor: Disconnection 40-464


Action code Failure code Acceleration sensor: Disconnection
Failure
(Power train controller system)
E01 DK60KA
Detail of failure q Signal voltage of acceleration sensor is below 0.5 V.
Action of con-
q Turns shoe slip control(SSC) function OFF.
troller
Problem on
q Even if shoe slips, engine speed does not change.
machine
q Input (voltage) from acceleration sensor can be checked in moniitoring function.
Related infor-
(Code: 60200 : Voltage of acceleration sensor)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

If failure code [DBB7KP] is also displayed, troubleshoot it first.

1. Turn starting switch to OFF position.


Defective 5 V power supply sys- 2. Disconnect connector SSA and connect T-adapter to female side.
1
tem 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to cause 3 or after.
Between SSA(female)(1)
Power supply Voltage 4.5 5.5 V
and (3)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connectorSSA.
3. Turn starting switch to ON position.
Defective acceleration sensor a If power supply voltage is normal and sensor output voltage is abnormal
2 sensor (Internal disconnection) or (below 0.5 V), internal disconnection and ground fault cannot be identified.
ground fault In this case, go to cause 4. If check result of cause 4 is normal, acceleration
sensor sensor is defective.
Between SSA (female) (2)
Sensor output Voltage 0.75 4.25 V
and (3)
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN1, PTCN3 and SSA, and connect T-adapters to
female side of them.
a If power supply voltage in cause 1 is nor-
mal, this check is not required.
Resistance Max. 1 z
Disconnection in wiring harness Between PTCN3 (female) (34) and SSA
3 (Open circuit in wiring or defective (female) (1)
contact in connector) a If power supply voltage in cause 1 is nor-
mal, this check is not required.
Resistance Max. 1 z
Between PTCN 1(female) (21) and SSA
(female) (3)
Between PTCN1 (female) (1) and SSA
Resistance Max. 1 z
(female) (2)
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN1, SSA, and connect T-adapter to female side
of either of them.
Ground fault of wiring harness
4 Between PTCN1 (female) (1) and (21), or
(Contact with ground circuit) Resistance Max. 1 Mz
between SSA (female) (2) and (3)
Between PTCN1 (female) (1) and ground, or
Resistance Max. 1 Mz
between SSA (female) (2) and ground

40-464 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DK60KA] Acceleration sensor: Disconnection

Cause Procedure, measuring location, criteria and remarks


If cause is not found by the above checks, power train controller is defective.
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
5 Defective power train controller 2. Insert T-adapter into connector PTCN1.
3. Turn starting switch to ON position.
Between PTCN1 (1) and (21) Voltage 0.75 4.25 V

Circuit diagram related to acceleration sensor 40-465

D375A-6R 40-465
(01)
Troubleshooting by failurecode
Failure code [DK60KB] Acceleration sensor: Short circuit

Failure code [DK60KB] Acceleration sensor: Short circuit 40-46


Action code Failure code Acceleration sensor: Short circuit
Failure
(Power train controller system)
E01 DK60KB
Detail of failure q Signal voltage of acceleration sensor is above 4.5 V.
Action of con-
q Turns shoe slip control(SSC) function OFF.
troller
Problem on
q Even if shoe slips, engine speed does not change.
machine
q Input (voltage) from acceleration sensor can be checked in moniitoring function.
Related infor-
(Code: 60200 : Voltage of acceleration sensor)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

If failure code [DBB7KP] is also displayed, troubleshoot it first.

1. Turn starting switch to OFF position.


Defective sensor 5 V power sup- 2. Disconnect connector SSA and connect T-adapter to female side.
1
ply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to cause 3 or after.
Between SSA (female) (1)
Power supply Voltage 4.5 5.5 V
and (3)
1. Turn starting switch to OFF position.
2. Disconnect connector SSA.
Defective acceleration sensor 3. Turn starting switch to ON position.
2 sensor (Internal disconnection) or
ground fault If failure code [DK60KB] is not displayed , acceleration sensor is defective. (If
failure code [DK60KB] is still displayed, it shows that wiring harness or power
train controller is defective.)
1. Turn starting switch to OFF position.
Hot short in wiring harness 2. Disconnect connector SSA and connect T-adapter to female side.
3 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between SSA (female) (2) and (3) or ground Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN1 and SSA, and connect T-adapter to female
side of PTCN1.
4 Short circuit in wiring harness
a Check with tester in continuity mode.
Between PTCN1 (female) (1) and (1) and No continuity(No sound is
each pin other than heard)
If cause is not found by the above checks, power train controller is defective.
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
5 Defective power train controller 2. Insert T-adapter into connector PTCN1.
3. Turn starting switch to ON position.
Between PTCN1 (1) and (21) Voltage 0.75 4.25 V

40-466 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DK60KB] Acceleration sensor: Short circuit

Circuit diagram related to acceleration sensor 40-467

D375A-6R 40-467
(01)
Troubleshooting by failurecode
Failure code [DKH1KA] Pitch angle sensor: Disconnection

Failure code [DKH1KA] Pitch angle sensor: Disconnection 40-468


Action code Failure code Pitch angle sensor: Disconnection
Failure
(Power train controller system)
E03 DKH1KA
Detail of failure q Signal voltage of inclination angle sensor is below 0.15 V.
Action of con- q Cannot sense pitch angle of machine.
troller q Limits operation of engine and transmission.
q Gearshift shock is made on slope or steering shock is made on level ground.
Problem on
q Once machine is stopped, engine speed is limited to medium (half).
machine
q Once machine is stopped, travel is limited to F1 and R1.
q State of pitch angle sensor signal can be checked with monitoring function.
Related infor- (Code: 60100 Pitch Angle Sensor)
mation q Method of reproducing failure code: Turn starting switch to ON position.
q If sensor connector is disconnected in normal condition, this code is displayed.

Cause Procedure, measuring location, criteria and remarks

If failure code [DBE6KK] is also displayed, troubleshoot it first.

1. Turn starting switch to OFF position.


Defective 24 V power supply sys- 2. Disconnect connector PT1 and connect T-adapter to female side.
1
tem 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to cause 3 or after.
Between PT1 (female) (C)
Power supply Voltage 20 30 V
and (A)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PT1.
3. Turn starting switch to ON position.
a If power supply voltage is normal and sensor output voltage is abnormal
Defective pitch angle sensor
2 (below 0.5 V), internal disconnection and ground fault cannot be identified.
(Internal defect) or ground fault
In this case, go to cause 4.
If check result of cause 4 is normal, pitch angle sensor is defective.
Between PT1 (female) (B)
Sensor output Voltage 0.24 4.76 V
and (A)
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 and PT1, and connect T-adapters to female
side of them.
a If power supply voltage in cause 1 is nor-
mal, this check is not required.
Resistance Max. 1 z
Open circuit in wiring harness Between PTCN3 (female) (16) and PT1
3 (Open circuit in wiring or defective (female) (C)
contact in connector) a If power supply voltage in cause 1 is nor-
mal, this check is not required.
Resistance Max. 1 z
Between PTCN1(female) (21) and PT1
(female) (A)
Between PTCN1 (female) (9) and PT1
Resistance Max. 1 z
(female) (B)
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN1 and PT1, and connect T-adapters to female
side of either of them.
Ground fault in wiring harness
4 Between PTCN1 (female) (9) and (21), or
(Contact with ground circuit) Resistance Max. 1 Mz
between PT1 (female) (B) and (A)
Between PTCN1 (female) (9) and ground, or
Resistance Max. 1 Mz
between PT1 (female) (B) and ground

40-468 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DKH1KA] Pitch angle sensor: Disconnection

Cause Procedure, measuring location, criteria and remarks


If cause is not found by the above checks, power train controller is defective.
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
5 Defective power train controller 2. Insert T-adapter into connector PTCN1.
3. Turn starting switch to ON position.
Between PTCN1 (9) and (21) Voltage 0.24 4.76 V

Circuit diagram related to inclination angle sensor 40-469

D375A-6R 40-469
(01)
Troubleshooting by failurecode
Failure code [DKH1KB] Pitch angle sensor: Short circuit

Failure code [DKH1KB] Pitch angle sensor: Short circuit 40-470


Action code Failure code Pitch angle sensor: Short circuit
Failure
(Power train controller system)
E03 DKH1KB
Detail of failure q Signal voltage of inclination angle sensor is above 4.85 V.
Action of con- q Cannot sense pitch angle of machine.
troller q Limits operation of engine and transmission.
q Gearshift shock is made on slope or steering shock is made on level ground.
Problem on
q Once machine stops, engine speed is limited to medium (half).
machine
q Once machine stops, travel is limited to F1 and R1.
q State of pitch angle sensor signal can be checked with monitoring function.
(Code: 60100 Pitch Angle Sensor)
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation
q If the sensor connector is disconnected in the normal condition and turn starting switch to ON po-
sition, failure code [DHT5KA] is displayed.

Cause Procedure, measuring location, criteria and remarks

If failure code [DBE6KK] is also displayed, troubleshoot it first.

1. Turn starting switch to OFF position.


Defective sensor 24 V power sup- 2. Disconnect connector PT1 and connect T-adapter to female side.
1
ply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to cause 3 or after.
Between PT1 (female) (C)
Power supply Voltage 20 30 V
and (A)
1. Turn starting switch to OFF position.
2. Disconnect connector PT1.
3. Turn starting switch to ON position.
Defective pitch angle sensor
2 If failure code [DKH1KB] is not displayed but [DKH1KA] of disconnection is
(Internal defect)
displayed, pitch angle sensor is defective.
(If failure code [DKH1KB] is still displayed, it shows that wiring harness or
power train controller is defective.)
1. Turn starting switch to OFF position.
Hot short in wiring harness 2. Disconnect connector PT1 and connect T-adapter to female side.
3 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between PT1 (female) (B) and (A) or ground Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN1 and PT1, and connect T-adapter to female
side of
4 Short circuit in wiring harness
a Check with tester in continuity mode.
Between PTCN1 (female ) (9) and each pin No continuity (No sound is
other than (9) heard)
If cause is not found by the above checks, power train controller is defective.
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
5 Defective power train controller 2. Insert T-adapter into connector PTCN1.
3. Turn starting switch to ON position.
Between PTCN1 (9) and (21) Voltage 0.24 4.76 V

40-470 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DKH1KB] Pitch angle sensor: Short circuit

Circuit diagram related to inclination angle sensor 40-471

D375A-6R 40-471
(01)
Troubleshooting by failurecode
Failure code [DLF1KA] T/C out-speed sensor: Disconnection

Failure code [DLF1KA] T/C out-speed sensor: Disconnection 40-472


Action code Failure code Torque converter oil temperature sensor disconnection
Failure
(Power train controller system)
DLF1KA
Detail of failure q No signal is input from torque converter output speed sensor.
Action of con-
q Recognizes that torque converter output speed is 0 rpm.
troller
Problem on
q Torque converter output speed cannot be monitored
machine
Related infor- q Method of reproducing failure code:Turn starting switch to ON position and travel (travel machine
mation or run tracks in the air with machine body put on the stands).

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective torque converter output 2. Disconnect connector C1 and connect T-adapter to male side.
1 shaft speed sensor (Internal open Approx.
Between TC1 (male) (1) and (2) Resistance
or short circuit) 560 z
Between TC1 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN2 and connect T-adapter to female side.
Open or short circuit in wiring har- a If resistance is above 1 Mz, wiring harness has disconnection. If resistance
2
ness is below 1 z, wiring harness has short circuit.
Approx.
Between PTCN2 (female) (29) and (20) Resistance
560 z
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN2 and TC1, and connect T-adapters to female
Open circuit in wiring harness
3 side of them.
(open circuit or defective contact)
Between PTCN2 (female) (29) and TC1 (female) (2) Resistance Max. 1 z
Between PTCN2 (female) (20) and TC1 (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector TC1 and connect T-adapter to female side.
4 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between TC1 (female) (1) and (2) Voltage 34V
If cause is not found by above checks, power train controller may be defective.
5 Defective power train controller
(Since failure is in it, troubleshooting cannot be performed.)

Circuit diagram related to torque converter output speed sensor 40-472

40-472 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DLF1KA] T/C out-speed sensor: Disconnection

D375A-6R 40-473
(01)
Troubleshooting by failurecode
Failure code [DLM3KA] Fan rev. sensor: Disconnection

Failure code [DLM3KA] Fan rev. sensor: Disconnection 40-474


Action code Failure code Fan speed sensor: Disconnection
Failure
(Work equipment controller system)
E02 DLM3KA
Detail of failure q No signal is input from the fan speed sensor.
Action of con-
q Recognizes that fan speed is 0 rpm.
troller
Problem on q The fan speed cannot be monitored.
machine q Fan PID control cannot be started.
q The fan speed can be checked with the monitoring function.
Related infor-
(Code: 10007 Fan speed)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector FRV and connect T-adapter to male side.
Defective fan speed sensor (Inter- Approx.
1 Between FRV (male) (1) and (2) Resistance
nal open circuit or short circuit) 2 kz
Between FRV (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector WECN2 and connect T-adapter to female side.
Open or short circuit in wiring har- a If resistance is above 1 Mz, wiring harness has disconnection. If resistance
2
ness is below 1 z, wiring harness has short circuit.
Approx.
Between WECN2 (female) (40) and (39) Resistance
2 kz
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors WECN2 and FRV, and connect T-adapters to
Open circuit in wiring harness female side of them.
3
(open circuit or defective contact) Between WECN2 (female) (39) and FRV (female)
Resistance Max. 1 z
(2)
Between WECN2 (female) (40) and FRV (female)
Resistance Max. 1 z
(1)
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector FRV and connect T-adapter to female side.
4 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between FRV (female) (1) and (2) Voltage 34V
Defective work equipment control- If cause is not found by above checks, work equipment controller may be
5
ler defective. (Since failure is in it, troubleshooting cannot be performed.)

40-474 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DLM3KA] Fan rev. sensor: Disconnection

Circuit diagram related to fan speed sensor 40-475

D375A-6R 40-475
(01)
Troubleshooting by failurecode
Failure code [DLM3MB] Fan control: Decline

Failure code [DLM3MB] Fan control: Decline 40-476


Action code Failure code Fan speed control function low
Failure
(Work equipment controller system)
E02 DLM3MB
q Difference between fan speed set value with work equipment controller and actual speed sensed
Detail of failure
by fan speed sensor exceeds 100 rpm.
Action of con-
q Work equipment controller does not perform PID control on fan.
troller
Problem on
machine
q Fan speed set value with work equipment controller can be checked with monitoring function.
(Code: 10000 Fan speed command)
Related infor- q Fan speed sensed by fan speed sensor can be checked with monitoring function.
mation (Code: 10007 Fan speed)
q This code is conditioned that fan solenoid is normal and fan speed sensor is also normal (it means
normal electrically).

Cause Procedure, measuring location, criteria and remarks


1 Defective hydraulic system Perform Testing and adjusting, "Testing fan hydraulic circuit".

40-476 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DLT3KA] T/M out-speed sensor: Disconnection

Failure code [DLT3KA] T/M out-speed sensor: Disconnection 40-47


Action code Failure code Transmission output speed sensor: Disconnection
Failure
(Power train controller system)
E01 DLT3KA
Detail of failure q No signal is input from transmission output speed sensor.
Action of con-
q Recognizes that transmission output speed is 0 rpm.
troller
q Transmission output speed cannot be monitored.
Problem on q Traction force cannot be calculated.
machine q Automatic shift down function does not operate.
q Once machine is stopped, gear shift mode is limited to manual gear shift mode.
q Transmission output speed can be checked with monitoring function.
Related infor- (Code: 31400 T/M Out Speed)
mation q Method of reproducing failure code: Turn starting switch to ON position and travel (travel machine
or run tracks in the air with machine body put on the stands).

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective transmission bevel gear 2. Disconnect connector TM1 and connect T-adapter to male side.
1 (output) speed sensor (Internal Approx.
Between TM1 (male) (1) and (2) Resistance
disconnection or short circuit) 560 z
Between TM1 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN2 and connect T-adapter to female side.
Open or short circuit in wiring har- a If resistance is above 1 Mz, wiring harness has disconnection. If resistance
2
ness is below 1 z, wiring harness has short circuit.
Approx.
Between PTCN2 (female) (39) and (30) Resistance
560 z
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN2 and TM1, and connect T-adapters to female
Open circuit in wiring harness
3 side of them.
(open circuit or defective contact)
Between PTCN2 (female) (39) and TM1 (female) (2) Resistance Max. 1 z
Between PTCN2 (female) (30) and TM1(female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector TM1 and connect T-adapter to female side.
4 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between TM1 (female) (1) and (2) Voltage 34V
If cause is not found by above checks, power train controller may be defective.
5 Defective power train controller
(Since failure is in it, troubleshooting cannot be performed.)

Circuit diagram related to transmission output speed sensor 40-47

D375A-6R 40-477
(01)
Troubleshooting by failurecode
Failure code [DLT3KB] T/M out-speed sensor: Abnormal

Failure code [DLT3KB] T/M out-speed sensor: Abnormal 40-478


Action code Failure code Transmission output speed sensor: Disconnection
Failure
(Power train controller system)
E01 DLT3KB
Detail of failure q No signal is input from transmission output speed sensor
Action of con-
q Recognizes that transmission output speed is 0 rpm.
troller
q Transmission output speed cannot be monitored
Problem on q Traction force cannot be calculated.
machine q Automatic shift down function may not operate correctly.
q Once machine stops, gear shift mode is limited to manual gear shift mode.
q Transmission output speed sensor can be checked with moniitoring function.
Related infor- (Code: 31400 T/M Out Speed)
mation q Method of reproducing failure code:Turn starting switch to ON position and travel (travel machine
or run tracks in the air with machine body put on the stands).

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective transmission bevel gear 2. Disconnect connector TM1 and connect T-adapter to male side.
1 (output) speed sensor (Internal Approx.
Between TM1 (male) (1) and (2) Resistance
disconnection or short circuit) 560 z
Between TM1 (male)(1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN2 and connect T-adapter to female side.
Disconnection or short circuit in a If resistance is above 1 Mz, wiring harness has disconnection. If resistance
2
wiring harness is below 1 z, wiring harness has short circuit.
Approx.
Between PTCN2 (female) (39) and (30) Resistance
560 z
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN2 and TM1, and connect T-adapter to female
Ground fault of wiring harness
3 side of either of them.
(Contact with ground circuit)
Between PTCN2 (female) (30) or TM1 (female) (1)
Resistance Min. 1 Mz
and ground
If cause is not found by the above checks, power train controller may be defec-
4 Defective power train controller
tive. (Since failure is in it, troubleshooting cannot be performed.)

Circuit diagram related to transmission output speed sensor 40-478

40-478 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DW59KA] Blade dual selector SOL disconnection

Failure code [DW59KA] Blade dual selector SOL disconnection 40-479


Action code Failure code Dual tilt selector solenoid: Disconnection
Failure
(Work equipment controller system)
E01 DW59KA
Detail of failure q Any current does not flow when power is output to the dual tilt selector solenoid circuit.
Action of con-
q Stops output to dual tilt selector solenoid circuit.
troller
Problem on
q Dual tilt cannot be selector.
machine
Related infor- q Method of reproducing failure code:Turn starting switch to ON position and operate dual tilt selector
mation switch.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective dual tilt selector sole- 2. Disconnect connector SOL2 and connect T-adapter to male side.
1
noid (Internal disconnection)
SOL2 (male) (1) and (2) Resistance 10 40 z
1. Turn starting switch to OFF position.
2. Disconnect connector WECN3 and connect T-adapter to female side.
Disconnection or short circuit in a If resistance is above 1 Mz, wiring harness has disconnection. If resistance
2
wiring harness is below 1 z, wiring harness has short circuit.
Between WECN3 (female) (7) and (23) Resistance 10 40 z
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector WECN3 and SOL2, and connect T-adapters to
Disconnection in wiring harness
female side of them.
3 (Open circuit in wiring or defective
Between WECN3 (female) (7) and SOL2 (female)
contact in connector) Resistance Max. 1 z
(1)
Between WECN3 (female) (23) and SOL2 (female)
Resistance Max. 1 z
(2)
Defective work equipment control- If cause is not found by the above checks, work equipmet controller may be
4
ler defective. (Since failure is in it, troubleshooting cannot be performed.)

Circuit diagram related to dual tilt selector solenoid 40-479

D375A-6R 40-479
(01)
Troubleshooting by failurecode
Failure code [DW59KB] Blade dual selector SOL short circuit

Failure code [DW59KB] Blade dual selector SOL short circuit 40-480
Action code Failure code Dual tilt selector solenoid: Short circuit
Failure
(Work equipment controller system)
E01 DW59KB
Detail of failure q Abnormal current flowed when power is output to dual tilt selector solenoid circuit.
Action of con-
q Stops output to dual tilt selector solenoid circuit.
troller
Problem on
q Dual tilt cannot be selector.
machine
Related infor- q Method of reproducing failure code:Turn starting switch to ON position and operate dual tilt selector
mation switch.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector OL2 and connect T-adapter to male side.
Defective dual tilt selector sole-
1
noid (Internal short circuit) Between SOL2 (male) (1) and (2) Resistance 10 40 z
Between SOL2 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector WECN3 and SOL2, and connect T-adapters to
Ground fault of wiring harness
2 female side of them.
(Contact with ground circuit)
Between WECN3 (female) (7) or SOL2 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connector WECN3 and SOL2, and connect T-adapters to
3 Short circuit in wiring harness female side of either of them.
Between WECN3 (female) (7) and (23) or between
Resistance Min. 1 Mz
SOL2 (female) (1) and (2)
Defective work equipment control- If cause is not found by the above checks, work equipment controller may be
4
ler defective. (Since failure is in it, troubleshooting cannot be performed.)

Circuit diagram related to dual tilt selector solenoid 40-480

40-480 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DW59KB] Blade dual selector SOL short circuit

D375A-6R 40-481
(01)
Troubleshooting by failurecode
Failure code [DW59KY] Blade dual selector SOL hot short

Failure code [DW59KY] Blade dual selector SOL hot short 40-482
Action code Failure code Dual tilt selector solenoid: Short circuit
Failure
(Work equipment controller system)
E01 DW59KY
Detail of failure q Current flows constantly to dual tilt selector solenoid circuit.
Action of con-
q Stops output to dual tilt selector solenoid circuit.
troller
Problem on q Only tilt can be operated and dual tilt cannot be operated.
machine q Blade single tilt does not operate .
Related infor- q Method of reproducing failure code:Turn starting switch to ON position and operate dual tilt selector
mation switch.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector SOL2 and connect T-adapter to male side.
Defective dual tilt selector sole-
1
noid (Internal short circuit) Between SOL2 (male) (1) and (2) Resistance 10 40 z
Between SOL2 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector SOL2 and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between SOL2 (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connectors WECN3 and SOL2, and connect T-adapter to
female side of WECN3.
a Check with circuit tester in continuity mode.
Between WECN3 (female) (7) and each pin other No continuity (No sound
than (7) is heard.)
1. Turn starting switch to OFF position.
3 Short circuit in wiring harness
2. Disconnect connectors WECN3, RB1 and SOL2, and connect T-adapter to
female side and male side of RB1 in 2 times.
a Check with circuit tester in continuity mode.
Between RB1 (female) (3) and each pin other than No continuity (No sound
(3) is heard.)
No continuity (No sound
Between RB1 (male) (3) and each pin other than (3)
is heard.)
Defective work equipment control- If cause is not found by above checks, work equipment controller may be
4
ler defective. (Since failure is in it, troubleshooting cannot be performed.)

40-482 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DW59KY] Blade dual selector SOL hot short

Circuit diagram related to dual tilt selector solenoid 40-483

D375A-6R 40-483
(01)
Troubleshooting by failurecode
Failure code [DW5AKA] Blade pitch selector SOL disconnection

Failure code [DW5AKA] Blade pitch selector SOL disconnection 40-484


Action code Failure code Work equipment pitch select solenoid: Disconnection
Failure
(Work equipment controller system)
E02 DW5AKA
Detail of failure q No current flows when power is output to the work equipment pitch select solenoid circuit.
Action of con-
q Stops output to pitch select solenoid circuit.
troller
Problem on
q Blade pitch cannot be changed.
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position and operate pitch selector
mation switch.

Cause Procedure, measuring location, criteria and remarks

Defective work equipment pitch 1. Turn starting switch to OFF position.


1 select solenoid (Internal discon- 2. Disconnect connector SOL1 and connect T-adapter to male side.
nection) Between SOL1 (male) (1) and (2) Resistance 10 40 z
1. Turn starting switch to OFF position.
2. Disconnect connector WECN3 and connect T-adapter to female side.
Open or short circuit in wiring har- a If resistance is above 1 Mz, wiring harness has disconnection. If resistance
2
ness is below 1 z, wiring harness has short circuit.
Between WECN3 (female) (17) and (23) Resistance 10 40 z
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector WECN3 and SOL1, and connect T-adapters to
Open circuit in wiring harness
female side of them.
3 (Open circuit in wiring or defective
Between WECN3 (female) (17) and SOL1 (female)
contact in connector) Resistance Max. 1 z
(1)
Between WECN3 (female) (23) and SOL1 (female)
Resistance Max. 1 z
(2)
Defective work equipment control- If cause is not found by the above checks, work equipmet controller may be
4
ler defective. (Since failure is in it, troubleshooting cannot be performed.)

Circuit diagram related to work equipment pitch select solenoid 40-484

40-484 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DW5AKB] Blade pitch selector SOL short circuit

Failure code [DW5AKB] Blade pitch selector SOL short circuit 40-485
Action code Failure code Work equipment pitch select solenoid: Short circuit
Failure
(Work equipment controller system)
E02 DW5AKB
Detail of failure q Abnormal current flowed when power was output to work equipment pitch select solenoid circuit.
Action of con-
q Stops output to pitch select solenoid circuit.
troller
Problem on
q Blade pitch cannot be changed.
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position and operate pitch selector
mation switch.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective work equipment pitch 2. Disconnect connector SOL1 and connect T-adapter to male side.
1 select solenoid (Internal short cir-
Between SOL1 (male) (1) and (2) Resistance 10 40 z
cuit)
Between SOL1 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector WECN3 and SOL1, and connect T-adapter to female
Short circuit in wiring harness side of either of them.
2
(Contact with ground circuit)
WECN3 (female) (17) or SOL1 (female) (1) and
Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector WECN3 and SOL1, and connect T-adapter to female
3 Short circuit in wiring harness side of either of them.
Between WECN3 (female) (17) and (23) or between
Resistance Min. 1 Mz
SOL1 (female) (1) and (2)
Defective work equipment control- If cause is not found by the above checks, work equipmet controller may be
4
ler defective. (Since failure is in it, troubleshooting cannot be performed.)

Circuit diagram related to work equipment pitch select solenoid 40-485

D375A-6R 40-485
(01)
Troubleshooting by failurecode
Failure code [DW5AKY] Blade pitch selector SOL Short circuit

Failure code [DW5AKY] Blade pitch selector SOL Short circuit 40-486
Action code Failure code Work equipment pitch select solenoid: Short circuit
Failure
(Work equipment controller system)
E02 DW5AKY
Detail of failure q Current flows constantly to work equipment pitch select solenoid circuit.
Action of con-
q Stops output to pitch select solenoid circuit.
troller
Problem on
q Only pitch operation can be changed and tilt operation cannot be changed.
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position and operate pitch selector
mation switch.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective work equipment pitch 2. Disconnect connector SOL1 and connect T-adapter to male side.
1 select solenoid (Internal short cir-
Between SOL1 (male) (1) and (2) Resistance 10 40 z
cuit)
Between SOL1 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector SOL1 and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between SOL1 (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connector WECN3 and SOL1 and connect T-adapter to female
side of WECN3.
a Check with multimeter in continuity mode.
Between WECN3 (female) (17) and each pin other No continuity (No sound
than (17) is heard.)
1. Turn starting switch to OFF position.
3 Short circuit in wiring harness
2. Disconnect connectors WECN3, RB1 and SOL1, and connect T-adapter to
female side and male side of RB1 separately in 2 times
a Check with multimeter in continuity mode.
Between RB1 (female) (1) and each pin other than No continuity (No sound
(1) is heard.)
No continuity (No sound
Between RB1 (male) (1) and each pin of (1)
is heard.)
Defective work equipment control- If cause is not found by the above checks, work equipmet controller may be
4
ler defective. (Since failure is in it, troubleshooting cannot be performed.)

40-486 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DW5AKY] Blade pitch selector SOL Short circuit

Circuit diagram related to work equipment pitch selector solenoid 40-487

D375A-6R 40-487
(01)
Troubleshooting by failurecode
Failure code [DW7BKA] Fan rev EPC: Disconnection

Failure code [DW7BKA] Fan rev EPC: Disconnection 40-48


Action code Failure code Fan reverse solenoid: Disconnection
Failure
(Work equipment controller system)
E01 DW7BKA
Detail of failure q When power is output to fan reverse solenoid circuit, no current flows.
Action of con-
q Stops output to fan reverse solenoid circuit.
troller
Problem on
q Fan reverse function cannot be used.
machine
q Output condition to fan reverse solenoid can be checked with monitoring function.
Related infor- (Code: 40983 W/E control SW output)
mation q Method of reproducing failure code:Turn starting switch to ON position and select fan reverse
mode.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective fan reverse solenoid 2. Disconnect connector FAR2 and connect T-adapter to male side.
1
(Internal disconnection)
Between FAR2 (male) (1) and (2) Resistance 34 44 z
1. Turn starting switch to OFF position.
2. Disconnect connector WECN3 and connect T-adapter to female side.
Disconnection or short circuit in a If resistance is above 1 Mz, wiring harness has disconnection. If resistance
2
wiring harness is below 1 z, wiring harness has short circuit.
Between WECN3 (female) (18) amd (13) Resistance 34 44 z
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector WECN3 and FAR2, and connect T-adapters to their
Disconnection in wiring harness
female sides.
3 (Open circuit in wiring or defective
Between WECN3 (female) (18) and FAR2 (female)
contact in connector) Resistance Max. 1 z
(1)
Between WECN3 (female) (13) and FAR2 (female)
Resistance Max. 1 z
(2)
1. Turn starting switch to OFF position.
Hot short in wiring harness 2. Disconnect connector FAR2 and connect T-adapter to female side.
4 3. Turn starting switch ON position.
(Contact with 24 V circuit)
Between FAR2 (female) (1) and ground Voltage Max. 1 V
Defective work equipment control- If cause is not found by the above checks, work equipment controller may be
5
ler defective. (Since failure is in it, troubleshooting cannot be performed.)

Circuit diagram related to fan reverse EPC 40-48

40-488 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DW7BKB] Fan rev EPC: Short circuit

Failure code [DW7BKB] Fan rev EPC: Short circuit 40-489


Action code Failure code Fan reverse solenoid: Short circuit
Failure
(Work equipment controller system)
E01 DW7BKB
Detail of failure q When power was output to fan reverse solenoid circuit, abnormal current flowed.
Action of con-
q Stops output to fan reverse solenoid circuit.
troller
Problem on
q Fan reverse function cannot be used.
machine
q Output condition of fan reverse solenoid can be checked with monitoring function.
Related infor- (Code: 40983 W/E control SW output)
mation q Method of reproducing failure code:Turn starting switch to ON position and select fan reverse
mode.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector FAR2 and connect T-adapter to male side.
Defective fan reverse solenoid
1
(Internal short circuit) Between FAR2 (male) (1) and (2) Resistance 34 44 z
Between FAR2 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector WECN3 and FAR2, and connect T-adapter to female
Ground fault of wiring harness side of either of them.
2
(Contact with GND circuit)
Between WECN3 (female) (18) or FAR2 (female)
Resistance Min. 1 Mz
(1) or ground
1. Turn starting switch to OFF position.
2. Disconnect connector WECN3 and FAR2, and connect T-adapter to female
3 Short circuit in wiring harness side of either of them.
Between WECN3 (female) (18) and (13) or betwen
Resistance Min. 1 Mz
FAR2 (female) (1) and (2)
Defective work equipment control- If cause is not found by the above checks, work equipment controller may be
4
ler defective. (Since failure is in it, troubleshooting cannot be performed.)

Circuit diagram related to fan reverse EPC 40-489

D375A-6R 40-489
(01)
Troubleshooting by failurecode
Failure code [DWN3KA] Ssp solenoid: Disconnection

Failure code [DWN3KA] Ssp solenoid: Disconnection 40-490


Action code Failure code Sudden stop prevention solenoid disconnection
Failure
(Power train controller system)
E04 DWN3KA
Detail of failure q When power is output to sudden stop prevention solenoid circuit, no current flows.
Action of con- q Stops output to sudden stop prevention solenoid circuit.
troller q Restricts operations of engine, transmission, and brake.
Problem on q Once machine is stopped, engine speed is restricted to medium (half).
machine q Once machine is stopped, it becomes impossible to travel.
q Output condition to sudden stop prevention solenoid can be checked with monitoring function.
Related infor-
(Code: 31628 Sudden stop prevention valve current (F/B))
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective sudden stop prevention 1. Turn starting switch to OFF position.


1 solenoid 2. Disconnect connector STB and connect T-adapter to male side.
(internal open circuit) Between STB (male) (1) and (2) Resistance 5 15 z
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN3 and connect T-adapter to female side.
Open or short circuit in wiring har- a If resistance is above 1 Mz, wiring harness has disconnection. If resistance
2
ness is below 1 z, wiring harness has short circuit.
Between PTCN3 (female) (7) and (13) Resistance 5 15 z
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors PTCN3 and STB, and connect T-adapters to their
3 (Open circuit in wiring or defective female sides.
contact in connector) Between PTCN3 (female) (7) and STB (female) (1) Resistance Max. 1 z
Between PTCN3 (female) (13) and STB (female) (2) Resistance Max. 1 z
If cause is not found by above checks, power train controller may be defective.
4 Defective power train controller
(Since failure is in it, troubleshooting cannot be performed.)

40-490 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DWN3KA] Ssp solenoid: Disconnection

Circuit diagram related to sudden stop prevention solenoid 40-491

D375A-6R 40-491
(01)
Troubleshooting by failurecode
Failure code [DWN3KB] Ssp solenoid: Short circuit

Failure code [DWN3KB] Ssp solenoid: Short circuit 40-492


Action code Failure code Sudden stop prevention solenoid short circuit
Failure
(Power train controller system)
E04 DWN3KB
Detail of failure q When power is output to sudden stop prevention solenoid circuit, abnormal current flowed.
Action of con- q Stops output to sudden stop prevention solenoid circuit.
troller q Restricts operations of engine, transmission, and brake.
Problem on q Once machine stops, engine speed is restricted to medium (half).
machine q Once machine is stopped, it becomes impossible to travel.
q Output condition to sudden stop prevention solenoid can be checked with monitoring function.
Related infor-
(Code: 31628 Sudden stop prevention valve current (F/B))
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective sudden stop prevention 2. Disconnect connector STB and connect T-adapter to male side.
1 solenoid
Between STB (male) (1) and (2) Resistance 5 15 z
(Internal short circuit)
Between STB (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN3 and STB, and connect T-adapter to female
Ground fault of wiring harness
2 side of either of them.
(Contact with ground circuit)
Between PTCN3 (female) (7) or STB (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN3 and STB, and connect T-adapter to female
3 Short circuit in wiring harness side of either of them.
Between PTCN3 (female) (7) and (13) ro between
Resistance Min. 1 Mz
STB (female) (1) and (2)
If cause is not found by the above checks, work equipment controller may be
4 Defective power train controller
defective. (Since failure is in it, troubleshooting cannot be performed.)

40-492 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DWN3KB] Ssp solenoid: Short circuit

Circuit diagram related to sudden stop prevention solenoid 40-493

D375A-6R 40-493
(01)
Troubleshooting by failurecode
Failure code [DWN3KY] SSP solenoid: Short circuit

Failure code [DWN3KY] SSP solenoid: Short circuit 40-494


Action code Failure code Sudden stop prevention solenoid short circuit
Failure
(Power train controller system)
E04 DWN3KY
Detail of failure q When power is output to sudden stop prevention solenoid circuit, current flows.
Action of con- q Stops output to sudden stop prevention solenoid circuit.
troller q Restricts operations of engine, transmission, and brake.
q Emergency sudden stop prevention function does not work.
Problem on
q Once machine is stopped, engine speed is limited to medium (half) speed.
machine
q Once machine stops, machine does not travel.
q Output to sudden stop prevention solenoid can be checked with monitoring function
Related infor-
(Code: 31628 Sudden stop prevention valve current (F/B))
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective sudden stop prevention 2. Disconnect connector STB and connect T-adapter to male side.
1 solenoid
Between STB (male) (1) and (2) Resistance 5 15 z
(Internal short circuit)
Between STB (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector STB and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between STB (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN3 and STB, and connect T-adapter to female
side of PTCN3.
a Check with circuit tester in continuity mode.
Between PTCN3 (female) (7) and each pin other No continuity (No sound
than (7) is heard)
1. Turn starting switch to OFF position.
3 Short circuit in wiring harness
2. Disconnect connectors PTCN3, STB, PL2 and PL2, and connect T-adapter
to female side and male side of RB1 separately in 2 times
a Check with circuit tester in continuity mode.
Between PL2 (female) (23) and each pin other than No continuity (No sound
(23) is heard)
Between PL2 (male) (23) and each pin other than No continuity (No sound
(23) is heard)
If cause is not found by the above checks, power train controller may be defec-
4 Defective power train controller
tive. (Since failure is in it, troubleshooting cannot be performed.)

40-494 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DWN3KY] SSP solenoid: Short circuit

Circuit diagram related to sudden stop prevention solenoid 40-495

D375A-6R 40-495
(01)
Troubleshooting by failurecode
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection

Failure code [DWN5KA] Fan pump solenoid 1: Disconnection 40-496


Action code Failure code Fan pump solenoid 1: Disconnection
Failure
(Work equipment controller system)
E01 DWN5KA
Detail of failure q When power is output to fan pump EPC solenoid 1 circuit (LPV90), no current flows.
Action of con-
q Stops output to fan pump EPC solenoid 1 circuit(LPV90).
troller
Problem on
q The output of fan pump(LPV90) is always at maximum speed.
machine
q Output to fan pump EPC solenoid 1 can be checked with monitoring function.
Related infor-
(Code: 31624 Fan pump Solenoid (F/B))
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective fan pump solenoid 1 2. Disconnect connector FA1 and connect T-adapter to male side.
1
(Internal disconnection)
Between FA1 (male) (1) and (2) Resistance 2 12 z
1. Turn starting switch to OFF position.
2. Disconnect connector WECN3 and connect T-adapter to female side.
Disconnection or short circuit in a If resistance is above 1 Mz, wiring harness has disconnection. If resistance
2
wiring harness is below 1 z, wiring harness has short circuit.
Between WECN3 (female) (36) and (23) Resistance 2 12 z
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector WECN3 and FA1, and connect T-adapters to their
Disconnection in wiring harness
female sides.
3 (Open circuit in wiring or defective
Between WECN3 (female) (36) and FA1 (female)
contact in connector) Resistance Max. 1 z
(1)
Between WECN3 (female) (23) and FA1 (female)
Resistance Max. 1 z
(2)
Defective work equipment control- If cause is not found by the above checks, work equipment controller may be
4
ler defective. (Since failure is in it, troubleshooting cannot be performed.)

40-496 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection

Circuit diagram related to fan pump solenoid 1 40-497

D375A-6R 40-497
(01)
Troubleshooting by failurecode
Failure code [DWN5KB] Fan pump solenoid 1: Short circuit

Failure code [DWN5KB] Fan pump solenoid 1: Short circuit 40-498


Action code Failure code Fan pump solenoid 1: Short circuit
Failure
(Work equipment controller system)
E01 DWN5KB
Detail of failure q When power was output to fan pump control solenoid 1 (LPV90)circuit, abnormal current flowed.
Action of con-
q Stops output to fan pump control solenoid 1 (LPV90) circuit.
troller
Problem on
q Output of fan pump solenoid 1 (LPV90) is always at maximum speed.
machine
q Output condition to fan pump control solenoid 1 can be checked with monitoring function.
Related infor-
(Code: 31624 Fan pump Solenoid (F/B))
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective fan pump control sole- 2. Disconnect connector FA1 and connect T-adapter to male side.
1 noid 1
Between FA1 (male) (1) and (2) Resistance 2 12 z
(Internal disconnection)
Between FA1 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector WECN3 and FA1, and connect T-adapter to female
Ground fault of wiring harness
2 side of either of them.
(Contact with ground circuit)
Between WECN3 (female) (36) or FA1 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connector WECN3 and FA1, and connect T-adapter to female
3 Short circuit in wiring harness side of either of them.
Between WECN3 (female) (36) and (23) or between
Resistance Min. 1 Mz
FA1 (female) (1) and (2)
Defective work equipment control- If cause is not found by the above checks, work equipment controller may be
4
ler defective. (Since failure is in it, troubleshooting cannot be performed.)

40-498 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DWN5KB] Fan pump solenoid 1: Short circuit

Circuit diagram related to fan pump solenoid 1 40-49

D375A-6R 40-499
(01)
Troubleshooting by failurecode
Failure code [DWN5KY] Fan pump solenoid 1: Short circuit

Failure code [DWN5KY] Fan pump solenoid 1: Short circuit 40-50


Action code Failure code Fan pump solenoid 1: Short circuit
Failure
(Work equipment controller system)
E02 DWN5KY
Detail of failure q Current flows constantly to fan pump EPC solenoid 1 (LPV90)circuit.
Action of con-
q Stops output to fan pump control solenoid 1 (LPV90) circuit.
troller
Problem on q The output of fan pump (LPV90) is always at minimum speed.
machine q Machine may be overheat.
q Output condition to fan pump control solenoid 1 can be checked with monitoring function.
Related infor-
(Code: 31624 Fan pump Solenoid (F/B))
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective fan pump control sole- 2. Disconnect connector FA1 and connect T-adapter to male side.
1 noid 1
Between FA1 (male) (1) and (2) Resistance 2 12 z
(Internal short circuit)
Between FA1 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector FA1 and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between FA1 (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connector WECN3 and FA1, and connect T-adapter to female
side of WECN3.
a Check with multimeter in continuity mode.
Between WECN3 (female) (36) and each pin other No continuity (No sound
than (36) is heard.)
1. Turn starting switch to OFF position.
3 Short circuit in wiring harness
2. Disconnect connectors WECN3, FA1 and PL3, and connect T-adapter to
female side and male side of PL3 separately in 2 times
a Check with multimeter in continuity mode.
Between PL3 (female) (21) and each pin other than No continuity (No sound
(21) is heard.)
Between PL3 (male) (21) and each pin other than No continuity (No sound
(21) is heard.)
Defective work equipment control- If cause is not found by the above checks, work equipmet controller may be
4
ler defective. (Since failure is in it, troubleshooting cannot be performed.)

40-500 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DWN5KY] Fan pump solenoid 1: Short circuit

Circuit diagram related to fan pump solenoid 1 40-501

D375A-6R 40-501
(01)
Troubleshooting by failurecode
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection

Failure code [DWNCKA] Fan pump solenoid 2: Disconnection 40-502


Action code Failure code Fan pump solenoid 2: Disconnection
Failure
(Work equipment controller system)
E01 DWNCKA
Detail of failure q When power is output to fan pump EPC solenoid 2 (LPV30) circuit, no current flows.
Action of con-
q Stops output to fan pump EPC solenoid 2 circuit.
troller
Problem on
q Fan pump solenoid 2 (LPV30) is always at maximum speed.
machine
q Output condition to fan pump EPC solenoid 2 can be checked with monitoring function.
Related infor-
(Code: 31634 Fan pump Solenoid 2 (F/B))
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective fan pump EPC solenoid 1. Turn starting switch to OFF position.
1 2 2. Disconnect connector FA2 and connect T-adapter to male side.
(internal open circuit) Between FA2 (male) (1) and (2) Resistance 2 12 z
1. Turn starting switch to OFF position.
2. Disconnect connector WECN3 and connect T-adapter to female side.
Open or short circuit in wiring har- a If resistance is above 1 Mz, wiring harness has disconnection. If resistance
2
ness is below 1 z, wiring harness has short circuit.
Between WECN3 (female) (26) and (23) Resistance 2 12 z
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector WECN3 and FA2, and connect T-adapters to their
Open circuit in wiring harness
female sides.
3 (Open circuit in wiring or defective
Between WECN3 (female) (26) and FA2 (female)
contact in connector) Resistance Max. 1 z
(1)
Between WECN3 (female) (23) and FA2 (female)
Resistance Max. 1 z
(2)
Defective work equipment control- If cause is not found by the above checks, work equipment controller may be
4
ler defective. (Since failure is in it, troubleshooting cannot be performed.)

40-502 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection

Circuit diagram related to fan pump solenoid 2 40-503

D375A-6R 40-503
(01)
Troubleshooting by failurecode
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit

Failure code [DWNCKB] Fan pump solenoid 2: Short circuit 40-504


Action code Failure code Fan pump solenoid 2: Short circuit
Failure
(Work equipment controller system)
E01 DWNCKB
Detail of failure q When power is output to fan pump EPC solenoid 2 (LPV30) circuit, abnormal current flows.
Action of con-
q Stops output to fan pump EPC solenoid 2 circuit.
troller
Problem on
q Outputto fan pump solenoid 2 (LPV30) is kept at maximum.
machine
q Output condition to fan pump EPC solenoid 2 can be checked with monitoring function.
Related infor-
(Code: 31634 Fan pump Solenoid 2 (F/B))
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective fan pump EPC solenoid 2. Disconnect connector FA2 and connect T-adapter to male side.
1 2
Between FA2 (male) (1) and (2) Resistance 2 12 z
(Internal disconnection)
Between FA2 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector WECN3 and FA2, and connect T-adapter to female
Ground fault of wiring harness
2 side of either of them.
(Contact with GND circuit)
Between WECN3 (female) (26) or FA2 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connector WECN3 and FA2, and connect T-adapter to female
3 Short circuit in wiring harness side of either of them.
Between WECN3 (female) (26) and (23) or between
Resistance Min. 1 Mz
FA2 (female) (1) and (2)
Defective work equipment control- If cause is not found by the above checks, work equipment controller may be
4
ler defective. (Since failure is in it, troubleshooting cannot be performed.)

40-504 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit

Circuit diagram related to fan pump solenoid 2 40-505

D375A-6R 40-505
(01)
Troubleshooting by failurecode
Failure code [DWNCKY] Fan pump solenoid 2: Short circuit

Failure code [DWNCKY] Fan pump solenoid 2: Short circuit 40-506


Action code Failure code Fan pump solenoid 2: Short circuit
Failure
(Work equipment controller system)
E02 DWNCKY
Detail of failure q Current flows always in fan pump EPC solenoid 2 (LPV30) circuit, no current flows.
Action of con-
q Stops output to fan pump EPC solenoid 2 circuit.
troller
Problem on q Fan pump (LPV30) output is always at minimum speed.
machine q Fan speed does not increase.
q Output condition to fan pump EPC solenoid 2 can be checked with monitoring function.
Related infor-
(Code: 31634 Fan pump Solenoid 2 (F/B))
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective fan pump EPC solenoid 2. Disconnect connector FA2 and connect T-adapter to male side.
1 2
Between FA2 (male) (1) and (2) Resistance 2 12 z
(Internal short circuit)
Between FA2 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short in wiring harness 2. Disconnect connector FA2 and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between FA2 (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connectors WECN3 and FA2, and connect T-adapter to female
side of WECN3.
a Check with circuit tester in continuity mode.
Between WECN3 (female) (26) and each pin other No continuity (No sound
than (26) is heard.)
1. Turn starting switch to OFF position.
3 Short circuit in wiring harness
2. Disconnect connectors WECN3, PL3 and FA2, and connect T-adapter to
female side and male side of PL3 separately in 2 times.
a Check with circuit tester in continuity mode.
Between PL3 (female) (24) and each pin other than No continuity (No sound
(24) is heard.)
Between PL3 (male) (24) and each pin other than No continuity (No sound
(24) is heard.)
Defective work equipment control- If cause is not found by above checks, work equipment controller may be
4
ler defective. (Since failure is in it, troubleshooting cannot be performed.)

40-506 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DWNCKY] Fan pump solenoid 2: Short circuit

Circuit diagram related to fan pump solenoid 2 40-507

D375A-6R 40-507
(01)
Troubleshooting by failurecode
Failure code [DXH1KA] Lock-up ECMV: Disconnection

Failure code [DXH1KA] Lock-up ECMV: Disconnection 40-508


Action code Failure code Lock-up solenoid: Disconnection
Failure
(Power train controller system)
E02 DXH1KA
Detail of failure q When power is output to torque converter lockup clutch ECMV solenoid circuit, no current flows.
Action of con-
q Stops output to torque converter lockup clutch ECMV solenoid circuit.
troller
Problem on
q Torque converter lockup function does not operate.
machine
q Output condition to torque converter lockup clutch ECMV solenoid can be checked with monitoring
Related infor- function.
mation (Code: 31642 L/U ECMV (F/B))
q Method of reproducing failure code:Start engine and travel reverse (in auto gearshift mode).

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective lockup clutch ECMV 2. Disconnect connector SLUC and connect T-adapter to male side.
1
solenoid (Internal disconnection)
Between SLUC (male) (1) and (2) Resistance 3 13 z
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN3 and connect T-adapter to female side.
Disconnection or short circuit in a If resistance is above 1 Mz, wiring harness has disconnection. If resistance
2
wiring harness is below 1 z, wiring harness has short circuit.
Between PTCN3 (female) (16) and (23) Resistance 3 13 z
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN3 and SLUC, and connect T-adapters to their
Disconnection in wiring harness
female sides.
3 (Open circuit in wiring or defective
Between PTCN3 (female) (16) and SLUC (female)
contact in connector) Resistance Max. 1 z
(1)
Between PTCN3 (female) (23) and SLUC (female)
Resistance Max. 1 z
(2)
If cause is not found by the above checks, power train controller may be defec-
4 Defective power train controller
tive. (Since failure is in it, troubleshooting cannot be performed.)

Circuit diagram related to lockup solenoid 40-508

40-508 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXH1KB] Lock-up ECMV: Short circuit

Failure code [DXH1KB] Lock-up ECMV: Short circuit 40-509


Action code Failure code Lock-up solenoid: Short circuit
Failure
(Power train controller system)
E02 DXH1KB
q When power is output to torque converter lockup clutch ECMV solenoid circuit, abnormal current
Detail of failure
flows.
Action of con-
q Stops output to torque converter lockup clutch ECMV solenoid circuit.
troller
Problem on
q Torque converter lockup function does not operate.
machine
q Output condition to torque converter lockup clutch ECMV solenoid can be checked with monitoring
Related infor- function.
mation (Code: 31642 L/U ECMV (F/B))
q Method of reproducing failure code: Start engine and travel reverse (in auto gearshift mode).

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector SLUC and connect T-adapter to male side.
Defective lockup clutch ECMV
1
solenoid (Internal disconnection) Between SLUC (male) (1) and (2) Resistance 3 13 z
Between SLUC (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN3 and SLUC, and connect T-adapter to female
Ground fault of wiring harness
2 side of either of them.
(Contact with ground circuit)
Between PTCN3 (female) (16) or SLUC (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN3 and SLUC, and connect T-adapter to female
3 Short circuit in wiring harness side of either of them.
Between PTCN3 (female) (16) and (23)or between
Resistance Min. 1 Mz
SLUC (female) (1) and (2)
If cause is not found by the above checks, work equipment controller may be
4 Defective power train controller
defective. (Since failure is in it, troubleshooting cannot be performed.)

Circuit diagram related to lock-up solenoid 40-509

D375A-6R 40-509
(01)
Troubleshooting by failurecode
Failure code [DXH1KY] Lock-up ECMV: Short circuit

Failure code [DXH1KY] Lock-up ECMV: Short circuit 40-510


Action code Failure code Lock-up solenoid: Short circuit
Failure
(Power train controller system)
E03 DXH1KY
Detail of failure q Current flows constantly to torque converter lockup clutch ECMV solenoid circuit.
Action of con- q Stops output to torque converter lockup clutch ECMV solenoid circuit.
troller q Limits operation of engine and transmission.
q Torque converter lockup function operates constantly.
Problem on q Engine may stall during travel.
machine q Once machine stops, engine speed is restricted to medium (half).
q Once machine stops, travel is restricted to F1 and R1.
q Output condition to lockup clutch ECMV solenoid can be checked with monitoring function.
Related infor- (Code: 31642 L/U ECMV (F/B))
mation q Method of reproducing failure code: Start engine and travel in auto gearshift mode (while lockup is
in operation).

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector SLUC and connect T-adapter to male side.
Defective lockup clutch ECMV
1
solenoid (Internal disconnection) Between SLUC (male) (1) and (2) Resistance 3 13 z
Between SLUC (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short in wiring harness 2. Disconnect connector SLUC and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between SLUC (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN3 and SLUC, and connect T-adapter to female
side of PTCN3.
a Check with tester in continuity mode.
Between PTCN3 (female) (16) and each pin other No continuity (No sound
than (16) is heard)
1. Turn starting switch to OFF position.
3 Short circuit in wiring harness
2. Disconnect connector PTCN1 to 3 and SLUC, and connect T-adapter to
female side of PTCN1 to 3.
a Check with tester in continuity mode.
Between PTCN3 (female) (16) and each pin of No continuity (No sound
PTCN1 (female) is heard)
Between PTCN3 (female) (16) and each pin of No continuity (No sound
PTCN2 (female) is heard)
If cause is not found by the above checks, work equipment controller may be
4 Defective power train controller
defective. (Since failure is in it, troubleshooting cannot be performed.)

40-510 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXH1KY] Lock-up ECMV: Short circuit

Circuit diagram related to lock-up solenoid 40-51

D375A-6R 40-511
(01)
Troubleshooting by failurecode
Failure code [DXH4KA] 1st clutch ECMV: Disconnection

Failure code [DXH4KA] 1st clutch ECMV: Disconnection 40-512


Action code Failure code 1st clutch ECMV: Disconnection
Failure
(Power train controller system)
E03 DXH4KA
Detail of failure q When power is output to transmission 1st clutch ECMV solenoid circuit, no current flows.
Action of con- q Stops output to transmission 1st clutch ECMV solenoid circuit.
troller q Restricts operation of engine and transmission.
q Automatic gear shifting function does not operate.
Problem on
q Once machine is stopped, engine speed is limited to medium (half) speed.
machine
q Once machine stops, travel is limited to F2 and R2.
q Output condition to 1st clutch ECMV solenoid can be checked with monitoring function.
Related infor-
(Code: 31612 1st ECMV output current (F/B))
mation
q Method of reproducing failure code:Start engine and travel at F1 or R1.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective 1st clutch ECMV sole- 2. Disconnect connector S1T and connect T-adapter to male side.
1
noid (Internal disconnection)
Between S1T (male) (1) and (2) Resistance 3 - 13 z
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN3 and connect T-adapter to female side.
Open or short circuit in wiring har- a If resistance is above 1 Mz, wiring harness has disconnection.If resistance
2
ness is below 1 z, wiring harness has short circuit.
Between PTCN3 (female) (37) and (23) Resistance 3 - 13 z
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and S1T, and connect T-adapters to their
Open circuit in wiring harness
female sides.
3 (Open circuit in wiring or defective
Between PTCN3 (female) (37) and S1T
contact in connector) Resistance Max. 1 z
(female) (1)
Between PTCN3 (female) (23) and S1T
Resistance Max. 1 z
(female) (2)
If cause is not found by the above checks, power train controller may be defec-
4 Defective power train controller
tive. (Since failure is in it, troubleshooting cannot be performed.)

40-512 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXH4KA] 1st clutch ECMV: Disconnection

Circuit diagram related to 1st clutch ECMV 40-513

D375A-6R 40-513
(01)
Troubleshooting by failurecode
Failure code [DXH4KB] 1st clutch ECMV: Short circuit

Failure code [DXH4KB] 1st clutch ECMV: Short circuit 40-514


Action code Failure code 1st clutch ECMV: Short circuit
Failure
(Power train controller system)
E03 DXH4KB
Detail of failure q When power was output to transmission 1st clutch ECMV solenoid circuit, abnormal current flowed.
Action of con- q Stops output to transmission 1st clutch ECMV solenoid circuit.
troller q Restricts operation of engine and transmission.
q Automatic gear shifting function does not operate.
Problem on
q Once machine is stopped, engine speed is limited to medium (half) speed.
machine
q Once machine stops, travel is restricted to F2 and R2.
q Output condition to 1st clutch ECMV solenoid can be checked with monitoring function.
Related infor-
(Code: 31612 1st ECMV output current (F/B))
mation
q Method of reproducing failure code:Start engine and travel at F1 or R1.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector S1T and connect T-adapter to male side.
Defective 1st clutch ECMV sole-
1
noid (Internal short circuit) Between S1T (male) (1) and (2) Resistance 3 13 z
Between S1T (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and S1T and connect T-adapter to female
Ground fault in wiring harness side of either of them.
2
(Contact with ground circuit)
Between PTCN3 (female) (37) or S1T
Resistance Min. 1 Mz
(female) (1) and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and S1T and connect T-adapter to female
3 Short circuit in wiring harness side of either of them.
Between PTCN3 (female) (37) and (23), or
Resistance Min. 1 Mz
between S1T (female) (1) and (2)
If cause is not found by the above checks, power train controller may be defec-
4 Defective power train controller
tive. (Since failure is in it, troubleshooting cannot be performed.)

40-514 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXH4KB] 1st clutch ECMV: Short circuit

Circuit diagram related to 1st clutch ECMV 40-515

D375A-6R 40-515
(01)
Troubleshooting by failurecode
Failure code [DXH4KY] 1st clutch ECMV: Short circuit

Failure code [DXH4KY] 1st clutch ECMV: Short circuit 40-516


Action code Failure code 1st clutch ECMV: Short circuit
Failure
(Power train controller system)
E03 DXH4KY
Detail of failure q Current flows constantly to transmission 1st clutch ECMV solenoid circuit.
Action of con- q Stops output to transmission 1st clutch ECMV solenoid circuit.
troller q Restricts operation of engine and transmission.
q Automatic gear shifting function does not operate.
Problem on
q Once machine is stopped, engine speed is limited to medium (half) speed.
machine
q Once machine stops, travel is restricted to F1 and R1.
q Output condition to 1st clutch ECMV solenoid can be checked with monitoring function.
Related infor-
(Code: 31612 1st ECMV output current (F/B))
mation
q Method of reproducing failure code:Start engine and travel at F1 or R1.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector S1T and connect T-adapter to male side.
Defective 1st clutch ECMV sole-
1
noid (Internal short circuit) Between S1T (male) (1) and (2) Resistance 3 - 13 z
Between S1T (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector S1T and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between S1T (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and S1T and connect T-adapter to female
side of PTCN3.
a Check with circuit tester in continuity mode.
Between PTCN3 (female) (37) and each pin No continuity (No sound is
other than (37) heard)
1. Turn starting switch to OFF position.
3 Short circuit in wiring harness
2. Disconnect connectors PTCN1 to PTCN3 and S1T, and connect T-adapters
to female sides of PTCN1 to PTCN3.
a Check with circuit tester in continuity mode.
Between PTCN3 (female) (6) and each pin of No continuity (No sound is
PTCN1 (female) heard)
Between PTCN3 (female) (6) and each pin of No continuity (No sound is
PTCN2 (female) heard)
If cause is not found by the above checks, power train controller may be defec-
4 Defective power train controller
tive. (Since failure is in it, troubleshooting cannot be performed.)

40-516 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXH4KY] 1st clutch ECMV: Short circuit

Circuit diagram related to 1st clutch ECMV 40-517

D375A-6R 40-517
(01)
Troubleshooting by failurecode
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection

Failure code [DXH5KA] 2nd clutch ECMV: Disconnection 40-518


Action code Failure code 2nd clutch ECMV: Disconnection
Failure
(Power train controller system)
E03 DXH5KA
Detail of failure q When power is output to transmission 2nd clutch ECMV solenoid circuit, no current flows.
Action of con- q Stops output to transmission 2nd clutch ECMV solenoid circuit.
troller q Restricts operation of engine and transmission.
q Automatic gear shifting function does not operate.
Problem on
q Once machine stops, engine speed is restricted to medium (half).
machine
q Once machine stops, travel is restricted to F1 and R1.
q Output condition to 2nd clutch ECMV solenoid can be checked with monitoring function.
Related infor-
(Code: 31613 T/M Clutch 2nd ECMV (F/B))
mation
q Method of reproducing failure code:Start engine and travel at F2 or R2.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective 2nd clutch ECMV sole- 2. Disconnect connector S2T and connect T-adapter to male side.
1
noid (Internal disconnection))
Between S2T (male) (1) and (2) Resistance 3 - 13 z
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN3 and connect T-adapter to female side.
Disconnection or short circuit in a If resistance is above 1 Mz, wiring harness has disconnection. If resistance
2
wiring harness is below 1 z, wiring harness has short circuit.
Between PTCN3 (female) (28) and (3) Resistance 3 - 13 z
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and S2T, and connect T-adapters to their
Disconnection in wiring harness
female sides.
3 (Open circuit in wiring or defective
Between PTCN3 (female) (28) and S2T
contact in connector) Resistance Max. 1 z
(female) (1)
Between PTCN3 (female) (3) and S2T
Resistance Max. 1 z
(female) (2)
If cause is not found by the above checks, power train controller may be defec-
4 Defective power train controller
tive. (Since failure is in it, troubleshooting cannot be performed.)

40-518 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection

Circuit diagram related to 2nd clutch ECMV 40-519

D375A-6R 40-519
(01)
Troubleshooting by failurecode
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit

Failure code [DXH5KB] 2nd clutch ECMV: Short circuit 40-520


Action code Failure code 2nd clutch ECMV: Short circuit
Failure
(Power train controller system)
E03 DXH5KB
q When power was output to transmission 2nd clutch ECMV solenoid circuit, abnormal current
Detail of failure
flowed.
Action of con- q Stops output to transmission 2nd clutch ECMV solenoid circuit.
troller q Restricts operation of engine and transmission.
q Automatic gear shifting function does not operate.
Problem on
q Once machine stops, engine speed is restricted to medium (half).
machine
q Once machine stops, travel is restricted to F1 and R1.
q Output condition to 2nd clutch ECMV solenoid can be checked with monitoring function.
Related infor-
(Code: 31613 T/M Clutch 2nd ECMV (F/B))
mation
q Method of reproducing failure code:Start engine and travel at F2 or R2.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective 2nd clutch ECMV sole- 2. Disconnect connector S2T and connect T-adapter to male side.
1
noid (Internal short circuit) Between S2T (male) (1) and (2) Resistance 3 - 13 z
Between S2T (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and S2T and connect T-adapter to female
Ground fault of wiring harness side of either of them.
2
(Contact with ground circuit)
Between PTCN3 (female) (28) or S2T
Resistance Min. 1 Mz
(female) (1) and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and S2T and connect T-adapter to female
3 Short circuit in wiring harness side of either of them.
Between PTCN3 (female) (28) and (3), or
Resistance Min. 1 Mz
between S2T (female) (1) and (2)
If cause is not found by the above checks, power train controller may be defec-
4 Defective power train controller
tive. (Since failure is in it, troubleshooting cannot be performed.)

40-520 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit

Circuit diagram related to 2nd clutch ECMV 40-521

D375A-6R 40-521
(01)
Troubleshooting by failurecode
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit

Failure code [DXH5KY] 2nd clutch ECMV: Short circuit 40-52


Action code Failure code 2nd clutch ECMV: Short circuit
Failure
(Power train controller system)
E03 DXH5KY
Detail of failure q Current flows constantly to transmission 2nd clutch ECMV solenoid circuit.
Action of con- q Stops output to transmission 2nd clutch ECMV solenoid circuit.
troller q Restricts operation of engine and transmission.
q Automatic gear shifting function does not operate.
Problem on
q Once machine stops, engine speed is restricted to medium (half).
machine
q Once machine is stopped, travel is restricted to F2 and R2.
q Output condition to 2nd clutch ECMV solenoid can be checked with monitoring function.
Related infor-
(Code: 31613 T/M Clutch 2nd ECMV (F/B))
mation
q Method of reproducing failure code:Start engine and travel at F2 or R2.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector S2T and connect T-adapter to male side.
Defective 2nd clutch ECMV sole-
1
noid (Internal short circuit) Between S2T (male) (1) and (2) Resistance 3 - 13 z
Between S2T (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short in wiring harness 2. Disconnect connector S2T and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between S2T (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and S2T and connect T-adapter to female
side of PTCN3.
a Check with tester in continuity mode.
Between PTCN3 (female) (28) and each pin No continuity (No sound is
other than (28) heard)
1. Turn starting switch to OFF position.
3 Short circuit in wiring harness 2. Disconnect connectors PTCN1 to PTCN3 and S2T, and connect T-adapters
to female side of PTCN1 to PTCN3.
a Check with tester in continuity mode.
Between PTCN3 (female) (28) and each pin No continuity (No sound is
of PTCN1 (female) heard)
Between PTCN3 (female) (28) and each pin No continuity (No sound is
of PTCN2 (female) heard)
If cause is not found by the above checks, power train controller may be defec-
4 Defective power train controller
tive. (Since failure is in it, troubleshooting cannot be performed.)

40-522 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit

Circuit diagram related to 2st clutch ECMV 40-523

D375A-6R 40-523
(01)
Troubleshooting by failurecode
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection

Failure code [DXH6KA] 3rd clutch ECMV: Disconnection 40-524


Action code Failure code 3rd clutch ECMV: Disconnection
Failure
(Power train controller system)
E03 DXH6KA
Detail of failure q When power is output to transmission 3rd clutch ECMV solenoid circuit, no current flows.
Action of con- q Stops output to transmission 3rd clutch ECMV solenoid circuit.
troller q Restricts operation of engine and transmission.
Problem on q Once machine stops, engine speed is restricted to medium (half).
machine q Once machine stops, travel is restricted to F1 and R1.
q Output condition to 3rd clutch ECMV solenoid can be checked with monitoring function.
Related infor-
(Code: 31614 T/M Clutch 3rd ECMV (F/B))
mation
q Method of reproducing failure code:Start engine and travel at F3 or R3.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective 3rd clutch ECMV sole- 2. Disconnect connector S3T and connect T-adapter to male side.
1
noid (Internal disconnection)
Between S3T (male) (1) and (2) Resistance 3 13 z
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN3 and connect T-adapter to female side.
Disconnection or short circuit in a If resistance is above1 Mz, wiring harness has disconnection. If resistance
2
wiring harness is below1 z, wiring harness has short circuit.
Between PTCN3 (female) (38) and (13) Resistance 3 13 z
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and S3T, and connect T-adapters to their
Disconnection in wiring harness
female sides.
3 (Open circuit in wiring or defective
Between PTCN3 (female) (38) and S3T
contact in connector) Resistance Max. 1 z
(female) (1)
Between PTCN3 (female) (13) and S3T
Resistance Max. 1 z
(female) (2)
If cause is not found by the above checks, power train controller may be defec-
4 Defective power train controller
tive. (Since failure is in it, troubleshooting cannot be performed.)

40-524 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection

Circuit diagram related to 3rd clutch ECMV 40-525

D375A-6R 40-525
(01)
Troubleshooting by failurecode
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit

Failure code [DXH6KB] 3rd clutch ECMV: Short circuit 40-526


Action code Failure code 3rd clutch ECMV: Short circuit
Failure
(Power train controller system)
E03 DXH6KB
Detail of failure q When power was output to transmission 3rd clutch ECMV solenoid circuit, abnormal current flowed.
Action of con- q Stops output to transmission 3rd clutch ECMV solenoid circuit.
troller q Restricts operation of engine and transmission.
Problem on q Once machine stops, engine speed is restricted to medium (half).
machine q Once machine stops, travel is restricted to F1 and R1.
q Output condition to 3rd clutch ECMV solenoid can be checked with monitoring function.
Related infor-
(Code: 31614 T/M Clutch 3rd ECMV (F/B))
mation
q Method of reproducing failure code:Start engine and travel at F3 or R3.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector S3T and connect T-adapter to male side.
Defective 3rd clutch ECMV sole-
1
noid (Internal short circuit) Between S3T (male) (1) and (2) Resistance 3 13 z
Between S3T (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and S3T, and connect T-adapter to female
Ground fault of wiring harness side of either of them.
2
(Contact with ground circuit)
Between PTCN3 (female) (38) or S3T
Resistance Min. 1 Mz
(female) (1) and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and S3T and connect T-adapter to female
3 Short circuit in wiring harness side of either of them.
Between PTCN3 (female) (38) and (13), or
Resistance Min. 1 Mz
between S3T (female) (1) and (2)
If cause is not found by the above checks, power train controller may be defec-
4 Defective power train controller
tive. (Since failure is in it, troubleshooting cannot be performed.)

40-526 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit

Circuit diagram related to 3rd clutch ECMV 40-527

D375A-6R 40-527
(01)
Troubleshooting by failurecode
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit

Failure code [DXH6KY] 3rd clutch ECMV: Short circuit 40-528


Action code Failure code 3rd clutch ECMV: Short circuit
Failure
(Power train controller system)
E03 DXH6KY
Detail of failure q Current flows constantly to transmission 3rd clutch ECMV solenoid circuit.
Action of con- q Stops output to transmission 3rd clutch ECMV solenoid circuit.
troller q Restricts operation of engine and transmission.
Problem on q Once machine stops, engine speed is restricted to medium (half).
machine q Once machine is stopped, travel is restricted to F3 and R3.
q Output condition to 3rd clutch ECMV solenoid can be checked with monitoring function.
Related infor-
(Code: 31614 T/M Clutch 3rd ECMV (F/B))
mation
q Method of reproducing failure code:Start engine and travel at F3 or R3.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector S3T and connect T-adapter to male side.
Defective 3rd clutch ECMV sole-
1
noid (Internal short circuit) Between S3T (male) (1) and (2) Resistance 3 - 13 z
Between S3T (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short in wiring harness 2. Disconnect connector S3T and connect T-adapter to female side.
2 3. Turn starting switch ON position.
(Contact with 24 V circuit)
Between S3T (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and S3T and connect T-adapter to female
side of PTCN3.
a Check with tester in continuity mode.
Between PTCN3 (female) (38) and each pin No continuity (No sound is
other than (38) heard)
1. Turn starting switch to OFF position.
3 Short circuit in wiring harness 2. Disconnect connectors PTCN1 to PTCN3 and S3T, and connect T-adapters
to female sides of PTCN1 to PTCN3.
a Check with tester in continuity mode.
Between PTCN3 (female) (38) and each pin No continuity (No sound is
of PTCN1 (female) heard)
Between PTCN3 (female) (38) and each pin No continuity (No sound is
of PTCN2 (female) heard)
If cause is not found by the above checks, power train controller may be defec-
4 Defective power train controller
tive. (Since failure is in it, troubleshooting cannot be performed.)

40-528 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit

Circuit diagram related to 3rd clutch ECMV 40-529

D375A-6R 40-529
(01)
Troubleshooting by failurecode
Failure code [DXH7KA] R clutch ECMV: Disconnection

Failure code [DXH7KA] R clutch ECMV: Disconnection 40-530


Action code Failure code Reverse clutch ECMV: Disconnection
Failure
(Power train controller system)
E03 DXH7KA
Detail of failure q When power is output to transmission R clutch ECMV solenoid circuit, no current flows.
Action of con- q Stops output to transmission R clutch ECMV solenoid circuit.
troller q Restricts operation of engine and transmission.
Problem on q Once machine stops, engine speed is restricted to medium (half).
machine q Once machine stops, travel is restricted to F1.
q Output condition to R clutch ECMV solenoid can be checked with monitoring function.
Related infor-
(Code: 31616 T/M Clutch R ECMV (F/B))
mation
q Method of reproducing failure code:Start engine and travel at R (Reverse).

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective R clutch ECMV solenoid 2. Disconnect connector SRT and connect T-adapter to male side.
1
(Internal disconnection)
Between SRT (male) (1) and (2) Resistance 3 13 z
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN3 and connect T-adapter to female side.
Disconnection or short circuit in a If resistance is above 1 Mz, wiring harness has disconnection. If resistance
2
wiring harness is below 1 z, wiring harness has short circuit.
Between PTCN3 (female) (27) and (3) Resistance 3 13 z
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SRT, and connect T-adapters to their
Disconnection in wiring harness
female sides.
3 (Open circuit in wiring or defective
Between PTCN3 (female) (27) and SRT
contact in connector) Resistance Max. 1 z
(female) (1)
Between PTCN3 (female) (3) and SRT
Resistance Max. 1 z
(female) (2)
If cause is not found by the above checks, power train controller may be defec-
4 Defective power train controller
tive. (Since failure is in it, troubleshooting cannot be performed.)

40-530 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXH7KA] R clutch ECMV: Disconnection

Circuit diagram related to reverse clutch ECMV40-531

D375A-6R 40-531
(01)
Troubleshooting by failurecode
Failure code [DXH7KB] R clutch ECMV: Short circuit

Failure code [DXH7KB] R clutch ECMV: Short circuit 40-532


Action code Failure code Reverse clutch ECMV: Short circuit
Failure
(Power train controller system)
E03 DXH7KB
Detail of failure q When power was output to transmission R clutch ECMV solenoid circuit, abnormal current flowed.
Action of con- q Stops output to transmission R clutch ECMV solenoid circuit.
troller q Restricts operation of engine and transmission.
Problem on q Once machine stops, engine speed is restricted to medium (half).
machine q Once machine is stopped, travel is restricted to F1.
q Output condition to R clutch ECMV solenoid can be checked with monitoring function.
Related infor-
(Code: 31616 T/M Clutch R ECMV (F/B))
mation
q Method of reproducing failure code:Start engine and travel at R (Reverse).

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector SRT and connect T-adapter to male side.
Defective R clutch ECMV solenoid
1
(Internal short circuit) Between SRT (male) (1) and (2) Resistance 3 13 z
Between SRT (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SRT, and connect T-adapter to female
Ground fault of wiring harness side of either of them.
2
(Contact with ground circuit)
Between PTCN3 (female) (27) or SRT
Resistance Min. 1 Mz
(female) (1) and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SRT and connect T-adapter to female
3 Short circuit in wiring harness side of either of them.
Between PTCN3 (female) (27) and (3), or
Resistance Min. 1 Mz
between SRT (female) (1) and (2)
If cause is not found by the above checks, power train controller may be defec-
4 Defective power train controller
tive. (Since failure is in it, troubleshooting cannot be performed.)

40-532 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXH7KB] R clutch ECMV: Short circuit

Circuit diagram related to reverse clutch ECMV40-53

D375A-6R 40-533
(01)
Troubleshooting by failurecode
Failure code [DXH7KY] R clutch ECMV: Short circuit

Failure code [DXH7KY] R clutch ECMV: Short circuit 40-534


Action code Failure code Reverse clutch ECMV: Short circuit
Failure
E04 DXH7KY (Power train controller system)
Detail of failure q Current flows constantly to transmission R clutch ECMV solenoid circuit.
Action of con- q Stops output to transmission R clutch ECMV solenoid circuit.
troller q Restricts operation of engine and transmission.
Problem on q Once machine stops, engine speed is restricted to medium (half).
machine q Once machine stops, machine does not travel at all.
q Output condition to R clutch ECMV solenoid can be checked with monitoring function.
Related infor-
(Code: 31616 T/M Clutch R ECMV (F/B))
mation
q Method of reproducing failure code:Start engine and travel at R (Reverse).

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector SRT and connect T-adapter to male side.
Defective R clutch ECMV solenoid
1
(Internal short circuit) Between SRT (male) (1) and (2) Resistance 3 13 z
Between SRT (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short in wiring harness 2. Disconnect connector SRT and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between SRT (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SRT and connect T-adapter to female
side of PTCN3.
a Check with tester in continuity mode.
Between PTCN3 (female) (27) and each pin No continuity (No sound is
other than (27) heard)
1. Turn starting switch to OFF position.
3 Short circuit in wiring harness 2. Disconnect connectors PTCN1 to PTCN3 and SRT, and connect
T-adapters to female side of PTCN1 to PTCN3.
a Check with tester in continuity mode.
Between PTCN3 (female) (27) and each pin No continuity (No sound is
of PTCN1 (female) heard)
Between PTCN3 (female) (27) and each pin No continuity (No sound is
of PTCN2 (female) heard)
If cause is not found by the above checks, power train controller may be defec-
4 Defective power train controller
tive. (Since failure is in it, troubleshooting cannot be performed.)

40-534 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXH7KY] R clutch ECMV: Short circuit

Circuit diagram related to reverse clutch ECMV 40-535

D375A-6R 40-535
(01)
Troubleshooting by failurecode
Failure code [DXH8KA] F clutch ECMV: Disconnection

Failure code [DXH8KA] F clutch ECMV: Disconnection 40-536


Action code Failure code Forward clutch ECMV: Disconnection
Failure
E03 DXH8KA (Power train controller system)
Detail of failure q When power is output to transmission F clutch ECMV solenoid circuit, no current flows.
Action of con- q Stops output to transmission F clutch ECMV solenoid circuit.
troller q Restricts operation of engine and transmission.
Problem on q Once machine stops, engine speed is restricted to medium (half).
machine q Once machine stops, travel is restricted to R1.
q Output condition to F clutch ECMV solenoid can be checked with monitoring function.
Related infor-
(Code: 31622 T/M Clutch F ECMV (F/B))
mation
q Method of reproducing failure code:Start engine and travel at F (Forward).

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective F clutch ECMV sole- 2. Disconnect connector SFT and connect T-adapter to male side.
1
noid (Internal disconnection)
Between SFT (male) (1) and (2) Resistance 3 13 z
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN3 and connect T-adapter to female side.
Disconnection or short circuit in a If resistance is above 1 Mz, wiring harness has disconnection. If resistance
2
wiring harness is below 1 z, wiring harness has short circuit.
Between PTCN3 (female) (17) and (13) Resistance 3 13 z
a If cause 2 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SFT, and connect T-adapters to their
Disconnection in wiring harness
female sides.
3 (Open circuit in wiring or defective
Between PTCN3 (female) (17) and SFT
contact in connector) Resistance Max. 1 z
(female) (1)
Between PTCN3 (female) (13) and SFT
Resistance Max. 1 z
(female) (2)
If cause is not found by the above checks, power train controller may be defec-
4 Defective power train controller
tive. (Since failure is in it, troubleshooting cannot be performed.)

40-536 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXH8KA] F clutch ECMV: Disconnection

Circuit diagram related to forward clutch ECMV40-537

D375A-6R 40-537
(01)
Troubleshooting by failurecode
Failure code [DXH8KB] F clutch ECMV: Short circuit

Failure code [DXH8KB] F clutch ECMV: Short circuit 40-538


Action code Failure code Forward clutch ECMV: Short circuit
Failure
(Power train controller system)
E03 DXH8KB
Detail of failure q When power was output to transmission F clutch ECMV solenoid circuit, abnormal current flowed.
Action of con- q Stops output to transmission F clutch ECMV solenoid circuit.
troller q Restricts operation of engine and transmission.
Problem on q Once machine stops, engine speed is restricted to medium (half).
machine q Once machine is stopped, travel is restricted to R1.
q Output condition to F clutch ECMV solenoid can be checked with monitoring function.
Related infor-
(Code: 31622 T/M Clutch F ECMV (F/B))
mation
q Method of reproducing failure code:Start engine and travel at F (Forward).

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector SFT and connect T-adapter to male side.
Defective F clutch ECMV sole-
1
noid (Internal short circuit) Between SFT (male) (1) and (2) Resistance 3 13 z
Between SFT (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SFT and connect T-adapter to female
Ground fault of wiring harness side of either of them.
2
(Contact with ground circuit)
Between PTCN3 (female) (17) or SFT
Resistance Min. 1 Mz
(female) (1) and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and F SET and connect T-adapter to female
3 Short circuit in wiring harness side of either of them.
Between PTCN3 (female) (17) and (13), or
Resistance Min. 1 Mz
between SFT (female) (1) and (2)
If cause is not found by the above checks, power train controller may be defec-
4 Defective power train controller
tive. (Since failure is in it, troubleshooting cannot be performed.)

40-538 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXH8KB] F clutch ECMV: Short circuit

Circuit diagram related to forward clutch ECMV40-539

D375A-6R 40-539
(01)
Troubleshooting by failurecode
Failure code [DXH8KY] F clutch ECMV: Short circuit

Failure code [DXH8KY] F clutch ECMV: Short circuit 40-540


Action code Failure code Forward clutch ECMV: Short circuit
Failure
(Power train controller system)
E04 DXH8KY
Detail of failure q Current flows constantly to transmission F clutch ECMV solenoid circuit.
Action of con- q Stops output to transmission F clutch ECMV solenoid circuit.
troller q Restricts operation of engine and transmission.
Problem on q Once machine stops, engine speed is restricted to medium (half).
machine q Once machine stops, machine does not travel at all.
q Output condition to F clutch ECMV solenoid can be checked with monitoring function.
Related infor-
(Code: 31622 T/M Clutch F ECMV (F/B))
mation
q Method of reproducing failure code:Start engine and travel at F (Forward).

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector SFT and connect T-adapter to male side.
Defective F clutch ECMV sole-
1
noid (Internal short circuit) Between SFT (male) (1) and (2) Resistance 3 13 z
Between SFT (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short in wiring harnesss 2. Disconnect connector SFT and connect T-adapter to female side.
2 3. Turn starting switch ON position.
(Contact with 24 V circuit)
Between SFT (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SFT and connect T-adapter to female
side of PTCN3.
a Check with tester in continuity mode.
Between PTCN3 (female) (17) and each pin No continuity (No sound is
other than (17) heard)
1. Turn starting switch to OFF position.
3 Short circuit in wiring harness 2. Disconnect connectors PTCN1 to PTCN3 and SFT, and connect
T-adapters to female sides of PTCN1 to PTCN3.
a Check with tester in continuity mode.
Between PTCN3 (female) (17) and each pin No continuity (No sound is
of PTCN1 (female) heard)
Between PTCN3 (female) (17) and each pin No continuity (No sound is
of PTCN2 (female) heard)
If cause is not found by the above checks, power train controller may be defec-
4 Defective power train controller
tive. (Since failure is in it, troubleshooting cannot be performed.)

40-540 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXH8KY] F clutch ECMV: Short circuit

Circuit diagram related to forward clutch ECMV40-541

D375A-6R 40-541
(01)
Troubleshooting by failurecode
Failure code [DXH9KA] Right clutch ECMV: Disconnection

Failure code [DXH9KA] Right clutch ECMV: Disconnection 40-542


Action code Failure code Right steering clutch ECMV disconnection
Failure
(Power train controller system)
E03 DXH9KA
Detail of failure q When power is output to right steering clutch ECMV solenoid circuit, current does not flow.
Action of con- q Stops outputting to right steering clutch ECMV solenoid circuit.
troller q Restricts operation of engine and transmission.
q Machine cannot be steered to right.
Problem on
q Once machine is stopped, engine speed is limited to half of full speed.
machine
q Once machine is stopped, travel is restricted to F1 and R1.
q Output (current) condition to right steering clutch ECMV solenoid can be checked with monitoring
Related infor- function. (Code: 90601 Right steering clutch ECMV output current (F/B))
mation q Method of reproducing failure code:Turn starting switch to ON position, release parking brake lever,
and operate PCCS lever (to steer right)

Cause Procedure, measuring location, criteria and remarks

Defective right steering clutch 1. Turn starting switch to OFF position.


1 ECMV solenoid (Internal short cir- 2. Disconnect connector SRC and connect T-adapter to male side.
cuit) Between SRC (male) (1) and (2) Resistance 3 - 13 z
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN3 and connect T-adapter to female side.
Open or short circuit in wiring har- a If resistance is above 1 Mz, wiring harness has disconnection. If resistance
2
ness is below 1 z, wiring harness has short circuit.
Between SRC (female) (35) and (23) Resistance 3 - 13 z
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SRC , and connect T-adapters to their
Open circuit in wiring harness
female sides.
3 (Open circuit in wiring or defective
Between PTCN3 (female) (35) and SRC (female)
contact in connector) Resistance Max. 1 z
(1)
Between PTCN3 (female) (23) and SRC (female)
Resistance Max. 1 z
(2)
If cause is not found by the above checks, power train controller may be defec-
4 Defective power train controller
tive. (Since failure is in it, troubleshooting cannot be performed.)

40-542 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXH9KA] Right clutch ECMV: Disconnection

Circuit diagram related to right steering clutch ECMV 40-543

D375A-6R 40-543
(01)
Troubleshooting by failurecode
Failure code [DXH9KB] Right clutch ECMV: Short circuit

Failure code [DXH9KB] Right clutch ECMV: Short circuit 40-54


Action code Failure code Right steering clutch ECMV short circuit
Failure
(Power train controller system)
E03 DXH9KB
Detail of failure q When power was output to right steering clutch solenoid circuit, abnormal current flowed.
Action of con- q Stops output to right steering clutch solenoid circuit.
troller q Restricts operation of engine and transmission.
q Machine cannot be steered to right.
Problem on
q Once machine is stopped, engine speed is limited to half of full speed.
machine
q Once machine is stopped, travel is restricted to F1 and R1.
q Output (current) condition to right steering clutch ECMV solenoid can be checked with monitoring
Related infor- function. (Code: 90601 Right steering clutch ECMV output current (F/B))
mation q Method of reproducing failure code:Turn starting switch to ON position, release parking brake lever,
and operate PCCS lever (to steer right)

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective rihht steering clutch 2. Disconnect connector SRC and connect T-adapter to male side.
1 ECMV solenoid (Internal short cir-
Between SRC (male) (1) and (2) Resistance 3 13 z
cuit)
Between SRC (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SRC and connect T-adapter to female
Ground fault in wiring harness side of either of them.
2
(Contact with ground circuit)
Between PTCN3 (female) (35) or SRC (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SRC and connect T-adapter to female
3 Short circuit in wiring harness side of either of them.
Between PTCN3 (female) (35) and (23), or between
Resistance Min. 1 Mz
SRC (female) (1) and (2)
If cause is not found by the above checks, power train controller may be defec-
4 Defective power train controller
tive. (Since failure is in it, troubleshooting cannot be performed.)

40-544 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXH9KB] Right clutch ECMV: Short circuit

Circuit diagram related to right steering clutch ECMV 40-545

D375A-6R 40-545
(01)
Troubleshooting by failurecode
Failure code [DXH9KY] Right clutch ECMV: Short circuit

Failure code [DXH9KY] Right clutch ECMV: Short circuit 40-546


Action code Failure code Right steering clutch ECMV short circuit
Failure
(Power train controller system)
E04 DXH9KY
Detail of failure q Current flows constantly to right steering clutch ECMV solenoid circuit.
Action of con- q Stops outputting to right steering clutch solenoid circuit.
troller q Restricts operation of engine and transmission.
q Right clutch cannot be engaged (machine cannot travel straight).
Problem on
q Once machine is stopped, engine speed is restricted to medium (half).
machine
q Once machine is stopped, it cannot travel at all.
q Output (current) condition to right steering clutch ECMV solenoid can be checked with monitoring
Related infor- function. (Code: 90601 Right steering clutch ECMV output current (F/B))
mation q Method of reproducing failure code: Turn starting switch to ON position and release parking brake
lever.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective right steering clutch 2. Disconnect connector SRC and connect T-adapter to male side.
1 ECMV solenoid (Internal short cir-
Between SRC (male) (1) and (2) Resistance 313 z
cuit)
Between SRC (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector SRC and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between SRC (female) (1) and ground Voltage Max. 1V
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SRC, and connect T-adapter to female
side of PTCN3.
a Check with multimeter in continuity mode.
Between PTCN3 (female) (35) and each pin other No continuity (No sound
than (35) is heard.)
1. Turn starting switch to OFF position.
3 Short circuit in wiring harness
2. Disconnect connectors PTCN1 to 3 and SRC, and connect T-adapter to
female sides of PTCN1 to 3.
a Check with circuit tester in continuity mode.
Between PTCN3 (female) (35) and each pin of No continuity (No sound
PTCN1 (female) is heard.)
Between PTCN3 (female) (35) and each pin of No continuity (No sound
PTCN2 (female) is heard.)
If cause is not found by above checks, power train controller may be defective.
4 Defective power train controller
(Since failure is in it, troubleshooting cannot be performed.)

40-546 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXH9KY] Right clutch ECMV: Short circuit

Circuit diagram related to right steering clutch ECMV 40-547

D375A-6R 40-547
(01)
Troubleshooting by failurecode
Failure code [DXHAKA] Left clutch ECMV: Disconnection

Failure code [DXHAKA] Left clutch ECMV: Disconnection 40-548


Action code Failure code Left steering clutch ECMV disconnection
Failure
(Power train controller system)
E03 DXHAKA
Detail of failure q When power is output to left steering clutch solenoid circuit, current does not flow.
Action of con- q Stops output to left steering clutch solenoid circuit.
troller q Restricts operation of engine and transmission.
q Machine cannot be steered to left.
Problem on
q Once machine is stopped, engine speed is limited to half of full speed.
machine
q Once machine is stopped, travel is restricted to F1 and R1.
q Output condition (current) to left steering clutch ECMV solenoid can be checked with monitoring
Related infor- function. (Code: 90600 Left steering clutch ECMV output current (F/B))
mation q Method of reproducing failure code:Turn starting switch to ON position, release parking brake le-
ver, and operate PCCS lever (to steer left)

Cause Procedure, measuring location, criteria and remarks


Defective left steering clutch 1. Turn starting switch to OFF position.
1 ECMV solenoid (Internal discon- 2. Disconnect connector SLC and connect T-adapter to male side.
nection) Between SLC (male) (1) and (2) Resistance 3 13 z
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN3 and connect T-adapter to female side.
Open or short circuit in wiring har-
2 a If resistance is above 1 Mz, wiring harness has disconnection. If resistance
ness
is below 1 z, wiring harness has short circuit.
Between PTCN3 (female) (25) and (23) Resistance 3 13 z
a If cause 2 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SLC, and connect T-adapters to their
Open circuit in wiring harness
female sides.
3 (Open circuit in wiring or defective
Between PTCN3 (female) (25) and SLC (female)
contact in connector) Resistance Max. 1 z
(1)
Between PTCN3 (female) (23) and SLC (female)
Resistance Max. 1 z
(2)
If cause is not found by the above checks, power train controller may be defec-
4 Defective power train controller
tive. (Since failure is in it, troubleshooting cannot be performed.)

40-548 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXHAKA] Left clutch ECMV: Disconnection

Circuit diagram related to left steering clutch ECMV 40-549

D375A-6R 40-549
(01)
Troubleshooting by failurecode
Failure code [DXHAKB] Left clutch ECMV: Short circuit

Failure code [DXHAKB] Left clutch ECMV: Short circuit 40-5 0


Action code Failure code Left steering clutch ECMV short circuit
Failure
E03 DXHAKB (Power train controller system)
Detail of failure q When signal was output to left steering clutch ECMV solenoid circuit, abnormal current flowed.
Action of con- q Stops outputting to left steering clutch ECMV solenoid circuit.
troller q Restricts operation of engine and transmission.
q Machine cannot be steered to left.
Problem on
q Once machine is stopped, engine speed is limited to half of full speed.
machine
q Once machine is stopped, travel is restricted to F1 and R1.
q Output condition (current) to left steering clutch ECMV solenoid can be checked with monitoring
Related infor- function. (Code: 90600 Left steering clutch ECMV output current (F/B))
mation q Method of reproducing failure code:Turn starting switch to ON position, release parking brake lever,
and operate PCCS lever (to steer left)

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective left steering clutch 2. Disconnect connector SLC and connect T-adapter to male side.
1 ECMV solenoid (Internal short cir-
Between SLC (male) (1) and (2) Resistance 3 13 z
cuit)
Between SLC (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SLC, and connect T-adapter to female
Ground fault in wiring harness
2 side of either of them.
(Contact with ground circuit)
Between PTCN3 (female) (25) or SLC (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SLC and connect T-adapter to female
3 Short circuit in wiring harness side of either of them.
Between PTCN3 (female) (25) and (23), or between
Resistance Min. 1 Mz
SLC (female) (1) and (2)
If cause is not found by the above checks, power train controller may be defec-
4 Defective power train controller
tive. (Since failure is in it, troubleshooting cannot be performed.)

40-550 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXHAKB] Left clutch ECMV: Short circuit

Circuit diagram related to left steering clutch ECMV 40-5 1

D375A-6R 40-551
(01)
Troubleshooting by failurecode
Failure code [DXHAKY] Left clutch ECMV: Short circuit

Failure code [DXHAKY] Left clutch ECMV: Short circuit 40-5 2


Action code Failure code Hot short circuit in left steering clutch ECMV
Failure
(Power train controller system)
E04 DXHAKY
Detail of failure q Current flows constantly to left steering clutch ECMV solenoid circuit.
Action of con- q Stops outputting to left steering clutch ECMV solenoid circuit.
troller q Restricts operation of engine and transmission.
q Left clutch cannot be engaged (machine cannot travel straight).
Problem on
q Once machine is stopped, engine speed is limited to half of full speed.
machine
q Once machine is stopped, it cannot travel at all.
q Output condition (current) to left steering clutch ECMV solenoid can be checked with monitoring
Related infor- function. (Code: 90600 Left steering clutch ECMV output current (F/B))
mation q Method of reproducing failure code:Turn starting switch to ON position and release parking brake
lever.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective left steering clutch 2. Disconnect connector SRC and connect T-adapter to male side.
1 ECMV solenoid (Internal short cir-
Between SLC (male) (1) and (2) Resistance 3 13 z
cuit)
Between SLC (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector SRC and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between SLC (female) (1) and ground Voltage Max. 1V
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SLC and connect T-adapter to female
side of PTCN3.
a Check with multimeter in continuity mode.
Between PTCN3 (female) (25) and each pin other No continuity (No sound
than (25) is heard.)
1. Turn starting switch to OFF position.
3 Short circuit in wiring harness
2. Disconnect connectors PTCN1 to PTCN3 and SLC, and connect
T-adapters to female side of PTCN1 to PTCN3.
a Check with multimeter in continuity mode.
Between PTCN3 (female) (25) and each pin of No continuity (No sound
PTCN1 (female) is heard.)
Between PTCN3 (female) (25) and each pin of No continuity (No sound
PTCN2 (female) is heard.)
If cause is not found by above checks, power train controller may be defective.
4 Defective power train controller
(Since failure is in it, troubleshooting cannot be performed.)

40-552 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXHAKY] Left clutch ECMV: Short circuit

Circuit diagram related to left steering clutch ECMV 40-5 3

D375A-6R 40-553
(01)
Troubleshooting by failurecode
Failure code [DXHBKA] Right brake ECMV: Disconnection

Failure code [DXHBKA] Right brake ECMV: Disconnection 40-5 4


Action code Failure code Right brake ECMV disconnection
Failure
(Power train controller system)
E04 DXHBKA
Detail of failure q When signal is output to right steering brake solenoid circuit, no current flows.
q Stops outputting to right steering brake ECMV solenoid circuit.
Action of con-
q Restricts operation of engine, transmission and brake.
troller
q Operates sudden stop prevention valve.
q Right brake keeps applied.
Problem on
q Once machine is stopped, engine speed is limited to half of full speed.
machine
q Once machine is stopped, it cannot travel any more.
q Output condition (current) to right steering brake ECMV solenoid can be checked with monitoring
Related infor- function. (Code: 31618 Right steering brake ECMV output current (F/B))
mation q Method of reproducing failure code:Turn starting switch to ON position and release parking brake
lever.

Cause Procedure, measuring location, criteria and remarks

Defective right steering brake 1. Turn starting switch to OFF position.


1 ECMV solenoid (Internal discon- 2. Disconnect connector SRB and connect T-adapter to male side.
nection) Between SRB (male) (1) and (2) Resistance 3 13 z
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN3 and connect T-adapter to female side.
Open or short circuit in wiring har- a If resistance is above 1 Mz, wiring harness has disconnection. If resistance
2
ness is below 1 z, wiring harness has short circuit.
Between PTCN3 (female) (15) and (13) Resistance 3 13 z
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SRB, and connect T-adapters to their
Open circuit in wiring harness
female sides.
3 (Open circuit in wiring or defective
Between PTCN3 (female) (15) and SRB (female)
contact in connector) Resistance Max. 1 z
(1)
Between PTCN3 (female) (13) and SRB (female)
Resistance Max. 1 z
(2)
If cause is not found by the above checks, power train controller may be defec-
4 Defective power train controller
tive. (Since failure is in it, troubleshooting cannot be performed.)

40-554 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXHBKA] Right brake ECMV: Disconnection

Circuit diagram related to right brake ECMV 40-5 5

D375A-6R 40-555
(01)
Troubleshooting by failurecode
Failure code [DXHBKB] Right brake ECMV: Short circuit

Failure code [DXHBKB] Right brake ECMV: Short circuit 40-5 6


Action code Failure code Right brake ECMV short circuit
Failure
(Power train controller system)
E04 DXHBKB
Detail of failure q When power was output to right steering brake ECMV solenoid circuit, abnormal current flowed.
q Stops outputting to right steering brake ECMV solenoid circuit.
Action of con-
q Restricts operations of engine, transmission, and brake.
troller
q Operates sudden stop prevention valve.
q Right brake keeps applied.
Problem on
q Once machine is stopped, engine speed is limited to half of full speed.
machine
q Once machine is stopped, it cannot travel any more.
q Output condition (current) to right steering brake ECMV solenoid can be checked with monitoring
Related infor- function. (Code: 31618 Right steering brake ECMV output current (F/B))
mation q Method of reproducing failure code:Turn starting switch to ON position and release parking brake
lever.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective right steering brake 2. Disconnect connector SRB and connect T-adapter to male side.
1 ECMV solenoid (Internal short cir-
Between SRB (male) (1) and (2) Resistance 3 13 z
cuit)
Between SRB (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SRB, and connect T-adapter to female
Ground fault in wiring harness side of either of them.
2
(Contact with ground circuit)
Between PTCN3 (female) (15) or SRB (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SRB, and connect T-adapter to female
3 Short circuit in wiring harness side of either of them.
Between PTCN3 (female) (15) and (13), or between
Resistance Min. 1 Mz
SRB (female) (1) and (2)
If cause is not found by the above checks, power train controller may be defec-
4 Defective power train controller
tive. (Since failure is in it, troubleshooting cannot be performed.)

40-556 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXHBKB] Right brake ECMV: Short circuit

Circuit diagram related to right brake ECMV 40-5 7

D375A-6R 40-557
(01)
Troubleshooting by failurecode
Failure code [DXHBKY] Right brake ECMV: Short circuit

Failure code [DXHBKY] Right brake ECMV: Short circuit 40-5 8


Action code Failure code Right brake ECMV hot short circuit
Failure
(Power train controller system)
E04 DXHBKY
Detail of failure q When power is output to right steering brake ECMV solenoid circuit, no current flows.
q Stops outputting to right steering brake ECMV solenoid circuit.
Action of con-
q Restricts operation of engine, transmission and brake.
troller
q Operates sudden stop prevention valve.
q Right brake does not operate.
Problem on
q Once machine is stopped, engine speed is limited to half of full speed.
machine
q Once machine is stopped, it cannot travel any more.
q Output condition (current) to right steering brake ECMV solenoid can be checked with moniitoring
Related infor- funtion. (Code: 31618 output current (F/B) of right steering brake ECMV)
mation q Method of reproducing failure code: Turn starting switch to ON position and operate parking brake
lever (LOCK).

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective right steering brake 2. Disconnect connector SRB and connect T-adapter to male side.
1 clutch ECMV solenoid (Internal
Between SRB (male) (1) and (2) Resistance 3 13 z
short circuit)
Between SRB (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector SRB and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between SRB (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SRB and connect T-adapter to female
side of PTCN3.
a Use continuity check mode of the tester.
Between PTCN3 (female) (15) and each pin other No continuity (No sound
than (15) is heard)
1. Turn starting switch to OFF position.
3 Short circuit in wiring harness
2. Disconnect connectors PTCN1 to PTCN3 and SRB, and connect
T-adapters to female sides of PTCN1 to PTCN3.
a Use continuity check mode of the tester.
Between PTCN3 (female) (15) and each pin of No continuity (No sound
PTCN1 (female) is heard)
Between PTCN3 (female) (15) and each pin of No continuity (No sound
PTCN2 (female) is heard)
If cause is not found by the above checks, power train controller may be defec-
4 Defective power train controller
tive. (Since falure is in it, troubleshooting cannot be performed.)

40-558 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXHBKY] Right brake ECMV: Short circuit

Circuit diagram related to right brake ECMV 40-5 9

D375A-6R 40-559
(01)
Troubleshooting by failurecode
Failure code [DXHCKA] Left brake ECMV: Disconnection

Failure code [DXHCKA] Left brake ECMV: Disconnection 40-560


Action code Failure code Left brake ECMV:Disconnection
Failure
(Power train controller system)
E04 DXHCKA
Detail of failure q When power was output to left steering brake ECMV solenoid circuit, abnormal current flowed.
q Stops output to left steering brake ECMV solenoid circuit.
Action of con-
q Restricts operations of engine, transmission, and brake.
troller
q Operates sudden stop prevention valve.
q Left brake keeps applied.
Problem on
q Once machine is stopped, engine speed is limited to half of full speed.
machine
q Once machine is stopped, it cannot travel any more.
q Output (current) to left steering brake ECMV solenoid can be checked by using monitoring function.
Related infor- (Code: 31619 Left brake ECMV output current (F/B))
mation q Method of reproducing failure code:Turn starting switch to ON position and set parking brake lever
to FREE position.

Cause Procedure, measuring location, criteria and remarks

Defective left steering brake 1. Turn starting switch to OFF position.


1 ECMV solenoid (Internal discon- 2. Disconnect connector SLB and connect T-adapter to male side.
nection) Between SLB (male) (1) and (2) Resistance 3 13 z
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN3 and connect T-adapter to female side.
Open or short circuit in wiring har- a If resistance is above 1 Mz, wiring harness has disconnection. If resistance
2
ness is below 1 z, wiring harness has short circuit.
Between PTCN3 (female) (5) and (13) Resistance 3 13 z
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors PTCN3 and SLB, and connect T-adapters to their
3 (Open circuit: Defective contact of female sides.
connectors) Between PTCN3 (female) (5) and SLB (female) (1) Resistance Max. 1 z
Between PTCN3 (female) (13) and SLB (female) (2) Resistance Max. 1 z
If cause is not found by above checks, power train controller may be defective.
4 Defective power train controller
(Since failure is in it, troubleshooting cannot be performed.)

40-560 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXHCKA] Left brake ECMV: Disconnection

Circuit diagram related to left brake ECMV 40-561

D375A-6R 40-561
(01)
Troubleshooting by failurecode
Failure code [DXHCKB] Left brake ECMV: Short circuit

Failure code [DXHCKB] Left brake ECMV: Short circuit 40-562


Action code Failure code Left brake ECMV short circuit
Failure
(Power train controller system)
E04 DXHCKB
Detail of failure q When power was output to left steering brake ECMV solenoid circuit, abnormal current flowed.
q Stops output to left steering brake ECMV solenoid circuit.
Action of con-
q Restricts operations of engine, transmission, and brake.
troller
q Operates sudden stop prevention valve.
q Left brake keeps applied.
Problem on
q Once machine is stopped, engine speed is limited to half of full speed.
machine
q Once machine is stopped, it cannot travel any more.
q Output (current) to left steering brake ECMV solenoid can be checked by using monitoring function.
Related infor- (Code: 31619 Left brake ECMV output current (F/B))
mation q Method of reproducing failure code:Turn starting switch to ON position and set parking brake lever
to FREE position.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective left steering brake 2. Disconnect connector SLB and connect T-adapter to male side.
1 ECMV solenoid (Internal discon-
Between SLB (male) (1) and (2) Resistance 3 13 z
nection)
Between SLB (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SLB and connect T-adapter to female
Ground fault in wiring harness
2 side of either of them.
(Contact with ground circuit)
Between PTCN3 (female) (5) or SLB (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SLB and connect T-adapter to female
3 Short circuit in wiring harness side of either of them.
Between PTCN3 (female) (5) and (13), or between
Resistance Min. 1 Mz
SLB (female) (1) and (2)
If cause is not found by above checks, power train controller may be defective.
4 Defective power train controller
(Since failure is in it, troubleshooting cannot be performed.)

40-562 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXHCKB] Left brake ECMV: Short circuit

Circuit diagram related to left brake ECMV 40-563

D375A-6R 40-563
(01)
Troubleshooting by failurecode
Failure code [DXHCKY] Left brake ECMV: Short circuit

Failure code [DXHCKY] Left brake ECMV: Short circuit 40-564


Action code Failure code Hot short circuit in left brake ECMV
Failure
(Power train controller system)
E04 DXHCKY
Detail of failure q When power is output left steering brake solenoid circuit,current flows.
q Stops output to left steering brake ECMV solenoid circuit.
Action of con-
q Restricts operation of engine, transmission and brake.
troller
q Operates sudden stop prevention valve.
q Left brake does not operate.
Problem on
q Once machine is stopped, engine speed is limited to half of full speed.
machine
q Once machine is stopped, it cannot travel any more.
q Output condition (current) to left steering brake ECMV solenoid can be checked with monitoring
Related infor- function. (Code: 31619 Left brake ECMV output current(F/B))
mation q Method of reproducing failure code: Turn starting switch to ON position and operate parking brake
lever (LOCK).

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective left steering brake 2. Disconnect connector SLB and connect T-adapter to male side.
1 ECMV solenoid (Internal discon-
Between SLB (male) (1) and (2) Resistance 3 13 z
nection)
Between SLB (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector SLB and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between SLB (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SLB, and connect T-adapter to female
side of PTCN3.
a Check with multimeter in continuity mode.
Between PTCN3 (female) (5) and each pin other No continuity (No sound
than (5) is heard)
1. Turn starting switch to OFF position.
3 Short circuit in wiring harness
2. Disconnect connectors PTCN1 to PTCN3 and SLB, and connect
T-adapters to female sides of PTCN1 to PTCN3.
a Check with multimeter in continuity mode.
Between PTCN3 (female) (5) and each pin of No continuity (No sound
PTCN1 (female) is heard)
Between PTCN3 (female) (5) and each pin of No continuity (No sound
PTCN2 (female) is heard)
If cause is not found by the above checks, power train controller may be defec-
4 Defective power train controller
tive. (Since failure is in it, troubleshooting cannot be performed.)

40-564 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXHCKY] Left brake ECMV: Short circuit

Circuit diagram related to left brake ECMV 40-565

D375A-6R 40-565
(01)
Troubleshooting by failurecode
Failure code [DXJBKA] S/C ECMV: Disconnection

Failure code [DXJBKA] S/C ECMV: Disconnection 40-56


Action code Failure code Open circuit in stator clutch ECMV
Failure
(Power train controller system)
E02 DXJBKA
Detail of failure q Although the current is output to stator clutch ECMV solenoid circuit, no current flows.
Action of con- q Stops output to stator clutch ECMV solenoid circuit.
troller q Restritcs operation of engine and transmission.
Problem on
q Engine speed may not be transmitted normally.
machine
q Output condition to stator clutch ECMV solenoid can be checked with monitoring function.
Related infor-
(Code: 90700 S/C ECMV output current (F/B))
mation
q Method of reproducing failure code: Engine started + Travel

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective stator clutch ECMV 2. Disconnect connector SSTC and connect T-adapter to male side.
1
solenoid (internal short circuit)
Between SSTC (male) (1) and (2) Resistance 3 - 13 z
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN3 and connect T-adapter to female side.
Open or short circuit in wiring har- a If resistance is above 1 Mz, wiring harness has disconnection. If resistance
2
ness is below 1 z, wiring harness has short circuit.
Between PTCN3 (female) (6) and (3) Resistance 3 - 13 z
a If cause 2 is not the cause for the failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors PTCN3 and SSTC, and connect T-adapters to their
Open circuit in wiring harness
female sides.
3 (Open circuit in wiring or defective
Between PTCN3 (female) (6) and SSTC
contact in connector) Resistance Max. 1 z
(female) (1)
Between PTCN3 (female) (3) and SSTC
Resistance Max. 1 z
(female) (2)
If cause is not found by above checks, power train controller may be defective.
4 Defective transmission controller
(Since fialure is in it, troubleshooting cannot be performed.)

Circuit diagram related to stator clutch ECMV 40-56

40-566 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXJBKB] S/C ECMV: Short circuit

Failure code [DXJBKB] S/C ECMV: Short circuit 40-567


Action code Failure code Stator clutch ECMV: Short circuit
Failure
(Power train controller system)
E02 DXJBKB
Detail of failure q When power is output to stator clutch ECMV solenoid circuit, abnormal current flow.
Action of con- q Stops output to transmission stator clutch ECMV solenoid circuit.
troller q Restricts operation of engine and transmission.
Problem on
q Engine speed may not be transmitted normally.
machine
q Output condition to stator clutch ECMV solenoid can be checked with monitoring function.
Related infor-
(Code: 90700 S/C ECMV output current (F/B))
mation
q Method of reproducing failure code: Engine started + Travel

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector SSTC and connect T-adapter to male side.
Defective stator clutch ECMV
1
solenoid (Internal short circuit) Between SSTC (male) (1) and (2) Resistance 3 13 z
Between SSTC (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN3 and SSTC , and connect T-adapter to female
Ground fault of wiring harness side of either of them.
2
(Contact with GND circuit)
Between PTCN3 (female) (6) or SSTC
Resistance Min. 1 Mz
(female) (1) and ground
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN3 and SSTC , and connect T-adapter to female
3 Short circuit in wiring harness side of either of them.
Between PTCN 3(female) (6) and (3) or
Resistance Min. 1 Mz
between SSTC (female) (1) and (2)
If cause is not found by the above checks, work equipment controller may be
4 Defective power train controller
defective. (Since failure is in it, troubleshooting cannot be performed.)

Circuit diagram related to stator clutch ECMV 40-567

D375A-6R 40-567
(01)
Troubleshooting by failurecode
Failure code [DXJBKY] S/C ECMV: Short circuit

Failure code [DXJBKY] S/C ECMV: Short circuit 40-568


Action code Failure code Short circuit in stator clutch ECMV
Failure
(Power train controller system)
E02 DXJBKY
Detail of failure q Electric current is always flowing to stator clutch ECMV solenoid circuit.
Action of con- q Stops output to stator clutch ECMV solenoid circuit.
troller q Restricts operation of engine and transmission.
Problem on
q Engine speed may not be transmitted normally.
machine
q Output to stator clutch ECMV solenoid can be checked by using the monitoring function.
Related infor-
(Code: 90700 S/C ECMV output current (F/B))
mation
q Method of reproducing failure code:Start engine and travel at F1 or R1.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector SSTC and connect T-adapter to male side.
Defective stator clutch ECMV
1
solenoid (internal short circuit) Between SSTC (male) (1) and (2) Resistance 3 13 z
Between SSTC (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector SSTC and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between SSTC (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN3 and SSTC , and connect T-adapter to female
side of PTCN3.
a Check with circuit tester in continuity mode.
Between PTCN3 (female) (6) and each pin No continuity (No sound is
other than (6) heard)
1. Turn starting switch to OFF position.
3 Short circuit in wiring harness
2. Disconnect connector PTCN1 to 3 and SSTC , and connect T-adapters to
female sides of PTCN1 to 3.
a Check with circuit tester in continuity mode.
Between PTCN3 (female) (6) and each pin of No continuity (No sound is
PTCN1 (female) heard)
Between PTCN3 (female) (6) and each pin of No continuity (No sound is
PTCN2 (female) heard)
If cause is not found by the above checks, work equipment controller may be
4 Defective power train controller
defective. (Since failure is in it, troubleshooting cannot be performed.)

40-568 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DXJBKY] S/C ECMV: Short circuit

Circuit diagram related to stator clutch ECMV 40-569

D375A-6R 40-569
(01)
Troubleshooting by failurecode
Failure code [DY2HKA] Pre lub. motor: Disconnection

Failure code [DY2HKA] Pre lub. motor: Disconnection 40-570


Action code Failure code Pre-lubricating motor open circuit
Failure
(Power train controller system)
E02 DY2HKA

Detail of failure q After power train controller starts pre-lubrication, power is not supplied to pre-lubricating motor.

Action of con-
q None in particular
troller
Problem on
q Engine does not operate (It operates in skip mode, however).
machine
q Whether pre-lubricating motor is operating can be checked with monitoring function.
Related infor-
(Code: 40910 PT controller SW input 2)
mation
q Primary side of pre-lubricating relay is checked with failure codes [D1EFKA] and [D1EFKB].

Cause Procedure, measuring location, criteria and remarks


If circuit breaker is operating, the circuit probably has ground fault. In this case,
1 Defective circuit breaker (CBH1)
perform troubleshooting for cause 6 first.
1. Turn starting switch to OFF position.
Loose terminal or disconnection at
2 Check the terminals of battery relay, preheater relay, pre-lubricating relay,
terminal
pre-lubricating motor, etc.
1. Turn starting switch to OFF position.
2. Replace relay (PLUB) with another relay (e.g. backup alarm relay: BKA).
3 Defective relay (PLUB) 3. Turn starting switch to ON position.
If pre-lubrication is completed, original relay (PLUB) is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector PLS.
4 Defective diode (PLS) 3. Turn starting switch to ON position.
If the pre-lubrication is completed, diode (PLS) is defective.
1. Turn starting switch to OFF position.
2. Disconnect terminal PM1.
5 Defective pre-lubricating motor
Between terminal PM1 (on pre-lubricating motor
Continuity
side) and ground
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PLUB.
3. If circuit breaker trips, reset it.
4. Turn starting switch to ON position.
a If voltage is 0 V, wiring harness has disconnection or ground fault (If voltage
is abnormal and check result of cause 8 is normal, wiring harness has dis-
connection).
Open circuit or ground fault in wir- Between PLUB (3) and ground Voltage 20 30 V
6
ing harness
Between PLUB (5) and ground Voltage 20 30 V
Between PR1 and ground Voltage 20 30 V
Between PR2 and ground Voltage 20 30 V
Between PR3 and ground Voltage 20 30 V
Between PM1 and ground Voltage 20 30 V
If voltages at terminals PR1 and PR3 are normal and voltage at terminal PR2
7 Defective pre-lubrication relay
is abnormal as check result of cause 6, pre-lubricating relay is defective.

40-570 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [DY2HKA] Pre lub. motor: Disconnection

Cause Procedure, measuring location, criteria and remarks


a If cause 6 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN1 and connect T-adapter to female side.
3. Disconnect terminal PR3.
Ground fault in wiring harness 4. If circuit breaker trips, reset it.
8
(Contact with ground circuit) Between PTCN1 (female) (23) and ground Resistance Min. 1 Mz
Between terminal PR1 and ground Resistance Min. 1 Mz
Between terminal PR3 (on wiring harness side) and
Resistance Min. 1 Mz
ground
If cause is not found by the above checks, power train controller is defective.
q Reference: the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
9 Defective power train controller 2. Insert T-adapter into connector PTCN1.
3. Turn starting switch to ON position.
Between PTCN1 (23) and (10) Voltage 20 30 V

Circuit diagram related to pre-lubricating motor 40-571

D375A-6R 40-571
(01)
Troubleshooting by failurecode
Failure code [F@BBZL] ENG blow-by pressure high level

Failure code [F@BBZL] ENG blow-by pressure high level 40-572


Action code Failure code
Failure Engine blow-by pressure abnormally high level
F@BBZL
Detail of failure q Engine blowby pressure is higher than threshold value of 900 mmH2O{8.83 kPa}.
Action of con-
q None in particular
troller
Problem on
q If machine is used as it is, engine may be broken.
machine
Related infor- q Blowby pressure can be checked with monitoring code 42801(kPa).
mation q The LED of the VHMS controller displays "n3" and "38" alternately and repeatedly.

Cause Procedure, measuring location, criteria and remarks


Abnormal increase of engine q Check engine and then repair if necessary.
1
blow-by pressure q Check the breather hose outlet for clogging, bend, or break. If any, repair it.
Defective engine blow-by pres-
2
sure sensor Troubleshooting for failure codes [DHE5KB] and [DHE5KY].
3 Defective VHMS controller

40-572 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [F@BYNR] F exhaust temp high level (2)

Failure code [F@BYNR] F exhaust temp high level (2) 40-573


Action code Failure code Front exhaust temperature abnormal increase (2)
Failure
(VHMS controller system)
F@BYNR
q Signal voltage of exhaust temperature sensor for No. 1, 2 and 3 cylinders (front side)increased and
VHMS controller detected temperature higher than exhaust temperature sensor limit line 2 for more
Detail of failure than 10 seconds.
(Exhaust gas temperature limit line 2: Straight line between 750 C at rated output speed at
minimum and 800 C at max. torque speed at maximum)
Action of con-
q None in particular
troller
Problem on
q If machine is used as it is, engine may be broken.
machine
Related infor- q Front exhaust temperature can be checked with monitoring code: 42610 ( C).
mation q The LED of the VHMS controller displays "n3" and "62" alternately and repeatedly.

Cause Procedure, measuring location, criteria and remarks


Abnormal increase of front
1 exhaust temperature (When sys- Check the engine for abnormality. Correct, if any.
tem is normal)
Front exhaust temperature sensor
2
system defective Troubleshooting for failure codes [DGT5KA] and [DGT5KB].
3 Defective VHMS controller

D375A-6R 40-573
(01)
Troubleshooting by failurecode
Failure code [F@BYNS] F exhaust temp high level (1)

Failure code [F@BYNS] F exhaust temp high level (1) 40-574


Action code Failure code Front exhaust temperature abnormal increase (1)
Failure
(VHMS controller system)
F@BYNS
q Signal voltage of exhaust temperature sensor for No. 1, 2 and 3 cylinders (front side) increased and
VHMS controller detected temperature higher than exhaust temperature sensor limit line 1 for more
Detail of failure than 20 seconds.
(Exhaust gas temperature limit line 1: Straight line between 700 C at rated output speed at
minimum and 750 C at max. torque speed at maximum)
Action of con-
q None in particular.
troller
Problem on
q If machine is used as it is, engine may be broken.
machine
Related infor- q Front exhaust temperature can be checked with monitoring code: 42610 ( C).
mation q VHMS controller LED indicates "n3" and "61" alternately and repeatedly.

Cause Procedure, measuring location, criteria and remarks


Abnormal increase of front
1 exhaust temperature (When sys- Check the engine for abnormality, Correct, if any.
tem is normal)
Front exhaust temperature sensor
2
system defective Troubleshooting for failure codes [DGT5KA]and [DGT5KB].
3 Defective VHMS controller

40-574 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [F@BZNR] R exhaust temp high level (2)

Failure code [F@BZNR] R exhaust temp high level (2) 40-575


Action code Failure code Rear exhaust temperature abnormal increase (2)
Failure
(VHMS controller system)
F@BZNR
q Signal voltage from exhaust temperature sensor for No. 4, 5 and 6 cylinders (rear side) increases
and VHMS controller detects unusual high temperatures above exhaust temperature limit line 2 for
Detail of failure more than 10 seconds.
(Exhaust gas temperature limit line 2: Straight line connecting point of 750 C at rated output speed
and point of 800 C at max. torque speed)
Action of con-
q Flashes warning lamp and turns on caution buzzer. (Function of monitor panel)
troller
Problem on
q If machine is used as it is, engine may be broken.
machine
q Exhaust temperature of rear cylinders can be checked by using monitoring function. (Code: 42611
Related infor-
( C)
mation
q The LED of the VHMS controller displays "n3" and "82" alternately and repeatedly.

Cause Procedure, measuring location, criteria and remarks


Abnormal increase of rear exhaust
1 temperature (When system is nor- Check the engine for abnormality, Correct, if any.
mal)
Rear exhaust temperature sensor
2
system defective Troubleshooting for failure codes[DGT6KA] and [DGT6KB]
3 Defective VHMS controller

D375A-6R 40-575
(01)
Troubleshooting by failurecode
Failure code [F@BZNS] R exhaust temp high level (1)

Failure code [F@BZNS] R exhaust temp high level (1) 40-576


Action code Failure code Rear exhaust temperature abnormal increase (1)
Failure
(VHMS controller system)
F@BZNS
q Signal voltage from exhaust temperature sensor for No. 4, 5 and 6 cylinders (rear side) increases
and VHMS controller detects unusual high temperatures above exhaust temperature limit line 1 for
Detail of failure more than 20 seconds.
(Exhaust gas temperature limit line 1: Straight line between 700 C at rated output speed at
minimum and 750 C at max. torque speed at maximum)
Action of con-
q Flashes warning lamp and turns on caution buzzer. (Function of monitor panel)
troller
Problem on
q If machine is used as it is, engine may be broken.
machine
q Exhaust temperature of rear cylinders can be checked by using monitoring function. (Code: 42611
Related infor-
( C)
mation
q The LED of the VHMS controller displays "n3" and "38" alternately and repeatedly.

Cause Procedure, measuring location, criteria and remarks


Abnormal increase of rear exhaust
1 temperature (When system is nor- Check the engine for abnormality, Correct, if any.
mal)
Rear exhaust temperature sensor
2
system defective Troubleshooting for failure codes [DGT6KA] and [DGT6KB].
3 Defective VHMS controller

40-576 D375A-6R
(01)
Troubleshooting by failurecode
Failure code [F@BZNS] R exhaust temp high level (1)

D375A-6R 40-577
(01)
Troubleshooting of electrical system (E-mode)
Information contained in troubleshooting table

Troubleshooting of electrical system (E-mode) 40-578


Information contained in troubleshooting table 40-578
a Troubleshooting Table and Circuit Diagram Related collectively include the following information. Perform
troubleshooting work after fully grasping their contents.
Failure Problem on machine
Related infor-
Information related to detected failure or troubleshooting
mation
Cause Procedure, measuring location, criteria and remarks
<Contents of description>
q Procedure
q Measuring location
Possible causes a "Between A and B" means the measurement of voltage, resistance or others
between terminals A and B.
q Criteria in normal state to judge possible causes
q Remarks on judgment
<Troubles in wiring harness>
q Perform troubleshoot in following procedure in numerical order.
1 - defective q If the testing result shows abnormality, the cause described on the left column con-
forms.
q If it shows normal, and unless otherwise specified particularly, proceed to the next
step (cause).
Open circuit in wiring har- q After correction of a single failure, check to see that this problem has been solved.
ness Then, start the next troubleshooting.
2 (Open circuit in wiring or <Troubles in wiring harness>
defective contact in connec- q Disconnection
tor) Connector is connected imperfectly or wiring harness is broken.
q Ground fault
Wiring harness which is not connected to chassis ground circuit is in contact with
Ground fault in wiring har- chassis ground circuit.
3 ness q Hot short circuit
(Contact with ground circuit) Wiring harness which is not connected to power source (24 V) circuit is in contact
with power source (24 V) circuit.
q Short circuit
Independent wiring harnesses are in contact with each other abnormally.
Hot short circuit (Poor insulation of connector or others)
4 (Short circuit with 24 V cir- <Precautions for troubleshooting>
cuit) (1) Method of indicating connector No. and handling of T-adapter
Insert or connect T-adapter as explained below for troubleshooting, unless other-
wise specified.
q If connector No. has no marks of "male" and "female", disconnect connector
and insert T-adapters in both male side and female side.
Short circuit in wiring har- q If connector No. has marks of "male" and "female", disconnect connector and
5
ness connect T-adapter to only male side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative () lead of tester as explained below for
troubleshooting, unless otherwise specified.
q Connect positive (+) lead to pin No. or wiring harness entered on front side.
q Connect negative (-) lead to pin No. or harness entered on rear side.
6 Defective controller

40-578 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
Information contained in troubleshooting table

Related circuit diagram 40-579


This is the excerpted circuit diagram related to trouble-
shooting
q Connector No.: Indicates (Type-number of pin) (Color)
q "Connector No. and pin No." from each branching/merg-
ing point: Shows the ends of branch or source of merg-
ing within the parts of the same wiring harness.
q Arrow(io): Roughly shows the location on the ma-
chine.
q NO: Normally Open
q NC: Normally Closed

D375A-6R 40-579
(01)
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (starting motor does not turn)

E-1 Engine does not start (starting motor does not turn) 40-580
Failure q The starting motor does not turn and accordingly the engine does not start.
q Since the engine start circuit has the neutral safety function, the engine does not start unless
the work equipment lock lever and parking brake lever are in the lock position and the travel
lever is in the neutral position.
q Before carrying out troubleshooting, check that no related failure code is displayed.
(If the failure code
Related information
[D110KB][D130KA][D130KB][D190KA][D190KB][D1EFKA][D1EFKB][DD14KA][DD14KB]
[7RFAKA][7RFAKB][DDE2KA][DY2HKA] is displayed, troubleshoot them first.)
q In the case of "the battery relay does not make operating sound" when turning the starting
switch ON, perform E-1 also.
q If engine does not stop, replace engine holding relay.

Cause Procedure, measuring location, criteria and remarks


Defective circuit breaker CB30 or If CB30 or CB6 circuit breaker is turned ON, circuit probably has ground fault.
1
CB6 In this case, perform troubleshooting for cause 16 first.
If fuse FS31-5 is blown, the circuit probably has ground fault. Troubleshoot for
2 Defective fuse FS31-5
cause 16 first.
1. Turn starting switch to OFF position.
Loose terminal or disconnection at
3 Check the terminals of battery relay, alternator, starting motor, ground, ground
terminal
01, ground 11 etc.
Battery voltage Min. 24 V
4 Insufficient battery capacity
Electrolyte specific gravity Min. 1.26
1. Turn starting switch to ON position.
Defective parking lever switch 2. Operate parking brake lever and troubleshoot.
5 (internal defect or defective adjust- Free position Other than "P"
Display of "P" on monitor
ment)
panel Lock position "P" is displayed.
1. Turn starting switch to ON position.
Defective work equipment lock
2. Operate work equipment lock lever switch and troubleshoot.
lever switch
6
(internal defect or defective adjust- Display of "Lock work Free position Symbol OFF
ment) equipment" symbol on
monitor panel Lock position Symbol ON
1. Turn starting switch to OFF position.
2. Disconnect ground strap.
3. Disconnect connector KEY.
4. Turn starting switch to ON, OFF and START positions and troubleshoot.
OFF Resistance Min. 1 Mz
Between terminals 250 and 260
Defective starting switch ON Resistance Max. 1 z
7
(Internal disconnection)
OFF Resistance Min. 1 Mz
Between terminals 250 and 270
ON Resistance Max. 1 z
OFF Resistance Min. 1 Mz
Between terminals 250 and 280
START Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Replace neutral safety relay (NSF) with another relay (such as BKA).
8 Defective neutral safety relay 3. Start engine.

If engine starts, original neutral safety relay (NSF) is defective.

40-580 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (starting motor does not turn)

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Replace engine ACC cutout relay (ACT) with another relay (such as BKA).
9 Defective engine ACC cutout relay 3. Start engine.
If engine starts, original engine ACC cutout relay (ACT) is defective.

a If the engine does not stop


1. Turn starting switch to OFF position.
2. Disconnect the ground cable.
10 Defective engine holding relay 3. Replace engine holding relay (EHL) with another relay (such as BKA).
4. Connect ground strap.

If engine stops, original engine holding relay (EHL) is defective.

1. Turn starting switch to OFF position.


2. Remove connector RSD and connect T-adapter to diode.
Defective diode RSD
a Measure in diode range of tester.
11 (internal open circuit or short cir-
cuit) Between RSD (male) (1) (+) and (2) (-) No continuity
Between RSD (male) (2) (+) and (1) (-) Continuity

Defective alternator 1. Turn starting switch to ON position.


12
(Internal short circuit) Between terminal AL/R and ground Voltage Max. 12 V
1. Turn starting switch to OFF position.
2. Start the engine for troubleshooting.
Power supply: Between terminal B
Voltage 20 30 V
and chassis ground
Detective starting motor (internal Between charge terminal R and
13 Voltage Max. 12 V
defect) ground
Between starting motor terminal C and
Voltage 20 30 V
ground
When voltages of power supply, charging and starting circuits are normal but
starting motor does not rotate, starting motor is defective.

D375A-6R 40-581
(01)
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (starting motor does not turn)

Cause Procedure, measuring location, criteria and remarks


q Battery relay
1. Turn starting switch to OFF position.
Between terminal BRE and ground Resistance Max. 1 z
q Battery relay
1. Turn starting switch to OFF position.
2. Turn starting switch to START position.
a Check to where 24 V is supplied to identify disconnected place.
Between terminal 260 and ground Voltage 20 30 V
Between terminal SW and ground Voltage 20 30 V
Between terminal BRB and ground Voltage 20 30 V
Between terminal BRC and ground Voltage 20 30 V
q Alternator and starting motor
1. Turn starting switch to OFF position.
14 Open circuit in wiring harness 2. Disconnect ground strap.
3. Insert T-adapters into connectors NSF, ST1 and ST2.
4. Connect ground strap.
5. Turn starting switch to START position and troubleshoot.
a Check to where 24 V is supplied to identify disconnected place.
Between terminal 280 and ground Voltage 20 30 V
Between NSF (1) and ground Voltage 20 30 V
Between NSF (3) and ground Voltage 20 30 V
Between NSF (5) and ground Voltage 20 30 V
Between ST1 (1) and ground Voltage 20 30 V
Between ST2 (1) and ground Voltage 20 30 V
Between terminal AL/B and ground Voltage 20 30 V
Between terminal ST/B and ground Voltage 20 30 V
Defective battery relay If only terminal BRC voltage is abnormal during battery relay check for cause
15
(Does not turn ON) 14, battery relay is defective.
a If cause 14 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect ground strap.
Ground fault in wiring harness 3. Disconnect connectors NSF, PTCN1, WECN1, CM01 and ST.
16
(Contact with ground circuit) Between terminal 250 and ground Resistance Min. 1 Mz
Between terminal 280 or NSF (3) and ground Resistance Min. 1 Mz
Between NSF (5), ST2 (1) or ST1 (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect terminal AL/R.
Hot short circuit in wiring harness
17 3. Turn starting switch to ON position.
(Short circuit with 24 V circuit)
Between terminal AL/R (Wiring harness side) and
Voltage Max. 1 V
ground

40-582 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (starting motor does not turn)

Circuit diagram related to engine start circuit 40-583

D375A-6R 40-583
(01)
Troubleshooting of electrical system (E-mode)
E-2 Preheater does not operate

E-2 Preheater does not operate 40-584


Failure 1)Manual preheater does not operate.
a This troubleshooting describes the procedures to be followed when the automatic and manual pre-
heating does not function to heat the electrical intake air heater mounting section.
q For preheating, both the Automatic preheating function and Manual preheating function are
available. When either function is performed, the preheating lamp lights up.
(When only the preheating lamp does not light up, perform troubleshooting "3) While the preheater
Related informa- is operating, the preheating monitor does not light up")
tion q If "the machine monitor does not light up" or "the battery relay does not make operating sound"
when turning the starting switch ON, the main electric power supply system is supposed to be de-
fective. So, troubleshoot E-3 and E-1.
q Before carrying out troubleshooting, check that no related failure code is displayed.
(If the failure code [CA153], [CA154], [D110KB] or [D182KZ] is displayed, firstly perform these
troubleshooting.)

Cause Procedure, measuring location, criteria and remarks


Defective circuit breaker If CBH1 circuit breaker is turned ON, circuit probably has ground fault. In this case,
1
CBH1 perform troubleshooting for cause 7 first.

Loose terminal or disconnec- 1. Turn starting switch to OFF position.


2
tion at terminal Check terminals of heater relay, battery relay, etc.
1. Turn starting switch to OFF position.
2. Remove connector HTD and connect T-adapter to diode.
Defective diode HTD
a Measure in diode range of tester.
3 (internal open circuit or short
circuit) Between HTD (male) (1) (+) and (2) (-) No continuity
Between HTD (male) (2) (+) and (1) (-) Continuity
Defective electrical intake air 1. Turn starting switch to OFF position.
heater 2. Disconnect terminal HT/B.
4
(Internal open circuit in wir-
ing) Between terminal HT/B and ground There is continuity
1. Turn starting switch to OFF position.
2. Disconnect ground strap.
3. Disconnect connector KEY and connect T-adapter to male side.
5 Defective starting switch
4. Turn starting switch to OFF/HEAT position and troubleshoot.
OFF Resistance Min. 1 Mz
Between terminals 250 and 255
HEAT Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector CM01.
Between terminal 255 and ground There is continuity
1. Turn starting switch to OFF position.
2. Turn starting switch to ON position.
Open circuit or ground fault in Between terminal HT/A and ground Voltage 20 30 V
6
wiring harness 1. Turn starting switch to OFF position.
2. Disconnect terminal HT/B.
3. Turn starting switch to HEAT position (Connect R1).
a Disconnect so that current will not flow in heater when starting switch is turned to
HEAT position.
Between terminal HT and ground Voltage 20 30 V
a If cause 6 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring har-
2. Disconnect connectors KEY and CM01 and terminals HT and BRC.
7 ness
Between terminal HT/A and ground Resistance Min. 1 Mz
(Contact with ground circuit)
Between terminal HT (on wiring harness side) and
Resistance Min. 1 Mz
ground
Defective preheater relay
If cause 6 is not the cause for the trouble and preheater relay operation sound is not
8 (Does not turn ON) (Terminal
heard, preheater relay is defective.
HT/B)

40-584 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-2 Preheater does not operate

Circuit diagram related to preheating of engine 40-585

D375A-6R 40-585
(01)
Troubleshooting of electrical system (E-mode)
E-2 Preheater does not operate

Failure 2) Automatic preheater does not operate.


q Automatic preheater operates when intake air (boost) temperature is below -5 C.
Related informa- (Monitoring code: Engine coolant temperature 04107)
tion q If automatic preheater does not operate, check if manual preheater operates.
q Engine controller troubleshoots primary (coil) side of preheater relay by failure code [D182KZ].

Cause Procedure, measuring location, criteria and remarks


If fuse FS22-4 is broken, circuit probably has ground fault. In this case, perform trou-
1 Defective fuse FS22-4
bleshooting for cause 5 first.
1. Turn starting switch to OFF position.
2. Replace the preheater relay (connector: PHR) with the backup alarm relay
Defective preheater relay
(connector: BKA).
2 (internal open circuit or short
3. Turn starting switch to ON position.
circuit)
If automatic preheater operates when intake air (boost) temperature is below -5 C,
original preheater relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector PTCN2 and connect T-adapter to female side.
Open circuit or ground fault a If resistance is above 1 Mz, wiring harness has disconnection. If resistance is be-
3
of wiring harness low 1 z, wiring harness has short circuit.
a Preheater relay coil resistance
Between PTCN2 (female) (19) and ground Resistance 200 400 z
1. Turn starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connectors PHR and CM01, and connect T-adapter to female side of
ness PHR.
4
(open circuit or defective 3. Remove fuse FS22-4.
contact) Between PHR (female) (3) and ground Continuity
Between PHR (female) (5) and FS22-4 Resistance Max. 1 z
If the fuse is not blown, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring har-
2. Disconnect connectors PHR, FSB and ASUS, and connect T-adapter to female
5 ness
side of PHR.
(Contact with ground circuit)
3. Remove fuse FS22-4.
Between PHR (female) (5) and ground Resistance Min. 1 Mz

Failure 3) While preheater is operating, the preheating monitor does not light up.
Related informa- q There are "Automatic preheater" and "Manual preheater" installed. When either function is oper-
tion ated, the preheating lamp lights up.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Open circuit in wiring har-
2. Disconnect connectors PHR and CM01, and connect T-adapters to female side
ness
1 of them.
(open circuit or defective
Between PHR (female) (3) and CM01 (female) (16) Resistance Max. 1 z
contact)
Between terminal 255 and CM01 (female) (16) Resistance Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring har-
2. Disconnect connectors PHR, CM01 and terminal HT, and connect T-adapter to
2 ness
female side of CM01.
(Contact with ground circuit)
Between CM01 (female) (16) and ground Resistance Min. 1 Mz
If cause is not found by above checks, machine monitor is defective.
q Reference (the followings are standard values in normal condition)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector CM01.
3 Defective machine monitor 3. Disconnect terminal HT.
a Disconnect so that current will not flow in heater when starting switch is turned to
HEAT position.
4. Turn the starting switch to the HEAT position.
Between CM01 (16) and (3) Resistance 20 30 V

40-586 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-2 Preheater does not operate

Circuit diagram related to preheating of engine 40-587

D375A-6R 40-587
(01)
Troubleshooting of electrical system (E-mode)
E-3 When starting switch is turned ON, machine monitor displays nothing

E-3 When starting switch is turned ON, machine monitor displays


nothing 40-58
Failure q When starting switch turned ON, machine monitor displays nothing
q When starting switch is turned ON, machine monitor displays KOMATSU logo, screen to input
password (if set), screen of check before starting, screen to check setting of preset, and ordinary
screen in order.
q When the engine is started, the battery voltage may lower suddenly, depending on the ambient
Related information temperature and the condition of the battery.
In this case, the machine monitor goes off for a moment. This phenomenon is not a failure,
however.
q In the case of "the battery relay does not make operating sound" when turning the starting switch
ON, perform E-1.

Cause Standard value in normal condition/Remarks on troubleshooting


Defective circuit breaker CB30 or If CB30 or CB6 circuit breaker is turned ON, circuit probably has ground fault.
1
CB6 In this case, perform troubleshooting for cause 8 first.

Loose terminal or disconnection at 1. Turn starting switch to OFF position.


2
terminal Check terminals of battery, battery relay, etc.
1. Turn starting switch to OFF position.
3 Insufficient battery capacity Battery voltage (two pieces) Min. 24 V
Electrolyte specific gravity Min. 1.26
a If machine monitor has not been replaced, this check is not required.
Misalignment of wiring harness 1. Turn starting switch to OFF position.
4 (Numbers of pins of CM01 and 2. Remove machine monitor.
CM03 are same) Check that connectors CM01 (white) and CM03 (green) are matched to con-
nector colors of machine monitor unit.
1. Turn starting switch to OFF position.
2. Disconnect ground strap.
3. Disconnect connector CM01 and connect T-adapter to female side.
4. Connect ground strap.
a If voltage is 0 V, wiring harness has disconnection or ground fault.
Open circuit or ground fault in wir-
5 ing harness or defective starting Between CM01 (female) (1) and (3) Voltage 20 30 V
switch Between CM01 (female) (2) and (4) Voltage 20 30 V
1 - 4 are same as above.
5. Turn starting switch to ON position (Connect ACC).
Between CM01 (female) (14) and (4) Voltage 20 30 V
1. Turn starting switch to OFF position.
2. Disconnect ground strap.
3. Disconnect connector KEY.
6 Defective starting switch 4. Turn starting switch to ON/OFF position and troubleshoot.
OFF Resistance Min. 1 Mz
Between terminals 250 and 270
ON Resistance Max. 1 z

40-588 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-3 When starting switch is turned ON, machine monitor displays nothing

Cause Standard value in normal condition/Remarks on troubleshooting


a If cause 5 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect ground strap.
3. If circuit breaker is turned ON, reset it.
4. Disconnect connector CM01 and connect T-adapter to female side.
Between CM01 (female) (3), (4) and ground
Open circuit in wiring harness Resistance Max. 1 z
7 a Check terminal GND01 for looseness and rust.
(open circuit or defective contact)
Between CM01 (female) (1), (2) and battery (+) Resistance Max. 1 z
1 - 4 are same as above.
5. Turn starting switch to ON position (Connect ACC with ground strap discon-
nected).
Between CM01 (female) (14) and battery (+) Resistance Max. 1 z
a If cause 5 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect ground strap.
Ground fault in wiring harness 3. If circuit breaker is turned ON, reset it.
8 4. Disconnect connector CM01 and connect T-adapter to female side.
(Contact with ground circuit)
a Check that condition is normal when starting switch is turned to ON position
(Connect ACC with ground strap disconnected).
Between CM01 (female) (1) and ground Resistance Min. 1 Mz
9 Defective machine monitor If cause is not found by above checks, machine monitor is defective.

D375A-6R 40-589
(01)
Troubleshooting of electrical system (E-mode)
E-3 When starting switch is turned ON, machine monitor displays nothing

Circuit diagram related to machine monitor 40-590

40-590 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-3 When starting switch is turned ON, machine monitor displays nothing

D375A-6R 40-591
(01)
Troubleshooting of electrical system (E-mode)
E-4 When starting switch is turned ON (before starting engine), basic check item lights up

E-4 When starting switch is turned ON (before starting engine), basic


check item lights up 40-592
1) When starting switch is turned to ON position (with engine stopped), engine oil pressure moni-
Failure
tor lights up.
q Engine oil pressure sensed by engine oil pressure sensor can be checked with monitoring func-
Related information tion.
(Code: 37200 Engine Oil Pressure Sensor)

Cause Procedure, measuring location, criteria and remarks


Defective engine oil pressure
1 caution lamp circuit Perform troubleshooting for failure codes [CA135], [CA141].
(Engine controller circuit)
If cause 1 is not detected, machine monitor may be defective.
2 Defective machine monitor
(Since trouble is in system, troubleshooting cannot be performed.)

2) When starting switch is turned to ON position (with engine stopped), engine oil level monitor
Failure
lights up.
Related information q Engine oil level monitor (oil level switch) is optional.

Cause Procedure, measuring location, criteria and remarks


Defective engine oil level switch
1 system (machine monitor sys- Perform troubleshooting for failure code [B@BAZK].
tem)
If cause 1 is not detected, machine monitor may be defective.
2 Defective machine monitor
(Since trouble is in system, troubleshooting cannot be performed.)

Failure 3) Radiator coolant level monitor lights.


Related information

Cause Procedure, measuring location, criteria and remarks


Radiator coolant level decrease The coolant level monitor may be insufficient. Check coolant level and add cool-
1
(When system is normal) ant if necessary.
1. Turn starting switch to OFF position.
2. Disconnect connector WLD and connect T-adapter to male side.
Defective coolant level sensor
2 Between FULL and LOW Resistance Max. 1 z
(Internal defect) Between WLD (male) (1)
and (2) Value when coolant level
Resistance Min. 1 Mz
is low
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connector CM02 and connect T-adapter to female side.
3 (open circuit or defective con- a Add coolant.
tact)
Between CM02(female)(3)and WLD(female)(1) Resistance Max. 1 z
If cause is not found by above checks, machine monitor is defective.
q Reference; the followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector CM02.
4 Defective machine monitor 3. Turn starting switch to ON position.
Between FULL and LOW Voltage Max. 1 V
Between CM02 (female)
(3) and ground Value when coolant level
Voltage Min. 7 V
is low

40-592 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-4 When starting switch is turned ON (before starting engine), basic check item lights up

Circuit diagram related to radiator coolant level 40-593

D375A-6R 40-593
(01)
Troubleshooting of electrical system (E-mode)
E-5 Precaution item lights up while engine is running

E-5 Precaution item lights up while engine is running 40-594


Failure q Precaution item lights up while engine is running.
q Check item is only charge level monitor.
Related information q State of generation signal of alternator can be checked with monitoring function.
(Code: 04300 Charge voltage)

Cause Procedure, measuring location, criteria and remarks

Loose terminal or disconnection 1. Turn starting switch to OFF position.


1
at terminal Check terminals of alternator etc.
1. Turn starting switch to OFF position.
Defective alternator 2. Start engine and troubleshoot while running engine at medium speed or
2 higher.
(insufficient power generation)
Between terminal AL/R and ground Voltage 20 30 V
1. Turn starting switch to OFF position.
2. Remove connector RSD and connect T-adapter to diode.
Defective diode RSD
a Measure in diode range of tester.
3 (internal open circuit or short cir-
cuit) Between RSD (male) (1) (+) and (2) (-) No continuity
Between RSD (male) (2) (+) and (1) (-) Continuity
1. Turn starting switch to OFF position.
2. Disconnect ground strap.
3. Disconnect connectors CM01 and RSD, and connect T-adapter to female side
Open circuit in wiring harness
of CM01.
4 (Open circuit in wiring or defec-
4. Disconnect terminal AL/R.
tive contact in connector)
Between CM01 (female) (11) and AL/R Resistance Max. 1 z
Between alternator terminal E and ground Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect ground strap.
Ground fault in wiring harness 3. Disconnect connectors CM01, RSD, PTCN1, WECN1, ST1 and ST2, and
5 connect T-adapter to female side of CM01.
(Contact with ground circuit)
4. Disconnect terminal AL/R.
Between CM01 (female) (11) and ground Resistance Min. 1 Mz
If cause is not found by above checks, machine monitor is defective.
q Reference: Following shows standard values in normal condition.
1. Turn starting switch to OFF position.
2. Disconnect ground strap.
6 Defective machine monitor panel 3. Insert T-adapter into connector CM01.
4. Connect ground strap.
5. Start engine and troubleshoot while running engine at medium speed or
higher.
Between CM01 (11) and (3) Voltage 20 30 V

40-594 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-5 Precaution item lights up while engine is running

Electrical diagram related to charging cricuit 40-595

D375A-6R 40-595
(01)
Troubleshooting of electrical system (E-mode)
E-6 Emergency stop item lights up while engine is running

E-6 Emergency stop item lights up while engine is running 40-596


Failure 1)Engine coolant temperature monitor lights up.
q Signal voltage of engine coolant temperature sensor is input to engine controller and then the
data is transmitted to machine monitor through CAN communication system.
Related information
q Engine coolant temperature can be checked with monitoring function
(Code: 04107 Engine coolant temperature)

Cause Procedure, measuring location, criteria and remarks


Overheating of engine coolant
1 Engine coolant may be overheated. If it is overheated, remove cause.
(when system is normal)
Defective coolant temperature If cause 1 is not detected, engine coolant temperature sensor system may be
2
sensor system defective. Perform troubleshooting for failure codes [CA144] and [CA145].
If causes 1 2 are not detected, machine monitor may be defective
3 Defective machine monitor
(Since trouble is in system, troubleshooting cannot be carried out.)

Failure 2) Engine oil pressure monitor lights up.


q Signal of engine oil pressure sensor is input to engine controller and then the data is transmitted
to machine monitor through CAN communication system.
Related information
q Engine oil pressure can be checked with monitoring function.
q (Code: 37200 Engine Oil Pressure Sensor)

Cause Procedure, measuring location, criteria and remarks


Reduction of engine oil pressure Check the engine oil pressure as the drop of engine oil pressure is detected.
1
(When system is normal) q Perform troubleshooting "S-12 (Oil pressure drop)".

Defective engine oil pressure If cause 1 is not the cause for the trouble, engine oil pressure switch system may
2
system be defective. Perform troubleshooting for failure codes [CA135] and [CA141].
If causes 1 2 are not detected, machine monitor may be defective
3 Defective machine monitor
(Since trouble is in system, troubleshooting cannot be performed.)

Failure 3) Torque converter oil temperature monitor lights up.


q Signal voltage of torque converter oil temperature sensor is input to power train controller and
then the data is transmitted to machine monitor through CAN communication system.
Related information
q Torque converter oil temperature can be checked with monitoring function.
q (Code: 30100 T/C Oil Temperature)

Cause Procedure, measuring location, criteria and remarks


Overheating of torque converter
1 Torque converter oil may be overheated. If it is overheated, remove cause.
oil (When system is normal)
If cause 1 is not the cause for the trouble, torque converter oil temperature sen-
Defective torque converter oil
2 sor system may be defective. Perform troubleshooting for failure codes
temperature sensor system
[DGT1KA] and [DGT1KX].
If causes 1 2 are not detected, machine monitor may be defective
3 Defective machine monitor
(Since trouble is in system, troubleshooting cannot be carried out.)

Failure 4) Hydraulic oil temperature monitor lights up.


q Hydraulic oil temperature can be checked with monitoring function
Related information
q (Code: 04401 Hyd Oil Temperature)

Cause Procedure, measuring location, criteria and remarks


Overheating of hydraulic oil
1 Hydraulic oil may be overheating. Check it and remove cause if it is overheating.
(When system is normal)
Defective hydraulic oil tempera- If cause 1 is not the cause for the trouble, hydraulic oil temperature sensor sys-
2 ture gauge system or machine tem or machine monitor may be defective. Perform troubleshooting for failure
monitor code [DGS1KX].

40-596 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-7 Engine coolant temperature gauge does not indicate normally

E-7 Engine coolant temperature gauge does not indicate normally 40-597
1) While engine coolant temperature is rising normally, temperature gauge does not rise from
white range (C).
Failure
2) While engine coolant temperature is stabilized normally, temperature gauge rises to red range
(H).
q Signal of engine coolant temperature sensor is input to engine controller and then the data is
transmitted to machine monitor through CAN communication system.
Related information
q Engine coolant temperature can be checked with monitoring function
(Code: 04107 Engine coolant temperature)

Cause Procedure, measuring location, criteria and remarks


Defective coolant temperature Engine coolant temperature sensor system may be defective. Perform trouble-
1
sensor system shooting for failure codes [CA144] and [CA145].
If cause 1 is not detected, machine monitor may be defective.
2 Defective machine monitor
(Since trouble is in system, troubleshooting cannot be performed.)

3) Display of coolant temperature gauge is different from actual engine coolant temperature.
Failure 4) Display of engine coolant temperature gauge is different from display of engine coolant temper-
ature monitor.
q Signal voltage of engine coolant temperature sensor is input to engine controller and then the
data is transmitted to machine monitor through CAN communication system.
Related information
q Engine coolant temperature can be checked with monitoring function
(Code: 04107 Engine coolant temperature)

Cause Procedure, measuring location, criteria and remarks


a Turn starting switch ON or start engine and troubleshoot.
Engine coolant tempera- Coolant temperature
Color of monitor light (a)
ture gauge level
105 C 6
Red
102 C 5
1 Defective machine monitor
100 C 4
85 C 3
Blue
60 C 2
30 C 1

Engine coolant temperature gauge and coolant


temperature monitor 40-597

D375A-6R 40-597
(01)
Troubleshooting of electrical system (E-mode)
E-8 Fuel gauge does not indicate properly

E-8 Fuel gauge does not indicate properly 40-598


Failure 1) Fuel gauge does not indicate properly.
q Input (signal voltage) from fuel level sensor can be checked by using monitoring function.
Related information
(Code: 04200 Fuel level sensor voltage)

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector FGS and connect T-adapter to male side.
Defective fuel level sensor
1 (internal open circuit or short cir- Between FGS (male) (1) and (2) FULL Resistance Approx. 4 z
cuit) a Fuel level sensor characteristics EMPTY Resistance Approx. 85 z
Between FGS (male) (2) and ground Resistance Max. 1 z
1.Turn starting switch to OFF position.
2.Disconnect connector FGS and connect T-adapter to female side.
3.Turn starting switch to ON position.
Open circuit or short circuit or a If voltage is 0 V, wiring harness has open circuit or ground fault or short circuit,
2 ground fault or hot short circuit in and if voltage is 24 V, wiring harness has hot short circuit.
wiring harness a Voltage of approx. 3.3 V is applied to fuel level sensor signal lines through re-
sistor inside machine monitor.
Between FGS (female) (1) and (2) Voltage Approx. 3.3 V
a If cause 2 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector CM01 and connect T-adapter to female side.
Open or short circuit in wiring a Resistance accords with fuel level sensor characteristics table in cause 1.
3
harness a If resistance is above 1 Mz, wiring harness has disconnection. If resistance is
below 1 z, wiring harness has short circuit.
Approx. 4
Between CM01 (female) (9) and (12) Resistance
85 z
a If neither of causes 2 and 3 is the cause for the trouble, this check is not re-
quired.
1. Turn starting switch to OFF position.
Open circuit in wiring harness
2. Disconnect connectors CM01 and FGS, and connect T-adapters to female
4 (open circuit or defective con-
side of them.
tact)
Between CM01 (female) (9) and FGS (female) (1) Resistance Max. 1 z
Between CM01 (female) (12) and FGS (female) (2) Resistance Max. 1 z
a If cause 2 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors CM01 and FGS, and connect T-adapter to female side
5
(Contact with ground circuit) of either of them.
Between CM01 (female) (9) or FGS (female) (1) and
Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
2. Disconnect connectors CM01 and FGS, and connect T-adapter to female side
of CM01.
6 Short circuit in wiring harness
a Check with multimeter in continuity mode.
Between CM01 (female) (9) and each pin other than No continuity
(9) (No sound is heard)
7 Defective machine monitor If cause is not found by above checks, machine monitor is defective.

40-598 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-8 Fuel gauge does not indicate properly

Circuit diagram related to fuel level gauge 40-59

2) Display of fuel level gauge is different from actual fuel level.


Failure
3) The indication of the fuel level gauge is different from the display of the fuel level monitor.
q Signal voltage of fuel sensor can be checked with monitoring function.
Related information
(Code: 04200 Fuel level sensor voltage)

Cause Procedure, measuring location, criteria and remarks


a Turn starting switch ON or start engine and troubleshoot.
Reading of fuel level
Fuel level Color of monitor light (a)
gauge
1005 l 6
756 l 5
1 Defective machine monitor
556 l 4 Blue
398 l 3
276 l 2
144 l 1 Red

Fuel level gauge and fuel level monitor 40-59

D375A-6R 40-599
(01)
Troubleshooting of electrical system (E-mode)
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally

E-9 Power train oil temperature gauge (multi-gauge) does not indicate
normally 40-60
1) While power train oil temperature is rising normally, temperature gauge does not rise from white
range (C).
Trouble
2) While power train oil temperature is stabilized normally, temperature gauge rises to red range
(H).
q Torque converter oil temperature is considered as power train oil temperature.
q Signal voltage of power train oil temperature sensor is input to power train controller and then
Related information the data is transmitted to machine monitor through CAN communication system.
q Torque converter (power train) oil temperature can be checked with monitoring function.
(Code: 30100 T/C Oil Temperature)

Cause Procedure, measuring location, standard (value) and remarks


Defective torque converter oil Power train oil temperature sensor system may be defective. Perform trouble-
1
temperature sensor system shooting for failure codes [DGT1KA] and [DGT1KX].
If cause 1 is not detected, machine monitor may be defective.
2 Defective machine monitor
(Since trouble is in system, troubleshooting cannot be performed.)

3) Display of power train temperature gauge is different from actual power train oil temperature.
Trouble 4) Display of power train oil temperature gauge is different from display of power train oil tempera-
ture monitor.
q Torque converter oil temperature is considered as power train oil temperature.
q Signal voltage of power train oil temperature sensor is input to power train controller and then
Related information the data is transmitted to machine monitor through CAN communication system.
q Torque converter (power train) oil temperature can be checked with monitoring function.
(Code: 30100 T/C Oil Temperature)

Cause Procedure, measuring location, standard (value) and remarks

a Turn starting switch ON or start engine and troubleshoot.


Power train oil tempera- Power train oil tempera-
Color of monitor light (a)
ture ture gauge level
130 C 6
Red
120 C 5
1 Defective machine monitor
118 C 4
90 C 3
Blue
50 C 2
0 C 1

Power train oil temperature gauge and power


train oil temperature monitor 40-60

40-600 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally

E-10 Hydraulic temperature gauge (multi-gauge) does not indicate


normally 40-601
1) While hydraulic oil temperature is rising normally, temperature gauge does not rise from white
Trouble range (C).
2) While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range.
q Hydraulic oil temperature can be checked with monitoring function
Related information
(Code: 04401 Hyd Oil Temperature)

Cause Procedure, measuring location, standard (value) and remarks


1 Perform troubleshooting for failure code [DGS1KX].
If cause 1 is not detected, machine monitor may be defective.
2 Defective machine monitor
(Since trouble is in system, troubleshooting cannot be carried out.)

3) Display of hydraulic oil temperature gauge is different from actual hydraulic oil temperature.
Trouble 4) Display of hydraulic oil temperature gauge is different from display of hydraulic oil temperature
monitor.
q Hydraulic oil temperature can be checked with monitoring function
Related information
(Code: 04401 Hyd Oil Temperature)

Cause Procedure, measuring location, standard (value) and remarks


a Turn starting switch ON or start engine and troubleshoot.
Reading of hydraulic oil
Hydraulic oil temperature Color of monitor light (a)
temperature gauge
105 C 6
Red
102 C 5
1 Defective machine monitor
98 C 4
70 C 3
Blue
20 C 2
0 C 1

Hydraulic oil temperature gauge and hydraulic


oil temperature monitor 40-601

D375A-6R 40-601
(01)
Troubleshooting of electrical system (E-mode)
E-11 Contents of display by machine monitor are different from applicable machine

E-11 Contents of display by machine monitor are different from appli-


cable machine 40-602
Trouble q Contents of display by machine monitor are different from applicable machine.
Related information

Cause Procedure, measuring location, standard (value) and remarks


Machine monitor may be defective.(Since trouble is in system, troubleshooting
1 Defective machine monitor
cannot be performed.)

E-12 Machine monitor does not display some items 40-602


Trouble q Machine monitor does not display some items
q The LCD panel sometimes has black points (points which are not lighted) and bright points
Related information (points which do not go off) for the reason of its characteristics. If the number of the bright points
and black points does not exceed 10, those points are not a failure or a defect.

Cause Procedure, measuring location, standard (value) and remarks


a Turn starting switch ON and carry out troubleshooting.
Defective machine monitor When following switches are operated, if all LCD panel is lighted up (all surface
1
(LCD panel) becomes white), LCD panel is normal.
q Operation of switches: [4] + [F2] (Press simultaneously)
Defective machine monitor If cause 1 is not detected, machine monitor may be defective.
2
(body) (Since trouble is in system, troubleshooting cannot be performed.)

E-13 Function switch does not work 40-602


Trouble q Function switch does not work
Related information

Cause Procedure, measuring location, standard (value) and remarks


Machine monitor may be defective.(Since trouble is in system, troubleshooting
1 Defective machine monitor
cannot be performed.)

40-602 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-14 Operation mode does not change

E-14 Operation mode does not change 40-603


Trouble 1) When operation mode switch is operated, display of operation mode monitor does not change.
q Before carrying out troubleshooting, check that no related failure code is displayed.
Related information
(If failure codes [DAFRMC] and/or [DB2RKR] are displayed, troubleshoot them first.)

Cause Procedure, measuring location, standard (value) and remarks


Machine monitor may be defective.(Since trouble is in system, troubleshooting
1 Defective machine monitor
cannot be performed.)

Trouble 2) When operation mode is changed, engine output is not changed.


q Engine output mode recognized by engine controller can be checked with monitoring function.
(Code: 17500 Engine Power Mode)
Related information
q Before carrying out troubleshooting, check that no related failure code is displayed.
(If failure codes [DAFRMC] and/or [DB2RKR] are displayed, troubleshoot them first.)

Cause Procedure, measuring location, standard (value) and remarks


Machine monitor may be defective. (Since trouble is in system, troubleshooting
1 Defective machine monitor
cannot be performed.)
Engine controller may be defective. (Since trouble is in system, troubleshooting
2 Defective engine controller
cannot be performed.)

E-15 Gearshift mode does not change 40-603


Failure 1) When gearshift mode switch is operated, display of speed mode section does not change.
q Before carrying out troubleshooting, check that no related failure code is displayed.
Related information (If failure codes [DAFRMC], [DK40KA], [DK40KB], [DLT3KA] and/or [DLT3KB] are displayed,
troubleshoot them first.)

Cause Procedure, measuring location, criteria and remarks


Machine monitor may be defective. (Since trouble is in system, troubleshooting
1 Defective machine monitor
cannot be performed.)
The power train controller may be defective. (Since the trouble is in the system,
2 Defective power train controller
the troubleshooting cannot be performed.)

Failure 2) When gearshift mode is changed, gearshift setting of power train is not changed.
q Before carrying out troubleshooting, check that no related failure code is displayed.
Related information (If failure codes [DAFRMC], [DK40KA], [DK40KB], [DLT3KA] and/or [DLT3KB] are displayed,
troubleshoot them first.)

Cause Procedure, measuring location, criteria and remarks


Machine monitor may be defective. (Since trouble is in system, troubleshooting
1 Defective machine monitor
cannot be performed.)
The power train controller may be defective. (Since the trouble is in the system,
2 Defective power train controller
the troubleshooting cannot be performed.)

D375A-6R 40-603
(01)
Troubleshooting of electrical system (E-mode)
E-16 Customize function does not operate normally

E-16 Customize function does not operate normally 40-604


Trouble 1) When customize switch is operated, customize screen is not displayed.
Related information

Cause Procedure, measuring location, standard (value) and remarks


Machine monitor may be defective.(Since trouble is in system, troubleshooting
1 Defective machine monitor
cannot be performed.)

Trouble 2) When setting is changed on customize screen, setting of machine is not changed.
Related information

Cause Procedure, measuring location, standard (value) and remarks


Machine monitor may be defective.(Since trouble is in system, troubleshooting
1 Defective machine monitor
cannot be performed.)
Defective engine controller or Engine controller or power train controller may be defective. (Since trouble is in
2
defective power train controller system, troubleshooting cannot be performed.)

E-17 Customize memory function does not operate normally 40-604


Trouble 1) When customize memory switch is operated, customize memory screen is not displayed.
Related information

Cause Procedure, measuring location, standard (value) and remarks


Machine monitor may be defective. (Since trouble is in system, troubleshooting
1 Defective machine monitor
cannot be performed.)

Trouble 2) When selection is changed on customize memory screen, setting of machine is not changed.
Related information

Cause Procedure, measuring location, standard (value) and remarks


Machine monitor may be defective. (Since trouble is in system, troubleshooting
1 Defective machine monitor
cannot be performed.)
Defective engine controller or Engine controller or power train controller may be defective. (Since trouble is in
2
defective power train controller system, troubleshooting cannot be performed.)

40-604 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-18 Alarm buzzer does not sound or does not stop

E-18 Alarm buzzer does not sound or does not stop 40-605
Trouble q Alarm buzzer does not sound or does not stop.
Related information

Cause Procedure, measuring location, standard (value) and remarks


Machine monitor may be defective. (Since trouble is in system, troubleshooting
1 Defective machine monitor
cannot be performed.)
Power train controller may be defective. (Since trouble is in system, troubleshoot-
2 Defective power train controller
ing cannot be performed.)

E-19 When starting switch is turned OFF, service meter is not displayed40-605
Trouble q When starting switch is turned OFF, service meter is not displayed.
q While starting switch is at OFF position, if following switches are operated, service meter is dis-
Related information
played at top center of screen.Operation of switches:[4]+[1] (Press simultaneously)

Cause Procedure, measuring location, standard (value) and remarks


When starting switch is turned ON, if machine monitor displays nothing, backup
Defective backup power supply
1 power supply system may be defective. In this case, perform troubleshooting for
system
"E-3 When starting switch is turned ON, machine monitor displays nothing".
If cause 1 is not detected, machine monitor may be defective.
2 Defective machine monitor
(Since trouble is in system, troubleshooting cannot be performed.)

E-20 Machine monitor cannot be set in service mode 40-605


Trouble q Machine monitor cannot be set in service mode
q If following switches are operated, machine monitor is set in service mode.
Related information
Switch operation: [4] + [1] o [2] o [3] (While pressing [4], press [1], [2], and [3] in order)

Cause Procedure, measuring location, standard (value) and remarks


Machine monitor may be defective. (Since trouble is in system, troubleshooting
1 Defective machine monitor
cannot be performed.)

D375A-6R 40-605
(01)
Troubleshooting of electrical system (E-mode)
E-21 The ripper pin puller cylinder does not operate

E-21 The ripper pin puller cylinder does not operate 40-606
Failure q The ripper pin puller cylinder does not work.
Related information

Cause Procedure, measuring location, criteria and remarks


If fuse FS22-4 is broken, circuit probably has ground fault. In this case, perform
1 Defective fuse FS22-4
troubleshooting for cause 6 first.
1. Turn starting switch to OFF position.
2. Disconnect connector PLSW and connect T-adapter to male side.
Defective pin puller switch 3. Operate switch and troubleshoot.
2
(Internal defect) Pull Resistance Max. 1 z
Between PLSW (male) (1) and (2)
Blow out Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector PPL and connect T-adapter to male side.
Defective pin puller solenoid
3 Between PPL (male) (1) and (2) Resistance 10 40 z
(Internal defect)
Between PPL (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors ASUS and PHR.
Open or short circuit in wiring 3. Remove fuse FS22-4.
4 4. Turn pin puller switch to ON position (lead-in).
harness
Between terminal FS22-4 of fuse and ground
Resistance 10 40 z
a Pin puller solenoid resistance
a If cause 4 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Remove fuse FS22-4.
3. Disconnect connectors PLSW and PPL, and connect T-adapters to female
5 Open circuit in wiring harness side of them.
Between PPL (female) (2) and ground Resistance Max. 1 z
Between PPL (female) (1) and PLSW (female) (2) Resistance Max. 1 z
Between fuse FS22-4 and PLSW (female) (1) Resistance Max. 1 z
a If cause 4 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Remove fuse FS22-4.
Ground fault in wiring harness 3. Disconnect connectors PLSW and PPL, and connect T-adapters to female
6
(Contact with ground circuit) side of PLSW.
Between PPL (female) (1) and PLSW (female) (2) Resistance Min. 1 Mz
Between PLSW (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors PPL, and connect T-adapter to female side.
Hot short in wiring harness 3. Turn starting switch to ON position.
7
(Contact with 24 V circuit) 4. Turn pin puller switch to OFF position (pull-out).
Between PPL (female) (1) and (2) Voltage Max. 1 V

40-606 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-21 The ripper pin puller cylinder does not operate

Circuit diagram related to ripper pin puller cylinder 40-607

D375A-6R 40-607
(01)
Troubleshooting of electrical system (E-mode)
E-22 Horn does not sound or does not stop

E-22 Horn does not sound or does not stop 40-608


Trouble q The horn does not sound or does not stop.
q Troubleshoot for causes 1 7 and 9, when horn does not sound and for causes 2, 8 and 9 when
horn does not stop.
Related information
q Troubleshooting at connector HRN (female) does not perform but perform at connector RDG
because T-adapter for connector HRN is not prepared.

Cause Procedure, measuring location, standard (value) and remarks


If fuse FS32-4 is broken, circuit probably has ground fault. In this case, trouble-
1 Defective fuse FS32-4
shoot cause 7 first.
1. Turn starting switch to OFF position.
2. Disconnect horn switch terminals (No polarity).
3. Turn horn switch ON/OFF and troubleshoot.
2 Defective horn switch
OFF Resistance Min. 1 Mz
Between horn switch terminals
ON Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector RDG and connect T-adapter to female side.
3 Defective wiring harness 3. Turn starting switch ON position.
4. Turn horn switch ON.
Between RDG (female) (3) and ground Voltage 20 30 V
1. Turn starting switch to OFF position.
Disconnection in wiring harness 2. Remove fuse FS32-4.
4 3. Turn horn switch ON.
or horn
Between FS32-4 and ground Continuity
a If cause 4 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
5 Disconnection in horn 2. Disconnect connector HRN.
Between HRN(male) and ground Continuity
Disconnection in wiring harness
If check of cause 4 is abnormal and check of cause 5 is normal, wiring harness is
6 (open circuit or defective con-
disconnected.
tact)
a If fuse is not broken, this check is not required.
Ground fault of wiring harness 1. Turn starting switch to OFF position.
7 2. Disconnect connector HRN and insert T-adapter into RDG.
(Contact with GND circuit)
Between RDG (female) (2) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short in wiring harness 2. Disconnect connector HRN and insert T-adapter into RDG.
8 3. Turn horn switch ON.
(Contact with 24 V circuit)
Between RDG (female) (2) and ground Voltage Max. 1 V
9 Defective horn (Internal defect) If the cause cannot be found by above checks, horn may be defective.

40-608 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-22 Horn does not sound or does not stop

Circuit diagram related to horn 40-609

D375A-6R 40-609
(01)
Troubleshooting of electrical system (E-mode)
E-23 Back-up alarm does not sound or does not stop

E-23 Back-up alarm does not sound or does not stop 40-610
Trouble 1) Back-up alarm does not sound.
q When a failure occurs on the primary side (coil side) of the back-up alarm relay, relevant failure codes
Related infor-
[D161KA], [D161KB] are displayed, but in case of failure on the secondary side (contact side), no
mation
failure code is displayed.

Cause Procedure, measuring location, standard (value) and remarks


If fuse FS22-5 is broken, circuit probably has ground fault. In this case, trouble-
1 Defective fuse FS22-5
shoot cause 6 first.
1. Turn starting switch to OFF position.
Defective backup alarm relay 2. Replace backup alarm relay (connector: BKA) with another relay.
2 (internal open circuit or short cir- 3. Turn starting switch ON position.
cuit) 4. Perform reverse travel operation.
If backup alarm sounds, original backup alarm relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector BKAL and connect T-adapter to female side.
3 Defective wiring harness 3. Turn starting switch ON position.
4. Perform reverse travel operation.
Between BKAL (1) and (2) Voltage 20 30 V
1. Turn starting switch to OFF position.
Disconnection in wiring harness 2. Disconnect connector BKA and connect T-adapter to female side.
4
or backup alarm
Between BKA (female) (5) and ground Continuity
a If neither of causes 3 and 4 is the cause for the trouble, this check is not re-
quired.
1. Turn starting switch to OFF position.
2. Remove fuse FS22-5.
Disconnection in wiring harness 3. Disconnect connectors BKA and BKAL and connect T-adapters to female side
5 (open circuit or defective con- of them.
tact)
Between BKA (female) (5) and BKAL (female) (1) Resistance Max. 1 z
Between BKAL (female) (2) and ground Resistance Max. 1 z
Between BKA (female) (1), (3) and FS22-5 Resistance Max. 1 z
a If fuse is not broken, this check is not required.
1. Turn starting switch to OFF position.
2. Remove fuse FS22-5.
Ground fault of wiring harness 3. Disconnect connectors BKA and BKAL and connect T-adapter to female side
6
(Contact with GND circuit) of either of them.
Between BKA (female) (1) or (3) and ground Resistance Min. 1 Mz
Between BKA (female) (5) and ground Resistance Min. 1 Mz
Defective backup alarm
7 If cause cannot be found by above checks, back-up alarm may be defective.
(Internal defect)

40-610 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-23 Back-up alarm does not sound or does not stop

Trouble 2) Back-up alarm does not stop.


Related infor-
mation

Cause Procedure, measuring location, standard (value) and remarks

1. Turn starting switch to OFF position.


Defective backup alarm relay 2. Replace backup alarm relay (connector: BKA) with another relay.
1 (internal open circuit or short cir- a The above can be checked with backup alarm relay removed only.
cuit) 3. Turn starting switch ON position.

If backup alarm stops, original backup alarm relay is defective.


1. Turn starting switch to OFF position.
2. Disconnect connector BKAL and connect T-adapter to female side.
Hot short in wiring harness 3. Turn starting switch ON position.
2
(Contact with 24 V circuit) Between BKAL (female) (1) and (2) Voltage Max. 1 V
Between BKAL (female) (1) and ground Voltage Max. 1 V
Defective backup alarm
3 If cause cannot be found by above checks, back-up alarm may be defective.
(Internal defect)

Circuit diagram related to backup alarm 40-61

D375A-6R 40-611
(01)
Troubleshooting of electrical system (E-mode)
E-24 Fan does not reverse

E-24 Fan does not reverse 40-612


Failure The fan does not rotate in reverse.
Related
q See "Reverse rotation of hydraulic fan" in Machine monitor sections of Structure and Operation section.
information

Cause Procedure, measuring location, criteria and remarks


1 Defective fan reverse solenoid Perform troubleshooting for failure codes [DW7BKA] and [DW7BKB].

Circuit diagram related to fan 40-612

40-612 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-25 The head lamp and rear lamp do not light up

E-25 The head lamp and rear lamp do not light up 40-613
Failure 1) Head lamp does not light up.
q If section between headlamp relay and headlamps, one headlamp lights up.
Related
q If headlamp switch, diode or wiring harness common to right and left headlamps is defective, right and
information
left headlamps and working lamp do not light up.

Cause Procedure, measuring location, criteria and remarks


Defective head lamp (Breakage
1 Since the head lamp may be defective, check its bulb for breakage.
of bulb)
Defective circuit breaker (CB105
2 If circuit breaker is turned ON, circuit probably has ground fault etc.
or CB5)
1. Turn starting switch to OFF position.
Defective head lamp relay 2. Replace relay (connector: LMFL or LMFR) with backup alarm relay
(LMFR, LMFL) (connector: BKA).
3 3. Turn starting switch to ON position.
(internal open circuit or short cir-
cuit) 4. Turn headlamp switch to ON position.
If headlamp lights up, original headlamp relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector FLSW and connect T-adapter to male side.
3. Turn headlamp switch to ON/OFF position and troubleshoot.
4 Defective head lamp switch a ON position is located in both directions.
Between FLSW (male) (5) and (6), or OFF Resistance Min. 1 Mz
between (4) and (5) ON Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors LMD1 and LMD2, and connect T-adapter to diode.
a Measure in diode range of tester.
Defective diode LMD1 or LMD2 Between LMD1 (male) (1) (+) and (2) (-) No continuity
5 (internal open circuit or short cir-
cuit) Between LMD1 (male) (2) (+) and (1) (-) Continuity
Between LMD2 (male) (1) (+) and (2) (-) No continuity
Between LMD2 (male) (2) (+) and (1) (-) Continuity

D375A-6R 40-613
(01)
Troubleshooting of electrical system (E-mode)
E-25 The head lamp and rear lamp do not light up

Cause Procedure, measuring location, criteria and remarks


a Check location where voltage abnormality occurs and locate defective point of
wiring harness.
1. Turn starting switch to OFF position.
2. Disconnect connectors LHDR and LHDL, and connect T-adapters to female
side of them.
3. Turn starting switch to ON position.
4. Turn headlamp switch to ON position.
Between LHDL (female) (1) and (2) Voltage 20 30 V
Between LHDR (female) (1) and (2) Voltage 20 30 V
a If no failure is detected by above checks, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors LMFL and LMFR, and connect T-adapter to female
Open circuit or ground fault in
6 side.
wiring harness
3. Turn starting switch to ON position.
4. Turn headlamp switch to ON position.
Between LMFL (female) (1) and (2) Voltage 20 30 V
Between LMFL (female) (3) and (2) Voltage 20 30 V
Between LMFR (female) (1) and (2) Voltage 20 30 V
Between LMFR (female) (3) and (2) Voltage 20 30 V
a If no failure is detected by above checks, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector FLSW and connect T-adapter to female side.
3. Turn starting switch to ON position.
Between FLSW (female) (5) and (2) Voltage 20 30 V
a If cause 6 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors FLSW, LMD1, LMD2, LMFL, LMFR, LHDR, LHDL and
KEY, and connect T-adapters to female side of them.
Between LHDR (female) (2) and ground Resistance Max. 1 z
Between LHDL (female) (2) and ground Resistance Max. 1 z
Between LHDR (female) (1) and LMFR (female) (5) Resistance Max. 1 z
Between LHDL (female) (1) and LMFL (female) (5) Resistance Max. 1 z
Between LMFL (female) (1) and LMD1 (female) (1) Resistance Max. 1 z
Open circuit in wiring harness Between LMD1 (female) (1) and LMD2 (female) (1) Resistance Max. 1 z
7 (open circuit or defective con-
Between LMFL (female) (2) and ground Resistance Max. 1 z
tact)
Between LMFL (female) (3) and CB5 (2) Resistance Max. 1 z
Between LMFL (female) (1) and LMFR (female) (1) Resistance Max. 1 z
Between LMFL (female) (2) and LMFR (female) (2) Resistance Max. 1 z
Between LMFL (female) (3) and LMFR (female) (3) Resistance Max. 1 z
Between FLSW (female) (6) and LMD1 (female) (2) Resistance Max. 1 z
Between FLSW (female) (4) and LMD2 (female) (2) Resistance Max. 1 z
Between FLSW (female) (5) and KEY (female) (1) Resistance Max. 1 z
Between FLSW (female) (2) and ground Resistance Max. 1 z
a If cause 6 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors LMD1, LMD2, LMFL, LHDR and LHDL, and connect
Ground fault in wiring harness T-adapter to female side of LMFL.
8
(Contact with ground circuit) Between LMFL (female) (1) and ground Resistance Min. 1 Mz
Between LMFL (female) (3) and ground Resistance Min. 1 Mz
Between LMFL (female) (5) and ground Resistance Min. 1 Mz

40-614 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-25 The head lamp and rear lamp do not light up

Circuit diagram related to headlamp, backup lamp and ripper point lamp 40-615

D375A-6R 40-615
(01)
Troubleshooting of electrical system (E-mode)
E-25 The head lamp and rear lamp do not light up

Failure 2) Working lamp does not light up.


Related
q If headlamps do not light up, see "1) Headlamp does not light up" first.
information

Cause Procedure, measuring location, criteria and remarks


Defective working lamp (Break-
1 Since the working lamp may be defective, check its bulb for breakage.
age of bulb)

2 Defective fuse (FS22-2) When the fuse is blown, a ground fault may have probably occurred in the circuit.
1. Turn starting switch to OFF position.
Defective working lamp relay 2. Replace relay (connector: LMW) with backup alarm relay (connector: BKA).
3 (internal open circuit or short cir- 3. Turn starting switch to ON position.
cuit) 4. Turn headlamp switch to ON position.
If working lamp lights up, original working lamp relay is defective.
a Check location where voltage abnormality occurs and locate defective point of
wiring harness.
1. Turn starting switch to OFF position.
2. Disconnect connectors LWKR and LWKL, and connect T-adapters to female
side of them.
3. Turn starting switch to ON position.
4. Turn headlamp switch to ON position.
Between LWKL (female) (1) and (2) Voltage 20 30 V
Between LWKR (female) (1) and (2) Voltage 20 30 V
a If no failure is detected by above checks, this check is not required.
Open circuit or ground fault of 1. Turn starting switch to OFF position.
4
wiring harness 2. Disconnect connector LMW and connect T-adapter to female side.
3. Turn starting switch to ON position.
4. Turn headlamp switch to ON position.
Between LMW (female) (1) and (2) Voltage 20 30 V
Between LMW (female) (3) and (2) Voltage 20 30 V
a If no failure is detected by above checks, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector FLSW and connect T-adapter to female side.
3. Turn starting switch to ON position.
Between FLSW (female) (5) and (2) Voltage 20 30 V
a If cause 4 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Remove fuse FS22-2.
3. Disconnect connectors LMW, LWKR and LWKL, and connect T-adapters to
female side of them.
Between LWKR (female) (2) and ground Resistance Max. 1 z
Open circuit in wiring harness
Between LWKL (female) (2) and ground Resistance Max. 1 z
5 (open circuit or defective con-
tact) Between LWKR (female) (1) and LMW (female) (5) Resistance Max. 1 z
Between LWKL (female) (1) and LMW (female) (5) Resistance Max. 1 z
Between LMW (female) (1) and LMFL (female) (1) Resistance Max. 1 z
Between LMW (female) (2) and ground Resistance Max. 1 z
Between LMW (female) (3) and FS22-2 Resistance Max. 1 z
a If cause 4 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Remove fuse FS22-2.
Ground fault in wiring harness 3. Disconnect connectors LMW, LWKR and LWKL, and connect T-adapters to
6
(Contact with ground circuit) female side of LMW.
Between LMW (female) (3) and ground Resistance Min. 1 Mz
Between LMW (female) (5) and ground Resistance Min. 1 Mz

40-616 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-25 The head lamp and rear lamp do not light up

Circuit diagram related to headlamp, backup lamp and ripper point lamp 40-617

D375A-6R 40-617
(01)
Troubleshooting of electrical system (E-mode)
E-25 The head lamp and rear lamp do not light up

Failure 3) Back-up lamp and ripper point lamp do not light.


q If fuse, back-up lamp relay, back-up lamp switch or common wiring harness of back-up lamp and ripper
Related point lamp is defective, neither of back-up lamp and ripper point lamp does not light up (If either of
information back-up lamp and ripper point lamp lights up, this check is not required).
q For related circuit diagram, see 2).

Cause Procedure, measuring location, criteria and remarks


Defective rear lamp (Breakage
1 Since the rear lamp may be defective, check its bulb for breakage.
of bulb)
Defective ripper point lamp (Bro-
2 Since the ripper point lamp may be defective, check its bulb for breakage.
ken bulb)
3 Defective fuse FS22-1 If fuse FS22-1 is broken, circuit probably has ground fault.
1. Turn starting switch to OFF position.
Defective back-up lamp relay 2. Replace relay (connector: LMRE) with backup alarm relay (connector: BKA).
4 (internal open circuit or short cir- 3. Turn starting switch to ON position.
cuit) 4. Turn back-up lamp switch to ON position.
If back-up lamp lights up, original back-up lamp relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector RLSW and connect T-adapter to male side.
3. Turn back-up lamp switch to ON/OFF position and troubleshoot.
5 Defective rear lamp switch
OFF Resistance Min. 1 Mz
Between RLSW (female) (5) and (6)
ON Resistance Max. 1 z
a Check location where voltage abnormality occurs and locate defective point of
wiring harness.
1. Turn starting switch to OFF position.
2. Disconnect connectors LREL, LRER and LRP, and connect T-adapter to
female side of them.
3. Turn starting switch to ON position.
4. Turn back-up lamp switch to ON position.
Between LREL (female) (1) and (2) Voltage 20 30 V
Between LRER (female) (1) and (2) Voltage 20 30 V
Between LRP (female) (1) and (2) Voltage 20 30 V
Open circuit or ground fault of a If no failure is detected by above checks, this check is not required.
6
wiring harness 1. Turn starting switch to OFF position.
2. Disconnect connector LMRE and connect T-adapter to female side.
3. Turn starting switch to ON position.
4. Turn back-up lamp switch to ON position.
Between LMRE (female) (1) and (2) Voltage 20 30 V
Between LMRE (female) (3) and (2) Voltage 20 30 V
a If no failure is detected by above checks, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector RLSW and connect T-adapter to female side.
3. Turn starting switch to ON position.
Between RLSW (female) (5) and (2) Voltage 20 30 V

40-618 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-25 The head lamp and rear lamp do not light up

Cause Procedure, measuring location, criteria and remarks


a If cause 6 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Remove fuse FS22-1.
3. Disconnect connectors FLSW, DIODE, FLP, LHDR, LHDL and KEY, and
connect T-adapters to female side of them.
Between LRER (female) (2) and ground Resistance Max. 1 z
Between LREL (female) (2) and ground Resistance Max. 1 z
Between LRP (female) (2) and ground Resistance Max. 1 z
Between LRER (female) (1) and LMRE (female) (5) Resistance Max. 1 z
Open circuit in wiring harness
7 (open circuit or defective con- Between LREL (female) (1) and LMRE (female) (5) Resistance Max. 1 z
tact)
Between LRP (female) (1) and LMRE (female) (5) Resistance Max. 1 z
Between LRP (female) (2) and ground Resistance Max. 1 z
Between LMRE (female) (1) and RLSW (female)(1),
Resistance Max. 1 z
(6)
Between LMRE (female) (2) and ground Resistance Max. 1 z
Between LMRE (female) (3) and FS22-1 Resistance Max. 1 z
Between RLSW (female) (5) and KEY (female) (1) Resistance Max. 1 z
Between RLSW (female) (2) and ground Resistance Max. 1 z
a If cause 6 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Remove fuse FS22-1.
3. Disconnect connectors LRER, LREL, LRP, LMRE and RLSW, and connect
Ground fault in wiring harness T-adapter to female side of LMRE.
8
(Contact with ground circuit)
Between LMRE (female) (1) and ground Resistance Min. 1 Mz
Between LMRE (female) (3) and ground Resistance Min. 1 Mz
Between LMRE (female) (5) and ground Resistance Min. 1 Mz

D375A-6R 40-619
(01)
Troubleshooting of electrical system (E-mode)
E-25 The head lamp and rear lamp do not light up

Circuit diagram related to headlamp, backup lamp and ripper point lamp 40-620

40-620 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-25 The head lamp and rear lamp do not light up

D375A-6R 40-621
(01)
Troubleshooting of electrical system (E-mode)
E-26 Windshield wiper does not operate

E-26 Windshield wiper does not operate 40-62


Trouble 1) None of the wipers operate.
Related
information
Cause Procedure, measuring location, criteria and remarks
If CB105 circuit breaker is turned ON, the circuit probably has ground fault. In this
1 Defective CB105 circuit breaker
case, perform troubleshooting for cause 4 first.
Open circuit or ground fault of 1. Turn starting switch to OFF position.
2
wiring harness Between terminal (B) in cab fuse box and ground Voltage 20 30 V
a If cause 2 is not the cause for the trouble, this check is not required.
Open circuit in wiring harness a If CB105 circuit breaker is turned ON, reset it first.
3 (open circuit or defective con- 1. Turn starting switch to OFF position.
tact) Between battery relay BRC terminal and cab fuse box
Resistance Max. 1 z
(B) terminal
a If neither of causes 1 and 2 is the cause for the trouble, this check is not re-
quired.
Ground fault in wiring harness 1. Turn starting switch to OFF position.
4
(Contact with ground circuit) 2. Remove terminal (B) from cab fuse box.
Between terminal (B) in cab fuse box (Wiring harness
Resistance Min. 1 Mz
side) and ground

Circuit diagram related to wiper 40-62

40-622 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-26 Windshield wiper does not operate

Trouble 2) Front windshield wipers do not operate.


Related q T-adapter is not prepared for each connector. (Perform troubleshooting without using T-adapters.)
information q For related circuit diagram, see Trouble 1).

Cause Procedure, measuring location, criteria and remarks


If fuse shown at left is broken, circuit probably has ground fault. In this case, per-
1 Defective fuse 4 in cab fuse box
form troubleshooting for cause 6 first.
1. Turn starting switch to OFF position.
Defective front wiper motor 2. Disconnect connector CN-9 and connect T-adapter to male side.
2
(Internal open circuit in wiring)
Between CN-9 (male) (2) and (5) Continuity
1. Turn starting switch to OFF position.
2. Disconnect connector CN-12.
3. Turn front wiper switch ON and OFF, and troubleshoot.
OFF Resistance Min. 1 Mz
3 Defective front wiper switch Between CN-12 (male) (3) and (4)
ON Resistance Max. 1 z
OFF Resistance Max. 1 z
Between CN-12 (male) (4) and (5)
ON Resistance Min. 1 Mz
1. Turn starting switch to ON position.
4 Power supply line a If any abnormality occurs, go to Cause 6 and Trouble 1).
Between terminal (4) in cab fuse box and ground Voltage 20 30 V
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Remove fuse 4 from cab fuse box.
5 (open circuit or defective con- 3. Turn front wiper switch to ON position.
tact) Between terminal (4) in cab fuse box (Wiring harness
Continuity
side) and ground
1. Turn starting switch to OFF position.
Between terminal (4) in cab fuse box and ground Voltage 20 30 V
a If cause 4 is not the cause for the trouble, this check is not required.
Ground fault in wiring harness 1. Turn starting switch to OFF position.
6
(Contact with ground circuit) 2. Remove fuse 4 from cab fuse box.
3. Disconnect connectors CN-9 and CN-12.
Between terminal (4) in cab fuse box (Wiring harness
Resistance Min. 1 Mz
side) and ground

D375A-6R 40-623
(01)
Troubleshooting of electrical system (E-mode)
E-26 Windshield wiper does not operate

Trouble 3) Rear wiper does not operate.


Related q T-adapter is not prepared for each connector. (Perform troubleshooting without using T-adapters.)
information q For related circuit diagram, see Trouble 1).

Cause Procedure, measuring location, criteria and remarks


If fuse shown at left is broken, circuit probably has ground fault. In this case, per-
1 Defective fuse 2 in cab fuse box
form troubleshooting for cause 6 first.
1. Turn starting switch to OFF position.
Defective rear wiper motor 2. Disconnect connector CN-4 and connect T-adapter to male side.
2
(Internal open circuit in wiring)
Between CN-4 (male) (2) and (1) Continuity
1. Turn starting switch to OFF position.
2. Disconnect connector CN-14.
3. Turn rear wiper switch ON and OFF, and troubleshoot.
OFF Resistance Min. 1 Mz
3 Defective rear wiper switch Between CN-14 (male) (3) and (4)
ON Resistance Max. 1 z
OFF Resistance Max. 1 z
Between CN-14 (male) (4) and (5)
ON Resistance Min. 1 Mz
1. Turn starting switch to ON position.
4 Power supply line a If any abnormality occurs, go to Cause 6 and Trouble 1).
Between terminal (2)in cab fuse box and ground Voltage 20 30 V
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Remove fuse 2 from cab fuse box.
5 (open circuit or defective con- 3. Turn rear wiper switch to ON position.
tact) Between terminal (2) in cab fuse box (Wiring harness
Continuity
side) and ground
1. Turn starting switch to OFF position.
Between terminal (2)in cab fuse box and ground Voltage 20 30 V
a If cause 4 is not the cause for the trouble, this check is not required.
Ground fault in wiring harness 1. Turn starting switch to OFF position.
6
(Contact with ground circuit) 2. Remove fuse 2 from cab fuse box.
3. Disconnect connectors CN-4 and CN-14.
Between terminal (2) in cab fuse box (Wiring harness
Resistance Min. 1 Mz
side) and ground

40-624 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-26 Windshield wiper does not operate

Circuit diagram related to wiper 40-625

D375A-6R 40-625
(01)
Troubleshooting of electrical system (E-mode)
E-26 Windshield wiper does not operate

Trouble 4) Left door wiper does not operate.


Related q T-adapter is not prepared for each connector. (Perform troubleshooting without using T-adapters.)
information q For related circuit diagram, see Trouble 1).

Cause Procedure, measuring location, criteria and remarks


If fuse shown at left is broken, circuit probably has ground fault. In this case, per-
1 Defective fuse 5 in cab fuse box
form troubleshooting for cause 6 first.
1. Turn starting switch to OFF position.
Defective left door wiper motor 2. Disconnect connector CN-18 and connect T-adapter to male side.
2
(Internal open circuit in wiring)
Between CN-18 (male) (2) and (3) Continuity
1. Turn starting switch to OFF position.
2. Disconnect connector CN-11.
3. Turn left door wiper switch ON and OFF, and troubleshoot.
OFF Resistance Min. 1 Mz
3 Defective left door wiper switch Between CN-11 (male) (3) and (4)
ON Resistance Max. 1 z
OFF Resistance Max. 1 z
Between CN-11 (male) (4) and (5)
ON Resistance Min. 1 Mz
1. Turn starting switch to ON position.
4 Power supply line a If any abnormality occurs, go to Cause 6 and Trouble 1).
Between terminal (5) in cab fuse box and ground Voltage 20 30 V
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Remove fuse 5 from cab fuse box.
5 (open circuit or defective con- 3. Turn left door wiper switch ON.
tact) Between terminal (5) in cab fuse box (Wiring harness
Continuity
side) and ground
1. Turn starting switch to OFF position.
Between terminal (5) in cab fuse box and ground Voltage 20 30 V
a If cause 4 is not the cause for the trouble, this check is not required.
Ground fault in wiring harness
6 1. Turn starting switch to OFF position.
(Contact with ground circuit)
2. Remove fuse 5 from cab fuse box.
3. Disconnect connectors CN-18 and CN-11.
Between terminal (5) in cab fuse box (Wiring harness
Resistance Min. 1 Mz
side) and ground

40-626 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-26 Windshield wiper does not operate

Circuit diagram related to wiper 40-627

D375A-6R 40-627
(01)
Troubleshooting of electrical system (E-mode)
E-26 Windshield wiper does not operate

Trouble 5) Right door wiper does not operate.


Related
q T-adapter is not prepared for each connector. (Perform troubleshooting without using T-adapters.)
information

Cause Procedure, measuring location, criteria and remarks


If fuse shown at left is broken, circuit probably has ground fault. In this case, per-
1 Defective fuse 3 in cab fuse box
form troubleshooting for cause 6 first.
1. Turn starting switch to OFF position.
Defective right door wiper motor 2. Disconnect connector CN-17 and connect T-adapter to male side.
2
(Internal open circuit in wiring)
Between CN-17 (male) (2) and (3) Continuity
1. Turn starting switch to OFF position.
2. Disconnect connector CN-13.
3. Turn right door wiper switch ON and OFF, and troubleshoot.
OFF Resistance Min. 1 Mz
3 Defective right door wiper switch Between CN-13 (male) (3) and (4)
ON Resistance Max. 1 z
OFF Resistance Max. 1 z
Between CN-13 (male) (4) and (5)
ON Resistance Min. 1 Mz
1. Turn starting switch to ON position.
4 Power supply line a If any abnormality occurs, go to Cause 6 and Trouble 1).
Between terminal (3) in cab fuse box and ground Voltage 20 30 V
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Remove fuse 3 from cab fuse box.
5 (open circuit or defective con- 3. Turn right door wiper switch ON.
tact) Between terminal (3) in cab fuse box (Wiring harness
Continuity
side) and ground
1. Turn starting switch to OFF position.
Between terminal (3) in cab fuse box and ground Voltage 20 30 V
a If cause 4 is not the cause for the trouble, this check is not required.
Ground fault in wiring harness
6 1. Turn starting switch to OFF position.
(Contact with ground circuit)
2. Remove fuse 3 from cab fuse box.
3. Disconnect the connectors CN-17 and CN-13.
Between terminal (3) in cab fuse box (Wiring harness
Resistance Min. 1 Mz
side) and ground

40-628 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-26 Windshield wiper does not operate

Circuit diagram related to wiper 40-629

D375A-6R 40-629
(01)
Troubleshooting of electrical system (E-mode)
E-27 Window washer does not operate

E-27 Window washer does not operate 40-630


Failure 1) Front window washer does not operate.
q If wiper also does not operate, see E-26 1) or 2).
Related
q T-adapter is not prepared for window washer motor connector (Perform Troubleshooting without
information
T-adapter).

Cause Procedure, measuring location, criteria and remarks


a Check that rear window washer sprays water normally.
1. Turn starting switch to OFF position.
Defective front window washer 2. Replace connector WSFR with WSRR.
1 motor 3. Turn starting switch to ON position.
(Internal open circuit in wiring) 4. Turn front window washer switch to ON position.
If rear window washer sprays water, original front window washer motor is defec-
tive.
1. Turn starting switch to OFF position.
2. Disconnect ground strap.
3. Disconnect connector CN-12 and connect T-adapter to male side.
2 Defective front wiper switch 4. Turn switch ON and OFF, and troubleshoot.
OFF Resistance Min. 1 Mz
Between CN-12 (male) (1) and (2)
ON Resistance Max. 1 z
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Remove fuse 4 from cab fuse box.
3 (open circuit or defective con- 3. Turn front window washer switch to ON position.
tact) Between terminal (4) in cab fuse box (Wiring harness
Continuity
side) and ground
1. Turn starting switch to OFF position.
2. Remove fuse 4 from fuse box.
Ground fault in wiring harness
4 3. Disconnect connectors CN-12 and WSFR.
(Contact with ground circuit)
Between terminal (4) in cab fuse box (Wiring harness
Resistance Min. 1 Mz
side) and ground

40-630 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-27 Window washer does not operate

Circuit diagram related to window washer 40-631

D375A-6R 40-631
(01)
Troubleshooting of electrical system (E-mode)
E-27 Window washer does not operate

Trouble 2) Rear window washer does not operate.


q If wiper also does not operate, see E-26 1) or 3).
Related
q T-adapter is not prepared for window washer motor connector (Perform Troubleshooting without
information
T-adapter).

Cause Procedure, measuring location, criteria and remarks


a Check that front window washer sprays water normally.
1. Turn starting switch to OFF position.
Defective rear window washer 2. Replace connector WSFR with WSRR.
1 motor 3. Turn starting switch to ON position.
(Internal open circuit in wiring) 4. Turn rear window washer switch to ON position.
If front window washer spouts water, original rear window washer motor is defec-
tive.
1. Turn starting switch to OFF position.
2. Disconnect ground strap.
3. Disconnect connector CN-14 and connect T-adapter to male side.
2 Defective rear wiper switch 4. Turn switch ON and OFF, and troubleshoot.
OFF Resistance Min. 1 Mz
Between CN-14 (male) (1) and (2)
ON Resistance Max. 1 z
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Remove fuse 2 from cab fuse box.
3 (open circuit or defective con- 3. Turn rear window washer switch to ON position.
tact) Between terminal (2) in cab fuse box (Wiring harness
Continuity
side) and ground
1. Turn starting switch to OFF position.
2. Remove fuse 2 from fuse box.
Ground fault in wiring harness 3. Disconnect connectors CN-14 and WSRR.
4
(Contact with ground circuit)
Between terminal (2) in cab fuse box (Wiring harness
Resistance Min. 1 Mz
side) and ground

40-632 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-27 Window washer does not operate

Circuit diagram related to window washer 40-63

D375A-6R 40-633
(01)
Troubleshooting of electrical system (E-mode)
E-27 Window washer does not operate

Trouble 3) Right door window washer does not operate.


q If wiper also does not operate, see E-26 1) or 5).
Related q T-adapter is not prepared for window washer motor connector (Perform Troubleshooting without
information T-adapter).
q For related circuit diagram, see 1).

Cause Procedure, measuring location, criteria and remarks


a Check that left door window washer sprays water normally.
1. Turn starting switch to OFF position.
Defective right door washer 2. Replace connector WSLH with WSRH.
1 motor 3. Turn starting switch to ON position.
(Internal open circuit in wiring) 4. Turn right door window washer switch to ON position.
If left door window washer sprays water, original right door window washer motor
is defective.
1. Turn starting switch to OFF position.
2. Disconnect ground strap.
3. Disconnect connector CN-13 and connect T-adapter to male side.
2 Defective right door wiper switch 4. Turn switch ON and OFF, and troubleshoot.
OFF Resistance Min. 1 Mz
Between CN-13 (male) (1) and (2)
ON Resistance Max. 1 z
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Remove fuse 3 from cab fuse box.
3 (open circuit or defective con- 3. Turn right door window washer switch to ON position.
tact) Between terminal (3) in cab fuse box (Wiring harness
Continuity
side) and ground
1. Turn starting switch to OFF position.
2. Remove fuse 3 from fuse box.
Ground fault in wiring harness 3. Disconnect connectors CN-13 and WSRH.
4
(Contact with ground circuit)
Between terminal (3) in cab fuse box (Wiring harness
Resistance Min. 1 Mz
side) and ground

40-634 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-27 Window washer does not operate

Circuit diagram related to window washer 40-635

D375A-6R 40-635
(01)
Troubleshooting of electrical system (E-mode)
E-27 Window washer does not operate

Trouble 4) Left door window washer does not operate.


q If wiper also does not operate, see E-26 1) or 4).
Related q T-adapter is not prepared for window washer motor connector (Perform Troubleshooting without
information T-adapter).
q For related circuit diagram, see 1).

Cause Procedure, measuring location, criteria and remarks


a Check that right door window washer sprays water normally.
1. Turn starting switch to OFF position.
2. Replace connector WSLH with WSRH.
Defective left door washer motor 3. Turn starting switch to ON position.
1
(Internal open circuit in wiring) 4. Turn left door window washer switch to ON position.
If right door window washer sprays water, original left door window washer motor
is defective.
1. Turn starting switch to OFF position.
2. Disconnect ground strap.
3. Disconnect connector CN-11 and connect T-adapter to male side.
2 Defective left door wiper switch 4. Turn switch ON and OFF, and troubleshoot.
OFF Resistance Min. 1 Mz
Between CN-11 (male) (1) and (2)
ON Resistance Max. 1 z
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Remove fuse 5 from cab fuse box.
3 (open circuit or defective con- 3. Turn left door window washer switch to ON position.
tact) Between terminal (5) in cab fuse box (Wiring harness
Continuity
side) and ground
1. Turn starting switch to OFF position.
2. Remove fuse 5 from fuse box.
Ground fault in wiring harness 3. Disconnect connectors CN-11 and WSLH.
4
(Contact with ground circuit)
Between terminal (5) in cab fuse box (Wiring harness
Resistance Min. 1 Mz
side) and ground

40-636 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-27 Window washer does not operate

Circuit diagram related to window washer 40-637

D375A-6R 40-637
(01)
Troubleshooting of electrical system (E-mode)
E-28 Electric priming pump does not operate or does not stop automatically

E-28 Electric priming pump does not operate or does not stop automati-
cally 40-638
Failure q Electric priming pump does not operate or does not stop automatically.
Related
information

Cause Procedure, measuring location, criteria and remarks


1 Low battery charge level The battery charge level may be low. Check the battery itself.
If circuit breaker CB7 is turned OFF, circuit probably has ground fault. (Check
2 Defective circuit breaker CB7
cause No. 5)
1. Disconnect ground strap.
2. Disconnect connectors EPP, and connect T-adapter to female side.
Open circuit in wiring harness 3. Connect ground strap.
(Drive power supply system) Between EPP (1) - (2) Voltage 20 30 V
3
(open circuit or defective contact
1. Disconnect ground strap (to turn constant power supply OFF).
in connector)
2. Disconnect connectors EPP, and connect T-adapter to female side.
Between EPP (female) (2) and ground Resistance Max. 1 z
1. Disconnect ground strap (to turn constant power supply OFF).
2. Disconnect connectors EPP, and connect T-adapter to female side.
Ground fault in wiring harness 3. Disconnect connectors USB, EG1 and EFP.
4
(Contact with ground circuit) Between EPP (female) (1) and ground Resistance Min. 1 Mz
Between EPP (female) (3) and ground Resistance Min. 1 Mz
1. Disconnect ground strap.
2. Disconnect connectors EPP, and connect T-adapter to female side.
3. Connect ground strap.
4. Defective electric priming pump ON
5 Defective electric priming pump
Between EPP (3) and (4) Voltage 20 30 V
If lamp flashes but output voltage is defective or if result of troubleshooting 1-4
q
is normal and lamp does not flash, electric priming pump is defective.
Defective electric priming pump When electric priming pump does not stop automatically, electric priming pump
6 switch (Malfunction or auto- switch may be defective.
matic stop failure) (Turn toggle switch OFF to stop pump and then replace switch.)
q Lamp blinks but stops in about 5 seconds.
Overload on electric priming
7 * If pump is overloaded, power supply is turned OFF automatically to protect cir-
pump
cuit (Priming switch is reset automatically).
1. Disconnect ground strap.
2. Disconnect connectors EPP, and connect T-adapter to male side.

8 Trouble in electric priming pump Between EFP (male) (1) and (2) Resistance 13z
Between EFP (male) (1) and pump body Resistance Min. 1 Mz
Between EFP (male) (2) and pump body Resistance Min. 1 Mz

40-638 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-28 Electric priming pump does not operate or does not stop automatically

Circuit diagram related to electric priming pump 40-639

D375A-6R 40-639
(01)
Troubleshooting of electrical system (E-mode)
E-29 Orbcomm terminal does not operate normally (Data are not transmitted)

E-29 Orbcomm terminal does not operate normally (Data are not trans-
mitted) 40-640
Failure q The ORBCOMM terminal does not operate normally (Data are not transmitted).
Related infor-
q Even if the ORBCOMM terminal is abnormal, it does not cause a trouble in the machine.
mation

Cause Procedure, measuring location, criteria and remarks


After 3 minutes or later from VHMS startup, check the VHMS controller decimal
point (dot LED at right lower position of 7-segment display) (*1) or check the
machine monitor display (*2).
*1 Lamp is Power is not applied to ORBCOMM terminal or the communication
Terminal power supply is abnor- OFF with VHMS controller is abnormal.
1
mal or satellite is not captured
*1 Lamp is Power is applied to ORBCOMM terminal and the communication
ON with VHMS controller is normal. But it does not capture satellite.
Power is applied to ORBCOMM terminal, capturing satellie and the
*1 Blinking
communication with VHMS controller is normal.
1. Disconnect ground strap.
2. Turn starting switch to OFF position.
3. Disconnect connectors KOM1 and V4B, and connect T-adapters to female
side of them.
a Unswitched power supply is used. When disconnecting connector and carry-
ing out troubleshooting, take care.
Open circuit in wiring harness
Between KOM1 (female) (36), (39) and VF2 (male)
2 (Disconnection or defective con- Resistance Max. 1 z
(5)
tact in connector)
Between KOM1 (female) (37), (38) and ground Resistance Max. 1 z
Between V4B (female) (3) KOM1 (female) (11) Resistance Max. 1 z
Between V4B (female) (4) KOM1 (female) (4) Resistance Max. 1 z
Between V4B female) (10) KOM1 (female) (5) Resistance Max. 1 z
1. Disconnect ground strap.
2. Turn starting switch to OFF position.
3. Disconnect connectors KOM1, and connect T-adapter to female side.
Defective ORBCOMM terminal
3 4. Connect ground strap.
(When LED is turned off)
Between KOM1 (female) (36) and (37) Voltage 20 30V
Between KOM1 (female) (39) and (38) Voltage 20 30V

*1 Location of VHMS controller decimal point (dot LED at right lower position of 7-segment display)

*2 Checking on the machine monitor


1) Turn starting switch to ON position.
2) Switch machine monitor to Service menu.
3) Select Monitoring.
4) Enter "99003".

40-640 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-29 Orbcomm terminal does not operate normally (Data are not transmitted)

Circuit diagram related to ORBCOMM terminal 40-641

D375A-6R 40-641
(01)
Troubleshooting of electrical system (E-mode)
E-30 Gear cannot be shifted

E-30 Gear cannot be shifted 40-642


Trouble q Gear cannot be shifted (Shift switch does not work).
Related information

Cause Procedure, measuring location, standard (value) and remarks


a When failure code related to shift operation switch is not displayed.
Trouble in shift operation switch Press shift operation switch for more than 10 seconds. If any of following failure
q Shift up switch code is displayed at this time, carry out troubleshooting for it.
1 q Shift down switch [DD12KA], [DD12KB], [DD13KA], [DD13KB], [DDK5KA], [DDK5KB]
q Shift switch
(Optional-type lever) a When failure code related to shift operation switch is displayed.
Carry out troubleshooting for displayed failure code.
Internal defect of transmission The inside of the transmission clutch is supposed to be defective, check it
2
clutch directly.

40-642 D375A-6R
(01)
Troubleshooting of electrical system (E-mode)
E-30 Gear cannot be shifted

D375A-6R 40-643
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
Information in troubleshooting table

Troubleshooting of hydraulic and mechanical system (H-mode) 40-64


Information in troubleshooting table 40-64

a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before performing troubleshooting, understand that information fully.

Trouble Trouble in machine


Related infor-
Information related to detected failure or troubleshooting
mation

Cause Standard value in normal condition/Remarks on troubleshooting

2
Possible
causes and Possible causes for trouble
<Contents of description>
standard value (Given numbers are refer-
q Standard value to determine possible causes
for judgment ence numbers, which do not
q Remarks on judgment
indicate priority)

40-644 D375A-6R
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
Information in troubleshooting table

D375A-6R 40-645
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
List of Failure Modes and Causes

List of Failure Modes and Causes 40-646


Components causing failures Hydraulic components
Main
ECMV
pump

Torque converter operation valve

For forward and reverse clutch


Transmission main relief valve
Transmission operation valve

Self-pressure reducing valve


Torque converter relief valve

Hydraulic tank strainer


For gearshift clutch
For steering clutch
Power train pump

For lockup clutch

For brake clutch


Steering valve

Servo valve
EPC valve
Main body
Failure
No force (No drawbar pull). Q Q Q Q Q Q Q
No travel (at 2nd or 3rd speed). Q Q Q Q Q
No travel at all gear speeds. Q Q Q Q Q Q Q Q Q
Power train system

Machine travels only in one direction forward or in reverse. Q Q


Large time lag at gear speed shifting or forward-reverse shift-
Q Q Q Q Q
ing.
Steering is not possible. Q Q
Steering is possible only on one side. Q Q Q
Steering overrun occurs. Q Q
The brake does not work. Q Q
Torque converter is not locked-up. Q Q Q
The power train oil overheats.
All work equipment operates slowly or lacks power. Q Q Q Q Q
All work equipment does not operate. Q Q Q Q Q
Blade lift speed is slow or lacks power.
Related to work equipment

Blade tilt speed is slow or lacks power.


Ripper lift speed is slow or lacks power
Ripper tilt speed is slow or lacks power
Excessive hydraulic drift of blade lift.
Excessive hydraulic drift of blade tilt.
Excessive hydraulic drift of ripper lift.
Ripper pin puller cylinder does not work (giant ripper attach-
ment machine).
Blade pitch does not work (dual tilt attachment machine).
Abnormal sound comes out from around work equipment
Q Q Q Q
pump.
The fan speed is abnormal (excessive noise from or vibration
of fan, or overheating).

40-646 D375A-6R
(01)
Q
Q
Q
Q
Q
PPC valve

(01)
Q
PPC lock valve
Valve body

D375A-6R
Spool

Q
Q Q
Q Q
Q Q
Q
Q
Q
Q
Unload valve
Main relief valve
LS relief valve

Q Q Q
Q Q Q
Suction valve

Q
Q
Control valve

Pressure compensation valve


LS check valve

Q
Q
Hydraulic cylinder
Hydraulic components

Q
Q
Q
Q
Q Q Q
Q Q
Ripper pin-puller solenoid valve

Q Q
Pitch selection solenoid valve

Q
Fan pump
Fan motor

Q Q
Q
Q
Q
Q
Q
Brake pedal linkage

Q Q
Parking brake linkage

Q
Q Q Q
Q Q Q
Steering clutch (discs, plates, etc.)

Q
Q
Q Q
Q Q
Steering brake (discs, plates, etc.)

Q
Q
Inside of transmission

Q Q
Q Q Q Q Q Q
Q Q
Q Q

Q
Inside of torque converter

Q
Q
PTO
QEngine
Mechanical system

Cooling system

Q
Q Q Q
Loosening of piping clamp, air in hydraulic oil and oil leakage

Diagnosis codes

H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1

H-11

Q Q H-24
Q H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-10

40-647
Troubleshooting of hydraulic and mechanical system (H-mode)
List of Failure Modes and Causes
Troubleshooting of hydraulic and mechanical system (H-mode)
H-1 Machine lacks power(or drawbar pull)

H-1 Machine lacks power(or drawbar pull) 40-648


Failure q Power is low (Insufficient drawbar pull)
q When Manual transmission or show slip control is selected for the gear shift mode, and when oper-
Related infor-
ation is in the E mode, the contents of this section are not applied.
mation
q Make sure that hydraulic oil level of power train is normal, and start troubleshooting.

Cause Standard value in normal condition/Remarks on troubleshooting


a Prepare by turning starting switch to OFF position, then trouble-
shoot by rotating engine at high idling speed.
Measuring conditions Engine speed
Defective engine or trans-
1
mission F3 stall 1,450 rpm
Stall in F3 + Relief of work equip-
1,400 rpm
ment system (Pitch back)
The power train pump is suspected to be defective. Check it
2 Defective power train pump
directly.
a Prepare by turning starting switch to OFF position, then trouble-
shoot by rotating engine at high idling speed.
Internal defect of torque con- Torque converter Torque converter
3 PCCS lever
verter inlet pressure outlet pressure
0.69 1.08 MPa 0.44 0.74 MPa
All neutral position
{7.0 11.0 kg/cm2} {4.5 7.5 kg/cm2}
a Prepare by turning starting switch to OFF position, then trouble-
shoot by rotating engine at high idling speed.
Transmission
PCCS lever
main relief pressure
2.53 3.12 MPa
Possible Defective set pressure of All neutral position
4 transmission main relief {25.8 31.8 kg/cm2}
causes and
valve and internal defect a Prepare with starting switch OFF, then carry out troubleshooting
standard value
without turning starting switch ON.
in normal state
Directly check that the spring length and the number of shims are
normal and also that the spool rotates smoothly.
q Free length of spring: 120.3 mm
q Number of shims: 4
a Prepare by turning starting switch to OFF position, then trouble-
shoot by rotating engine at low idling speed.
Transmission clutch Clutch pressure
FWD Min. 2.06 MPa {Min. 21.0 kg/cm2}
Operation failure of trans-
5 REV Min. 2.06 MPa {Min. 21.0 kg/cm2}
mission valve (ECMV)
1ST Min. 1.86 MPa {Min. 19.0 kg/cm2}
2ND Min. 2.06 MPa {Min. 21.0 kg/cm2}
3RD Min. 2.06 MPa {Min. 21.0 kg/cm2}
a Move the machine to a flat ground and start the engine for trou-
bleshooting.
Defective operation (drag-
6 If machine does not move when engine is low-idling and F2 shift is
ging) of brake
selected, braking is applied (troubleshoot by referring to "H-9 Brake
system does not operate".
If the result of the troubleshooting in cause 6 is abnormal, the park-
Defective parking brake
7 ing brake lever or brake pedal linkage is not assumed to be
lever or brake pedal linkage
adjusted normally. Directly check it.

40-648 D375A-6R
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-1 Machine lacks power(or drawbar pull)

Cause Standard value in normal condition/Remarks on troubleshooting


a After checking that the transmission main relief pressure is nor-
mal.
a Prepare by turning starting switch to OFF position, then trouble-
shoot by rotating engine at high idling speed.+
PCCS lever Left stroke end Right stroke end
Min. 2.4 MPa 0 MPa
Left clutch pressure
{Min. 24 kg/cm2} {0 kg/cm2}
Possible 8 Defective steering clutch 0 MPa Min. 2.4 MPa
Right clutch pressure
causes and {0 kg/cm2} {Min. 24 kg/cm2}
standard value
0 MPa Min. 2.4 MPa
in normal state Left brake pressure
{0 kg/cm2} {Min. 24 kg/cm2}
Min. 2.4 MPa 0 MPa
Right brake pressure
{Min. 24 kg/cm2} {0 kg/cm2}
When the oil pressure is abnormal, execute the troubleshooting of
"H-6 Steering is not possible."
Internally defective transmis- The transmission is assumed to be defective internally; directly
9
sion check it.

D375A-6R 40-649
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-2 Machine cannot travel (at 2nd or 3rd each speed)

H-2 Machine cannot travel (at 2nd or 3rd each speed) 40-650
Failure q Machine cannot start (at 2nd or 3rd gear speed)
q Before performing troubleshooting, check that the power train oil level is normal.
q Before performing troubleshooting, check that the transmission main relief pressure is normal.
Related infor-
(See H-1.)
mation
q If any one of failure code of [15SFL1], [15SFLH], [15SGL1] or [15SGLH] is displayed, perform trou-
bleshooting for the failure code first.

Cause Standard value in normal condition/Remarks on troubleshooting


a Prepare with starting switch to OFF position , then run the en-
gine at full speed to perform troubleshooting.
Internal defect of torque con- Torque converter Torque converter out-
1 PCCS lever
verter inlet pressure let pressure
Neutral for all con- 0.69 1.08 MPa 0.44 0.74 MPa
trols {7.0 11.0 kg/cm2} {4.5 7.5 kg/cm2}
a Prepare with starting at switch OFF positon , then run the en-
gine at low speed to perform troubleshooting.
Transmission clutch Clutch pressure
Defective operation of trans-
2 Min. 2.06 MPa
mission valve (ECMV) 2ND
{Min. 21.0 kg/cm2}
Min. 2.06 MPa
3RD
{Min. 21.0 kg/cm2}
Defective operation (drag-
3 Defective operation (dragging) is supposed, check linkage valves.
ging) of parking brake
Possible a Move the machine to flat ground and start the engine to perform
causes and troubleshooting.
Defective operation (drag-
standard value 4 Run the engine at low speed and set the gear to F2. If the machine
ging) of brake
for judgment move, the brake drags. (Perform the troubleshooting for "H-9
Brake does not work.")
a Prepare with starting switch at OFF position , then run the en-
gine at full speed to perform troubleshooting
PCCS lever Left stroke end Right stroke end
Min. 2.4 MPa 0 MPa
Left clutch pressure
{Min. 24 kg/cm2} {0 kg/cm2}
0 MPa Min. 2.4 MPa
Defective seal of steering Right clutch pressure
5 {0 kg/cm2} {Min. 24 kg/cm2}
clutch or brake
0 MPa Min. 2.4 MPa
Left brake pressure
{0 kg/cm2} {Min. 24 kg/cm2}
Min. 2.4 MPa 0 MPa
Right brake pressure
{Min. 24 kg/cm2} {0 kg/cm2}
When the oil pressure is abnormal, perform the troubleshooting for
"H-6 machine cannot turn."
Internal defect of transmis-
6 Transmission may have an internal defect. Check it directly.
sion

40-650 D375A-6R
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-3 Machine cannot travel at any gear speeds

H-3 Machine cannot travel at any gear speeds 40-651


Failure q Machine does not start at all gear speeds
q Performing troubleshooting, check that the power train oil level is normal.
Related infor- q If any one of failure code of [1500L0], [2201L1], [2201LH], [2202L1], [2202LH], [DDT5KA],
mation [DDT5KB], [DK30KX], [DK30KZ], [DK55KX] or [DK55KZ] is displayed, perform troubleshooting for
the failure code first.

Cause Standard value in normal condition/Remarks on troubleshooting


The power train pump is suspected to be defective. Check it
1 Defective power train pump
directly.
a Prepare with starting switch at OFF position, then run the engine
at full speed to perform troubleshooting.
Incorrect set pressure of Transmission
2 transmission main relief PCCS lever
main relief pressure
valve
2.53 3.12 MPa
Neutral for all controls
{25.8 31.8 kg/cm2}
a Prepare with starting switch at OFF position, then perform trou-
bleshooting leaving starting switch intact.
Defective operation of trans- Directly check that the spring length and the number of shims are
3
mission main relief valve normal and also that the spool moves smoothly.
q Free length of spring: 120.3 mm
q Number of shims: 4 sheets
a After checking that the transmission main relief pressure is nor-
mal.
a Prepare with starting at OFF position, then run the engine at low
speed to perform troubleshooting.
Possible
causes and Transmission clutch Clutch pressure
standard value Min. 2.06 MPa
for judgment FWD
{Min. 21.0 kg/cm2}
Defective operation of trans-
4 Min. 2.06 MPa
mission valve (ECMV) REV
{Min. 21.0 kg/cm2}
Min. 1.86 MPa
1ST
{Min. 19.0 kg/cm2}
Min. 2.06 MPa
2ND
{Min. 21.0 kg/cm2}
Min. 2.06 MPa
3RD
{Min. 21.0 kg/cm2}
a After checking that the transmission main relief pressure is nor-
mal.
a Move the machine to level ground, raise parking the brake lever,
run the engine at full speed to perform troubleshooting.(Before
starting troubleshooting ,check that transmission main relief
5 Defective operation of brake pressure is normal).
Brake pedal Brake oil pressure (right and left)
Release Min. 2.4 MPa {Min. 24 kg/cm2}
0 MPa
Depressed
{0 kg/cm2}

D375A-6R 40-651
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-3 Machine cannot travel at any gear speeds

Cause Standard value in normal condition/Remarks on troubleshooting


a After checking that the transmission main relief pressure is nor-
mal.
a Prepare with starting at switch OFFposition, raise parking brake
lever to release the brake , run the engine at full speed to per-
form troubleshooting (Before starting troubleshooting ,check
that transmission main relief pressure is normal).
PCCS lever Left stroke end Right stroke end
Defective seal of steering Min.2.4 MPa 0 MPa
6 Left clutch pressure
clutch or brake {Min. 24 kg/cm2} {0 kg/cm2}
Possible 0 MPa Min.2.4 MPa
Right clutch pressure
causes and {0 kg/cm2} {Min. 24 kg/cm2}
standard value 0 MPa Min.2.4 MPa
for judgement Left brake pressure
{0 kg/cm2} {Min. 24 kg/cm2}
Min.2.4 MPa 0 MPa
Right brake pressure
{Min. 24 kg/cm2} {0 kg/cm2}
Internal defect of steering
7 Steering clutch may be defective, check it directly.
clutch and brake
Perform troubleshooting for the failure codes [DDQ2KA],
Malfunction of parking brake [DDQ2KB], [DDQ2L4] and [dDQ2L4].
8
lever switch Even if failure code is not displayed, check that switch operates
normally.
Internal defect of transmis- The inside of transmission clutch may be defective. Check it
9
sion clutch directly.

40-652 D375A-6R
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-4 Machine travels only in one direction, forward or reverse

H-4 Machine travels only in one direction, forward or reverse 40-653


Trouble q Machine travels only in one direction ,forward or in Reverse.
q Before performing troubleshooting, check that the power train oil level is normal.
Related infor- q Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.)
mation q If any one of failure code of [15SAL1], [15SALH], [15SBL1] or [15SBLH] is displayed, perform trou-
bleshooting for the failure code first.

Cause Standard value in normal condition/Remarks on troubleshooting


a Prepare with starting switch at OFFposition, then run the engine
at low speed to perform troubleshooting.
q Before troubleshooting, check that the transmission main relief
pressure is normal. (See H-1.)
Transmission clutch Clutch pressure
Min. 2.06 MPa
FWD
{Min. 21.0 kg/cm2}
Defective operation of trans- Min. 2.06 MPa
1 REV
mission valve (ECMV)
{Min. 21.0 kg/cm2}
Min. 1.86 MPa
Possible 1ST
causes and {Min. 19.0 kg/cm2}
standard value Min. 2.06 MPa
2ND
in normal state {Min. 21.0 kg/cm2}
Min. 2.06 MPa
3RD
{Min. 21.0 kg/cm2}
Defectively sealed of trans- If the result of the test for cause 4 shows malfunction of the brake,
2
mission clutch the clutch seal may be defective. Check it directly.
Internal defect of transmis-
The inside of the transmission clutch is supposed to be defective.
3
sion clutch Check it directly.
a Move the machine to flat ground and start the engine to perform
troubleshooting.
Defective operation of brake
4 Run the engine at low speed mode and set to gear to F2. If the
(dragging)
machine does not move, the brake drags. (Perform the trouble-
shooting for "H-9 Brake does not work").

D375A-6R 40-653
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-5 Large time lag at gear shifting or directional change

H-5 Large time lag at gear shifting or directional change 40-654


Failure q Large time lag at gear shifting or directional change.
Related infor-
q Before performing troubeshooting ,check that the power train oil level is normal.
mation

Cause Standard value in normal condition/Remarks on troubleshooting

1 Defective power train pump The power train pump may be defective. Check it directly.

a Prepare by turning starting switch at OFF position, then run the


engine at full speed to perform troubleshooting.
Transmission
PCCS lever
Defective operation of trans- main relief pressure
2
mission main relief valve 2.45 2.94 MPa
Neutral for all controls
{25.0 30.0 kg/cm2}
When the oil pressure is abnormal, clean the valve and then check
the oil pressure again.
a Prepare with starting switch at OFF position , then perform trou-
ble starting switch intact..
Defective operation of trans- Directly check that the spring free length and the number of shims
3
mission main relief valve are normal and that the spool moves smoothly.
q Free length of spring: 120.3 mm
q Number of shims: 4 sheets
a After checking that the transmission main relief pressure is nor-
mal.
a Prepare by turning starting switch at OFF position, then run the
Possible engine at low speed to perform troubleshooting .
causes and Transmission clutch Clutch pressure
standard value
Min. 2.06 MPa
in normal state FWD
{Min. 21.0 kg/cm2}
Operation failure of trans- Min. 2.06 MPa
4 REV
mission valve (ECMV)
{Min. 21.0 kg/cm2}
Min. 1.86 MPa
1ST
{Min. 19.0 kg/cm2}
Min. 2.06 MPa
2ND
{Min. 21.0 kg/cm2}
Min. 2.06 MPa
3RD
{Min. 21.0 kg/cm2}
Defectivly sealed transmis- When the standard values for the cause 3 are not satisfied, the
5
sion clutch clutch seal may be defective. Check it directly.
Internal defect of transmis-
6 Inside of transmission clutch may be defective. Check it directly.
sion clutch
a Move the machine to flat ground and start the engine to perform
troubleshooting.
Defective operation of brake
7 If machine does not move when engine is low-idling and F2 shift is
(dragging)
selected, braking is applied (troubleshoot by referring to "H-9
Brake system does not operate".
8 Type of oil used Check if an oil other than the specified oil (T030) is being used.

40-654 D375A-6R
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-6 Machine connot turn

H-6 Machine connot turn 40-65


Trouble q Machine connot turn.
q Before performing troubleshooting, check that the power train oil level is normal.
Related infor-
q Before performing troubleshooting, check that the transmission main relief pressure is normal.
mation
(See H-1.)

Cause Standard value in normal condition/Remarks on troubleshooting


a Prepare with engine started , then run the engine at low speed
whild performing troubleshooting.
Raise machine by using blade and ripper, run tracks with gear at
1 Defective operation of brake
F3 (or R3), and make steering operation .If track stops running,
brake is defective. (Perform troubleshooting for "H-9 Brake does
not work".)
a Prepare with starting switch at OFF positon, then run the engine
at full speed to perform troubleshooting
PCCS lever Left stroke end Right stroke end
Min. 2.4MPa 0MPa
Left clutch pressure
Possible {Min. 24 kg/cm2} {0 kg/cm2}
causes and Defective operation of steer-
2 0MPa Min. 2.4MPa
standard value ing clutch valve (ECMV) Right clutch pressure
{0 kg/cm2} {Min. 24 kg/cm2}
for judgment
0MPa Min. 2.4MPa
Left brake pressure
{0 kg/cm2} {Min. 24 kg/cm2}
Min. 2.4MPa 0MPa
Right brake pressure
{Min. 24 kg/cm2} {0 kg/cm2}
Defectively sealed steering When standard values for the cause 2 are not satisfted, the clutch
3
clutch seal may be sealed diffectively. Check it directly.
Internal defect of steering
4 Steering clutch may be defective, check it directly.
clutch
Defective operation of steer-
5 ing potentiometer of travel Perform troubleshooting related to steering potentiometer.
control lever

D375A-6R 40-655
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-7 Machine turns only to one side

H-7 Machine turns only to one side 40-656


Trouble q Machine turns only to one side.
q Before performing troubleshooting, check that the power train oil level is normal.
Related infor-
q Before performing troubleshooting, check that the transmission main relief pressure is normal.
mation
(See H-1.)

Cause Standard value in normal condition/Remarks on troubleshooting


a Prepare with engine started, then run the engine at low speed
while performing troubleshooting.
Raise machine by using blade and ripper, drive it in F3 (or R3), and
1 Defective operation of brake
steer it in direction in which machine cannot turn. If track shoe
stops at this time, brake is defective. (Carry out troubleshooting for
"H-9 Brake does not work".)
a Prepare with starting switch OFF, then run the engine at full
speed position to perform troubleshooting
PCCS lever Left stroke end Right stroke end
Min. 2.4MPa 0MPa
Left clutch pressure
Possible {Min. 24 kg/cm2} {0 kg/cm2}
causes and Defective operation of steer-
2 0MPa Min. 2.4MPa
standard value ing clutch valve (ECMV) Right clutch pressure
{0 kg/cm2} {Min. 24 kg/cm2}
for judement
0MPa Min. 2.4MPa
Left brake pressure
{0 kg/cm2} {Min. 24 kg/cm2}
Min. 2.4MPa 0MPa
Right brake pressure
{Min. 24 kg/cm2} {0 kg/cm2}
Defectively sealed steering When the standard the cause 2 are not satisfied , the clutch seal
3
clutch may be sealed defectively. Check it directly.
Internal defect of steering
4 Steering clutch may be defective, check it directly.
clutch
Defective operation of steer-
5 ing potentiometer of travel Perform troubleshooting related to steering potentiometer.
control lever

40-656 D375A-6R
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-8 Machine overruns at turnning

H-8 Machine overruns at turnning 40-657


Trouble q Machine overruns at turnning.
q Before performing troubleshooting, check that the power train oil level is normal.
Related infor-
q Before performing troubleshooting, check that the transmission main relief pressure is normal.
mation
(See H-1.)

Cause Standard value in normal condition/Remarks on troubleshooting


a Prepare with starting switch OFF, then drive the engine in low
idle mode for troubleshooting.
Possible Raise the machine by using the blade and run the engine with gear
causes and 1 Defective operation of brake
at F3 travel (or R3 travel) and make steering operation. If the shoe
standard value stops running ,the brake is defective. (Perform the troubleshooting
for judgment for H-9 Brake does not work.)
When track shoe does not stop running in the troubleshooting for
Defective operation of steer-
2 the cause 1, the steering clutch is defective. (Perform the trouble-
ing clutch
shooting fro H-6 Machine cannot turn.)

D375A-6R 40-657
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-9 Brake does not work

H-9 Brake does not work 40-658


Trouble q Brake does not work.
q Before performing troubleshooting, check that the power train oil level is normal.
Related infor- q Before performing troubleshooting, check that the transmission main relief pressure is normal.
mation (See H-1.)
q If failure code [DK40KA] or [DK40KB] is displayed, perform diagnoses for the failure code first .

Cause Standard value in normal condition/Remarks on troubleshooting


a Start the engine to perform troubleshooting.
1 Degradation of brake Depress the brake pedal, shift the gear to F2 and run the engine at
full speed. If the machine moves, the brake performance is
degraded.
Defective operation of brake Brake pedal, linkage and the brake valve may have a malfunction.
2
pedal Check them directly.
a Prepare with starting switch at OFF position, then run the en-
gine at full speed to perfrom troubleshooting.
Possible PCCS lever Left stroke end Right stroke end
causes and Min. 2.4MPa 0MPa
standard value Left clutch pressure
{Min. 24 kg/cm2} {0 kg/cm2}
for judgment Defective operation of steer-
3 0MPa Min. 2.4MPa
ing brake valve (ECMV) Right clutch pressure
{0 kg/cm2} {Min. 24 kg/cm2}
0MPa Min. 2.4MPa
Left brake pressure
{0 kg/cm2} {Min. 24 kg/cm2}
Min. 2.4MPa 0MPa
Right brake pressure
{Min. 24 kg/cm2} {0 kg/cm2}
When standard the cause 3 are not satisfied , the brake seals may
4 Defective brake seal
be defective. Check it directly.
5 Internal defect of brake Brakes may be defective. Check it directly.

40-658 D375A-6R
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-10 Torque converter does not lock up

H-10 Torque converter does not lock up 40-659


Failure q The torque converter does not lock up.
q Before performing troubleshooting, check that the power train oil level is normal.
q Before performing troubleshooting, check that the transmission main relief pressure is normal.
Related infor-
(See H-1.)
mation
q If any one of failure code of [DDTSL1], [DDTSLH], [DXH1KA], [DXH1KB], [DXJBKA] or [DXJBKB]
is displayed, perform diagnoses for the failure code first.

Cause Standard value in normal condition/Remarks on troubleshooting

1 Defective power train pump The power train pump may be defective. Check it directly.

a Prepare with starting switch at OFF position, then run the en-
gine at full speed to perform troubleshooting.
Torque converter Clutch pressure
Defective operation of torque
2 converter lock up valve Stator 2.50 2.79 MPa
(ECMV) clutch {25.5 28.5 kg/cm2}
At lock up
Lockup clutch 1.24 1.54 MPa
Possible
causes and {12.7 15.7 kg/cm2}
standard value Defectively sealed of lock up When standard value for the case 2 is not satisfied, the lock up
3
for judgment clutch clutch may sealed defectively. Check it directly.
Internal defect of lock up
4 Lock up clutch may be defective. Check it directly.
clutch
a Prepare with starting at switch OFF position, then run the en-
gine at full speed to perform troubleshooting.
Measurement conditions Engine speed
Internal defect of torque con-
5 F3,torque converter stall 1,450 rpm
verter
F3,torque converter stall + Work
equipment relief 1,170 rpm
(pitch back)

D375A-6R 40-659
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-11 Power train oil overheats

H-11 Power train oil overheats 40-6 0


Failure q Overheating of power train oil
q Make sure that hydraulic oil level of power train is normal, and start troubleshooting.
q Make sure that power train oil temperature gauge indication matches actual oil temperature of
Related infor-
torque converter and start troubleshooting. (If no match, follow "E-9 Power train oil temperature
mation
gauge (multi-gauge) does not indicate normally".)
q Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.)

Cause Standard value in normal condition/Remarks on troubleshooting


Engine cooling system may be defective and engine output may be
1 Defective engine system increased abnormally. Carry out troubleshooting according to
Engine volume, Shop manual.
Defective power train pump Since the defective power train pump or air mixing in from the suc-
2
or air mixing in suction circuit tion circuit is suspected, check it directly.
a Prepare by turning starting switch to OFF position, then trouble-
shoot by rotating engine at high idling speed.
Internal defect of torque con- Torque converter Torque converter
3 PCCS lever
verter inlet pressure outlet pressure
0.69 1.08 MPa 0.44 0.74 MPa
All neutral position
Possible {7.0 11.0 kg/cm2} {4.5 7.5 kg/cm2}
causes and Defective operation (slide) of The inside of the transmission clutch is supposed to be defective
standard value 4
transmission clutch (the clutch slides). Check it directly.
in normal state
a Start the engine for troubleshooting.
Defective operation of brake If machine does not move when engine is low-idling and F2 shift is
5
(dragging) selected, braking is applied (troubleshoot by referring to "H-9
Brake system does not operate".
Defective operation (slide) of The inside of the steering clutch is supposed to be defective (the
6
steering clutch clutch slides). Check it directly.
a Start the engine for troubleshooting.
Defective operation of brake
7 If the machine cannot be stopped completely while performing F3
(Slip)
stall, the brake is slipping.
Defective power train oil
8 Check the filter element for clogging.
cooler

40-660 D375A-6R
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-12 All work equipment operates too slow or lacks power

H-12 All work equipment operates too slow or lacks power 40-6 1
Failure q All work equipment operates slowly or lacks power.
Related infor-
q Make sure that hydraulic oil level is normal, and start troubleshooting.
mation

Cause Standard value in normal condition/Remarks on troubleshooting


Defective PTO (work equip- The work equipment pump drive of the PTO is supposed to be
1
ment pump drive) defective. Check it directly.
Defective work equipment The work equipment large pump is supposed to be defective.
2
large pump Check it directly.
Defective work equipment The work equipment small pump is supposed to be defective.
3
small pump Check it directly.
a Prepare by turning starting switch to OFF position, then trouble-
shoot by rotating engine at high idling speed.
Defective operation of Work equipment control levers Unload pressure
4
unload valve
2.45 (+1.37/0) MPa
All neutral position
{25 (+14/0) kg/cm2}
a Prepare by turning starting switch to OFF position, then trouble-
shoot by rotating engine at high idling speed.
Improper pressure set to
5 main relief valve for blade lift Blade control lever Main relief pressure
valve Min. 26.5 MPa
Raise
{Min. 270 kg/cm2}
Internal failure of main relief
The main relief valve for the blade lift control valve may have a fail-
6 valve for blade lift control
ure inside. Check it directly.
valve
Possible
a Prepare by turning starting switch to OFF position, then trouble-
causes and
shoot by rotating engine at high idling speed.
standard value Improper pressure set to
in normal state 7 main relief valve for blade tilt Blade control lever Main relief pressure
and ripper Lo valve Min. 26.5 MPa
Raise
{Min. 270 kg/cm2}
Internal failure of main relief
The main relief valve for blade tilt and ripper Lo valve may have a
8 valve for blade tilt and ripper
failure inside. Check it directly.
Lo valve
a Prepare by turning starting switch to OFF position, then trouble-
shoot by rotating engine at high idling speed.
Defective pressure setting or
9 defective operation of LS Work equipment control levers LS relief pressure
relief valve Min. 24.52 MPa
At stroke end
{Min. 250 kg/cm2}
a Prepare by turning starting switch to OFF position, then trouble-
shoot by rotating engine at high idling speed.
Malfunction of self pressure
10 reducing valve (PPC basic Work equipment control levers Control relief pressure
pressure) Min. 3.1 MPa
All neutral position
{Min. 32 kg/cm2}
If cause 8 is detected, oil may be leaking in PPC valve. Check
11 Internal leak of PPC valve
PPC valve directly.
Operation failure of check
12 Directly inspect the check valve for clogging.
valve of PPC control circuit

D375A-6R 40-661
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-13 All work equipment does not operate

H-13 All work equipment does not operate 40-6 2


Failure q All work equipment does not operate.
Related infor-
q Make sure that hydraulic oil level is normal, and start troubleshooting.
mation

Cause Standard value in normal condition/Remarks on troubleshooting


Defective PTO (work equip- The work equipment pump drive of the PTO is supposed to be
1
ment pump drive) defective. Check it directly.
Defective work equipment The work equipment large pump is supposed to be defective.
2
large pump Check it directly.
Defective work equipment The work equipment small pump is supposed to be defective.
3
small pump Check it directly.
Prepare by turning starting switch to OFF position, then trouble-
shoot by rotating engine at high idling speed.
Defective operation of Work equipment control levers Unload pressure
4
unload valve
2.45(+1.37/0) MPa
All neutral position
{25(+14/0) kg/cm2}
a Prepare by turning starting switch to OFF position, then trouble-
shoot by rotating engine at high idling speed.
Improper pressure set to
5 main relief valve for blade lift Blade control lever Main relief pressure
control valve Min. 26.5 MPa
Raise
{Min. 270 kg/cm2}
Internal failure of main relief
The main relief valve for the blade lift control valve may have a fail-
6 valve for blade lift control
ure inside. Check it directly.
valve
a Prepare by turning starting switch to OFF position, then trouble-
Possible shoot by rotating engine at high idling speed.
Improper pressure set to
causes and 7 main relief valve for blade tilt Blade control lever Main relief pressure
standard value and ripper Lo valve Min. 26.5 MPa
in normal state Raise
{Min. 270 kg/cm2}
Internal failure of main relief
The main relief valve for blade tilt and ripper Lo valve may have a
8 valve for blade tilt and ripper
failure inside. Check it directly.
Lo valve
a Prepare by turning starting switch to OFF position, then trouble-
shoot by rotating engine at high idling speed.
Defective pressure setting or
9 defective operation of LS Work equipment control levers LS relief pressure
relief valve 27.44 1.37 MPa
At stroke end
{280 14 kg/cm2}
a Prepare by turning starting switch to OFF position, then trouble-
shoot by rotating engine at high idling speed.
Malfunction of self pressure
10 reducing valve (PPC basic Work equipment control levers Control relief pressure
pressure) Min. 3.1 MPa
All neutral position
{Min. 32 kg/cm2}
Defective operation of PPC The PPC lock valve is supposed to operate abnormally. Check the
11
lock valve lever linkage or the lock valve directly.
a Prepare by turning starting switch to OFF position, then trouble-
shoot by rotating engine at high idling speed.
Operation failure of check Work equipment control levers Control relief pressure
12
valve of PPC control circuit
Min. 3.1 MPa
All neutral position
{Min. 32 kg/cm2}

40-662 D375A-6R
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-14 Blade lift cylinder speed is too slow or lacks power

H-14 Blade lift cylinder speed is too slow or lacks power 40-6 3
Trouble q Blade lift cylinders speed is too slow or lacks power.
q Before performing troubleshooting, check that hydraulic tank oil level is normal.
q Check whether the blade is remodeled.
Related infor- q When hydraulic drift rate of the blade lift cylinders is also high, perform troubleshooting for H-18
mation Excessive hydraulic drift of blade Lift cylinders.
q If either one of failure code of [DDNALD] or [DDNFLD] is displayed, troubleshooting corresponding
to such code are to be reformed.

Cause Standard value in normal condition/Remarks on troubleshooting


a Prepare with starting switch OFF, then run the engine of the full
speed position to perform troubleshooting.
Defective operation of PPC Blade control lever PPC valve output pressure
Possible 1
valve
causes and Min. 3.1 MPa
Raise stroke end
standard value {Min. 32 kg/cm2}
for judgement Defective operation of blade Operation of the blade lift valve spool may be defective. Check it
2
lift control valve (spool) directly.
Air entering blade lift cylin- Air blade lift cylinders.Bleed air and check whether the phenome-
3
ders non changes.

D375A-6R 40-663
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-15 Blade tilt cylinder speed is too slow or lacks power

H-15 Blade tilt cylinder speed is too slow or lacks power 40-6 4
Trouble q Blade tilt cylinders speed is too slow or lacks power.
q Before performing troubleshooting, check the hydraulic oil level is normal.
q Check whether the blade is remodeled.
Related infor- q When the hydraulic drift rate of the blade tilt cylinders is also high, perform troubleshooting for H-19
mation Excessive hydraulic drift of blade tilt cylinders.
q If either one of failure code of [DDNZLD] or [DDN3LD] is displayed, troubleshooting corresponding to
such code are to be performed.

Cause Standard value in normal condition/Remarks on troubleshooting


a Prepare with starting switch OFF, then run the engine at the full
speed position to performe troubleshooting.
Defective operation of PPC Blade control lever PPC valve output pressure
Possible 1
valve
causes and Min. 3.1 MPa
Raise stroke end
standard value {Min. 32 kg/cm2}
for judgement
Defective operation of blade Operation of the blade tilt valve spool may be defective.Check it
2
tilt control valve (spool) directly.
Air entering blade tilt cylin- Air may enter the blade tilt cylinders.Bleed air and check wether the
3
ders phenomenon changes.

40-664 D375A-6R
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-16 Ripper lift cylinder speed is too slow or lacks power

H-16 Ripper lift cylinder speed is too slow or lacks power 40-6 5
Failure q Ripper lift cylinders speed is too slow or lacks power.
q Before performing troubleshooting, check the hydraulic tank oil level is normal.
q Check whether the ripper is remodeled.
Related infor- q When the hydraulic drift rate of the ripper lift cylinders is also high, perform troubleshooting for
mation H-20 Excessive hydraulic drift of ripper Lift cylinders.
q If either one of failure code of [DDNBLD] or [DDNCLD] is displayed, troubleshooting corresponding
to such code are to be performed.

Cause Standard value in normal condition/Remarks on troubleshooting


a Prepare with starting switch OFF, then run the engine at the full
speed position to perform troubleshooting
Defective operation of PPC Ripper control lever PPC valve output pressure
1
valve
Min. 3.1 MPa
Raise stroke end
Possible {Min. 32 kg/cm2}
causes and Defective operation of ripper Operation of the ripper lift control valve may be defective.Check it
2
standard value lift control valve (Spool) directly.
for judgement The operation of the suction valve for the ripper lift control valve
Defective operation of ripper may be defective. Check it directly.
3 lift control valve (suction a Judgment may be made by checking a change of phenomenon
valve) after exchanging suction valves on the head side and on the
bottom side.
Air entering ripper lift cylin- Air may enter The ripper lift cylinders.Bleed air and check whether
4
der the phenomenon changes.

D375A-6R 40-665
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-17 Ripper tilt cylinder speed is too slow or lacks power

H-17 Ripper tilt cylinder speed is too slow or lacks power 40-6 6
Trouble q Ripper tilt cylinders speed is too slow or lacks power.
q Before performing troubleshooting, check that the hydraulic oil level tank is normal.
Related infor- q Check whether the ripper is remodeled.
mation q If either one of [DDNDLD] or [DDNELD] is displayed, troubleshooting corresponding to such
code are to be performed first.

Cause Standard value in normal condition/Remarks on troubleshooting


a Prepare with starting switch OFF, then run the engine at full
speed position to perform troubleshooting
Defective operation of Ripper lever PPC valve output pressure
1
PPC valve
Min.3.1 MPa
Tilt stroke end
Possible {Min. 32 kg/cm2}
causes and Defective operation of rip- Operation of the ripper tilt control valve spool may be defective.
2
standard value per tilt control valve(spool) Check it directly.
for judgement Operation of the suction valve for the ripper tilt control valve may
Defective operation of rip- be defective. Check it directly.
3 per tilt operation a Judgement may be made by checking a change of phenome-
valve(suction valve) non after exchanging suction valves on the head side and on
the bottom side.
Air entering ripper tilt cylin- Air may enter ripper tilt cylinders. Bleed air and check whether the
4
ders phenomenon changes.

40-666 D375A-6R
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-18 Excessive hydraulic drift of blade lift cylinder

H-18 Excessive hydraulic drift of blade lift cylinder 40-6 7


Failure q Excessive hydraulic drift of blade lift cylinders.
Related infor- q Check whether the blade is remodeled.
mation q Before performing troubleshooting, check that no oil leaks in the work equipment circuit.

Cause Standard value in normal condition/Remarks on troubleshooting


a Prepare with the engine started, then stop the engine to perform
troubleshooting.
Follow the procedure below for troubleshooting. If the hydraulic drift
speed becomes higher,sealing of the blade lift control valve spool
Defectively sealed blade lift may be sealed defectively.
1
control valve (spool) 1. Use the blade lift cylinders to thrust the blade againment the
ground, and raise the front of the machine.
2. Stop the engine, and release the work equipment lock lever.
3. Set the blade control lever to LOWER side, and check whether
the speed changes.
Defectively sealed of blade
2 The blade lift cylinders may be sealed defectively. Check it directly.
lift cylinder
Raise blade about 1,000 mm above the ground and check hydraulic
Possible Defective fitting of quick drop
3 drift of its cutting edge.
causes and valve
q 400 mm /15 min
standard value a Prepare by starting the engine, and troubleshoot by rotating en-
for judgement gine at high idling speed.
Troubleshoot using the following procedure and if the work equip-
ment pump pressure is below the limit, cylinder piston valve is
defective.
1. Raise the blade about 1,000 mm and hook the end bit on a rock
or other object. (Do not move the blade.)
Operation failure of piston 2. Raise blade in the above conditions, and measure the pump
4
valve pressure.
3. If pump pressure is within the limit, cylinder piston valve is defec-
tive.
4. Disassemble the cylinder, and check piston valve.
Blade lever Blade Pump pressure
24.5 MPa
Raising stroke end Cannot move
{250 kg/cm2}

D375A-6R 40-667
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-19 Excessive hydraulic drift of blade tilt cylinder

H-19 Excessive hydraulic drift of blade tilt cylinder 40-6 8


Failure q Hydraulic drift of tilted blade is large.
Related infor- q Check whether or not the blade is modified.
mation q Before performing troubleshooting, check that no oil leaks in the work equipment circuit.

Cause Standard value in normal condition/Remarks on troubleshooting


a Prepare with the engine started, then stop the engine to per-
forming troubleshooting.
Follow the troubleshooting procedure shown below. If the hydraulic
drift speed becomes higher, the sealing of the blade tilt valve spool
Defective seal of blade tilt is defective.
Possible 1
control valve (Spool) 1. Use the blade tilt cylinder to thrust the blade against the ground,
causes and and raise the right of the machine.
standard value 2. Stop the engine, and release the work equipment lock lever.
for judgement 3. Check the phenomenon when the blade control lever is oper-
ated to the right tilt.
a Prepare with starting switch OFF, then run the engine at the full
speed position to perform troubleshooting
Defective seal of blade tilt
2 Blade tilt cylinder Oil leak from cylinder
cylinder
Right tilt stroke end 12 cc/min

40-668 D375A-6R
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-20 Excessive hydraulic drift of ripper lift cylinder

H-20 Excessive hydraulic drift of ripper lift cylinder 40-6 9


Failure q Excessive hydraulic drift of ripper lift cylinders.
q Check whether the ripper is remodeled.
Related infor-
q Before performing troubleshooting, check that no oil leaks the circuits in the work equipment before
mation
troubleshooting.

Cause Standard value in normal condition/Remarks on troubleshooting


a Prepare with the engine started, then stop the engine for trou-
bleshooting.
Follow the troubleshooting procedure shown below. If the hydraulic
drift speed becomes higher, the sealing of the ripper lift (Hi) valve
Defectively sealed of ripper spool is defective.
Possible 1
lift control valve (spool) 1. Use the ripper lift cylinders to thrust the ripper against the
causes and ground, and raise the rear of the machine.
standard value 2. Stop the engine, and release the work equipment lock lever.
for judgement 3. Set the ripper control lever to the LOWER side, and check
whether the speed changes.
a Prepare with starting switch OFF, then run the engine at full
speed position to perform troubleshooting
Defectively sealed of ripper
2 Ripper lift cylinder Oil leak from cylinder
lift cylinder
LOWER stroke end 12 cc/min

D375A-6R 40-669
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-21 Ripper pin puller cylinder does not operate (machine with giant ripper)

H-21 Ripper pin puller cylinder does not operate (machine with giant
ripper) 40-670
Failure q The ripper pin puller cylinder does not operate.
Related infor-
q Check that the transmission main relief pressure is normal before troubleshooting.
mation

Cause Standard value in normal condition/Remarks on troubleshooting


a Prepare with starting switch at OFF position, then run the en-
gine at high speed to perform troubleshooting
Pin puller operating
Possible Defective operation of pin Pin puller switch Measuring position
1 pressure
causes and puller solenoid
Push-in Cylinder bottom side Min. 2.2 MPa
standard value
for judgment Pull-in Cylinder head side {Min. 22 kg/cm2}
Internal defect of pin puller The pin puller cylinder is suspected to be defective internally.
2
cylinder Check it directly.
Defective fuse FS2-2 (20 A) Check that the fuse is not blown.
3
for pin puller Check wiring harness of related circuit.

40-670 D375A-6R
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-22 Blade pitch does not work (machine with dual tilt specification)

H-22 Blade pitch does not work (machine with dual tilt specification) 40-671
Trouble q The blade pitch does not work.
Related infor- q If either one failure code of [DW5AKA] or [DW5AKB] is displayed, failure diagnoses corresponding
mation to such code are to be performed first.

Cause Standard value in normal condition/Remarks on troubleshooting


Defective operation of blade Operation of the blade pitch selector valve may be defective.
1
pitch selector solenoid valve Check it directly .
Possible Defective function of blade Operation of the blade pitch cylinder may be defective. Check it
causes and 2
pitch control valve (Spool) directly.
standard value
Defective operation of blade Operation of the blade pitch cylinder may be defective. Check it
for judgment 3
pitch cylinder directly.
Perform troubleshooting related to blade pitch switch.
Defective function of blade
4 Even if failure code is not displayed, check that switch operates
pitch switch
normally.

D375A-6R 40-671
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-23 Abnormal noise from around work equipment pump

H-23 Abnormal noise from around work equipment pump 40-672


Failure q Abnormal noise from around work equipment pump.
Related infor-
q Befor performing troubleshooting , check hydraulic oil lever is normal.
mation

Cause Standard value in normal condition/Remarks on troubleshooting

1 Inappropriate oil The oil may be inappropriate. Check it directly.


Possible
causes and Clogged hydraulic tank
2 The strainer of the hydraulic tank may be clogged. Check it directly.
standard value strainer
for judgment Air may be inhaled in the suction circuit of the work machine pump.
3 Air inhaled in suction circuit
Check the circuit directly.
Internal defect of work equip-
4 The work equipment pump may be defective. Check it directly.
ment pump

40-672 D375A-6R
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-24 Abnormal fan rotation(noise and/or vibration are abnormally large or engine overheats)

H-24 Abnormal fan rotation(noise and/or vibration are abnormally large


or engine overheats) 40-673
Failure q The fan speed is abnormal (excessive noise from or vibration of fan, or overheating).
Related infor-
q Before performing troubleshooting, check that the hydraulic oil level tank is normal.
mation

Cause Standard value in normal condition/Remarks on troubleshooting


a Start engine to performing troubleshooting.
Measurement conditions Engine speed
Engine at low idling 750 50 rpm
1 Defective engine speed
Engine at high idling 1,900 (0/-50) rpm
If engine speed does not increase to the specified level, perform
troubleshooting for "S-5 Engine dose not rotate smoothly(hunts)".
Defective PTO (fan pump
2 Fan pump drive of PTO may be defective. Check it directly.
drive)
a Prepare with starting switch OFF, then run the engine at full
speed position to perform troubleshooting
Fan pump EPC circuit source
Measurement conditions
Possible pressure
causes and Min.3.1 MPa

standard value {Min. 32 kg/cm2}
for judgement a Prepare with starting switch OFF, then run the engine at full
Defect in fan pump or fan speed position to perform troubleshooting
3
motor Measurement conditions Fan drive circuit pressure
15.7 2.5 MPa
Fan 100 % mode
{160 25 kg/cm2}
a Prepare with starting switch OFF, then run the engine at full
speed position to perform troubleshooting
Measurement conditions Fan speed
Fan 100 % mode Max. 1,110 rpm
4 Defective fan The fan may be broken or installed defectively. Check itself directly.
Defective sensor for engine
water temperature, power
5 Any of these sensors may be defective. Check them directly.
train oil temperature, or
hydraulic oil temperature

D375A-6R 40-673
(01)
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart

Troubleshooting of engine (S-mode) 40-674


Method of using troubleshooting chart 40-674
This troubleshooting chart is divided into four sections: Questions, Check items, Causes and Troubleshooting.
First, use the Questions and Check items to select highly probable causes among the Causes. The Questions
and Check items allows for the selection based on the failure symptoms or simple inspection results without
using troubleshooting tools.
Next, use troubleshooting tools or perform direct inspection to check the selected causes in the order of prob-
ability to determine the real cause.

Questions:
Questions placed in the sections A and B in the table on the next page are those to be answered by the user
or operator.
Questions in section A are for basic information about the failure. Depth and accuracy of their answers to the
questions in section B may depend on their skill level.

Check items:
Check items placed in the section C in the table on the right are to be simply checked by the technician to
select highly probable causes.

Causes:
The technician selects highly probable causes from among the Causes based on the answers to the Ques-
tions in sections A and B and the check results of Check items in section C.

Troubleshooting:
The Troubleshooting indicates the items to be checked by the serviceman in order to ultimately check that the
selected causes are truly the defect factors by using troubleshooting tools or making direct checking starting
with probable causes of higher order.

This troubleshooting chart marks the content of the questions and check items with E, Q or w according to
their closer relationship with the causes.
E: A cause that can be referred to in relation to the question or check item.
Q: A cause that relates to the question or check item.
w: A cause particularly probable among those marked with Q above.
a Count the priority level of each marking as w > Q when determining the cause.
Dont count E when determining the cause. The item with this marking may be counted, however, if no
difference is present than this and the cause cannot be determined.

40-674 D375A-6R
(01)
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart

D375A-6R 40-675
(01)
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart

<Example of troubleshooting> Exhaust smoke is black (Incomplete combustion) 40-676


Let us assume that a problem of "Exhaust smoke is black" occurred and we checked the [Questions] and
[Check items] and found the following 3 items to be the causal symptoms; "Exhaust smoke gradually became
black", "Power was lost gradually", and "Dust indicator piston indicates red zone".

40-676 D375A-6R
(01)
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart

There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in
the [Causes] section.
The method of pinpointing the [Causes] from the causal relationship and approaching the [troubleshooting] is
explained according to Step 1 - Step 3 shown below.

D375A-6R 40-677
(01)
Troubleshooting of engine (S-mode)
S-1 Engine does not start easily

S-1 Engine does not start easily 40-678


General causes that engine does not start easily Cause

q Electrical system is defective.


q Insufficient supply of fuel

Leaking or clogged fuel piping or entry of air


q Insufficient intake of air

Clogged air breather hole in fuel tank cap


Defective contact of valve with valve seat
Improper selection of fuel

Defective alternator (generator section)


q

Defective alternator (regulator section)


Defective intake air heater system
a Common rail fuel injection system (CRI) controls the fuel

Defective or deteriorated battery


Clogged feed pump gauze filter
injection timing electrically. Therefore, there are cases

Clogged air cleaner element

Worn piston ring or cylinder


where the engine does not start before the crankshaft

Clogged fuel filter, strainer

Clogged, seized injector


makes two revolutions maximum after starting operation.
This is not an abnormal state, however.

Defective injector
Confirm recent repair history
Degree of use of
machine
Operated for long period E E E E
Became worse gradually Q w w Q Q
Starting performance
Engine starts easily when warm w w
Questions

Non-specified fuel is being used Q Q Q Q


Replacement of filters has not been carried out according to Operation and Main-
tenance Manual
w w w Q Q
Oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does
not indicate normally
w
Charge monitor indicates abnormal charging during operation. w w
Dust indicator is red w
Clogged air breather hole in fuel tank cap w
Leaking from fuel piping w Q
No response or heavy resistance felt when operating priming pump w Q Q
Starting motor rotates engine slowly. w
When engine is and air bleeding plug is removed from fuel filter, fuel does
w w
rotated with starting not flow out.
motor, and spill hose is separated from injector, spill flow is small. w
Check items

When exhaust manifold is touched immediately after starting engine, temperature


of some cylinders is low
w
Engine does not pick up smoothly , and combustion is irregular Q Q w
There is hunting from engine (rotation is irregular) Q w Q Q
Blow-by gas is excessive w
Inspect air cleaner directly q
When compression pressure is measured, it is found to be low q q
Air is discharged when the air is bled from the fuel system q
Check fuel filter or strainer. q
Troubleshooting

Inspect feed pump gauze filter directly. q


Carry out troubleshoot by "Rail Press Very Low Error (*1)" q
Speed of some cylinders does not change when operated in reduced cylinder
mode
q
Intake air heater mounting portion does not warm up during preheating. q
Does voltage (25 30 V) appear between alternator terminals B Yes q
and E with engine at low idle? None q
Specific gravity of electrolyte and voltage of battery are low. q
Replace,
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Correct

Remedy
Clean

Clean

Clean
Clean

*1: Troubleshooting for failure codes [CA559] and [CA2249] described in "Troubleshooting by failure code
(Display of code)"

40-678 D375A-6R
(01)
Troubleshooting of engine (S-mode)
S-2 Engine does not start

S-2 Engine does not start 40-679


a) Engine does not crank Cause

Defective starting motor (safety relay section)


General causes that engine does not rotate
q Seized parts inside engine

Defective starting motor (motor section)


o See "S-4 Engine stops during operations".

Defective battery terminal connection


q Coolant leaking inside cylinder causes water hammer.

Defective hydraulic pump or PTO


Defective wiring of starting circuit
Defective or deteriorated battery
q Electrical system is defective.
q Defective hydraulic pump or PTO

Demaged flywheel ring gear

Defective starting switch


Defective battery relay
Confirm recent repair history
Questions

Degree of use of machine Operated for long period EE


Condition of horn when Horn does not sound. Q Q w
starting switch is turned ON Horn volume is slow. w
Battery electrolyte is low. w
Cable is loosely connected to battery terminal. w
No operating sound from battery relay when starting switch is set to ON position. Q w
When starting switch is set to START position, pinion does not come out. Q Q w
Check items

Speed of rotation is low. w


When starting switch is
Grating noise is heard. w w
turned to START, starting
Soon pinion again. w
pinion moves out, but
Ratting noise is heard and engine does not turn. Q Q w
Inspect flywheel ring gear directly q

Perform troubleshooting for H-mode


Perform troubleshooting for E-mode
Specific gravity of electrolyte and voltage of battery are low. q
Voltage (20 30 V) does not appear between battery
q
relay terminal B and terminal E.
Troubleshooting

When terminal B and terminal C of starting switch are


q
Set starting switch to OFF connected, engine cranks.
position, connect the cord, When terminal B at safety relay outlet and terminal C q
then set starting switch to are connected, engine cranks.
ON position to perform trou-
bleshooting
Even if terminals B and C at safety relay outlet are
q
connected, engine does not start.
Replace
Replace

Replace
Replace
Replace
Replace
Correct

Remedy
-
-

D375A-6R 40-679
(01)
Troubleshooting of engine (S-mode)
S-2 Engine does not start

b) Engine rotates but no exhaust smoke comes out Cause


(Fuel is not injected)

Defective operation of overflow valve (does not close)


General causes that engine rotates but no exhaust
smoke comes out

Leaking or clogged fuel piping or entry of air


q Fuel is not being supplied.

Clogged air breather hole in fuel tank cap


q Supply of fuel is extremely small.

Wrong connection of supply pump PCV


Seized or prematurely worn feed pump
q Improper selection of fuel (particularly in winter)

Clogged feed pump gauze filter

Broken supply pump shaft key


Clogging of fuel filter strainer

Defective supply pump PCV


Clogged, seized injector
Insufficient fuel in tank
Improper fuel
Confirm recent repair history
Degree of use of
Questions

Operated for long period E E E


machine
Exhaust smoke suddenly stopped coming out (when starting again). wQ w w w
Replacement of filters has not been carried out according to Operation and
w w E
Maintenance Manual
Fuel tank is found to be empty w
Clogged air breather hole in fuel tank cap Q w
Rust and water are detected when fuel tank is drained Q QQ Q Q
When fuel filter is removed, no fuel is inside the fuel filter. w w
Check items

Leakage from fuel piping w


and air bleeding plug is removed from fuel filter,
Q Q wQ
When engine is rotated fuel does not flow out.
with starting motor, and spill hose is separated from injector, spill
Q w w w w
flow is small.
Air is discharged when the air is bled from the fuel system q
Troubleshooting

Check fuel filter or strainer. q


Inspect feed pump gauze filter directly q
Inspect feed pump directly q
Carry out troubleshoot by "Rail Press Very Low Error (*1)" q q q
Perform troubleshoot for "PCV1 Error (*2) or PCV2 Error" (*3) q
Inspect overflow valve directly. q
Replace,
Replace

Replace
Replace
Replace
Replace

Replace
Correct

Correct

Remedy
Clean

Clean
Clean
Add

*1: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
*2: Troubleshooting by failure code (Display of code), Code [CA271] and Code [CA272]
*3: Troubleshooting by failure code (Display of code), Code [CA273] and Code [CA274]

40-680 D375A-6R
(01)
Troubleshooting of engine (S-mode)
S-2 Engine does not start

c) Exhaust smoke comes out but engine does Cause


not start (Fuel is injected)

Leakage or clogging of fuel piping or air in the fuel system

Defective coolant temperature sensor or wiring harness


General causes that exhaust smoke comes out
but engine does not start
q Starting motor lacks in rotating force due to
defective electrical system.

Worn valve system (valve, rocker lever, etc.)

Clogged injection nozzle, or defective spray


q Supply of fuel is small.

Clogged air breather hole in fuel tank cap


q Small air intake
q Improper selection of fuel

Defective intake air heater system


Clogged breather, breather hose

Defective or deteriorated battery


Clogged feed pump gauze filter
Clogged air cleaner element

Clogged fuel filter, strainer

Clogged, seized injector


Improper fuel
Confirm recent repair history
Degree of use of
Operated for long period E E E E
machine
Engine suddenly failed to start. w w Q
Questions

Non-specified fuel is being used Q Q


Replacement of filters has not been carried out according to Opera-
w w w
tion and Maintenance Manual
Oil must be added more frequently w
When engine is preheated or when temperature is low, preheating
w
monitor does not indicate normally
Dust indicator is red w
Clogged air breather hole in fuel tank cap w
Rust and water are detected when fuel tank is drained w w
When fuel filter is removed, no fuel is inside the fuel filter. w
Leakage from fuel piping w
Starting motor rotates engine slowly. w
When engine is rotated, abnormal sound is generated around cylin-
w
der head.
Check items

and air bleeding plug is removed from fuel filter,


When engine is Q w w
fuel does not flow out.
rotated with start-
and spill hose is separated from injector, spill
ing motor, w
flow is small.
When exhaust manifold is touched immediately after starting engine,
w
temperature of some cylinders is low
Inspect air cleaner directly q
Inspect valve system directly q
When compression pressure is measured, it is found to be low q
Air is discharged when the air is bled from the fuel system q
Troubleshooting

Check fuel filter or strainer. q


Inspect feed pump gauze filter directly q
Carry out troubleshoot by "Rail Press Very Low Error (*1)" q
Testing a single unit injector indicates defective spraying. q
Specific gravity of electrolyte and voltage of battery are low. q
Coolant temperature gauge indication is not normal (if equipped the
q
gauge).
Intake air heater mounting portion does not warm up during preheat-
q
ing.
Replace,
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Correct

Remedy
Clean

Clean

Clean
Clean

*1: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]

D375A-6R 40-681
(01)
Troubleshooting of engine (S-mode)
S-3 Engine does not rev up smoothly (response-up is poor)

S-3 Engine does not rev up smoothly (response-up is poor) 40-682


General causes why engine does not pick up Cause
smoothly

Defective operation of flow damper (excessive injector leakage)


q Insufficient intake of air
q Insufficient supply of fuel
q Defective condition of fuel injection
q Improper selection of fuel
q Controller is controlling in derate mode

Leaking or clogged fuel piping or entry of air

Clogged injection nozzle, or defective spray


(limiting injection rate (output) because of

Clogged air breather hole in fuel tank cap


an error in electrical system)

Seizure or interference at turbocharger


Defective contact of valve, valve seat

Clogged breather, breather hose

Clogged feed pump gauze filter


Clogged air cleaner element

Clogged fuel filter, strainer


Improper valve clearance

Clogged, seized injector


Confirm recent repair history
Degree of use of
machine
Operated for long period EE E E E
Questions

Engine pick-up suddenly became poor w Q Q Q


Non-specified fuel is being used w w w w
Replacement of filters has not been carried out according to Operation & Main-
tenance Manual
w w w
Oil must be added more frequently w
Dust indicator is red w
Clogged air breather hole in fuel tank cap w
Rust and water are observed when fuel tank is drained w w
Leakage from fuel piping w
No response or heavy resistance felt when operating priming pump w Q Q
When exhaust manifold is touched immediately after starting engine, tempera-
ture of some cylinders is low
Q w
Blue under light load w
Color of exhaust gas
Black w Q w w
Check items

When engine is cranked, abnormal sound is generated around cylinder head w


When engine is cranked, abnormal noise is heard from around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is
applied
Q w w
There is hunting from engine (rotation is irregular) Q Q w Q
Blow-by gas is excessive w w
Inspect air cleaner directly q
When compression pressure is measured, it is found to be low q q
Inspect valve clearance directly q
Troubleshooting

When turbocharger is rotated by hand, it is found to be heavy q


Air is discharged when the air is bled from the fuel system q
Check fuel filter or strainer. q
Inspect feed pump gauze filter directly q
Carry out troubleshoot by "Rail Press Very Low Error (*1)" q
Speed of some cylinders does not change when operated in reduced cylinder
mode
q q
Replace,
Replace

Replace
Replace

Replace
Replace
Replace
Correct
Adjust

Remedy
Clean

Clean

Clean
Clean

*1: Troubleshooting for failure codes [CA559] and [CAss49] described in "Troubleshooting by failure code
(Display of code)"

40-682 D375A-6R
(01)
Troubleshooting of engine (S-mode)
S-4 Engine stops during operation

S-4 Engine stops during operation 40-683


General causes why engine stops during opera- Cause
tions

Clogged air breather hole in fuel tank cap

Defective engine controller power supply


Broken auxiliary equipment (pump or air
Broken or seized piston connecting rod
Seized parts inside engine

Damage of valve system (valve, rocker


q
Insufficient supply of fuel

Broken or seized crankshaft bearing


q
q Overheating

Clogged feed pump gauze filter


q Trouble in power train

Broken supply pump shaft key


Clogged or leaking fuel piping

Broken or seized feed pump


Broken or seized gear train

Clogged fuel filter, strainer

Defective starting switch


Clogged, seized injector
Insufficient fuel in tank

Trouble power train


compressor, etc.)
lever, etc.)

wiring
Confirm recent repair history
Degree of use of
Operated for long period E E
machine
Abnormal noise was heard and engine
w www QwQ w w
stopped suddenly
Questions

Condition when
Engine overheated and stopped wQ Q
engine stopped
Engine stopped slowly w Q Q Q Q
There was hunting and engine stopped wQ Q QQ Q Q
Non-specified fuel is being used Q QQ Q
Replacement of filters not carried out according to Opera-
w w
tion & Maintenance Manual
Fuel level monitor indicates low fuel level w
Fuel tank is found to be empty w
Clogged air breather hole in fuel tank cap w
Leakage from fuel piping w
Rust and water are detected when fuel tank is drained w w
Metal particles are found when oid pan is drained www
Check items

Does not turn at all ww


When engine is Turns in opposite direction w
cranked manually Moves by the amount of gear backlash w w
Supply pump shaft does not turn w
Engine rotates, but stops when load is applied to machine w
Inspect valve system directly q
Perform troubleshooting for H-mode
Inspect piston connecting rod. q
Check crankshaft bearing directly q
Inspect gear train directly q
Check fuel filter or strainer. q
Troubleshooting

Inspect feed pump gauze filter directly q


Inspect feed pump directly q
Carry out troubleshoot by "Rail Press Very Low Error (*1)" qq

Engine operates if auxiliary equipment (pump, air compres-


q
sor, etc.) is removed.

Inspect controller power supply wiring q


Check starting switch wiring q
Replace,
Replace
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Correct

Correct
Correct

Remedy
Clean

Clean
Clean

-
Add

*1: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]

D375A-6R 40-683
(01)
Troubleshooting of engine (S-mode)
S-5 Engine does not rotate smoothly (hunting)

S-5 Engine does not rotate smoothly (hunting) 40-684


General causes why engine does not rotate smoothly Cause

Defective operation of flow damper (excessive injector leakage)


q Air in fuel system
q Defective speed sensor (Error at degree that it is not indicat-

Clogged injector nozzle, or defective spray (dirt in injector)


ed)

Defective Bkup speed sensor, or wiring harness


Defective Ne speed sensor, or wiring harness
Leaking or clogged fuel piping or entry of air
Clogged air breather hole in fuel tank cap

Clogged feed pump gauze filter


Low setting of low idle speed

Clogged fuel filter, strainer


Insufficient fuel in tank
Confirm recent repair history
Degree of use of machine Operated for long period EE
Occurs at a certain speed range Q Q Q
Questions

Occurs at low idle w Q Q Q Q Q Q Q


Condition of hunting
Occurs even when speed is raised Q Q Q
Occurs on slopes w Q Q
Replacement of filters has not been carried out according to Operation and
w w
Maintenance Manual
Fuel tank is found to be empty w
Clogged air breather hole in fuel tank cap w
Check items

Rust and water are detected when fuel tank is drained Q Q

Leakage from fuel piping w

Air is discharged when the air is bled from the fuel system q
Inspect feed pump gauze filter directly q
Troubleshooting

Check fuel filter or strainer. q


Speed of some cylinders does not change when operated in reduced cylin-
q q
der mode
Perform troubleshooting according to "Abnormality in engine Ne speed
q
sensor (*1)"
Perform troubleshooting according to "Abnormality in engine Bkup speed
q
sensor (*2)".
Correct or replace
Correct or replace
Replace, Clean
Replace
Replace
Correct

Correct
Clean

Clean
Add

Remedy

*1: "Troubleshooting for failure code [CA689] described in "Troubleshooting by failure code (Display of code)"
*2: Troubleshooting for failure code [CA778] described in "Troubleshooting by failure code (Display of code)"

40-684 D375A-6R
(01)
Troubleshooting of engine (S-mode)
S-6 Engine lacks power (or output shortage)

S-6 Engine lacks power (or output shortage) 40-685


General causes why engine lacks output Cause

Clogged injector nozzle, or defective spray (dirt in injector)


q Insufficient intake of air

Defective boost pressure sensor or defective wiring har-


q Insufficient supply of fuel
Defective condition of fuel injection

Defective fuel temperature sensor, wiring harness


q
q Improper selection of fuel

Defective mounting of boost pressure sensor


q There is overheating

Defective injector drive (signal or solenoid)


Clogged air breather hole of fuel tank cap
o See the troubleshooting for "S-14 Coolant Tempera-

Seizure or interference at turbocharger


Defective contact of valve, valve seat

Stuck or seized supply pump plunger


ture too High (Overheat)"
q Controller is controlling in derate mode

Air leakage from air intake piping

Clogged breather, breather hose

Clogged feed pump gauze filter


(limiting injection rate (output) because of an error in

Clogged or leaking fuel piping


Clogged air cleaner element
electrical system)

Clogged fuel filter, strainer


Improper valve clearance

(air leak)
Confirm recent repair history
Degree of use Operated for long period E E E E E
Suddenly Q Q Q Q
Questions

Power was lost


Gradually Q Q Q Q Q Q Q
Non-specified fuel is being used Q Q
Replacement of filters has not been carried out according to Operation and
Maintenance Manual
w
Oil must be added more frequently QQ Q
Dust indicator is red w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w
Output becomes insufficient after short stop of operation w
Black w w w
Color of exhaust gas
Blue under light load w
When exhaust manifold is touched immediately after starting engine, tempera-
ture of some cylinders is low
w
Check items

When engine is cranked, interference sound is generated around turbocharger w


When engine is cranked, abnormal sound is generated around cylinder head w
High idle speed is too low Q
High idle speed under no load is normal, but speed suddenly drops when load is
applied
w wQ
Engine does not pick up smoothly and combustion is irregular w Q Q w
There is hunting from engine (rotation is irregular) Q Q Q Q
Blow-by gas is excessive w w
Inspect air cleaner directly q
Inspect air intake piping directly q
When charge (boost) pressure is measured, the oil pressure is low q q q
When compression pressure is measured, it is found to be low q q
Inspect valve clearance directly q
Troubleshooting

Check fuel filter or strainer. q


Inspect feed pump gauze filter directly q
Carry out troubleshooting according to No-pressure feed by supply pump (*1) q
When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change
q q
Check the mount of charge (boost) pressure sensor directly q
Carry out troubleshoot by "Chg Air Press Sensor Error (*2)" q
Carry out troubleshooting according to Abnormality in fuel temperature sensor
(*3)
q
Replace,
Replace
Replace

Replace

Replace
Replace
Replace

Replace
Replace
Repair

Repair

Repair
Adjust

Remedy
Clean

Clean

Clean
Clean

*1: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
*2: Troubleshooting by failure code (Display of code), Code [CA122], and Code [CA123]
*3: Troubleshooting by failure code (Display of code), Code [CA263], and Code [CA265]

D375A-6R 40-685
(01)
Troubleshooting of engine (S-mode)
S-7 Exhaust smoke is black (Incomplete combustion)

S-7 Exhaust smoke is black (Incomplete combustion) 40-686


General causes why exhaust smoke is black Cause

Leakage of air between turbocharger and cylinder head

Defective coolant temperature sensor or wiring harness


q Insufficient intake of air
q Excessive injection of fuel

Clogged fuel spill piping (on cylinder head side)


q Defective condition of fuel injection
q Improper selection of fuel

Defective contact of valve with valve seat


q There is overheating

Seizure or interference at turbocharger


o See the troubleshooting for "S-14 Coolant Temperature too High (Over-
heat)"

Clogged breather, breather hose


q Controller is controlling in derate mode

Clogged air cleaner element


(limiting injection rate (output) because of an error in electrical system)

Crushed or clogged muffler


Improper valve clearance

Clogged, seized injector


Dirt caught in injector
Worn fuel injector
Confirm recent repair history
Degree of use of machine Operated for long period E E E E
Suddenly became black w Q Q
w Q Q Q
Questions

Color of exhaust gas Gradually became black


Blue under light load w
Non-specified fuel is being used Q Q
Engien oil must be added more frequently. w
Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Dust indicator is red w
Muffler is crushed w
Air leaks between turbocharger and cylinder head, clamp worked loose w
Operates in low-temperature mode even at normal temperatures Q
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low
w
When engine is cranked, abnormal noise is heard from around turbocharger w
Check items

When engine is rotated, abnormal noise is heard from around cylinder head. w
Torque converter stall speed or pump relief speed is high (Fuel is injected excessively) Q Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly , and combustion is irregular Q Q Q Q Q w
Blow-by gas is excessive w w
When hose from injector to spill collection portion is disconnected, spill flow is found to
be abnormally high
w

Inspect air cleaner directly q


When turbocharger is rotated by hand, it is found to be heavy. q
When compression pressure is measured, it is found to be low q q
Troubleshooting

Inspect valve clearance directly q


When muffler is removed, exhaust color returns to normal q
Carry out troubleshoot by "Rail Press Very Low Error (*1)" q q
Engine speed does not change when operation of certain cylinders is stopped in
reduced cylinder mode
q
Inspect fuel spill piping (on cylinder head side) directly q
Carry out troubleshoot by "Coolant Temp Sensor Error (*2)" q
Replace
Replace

Replace
Replace
Replace
Replace
Replace

Replace
Correct

Correct
Adjust
Clean

Remedy

*1: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
*2: Troubleshooting by failure code (Display of code), Code [CA144], and Code [CA145]

40-686 D375A-6R
(01)
Troubleshooting of engine (S-mode)
S-8 Oil is consumption is excessive(or exhaust smoke is blue)

S-8 Oil is consumption is excessive(or exhaust smoke is blue) 40-687


General causes why oil consumption is excessive Cause

q Abnormal oil combustion


q Extended operation for long hours in low or high idle (continuous
no load operation for 20 minutes and longer inhibited)
q Oil leakage to outside
q Wear of lubricating system

Turbocharger

Leakage from oil pan, cylinder head, etc.


Worn/damaged valve (stem, guide, seal)

Clogged breather or breather hose


Dust sucked in from intake system

Clogged breather, breather hose


Worn or damaged rear oil seal

Leakage from oil drain plug


Worn seal at turbine end
Worn seal at blower end

Leakage from oil cooler

Leakage from oil piping


Leakage from oil filter
Broken piston ring

Broken oil cooler


Confirm recent repair history
Questions

Degree of use of machine Operated for long period E EE E


Oil consumption suddenly increased w Q
Engien oil must be added more frequently. w Q
Oil contaminates quickly Q Q w
Outside of engine is dirty with oil w w w w w
Pipe clamps for intake system are loose w
Inside of turbocharger air intake outlet pipe is contaminated with oil w
Inside of turbocharger exhaust outlet pipe is contaminated with oil Q w
Check items

Oil in coolant. w
Oil level in damper chamber is high w
Color of exhaust gas blue under light load w w
Excessive Q QQ w w
Amount of blow-by gas
None w
When intake manifold is removed, dust is found inside q
When intake manifold is removed, inside is contaminated abnor-
q
Troubleshooting

mally
Excessive play of turbocharger shaft qq
Check breather or breather hose. q
When compression pressure is measured, it is found to be low q q
Inspect rear oil seal directly. q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Correct

Correct
Correct
Correct
Correct
Clean

Remedy

D375A-6R 40-687
(01)
Troubleshooting of engine (S-mode)
S-9 Engine oil becomes contaminated quickly

S-9 Engine oil becomes contaminated quickly 40-68


General causes why oil becomes contaminated quickly Cause
q Entry of exhaust gas into oil due to internal wear

Clogged turbocharger lubrication drain tube


Defective seal at turbocharger turbine end
q Clogging of lubrication passage
q Use of improper fuel
q Use of improper oil

Clogged breather or breather hose


q Operation under excessive load

Clogged breather, breather hose

Defective oil filter safety valve


Worn valve or valve guide

Exhaust smoke is bad


Clogged oil cooler
Clogged oil filter
Confirm recent repair history
Questions

Degree of use of machine Operated for long period EEE


Non-specified fuel is being used Q
Oil must be added more frequently w
Even when engine oil temperature rises, oil filter clogging monitor indicates clogging w Q
Metal particles are found when oil is drained from oil filter. Q Q
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Blue under light load w
Check items

Color of exhaust gas


Black w
Excessive Q Q w
Amount of blow-by gas
None w

Excessive play of turbocharger shaft q


Troubleshooting

When compression pressure is measured, it is found to be low q q

(See S-7)
Check breather or breather hose. q
Inspect oil cooler directly. q
Inspect oil filter directly. q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace

Replace
Replace
Replace
Clean

Clean

Remedy
-

40-688 D375A-6R
(01)
Troubleshooting of engine (S-mode)
S-10 Fuel consumption is excessive

S-10 Fuel consumption is excessive 40-689


General causes why fuel consumption is excessive Cause

Defective coolant temperature sensor or wiring harness


q Leakage of fuel
q Fuel injection condition (fuel pressure and injection timing) not normal
q Excessive fuel injection

Fuel leakage from fuel filter, piping, etc.

Defective common rail fuel pressure


Leakage of fuel inside head cover

Defective supply pump plunger


Defective feed pump oil seal

Defective injector operation


Defective injector spray
Confirm recent repair history
Questions

Degree of use of machine Operated for long period E E E


More than for other machines of same model Q Q Q
Condition of fuel consumption Gradually increased Q Q
Suddenly increased Q Q
Fuel leakage to outside w
There is irregular combustion w
Oil increasing, smelling of diesel oil w w
When exhaust manifold is touched immediately after starting engine, temperature of
w w
Check items

some cylinders is low


Low idle speed is high Q
Torque converter stall or hydraulic pump relief speed is high Q
Black Q Q Q
Color of exhaust gas
White Q
Remove head cover and inspect directly q
Troubleshooting

Inspect feed pump oil seal directly q


Carry out troubleshoot by "Rail Press Very Low Error (*1)" q
Speed of some cylinders does not change when operated in reduced cylinder mode q q
Spill flow is excessive when spill hose is separated from injector q
Carry out troubleshoot by "Coolant Temp Sensor Error (*2)" q
Replace
Replace
Replace
Replace
Replace
Correct
Correct

Correct

Remedy

*1: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
*2: Troubleshooting by failure code (Display of code), Code [CA144], and Code [CA145]

D375A-6R 40-689
(01)
Troubleshooting of engine (S-mode)
S-11 Oil mixes into coolant(coolant blows back or is reduced)

S-11 Oil mixes into coolant(coolant blows back or is reduced) 40-690


General causes why oil is in coolant Cause
q Internal leakage in lubrication system
q Internal leakage in cooling system
q Internal leakage in hydraulic oil cooler or power train oil cooler

Broken hydraulic oil cooler, power train oil cooler


Broken cylinder head or cylinder head gasket

Insufficient protrusion of cylinder liner


Broken oil cooler core/O-ring
Cracks inside cylinder block
Clogged, broken oil cooler
Confirm recent repair history
Questions

Degree of use Operated for long period E E


Sudden overheated Q Q Q
Oil level
Gradually occurred Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
There are excessive air bubbles in radiator, coolant spurts back w w
Check items

Power train oil is milky w

When power train oil is drained, water is found w

Perform troubleshoot-
Pressure-tightness test of cylinder head shows there is leakage q
Troubleshooting

Inspect cylinder block directly q q ing for H-mode

Check cylinder liner directly q q

Pressure-tightness test of oil cooler shows there is leakage q


Replace
Replace
Replace
Replace
Replace

Remedy
-

40-690 D375A-6R
(01)
Troubleshooting of engine (S-mode)
S-12 Engine pressure monitor lights up (drop in engine oil pressure)

S-12 Engine pressure monitor lights up (drop in engine oil pressure) 40-691
General causes that oil pressure drops Cause

Defective oil pressure sensor and/or defective wiring harness


q Leakage, clogging or wear of lubricating system
q Defective hydralic control
q Wrong oil selection (viscosity not appropriate)
q Oil deteriorated byoverheating

Leaking, crushed, clogged oil piping


Clogged, broken pipe in oil pan
Clogged strainer inside oil pan

Defective oil pump relief valve


Wear of metal journal

Coolant or fuel in oil


Lack of oil in oil pan

Defective oil pump

Clogged oil filter


Confirm recent repair history
Degree of use of machine Operated for long period E E E
Questions

Engine oil pressure monitor lights up. Q w


Non-specified oil is used. Q Q
Replacement of filters has not been carried out according to Operation and
w
Maintenance Manual
Lights up with engine at low dile. w Q
Lights up with engine at low and idle. Q w w w Q
Engine oil pressure monitor
Lights up with machine on a slope. w
Lights up occasionally. w Q
Oil level monitor indicates low amount of oil (when monitor is installed) w
Oil level in oil pan is low w
External lubrication piping is leaking or crushed. w
Check items

Oil is cloudy white or smells of diesel oil. w


Metal particles are found when oil is drained from oil pan. w
Metal particles are found when oil is drained from oil filter. w Q

Metal particles are found in oil filter. q


Troubleshooting

Inspect oil pan strainer and pipe. q q


See S - 13

Oil pump rotation is heavy or it has play. q


Valve spring of oil pump relief valve is fatigued, damaged q
Inspect oil filter directly. q
Perform troubleshooting for "Eng Oil Press. Sensor Error"(*1) q
Replace

Replace
Replace
Replace
Replace
Replace
Clean
Clean
Add

Remedy
-

*1: Troubleshooting by failure code, Codes [CA135] and [CA141]

D375A-6R 40-691
(01)
Troubleshooting of engine (S-mode)
S-13 Oil level rises (Coolant or fuel mixes into oil)

S-13 Oil level rises (Coolant or fuel mixes into oil) 40-692
General causes that oil level rises Cause

q Coolant mixing into oil (oil becomes clouded)


q Fuel mixing into oil (smells diluted diesel fuel)

Defective seal of auxiliary equipment (pump, compressor)


a If oil is in coolant, perform troubleshooting for "S-11 Oil mixes into coolant"(or
coolant spurts back or coolant level goes down)

Broken cylinder head or cylinder head gasket

Defects in thermostat seat section


Leakage of fuel inside head cover

Worn or damaged rear oil seal


Broken oil cooler core/O-ring
Cracks inside cylinder block

Defect inside supply pump


Clogged, broken oil cooler
Confirm recent repair history
Questions

Degree of use of machine Operated for long period E E E E


Fuel consumption is increased. w w
Coolant must be added more frequently. Q
Oil in coolant. Q Q Q w
Engine oil smells of diesel fuel. w w
Oil become clouded. Q Q
After starting engine, drops of water come out of muffler. Q
When radiator cap is removed and engine is run at low idle, an abnormal number
w Q
of bubbles appears, or coolant spurts back
Check items

Exhaust smoke is white. Q


Clogged water pump drain hole (weep hole). w
Coolant comes out when water pump drain hole (weep hole) is cleaned. w
Oil level in clutch or damper chambers of machine lower w
Oil level in hydraulic tank of machine decreases. w
When compression pressure is measured, it is found to be low q
Remove head cover and inspect directly q
Troubleshooting

Inspect cylinder block and liner directly q q


Inspect rear oil seal directly. q
Pressure-tightness test of oil cooler shows there is leakage q
Remove water pump and inspect directly. q
Remove supply pump and inspect directly. q
Inspect seals for auxiliaries directly. q
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct

Remedy

40-692 D375A-6R
(01)
Troubleshooting of engine (S-mode)
S-14 Coolant temperature rises too high (overheating)

S-14 Coolant temperature rises too high (overheating) 40-693


General causes that coolant temperature becomes too high Cause

q Lack of cooling air (deformation or damage of fan)


q Drop in heat dissipation efficiency
q Defective coolant circulation system
q Rise of power train oil temperature
q Defective fan drive pump or fan motor

Broken cylinder head or cylinder head gasket

Defective radiator cap (pressure valve)

Defective fan drive pump or fan motor


Defective coolant temperature gauge
Rise of power train oil temperature
Defective operation of thermostat
Clogged, broken oil cooler

Clogged radiator core


Clogged radiator core
Broken water pump

Wear of fan pulley


Lack of coolant
Lack of coolant
Confirm recent repair history
Degree of use of machine Operated for long period EE EE
Questions

Sudden overheated Q w Q Q
Condition of overheating
Engine tends to overheat. Q w w Q Q
Coolant temperature rises quickly. Q w
Coolant temperature gauge Coolant temperature does not go down
w
below red range
Radiator coolant level monitor indicates low level w
Engine oil level has risen, oil is cloudy white w Q
Cloudy white oil is floating on coolant w
There are excessive air bubbles in radiator, coolant spurts back w
Check items

When light bulb is held behind radiator, no light passes. w


Radiator shroud and inside of under cover are clogged with dirt or mud. w w
Coolant leaks from cracks in the radiator hose or clamps are loosened. w
Coolant flows out from radiator overflow hose. w
The power train oil temperature gauge reaches the red range faster
w
than the engine coolant temperature gauge.
When compression pressure is measured, it is found to be low q
Perform troubleshooting for H-mode
Perform troubleshooting for H-mode

Inspect cylinder block and liner directly q


Inspect oil cooler directly. q
Temperature difference between upper and lower tanks of radiator is
q
large.
Troubleshooting

When function test is preformed on thermostat, it does not open even at


q
cracking temperature.
Temperature difference between upper and lower tanks of radiator is
q
slight.
Inspect radiator core directly. q
When function test is preformed on the radiator cap, cracking pressure
q
is low.
When coolant temperature is measured, it is found to be normal. q
Measured fan speed is low. q
Replace
Replace
Replace

Replace
Replace

Replace

Replace
Correct
Correct

Correct
Add

Remedy
-
-

D375A-6R 40-693
(01)
Troubleshooting of engine (S-mode)
S-15 Abnormal noise is heard

S-15 Abnormal noise is heard 40-694


General causes that abnormal noise is heard Cause

Deformed cooling fan, loose fan belt, interference of fan belt


q Noise from defective parts

Air leakage from piping between turbocharger and cylinder


q Abnormal combustion

Defective coolant sensor (improper fuel injection timing)


q Air sucked in from intake system
a Detemine whether the noise from inside or outside before proceed-

Defec inside muffler (dividing board out of position)


ing with troubleshooting.

Damage of valve system (valve or rocker lever)


a When engine is not fully warmed up, engine noise rises slightly be-
cause it runs in the low temperature mode. This is not abnormal,
however.

Seizure or interference at turbocharger


a When the engine is accelerated, it runs in the acceleration mode,
where engine noise remains slightly higher for about 5 seconds max-
imum, This is not abnormal, however.

Improper gear train backlash


Improper gear train backlash
Improper valve clearance

Dirt caught in injector


Dirt caught in injector
Deformed fan
head
Confirm recent repair history
Degree of use of machine Operated for long period E
Questions

Gradually occurred Q Q Q
Abnormal noise
Sudden overheated Q Q Q
Non-specified fuel is being used Q
Engien oil must be added more frequently. w
Metal particles are found when oil is drained from oil filter. Q w w
Leakage of air between turbocharger and cylinder head w
When engine is cranked, abnormal noise is heard from around turbo-
w
charger
When engine is rotated, abnormal noise is heard from around cylinder
w w
head.
When engine is rotated, abnormal noise is heard from around muffler. w
Check items

When exhaust manifold is touched immediately after starting engine,


w Q
temperature of some cylinders is low
Blue under light load w
Color of exhaust gas
Black Q w Q
Engine rev-up is poor and combustion is abnormal. w
Abnormal noise is loud when engine is accelerated. Q Q Q Q
Blow-by gas is excessive w w
When turbocharger is rotated by hand, it is found to be heavy. q
Inspect valve system directly q
When muffler is removed, abnormal noise disappears. q
Troubleshooting

Inspect valve clearance directly q


When compression pressure is measured, it is found to be low q
Inspect gear train directly q q
Inspect fan directly. q
Speed of some cylinders does not change when operated in reduced
q q
cylinder mode
Abnormal noise is heard only when engine is started. q
Perform troubleshoot for "Coolant Temp Sensor Error (*1)". q
Replace

Replace
Replace
Replace

Replace
Replace
Replace

Replace
Replace
Replace
Correct
Adjust

Remedy

*1: Troubleshooting for failure codes [CA144] and [CA145] described in "Troubleshooting by failure code (Dis-
play of code)"

40-694 D375A-6R
(01)
Troubleshooting of engine (S-mode)
S-16 Vibration is excessive

S-16 Vibration is excessive 40-695


General causes that vibration is excessive Cause

q Defective parts (abnormal wear, breakage,etc)

Misalignment between engine and torque converter


q Misalignment of engine and chassis

Wear of main bearing and connecting rod bearing


q Abnormal combustion
a If there is abnormal noise together with the vibration, perform troubleshooting also for

Loose engine mount bolts or broken cushions


S-15 Abnormal noise is heard.

Stuck valve system (valve, rocker arm)

Wear of front support spigot joint


Improper gear train backlash
Worn camshaft bushing

Broken parts in damper


Confirm recent repair history
Questions

Degree of use of machine Operated for long period E EE E


Suddenly increased. Q Q
Vibration
Gradually increased. Q Q Q Q
Non-specified fuel is being used Q Q
Metal particles are found when oil is drained from oil filter. w w
Metal particles are found when oil is drained from oil pan. w w
Oil pressure is when running engine low at low idle. Q Q
Check items

Vibration occurs when running engine at mid-range speed. Q Q


Vibration follows engine speed. Q Q Q Q Q
Exhaust smoke is black. w

Inspect valve system directly q


Check main bearing and connecting rod bearing. q
Troubleshooting

Inspect gear train directly q


Inspect camshaft bushing directly. q
Check engine mounting bolts and cushions. q
When face runout and radial runout are inspected, they are found to be incorrect. q
Inspect front support portion directly. q
Inspect inside of damper directly. q
Replace
Replace
Replace
Replace
Replace

Replace
Replace
Adjust

Remedy

D375A-6R 40-695
(01)
Troubleshooting of engine (S-mode)
S-17 Air cannot be bled from fuel circuit (when air bleeding is performed after filter is replaced or fuel is used up and then

S-17 Air cannot be bled from fuel circuit (when air bleeding is performed
after filter is replaced or fuel is used up and then air is bled, engine does
not start or it starts but stalls) 40-696
General causes why that cannot be bled Cause

Defective wiring harness of electric priming pump


q Electric priming pump does not operate.

Improper setting of air bleeding valve (closed)


Fuel is not supplied or is supplied very little.

Leaking or clogged fuel piping or entry of air


q

Malfunction of electric priming pump switch


q Fuel valve or air bleeding valve is not set properly.
q Air bleeding piping is clogged.

Improper setting of fuel valve (closed)

Malfunction of electric priming pump


q Fuel return piping is clogged.

Clogged water separator screen


Clogged fuel tank breather hole

Clogged air bleeding pipe

Low battery charge level


Clogged fuel filter
Lack of fuel
Check recent repair history
Questions

Degree of use of macine Operated for long period EE


Non-specified fuel is being used Q Q
Fuel tank is empty w
Fuel tank breather cap is clogged w
Fuel leaks from fuel piping w
Check items

Switch lamp does not blink w w Q


Lamp blinks but pump operation sound is not
When electric priming w w
heard.
pump switch is operated
Pump operation sound is heard but fuel does
Q Q Q Q w w w Q Q
not flow out of hose return soon.
Air bleeding valve is closed q
Fuel valve (supply side) is closed q
Fuel valve (return side) is closed q
Water drain valve and air intake plug of water separator are loosened q
Troubleshooting

Water drain valve of fuel pre-filter is loosened q


There is flaw or dirt on sealing face of fuel pre-filter or main filter q
Check air bleeding piping and orifice directly (see Note 1) q
Check fuel piping (supply side and return side) directly (for clogging and
q
breakage)
Check electric priming pump directly q
Check electric priming system directly (see E-28 in E-mode) q q
Check water separator screen directly q
Check fuel filter for clogging (see failure code CA559, Note 2) q
Replace
Replace
Replace

Replace
Charge
Correct
Correct
Correct
Correct
Correct

Clean
Add

Remedy

40-696 D375A-6R
(01)
Troubleshooting of engine (S-mode)
S-17 Air cannot be bled from fuel circuit (when air bleeding is performed after filter is replaced or fuel is used up and then

Note 1: Check of air bleeding piping for clogging


q Remove joint bolt (1) and blow clean compressed air into hole (a) of the orifice to check for clogging.
q Remove both ends of air bleeding pipes (2) and (3), and blow compressed air to check for clogging.

D375A-6R 40-697
(01)
Troubleshooting of engine (S-mode)
S-17 Air cannot be bled from fuel circuit (when air bleeding is performed after filter is replaced or fuel is used up and then

40-698 D375A-6R
(01)
0 50-1

BULLDOZER
Shop Manual 50-1

D375A-6R

Machine model Serial number


D375A-6R 65001 and up

50 Disassembly and assembly 50-1

D375A-6R 50-1
(01)
Contents

Contents 50-2
50 Disassembly and assembly
General information on disassembly and assembly ............................................................... 50- 4
How to read this manual ...................................................................................................... 50- 4
Coating materials list............................................................................................................ 50- 6
Special tool list ..................................................................................................................... 50- 9
Sketches of special tools ..................................................................................................... 50- 17
Engine and cooling system ..................................................................................................... 50- 25
Removal and installation of fuel supply pump assembly ..................................................... 50- 25
Removal and installation of fuel injector assembly .............................................................. 50- 30
Removal and installation of cylinder head assembly ........................................................... 50- 35
Removal and installation of radiator guard assembly .......................................................... 50- 50
Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler)50- 55
Removal and installation of radiator..................................................................................... 50- 60
Removal and installation of hydraulic oil cooler ................................................................... 50- 62
Removal and installation of aftercooler................................................................................ 50- 63
Removal and installation of engine assembly...................................................................... 50- 64
Removal and installation of engine hood assembly............................................................. 50- 71
Removal and installation of engine front seal ...................................................................... 50- 74
Removal and installation of engine rear seal ....................................................................... 50- 76
Removal and installation of fan drive assembly................................................................... 50- 80
Removal and installation of fan motor assembly ................................................................. 50- 82
Removal and installation of fuel tank assembly ................................................................... 50- 84
Power train.............................................................................................................................. 50- 86
Removal and installation of damper assembly .................................................................... 50- 86
Disassembly and assembly of damper assembly ................................................................ 50- 90
Removal and installation of power train unit assembly ........................................................ 50- 93
Disconnection and connection of power train unit assembly ............................................... 50- 99
Disassembly and assembly of PTO assembly..................................................................... 50- 108
Disassembly and assembly of torque converter assembly .................................................. 50- 114
Disassembly and assembly of TORQFLOW transmission assembly .................................. 50- 123
Disassembly and assembly of steering case assembly....................................................... 50- 150
Removal and installation of power train pump and lubrication pump assembly .................. 50- 166
Removal and installation of scavenging pump assembly .................................................... 50- 167
Removal and installation of final drive assembly ................................................................. 50- 168
Disassembly and assembly of final drive assembly............................................................. 50- 170
Undercarriage and frame ........................................................................................................ 50- 183
Removal and installation of track frame assembly............................................................... 50- 183
Removal and installation of idler assembly.......................................................................... 50- 188
Disassembly and assembly of idler assembly ..................................................................... 50- 189
Removal and installation of recoil spring assembly ............................................................. 50- 193
Disassembly and assembly of recoil spring assembly......................................................... 50- 198
Removal and installation of track roller assembly................................................................ 50- 200
Disassembly and assembly of track roller assembly ........................................................... 50- 203
Removal and installation of carrier roller assembly ............................................................. 50- 206
Disassembly and assembly of carrier roller assembly ......................................................... 50- 207
Removal and installation of bogie assembly........................................................................ 50- 211
Disassembly and assembly of bogie assembly ................................................................... 50- 216
Removal and installation of first bogie assembly ................................................................. 50- 218
Separation and connection of track shoe assembly ............................................................ 50- 223
Overall disassembly and assembly of track shoe ................................................................ 50- 227
Link press press-fitting jig dimensions ................................................................................. 50- 244

50-2 D375A-6R
(01)
Contents

Disassembly and assembly of one link assembly in the field .............................................. 50- 245
Disassembly and assembly of master link........................................................................... 50- 250
Removal and installation of pivot shaft assembly ................................................................ 50- 254
Removal and installation of equalizer bar............................................................................ 50- 255
Disassembly and assembly of equalizer bar bushing.......................................................... 50- 259
Removal and installation of segment tooth.......................................................................... 50- 261
Hydraulic system .................................................................................................................... 50- 262
Removal and installation of hydraulic tank assembly .......................................................... 50- 262
Removal and installation of work equipment pump assembly ............................................. 50- 265
Removal and installation of fan pump assembly ................................................................. 50- 269
Removal and installation of control valve assembly ............................................................ 50- 271
Disassembly and assembly of control valve assembly........................................................ 50- 273
Disassembly and assembly of blade PPC valve assembly ................................................. 50- 278
Disassembly and assembly of ripper PPC valve assembly ................................................. 50- 281
Disassembly and assembly of hydraulic cylinder assembly ................................................ 50- 283
Disassembly and assembly of ripper pin puller cylinder assembly ...................................... 50- 291
Work equipment...................................................................................................................... 50- 294
Removal and installation of blade assembly........................................................................ 50- 294
Disassembly and assembly of blade assembly ................................................................... 50- 296
Disassembly and assembly of giant ripper assembly .......................................................... 50- 300
Cab and its attachments ......................................................................................................... 50- 303
Removal and installation of ROPS guard ............................................................................ 50- 303
Removal and installation of operator's cab assembly.......................................................... 50- 304
Removal and installation of floor frame assembly ............................................................... 50- 308
Removal and installation of air conditioner unit assembly ................................................... 50- 313
Electrical system ..................................................................................................................... 50- 319
Removal and installation of transmission controller assembly and steering controller assembly50-319
Removal and installation of engine controller assembly...................................................... 50- 320
Removal and installation of VHMS controller assembly ...................................................... 50- 322
Removal and installation of machine monitor assembly...................................................... 50- 323

D375A-6R 50-3
(01)
General information on disassembly and assembly
How to read this manual

General information on disassembly and assembly 50-4


How to read this manual 50-4

1. Removal and installation of assemblies 50-4


Special tools 50-4 Connection 50-4
q Special tools which are necessary for removal or q Unless otherwise instructed, installation of parts
installation of parts are described as A1, ... X1 is to be done in the reverse order to removal.
etc. and their part numbers, part names and q Instructions and precautions for parts installion
quantities are described in the special tool list. is shown with the mark ([*1] which corresponds
q In the special tools table, the follwing information to the mark in "Removal" section).
is described, as well as the above items. q General purpose tools that are necessary for re-
1) Necessity moval are described as [1], [2] etc. and their
t: Special tools that cannot be substituted part numbers, part names, and quantities are not
and should always be used. described.
q: Special tools that will be useful if available q Marks shown in the "Installation" section stand
and are substitutable with tools available for the following.
on the market. k : Precautions related to work safety.
2) New/redesign a : Know-how or precautions for work
N : Tools newly developed for this model. 2 : Type of coating material
They have a new part number respec- 3 : Tightening torque
tively. 5 : Amount of oil or coolant to be replen-
R : Tools made available by redesigning ished
the existing tools which were devel-
oped for other models. Each of them Sketches of special tools 50-4
has a new part number assigned by q Various special tools are illustrated for the local
setting forward the part number of the manufacture.
existing tool.
Blank :Tools already available for other
models. They can be used without any
modification.
3) Circle mark Q in sketch column:
q The sketch of the special tool is present-
ed in the section of "Sketches of special
tools".
q Tools with part number 79*T-***-****
means that they are not available from
Komatsu Ltd. (i.e. tools to be made local-
ly).

50-4 D375A-6R
(01)
General information on disassembly and assembly
How to read this manual

2. Disassembly and assembly of assemblies 50-5


Special tools 50-5 Assembly 50-5
q Special tools which are necessary for disassem- q In "Assembly" section, the work procedures, pre-
bly and assembly of parts are described as A1, cautions and know-how to do the work, and the
... X1 etc. and their part numbers, part names amount of oil and coolant to be replenished are
and quantities are described in the special tool described.
list. q Common tools that are necessary for the disas-
q In the special tools table, the follwing information sembly work are indicated as [1],[2]etc. and
is described, as well as the above items. their part numbers, part names, and quantities
1) Necessity are not described.
t: Special tools that cannot be substituted q The meanings of the symbols used in "Assem-
and should always be used. bly" section are as follows.
q: Special tools that will be useful if available k : Precautions related to work safety
and are substitutable with tools available a : Know-how or precautions for work
on the market. 2 : Type of coating material
2) New/redesign 3 : Tightening torque
N : Tools newly developed for this model. 5 : Amount of oil or coolant to be replen-
They have a new part number respec- ished
tively.
R : Tools made available by redesigning Sketches of special tools 50-5
the existing tools which were devel- q Various special tools are illustrated for the local
oped for other models. Each of them manufacture.
has a new part number assigned by
setting forward the part number of the
existing tool.
Blank :Tools already available for other
models. They can be used without any
modification.
3) Circle mark Q in sketch column:
q The sketch of the special tool is present-
ed in the section of "Sketches of special
tools".
q Part No. of special tools starting with
79*T-***-****:
means that they are not available from
Komatsu Ltd. (i.e. tools to be made
locally).

D375A-6R 50-5
(01)
General information on disassembly and assembly
Coating materials list

Coating materials list 50-6


(Rev. 2009. 02)
a The recommended coating materials such as adhesives, liquid gaskets, and greases used for disassem-
bly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate
Komatsu code Part No. Capacity Container Main features and applications
gory
q Use to prevent rubber gaskets, rubber cushions,
LT-1A 790-129-9030 150 g Tube
and cork plugs from coming out.
q Use for plastic (except polyethylene, polypropyl-
20 g Polyethyl-
ene, tetrafluoroethylene and vinyl chloride), rub-
LT-1B 790-129-9050 (2 pcs. ene con-
ber, metal, and non-metal parts which require
contained ) tainer
immediate and strong adhesion.
Polyethyl-
q Features: Resistance to heat and chemicals.
LT-2 790-129-9040 50 g ene con-
q Use to fix and seal bolts and plugs.
tainer
Adhesive:
790-129-9060
1 kg
LT-3 (Set of adhesive Can q Use to bond and seal metal, glass and plastics.
Hardener:
and hardener)
500 g
Adhesive

Polyethyl-
LT-4 790-129-9040 250 g ene con- q Use to seal plugs for blank holes
tainer
Holtz
790-129-9120 75 g Tube q Heat-resistant seal used to repair engines.
MH 705
q Instanetaneous adhesive.
Polyethyl-
ThreeBond q Curing time: From 5 sec. to 3 min.
790-129-9140 50 g ene con-
1735 q Use mainly to bond metals, rubbers, plastics, and
tainer
woods.
q Instanetaneous adhesive.
Polyethyl-
q Quick-curing type (max. strength is obtained after
Aron-alpha 201 790-129-9130 2g ene con-
30 minutes)
tainer
q Use mainly to bond rubbers, plastics, and metals.
Polyethyl-
q Features: Resistance to heat and chemicals.
Loctite 648-50 79A-129-9110 50 cc ene con-
q Used for fitted portions used at high temperatures.
tainer
q Use to seal various threaded portions, pipejoints,
Polyethyl-
and flanges.
LG-5 790-129-9080 1 kg ene con-
q Use to seal taper plugs, elbows, and nipples for
tainer
hydraulic piping.
q Features: Silicon-based heat and cold-resistant
sealant.
LG-6 790-129-9160 200 g Tube q To be used to seal threaded portions on flange
surface
Liquid gasket

q Use to seal oil pan, final drive case, etc.


q Features: Silicon-based quick-curing sealant.
LG-7 790-129-9170 1 kg Tube q Use to seal flywheel housing, intake manifold,
thermostat old, oil pan, thermostat housing, etc.
LG-8 q Features: Silicon-based, heat and cold-resistant,
ThreeBond 419-15-18131 100 g Tube vibration-resistant, impact-resistant sealant.
1207B q Use to seal transfer case, etc.
q Use for rough surfaces such as the circle gear top
LG-9
seal which is not clamped by bolts, gaps in the
ThreeBond 790-129-9310 200 g Tube
weld which must be caulked, etc.
1206D
q Can be coated with paint.
LG-10 q Use as lubricant/sealant when installing the radia-
ThreeBond 790-129-9320 200 g Tube tor hoses to the water tubes.
Liquid gasket

1206E q Can be coated with paint.


q Feature: Can be used together with solid gaskets.
LG-11
790-129-9330 200 g Tube q Use for covers of the transmission case and steer-
ThreeBond 1121
ing case etc.
ThreeBond 1211 790-129-9090 100 g Tube q Liquid gasket used to repair engine.

50-6 D375A-6R
(01)
General information on disassembly and assembly
Coating materials list

Cate
Komatsu code Part No. Capacity Container Main features and applications
gory
q Use to prevent galling and seizure of press-fitted
Molybdenum disulphide

portions, shrinkage-fitted portions, and threaded


LM-P 09940-00040 200 g Tube
portions.
lubricant

q Use to lubricate linkages, bearings, etc.


q Spray type
q Thin molybdenum disulphide films are made on
09995-00250 190 g Can metal surfaces to prevent the metals from galling.
q Use for the drive shaft splines, needle bearings,
various link pins, bolts, etc.
prevention compound

q Feature: Seizure and galling prevention com-


pound with metallic super-fine-grain, etc.
Seizure

LC-G
Can q Use for the mounting bolt in the high temperature
NEVER-SEEZ
area of the exhaust manifold and the turbocharg-
er, etc.

SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI (*) q Feature: Lithium grease with extreme pressure lu-
SYGA-160CNLI Various Various
*: For cold dis- brication performance, general purpose type.
SYG0-400LI-A
trict
(*)
SYG0-160CNLI
(*)
q Used for parts under heavy load.
Bel- Caution:
Molybdenum
SYG2-400M 400 g x 10 lows-type q Do not use this grease for rolling bearings like
disulphide
SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
grease
SYGA-16CNM 16 kg q Use this grease for work equipment pins only
LM-G (G2-M)
Can when installing them, but do not use it after-
ward.
Grease

SYG2-400T-A
Hyper White
SYG0-400T-A Bel- q Seizure resistance, heat resistance and water re-
G2-T,
(*) 400 g lows-type sistance higher than molybdenum disulphide
G0-T (*)
(*) 16 kg container grease.
*: For cold dis-
SYG0-16CNT Can q Not conspicuous on machine since color is white.
trict
(*)
Biogrease
SYG2-400B
G2-B
SYG2-400BT Bel-
G2-BT (*) q Since this grease is biodegradable in short period,
(*) 400 g lows-type
*: For use at it has less impact on microorganisms, animals,
(*) 16 kg container
high tempera- and plants.
SYGA-16CNBT Can
ture and under
(*)
high load
q Feature: Silicone grease with wide usable temper-
G2-S ature range, high resistance to thermal-oxidative
ThreeBond 200 g Tube degradation and performance to prevent deterio-
1855 ration of rubber and plastic parts.
q Use for oil seals of the transmission, etc.
q Feature: Urea (organic system) grease with heat
resistance and long life, can be packed into the
Grease

G2-U-S
427-12-11871 2 kg Can confined space and left intact until next overhaul.
ENS grease
q Use for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.

D375A-6R 50-7
(01)
General information on disassembly and assembly
Coating materials list

Cate
Komatsu code Part No. Capacity Container Main features and applications
gory

q Use as primer for painted cab sheet metal


SUNSTAR
Glass con- surface.
PAINT 20 ml
tainer (Effective period: four months after date of
PRIMER580
manufacture)
SUPER 417-926-3910
SUNSTAR
q Use as primer for glass.
GLASS Glass con-

For adhered window glass


20 ml (Effective period: four months after date of
PRIMER 580 tainer
manufacture)
SUPER
q Use as primer for painted cab sheet metal
SUNSTAR
Primer

Glass con- surface.


PAINT PRIMER 22M-54-27230 20 ml
tainer (Effective period: four months after date of
435-95
manufacture)
q Use as primer for black ceramic-coated
SUNSTAR glass surface and for hard polycarbon-
GLASS 22M-54-27240 150 ml Can ate-coated surface.
PRIMER 435-41 (Effective period: four months after date of
manufacture)
q Use as primer for sash (anodized aluminum
SUNSTAR
Glass con- surface).
SASH PRIMER 22M-54-27250 20 ml
tainer (Effective period: four months after date of
GP-402
manufacture)
SUNSTAR PEN- q Use S" in high-temperature season and W"
GUINE Polyethyl- in low-temperature season as adhesive for
SEAL580 417-926-3910 320 ml ene con- glass.
SUPER S" or tainer (Effective period: four months after date of
Adhesive

W" manufacture)
Polyethyl- q Use as adhesive for glass.
Sika Japan,
For adhered window glass

20Y-54-39850 310 ml ene con- (Effective period: six months after date of
Sikaflex 256HV
tainer manufacture)
SUNSTAR PEN- Ecocart q Use as adhesive for glass.
GUINE SUPER 22M-54-27210 320 ml (Special (Effective period: six months after date of
560 container) manufacture)
SUNSTAR PEN- Polyethyl- q Use to seal glass-to-glass joints.
GUINE SEAL 417-926-3920 320 ml ene con- (Effective period: four months after date of
Caulking material

No. 2505 tainer manufacture)


SEKISUI SILI- Polyethyl- q Use to seal front window.
CONE SEAL- 20Y-54-55130 333 ml ene con- (Effective period: six months after date of
ANT tainer manufacture)
q Use to seal glass-to-glass joint. Translucent
GE TOSHIBA
white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Effective period: 12 months after date of
TOSSEAL381
manufacture)

50-8 D375A-6R
(01)
General information on disassembly and assembly
Special tool list

Special tool list 50-9


a Tools with part number 79*T-***-**** means that they are not available from Komatsu Ltd. (i.e. tools to be
made locally).
a Necessity:
t. . . . . . Cannot be substituted, must always be installed (used).
q. . . . . . Extremely useful if available or, can be substitutable with commercially available part.
a New/redesign:
N: . . . . . . Tools with new part numbers, newly developed for this model.
R: . . . . . . Tools with upgraded part numbers, remodeled from items already available for other models.
Blank .............Tools already available for other models. They can be used without any modification.
a Tools marked with Q in the sketch column are presented in the sketches of the special tools. (See "Sketch-
es of special tools")

New/redesign
Necessity
Quantity

Sketch
Device Symbol Part No. Part name Nature of work, remarks

795-799-5410 Adapter t 1
1 Removal and installation of
795-799-5420 Remover t 1
fuel injector assembly
2 795T-675-1110 Socket q 1 N Q
Removal and installation of
3 795-931-1100 Seal puller assembly t 1 engine front seal and rear
seal
Push tool
795T-621-1180 t 1 Q
(For oil seal)
Push tool Removal and installation of
4 795T-621-1171 t 1 Q
(For dust seal) engine front seal
795-902-1460 Bolt t 3
Engine assem- 01582-02218 Nut t 3
A
bly Push tool
795T-621-1161 (for standard seal and t 1 Q
sleeved seal)
Removal and installation of
5 Push tool
795T-621-1190 t 1 Q engine rear seal
(for sleeved seal)
01050-32235 Bolt t 6
01050-32245 Bolt t 6
Tightening of cylinder head
6 790-331-1120 Wrench (angle) q 1
bolt
791-451-1000 Remover t 1
Removal and installation of
7 790 - 101 - 2102 Puller (294 kN {30 ton}) t 1
radiator guard assembly
790 - 101 - 1102 Pump t 1
Torque con- 790-413-1010 Bracket t 1 Disassembly and assembly
verter valve C of torque converter assem-
790-501-5000 Repair stand (100 V) t 1
assembly bly
790-415-1011 Bracket t 1 Disassembly and assembly
1 of TORQFLOW transmis-
750-501-5000 Repair stand (100 V) t 1
sion assembly
Removal and installation of
2 791-615-1130 Push tool t 1
snap ring
791-615-1200 Ring assembly t 1
791-615-1210 q Ring 1
TORQFLOW 3 135-A90-1150 q Bolt 1 Installation of No.3 ring gear
transmission D 01580-01008 q Nut 1
assembly 01641-51032 q Washer 2
791-615-1101 Ring assembly t 1
791-615-1111 q Ring 1
4 135-A90-1150 q Bolt 1 Installation of No.1 ring gear
01580-01008 q Nut 1
01641-51032 q Washer 2
Checking actuation of pis-
5 799-301-1600 Oil leak checker t 1
ton

D375A-6R 50-9
(01)
General information on disassembly and assembly
Special tool list

New/redesign
Necessity
Quantity

Sketch
Device Symbol Part No. Part name Nature of work, remarks

Removal and installation of


1 790-337-1001 Lifting tool t 1
final drive assembly
791-580-3200 Remover t 1
Separation of sprocket hub
2 790 - 101 - 2102 Puller (294 kN {30 ton}) t 1
assembly and bearing
790 - 101 - 1102 Pump t 1
791-580-3300 Installer t 1
Press-fitting of bearing
3 790 - 101 - 2102 Puller (294 kN {30 ton}) t 1
(sprocket hub assembly)
790 - 101 - 1102 Pump t 1
4 790-431-1071 Installer t 1 N Installation of floating seal
Final drive
J 791-580-3400 Remover t 1
assembly Disassembly of hub shaft
5 790 - 101 - 2102 Puller (294 kN {30 ton}) t 1
assembly
790 - 101 - 1102 Pump t 1
791-580-3500 Installer t 1
Press-fitting of bearing (hub
6 790 - 101 - 2102 Puller (294 kN {30 ton}) t 1
shaft assembly)
790 - 101 - 1102 Pump t 1
790-431-1230 Remover and installer t 1
Removal and installation of
7 790 - 101 - 2102 Puller (294 kN {30 ton}) t 1
planetary gear shaft
790 - 101 - 1102 Pump t 1
8 790-431-1250 Guide t 1 Installation of gear assembly
791T-630-2210 Plate t 1 Q
792-530-1630 Stud t 2
790-101-2510 Block t 1
790-101-2570 Washer t 2
1 Press fit of bushing
01580-01613 Nut t 2
Idler assembly L 01643-31645 Washer t 2
790 - 101 - 2102 Puller (294 kN {30 ton}) t 1
790 - 101 - 1102 Pump t 1
2 791-515-1520 Installer t 1 Installation of floating seal
3 791-685-8310 Push tool t 1 Press fitting of seal guide
4 791-601-1000 Oil pump t 1 Supplying oil
791-730-1110 Bolt t 4
01580-12722 Nut t 4
1 01643-32780 Washer t 1 Removal of pin
790 - 101 - 2102 Puller (294 kN {30 ton}) t 1
Recoil spring
M 790 - 101 - 1102 Pump t 1
assembly
791-685-8501 Compressor t 1
790-101-1600 Cylinder (686 kN {70 ton}) t 1 Disassembly and assembly
2
790 - 101 - 1102 Pump t 1 of recoil spring assembly
791-635-3160 Extension t 1
195-30-66611 Grip t 3 N
01010-62490 Bolt t 5
01010-62455 Bolt t 5 Secure bogie assembly
13
Track frame 01643-32460 Washer t 5 (For 7 track roller)
L
assembly 19M-54-11770 Washer t 5 N
198-30-66190 Collar t 5 N
Removal and installation of
24 791-685-1320 Lifting tool t 1
track frame assembly

50-10 D375A-6R
(01)
General information on disassembly and assembly
Special tool list

New/redesign
Necessity
Quantity

Sketch
Device Symbol Part No. Part name Nature of work, remarks

8 791T-630-2220 Plate t 1 Q Press fit of bushing


9 796-670-1020 Installer t 1 Installation of floating seal
10 791T-630-2230 Push tool t 1 Q Press fitting of seal guide
11 791-601-1000 Oil pump t 1 Supplying oil
790-401-1700 Lifting tool t 1
790-401-1761 Adapter t 1 Lifting of track roller assem-
12
790-401-1540 Shackle t 2 bly
790-401-1770 T-bolt t 2
Track roller 195-30-68610 Plate t 5 N
L 01010-62450 Bolt t 5
assembly
01010-62455 Bolt t 5
22
19M-54-11770 Washer t 5 N
01643-32460 Washer t 5
198-30-66190 Collar t 5 N Fixing of bogie assembly
195-30-69540 Plate t 2 N
01011-82410 Bolt t 2
23 01011-82420 Bolt t 2
19M-54-11770 Washer t 4 N
195-30-69550 Collar t 2 N
4 791-601-1000 Oil pump t 1
Carrier roller 5 791-515-1520 Installer t 1
L Carrier roller assembly
assembly 6 791-830-1770 Push tool t 1
7 791-630-1270 Wrench t 1
1 791-630-2260 Plate t 1
2 790-201-2730 Spacer t 1
3 791-630-2270 Screw t 3
14 4 01580-12419 Nut t 3
5 01643-32460 Washer t 3
6 790-101-4000 Puller (490 kN {50 ton}) t 1
7 790 - 101 - 1102 Pump t 1
1 791-630-2280 Adapter t 1 Removal of shaft and ring
2 790-201-2770 Spacer t 1
3 791-630-2250 Plate t 1
4 790-434-1070 Screw t 1
15
5 01580-13629 Nut t 2
6 01643-33690 Washer t 2
7 790-101-4000 Puller (490 kN {50 ton}) t 1
8 790 - 101 - 1102 Pump t 1
1 791-630-2260 Plate t 1
2 791-630-2270 Screw t 3
3 01580-12419 Nut t 3
Bogie assembly L 16 Press-fitting of pin assembly
4 01643-32460 Washer t 3
5 790-101-4000 Puller (490 kN {50 ton}) t 1
6 790 - 101 - 1102 Pump t 1
Alignment of track frame
17 791T-630-2290 Guide t 2 Q
and bogie pin holes
18 791-530-1510 Installer t 1 Installation of floating seal
19 791-601-1000 Oil pump t 1 Supplying oil
195-30-68610 Plate t 5 N
01010-62450 Bolt t 5
01010-62455 Bolt t 5
22
19M-54-11770 Washer t 5 N
01643-32460 Washer t 5
198-30-66190 Collar t 5 N Fixing of bogie assembly
195-30-69540 Plate t 2 N
01011-82410 Bolt t 2
23 0101-82420 Bolt t 2
19M-54-11770 Washer t 4 N
195-30-69550 Collar t 2 N

D375A-6R 50-11
(01)
General information on disassembly and assembly
Special tool list

New/redesign
Necessity
Quantity

Sketch
Device Symbol Part No. Part name Nature of work, remarks

1 791-630-2260 Plate t 1
2 790-201-2730 Spacer t 1
3 791-630-2270 Screw t 3
14 4 01580-12419 Nut t 3
5 01643-32460 Washer t 3
6 790-101-4000 Puller (490kN {50 ton}) t 1
7 790 - 101 - 1102 Pump t 1
1 791-630-2280 Adapter t 1 Removal of shaft and ring
2 790-201-2770 Spacer t 1
3 791-630-2250 Plate t 1
4 790-434-1070 Screw t 1
15
5 01580-13629 Nut t 2
6 01643-33690 Washer t 2
7 790-101-4000 Puller (490 kN {50 ton}) t 1
8 790 - 101 - 1102 Pump t 1
1 791-630-2260 Plate t 1
2 791-630-2270 Screw t 3
3 01580-12419 Nut t 3
No. 1 bogie 16 Press-fitting of pin assembly
L 4 01643-32460 Washer t 3
assembly 5 790-101-4000 Puller (490 kN {50 ton}) t 1
6 790 - 101 - 1102 Pump t 1
Alignment of track frame
17 791T-630-2290 Guide t 2 Q
and bogie pin holes
18 790-434-1350 Installer t 1 Installation of floating seal
19 791-601-1000 Oil pump t 1 Supplying oil
1 791-630-1860 Bracket (L. H) t 1 N
2 791-630-1870 Bracket (R.H) t 1 N Setting bogie to installed
20
3 01010-62760 Bolt t 2 position
4 01643-32780 Washer t 2
791T-630-1900 Lifting tool q 1 Q
791T-630-1910 q Tube 1 Q
791T-630-1920 q Plate 1 Q
07283-38973 q Grip 1 Installation of track roller
21
040-11628 q Eyebolt 1 assembly
01643-31645 q Washer 1
01643-31232 q Washer 2
01582-01210 q Nut 2
1 791-646-7351 Push tool t 1 Removal of pin small plug
2 791-660-7460 Pin brush t 1 Cleaning of pin hole
Push tool
3 791-646-7900 t 1 Drive-in of large plug
(For large plug)
Track shoe
R 791-701-3000 Seal checker
assembly 4 t 2 Filling with oil
or 791-601-1000 Oil pump
Push tool
5 791-932-1110 t 1 Drive-in of small plug
(For small plug)
6 791-632-1021 Installer t 1 Installation of seal assembly

50-12 D375A-6R
(01)
General information on disassembly and assembly
Special tool list

New/redesign
Necessity
Quantity

Sketch
Device Symbol Part No. Part name Nature of work, remarks

1 791-632-1300 Push tool assembly t 1 N


2 791-632-1260 q Push tool 1
3 791-632-1270 q Adapter 1
4 791-632-1220 q Adapter (small) 1
5 791-632-1230 q Ring 1
8 6 791-632-1240 q Plate 1
7 791-685-5730 q Bar 1
8 791-632-1250 q Ring 1
9 791-632-1280 q Spring 1
10 01252-30605 q Bolt 1
11 01580-01210 q Nut 1
1 791-632-1200 Push tool assembly t 1 N
Assembly of link
2 791-632-1260 q Push tool 1
3 791-632-1270 q Adapter 1
4 791-631-1210 q Adapter (large) 1
5 791-632-1230 q Ring 1
9 6 791-632-1240 q Plate 1
7 791-685-5730 q Bar 1
8 791-632-1250 q Ring 1
9 791-632-1280 q Spring 1
10 01252-30650 q Bolt 1
11 01580-01210 q Nut 1
1 791-632-1290 Push tool assembly t 2 N
10 2 791-685-5730 Bar 1
Track shoe
R 3 01580-01210 Nut 1
assembly 1 791-646-7351 Push tool t 1
2 791-660-7460 Pin brush t 1
3 791-646-7900 Push tool (for large plug) t 1
791-701-3000
Seal checker
4 or t 2
Oil pump
791-601-1000
5 791-932-1110 Push tool (for small plug) t 1
6 791-632-1021 Installer t 1
Remover & installer assem-
1 791-632-1100 t 1
bly
2 791-632-1130 q Adapter 1
3 790-434-1610 q Guide 1 Disassembly and assembly
4 01010-51440 q Bolt 2 of one link assembly in field
5 791-685-9510 q Frame 1
6 791-685-9520 q Rod 1
7 791-685-9520 q Frame 1
7
8 791-685-9550 q Nut 3
9 040-12030 q Eyebolt 1
10 791-685-9560 q Bolt 4
11 791-126-0150 q Adapter 1
12 791-685-9540 q Rod 1
13 791-632-1140 q Adapter 1
14 791-680-5520 q Guide 1
15 01010-51030 q Bolt 1

D375A-6R 50-13
(01)
General information on disassembly and assembly
Special tool list

New/redesign
Necessity
Quantity

Sketch
Device Symbol Part No. Part name Nature of work, remarks

16 791-632-1150 q Pusher 1
17 791-685-9620 q Extension 1
18 791-632-1180 q Adapter 1
19 791-680-5543 q Adapter 1
20 791-632-1170 q Guide 1
21 791-680-5551 q Guide 1
22 791-680-9630 q Adapter 1 Disassembly and assembly
7
23 791-632-1160 q Guide 1 of one link assembly in field
24 195-32-61210 Bolt 1
Cylinder (1,470 kN {150
25 790-101-4300 t 1
ton})
26 790 - 101 - 1102 Pump t 1
27 790-101-4200 Cylinder (294 kN {30 ton}) t 1
28 791-680-1630 Spacer t 1 N
1 791-646-7351 Push tool t 1
2 791-660-7460 Pin brush t 1
3 791-646-7900 Push tool (for large plug) t 1
Seal checker
791-701-3000
4 t 2
or 791-601-1000
Oil pump
5 791-932-1110 Push tool (for small plug) t 1
6 791-632-1021 Installer t 1
Remover & installer assem-
1 791-632-1100 t 1
Track shoe bly
R 2 791-632-1130 q Adapter 1
assembly
3 790-434-1610 q Guide 1
4 01010-51440 q Bolt 2
5 791-685-9510 q Frame 1
6 791-685-90 q Rod 1
7 791-685-9520 q Frame 1
8 791-685-9550 q Nut 3
Disassembly and assembly
9 040-12030 q Eyebolt 1
of master link
10 791-685-9560 q Bolt 4
11 791-126-0150 q Adapter 1
12 791-685-9540 q Rod 1
7 13 791-632-1140 q Adapter 1
14 791-680-5520 q Guide 1
15 01010-51030 q Bolt 1
16 791-632-1150 q Pusher 1
17 791-685-9620 q Extension 1
18 791-632-1180 q Adapter 1
19 791-630-5543 q Adapter 1
20 791-632-1160 q Guide 1
21 791-680-5551 q Guide 1
22 791-680-9630 q Adapter 1
23 791-632-1160 q Guide 1
24 195-32-61210 Bolt 2
Cylinder (1,470 kN {150
25 790-101-4300 t 1
ton})

50-14 D375A-6R
(01)
General information on disassembly and assembly
Special tool list

New/redesign
Necessity
Quantity

Sketch
Device Symbol Part No. Part name Nature of work, remarks

26 790 - 101 - 1102 Pump t 1


7 27 790-101-4200 Cylinder (294 kN {30 ton}) t 1
28 791-680-1630 Spacer t 1
1 791-632-1300 Push tool assembly t 1 N
2 791-632-1260 q Push tool 1
3 791-632-1270 q Adapter 1
4 791-632-1220 q Pin (small) 1
5 791-632-1230 q Ring 1
8 6 791-632-1240 q Plate 1
7 791-685-5730 q Bar 1
8 791-632-1250 q Ring 1
9 791-632-1280 q Spring 1
10 01252-30605 q Bolt 1
Track shoe 11 01580-01210 q Nut 1 Disassembly and assembly
R
assembly 1 791-632-1200 Push tool assembly t 1 N of master link
2 791-632-1260 q Push tool 1
3 791-632-1270 q Adapter 1
4 791-632-1210 q Pin (large) 1
5 791-632-1230 q Ring 1
9 6 791-632-1240 q Plate 1
7 791-685-5730 q Bar 1
8 791-632-1250 q Ring 1
9 791-632-1280 q Spring 1
10 01252-30650 q Bolt 1
11 01580-01210 q Nut 1
1 791-632-1290 Push tool assembly t 2 N
10 2 791-632-1260 Bar 1
3 01580-01210 Nut 1
1 791T-650-2330 Sleeve t 1 N Q
2 791T-650-2340 Plate t 1 N Q
3 790-201-3310 Bolt t 2
Pivot shaft 4 790-101-2510 Block t 1 Removal and installation of
P 5 790-101-2570 Washer t 2
assembly pivot shaft assembly
6 01580-01613 Nut t 2
7 01643-31645 Washer t 2
8 790-105-2300 Jack assembly t 1
9 790 - 101 - 1102 Pump t 1
791-650-1300 Remover q 1
791-735-1123 q Sleeve 1
790-434-1050 q Screw 1
Removal and installation of
Equalizer bar N 1 01580-02419 q Nut 1
equalizer bar assembly
01643-32460 q Washer 1
790 - 101 - 2102 Puller (294 kN {30 ton}) q 1
790 - 101 - 1102 Pump q 1
1 791T-650-2410 Bracket t 1 N Q
2 791T-650-2420 Bracket t 1 N Q
Equalizer bar 3 790-438-1110 Screw t 1 Disassembly and assembly
N 2 4 791-112-1180 Nut t 2
bushing of equalizer bar bushing
5 790-101-2540 Washer t 2
6 790 - 101 - 2102 Puller (294 kN {30 ton}) t 1
7 791-101-1102 Pump t 1

D375A-6R 50-15
(01)
General information on disassembly and assembly
Special tool list

New/redesign
Necessity
Quantity

Sketch
Device Symbol Part No. Part name Nature of work, remarks

Disassembly and assembly


Cylinder
1 790-502-1003 q 1 of hydraulic cylinder assem-
Repair stand
bly
790-201-1702 Push tool kit t 1
790-201-1841 q Push tool 1
2 790-201-1861 q Push tool 1 Press fit of bushing
790-101-5021 q Grip 1
01010-50816 q Bolt 1
790-201-1500 Push tool kit t 1
790-201-1650 q Plate 1
3 790-201-1670 q Plate 1 Press fitting of seal
Hydraulic cylin-
U 790-101-5021 q Grip 1
der assembly
01010-50816 q Bolt 1
4 790-720-1000 Expander t 1
796-720-1680 Ring t 1
07281-01589 Clamp t 1
796-720-1720 Ring t 1 Installation of piston ring
5
07281-02429 Clamp t 1
796-720-1690 Ring t 1
07281-02169 Clamp t 1
790-102-4300 Wrench t 1 Disassembly and assembly
6 of ripper cylinder piston
790-102-4310 Pin t 2
assembly
Assembly and disassembly
Cylinder
1 790-502-1003 q 1 of ripper pin puller cylinder
Repair stand
assembly
790-201-1702 Push tool kit t 1
790-201-1721 q Push tool 1
2 Press fit of bushing
790-101-5021 q Grip 1
Ripper pin puller 01010-50816 q Bolt 1
cylinder assem- U 790-201-1500 Push tool kit t 1
bly 790-201-10 q Plate 1
3 Press fitting of dust seal
790-101-5021 q Grip 1
01010-50816 q Bolt 1
4 790-720-1000 Expander t 1
796-720-1630 Ring t 1 Press fitting of dust seal
5
07281-00709 Clamp t 1
7 790-102-2302 Wrench t 1 Tightening cylinder head

50-16 D375A-6R
(01)
General information on disassembly and assembly
Sketches of special tools

Sketches of special tools 50-17


Caution: Komatsu will not accept any responsibility for any special tools manufactured according to these
sketches.
A2 socket 50-17

A4 Push tool (For oil seal) 50-17

D375A-6R 50-17
(01)
General information on disassembly and assembly
Sketches of special tools

A4 push tool (For dust seal) 50-18

A5 push tool (For both standard and sleeved seal) 50-18

50-18 D375A-6R
(01)
General information on disassembly and assembly
Sketches of special tools

A5 push tool (For sleeved seal) 50-19

L1 Plate 50-19

D375A-6R 50-19
(01)
General information on disassembly and assembly
Sketches of special tools

L8 Plate 50-20

L10 Push tool 50-20

50-20 D375A-6R
(01)
General information on disassembly and assembly
Sketches of special tools

L17 Guide 50-21

L21 Lifting tool 50-21

D375A-6R 50-21
(01)
General information on disassembly and assembly
Sketches of special tools

L21 Tube 50-2

L21 Plate 50-2

50-22 D375A-6R
(01)
General information on disassembly and assembly
Sketches of special tools

P1 Sleeve 50-23

P2 Plate 50-23

D375A-6R 50-23
(01)
General information on disassembly and assembly
Sketches of special tools

N2-1 Bracket 50-24

N2-2 Bracket 50-24

50-24 D375A-6R
(01)
Engine and cooling system
Removal and installation of fuel supply pump assembly

Engine and cooling system 50-25


Removal and installation of fuel supply pump assembly 50-25

Removal 50-25
k Park the machine on a level surface and low-
er the work equipment to the ground.
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
k Stop the engine and disconnect the cable
from the negative (-) terminal of the battery.
a Remove the wiring clamp and move the wiring
aside.

1. Close the fuel valve under the fuel tank.

2. Open the left side cover and remove lower side


cover (1).

q Portion Y
3. Remove mounting bolt (4-2), and disconnect
clamp of breather tube (4-1).

4. Disconnect breather hose (4-3) in the same way.

5. Remove mounting bolts (4-4), and lift breather


assembly slightly to remove.

6. Remove wiring covers (5-1) - (5-3).


a The washer falls off as the rear side bolt is re-
moved. Thus, reasonable care is needed in
this operation.
a Carefully remove cover (5-3).
Cover (5-3) is made of plastic. Avoid applying
a large force but lift it off gradually to prevent
cracks at (B).
a An O-ring instead of a gasket is installed at
the breather mounting portion.

D375A-6R 50-25
(01)
Engine and cooling system
Removal and installation of fuel supply pump assembly

13. Disconnect connector (15).


LEFT: PCV2, RIGHT: PCV1

7. Remove bracket (6).


a 5 mounting bolts
14. Disconnect connector G (16).

15. Disconnect connector INJ (17).

16. Remove tube (18).


a Before removing the tube, clean the area
around carefully so that inside of the supply
pump and common rail may not be contami-
nated by foreign substances.

17. Disconnect clamp (19).

8. Disconnect connector PFUEL (7)

9. Disconnect clamp (8).

10. Remove cover (9).

11. Remove clamps (10) - (12).

12. Remove covers (13) and (14).

50-26 D375A-6R
(01)
Engine and cooling system
Removal and installation of fuel supply pump assembly

18. Remove the fuel pre-filter. 21. Remove the bracket (16) mounting bolts and oil
a The fuel pre-filter may be removed first. pipings (17), then remove the fuel supply pump
assembly (18).
19. Remove tubes (11), (12), (13), and (14).
[*1]

22. Remove the following parts from fuel supply


pump assembly (18).
1) Oil tube (19)
2) Plate (20)
3) Overflow valve (21)

20. Disconnect G sensor connector (15) on the


opposite side of the supply pump.

D375A-6R 50-27
(01)
Engine and cooling system
Removal and installation of fuel supply pump assembly

Connection 50-28
1. Install the following parts to fuel supply pump
assembly (18).
1) Plate (20)
2) Oil tube (19)
a Replace gaskets (GA) and (G10) with
new ones.
q GA: Accessories of supply pump
q G10: Part No. (07005-01012)
3) Overflow valve (21)
3 Plate (20) mounting bolt:
19.6 29.4 Nm {2.0 3.0 kgm}
3 Oil tube (19) joint bolt
Upper side: 7.9 -12.7 Nm {0.8 - 1.3 kgm}
Lower side: 9.8 -12.7 Nm {1.0 - 1.3 kgm}
3 Overflow valve (21):
3. Install fuel supply pump assembly (18) and lower
bracket (17).
3 Fuel supply pump mounting bolt:
14.819.6 Nm {1.511.99 kgm}
5974 Nm {67.5 kgm}
3 Lower bracket (17) mounting bolt:
5974 Nm {6.07.5 kgm}

4. Install oil tube (22).


a Replace 4 gaskets (G) with new ones.
(Part No.: 07005-01012)
3 Oil tube (22) joint bolt:
9.812.7 Nm {1.01.3 kgm}

2. Place the fuel supply pump assembly to the drive


case according to the following procedure.
a Match part (A) of the fuel supply pump drive
gear where there is one tooth missing with
part (AA) of the coupling where there is one
spline missing to set the fuel supply pump as-
sembly.

50-28 D375A-6R
(01)
Engine and cooling system
Removal and installation of fuel supply pump assembly

High-pressure pipe
k When handling the high-pressure pipe
and clamp, observe the following.
q Never bend the high-pressure pipe to in-
stall or use it in other locations.
q Install the specified clamp to the specified
position securely and tighten it to the
specified torque.
q Do not apply lubricant to the high-pres-
sure pipe sleeve nuts and the threads of
the mating part.
a Axial force in the tightening can be exces-
sive, potentially damaging the high-pres-
sure pipe.
k Before installing the high-pressure pipe,
q Carry out the subsequent installation in the re-
check it for the following defects. If it has verse order to removal.
any defect, replace it with new one since
fuel may leak. [*1]
3
q Taper seal (a) at connecting part: Check
Tube (12)
for visible lengthwise slits (b) and dents Joint bolt (Supply pump side):
(c) at area within 2 mm from the end. 14.819.6 Nm {1.511.99 kgm}
q Make sure that there are no deformation
Sleeve nut:
or wear which your fingernail can feel on 4347 Nm {4.44.8 kgm}
3
the portion (d) (end of taper seal: portion Tube (13)
at 2 mm from the tip). (Namely, this por- Joint bolt (Overflow valve):
tion must be free from fatigue.) 14.819.6 Nm {1.511.99 kgm}
Joint bolt (Supply pump side):
24.534.3 Nm {2.53.5 kgm}
Sleeve nut (Fuel block side):
2427 Nm {2.42.7 kgm}

3 Tube (14)
Joint bolt (Supply pump side):
14.819.6 Nm {1.511.99 kgm}
Sleeve nut:
4347 Nm {4.44.8 kgm}

k Check that each high-pressure pipe and wir-


ing harness are at least 10 mm apart from
each other.If not, secure the clearance by re-
5. Connect G sensor connector (15). positioning the wiring harness.
q Air bleeding
6. Tighten high-pressure pipes (7) lightly. Bleed air from the fuel circuit. For detail, see
Testing and adjusting, "Bleeding air from fuel
7. Tighten clamps (8) - (10) lightly. circuit".

8. Tighten high-pressure pipe (7) to the specified


torque.
3 High-pressure pipe sleeve nut:
39.244.1 Nm {4.04.5 kgm}

9. Tighten clamps (8) - (10) to the specified torque.


3 Clamp bolt :
9.8 1.0 Nm {1 0.1 kgm}

10. Install cover (11) at 2 places.


a When installing it, direct the slit downward.

D375A-6R 50-29
(01)
Engine and cooling system
Removal and installation of fuel injector assembly

Removal and installation of fuel injector assembly 50-30

Special tools 50-30 35. Disconnect high-pressure pipe clamps (7) and
(8).

Necessity
Quantity

Sketch
Sym- a A clamp is provided on the fuel supply pump

N/R
Part No. Part name
bol side.
795-799-5410 Adapter t 1
1
A 795-799-5420 Remover t 1
2 795T-675-1110 Socket q 1 N Q

Removal 50-30
k Park the machine on a level surface and low-
er the work equipment to the ground.
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
k Stop the engine and disconnect the cable
from the negative (-) terminal of the battery.

1. Perform steps 1 to 31 of Removal and installa-


tion of cylimder head assembly. (See "Removal
and installation of cylinder head assembly") 36. Remove clamp (9).

32. Disconnect high-pressure pipe clamps (1) to (3). 37. Remove cover (10).

33. Remove tubes (4) and (5).


[*1]
34. Remove bracket (6).

50-30 D375A-6R
(01)
Engine and cooling system
Removal and installation of fuel injector assembly

38. Disconnect sleeves (11) and (12) at 6 places 41. Remove terminal mounting nuts (15).
each. a Loosen the nuts alternately.

39. Remove high-pressure pipes (13). 42. Remove wiring harness assembly mounting
bolts (16) and spacer (17).
40. Remove cylinder head cover (14).
43. Remove fuel injector holder (21).

44. Using tool A1, remove fuel injector assembly


(22).
a Hook the end of tool A1 onto hole (H) of the fuel
injector to pull out.
a Never grip the solenoid valve on the top of the
fuel injector with pliers, etc. to pull out.
a The figure shows the fuel injector after the rocker
arm and shaft assembly is removed.

a If tool A2 is not available, disconnect sleeve (12)


from above.
q Tool A2

D375A-6R 50-31
(01)
Engine and cooling system
Removal and installation of fuel injector assembly

Connection 50-32 2) Install terminal mounting nuts (15) and wiring


1. Fuel injector harness fixing bolts (16).
a Check that the injector mounting bore is free a Tighten the terminal mounting nuts alter-
from dirt. nately
2 O-ring: 3 Terminal mounting nut:
Engine oil (EO30) 2 0.2 Nm {0.2 0.02 kgm}

1) Install gasket (24) and O-rings (25) and (26)


to fuel injector (22).
a Take care not to fit O-ring (25) to center
groove (A).

2) Fit fuel injector (22) to adapter (27) and


injector holder (21).

3) Tighten bolt (29) with spherical washer (30)


to fix injector holder (31) lightly.
2 Spherical washer:
Engine oil (EO30)
a The bolt of injector holder (21) is to be
tightened to the specified torque after
3. High-pressure pipe
k When handling the high-pressure pipe
tightening the high-pressure pipe partial-
ly.
and clamp, observe the following.
q Never bend the high-pressure pipe to in-
stall or use it in other locations.
q Install the specified clamp to the specified
position securely and tighten it to the
specified torque.
q Do not apply lubricant to the high-pres-
sure pipe sleeve nuts and the threads of
the mating part.
a If lubricant is applied, the axial
force becomes too high and can
break the high-pressure pipe.

2. Injector wiring harness


1) Install spacer (17).
a Install the spacer with its slit (B) up.

50-32 D375A-6R
(01)
Engine and cooling system
Removal and installation of fuel injector assembly

k Before installing the high-pressure pipe, 5) Tighten high-pressure pipe sleeve nuts (11)
check it for the following defects. If it has and (12) to the specified torque by using the
any defect, replace it with new one since spanner type torque wrench.
fuel may leak. 3 Sleeve nut:
q Taper seal (a) at connecting part: Check 39.244.1 Nm {44.5 kgm}
for visible lengthwise slits (b) and dents a After finishing the work, check that
(c) at area within 2 mm from the end. O-ring (32) is not projected from the
q Make sure that there are no deformation end of the sleeve nut (12).
or wear which your fingernail can feel on
the portion (d) (end of taper seal: portion 6) Install cylinder head cover (14).
at 2 mm from the tip). (Namely, this por- a A different tightening torque is employed
tion must be free from fatigue.) for No. 2 cylinder head cover mounting
bolt alone.
3 Cylinder head cover mounting bolt:
No. 1, 3, 4, 5, and 6 cylinders:
9.8 1.0 Nm {1.0 0.1 kgm}
No. 2 cylinder:
5974 Nm {67.5 kgm}

1) Install O-ring (32) to high-pressure pipe(13)


sleeve (31).
2 O-ring:
Engine oil (EO30)

2) Tighten sleeve nut (12) partially aligning it


with connector (28) of the injector.
a If sleeve nut (12) does not catch the
threads, press the end of sleeve nut (12)
with a small rod, etc. toward the injector
and turn the spanner.

3) Tighten sleeve nut (11) on the common rail


side partially, too.

4) Tighten injector holder (21) to the specified


torque.
3 Injector holder mounting bolt:
5974 Nm {6.07.5 kgm}

D375A-6R 50-33
(01)
Engine and cooling system
Removal and installation of fuel injector assembly

4. High-pressure pipe clamp k Make sure that a clearance of 10 mm mini-


1) Install the clamps on the high-pressure pipes mum is provided between the high-pressure
according to the following procedure. pipe and adjacent wiring harness. If not, se-
1] Finger-tighten seventeen high-pressure cure the clearance by repositioning the wir-
pipe clamps (33) in the position indicated ing harness.
in the figure.
2] Finger-tighten common rail side clamp q Bleeding air
bracket (34) and clamp (9) and then Bleed air from the fuel circuit. For detail, see
tighten clamp (9). Testing and adjusting, "Bleeding air from fuel
3 Common rail side clamp bolt: circuit".
9.8 1.0 Nm {1 0.1 kgm}
3] Tighten common rail side clamp bracket
(34) to the specified torque.
4] Tighten high-pressure pipe clamps (33).
3 High-pressure pipe side clamp
bolt:
11.814.7 Nm {1.21.5 kgm}
5] Install covers (10) on the common rail
side sleeve nuts.
a When installing it, direct the slit down-
ward.

q Carry out the subsequent installation in the re-


verse order to removal.

[*1]
3 Tube (4) joint bolt:
7.89.8 Nm {0.81.0 kgm}
3 Tube (5) sleeve nut:
2427 Nm {2.42.7 kgm}
Joint bolt:
24.534.3 Nm {2.53.5 kgm}

a Refer to the precautions in "Installation of cylin-


der head" for the installation.

50-34 D375A-6R
(01)
Engine and cooling system
Removal and installation of cylinder head assembly

Removal and installation of cylinder head assembly 50-35

Special tools 50-35 4. Loosen the clamp and disconnect boost tube (2).

New/Remodel
Necessity
5. Disconnect exhaust temperature sensor wiring

Quantity

Sketch
Sym
Part No. Part name (3).
bol

6. Remove front heat insulation cover (4), center


795-799-5410 Adapter t 1 heat insulation cover (5), and rear heat insula-
1
795-799-5420 Remover t 1 tion cover (6).
A
2 795T-675-1110 Socket q 1 N Q
6 790-331-1120 Wrench (angle) q 1 7. Disconnect the muffler drain tube.

Removal 50-35 8. Sling and remove muffler (7).


k Park the machine on a level surface and low- 4 Muffler assembly:
er the work equipment to the ground. 95 kg
k Set the parking brake lever and work equip-
ment lock lever in the lock position. 9. Remove muffler mounting bracket (8).
k Stop the engine and disconnect the cable
from the negative (-) terminal of the battery.
k You should disconnect the heater hose or
drain the engene coolant after the engine
coolant temperature goes down as you may
be scalded if you do the works while the en-
gine coolant in the radiator is hot.

1. Drain the coolant.


6 Coolant:
120 l

2. Remove the engine hood assembly. For details,


see "Removal and installation of engine hood
assembly".
10. Disconnect fuel hoses (9) and (11).
[*1]
3. Remove right and left lower side covers (1).
4 Left lower side cover:
11. Disconnect tube (10).
40 kg
[*2]
Right lower side cover:
50 kg
12. Remove fuel pre-filter assembly (12).

D375A-6R 50-35
(01)
Engine and cooling system
Removal and installation of cylinder head assembly

13. Remove fuel tube clamps (17).

14. Remove fuel tubes (18), (18-1), and (19).


[*3]
15. Disconnect connector TOIL (20).
a Drive lock (L) upward to pull out the connec-
tor.

16. Disconnect connector POIL (21) according to


the following procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connector
POIL (21).

17. Remove tube assembly (22). 20. Remove each tube of the turbocharger.
[*4]
q Lubrication tube (28)
q Lubrication drain tube (29)
q Coolant tube (30)
q Coolant drain tube (31)

18. Sling and remove engine oil filter assembly (23).

19. Disconnect wiring harnesses (24).

50-36 D375A-6R
(01)
Engine and cooling system
Removal and installation of cylinder head assembly

21. Disconnect connector V30 (31-1) and V29 25. Disconnect connector PFUEL (36)
(31-2).
26. Remove common rail cover (37).

22. Sling and remove turbocharger and exhaust


manifold assembly (32). 27. Disconnect six injector connectors (38).
[*5]
4 Turbocharger and exhaust mainfold 28. Disconnect connector CN6 (39).
assembly:
120 kg 29. Remove harness bracket (40).

23. Remove breather and tube assembly (33). 30. Disconnect high-pressure pipe clamps (41) -
(43).
24. Remove harness covers (34) and (35).
31. Remove tubes (44) - (46).
[*6]

32. Remove brackets (47) and (48).

D375A-6R 50-37
(01)
Engine and cooling system
Removal and installation of cylinder head assembly

33. Disconnect high-pressure pipe clamps (49) and


(50).

34. Remove fuel tube (51).


[*7]

42. Disconnect wiring harness clamp (59) from rear


side of the fuel supply pump.

43. Disconnect the connector from the bottom of


clamp (59).
35. Remove clamp (52).

36. Remove covers (53) and (54).

37. Loosen clamps (55) and (56).

38. Remove high-pressure tube assembly (57).


a Before removal, thoroughly wash the area to
prevent foreign materials from entering the
supply pump and common rail.

39. Disconnect connector (58).

40. Disconnect fuel hose (120).


44. Disconnect connectors PCV1 (60) and PCV2
41. Disconnect connector PIM (121). (61).

45. Disconnect wiring harness clamp (62).

46. Remove tubes (63) - (65).


[*8]
47. Remove fuel supply pump assembly (66).
a Do not loosen overflow valve (ofv).
a Do not remove oil tube (t) and plate (p).

50-38 D375A-6R
(01)
Engine and cooling system
Removal and installation of cylinder head assembly

50. Remove high-pressure pipe (70).

48. Disconnect sleeve (69).


51. Remove bracket (71).
49. Disconnect high-pressure pipe sleeve nut (75)
on the injector side. 52. Remove four mounting bolts (73) of air intake
a If tool A2 is available, you can work from the manifold assembly (72) from the radiator side.
side, not from above.

a Tool A2

D375A-6R 50-39
(01)
Engine and cooling system
Removal and installation of cylinder head assembly

53. Remove high-pressure pipe (74).

54. Sling air intake manifold assembly (72).


a Install eyebolt [1] to the mounting hole of
bracket (71) (described above) and sling by
using lifting tool [2].

55. Remove the mounting bolts of air intake mani-


fold assembly (72), leaving some of them tight-
ened.

56. Install guide bolts [3].


a Use the filter mounting bolt as the guide bolt.

57. Remove the remaining mounting bolts of air 60. Remove bracket (77).
intake manifold assembly (72).
61. Remove turbocharger lubrication tube (78) and
coolant tube (79).

62. Remove air vent tube (80).

58. Disconnect air intake connector (76).

63. Remove pin (A) and then push in bolt (B).

64. Rotate the crankshaft by using bolt (B) as a


barring location to set the No. 1 or No. 6 cylinder
to the compression top dead center.
a Remove plug (BB) to check the result visual-
ly.
a For above operation, see Testing and adjust-
ing, "Testing and adjusting valve clearance".

59. Sling and remove air intake manifold assembly


(72).
4 Air intake manifold assembly:
110 kg

50-40 D375A-6R
(01)
Engine and cooling system
Removal and installation of cylinder head assembly

65. Remove cylinder head cover (81).


a Check that you can move the rocker arm of
the No. 1 or No. 6 cylinder with fingers by the
distance of the valve clearance.

74. Using tool A1, remove fuel injector assembly


(92).
a Hook the end of tool A1 onto hole (H) of the
fuel injector to pull out.
66. Remove terminal mounting nuts (82). a Never grip the solenoid valve on the top of
a Loosen the nuts alternately. the fuel injector with pliers, etc. to pull out.
67. Remove wiring harness assembly mounting
bolts (83) and spacer (84).
68. Loosen locknut (85) and loosen adjustment
screw (86).

69. Remove the rocker arm and shaft assembly (87).

75. Sling and remove cylinder head assembly (93).


4 Cylinder head assembly:
50 kg
76. Remove the cylinder head gasket.

70. Remove push rods (88).

71. Remove cross head assembly (89).

72. Remove rocker housing (90).

73. Remove fuel injector holder (91).

D375A-6R 50-41
(01)
Engine and cooling system
Removal and installation of cylinder head assembly

Connection 50-42
1. Cylinder head assembly
1) Install the cylinder head gasket.

2) Sling and install cylinder head assembly (93).


4 Cylinder head assembly:
50 kg
a If there are 5 punch marks on the head of
a bolt, do not reuse that bolt but replace it.
a Tighten the mounting bolts in the order
shown in the figure.
2 Cylinder head assembly mounting
bolt:
Molybdenum disulphide lubricant
(LM-P)
3 Cylinder head assembly mounting
bolts (1 7):
1st time: 245 9.8 Nm {25 1 kgm}
2nd time: 382.5 9.8 Nm {39 1
kgm}
3rd time: Retighten 90120
a Use tool A6 (see the tool table) to retight-
en.When not using tool A6, make marks
on the cylinder head and bolt using paint,
etc., and then retighten the bolt to
90120 (target: 120).
3 Cylinder head assembly mounting
bolts (8, 9):
93.2103 Nm {9.510.5 kgm} a After tightening the bolt, make punch
mark "(a)" on the main bolt head (Do not
make it when new bolt is used, however).

50-42 D375A-6R
(01)
Engine and cooling system
Removal and installation of cylinder head assembly

2. Fuel injector a Do not forget to install O-ring (OR).


a Check that the fuel injector mounting bore is 3 Rocker arm housing mounting bolt:
free from dirt or other particles. 78.493.2 Nm {8.09.5 kgm}
2 O-ring:
Engine oil (EO30)

1) Install gasket (94) and O-rings (95) and (96)


to fuel injector (92).
a Take care not to fit O-ring (95) to center
groove (A).

2) Insert fuel injector (92) to adapter (97) and


injector holder (91).

3) Attach spherical washer (100) to bolt (99)


and then tighten injector holder (91) partially.
2 Spherical washer:
Engine oil (EO30) 6) Install cross head (89).

a Injector holder (91) is to be tightened to 7) Adjust the crossheads according to the


the specified torque after installing the in- following procedure.
take manifold and tightening the 1] Loosen locknut (102) and then loosen
high-pressure pipe lightly. adjustment screw (103) to a position
where it will not touch valve stem (104).
4) Install push rod (88). 2] Hold the contact face to the rocker arm
a Check that the push rod end is securely with the finger to keep crosshead in
placed in the cam follower socket. contact with valve stem (105) on the push
rod side.
5) Apply liquid gasket and then install rocker 3] Slowly tighten adjustment screw (103)
housing (90). and check the position at which adjust-
2 Rocker housing:
ment screw (103) touches valve stem
Liquid gasket (LG-7) (104).
a Apply the liquid gasket 2 to 3 mm in bead 4] Screw in adjustment screw (103) further
diameter along the housing groove as by 20 30 from the contacting position
shown in the figure. against valve stem (104).

D375A-6R 50-43
(01)
Engine and cooling system
Removal and installation of cylinder head assembly

5] While holding adjustment screw (103) to


prevent it from moving, tighten locknut
(102).
3 Locknut:
53.064.7 Nm {5.46.6 kgm}

4. Injector wiring harness


1) Install spacer (84).
a Install the spacer with its slit (B) up.

3. Rocker arm assembly


1) Install rocker arm assembly (87).
a Install each rocker arm assembly with the
riveted side of its shaft facing the front
side of the engine.
a When installing, direct the wider seat of
the shaft to the rocker arm housing.
a Make sure that the ball of adjustment
screw (86) is securely placed in the push
rod socket.
a When tightening the mounting bolt, check
that adjustment screw (86) does not
press the push rod. 2) Install terminal mounting nuts (82) and wiring
2 Threaded part and seat of rocker
harness fixing bolts (83).
arm assembly mounting bolt: a Tighten the terminal mounting nuts alter-
Engine oil (EO30) nately
3 Rocker arm assembly mounting
3 Terminal mounting nut:
bolt : 2 0.2 Nm {0.2 0.02 kgm}
235.2254.8 Nm {2426 kgm}
a Adjust the valve clearance. For details,
see Testing and adjusting, "Testing and
adjusting valve clearance".
3 Locknut (85):
57.877.4 Nm {5.97.9 kgm}
a After tightening the locknut, check the
valve clearance again.

50-44 D375A-6R
(01)
Engine and cooling system
Removal and installation of cylinder head assembly

5. Air intake manifold assembly: k Before installing the high-pressure pipe,


1) Place air intake connector (76) on air intake check it for the following defects. If it has
manifold assembly (72) being slung. any defect, replace it with new one since
4 Air intake manifold, connector as- fuel may leak.
sembly: q Taper seal (a) at connecting part: Check
135 kg for visible lengthwise slits (b) and dents
(c) at area within 2 mm from the end.
q Make sure that there are no deformation
or wear which your fingernail can feel on
the portion (d) (end of taper seal: portion
at 2 mm from the tip). (Namely, this por-
tion must be free from fatigue.)

2) Install air intake manifold assembly (72).


a Tighten the mounting bolts in the order
shown in the figure.

1) Install O-ring (106) to high-pressure pipe


sleeve (101).
2 O-ring:
Engine oil (EO30)

2) Tighten sleeve nut (75) lightly aligning it with


connector (98) of the injector.
a If sleeve nut (75) does not catch the
threads, press the end of sleeve nut (75)
with a small rod, etc. toward the injector
and turn the spanner.
6. High-pressure pipe
k When handling the high-pressure pipe 3) Tighten the common rail side sleeve nuts
and clamp, observe the following. (69) lightly, too.
q Never bend the high-pressure pipe to in- 4) Tighten injector holder (91) to the specified
stall or use it in other locations. torque.
q Install the specified clamp to the specified 3 Injector holder mounting bolt:

position securely and tighten it to the 58.973.5 Nm {6.07.5 kgm}


specified torque.
q Do not apply lubricant to the high-pres-
sure pipe sleeve nuts and the threads of
the mating part.
a If lubricant is applied, the axial
force becomes too high and can
break the high-pressure pipe.

D375A-6R 50-45
(01)
Engineandcoolingsystem
Removal and installation of cylinder head assembly

5) Tighten high-pressure pipe sleeve nuts (69) 9) Install brackets (77).


and (75) to the specified torque by using the
spanner type torque wrench.
3 Sleeve nut:
39.244.1 Nm {44.5 kgm}
a After finishing the work, check that
O-ring (106) is not projected from the
end of the sleeve nut (75).

7. High-pressure pipe clamp


1) Install the high-pressure pipe clamps
according to the following procedure.
1] Finger-tighten seventeen high-pressure
pipe clamps (107) in the position indi-
cated in the figure.
2] Finger-tighten common rail side clamp
bracket (108) and clamp (52) and then
tighten clamp (52).
3 Common rail side clamp bolt:
9.8 1.0 Nm {1 0.1 kgm}
3] Tighten common rail side clamp bracket
(108) to the specified torque.
4] Tighten high-pressure pipe clamps (107).
3 High-pressure pipe side clamp
bolt:
11.814.7 Nm {1.21.5 kgm}
5] Install covers (53) on the common rail
side sleeve nuts.
a When installing it, direct the slit down-
6) Install the cylinder head cover (81). ward.
a A different tightening torque is employed
for No. 2 cylinder head cover mounting
bolt alone.
3 Cylinder head cover mounting bolt:
No. 1, 3, 4, 5, and 6 cylinders:
9.8 1.0 Nm {1.0 0.1 kgm}
No. 2 cylinder:
5974 Nm {67.5 kgm}
7) Install air vent tube (80).
3 Air bleeding tube joint bolt (cylin-
der head side):
9.812.7 Nm {1.01.3 kgm}
8) Install turbocharger coolant tube (79) and
lubricant tube (78).

50-46 D375A-6R
(01)
Engine and cooling system
Removal and installation of cylinder head assembly

8. Fuel supply pump 3 Fuel supply pump (66) mounting


a If overflow valve (ofv) is loosened or oil tube bolt:
(t) and plate (p) are removed, install them, re- 5974 Nm {67.5 kgm}
ferring to "Removal and installation of fuel 3 Lower bracket (111) mounting bolt:
supply pump assembly". 5974 Nm {6.07.5 kgm}
2) Install oil tube (112).
Replace four gaskets (G) with new ones.
(Part No.: 07005-01012)
3 Oil tube (112) joint bolt:
9.812.7 Nm {1.01.3 kgm}

1) Place the fuel supply pump assembly to the


drive case according to the following proce-
dure.
a Match part (A) of the fuel supply pump
drive gear where there is one tooth miss-
ing with part (AA) of the coupling where
there is one spline missing to place the
fuel supply pump assembly.

9. High-pressure pipe
k Handle the high-pressure pipe and clamp
in the same way as the pipe between the
fuel injector and common rail (noted in
the foregoing) is handled.
1) Tighten high-pressure pipes (57) lightly.

2) Tighten clamps (55), (56), and (109) lightly.

3) Tighten bracket (110) lightly.

4) Tighten high-pressure pipes (57) to the spec-


ified torque.
3 High-pressure pipe sleeve nut:
39.244.1 Nm {4.04.5 kgm}

D375A-6R 50-47
(01)
Engine and cooling system
Removal and installation of cylinder head assembly

5) Tighten clamps (55), (56), and (109) to the [*4]


specified torque. 3 Coolant tube (30)
3 Clamp bolt : Joint bolt:
9.8 1.0 Nm {1 0.1 kgm} 24.534.3 Nm {2.53.5 kgm}
Sleeve nut:
6) Tighten bracket (110) to the specified torque. 24.559 Nm {2.56.0 kgm}
3 Lubrication tube (28), coolant tube (31)
7) Install cover (54). joint bolt:
a When installing it, direct the slit down- 24.534.3 Nm {2.53.5 kgm}
ward.
[*5]
Exhaust manifold assembly
1. If the exhaust manifold assembly was divided,
apply liquid adhesive (heat-resistant sealant) to
joints (A) (2 places) when assembling.
2 Exhaust manifold joint:
Liquid adhesive (HOLTS MH705)

q Carry out the subsequent installation in the re-


verse order to removal.

[*1]
3 Fuel hose (9):
9095 Nm {9.29.7 kgm}
3 Fuel hose (11) sleeve nut:
4347 Nm {4.44.8 kgm} a Tighten the mounting bolts in the order
shown in the figure.
[*2] 2 Exhaust manifold mounting bolt:
3 Tube (10) joint bolt: Seizure prevention compound (LC-G)
19.6 29.4 Nm {2.0 3.0 kgm} (NEVER-SEEZ [Bostik Inc] or equiva-
lent)
[*3] 3 Exhaust manifold mounting bolt:
3 Tube (18-1) joint bolt (filter side): 1st time: 39.258.8 Nm {4.06.0 kgm}
24.534.3 Nm {2.53.5 kgm} 2nd time: 98.1122.6 Nm {1012.5
3 Tube (18-1) joint bolt (supply pump side): kgm}
14.819.6 Nm {1.511.99 kgm}
3 Tube (18-2) joint bolt:
24.534.3 Nm {2.53.5 kgm}
3 Tube (18) sleeve nut:
2427 Nm {2.42.7 kgm}
3 Tube (19) joint bolt:
7.89.8 Nm {0.81.0 kgm}

50-48 D375A-6R
(01)
Engine and cooling system
Removal and installation of cylinder head assembly

Reference 50-49 k Confirm that each high-pressure pipe and


Installation of turbocharger assembly adjacent wiring harness are at least 10 mm
1. Sling and install turbocharger assembly (112). apart from each other.If not, secure the clear-
4 Turbocharger assembly: ance by repositioning the wiring harness.
55 kg
2 Turbocharger mounting bolt and nut: q Bleeding air
Seizure prevention compound (LC-G) Bleed air from the fuel circuit. For detail, see
(NEVER-SEEZ [Bostik Inc] or equiva- Testing and adjusting, "Bleeding air from fuel
lent) circuit".
3 Turbocharger mounting bolt and nut:
78.588.3 Nm {8.09.0 kgm}

[*6]
3 Air vent tube (44) joint bolt:
7.89.8 Nm {0.81.0 kgm}
3 Tube (45), (46) sleeve nut:
2427 Nm {2.42.7 kgm}
3 Tube (45), (46) joint bolt:
24.534.3 Nm {2.53.5 kgm}

[*7]
3 Tube (51) joint bolt:
19.6 29.4 Nm {2.0 3.0 kgm}

[*8]
3 Oil tube (63) joint bolt (supply pump side):
9.812.7 Nm {1.01.3 kgm}
3 Oil tube (63) joint bolt (block side):
9.812.7 Nm {1.01.3 kgm}
3 Tube (65)
Joint bolt (Supply pump side):
14.819.6 Nm {1.511.99 kgm}
Sleeve nut:
4347 Nm {4.44.8 kgm}
3 Tube (64) joint bolt:
19.6 29.4 Nm {2.0 3.0 kgm}

D375A-6R 50-49
(01)
Engine and cooling system
Removal and installation of radiator guard assembly

Removal and installation of radiator guard assembly 50-50

Special tools 50-50

Necessity
Quantity

Sketch
Sym-

N/R
Part No. Part name
bol

791-451-1000 Remover t 1
Puller
A 7 790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1

Removal 50-50
a Move the machine forward and backward to set
the master link of the track shoe away from the
radiator guard.
k Park the machine on a level surface and low-
er the work equipment to the ground. 5. Drain the hydraulic oil and coolant.
k Set the parking brake lever and work equip- 6 Hydraulic oil:
ment lock lever in the lock position. 130 l
k Stop the engine and disconnect the cable 6 Coolant:
from the negative (-) terminal of the battery. 120 l
k If the radiator coolant temperature is high,
wait until the temperature decreases to avoid 6. Remove the engine hood assembly. For details,
getting scalded, and then drain the coolant or see "Removal and installation of engine hood
disconnect the radiator hoses/tubes. assembly".

1. Sling the blade lift cylinders. 7. Disconnect radiator inlet hose (4).
[*1]
2. Remove the lock plate and remove connecting a Disconnect the hose from the radiator and re-
pin (1) on the piston rod side of the blade lift position the hose on the engine side.
cylinder.
8. Disconnect air vent hose (5).
3. Start the engine and retract the piston rod fully [*2]
and bind it with a wire so that it does not come a Disconnect the hose from the radiator, re-
off. move the 2 clamps, and reposition the hose
on the engine side.
4. Sling blade lift cylinder (2) and fix bracket (2-1) to
cylinder fixing portion (A) of the radiator guard.

50-50 D375A-6R
(01)
Engine and cooling system
Removal and installation of radiator guard assembly

9. Remove clamp (20).

10. Remove air conditioner condenser (21) without


disconnecting the air conditioner hoses.
a Place air conditioner condenser on the track
shoes.
k When disconnecting the air conditioner
hoses, collect the refrigerant, referring to
"Removal and installation of floor frame
assembly".

15. Loosen U-bolt (9) of the aftercooler outlet tube.

16. Disconnect aftercooler outlet tube (8).


[*3]
a Do not loosen hose clamp (MC).

17. Disconnect blade piping (10) and (11).

11. Disconnect oil cooler hose (22).

12. Open the undercover. For details, see "Removal


and installation of engine assembly".

13. Disconnect two hoses (6) for the fan motor.

14. Disconnect radiator outlet tube (7).

D375A-6R 50-51
(01)
Engine and cooling system
Removal and installation of radiator guard assembly

18. Sling the radiator guard assembly, remove the 20. Lift off the radiator guard and blade lift cylinder
lock bolt of the pin, and push rear pin (12) toward assembly (14).
the inside of the radiator guard to remove it by a When removing, take extreme care not to
using tool A7. damage the wiring, pipes, etc.
a Remove the shoe plates to secure a working 4 Radiator guard and blade lift cylinder
space. assembly:
3,300 kg
19. Remove the lock plate and pull front pin (13) (Radiator guard assembly only:)
toward the outside of the radiator to remove it by 2,750 kg)
using tool A7.

Connection 50-52
q Carry out installation in the reverse order to re-
moval.

[*1]
3 Radiator inlet hose clamp:
8.8 0.5 Nm {0.9 0.05 kgm}
[*2]
3 Air vent hose clamp:
3.3 0.5 Nm {0.34 0.05 kgm}

50-52 D375A-6R
(01)
Engine and cooling system
Removal and installation of radiator guard assembly

[*3] q When using a new hose


MIKALOR clamps (MC10), (MC20), and (MC23) a Tighten the clamp so that dimension BDG
a Use a new MIKALOR clamp. is as follows.
1) Set the hose to the original position. MC10: 7 10 mm
(Hose insertion depth: 80 mm) MC20: 17 20 mm
2) Set the clamp with bridge (BR) under the MC23: 20 23 mm
clamp bolt and secure at least 5 mm of
overlap (b) between the bridge and band
(BD).
3) Tighten the clamp.
a Do not use an impact wrench for tighten-
ing.
2 Clamp bolt (BC):
Lubricating oil (Threebond PAN-
DO 18B)
q When reusing the hose
a Install the clamp aligning it with the clamp
mark made on the hose.
3 Clamp bolt (BC):
6 Nm {0.6 kgm} or more
Constant torque clamp (CTC)
3 10.5 0.5 Nm {1.07 0.05 kgm}
(TC): Turbocharger

D375A-6R 50-53
(01)
Engine and cooling system
Removal and installation of radiator guard assembly

q Refilling of coolant
Supply coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
5 Coolant:
120 l

q Refilling of oil (Hydraulic tank)


Supply oil through the oil filler to the specified
level. Run the engine to circulate the oil through
the system. Then, check the oil level again.
5 Hydraulic tank:
130 l

50-54 D375A-6R
(01)
Engine and cooling system
Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler)

Removal and installation of cooling assembly (radiator, after cooler, and


hydraulic oil cooler) 50-5

Removal 50-5 8. Remove clamp (20).


k Park the machine on a level surface and low-
er the work equipment to the ground. 9. Remove air conditioner condenser (21) without
k Set the parking brake lever and work equip- disconnecting the air conditioner hoses.
ment lock lever in the lock position. a Place air conditioner condenser on the track
k Stop the engine and disconnect the cable shoes.
from the negative (-) terminal of the battery. k When disconnecting the air conditioner
k If the radiator coolant temperature is high, hoses, collect the refrigerant, referring to
wait until the temperature decreases to avoid "Removal and installation of floor frame
getting scalded, and then drain the coolant or assembly".
disconnect the radiator hoses.

1. Drain the coolant.


6 Coolant:
120 l
2. Drain the hydraulic oil.
6 Hydraulic oil:
130 l

3. Remove the engine hood assembly. For details,


see "Removal and installation of engine hood
assembly".

4. Disconnect radiator inlet hose (3).


[*1] 10. Open the undercover. For details, see "Removal
and installation of engine assembly".
5. Disconnect air vent hose (4).
[*2]

6. Remove the mounting bolts and disconnect


aftercooler duct (5).
[*3]
a Do not loosen clamp (MC).
7. Disconnect 4 wiring clamps (6) and disconnect
each wiring connector.
q Headlamp intermediate: CN-LHD
q Radiator guard intermediate: CN-RDG
q Fan motor: FAR2
q Horn: CN-HRN
q Radiator coolant level sensor: CN-WLD

D375A-6R 50-55
(01)
Engine and cooling system
Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler)

11. Disconnect hydraulic oil cooler upper hose (7) 15. Remove shroud (22).
and lower hose (7-1).

16. Remove 2 upper mounting bolts (12) on both


12. Disconnect radiator outlet tube (8). right and left sides.

13. Disconnect aftercooler outlet tube (9). 17. Remove lower mounting bolts (12-1) on both
[*4] right and left sides.
a Do not loosen clamp (MC). a Remove the bolts through the fan.

14. Remove radiator mask (10) and remove right 18. Sling and remove cooling assembly (13).
and left fan nets (11). 4 Cooling assembly:
480 kg

50-56 D375A-6R
(01)
Engine and cooling system
Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler)

Connection 50-57
q Carry out installation in the reverse order to re-
moval.
a When installing the cooling assembly, adjust the
direction of windbreaker rubbers (R) so that they
do not get caught.

[*1]
3 Radiator inlet hose clamp:
8.8 0.5 Nm {0.9 0.05 kgm}
[*2]
3 Air vent hose clamp:
3.3 0.5 Nm {0.34 0.05 kgm}

D375A-6R 50-57
(01)
Engine and cooling system
Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler)

[*3][*4] q When using a new hose


MIKALOR clamps (MC10), (MC20) and (MC23) a Tighten the clamp so that dimension BDG
a Use a new MIKALOR clamp. is as follows.
1) Set the hose to the original position. MC10: 7 - 10 mm
(Hose insertion depth: 80 mm) MC20: 17 - 20 mm
2) Set bridge (BR) under the clamp bolt and MC23: 20 - 23 mm
secure at least 5 mm of overlap (b) between
the bridge and band (BD).
3) Tighten the clamp.
a Do not use an impact wrench for tighten-
ing.
2 Clamp bolt (BC):
Lubricating oil (Threebond PAN-
DO 18B)
q When reusing the hose
a Install the clamp aligning it with the clamp
mark made on the hose.
3 Clamp bolt (BC):
6 Nm {0.6 kgm} or more

Constant torque clamp (CTC)


3 10.5 0.5Nm {1.07 0.05 kgm}
(TC): Turbocharger

50-58 D375A-6R
(01)
Engine and cooling system
Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler)

q Refilling of coolant
Supply coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
5 Coolant:
120 l

q Refilling of oil (Hydraulic tank)


Supply oil through the oil filler to the specified
level. Run the engine to circulate the oil through
the system. Then, check the oil level again.
5 Hydraulic tank:
130 l

D375A-6R 50-59
(01)
Engine and cooling system
Removal and installation of radiator

Removal and installation of radiator 50-60

Removal 50-60 7. Remove cushion (7) and plate (8).


k Park the machine on a level surface and low-
er the work equipment to the ground.
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
k Stop the engine and disconnect the cable
from the negative (-) terminal of the battery.
k If the radiator coolant temperature is high,
wait until the temperature decreases to avoid
getting scalded, and then drain the coolant or
disconnect the radiator hoses.

1. Drain the coolant.


6 Coolant:
120 l

2. Remove the radiator upper cover. For details,


see "Removal and installation of engine hood
assembly".

3. Remove stay (1).

8. Sling and remove radiator (9).


4 Radiator:
25 kg

4. Disconnect upper hose (2).

5. Remove front bolts (3) of bracket (6) and remove


mounting bolts (4).

6. Remove collar (5) and bracket (6).

50-60 D375A-6R
(01)
Engine and cooling system
Removal and installation of radiator

Connection 50-61 2) Install collar (5) upside down (with 13 mm


1. Install the radiator unit. side up) and tighten mounting bolt (4).
a Replace O-rings (10) with new ones. a This compresses cushion (7).(L1 o L2)
a Apply detergent (undiluted) to the O-rings. 3) Tighten mounting bolts (3) of bracket (6).
a Remove the fan net and check that the con- 4) Remove mounting bolt (4).
vex part of the radiator is matched with the
concave part of the lower tank, and then in-
stall the radiator securely.

5) Install collar (5) again in the normal direction


(with 6 mm side up).
6) Tighten mounting bolts (4).
2. Install radiator mounting brackets (6) and cush- 7) Check clearance (L3).
ions (7) according to the following procedure. q Clearance (L3): Approx. 7 mm
1) Set plate (8), cushion (7) and bracket (6) on
the mounting boss of radiator (9).
a At this time, fit bracket (6) tightly to the
mounting seat of upper tank (11).
(You may tighten bracket mounting bolts
(3) lightly)

3. Carry out the subsequent installation in the


reverse order to removal.

q Refilling of coolant
Supply coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
5 Coolant:
120 l

D375A-6R 50-61
(01)
Engine and cooling system
Removal and installation of hydraulic oil cooler

Removal and installation of hydraulic oil cooler 50-62

Removal 50-62 4. Open the undercover.


k Park the machine on a level surface and low-
er the work equipment to the ground. 5. Disconnect lower hydraulic oil cooler hose (3).
k Set the parking brake lever and work equip-
ment lock lever in the lock position. 6. Remove the upper and lower mounting bolts and
k Stop the engine and disconnect the cable remove hydraulic oil cooler assembly (4).
from the negative (-) terminal of the battery. 4 Hydraulic oil cooler assembly:
105 kg
1. Drain the hydraulic oil.
6 Hydraulic oil:
130 l
2. Open the left side cover and remove lower side
cover (1).
4 Lower side cover:
40 kg

Connection 50-62
q Carry out installation in the reverse order to re-
moval.

q Refilling of oil (Hydraulic tank)


Supply oil through the oil filler to the specified
level. Run the engine to circulate the oil through
3. Disconnect upper hydraulic oil cooler hose (2). the supply. Then, check the oil level again.
5 Hydraulic tank:
130 l

50-62 D375A-6R
(01)
Engine and cooling system
Removal and installation of aftercooler

Removal and installation of aftercooler 50-63

Removal 50-63 5. Open the undercover.


k Park the machine on a level surface and low-
er the work equipment to the ground. 6. Remove lower mounting bolts (4) of the after-
k Set the parking brake lever and work equip- cooler.
ment lock lever in the lock position.
k Stop the engine and disconnect the cable
from the negative (-) terminal of the battery.

1. Remove the radiator upper cover. For details,


see "Removal and installation of engine hood
assembly".

2. Remove right side stay (1).

3. Remove upper mounting bolts (2) of the after-


cooler.

4. Open the right side cover and disconnect after-


cooler inlet duct (3).
7. Lift off aftercooler (5).
a Loosen the mounting bolts of the aftercooler
4 Aftercooler (one cooler):
that is not being removed, too.
40 kg

Connection 50-63
q Carry out installation in the reverse order to re-
moval.

D375A-6R 50-63
(01)
Engine and cooling system
Removal and installation of engine assembly

Removal and installation of engine assembly 50-64


4. Remove right and left lower side covers (1).
Removal 50-64 4 Left lower side cover:
k Park the machine on a level surface and low- 40 kg
er the work equipment to the ground. Right lower side cover:
k Set the parking brake lever and work equip- 50 kg
ment lock lever in the lock position.
k Stop the engine and disconnect the cable
from the negative (-) terminal of the battery.
k If the radiator coolant temperature is high,
wait until the temperature decreases to avoid
getting scalded, and then drain the coolant or
disconnect the radiator hoses.

1. Drain the coolant.


6 Coolant:
120 l

2. Using sling [1], gradually open the undercover of


the engine and power train.
5. Disconnect starting motor wiring (2) and wiring
clamp (3).

6. Close heater valve (4) and disconnect heater


pipings (5a) and (5b).
7. Disconnect four heater pipe clamps (6).
8. Disconnect nine wiring connectors (7a) to (7g).
9. Disconnect two wiring clamps (8).
10. Remove wiring connector bracket (9).

3. Remove the engine hood assembly. For details,


see "Removal and installation of engine hood
assembly".

50-64 D375A-6R
(01)
Engine and cooling system
Removal and installation of engine assembly

11. Disconnect radiator outlet hose (10) from the


engine.

17. Disconnect wiring connector (17).

12. Loosen locknut (11) and fully tighten belt tension


adjustment bolt (12).
[*1]

13. Remove belt (13).

14. Disconnect air conditioner compressor (14).


a Do not disconnect the air conditioner hoses
from the air conditioner compressor.
a Remove all clamps from the air conditioner
hoses.
a Place air conditioner compressor (14) on the
track shoes.
k When disconnecting the air conditioner
18. Disconnect radiator inlet hose (18).
hoses, collect the refrigerant, referring to [*3]
"Removal and installation of floor frame
assembly". 19. Disconnect air vent hose (19).
[*4]

20. Disconnect aftercooler duct (20) and air hose


(21).
[*5]

15. Disconnect fuel supply hose (15).


[*2]

16. Disconnect fuel return hoses (16a) and (16b).


a Disconnect the hose clamps.

D375A-6R 50-65
(01)
Engine and cooling system
Removal and installation of engine assembly

21. Disconnect aftercooler outlet tube (22).


[*6]
a Loosen clamp (23) and disconnect the tube
at the hose clamping point.

22. Disconnect oil cooler pipes (24) and (25).

6) Disconnect air conditioner hose clamps (38).


(This task is not necessary if the air condi-
tioner hoses are disconnected.)

23. Remove the bulkhead bracket according to the


following procedure.
1) Remove relay protection cover (26) at the
rear of the bulkhead bracket.

7) Sling bulkhead bracket (39) and remove


mounting bolts (40).

2) Disconnect electrical intake air heater relay


wiring (27) to (29).
3) Disconnect wiring connectors PRT2 (30),
SS8A (31) and PRT1 (32).
4) Disconnect wiring clamps (33), (34) and (35).
5) Remove electrical intake air heater relay
bracket assembly (36) and sensor bracket
assembly (37).

50-66 D375A-6R
(01)
Engine and cooling system
Removal and installation of engine assembly

8) While slinging bulkhead bracket (39), discon- 25. Remove dashboard front duct (44).
nect starting motor cable clamps (41) from
bulkhead bracket (39).

26. Sling universal joint (45) and remove the


9) Remove bulkhead bracket (39) and sub tank mounting bolts.
(42) as a unit. [*7]
4 Bulkhead bracket assembly: 4 Universal joint assembly:
250 kg 40 kg

27. Remove front mounting bolts (46) and rear


mounting bolts (47).
[*8]

24. Remove damper case oil level gauge (43) and


the bracket as a unit.

D375A-6R 50-67
(01)
Engine and cooling system
Removal and installation of engine assembly

28. Remove the engine assembly according to the Connection 50-68


following procedure. q Carry out installation in the reverse order to re-

1) Install the lifting tools to parts [A] and [B]. moval.

[*1]
a Install the belt. For details, see Testing and ad-
justing (Part 1), "Replacement and adjusting of
alternator and air conditioner compressor belts".

[*2]
3 Fuel supply hose:
9095 Nm {9.29.7 kgm}

[*3]
3 Radiator inlet hose clamp:
8.8 0.5 Nm {0.9 0.05 kgm}

[*4]
3
2) Sling up engine assembly (48).
4 Engine assembly:
Air vent hose clamp:
3.3 0.5 Nm {0.34 0.05 kgm}
3,320 kg
[*5] [*6]
3) While moving engine assembly (48) toward
MIKALOR clamps (MC10), (MC20) and (MC23)
the front of the machine, operate the chain
a Use a new MIKALOR clamp.
block to raise the front of the engine to slant
1) Set each hose to the original position.
the engine assembly.
(Hose insertion depth: 80 mm)
4) After the front and rear portions of the engine
2) Adjust the position of bridge (BR) so that the
assembly (48) clear the machine body parts
bridge is under the band.
(the aftercooler assembly), turn the engine
a Secure at least 5 mm of overlap (b) be-
assembly toward the right of the machine by
tween the bridge and band (BD).
90 degrees to allow it to clear the blade lift
3) Tighten clamp bolt (BC).
cylinder and cab, and then remove it.
a Do not use an impact wrench for tighten-
a When removing, take care not to damage
ing.
2 Clamp bolt (BC):
the wiring and hoses.
Lubricating oil (Threebond PAN-
DO 18B)
q When reusing the hose
a Install the clamp aligning it with the clamp
mark made on the hose.
3 Clamp bolt (BC):
6 Nm {0.6 kgm} or more
q When using a new hose
a Tighten the clamp so that dimension BDG
is as follows.
MC10: 7 - 10 mm
MC20: 17 - 20 mm
MC23: 20 - 23 mm

50-68 D375A-6R
(01)
Engine and cooling system
Removal and installation of engine assembly

Constant torque clamp (CTC)


3 10.5 0.5 Nm {1.07 0.05 kgm}
(TC): Turbocharger

D375A-6R 50-69
(01)
Engine and cooling system
Removal and installation of engine assembly

[*7]
3 Universal joint mounting bolt:
156.9196.1 Nm {1620 kgm}

[*8]
3 Engine mounting bolt:
8231,029 Nm {84105 kgm}

q Refilling of coolant
Supply coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
5 Coolant:
120 l

50-70 D375A-6R
(01)
Engine and cooling system
Removal and installation of engine hood assembly

Removal and installation of engine hood assembly 50-71

Removal 50-71 5. Remove right cover (3-1) and left cover (3-2).
k Park the machine on a level surface and low-
er the work equipment to the ground. 6. Remove cover (3).
k Set the parking brake lever and work equip-
ment lock lever in the lock position. 7. Remove pre-cleaner cover (4).
k Stop the engine and disconnect the cable
from the negative (-) terminal of the battery.
1. Remove radiator upper inspection cover (1).

2. Disconnect headlamp connector LHD (1-1).

3. Disconnect reservoir tank hose (1-2).

4. Lift off radiator upper cover (2).


4 Radiator upper cover:
80 kg

8. Disconnect connectors EG5 (5-1) and EG4 (5-2)


at the right rear of the hood.

9. Disconnect clamp (5-3) at the right rear of the


hood.

D375A-6R 50-71
(01)
Engine and cooling system
Removal and installation of engine hood assembly

10. Disconnect connector RDG (6) at the front of the 13. Disconnect reservoir tank hose (9) from the
hood. reservoir tank.

14. Disconnect reservoir tank hose clamp (9a).

15. Disconnect duct (10).


16. Remove rear mounting bolts (11).
a Take care not to drop plate NP.

11. Loosen the clamp and remove air cleaner hose


(7).
[*1]
a Securely cover the air cleaner outlet and the
air intake port on the impeller side of the tur-
bocharger to prevent foreign matter from en-
tering.

17. Remove front mounting bolts (12a).


[*2]
12. Remove the bolts and remove KOMACLONE
hose and tube assembly (8) from the muffler.

50-72 D375A-6R
(01)
Engine and cooling system
Removal and installation of engine hood assembly

18. Lift up engine hood assembly (12).


4 Engine hood assembly:
350 kg

Connection 50-73
q Carry out installation in the reverse order to re-
moval.
[*1]
3 Air cleaner hose clamp:
10.5 0.5 Nm {1.07 0.05 kgm}

[*2]
q Install the front mounting bolts according to the
following procedure.
1) Install resin plates (14) so that hood (13) is
sandwitched between them.
2) Install washer (15).
3) Install bolt (16).

D375A-6R 50-73
(01)
Engine and cooling system
Removal and installation of engine front seal

Removal and installation of engine front seal 50-74

Special tools 50-74 4. Remove dust seal (7).

Necessity
Quantity

Sketch
Sym- 5. Remove front seal (8) according to the following

N/R
Part No. Part name
bol procedure.
Seal puller
3 795-931-1100 t 1
assembly
Push tool (for oil
795T-621-1180 t 1 Q
seal)
A
Push tool (for
4 795T-621-1171 t 1 Q
dust seal)
795-902-1460 Bolt t 3
01582-02218 Nut t 3

Removal 50-74
k Park the machine on a level surface and low-
er the work equipment to the ground.
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
k Stop the engine and disconnect the cable
1) Change the end of tool A3 to the hook type
from the negative (-) terminal of the battery.
one.
2) Hitch the hook to the metal ring of front seal
1. Remove the radiator guard assembly. For
(8).
details, see "Removal and installation of radiator
3) Remove the rear seal with impacts of slide
guard assembly".
hammer (SH).
2. Sling damper assembly (1).
q Tool A3
3. Lift off damper assembly (1).
[*1]
4 Damper assembly (1):
40 kg

a CS: Crankshaft

50-74 D375A-6R
(01)
Engine and cooling system
Removal and installation of engine front seal

Connection 50-75
1. Clean, degrease, and dry the contacting surface
against the front cover.

2. Using a clean cloth, remove foreign matter


deposited on the crankshaft flange.
a Clean, degrease, and dry the seal lip sliding
surface (peripheral surface of the crank-
shaft).
a Check that the crankshaft end face corners,
seal lip sliding surface and housing are free
from dents, burrs, rust, oil, grease or water.

3. Install front oil seal (8) according to the following


procedure. 3) Using tool A4 (for dust seal), press fit dust
a Before installing the seal, check that crank- seal (7) to the front cover to dimension (b)
shaft end face corners, seal lip sliding surfac- shown in the figure.
es and housing are free from flaws, burr, fins, a Dust seal press-fitting dimension (b): 2
rust, etc. mm (projection from the front cover end
a When installing the seal, do not apply oil or face)
grease to the crankshaft and seal lip. Wipe
off oil from the crankshaft thoroughly.
1) Install the oil seal directing its side stamped
with "IN" toward the inside of the engine.
a The "OUT" stamped side is directed to-
ward the outside of the engine.

q Carry out the subsequent installation in the re-


verse order to removal.

[*1]
3 Mounting bolt:
a Take care not to install the wrong end. 1st time: 53.993.1 Nm {5.59.5 kgm}
2) Using tool A4 (for oil seal), press fit oil seal 2nd time: 225.4264.6 Nm {2327 kgm}
(8) to the front case to dimension (a) shown 3rd time: 617.4656.6 Nm {6367 kgm}
in the figure.
a Oil seal press-fitting dimension (a): 18.5
mm (when measured from the front cover
end face)

D375A-6R 50-75
(01)
Engine and cooling system
Removal and installation of engine rear seal

Removal and installation of engine


rear seal 50-76

Special tools 50-76 5. Remove rear seal (2).


a Take care not to damage the seal installation

Necessity
Quantity

Sketch
Sym- position on the flywheel housing and the seal

N/R
Part No. Part name
bol contact surface on the crankshaft.
Seal puller assem-
a Before removing, slightly tap the front seal
3 795-931-1100 t 1 once to unstick it.
bly
Push tool a When rear seal (2) is fixed too hard to the fly-
795T-621-1161 (for standard seal t 1 Q wheel housing (FWH), perform the following
A and sleeved seal) procedure.
5
795T-621-1190
Push tool
t 1 Q a The left one in the following figure shows
(for sleeved seal) the standard seal and the right one shows
01050-32235 Bolt t 5 the sleeved seal.
01050-32245 Bolt t 5
1] Change the end of tool A3 to the drill type
one.
Removal 50-76 2] Drill several holes about 3 mm in diameter
k Park the machine on a level surface and low- in rear seal (2).
er the work equipment to the ground. 3] Set tool A3 to the drilled hole.
k Set the parking brake lever and work equip- 4] Remove the rear seal with impacts of
ment lock lever in the lock position. slide hammer (SH).
k Stop the engine and disconnect the cable a If the seal is sleeved, cut and remove sleeve
from the negative (-) terminal of the battery. (5) with a chisel and a hammer.
a Take care not to damage crankshaft (4).
1. Remove the damper assembly. For details, see a Remove all the broken pieces of the rear
"Removal and installation of damper assembly". seal.
2. Remove one of the mounting bolts of flywheel (1)
and install guide bolt [1].
3. Using eyebolt [2], sling flywheel (1) and remove
the remaining mounting bolts.
[*1]
4. Move flywheel (1) toward this side and lift it off.
k Since the socket portion of the flywheel is
shallow, the flywheel may fall suddenly.
Take care not to get your finger caught.
4 Flywheel:
85 kg

q Tool A3

50-76 D375A-6R
(01)
Engine and cooling system
Removal and installation of engine rear seal

Connection 50-7 q Installation procedure for standard seal


a Check the wear of the crankshaft and select the a Do not apply grease, oil, etc. to the seal lip slid-
type of the Teflon seal (laydown lip seal) to in- ing surface.
stall, "standard seal" or "sleeved seal", depend- 1) Set the large inside diameter side (b) of
ing on the wear of the crankshaft. plastic inside cylinder (3) of rear seal (2) to
a If the crankshaft is worn to a degree of luster the end of crankshaft (4).
(you can feel the wear with the pad of your finger a Take care not to install the wrong end of
and the wear depth is a maximum of 10 mm) and the plastic inside cylinder.
there are no scratches, install standard seal A.In
other cases, install sleeved seal B.
a (3): Shows the plastic inside cylinder doubling as
the installation guide.
a (5): Shows the sleeve.
a Do not remove installation guide (3) from rear
seal (2) before installing it.
a Handle rear seal (2) and sleeve (5) as an assem-
bly and never separate them from each other.

2) Hold the metal ring of rear seal (2) with both


hands and push it in firmly.
3) After pushing in the rear seal, remove plastic
inside cylinder (3).
a When removing the inside cylinder, take
care not to damage the seal lip.

a Clean, degrease, and dry the contacting surface


against the flywheel housing.
a Clean, degrease, and dry the seal lip sliding sur-
face (peripheral surface of the crankshaft).
a Check that the crankshaft end face corners, seal
lip sliding surface and housing are free from
burrs, dents, rust, etc.

D375A-6R 50-77
(01)
Engine and cooling system
Removal and installation of engine rear seal

4) Tighten the bolts evenly to press fit rear seal 3) Remove tool A5 (for press fitting the sleeved
(2) until the end face of tool A5 touches the seal) and install tool A5 (for press fitting the
end face of crankshaft (4). standard seal).
a Oil seal press fitting dimension (when 4) Tighten the five bolts evenly to press fit
measured from the crankshaft end face) sleeve and rear seal assembly (6) until the
(a): 20 mm end face of tool A5 (for press fitting the stan-
a After press fitting the rear seal, remove the dard seal) touches the end face of crankshaft
red sealant layer from its periphery. (4).
a Use the bolts (stem length of 45 mm) to
tighten tool A5 (for press fitting the stan-
dard seal) first, and then tighten tool A5
(for press fitting standard seal) with the
bolts (stem length of 35 mm).
a Driving depth of rear seal (a) (from crank-
shaft end face): 20 mm
a After press fitting the rear seal, remove
the red sealant layer from its periphery.

q Installation procedure for sleeved seal


a When installing the rear seal, do not apply oil,
grease, etc. to the crankshaft, the inside cy-
lindrical surface (C) of the sleeve, or the seal
lip surface.
1) Set the sleeve and rear seal assembly (6) to
tool A5 (for press fitting the sleeved seal).
3 Inside surface (C) of sleeve:
Liquid gasket (LG-7)
2) Place sleeve (5) of the rear seal to the end q Carry out the subsequent installation in the re-
face of crankshaft (4) and tighten the five verse order to removal.
bolts evenly to press fit sleeve and rear seal
assembly (6) until the end face of tool A5 [*1]
touches the end face of the crankshaft (4). Flywheel assembly
a If there are 5 punch marks on the head of a bolt,
do not reuse that bolt but replace it.
a Fix the flywheel by using the bolt holes in the fly-
wheel and flywheel housing so that the flywheel
does not turn.
a Tighten the mounting bolts in the order shown in
the figure.
2 Flywheel assembly mounting bolt:
Engine oil (EO30)

50-78 D375A-6R
(01)
Engine and cooling system
Removal and installation of engine rear seal

3 Flywheel assembly mounting bolt: q Measure radial runout and facial runout of the
1st time: 196.1 19.6 Nm {20 2 kgm} flywheel using dial gauge [1].
2nd time: 460.9 19.6 Nm {47 2 kgm} a Standard radial and facial runout:
3rd time: Retighten 90 120 Measurement
Tolerance (mm)
a After tightening, put a punch mark (a) on the bolt items
head to indicate the number of uses.(do not Radial runout 0.13
mark when a new bolt is used). 0.0005 x Diameter of
Facial runout
measuring point

a When the measured value is out of the standard,


determine the cause by disassembling the fly-
wheel.

D375A-6R 50-79
(01)
Engine and cooling system
Removal and installation of fan drive assembly

Removal and installation of fan drive assembly 50-80

Removal 50-80
k Park the machine on a level surface and low-
er the work equipment to the ground.
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
k Stop the engine and disconnect the cable
from the negative (-) terminal of the battery.
1. Drain the hydraulic oil.
6 Hydraulic oil:
130 l

2. Remove radiator mask (1).

5. Remove fan nets (4), (5), and (6).

6. Remove wiring harness clamp (7) and discon-


nect the connector.

3. Remove mark plate (2).

7. Disconnect fan motor pipes (8), (9), and (10).

4. Remove bracket (3).


a Disconnect the horn connector and then re-
move it.

50-80 D375A-6R
(01)
Engine and cooling system
Removal and installation of fan drive assembly

8. Sling and remove fan drive assembly (11). Connection 50-81


[*1] q Carry out installation in the reverse order to re-

4 Fan drive assembly: moval.


200 kg [*1]
a Install the wire to the left and right of the fan a Ensure that position (m) of the reflector tape for
drive, lift it at a point, and pull out it evenly to measuring the fan speed is of the specified di-
remove. mension.
Distance (m) from fan blade end: Max. 5 mm

a After installing the fan, check clearance (l) be-


tween the fan blade and the shroud. If the clear-
ance is larger or smaller than the specified
dimension, adjust it.
Clearance(l): 6(+3/-1) mm

q Refilling (hydraulic tank)


Supply oil through the oil filler to the specified
level. Run the engine to circulate the oil through
the system. Then, check the oil level again.
5 Hydraulic tank:
130 l

D375A-6R 50-81
(01)
Engine and cooling system
Removal and installation of fan motor assembly

Removal and installation of fan motor assembly 50-82

Removal 50-82
k Park the machine on a level surface and low-
er the work equipment to the ground.
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
k Stop the engine and disconnect the cable
from the negative (-) terminal of the battery.
1. Remove the fan drive assembly. For details, see
"Removal and installation of fan drive
assembly".

2. Remove the mounting bolt and lock plate (1).


[*1]

3. Remove nut (2).


[*2]

4. Using puller [1], remove fan (3).


[*3]

5. Remove the four mounting bolts and fan motor


assembly (4).
4 Fan motor assembly:
60 kg

50-82 D375A-6R
(01)
Engine and cooling system
Removal and installation of fan motor assembly

Connection 50-83
q Carry out installation in the reverse order to re-
moval.

[* 1]
Be sure to adjust the hole of lock plate (1) by turning
nut (2) in the tightening direction.

[* 2]
3 Mounting (2):
1,079 1,275 Nm {110 130 kgm}
a After tightening the nut, measure dimension (d)
shown in the following figure.
q Min.: 1.2 mm
q Max.: 3.0 mm

[* 3]
a Wipe off dirt from fitting parts (P) of the fan motor
and fan boss and degrease those parts.

D375A-6R 50-83
(01)
Engine and cooling system
Removal and installation of fuel tank assembly

Removal and installation of fuel tank assembly 50-84

Removal 50-84 7. Remove cover (12).


k Park the machine on a level surface and low-
er the work equipment to the ground.
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
k Stop the engine and disconnect the cable
from the negative (-) terminal of the battery.

1. Remove (1) and (2).

8. Disconnect fuel return hoses (13).

2. Open fuel drain valve (3) to drain fuel.


6 Fuel:
1,200 l (at full)
3. Close fuel stop valve (4), and disconnect fuel
drain hose (5).
4. Remove mounting bolts (7) of filter assembly (6),
and remove filter assembly (6) together with the
fuel hose.
9. Disconnect wiring connector FGS (14) of the fuel
5. Close fuel drain valve (3), and disconnect hose
level sensor.
clamps (8).
6. Remove mounting bolt (10) of bracket (9), and
disconnect fuel drain hose (11).

50-84 D375A-6R
(01)
Engine and cooling system
Removal and installation of fuel tank assembly

10. Remove three mounting bolts (15) from each Connection 50-85
side of the fuel tank.
q Carry out installation in the reverse order to re-
moval.

(Refilling)
Fill fuel through the fuel filler port.
5 Fuel tank:
1,200 l (at full)

11. Lift off fuel tank assembly (16).


4 Fuel tank assembly:
600 kg (tank only)
a Reference: 1,500 kg (when tank is full)

D375A-6R 50-85
(01)
Power train
Removal and installation of damper assembly

Power train 50-86


Removal and installation of damper assembly 50-86

Removal 50-86 4. Remove covers (4), (5) and (6).


k Park the machine on a level surface and low-
er the work equipment to the ground.
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
k Stop the engine and disconnect the cable
from the negative (-) terminal of the battery.

1. Open left and right engine side covers (1) and


lock them.
a Check that they are securely locked.

5. Open undercover (7) slowly using lifting tools [1].

2. Remove cover (2).

3. Remove cover (3).

50-86 D375A-6R
(01)
Power train
Removal and installation of damper assembly

8. Remove oil level gauge (10) and bracket as a


unit.

6. Remove universal joint assembly (8).


[*1]
a Sling the universal joint assembly and lower
it to remove. 9. Remove divider board (11).
4 Universal joint assembly:
40 kg

10. Remove bolt (12) and remove holder (13).


[*2]
7. Loosen drain plug (9) to drain damper case oil. 11. Remove coupling (14).
6 Damper case:
2.1 l

D375A-6R 50-87
(01)
Power train
Removal and installation of damper assembly

12. Remove the damper cover according to the 13. Remove the damper according to the following
following procedure. procedure.
[*3] [*4]
1) Using eyebolt [1] attached to the damper, 1) Sling damper (17) by using eyebolt [4].
sling damper cover (15). 2) Install guide bolts [5].
2) Remove two damper cover mounting bolts k Be sure to use guide bolts to prevent
(16) (marked with a) in the drawing, and the damper from coming off abruptly.
install guide bolts [2]. (M16 x 2 x 200 mm)
k Be sure to use guide bolts to prevent 3) Remove mounting bolts (18), and lift off
the damper cover from coming off damper (17).
abruptly. (M12 x 1.75 x 200 mm) a If it is difficult to remove the damper, use
3) Remove the remaining damper cover forcing screws [3].
mounting bolts (16) (marked with *), and sling a Tighten forcing screws [3] evenly.
down damper cover (15) to remove. 4 Damper assembly:
a If it is difficult to remove the damper cov- 70 kg
er, use forcing screws [3] (M12 x 1.75).
a Install forcing screws [3] at 3 places, and
tighten them evenly.
4 Damper cover:
75 kg

14. If bearing (19) is damaged, remove bearing (19).

50-88 D375A-6R
(01)
Power train
Removal and installation of damper assembly

Connection 50-89 Fill gap (a) at the hatched area in the illustration with
grease (G2-LI) by approximately 50% (11 g).
q Carry out installation in the reverse order to re-
moval.

[*1]
3 Universal joint mounting bolt:
156.8196 Nm{1620 kgm}

[*2]
3 Holder mounting bolt :
245309 Nm{2531.5 kgm}

[*3]
a Install the damper cover according to the follow-
ing procedure.
1) Using guide bolts [2] (M12 x 1.75 x 200 mm),
position the damper cover. (Refilling)
2) Finger-tighten twelve mounting bolts (16) Fill the damper case with oil.
5 Damper case:
(indicated by * mark).
3) Remove guide bolts [2] and finger-tighten the 2.1 l(Engine oil EO-DH)
remaining two bolts.
4) While tightening fourteen mounting bolts
gradually and evenly, press fit bearing (19)
and damper shaft (3) to install.

[*4]
a Using guide bolts [5] (M12 x 2 x 200 mm), posi-
tion the damper.

[*5]

D375A-6R 50-89
(01)
Power train
Disassembly and assembly of damper assembly

Disassembly and assembly of damper assembly 50-90

Disassembly of damper assembly 50-90 6. Remove seals (7) from flanges (2) and (5).
1. Place the damper assembly on block [1].

2. Remove mounting nuts (1) and remove flange


(2) by using forcing screws [2].

Disassembly of damper cover assembly 50-90


1. Remove bearing (8) and oil seal (9) from cover
(10).

3. Remove shaft (3). 2. Remove oil seal (11) from retainer (12).

4. Remove rubbers (4).

5. Using forcing screws [2], remove flange (5) from


body (6).

50-90 D375A-6R
(01)
Power train
Disassembly and assembly of damper assembly

Assembly of damper assembly 50-91


1. Install seals (7) to flanges (2) and (5).
a Install the seal with the lip facing the inside as
shown in the figure.

5. Install flange (2).


2 Mating surface of flange:
Gasket sealant (LG-6)
a Check that the mating faces are free from
2. Install flange (5) to body (6), while matching their dents, rust, oil, grease and water, and apply
bolt holes with each other. the liquid gasket to the surfaces of both the
2 Mating surface of flange: flange and the body.
Liquid gasket (LG-4)
a Check that the mating faces are free from 6. Set the bolts and tighten mounting nuts (1).
dents, rust, oil, grease and water, and apply
the liquid gasket to the surfaces of both the
flange and the body.

3. Place the flange and body assembly on the block


and set shaft (3).

4. Install the rubbers.


a Check the installed positions of large rubber
(4a) and small rubber (4b).
(Install the large rubber to large diameter
side (R) of body (BD) and install the small
rubber to small diameter side (r).)
a When installing the rubbers, apply grease
(G2-LI)) to all surfaces of the rubbers, the
outside of the shaft, and the inside of the
body (BD).
a After installing the rubbers, supply grease
(G2-LI) of approx. 30% (approx. 190 g) to
gaps (CL) (16 places) between the shaft and
body.

D375A-6R 50-91
(01)
Power train
Disassembly and assembly of damper assembly

Assembly of damper cover assembly 50-92


1. Use push tool [3] to press fit oil seal (11) to
retainer (12).
2 Oil seal press-fitting surface:
Liquid gasket (LG-1)
a Apply a thin film of the liquid gasket to the in-
side of the retainer and wipe off any liquid
gasket that is squeezed out.
2 Oil seal lip:
Grease(G2-LI)

2. Press fit bearing (8) to cover (10) by using push


tool [4].

3. Press fit oil seal (9) to cover (10) by using push


tool [5].
2 Oil seal press-fitting surface:
Liquid gasket (LG-1)
a Apply a thin film of the liquid gasket to the in-
side of the cover and wipe off any liquid gas-
ket that is squeezed out.
2 Oil seal lip:
Grease(G2-LI)

50-92 D375A-6R
(01)
Power train
Removal and installation of power train unit assembly

Removal and installation of power train unit assembly 50-93

Removal 50-93
k Park the machine on a level place and lower
the work equipment to the ground complete-
ly.
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
k Release the internal pressure of the hydrau-
lic tank and residual pressure inside piping.
For details, see Testing and adjusting "Re-
leasing residual pressure of hydraulic cir-
cuit".
k Stop the engine and disconnect the cable
from the negative (-) terminal of the battery.

1. Drain the oil from the hydraulic tank.


6 Hydraulic tank:
130 l

2. Remove the fuel tank assembly. For details, see


"Removal and installation of fuel tank assembly."

3. Remove the ROPS guard. For details, see


"Removal and installation of ROPS guard."

4. Remove the operator cab assembly. For details,


see "Removal and installation of operator cab
assembly."

5. Remove the floor frame assembly. For details, 7. Sling universal joint assembly (2) and lower it to
see "Removal and installation of floor frame remove.
assembly". [*1]
4 Universal joint assembly:
6. Using sling [1], open undercover (1) gradually. 40 kg

D375A-6R 50-93
(01)
Power train
Removal and installation of power train unit assembly

8. Disconnect wiring connectors (3) from bracket 12. Disconnect wiring connectors VDA (9), LRR
(3a). (10), FD2 (11), and VDB (12).

9. Disconnect wiring clamps (4) and (5). 13. Disconnect wiring clamps (13) and (14).

14. Remove bracket (15).

10. Disconnect wiring (6) and (7).

15. Disconnect ripper lift hoses (16) and ripper tilt


hoses (17).

11. Disconnect wiring connector 241 (8).

16. Disconnect ripper pin puller hoses (18).

50-94 D375A-6R
(01)
Power train
Removal and installation of power train unit assembly

17. Disconnect hose (19) and clamps (20).

21. Disconnect work equipment hose (29) from the


18. Disconnect return hoses (21) to (24) running to work equipment valve.
the hydraulic tank.

22. Disconnect hose clamps (30) to (33).


19. Disconnect work equipment valve hose (25).

20. Disconnect suction tube (26) from coupling (27)


and flange (28).

D375A-6R 50-95
(01)
Power train
Removal and installation of power train unit assembly

23. Disconnect oil cooler hose (34) on the left side of 26. Remove cover (37).
the torque converter from the torque converter.

27. Pull out left and right drive shafts (39) according
to the following procedure.
24. Disconnect oil cooler hose (35) at the left bottom [*3]
of the power train. 1) Remove cover (38).
2) Install eyebolt [2] to drive shaft (39).
3) Pull out drive shaft (39).
a If the drive shaft cannot be pulled out, push
up the shoe grouser by using jack [3] from the
ground to rotate the sprocket clockwise or
counterclockwise, and set it to a position
where the shaft can be pulled out easily.
a Pull out the shaft until it touches the sprocket.

25. Remove damper oil level gauge (36).

50-96 D375A-6R
(01)
Power train
Removal and installation of power train unit assembly

28. Remove left and right rear mount caps (40). 32. Remove four power train mounting bolts (44)
each on the left and right sides.
[*4]

29. Loosen left and right rear coupling clamps (41).


[*2]
a Reposition the clamp toward the main frame, 33. Lift off power train assembly (45).
and open the coupling to reposition the seal a Install sling to parts [A] and [B] and lift up the
toward the main frame. power train assembly while balancing it hori-
zontally.

30. Remove oil filler tube clamp (42) of the power


train case.

31. Remove bracket (43).

D375A-6R 50-97
(01)
Power train
Removal and installation of power train unit assembly

Installation 50-98 Bleed air from the piping. For details, see
Testing and adjusting "Bleeding air from
q Carry out installation in the reverse order to re- hydraulic circuit".
moval.

a When installing the power train unit assembly,


focus your attention on the mating face of the
coupling in order not to damage the seal of the
coupling.
[* 1]
3 Universal joint mounting bolt:
156.8196 Nm {1620 kgm}

[* 2]
3 Mounting nut of rear coupling clamp:
4.98.82 Nm {0.50.9 kgm}

[* 3]
a If the drive shaft cannot be inserted, push up the
shoe grouser by using a jack from the ground to
rotate the sprocket clockwise or counterclock-
wise, and set it to a position where the shaft can
be inserted easily.

[*4]
a Install left front mount (46a) and right front mount
(46b) of the power train unit with the tap holes (t)
on their side facing the front of the machine.

Refilling of oil (Hydraulic tank)


a Supply oil through the oil filler to the specified
level. Run the engine to circulate the oil through
the system. Then check the oil level again.
5 Hydraulic tank:
130 l(power train oil)

Refilling of oil (Power train case)


a Supply oil through the oil filler to the specified
level. Run the engine to circulate the oil through
the system. Then, check the oil level again.
Reference
Power train case: 150 l(power train oil)

q Bleeding air

50-98 D375A-6R
(01)
Power train
Disconnection and connection of power train unit assembly

Disconnection and connection of power train unit assembly 50-9


Disconnection 50-9
a Before disconnecting the wires and hoses, fit 2) FA2 (7), intermediate connector (8)
them with tags to show their connecting loca-
tions.

1. Lift power train unit assembly (1) and place it on


blocks [1] to [4].
a Use blocks of sufficient height so that the oil
can be easily drained.

2. Drain the oil from the power train case.


6 Power train case:
150 l

3) SLB (9), FLB (10), SRB (11), FRB (12), FRC


(13), SRC (14), FLC (15), SLC (16)

3. Disconnect the following wiring connectors and


remove the wiring.
a Disconnect all the related wiring clamps.
1) SSTC (2), FSTC (3), SLUC (4), FLUC (5),
FA1 (6) 4) STB (17), TM1 (18), TC1 (19)

D375A-6R 50-99
(01)
Power train
Disconnection and connection of power train unit assembly

5) TOP (20), 453 (21)

4. Remove hydraulic hoses (22) to (36).


a Remove hoses (24) and (28) as a unit.

50-100 D375A-6R
(01)
Power train
Disconnection and connection of power train unit assembly

5. Disconnect the fifteen pressure pickup hoses 4) Disconnect transmission gear shift clutch
and remove them together with the central pres- pressure pickup hoses (44) to (48).
sure pickup bracket according to the following (Hose band color)
procedure. 1st (44): Red
1) Remove suction tube (37). 3rd (45): Yellow/Black
2) Remove covers (38) and (39). Reverse (46): Red/Blue
2nd (47): White/Yellow
Forward (48): White/Blue

3) Disconnect steering clutch pressure pickup


hoses (40) and (42) and brake pressure
pickup hoses (41) and (43). 5) Disconnect torque converter output pressure
(Hose band color) pickup hose (49).
Left cluth oil pressure (40): Black (Hose band color): White/Red
Left brake oil pressure (41): White
Right clutch oil pressure (42): White/Black
Right brake oil pressure (43): Yellow

D375A-6R 50-101
(01)
Power train
Disconnection and connection of power train unit assembly

6) Disconnect pressure pickup hoses (50) to 7. Remove the following parts.


(53) connected to the ECMV valves. 1) Oil level gauge (57)
(Hose band color) 2) Oil filler pipe (58)
Transmission main relief pressure (50): 3) Oil filter assembly (59)
Torque converter inlet pressure (51): Blue 4 Oil filter assembly:
Lockup clutch pressure (52): Yellow/Red 120 kg
Stator clutch pressure (53): Yellow/Blue 4) Strainer assembly (60)
4 Strainer assembly:
7) Disconnect power train lubrication pressure 50 kg
pickup hose (54). 5) Work equipment pump assembly (61)
8) Remove pressure pickup hose (55) and pres- 4 Work equipment pump assembly:
sure pickup block (56) as a unit. 110 kg
6) Power train pump and lubrication pump
6. Remove hydraulic tube (88) between the torque assembly (62)
converter and transmission. 4 Power train and lubrication pump
assembly:
40 kg
7) Scavenging pump assembly (63)
4 Scavenging pump assembly:
25 kg
8) Fan pump assembly (64)
4 Fan pump assembly:
80 kg

50-102 D375A-6R
(01)
Power train
Disconnection and connection of power train unit assembly

8. Disconnect the steering case assembly


according to the following procedure.
1) Remove case mounting bolts (65).
2) Remove case (66) and bearing cage
assembly (67) and torque converter speed
sensor (67a) as a unit.
3) Remove shaft (68).
[*1]

9. Disconnect the PTO unit assembly according to


the following procedure.
1) Remove coupling (71).
2) Remove front mount (71a).
4 Front mount:
150 kg

4) Sling steering case assembly (69).


5) Remove two mounting bolts (70) and install
two guide bolts [5].
6) Remove remaining mounting bolts (70).
7) Sling steering case assembly (69) to discon-
nect it. [*2]
4 Steering case assembly:
1,800 kg
a Lift the steering case assembly by 3-point
lifting and disconnect it along the guide
bolts.
a After disconnecting the steering case as-
sembly, remove the guide bolts.
3) Remove bracket (72).

D375A-6R 50-103
(01)
Power train
Disconnection and connection of power train unit assembly

4) Remove eye plates (73), reverse them, and 4] Shorten sling [6] to set "PTO, torque
install them in the same positions at the left converter, and transmission" assembly
and right. (74) upright.

5) Place PTO, torque converter and transmis- 6) Sling oil pan case (75) and remove two
sion assembly (74) on blocks with the PTO mounting bolts (76), eight mounting bolts
unit up according to the following procedure. (77) and four mounting bolts (78).
1] Install slings [6] and [7]. 7) Lift off oil pan case (75).
a Install sling [7] so that its length is ad- [*3]
justable. 4 Oil pan case:
110 kg

2] Shorten sling [7] to slant PTO, torque


converter and transmission assembly
(74).

8) Sling PTO assembly (79).

3] Disconnect sling [6] from the transmission


and connect sling [6] to the PTO unit.

50-104 D375A-6R
(01)
Power train
Disconnection and connection of power train unit assembly

9) Remove retainer (80).


[*4]
a Note the thickness and quantity of the
shims.
10)Remove snap ring (81), then remove spacer
(82).

11)Remove PTO assembly mounting bolts.


12)Lift off PTO assembly.
4 PTO Ass'y:
300 kg

10. Sling torque converter assembly (89) and


remove the 19 mounting bolts.
[*5]
a The upper three mounting bolts are installed
from the transmission side.
11. Lift off torque converter assembly (89).
4 Torque converter assembly:
550 kg

D375A-6R 50-105
(01)
Power train
Disconnection and connection of power train unit assembly

Connection 50-106 3 Steering case mounting bolt:


245309 Nm{2531.5 kgm}
q Carry out connection in the reverse order to dis-
connection.

[*1]
a Check that shaft (68) is inserted in boss (83) at
the end of the transmission input shaft.

[*3]
q When installing the gasket, carefully observe the
following.
a Use a new gasket.
a Check that the mating faces of the case and
. cover are free from dents, rust, oil, grease
and water.
a Apply liquid gasket to both the mating faces
of the case and cover.
2 Mating faces of case and cover:
Gasket sealant (LG-6)
a Apply liquid gasket continuously around the
tap holes and bolt holes as shown in the fig-
ure.
(Positions to apply liquid gasket)
(L1): Intermediate position between inside
face of oil pan case and tap holes or bolt
holes
(L2): Intermediate position between inside
and outside faces of oil pan case
a When installing case (66) and bearing cage as- (Quantity of liquid gasket to apply)
sembly (67), check that shaft (68) is inserted in B x H = 2 to 5 cc
drum (84) of the bearing cage assembly secure-
ly and then install the case mounting bolts. (OUT): Outside of oil pan case
(IN): Inside of oil pan case
(TP): Tap holes
(HL): Bolt holes

[*2]
a When installing steering case (69), install guide
bolts [5] and install the steering case along them.

50-106 D375A-6R
(01)
Power train
Disconnection and connection of power train unit assembly

[*4] 3) Determine the total thickness of the shim


q Adjust the retainer shim according to the follow- pack and select shims to tbe installed in
ing procedure. clearance (a).
1) Install retainer (80) without inserting any a Thickness of shim pack: (a) + 00.05 mm
shim and tighten the mounting bolts to the a Available shims: 0.15 mm?0.2 mm?and
following torque. 0.5 mm
2 Oil seal: 4) Install the shims of the calculated thickness
Grease(G2-LI) and tighten the mounting bolts of retainer
3 Retainer mounting bolt : (80) to the specified torque.
9.8 Nm {1 kgm} 3 Retainer mounting bolt :
2) Using thickness gauges, measure clearance 58.873.5 Nm {67.5 kgm}
(a) between retainer (80) and PTO housing a Determine the quantity and thickness of
(86). the shims so that the thickness is the
a Measure clearance (a) at 4 places (A, B, same on both the left and right sides.
C, and D) on the periphery and calculate a Set shims (87) as shown in the figure so
the average. that they do not block forcing screw tap
holes (H) of retainer (80).

[*5]
3 Torque converter assembly mounting
bolt:
245 to 309 Nm {25 to 31.5 kgm}

Refilling of oil (power train case)


a Supply oil through oil filler to the specified level.
a After installing the power train unit assembly on
the machine, start the engine to circulate the oil
through the system. Then, check the oil level
again.
5 Power train case:
150 l(power train oil)

D375A-6R 50-107
(01)
Power train
Disassembly and assembly of PTO assembly

Disassembly and assembly of PTO assembly 50-108

Disassembly 50-108 3) Using puller [2], remove bearings (5) and (6)
from gear (7).
1. PTO lubrication tube

Sling the PTO assembly and remove lubrication


tube (1).
a Remove the three lubrication tubes installed
on the opposite side, then lower the assem-
ble on blocks with its face to be jointed to the
torque conventer up.

3. Power train pump gear assembly


1) Using forcing screws [1], pull out cover
assembly (8) and lift it off.
2) Using the puller, remove gear assembly (10)
from cover (9).

2. Work equipment pump and PPC pump gear


assembly
1) Using forcing screws [1], pull out cover
assembly (2) and lift it off.
2) Using puller [2], remove gear assembly (3)
from cover (4).

3) Using puller [2], remove bearings (11) and


(12) from gear (13).

50-108 D375A-6R
(01)
Power train
Disassembly and assembly of PTO assembly

4) Reverse the PTO case and remove cover


(14).

4. Scavenging pump gear


1) Remove snap ring (15) from under the PTO
case, then remove gear (16).

4) Remove bearing outer races (21) and (22)


from gear (23).

5. Idler gear assembly


1) Remove plate (17).

6. PTO case
1) Remove race assembly (24) and bearing
outer race (25) as a unit.

2) Reverse the PTO case and remove shaft


assembly (18) by using forcing screws [1].
a Since the bearing outer race and gear as-
sembly come off the bottom of the PTO
case, place wooden blocks under them to
protect them from being damaged.
3) Remove plugs (19) and push out bearing
inner race (20) by using forcing screws.
a After removing the bearing, install the
plugs.

D375A-6R 50-109
(01)
Power train
Disassembly and assembly of PTO assembly

2) Remove bearing inner races (26) and (27) Assembly 50-1 0


from race (28). a Clean all parts, and check them for dirt and dam-
age before installing.
a Make sure that the snap ring is settled in the
groove completely.

1. Bearing
1) Using the push tool, press fit bearing (32) to
the case.
a Drop approx. 6 cc of power train oil
(TO-10 or TO-30) on the bearing and ro-
tate the bearing approximately 10 turns.
2) Install snap ring (31).

3) Remove bearing outer race (29).


4) Remove sleeve (30).

2. PTO case
1) Install sleeve (30) to the case.
a Install the sleeve with the chamfered in-
side edge facing down.
a Expand-fit the sleeve.
7. Bearing 2) Using the push tool, press fit bearing outer
Remove snap ring (31) and bearing (32). race (29).

50-110 D375A-6R
(01)
Power train
Disassembly and assembly of PTO assembly

3) Using the push tool, press fit bearing inner 2) Using push tool[4], press fit bearing inner
races (27) and (26) to race (28). race (20) to the shaft.
3) Fit the O-ring and install shaft assembly (18).

4) Install race assembly (24).


2 Inside surface of race:
4) Reverse the PTO case and install gear
Molybdenum disulphide lubricant assembly (33).
(LM-P) 5) Press fit bearing spacer (34) and bearing
5) Using the push tool, press fit bearing outer inner race (35).
race (25). a Drop approx. 6 cc of power train oil
a Drop approx. 6 cc of power train oil (TO-10 or TO-30) on the bearing and ro-
(TO-10 or TO-30) on the bearing and ro- tate the bearing approximately 10 turns.
tate the bearing approximately 10 turns.

.
3. Idler gear
1) Using push tool [3], press fit bearing outer
races (22) and (21) to gear (23).

D375A-6R 50-111
(01)
Power train
Disassembly and assembly of PTO assembly

6) Install plate (17). 2) Using push tool [5], install bearings (11) and
2 Mounting bolt: (12) to gear (13).
Adhesive (LT-2)
3 Mounting bolt:
110.35 12.25 Nm {11.25 1.25
kgm}

4. Scavenging pump gear


1) Install gear (16).
2 Spline:
Grease(G2-LI)

3) Using push tool [6], press fit gear assembly


(10) to cover (9).
2 Gear spline:
Grease(G2-LI)
4) Hoist cover assembly (8) with the O-ring and
install it to the case.
a If the cover assembly does not fit in the
case, tap its periphery evenly with a plas-
tic hammer to install.
2) Install snap ring (15) from under the PTO a Drop approx. 6 cc of power train oil
case. (TO-10 or TO-30) on the bearing and ro-
tate the bearing approximately 10 turns.
5. Power train pump gear assembly
1) Fit the O-ring and install cover (14).

50-112 D375A-6R
(01)
Power train
Disassembly and assembly of PTO assembly

6. Work equipment pump and PPC pump gear 7. Lubrication tube


assembly Sling the PTO assembly and install lubrication
1) Using push tool [5], press fit bearings (5) and tube (1).
(6) to gear (7). a Install three lubrication tubes also on the op-
posite side.

2) Using push tool [6], press fit gear assembly


(3) to cover (4).
a Set the assembly with the side where the
bearing end face is flush with the gear
end face facing the cover.
2 Gear spline:
Molybdenum disulphide lubricant
(LM-P)
3) Hoist cover assembly (2) with the O-ring and
install it to the case.
a If the cover assembly does not fit in the
case, tap its periphery evenly with a plas-
tic hammer to install.
a Drop approx. 6 cc of power train oil
(TO-10 or TO-30) on the bearing and ro-
tate the bearing approximately 10 turns.

D375A-6R 50-113
(01)
Power train
Disassembly and assembly of torque converter assembly

Disassembly and assembly of torque converter assembly 50-1 4

Special tools 50-1 4 2) Using eyebolts [1], remove lockup clutch and
drive case assembly (4).

New/redesign
Necessity
3) Disassemble the lockup clutch and drive

Quantity

Sketch
Sym-
Part No. Part name case assembly according to the following
bol
procedure.
1] Remove two seal rings (5).
790-413-1010 Bracket t 1 2] Using forcing screws [2], remove input
C Repair stand
790-501-5000 t 1 shaft (6).
(100 V)

Disassembly 50-1 4

q Preparatory work
Set torque converter assembly (56) to tool C.

3] Remove snap ring (7) to remove plate (8).


4] Set the assembly with the clutch housing
side down, and use forcing screws [3] to
remove turbine (9).

1. Torque converter valve assembly


Remove torque converter valve assembly (1).

2. Draining of oil
Remove two drain plugs (2) to drain the oil in the
pump case.
a After draining the oil, tighten the plugs.

3. Lockup clutch and drive case assembly


1) Leaving two mounting bolts (3) in position,
remove other mounting bolts, then place the
assembly with the input shaft side up and
remove the remaining two mounting bolts.

50-114 D375A-6R
(01)
Power train
Disassembly and assembly of torque converter assembly

5] Set the assembly with the clutch housing 10] Remove two discs (16) and one plate (17)
side up and remove housing and piston from drive case (18).
assembly (10) by using eyebolts [4]. a Keep the disc and plate on a flat sur-
a When the assembly is removed, the face so that they do not warp.
piston may fall out, so support it by
hand when removing
6] Remove piston (11) from housing (12).

4. Stator assembly
1) Remove snap ring (19) to remove stator
assembly (20).
7] Remove seal ring (13) from the piston. 2) Disassemble the stator assembly according
8] Remove seal ring (14) from the housing. to the following procedure.
1] Remove snap ring (21) to remove race
(22) from stator (23).

9] Using push tool [5], remove bearing (15)


from the housing.
2] Remove snap ring (24) from stator (23).

5. Pump assembly
1) Remove snap ring (25).
2) Remove pump assembly (26).

D375A-6R 50-115
(01)
Power train
Disassembly and assembly of torque converter assembly

3) Disassemble the pump assembly as follows. 7. Spring


1] Remove retainer (27). Remove spring (33).
2] Remove bearing and guide assembly
(28) from pump (29). 8. Spring, disc, and plate
Remove springs (34), two discs (35), and one
plate (36) in turn.
a Keep the disc and plate on a flat place so that
they do not warp.

9. Pin
Remove pin (37).

3] Remove bearing outer race (30) from


guide (31).

6. Stator clutch housing


Set the assembly with the stator clutch housing
up and remove stator clutch housing (32).

10. Inner gear


Remove snap ring (38) to remove inner gear
(39).

11. Piston
Remove piston (40) from case (41).

50-116 D375A-6R
(01)
Power train
Disassembly and assembly of torque converter assembly

1) Remove seal ring (42) from the piston. 2] Remove snap ring (47) and remove
2) Remove seal ring (43) from the case. bearing inner race (48), bushing (49), and
seal ring (50) from the shaft.
3] Remove seal ring (51), then remove plate
(54).
4] Remove snap ring (53) to remove plate
(54).

12. Stator shaft assembly


1) Tap stator shaft assembly (44) with a plastic
hammer to remove it from case (45).
2) Disassemble the stator shaft assembly
accoring to the following procedure.
1] Using push tool [6], remove shaft 5] Using the push tool [7], remove bearing
assembly (45) from the stator shaft (55).
assembly.

D375A-6R 50-117
(01)
Power train
Disassembly and assembly of torque converter assembly

Assembly 50-1 8 4] Install seal ring (50) to the shaft.


a Clean all parts, and check them for dirt and dam- a After installing the seal ring, apply
age before installing. grease (G2-LI) to securely fix the seal
a Make sure that the snap ring is settled in the ring to the shaft.
groove completely. 5] Using push tool [9], press fit bushing (49).
a When press fitting the bushing, take
q Preparatory work care not to deform it.
Set case (41) to tool C.

6] Using push tool [10], press fit bearing


1. Stator shaft assembly inner race (48).
1) Assemble the stator shaft assembly 7] Install snap ring (47) to fix the bearing
according to the following procedure. inner race.
1] Using the push tool, press fit bearing (55)
to stator shaft (52).
2] Install plate (54) and secure it with snap
ring (53).
3] Install seal ring (51).
a After installing the seal ring, apply
grease (G2-LI) to securely fix the seal
ring to the shaft.

50-118 D375A-6R
(01)
Power train
Disassembly and assembly of torque converter assembly

2) Tap stator shaft (52) with a plastic hammer to a Install the seal ring as shown in the figure
press fit the bearing portion to the case. since it has directional properties.
3) Set shaft (46) to the stator shaft and press fit (P: Direction of pressure)
the bearing portion by using the push tool.
4) Turn over the case and tighten mounting
bolts of the shaft from the case end.
2 Periphery of seal ring:
Grease(G2-LI)
3 Mounting bolt:
66.15 7.35 Nm {6.75 0.75 kgm}

3) Install piston (40) to case (41).


2 Seal ring contact surface:
Grease(G2-LI)

3. Inner gear
Install inner gear (39) and secure it with snap
ring (38).
2. Piston
1) Install seal ring (43) to the case.
2 Periphery of seal ring:
Grease(G2-LI)
a Install the seal ring as shown in the figure
since it has directional properties.
2) Install seal ring (42) to the piston.
2 Periphery of seal ring:
Grease(G2-LI)

D375A-6R 50-119
(01)
Power train
Disassembly and assembly of torque converter assembly

4. Pin 2] Set bearing and guide assembly (28) to


Install pin (37). pump (29), then tap the assembly with a
plastic hammer to press fit the bearing
5. Plate, disc, and spring portion.
Install one plate (36), two discs (35), and spring 3] Install retainer (27).
(34). 2 Mounting bolt:
Adhesive (LT-2)
6. Spring 3 Mounting bolt:
Install spring (33). 66.15 7.35 Nm {6.75 0.75
kgm}
2) Install pump assembly (26).
a When installing the pump, take care not
to damage the seal ring fitted to the shaft.
3) Install snap ring (25).

7. Stator clutch housing


Install stator clutch housing (32).
a Check that the springs are fitted securely in
the holes in the housing and piston.
2 Mounting bolt:
Adhesive (LT-2) 9. Stator assembly
3 Mounting bolt: 1) Assemble the stator assembly according to
110.35 12.25 Nm {11.25 1.25 the following procedure.
kgm} 1] Install snap ring (24) to stator (23).

8. Pump assembly
1) Assemble the pump assembly as follows.
1] Using the push tool, press fit bearing
outer race (30) to guide (31).
a Drop approx. 6 cc of power train oil
(TO-10 or TO-30) on the bearing and
rotate the bearing approximately 10
turns.

50-120 D375A-6R
(01)
Power train
Disassembly and assembly of torque converter assembly

2] Install race (22) to stator (23) and secure 3] Install seal ring (14) to the housing.
it with snap ring (21). 2 Periphery of seal ring:
2) Install stator assembly (20) to the stator Grease(G2-LI)
shaft, and secure it with snap ring (19). 4] Install seal ring (13) to the piston.
2 Periphery of seal ring:
Grease(G2-LI)

10. Lockup clutch and drive case assembly


1) Assemble the lockup clutch and drive case
assembly as follows. 5] Install piston (11) to housing (12).
1] Set turbine (9) to block [11], and set drive 2 Seal ring contact surface:
case (18) to the turbine. Grease(G2-LI)
a When installing, take care not to dam-
age the seal ring.
6] Using eyebolt [4], install housing and
piston assembly (10).
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
110.35 12.25 Nm {11.25 1.25
kgm}

2] Install two discs (16) and one plate (17).

D375A-6R 50-121
(01)
Power train
Disassembly and assembly of torque converter assembly

7] Using the push tool, press fit bearing (15).


8] Install plate (8) and secure it with snap
ring (7).
9] Install input shaft (6).
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
277.0 31.9 Nm {28.5 3.25
kgm}
10] Install two seal rings (5).

11. Torque converter valve assembly


Install torque converter valve assembly (56).
a Tighten the mounting bolts uniformly in turn
and be careful not to tighten them unevenly.
3 Mounting bolt:
49.0 4.9 Nm {5.0 0.5 kgm}

12. Remove the torque converter assembly from


tool C.

2) Using eyebolts [1], install lockup clutch and


drive case assembly (4).
a When installing, match oil groove (a) of
the turbine with drain plugs (2).

3) Tighten mounting bolts (3).


a Check that drain plugs (2) are tightened.
3 Mounting bolt:
53.9 4.9 Nm {5.5 0.5 kgm}
3 Drain plug :
11.25 1.45 Nm {1.15 0.15
kgm}

50-122 D375A-6R
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly

Disassembly and assembly of TORQFLOW transmission assembly 50-123

Special tools 50-123 2. Control valve assembly


1) Remove nut (2-1) from connector (P).

Necessity
Quantity

Sketch
Sym- 2) Remove cover (2).

N/R
Part No. Part name
bol a Note that cover (2) is wired.
790-415-1011 Bracket t 1
1 Repair stand (100
750-501-5000 t 1
V)
2 791-615-1130 Push tool t 1
791-615-1200 Ring assembly t 1
791-615-1210 q Ring 1
3 135-A90-1150 q Bolt 1
D 01580-01008 q Nut 1
01641-51032 q Washer 2
791-615-1101 Ring assembly t 1
791-615-1111 q Ring 1
4 135-A90-1150 q Bolt 1
01580-01008 q Nut 1
01641-51032 q Washer 2
5 799-301-1600 Oil leak tester t 1

3) Remove sleeve (3).


Disassembly 50-123 4) Remove control valve assembly (4).
(G): Gasket
1. Preparatory work
Set transmission assembly (1) to toolD1.

3. Lubrication valve assembly


Remove lubrication valve assembly (5).

D375A-6R 50-123
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly

4. Front case 3) Using eyebolts [2], lift off input shaft and No.
1) Set the transmission assembly with the input 1 carrier assembly (8).
shaft up. 4) Reverse the input shaft and No. 1 carrier
2) Using eyebolts, remove front case (6). assembly and remove seal ring (9).

5. Input shaft and No. 1 carrier assembly 5) Disassemble the input shaft and No. 1 carrier
1) Remove 17 tie bolts (7). assembly according to the following proce-
2) Using forcing screws [1], disconnect input dure.
shaft and No. 1 carrier assembly (8). 1] Remove snap ring (10) and remove No. 2
a Tighten the forcing screws evenly and sun gear (11).
take care not to twist the input shaft and 2] Remove spacer and bearing assembly
No. 1 carrier assembly. (12).

3] Using the push tool, remove ball bearings


(13) and (14) from spacer (15).

50-124 D375A-6R
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly

4] Remove No. 1 sun gear (16).


5] Remove spacer (17).

10] Remove snap ring (24) from housing and


No. 1 carrier assembly (20).
6] Using eyebolt [3], sling housing and No. 1 11] Set the housing and No. 1 carrier
carrier assembly (18) and set it on the assembly on the blocks and remove
blocks. housing (25) from No. 1 carrier assembly
a Lower the input shaft end to the (26) by using push tool [4].
ground and make a clearance of ap-
prox. 20 mm between the "housing
and No. 1 carrier assembly" and the
blocks.
7] Remove snap ring (19).

12] Remove snap ring (27) from housing (25).


13] Reverse the housing and set it on the
blocks and remove seal ring (146).

8] Tap the housing with a plastic hammer to


drop housing and No. 1 carrier assembly
(20) onto the blocks and remove input
shaft assembly (21).
9] Using the press, remove ball bearing (22)
from input shaft (23).

D375A-6R 50-125
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly

14] Using push tool [5], remove ball bearing


(28) from the housing.
15] Remove spacer (29) from No. 1 carrier
assembly (26).

6. No. 1 disc, plates, and springs


1) Remove twelve springs (37).
2) Remove six discs (38), six springs (40), and
five plates (39) in turn to remove the guide
16] Reverse the No. 1 carrier assembly, plate.
remove snap ring (30), and remove collar a Keep the disc and plate on a flat place so
(31). that they do not warp.
17] Reverse the No. 1 carrier assembly, pull
out shafts (33) halfway from carrier (32),
remove balls (34), and remove shafts
(33).
a Take care not to lose the balls and
store them carefully.

7. No. 1 clutch ring gear


Remove No. 1 clutch ring gear (41).

18] Remove gear (34) and thrust washer (34)


from the carrier.
19] Remove needle bearings (36) from gears
(34).

50-126 D375A-6R
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly

8. No. 1 housing 9. No. 2 disc, plate, and spring


1) Using eyebolt [5], remove No. 1 housing 1) Remove twelve springs (47).
assembly (42). 2) Remove six discs (48), five plates (49), and
six springs (50) in turn.
a Keep the disc and plate on a flat place so
that they do not warp.

2) Disassemble the No. 1 housing assembly


according to the following procedure.
1] Remove piston (43) from housing (44).
3) Remove seventeen sleeves (51).

2] Remove seal ring (45) from piston (43).


3] Remove seal ring (46) from housing (44). 4) Remove seal ring (52) from the No. 2 and No.
3 carrier.
5) Remove six torque pins (53).
6) Remove twelve guide pins (54).

D375A-6R 50-127
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly

10. No. 1 ring gear and No. 2 and No. 3 carrier 4] Remove gear (63) and thrust washer (64)
assembly from the carrier.
1) Using eyebolts [6], lift off "No. 1 ring gear, No. 5] Remove needle bearings (65) from gears
2 and No. 3 carrier" assembly (55). (63).
a Since No. 2 and No. 3 carrier (60) is
embedded in No. 1 ring gear (66),
they cannot be disassembled.

2) Disassemble the "No. 1 ring gear, No. 2 and


No. 3 carrier" assembly according to the
following procedure.
1] Remove seal rings (57) and (58). 11. No. 2 ring gear
2] Remove ring (59). Remove No. 2 ring gear (67).

3] Pull out shafts (61) halfway from carrier


(60), remove balls (62), and remove
shafts (61).
a Take care not to lose the balls and
store them carefully.

50-128 D375A-6R
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly

12. No. 2 and No. 3 housing assembly


1) Using eyebolts [7], remove No. 2 and No. 3
housing assembly (68) and the upper and
lower pistons as a unit.
a Bind the lower piston with a wire to pre-
vent it from coming off.

13. No. 3 disc, plate, and spring


1) Remove the guide plate and remove twelve
springs (76).
2) Remove four discs (77), four springs (79),
and three plates (78) in turn.
a Keep the disc and plate on a flat surface
2) Disassemble the No. 2 and No. 3 housing so that they do not warp.
assembly according to the following proce-
dure.
1] Remove pistons (69) and (70) from
housing (71).

14. No. 3 and No. 4 clutch plate


Using eyebolts [8], remove plate (80).

2] Remove seal ring (72) from piston (69).


3] Remove seal ring (73) from piston (70).

4] Remove seal rings (74) and (75) from


housing (71).

D375A-6R 50-129
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly

15. No. 4 disc, plate, and spring


1) Remove three discs (81), three springs (83),
and two plates (82) in turn, and then remove
the guide plate (147).
a Keep the disc and plate on a flat place so
that they do not warp.
2) Remove six torque pins (84).

17. "No. 3 ring gear, No. 4 carrier and No. 5


clutch" assembly
1) Operate tool D1 to turn the transmission
assembly sideways.
2) Remove plate (90).
3) Remove snap ring (91) to remove plate (92).

16. No. 4 housing assembly


1) Using eyebolts [9], remove housing
assembly (85) and the piston as a unit.

4) Remove snap ring (93) and spacer (94).

2) Disassemble the No. 4 housing assembly


according to the following procedure.
1] Remove piston (86) from housing (87).

5) Set the transmission assembly with the No. 4


carrier up.
6) Using eyebolts [10}, sling "No. 3 ring gear,
No. 4 carrier and No. 5 clutch" assembly (95)
and hit the bottom of the output shaft with a
copper hammer to remove.
2] Remove seal ring (88) from piston (86).
3] Remove seal ring (89) from housing (87).

50-130 D375A-6R
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly

7) Disassemble the "No. 3 ring gear, No. 4 6] Using eyebolts [11], remove No. 3 ring
carrier and No. 5 clutch" assembly according gear and No. 4 carrier assembly (101)
to the following procedure. and the No. 4 sun gear as a unit.
1] Remove two seal rings (56) from the 7] Remove No. 4 sun gear (102) from No. 3
housing. ring gear and No. 4 carrier assembly
2] Remove seal ring (118) from the input (101).
shaft.

3] Remove snap ring (96) and remove No. 3


sun gear (97).
4] Remove collar and bearing assembly
(98).

5] Using the push tool, remove ball bearings


(99) from collar (100).

D375A-6R 50-131
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly

8] Reverse the No. 3 ring gear and No. 4


carrier assembly and remove hub (103).
9] Remove seal rings (104) and (105) from
hub (103).

15] Reverse carrier (109) and remove snap


ring (115).
16] Reverse the carrier and remove ball
bearing (119) by using the push tool.
10] Remove snap ring (106) to remove collar a Since No. 4 carrier (109) is embedded
(107) from No. 3 ring gear and No. 4 in No. 3 ring gear (117), they cannot
carrier assembly (101). be disassembled.
11] Remove seal ring (108) from collar (107).

17] Set output shaft and housing assembly


12] Pull out shafts (110) halfway from carrier (118) on the blocks with the output side of
(109), remove balls (111), and remove the output shaft up.
shafts (110). 18] Using the forcing screws, disconnect
a Take care not to lose the balls and input shaft and housing assembly (118)
store them carefully. and remove it by using eyebolts [12].
13] Remove gear (112) and thrust washer a Tighten the forcing screws evenly to
(113) from carrier. disconnect the output shaft and hous-
14] Remove needle bearings (114) from ing assembly.
gears (112).

50-132 D375A-6R
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly

21] Set housing assembly (123) to the press


19] Remove six discs (119), six springs (121), and compress the spring to remove snap
and five plates (120) in turn from housing ring (125) by using tool D2.
(122). a Operate the press slowly to push up
a Keep the disc and plate on a flat sur- the spring evenly.
face so that they do not warp. 22] Remove retainer (126) and spring (127)
from housing (128).

20] Set the output shaft and housing


assembly to the press and remove 23] Remove piston (129) from the housing.
housing assembly (123) from output shaft Remove seal ring (130) from piston (129).
assembly (124) by using push tool [13].
a Set blocks [14] under the housing as-
sembly to prevent the housing assem-
bly from falling out.

D375A-6R 50-133
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly

24] Remove seal ring (131) from housing


(128).
25] Remove snap ring (132) from the
housing.
26] Using the push tool, remove ball bearing
(133) from the housing.

3) Reverse the rear case, remove snap ring


(141), and remove ball bearing (142).

27] Remove snap ring (134) and remove


needle bearings (135) from input shaft
(124).
28] Reverse the output shaft, remove snap
ring (136), and remove roller bearing
(137) from the output shaft.

18. Rear case assembly


1) Remove collar (138) from rear case (139).

2) Remove seal ring (140) from collar (138).

50-134 D375A-6R
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly

Assembly 50-135 2) Reverse rear case (139) and install collar


a Clean all the parts thoroughly (oil holes etc. in (138).
particular), check them for dirt and dents, and a Take care not to get the seal ring caught.
apply engine oil to the sliding parts before install-
ing.
a Apply grease (G2-LI) to each spline.

1. Preparatory work
Set rear case (139) to tool D1.

3. Output shaft assembly


1) Using the push tool, press fit needle bearing
(135) to output shaft (124) and fix it with snap
ring (134).
2) Using the push tool, press fit ball bearing
(142) to the output shaft.
2. Rear case assembly
1) Install seal ring (149) to collar (138).
a Direct the seal ring as shown in the figure
below.
2 Seal ring:
Grease(G2-LI)

3) Install spacer (94) and secure it with snap


ring (93).
2 Inside surface of spacer:
Molybdenum disulphide lubricant
(LM-P)
4) Install plate (90).
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
66.15 7.35 Nm {6.75 0.75 kgm}
5) Install seal ring (118).
2 Seal ring:
Grease(G2-LI)

D375A-6R 50-135
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly

4. "No. 3 ring gear, No. 4 carrier and No. 5


clutch" assembly
1) Assemble the "No. 3 ring gear, No. 4 carrier
and No. 5 clutch" assembly according to the
following procedure.
q When No. 3 ring gear and No. 4 carrier
are supplied individually:
Using tool D3, compress ring (143), set
No. 3 ring gear (117) on No. 4 carrier
(109), and tap No. 3 ring gear (117) with
a plastic hammer to install.
a Check that the ring is fitted securely
into the groove.

6) Reverse rear case (139), set output shaft


assembly (124) to the case, and press fit the
bearing portion by using the push tool.
7) Install snap ring (141).

1] Using the push tool, press fit ball bearing


(116) to carrier (109) and fix it with snap
ring (115).

8) Install plate (92) and secure it with snap ring


(91).

50-136 D375A-6R
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly

2] Reverse the carrier. 7] Install seal rings (105) and (104) to hub
3] Install needle bearings (114) to gears (103).
(112), fit thrust washers (113) to both 2 Seal ring:
sides of the gears, and set them to the Grease(G2-LI)
carrier. 8] Install hub (103) to No. 3 ring gear and
4] Fit balls (111) and install shafts (110) to No. 4 carrier assembly (101).
the carrier. a Take care not to get the seal ring
a Check that each gear rotates smooth- caught.
ly.

9] Using eyebolts [15], install housing (122)


5] Install seal ring (108) to collar (107). to No. 3 ring gear and No. 4 carrier
2 Seal ring: assembly.
Grease(G2-LI)
6] Install collar (107) to No. 3 ring gear and
No. 4 carrier assembly (101), alining its
dowel hole with the dowel pin, and fix it
with snap ring (106).
a Tap the dowel pin fitting portion with a
plastic hammer until the clearance be-
tween the mating faces is eliminated.

D375A-6R 50-137
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly

10] Install six discs (119), six springs (121), 13] Install seal ring (130) to piston (129).
and five plates (120) in turn. a Install the seal ring as shown in the fig-
ure below.
2 Seal ring:
Grease(G2-LI)
14] Install piston (129) to housing (128).
a Take care not to get the spring caught.

11] Using the push tool, press fit ball bearing


(133) to housing (128) and fix it with snap
ring (132).

15] Set springs (127) and retainer (126) to the


housing.
a Set the three springs as shown in the
following figure.
16] Set housing assembly (123) to the press
and compress the spring to install snap
ring (125) by using tool D2.
a Load at installed length of spring:
2,175 N {222 kg}

12] Install seal ring (131) to the housing.


a Install the seal ring as shown in the fig-
ure below.
2 Seal ring:
Grease(G2-LI)

50-138 D375A-6R
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly

17] Using bolt [16], install housing assembly 4) Using eyebolts [17], press fit the bearing
(123). portion of "No. 3 ring gear, No. 4 carrier and
2 Mounting bolt: No. 5 clutch" assembly (95) to the output
Adhesive (LT-2) shaft.
3 Mounting bolt:
176.4 19.6 Nm {18 2 kgm}
18] Install two seal rings (56) to the housing.
2 Seal ring:
Grease(G2-LI)

5. No. 4 sun gear


Install No. 4 sun gear (102).
2 Spline:
Molybdenum disulphide lubricant
(LM-P)
2) Reverse rear case (139) and "No. 3 ring
gear, No. 4 carrier and No. 5 clutch"
assembly (95).

3) Using eyebolts [10], set "No. 3 ring gear, No.


4 carrier and No. 5 clutch" assembly (95) to
the rear case and output shaft.
a Take care not to get the seal ring caught.

6. No. 3 sun gear


1) Using the push tool, press fit ball bearing (99)
to collar (100).
2 Spline:
Molybdenum disulphide lubricant
(LM-P)

D375A-6R 50-139
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly

2) Install collar and bearing assembly (98). 3) Install piston (86) to housing (87).
a Install the assembly with collar flange a Take care not to get the seal ring caught.
side up.
3) Install No. 3 sun gear (97) and secure it with
snap ring (96).
2 Spline:
Molybdenum disulphide lubricant
(LM-P)

4) Using eyebolts [9], install No. 4 housing


assembly (85) aligning the dowel holes with
the dowel pins.
a Tap the dowel pin fitting portions with a
plastic hammer until the clearance be-
tween the mating faces is eliminated.
7. No. 4 housing assembly
1) Install seal ring (89) to housing (87).
a Direct the seal ring as shown in the figure
below.
2 Seal ring:
Grease(G2-LI)
2) Install seal ring (88) to piston (86).
a Direct the seal ring as shown in the figure
below.
2 Seal ring:
Grease(G2-LI)

8. No. 4 disc, plate, and spring


1) Install six torque pins (84).
a Torque pin length: 162 mm
2) Install guide plate (147), and install three
discs (81), three springs (83) and two plates
(82) in turn.

50-140 D375A-6R
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly

9. No. 3 and No. 4 clutch plate 11. No. 1 ring gear and No. 3 housing assembly
Using eyebolts [8], install plate (80) aligning the 1) Install seal rings (74) and (75) to housing
dowel holes with the dowel pins. (71).
a Tap the dowel pin fitting portions with a plas- a Install the seal ring as shown in the figure.
tic hammer until the clearance between the 2 Seal ring:
mating faces is eliminated. Grease(G2-LI)

10. No. 3 disc, plate, and spring 2) Install seal ring (73) to piston (70).
1) Install four discs (77), four springs (79), and a Direct the seal ring as shown in the figure.
three plates (78) in turn. 2 Seal ring:
2) Install twelve guide pins (54). Grease(G2-LI)
a Guide pin length: 360 mm 3) Install seal ring (72) to piston (69).
3) Install twelve springs (76) and install the a Direct the seal ring as shown in the figure.
guide plate. 2 Seal ring:
a Spring free length: 97 mm Grease(G2-LI)

D375A-6R 50-141
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly

4) Install pistons (70) and (69) to housing (71). 13. "No. 1 ring gear and No. 2 and No. 3 carrier"
a Take care not to get the seal ring caught. assembly
a Bind piston (70) with a fine wire to prevent 1) Assemble the "No. 1 ring gear and No. 2 and
it from falling when the housing is lifted No. 3 carrier" assembly according to the
up. following procedure.
q When No. 1 ring gear, No. 2 and No. 3
carrier are supplied individually:
Using tool D4, compress ring (144), set
No. 1 ring gear (66) on No. 2 and No. 3
carrier (60), and tap No. 1 ring gear (66)
with a plastic hammer to install.
a Check that the ring is fitted securely into
the groove.

5) Install housing assembly (68) aligning the


dowel holes with the dowel pins.
a Tap the dowel pin fitting portions with a
plastic hammer until the clearance be-
tween the mating faces is eliminated.

1] Install needle bearings (65) to gears (63),


fit thrust washers (64) to both sides of the
gears, and set them to carrier (60).

12. No. 2 ring gear


Install ring gear (67).

50-142 D375A-6R
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly

2] Fit balls (62) and install shafts (61) to the 2) Using eyebolts [6], install "No. 1 ring gear,
carrier. No. 2 and No. 3 carrier" assembly (55).
a Check that each gear rotates smooth- a Take care no to get the seal ring caught.
ly.

3) Using push tool [18], press fit the bearing


3] Install ring (59) to the carrier. portion of "No. 1 ring gear and No. 2 and No.
a Check that the ring is fitted securely 3 carrier assembly" (55).
into the groove.
4] Install seal rings (58) and (57) to the
carrier.
2 Seal ring:
Grease(G2-LI)
a Align seal ring (58) with the carrier and
fix it with grease(G2-LI).

14. No. 2 disc, plate, and spring


1) Install six torque pins (53).
a Torque pin length: 199 mm
2) Install seal ring (52) to the No. 2 and No. 3
carrier.
2 Seal ring:
Grease(G2-LI)

D375A-6R 50-143
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly

3) Install 17 sleeves (51). 15. No. 1 housing assembly


1) Install seal ring (46) to housing (44).
a Install the seal ring as shown in the figure.
2 Seal ring:
Grease(G2-LI)
2) Install seal ring (45) to piston (43).
a Direct the seal ring as shown in the figure.
2 Seal ring:
Grease(G2-LI)

a Install sleeve (51) into the bolt hole


marked with *, with the slit (part S) down.

3) Install piston (43) to housing (44).


a Take care not to get the seal ring caught.

4) Install twelve springs (47).


a Spring free length: 70 mm
5) Install six discs (48), six springs (50), and five
plates (49) in turn.
a Align the notches of the oil grooves on the
periphery of the discs.

50-144 D375A-6R
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly

4) Using eyebolts [5], install housing (42) 17. No. 1 disc, plate, and spring
aligning the dowel holes with the dowel pins. 1) Install the guide plate and install twelve
a Check that the springs are fitted securely springs (37).
into the grooves of the housing. a Spring free length: 66 mm
a Tap the dowel pin fitting portions with a 2) Install six discs (38), six springs (40), and five
plastic hammer until the clearance be- plates (39) in turn.
tween the mating faces is eliminated.

18. Input shaft and No. 1 carrier assembly


16. No. 1 clutch ring gear 1) Assemble the input shaft and No. 1 carrier
Install No. 1 clutch ring gear (41). assembly according to the following proce-
dure.
1] Install needle bearings (36) to gears (34),
fit thrust washers (35) to both sides of the
gears, and set them to carrier (32).

D375A-6R 50-145
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly

2] Fit balls (34) and install shafts (33) to the


carrier.
3] Install collar (31) to the carrier and secure
it with snap ring (30).

8] Using the press, install ball bearing (22)


to input shaft assembly (23).
9] Set housing and No. 1 carrier assembly
(20) to the blocks.
4] Using push tool [19], press fit ball bearing 10] Using eyebolt [3], install input shaft
(28) to plate (25) and fix it with snap ring assembly (18) to the housing and No. 1
(27). carrier assembly.

5] Reverse the plate and install seal ring 11] Install snap ring (19).
(146).
a Align seal ring with the plate and fix it
with grease (G2-LI).
6] Install spacer (29) to No. 1 carrier
assembly (26).

12] Turn the input shaft and No. 1 carrier


assembly sideways and install spacer
(17).
13] Install No. 1 sun gear (16).
7] Set plate (25) to No. 1 carrier (26), press 2 Spline:

fit the bearing portion with push tool [20] Molybdenum disulphide lubri-
and fix it with snap ring (24). cant (LM-P)

50-146 D375A-6R
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly

a Align seal ring with the carrier and fix


it with grease (G2-LI).
2) Reverse input shaft and No. 1 carrier
assembly (8) and set it to the No. 1 housing
by using eyebolt [2].
a Take care not to get the seal ring caught.
a Lower the input shaft slowly while check-
ing that its end does not interfere with the
output shaft bearing.

14] Using the push tool, press fit ball bearings


(13) and (14) to spacer (15).

3) Evenly tighten four tie bolts (12) diagonally.


4) Tighten remaining tie bolts (12).
3 Tie bolt:
259.7 14.7 Nm {26.5 1.5 kgm}

15] Install spacer and bearing assembly (12).


a Install the assembly with the small-di-
ameter bearing toward the No. 1 sun
gear.
2 Spline:
Molybdenum disulphide lubri-
cant (LM-P)
16] Install No. 2 sun gear (11) and secure it
with snap ring (10).
2 Spline:
Molybdenum disulphide lubri-
cant (LM-P) 19. Checking piston stroke
Using tool D5, check the stroke of each clutch
piston.
a Air pressure: 490 588 kPa {5 6 kg/cm2}
a Standard stroke of piston
Piston No. 1 No. 2 No. 3 No. 4 No. 5
Stroke (mm) 6.7 7.0 5.6 4.7 7.0

17] Install seal ring (9) to the No. 1 carrier.

D375A-6R 50-147
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly

21. Output shaft bearing


1) Set the transmission assembly with the
output shaft side up.
2) Using the push tool, press fit roller bearing
(137) to the output shaft and fix it with snap
ring (136).
a Take care not to hit or scratch the cage or
rollers of the bearing.
Use a push tool of a size which pushes
only the outer race.

20. Front case


Install front case (6) with the O-ring by using the
eyebolts.
a Lower the front case gradually while check-
ing that it does not interfere with other parts.

22. Lubrication valve assembly


Install lubrication valve assembly (5).

50-148 D375A-6R
(01)
Power train
Disassembly and assembly of TORQFLOW transmission assembly

23. Control valve assembly (OUT): Outside face of cover


1) Install gasket (G) to the control valve. (IN): Inside face of cover
3 Mounting bolt: (HL): Bolt holes
49.0 4.9 Nm {5.0 0.5 kgm}
2) Install the O-rings to sleeves (3).
2 All O-rings:
Grease(G2-LI)

3) Install nut (2-1) to connector cover (2).


2 Nut:
39.6 42.4 Nm {4.0 4.3 kgm}
4) Install cover (2).
a Check that the mating faces of the case
and cover (2) are free from dents, rust, oil,
grease and water.
2 Both mating faces of case and cov-
er (2):
Gasket sealant (LG-6)
a Apply liquid gasket continuously around
the bolt holes as shown in the figure.
(Positions to apply liquid gasket)
(L1): Intermediate position between bolt
holes and inside face of cover
(L2): Intermediate position between
inside and outside faces of cover
(Quantity of liquid gasket to apply)
B x H = 2 - 5 cc

D375A-6R 50-149
(01)
Power train
Disassembly and assembly of steering case assembly

Disassembly and assembly of steering case assembly 50-150

Disassembly 50-150
1. Clutch and brake assembly
1) Using the eyebolts, sling the clutch and brake
assembly. Remove the mounting bolts to
remove clutch and brake assembly (3).
a Remove the clutch and brake assembly
from the opposite side in the same way.
a When removing the clutch and brake as-
sembly, take care not to scratch or dam-
age discs and plates.

5] Reverse the clutch and brake assembly.


Using eyebolts [3], separate clutch
assembly (9) from brake assembly (10).

2) Remove the clutch and brake assembly as


follows:
1] Remove plate (4), then remove collar (5).
2] Remove plate (6).

3) Disassemble the clutch assembly as follows:


1] Remove stopper (11).
2] Remove discs (12), springs (13), and
plates (14) in turn.
a Keep the disc and plate on a flat sur-
face so that they do not warp.

3] Using forcing screws [1], remove sleeve


(7).
4] Using puller [2], pull out bearing inner
race (8) from the sleeve.

50-150 D375A-6R
(01)
Power train
Disassembly and assembly of steering case assembly

3] Remove torque pin (15).


4] Using eyebolts, remove clutch hub (16).
5] Using forcing screws [4], remove plate
(17).

10] Remove clutch cage (27) by using


eyebolts.
11] Remove seal ring (28) from the clutch
cage.
6] Remove outer race (18) from the plate. 12] Remove piston (29).
7] Remove bearing and cage assembly 13] Remove seal ring (30) from the piston.
(19).

14] Remove bearing outer race (31) from the


8] Remove plate (20) and nut (22) from cage clutch cage.
(20). 15] Remove Belleville springs (32).
9] Remove bearing and inner race (23),
spacers (24) and (25), and bearing outer
race (26).

D375A-6R 50-151
(01)
Power train
Disassembly and assembly of steering case assembly

16] Using eyebolts [6], remove brake hub


(33).
17] Remove bearing (34) from the brake hub.

8] Remove Belleville springs (45).

4) Disassemble the brake assembly as follows:


1] Remove stopper (35).
2] Remove discs (36), springs (37), and
plates (38) in turn.
a Keep the disc and plate on a flat sur-
face so that they do not warp.

2. Shaft
Remove right and left shafts (46).

3] Using eyebolts [7], remove brake cage


(39).
4] Remove bearing outer race (40) and seal
ring (41) from the brake cage.

5] Remove torque pin (42).


6] Remove piston (43).
7] Remove seal ring (44) from the piston.

50-152 D375A-6R
(01)
Power train
Disassembly and assembly of steering case assembly

3. Lubrication tube 6. Transfer and gear housing assembly


Remove lubrication tubes (47), (47-1), and 1) Install guide bolts [8] to housing assembly
(47-2). (50). Lift off the housing assembly by using
eyebolts [9].
2) Disassemble transfer and gear housing
assembly (50) as follows:
1] Place the transfer and gear assembly
onto blocks.
2] Remove lubrication tubes (51).

4. Pipe
1) Remove right and left pipes (48).
2) Remove pipe (49).

3] Using the push tool, remove bearing (53).


4] Remove drive gear (54).

5. Steering control valve and seat assembly


Remove steering control valve and valve seat
assembly (2).
4 Steering control valve and valve seat
assembly:
75 kg
a Check that lubrication tubes are already re-
moved.

D375A-6R 50-153
(01)
Power train
Disassembly and assembly of steering case assembly

5] Using puller [10], remove bearing inner


races (55) on both sides. 13] Remove collar (63) from gear (64).
6] Remove lubrication tubes (56). 14] Using push tool [13], remove bearing
outer races (65) and (69), bearing inner
races (66) and (67), and collar (68).

7] Using eyebolt [11], remove pinion


housing assembly (57).
a Note the quantity and thickness of the 15] Remove bearing (70) from the case.
shims for installation purpose. 16] Remove bearing (71) from the case.
8] Using forcing screws, remove cover (58).
9] Remove holder (59).

10] Pull out pinion gear (60) by pressing the


pinion shaft with the press.
11] Remove the holder, and remove bearing
inner race (61) from pinion gear (60) by
using puller [12].
12] Remove cage and bearing assembly
(62).

50-154 D375A-6R
(01)
Power train
Disassembly and assembly of steering case assembly

7. Right cage 2] Using puller [15], remove bearing inner


1) Turn the steering case to put the right cage races (77) and (78) from the shaft.
up.
2) Remove cage and bearing assembly (72). 9. Left cage
a Note the quantity and thickness of the 1) Turn the steering case to set the left side of
shims for installation purpose. the case up, and remove cage and bearing
3) Remove the bearing outer race from the assembly (79).
cage bearing assembly. a Note the quantity and thickness of shims
4) Using eyebolts [14], remove cage (73). for installation purpose.

8. Bevel gear and shaft assembly 2) Remove bearing outer race (80) from the
1) Remove bevel gear and shaft assembly (74) cage and bearing assembly.
by using eyebolts.
2) Disassemble the bevel gear and shaft
assembly (74) as follows.
1] Pull out the reamer bolts, and remove
bevel gear (75) from shaft (76).

D375A-6R 50-155
(01)
Power train
Disassembly and assembly of steering case assembly

Assembly 50-156 2. Bevel gear and shaft assembly


a Clean all parts, and check them for dirt and dam- 1) Assemble the bevel gear and shaft assembly
age before installing. as follows:
a Apply engine oil to the rotating part of the bear- 1] Press fit bearing inner races (78) and (77)
ing, and rotate it several times. by using push tool [16].
a Also, apply engine oil to the sliding parts before 2] Set bevel gear (75) to shaft (76), and
installing. secure them by tightening the reamer
a Make sure that the snap ring is settled in the bolts.
groove completely. 3 Reamer bolt :
274.4 29.4 Nm {28 3 kgm}
1. Left cage 2) Install bevel gear and shaft assembly (74) by
1) Using the push tool, press fit bearing outer using eyebolts.
race (80).
2) Install the shims and install cage and bearing
assembly (79).
a Standard thickness of shim: 2 mm
3 Cage and bearing assembly mount-
ing bolts:
176.4 19.6 Nm {18 2 kgm}

3. Right cage
1) Using eyebolts [14], install cage (73).

50-156 D375A-6R
(01)
Power train
Disassembly and assembly of steering case assembly

2) Install the shims and install cage and bearing 3] Press fit bearing outer race (69) into the
assembly (72). cage by using the push tool.
a Standard thickness of shims: 2 mm 4] Install bearing inner races (67) and (66),
3 Cage and bearing assembly mount- and collar (68).
ing bolts: 5] Using the push tool, press fit bearing
176.4 19.6 Nm {28 2 kgm} outer race (65).

4. Preload adjustment 6] Press fit inner race (61) to pinion gear


Adjust the rotating force of the bevel gear shaft (60) by using push tool [18].
by adjusting the thickness of shims on the cage. 7] Install the holder.
a Rotate the bevel gear two or three times, and 3 Holder mounting bolt :
place the push-pull scale onto the tip of the 276.85 31.85 Nm {28.25 3.25
gear teeth to measure the force. kgm}
a Rotating force (when bevel gear is not en- 8] Install gear (64) and collar (63) to the
gaged): pinion gear.
4.9 5.88 N {0.5 0.6 kg} 2 Spline of gear:
(Rotating torque: 23.52 28.42 Nm {2.4 Molybdenum disulphide lubri-
2.9 kgm}) cant (LM-P)

5. Transfer and gear housing assembly


1) Assemble the transfer and gear housing
assembly according to the following proce-
dure.
1] Press fit transfer gear bearing (71) into
the case by using push tool [16].
2] Using push tool [17], press fit pinion
bearing (70) into the case.

D375A-6R 50-157
(01)
Power train
Disassembly and assembly of steering case assembly

9] Using push tool [19], press fit cage and 12] Check clearance (A) between the cover
bearing assembly (62). and cage, and check that it is as follows.
10] Install holder (59). a Clearance (A): 0.48 0.27 mm
3 Holder mounting bolt : a Make sure that the variation of entire
276.85 31.85 Nm {28.25 3.25 periphery is 0.05 mm maximum, bear-
kgm} ings have been press fitted completely
and are not at an angle.

11] Tighten the mounting bolts of cover (58)


in the order shown in the following figure 13] Tighten the mounting bolts of cover (58)
and to the torque shown below, to install to the specified toque in the following
the cover temporarily. order.
3 Mounting bolt: 3 Mounting bolt:

49 Nm {5 kgm} 66.15 7.35 Nm {6.75 0.75


kgm}

50-158 D375A-6R
(01)
Power train
Disassembly and assembly of steering case assembly

14] Install the shims to pinion housing 18] Press fit bearing (53) by using push tool
assembly (57), and install the housing by [21].
using eyebolts [11]. 19] Install bearing assembly (52) to the case.
a Standard thickness of shims: 2 mm 20] Install lubrication tube (51) and the block
15] Install lubrication tube (56). as a unit.

16] Press fit bearing inner race (55) to both 2) Install guide bolt [8] to the steering case.
sides of the drive gear by using push tool Using eyebolts [9], install transfer and gear
[20]. housing assembly (50) in position.
17] Set drive gear (54) to the case. 3 Mounting bolt:
2 Spline of gear: 276.85 31.85 Nm {28.25 3.25
Molybdenum disulphide lubri- kgm}
cant (LM-P)

D375A-6R 50-159
(01)
Power train
Disassembly and assembly of steering case assembly

6. Adjusting backlash and gear tooth contact 2] When backlash is too large
1) Adjusting backlash Adjust the thickness of the shim pack for
Testing the bevel pinion to move it in direction (C).
Apply the probe of dial gauge [22] to the tooth Or, adjust the thickness of the shim packs
surface at the top of the bevel gear at right for the bearing cages of the bevel gear
angle to the surface. Holding the bevel pinion shaft to move the bevel gear in direction
stationary, wiggle the bevel gear forward and (D).
and backward, and read the gauge at this a When adjusting the thickness of the shim
time. packs for the bearing cages of the bevel
a Standard backlash: 0.3 0.4 mm gear shaft, if the thickness of the shim
a Measure the backlash at diagonal three pack on one side is decreased, increase
points or more. the thickness on the other side by the
same quantity and vice versa, in order not
to change the preload of the bearings.

Adjustment
If the measured backlash is out of the stan-
dard range, adjust it according to the 2) Adjusting tooth contact
following procedure: Testing
1] When backlash is too small 1] Apply red lead thinly to the tooth surfaces
Adjust the thickness of the shim pack for of the bevel pinion and turn the bevel gear
the bevel pinion to move it in direction (A). in the forward and reverse directions,
Or, adjust the thickness of the shim packs then check the tooth contact pattern left
for the bearing cages of the bevel gear on tooth surfaces of the bevel gear.
shaft to move the bevel gear in direction (Be): Big end
(B). (Se): Small end
(Rt): Root of tooth
(Tt): Top of tooth

50-160 D375A-6R
(01)
Power train
Disassembly and assembly of steering case assembly

2] The standard values for the tooth contact


are as follows:
(From the small end of the bevel gear)
a) Width of tooth contact: 30 75%
b) Center of tooth contact: 25 50%
c) Position of tooth contact: 25 50%
a The standard values for the tooth contact
must be satisfied under the following con-
ditions; the taper roller bearings support-
ing the bevel gear are given with the
preload, the bevel gear is meshed only
with the bevel pinion, and no load is ap-
plied.
a Check that the center of tooth contact is at
the center of the tooth height and there is 2] If the bevel pinion is too close to the
not a strong contact at the dedendum. center line of the bevel gear, the contacts
The contact pattern must be made in are at the convex faces close to the big
almost the same position when the bevel end and concave faces close to the small
gear is rotated in forward and reverse end of the bevel gear.
directions. [Adjustment]
(Be): Big end The adjustment is the same as that
(Se): Small end described in step 1] except for reversed
direction (A) of the bevel pinion and for
reversed direction (B) of the bevel gear.
a When changing the position of the bevel
gear, if the thickness of the shim pack on
one side is decreased, increase the thick-
ness on the other side by the same quan-
tity and vice versa, in order not to change
the preload of the bearings.

Adjustment
If the tooth contact pattern is not proper,
adjust the tooth contact according to the
following procedure.
1] If the bevel pinion is too far from the
center line of the bevel gear, the contacts
are at the convex faces colse to the samll
end and at the concave faces close to the
big end of the bevel gear.
[Adjustment]
Adjust the thickness of the shim pack for
the bevel pinion to move the bevel pinion
in direction (A) .
Also move the bevel gear in direction (B)
by adjusting the thickness of the shim
packs for bearing cages of the bevel gear
shaft, then check the tooth contact
pattern and backlash again.

D375A-6R 50-161
(01)
Power train
Disassembly and assembly of steering case assembly

7. Steering control valve and seat assembly 10. Lubrication tube


1) Install the steering control valve and valve Install lubrication tubes (47), (47-1), and (47-2).
seat assembly (2).
2) As for the mounting bolts, tighten them after
installing pipes (48) described in the next
step.
q Mounting bolt:
49.0 4.9 Nm {5.0 0.5 kgm}

11. Clutch and brake assembly


1) Assemble the clutch and brake assembly as
follows:
1] Install Belleville springs (45).
a Set the belleville springs back to back
to install.
8. Pipes 2] Install seal ring (44) to piston (43).
1) Install pipe (49).
2) Install right and left pipes (48).

3] Install piston (43).


4] Install torque pins (42).
9. Shaft 5] Install seal ring (41) and bearing outer
Install right and left shafts (46). race (40) to the brake cage by using the
push tool.

.
6] Using eyebolts [7], install brake cage
(39).

50-162 D375A-6R
(01)
Power train
Disassembly and assembly of steering case assembly

3 Mounting bolt: 2] Install brake hub (33) to the clutch


110.25 12.25 Nm {11.25 1.25 housing by using eyebolts [6].
kgm} 3] Install Belleville springs (32).
7] Install plates (38), springs (37), and discs a Set the Belleville springs back to back
(36). to install.
a Check that a mating face between the
disc and plate is free from scratches
and foreign materials. Then, apply a
thin film of engine oil to the surfaces
before installing.

4] Install outer race (31) to the clutch cage.


5] Install seal ring (30) to the piston.
6] Install piston (29).

8] Install stopper (35).


3 Mounting bolt:
276.85 31.85 Nm {28.25 3.25
kgm}
2) Assemble the clutch assembly as follows:
1] Using the push tool, install bearing (34) to
the brake hub.

7] Install seal ring (28) to the clutch cage.


8] Using eyebolts, install clutch cage (27) to
the housing.

9] Install bearing inner race (26), spacers


(25) and (24), and bearing inner race (23)
to cage (20).
10] Tighten nut (22) and install plate (21).

D375A-6R 50-163
(01)
Power train
Disassembly and assembly of steering case assembly

a Using the push tool, hold the cage 13] Install plate (17).
with the press, and use a hook wrench 3 Mounting bolt:
to tighten the nut. 110.25 12.25 Nm {11.25 1.25
kgm}
14] Set the guide bolts to the housing.
15] Using eyebolts, install clutch hub (16).
a Check that the rotating force of the
housing is 29.4 N {3 kg} or less and
that the housing rotates smoothly.
16] Install torque pins (15).

17] Install plates (14), springs (13), and discs


(12) in turn.
a Check that a mating face between the
disc and plate is free from scratches
and foreign materials. Then, apply a
thin film of engine oil to the surfaces
before installing.
18] Install stopper (11).
3 Mounting bolt:
11] Install bearing and cage assembly (19).
12] Using the push tool, install outer race (18)
276.85 31.85 Nm {28.25 3.25
to the plate.
kgm}

50-164 D375A-6R
(01)
Power train
Disassembly and assembly of steering case assembly

3) Connect the clutch assembly to the brake 4] Install plate (6).


assembly as follows: 3 Mounting bolt:
1] Using eyebolts [13], install brake 110.25 12.25 Nm {11.25 1.25
assembly (10) to clutch assembly (9). kgm}
2] Press fit bearing inner race (8) to the 5] Fit collar (5) and install plate (4).
sleeve by using push tool [14]. 4) Using the eyebolts, install the clutch and
brake assembly.
3 Mounting bolt:
276.85 31.85 Nm {28.25 3.25
kgm}

3] Set sleeve (7) to the clutch and brake


assembly.

12. Final drive shaft


Install right and left shafts (83).
a If the bevel gear is locked and it is hard to in-
sert the final drive shaft, release the steering
brake and insert the shaft.
Remove plugs (81) and bolts (82). Then,
screw in the bolts in the plug holes to
compress the clutch spring in order to
release the brake.

D375A-6R 50-165
(01)
Power train
Removal and installation of power train pump and lubrication pump assembly

Removal and installation of power train pump and lubrication pump


assembly 50-16

Removal 50-16 Connection 50-16


k Park the machine on a level surface and low- q Carry out installation in the reverse order to re-
er the work equipment to the ground. moval.
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
k Stop the engine, and disconnect the cable
from the negative terminal of the battery.

1. Remove the power train underguard (front).


4 Power train underguard (front):
280 kg
2. Remove cover (1).

3. Disconnect tube (2).

4. Sling and remove power train and lubrication


pump assembly (3).
4 Power train and lubrication pump as-
sembly:
50 kg

50-166 D375A-6R
(01)
Power train
Removal and installation of scavenging pump assembly

Removal and installation of scavenging pump assembly 50-167

Removal 50-167 Connection 50-167


k Park the machine on a level surface and low- q Carry out installation in the reverse order to re-
er the work equipment to the ground. moval.
k Set the parking brake lever and work equip-
ment lock lever in the lock position. q Refilling (Power train case)
k Stop the engine, and disconnect the cable Supply oil through the oil filler to the specified
from the negative terminal of the battery. level. Run the engine to circulate the oil through
the system. Then check the oil level again.
1. Remove the power train underguard (front).
4 Power train underguard (front):
280 kg
2. Disconnect inlet tube (1).
a The oil in the piping will leak out, so prepare
a container to catch the oil.

3. Disconnect outlet tube (2).

4. Remove scavenging pump assembly (3).

D375A-6R 50-167
(01)
Power train
Removal and installation of final drive assembly

Removal and installation of final drive assembly 50-168

Special tools 50-168

Necessity
Quantity

Sketch
Sym

N/R
Part No. Part name
- bol

J 1 790-337-1001 Lifting tool t 1

Removal 50-168
k Park the machine on a level surface and low-
er the work equipment to the ground.
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
k Stop the engine, and disconnect the cable
from the negative terminal of the battery.

1. Separate the track shoe assembly. For details,


see "Separation of track shoe assembly".

2. Raise the machine off the ground by using jacks


or ripper, and set stand [1] under the frame.

3. Remove (1) and (2).

5. Remove three bolts from the final drive, and


install tool J1 instead.

6. Sling final drive assembly (5), remove the


mounting bolts, and remove the final drive
assembly.
[*2]
4 Final drive assembly:
2,300 kg
4. Pull out drive shaft (4) as follows:
[*1]
1)Remove cover (3).
2)Install eyebolts [2] to the drive shaft.
3)Pull out drive shaft (4).
a If it is difficult to pull out the shaft, push up the
shoe grouser by using jack [3] or other device
set on the ground to move the sprocket back-
ward and forward, and set the sprocket to a
position where the shaft can be pulled out
easily.
a Pull the shaft to a point where it touches the
sprocket.

50-168 D375A-6R
(01)
Power train
Removal and installation of final drive assembly

Connection 50-169
q Carry out installation in the reverse order to re-
moval.

[*1]
a If it is difficult to insert the shaft into position,
push up the shoe grouser by using a jack or oth-
er device set on the ground to move the sprocket
backward and forward, and set the sprocket to a
position where the shaft can be inserted easily.

[*2]
2 Final drive assembly mounting bolt :
Adhesive (LT-2)
3 Final drive assembly mounting bolt :
1,720 190 Nm {175 20 kgm}

q Refilling (Final drive case)


Supply the oil through the oil filler port to the
specified level.
5 Final drive case:
Approx. 61 l(TO 30)

D375A-6R 50-169
(01)
Power train
Disassembly and assembly of final drive assembly

Disassembly and assembly of final drive assembly 50-170

Special tools 50-170 Disassembly 50-170


1. Draining oil

Necessity

Sketch
Sym- Remove the drain plug and drain the oil from the

Q'ty
N/R
Part No. Part name
bol final drive case.
6 Final drive case:
791-580-3200 Remover t 1 approx. 61 l
Puller
2 790-101-2102 t 1
(294 kN {30 ton}) 2. Sprocket
790-101-1102 Pump t 1 1) Place the final drive assembly on blocks
791-580-3300 Installer t 1 (approx. 50 mm high).
Puller 2) Remove sprocket (1).
3 790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
4 790-431-1071 Installer t 1 N
791-580-3400 Remover t 1
Puller
J 5 790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
791-580-3500 Installer t 1
Puller
6 790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
Remover and
790-431-1230 t 1
installer
7 790-101-2102 Puller t 1
(294 kN {30 ton}) 3. Cover
790-101-1102 Pump t 1 Using eyebolts [1], remove cover (2).
8 790-431-1250 Guide t 1

50-170 D375A-6R
(01)
Power train
Disassembly and assembly of final drive assembly

4. Hub
1) Remove plate (3).
2) Using eyebolts [2], lift off hub (4).

4) Remove bearing inner race (8) from the


sprocket hub assembly.

5. Sprocket hub assembly


1) Remove holder (5).

5) Turn over the sprocket hub assembly, then


remove floating seal cover (9) and bearing
outer races (10) and (11).
2) Using tool J2, disconnect sprocket hub 6) Remove floating seal (12) from the floating
assembly (6) and the bearing (7) portion. seal cover.
3) Using eyebolt [3], remove sprocket assembly a Take care not to damage the floating
(6). seal, and keep it in a safe place.

D375A-6R 50-171
(01)
Power train
Disassembly and assembly of final drive assembly

6. Wear guard 3] Remove spacer (17) and bearing inner


Lift off wear guide (13). race (18).

7. Cover assembly
1) Using eyebolts [4], remove cover assembly
(14).

4] Remove the plate, then remove ring gear


(19).

8. Carrier assembly
2) Disassemble the cover assembly as follows. 1) Remove carrier assembly (20) by using
1] Remove floating seal cover (15). eyebolts [5].
2] Remove floating seal (16) from the
floating seal cover.
a Take care not to damage the floating
seal, and keep it in a safe place.

2) Disassemble the carrier assembly as follows.


1] Place the carrier assembly on the block
(approx. 100 mm high).
2] Remove spacer (26) and bearing (26-1).

50-172 D375A-6R
(01)
Power train
Disassembly and assembly of final drive assembly

3] Remove holder (21). 9. Sun gear and shaft assembly


4] Using tool J7 , remove planetary gear 1) Remove sun gear and shaft (25).
shafts (22). 2) Remove plate (25-1) and bearing inner race
(26-2).
3) Remove plate (25-2) and sun gear (27).

5] Remove planetary gear (23), bearing


inner races (24A) and (24B), and spacer
(24C). 10. Hub and shaft assembly
1) Remove plate (28).

6] Remove bearing outer race (24D).


2) Using tool J5, pull out hub assembly (29) and
bearing inner race (30) from shaft assembly
(31).

D375A-6R 50-173
(01)
Power train
Disassembly and assembly of final drive assembly

3) Disassemble the hub assembly according to 11. Cage assembly


the following procedure. 1) Using eyebolts [7], remove cage assembly
1] Remove gear (32) from hub (33). (39).
2] Remove hub (33) from boss (34). 2) Remove shim (40).
3] Using the puller, remove bearing outer a Note the quantity and thickness of shims
races (35) from boss (34). for installation purpose.

4) Using eyebolts [6], pull out shaft assembly 3) Disassemble the cage assembly as follows:
(31) from the case. 1] Using puller [8], remove bearing outer
5) Disassemble the shaft assembly as follows. race (41).
1] Remove collar (36). 2] Remove oil seal (42).
2] Remove bearing inner race (37) and
collar (38).

50-174 D375A-6R
(01)
Power train
Disassembly and assembly of final drive assembly

12. Gear assembly Assembly 50-175


1) Remove gear assembly (44). a Clean all parts, and check them for dint and
2) Using puller [9], remove bearing inner races dents. Apply engine oil to the sliding surface be-
(45) and (46) from the gear. fore installing.

1. Oil seal and bearing outer race


1) Using push tool [11], install oil seals (49).
a Install the lower oil seal with its pressure
receiving side down and the top oil seal
with its pressure receiving side up.
2 Oil seal lip:
Grease(G2-LI)
2 Oil seal press-fitting surface:
Liquid gasket (LG-1)
a Apply a thin film of liquid gasket on the in-
side surface of the case and wipe off any
liquid gasket that is squeezed out.

13. Outer race and oil seal


1) Using puller [10], remove bearing outer race
(48).
2) Remove oil seal (49) from the case.

2) Press fit bearing outer race (48) with push


tool [13].

D375A-6R 50-175
(01)
Power train
Disassembly and assembly of final drive assembly

2. Gear assembly 2] Press fit bearing outer race (41) with push
1) Press fit bearing inner races (46) and (45) to tool [15].
the gear with push tool [14].
2) Set tool J8 to the case to install gear
assembly (44) in position.
a Do not remove tool J8 until the cage is in-
stalled.

2) Using eyebolts [7], set cage assembly (39) to


the case, and equally tighten portions (C)
and (D) with cage mounting bolts.
3 Mounting bolt:
14.7 Nm {1.5 kgm}
3. Cage assembly
1) Assemble the cage assembly as follows.
1] Using push tool [11], install oil seals (42).
a Install the lower oil seal with its pres-
sure receiving side down and the top
oil seal with its pressure receiving side
up.
2 Oil seal lip (OL):
Grease(G2-LI)
2 Oil seal press-fitting surface
(OP):
Liquid gasket (LG-1)
a Apply a thin film of liquid gasket on the
inner surface of the case and wipe off
any liquid gasket that is squeezed out.

50-176 D375A-6R
(01)
Power train
Disassembly and assembly of final drive assembly

3) Using feeler gauge [16] as shown in the 4. Hub and shaft assembly
figure below, measure the clearances (a) and 1) Assemble the shaft assembly as follows.
(b) between cage (A) and case (B), at the two 1] Install collar (38).
points "m" distance away from bolts (C) and 2] Press fit bearing inner race (37) with push
(D), respectively. tool [17].
4) Determine total thickness (c) of the shim 3] Install collar (36).
pack and select shims to use according the
table below.
5) Insert the shims selected in step 4 in position,
and tighten four cage mounting bolts.
3 Mounting bolt:
227.3 80.85 Nm {23.25 8.25 kgm}
a Equally tighten the bolts while rotating the
gear by hand, and then remove tool J8.

2) Using eyebolts [6], install shaft assembly (31)


to the case.
3) Make the hub assembly according to the
following procedure.
1] Using the push tool, press fit bearing
outer race (35) to boss (34).

Number of shims to be
(a) + (b) [mm]
used Total
thickness
Larger
Below t = 0.1 t = 0.5 t = 1.0 of shims
than
(c) [mm]
1.6 1.8 1 1.0
1.8 2.0 1 1 1.1
2.0 2.2 2 1 1.2
2.2 2.4 3 1 1.3
2.4 2.6 4 1 1.4
2.6 2.8 1 1 1.5
2.8 3.0 1 1 1 1.6
3.0 3.2 2 1 1 1.7
3.2 3.4 3 1 1 1.8
3.4 3.6 4 1 1 1.9 2] Set boss (34) to hub (33).
3.6 3.8 2 2.0
3.8 4.0 1 2 2.1
4.0 4.2 2 2 2.2
4.2 4.4 3 2 2.3
4.4 4.6 4 2 2.4
4.6 4.8 1 2 2.5
4.8 5.0 1 1 2 2.6
5.0 5.2 2 1 2 2.7
5.2 5.4 3 1 2 2.8
5.4 5.6 4 1 2 2.9
5.6 5.8 5 1 2 3.0

D375A-6R 50-177
(01)
Power train
Disassembly and assembly of final drive assembly

4) Set shaft assembly (31) to hub assembly


(29). Using tool J6, press fit bearing (30)
portion.

6. Carrier assembly
1) Assemble the carrier assembly as follows.
a As each bearing of the planetary gear is a
5) Tighten mounting bolts of hub assembly (29). selective combination part, match the ID
3 Mounting bolt: marks on the inner race, outer race and
276.85 31.85 Nm {28.25 3.25 spacer when assembling.
kgm} *1. Bearing ID mark
6) Install plate (28). *2. Spacer ID mark
2 Mounting bolt: (ID mark "MZ-12B" is an example in this
Adhesive (LT-2) figure.)
3 Mounting bolt:
548.8 58.8 Nm {56 6 kgm}
7) Install gear (32).
3 Mounting bolt:
539 49 Nm {55 5 kgm}

1] Install the rings and spacer to the plane-


tary gear. Using push tool [18], press fit
upper and lower bearing outer races
(24D) into position.

5. Sun gear
1) Install inner race (26-2) to the shaft of plate
(25-1).
2) Install sun gear (27) to the shaft of plate
(25-2).
3) Install shaft (25).

50-178 D375A-6R
(01)
Power train
Disassembly and assembly of final drive assembly

2] Install spacer (24C) and bearing inner


races (24B) and (24A) to each planetary 7. Cover assembly
gear (23), and set it to the carrier. 1) Assemble the cover assembly as follows.
1] Fit ring gear (19) and install the plate.
a Install the plate with its chamfered sur-
face up.

3] Using tool J7, press fit planetary gear


shaft (22) in position.
a Press fit the shaft gradually matching
the holes of the bearing and spacer. 2] Using tool J3, press fit bearing inner race
4] Install holder (21). (18).
3 Mounting bolt: 3] Install spacer (17).
548.8 58.8 Nm {56 6 kgm}
a After tightening the bolts, check that
each gear rotates smoothly.

4] Using tool J4, press fit floating seal (16) to


the floating seal cover.
a Thoroughly degrease and dry the
2) Install bearing (26-1) and spacer (26) to O-ring and O-ring contact surfaces of
carrier assembly (20). the floating seal before installing.
a After installing the floating seal, check
that its leaning is less than 1 mm.

3) Using eyebolts [5], install carrier assembly


(20).

D375A-6R 50-179
(01)
Power train
Disassembly and assembly of final drive assembly

8. Wear guard
5] Install floating seal cover (15). Lift and install wear guide (13).
a Fit a cork plug in the forcing tap.

9. Sprocket hub assembly


a Install the floating seal cover with its 1) Using tool J4, install floating seal (12) to the
cut-out portion facing down as shown floating seal cover.
in the diagram below. a Thoroughly degrease and dry the O-ring
and O-ring contact surfaces of the floating
seal before installing.
a After installing the floating seal, check
that its leaning is less than 1 mm.

2) Using eyebolts [4], lift and install cover


assembly (14).
a Apply the 1216 ThreeBond adhesive to
the mating surfaces.
2) Using the push tool, press fit bearing outer
races (11) and (10).
3) Install floating seal cover (9).

50-180 D375A-6R
(01)
Power train
Disassembly and assembly of final drive assembly

4) Set bearing (8) to the sprocket hub 7) Install holder (5).


assembly. 2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
276.85 31.85 Nm {28.25 3.25
kgm}

5) Using eyebolt [3], sling sprocket hub


assembly (6) and set it to the cover.
a Check that the sliding surface of floating
seal is free from dirt, and apply a thin film
of engine oil on it. 10. Hub
1) Lift and install hub (4) using eyebolts [2].
2) Install plate (3).

6) Using tool J3, press fit bearing (7) portion.


a Press fit the sprocket hub assembly while
rotating it by hand. 11. Cover
Using eyebolts [1], install cover (2).

D375A-6R 50-181
(01)
Power train
Disassembly and assembly of final drive assembly

12. Sprocket
Install sprocket (1).
2 Mounting bolt:
Molybdenum disulphide lubricant
(LM-P)
3 Mounting bolt:
1,813 98 Nm {185 10 kgm}
13. Refilling of oil
Tighten the drain plug, and supply engine oil
through the filler port.
5 Final drive case:
approx. 61 l
a After installing the final drive assembly on the
machine, finally check that the oil is at the
specified level.

50-182 D375A-6R
(01)
Undercarriage and frame
Removal and installation of track frame assembly

Undercarriage and frame 50-183


Removal and installation of track frame assembly 50-183

Special tools 50-183 6. Using tool L13, lock the bogie assembly.
7. Remove cover (1).

Necessity

Sketch
Sym-

Q'ty
N/R
Part No. Part name
bol

L 24 791-685-1320 Lifting tool t 1

Removal 50-183
1. Remove the track shoe assembly. For details,
see Separation and connection of track shoe
assembly.

2. Place blocks [3] (at right and left sides) between


the equalizer bar and frame, to lock the equalizer
bar.

8. Remove cover (2).


[*1]
9. Remove grease tube (4).
10. Remove cover (3).
[*1]
11. Loosen front and rear bolts (6-1).
[*2]
a Bolt: M30, width across flats: 46 mm
12. Remove cover (5).

3. Raise the machine off the ground by using the


ripper or a crane, place stands [1] under the
frame, and lift the rear of machine off the ground.
k Stand [1] must be able to support the
weight of 25 tons or more .

4. Place hydraulic jack [2] (490 kN {50 ton}) at the


center of the equalizer bar, and lift the front of the
machine off the ground.

5. Sling the track frame assembly.

D375A-6R 50-183
(01)
Undercarriage and frame
Removal and installation of track frame assembly

13. Place a pad on the rear of pin (6), and drive out a Perform this step for only the right track
the pin by hammering. frame of the single tilt specification machine,
[*3] or both track frames of the dual tilt specifica-
a If the equalizer bar hole is not aligned with tions machine.
the track frame hole, the pin cannot be re-
moved easily. Adjust the lifting height of 17. Remove the mounting bolts and cover (11).
the track frame properly. a Take care not to damage the hose connected
a Put an "UP" mark at the top of the pin. to the inside face of the cover.

14. Remove the mounting bolts and remove cover 18. Disconnect hoses (12) and (13) from the inside
(7) from the track frame. face of cover (11), and remove cover (11).
[*4]
a Perform this step for only the right track
frame of the single tilt specification machine,
or both track frames of the dual tilt specifica-
tions machine.
a Note the color of hose band for installation
purpose.
(Single tilt specification)
(12a) (13a)
Right track frame: Red -
(Dual tilt specification)
(12a) (13a)
Right track frame: Red -
(12a) (13a)
15. Remove cover (8). Left track frame: Blue -
RH: Both dual tilt and single tilt specifications
LH: Dual tilt specification

16. Disconnect lower hose (9) and upper hose (10)


of the blade tilt cylinder.

50-184 D375A-6R
(01)
Undercarriage and frame
Removal and installation of track frame assembly

LH: Dual tilt specification


RH: Both single tilt and dual tilt specifications

19. Remove cover (14).


[*5]
a Three mounting bolts are used on the track 22. Using tool L24, sling and remove track frame
frame, and six bolts are used on the pivot assembly (18).
frame. 4 Track frame:
a Take care not to damage O-rings. 7,940 kg (each)
a As the oil drains from the pivot shaft case,
place an oil container to receive it.
6 Pivot shaft case:
18 l
20. Remove seal (15) and cover (14) as a unit.
[*6]
a Perform this step for only the right track
frame of the single tilt specification machine,
or both track frames of the dual tilt specifica-
tions machine.

21. Remove washer (16) and spacer (17).

D375A-6R 50-185
(01)
Undercarriage and frame
Removal and installation of track frame assembly

Connection 50-186 q Carry out the subsequent installation in the re-


a Take care not to install seal (19) twisted to the verse order to removal.
track frame.
a When replacing seal (19), see "Removal and in- [*1]
stallation of pivot shaft assembly". a Install covers (2) and (3), then tighten bolts (6-1).
3 Covers (2) and (3):
245 to 309 Nm {25 to 31.5 kgm}

[*2]
3 Bolt (6-1):
1,9602,450 Nm {200250 kgm}

[*3]
2 Bushing inner surface:
Grease(G2-LI)
a Install pin (6) with the "UP" mark up, which was
put upon removal.
a Align the notch of pin (6) with the mark of ma-
chine.
2 Apply grease (G2-LI) on (GR) portions be-
fore installing equalizer bar (EB), bushing
(7) and pin (6).
a Before installing pin (6), adjust the lifting height
of the track frame so that the center of equalizer
bar (EB) hole matches that of track frame hole.
a When aligning the pin holes, never insert your
fingers in the holes.
2 Bushing contact surface on pivot shaft:
Molybdenum disulphide lubricant (LM-P)
a When replacing the pivot shaft bushing of track
frame assembly, install a new bushing with its
abutment joint up.

50-186 D375A-6R
(01)
Undercarriage and frame
Removal and installation of track frame assembly

[*4] [*5]
q Install the hoses taking care not to install hoses a Install cover (14) using three bolts (indicated by
with wrong band colors. arrows).
a Hose band colors
(Single tilt specification) [*6]
(12a) (13a) a Completely degrease the contact surface (15) of
Right track frame: Red - seal when mounting it.
(Dual tilt specification) 2 Seal contact surface (15):
(12a) (13a) Gasket sealant (LG-6)
Right track frame: Red - a Be careful not to install the seal twisted.
(12a) (13a)
Left track frame: Blue -
RH: Both dual tilt and single tilt specifications
LH: Dual tilt specification

q Refilling (Pivot shaft case)


Supply oil through the oil filler to the specified
level.
5 Pivot case:
18 l (EO30)

D375A-6R 50-187
(01)
Undercarriage and frame
Removal and installation of idler assembly

Removal and installation of idler assembly 50-18

Removal 50-18 Connection 50-18


1. Remove the track shoe assembly. For details, q Carry out installation in the reverse order to re-
see Separation and connection of track shoe moval.
assembly.
a For both the right and left idler assemblies,
2. Remove scraper (1). install the assembly with the oil filler plug fac-
a Remove the inside scraper, too. ing the left side of machine.
a Tighten idler cap mounting bolts in the follow-
3. Remove cover (2). ing order.
a Remove the inside cover, too. Tightening order:
1] Two bolts at side (a)
2] Two bolts at side (b)
3] Two bolts at side (a)
4] Tighten all bolts to the specified torque.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
1,470 1,813 Nm {150 185 kgm}
a After tightening the idler cap mounting bolts,
check that clearance (c) between the bottom
of idler cap and the yoke is zero.

4. Sling the idler assembly, and remove idler cap


(3).
a For both the left and right idler assemblies, a
ball is installed to the left idler cap. Take care
not to lose the ball.

5. Sling and remove idler assembly (4).


4 Idler assembly:
480 kg

50-188 D375A-6R
(01)
Undercarriage and frame
Disassembly and assembly of idler assembly

Disassembly and assembly of idler assembly 50-189

Special tools 50-189 5. Remove the mounting bolts. Using eyebolts [3],
remove shaft (5) and the retainer as a unit.

New/redesign
Necessity
Quantity

Sketch
Sym-
Part No. Part name 6. Using puller [4], remove retainers (3) and (7) and
bol
seal guide (6).

791T-630-2210 Plate t 1 Q
791-530-1630 Rod t 2
790-101-2510 Block t 1
790-101-2570 Washer t 2
1 01580-01613 Nut t 2
L 01643-31645 Washer t 2
Puller
790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
2 791-515-1520 Installer t 1
3 791-685-8310 Push tool t 1
4 791-601-1000 Oil pump 1

Disassembly 50-189
1. Remove the oil filler plug to drain oil.
6 Idler: 7. Remove seal guides (2) and (6) from retainers
0.951.05 l (3) and (7).

2. Place idler assembly (1) on blocks [1] (approxi- 8. Remove plates (4) and (8) from the respective
mately 140 mm high). retainers.

3. Remove mounting bolts, then using forcing


screws [2], remove seal guide (2), retainer (3)
and plate (4).

4. Turn over the idler assembly (1).

D375A-6R 50-189
(01)
Undercarriage and frame
Disassembly and assembly of idler assembly

9. Remove floating seal (9) from seal guides (2) Assembly 50-190
and (6). a Clean all parts and check them for dirt and dam-
a Keep the floating seal in a safe place so that age before installing.
it does not get damaged.
1. Place bushings (11) and tool L1 on idler (12),
10. Remove floating seal (10) from retainers (3) and and press fit bushings (11) in position.
(7). a First, center the bushing with a plastic ham-
a Keep the floating seal in a safe place so that mer, then press fit with the puller.
it does not get damaged. a Press fit the bushing so that press-fitting di-
mension (a) from the end face of the idler to
the top surface of the bushing is as follows.
q Dimension (a): 17 0.5 mm

11. Remove bushing (11) from idler (12).

2. Using tool L2, install respective floating seals


(10) to seal guides (3) and (7).
a Completely degrease and dry the O-ring and
the O-ring contact surfaces (hatched por-
tions) of floating seal.
a Apply oil to the sliding surface of floating seal,
and take care not to allow dirt and foreign
matter to attach on the seal.
a After installing the floating seal, check that its
leaning is less than 1 mm and that the protru-
sion (a) of the seal is between 7 to 11 mm.

50-190 D375A-6R
(01)
Undercarriage and frame
Disassembly and assembly of idler assembly

3. Install retainer (3) with the O-ring and plate (4) to 6. Install retainer (7) with the O-ring and plate (8) to
the idler. the idler.
a Check that the plate can be turned smoothly
by hand.

7. Using tool L2, install respective floating seals (9)


. to seal guides (2) and (6).
a For installation procedures, refer to Step 2.

4. Using eyebolts [3], set idler (12) to shaft (5).


a Place blocks (approximately 140 mm high) 8. Set seal guide (2) to the shaft, and press fit seal
under the idler. guide (2) using tool L3.
a Seal guide press-fitting force: 43 71 kN {4.4
5. Turn over the idler assembly. 7.2 ton}
a Tie the shaft with wire to prevent it from fall-
ing out.

D375A-6R 50-191
(01)
Undercarriage and frame
Disassembly and assembly of idler assembly

a Press fit the seal guide so that press-fitting di-


mension (b) from the end face of the shaft to
the top surface of the seal guide is as follows.
q Dimension (b): 102 0.2 mm
a Turn over the idler assembly and repeat the
same procedure to press fit the seal guide (6)
on the opposite side.

9. Using tool L4, supply oil to the specified level


and tighten the oil filler plug.
6 Idler:
0.951.05 l(GO140)
3 Oil filler plug:
206 49 Nm {21 5 kgm}
VT: To vacuum tank
OP: To oil pump

50-192 D375A-6R
(01)
Undercarriage and frame
Removal and installation of recoil spring assembly

Removal and installation of recoil spring assembly 50-193

Special tools 50-193 4. Remove cover (2).


5. Sling and remove trunnion (3).

Necessity
4 Trunnion:

Sketch
Sym-

Q'ty
N/R
Part No. Part name
bol 75 kg
791-730-1110 Bolt t 5
01580-12722 Nut t 5
01643-32780 Washer t 1
M 1 790 - 101 - Puller
t 1
2102 (294 kN {30 ton})
790 - 101 -
Pump t 1
1102

Removal 50-193
1. Separate the track shoe assembly. For details,
see Separation and connection of track shoe
assembly.
k Set the parking brake lever and work
equipment lock lever in the lock position.
k Stop the engine and disconnect the cable
6. Remove cover (4).
from the negative (-) terminal of the bat-
a Remove both the inside and outside pins.
tery.
2. Drain the oil from the recoil cylinder chamber by
7. Remove pin (5) using tool M1.
using the oil pump.
6 Recoil cylinder chamber:
[*1]
a Remove both the inside and outside pins.
approx. 50 l

3. Using eyebolts [1], remove cover (1).


4 Cover:
40 kg

D375A-6R 50-193
(01)
Undercarriage and frame
Removal and installation of recoil spring assembly

8. Sling and remove the idler and recoil spring 2) Loosen idler yoke assembly mounting bolts
assembly (6). (9) on diagonally opposite sides gradually in
[*2] turn.
a Keep the assembly horizontal by using lever [*4]
blocks, and take care not to damage the oil k For safety reasons, no one is allowed
seal installed on the track frame during re- to be in front of the idler yoke during
moval. the work.
4 Idler and recoil spring cushion assem- k The recoil spring mounted in the recoil
bly: cylinder is under the load of approxi-
2,180 kg mately 500 kN {approx. 51 tons} at in-
stalled length. Never loosen the
mounting bolts quickly. Gradually
loosen the bolts until clearance (a) be-
tween the idler yoke and recoil cylin-
der flange (FL) becomes 8 to 12 mm.

9. Disconnect recoil cylinder assembly (7) from


idler yoke assembly (8) according to the
following procedure.
[*3]
1) Place idler yoke assembly (8) on the ground,
and sling idler cushion assembly (7).
a Check the welded area of idler cushion
assembly (7) for any defect.
a Protect the chrome plated bushing (CP)
by covering it with cloths.

50-194 D375A-6R
(01)
Undercarriage and frame
Removal and installation of recoil spring assembly

3) Check that the loosening torque of all the 1] Prepare the following parts of tool M1:
bolts suddenly drop. If so, it indicates that the q Six bolts [1]: 791-730-1110
force of the recoil spring is not applied on the q Six nuts [2]: 01580-12722
mounting bolts. Then, remove all bolts. q Six washers [3]: 01643-32780 (reuse)
a If the torque increases (the force of the re-
coil spring is applied) during the loosen-
ing operation, stop the loosening
operation and disassemble as follows.
k If the torque is not reduced in Steps (2)
or (3) and if the loosening torque is still
large, recoil spring set bolt (10) may be
broken or shaft end nut (11) may fall
out. In such a case, the idler yoke as-
sembly may fly off to the front of the
machine. Disassemble it as follows:
k Do not allow anyone to remain in front
of the idler yoke or at the back of the
recoil cylinder until the idler yoke as-
sembly is separated from the idler
2] Remove six bolts marked with *, then
cushion assembly and the recoil
install bolts [1], nuts [2], and washers [3].
spring is removed.
a Check that dimension (L) is below 30
mm.
a Screw in bolts [1] until they reach the
bottom of yoke threaded holes.
3] Remove remaining twelve bolts (those
not marked).
4] Hold bolts [1] with a wrench to prevent
them from turning, and loosen two nuts
[2] simultaneously on diagonally opposite
sides.
a Take care not to let the load bear on
only one bolt.

D375A-6R 50-195
(01)
Undercarriage and frame
Removal and installation of recoil spring assembly

5] Loosen bolts until the recoil spring is 12. Disassemble the piston assembly (15) according
extended completely and the loosening to the following procedure.
torque of nuts [2] is reduced. Then, 1) Remove wear ring (16) from the piston.
remove bolts [1]. 2) Remove snap ring (17) and packing (18).
a When clearance (b) reaches approxi-
mately 230 mm, the spring is extend-
ed completely.

13. Remove recoil spring assembly (19).


4 Recoil spring assembly:
550 kg
10. Remove ring (12).

14. Remove holder (20) from the recoil spring


11. Pump in grease through lubricator (13), and assembly.
remove cylinder (14) and piston assembly (15).

50-196 D375A-6R
(01)
Undercarriage and frame
Removal and installation of recoil spring assembly

Connection 50-197
q Carry out installation in the reverse order to re-
moval.
3 Cover mounting bolt:
277 32 Nm {28.25 3.25 kgm}

[*1]
a Before installing the pin, align the dowel hole in
the track frame with the dowel pin on the recoil
cylinder by using a pinch bar.

[*2]
a Keep the assembly horizontal by using lever
blocks, and take care not to damage the oil seal
installed on the track frame during installation.

[*3]
a If the recoil spring set bolt is broken or the shaft
end nut falls out, see "Disassembly and assem-
bly of idler cushion assembly".

[*4]
2 Idler yoke assembly mounting bolt:
Adhesive (LT-2)
3 Idler yoke assembly mounting bolt:
1,519 1,911 Nm {155 195 kgm}

a To prevent a trapped air in the cylinder, pump in


grease as follows:
1) Refill the cylinder with approximately 1.3 l of
grease.
2) Set the cylinder with the drain hole up, then
loosen the lubricator.
3) Push the piston until it reaches the stopper to
remove any air and excess grease from the
cylinder.

D375A-6R 50-197
(01)
Undercarriage and frame
Disassembly and assembly of recoil spring assembly

Disassembly and assembly of recoil spring assembly 50-198

Special tools 50-198 4. Remove rear pilot (5), spacer (6), bolt (7), and
pilot (8) from spring (4).

New/redesign
Necessity
Quantity

Sketch
Sym-
Part No. Part name
bol

791-685-8501 Compressor t 1
Cylinder
790-101-1600 t 1
M 2 (980 kN {100 tons})
790-101-1102 Pump t 1
791-635-3160 Extension t 1

Disassembly 50-198
1. Set recoil spring assembly (1) to tool M2.
k Since the load at installed length of the
spring is large and dangerous, set the
spring securely to the tool.
a Load at installed length of spring: Approx.
500 kN {approx. 51 tons}

2. Apply hydraulic pressure slowly to compress the


spring, then remove lock plate (2) and remove
nut (3).

3. Release hydraulic pressure gradually and


relieve tension of the spring.

50-198 D375A-6R
(01)
Undercarriage and frame
Disassembly and assembly of recoil spring assembly

Assembly 50-19 3. Install nut (3) and install lock plate (2).
1. Install pilot (8), bolt (8), spacer (6), and pilot (5) a To prevent the nut from protruding from the
to spring (4), and set them to tool M2. end of bolt (7), make a clearance of 01.0
mm between the nut and lock plate.
a Bring lock plate (2) and bolt (7) (CE portion)
into tight contact to secure.
2 Lock plate mounting bolt:
Adhesive (LT-2)

4. Gradually release hydraulic pressure to reduce


the spring tension, and then remove recoil spring
assembly (1) from tool M2.

k Since the load at installed length of the


spring is large and dangerous, set the
spring securely to the tool.

2. Apply hydraulic pressure gradually to compress


the spring until the spring installed length is the
standard length.
a Installing length (a) of spring: 1,329.5 mm
a Load at installed length of spring: 500 kN
{50,994 kg}

D375A-6R 50-199
(01)
Undercarriage and frame
Removal and installation of track roller assembly

Removal and installation of track roller assembly 50-20

Special tools 50-20 Removal 50-20


1. Decrease the track tension. For details, see

Necessity
Quantity

Sketch
Sym- "Separation and connection of track shoe

N/R
Part No. Part name
bol assembly".
k Set the parking brake lever and work
790-401-1700 Lifting tool t 1
equipment lock lever in the lock position.
t
k Stop the engine and disconnect the cable
790-401-1761 Adapter 1
12
790-401-1540 Shackle t 2
790-401-1770 T-bolt t 2 from the negative (-) terminal of the bat-
195-30-66611 Grip t 3 tery.
L
01010-62490 Bolt t 5
01010-62455 Bolt t 5
13
01643-32460 Washer t 5 2. Install tool L13 to lock the bogie assembly (1).
19M-54-11770 Washer t 5
[*1]
198-30-66190 Collar t 5
S: Single flange
D: Double flange

50-200 D375A-6R
(01)
Undercarriage and frame
Removal and installation of track roller assembly

3. Raise the machine until track roller assembly (2) 7. Using the crane and tool L12, pull out track roller
leaves the track by operating the blade and assembly (2) on the steel plate to the outside of
ripper. the machine.
4 Track roller assembly:
4. Place steel plate [1] on the track and operate the 150 kg (single flange)
blade and ripper to lower the machine until the 160 kg (double flange)
track roller assembly comes in contact with the
steel plate.
a Operate the blade and ripper slowly, running
the engine at the low speed.

5. Remove the mounting bolts, and place track


roller assembly (2) on steed plate [1].

6. Raise the machine until track roller assembly (2)


leaves the bogie by operating the blade and
ripper.

D375A-6R 50-201
(01)
Undercarriage and frame
Removal and installation of track roller assembly

Connection 50-202
q Carry out installation in the reverse order to re-
moval.

[*1]
a After removing tool L13, replace the mounting
bolt of cover (3) with the normal bolt.
3 Cover mounting bolt :
927 103 Nm { 94.5 10.5 kgm}
a Note that the installation location differs be-
tween single flange and double flange track
roller assemblies. Install them in the correct
locations.
S: Single flange
D: Double flange
a Install the track roller assembly with the oil
filler plug outside.

50-202 D375A-6R
(01)
Undercarriage and frame
Disassembly and assembly of track roller assembly

Disassembly and assembly of track roller assembly 50-203

Special tools 50-203 6. Using the press, remove seal guide (6), retainer
(7) and plate (8) from the shaft.

New/redesign
Necessity
Quantity

Sketch
Sym-
Part No. Part name 7. Remove seal guides (2) and (6) from retainers
bol
(3) and (7).

8 791T-630-2220 Plate t 1 Q
9 796-670-1020 Installer t 1
L
10 791T-630-2230 Push tool t 1 Q
11 791-601-1000 Oil pump t 1

Disassembly 50-203
1. Remove oil filler plug to drain oil.
6 Track roller:
1.4 1.5 l

2. Place track roller assembly (1) on block [1].

3. Remove mounting bolts, then using forcing


screws [2], remove seal guide (2), retainer (3)
8. Remove floating seal (9) from seal guides (2)
and plate (4) as a unit.
and (6).
a Keep the floating seal in a safe place to pre-
4. Turn over the track roller assembly.
vent it from damaging.
5. Remove the mounting bolts. Using eyebolts [3],
9. Remove floating seal (10) from retainers (3) and
remove shaft (5) and the retainer as a unit.
(7).
a Keep the floating seal in a safe place to pre-
vent it from damaging.

D375A-6R 50-203
(01)
Undercarriage and frame
Disassembly and assembly of track roller assembly

10. Remove bushing (11) from roller (12). 3. Using tool L9, install respective floating seals
(10) to retainers (3) and (7).

4. Install the O-rings, and install retainers (3) and


(7) and plate (8) to the roller.
a Check that the plate can be turned smoothly
by hand.

Assembly 50-204
a Clean all parts, and check them for dirt and dam-
age before installing.

1. Set roller (12) to the press, and press fit bushing


(11) using tool L8.
a First, center the bushing by using a plastic 5. Using tool L9, install respective floating seals (9)
hammer, then press fit it with the press. to seal guides (2) and (6).
a Press fit the bushing so that press-fitting di-
mension (a) from the end face of the roller to 6. Using tool L10, press fit seal guide (2) to the
the top surface of the bushing is as follows. shaft.
q Dimension (a): 17 0.5 mm a Seal guide press-fitting force:
36 63 kNm {3.7 6.4 ton}
2. Set shaft (5) to the roller.

50-204 D375A-6R
(01)
Undercarriage and frame
Disassembly and assembly of track roller assembly

a Press fit the seal guide so that press-fitting di-


mension (b) from the end face of the shaft to
the top surface of the seal guide is as follows.
q Dimension (b): 77 0.2 mm
a Turn over the track roller assembly and press
fit seal guide (6) on the opposite side accord-
ing to the above procedure.

7. Using tool L11, refill with the specified amount of


oil and tighten the oil filler plug.
6 Track roller:
1.4 1.5 l (GO140)
3 Oil filler plug:
206 49 Nm {21 5 kgm}

D375A-6R 50-205
(01)
Undercarriage and frame
Removal and installation of carrier roller assembly

Removal and installation of carrier roller assembly 50-206

Removal 50-206 Connection 50-206


1. Decrease the track tension. For details, see q Carry out installation in the reverse order to re-
"Sepatation and connection of track shoe moval.
assembly".
k Set the parking brake lever and work [*1]
equipment lock lever in the lock position. a Make a clearance of 1.75 mm between the car-
k Stop the engine and disconnect the cable rier roller and support (a).
from the negative (-) terminal of the bat- 2 Carrier roller assembly mounting bolt :
tery. Adhesive (LT-2)
3 Carrier roller assembly mounting bolt :
2. Push up the track shoe by using hydraulic jack 662829 Nm {67.584.5 kgm}
[1].

3. Sling and remove carrier roller assembly (1).


[*1]
4 Carrier roller assembly:
75 kg

50-206 D375A-6R
(01)
Undercarriage and frame
Disassembly and assembly of carrier roller assembly

Disassembly and assembly of carrier roller assembly 50-207

Special tools 50-207 5. Remove nut (4) using tool L7.

New/redesign
Necessity
6. Using puller [2], remove the press-fitted seal

Quantity

Sketch
Sym-
Part No. Part name guide, and remove bearing (5) and roller (6) as a
bol
unit using eyebolts.

4 791-601-1000 Oil pump t 1


5 791-515-1520 Installer t 1
L
6 791-830-1770 Push tool t 1
7 791-630-1270 Wrench t 1

Disassembly 50-207
1. Remove the oil filler plug to drain oil.
a Drain the oil while rotating the shaft.
6 Carrier roller :
0.70.8 l

2. Place carrier roller assembly (1) on block [1].

3. Remove the mounting bolts and cover (2). 7. Remove bearing outer race (7) from the roller.

4. Remove snap ring (3). 8. Using puller [3], remove seal guide (8) and
bearing inner race (9) as a unit.

D375A-6R 50-207
(01)
Undercarriage and frame
Disassembly and assembly of carrier roller assembly

9. Remove floating seal (10) from seal guide (8). Assembly 50-208
a Clean all parts, and check them for dirt and dam-
age before installing.

1. Press fit bearing inner race (9) using push tool


[5].

2. Press fit bearing outer race (7) using push tool


[6].

10. Using push tool [4], remove seal guide (11).

11. Remove floating seal (12) from seal guide (11).

3. Set roller (6) and bearing inner race (5) to the


shaft.

4. Press fit bearing inner race (5) to the shaft using


push tool [7].
a Press-fit the bearing inner race while turning
the roller, until the roller becomes a little hard
to turn.
.

50-208 D375A-6R
(01)
Undercarriage and frame
Disassembly and assembly of carrier roller assembly

5. Using tool L7, tighten nut (4). 8. Using tool L5, install floating seal (10) to seal
3 Nut: guide (8).
98 Nm {10 kgm}
a After the nut is tightened, If the nut hole is not 9. Fit the O-ring to seal guide (8) and install them,
aligned with the shaft hole, loosen the nut to matching the dowel hole to the dowel pin.
align them. a Completely degrease and dry the O-ring and
the O-ring contact surfaces (shaded area) of
6. Install snap ring (3). the floating seal before installing. Also, take
a Check that the end play (clearance between care not to allow dirt to attach the floating
bearing and nut) is within 0.010.22 mm. seal contact surfaces.
a After installing the floating seal, check that its
leaning is less than 1 mm and that the protru-
sion (a) of the seal is between 7 to 11 mm.

7. Fit the O-ring and install cover (2).

D375A-6R 50-209
(01)
Undercarriage and frame
Disassembly and assembly of carrier roller assembly

10. Using tool L5, install floating seal (12) to seal 12. Using tool L4, supply the specified amount of oil
guide (11). and tighten the oil filler plug.
a For precautions for installing the floating 6 Carrier roller :
seal, see a in Step 9. 0.7 0.8 l (GO140)
3 Oil filler plug:
11. Using tool L6, press fit seal guide (11). 157 255 Nm {16 26 kgm}
a Press fit the seal guide so that dimension (a)
between the shaft end surface and seal
guide top surface is 158.75 0.2 mm.
a After press-fitting of the seal guide, check
that its learning from the shaft is less than 1
mm.

50-210 D375A-6R
(01)
Undercarriage and frame
Removal and installation of bogie assembly

Removal and installation of bogie assembly 50-21

Special tools 50-21

Necessity

Necessity
Quantity

Quantity
Sketch

Sketch
N/R

N/R
Symbol Part No. Part name Symbol Part No. Part name

195-30-66611 Grip t 3 1 791-630-2280 Adapter t 1


01010-62490 Bolt t 5 2 790-201-2770 Spacer t 1
01010-62455 Bolt t 5 3 791-630-2250 Plate t 1
13
01643-32460 Washer t 5 4 790-434-1070 Screw t 1
19M-54-11770 Washer t 5 15 5 01580-13629 Nut t 2
198-30-66190 Collar t 5
6 01643-33690 Washer t 2
1 791-630-2260 Plate t 1
L Puller
2 790-201-2730 Spacer t 1 7 790-101-4000 t 1
(490 kN {50 ton})
3 791-630-2270 Screw t 3
8 790-101-1102 Pump t 1
4 01580-12419 Nut t 3
14 L 1 791-630-2260 Plate t 1
5 01643-32460 Washer t 3
Puller 2 791-630-2270 Screw t 3
6 790-101-4000 t 1 3 01580-12419 Nut t 3
(490 kN {50 ton})
7 790-101-1102 Pump t 1 16 4 01643-32460 Washer t 3
Puller
5 790-101-4000 t 1
(490 kN {50 ton})
6 790-101-1102 Pump t 1
17 791T-630-2290 Guide t 2 Q
18 791-530-1510 Installer t 1
19 791-601-1000 Oil pump t 1
Removal 50-21
1. Decrease the track tension. For details, see "Sepatation and connection of track shoe assembly".
k Set the parking brake lever and work equipment lock lever in the lock position.
k Stop the engine and disconnect the cable from the negative (-) terminal of the battery.
2. Install tool L13 to lock the bogie assembly.

D375A-6R 50-211
(01)
Undercarriage and frame
Removal and installation of bogie assembly

3. Raise the machine body until the track rollers 8. Removal of shaft and ring
leave the track links, by operating the blade and 1) Set tool L14 in position.
ripper. 2) Push out shaft (3) and ring (4) to the opposite
k Place a block between the track roller and side simultaneously.
the track link so that the machine does a Pressing force: 137.2 274.4 kN {14 28
not lower. tons}
Pressing force C 1.8 x Average pressure
4. Set block [1] outside of the track shoes, (Adjust the relief pressure of the link
matching it to the height of the track link. press to obtain the pressing force.)

5. Place steel plate [2] on the track shoes and block


[1].

6. Operate the blade and ripper to lower the


machine until the track roller of bogie assembly
(1) touches steel plate [2].
a Operate the blade and ripper slowly, running
the engine at low speed.

3) Remove floating seal (5) from the end face of


rings (4) and (7).
a Keep the floating seal in a safe place so
that it does not get damaged.

7. Remove (outside and inside) covers (2).

50-212 D375A-6R
(01)
Undercarriage and frame
Removal and installation of bogie assembly

4) Set tool L15 in position.


5) Pull out spacer (6) and rings (7) and (8).
a Pulling force: 205.8 382.2 kN {21 39
tons}

6) Remove spacer (6).


7) Remove spacer (9) and floating seal (10)
from between rings (7) and (8).
a Keep the floating seal in a safe place so
that it does not get damaged.
8) Pull out the shaft and rings on the opposite
side of the bogie according to above steps 1)
to 7).

9. Remove tool L22 or L23 that locks the bogie to


be removed.

10. Place bogie assembly (1) on steel plate [2].

11. Operate the blade and ripper to raise the


machine body until the bogie assembly can be
pulled out.
k Place a block between the track roller and
track link so that the machine does not
lower.

12. Sling bogie assembly (1), slide it on steel plate


[2] towards outside to remove.
4 Bogie assembly:
720 kg

D375A-6R 50-213
(01)
Undercarriage and frame
Removal and installation of bogie assembly

Connection 50-214 2. Apply lever block [3] between the guard of bogie
1. Assembly of pin assembly. assembly (1) and that of the bogie assembly on
1) Using tool L18, install floating seal (5) to rings the opposite side, slide bogie assembly (1) on
(4) and (7). Also, install floating seal (10) to the steel plate, and place it in the mounting posi-
the opposite surface of ring (7) and to ring tion.
(8).
a Completely degrease the O-ring and the
O-ring contact surfaces of floating seal
before installing.
a Check that the leaning of the floating seal
is less than 1 mm.

3. Align pin holes of the track frame and bogie with


each other, and set guidance tool L17 in posi-
tion.

2) Press fit shaft (3) to ring (8).


3) Install spacer (9).
4) Press fit ring (7) to shaft (3).
5) Install spacer (6).
6) Press fit ring (4) to shaft (3).
2 Portion (a) of ring (8) and ring (4)
(approximately 10 mm):
Molybdenum disulphide lubricant
(LM-P)

4. Press-fitting of pin assembly


1) Set tool L16 and cover (2) in position.

50-214 D375A-6R
(01)
Undercarriage and frame
Removal and installation of bogie assembly

2) Press-fit the pin assembly. 6. Press fit the pin assembly on the opposite side of
a Install the pin assembly with arrow (a) on the bogie according to above steps 3 and 4.
its end face up (when it is mounted on the
machine). 7. Tighten the mounting bolts of pin assembly
a Push in the pin assembly with cover (2). cover (2).(two places, inside and outside)
a Push in the pin assembly to machined 3 Cover mounting bolt:
face (b) of the bogie. 927 103 Nm {94.5 10.5 kgm}
2 Periphery of pin:
Molybdenum disulphide lubri-
cant (LM-P)
a Press-fitting force of pin assembly:
245441 kN {2545 ton}

8. Adjust the track tension. For details, see Testing


and adjusting, "Inspection and adjustment of
track tension".

5. Refilling with oil


Using tool L19, supply the specified amount of
oil.
a Refilling oil pressure: 0.49 MPa {5 kg/cm2}
5 Pin assembly:
95 115 cc(GO140)

D375A-6R 50-215
(01)
Undercarriage and frame
Disassembly and assembly of bogie assembly

Disassembly and assembly of bogie assembly 50-216

Special tools 50-216 3. Remove the pin assembly following the same
procedure as described in the "Removal of bogie

New/redesign
Necessity
assembly".

Quantity

Sketch
Symbol Part No. Part name (See Step 8.)

4. Disconnection of bogie
1 791-630-2260
Plate t 1 Disconnect inner bogie (4) and outer bogie (5).
2 791-630-2270
Screw t 3
3 01580-12419
Nut t 3
4 01643-32460
Washer t 3
16 Puller
L
5 790-101-4000 (490 kN {50 t 1
ton})
790 - 101 -
6 Pump t 1
1102
19 791-601-1000 Oil pump t 1

Disassembly 50-216
1. Track roller assembly
Turn over bogie assembly (1). Then, sling off two
track roller assemblies (2).

2. Remove cover (3).

50-216 D375A-6R
(01)
Undercarriage and frame
Disassembly and assembly of bogie assembly

Assembly 50-217 4. Refilling of oil


1. Assembly of pin assembly Using tool L19, supply the specified amount of
Assembly the pin assembly following the same oil.
procedure as described in the "Installation of a Refilling oil pressure: 0.49 MPa {5 kg/cm2}
5 Pin assembly:
bogie assembly".
(See Steps 3 to 5.) 90 115 cc(GO140)

2. Set inner bogie (4) to outer bogie (5).

3. Press-fitting of pin assembly


1) Set tool L16 and cover (3) in position.
2) Press-fit the pin assembly.
a Install the pin assembly with arrow (a) on
its end face up (when it is mounted on the
machine).
a Push in the pin assembly with cover (3).
a Push in the pin assembly to the machined
surface of the bogie and maintain step (b)
of 5 mm between the bogie and the pin
assembly.
2 Periphery of pin:
Molybdenum disulfide lubricant 5. Press fit the pin assembly at the opposite side of
(LM-P) bogie in the same way as shown in Steps 3 and
a Full press-fitting force for pin assembly : 4.
245441 kN {2545 ton} a After press-fitting of pin assembly, rock the
small bogie so that it can move smoothly.

6. Tighten the mounting bolts of pin assembly


cover (3). (two places, inside and outside)
3 Cover mounting bolt:
8241,030 Nm {84105 kgm}

7. Track roller assembly


Sling and install two track roller assemblies (2) to
bogie assembly (1).
2 Track roller mounting bolt:
Adhesive (LT-2)
3 Track roller mounting bolt:
1,1801,470 Nm {120150 kgm}

D375A-6R 50-217
(01)
Undercarriage and frame
Removal and installation of first bogie assembly

Removal and installation of first bogie assembly 50-218

Special tools 50-218 Removal 50-218


1. Separate the track shoe assembly. For details,

Necessity
Quantity

Sketch
see Separation and connection of track shoe

N/R
Symbol Part No. Part name
assembly.
1 791-630-2360 Plate t 1
2. Raise the machine so that the track rollers of the
2 790-201-2730 Spacer t 1
3 791-630-2270 Screw t 3 second bogie assembly leave the track link, by
4 01580-12419 Nut t 3 operating the blade and ripper.
5 01643-32460 Washer t 3 k Place a block between track roller and
14
Puller track link so that the machine does not
6 790-101-4000 (490 kN {50 t 1 lower.
ton}) k Set the parking brake lever and work
790 - 101 - equipment lock lever in the lock position.
7 Pump t 1
k Stop the engine and disconnect the cable
1102
1 791-630-2280 Adapter t 1
2 790-201-2770 Spacer t 1 from the negative (-) terminal of the bat-
3 791-630-2250 Plate t 1 tery.
4 790-434-1070 Screw t 1
5 01580-13629 Nut t 2 3. Install eyebolts to the pad mounting bolts (two
15 6 01643-33690 Washer t 2 M12 bolts) at the rear of the first bogie assembly
Puller (1), and lift the first bogie assembly (1).
7 790-101-4000 (490 kN {50 t 1
ton})
790 - 101 -
8 Pump t 1
1102
1 791-630-2260 Plate t 1
2 791-630-2270 Screw t 3
3 01580-12419 Nut t 3
4 01643-32460 Washer t 3
L 16 Puller
5 790-101-4000 (490 kN {50 t 1
ton})
790 - 101 -
6 Pump t 1
1102
791T-630-229
17 Guide t 2 Q
0
18 790-434-1350 Installer t 1
19 791-601-1000 Oil pump t 1
Bracket
1 791-630-1860 t 1 N
(L, H)
Bracket
20 2 791-630-1870 t 1 N
(R, H)
3 01010-62760 Bolt t 2
4 01643-32780 Washer t 2
791T-630-190
Lifting tool q 1
0
791T-630-191
q Tube 1 Q
0
791T-630-192
21
q Plate 1 Q
0
07283-38973 q Grip 1
040-11628 q Eyebolt 1
01643-31645 q Washer 1
01643-31232 q Washer 2
01582-01210 q Nut 2

50-218 D375A-6R
(01)
Undercarriage and frame
Removal and installation of first bogie assembly

4. Place a steel plate between the track shoe and 9. Pulling out shaft and ring
roller, and loosen roller cap bolts (2) for approxi- 1) Set tool L14 in position.
mately 20 mm. 2) Push out shaft (7) and ring (8) to the opposite
(both inside and outside) side simultaneously.
a Push out force: 137.3274.6 kN {1428
5. Hit the end face of shaft (3) with a hammer to ton}
remove track roller assembly (4). a To avoid an interference with the idler
a Take care not to break the dowel pin installed when pressing the ring, pump grease in
on the front side (oil plug side) of the track the track tension adjusting section in ad-
roller assembly. vance to move the idler cushion forward.
(Insertion depth of dowel pin: 5 6 mm)

6. Remove roller cap bolts (2), place track roller


assembly (4) on the steel plate, and pull it out
from the machine.
4 Track roller assembly:
150 kg

3) Remove floating seal (9) from the end face of


rings (8) and (12).
a Keep the floating seal in a safe place so
that it does not get damaged.

7. Sling first bogie (5) by using tool L20.

8. Remove cover (6).

D375A-6R 50-219
(01)
Undercarriage and frame
Removal and installation of first bogie assembly

4) Set tool L15 in position. Connection 50-2 0


1. Assembly of pin assembly
1) Using tool L18, install floating seal (9) to rings
(8) and (12). Also, install floating seal (10) to
the opposite surface of ring (12) and to ring
(13).
a Completely degrease the O-ring and the
O-ring contact surfaces of the floating
seal before installing.
a Check that the leaning of the floating seal
is less than 1 mm.

5) Pull out spacer (11) and rings (12) and (13).


a Pulling force: 205.8382.2 kN {2137
ton}
6) Remove spacer (11).
7) Remove spacer (14) and floating seal (10)
from between rings (12) and (13).
a Keep the floating seal in a safe place so
that it does not get damaged.

2) Press fit shaft (7) to ring (13).


3) Install spacer (14).
4) Press fit ring (12) to shaft (7).
5) Install spacer (11).
6) Press fit ring (8) to shaft (7).
2 Portion (a) of ring (13) and ring (8)
(approximately 10 mm):
Molybdenum disulphide lubricant
(LM-P)

10. Lower bogie (5) on the steel plate and pull it out.
4 Bogie assembly:
110 kg

50-220 D375A-6R
(01)
Undercarriage and frame
Removal and installation of first bogie assembly

2. Place bogie (5) on steel plate [1], and slide them 2) Press-fit the pin assembly.
beneath the center of the mounting position. a Install the pin assembly with arrow (a) on
its end face up (when it is mounted on the
3. Using tool L20, set the bogie to the mounting machine).
position. a Push in the pin assembly with cover (6).
a Push in the pin assembly to the machined
surface (b) of the bogie and maintain step
of 5 mm between the bogie and the pin
assembly.
2 Periphery of pin:
Molybdenum disulphide lubri-
cant (LM-P)
a Press-fitting force of pin assembly:
245441 kN {2545 ton}

4. Align the pin holes of the track frame and bogie,


and install guidance tool L17 in position.

6. Refilling of oil
Using tool L19, supply the specified amount of
oil.
a Refilling oil pressure: 0.49 MPa {5 kg/cm2}
5 Pin assembly:
95 115 cc(GO140)

5. Press-fitting of pin assembly


1) Set tool L16 and cover (6) in position.

D375A-6R 50-221
(01)
Undercarriage and frame
Removal and installation of first bogie assembly

7. Press fit the pin assembly at the opposite side of 11. Gradually lower the machine and when the
the bogie following the same procedure in Steps clearance between bogie (5) and shaft (3)
5 and 6. becomes approximately 20 mm, install cap (15)
and tighten bolts (2) lightly.
8. Install cover (6). (two places, inside and outside)
12. Matching the dowel hole with the dowel pin,
9. Install eyebolts to the bolt holes of the pad tighten bolts (2) to the specified torque.
mounting bolts (M12 x 2 pieces) of bogie (5) and 2 Cap mounting bolt:
sling the bogie. Adhesive (LT-2)
3 Cap mounting bolt:
1,1801,470 Nm {120150 kgm}

10. Insert tool L21 into the shaft of track roller


assembly (4), sling and balance the track roller
assembly, and place it on the track shoes. 13. Adjust the track tension. For details, see Testing
4 Track roller assembly: and adjusting, "Inspection and adjustment of
150 kg track tension".

50-222 D375A-6R
(01)
Undercarriage and frame
Separation and connection of track shoe assembly

Separation and connection of track shoe assembly 50-2 3

Separation 50-2 3 Checking before separation of the track shoe as-


1. Remove the blade assembly. For details see sembly 50-2 3
"Removal and installation of blade assembly". k In some cases, it may be extremely danger-
ous to separate the track shoe assembly. To
2. Remove cover (1). prevent danger, perform the following
checks before separation of the track shoe
assembly.
k Do not loosen the lubricator more than one
turn.
q Loosen lubricator (2) of the adjustment cylin-
der to drain the grease. Move the machine
forward a short distance and check that the
track tension is decreased.
a When the track tension is decreased, fol-
low the procedure in the "Separation of
track shoe assembly (normal)".

a Because the machine needs to move later,


do not disconnect battery cables.

q If the track tension is not decreased and is


still high, a problem may have occurred in-
side the track frame (such as damaged recoil
spring case, broken recoil spring set bolts, or
coming off of shaft end nut).
a If the track tension is not decreased, fol-
low the procedure in the "Separation of
track shoe assembly (when track frame
has internal defect)".

D375A-6R 50-223
(01)
Undercarriage and frame
Separation and connection of track shoe assembly

Separation of track shoe assembly 50-2 4 4. Sling the front end of master link (3), move the
(When track frame has internal defect) machine backward slowly to spread track shoe
a If any abnormality is detected by "Checking be- assembly (5).
fore separation of track shoe assembly", perform a Length of track: Approximately 12.5 m
the following procedure.
k If a problem has occurred inside the track
frame, the track shoe may spring back when
the assembly is separated. Also, the idler
may fly out when the track shoe assembly is
separated. This is potentially very danger-
ous. Be sure to separate the track shoe as-
sembly as follows.

1. Loosen lubricator (2), and move the machine


backward and forward to drain the grease.
[*1]
k Do not loosen lubricator (2) more than
one turn.
a Check that all the grease is discharged.

2. Move the machine forward slowly to press the


track shoes on the idler side against large block
[3] or a wall (or a blade of another machine of
same size). When the recoil spring is
compressed and the track shoe assembly sags,
stop the machine and apply the brake.
Locate master link (3) between the idler and front
carrier roller.
a Apply chain block [4] between the carrier roll-
er support and link to assure safety.

3. Remove track shoe (4) and separate master link


(3).
[*2]

50-224 D375A-6R
(01)
Undercarriage and frame
Separation and connection of track shoe assembly

Separation of track shoe assembly (normal) 50-2 5 3. Remove track shoe (4).
a If no abnormality is detected by "Checking be- [* 2]
fore separation of track shoe assembly", perform a Loosen each of four bolts by one or two turns.
the following procedure. Check that they can be unscrewed smoothly,
and then remove them. Do not remove only
1. Position the master link. one bolt without loosening the other three.
a Locate master link (3) above the idler (a little a If a bolt does not turn smoothly and it is un-
backward from the center). screwed forcibly, the threads of the bolt and
a Place block [1] between the carrier rollers master link (3) may be damaged.
and place block [2] under the front track so
that the mating faces of master link do not
open until the master bolts are removed.

4. Sling the front end of the master link, move the


machine backward slowly to spread track shoe
assembly (5).
2. Loosen lubricator (2). a Length of track: Approximately 12.5 m
[* 1] k For purposes of safety, check that no one
k Do not loosen lubricator (2) more than remains in front of the idler.
one turn.

D375A-6R 50-225
(01)
Undercarriage and frame
Separation and connection of track shoe assembly

Connection 50-2 6
q Perform connection in the reverse to separation.

[*1]
a Adjust the track tension. For details, see Testing
and adjusting, Testing and adjusting track ten-
sion.

[*2]
a Finger-tighten the four bolts until the mating fac-
es of the master link are fitted.
a If the bolts are tightened forcibly before the mas-
ter link mating faces are fitted, the threads of
bolts and master link may be damaged.
a Tighten the bolts in the order shown in the figure.
2 Shoe bolt:
Molybdenum disulphide lubricant
(LM-P)
3 Shoe bolt:
(Master link)
Initial torque: 686 69 Nm {70 7 kgm}
Retightening angle: 180 10
(Regular link)
Initial torque: 1,372 140 Nm {140 14
kgm}
Retightening angle: 120 10

50-226 D375A-6R
(01)
Undercarriage and frame
Overall disassembly and assembly of track shoe

Overall disassembly and assembly of track shoe 50-2 7

Special tools 50-2 7 Overall disassembly 50-2 7


a For the overall disassembly of the track shoe as-

New/Remodel
sembly, see Parts judgment guide, Undercar-

Necessity
Quantity

Sketch
Symbol Part No. Part name riage, Lubricated track" and Parts judgment
guide, Undercarriage, Reversing procedure for
pin and bushing.".
1 791-646-7351 Push tool t 1
2 791-660-7460 Pin brush t 1
1. Removal of track shoe
Sling the track shoe assembly and place the
Push tool
3 791-646-7900 t 1 assembly on the floor with shoes (1) up. Remove
(For large plug)
791-701-3000 Seal checker the track shoes by using shoe bolt impact
4 or t 2 wrench [1].
791-601-1000 Oil pump a If shoe bolt (2) is not loosened (if its rotational
5 791-932-1110
Push tool
t 1
torque is not reduced to zero) even after it is
(For small plug) loosened by one turn, loosen other bolts so
6 791-632-1021 Installer t 1 that the bolt can be loosened smoothly.
1 791-632-1300
Push tool assem-
t 1 N a Forcibly rotating the bolt the rotational torque
bly of which is not reduced to zero may cause
2 791-632-1260 q Push tool 1 adhesive transformation between the bolt
3 791-632-1270 q Adapter 1 and link, which may require repairs.
q Adapter a When repositioning the track shoe assembly,
4 791-632-1220 1
(small) take care not to damage the master links.
5 791-632-1230 q Ring 1 a If the shoe nut needs to be removed by gas
7
6 791-632-1240 q Plate 1 cut, keep the temperature in the seal section
7 791-685-5730 q Bar 1 below 80 C to prevent thermal deterioration
of the seals and take measures to prevent
8 791-632-1250 q Ring 1
the spatters from entering through the clear-
R 9 791-632-1280 q Spring 1 ances between the links.
10 01252-30605 q Bolt 1
11 01580-01210 q Nut 1
Push tool assem-
1 791-632-1200 t 1 N
bly
2 791-632-1260 q Push tool 1
3 791-632-1270 q Adapter 1
q Adapter
4 791-632-1210 1
(large)
5 791-632-1230 q Ring 1
8
6 791-632-1240 q Plate 1
7 791-685-5730 q Bar 1
8 791-632-1250 q Ring 1
9 791-632-1280 q Spring 1
10 01252-30650 q Bolt 1 2. Disassembly of track links
11 01580-01210 Nut q 1 1) Place the link assembly on the link press and
Push tool assem- hit it with a hammer to fit the bushing to jaw
1 791-632-1290 t 2 N
bly [2] firmly.
9 2 791-685-5730 Bar 1 a If the link tread or outer periphery of the
3 01580-01210 Nut 1 bushing is worn, adjust the height of jaw
[2] or guide plate to align the pin or bush-
ing with the disassembly jigs so that the
pin-bore or bushing-bore in the link is not
damaged during disassembly.

D375A-6R 50-227
(01)
Undercarriage and frame
Overall disassembly and assembly of track shoe

a If the pin or bushing is not aligned with the 3) Return the left cylinder and operate the right
jig, the bore in the link may be damaged cylinder to pull out the pin and bushing from
or the pin or bushing may be broken dur- the right link simultaneously.
ing disassembly.
a Using tool R5, drive out the small plug of
the pin towards inside after disassembly
so that the work place does not become
dirty.

4) Return the right cylinder, take out the right


and left links, pins, bushings and spacers,
and feed the next set of the link assembly to
the jaw.
k Because the broken wedge ring has
sharp edges, take care not to cut your
2) Operate the left cylinder to pull out the pin hands with them.
and bushing from the left link simultaneously. a If the bushing end faces and its sealing
a Check the pulling-out force of the pin and surface are damaged, oil will leak. Ac-
bushing to see if the press-fitting force is cordingly, handle them carefully.
obtained, that is required when they are
reused by being turned 180 degree.
a The wedge ring is broken with a bang.
This sound does not indicate abnormality

50-228 D375A-6R
(01)
Undercarriage and frame
Overall disassembly and assembly of track shoe

3. Checking
Check the removed parts for following items,
then determine to reuse them for a lubricated
track or grease-lubricated track, depending on
the check results.
a For judgment of reuse of the parts,
see Parts judgment guide, Undercarriage,
Lubricated track".
1) Check the parts visually for damage. If a
parts seems to be damaged, check it by dye
penetrant test or magnaflux inspection.
If it has any crack, it cannot be reused.
Discard it.
2) Measure the outside diameter of the
press-fitting portions of the pin and bushing
a Precautions for storage
and the inside diameter of the link bores
1) Store the seal without removing it from the
where the pin and bushing are press fitted to
link so that the link bore does not rust, and
by using micrometer [5] and cylinder gauge
take care not to damage the seal lip.
[6], to see if the allowable interference is
2) Apply rust-preventive oil to the pin and
obtained. Note that the standard interference
bushing press-fitting bores, shoe mounting
must be secured between the pin and link
surface of the link, and mating face of the
when they are reused for a lubricated track.
master link.
a If the allowable interference is not ob-
3) Apply rust-preventive oil to the all surfaces of
tained, replace the parts with new ones.
the pin, bushing, and spacer prior to storage.
a For the dimensional criteria, see "Mainte-
Take extreme care not to damage the
nance standard".
bushing end faces.

D375A-6R 50-229
(01)
Undercarriage and frame
Overall disassembly and assembly of track shoe

Overall assembly 50-230


a For the overall assembly of the track shoe as-
sembly, see Parts judgment guide, Undercar-
riage, Lubricated track" and Parts judgment
guide, Undercarriage, Reversing procedure for
pin and bushing.".

Rebuilding the link assembly for lubricated


track 50-230
1. Preparatory work
1) Cleaning of seal assembly
Remove the seal assembly from the link,
divide it into seal ring (3) and load ring (4),
and clean them.
4) If the large plug was removed from the pin,
a Clean seal ring (3) and load ring (4) quick-
drive in large plug (5) by using tool R3.
ly because they are easily deteriorated by
At this time, clean the pin hole in advance by
the cleaning agent (trichloroethylene,
using tool R2.
etc.). Wipe off the cleaning agent with a
1] Insert the plug in the hole of the guide
cloth from them.
through the plug inserting window.
2] Press the bar with hand until the plug
stops.
3] Press the plug with the bar until the guide
touches the pin.
4] Hit the bar with a hammer to drive in the
plug.
a Driving distance (a) from pin end face:
11 2 mm
a If chamfered face of the pin hole is lost
due to wear, chamfer it by using a
small-sized grinder (grindstone end
angle: 4560) so that the plug is not
damaged.
2) When reusing the pin, chamfer the edges of a If the hole face of the pin is chamfered
its end faces with a grinder. Remove the with the grinder, clean the pin hole
nodules formed on its press-fitting portions again by using tool R2.
with the grinder. a Apply oil (GO90) on the outside pe-
a If the edge of its end face is worn and riphery of the plug, and drive it with its
sharpened, the press-fitting portion of the smaller diameter end facing pin (6).
pin may cause galling, resulting in oil
leak.
3) Clean the dirty links, pins, bushings, and
spacers. Remove the nodules formed on the
link and bushing with the grinder, too.
a Clean the parts immediately before the
assembly because they easily rust.
a Do not grind the bushing end faces be-
cause doing so may cause oil leak.

50-230 D375A-6R
(01)
Undercarriage and frame
Overall disassembly and assembly of track shoe

5) Installation of seal assembly


Clean the bores of the link, and push in the
seal to the bottom by using tool R6.
a Do not apply oil to the link bores and the
seal assembly (portion (d)) because any
adhered oil causes the seal to turn and its
sealing performance is lowered. Accord-
ingly, take care not to allow any oil to ad-
here to the seal when installing the seal to
the link bore.

6) Adjust the installed dimensions of the link


press press-fitting jigs to keep the protrusion
of the pin and bushing constant and to keep
the installed dimensions of the seal within the
standard range.
a If the pin end faces (portion P) or link side
faces (portions Q and R) are worn, add
the wear reduction to the standard in-
stalled dimensions of the press-fitting jigs
so that the right and left protrusions of the
pin and bushing are even.

D375A-6R 50-231
(01)
Undercarriage and frame
Overall disassembly and assembly of track shoe

7) Adjust the relief pressure of the link press so 2. Assembly of link


that the pressing force of the press does not 1) Apply oil (GO90) between pin (3) and
exceed the standard value. bushing (4) with a clean brush and assemble
a If the pressing force is excessive, the them, then set them on the bushing jaw of the
spacer is pressed against the bushing ex- link press.
cessively. As a result, the spacer may be a When reusing the bushing (by turning it
broken or abnormal wear may occur be- 180 degree), set it with the worn outside
tween the spacer and bushing end face. surface facing the shoe mounting face of
a Pressing force for pin and bushing: the link (set the bushing on the link press
980 kN {100 ton} with the face up).
Pressing force C 1.8 x Average pressure
(Adjust the relief pressure of the link
press to obtain the pressing force.)

2) Set the right and left master links having


bushing-bore with their shoe mounting faces
up, and press fit them to the bushing.
a At this time, use the master links having
pin-bore as supports.
a Bushing press-fitting force:
196343 kN {2035 ton}

50-232 D375A-6R
(01)
Undercarriage and frame
Overall disassembly and assembly of track shoe

3) While checking the distance between the 6) Send out the master link portion, and then set
shoe bolt holes of the right and left master the next pins and bushings.
links by using the shoe bolt pitch gage, press a Install the pin, even it is reused, with its
fit the master links to the bushing until the cross hole (its direction is indicated with
distance is the standard value. mark (e)) facing the link tread as in the
a Remove all steel chips generated by the case of new one.
press-fitting process completely with If it is not installed so, the strength of the
compressed air. assembly may be lowered. Accordingly,
indicate the direction of the cross hole on
the end face to prevent wrong installation.

4) Turn over the master links and check that


they are press-fitted in parallel.
5) Measure the right and left protrusions of the 7) Apply liquid gasket (198-32-19890) to all
bushing by using depth gauge [7]. surfaces of pin press-fitting portion (f) and
a Adjust the link press press-fitting jigs so link bore (g).
that the right and left protrusions of the a This prevents the galling of the pin
bushing are even. press-fitting portion that may cause oil to
seep out.

D375A-6R 50-233
(01)
Undercarriage and frame
Overall disassembly and assembly of track shoe

8) Set the right link and install the spacer to the 10)Use minor adjustment spacer (8) to press fit
pin. the pin until its end face reaches the bottom
a Check that the seal surfaces and bushing of the receiver jig.
end faces are free from dirt, then apply oil a Adjust the depth of the receiver jig hole so
(GO90) on them using a clean cloth or that the right and left protrusions of the pin
brush. are even.
a Wipe the spacer with a clean cloth before
installing.

11)Set the left link and install the spacer to the


pin.
a Apply oil similarly to the right link.
9) Using the right jig as receiver jig and the left
jig as pusher jig, press fit the pin and bushing
simultaneously.
a Press fit them smoothly because bumpy
press-fitting may cause the seal to come
off the link.
When the seal comes off the link, stop the
press-fitting and set the seal to the link
correctly, then restart the press-fitting.
a Press-fitting force for pin and bushing:
392686 kN {4070 ton}

12)By using the left jig as receiver jig, and the


right jig as pusher jig, press fit the left link.
a When press fitting, take care that the right
and left seals and spacers do not come
off.
a Press-fitting force for pin and bushing:
392686 kN {4070 ton}

13)Perform the press fitting until the link,


spacers, and bushing are mutually fitted.

50-234 D375A-6R
(01)
Undercarriage and frame
Overall disassembly and assembly of track shoe

a Actually, you cannot see from outside if 15)Set the ring on jig R8.
the above parts are fitted. Accordingly,
control the hydraulic pressure of the link
press. Set the relief pressure to a proper
level and raise the pressure of the link
press to that level while performing the
press fitting.
For the relief pressure settings, see
"Preparatory work."
a Check that adjacent two sets of links pivot
on the pin.

16)Match the jig to the pin-bore of the link and


push the ring in until the ring is fitted in the pin
groove.
a A click is heard when the ring is fitted in
the pin groove.

14)Using the shoe bolt pitch gage, check that the


distance between the shoe bolt holes is
within the standard range.
a If the distance between the shoe bolt
holes is longer than the standard range,
disassemble and check for abnormality,
then assemble them again if no abnor-
mality is found.
a If the distance between the shoe bolt
holes is less than the standard range and 17)Using jig R9, install the ring into the pin
the track shoe cannot be installed, then groove on the other side similarly.
wear of the spacer or bushing end face
may exceeds the allowable limit. In this
case, disassemble it and replace the rele-
vant part.

D375A-6R 50-235
(01)
Undercarriage and frame
Overall disassembly and assembly of track shoe

18)Press the ring by using jig R10. a For cold or extremely cold district, supply
a Pressing force: 294372 kN {3038 ton} Komatsu genuine engine oil
(150-09-19270 or 195-32-61990), which
has excellent low-temperature character-
istics, instead of oil (GO90).
a If the charged oil pressure is increased
too much, it has bad effects on the seals.
a Supply oil (d) up to the level (a) where
depth (L) of the hollow of the hole of pin
(c) is in the following range when the pin
is left with the small plug side (b) up (the
link assembly placed on its side) for thirty
minutes.
a (L) Dimension: 4070 mm

19)Use tool R4 for each link assembly to remove


air from inside the pin, and check the sealing
performance.
a Keep the degree of vacuum inside the pin
at 86.7 93.3 kPa {650 700 mmHg} for
5 seconds to check that the pressure
does not change.
If the pressure changes, disassemble the
link assembly to check the seals. If no
abnormality is found, assemble them.

21)After supplying oil, drive in the small plug to


the specified position by using tool R5.
a Apply oil (GO90) on the outside periphery
of the small plug.
a Drive in the plug to the following depth.
Press-fitting length from end face: 7.5 1
mm

20)Use tool R4 to supply oil (GO90) until the


charged pressure rises to 196.1294.2 kPa
{23 kg/cm2}.

22)Install the master links having pin-bore at


last.
a Check that the right and left master links
are press fitted in parallel.

50-236 D375A-6R
(01)
Undercarriage and frame
Overall disassembly and assembly of track shoe

3. Installation of track shoe 2) For the track that has two master link joints
1) Place the link assembly on the bed, and and consists of two track shoe assemblies,
install track shoes (1) by using shoe bolt connect the two track shoe assemblies as
impact wrench [1] and torque wrench. follows. Place the two assemblies on a level
3 Shoe bolt (2) (Regular link) place in a line with the track shoes up. Pull
Initial torque: master links with pin-bore (1) of one
1,372 140 Nm {140 14 kgm} assembly and master links with bushing-bore
Retightening angle: (2) together to contact their mating faces
120 10 each other. Place shoe (3) on the master
2 Shoe bolt: links, and finger-tighten shoe bolts (4) for
Molybdenum disulphide lubricant master link so that their mating faces are in
(LM-P) close contact. Then tighten the bolts to the
specified torque to complete the connection.
2 Shoe bolt:
Molybdenum disulphide lubricant
(LM-P)
3 Shoe bolt (Master link)
Initial torque:
686 68.6 Nm {70 7 kgm}
Retightening angle:
180 10

a Tighten the bolts in the order of [1] [4].

D375A-6R 50-237
(01)
Undercarriage and frame
Overall disassembly and assembly of track shoe

Rebuilding the link assembly for grease lubri- 3) Clean any dirty surfaces among the outside
cated track 50-238 periphery of the pin, spacer surface, and end
1. Cleaning of seal assembly faces and inside surface of the bushing.
1) Cleaning of seal assembly 4) Drive in the large plug by using tool R3.
q Remove seal assembly from the link, di- 1] Insert the plug in the hole of the guide
vide it into seal ring (3) and load ring (4), through the plug inserting window. (Apply
and clean them. oil to the plug.)
a Clean seal ring (3) and load ring (4) 2] Press the bar with hand until the plug
quickly because they are easily deteri- stops.
orated by the cleaning agent. Wipe off 3] Press the plug with the bar until the guide
the cleaning agent with a cloth from touches the pin.
them. 4] Hit the bar with a hammer to drive in the
plug.
a Driving distance (a) from pin end face:
Large plug: 11 2 mm
a If the plug was not removed from the
pin when disassembling the track
shoe assembly, reuse as it is.

2) When reusing the pin, chamfer the edges of


its end faces with a grinder to allow for
smooth press fitting.

5) Apply grease on the outside periphery of the


pin and surfaces of the spacer.
6) Installation of seal assembly
q Clean the bores of the link, and push in
the seal to the bottom by using tool R6.
a Do not apply grease to the link bores
and the seal assembly because any
adhered grease causes the seal to
turn and its sealing performance is
lowered.

50-238 D375A-6R
(01)
Undercarriage and frame
Overall disassembly and assembly of track shoe

7) Adjust the installed dimensions of the link 2. Assembly of link


press press-fitting jigs to keep the protrusion 1) Apply lithium grease (G2-LI) between pin (3)
of the pin and bushing constant and to keep and bushing (4) and assemble them, then set
the installed dimensions of the seal within the them on the bushing jaw of the link press.
standard range. a When reusing the bushing (by turning it
a For the standard dimensions of the link 180 degree), set it with the worn outside
press press-fitting jigs, see "Link press surface facing the shoe mounting face of
press-fitting jig dimensions." the link (set the bushing on the link press
a If the pin end faces (portion P) or link side with the face up).
faces (portions Q and R) are worn, add
the wear reduction to the standard in-
stalled dimensions of the press-fitting jigs
so that the right and left protrusions of the
pin and bushing are even.

2) Set the right and left master links having


bushing-bore with their shoe mounting faces
up, and press fit them to the bushing.
a Bushing press-fitting force:
196343 kN {2035 ton}

D375A-6R 50-239
(01)
Undercarriage and frame
Overall disassembly and assembly of track shoe

3) While checking the distance between the 6) Send out the master link portion, and then set
shoe bolt holes of the right and left master the next pins and bushings.
links by using the shoe bolt pitch gage, press a Install the pin, even it is reused, with its
fit the master links to the bushing until the cross hole (its direction is indicated with
distance is the standard value. mark (e)) facing the link tread as in the
a Remove all steel chips generated by the case of new one.
press-fitting process completely with If it is not installed so, the strength of the
compressed air. assembly may be lowered. Accordingly,
4) Turn over the master links and check that indicate the direction of the cross hole on
they are press-fitted in parallel. the end face to prevent wrong installation.

a If a pin has worn outside periphery, it is to


5) Measure the right and left protrusions of the be installed with its un-worn periphery to-
bushing by using depth gauge [7]. ward the traction side. Even in this case,
a Adjust the link press press-fitting jigs so the pin must be installed with its cross
that the right and left protrusions of the hole facing the link tread.
bushing are even.

50-240 D375A-6R
(01)
Undercarriage and frame
Overall disassembly and assembly of track shoe

7) Set the left and right links, and operate the 9) Set the ring on jig R8.
left and right press-fittng jigs to press fit the
pin and bushing simultaneously.
a Press fit them smoothly because bumpy
press-fitting may cause the seal to come
off the link. When the seal comes off the
link, stop the press-fitting and set the seal
to the link correctly, then restart the
press-fitting.
a Pressing force for pin and bushing:
980 kN {100 ton}
Pressing forceC 1.8 x Average
press-fitting force
(Adjust the relief pressure of the link
press to obtain the pressing force.)
10)Match the jig to the pin-bore of the link and
push the ring in until the ring is fitted in the pin
groove.
Using jig R9, install the ring into the pin
groove on the other side similarly.
a A click is heard when the ring is fitted in
the pin groove.

8) Check the distance between the shoe bolt


holes by using the shoe bolt pitch gage, and
when it reaches the standard range, stop the
press-fitting.

11)Press the ring by using jig R10.


a Pressing force:
294372 kN {3038 ton}

D375A-6R 50-241
(01)
Undercarriage and frame
Overall disassembly and assembly of track shoe

12)Pump in grease. 3. Installation of track shoe (to regular links)


a Pump in grease (d) up to the level (a) Place the link assembly on the bed, and install
where depth (L) of the hollow of the hole track shoes (1) by using shoe bolt impact wrench
of pin (c) is in the following range when [1] and torque wrench.
the pin is left with the small plug side (b) 2 Shoe bolt (2):
up (the link assembly placed on its side). Molybdenum disulphide lubricant
a (L) Dimension: 4070 mm (LM-P)
3 Shoe bolt (2) (Regular link)
Initial torque:
1,372 140 Nm {140 14 kgm}
Retightening angle:
120 10

13)After filling grease, drive in the small plug to


the specified position by using tool R5.
a Drive in the plug to the following depth.
Press-fitting length from end face: 7.5 1
mm
4. Connection of track consisting of two track
shoe assemblies
Place the two assemblies on a level place in a
line with the track shoes up. Pull master links
with pin-bore (1) of one assembly and master
links with bushing-bore (2) together to contact
their mating faces each other. Place shoe (3) on
the master links, and finger-tighten shoe bolts
(4) for master link so that their mating faces are
in close contact. Then tighten the bolts to the
specified torque to complete the connection.
2 Shoe bolt:
Molybdenum disulphide lubricant
(LM-P)
3 Shoe bolt (Master link)
14)Install the master links having pin-bore at
Initial torque:
last.
686 68.6 Nm {70 7 kgm}
a Check that the right and left master links
Retightening angle:
are press fitted in parallel.
180 10
a Tighten the bolts in the order of [1] [4].

50-242 D375A-6R
(01)
Undercarriage and frame
Overall disassembly and assembly of track shoe

D375A-6R 50-243
(01)
Undercarriage and frame
Link press press-fitting jig dimensions

Link press press-fitting jig dimensions 50-24

Unit: mm
Jig dimensions
(a) 4.2
(b) 2.0
(c) 52.1

Precaution
The link receiving face of jaw (1) must be vertical.
Replaceable wear plate (2) shown below is desir-
able.

50-244 D375A-6R
(01)
Undercarriage and frame
Disassembly and assembly of one link assembly in the field

Disassembly and assembly of one link assembly in the field 50-245

Special tools 50-245

New/Remodel

New/Remodel
Necessity

Necessity
Quantity

Quantity
Sketch

Sketch
Symbol Part No. Part name Symbol Part No. Part name

1 791-646-7351 Push tool t 1 21 791-680-5551 q Guide 1


2 791-660-7460 Pin brush t 1 22 791-680-9630 q Adapter 1
Push tool (for 23 791-632-1160 q Guide 1
3 791-646-7900 t 1
large plugs) 24 195-32-61210 Bolt 2
791-701-3000 Cylinder
Seal checker oil
4 or t 2 R 7 25 790-101-4300 (1,470 kN {150 t 1
pump
791-601-1000 ton})
Push tool (for 26 790-101-1102 Pump t 1
5 791-932-1110 t 1 Cylinder
small plug) 27 790-101-4200 t 1
6 791-632-1021 Installer t 1 (294 kN {30 ton})
Remover & 28 791-680-1630 Spacer t 1 N Q
1 791-632-1100 t 1
installer assembly
2 791-632-1130 q Adapter 1
3 790-434-1610 q Guide 1 Disassembly 50-245
4 01010-51440 q Bolt 2 q Separate the track shoe assembly. For details,
R 5 791-685-9510 q Frame 1 see Separation and connection of track shoe
6 791-685-9530 q Rod 1 assembly.
7 791-685-9520 q Frame 1 a Move the machine forward or backward to
8 791-685-9550 q Nut 3 bring the link assembly to be disassembled
9 04530-12030 q Eyebolt 1 to a position where tool 7 can be easily in-
7 10 791-685-9560 q Bolt 4
11 791-126-0150 q Adapter 1
stalled on the link when the track shoe as-
12 791-685-9540 q Rod 1 sembly is separated.
13 791-632-1140 q Adapter 1 k Set the parking brake lever and work equip-
14 791-680-5520 q Guide 1 ment lock lever in the lock position.
15 01010-51030 q Bolt 1 k Stop the engine and disconnect the cable
16 791-632-1150 q Pusher 1 from the negative (-) terminal of the battery.
17 791-685-9620 q Extension 1 1. Install tool R7-2 on link (1) with R7-24, and install
18 791-632-1180 q Adapter 1
19 791-680-5543 q Adapter 1
tool R7-3to the link withR7-4.
20 791-632-1170 q Guide 1 a Use the shoe bolts for installing tool R7-24.

D375A-6R 50-245
(01)
Undercarriage and frame
Disassembly and assembly of one link assembly in the field

2. Assemble tools R7-25 and R7-5 to R7-11, then a If cylinder reaches its stroke end, connect
sling them to place on the shoe. tool R7-17 and repeat the work.

5. Set tools R7-27 and R7-28 in the middle of the


3. Insert tool R7-12 from the cylinder side, and links to be disassembled on their tread side,
install it by using two tools R7-8. connect tool R7-26, then apply oil pressure to
open the links by 56 mm to disconnect them.

4. Set tools R7-13 to R7-16, connect tool R7-26,


and then apply oil pressure to pull out the pin (2). 6. Repeat steps 1 to 4 to pull out another pin (3) on
the other side.

7. Repeat step 5 to remove links (4).

50-246 D375A-6R
(01)
Undercarriage and frame
Disassembly and assembly of one link assembly in the field

Assembly 50-247
1. Assemble the link sub-assembly according to
the following procedure.
1) Set tool R7-18 to the bushing-bore end of link
(5), and press fit bushing (6).
a Bushing press-fitting force:
196294 kN {2035 ton}

2) Set tool R7-19 to the pin-bore end of the link,


and press fit pin (7).
a Install the pin with the cross hole (a) fac-
ing link tread (b).
a Press-fitting force for pin:
206323 kN {2133 ton}

D375A-6R 50-247
(01)
Undercarriage and frame
Disassembly and assembly of one link assembly in the field

2. Set link sub-assembly (8) to the link to be 4. Similarly to the disassembly procedure, set tools
connected. R7-25, R7-5 to R7-12, and R7-17 to the links.

5. Use tools R7-19 and R7-21 to press fit the


pin-bore end and use toolR7-22, R7-18,
andR7-21 to press fit the bushing-bore end of
the link. Press fit them alternately.
a First press fit the pin-bore end of the link.
When the bushing is partially inserted into
the link bore, remove tool R7-20 that is in-
stalled in step 3, then press fit the bush-
ing-bore end of the link.
a Press-fitting force for pin:
206323 kN {2133 ton}
a Press-fitting force for bushing:
196294 kN {2030 ton}
3. Set counterpart link (9) and support it with tool
R7-20.

6. Similarly to the disassembly procedure, use


tools R7-27 and R7-28 to push open links (10) to
be connected.

50-248 D375A-6R
(01)
Undercarriage and frame
Disassembly and assembly of one link assembly in the field

7. Set link (11) to be connected to link (10), connect


them by using tool R7-23, and then remove tools
R7-27and R7-28.

8. Similarly to the disassembly procedure, set tool


R7-2 and press fit pin R7-12 (12) to the links.
2 Pin press-fitting hole in link:
Liquid gasket (198-32-19890)
a Set the pin with its side hole facing the link
tread.
a Press-fitting force for pin:
412646 kN {4266 ton}
a When the cylinder reaches its stroke end,
add tool R7-17, and R7-14 toR7-16, then re-
peat the work.

D375A-6R 50-249
(01)
Undercarriage and frame
Disassembly and assembly of master link

Disassembly and assembly of master link 50-250

Special tools 50-250

Necessity

Necessity
Quantity

Quantity
Sketch

Sketch
N/R

N/R
Symbol Part No. Part name Symbol Part No. Part name

1 791-646-7351 Push tool t 1 26 790-101-1102 Pump t 1


2 791-660-7460 Pin brush t 1 Cylinder
7 27 790-101-4200 t 1
Push tool (for (294 kN {30 ton})
3 791-646-7900 t 1 28 791-680-1630 Spacer t 1
large plug)
791-701-3000 Push tool assem-
Seal checker oil 1 791-632-1300 t 1 N
4 or t 2 bly
pump
791-601-1000 2 791-632-1260 q Push tool 1
Push tool (for
5 791-932-1110 t 1 3 791-632-1270 q Adapter 1
small plug)
6 791-632-1021 Installer t 1 4 791-632-1220 q Pin (small) 1
Remover & 5 791-632-1230 q Ring 1
1 791-632-1100 t 1 8 6 791-632-1240
installer assembly q Plate 1
2 791-632-1130 q Adapter 1 7 791-685-5730 q Bar 1
3 790-434-1610 q Guide 1 8 791-632-1250 q Ring 1
4 01010-51440 q Bolt 2 9 791-632-1280 q Spring 1
5 791-685-9510 q Frame 1 10 01252-30605 q Bolt 1
6 791-685-9530 q Rod 1 11 01580-01210 q Nut 1
7 791-685-9520 Frame 1 R
q Push tool assem-
1 791-632-1200 t 1 N
8 791-685-9550 q Nut 3 bly
9 04530-12030 q Eyebolt 1 2 791-632-1260 q Push tool 1
R
10 791-685-9560 q Bolt 4 3 791-632-1270 q Adapter 1

11 791-126-0150 q Adapter 1 4 791-632-1210 q Pin (large) 1

12 791-685-9540 q Rod 1 5 791-632-1230 q Ring 1


9 6 791-632-1240 q Plate 1
13 791-632-1140 q Adapter 1
7 7 791-685-5730
14 791-680-5520 q Guide 1 q Bar 1

15 01010-51030 q Bolt 1 8 791-632-1250 q Ring 1

16 791-632-1150 q Pusher 1 9 791-632-1280 q Spring 1

17 791-685-9620 q Extension 1 10 01252-30650 q Bolt 1

18 791-632-1180 q Adapter 1 11 01580-01210 q Nut 1


Push tool assem-
19 791-680-5543 q Adapter 1 1 791-632-1290 t 2 N
bly
20 791-632-1160 q Guide 1 10 2 791-685-5730 Bar 1
21 791-680-5551 q Guide 1 3 01580-01210 Nut 1
22 791-680-9630 q Adapter 1
23 791-632-1160 Guide 1
24 195-32-61210 Bolt 2
Cylinder
25 790-101-4300 (1,470 kN {150 t 1
ton})

50-250 D375A-6R
(01)
Undercarriage and frame
Disassembly and assembly of master link

Disassembly 50-251 q For master link type


a For the method of using tool R7, see "Disassem- 1) Gas cut and removal of master link with
bly of one link assembly in the field." bushing-bore.
1. Removal of track shoe assembly Gas cut the pin and bushing along the wavy
Remove the track shoe assembly from the track lines and remove the hatched parts. Move
frame. For details, see Separation of track shoe master links (4) vertically as shown by the
assembly. arrow to remove them, and then pull out
remaining pins (5a) and (5b) press fitted in
2. Disassembly of track shoe assembly respective regular links (2) by moving them
Disconnect the all master link joints to divide the vertically as shown by the arrow using the
track into two track shoe assemblies. press.
q Necessary special tools:
3. Removal of master link 1. Gas cutting machine
q For master pin type 2. ToolR7
1) Gas cutting of regular link
Gas cut the links along the wavy lines, and
remove the hatched parts.
q Necessary special tool: Gas cutting ma-
chine

2) Removal of master link with pin-bore


Gas cut the master links along the wavy lines
and remove the hatched parts. Press pin (6)
downward as shown by the arrow by using
the press to pull it out from link (2a), then pull
2) Removal of regular link out pin (6) and link (2b) from bushing (3)
Press pin (1) downward as shown by the simultaneously.
arrow by using the press to pull it out from link q Special tools:
(2), and then pull out the pin (1) and the other 1. Gas cutting machine
link (2) from bushing (3) at the same time. 2. ToolR7

D375A-6R 50-251
(01)
Undercarriage and frame
Disassembly and assembly of master link

Assembly 50-252
a For the method of using tool R7, see "Disassem- 2) Set spacers (6) and seal assemblies (7) to
bly of one link assembly in the field." the bores of links (2a) to be connected.
(3): Bushing
1. Assembly of master links with bushing-bore
1) Press fit master links with bushing-bore (4) to
bushing (3) using the press.
a When press fitting the left and right mas-
ter links, take care so that the links are fit
in parallel.
a Do not damage the mating face of the
master link and the end faces of the
bushing.

Unit: mm
L1 184 0.7

L2 253.4 0.7
3) Match the pin bores of the links and the bores
D1 33 drill
for bushing (3) of the master links, and
connect them with guide pin [1].
D2 30 x 2.0

4) Press fit pin (5) by using tool R7 to install


master links (4) with bushing bore.
2 Pin press-fitting bore in link:
2. Installation of master link with bushing-bore
1) Increase the space between the links at the Liquid gasket(198-32-19890)
centers of their treads by using tool R7 as a Install the pin with its cross hole facing the
shown in the figure. link tread.
a: 5 mm 5) Install the rings by using tool R7 and tools
(Increase by 10 mm between the ends of the R8, R9, and R10.
links.))

50-252 D375A-6R
(01)
Undercarriage and frame
Disassembly and assembly of master link

6) Install the track shoe to the links of the 2) Pass pin (5) through bushing (3), set right
connecting part. and left master links (4) with pin-bore, and
7) Drive in large plug (8) by using tool R3, fill oil press fit them from both sides by using tool
by using tool R4, and then drive in small plug R7.
(9) by using tool R5. 3) Install the rings by using tool R7 and tools
R8, R9, and R10.
4) Drive in large plug (8) by using tool R3, fill oil
by using tool R4, and then drive in small plug
(9) by using tool R5.

a When press fitting the right and left mas-


ter links, take care so that the links are in
parallel (both for master links with bush-
ing bore and pin-bore).
a Do not damage the mating face of the 4. Connection of master links
master link and the end faces of the Place the two track shoe assemblies on a level
bushing. place in a line with the track shoes up. Pull
a Adjust the end play of the connecting part master links (4a) with pin-bore of one assembly
(the thrust end play between the links and master links (4b) with bushing-bore together
connected with the pin) to 00.13 mm. to contact their mating faces each other. Place
a Take care not to allow dirt, sand, or dust the track shoe on the master links, and
to attach the seal, spacer, end face of the finger-tighten the shoe bolts for master link so
bushing, and the master link mating face that their mating faces are in close contact. Then
with tap holes. tighten the bolts to the specified torque to
complete the connection.
3. Assembly of master link with pin-bore 3 Shoe bolt (Master link)
1) Set spacers (6) and seal assemblies (7) to Initial torque:
the bores of master links (4a). 686 68.6 Nm {70 7 kgm}
(3): Bushing Retightening angle:
180 10

D375A-6R 50-253
(01)
Undercarriage and frame
Removal and installation of pivot shaft assembly

Removal and installation of pivot shaft assembly 50-254

Special tools 50-254 3. Remove seal (2), then remove cover (3).
[*2]

New/redesign
Necessity
Quantity

Sketch
Sym-b
Part No. Part name
ol

1 791T-650-2330 Sleeve t 1 N Q
2 791T-650-2340 Plate t 1 N Q
3 790-201-3310 Bolt t 2
4 790-101-2510 Block t 1
P 5 790-101-2570 Washer t 2
6 01580-01613 Nut t 2
7 01643-31645 Washer t 2
8 790-105-2300 Jack assembly t 1
9 790-101-1102 Pump t 1

Removal 50-254
1. Remove the track frame assembly. Connection 50-254
Separate the track shoe assembly from the track q Carry out installation in the reverse order to re-
frame. For details, see "Separation and connec- moval.
tion track shoe assembly.
[*1]
2. Sling pivot shaft assembly (1), remove the 2 Press-fitting surface of pivot shaft :
mounting bolts, and pull out the pivot shaft Molybdenum disulphide lubricant (LM-P)
assembly using forcing screws [1].
[*1] [*2]
4 Pivot shaft assembly: a Press fit the seal (2) to the pivot shaft using tool
390 kg P.
2 Press-fitting surface of seal:
Gasket sealant (LG-6)
a Check that press-fitting dimension (a) of the seal
from the end face of the shaft is the specified di-
mension.
q Dimension (A): 665 1.0 mm

50-254 D375A-6R
(01)
Undercarriage and frame
Removal and installation of equalizer bar

Removal and installation of equalizer bar 50-25

Special tools 50-25 4. Remove washer (4) and spacer (5).


a Oil will flow out from the pivot case, so use a

New/redesign
Necessity
container to receive the oil.

Quantity

Sketch
Symbol Part No. Part name 6 Pivot case:
18 l

791-650-1300 Remover t 1
791-735-1123 Sleeve 1
790-434-1050 Screw 1
01580-02419 Nut 1
N 1
01643-32460 Washer
Puller
790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1

Removal 50-25
k Park the machine on a level surface and low-
er the work equipment to the ground.
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
5. Place hydraulic jack [1] (490 kN {50 ton}) under
1. Remove the engine underguard and the power the radiator guard.
train underguard (front).
4 Engine underguard:
290 kg
Power train underguard (front):
280 kg

2. Remove pivot shaft cover (1).


a For the right track frame, disconnect four
blade tilt cylinder hoses from the cover.
a Because the machine will be raised up using
the blade, install blind plugs to the tilt cylinder
hoses.

3. Remove seal (2) and washer (3) as a unit.


a Perform this procedure for only right track
frame. 6. Remove cover (6).
[*1] [*2]

7. Remove grease tube (7-1).

8. Remove cover (7).


[*2]

9. Loosen clamping bolts (9-1) and (9) of the equal-


izer bar side pin.
[ * 3]
a Bolt: M30, width across flats: 46 mm

D375A-6R 50-255
(01)
Undercarriage and frame
Removal and installation of equalizer bar

10. Remove cover (8). 12. Repeat steps 6 - 11 to remove the side pin on the
other side.

13. Operate hydraulic jack [1] slowly, and lower the


machine to the position where the equalizer bar
touches right and left track frames.

14. Disconnect lubrication tube (12).

15. Remove two lock plates (13).


[*5]

16. Remove center pin (14) using tool N1.[*6]


a If the equalizer bar hole is not aligned with
the main frame hole, the pin cannot removed
easily. Adjust the height of the main frame by
11. Remove side pin (10). operating hydraulic jack [1].
[ *4]
k Support the track frame on the opposite
side with a block as it lowers when the pin
is removed.
a If the equalizer bar hole is not aligned with
the track frame hole, the pin cannot be re-
moved easily. Adjust the height of the equal-
izer bar by operating hydraulic jack [1].
a Put an "UP" mark at the top of the pin.

50-256 D375A-6R
(01)
Undercarriage and frame
Removal and installation of equalizer bar

17. Raise the front of the machine by operating the Connection 50-257
blade, and place stand [3] under the radiator q Carry out installation in the reverse order to re-
guard. moval.

[*1]
a Degrease the press-fitting surface of the seal.
2 Press-fitting surface of seal:
Gasket sealant (LG-6)
a Be careful not to install the seal twisted.

[*2]
a Install covers (6) and (7), then tighten bolts (9)
and (9-1).
3 Covers (6) and (7):
245 309 Nm {25 31.5 kgm}

[*3]
3 Bolts (9) and (9-1):
18. Sling equalizer bar (15) and remove it clearing 1,960 2,450 Nm {200 250 kgm}
the main frame and the track frames.
k Do not lower the machine after removing
[*4]
2
the equalizer bar. Bushing inner surface:
4 Equalizer bar assembly:
Grease(G2-LI)
500 kg a Before installing the pin, adjust the height of the
main frame by operating hydraulic jack [1] to
align the center of the equalizer bar hole with
that of track frame hole.
a Install pin (10) with the "UP" mark up, which was
put upon removal.

D375A-6R 50-257
(01)
Undercarriage and frame
Removal and installation of equalizer bar

[*5]
3 Lock plate mounting bolt :
549 59 Nm {56 6 kgm}

[*6]
2 Equalizer bar bushing and main frame
bushing:
Grease(G2-LI)
a Before installing the pin, operate the crane to
align the main frame hole with the equalizer bar
hole.

q Refilling of oil
Supply oil through the oil filler to the specified
level.
5 Pivot case:
18 l (SAE30)

50-258 D375A-6R
(01)
Undercarriage and frame
Disassembly and assembly of equalizer bar bushing

Disassembly and assembly of equalizer bar bushing 50-259

Special tools 50-259 3) Set toolN2 to remove side bushing (4) from
equalizer bar (5).

New/redesign
Necessity

Sketch
Q'ty
Symbol Part No. Part name

1 791T-650-2410 Bracket t 1 N Q
2 791T-650-2420 Bracket t 1 N Q
3 790-438-1110 Screw t 1
4 791-112-1180 Nut t 2
N 2 5 790-101-2540 Washer t 2
Puller
6 790-101-2102 (294 kN {30 t 1
ton})
7 790-101-1102 Pump t 1

Disassembly 50-259
1. Center bushing
1) Remove center bushing (1).

2. Guide bushing
1) Remove seal (2).
2) Remove snap ring (3).

D375A-6R 50-259
(01)
Undercarriage and frame
Disassembly and assembly of equalizer bar bushing

Assembly 50-260 2) Install snap ring (3).


1. Side bushing a After installing the snap ring, fill parts (c)
1) Set side bushing (4) and tool N2, and press before and after the side bushing with
fit side bushing (4) to equalizer bar (5). grease (G2-LI).
2 Outside surface of side bushing: 2 Grease to be supplied to side bush-
Molybdenum disulphide lubricant ing:
(LM-P) 0.3 l
a Install the side bushing in the direction 3) Press fit seals (2) by using the press.
shown in the following figure. a Press-fitting force for seal:
9.829.4 kN {13 ton}
a Press fit the seal so that its metal ring
does not protrude from the end face of the
equalizer bar.
2 Seal lip:
Grease(G2-LI)

1] Set the outer bushing with split faces


(a) (mating face) level.
2] Set the greasing holes (b) of the inner
and outer bushings at an angle.
a Press-fitting force for side bushing:
34.373.5 kN {3.57.5 ton}
2. Center bushing
Press fit bushing (1) by using the press.
2 Outside surface of center bushing:
Molybdenum disulphide lubricant
(LM-P)
a Press-fitting force for center bushing:
4.9186.2 kN {519 ton}

50-260 D375A-6R
(01)
Undercarriage and frame
Removal and installation of segment tooth

Removal and installation of segment tooth 50-261

Removal 50-261 Connection 50-261


1. Set the segment tooth to be removed to a posi- q Carry out installation in the reverse order to re-
tion where it can be removed easily (between the moval.
track and track frame). 2 Seat of segment tooth mounting nut:
k Park the machine on a level surface and Molybdenum disulphide lubricant
lower the work equipment to the ground. (LM-P)
k Set the parking brake lever and work 3 Segment tooth mounting nut:
equipment lock lever in the lock position. 1,813 98 Nm {185 10 kgm}
k Stop the engine and disconnect the cable
from the negative (-) terminal of the bat-
tery.

2. Remove covers (1) and (2).

3. Remove the mounting bolts and remove


segment tooth (3).
a Before removing all mounting bolts, insert the
bar [1] into the upper mounting bolt hole, then
slide the segment tooth outward to remove it.
4 Segment tooth:
35 kg

D375A-6R 50-261
(01)
Hydraulic system
Removal and installation of hydraulic tank assembly

Hydraulic system 50-262


Removal and installation of hydraulic tank assembly 50-262

Removal 50-262
k Park the machine on a level surface and low-
er the work equipment to the ground.
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
k Release the internal pressure of the hydrau-
lic tank and residual pressure inside the pip-
ing. For details, see Testing and adjusting
"Releasing residual pressure of hydraulic
circuit".
k Stop the engine and disconnect the cable
from the negative (-) terminal of the battery.

1. Drain the hydraulic tank.


6 Hydraulic tank:
3. Loosen drain valve (2) to drain oil in the suction
130 l
hose.
a Prepare a container to catch the oil, and take
2. Sling undercover (1) and lower it by using lifting
care not to allow the drained oil to splash any.
tool [1].
a Because one side of the undercover is
hinged, remove bolts on the other side to
sling the undercover.

4. Remove covers (3) and (4).

50-262 D375A-6R
(01)
Hydraulic system
Removal and installation of hydraulic tank assembly

5. Disconnect main valve return hose (5) and fan 8. Remove four hydraulic tank mounting bolts (16).
motor return hose (6) from the hydraulic tank.

9. Sling and remove hydraulic tank assembly (17).


6. Disconnect suction tube (8). [*1]
4 Hydraulic tank assembly:
7. Disconnect following return hoses (9) to (15). 240 kg
(9): Self-pressure reducing valve drain hose
(10): Work equipment pump drain hose
(11): Fan motor drain hose
(12): Blade PPC drain hose
(13): Ripper PPC drain hose
(14): Fan pump (LPV90) drain hose
(15): Fan pump (LPV30) drain hose

D375A-6R 50-263
(01)
Hydraulic system
Removal and installation of hydraulic tank assembly

Connection 50-264
q Carry out installation in the reverse order to re-
moval.
a Install the tank assembly properly, so that the
tank side is flush with the fender outside surface.
Step (d): Max. 3 mm

(Refilling)
Supply oil through the oil filler to the specified level.
Run the engine to circulate the oil through the sys-
tem. Then, check the oil level again.
5 Hydraulic tank:
130 l

q Air bleeding
Bleed air from the piping. For details, see
Testing and adjusting "Bleeding air from
hydraulic circuit".

50-264 D375A-6R
(01)
Hydraulic system
Removal and installation of work equipment pump assembly

Removal and installation of work equipment pump assembly 50-265

Removal 50-265
k Park the machine on a level surface and low-
er the work equipment to the ground.
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
k Release the internal pressure of the hydrau-
lic tank and residual pressure inside piping.
For details, see Testing and adjusting "Re-
leasing residual pressure of hydraulic cir-
cuit".
k Stop the engine and disconnect the cable
from the negative (-) terminal of the battery.
1. Drain the hydraulic tank.
6 Hydraulic tank:
130 l
3. Loosen drain valve (2) to drain oil in the suction
hose.
2. Sling undercover (1) and lower it by using lifting
a Prepare a container to catch the oil, and take
tool [1].
care not to allow the drained oil to splash any.
a Because one side of the undercover is
hinged, remove bolts on the other side to
sling the undercover.

4. Remove the floor plate and brake pedal


assembly according to the following procedure.
1) Remove inspection cover (3).

D375A-6R 50-265
(01)
Hydraulic system
Removal and installation of work equipment pump assembly

2) Disconnect connectors DEC (4) and BRK (5). 5. Remove the cover according to the following
3) Remove the mounting bolts of floor plate (6). procedure.
4) Disconnect brake rod (7) according to the 1) Remove covers (10), (11) and (12).
following procedure. 2) Remove headlamp protection cover (13).
[*1] 3) Remove the mounting bolts of battery case
1] Raise floor plate (6) and support it with a (14) and reposition battery case (14)
block. outward.
2] Remove cotter pin (8), and then remove 4) Remove covers (15) and (16).
nut (9) under floor plate (6).
3] Disconnect brake rod (7).
a Note the installed dimensions of the
rod for installation purpose.
5) Remove floor plate and brake pedal
assembly (6).

6. Remove damper case oil level gauge (17) and


bracket (18) as a unit from the damper case.

50-266 D375A-6R
(01)
Hydraulic system
Removal and installation of work equipment pump assembly

7. Disconnect hose (19). k Never operate the crane while imple-


a Also disconnect two hose clamps. menting steps 2) and 3). This is very
dangerous.

8. Disconnect mounting bracket (20) of the wiring


clamp from filter assembly (21). 4) Pull out filter assembly (21) toward frame
9. Disconnect wiring clamps (22), (23), and (24) (29) keeping the assembly level.
from filter assembly (21).
10. Remove twelve mounting bolts (25) and (25a) of
the filter assembly.

5) Lift off filter assembly (21) at an angle gradu-


ally.

11. Remove filter assembly (21) according to the


following procedure.
[*2]
1) Lift filter assembly (21) to the position very
close to frame (26).
2) Disconnect tube (27).
3) Disconnect connector (28).

D375A-6R 50-267
(01)
Hydraulic system
Removal and installation of work equipment pump assembly

12. Remove hose (30). q Carry out installation in the reverse order to re-
13. Disconnect suction tube clamp (31). moval.
[*3]
[* 1]
a Install the brake rod according to the installed di-
mensions noted when it is removed.
a Be sure to bend the split pin installed on the cot-
ter pin.
a Adjust the brake rod. For details, see Testing
and adjusting "Adjusting brake pedal and park-
ing brake lever".

[*2]
a Install the filter assembly aligning it with the
block so that the O-ring does not come off.

[*3]
3 Clamp mounting bolt:
14. Disconnect hose (32).
15. Disconnect tube (33) from work equipment 24.529.4 Nm {2.53.0 kgm}
pump assembly (34).
q Refilling (hydraulic tank)
Supply oil through the oil filler to the specified
level. Run the engine to circulate the oil through
the system. Then, check the oil level again.
5 Hydraulic tank:
130 l

q Air bleeding
Bleed air from the piping. For details, see
Testing and adjusting "Bleeding air from
hydraulic circuit".

16. Remove four mounting bolts (35) of the work


equipment pump.
17. Sling work equipment pump assembly (34), then
lower it to remove.
4 Work equipment pump assembly:
110 kg

50-268 D375A-6R
(01)
Hydraulic system
Removal and installation of fan pump assembly

Removal and installation of fan pump assembly 50-269


. 9. Loosen suction tube clamp (8) and disconnect
Removal 50-269 suction tube (9).
k Park the machine on a level surface and low-
er the work equipment to the ground.
k Stop the engine and disconnect the cable
from the negative (-) terminal of the battery.
k Loosen the oil filler cap of the hydraulic oil
tank gradually to release the internal pres-
sure of the hydraulic tank.

1. Drain the oil from the hydraulic tank.


6 Hydraulic tank: 130 l

2. Remove the fuel tank assembly. For details, see


"Removal and installation of fuel tank assembly."

3. Remove the ROPS guard. For details, see


10. Remove two mounting bolts (10) and lift off fan
"Removal and installation of ROPS guard
pump assembly (11).
4 Fan pump assembly: 80 kg
assembly."
a Steps 2 to 5 are not required when removing
4. Remove the operator cab assembly. For details,
the pump unit only.
see "Removal and installation of operator cab
assembly."

5. Remove the floor frame assembly. For details,


see "Removal and installation of floor frame
assembly."

6. Disconnect pilot valve sensor connector FA2 (2).

7. Disconnect four hose clamps (3).

8. Disconnect hoses (4) to (7).

D375A-6R 50-269
(01)
Hydraulic system
Removal and installation of fan pump assembly

Installation 50-270

q Carry out installation in the reverse order to re-


moval.

(Refilling)
Supply oil through the oil filler to the specified level.
Run the engine to circulate the oil through the sys-
tem. Then, check the oil level again.
5 Hydraulic tank: 130 l

q Air bleeding
a Bleed air from the piping. For details, see
Testing and adjusting "Bleeding air from fan
pump".

50-270 D375A-6R
(01)
Hydraulic system
Removal and installation of control valve assembly

Removal and installation of control valve assembly 50-271


.
Removal 50-271 3. Disconnect three hose clamps (9).
k Park the machine on a level surface and low-
er the work equipment to the ground.
k Release the internal pressure of the hydrau-
lic tank and remaining pressure inside pip-
ing. For details, see Testing and adjusting
"Releasing remaining pressure of hydraulic
cylinder".
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
k Stop the engine and disconnect the cable
from the negative (-) terminal of the battery.
a Note the connection points of each disconnected
hose.

1. Remove covers (1) and (2).


4. Disconnect wiring connector (10).

2. Disconnect PPC hoses (3) to (8).


(hose band color)
(3): White
(4): Green
(5): Black/Blue
(6): Brown
(7): Black
(8): Yellow

D375A-6R 50-271
(01)
Hydraulic system
Removal and installation of control valve assembly

5. Disconnect hoses (11) to (24). 6. Remove four control valve mounting bolts (25).
(11): Ripper tilt BACK 7. Lift off control valve assembly (26).
(12): Ripper tilt IN 4 Control valve assembly:
(13): Ripper lift RAISE 130 kg
(14): Ripper lift LOWER
(15): Blade left tilt BACK (only for dual tilt speci-
fication machine)
(16): Blade left tilt DUMP (only for dual tilt speci-
fication machine)
(17): Blade right tilt BACK
(18): Blade right tilt DUMP
(19): Blade lift RAISE
(20): Blade lift LOWER
(21): Blade lift RAISE
(22): Blade lift LOWER
(23): From work equipment pump
(24): To work equipment pump Ls port

Connection 50-272
q Carry out installation in the reverse order to re-
moval.

(Refilling)
Supply oil through the oil filler to the specified level.
Run the engine to circulate the oil through the sys-
tem. Then, check the oil level again.
5 Hydraulic tank:
130 l
q Bleeding air
Bleed air from the piping. For details, see
Testing and adjusting "Bleeding air from
hydraulic circuit".

50-272 D375A-6R
(01)
Hydraulic system
Disassembly and assembly of control valve assembly

Disassembly and assembly of control valve assembly 50-273

a This section provides only the precautions when assembling the control valve assembly.

Assembly 50-273 3. Assembly of suction valve assembly


a Clean all parts, check them for dirt and flaw, and Check that O-ring (38) is fitted to suction valve
apply oil to the sliding surfaces before assem- assembly (37), and install suction valve
bling. assembly (37) to valve body (1).
3 Suction valve assembly (37):
1. Assembly of main relief valve assembly 176.6196.1 Nm {1820 kgm}
Check that O-ring (3) is fitted to main relief valve
assembly (2), and install main relief valve 4. Assembly of check valve assembly
assembly (2) to valve body (1). 1) Install valve (39) and spring (40) to valve
3 Main relief valve assembly (2): body (1).
176.6196.1 Nm {1820 kgm} 2) Fit backup ring (42) and O-ring (41) to plug
(43), and install plug (43) to valve body (1).
2. Assembly of LS relief valve assembly 3 Plug (43):
a Install backup ring (15), O-rings (16) and (17) 176.6196.1 Nm {1820 kgm}
to LS relief valve assembly (14), and install
LS relief valve assembly (14) to valve body 5. Assembly of check valve assembly
(1). Check that O-ring (45) is fitted in check valve
3 LS relief valve assembly (14): assembly (44), and install check valve assembly
137157 Nm {1416 kgm} (41) to valve body (1).
3 Check valve assembly (44):
58.878.5 Nm {68 kgm}

D375A-6R 50-273
(01)
Hydraulic system
Disassembly and assembly of control valve assembly

6. Installation of plug (54) and (55):


1) Installation of plug (46) 107.8140.7 Nm {11.015.0 kgm}
1] Install retainer (50) to valve body (1). (56):
2] Fit O-ring (47) and backup ring (48) to 29.439.2 Nm {34.8 kgm}
plug (46), and install plug (46) to valve (57):
body (1). 107.7161.8 Nm {1216.5 kgm}
3 Plug (46): 3) Installation of plugs (58) and (59)
274.6367.7 Nm {2837.5 kgm} 1] If plugs (58) (2 places) are removed, wrap
2) Installation of plugs (51) to (60) sealing tape around the thread portion
a Check that O-ring or backup ring is fitted when installation.
to each plug, and then install the plug to 3 Plug (58):
valve body (1). 58.9 6.9 Nm {6 0.7 kgm}
3 Plug: 2] If plugs (59) (11 places) have been
(51) (2 places): removed, replace with new ones.
176.6196.1 Nm {1820 kgm} a The plug is a dry-seal type with spe-
(52) (2 places), (53), and (58) (2 cial nylon coated on its threads.
places): 3 Plug (59):
19.627.5 Nm {22.8 kgm} 7.813.7 Nm {0.81.4 kgm}

(Blade tilt valve)


7. Assembly of suction valve assembly 3 Suction safety valve assembly (30a):
1) Install spool (19a) to valve body (1a). 176.6196.1 Nm {1820 kgm}
2) Fit spring (20a), O-ring (23a), backup ring
(22a) and O-ring (21a) to plug (24a), and
install plug (24a) to valve body (1a).
3 Plug (24a):
372.7465.8 Nm {3847.5 kgm}
8. Assembly of suction safety valve assembly
Fit O-ring (31a) to suction safety valve assembly
(30a), and install suction safety valve assembly
(30a) to valve body (1a).

50-274 D375A-6R
(01)
Hydraulic system
Disassembly and assembly of control valve assembly

9. Assembly of check valve assembly 58.878.5 Nm {68 kgm}


1) Install valve (25a) and spring (24a) to valve 11. Installation of plug
body (1a). 1) Fit O-ring (35a), O-ring (36a), backup ring
2) Fit backup ring (28a) and O-ring (27a) to plug (37a) to plug (34a), and install plug (34a) to
(29a), and install plug (29a) to valve body valve body (1a).
(1a). 3 Check valve assembly (32a):
3 Plug (29a): 58.878.5 Nm {68 kgm}
176.6196.1 Nm {1820 kgm} 2) If plugs (38a) (2 places) are removed,
10. Assembly of check valve assembly replace with new ones.
Fit O-ring (33a) to check valve assembly (32a), a The plug is a dry-seal type with special
and install check valve assembly (32a) to valve nylon coated on its threads.
body (1a). 3 Plug (38a):
3 Check valve assembly (32a): 7.813.7 Nm {0.81.4 kgm}

(Ripper lift valve)


12. Assembly of check valve assembly 13. Assembly of suction valve assembly
1) Install valve (14b) and spring (15b) to valve Fit O-ring (22b) to suction valve assembly (21b),
body (1b). and install suction valve assembly (21b) to valve
2) Fit spring (15b), backup ring (17b) and O-ring body (1b).
(16b) to plug (18b), and install plug (18b) to 3 Suction valve assembly (21b):
valve body (1b). 176.6196.1 Nm {1820 kgm}
3 Plug (18b):
176.6196.1 Nm {1820 kgm} 14. Assembly of check valve assembly
Fit O-ring (20b) to check valve assembly (19b),
and install check valve assembly (19b) to valve
body (1b).
3 Check valve assembly (19b):
58.878.5 Nm {68 kgm}

D375A-6R 50-275
(01)
Hydraulic system
Disassembly and assembly of control valve assembly

15. Installation of plug 3 Plug (27b):


1) Installation of plug (27b) 176.6196.1 Nm {1820 kgm}
1] Install plug (23b) to valve body (1b). 2) If plug (28b) is removed, replace with new
2] Fit O-ring (24b), backup ring (25b) and one.
O-ring (26b) to plug (27b), and install plug a The plug is a dry-seal type. Special nylon
(27b) to valve body (1b). is coated on its threads.
3 Plug (28b):
7.813.7 Nm {0.81.4 kgm}

(Ripper tilt valve)


16. Assembly of check valve assembly 18. Assembly of check valve assembly
1) Install valve (14c) and spring (15c) to valve Fit O-ring (20c) to check valve assembly (19c),
body (1c). and install check valve assembly (19c) to valve
2) Fit spring (15c), backup ring (17c) and O-ring body (1c).
(16c) to plug (18c), and install plug (18c) to 3 Check valve assembly (19c):
valve body (1c). 58.878.5 Nm {68 kgm}
3 Plug (18c):
176.6196.1 Nm {1820 kgm}
17. Assembly of suction valve assembly
Fit O-ring (22c) to suction valve assembly (21c),
and install suction valve assembly (21c) to valve
body (1c).
3 Suction valve assembly (21c):
176.6196.1 Nm {1820 kgm}

50-276 D375A-6R
(01)
Hydraulic system
Disassembly and assembly of control valve assembly

19. Installation of plug


1) Installation of plug (27c)
1] Install plug (23c) to valve body (1c).
2] Fit O-ring (24c), backup ring (25c) and
O-ring (26c) to plug (27c), and install plug
(27c) to valve body (1c).
3 Plug (27c):
176.6196.1 Nm {1820 kgm}
2) Installation of plug (28c)
Fit O-ring (29c), backup ring (30c) and O-ring
(31c) to plug (28c), and install plug (28c) to
valve body (1c).
3 Plug (28c):
176.6196.1 Nm {1820 kgm}

3) If plugs (32c) and (33c) are removed, replace


with new ones.
a The plug is a dry-seal type with special
nylon coated on its threads.
3 Plug:
(32c)(4 places):
16.7 2.9 Nm {1.7 0.3 kgm}
(33c)(3 places):
7.813.7 Nm {0.81.4 kgm}

D375A-6R 50-277
(01)
Hydraulic system
Disassembly and assembly of blade PPC valve assembly

Disassembly and assembly of blade PPC valve assembly 50-278


.

a This section provides only the precautions when


assembling the blade PPC valve assembly.
a As the parts look alike, note the locations to
which they are installed during disassembly.
a Spare part cannot be supplied individually for the
following parts. If any of them needs to be re-
placed, replace the blade PPC valve assembly
with new one.
(2),(3),(4),(5),(6),(7),(8),(9),
(11),(12),(13),(14),(15),(16),(17),
(18),(19),(20),(21),(22),(23),(24),
(39),(40),(41),(42),(43),(44)
a Do not remove nipples (39) to (41) unless it is
necessary.

50-278 D375A-6R
(01)
Hydraulic system
Disassembly and assembly of blade PPC valve assembly

Assembly 50-279
1. Install the blade RAISE valve. 5. Fit O-rings (26) and (27), and install plate (28).
1) Install valve (2) to valve body (1).
2) Install shims (3) and spring (4) to valve (2). 6. Fit O-rings (26) and (27), and install valve body
a Install spring (4) with its small diameter (29).
(inside diameter) end facing shims (3).
3) Install spring (5), retainer (6), piston (7), 7. Install seal (30) to valve body (29).
spring (8), shim (3), piston (9) and seat (10).
a When installing piston (7), apply 8. Install plates (31) and (32).
grease(G2-LI) to the periphery of the pis- 3 Mounting bolt:
ton and inner surface of the body bore. 11.814.7 Nm {1.21.5 kgm}
a When installing piston (9), apply
grease(G2-LI) to the inner surface of the 9. Install joint (33).
body bore. a When installing joint (33) to body (29), apply
Loctite in the following manner.
2. Install the blade LOWER valve. 1] When installing the joint, apply a drop
1) Install valve (11) to valve body (1). (approx. 0.02 g) of Loctite (No. 648) to
2) Install shims (3) and spring (12) to valve (11). each female thread portion (A) (2 places)
a Install spring (12) with its small diameter of the valve body. Before installing the
(inside diameter) end facing shims (3). joint, degrease its male threads and
3) Install spring (13), retainer (14), piston (7), female threads of the valve body with
shims (42), retainer (15), balls (16), collar Drysol and dry them.
(17), spring (18), spacers (19) and piston 2] Drop LOCTITE to the following positions.
(44). (L): 57 mm from end face
a When installing piston (7), apply 2 Body female threads (A):
grease(G2-LI) to the periphery of the pis- Liquid adhesive (Loctite No.
ton and inner surface of the body bore. 648)
a When installing piston (20), apply 3 Joint (33):
grease(G2-LI) to the inner surface of the 3949 Nm {45 kgm}
body bore.

3. Install the blade tilt valve.


1) Install valve (2) to valve body (1).
2) Install shims (3) and spring (20) to valve (2).
a Install spring (20) with its small diameter
(inside diameter) end facing shims (3).
3) Install spring (21), retainer (22), piston (23),
shim (43) and piston (24).
a When installing piston (23), apply
grease(G2-LI) to the periphery of the pis-
ton and inner surface of the body bore.
a When installing piston (24), apply
grease(G2-LI) to the inner surface of the
body bore.
a Apply gear oil grease(G2-LI) to the sliding
portion of the joint.
4. Install orifice (25).
3 Orifice:
(J area): Apply grease (G2-LI) 710 ml to
entire surface.
11.814.7 Nm {1.21.5 kgm}
(P portion): Apply gear oil 0.20.4 ml to the
sliding portions (4 places) between joint and
pin.

D375A-6R 50-279
(01)
Hydraulic system
Disassembly and assembly of blade PPC valve assembly

10. Install boot (37) and disc (35), and tighten nut
(36).
1) Install disc (35), so that each bolt (38) is posi-
tioned at the center of each side of disc (35)
to prevent the disc from interfering with any
bolt (38) during combined operation.
2) When installing disc (35), adjust the play at
lever end (400 mm from the fulcrum of the
lever) to 1 - 6 mm.
3) Holding disc (35) with tool [1], tighten nut
(36).
a At this time, allow valve body (29) or plate
(31) to have play (a) and (b), and lock with
tool [2].
3 Nut (36):
93.1112.7 Nm {9.511.5 kgm}

a After installing the disc, adjust the disc


height. For details, see Testing and adjust-
ing, "Adjusting PPC valve".

50-280 D375A-6R
(01)
Hydraulic system
Disassembly and assembly of ripper PPC valve assembly

Disassembly and assembly of ripper PPC valve assembly 50-281

a This section provides only the precautions when 1. Install valve (2) to valve body (1).
assembling the ripper PPC valve assembly.
a Spare part is not available for nipples (18) and 2. Install shims (3) and spring (4) to valve (2).
(19). Do not remove them unless necessary. a Install spring (4) with its small diameter end
(inside diameter) facing shims (3).
Assembly 50-281
3. Install spring (5), (6), retainer (7) and piston (8).
a Springs (5) and (6) having different number
of turns are used for the oil pressure ports
shown below. Take care not to install wrong
springs.

Port Total number of turns


P1, P2 11
P3, P4 9
a Each port is stamped on the bottom of the
valve body.
a When installing pistons (8), apply grease to
their outside and the inside of the valve body
holes.
2 Piston:
Grease(G2-LI)

4. Install seat (9) and seal (10) to valve body (1).

5. Install plates (11) and (12).


3 Mounting bolt:
11.814.7 Nm {1.21.5 kg}

6. Install joint (13).


a When installing joint (13) to valve body (1),
apply Loctite in the following manner.
1] When installing the joint, apply a drop
(approx. 0.02 g) of Loctite (No. 648) to
each female thread portion (A) (2 places)
of the valve body.
Before installing the joint, degrease its
male threads and the female threads of
the valve body with Drysol and dry them.
2] Drop LOCTITE to the following positions.
(L): 57 mm from end face
2 Body female threads (A):
Liquid adhesive (Loctite No.
648)
3 Joint (13):
3949 Nm {45 kgm}

D375A-6R 50-281
(01)
Hydraulic system
Disassembly and assembly of ripper PPC valve assembly

.
a Apply gear oil and grease(G2-LI) to the slid-
ing portions of the joint.
(J area): Apply grease (G2-LI) 710 ml to
entire surface.
(P area): Apply gear oil 0.2-0.4 ml to the
sliding portions (4 places) between the joint
and pin.

7. Install disc (14) and boot (15), and tighten with


nut (16).
3 Nut:
6988 Nm {79 kgm}
a After installing the disc, adjust the disc
height. For details, see Testing and adjust-
ing, "Adjusting PPC valve".

50-282 D375A-6R
(01)
Hydraulic system
Disassembly and assembly of hydraulic cylinder assembly

Disassembly and assembly of hydraulic cylinder assembly 50-283

Special tools 50-283 Disassembly 50-283


1. Cylinder tube

New/redesign
Remove the cylinder tube.

Necessity
Quantity

Sketch
Sym-
Part No. Part name
bol
2. Quick drop valve assembly
a Blade lift cylinder only.
1 790-502-1003 Stand t 1 1) Remove quick drop valve assembly (1).
790-201-1702 Push tool kit t 1
790-201-1841 q Push tool 1
2 790-201-1861 q Push tool 1
790-101-5021 q Grip 1
01010-50816 q Bolt 1
790-201-1500 Push tool kit t 1
790-201-1650 q Plate 1
3 790-201-1670 q Plate 1
790-101-5021 q Grip 1
U
01010-50816 q Bolt 1
4 790-720-1000 Expander t 1
796-720-1680 Ring t 1
07281-01589 Clamp t 1 2) Disassemble the quick drop valve assembly
796-720-1720 Ring t 1 according to the following procedure.
5 1] Remove elbow (2).
07281-02429 Clamp t 1
2] Remove spring (3), washer (4), and
796-720-1690 Ring t 1
valves (5) and (6), and pull out collar (7).
07281-02169 Clamp t 1
790-102-4300 Wrench t 1
6
790-102-4310 Pin t 2

D375A-6R 50-283
(01)
Hydraulic system
Disassembly and assembly of hydraulic cylinder assembly

3. Piston rod assembly 2) Remove bolt (11).


1) Set cylinder assembly (8) to tool U1. 3) Remove spacer (12).
2) Remove head assembly (9). 4) Remove valve (13) from spacer (12). (Only
3) Pull out piston rod assembly (10). for lift cylinder)
a Put an oil container under the cylinder to 5) Remove piston assembly (14).
receive the oil. 6) Remove the backup ring (15) and O-ring
(16).
7) Remove retainer (17).(lift cylinder only)

4. Piston assembly
q Blade lift cylinder, and blade tilt cylinder .
1) Set piston rod assembly (10) to toolU1. 8) Disassemble the piston assembly according
to the following procedure.
1] Remove wear ring (18).
2] Remove piston ring (19).
a Do not reuse valve (V) and seat (S).
BL: Blade lift cylinder
BT: Blade tilt cylinder

50-284 D375A-6R
(01)
Hydraulic system
Disassembly and assembly of hydraulic cylinder assembly

q Ripper lift cylinder and ripper tilt cylinder 3) Using tool U6, remove piston assembly (30)
1) Set piston rod assembly (10) to toolD1. from piston rod (32).

2) Remove lock screw (31) of piston assembly 4) Disassembly of the piston assembly
(30). 1] Remove the backup ring and O-ring (33).
q Screw size: M12 x pitch 1.75 2] Remove wear ring (34).
3] Remove piston ring (35).

a If screw (31) cannot be removed because .


it is punched too tight, screw in it deeply
into the hole once, tap the hole by using
tap [1], then remove the screw.

D375A-6R 50-285
(01)
Hydraulic system
Disassembly and assembly of hydraulic cylinder assembly

5. Cylinder head assembly Assembly 50-286


1) Remove cylinder head assembly (20) from a Apply engine oil to the sliding surfaces of each
the piston rod. part and install the packings, dust seals, and
O-rings, taking care not to damage them.

1. Cylinder head assembly


1) Assemble the cylinder head assembly
according to the following procedure.
1] Using tool U2, press fit bushing (28) to the
cylinder head.
2] Install snap ring (27).
3] Install buffer ring (26) and rod packing
(25).
4] Using tool U3, press fit seal (24).
5] Install snap ring (23).

2) Disassemble the cylinder head assembly


according to the following procedure.
1] Remove O-ring (21) and backup ring (22).

2] Remove snap ring (23) and dust seal


(24).
3] Remove rod packing (25) and buffer ring
(26).
4] Take off snap ring (27) and remove
bushing (28).

50-286 D375A-6R
(01)
Hydraulic system
Disassembly and assembly of hydraulic cylinder assembly

6] Install backup ring (22) and O-ring (21). a Use new valve (V) and new seat (S).

2) Install cylinder head assembly (20) to the 2) Install retainer (17).(lift cylinder only)
piston rod. 3) Install O-ring (16) and backup rings (15).
a Apply grease to the O-ring and backup
rings so that the backup rings do not sep-
arate from each other.
4) Install piston assembly (14).
5) Install valve (13) to the spacer. (Only for lift
cylinder)

2. Piston assembly
q Blade lift cylinder and blade tilt cylinder
1) Assemble the piston assembly according to
the following procedure.
1] Using tool U4, expand piston ring (19).
a Set the piston ring on the tool and turn
the handle of the tool by eighy to ten
turns to expand the piston ring.
2] Remove piston ring (19) from tool U4 and
intall it to the piston.
3] Using tool U5, compress piston ring (19).
4] Install wear ring (18) to the piston.

D375A-6R 50-287
(01)
Hydraulic system
Disassembly and assembly of hydraulic cylinder assembly

6) Install spacer (12) and tighten the mounting 4] Install wear ring (34).
bolts (11). 5] Install backup rings and O-ring (33).
a After tightening the mounting bolts, leave a Install the backup rings after warming
the piston and piston rod assembly for 30 it in hot water at about 5060 C.
minutes. a Apply grease to the O-ring and back-
2 Mounting bolt: up rings, so that the backup rings do
Adhesive (LT-2) not separate from each other.
3 Mounting bolt:
Lift cylinder
98122.6 Nm {1012.5 kgm}
Tilt cylinder
157196 Nm {1620 kgm}

2) Install the piston assembly to piston rod (10),


and set them to tool U1.

q Ripper lift cylinder and ripper tilt cylinder


1) Assembly of the piston assembly
1] Using tool U4, expand piston ring (35).
a Set the piston ring to tool U4, and ro-
tate the handle 8 -10 turns to expand
the piston ring.
2] Remove piston ring (35) from tool U4 and
intall it to the piston.
3] Using tool U5, compress piston ring (35).

50-288 D375A-6R
(01)
Hydraulic system
Disassembly and assembly of hydraulic cylinder assembly

3) When reusing piston rod (32) and piston 4) When using new parts for either or both of
assembly (30), take the following steps for piston rod (10) and piston assembly (30),
installation. take the following steps for installation.
a Remove any flash or burr on the threaded 1] Using tool U6, tighten piston assembly
portion by using a file or other tool. (30).
a Clean the parts thoroughly and remove 3 Piston assembly:
metal chips and dust. 294 29.4 Nm {30 3.0 kgm}
1] Screw piston assembly (30) into piston 2] Make a hole to install the screw.
rod (32) by using tool U6, and tighten the a Apply the drill tip to the groove where
piston assembly until the tapped holes the piston and piston rod are en-
are aligned. gaged, and make a horizontal hole.
q Dimensions of a screw hole (mm):
Tap hole diameter: 10.3
Tap hole depth: 27
Tap used: 12x1.75
Tap depth: 20
3] Remove steel chips and dust and clean
the assembly completely.

2] Install screw (31) to piston (30).


a Install the screw after degreasing and
drying its threads adequately.
a After installing the screw, punch it at
four points on it periphery.
2 Threads of screw:
Liquid adhesive (Loctite No.262)
3 Screw:
58.973.6 Nm {6.07.5 kgm}

D375A-6R 50-289
(01)
Hydraulic system
Disassembly and assembly of hydraulic cylinder assembly

4] Install screw (31). 4. Quick drop valve assembly


a Install the screw after degreasing and a Blade lift cylinder only.
drying the threads completely. 1) Install the quick drop valve assembly as
a After tightening the screw, punch it at follows.
four points on its periphery. 1] Install collar (7), and install valves (6) and
2 Threads of screw: (5), washer (4), and spring (3).
Liquid adhesive (Loctite No.262)
3 Screw:
58.973.6 Nm {6.07.5 kgm}

2) Install quick drop valve assembly (1).

5. Cylinder tube
3. Piston rod assembly Install the cylinder tube.
1) Set cylinder (8) to tool U1.
2) Install piston rod (10) to cylinder (8).
a Apply grease to the sealing part of the pis-
ton.
a Retract the piston rod fully
3) Push in head assembly (9) to the cylinder
and tighten the mounting bolts.
a Apply grease to the backup ring.

50-290 D375A-6R
(01)
Hydraulic system
Disassembly and assembly of ripper pin puller cylinder assembly

Disassembly and assembly of ripper pin puller cylinder assembly 50-291

Special tools 50-291 Disassembly 50-291


1. Cylinder assembly

New/redesign
Necessity
1) Set pin puller cylinder assembly (1) to tool

Quantity

Sketch
Sym-
Part No. Part name U1.
bol
2) Using tool U7, remove cylinder head
assembly (2) and piston rod (3) as a unit.
1 790-502-1003
Cylinder repair
t 1 a Put an oil container under the cylinder to
stand receive the oil.
790-201-1702 Push tool kit t 1
790-201-1721 q Push tool 1
2
790-101-5021 q Grip 1
01010-50816 q Bolt 1
790-201-1500 Push tool kit t 1
U 790-201-1530 q Plate 1
3
790-101-5021 q Grip 1
01010-50816 q Bolt 1
4 790-720-1000 Expander t 1
796-720-1630 Ring t 1
5
07281-00709 Clamp t 1
7 790-102-2302 Wrench t 1

2. Cylinder head assembly


1) Remove cylinder head assembly (2) from
piston rod (3).

D375A-6R 50-291
(01)
Hydraulic system
Disassembly and assembly of ripper pin puller cylinder assembly

2) Remove O-ring (5) and backup ring (6). Assembly 50-292


3) Remove O-ring (7). a Apply engine oil to the sliding surfaces of each
4) Take off snap ring (8) and remove dust seal part and install the packings, dust seals, and
(9). O-rings, taking care not to damage them.
5) Take off rod packing (10) and remove
bushing (11). 1. Piston rod assembly
1) Using tool U4, expand piston ring (12).
a Set the piston ring to the tool and turn the
handle 8 10 turns to expand the ring.
2) Remove piston ring (12) from the tool, then
install it to piston rod (3).
3) Using toolU5, compress piston ring (12).

3. Piston rod assembly


Remove piston ring (12) from piston rod (3).

50-292 D375A-6R
(01)
Hydraulic system
Disassembly and assembly of ripper pin puller cylinder assembly

2. Cylinder head assembly 6) Install cylinder head assembly (2) to piston


1) Using tool U2, press fit bushing (11) to rod (3).
cylinder head (4).

3. Cylinder assembly
2) Using tool U3, press fit dust seal (9) to 1) Set the cylinder to tool U1 and support the
cylinder head (4). cylinder with block [1].
2) Install piston rod (3) and cylinder head
assembly (2) as a unit.
a Apply grease to the sealing part of the pis-
ton.
a Apply grease to the backup ring.
a Retract the piston fully.
3) Using tool U7, tighten cylinder head
assembly (2).
3 Cylinder head assembly:
441 44.1 Nm {45 4.5 kgm}

3) Install snap ring (8) and rod packing (10).


4) Install O-ring (7).
5) Install backup ring (6) and O-ring (4).

D375A-6R 50-293
(01)
Work equipment
Removal and installation of blade assembly

Work equipment 50-294


Removal and installation of blade assembly 50-294

Removal 50-294
k Park the machine on a level place and lower
the work equipment to the ground complete-
ly.

1. Set blocks [1] securely under right and left


straight frames (9).

k Release the residual pressure from the


piping. For details, see "Releasing residu-
al pressure of work equipment cylinder"
in Testing and adjusting.

6. Remove right and left covers (5).

2. Sling lift cylinder assembly (2). 7. Disconnect hose (6).


a Plug the hose to prevent dust etc. from enter-
3. Remove lock plate (1), and remove connecting ing the piping.
pin (1a) on the piston rod side of the blade lift
cylinder. 8. Remove right and left trunnion caps (7).

4. Start the engine and retract piston rod (3) fully. 9. Remove blade assembly (8).
[*1]
5. Sling up cylinder (2) and bracket (4) as a unit, a Start the engine and move the machine slow-
and secure it to the radiator guard at position (A). ly in reverse to separate the blade assembly
a Bind with wire to prevent the piston rod from from the trunnions.
pulling out.
a Use the same procedure to separate the cyl-
inder on the opposite side from the blade.

50-294 D375A-6R
(01)
Work equipment
Removal and installation of blade assembly

Connection 50-295
q Carry out installation in the reverse order to re-
moval.

[*1]
a Adjust height b of the right and left straight
frames and distance c between the frames by
using blocks [1] so that the dimensions are as
follows.
q Height at trunnion (b): 863 mm
q Distance between frames (c): 3,484 mm

q Refilling (hydraulic tank)


Supply oil through the oil filler to the specified
level. Run the engine to circulate the oil through
the system. Then, check the oil level again.

D375A-6R 50-295
(01)
Work equipment
Disassembly and assembly of blade assembly

Disassembly and assembly of blade assembly 50-296

Disassembly 50-296
k Place blocks [1] and [2] under the right and 3. Sling tilt cylinder assembly (4), remove the lock
left straight frames and blade to support the plate, and remove pin (5).
blade securely.
4. Remove the lock plate, remove pin (6), and
remove tilt cylinder assembly (4).
4 Tilt cylinder assembly:
380 kg

1. Remove right frame covers (1) and (2).

2. Disconnect tilt cylinder hoses (3).

5. Set block [3] under right center brace (7), and


remove the mounting bolt of cap (8) on the right
straight frame side.
a Shims are fitted in the cap. Note the quantity
and thickness of the shims for installation
purpose.

50-296 D375A-6R
(01)
Work equipment
Disassembly and assembly of blade assembly

6. Sling right straight frame (9) and disconnect right 11. Sling center brace (15), remove the mounting
center brace (7). bolts to remove cap (16). Then remove right and
left center braces (15) and (7).
7. Remove the lock plate, remove pin (10), and a Shims are fitted in the cap. Note the quantity
remove right straight frame (9). and thickness of the shims for installation
4 Straight frame: purpose.
1,150 kg 4 Center brace:
220 kg

8. Sling tilt brace (11), remove the lock plate, and


remove the pin from the blade. 12. Sling blade (17), and lay down the blade.
4 Blade:
9. Remove the lock plate, remove pin (13), and 4,900 kg
sling and remove tilt brace (11).
4 Tilt brace:
200 kg
10. Disconnect the left center brace using the same
procedure as steps 5 to 7, and remove left
straight frame (14).

D375A-6R 50-297
(01)
Work equipment
Disassembly and assembly of blade assembly

Assembly 50-298
a Check the quantity and thickness of the removed 3. Sling right straight frame (9), install pin (10), and
shims, and fit shims of the same quantity and secure with the lock plate.
same thickness to the original locations. 4 Straight frame:
a To adjust the shims, see Testing and adjusting, 220 kg
"Adjusting blade". 4. Sling right straight frame (9) and set the ball of
right center brace (7) to right straight frame (9).
1. Sling blade (17), place securely blocks or stands
under the blade to support the blade.
4 Blade:
4,900 kg

5. Install the shims to cap (8) of right center brace


(7), and tighten the mounting bolt.
a Standard shim thickness: 4.5 mm

2. Sling center brace (15), install shim(s), and


tighten the mounting bolt of cap (16).
a Set a block under the center brace to align its
height with the height of the straight frame.
a Standard shim thickness: 4.5 mm
4 Center brace:
220 kg
a Install center brace (7) of the opposite side in
the same manner.

50-298 D375A-6R
(01)
Work equipment
Disassembly and assembly of blade assembly

6. Sling tilt cylinder (4), install pin (6), and secure 10. Install left straight frame (14) using the same
with the lock plate. procedure as steps 3 to 5, and connect the left
4 Tilt cylinder assembly: center brace.
380 kg
7. Install pin (5), and secure with the lock plate. 11. Sling tilt brace (11), install pin (13), and secure
with the lock plate.
4 Tilt brace:
200 kg
12. Install pin (12), and secure with the lock plate.

8. Connect tilt cylinder hoses (3).

9. Install right frame covers (2) and (1).

13. Greasing
After assembly, apply sufficient amount of
grease to the points indicated by arrows in the
figure.
2 Each portion of the work equipment:
Grease(G2-LI)

D375A-6R 50-299
(01)
Work equipment
Disassembly and assembly of giant ripper assembly

Disassembly and assembly of giant ripper assembly 50-30

Disassembly 50-30
1. Make both tracks of the machine ride blocks [1], a Start the engine, retract the piston rod fully,
stop the machine and lower the blade to the and lower the tilt cylinder assemble on top of
ground. the lift cylinder.
k Set the parking brake to the lock position. k After stopping the engine, release the re-
sidual pressure from the piping. For de-
2. Sling the shank, then operate the pin-puller tails, see Testing and adjusting
switch to pull out the shank pin. "Releasing residual pressure of work
equipment cylinder".
3. Raise the ripper fully, and lower the shank to
remove. 7. Disconnect four lift cylinder hoses (4), four tilt
4 Shank: cylinder hoses (5), and two pin puller cylinder
470 kg hoses (6).
4. Set stand [2] under the arm and beam.

8. Sling tilt cylinder assembly (7), remove pin (8),


5. Sling the lift cylinder assembly and remove pin and remove tilt cylinder assembly (7).
(2). 4 Tilt cylinder assembly:
a Start the engine, retract the piston rod fully, 270 kg
and lower the lift cylinder assembly on top of
the arm.

6. Sling the tilt cylinder assembly and remove pin


(3).

50-300 D375A-6R
(01)
Work equipment
Disassembly and assembly of giant ripper assembly

9. Sling lift cylinder assembly (9), remove pin (10), Assembly 50-301
and remove lift cylinder assembly (9). 1. Sling arm (13) and set it to the mounting position,
4 Lift cylinder assembly: install right and left pins (14), and secure them
350 kg with the lock plates.
4 Arm:
1,000 kg
a Set a stand under the arm.

10. Sling beam (11), remove right and left pins (12),
and remove beam (11).
4 Beam:
2,000 kg 2. Sling beam (11) and set it to the mounting posi-
tion, install right and left pins (12), and secure
them with the lock plates.
4 Beam:
2,000 kg
a Set a stand under the beam.

11. Sling arm (13), remove right and left pins (14),
and remove arm (13).
4 Arm:
1,000 kg

D375A-6R 50-301
(01)
Work equipment
Disassembly and assembly of giant ripper assembly

3. Sling lift cylinder assembly (9) and set it to the 6. Sling the tilt cylinder assembly, start the engine
mounting position. Install pin (10), and secure it to extend the piston rod to align the pin holes.
with the lock plate. Install pin (3), and secure it with the lock plate.
4 Lift cylinder assembly:
350 kg 7. Sling the lift cylinder assembly, start the engine
to extend the piston rod to align the pin holes.
Install pin (2), and secure it with the lock plate.

4. Sling tift cylinder assembly (7) and set it to the


mounting position. Install pin (8), and secure it
with the lock plate. 8. Make both tracks of the machine ride blocks [1],
4 Tilt cylinder assembly: stop the machine and lower the blade to the
270 kg ground.
k Set the parking brake in the lock position.

9. Operate the ripper to raise the machine slightly


to remove stand [2].

10. Raise the ripper fully, pass wire through the


shank holder, then raise the shank slowly, align
the pin holes, and operate the pin puller switch to
insert the shank pin.

11. Raise the blade, and run the machine off blocks
[1].

12. Bleed air from the cylinders. For details, see


5. Connect two pin puller cylinder hoses (6), four tilt Testing and adjusting "Bleeding air from
cylinder hoses (5), and four lift cylinder hoses hydraulic cylinder".
(4).

50-302 D375A-6R
(01)
Cab and its attachments
Removal and installation of ROPS guard

Cab and its attachments 50-303


Removal and installation of ROPS guard 50-303

Removal 50-303 Connection 50-303


k Park the machine on a level surface and low- q Carry out installation in the reverse order to re-
er the work equipment to the ground. moval.
k Set the parking brake lever and work equip-
ment lock lever in the lock position. [*1]
k Stop the engine and disconnect the cable 3 ROPS guard mounting bolt :
from the negative (-) terminal of the battery. 1,5191,911 Nm {155195 kgm}
[*2]
1. Remove antenna (1). q Installed direction of ROPS guard

2. Sling ROPS guard (2), and remove the twelve


mounting bolts.
[*1]
3. Sling and remove ROPS guard (2).
[*2]
4 ROPS guard:
700 kg

D375A-6R 50-303
(01)
Cab and its attachments
Removal and installation of operator's cab assembly

Removal and installation of operator's cab assembly 50-304

Removal 50-304
k Park the machine on a level surface and low-
er the work equipment to the ground.
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
k Stop the engine and disconnect the cable
from the negative (-) terminal of the battery.

1. Remove the ROPS guard. For details, see


"Removal and installation of ROPS guard."

2. Remove cover (1) on the left side of the oper-


ators cab.

5. Remove three mounting bolts (8) of lower angle


(7).

3. Disconnect wiring connectors CN19 (2),


CN12VS (3), CN21 (4) and CN20 (5).

4. Disconnect four window washer hoses (6). [*1]


a Pull the wires and window washer hoses into 6. Remove back side cover (9) of the monitor
the operators cab. panel.

50-304 D375A-6R
(01)
Cab and its attachments
Removal and installation of operator's cab assembly

7. Remove angle (10). 10. Remove covers (13), (14) and (15).

8. Remove the operators cab mounting bolt 11. Remove twenty-one mounting bolts (indicated
according to the following procedure. by * mark) and sling and remve operator's cab
1) Remove right and left covers (11). assembly (16).
4 Operator cab assembly:
500 kg

9. Remove right and left covers (12).

D375A-6R 50-305
(01)
Cab and its attachments
Removal and installation of operator's cab assembly

Connection 50-306
a Before installing the operators cab, loosen the 2. Operators cab assembly
mounting bolts of angle (7) and those of angle 1) Lower the operators cab assembly slowly to
(10) inside the operators cab. the floor frame.
a Take care not to shift or damage the seal.
a Check that the air conditioner duct seal
on the cab mates tightly with the air con-
ditioner duct of the dashboard.
a Lower the operators cab assembly car-
fully, as the clearance between the air
conditioner duct on the cab and the mon-
itor is small.
2) Tighten twenty-one mounting bolts (indicated
by * mark) lightly.
a Note that the mounting bolts to be used at
the door portions differ in bolt length and
washer size from other mountinh bolts.
a Check that air conditioner bracket (20) is
fitted securely to the seal installed to the
1. Seal
cab (21).
1) Fit seal (17) to guide plate (18) of the air
a Check joint (B) between the seal and floor
conditioner box.
2 Part (A) on outside of seal (sealing
frame for gap.
If a clearance is found, remove the cab,
face agaist cab):
and reinstall it correctly. If the clearance is
Grease(G2-LI)
small, seal it with sealant.

2) Sling operators cab assembly (16), and bond


seal (19) to the mating face.

50-306 D375A-6R
(01)
Cab and its attachments
Removal and installation of operator's cab assembly

3) Tighten the mounting bolts to the specified


torque, that are tightened partially in step 2.
4) Tighten the mounting bolts of angle (7) and
those of angle (10) inside the cab to the spec-
ified torque.

a Perform the subsequent installation in the re-


verse order to removal from step 7.

[*1]
a When connecting the window washer hoses,
match their band colors.

D375A-6R 50-307
(01)
Cab and its attachments
Removal and installation of floor frame assembly

Removal and installation of floor frame assembly 50-308

Removal 50-308
k Park the machine on a level surface and low-
er the work equipment to the ground.
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
k Stop the engine and disconnect the cable
from the negative (-) terminal of the battery.
k If you drain the coolant or disconnect the
heater hose when the coolant temperature is
high, you may be scalded. In this case, wait
until the coolant temperature lowers and
then drain the coolant or disconnect the
heater hose.
a Note the installed positions of the hoses and wir-
ings for installation purpose.
a Plug the disconnected hoses to prevent oil from
flowing out.

1. Collect the air conditioner refrigerant (R134a)


a Ask a qualified distributor for collection and
charge of the refrigerant (R134a).
a Never discharge the refrigerant (R134a) into
the atmosphere.
k If refrigerant gas (R134a) gets in your
eyes, you may lose your sight. According-
ly, put on safety glasses, safety gloves
and long sleeved work clothes when col-
lecting or charging the refrigerant.
q Collected amount of refrigerant:1,100 100
g

2. Drain the hydraulic oil.


6 Hydraulic tank:
130 l(refill capacity)
3. Drain the coolant.
6 Radiator:
120 l
4. Remove the ROPS guard. For details, see
"Removal and installation of ROPS guard."

5. Remove the fuel tank assembly. For details, see


"Removal and installation of fuel tank assembly."

6. Remove the operator cab assembly. For details,


see "Removal and installation of operator cab
assembly."

7. Remove the covers according to the following


procedure.
1) Remove cover (1).
2) Remove cover (2).
3) Remove cover (3).
4) Remove cover (4).

50-308 D375A-6R
(01)
Cab and its attachments
Removal and installation of floor frame assembly

8. Remove cover (5). 15. Disconnect ground wire (13).


9. Disconnect clamp (6). 16. Disconnect following wiring connectors (14) to
10. Disconnect wiring connector (7). (22).
(From left top)
VED (14), PWR (15), USL (16)
(From right top)
VED (17), VDB (18), PL2 (19), PL1 (20), PL1
(21), PL1 (22)

17. Disconnect two clamps (23).

11. Disconnect two air conditioner hoses (8).


[*1]
a Plug the hoses to prevent entry of dirt and
water.
12. Disconnect heater hose clamp (9).
13. Disconnect two heater hoses (10).
a Close the heater valve on the engine side.
14. Remove clamp (11) and disconnect air hose 18. Disconnect clamps (24) and (25).
(12). [*2]

19. Disconnect PPC hose (26) (band color: green).


20. Disconnect hydraulic hose (27).
21. Disconnect clamp (28).

D375A-6R 50-309
(01)
Cab and its attachments
Removal and installation of floor frame assembly

22. Disconnect ripper PPC hose (29). a Take care not to loosen the turnbuckle in
wrong direction since it has left-hand
threads.

26. Disconnect right levers (38) and PPC valve as a


unit from the console according to the following
procedure.
1) Remove armrest (39).
2) Remove the mounting bolts of console cover
(40).
3) Remove each lever cover (41) from the
console cover and pull the console cover
away from levers (38).
a Lift up the console cover carefully since
the wiring connectors are installed to its
23. Remove wiring connectors RT1 (30), RPU (31), back side.
RTB (32), and BLD (33). 4) Disconnect wiring connectors PLSW (42)
and HNSW (43) from the back side of the
console cover.
5) Remove console cover (38).
6) Roll up lever cover (41) and remove four
mounting bolts (44) of each lever.
7) Lower the levers and PPC valve as a unit
below the console.

27. Remove left console cover (45).

24. Remove pin (34) and disconnect parking brake


cable (35) from lever (36).
[*3]
a Note the installed dimensions of the cable
before disconnecting.(Nut position: N)

25. Remove pin (37) and disconnect brake rod (38)


from lever (39).
[*4]
a Note the installed dimension of the brake rod
before disconnecting it.

50-310 D375A-6R
(01)
Cab and its attachments
Removal and installation of floor frame assembly

29. Remove four mounting bolts (48) at the left front


of the floor frame.
[*6]
30. Remove mounting bolt (49) at the right front of
the floor frame.
[*7]

31. Sling and remove floor frame assembly (50).


a Lift the assembly while checking all the hos-
es and wirings are disconnected.
a After removing the floor frame assembly, re-
move the spacer on the right front mount.
4 Floor frame assembly:
600 kg
28. Remove four mounting bolts (47) each at the
right rear and left rear of the floor frame.
[*5]

D375A-6R 50-311
(01)
Cab and its attachments
Removal and installation of floor frame assembly

Connection 50-312 [*4]


q Carry out installation in the reverse order to re- a Install the brake rod to the turnbuckle, set it to
moval. the installed dimension noted when it was re-
moved.
[*1] a Be sure to bend the cotterpin securely.
a Install the hose without twisting it. a Adjust the brake rod. For details, see testing and
a When installing the air conditioner circuit hose, adjusting,Adjusting brake pedal and parking
take care not to allow dint, dust and water to en- brake parking brake lever.
ter it.
a Check that the O-ring is fitted to the air condition- [*5][*6]
er hose adapter before tightening the adapter 3 Mounting bolts at the right rear, left rear
a When connecting the refrigerant pipes, apply and left front sides:
compressor oil for new refrigerant (R134a) 338. 1 39.2 Nm {34.5 4 kgm}
(DENSO: ND-OIL8) or ZEXEL:ZXL100PG
(PAG46 or the equivalent) to the O-rings. [*7]
3 Mounting bolt at right front:
1,370 1,666 Nm {140 170 kgm}

q Refilling of coolant
Supply coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
5 Coolant:
120 l

q Charging air conditioner with refrigerant


Charge the air conditioner circuit with refrigerant
(R134a).
3 Tightening torque for air conditioner a Refill capacity: 1,100 100 g
gas piping.
Thread size Tightening torque
16 x 1.5 12.23 1.47 Nm {1.35 0.15 kgm}
22 x 1.5 22.05 2.45 Nm {2.25 0.25 kgm}
24 x 1.5 31.85 2.45 Nm {3.25 0.25 kgm}
M6 bolt
5.39 1.47 Nm {0.55 0.15 kgm}
(receiver portion)
M6 bolt
9.8 1.96 Nm {1.0 0.2 kgm}
(compressor portion)

[*2]
3 Air hose clamp:
6.8 0.49 Nm {0.69 0.05 kgm}
[*3]
a Install the cable to the bracket setting it to the di-
mension noted when the cable was removed.
a Be sure to bend the cotter pin securely.
a Adjust the parking brake. For details, see Test-
ing and adjusting, "Adjusting PCCS lever".

50-312 D375A-6R
(01)
Cab and its attachments
Removal and installation of air conditioner unit assembly

Removal and installation of air conditioner unit assembly 50-313

Removal 50-313
k Park the machine on a level surface and low-
er the work equipment to the ground.
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
k Stop the engine and disconnect the cable
from the negative (-) terminal of the battery.
k If you drain the coolant or disconnect the
heater hose when the coolant temperature is
high, you may be scalded. In this case, wait
until the coolant temperature lowers and
then drain the coolant or disconnect the
heater hose.
a Note the installed positions of the hoses and wir-
ings for installation purpose.
a Plug the disconnected hoses to prevent oil from
flowing out.

1. Collect the air conditioner refrigerant (R134a).


a Ask a qualified distributor for collection and
charge of the refrigerant (R134a).
a Never discharge the refrigerant (R134a) into
the atmosphere.
k If refrigerant gas (R134a) gets in your
eyes, you may lose your sight. According-
ly, put on safety glasses, safety gloves
and long sleeved work clothes when col-
lecting or charging the refrigerant.
q Collected amount of refrigerant: 1,100 100
g 4. Disconnect two air conditioner hoses (5).
[*1]
2. Drain the coolant. a Plug the hoses to prevent entry of dirt, dust
6 Radiator: and water.
120 l 5. Disconnect heater hose clamp (6).
3. Remove the covers according to the following 6. Disconnect two heater hoses (7).
procedure. a Close the heater valve on the engine side.
1) Remove cover (1). 7. Loosen clamp (8) and remove duct (9).
2) Remove cover (2). [*2]
3) Remove cover (3).
4) Remove cover (4).

D375A-6R 50-313
(01)
Cab and its attachments
Removal and installation of air conditioner unit assembly

8. Disconnect wiring connectors DS3 (10), DS1


(11), DS2 (12), DS4 (13), and DS5 (14).

11. Remove covers (21a) and (21b).


[*4]
9. Open air conditioner filter cover (15). 12. Remove right and left foot rests (22).
13. Remove right and left ducts (23).

10. Remove monitor cover (16).


[*3]
a Four connectors are installed at the back of
the cover. Disconnect the connectors before
removing the cover.
(From left top) (From right top)
(17): FLSW (19): ADH
(18): RLSW (20): OPSW

50-314 D375A-6R
(01)
Cab and its attachments
Removal and installation of air conditioner unit assembly

14. Remove cover (24). 18. Disconnect wiring connectors CM01 (29) and
15. Remove right and left covers (25). CM02 (30).

16. Disconnect wiring connector AC1 (26). 19. Disconnect wiring connectors AC2 (31) and AC3
(32).

17. Remove four mounting bolts (27) and disconnect


monitor assembly (28) from the dashboard of the 20. Disconnect four relay wiring connectors (33).
monitor. 21. Disconnect wiring connector (34) of the servo-
a Wires are connected to the back side. Pull motor.
out the monitor assembly toward you careful- 22. Disconnect wiring connector M26 (35).
ly.

D375A-6R 50-315
(01)
Cab and its attachments
Removal and installation of air conditioner unit assembly

23. Remove back side cover (36) of the monitor 26. Remove each two mounting bolts (41a), (41b),
panel. and (41c) of the air conditioner unit assembly,
and remove air conditioner unit assembly (42).
(41a): 2 places, lower left and lower right of this
side
(41b): 2 places, lower left and lower right of
engine side
(41c): 2 places, engine upper side

24. Disconnect dummy connector (37) from clip


(38).
25. Disconnect clamp (40) of wiring (39).

50-316 D375A-6R
(01)
Cab and its attachments
Removal and installation of air conditioner unit assembly

(a): Installed position of bolts (41a) Connection 50-317


(b): Installed position of bolts (41b) q Carry out installation in the reverse order to re-

(c): Installed position of bolts (41c) moval.

[*1]
a Install the hose without twisting it.
a When installing the air conditioner circuit hose,
take care not to allow dint, dust and water to en-
ter it.
a Check that the O-ring is fitted to the air condition-
er hose adapter before tightening the adapter.
a When connecting the refrigerant pipes, apply
compressor oil for new refrigerant (R134a)
(DENSO: ND-OIL8) or ZEXEL: ZXL100PG
(PAG46 or the equivalent) to the O-rings.

3 Tightening torque for air conditioner gas


plping.
Thread size Tightening torque
16 x 1.5 12.23 1.47 Nm {1.35 0.15 kgm}
22 x 1.5 22.05 2.45 Nm {2.25 0.25 kgm}
24 x 1.5 31.85 2.45 Nm {3.25 0.25 kgm}
M6 bolt
5.39 1.47 Nm {0.55 0.15 kgm}
(receiver portion)
M6 bolt
9.8 1.96 Nm {1.0 0.2 kgm}
(compressor portion)

[*2]
3 Air hose clamp:
6.8 0.49 Nm {0.69 0.05 kgm}

D375A-6R 50-317
(01)
Cab and its attachments
Removal and installation of air conditioner unit assembly

[*3][*4]
a Adjust the monitor panel plate position according
to the following procedure.
1) Tighten bolts (A) and (B) partially.
2) Tighten bolts (A) so that gaps (C) are set
uniform in horizontal and vertical directions to
prevent interference between the monitor
panel, SW panel, and cover.
3) Tighten bolts (B).

q Charging air conditioner with refrigerant


Charge the air conditioner circuit with refrigerant
(R134a).

q Refilling of coolant
Supply coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
5 Coolant:
120 l

50-318 D375A-6R
(01)
Electrical system
Removal and installation of transmission controller assembly and steering controller assembly

Electrical system 50-319


Removal and installation of transmission controller assembly and
steering controller assembly 50-319

Removal 50-319 Connection 50-319


k Park the machine on a level surface and low- q Carry out installation in the reverse order to re-
er the work equipment to the ground. moval.
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
k Stop the engine and disconnect the cable
from the negative (-) terminal of the battery.

1. Remove plate (1).

2. Disconnect transmission controller wiring


connector (2) and steering controller wiring
connector (3). Remove the mounting bolts, and
remove transmission controller assembly (4)
and steering controller assembly (5).

D375A-6R 50-319
(01)
Electrical system
Removal and installation of engine controller assembly

Removal and installation of engine controller assembly 50-320

Removal 50-320
k Park the machine on a level surface and low- 3. Disconnect wiring connector GC3 (3), EGC1 (4)
er the work equipment to the ground. and EGC2 (5).
k Set the parking brake lever and work equip- [*1]
ment lock lever in the lock position. a E: ground cable
k Stop the engine and disconnect the cable
from the negative (-) terminal of the battery.

1. Open the left side cover and remove lower side


cover (1).

4. Remove the mounting bolt and remove engine


controller assembly (6).

2. Remove controller box cover (2).

Connection 50-320
q Carry out installation in the reverse order to re-
moval.
.
[*1]
3 Screw:
2.82 Nm {0.288 kgm}

50-320 D375A-6R
(01)
Electrical system
Removal and installation of engine controller assembly

a Reference
q Power supply connector EGC3 (5) seal replace-
ment procedure
Seal part No.: 1010-074-0406 [DEUTSCH
JAPAN]
1) Using tweezers [1], pinch the claw to remove
cover (8).

2) Using tweezers [1], remove seal (9).

D375A-6R 50-321
(01)
Electrical system
Removal and installation of VHMS controller assembly

Removal and installation of VHMS controller assembly 50-32

Removal 50-32
k Park the machine on a level surface and low- 5. Remove the mounting bolts and remove
er the work equipment to the ground. controller case cover (4).
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
k Stop the engine and disconnect the cable
from the negative (-) terminal of the battery.

1. Sling and remove cover (1) on the left side of the


operator's cab.

6. Remove the mounting bolts and remove VHMS


controller assembly (5).

2. Disconnect wiring connector (2).


3. Disconnect wiring clamp (2a).
4. Disconnect main harness cap (3).

Connection 50-32
q Carry out installation in the reverse order to re-
moval.

50-322 D375A-6R
(01)
Electrical system
Removal and installation of machine monitor assembly

Removal and installation of machine monitor assembly 50-323

Connection 50-323
k Park the machine on a level surface and low- 2. Remove four mounting bolts (6) and disconnect
er the work equipment to the ground. machine monitor assembly (7) from the dash-
k Set the parking brake lever and work equip- board.
ment lock lever to lock position. a Wrings are connected in the back side. Be
k Stop the engine and disconnect the cable careful of this when pulling it toward you.
from the negative (-) terminal of the battery.

1. Remove monitor cover (1).


[*1]
a Four connectors are installed at the back of
the cover. Disconnect the connectors before
removing the cover.
(From upper left) (From upper right)
(2): FLSW (4): ADH
(3): RLSW (5): OPSW

3. Disconnect wiring connectors CM01 (8) and


CM02 (9).
4. Remove four mounting bolts (10) and remove
machine monitor assembly (7).

D375A-6R 50-323
(01)
Electrical system
Removal and installation of machine monitor assembly

Connection 50-324

Carry out installation in the reverse order to remov-


al.

[*1]
a Adjust the machine monitor panel plate position
according to the following procedure.
1) Tighten bolts (A) partially.
2) Tighten bolts (A) so that gaps (C) are set
uniform in horizontal and vertical directions to
prevent interference between the momitor
cover and the monitor or the switch panel.

50-324 D375A-6R
(01)
D375A-6R
SEN0521429-00 60-1

BULLDOZER
Shop Manual 6-01

D375A-6R

Machine model Serial number


D375A-6R 65001 and up

60 Maintenance standard 60-1

D375A-6R 60-1
Contents

Contents 60-2
60 Maintenance standard
Engine and cooling system ..................................................................................................... 60- 3
Engine mount....................................................................................................................... 60- 3
Cooling fan pump................................................................................................................. 60- 5
Cooling fan motor................................................................................................................. 60- 12
Power train.............................................................................................................................. 60- 14
Power train unit .................................................................................................................... 60- 14
Damper and universal joint .................................................................................................. 60- 16
Torque converter and PTO .................................................................................................. 60- 19
Main relief valve and torque converter relief valve............................................................... 60- 22
Lockup clutch ECMV and stator clutch ECMV..................................................................... 60- 23
Scavenging pump ................................................................................................................ 60- 24
Transmission control............................................................................................................ 60- 25
Transmission........................................................................................................................ 60- 26
Transmission lubricating oil relief valve ............................................................................... 60- 31
Power train and lubrication pump ........................................................................................ 60- 32
Transfer, bevel gear shaft and steering unit ........................................................................ 60- 34
Steering control valve .......................................................................................................... 60- 40
Steering clutch ECMV and steering brake ECMV................................................................ 60- 41
Parking brake valve ............................................................................................................. 60- 42
Final drive ............................................................................................................................ 60- 43
Sprocket............................................................................................................................... 60- 46
Undercarriage and frame ........................................................................................................ 60- 48
Track frame.......................................................................................................................... 60- 48
Idler cushion......................................................................................................................... 60- 50
Idler ...................................................................................................................................... 60- 52
Track roller ........................................................................................................................... 60- 54
Carrier roller ......................................................................................................................... 60- 56
Track roller bogie ................................................................................................................. 60- 57
Track shoe ........................................................................................................................... 60- 58
Main frame ........................................................................................................................... 60- 62
Suspension .......................................................................................................................... 60- 64
Hydraulic system..................................................................................................................... 60- 68
PPC valve ............................................................................................................................ 60- 68
Hydraulic cylinder................................................................................................................. 60- 74
Quick drop valve .................................................................................................................. 60- 77
Work equipment pump......................................................................................................... 60- 78
Control valve ........................................................................................................................ 60- 81
Self-pressure reducing valve ............................................................................................... 60- 94
Work equipment...................................................................................................................... 60- 97
Cylinder stay ........................................................................................................................ 60- 97
Blade.................................................................................................................................... 60- 98
Cutting edge and end bit...................................................................................................... 60- 102
Ripper .................................................................................................................................. 60- 104

60-2 D375A-6R
Engine and cooling system
Engine mount

Engine and cooling system 60-3


Engine mount 60-3

Unit: mm

No. Item Criteria Remedy


Standard Tolerance Standard Clearance
Clearance between bracket and size Shaft Hole clearance limit
1
cushion +0.018 +0.078
70 0.014 0.090 0.2
-0.012 +0.032 Replace
Standard size Repair limit
2 Free height of mount rubber
102 100

D375A-6R 60-3
Engine and cooling system
Engine mount

60-4 D375A-6R
Engine and cooling system
Cooling fan pump

Cooling fan pump 60-4


Type: LPV90 + 30
Appearance 60-4

D375A-6R 60-5
Engine and cooling system
Cooling fan pump

LPV90 Hydraulic pump 10-8 60-6


Appearance 60-6

60-6 D375A-6R
Engine and cooling system
Cooling fan pump

Sectional view 60-7

D375A-6R 60-7
Engine and cooling system
Cooling fan pump

LPV30 Hydraulic pump 60-8


Appearance 60-8

60-8 D375A-6R
Engine and cooling system
Cooling fan pump

Sectional view 60-9

D375A-6R 60-9
Engine and cooling system
Cooling fan pump

Servo valve 60-10

60-10 D375A-6R
Engine and cooling system
Cooling fan pump

D375A-6R 60-11
Engine and cooling system
Cooling fan motor

Cooling fan motor 60-12


Type: LMF180 (150)
Appearance 60-12

60-12 D375A-6R
Engine and cooling system
Cooling fan motor

Sectional view 60-13

Unit: mm

No. Check item Criteria Remedy


Standard size Repair limit
Free length x Load at
Installed Load at Replace spring if
outside diame- installed Free length
1 Spool return spring length installed length damaged or
ter length
deformed.
172 N 137 N
83.8 x 19 67.5
{17.5} {14}

D375A-6R 60-13
Power train
Power train unit

Power train 60-14


Power train unit 60-14

60-14 D375A-6R
Power train
Power train unit

D375A-6R 60-15
Power train
Damper and universal joint

Damper and universal joint 60-16

60-16 D375A-6R
Power train
Damper and universal joint

Unit: mm

No. Item Criteria Remedy


Standard Tolerance Standard Clearance
Clearance between flywheel hous- size Shaft Hole clearance limit
1
ing and cover -0.024 +0.080
647.7 0.024 0.185 0.2
-0.105 0
Clearance between flywheel and -0.022 +0.110
2 546.0 0.022 0.202 0.25
damper -0.092 0
Standard size Tolerance Repair limit Replace
Outside diameter of oil seal contact
3 0
surface of coupling 110 109.9
-0.035
Outside diameter of oil seal contact 0
4 110 109.9
surface of output shaft -0.035
Dimension between bearing and
5 53 0.1 52.7
holder

D375A-6R 60-17
Power train
Damper and universal joint

60-18 D375A-6R
Power train
Torque converter and PTO

Torque converter and PTO 60-18

D375A-6R 60-19
Power train
Torque converter and PTO

60-20 D375A-6R
Power train
Torque converter and PTO

Unit: mm

No. Item Criteria Remedy


Standard size Tolerance Repair limit
Outside diameter of coupling
1 0
oil seal contact surface 125 124.8
-0.063 Apply hard
Inner diameter of seal ring +0.046 chrome plating or
2 190 190.5 replace
contact surface of retainer 0
Inside diameter of seal ring +0.035
3 110 110.2
contact surface of sleeve 0
Backlash between PTO drive
4 gear and scavenging pump 0.25 0.42
gear
Backlash between PTO drive
5 0.204 0.516
gear and idler gear
Thickness of lockup clutch disc 5.4 0.1 4.9
Thickness of lockup clutch
6 5.0 0.1 4.5
plate
Total thickness of lockup clutch
15.8 0.17 14.3
assembly
Replace
Thickness of stator clutch disc 5.4 0.1 4.9

7 Thickness of stator clutch plate 5.0 0.05 4.5


Total thickness of stator clutch
15.8 0.15 14.7
assembly
Standard size Repair limit
Installed Installation
Free length Installation load Free length
8 Stator clutch return spring length load
125.5 N 106.9 N
54.1 37.0 50.9
{12.8 kg} {10.9 kg}

D375A-6R 60-21
Power train
Main relief valve and torque converter relief valve

Main relief valve and torque converter relief valve 60-21

Unit: mm

No. Item Criteria Remedy


Tolerance Standard Clearance
Standard size
Clearance between main relief 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 converter relief valve and valve 40 0.035 0.061 0.08
-0.045 0
body
Replace
Standard size Repair limit
Installed Installation Installation
Free length Free length
3 Main relief valve spring length load load
1,419 N 1,348 N
120.3 102 116.7
{144.7 kg} {137.5 kg}
Torque converter relief valve 645.1 N 613 N
4 116.92 86.3 113.4
spring {65.83 kg} {62.5 kg}

60-22 D375A-6R
Power train
Lockup clutch ECMV and stator clutch ECMV

Lockup clutch ECMV and stator clutch ECMV 60-2


a ECMV: Abbreviation for Electronic Control Modulation Valve
a Don't try to disassemble it since adjustment for maintaining the performance will be needed.

D375A-6R 60-23
Power train
Scavenging pump

Scavenging pump 60-23

Unit: mm

No. Item Criteria Remedy

1 Spline shaft rotating torque


Delivery
Standard Allowable
Rotating pressure
Type delivery delivery
speed (rpm) MPa
Delivery (l/min) (l/min)
{kg/cm2}
Oil: TO10
Oil temperature: 45 50 C BAR 63 63.3
0.15
1,743
{1.5}
BAR 277 276.8

60-24 D375A-6R
Power train
Transmission control

Transmission control 60-24


PCCS lever
a Don't try disassemble PCCS lever because, adjustments will be required for the characteristics of voltage
output and operating efforts.

D375A-6R 60-25
Power train
Transmission

Transmission 60-25

60-26 D375A-6R
Power train
Transmission

D375A-6R 60-27
Power train
Transmission

60-28 D375A-6R
Power train
Transmission

Unit: mm

NO Item Criteria Remedy


Standard size Repair limit
Load at Load at
Installed
Free length installed Free length installed
1 R clutch spring (12 pcs) length
length length
126 N 107 N
66.0 57.0 62.0
{12.8 kg} {10.9 kg}
219 N 186 N
2 F clutch spring (12 pcs) 70.0 60.3 65.8
{22.3kg} {19.0 kg}
149 N 127 N
3 3rd and 2nd clutch spring (12 pcs) 97.0 82.4 91.2
{15.2 kg} {12.9 kg}
3,420 N 2,910 N
4 1st clutch spring (3 pcs) 7.75 6.75
{349 kg} {297 kg}
Standard size Tolerance Repair limit
Total thickness of R clutch consist-
5
ing of 6 discs and 6 plates 54.6 0.35 51.4
Total thickness of F clutch consist-
6 50.3 0.33 47.1
ing of 6 discs and 5 plates
Total thickness of 3rd clutch con-
7 36.4 0.28 34.3
sisting of 4 discs and 4 plates
Total thickness of 2nd clutch con-
8 27.3 0.24 25.7
sisting of 3 discs and 3 plates
Total thickness of 1st clutch consist-
9 50.0 0.33 46.8
ing of 6 discs and 5 plates
R, F,
3rd, 2nd
4.8 0.1 4.3
10 Thickness of clutch disc
1st 5.0 0.1 4.5

R, F,
3rd, 2nd
4.3 0.1 3.9
Thickness of clutch
11
plate
1st 4.0 0.1 3.6
-0.01 Replace
Width 3.0 2.7
Wear of transmission -0.03
12
input shaft seal ring
Thickness 3.5 0.1 3.35
-0.01
Width 4.0 3.6
Wear of front cover and -0.04
13
R clutch carrier seal ring
Thickness 4.0 0.15 3.85
-0.01
Wear of F clutch and Width 4.0 3.6
-0.03
14 3rd clutch carrier seal
ring (small) Thickness 5.0 0.15 4.85
-0.01
Wear of F clutch and Width 4.0 3.6
-0.04
15 3rd clutch carrier seal
ring (large) Thickness 4.0 0.15 3.85
-0.01
Width 4.0 3.6
Wear of 1st clutch col- -0.04
16
lar seal ring
Thickness 5.0 0.15 4.85
-0.01
Width 4.0 3.6
Wear of 1st clutch gear -0.03
17
seal ring
Thickness 5.1 0.12 4.95
-0.01
Width 4.5 4.1
Wear of 1st clutch gear -0.03
18
seal ring
Thickness 6.0 0.15 5.85
-0.01
Width 4.5 4.1
Wear of transmission -0.03
19
output shaft seal ring
Thickness 5.8 0.15 5.65

D375A-6R 60-29
Power train
Transmission

Unit: mm

NO Item Criteria Remedy


-0.01
Width 5.0 4.5
Wear of 1st clutch pis- -0.03
20
ton housing seal ring
Thickness 6.0 0.15 5.85
Backlash between R and F clutch
21 0.130.40
sun gear and planetary pinion
Backlash between R clutch plane-
22 0.130.40 Replace
tary pinion and ring gear teeth
Backlash between F, 3rd and 2nd
23 clutch planetary pinion and ring 0.140.40
gear teeth
Backlash between 3rd and 2nd
24 clutch planetary pinion and ring 0.130.37
gear

60-30 D375A-6R
Power train
Transmission lubricating oil relief valve

Transmission lubricating oil relief valve 60-30

D375A-6R 60-31
Power train
Power train and lubrication pump

Power train and lubrication pump 60-31


BAL180 + 112

Unit: mm
No. Item Criteria Remedy
Type Standard clearance Clearance limit

BAL180 0.070.12 0.15


1 Side clearance
BAL112 0.040.10 0.13

Clearance between plain BAL180


2 bearing inside diameter and 0.0600.145 0.20
gear shaft outside diameter BAL112

Type Standard size Tolerance Repair limit

BAL180
3 Pin driving depth 0 Replace
14
-0.5
BAL112

4 Spline shaft rotating torque 5.9 Nm {0.6 kgm} or less


Delivery pres- Standard Allowable
Rotating speed
Type sure delivery delivery
Delivery (rpm)
MPa {kg/cm2} (l/min) (l/min)
(Oil: E010-CD
2.52.7
Oil temperature: 45 50 C) BAL180 2,033 334 308
{2628}
(Engine speed at 1900 rpm)
0.26
BAL112 2,033 210 200
{2.7}

60-32 D375A-6R
Power train
Power train and lubrication pump

D375A-6R 60-33
Power train
Transfer, bevel gear shaft and steering unit

Transfer, bevel gear shaft and steering unit 60-32


Machines without VHMS controller 60-32

60-34 D375A-6R
Power train
Transfer, bevel gear shaft and steering unit

Unit: mm

NO Item Criteria Remedy


Standard clearance Clearance limit
1 Backlash between transfer gears Adjust or replace
0.240.63 0.75

Standard size Tolerance Repair limit


Thickness of collar between trans-
2 Replace
fer gear and bearing 24 0.1 23.6
Standard shim thickness for bear-
3 2.0 Adjust shim
ing cage mount

D375A-6R 60-35
Power train
Transfer, bevel gear shaft and steering unit

Machines equipped with VHMS controller 60-34

60-36 D375A-6R
Power train
Transfer, bevel gear shaft and steering unit

Unit: mm

NO Item Criteria Remedy


Standard clearance Clearance limit
1 Backlash between transfer gears Adjust or replace
0.240.63 0.75

Standard size Tolerance Repair limit


Thickness of collar between trans-
2 Replace
fer gear and bearing 24 0.1 23.6
Standard shim thickness for bear-
3 2.0 Adjust shim
ing cage mount

D375A-6R 60-37
Power train
Transfer, bevel gear shaft and steering unit

Bevel gear shaft, steering clutch and brake 60-36

60-38 D375A-6R
Power train
Transfer, bevel gear shaft and steering unit

Unit: mm

NO Item Criteria Remedy


Standard size Tolerance Repair limit
Replace
Plate for steering Thickness 2.9 0.1 2.6
1
brake and clutch
Strain Max. 0.3 0.4 Repair or replace

Thickness 4.7 0.1 4.2 Replace


Disc for steering brake
2
and clutch Strain Max. 0.3 0.4 Repair or replace

Total thickness of brake plate


3 68.4 0.42 65.4
and disc assembly
Total thickness of clutch plate
4 68.4 0.42 65.4
Replace
and disc assembly
Standard clearance Repair limit
Backlash between brake or
5
clutch disc and brake hub 0.170.52 1.0
Backlash between bevel gear
6 0.30.4 0.75 Adjust or replace
and pinion
Standard Tolerance Standard
Clearance limit
Inside diameter of seal ring con- size Shaft Hole clearance
7
tact surface of cage -0.5 +0.081
290 0.50.781
-0.7 0
Inside diameter of piston seal -0.100 +0.072
8 245 0.1000.244
ring contact surface of piston -0.172 0
Standard size Repair limit
Load at
Installed Load at
Free length installed Free length
9 Brake spring length installed length Replace
length
38.7 kN 36.8 kN
17.1 11.2 16.6
{3,950 kg} {3,750 kg}
37.9 kN 36.0 kN
10 Clutch spring 17.55 11.6 17.0
{3,860 kg} {3,670 kg}
Standard Tolerance Standard Interference
Interference between bevel gear size Shaft Hole interference limit
11
and reamer bolt + 0.019 + 0.027 -0.0260.01
16 Max. 0.019
+ 0.001 0 9
Runout of back face of bevel
12 Repair limit: 0.05 (to be measured after installation to bevel gear shaft) Repair or replace
gear
Standard rotation torque: 4.9 - 5.9 Nm {0.5 - 0.6 kgm}
Preload of bevel gear shaft taper
13 (At tip of bevel gear teeth when bevel pinion and gear are not engaged: Adjust
roller bearing
23.528.4 N {2.42.9 kg})
Standard shim thickness of bear-
14 2.0 Adjust shim
ing cage

D375A-6R 60-39
Power train
Steering control valve

Steering control valve 60-38

60-40 D375A-6R
Power train
Steering clutch ECMV and steering brake ECMV

Steering clutch ECMV and steering brake ECMV 60-39


a ECMV: Abbreviation for Electronic Control Modulation Valve
a Don't try to disassemble it since adjustment for maintaining the performance will be needed.

D375A-6R 60-41
Power train
Parking brake valve

Parking brake valve 60-40

Unit: mm

No. Item Criteria Remedy


Standard Tolerance Standard Clearance
Clearance between parking brake size Shaft Hole clearance limit
1 Replace
valve spool and valve body -0.020 +0.011
14 0.020 0.041 0.05
-0.030 0
Standard
Outside diameter of contact surface Tolerance Repair limit Repair hard
size
2 of dust seal and U-packing on park- chrome plating or
-0.020
ing brake valve spool 14 13.9 replace
-0.030
Standard size Repair limit
Installed
Free length Installed load Free length Installed load
3 Parking brake valve spool spring length Replace
38.2 N 36.4 N
65 47.7 63.1
{3.9 kg} {3.71 kg}

60-42 D375A-6R
Power train
Final drive

Final drive 60-41

D375A-6R 60-43
Power train
Final drive

60-44 D375A-6R
Power train
Final drive

Unit: mm

No. Item Criteria Remedy


Standard clearance Clearance limit
Backlash between No.1 pinion and
1
No.1 gear 0.25 0.99 1.5
Backlash betwee sun gear and
2 0.22 0.81 1.5
planetary pinion
Backlash between planetary pinion
3 0.25 0.81 1.5
and ring gear
Standard size Repair limit
Outside diameter of oil seal contact
4
surface of No.1 pinion 115.0 114.9
Replace
Thickness of thrust collar of inner
5 25.14 24.9
body roller bearing
Thickness of thrust coller of No.1
6 10.0 9.5
gear boss roller bearing
Dimensions from cover mounting
7 24.0 22.5
face to button head
Standard Tolerance Standard Clearance
Clearance between pinion shaft size Shaft Hole clearance limit
8
and carrie -0.036 -0.024
85 -0.023 0.034 0.1
-0.058 -0.059
Standard shim thickness for No.1
9 3
pinion bearing cage
Dimension of end face of final drive
10 7 (0/-0.2) Adjust
cover and end face of bearing
11 Clearance at floating seal guard 4.1 5.3

Standard size Repair limit


12 Wear of wear guard Rebuild or replace
47 18

D375A-6R 60-45
Power train
Sprocket

Sprocket 60-4

Unit: mm

No. Item Criteria Remedy


Standard size Repair limit
1 Wear of tooth tip
433 417 Replace or rebuild by
build up welding
2 Thickness of tooth root 28.7 22.7

60-46 D375A-6R
Power train
Sprocket

Full-scale drawing of sprocket tooth profile

D375A-6R 60-47
Undercarriage and frame
Track frame

Undercarriage and frame 60-46


Track frame 60-46

60-48 D375A-6R
Undercarriage and frame
Track frame

Unit: mm

NO Item Criteria Remedy


Item Repair limit

Bend 7 (per length 3,000)


Deformation of track frame outer
1
casing Torsion 3 (per level length 300)

Dents (pipe portion) 12


Repair or replace
Standard Tolerance Standard Clearance
Clearance between inner casing size Shaft Hole clearance limit
2
and stopper protruding portion -0.15 +0.3
30 0.150.65 2.0
-0.35 0
Clearance between track frame and +0.02 +0.063
3 128 0.0430.163
stopper -0.106 0
4 Press-fitting force for cartridge pin 245441 kN {2545 ton}

Standard clearance Clearance limit


Clearance between track frame and
5 Adjust
idler guide 00.5 3.0

D375A-6R 60-49
Undercarriage and frame
Idler cushion

Idler cushion 60-48

60-50 D375A-6R
Undercarriage and frame
Idler cushion

Unit: mm
NO Item Criteria Remedy
Standard size Repair limit
Load at
Installed Load at
1 Recoil spring Free length installed Free length
length installed length
length
499.7 kN 458.5 kN
1,461 1,230.5 1,440
{50,994 kg} {46,790 kg}
Replace
Standard Tolerance Standard
Clearance between outer diame- Clearance limit
size Shaft Hole clearance
2 ter of outer sleeve bushing and
inner diameter of outer sleeve -0.058 +0.317
380 0.1180.545 0.8
-0.228 +0.060
Clearance between adjustment -1.000 +0.063
3 135 1.0001.363
cylinder and bushing -1.300 0
Press-fitting force for inserting
4 outer sleeve bushing into outer 49.0109.8 kN {5.011.2 ton}
sleeve
Press-fitting force for installing
Adjust
5 outer sleeve bushing to spring cyl- 91.2322.6 kN {9.332.9 ton}
inder
Clearance between recoil spring
6 01.0
mounting nut and lock plate

D375A-6R 60-51
Undercarriage and frame
Idler

Idler 60-50

60-52 D375A-6R
Undercarriage and frame
Idler

Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
Outside diameter of protuding por-
1
tion 927

2 Outside diameter of tread 880 855

3 Depth of tread 23.5 36 Rebuild by build-up


welding or replace
4 Thickness of tread 32.5 20

5 Total width 294

6 Overall with of tread 79.0 87.5

Standard Tolerance Standard Clearance


Clearance between shaft and size Shaft Hole clearance limit
7 Replace bushing
bushing -0.350 +0.198
155 0.297 0.611
-0.413 -0.053
Standard size Repair limit
Rebuild by build-up
8 Collar width of shaft
252 welding or replace

Standard Tolerance Standard Interference


Interference between shaft and size Shaft Hole interference limit
9 Replace ring
ring +0.046 -0.15
95 0.15 0.246
0 -0.20
Standard clearance Clearance limit
10 End play Adjust or replace
0.490.86

Standard size Tolerance Repair limit


11 Outside diameter of shaft -0.410 Replace
95 - 0.5
-0.484

D375A-6R 60-53
Undercarriage and frame
Track roller

Track roller 60-52

q 2nd, 4th, and 6th track roller (double flanged roller)


Unit: mm

NO Item Criteria Remedy


Standard size Repair limit
Outer diameter of flange (outside
1
flange) 310
Outer diameter of flange (inside
2 300
flange)
3 Outside diameter of tread 270 210

4 Thickness of tread 30 29
Rebuild by build-up
5 Total width 358 welding or replace

6 Overall with of tread 82

7 Width of flange (outside flange) 29 14

8 Width of flange (inside flange) 27 12

9 Collar width of shaft 306

Tolerance Standard Clearance


Standard size
Clearance between shaft and bush- Shaft Hole clearance limit
10 Replace bushing
ing -0.350 +0.260 0.360
140
-0.413 +0.010 0.673
Tolerance Standard Interference
Standard size
Interference between shaft and Shaft Hole interference limit
11 Replace
seal ring +0.046 -0.13 0.130
75
+0 -0.18 0.226
Standard clearance Clearance limit
12 End play Adjust or replace
0.44 0.91

Standard size Tolerance Repair limit


13 Outside diameter of shaft 0 Replace
74.5 -0.2
-0.12

60-54 D375A-6R
Undercarriage and frame
Track roller

q 1st, 3rd, 5th, and 7th track roller (single flanged roller)
Unit: mm
NO Item Criteria Remedy
Standard size Repair limit
1 Outside diameter of flange
310

2 Outside diameter of tread 270 210

3 Thickness of tread 30 29
Rebuild by build-up
4 Total width 358 welding or replace

5 Overall with of tread 82

6 Width of flange 29 14

7 Collar width of shaft 306

Standard Tolerance Standard Clearance


Clearance between shaft and size Shaft Hole clearance limit
8 Replace bushing
bushing -0.350 +0.260
140 0.3600.673
-0.413 -0.010
Standard Tolerance Standard Interference
Interference between shaft and size Shaft Hole interference limit
9 Replace
ring +0.046 -0.13
75 0.1300.226
0 -0.18
Standard clearance Clearance limit
10 End play Adjust or replace
0.440.91

Standard size Tolerance Repair limit


11 Outside diameter of shaft 0 Replace
74.5 -0.2
-0.12

D375A-6R 60-55
Undercarriage and frame
Carrier roller

Carrier roller 60-54

Unit: mm

No. Item Criteria Remedy


Standard size Repair limit
1 Outside diameter of flange
242

2 Outside diameter of tread 210 185


Rebuild by build-up
3 Width of tread 79 welding or replace

4 Thickness of tread 40 27.5

5 Width of flange 23 12

Standard Tolerance
Standard interference
size Shaft Hole
6 Interference between shaft and ring
+0.245 +0.035
90 0.150 245
+0.185 0
Standard Tolerance
Standard clearance
Clearance between shaft and sup- size Shaft Hole Replace
7
port 0 +0.350
86 0 0.550
-0.2 0
Standard clearance Clearance limit
8 Axial play of roller
00.22

60-56 D375A-6R
Undercarriage and frame
Track roller bogie

Track roller bogie 60-5

Unit: mm

NO Item Criteria Remedy

1 Press-fitting force for cartridge pin 245441 kN {2545 ton}

D375A-6R 60-57
Undercarriage and frame
Track shoe

Track shoe 60-58

a Portion P shows the link on the side where the bushing is pressed fitted.

60-58 D375A-6R
Undercarriage and frame
Track shoe

Unit: mm

No. Item Criteria Remedy


Standard size Repair limit
1 Link pitch
280.3 283.3

Reverse
Standard size
Light load Heavy load Turn 180 or replace
2 Outside diameter of bushing
98.5 90 92.5

3 Thickness of bushing 18.8 10.3 12.8

Standard size Repair limit


4 Height of link
181 163 Rebuild by build-up
welding or replace
Thickness of link (bushing press-fit-
5 56 38
ting portion)
One side Both side
6 Clearance between links
1.4 2.8

Tolerance Standard inter-


Standard size
Interference between bushing and Shaft Hole ference Adjust or replace
7
link +0.622 +0.087
98 0.435 0.622
0.522 0
Interference between regular pin +0.426 +0.127
8 30 0.239 0.373
and link +0.366 +0.053
Tightening torque Retightening angle
(Nm {kgm}) (Degree)
a. Regular link
9 Shoe bolt 1,372 137 {140 14} 120 10 Retighten

b. Master link 686.4 68.6{70 7} 180 10

D375A-6R 60-59
Undercarriage and frame
Track shoe

Single grouser shoe 60-58

Unit: mm

No. Item Criteria Remedy


Standard size Repair limit
1 Height of grouser
93 29 Repair by lug weld-
ing or replace
2 Overall height of shoe 116 53

60-60 D375A-6R
Undercarriage and frame
Track shoe

D375A-6R 60-61
Undercarriage and frame
Main frame

Main frame 60-60

60-62 D375A-6R
Undercarriage and frame
Main frame

Unit: mm

No. Item Criteria Remedy


Standard Tolerance Standard inter- Interference
Interference between steering case size Shaft Hole ference limit
1
and bushing +0.108 +0.052
275 0.004 0.108 Min. 0
+0.056 0
Standard Tolerance Standard Clearance
Clearance between steering case size Shaft Hole clearance limit
2
and final drive cage -0.018 +0.057
332 0.018 0.132 0.2
-0.075 0
Clearance between bracket and +0.018 +0.046
3 70 0.018 0.058 0.1
cushion -0.012 0
Clearance between ripper beam -0.036 +0.166
4 120 0.064 0.256 1.5
mounting pin and bushing -0.090 +0.028
Clearance between ripper cylinder -0.036 +0.287
5 100 0.236 0.377 1.5 Replace
mounting pin and bushing -0.090 +0.200
Clearance between radiator guard -0.030 +0.371
6 80 0.299 0.477 1.5
mounting pin and bushing -0.076 +0.269
Clearance between radiator guard -0.036 +0.369
7 90 0.303 0.459 1.0
mounting pin and bushing -0.090 +0.267
Clearance between equalizer bar -0.036 +0.243
8 120 0.137 0.333 1.0
shaft and bushing -0.090 +0.101
Standard size Repair limit
Protrusion of rubber on seal end
9
face 1 0.5
Free height of front cab mount rub-
10 105 103
ber
Free height of rear cab mount rub-
11 58 56
ber
Press-fitting force for ripper beam
12 44.1 117.6 kN {4.5 12 ton}
mounting bushing
Press-fitting force for ripper cylinder
13 58.8 171.6 kN {6 17.5 ton}
mounting bushing
Press-fitting force for radiator guard
14 98.0 181.4 kN {10 18.5 ton} Adjust
mounting bushing
Press-fitting force for radiator guard
15 58.8 137.3 kN {6 14 ton}
mounting bushing
Press-fitting force for equalizer bar
16 31.4 105.9 kN {3.2 10.8 ton}
shaft mounting bushing

D375A-6R 60-63
Undercarriage and frame
Suspension

Suspension 60-62

60-64 D375A-6R
Undercarriage and frame
Suspension

Unit: mm

No. Item Criteria Remedy


Standard Tolerance Standard Clearance
Clearance between center pin and size Shaft Hole clearance limit
1
bushing -0.036 +0.243
120 0.137 0.333 1.0
-0.090 +0.101
Clearance between side pin and -0.048 +0.015
2 95 0.033 0.093 1.0 Replace bushing
bushing -0.078 -0.015
Standard Tolerance Standard inter- Interference
Interference between side pin boss size Shaft Hole ference limit
3
and bushing +0.045 -0.028
160 0.055 0.113
+0.027 -0.068
Press-fitting force for center pin
4 49.0 186.3 kN {5 19 ton}
bushing

Press-fitting force for side pin bush-
5 34.3 73.5 kN { 3.5 7.5 ton}
ing

D375A-6R 60-65
Undercarriage and frame
Suspension

*1. Shown in the figure is the left suspension of the single tilt specification machines.
*2. Shown in the figure are the right suspension of the single tilt specification machines, and
the right and left suspensions of the dual tilt specification machines.

60-66 D375A-6R
Undercarriage and frame
Suspension

Unit: mm

No. Item Criteria Remedy


Standard Tolerance Standard inter- Interference
Interference between thrust washer size Shaft Hole ference limit
6
and seal +0.213 -0.180
230 0.278 0.439
+0.098 -0.226 Replace
Interference between thrust washer +0.140 -0.061
7 165 0.161 0.264
and seal +0.100 -0.124
Interference between pivot shaft +0.096 -0.115
8 213 0.165 0.283
and seal +0.050 -0.187
Standard Tolerance Standard Clearance
Clearance between pivot shaft and size Shaft Hole clearance limit
9
bushing -0.145 +0.097
175 0.174 0.305 1.0 Replace bushing
-0.208 +0.029
Clearance between pivot shaft and -0.170 +0.072
10 210 0.170 0.314 1.0
bushing -0.242 0

D375A-6R 60-67
Hydraulic system
PPC valve

Hydraulic system 60-6


PPC valve 60-6
Blade PPC valve 60-6
Appearance 60-6

60-68 D375A-6R
Hydraulic system
PPC valve

Sectional view 60-67

D375A-6R 60-69
Hydraulic system
PPC valve

60-70 D375A-6R
Hydraulic system
PPC valve

Ripper PPC valve 60-69


Appearance 60-69

D375A-6R 60-71
Hydraulic system
PPC valve

Sectional view 60-70

60-72 D375A-6R
Hydraulic system
PPC valve

Unit: mm

NO Item Criteria Remedy


Standard size Repair limit
Free length x Installed Load at Load at
Centering spring Free length
1 Outside diame- length installed installed
(for ports P3 and P4)
55.9 N 44.7 N If damaged or
50.35 x 15.5 34
{5.7 kg} {4.56 kg} deformed, replace
Centering spring 71.4 N 57.1 N spring
2 50.05 x 15.5 34
(for ports P1 and P2) {7.28 kg} {5.82 kg}
16.7 N 13.3 N
3 Metering spring 26.53 x 8.15 24.9
{1.7 kg} {1.36 kg}

D375A-6R 60-73
Hydraulic system
Hydraulic cylinder

Hydraulic cylinder 60-72


Blade lift cylinder

Blade tilt cylinder (for single tilt)

Pin puller cylinder

Blade tilt cylinder (for dual tilt)

60-74 D375A-6R
Hydraulic system
Hydraulic cylinder

Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Clearance
size Shaft Hole clearance limit
-0.036 +0.257
Blade lift 90 0.084 0.347 0.693
-0.090 +0.048
Clearance between pis- Blade tilt -0.036 +0.274
1 110 0.096 0.364
ton rod and bushing (Single tilt) -0.090 +0.060
-0.065 +0.133
Pin puller 29 0.072 0.250 0.55
-0.117 +0.007
Blade tilt -0.036 +0.261
(Dual tilt )
110 0.083 0.351
-0.090 +0.047
Clearance between pis-
-0.3 +0.5
2 ton rod supporting shaft Blade lift 65 0.5 1.0 3
-0.5 +0.2
and bushing
Clearance between cyl-
-0.120 +0.035
3 inder support shaft Blade lift 105 0.120 0.242 0.5 Replace
-0.207 0
bushing and yoke
Blade tilt -0.200 +0.200
Clearance between pis- (Single tilt) 75 0.200 0.500 1.0
-0.300 0
4 ton rod supporting shaft
Blade tilt -0.200 +0.200
and bushing (Dual tilt)
75 0.200 0.500 1.0
-0.300 0
Blade tilt -0.200 +0.423
Clearance between cyl- (Single tilt) 75 0.542 0.723 1.0
-0.300 +0.342
5 inder bottom support
Blade tilt -0.200 +0.423
shaft and bushing (Dual tilt)
75 0.542 0.723 1.0
-0.300 +0.342
Clearance between pis-
-0.100 +1.300
6 ton rod spherical sur- Pin puller 29 1.3 1.5
-0.200 +1.200
face and cap
Clearance between cyl-
-1.1
7 inder bottom support Pin puller 26 0.1 1.0 1.3
-1.2
shaft and boss

D375A-6R 60-75
Hydraulic system
Hydraulic cylinder

Ripper lift cylinder

Ripper tilt cylinder

Unit: mm

No. Item Criteria Remedy


Standard Tolerance Standard Clearance
size Shaft Hole clearance limit
Clearance between pis- -0.036 +0.274
1 Ripper lift 110 0.096 0.364 0.697
ton rod and bushing -0.090 +0.060
-0.036 +0.274
Ripper tilt 110 0.096 0.364 0.697
-0.090 +0.060
-0.036 +0.207 Replace
Clearance between pis- Ripper lift 100 0.156 0.297 1.0
-0.090 +0.120
2 ton rod support shaft
-0.036 +0.207
and bushing Ripper tilt 100 0.156 0.297 1.0
-0.090 +0.120
-0.036 +0.207
Clearance between cyl- Ripper lift 100 0.156 0.297 1.0
-0.090 +0.120
3 inder bottom support
-0.036 +0.207
shaft and bushing Ripper tilt 100 0.156 0.297 1.0
-0.090 +0.120

60-76 D375A-6R
Hydraulic system
Quick drop valve

Quick drop valve 60-75

Unit: mm

No. Item Criteria Remedy


Tolerance Standard Clearance
Standard size
Clearance between spool and Shaft Hole clearance limit
1
valve body -0.011 +0.010
38.0 0.011 0.026 0.03
-0.016 0
Standard size Repair limit Replace
Load at Load at
Installed
Free length installed Free length installed
2 Valve spring length
length length
136.3 N 122.6 N
75.2 55.9 67.7
{13.9 kg} {12.5 kg}

D375A-6R 60-77
Hydraulic system
Work equipment pump

Work equipment pump 60-76


Model: HPV190 60-76
Appearance 60-76

60-78 D375A-6R
Hydraulic system
Work equipment pump

Sectional view 60-7

D375A-6R 60-79
Hydraulic system
Work equipment pump

60-80 D375A-6R
Hydraulic system
Control valve

Control valve 60-79


6-spool valve for dual tilt 60-79
Appearance 60-79

D375A-6R 60-81
Hydraulic system
Control valve

Sectional view (1/4) 60-80

60-82 D375A-6R
Hydraulic system
Control valve

Unit: mm

No. Item Criteria Remedy


Standard dimension Allowable limit
Free length x
Installed
Spool return spring Outside diame- Installed load Free length Installed load
1 length
(only for blade lift) ter
202 N 162 N
73.9 x 30 68.5
{20.6 kg} {16.5 kg}
Spool return spring 279 N 224 N
2 51.12 x 31.3 47.8
(for blade tilt) {28.5 kg} {22.8 kg}
If damaged or
140 N 112 N
3 Spool return spring (for ripper) 51.7 x 31.3 50 deformed, replace
{14.3 kg} {11.4 kg}
spring
Spool return spring 217 N 174 N
4 54.7 x 36.5 33.5
(only for blade lift) {22.1 kg} {17.7 kg}
12.7 N 10.2 N
5 Load check valve spring 20.8 x 12.2 13.5
{1.3 kg} {1.04 kg}
Pressure compensation valve 562 N 449 N
6 108.3 x 29.5 81
spring {57.3 kg} {45.8 kg}
193 N 154 N
7 Unload valve spring 86.7 x 30 66
{19.63 kg} {15.7 kg}

D375A-6R 60-83
Hydraulic system
Control valve

(2/4) 60-82

60-84 D375A-6R
Hydraulic system
Control valve

(3/4) 60-83

Unit: mm

No. Item Criteria Remedy


Standard dimension Allowable limit
Free length x
Installed
Outside diame- Installed load Free length Installed load
1 Suction valve spring length If damaged or
ter
deformed, replace
6.37 N 5.10 N
64.9 x 12.5 56 spring
{0.65 kg} {0.52 kg}
0.49 N 0.39 N
2 Check valve spring 9.4 x 4.6 7.75
{0.05 kg} {0.04 kg}

D375A-6R 60-85
Hydraulic system
Control valve

(4/4) 60-84

Unit: mm

No. Item Criteria Remedy


Standard dimension Allowable limit
Free length x
Outside diame- Installed length Installed load Free length Installed load
1 Check valve spring If damaged or
ter
deformed,
14.7 N 11.8 N
27.9 x 6.5 22.5 replace spring
{1.5 kg} {1.2 kg}
5.49 N 4.41 N
2 Suction valve spring 46.8 x 7.5 40.6
{0.56 kg} {0.45 kg}

60-86 D375A-6R
Hydraulic system
Control valve

5-spool valve for single tilt 60-85


Appearance 60-85

D375A-6R 60-87
Hydraulic system
Control valve

Sectional view (1/4) 60-86

60-88 D375A-6R
Hydraulic system
Control valve

Unit: mm

No. Item Criteria Remedy


Standard size Repair limit
Free length x Load at Load at
Installed
Steering signal spring Outside diame- installed Free length installed
1 length
(only for blade lift) ter length length
202 N 162 N
73.9 x 30 68.5
{20.6 kg} {16.5 kg}
Steering signal spring 94.1 N 75.3 N
2 51.12 x 31.3 50 If damaged or
(for blade tilt) {9.6 kg} {7.7 kg}
deformed, replace
140 N 112 N
3 Spool return spring (for ripper) 51.7 x 31.3 50 spring
{14.3 kg} {11.4 kg}
Steering signal spring 217 N 174 N
4 54.7 x 36.5 33.5
(only for blade lift) {22.1 kg} {17.7 kg}
12.7 N 10.2 N
5 Load check valve spring 20.8 x 12.2 13.5
{1.3 kg} {1.04 kg}
193 N 154 N
6 Unload valve spring 86.7 x 30 66
{19.63 kg} {15.7 kg}

D375A-6R 60-89
Hydraulic system
Control valve

(2/4) 60-8

60-90 D375A-6R
Hydraulic system
Control valve

(3/4) 60-89

Unit: mm

No. Item Criteria Remedy


Standard size Repair limit
Free length x Load at Load at
Installed
Outside diame- installed Free length installed
1 Suction valve spring length If damaged or
ter length length
deformed, replace
6.37 N 5.10 N
64.9 x 12.5 56 spring
{0.65 kg} {0.52 kg}
0.49 N 0.39 N
2 Check valve spring 9.4 x 4.6 7.75
{0.05 kg} {0.04 kg}

D375A-6R 60-91
Hydraulic system
Control valve

(4/4) 60-90

Unit: mm

No. Item Criteria Remedy


Standard size Repair limit
Free length x
Installed Load at Load at
Outside diame- Free length
1 Check valve spring length installed length installed length If damaged or
ter
deformed, replace
14.7 N 11.8 N
27.9 x 6.5 22.5 spring
{1.5 kg} {1.2 kg}
5.49 N 4.41 N
2 Suction valve spring 46.8 x 7.5 40.6
{0.56 kg} {0.45 kg}

60-92 D375A-6R
Hydraulic system
Control valve

D375A-6R 60-93
Hydraulic system
Self-pressure reducing valve

Self-pressure reducing valve 60-92


Appearance 60-92

60-94 D375A-6R
Hydraulic system
Self-pressure reducing valve

Sectional view 60-93

Unit: mm

No. Item Criteria Remedy


Standard size Repair limit
Free length x Load at Load at
Installed
Pressure reducing value main Outside diame- installed Free length installed
1 length
spool spring ter length length
250 N 200 N
70.91 x 18 56 If damaged or
{25.52 kg} {20.4 kg}
deformed, replace
Pressure reducing valve pilot 28.0 N 22.5 N
2 17.8 x 7.2 12.7 spring
spring {2.86 kg} {2.29 kg}
61.8 N 49.4 N
3 Safety valve spring 16.13 x 7.8 13.4
{6.3 kg} {5.04 kg}
19.6 N 15.7 N
4 Spool return spring 19.15 x 7.2 16.05
{2.0 kg} {1.6 kg}

D375A-6R 60-95
Hydraulic system
Self-pressure reducing valve

60-96 D375A-6R
Work equipment
Cylinder stay

Work equipment 60-95


Cylinder stay 60-95

Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between cylinder yoke size Shaft Hole clearance limit
1
and bushing -0.085 +0.063
150 0.085 0.211 0.5
-0.148 0 Replace
Clearance between cylinder yoke -0.072 +0.054
2 115 0.072 0.180 0.5
and bushing -0.126 0
Clearance between lift cylinder sup- -0.120 +0.035
3 105 0.120 0.242 0.5
port shaft and bushing -0.207 0

D375A-6R 60-97
Work equipment
Blade

Blade 60-96

Semi-U dozer
(The figure shows a single tilt specification machine. The spill guard is optional.) 60-96

60-98 D375A-6R
Work equipment
Blade

Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Clearance
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
Clearance between brace pin and -0.2 +0.2
4 75 0.2 0.5 1
bushing -0.3 0
Clearance between spherical sur- -0.2 +0.3 Adjust shims or
5 170 0.2 0.6 1
faces of center brace and cap -0.3 0 replace
Clearance between joint and -0.2 +0.3
6 200 0.3 1.0 3
bracket -0.7 +0.1
Clearance between frame pin and -0.3 +0.3
7 100 0.3 0.8 3
joint -0.5 0
Clearance between frame pin and -0.3 +0.5
8 100 0.5 1.0 2
bracket -0.5 +0.2
Clearance between straight frame +0.063 +0.174 0.071
9 160 1
joint bushings 0 +0.134 0.174
Clearance between spherical sur- -0.5 +0.5
10 200 0.5 1.5 8
faces of trunnion and cap -1.0 0
Clearance between joint and -0.2 +0.3
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
Clearance between blade pin and -0.3 +0.5
13 100 0.5 1.0 2
bracket -0.5 +0.2
Clearance between center link pin -0.3 +0.5
14 125 0.5 1.0 2
and blade bracket -0.5 +0.2
Clearance between center link pin -0.3 +0.5
15 125 0.5 1.0 2
and center link -0.5 +0.2
Clearance between center link and -0.2 +0.3
16 280 0.3 0.7 2
blade bracket -0.4 +0.1
Clearance between center brace -0.2 +0.3 Adjust shims or
17 170 0.2 0.6 1
spherical surfaceand cap -0.3 0 replace
Clearance between lift cylinder -0.3 +0.5
18 65 0.5 1.0 2
head pin and cylinder -0.5 +0.2
Clearance between lift cylinder -0.3 +0.3
19 65 0.3 0.8 2
head pin and cross joint -0.5 0
Replace
Clearance between bracket and -0.3 +0.3
20 65 0.3 0.8 2
side pin -0.5 0
Clearance between cross joint and -0.3 +0.5
21 65 0.5 1.0 2
side pin -0.5 +0.2

D375A-6R 60-99
Work equipment
Blade

Full-U dozer
(The figure shows a dual tilt specification machine) 60-98

60-100 D375A-6R
Work equipment
Blade

Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Clearance
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
Clearance between brace pin and -0.2 +0.2
4 75 0.2 0.5 1
bushing -0.3 0
Clearance between spherical sur- -0.2 +0.3 Adjust shims or
5 170 0.2 0.6 1
faces of center brace and cap -0.3 0 replace
Clearance between joint and -0.2 +0.3
6 200 0.3 1.0 3
bracket -0.7 +0.1
Clearance between frame pin and -0.3 +0.3
7 100 0.3 0.8 3
joint -0.5 0
Clearance between frame pin and -0.3 +0.5
8 100 0.5 1.0 2
bracket -0.5 +0.2
Clearance between straight frame +0.063 +0.174 0.071
9 160 1
joint bushings 0 +0.134 0.174
Clearance between spherical sur- -0.5 +0.5
10 200 0.5 1.5 8
faces of trunnion and cap -1.0 0
Clearance between joint and -0.2 +0.3
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
Clearance between blade pin and -0.3 +0.5
13 100 0.5 1.0 2
bracket -0.5 +0.2
Clearance between center link pin -0.3 +0.5
14 125 0.5 1.0 2
and blade bracket -0.5 +0.2
Clearance between center link pin -0.3 +0.5
15 125 0.5 1.0 2
and center link -0.5 +0.2
Clearance between center link and -0.2 +0.3
16 280 0.3 0.7 2
blade bracket -0.4 +0.1
Clearance between center brace -0.2 +0.3 Adjust shims or
17 170 0.2 0.6 1
spherical surface and cap -0.3 0 replace
Clearance between lift cylinder -0.3 +0.5
18 65 0.5 1.0 2
head pin and cylinder -0.5 +0.2
Clearance between lift cylinder -0.3 +0.3
19 65 0.3 0.8 2
head pin and cross joint -0.5 0
Replace
Clearance between bracket and -0.3 +0.3
20 65 0.3 0.8 2
side pin -0.5 0
Clearance between cross joint and -0.3 +0.5
21 65 0.5 1.0 2
side pin -0.5 +0.2

D375A-6R 60-101
Work equipment
Cutting edge and end bit

Cutting edge and end bit 60-10


(Standard) 60-10

Unit: mm

No. Item Criteria Remedy


Standard size Repair limit
1 Height of end bit, outside
478 380
Replace
2 Width of end bit 734 600

3 Height of end bit, inside 393 300


Turn 180 or
4 Height of cutting edge 406 335 (264 after reversed)
replace

60-102 D375A-6R
Work equipment
Cutting edge and end bit

(if equipped) 60-101

Unit: mm

No. Item Criteria Remedy


Standard size Repair limit
1 Height of end bit, outside
495 340
Replace
2 Width of end bit 740 600

3 Height of end bit, inside 395 335


Turn 180 or
4 Height of cutting edge 406 335 (264 after reversed)
replace

D375A-6R 60-103
Work equipment
Ripper

Ripper 60-102

Variable multi-shank ripper 60-102

60-104 D375A-6R
Work equipment
Ripper

Giant ripper 60-103

Unit: mm

No. Item Criteria Remedy


Standard Tolerance Standard Clearance
Clearance between bushing and pin size Shaft Hole clearance limit
1
for bracket and arm connection -0.036 +0.208
120 0.161 0.298 1.5
-0.090 +0.125
Clearance between bushing and pin -0.036 +0.208
2 120 0.161 0.298 1.5
for beam and arm connection -0.090 +0.125
Clearance between cylinder mounting -0.036 +0.207
3 100 0.156 0.207 1.5
pin and bushing -0.090 +0.120
Replace
Standard size Tolerance Repair limit
Clearance between shank and mount-
4
ing pin 82 0.3

Standard size Repair limit


5 Wear of point
420 255

6 Wear of protector 155 115

D375A-6R 60-105
Work equipment
Ripper

60-106 D375A-6R
D375A-6R 80-1

BULLDOZER
Shop Manual 80-1

D375A-6R

Machine model Serial number


D375A-6R 65001 and up

80 Appendix 80-1

D375A-6R 80-1
(01)
Contents

Contents 80-2
80 Appendix
Air conditioner ......................................................................................................................... 80- 3
Precautions for refrigerant ................................................................................................... 80- 3
Air conditioner component ................................................................................................... 80- 4
Configuration and function of refrigeration cycle.................................................................. 80- 6
Outline of refrigeration cycle ................................................................................................ 80- 7
Air conditioner unit ............................................................................................................... 80- 10
Blower unit ........................................................................................................................... 80- 14
FRESH/RECIRC air changeover damper ............................................................................ 80- 15
Compressor ......................................................................................................................... 80- 16
Condenser ........................................................................................................................... 80- 17
Receiver drier....................................................................................................................... 80- 18
Air conditioner control panel ................................................................................................ 80- 20
Procedure for testing and troubleshooting ........................................................................... 80- 22
Circuit diagram and arrangement of connector pins ............................................................ 80- 24
System diagram ................................................................................................................... 80- 26
Parts and connectors layout ................................................................................................ 80- 28
Testing temperature control ................................................................................................. 80- 32
Testing FRESH/RECIC air changeover ............................................................................... 80- 33
Testing relay ........................................................................................................................ 80- 34
Troubleshooting chart 1 ....................................................................................................... 80- 36
Troubleshooting chart 2 ....................................................................................................... 80- 38
Information in troubleshooting table..................................................................................... 80- 40
Troubleshooting for power supply system (Air conditioner does not operate) ..................... 80- 42
Troubleshooting for compressor system (Air is not cooled)................................................. 80- 44
Troubleshooting for blower motor system (Air does not come out or air flow is abnormal) . 80- 48
Troubleshooting for temperature control.............................................................................. 80- 54
Troubleshooting for FRESH/RECIRC air changeover ......................................................... 80- 56
Troubleshooting with gauge pressure.................................................................................. 80- 58
Connection of service tool.................................................................................................... 80- 60
Precautions for disconnecting and connecting .................................................................... 80- 62
Handling of compressor oil .................................................................................................. 80- 64

80-2 D375A-6R
(01)
Air conditioner
Precautions for refrigerant

Air conditioner 80-3


Precautions for refrigerant 80-3

k Collect the air conditioner refrigerant (R134a)


from air conditioner circuit before discon-
necting air conditioner hose to replace air
conditioner unit, air conditioner compressor
or receiver drier and so on.
a Ask a qualified shop for collecting, adding and
filling operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the at-
mosphere.
k If refrigerant gas (R134a) gets in your eyes,
you may lose your sight. And if it touches
your skins, you may suffer from frostbite. Ac-
cordingly, put on protective goggles, gloves
and working suits with long sleeves while
you are collecting the refrigerant (R134a) or
filling the air conditioner circuit with the re-
frigerant (R134a). Collecting and filling work
must be conducted by a qualifier person.

D375A-6R 80-3
(01)
Air conditioner
Air conditioner component

Air conditioner component 80-4

80-4 D375A-6R
(01)
Air conditioner
Air conditioner component

A: Front window glass warm/cool air outlet Specification 80-5


B: Overhead warm/cool air outlet Refrigerant R134a
C: Side warm/cool air outlet Refrigerant refill capacity (g) 1,100 100
D: Front warm/cool air outlet
E: Recirculation air inlet
F: Fresh air inlet
1. Condenser
2. Air conditioner unit
3. Fresh air filter
4. Blower unit
5. Refrigerant piping
6. Receiver drier
7. Compressor
8. Air intake cap
9. Hot water return piping
10. Hot water supply piping
11. FRESH/RECIRC air changeover damper
12. Recirculation air filter
13. Air conditioner control panel
14. Sight glass

D375A-6R 80-5
(01)
Air conditioner
Configuration and function of refrigeration cycle

Configuration and function of refrigeration cycle 80-6


Cycle
Compressor Condenser Expansion valve Evaporator
(Component)
In operators cab In operators cab
Location Engine compartment Front of radiator (Built-In air conditioner (Built-In air conditioner
unit) unit)
Circulates refrigerant
Lowers temperature and
gas and increases its Evaporates refrigerant to
Condenses refrigerant pressure of refrigerant liq-
temperature and pres- absorb heat from (or
to discharge heat uid and gas for easy evap-
sure so that it can be cool) air around evapora-
Function absorbed in evaporator. oration with throttle.
liquefied easily in con- tor.
(condensation of refrig- Controls flow rate, too.
denser. (Evaporation of refriger-
erant) (Throttle action of refriger-
(Compression of ant)
ant)
refrigerant)
GasoGas GasoLiquid
State of refriger- LiquidoLiquid and gas Liquid and gas oGas
Adiabatic compres- Constant pressure
ant Adiabatic expansion Cnstant pressure change
sion change

80-6 D375A-6R
(01)
Air conditioner
Outline of refrigeration cycle

Outline of refrigeration cycle 80-7


The refrigeration cycle is comprised of 4 cycles. The refrigerant is circulated while repeatedly liquefying and
vaporizing.

1. Compression (Compressor) The expansion valve controls the refrigerant


The compressor sucks in the refrigerant that has feed rate so that the optimum quantity of liquid
been vaporized in the evaporator and refrigerant is supplied to the evaporator.
compresses it into a state where it can be easily
liquefied at the ambient temperature. (*1) Throttle action
The gaseous refrigerant sucked into the If there is a narrow section in the passage
compressor cylinder is compressed to a temper- through which liquid is flowing at a constant rate,
ature and pressure at which it can be easily a resistance to the flow will be generated.
liquefied when cooled to the ambient tempera- The liquid expands when it passes through the
ture. narrow section and rushes into the passage
where the sectional area is larger,and conse-
2. Condensation (Condenser) quently, its pressure and temperature are
The condenser cools and liquefies the high pres- reduced.
sure and high-temperature gaseous refrigerant Heat is not transferred from or to the outside
sent from the compressor. during the throttle action.
The heat released to the outside from the 4. Evaporation (Evaporator)
condenser is called condensation heat. The evaporator evaporates the liquid refrigerant
The amount of condensation heat is the sum (superheated vapor).
total of the heat absorbed by the evaporator from The refrigerant evaporates, while absorbing an
the air in the cab and the quantity of the work amount of heat necessary for evaporation (evap-
applied (the value converted into a heat quantity) oration heat) from the air around the cooling fins
by compression of the compressor. (air in the cab).
The refrigerant liquefied in the condenser is sent After the heat has been removed, the cooled air
to the receiver drier, where moisture is removed. is sent into the cab by the blower fan, reducing
In the compression cycle, the gaseous refrig- the temperature inside the cab.
erant and liquid refrigerant coexist. The mist refrigerant that has been sent from the
The temperature (condensation temperature) expansion valve coexists with the evaporated
and the pressure (condensation pressure) at refrigerant in the evaporator
which the gaseous refrigerant is liquefied are The temperature (evaporation temperature) and
proportional to each other. the pressure (evaporation pressure) at which the
liquid refrigerant is evaporated are proportional
Reference: The pressure varies depending on to each other.
the condensation temperature of the refrigerant. The compressor sucks in the evaporated refrig-
erant in order to keep the pressure level in the
3. Expansion (Expansion valve) evaporator as low as possible so that the liquid
The expansion valve reduces the liquid refrig- refrigerant can be evaporated at a much lower
erant pressure to a level where liquid refrigerant temperature.
can be easily evaporated by the throttle action
(*1). Relationship between refrigerant and defective
The action of reducing the liquid refrigerant pres- air conditioning 80-7
q The refrigerant circulates in the refrigeration cir-
sure to a level where it can be easily evaporated
before it is sent to the evaporator is called cuit while repeating the refrigeration cycle to ex-
expansion. pel the heat from inside the cab.
q If there is an insufficient quantity of refrigerant,
The expansion valve, which reduces the refrig-
erant pressure, also adjusts the refrigerant flow all of it will be evaporated while it is passing
rate simultaneously. through the evaporator. This causes evaporator
The quantity of the liquid refrigerant that can be efficiency to deteriorate, which will result in de-
evaporated in the evaporator depends on the fective air conditioning.
q If there is excessive refrigerant, not all of it will be
amount of heat (refrigeration load) to be
removed under the specific evaporation temper- evaporated and part of it will be sucked into the
ature (evaporation pressure). compressor in liquid form, which will cause the
compressor to compress the liquid and may
damage the components.

D375A-6R 80-7
(01)
Air conditioner
Outline of refrigeration cycle

q If water gets into the refrigeration circuit, it will


freeze at a small hole in the expansion valve,
lower the refrigerant flow, and may result in de-
fective air conditioning.

80-8 D375A-6R
(01)
Air conditioner
Outline of refrigeration cycle

D375A-6R 80-9
(01)
Air conditioner
Air conditioner unit

Air conditioner unit 80-10

80-10 D375A-6R
(01)
Air conditioner
Air conditioner unit

A: Refrigerant inlet (from condenser) Functions of major components 80-1


B: Refrigerant outlet (to compressor) Evaporator 80-1
C: Hot water inlet q Evaporator (1) is cooled by the low-pressure,

D: Hot water outlet low-temperature refrigerant gas being sent from


expansion valve (3). Air from the blower fan is
1: Evaporator cooled and dehumidified when passing through
2: Heater core the evaporator fins.
3: Expansion valve
4: Air mix servomotor Heater core 80-1
5: Air mix door q Heater core (2) is warmed by the hot water (en-
6: Blower resistor gine coolant ) being sent from the engine. Air
7: Evaporator temperature sensor from the blower fan is warmed as it passes
8: Hot water valve through the heater core fins.
9: Dual pressure switch
10: Compressor clutch relay Air mix servomotor 80-1
11: Condenser relay (Not used)

Outline 80-1
q The air conditioner unit consists of the evapora-
tor (1) and heater core (2), and is used to cool
down or warm up the air in the cab.

Temperature control 80-1


q When the temperature control switch on the air
conditioner control panel is operated, the air
conditioner control panel controls the air mix ser-
vomotor (4) which opens or closes the air mix
door (5) and hot water valve (8) to adjust the
temperature.

Over-cooling(Freezing) prevention 80-1 q When the switch on the air conditioner control
q Evaporator temperature sensor (7) varies its panel is operated, the motor drive power (24 V)
electrical resistance according to temperature. is supplied to servomotor terminal (3) or (5).
q The air conditioner control panel converts the q The rotation direction of the motor changes ac-

variation in resistance of the evaporator temper- cording to the terminal that receives the power.
ature sensor (7) into voltage and uses the volt- q The variable resistor is built into the servomotor,

age for detecting the evaporator (1) and its resistance changes as the motor rotates.
temperature. q A voltage of 5V is supplied to the variable resis-

q The air conditioner control panel activates the tor from the air conditioner control panel, and the
compressor clutch relay (10) to stop the com- air conditioner control panel detects the motor
pressor and to prevent the evaporator (1) from rotation angle based on the potential difference.
freezing. q When the air mix door reaches the position spec-
ified by the air conditioner control panel, the air
Air flow adjustment 80-1 conditioner control panel stops current output to
q When the air flow control switch on the air condi- the servomotor to stop the air mix door.
tioner control panel is operated, the air condi- a Do not supply power directly between terminals
tioner control panel controls the blower motor of (3) and (5) of the servomotor to drive the servo-
the blower unit through blower resistor (6) to ad- motor for testing purposes.
just the air flow.

D375A-6R 80-11
(01)
Air conditioner
Air conditioner unit

Expansion valve 80-12

A: When evaporator outlet temperature is high Structure 80-12


B: When evaporator outlet temperature is low q The box-type expansion valve (1) consists of

C: From receiver drier (high-pressure refrigerant) needle valve (1a), spring (1b), etc.
D: To compressor (low-pressure refrigerant) q Refrigerant gas (2) is sealed in the diaphragm
chamber (hatched area) outside diaphragm
1. Expansion valve (1a-1) of needle valve (1a).
1a. Needle valve q The opening angle of needle valve (1a) is deter-

1a-1. Diaphragm mined based on the balance between the reac-


1a-2. Thermoprobe tion force exerted by spring (1b) in a rightward
1b. Spring direction, and force (Fg) of refrigerant gas (2)
2. Refrigerant gas pushing needle valve (1a) through diaphragm
3. Evaporator (1a-1) in a leftward direction.
q The refrigerant flow rate flowing from the receiv-

Outline 80-12 er drier to evaporator (3) is determined based on


q The expansion valve converts high pressure and the opening angle of needle valve (1a).
high-temperature liquid refrigerant from the re-
ceiver drier to low-pressure, low-temperature
misty refrigerant through the throttle action.
q It controls the flow rate of refrigerant by changing
the level of throttling depending on the tempera-
ture in the cab.
q The temperature of the air blown out of the air
vent is adjusted depending on the volume of re-
frigerant circulating in the evaporator (3).

80-12 D375A-6R
(01)
Air conditioner
Air conditioner unit

Operation 80-13 Dual pressure switch 80-13


q Thermoprobe (1a-2) senses the refrigerant tem- q The dual pressure switch turns "OFF" when the
perature after it passes through the evaporator refrigerant circuit pressure becomes abnormally
(3). low or abnormally high.
q After the refrigerant passes through evaporator q Turning the dual pressure switch "OFF" causes
(3), its temperature is transferred to the refriger- the compressor clutch relay to turn "OFF". Then
ant gas (2) in the diaphragm chamber (hatched the magnetic clutch of the compressor is re-
area) through the thermoprobe (1a-2). leased in order to protect air conditioner compo-
q The pressure of the refrigerant gas (2) sealed in nents.
the diaphragm chamber (hatched area) changes
in response to the temperature change of the
thermoprobe (1a-2), which therefore changes
the force (Fg) pushing the needle valve (1a).
q The opening angle of the needle valve (1a) is de-
termined based on the balance between the re-
action force exerted by the spring (1b) in a
rightward direction, and the force (Fg) of the re-
frigerant gas (2) pushing the needle valve (1a)
through the diaphragm (1a-1) in a leftward direc-
tion.

When evaporator (3) outlet temperature is high 80-13


[Air in the cab is not cooled: condition (A) in the
figure] 80-13 a LA or low: Abnormally low pressure
q The refrigerant gas (2) pressure and the volume
a HA or high: Abnormally high pressure
are increased.
q The force (Fg) of the refrigerant gas (2) pushing
LA: 0.20 MPa {2 kg/cm2}
the needle valve (1a) is increased, and the nee- LB: 0.02 MPa {0.2 kg/cm2}
dle valve (1a) moves leftward. HA: 3.14 MPa {32 kg/cm2}
q As a result, the opening angle of the needle
HB: 0.59 MPa {6 kg/cm2}
valve (1a) is increased and the refrigerant flow
rate to the evaporator (3) is increased to improve Evaporator temperature sensor 80-13
cooling capacity. q To prevent the evaporator from freezing, the
evaporator temperature sensor varies its electri-
When evaporator (3) outlet temperature is low 80-13 cal resistance with the evaporator temperature,
[Air in the cab is already cooled: condition (B) in and the temperature is monitored via the air con-
the figure] 80-13 ditioner control panel.
q The refrigerant gas (2) pressure and the volume
are decreased.
q The force (Fg) of the refrigerant gas (2) pushing
the needle valve (1a) is reduced, and the needle
valve (1a) is moved rightward by the spring force
(1b).
q The opening angle of the needle valve (1a) is re-
duced and the refrigerant flow rate to the evapo-
rator (3) is reduced to lower the cooling capacity.

D375A-6R 80-13
(01)
Air conditioner
Blower unit

Blower unit 80-14

1. Blower motor FRESH/RECIRC air changeover servomotor 80-14


2. Blower fan
3. FRESH/RECIRC air changeover servomotor

Outline 80-14
q The blower unit consists of a blower motor (1), a
blower fan (2) and a FRESH/RECIRC air
changeover servomotor (3). The blower unit
sends air into the cab.
q When the FRESH/RECIRC air changeover
switch on the air conditioner control panel is op-
erated, the air conditioner control panel supplies
a current to the servomotor (3).

Functions of major components 80-14


Blower motor 80-14
q The blower motor (1) rotates the blower fan (2) q The FRESH/RECIRC air changeover servomo-
to suck air and send it to the evaporator and tor (3) receives the drive current from the air con-
heater core. ditioner control panel, and opens or closes the
FRESH/RECIRC air changeover damper door to
switch between the fresh air and recirculated air
settings.
q When the switch on the air conditioner control
panel is operated, the motor drive power (24 V)
is supplied to servomotor terminal (3) or (5).
q The rotation direction of the motor changes ac-
cording to the terminal that receives the power.
a Do not supply power directly to drive the servo-
motor for testing purposes.

80-14 D375A-6R
(01)
Air conditioner
FRESH/RECIRC air changeover damper

FRESH/RECIRC air changeover damper 80-15

1. 1. Door open/close lever


2. FRESH/RECIRC air changeover door

Outline 80-15
q The door open/close lever (1) is connected to the
FRESH/RECIRC air changeover servomotor of
the blower unit with the cable and the
FRESH/RECIRC air changeover door (2) is
opened or closed by the operation of the
FRESH/RECIRC air changeover servomotor.

D375A-6R 80-15
(01)
Air conditioner
Compressor

Compressor 80-16

A: Refrigerant inlet port from air conditioner unit Function 80-16


B: Refrigerant outlet port to condenser q The compressor circulates the refrigerant and
compresses the gaseous refrigerant from the
1. Pulley evaporator into a misty refrigerant at high pres-
2. Magnetic clutch sure and high temperature so that it will be easily
3. Relief valve regenerated (liquefied) at the normal tempera-
ture.
q Its built-in magnetic clutch (2) is engaged or dis-
engaged according to the evaporator tempera-
ture and refrigerant pressure.
q If the clutch is engaged, the power of the engine
rotates the compressor shaft to drive the com-
pressor.

Specification 80-16
Number of cylinder Bore x
Stroke 10 - 32 x 20.8
(mm)
Piston capacity
157.3
(cc/rev)
Allowable maximum speed
6,000
(rpm)
Denso:ND-OIL8 (For
Refrigerant oil used
R134a)
Compressor oil refill capacity
180
(cc)

80-16 D375A-6R
(01)
Air conditioner
Condenser

Condenser 80-17

A: Refrigerant inlet (from compressor) Specification 80-17


B: Refrigerant outlet (to receiver drier) Fin pitch (mm) 4.0
Height x width x thickness
350 x 570 x 16
Function 80-17 (mm)
q The condenser cools and liquefies the high pres- Max. working pressure
3.6 {36}
sure and high temperature misty refrigerant from (MPa{kg/cm2})
the compressor.

a If the fin is crushed or is clogged with dust, heat


exchange efficiency is reduced and complete liq-
uefaction of refrigerant becomes impossible.
If the heat exchange efficiency is reduced, pres-
sure in the refrigerant circulation circuit will be
increased, applying extra load to the engine or
reducing the cooling effect. Take extreme care
not to crush or damage the fins when hangling
and performing daily inspection.

D375A-6R 80-17
(01)
Air conditioner
Receiver drier

Receiver drier 80-18


Function 80-18
q The receiver drier temporarily stores the high
pressure and high-temperature liquid refrigerant
from the condenser so that it can be supplied to
the evaporator according to the need of cooling.
q It sends the stored refrigerant from its bottom to
the evaporator, allowing the refrigerant to be liq-
uefied completely ever when it contains bubbles
due to the lowerd heat dissipation of the con-
denser.
q The built-in filter and desiccating agent eliminate
foreign substances in the circulation circuit and
water content in the refrigerant.

Specification 80-18
Effective volume (cc) 370
Weight of desiccating agent
290
(g)

A: Refrigerant inlet (from condenser)


B: Refrigerant outlet (to air conditioner unit)

80-18 D375A-6R
(01)
Air conditioner
Receiver drier

D375A-6R 80-19
(01)
Air conditioner
Air conditioner control panel

Air conditioner control panel 80-20

NO Model Function Operation


Switch to start and stop cooling, drying or heating function
(When the fan switch is turned "ON" and the air conditioner
1 Air conditioner switch OFFioON
switch is pressed, the indicator lamp above the switch lights
up.)
Switch to select RECIRC or FRESH air RECIRC
FRESH/RECIRC air selector
2 (When the switch is pressed, the indicator lamp above the IO
switch
selected switch lights up.) FRESH
OFF: Off
Switch to adjust fan speed in four levels LO: Low
3 Fan switch (When the switch is pressed, the indicator lamp above the t: Medium 1
selected switch lights up.) tt: Medium 2
HI: High
Switch to adjust outlet air temperature in 8 levels Low tempera-
4 Temperature control switch (The rough outlet air temperature is indicated by the tempera- tureioHigh temper-
ture level indicator lamp above the switch.) ature

80-20 D375A-6R
(01)
Air conditioner
Air conditioner control panel

Outline 80-21
q The air conditioner control panel has a CPU
(Central Processing Unit) that processes the in-
put signals from each sensor and the control sig-
nals from each switch, and displays them on the
panel and controls the servomotors and relays.

Input/Output signal
AMP 172021-2-16P AMP 172245-2-12P
Input/Out- Input/Out-
Pin No. Signal name Pin No. Signal name
put signal put signal
1 Power supply Input 17 NC (*)
2 Blower main relay Output 18 NC (*)
3 Blower medium 1 relay Output 19 Air mix servomotor (B) Output
4 Blower medium 2 relay Output 20 Air mix servomotor (A) Output
5 Blower high relay Output FRESH/RECIRC air changeover
21 Output
6 Compressor clutch relay Output servomotor (FRESH)
FRESH/RECIRC air changeover
7 NC (*) 22 Output
servomotor (RECIRC)
8 NC (*) 23 NC (*)
9 Evaporator temperature sensor Input 24 NC (*)
Air mix servomotor potentiometer
10 Input 25 NC (*)
signal
11 NC (*) 26 NC (*)
12 NC (*) 27 NC (*)
13 Sensor GND Input 28 NC (*)
14 DIS_SEL0 (GND) Output
15 NC (*)
Air mix servomotor potentiometer
16 Output
power supply

D375A-6R 80-21
(01)
Air conditioner
Procedure for testing and troubleshooting

Procedure for testing and troubleshooting 80-2


Reference: The air conditioner does not have a self-diagnosis function.
1. After basic check, find the defective part according to the problem that appears on the air conditioner.
2. Narrow down the probable causes by operating the switches on the control panel.
However, if the air conditioner unit or control panel does not operate at all, check to see whether power is
supplied to the control amplifier normally.
If any part of the air conditioner unit or control panel operates, the power supply should be considered
normal.
3. After narrowing down the probable causes, perform the relevant testing procedure to determine the defec-
tive part to be repaired.

Basic flow of testing and troubleshooting

*1. Self-diagnosis function is not installed.

80-22 D375A-6R
(01)
Air conditioner
Procedure for testing and troubleshooting

*2. Simple check of refrigerant quantity through sight glass.


Start the engine first, and then check the refrigerant level 5 minutes after turning the air conditioner switch
ON.
1) If bubbles are continually seen, the quantity of refrigerant is insufficient.
2) If bubbles in the refrigerant appear intermittently, the quantity of refrigerant is appropriate.
3) When no bubble can be seen (transparent), the refrigerant is excessive or no refrigerant is in the
system. However, there may be exception. In such cases, read the pressure gauge to judge the refrig-
erant level, referring to "Troubleshooting by gauge pressure".
S: View through sight glass
R: Refrigerant level in receiver dryer
LR: Liquid refrigerant

*3. If the refrigerant is leaking, the compressor oil circulating in the air conditioner circuit is also leaking from
the same place.
In this case, retighten the pipe fitting by referring to the tightening torque table in "Precautions for connecting
air conditioner piping".

*4. Start the engine first and turn the air conditioner switch ON to check the noise.

D375A-6R 80-23
(01)
Air conditioner
Circuit diagram and arrangement of connector pins

Circuit diagram and arrangement of connector pins 80-24

80-24 D375A-6R
(01)
Air conditioner
Circuit diagram and arrangement of connector pins

Input/output signals of control panel 80-25


Connector on control panel: AMP 172241-2 (DLI28PM)
Connector on wiring harness:
AC2: AMP 172021-2(DLI16PF)
AC3: AMP 172245-2(DLI12PF)
AC2
Pin No. Code Signal name Input/output
1 24V 24V power supply Input
2 RL-BM Blower main relay Output
3 RL-ME1 Blower medium 1 relay Output
4 RL-ME2 Blower medium 2 relay Output
5 RL-HI Blower HI relay Output
6 RL-CC Compressor clutch relay Output
7 NC
8 NC
Evaporator temperature sensor
9 TH-F Input
(Thermistor voltage)
A/M servo potentiometer volt-
10 S-AM Input
age
11 NC
12 NC
13 GS Sensor GND Output
14 GND GND Input
15 NC
A/M servo potentiometer 5V
16 AMP-5V Output
power supply

AC3
Pin No. Code Signal name Input/output
17 NC
18 NC
19 M-AMB A/M servo B terminal Output
20 M-AMA A/M servo A terminal Output
Fresh air terminal of
21 M-RFF FRESH/RECIRC air change- Output
over servomotor
Recirculated air terminal of
22 M-RFR FRESH/RECIRC air change- Output
over servomotor
23 NC
24 NC
25 NC
26 NC
27 NC
28 NC
q NC: No connection
q RL-: Relay
q M-: Servomotor
q AM: Air mix
q RF: Recirculation/Fresh (recirculated/fresh air)

D375A-6R 80-25
(01)
Air conditioner
System diagram

System diagram 80-26


a This air conditioner has manual temperature control only. (It is not Automatic air conditioner)

80-26 D375A-6R
(01)
Air conditioner
System diagram

Operation of control panel 80-27


a The air conditioner does not have a self-diagno-
sis function.
1. The control panel controls the air conditioner
according to each switch inputting.
2. The control panel adjust the temperature (AIR
MIX) by controlling the air mix servomotor
(A/MS).
3. The control panel switches the air between the
recirculated air and fresh air by controlling
FRESH/RECIRC air changeover servo motor
(R/FS).
4. The control panel turns the blower main relay
ON to drive the blower fan.
5. The control panel adjusts the air flow as follows.
1) The control panel turns ON one of the three
relays of blower HI, blower Me1 and blower
Me2. (If none of the three relays is turned
ON, the air flow is set to "LO")
2) The terminal that connects to "ON" relay of
the four blower resistor terminals is
connected to the GND.
3) The current flowing into the blower motor
changes, and consequently the blower fan
speed changes to control the air flow.
a The blower resistor has an overcurrent
protection fuse in it.
6. The control panel senses the evaporator
temperature with the evaporator temperature
sensor.
7. The control panel controls ON/OFF of the
compressor clutch relay to operate the
compressor so that the evaporator does not
freeze.
a If the dual pressure switch detects abnormal
pressure, it is turned OFF, then the compres-
sor clutch relay is turned OFF and the com-
pressor stops.

D375A-6R 80-27
(01)
Air conditioner
Parts and connectors layout

Parts and connectors layout 80-28


The air conditioner unit, blower unit and various re- a Condition with cover (4) removed
lays are in the dashboard. q AC2 and AC3: Air conditioner control
1. Remove cover (1). panel connectors
a Right figure shows condition with cover (1) q CP: Air conditioner control panel
removed.
q Circuit breaker CB4 (4th from the top) :
For power supply for blower motor, air condi-
tioner compressor and air conditioner unit
(All equipment related to air conditioner)
a If reset button (2) of the circuit breaker comes
out, the circuit is cut off (OFF). In this case,
push reset button (2) in. After setting starting
switch to ON position, if the reset button does
not come out but keeps pushed , it is no prob-
lem. If the reset button comes out soon after
pushing, the electrical circuit may has a
ground fault or another abnormality. (See
"Troubleshooting for power supply system")
4. Remove recirculated air filter cover (5).
5. Remove cover (6).

2. Pull out four switches (3) forward and disconnect


each connector.
3. Remove cover (4).

80-28 D375A-6R
(01)
Air conditioner
Parts and connectors layout

a Condition with recirculated air filter cover (5) 6. Disconnect connectors AC2 and AC3 and
removed remove air conditioner control panel CP and its
q BM: Blower motor bracket as a unit. (Described above)
q CN-B: Blower motor connector a Condition with air conditioner control panel
q R/FS: FRESH/RECIRC air changeover CP removed
servo motor q AC1: Connector between air conditioner con-
q CN-S: Connector of FRESH/RECIRC air trol panel and air conditioner unit
change over servo motor
q MAIN: Blower main relay 7. Remove brackets (7) and (8).
q CN-R1: Blower main relay connector
q HI: Blower HI relay
q CN-R2: Blower HI relay connector
q ME1: Blower medium 1 relay
q CN-R3: Blower medium 1 relay connector
q ME2: Blower medium 2 relay
q CN-R4: Blower medium 2 relay connector
q CN-M26: Air conditioner intermediate
connector
(24V power supply, GND, compressor)

D375A-6R 80-29
(01)
Air conditioner
Parts and connectors layout

a Condition with brackets (7) and (8) removed


q A/MS: Air mix servomotor
q CCR:Compressor clutch relay
q CDR: Condenser relay (Not used)
q TH: Evaporator temperature sensor
q [1]: Blower resistor connector
q [2]: Air mix servomotor connector
q [3]: Evaporator temperature sensor connector
q [4]: Dual pressure switch connector
q [5]: Compressor clutch relay connector
q [6]: Condenser relay connector (Not used)

80-30 D375A-6R
(01)
Air conditioner
Parts and connectors layout

8. Remove the cover between operator cab and


engine hood.
9. Remove bracket (9).
10. Remove duct (10).

q A/C UNIT: Air conditioner unit


q BR: Blower resistor

D375A-6R 80-31
(01)
Air conditioner
Testing temperature control

Testing temperature control 80-32


Outline 80-32
The angle of the door (damper) in the air conditioner
unit is changed with air mix servomotor (AM/S) in or-
der to switch the air path between the hot air path to
the heater and the cold air path to the evaporator.
Moreover, for heating, the hot water valve changes
the quantity of the hot water from engine by control-
ling the opening angle of valve through the shaft and
controls the outlet air temperature.The shaft and hot
water valve lever can be seen from outside.
.
1. With reference to "Parts and connector loca-
tions", remove the air conditioner control panel
and its bracket as a unit.
2. Remove bracket (1).

3. Check that shaft (2) is not disconnected.


4. Check that connector [2] of air mix servomotor
(A/MS) is connected securely. (Check for partial
connection.)
5. Start the engine and turn the air conditioner ON.
Set the temperature setting to the maximum and
minimum with the control panel and check visu-
ally that lever (3) moves smoothly between
COOL MAX and HOT MAX.

a For an electrical trouble, see "Troubleshoot-


ing for temperature control".

80-32 D375A-6R
(01)
Air conditioner
Testing FRESH/RECIC air changeover

Testing FRESH/RECIC air changeover 80-3


Outline 80-3
FRESH/RECIRC air changeover servo motor
changes the angle of FRESH/RECIRC air change-
over door (damper) through the lever and cable to
switch the air between the recirculated air and fresh
air. Visually check the operation of the lever and
opening and closing of the door (damper).

1. Remove the recirculated air filter cover from


lower part of the dashboard.
2. Check that cable (1) is not disconnected from the
level. (Check its connection to the
FRESH/RECIRC air changeover door (R/FD),
too.)
3. Check that connector (CN-S) is connected
securely.
4. Start the engine and turn the air conditioner ON.
5. Press FRESH/RECIRC air selector switch on
the air conditioner control panel and visually
check opening and closing of door (F/RD).
6. If door (R/FD) does not open or close, check that
lever (2) of FRESH/RECIRC air changeover
servomotor (R/FS) moves to the respective posi-
tions as shown in the figure when the RECIRC
air or FRESH air is selected.
F: FRESH air position
R: RECIRC air position

a For an electrical failure, see "Troubleshooting for


FRESH/RECIRC air changeover".

D375A-6R 80-33
(01)
Air conditioner
Testing relay

Testing relay 80-34


a If the air conditioner compressor is normal and a If the fan sound is so large that you cannot
the cool air flow rate is adjusted to the four lev- hear the operation sound of the compressor
els, skip this test. relay, set the starting switch to OFF position
a Listen closely to the relay to check the operation and disconnect connector R1 and then per-
sound. form the test.(*)
7. Operation check of relay responding to air flow
Out of six relays, condenser relay CDR is not used. switch operation
q Compressor clutch relay CCR, connector [5]: a If the fan sound is so large that you cannot
For ON/OFF of air conditioner compressor hear the operation sound of the compressor
(clutch) relay, set the starting switch to OFF position
q Blower main relay MAIN, connector R1: and disconnect connector R1 and then per-
For ON/OFF of blower motor form the test.(*)
q Blower relays of HI, ME2 and ME1: 1) Set starting switch to ON position (with
For air flow adjustment engine stopped) and turn air conditioner
1. Remove the recirculated air filter cover from switch ON.
lower part of the dashboard. 2) Set the air flow to HI, ".." and "." in order to
2. With reference to the parts and connectors turn relays HI, ME2 and ME1 ON respec-
arrangement, remove cover (1). tively. Check their operation sounds (click).
3. Remove bracket (2). a If the air flow is set to LO, ME1 relay turns
OFF.

q X view

4. Check the connection between connectors


CN-R1 and CN-R4, and connector [5].
(Check for partial connection.) q Y view
5. Turn the starting switch to the ON position (with
engine stopped) and turn the air conditioner
switch ON. If the blower main relay is normal, it
turns ON and you can hear its operation sound
(click).
6. If the compressor clutch relay (CCR) is normal, it
turns ON and you can hear its operation sound
(click).
a The control panel does not turn the compres-
sor relay ON in the following cases.
q When the evaporator temperature is 3C or
below (temperature sensed by the evapora-
tor temperature sensor)
a Compressor clutch relay (CCR) does not turn *: Since connector R1 is disconnected, blower
ON in the following cases. does not operate. Therefore pressure of air
q When the dual pressure switch detects ab-
conditioner hose in high-pressure line may
normal pressure (the dual pressure switch is increase.
OFF)

80-34 D375A-6R
(01)
Air conditioner
Testing relay

q Checking relay unit


a Since no T-adapter is available, it is actually
impossible to check each relay while apply-
ing voltage to its coil.
a Set the starting switch to the OFF position
and remove the relays.
a Common to each relay
1) Coil resistance between terminals (1) and (2)
is 140 340 z.
2) While the voltage (20 to 30 VDC) is not
applied between terminals (1) (+) and (2),
terminals (3) and (4) are disconnected.
3) While the voltage (20 to 30 VDC) is applied
between terminals (1) (+) and (2), terminals
(3) and (4) are connected.

D375A-6R 80-35
(01)
Air conditioner
Troubleshooting chart 1

Troubleshooting chart 1 80-36


The numbers in the boxes are the item numbers in the troubleshooting table.

1. Defective cooling 80-36

80-36 D375A-6R
(01)
Air conditioner
Troubleshooting chart 1

2. Defective heating 80-37

D375A-6R 80-37
(01)
Air conditioner
Troubleshooting chart 2

Troubleshooting chart 2 80-38


1. The blower fan motor does not rotate or the fan speed is different from the set value.
a See "Troubleshooting of blower motor system (Air does not come out or air flow is abnormal)".
Probable cause Check method Remedy
Defective blower main relay See "Testing relay" Replace
Check connector of blower fan motor for disconnection.
Open circuit or defective con- Repair broken parts and
See "Troubleshooting of blower motor system" and "Parts and
nection of wiring harness connect correctly
connector locations".
Check two lead wires of motor by using circuit tester. If there is
not continuity, motor is defective.
Defective blower fan motor Replace
See "Troubleshooting of blower motor system" and "Parts and
connector locations".
Defective blower resistor, Operate the fan switches in order and check the fan speed.
blower ME1 relay, blower ME2 See "Troubleshooting of blower motor system" and "Testing Replace
relay, blower HI relay relay".

2. The blower fan motor works properly but the air flow is insufficient.
Probable cause Check method Remedy
Large airflow resistance Check the filter for clogging and the duct for crushing. Repair
Check duct joints.
Air leakage through duct joints Repair
Check for defective duct seal and disconnection of duct
Obstruction on suction side of Remove obstruction
Check evaporator for dirt and obstruction
evaporator and clean
Defective evaporator tempera- Check evaporator for freeze.
ture sensor Check sensor clip. Check sensor for dirt.
Defective contact of evapora- Repair or replace
Check for frost on the hose near pressure switch (when freez-
tor temperature sensor or
ing advances furthermore)
defective expansion valve*
* The evaporator temperature sensor and expansion valve are in the air conditioner unit.

3. Low/high pressure
Probable cause Check method Remedy
Collect refrigerant, then
Excessive or insufficient refrig-
refill with proper amount
erant
of refrigerant again
Repair leaking part,
Check the normal refrigerant quantity through sight glass.
Insufficient refrigerant then refill with proper
To be exact, check by connecting gauge manifold.
amount of refrigerant.
Collect refrigerant, then
Excessive refrigerant refill with proper amount
of refrigerant again
Normal refrigerant pressure
Low pressure side: Approx.0.13 - 0.2 MPa {1.3 - 2.0 kg/cm2}
Judgment by pressure at High-pressure: Approx. 1.5 - 1.7 MPa {15 - 17 kg/cm2} See Troubleshooting
inlet/outlet of compressor However, under the following condition; with gauge pressure
Temperature inside cab: 30 -35 C
Engine speed: Approx. 1,500 rpm

80-38 D375A-6R
(01)
Air conditioner
Troubleshooting chart 2

4. Compressor does not revolve at all or its speed is low.


a See "Troubleshooting of compressor system (Air is not cooled)".
Troubled part Probable cause Check method Remedy
Compressor
Slack of belt Deflection of belt is large. Adjust tension
belt
Trouble in compressor Slip of belt Repair or replace
Insufficient compressor oil or
Compressor See "Handling compres-
seizure in the compressor Check for compressor overheat
sor oil".
Seizing on compressor
Drop of battery voltage Slip of clutch Charge battery
Disconnection or short circuit
Inspect with multimeter (10 to 20 z) Replace
in coil
Magnet clutch
Open circuit in wiring harness
Check ground wire and connections
or defective connection of Repair
See "Troubleshooting of compressor system".
ground cable
Defective compressor clutch
Relay See "Testing relay" Replace
relay
Refrigerant Low/high pressure (Operation See "Troubleshooting
See "Troubleshooting with gauge pressure".
pressure of pressure switch) with gauge pressure".
Pressure
Defective pressure switch See "Troubleshooting of compressor system". Replace
switch
Check diode (ACS). See "Troubleshooting of
Diode Defective diode(ACS) Replace
compressor system".

5. The blower fan motor works properly but the air flow is insufficient.
Probable cause Check method Remedy
Large airflow resistance Check the filter for clogging and the duct for crushing. Repair
Check duct joints for defective duct seal and disconnection of
Air leakage through duct joints Repair
duct
Clogging of heater core fins Check heater core fins for clogging Clean

6. Engine coolant temperature or level is abnormal.


Probable cause Check method Remedy
Low engine coolant tempera-
Warm up engine, and then check engine coolant temperature Find out cause
ture
Low engine coolant level Check coolant level in radiator Add coolant
Insufficient circulation of Check engine coolant piping for clogging
Bleed air and repair
engine coolant (Hose, pipe, and core)
The connection of IN and OUT
Check the destination of heater hoses Repair
heater hoses is in reverse.

7. Abnormal fan speed


Probable cause Check method Remedy
Fan speed is low See "Testing fan motor speed" and "Testing fan pump circuit
(Defective fan motor EPC or pressure" in chapter 30 "Testing and adjusting" of Shop Man- Repair
hydraulic system) ual.

8. Other abnormalities
Probable cause Check method Remarks
Temperature cannot be con- See "Testing temperature control" and "Troubleshooting for
trolled temperature control". Common to cooling and
FRESH/RECIRC air cannot be See "Testing FRESH/RECIRC air changeover" and "Trouble- heating
changed over shooting for FRESH/RECIRC air changeover"
Excessive compressor oil See "Handling compressor oil".
Cooling only
Water leakage into the cab Clogging of drain hole

D375A-6R 80-39
(01)
Air conditioner
Information in troubleshooting table

Information in troubleshooting table 80-40


Information in troubleshooting table 80-40
a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before troubleshooting, understand the information fully.
Failure Description of failure code
Related information Information related to detected trouble or troubleshooting
Cause Procedure, measuring location, criteria and remarks
<Information described>
q Procedure
q Measuring location
1 a "Between A B" means Measure voltage or resistance and so on between A and B.
Possible causes for
q Standard value in normal condition to evaluate probable cause if it is applicable or not
trouble
q Remarks requiredfor to evaluate the cause is correct
(Perform trouble-
shooting according
<Notes on troubleshooting>
to these numbers,
(1) Pin number description sequence and tester lead handling
however.)
2 For troubleshooting, connect the plus (+) and minus () leads as shown below unless other-
wise specified.
q Connect the plus (+) lead to pin or harness indicated in the front.
q Connect the minus () lead to a pin or harness indicated in the rear.
(2) Example of troubleshooting by inspection of multiple items
a Normal in 1 but abnormal in 2
At this time" - defective" shown at left is applied
3 defective

a If a wiring harness is burnt, replace it.


<Defective wiring harness>
q Disconnection in wiring harness
The connector connection is defective or wiring harness is disconnected.
q Ground fault
A harness not to be connected to the ground (earth) circuit comes into contact with the ground (earth)
circuit or chassis accidentally.
q Hot short circuit
A harness not to be connected to the power (24 V) circuit comes into contact with the power (24 V) circuit
accidentally.
q Short circuit
An independent wire in the harness abnormally comes into contact with one of another wire. (Defective
insulation in connector or others)

Related circuit diagram 80-40


This is the excerpted circuit diagram related to trouble
q Connector No.: Indicates (Model No. of pins).
q See "Circuit diagram and arrangement of connector pins" and "Parts and connector locations" for connector location
q The circuit diagram shows the size and colors of wires.
W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown, Gr: Gray, Sb:
Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown
a When there are 2 colors
Example: WY: Yellow line on white background
a The number before the wire color symbol indicates the wire size.
q N.C.: Normally closed (Normally ON)
q [1], [2], are numbers of unlabeled connectors.
q Arrow (): Roughly indicates their mounting place on the machine.

80-40 D375A-6R
(01)
Air conditioner
Information in troubleshooting table

D375A-6R 80-41
(01)
Air conditioner
Troubleshooting for power supply system (Air conditioner does not operate)

Troubleshooting for power supply system (Air conditioner does not


operate) 80-42
Failure Air conditioner does not operate due to failure in power supply system
Problem on
q When control panel is operated, related LED does not light up.
machine
qAir conditioner ground is housed in the chassis wiring harness toghether with those of electric equip-
ment installed on the machine and connected to the chassis ground.
q For connectors etc., see "Parts and connector locations".
Related infor- q T-adapter for connector CN-M26: 799-601-7130, T-adapter for connector AC1: 799-601-2730
mation a T-adapter is not prepared for other connectors.
q Turn starting switch to ON position and turn air conditioner switch A/C to ON position. At this time,
if LED above A/C switch lights up for a moment and circuit breaker trips immediately, see "Trouble-
shooting for compressor system" and "Troubleshooting for blower motor system".

Cause Procedure, measuring location, criteria and remarks


Activation of circuit breaker
1 If circuit breaker trips, circuit probably has ground fault etc.
(CB4)
1. Turn starting switch to OFF position.
Defective wiring harness 2. Disconnect connector AC2 from control panel.
2 3. Insert T-adapter into connector AC1.
(ground)
Between AC1 (1) and chassis ground Resistance Max. 1 z
a If circuit breaker trips, press its reset button in advance.
1. Turn starting switch to OFF position.
2. Disconnect connector AC2 from control panel.
3. Insert T-adapter into connector AC1.
4. Turn starting switch to ON position.
Between AC1 (10) and (1) Voltage 20 30 V A
a Perform the following when the test result "A" above is abnormal
a If circuit breaker trips, press its reset button in advance.
1. Turn starting switch to OFF position.
2. Disconnect connector M26 and connect T-adapter to female side.
3. Turn starting switch to ON position.
a If circuit breaker trips again or the test result "B" or "C" below is abnormal, wir-
ing harness on machine body side is defective.
Between M26 (2) and (6) Voltage 20 30 V B

3 Between M26 (5) and (6) Voltage 20 30 V C


Defective wiring harness a Perform the following when circuit breaker trips during test "A" above and the
test results "B" and "C" above are normal.
a If circuit breaker trips, press its reset button in advance.
1. Turn starting switch to OFF position.
2. Disconnect connector AC2 from control panel.
3. Insert T-adapter into connector AC1.
4. Disconnect connectors CN-B, R1 - R4 and [5].
5. Turn starting switch to ON position.
Between AC1 (10) and (1) Voltage 20 30 V D
a If the test result "D" above is abnormal, air conditioner wiring harness is defec-
tive.
a If circuit breaker trips during test "D" above, disconnect male side of connector
AC1 and perform test again to see on which side wiring harness is defective,
control panel side or air conditioner unit side.
a If the test result "A" is abnormal and test result "D" is normal, see "Trouble-
shooting for compressor system" and "Troubleshooting for blower motor sys-
tem".
Open circuit in wiring harness
4 a If circuit breaker does not trip, check with circuit diagram.
(on control panel side)
5 Defective control panel If cause is not found by above checks, control panel may be defective.

80-42 D375A-6R
(01)
Air conditioner
Troubleshooting for power supply system (Air conditioner does not operate)

Related electrical circuit diagram 80-43

D375A-6R 80-43
(01)
Air conditioner
Troubleshooting for compressor system (Air is not cooled)

Troubleshooting for compressor system (Air is not cooled) 80-4


Failure Air is not cooled because of trouble in compressor or refrigerant system
Problem on q When engine is started and A/C switch is pressed while the blower is turned ON, air is not cooled.
machine q Air conditioner compressor does not operate.
q If refrigerant pressure is abnormal, air is not cooled because the compressor is not turned ON.
q When evaporator temperature is below 3 C, control panel does not turn compressor relay ON to pre-
vent evaporator from freezing (this is normal operation).
Related infor- q For connectors etc., see "Parts and connector locations".
mation q T-adapter for connector CN-M26: 799-601-7130, T-adapter for connector AC1: 799-601-2730
a T-adapter is not prepared for connectors other than the above and for DT connectors. Accordingly,
perform troubleshooting by using connectors which T-adapter is avilable for.
q Since condenser relay is not used, it may be used as a replacement when replacing other relays.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector FEN from air conditioner compressor and connect
Defective air conditioner com-
1 T-adapter to male side.
pressor
Between FEN (1) and ground (air conditioner com-
Resistance Approx. 15 z
pressor coil resistance)
1. Turn starting switch to OFF position.
2. Remove diode ACS.
a Measure with circuit tester in diode range.
2 Defective diode No continuity
Between ACS (male) (1) (+) and (2) (-)
Max. 1 z
Between ACS (male) (2) (+) and (1) (-) Continuity
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connector M26 and connect T-adapter to female side.
3
(on machine side) Between M26 (female) (3) and ground
Resistance Approx. 15 z
(air conditioner compressor coil resistance)
a If circuit breaker does not trip, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connector FEN.
4 (Contact with ground circuit) 3. Insert T-adapter into connector M26.
(on machine side) Between M26 (female) (3) and ground Resistance Min. 1 Mz
Between M26 (female) (3) and (6) Resistance Min. 1 Mz
q Referring to "Testing relay", check operation sound Click is
A
of compressor clutch relay. heard.
a If the test result "A" above is normal, this check is not required.
a Check that air flow can be controlled.
Defective compressor clutch
5 1. Turn starting switch to OFF position.
relay (It does not turn ON)
2. Replace compressor clutch relay with blower Me2 relay (CN-R4).
3. Turn starting switch to ON position.
4. Turn air conditioner switch ON.
If compressor operates (air is cooled), original compressor clutch relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector AC1 and insert T-adapter into female side.
Defective evaporator tempera- 0 C Resistance 4.6 - 5.1 kz
6
ture sensor
Between AC1 (female) (15) and (17) 15 C Resistance 2.1 - 2.6 kz
25 C Resistance 1.5 kz

80-44 D375A-6R
(01)
Air conditioner
Troubleshooting for compressor system (Air is not cooled)

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector AC1 and connect T-adapter to female side.
a The switch may be turned OFF normally. If the following is abnormal (switch is
turned OFF), install pressure gauge to low-pressure side of air conditioner com-
pressor and check refrigerant pressure. (See "Troubleshooting with gauge pres-
7 Defective pressure switch
sure".)
Between AC1 (10) and (14)
Resistance 240 40 z
(compressor relay coil resistance)
k When replacing pressure switch, collect refrigerant in advance.
1. Turn starting switch to OFF position.
Check of voltage 2. Insert T-adapter into connector AC1.
8 (Defective wiring harness or 3. Turn starting switch to ON position.
defective control panel) 4. Turn air conditioner switch ON.
Between AC1 (14) and (1) Voltage Max. 1 V
a If cause 7 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors M26, AC2, R1 - R4 and [5].
3. Insert T-adapter into connector AC1.
9 Short circuit in wiring harness
a Check with circuit tester in continuity mode.
Between AC1 (10) and each pin other than (10) No continuity
Between AC1 (14) and each pin other than (14) No continuity
10 Open circuit in wiring harness a Check with circuit diagram.
If check result for cause 8 is abnormal and check results for causes 9 and 10 are
11 Defective control panel
normal, control panel is defective.

D375A-6R 80-45
(01)
Air conditioner
Troubleshooting for compressor system (Air is not cooled)

Related electrical circuit diagram 80-46

80-46 D375A-6R
(01)
Air conditioner
Troubleshooting for compressor system (Air is not cooled)

D375A-6R 80-47
(01)
Air conditioner
Troubleshooting for blower motor system (Air does not come out or air flow is abnormal)

Troubleshooting for blower motor system (Air does not come out or air
flow is abnormal) 80-48
No air comes out or air flow is improper due to blower motor system failure
Failure
1) Air does not come out in any air flow setting.
Problem on
q When any fan switch is pressed, air does not come out.
machine
q For connectors, relays, etc., see "Parts and connector locations".
Related infor- q Since condenser relay is not used, it may be used as replacement when replacing other relays.
mation q T-adapter for connector CN-M26: 799-601-7130, T-adapter for connector AC1: 799-601-2730
a T-adapter is not prepared for other connectors.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
1 Defective blower (fan) motor 2. Disconnect connector CN-B.
Between CN-B (male) (1) and (2) Continuity
q Referring to testing of relay, check turn-on sound of Click is
A
blower main relay. heard.
a If the test result "A" above is normal, this check is not required.
Defective blower main relay 1. Turn starting switch to OFF position.
2 2. Replace the blower main relay with blower Me2 relay (CN-R4).
(Does not turn ON)
3. Turn starting switch to ON position.
4. Turn air conditioner switch ON.
If air comes out, original blower main relay is defective.
q Primary output to relay from control panel
1. Turn starting switch to OFF position.
Check of voltage 2. Insert T-adapter into connector AC1.
3 (Defective wiring harness or 3. Turn starting switch to ON position.
defective control panel) 4. Turn air conditioner switch ON.
Between AC1 (11) and (1) Voltage Max. 1 V
a If cause 3 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors M26, AC2, R1 to R4, and [5].
4 Short circuit in wiring harness 3. Insert T-adapter into connector AC1.
a Check with circuit tester in continuity mode.
Between AC1 (11) and each pin other than (11) No continuity
5 Open circuit in wiring harness a Check with circuit diagram.
If check result for cause 3 is abnormal and check results for causes 4 and 5 are
6 Defective control panel
normal, control panel is defective.

80-48 D375A-6R
(01)
Air conditioner
Troubleshooting for blower motor system (Air does not come out or air flow is abnormal)

Related electrical circuit diagram 80-49

D375A-6R 80-49
(01)
Air conditioner
Troubleshooting for blower motor system (Air does not come out or air flow is abnormal)

No air comes out or air flow is improper due to blower motor system failure
Failure
2) Air does not come out or air flow is abnormal in certain air flow setting.
Problem on
Air does not come out or air flow is abnormal in certain air flow setting.
machine
q If air flow decreases (air does not come out) after a while in cooling mode, evaporator may have
frozen. The possible causes for this trouble are as follows.
1) Compressor clutch relay is defective (kept ON) (See "Troubleshooting for compressor system",
5-A).
2) Evaporator temperature sensor mounting holder is removed (Remove and disassemble air
Related infor- conditioner unit).
mation 3) Expansion valve is not adjusted properly (Remove air conditioner unit and replace expansion
valve).
q For connectors, relays, etc., see "Parts and connector locations".
q Since condenser relay is not used, it may be used as replacement when replacing other relays.
q T-adapter for connector CN-M26: 799-601-7130, T-adapter for connector AC1: 799-601-2730
a T-adapter is not prepared for other connectors.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to ON position.
2. Turn air conditioner switch ON.
3. Set air flow to each level in order.
If air comes out only in air flow HI, blower resistor is defective.
Defective blower resistor
1 (Breakage of fuse in blower q Reference: Between [1] (male) (1) and (2) Approx.
Resistance
resistor) a Fuses 600 z
Approx.
q Reference: Between [1] (male) (2) and (3) Resistance
900 z
Approx.
q Reference: Between [1] (male) (3) and (4) Resistance
530 z
1. Turn starting switch to ON position.
2. Turn air conditioner switch ON.
3. Set air flow to each level in order.
q Replace corresponding relay in each of following checks. Following phenome-
na show: 1. Relay is kept turned ON, 2. Relay is not turned ON.
1. Air flow is HI in any air flow setting.
2. Air flow is LO when the air flow is set to HI.
Defective blower HI relay, q Replace blower HI relay with condenser relay. If air flow becomes normal, orig-
2 blower Me2 relay or blower inal blower HI relay is defective.
Me1 relay 1. Air flow HI and ".."is normal, but air flow is ".." even if the air flow set to"." or LO.
2. Air flow is LO when air flow is set to "..".
q Replace blower Me2 relay with condenser relay. If air flow becomes normal,
original blower Me2 relay is defective.
1. Air flow HI ,".." and "." is normal, but air flow is "." even if the air flow is set to LO.
2. Air flow is LO when air flow is set to ".".
q Replace blower Me1 relay with condenser relay. If air flow becomes normal,
original blower Me1 relay is defective.

80-50 D375A-6R
(01)
Air conditioner
Troubleshooting for blower motor system (Air does not come out or air flow is abnormal)

Cause Procedure, measuring location, criteria and remarks


q Primary output to relay from control panel
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector AC1.
3. Turn starting switch to ON position.
4. Turn air conditioner switch ON.
5. Press each air flow switch and perform troubleshooting.
Between AC1 (13) and (1) HI Voltage Max. 1 V
Check of voltage
3 (Defective wiring harness or Other than
Between AC1 (13) and (1) Voltage 20 30 V
defective control panel) HI
Between AC1 (12) and (1) "" Voltage Max. 1 V
Other than
Between AC1 (12) and (1) Voltage 20 30 V
".."
Between AC1 (7) and (1) "" Voltage Max. 1 V
Other than
Between AC1 (7) and (1) Voltage 20 30 V
"."
a If cause 5 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors M26, AC2, CN-B, R1-R4, and [5]
3. Insert T-adapter into connector AC1.
4 Short circuit in wiring harness a Check with circuit tester in continuity mode.
Between AC1 (7) and each pin other than (7) No continuity
Between AC1 (12) and each pin other than (12) No continuity
Between AC1 (13) and each pin other than (13) No continuity
5 Open circuit in wiring harness a Check with circuit diagram.
If check result for cause 3 is abnormal and check results for causes 4 and 5 are
6 Defective control panel
normal, control panel is defective.

D375A-6R 80-51
(01)
Air conditioner
Troubleshooting for blower motor system (Air does not come out or air flow is abnormal)

Related electrical circuit diagram 80-52

80-52 D375A-6R
(01)
Air conditioner
Troubleshooting for blower motor system (Air does not come out or air flow is abnormal)

D375A-6R 80-53
(01)
Air conditioner
Troubleshooting for temperature control

Troubleshooting for temperature control 80-54


Failure q Temperature cannot be controlled
Problem on
q When temperature control switch is operated, temperature does not change.
machine
Referring to "Testing temperature control", check connector [2] for defecive contact and mechanical
q
trouble (desconnection of shaft, interference of lever, etc.)
Related infor- q For connectors etc., see "Parts and connector locations".
mation q T-adapter for connector CN-M26: 799-601-7130, T-adapter for connector AC1: 799-601-2730,
T-adapter for connector [2]: 799-601-2710
a T-adapter is not prepared for other connectors.

Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector [2] and connect T-adapter to male side.
Between connector [2] (male) (4) and (1) Resistance 6 kz
a If air mix servomotor does not operate (the test result "C" below is abnormal) while
the test results "A" and "B" below are normal, air mix servomotor is defective.
1. Turn starting switch to OFF position.
2. Insert T-adapter in connector [2]
3. Turn starting switch to ON position.
4. Turn air conditioner switch ON.
Between connector [2] (4) and (1) Voltage 5V A
1. Turn starting switch to OFF position.
2. Insert T-adapter in connector [2]
3. Turn starting switch to ON position.
4. Turn air conditioner switch ON.
Defective air mix servo- 5. Press left triangle temperature control switch many times to set to minimum temper-
1 ature in advance.
motor
6. Perform troubleshooting while pressing right triangle temperature control switch.
7. Press right triangle temperature control switch many times to set to maximum temper-
ature in advance.
8. Perform troubleshooting while pressing left triangle temperature control switch.
Between connector [2] (3) and (5)
a Voltage appears for only approximately 1
second (only while hot water valve is
moving) and polarity is reversed when
Voltage 24 V B
right triangle and left triangle tempera-
ture control switch is pressed. When right
triangle switch (WARM side) is pressed,
polarity of pin 3 becomes +.
Between [2] (2) and (1)
a Voltage changes only while hot water Varies below
Voltage C
valve is moving (Voltage settles after the 5V
door stops).
a If cause 1 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors AC1 and [2], and connect T-adapters to female side of them.
Between AC1 (2) and [2] (4) Resistance Max. 1 z
Open circuit in wiring
2 Between AC1 (3) and [2] (5) Resistance Max. 1 z
harness
Between AC1 (4) and [2] (3) Resistance Max. 1 z
Between AC1 (16) and [2] (2) Resistance Max. 1 z
Between AC1 (17) and [2] (1) Resistance Max. 1 z

80-54 D375A-6R
(01)
Air conditioner
Troubleshooting for temperature control

Cause Procedure, measuring location, criteria and remarks


a If cause 1 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors M26, AC2, AC3, and [2]
3. Insert T-adapter into connector AC1.
a Check with circuit tester in continuity mode.
Short circuit in wiring har- Between AC1 (2) and each pin other than (2) No continuity
3
ness
Between AC1 (3) and each pin other than (3) No continuity
Between AC1 (4) and each pin other than (4) No continuity
Between AC1 (19) and each pin other than (19) No continuity
Between AC1 (20) and each pin other than (20) No continuity
Open circuit in wiring
4 harness a Check with circuit diagram.
(on control panel side)
If check result for cause 1 is abnormal and check results for causes 2 to 4 are normal,
5 Defective control panel
control panel is defective.

Related electrical circuit diagram 80-5

D375A-6R 80-55
(01)
Air conditioner
Troubleshooting for FRESH/RECIRC air changeover

Troubleshooting for FRESH/RECIRC air changeover 80-56


Failure q FRESH/RECIRC air cannot be changed over
q When FRESH/RECIRC air changeover switch on control panel is operated, fresh air or recirculated
Problem on
air does not switch between them.
machine
(FRESH/RECIRC air changeover door (damper) does not rotate)
q Operate FRESH/RECIRD selector switch and check that there is not mechanical trouble (removal or
interference of lever, etc ) in fresh/recircculated air changeover door (damper). For details, see "Test-
ing FRESH/RECIRC changeover".
Related infor-
q For connectors etc., see "Parts and connector locations".
mation
q T-adapter for connector CN-M26: 799-601-7130, T-adapter for connector AC1: 799-601-2730,
T-adapter for S: 799-601-2710
a T-adapter is not prepared for other connectors.

Cause Procedure, measuring location, criteria and remarks


a If FRESH/RECIRC air changeover servo motor does not operate while following
is normal (See Testing FRESH/RECIRC air changeover), FRESH/RECIRC air
changeover servo motor is defective.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector CN-S.
3. Turn starting switch to ON position.
4. Turn air conditioner switch ON.
5. Perform troubleshooting while pressing RECIRC air switch and FRESH air
Defective FRESH/RECIRC air
1 switch.
changeover servo motor
a Voltage appears only for approx. 3 seconds (only while door is moving to
FRESH or RECIRC position).
From fresh
Between CN-S (5) (+) and (3) (-) air to recir- Voltage 24 V
culated air
From recir-
Between CN-S (5) (-) and (3) (+) culated air to Voltage 24 V
fresh air
a If cause 1 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors AC1 and [2], and connect T-adapters to female side of
2 Open circuit in wiring harness them.
Between AC1 (5) and CN-S (3) Resistance Max. 1 z
Between AC1 (6) and CN-S (5) Resistance Max. 1 z
a If cause 1 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors M26, AC2, AC3, and [2]
3. Insert T-adapter into connector AC1.
3 Short circuit in wiring harness
a Check with circuit tester in continuity mode.
Between AC1 (5) and each pin other than (5) No continuity
Between AC1 (6) and each pin other than (6) No continuity
Disconnection in wiring har-
4 ness a Check with circuit diagram.
(on control panel side)
If check result for cause 1 is abnormal and check results for causes 2 to 4 are nor-
5 Defective control panel
mal, control panel is defective.

80-56 D375A-6R
(01)
Air conditioner
Troubleshooting for FRESH/RECIRC air changeover

Related electrical circuit diagram 80-57

D375A-6R 80-57
(01)
Air conditioner
Troubleshooting with gauge pressure

Troubleshooting with gauge pressure 80-58


Perform troubleshooting according to the high and <Measurement condition for pressure>
low gauge pressures of the cooling cycle. For de- Item Condition value
tails, see "Connection of service tool". Ambient temperature 2050 C
a The gauge pressure varies largely with the Engine speed 1,500 rpm
weather condition and operating condition of the Air conditioner switch ON
machine. Check the gauge pressure under the
Fan switch HI
pressure measurement conditions.
Set temperature Full cool
q High-pressure line pressure is too high: Above

approx. 2.5 MPa {25 kg/cm2} q Dual pressure switch


q High-pressure line pressure is too low: Above a The swiths is normally "ON", and becomes
"OFF" for compressor operation when it detects
approx. 1 MPa {10 kg/cm2}
abnormal pressure.
q Low-pressure line pressure is too high: Above

approx. 0.3 MPa {3 kg/cm2}


q Low-pressure line pressure is too low: Approx.

0.05 MPa {0.5 kg/cm2}


a Dual pressure switch turns "OFF" to protect the
air conditioner circuit if the pressure of the
high-pressure or low-perssure line is abnormal.

LA: 0.20 MPa {2 kg/cm2}


LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}

80-58 D375A-6R
(01)
Air conditioner
Troubleshooting with gauge pressure

Indicated gauge
Cause Check method Remedy
pressure
Air conditioner cycle is normal.
If there is any trouble (cooling trouble), there is another cause.
Pressure is normal -
High-pressure line pressure: Approx 1.5 - 1.7 MPa {15 17 kg/cm2}
2
Low-pressure line pressure: Approx 0.13 - 0.2 MPa {1.3 2.0 kg/cm }
Collect refrigerant, then
Bubbles can be seen through sight glass refill with proper amount
Insufficient refrigerant
*1, *3 of refrigerant again
*2
There is a temperature difference between
Replace
Clogging of receiver drier inlet and outlet pipes of receiver drier.
*2
Tank is frosty
<Pressure of both Clean or replace
Clogging of expansion valve Expansion valve is frosty
high-pressure and *2
low-pressure lines Refrigerant leakage from thermoprobe Replace
Low pressure gauge reads vacuum
are too low> tube of expansion valve *2
Repair or replace
Evaporator is frozen
Low-pressure gauge Replace receiver drier
Defective evaporator temperature sensor Flow rate of refrigerant is reduced due to
reads vacuum Collect refrigerant, then
or defective contact of sensor (coming off freezing.
refill with proper amount
of mounting clip) (After setting to cool max. and HI fan
of refrigerant again
speed, air becomes not to be cooled.)
*2
Piping between receiver drier and com-
pressor is clogged or crushed. Clean or replace
Clogged or crushed piping
If clogged completely, low-pressure gauge *2
reads vacuum
Collect refrigerant, then
refill with proper amount
Excessive refrigerant Connect gauge manifold
of refrigerant again
*2
Clean, repair fins, or
<Pressure of both Dirty condenser, clogging or crushing of repair or replace con-
Defective cooling of condenser
high-pressure and fins, or defective revolution of cooling fan denser
low-pressure lines *2
are too high> Defective adjustment of expansion valve Replace
Bubbles can be seen through sight glass *3
(Valve is opened too wide) *2
Vacuum and then refill
with proper amount of
Air in cycle parts Bubbles can be seen through sight glass *3
refrigerant again
*2
<High-pressure line
pressure is too high Clean inside of cycle
Clogged or crushed piping between com- There is a remarkable temperature differ-
and low-pressure parts or replace
pressor and condenser ence across clogged part
line pressure is too *2
low>
<High-pressure line
Both high-pressure and low-pressure lines
pressure is too low
Defective compressor (Compression stop while compressor is in operation. Replace
and low-pressure
trouble of compressor) Compressor has seized and is extremely *2
line pressure is too
hot.
high>
*1 Where refrigerant leaks, compressor oil in the air conditioner circuit always leaks, too. So perform the check
mainly on pipe joints and dirty parts with oil.
*2
k When replacing a cooling cycle part, see Caution about refrigerant and collect refrigerant. After
replacing it, fill up the air conditioner system with refrigerant again.
*3 Sight glass is on the receiver drier.

D375A-6R 80-59
(01)
Air conditioner
Connection of service tool

Connection of service tool 80-60


Connect the gauge manifold, hoses and other ser-
Symbol Part No. Part name vice tools according to the following procedure.
X 799 - 703 - 1200 Service tool kit 1. Close the high-pressure valve (6) and low-pres-
sure valve (7) of gauge manifold (1).
a Use the service tool kit for R134a.
2. Connect red charging hose (2) to the (HI) side
Service tool kit X 80-60 and blue charging hose (3) to the (LO) side of the
(1): Gauge manifold
gauge manifold.
(2): High pressure charging hose (red)
(3): Low pressure charging hose (blue)
3. Connect quick joints (4) and (5) to each hose.
(4): Quick joint (Hi) (Large diameter)
(5): Quick joint (Lo) (Small diameter)
4. Connect the quick joints (4) and (5) to the service
valves (8) and (9) of the high and low-pressure
(a): As the thread is coarse, care should be taken
pipings.
with regard to loosening.

80-60 D375A-6R
(01)
Air conditioner
Connection of service tool

D375A-6R 80-61
(01)
Air conditioner
Precautions for disconnecting and connecting

Precautions for disconnecting and connecting 80-62


Precautions for disconnecting 80-62 Precautions for connecting 80-62

k Collect the air conditioner refrigerant (R134a) q When connecting the piping, apply compressor
from air conditioner circuit before discon- oil (ND-OIL8) for R134a to the O-rings. (See item
necting air conditioner hose to replace air 4. in "Handling of compressor oil")
conditioner unit, air conditioner compressor Do not apply oil to the threads of a bolt, nut or
or receiver drier and so on. union, however.
a Ask a qualified shop for collecting, adding and q Once an O-ring is used, it is deformed and dete-
filling operation of refrigerant (R134a). riorated. Accordingly, do not reuse it. When re-
a Never release the refrigerant (R134a) to the at- moving it, use a soft tool (such as a toothpick) so
mosphere. that the piping will not be damaged.
k If refrigerant gas (R134a) gets in your eyes, q Push in each pipe to the stopper and tighten the
you may lose your sight. And if it touches bolt or nut fully with your fingers.
your skins, you may suffer from frostbite. Ac- q Be sure to use two wrenches to tighten each nut
cordingly, put on safety glasses, gloves and (Use a torque wrench for tightening). Use one
working cloth with long sleeves while you are wrench to fix and tighten the nut with the other
collecting the refrigerant (R134a) or filling wrench to the specified torque.
the air conditioner circuit with the refrigerant
(R134a).

q When loosening the air conditioner hose nuts af-


ter collecting the refrigerant, be sure to use 2
wrenches; use one wrench to fix and use the oth-
er one to loosen the nuts.

80-62 D375A-6R
(01)
Air conditioner
Precautions for disconnecting and connecting

Table of tightening torque for refrigerant pipe joint.


Unit: Nm {kgm}
Screw size Tightening torque
3.9 - 6.9 {0.4 - 0.7} (Receiver drier)
M6 x 1.0
8 - 12 {0.8 - 1.2} (Air conditioner unit and compressor)
M16 x 1.5 12 15 {1.2 1.5}

M24 x 1.5 30 35 {3.1 3.6}

1. Engine
2. Compressor
3. Condenser
4. Receiver drier
5. Air conditioner unit

D375A-6R 80-63
(01)
Air conditioner
Handling of compressor oil

Handling of compressor oil 80-64


1. Compressor oil management (DENSO: q Quantity of oil to be added when cycle part is re-
ND-OIL8 for R134a) 80-64 placed
Quantity to be
Compressor oil does not need to be checked or add- Air conditioner par
added (cc)
ed so frequently as engine oil. Insufficiency or ex- Air conditioner unit, evaporator Approx. 40
cess of compressor oil can cause the following Condenser Approx. 40
troubles.
Receiver drier Approx. 20
Condition Content Hose (Compressor Cab) Approx. 30
Insufficiency of Lubrication trouble and seizure of com-
Hose (Compressor Condenser) Approx. 10
oil pressor
Cooling trouble Hose(Condenser
Approx. 10
Receiver driver)
Excess of oil (Excessive oil stick to parts and lower
heat exchange performance) Hose (Cab Receiver driver) Approx. 20

Accordingly, compressor oil must be filled to the


specified level, similarly to refrigerant.

2. Adding of compressor oil 80-64

k Since refrigerant is dangerous and bad for


environment, collect the refrigerant before
disconnecting the air conditioner hose. See
"Precaution for connecting and disconnect-
ing air conditioner piping".
a If oil for CFC-12 (R-12) is used, lubrication trou-
ble will occur and the compressor may be broken
or seized.
Be sure to use the specified oil for R134a
(Denso: ND-OIL8)
a Oil for R134a absorbs moisture very easily. Ac-
cordingly, fit the cap to the oil container immedi-
ately after using the oil to shield against the
atmosphere.
Store the oil container in a dry and ventilated
place.
a Precautions for using oil
Oil for R134a may dissolve acrylic resin and
polystyrene (excluding baked polystyrene paint
film). Accordingly, do not stick oil to those plas-
tics.
Check compressor oil in the following cases, and
then add new oil if necessary.
q When much refrigerant is discharged because of
leakage.
q When the compressor is troubled and replaced.
q When a cycle parts such as the air conditioner
unit, condenser, receiver drier, evaporator unit,
etc. is replaced.

80-64 D375A-6R
(01)
Air conditioner
Handling of compressor oil

3. Compressor replacement 80-65 4. Applying compressor oil to O-ring 80-65

q In case of compressor seizure or breakage. When connecting a pipe or hose, apply oil (Denso:
Metal chips will circulate through the air condi- ND-OIL8) to its O-ring to prevent refrigerant leak-
tioner circuit and contaminate the compressor oil age.
extremely.
In this case, flush the air conditioner circuit and
replace the compressor and receiver drier.
The compressor oil is removed from the air
conditioner circuit by flushing. Accordingly,
install a new compressor with the oil of the spec-
ified quantity (180 cc) filled in it.

q Other cases
a New compressor has 180 cc compressor oil in it.
1) Prepare an oil container and drain oil from
the old compressor.
2) Measure the quantity of the drained oil with a
measuring cylinder, and note the quantity.

3) Drain below-mentioned quantity of oil from


the new compressor.
180 cc - "Noted quantity"
Example:If 30 cc was drained from the
removed compressor, the amount to be
drained from the new compressor would be
150 cc (i.e., 180 - 30 cc).

D375A-6R 80-65
(01)
Air conditioner
Handling of compressor oil

80-66 D375A-6R
(01)
D375A-6R
SEN0521433-00 90-1

BULLDOZER
Shop Manual 9-01

D375A-6R

Machine model Serial number


D375A-6R 65001 and up

90 Diagrams and drawings 90-1

D375A-6R 90-1
Contents

Contents 90-2
90 Diagrams and drawings
Hydraulic diagrams and drawings ........................................................................................... 90- 3
Symbols used in hydraulic circuit diagrams ......................................................................... 90- 3
Power train hydraulic circuit diagram ................................................................................... 90- 5
Hydraulic circuit diagram...................................................................................................... 90- 7
Electrical diagrams and drawings ........................................................................................... 90- 11
Symbols used in electrical circuit diagrams ......................................................................... 90- 11
Electrical circuit diagram ...................................................................................................... 90- 15

90-2 D375A-6R
Hydraulic diagrams and drawings
Symbols used in hydraulic circuit diagrams

Hydraulic diagrams and drawings 90-3


Symbols used in hydraulic circuit diagrams 90-3
(Rev. 2010/02)

Symbol Substance

Main piping line

Pilot or drain line

Flexible pipe (hose, etc.)

Lines intersecting without joining

Lines joining (junction with a round black mark)

Direction of flow

Throttle in passage.

Variable

Electricity

Spring

Take-off port

Take-off port and pressure gauge

Check valves

Suction (with strainer)

Tank and return pipe

Filter

Oil cooler

Stop valve

Drive shaftunidirectional

Drive shaftbidirectional

D375A-6R 90-3
Hydraulic diagrams and drawings
Symbols used in hydraulic circuit diagrams

Symbol Substance

Pump
Note : Black triangle shows outlet port

Variable capacity hydraulic pump

Hydraulic motor (The figure shows bidirectional type.)


NoteTwo black triangles in the figure show direction of oil entering hydraulic motor
depending on the oil entry port, the direction of rotation is reversed.

Servo piston

PPC valve

Control valve

Single-acting solenoid

Hydraulic pilot valve

Hydraulic two-stage pilot valve

Lock valve

Drain valve

Pressure regulator valve/ Safety valve/ Abnormal pressure prevention valve

Pressure regulator valve/Safety valve/ Abnormal pressure prevention valve


When the figure shows air pressure, being released to atmosphere.

Bypass valve

Accumulator

Cylinder

Component group

90-4 D375A-6R
Power train hydraulic circuit diagram
D375A-6R
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

D375A-6R 90-5
Hydraulic circuit diagram(1/2) Hydraulic circuit diagram(1/2)
D375A-6R
DUAL TILT SPEC.
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

D375A-6R 90-7
Hydraulic circuit diagram(2/2) Hydraulic circuit diagram(2/2)
D375A-6R
SINGLE TILT SPEC.
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

D375A-6R 90-9
Electrical diagrams and drawings
Symbols used in electrical circuit diagrams

Electrical diagrams and drawings 90-1


Symbols used in electrical circuit diagrams 90-1
(Rev. 2010/02)

Symbol Substance

Electric wire

Electric wire Wires intersecting without connecting

Electric wire Wires intersecting and connecting (junction) with a round


black mark

Electric wire (Bundled drawing style)

Terminal

Chassis ground

Chassis ground using terminal

Contact
Switch

Push-button type switch (N.O. type)


*N.O.: Normally Open

Push-button type switch (N.C. type)


*N.C.: Normally Close

Pull-button type switch (N.O. type)


*N.O.: Normally Open

Pull-button type switch (N.C. type)


*N.C.: Normally Close

Variable

Resistance (resistor)

Variable resistance (variable resistor)

D375A-6R 90-11
Electrical diagrams and drawings
Symbols used in electrical circuit diagrams

Symbol Substance

Diode

Light emitting diode (LED)

Photo diode

Constant voltage diode (Zener diode)

Transistor (PNP type)

Transistor (NPN type)

Coil

Battery

Fuse

Connector
Note
Convex side of connecting portion (right in figure): male
Concave side of connecting portion (left in figure): female
*Figure shows a line disconnection status.

Plug and receptacle type connector (left: male, right: female)


Note: Figure shows a line connection status.

Solenoid

Motor

90-12 D375A-6R
Electrical diagrams and drawings
Symbols used in electrical circuit diagrams

Symbol Substance

Lamp

Pressure switch (N.O. type)


*N.O.: Normally Open

Pressure switch (N.C. type)


*N.C.: Normally Close

Potentiometer

Fuel dial

Temperature sensor

Starting switch

Backup alarm

Horn

Buzzer

Antenna

D375A-6R 90-13
Electrical diagrams and drawings
Symbols used in electrical circuit diagrams

90-14 D375A-6R
Electrical circuit diagram (1/14) Electrical circuit diagram (1/14)
D375A-6R
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

D375A-6R 90-15
Electrical circuit diagram (2/14) Electrical circuit diagram (2/14)
D375A-6R
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

D375A-6R 90-17
Electrical circuit diagram (3/14) Electrical circuit diagram (3/14)
D375A-6R
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

D375A-6R 90-19
Electrical circuit diagram (4/14) Electrical circuit diagram (4/14)
D375A-6R
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

D375A-6R 90-21
Electrical circuit diagram (5/14) Electrical circuit diagram (5/14)
D375A-6R
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

D375A-6R 90-23
Electrical circuit diagram (6/14) Electrical circuit diagram (6/14)
D375A-6R
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

D375A-6R 90-25
Electrical circuit diagram (7/14) Electrical circuit diagram (7/14)
D375A-6R
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

D375A-6R 90-27
Electrical circuit diagram (8/14) Electrical circuit diagram (8/14)
D375A-6R
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

D375A-6R 90-29
Electrical circuit diagram (9/14) Electrical circuit diagram (9/14)
D375A-6R
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

D375A-6R 90-31
Electrical circuit diagram (10/14) Electrical circuit diagram (10/14)
D375A-6R
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

D375A-6R 90-33
Electrical circuit diagram (11/14) Electrical circuit diagram (11/14)
D375A-6R
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

D375A-6R 90-35
Electrical circuit diagram (12/14) Electrical circuit diagram (12/14)
D375A-6R
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

D375A-6R 90-37
Electrical circuit diagram (13/14) Electrical circuit diagram (13/14)
D375A-6R
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

D375A-6R 90-39
Electrical circuit diagram (14/14) Electrical circuit diagram (14/14)
D375A-6R
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

D375A-6R 90-41
Index

Index
A Disassembly and assembly of blade PPC valve assembly
Accumulator 10-128 50-279
Adjusting blade 30-81 Disassembly and assembly of bogie assembly 50-216
Adjusting brake pedal and parking brake lever 30-58 Disassembly and assembly of carrier roller assembly
Adjusting fuel control dial and decelerator pedal 30-39 50-207
Adjusting play of PPC valve 30-72 Disassembly and assembly of control valve assembly
Adjusting position of pccs lever console 30-61 50-274
Adjusting ripper lever position 30-78 Disassembly and assembly of damper assembly 50-90
Adjusting transmission output speed sensor 30-56 Disassembly and assembly of equalizer bar bushing
Adjusting valve clearance 30-16 50-260
Adjusting work equipment lock lever 30-80 Disassembly and assembly of final drive assembly
Adjustment method when controller has been replaced 50-170
30-149 Disassembly and assembly of giant ripper assembly
Air conditioner component 80-4 50-301
Air conditioner control panel 80-20 Disassembly and assembly of hydraulic cylinder
Air conditioner unit 80-10 assembly 50-284
Disassembly and assembly of idler assembly 50-189
Disassembly and assembly of master link 50-251
B
Disassembly and assembly of one link assembly in the
Blade 60-98
field 50-246
Blade control lever (only for the machine with dual tilt
Disassembly and assembly of PTO assembly 50-108
specification) 10-148
Disassembly and assembly of recoil spring assembly
Bleeding air from fan pump 30-38
50-198
Bleeding air from fuel circuit 30-32
Disassembly and assembly of ripper pin puller cylinder
Bleeding air from work equipment cylinders 30-77
assembly 50-292
Blower unit 80-14
Disassembly and assembly of ripper PPC valve assembly
50-282
C Disassembly and assembly of steering case assembly
Cab 10-196 50-150
Cab mount 10-195 Disassembly and assembly of TORQFLOW transmission
Carrier roller 60-56 assembly 50-123
Checking location of cause of hydraulic drift of blade and Disassembly and assembly of torque converter assembly
ripper 30-74 50-114
Checks before troubleshooting 40-12 Disassembly and assembly of track roller assembly
Circuit diagram and arrangement of connector pins 50-203
80-24 Disconnection and connection of power train unit
Classification and procedures for troubleshooting 40-37 assembly 50-99
Classification and procedures for troubleshooting
numbers 40-50 E
Coating materials list 50-6
E-1 Engine does not start (starting motor does not turn)
Compressor 80-16
40-580
Condenser 80-17
E-2 Preheater does not operate 40-584
Configuration and function of refrigeration cycle 80-6
E-3 When starting switch is turned ON, machine monitor
Connection of service tool 80-60
displays nothing 40-588
Connection table for connector pin numbers 40-57
E-4 When starting switch is turned ON (before starting
Connector list and layout 40-96
engine), basic check item lights up 40-592
Control valve 10-162,60-81
E-5 Precaution item lights up while engine is running
Conversion table 00 -43
40-594
Cooling fan motor 10-28,60-12
E-6 Emergency stop item lights up while engine is running
Cooling fan pump 10-7,60-4
40-596
Cooling system 10-4
E-7 Engine coolant temperature gauge does not indicate
CRI engine control system 10-208
normally 40-597
Cutting edge and end bit 60-102
E-8 Fuel gauge does not indicate properly 40-598
Cylinder stay 10-194,60-97
E-9 Power train oil temperature gauge (multi-gauge) does
not indicate normally 40-600
E-10 Hydraulic temperature gauge (multi-gauge) does not
D indicate normally 40-601
Damper and universal joint 10-40,60-16 E-11 Contents of display by machine monitor are different
Diagnosis equipment list 30-4 from applicable machine 40-602
Disassembly and assembly of blade assembly 50-297 E-12 Machine monitor does not display some items
40-602

D375A-6R 1
(01)
Index

E-13 Function switch does not work 40-602 Failure code [2301NR] Steering Brake RH Themal Load
E-14 Operation mode does not change 40-603 Abnormality 40-158
E-15 Gearshift mode does not change 40-603 Failure code [2302L1] Left brake: Fill high 40-160
E-16 Customize function does not operate normally Failure code [2302LH] Left brake: Fill low 40-162
40-604 Failure code [2302NR] Steering Brake LH Themal Load
E-17 Customize memory function does not operate Abnormality 40-164
normally 40-604 Failure code [7RFAKA] ECM ACC CUT RELAY:
E-18 Alarm buzzer does not sound or does not stop Disconnection 40-166
40-605 Failure code [7RFAKB] ECM ACC CUT RELAY: Short
E-19 When starting switch is turned OFF, service meter is circuit 40-168
not displayed 40-605 Failure code [AA10NX] Air Cleaner Clogging 40-170
E-20 Machine monitor cannot be set in service mode Failure code [AB00MA] Battery Charge Abnormal 40-172
40-605 Failure code [B@BAZG] Eng Oil Press Low 40-173
E-21 The ripper pin puller cylinder does not operate Failure code [B@BAZK] Eng Oil Level Low 40-174
40-606 Failure code [B@BCNS] Eng Water Overheat 40-175
E-22 Horn does not sound or does not stop 40-608 Failure code [B@BCZK] Eng Water Level Low 40-176
E-23 Back-up alarm does not sound or does not stop Failure code [B@CENS] T/C Oil Overheat 40-177
40-610 Failure code [B@HANS] Hyd Oil Overheat 40-178
E-24 Fan does not reverse 40-612 Failure code [B@HAZK] Hyd Oil Level Low 40-179
E-25 The head lamp and rear lamp do not light up40-613 Failure code [CA111] ECM Critical Internal Failure
E-26 Windshield wiper does not operate 40-622 40-180
E-27 Window washer does not operate 40-630 Failure code [CA115] Eng Ne and Bkup Speed Sens Error
E-28 Electric priming pump does not operate or does not 40-182
stop automatically 40-638 Failure code [CA122] Chg Air Press Sensor High Error
E-29 Orbcomm terminal does not operate normally (Data 40-184
are not transmitted) 40-640 Failure code [CA123] Chg Air Press Sensor Low Error
E-30 Gear cannot be shifted 40-642 40-186
Electrical circuit diagram 90 -15 Failure code [CA131] Throttle Sensor High Error 40-188
Emergency escape method when there is failure in power Failure code [CA132] Throttle Sensor Low Error 40-190
train 30-62 Failure code [CA135] Eng Oil Press Sensor High Error
Engine control 10-198 40-192
Engine control system 10-199 Failure code [CA141] Eng Oil Press Sensor Low Error
Engine mount 60-3 40-194
Engine preheat (electrical intake air heater) control Failure code [CA144] Coolant Temp Sens High Error
10-231 40-196
Explanation of terms for maintenance standard 00 -12 Failure code [CA145] Coolant Temp Sens Low Error
40-198
F Failure code [CA153] Chg Air Temp Sensor High Error
Failure code [1380MW] Lock up clutch: Slip 40-114 40-200
Failure code [1500L0] Transmission clutch: Abnormal Failure code [CA154] Chg Air Temp Sensor Low Error
40-115 40-202
Failure code [15E0MW] Transmission clutch: Slip 40-116 Failure code [CA187] Sens Supply 2 Volt Low Error
Failure code [15SAL1] Forward clutch: Fill high 40-118 40-204
Failure code [15SALH] Forward clutch: Fill Low 40-120 Failure code [CA212] Eng Oil Temp Sensor High Error
Failure code [15SBL1] Reverse clutch: Fill high 40-122 40-206
Failure code [15SBLH] Reverse clutch: Fill Low 40-124 Failure code [CA213] Eng Oil Temp Sensor Low Error
Failure code [15SEL1] Speed 1st clutch: Fill high 40-126 40-208
Failure code [15SELH] Speed 1st clutch: Fill Low 40-128 Failure code [CA221] Ambient Press Sens High Error
Failure code [15SFL1] Speed 2nd clutch: Fill high 40-130 40-210
Failure code [15SFLH] Speed 2nd clutch: Fill Low 40-132 Failure code [CA222] Ambient Press Sens Low Error
Failure code [15SGL1] Speed 3rd clutch: Fill high 40-134 40-212
Failure code [15SGLH] Speed 3rd clutch: Fill Low 40-136 Failure code [CA227] Sens Supply 2 Volt High Error
Failure code [15SJL1] L/U: Fill high 40-138 40-214
Failure code [15SJLH] L/U: Fill low 40-140 Failure code [CA234] Eng Overspeed 40-215
Failure code [1800MW] P/T clutch: Slip 40-142 Failure code [CA238] Ne Speed Sens Supply Volt Error
Failure code [2201L1] Right clutch: Fill high 40-144 40-216
Failure code [2201LH] Right clutch: Fill low 40-146 Failure code [CA263] Fuel Temp Sensor High Error
Failure code [2202L1] Left clutch: Fill high 40-148 40-218
Failure code [2202LH] Left clutch: Fill low 40-150 Failure code [CA265] Fuel Temp Sensor Low Error
Failure code [2300NR] Brake Themal Load Abnormality 40-220
40-152 Failure code [CA271] IMV/PCV1 Short Error 40-222
Failure code [2301L1] Right brake: Fill high 40-154 Failure code [CA272] IMV/PCV1 Open Error 40-223
Failure code [2301LH] Right brake: Fill low 40-156 Failure code [CA273] PCV2 Short Error 40-224

2 D375A-6R
(01)
Index

Failure code [CA274] PCV2 Open Error 40-225 Failure code [D1EFKB] Pre lub. motor relay: Short circuit
Failure code [CA322] Inj #1 (L#1) Open/Short Error 40-284
40-226 Failure code [DAFRKR] Monitor: Can communication lost
Failure code [CA323] Inj #5 (L#5) Open/Short Error (PT) 40-286
40-228 Failure code [dAFRKR] Monitor: CAN communication lost
Failure code [CA324] Inj #3 (L#3) Open/Short Error (WE) 40-287
40-230 Failure code [DAFRMC] CAN Discon (Monitor Detected)
Failure code [CA325] Inj #6 (L#6) Open/Short Error 40-288
40-232 Failure code [DB2RKR] ENG cont.: Can communication
Failure code [CA331] Inj #2 (L#2) Open/Short Error lost (PT) 40-294
40-234 Failure code [dB2RKR] ENG controller: CAN
Failure code [CA332] Inj #4 (L#4) Open/Short Error communication lost (WE) 40-298
40-236 Failure code [DB90KT] WE controller: Abnormality in
Failure code [CA342] Calibration Code Incompatibility controller 40-299
40-238 Failure code [DB91KK] WE controller: Source voltage
Failure code [CA351] Injectors Drive Circuit Error 40-239 reduction 40-300
Failure code [CA352] Sens Supply 1 Volt Low Error Failure code [DB92KK] WE controller: Output voltage
40-240 reduction 40-302
Failure code [CA386] Sens Supply 1 Volt High Error Failure code [DB97KK] WE cont.: Sensor voltage 5 V (2)
40-242 reduction 40-304
Failure code [CA441] Battery Voltage Low Error 40-243 Failure code [DB99KQ] WE controller: Type select signal
Failure code [CA442] Battery Voltage High Error 40-244 40-306
Failure code [CA449] Rail Press Very High Error 40-245 Failure code [DB9RKR] WE controller: Can
Failure code [CA451] Rail Press Sensor High Error communication lost (PT) 40-307
40-246 Failure code [DBB0KK] VHMS controller:Source voltage
Failure code [CA452] Rail Press Sensor Low Error reduction 40-310
40-248 Failure code [DBB0KQ] VHMS connector connection
Failure code [CA553] Rail Press High Error 40-250 abnormality 40-312
Failure code [CA554] Rail Press Sensor In Range Error Failure code [DBB3KK] VHMS controller: Source voltage
40-251 reduction 40-313
Failure code [CA559] Rail Press Low Error 40-252 Failure code [DBB5KP] VHMS: Output sensor1 voltage
Failure code [CA689] Eng Ne Speed Sensor Error reduction 40-316
40-256 Failure code [DBB6KP] VHMS:Output sensor2 voltage
Failure code [CA731] Eng Bkup Speed Sens Phase Error reduction 40-318
40-258 Failure code [DBB7KP] VHMS:Output sensor3 voltage
Failure code [CA757] All Continuous Data Lost Error reduction 40-320
40-259 Failure code [DBBQKR] PT cont.: Can communication
Failure code [CA778] Eng Bkup Speed Sensor Error lost (VHMS) 40-322
40-260 Failure code [DBE0KT] PT controller: Abnormality in
Failure code [CA1633] KOMNET Datalink Timeout Error controller 40-323
40-262 Failure code [DBE1KK] PT controller: Source voltage
Failure code [CA2185] Throt Sens Sup Volt High Error reduction 40-324
40-263 Failure code [DBE2KK] PT controller: Output voltage
Failure code [CA2186] Throt Sens Sup Volt Low Error reduction 40-326
40-264 Failure code [DBE5KK] PT cont.: Sensor voltage 5 V (1)
Failure code [CA2249] Rail Press Very Low Error 40-265 reduction 40-328
Failure code [D110KB] Battery Relay: Drive Short Circuit Failure code [DBE6KK] PT cont.: Sensor voltage 24V
40-266 reduction 40-330
Failure code [D130KA] Neutral relay: Disconnection Failure code [DBE7KK] PT cont.: Sensor voltage 5 V
40-268 reduction 40-332
Failure code [D130KB] Neutral relay: Short circuit 40-270 Failure code [DBE9KQ] PT controller: Type select signal
Failure code [D161KA] Back-up alarm releay: 40-334
Disconnection 40-272 Failure code [DBERKR] PT controller: Can
Failure code [D161KB] Back-up alarm releay: Short circuit communication lost (WE) 40-335
40-274 Failure code [DD12KA] Shift up Sw: Disconnection
Failure code [D182KZ] Preheater Relay Abnormality 40-338
40-276 Failure code [DD12KB] Shift up Sw: Short circuit 40-340
Failure code [D190KA] ACC signal relay: Disconnection Failure code [DD13KA] Shift down Sw: Disconnection
40-278 40-342
Failure code [D190KB] ACC signal relay: Short circuit Failure code [DD13KB] Shift down Sw: Short circuit
40-280 40-344
Failure code [D1EFKA] Pre lub. motor relay: Failure code [DD14KA] Parking lever Sw: Dissconnection
Disconnection 40-282 40-346

D375A-6R 3
(01)
Index

Failure code [DD14KB] Parking lever Sw: Short circuit Failure code [DH21KA] Weq pressure sensor:
40-348 Disconnection 40-414
Failure code [DDB9L4] Reverse SW Signal disagreement Failure code [DH21KB] Weq pressure sensor: Short
40-350 circuit 40-416
Failure code [DDE2KA] Pre lub. oil press sw: Failure code [DHE5KB] ENG blow-by pressure sensor
Disconnection 40-352 disconnection 40-418
Failure code [DDK3L4] Forward SW Signal disagreement Failure code [DHE5KY] ENG blow-by pressure sensor
40-354 short circuit 40-420
Failure code [DDK5KA] Shift switch disconnection40-356 Failure code [DHT3KX] T/M oil pressure sensor
Failure code [DDK5KB] Shift switch short circuit 40-358 abnormality 40-422
Failure code [DDN2LD] Blade tilt RH pressure SW Failure code [DHT5KA] T/C in-pressure sensor:
abnormality 40-360 Disconnection 40-424
Failure code [DDN3LD] Blade tilt LH pressure SW Failure code [DHT5KB] T/C in-pressure sensor: Short
abnormality 40-362 circuit 40-426
Failure code [DDN7KA] WEQ Knob Sw (down): Failure code [DHT7KA] T/C out-pressure sensor:
Disconnection 40-364 Disconnection 40-428
Failure code [DDN7KB] WEQ Knob Sw (down): Short Failure code [DHT7KB] T/C out-pressure sensor: Short
circuit 40-366 circuit 40-430
Failure code [DDN9KA] WEQ Knob Sw (up): Failure code [DK10KA] Fuel control Dial: Disconnection
Disconnection 40-368 40-432
Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit Failure code [DK10KB] Fuel control Dial: Short circuit
40-370 40-434
Failure code [DDNALD] Blade lift up pressure SW Failure code [DK30KA] ST lever 1: Disconnection 40-436
abnormality 40-372 Failure code [DK30KB] ST lever 1: Short circuit 40-438
Failure code [DDNBLD] Ripper lift up pressure SW Failure code [DK30KX] ST lever: Out of normal range
abnormality 40-374 40-440
Failure code [DDNCLD] Ripper lift down pressure SW Failure code [DK30KZ] ST lever: Disconnection or short
abnormality 40-376 circuit 40-441
Failure code [DDNDLD] Ripper tilt in pressure SW Failure code [DK30L8] ST lever: Signal mismatch 40-442
abnormality 40-378 Failure code [DK31KA] ST lever 2: Disconnection 40-444
Failure code [DDNELD] Ripper tilt back pressure SW Failure code [DK31KB] ST lever 2: Short circuit 40-446
abnormality 40-380 Failure code [DK40KA] Brake potentiometer:
Failure code [DDNFLD] Blade lift down pressure SW Disconnection 40-448
abnormality 40-382 Failure code [DK40KB] Brake potentiometer: Short circuit
Failure code [DDNLKA] Weq lock Sw: Disconnection 40-450
40-384 Failure code [DK55KX] FR lever: Out of normal range
Failure code [DDNLKB] Weq lock Sw: Short circuit 40-452
40-386 Failure code [DK55KZ] FR lever: Disconnection or short
Failure code [DDT5KA] Neutral switch disconnection circuit 40-453
40-388 Failure code [DK55L8] FR lever: Signal mismatch 40-454
Failure code [DDT5KB] Neutral switch short circuit Failure code [DK56KA] FR lever 1: Disconnection 40-456
40-390 Failure code [DK56KB] FR lever 1: Short circuit 40-458
Failure code [DDT5KQ] Lever SPEC selection signal Failure code [DK57KA] FR lever 2: Disconnection 40-460
disagreement 40-392 Failure code [DK57KB] FR lever 2: Short circuit 40-462
Failure code [DDTSL1] S/C: Fill high 40-394 Failure code [DK60KA] Acceleration sensor:
Failure code [DDTSLH] S/C: Fill low 40-396 Disconnection 40-464
Failure code [DGE5KX] Ambient temp sensor abnormality Failure code [DK60KB] Acceleration sensor: Short circuit
40-398 40-466
Failure code [DGS1KX] Hyd oil temp: signal abnormal Failure code [DKH1KA] Pitch angle sensor:
40-400 Disconnection 40-468
Failure code [DGT1KA] T/C oil temp sensor: Abnormal Failure code [DKH1KB] Pitch angle sensor: Short circuit
40-402 40-470
Failure code [DGT1KX] T/C oil temp sensor: Abnormal Failure code [DLF1KA] T/C out-speed sensor:
40-404 Disconnection 40-472
Failure code [DGT5KA] F exhaust temp sensor Failure code [DLM3KA] Fan rev. sensor: Disconnection
disconnection 40-406 40-474
Failure code [DGT5KB] F exhaust temp sensor short Failure code [DLM3MB] Fan control: Decline 40-476
circuit 40-408 Failure code [DLT3KA] T/M out-speed sensor:
Failure code [DGT6KA] R exhaust temp sensor Disconnection 40-477
disconnection 40-410 Failure code [DLT3KB] T/M out-speed sensor: Abnormal
Failure code [DGT6KB] R exhaust temp sensor short 40-478
circuit 40-412 Failure code [DW59KA] Blade dual selector SOL
disconnection 40-479

4 D375A-6R
(01)
Index

Failure code [DW59KB] Blade dual selector SOL short Failure code [DXH8KA] F clutch ECMV: Disconnection
circuit 40-480 40-536
Failure code [DW59KY] Blade dual selector SOL hot short Failure code [DXH8KB] F clutch ECMV: Short circuit
40-482 40-538
Failure code [DW5AKA] Blade pitch selector SOL Failure code [DXH8KY] F clutch ECMV: Short circuit
disconnection 40-484 40-540
Failure code [DW5AKB] Blade pitch selector SOL short Failure code [DXH9KA] Right clutch ECMV:
circuit 40-485 Disconnection 40-542
Failure code [DW5AKY] Blade pitch selector SOL Short Failure code [DXH9KB] Right clutch ECMV: Short circuit
circuit 40-486 40-544
Failure code [DW7BKA] Fan rev EPC: Disconnection Failure code [DXH9KY] Right clutch ECMV: Short circuit
40-488 40-546
Failure code [DW7BKB] Fan rev EPC: Short circuit Failure code [DXHAKA] Left clutch ECMV: Disconnection
40-489 40-548
Failure code [DWN3KA] Ssp solenoid: Disconnection Failure code [DXHAKB] Left clutch ECMV: Short circuit
40-490 40-550
Failure code [DWN3KB] Ssp solenoid: Short circuit Failure code [DXHAKY] Left clutch ECMV: Short circuit
40-492 40-552
Failure code [DWN3KY] SSP solenoid: Short circuit Failure code [DXHBKA] Right brake ECMV:
40-494 Disconnection 40-554
Failure code [DWN5KA] Fan pump solenoid 1: Failure code [DXHBKB] Right brake ECMV: Short circuit
Disconnection 40-496 40-556
Failure code [DWN5KB] Fan pump solenoid 1: Short Failure code [DXHBKY] Right brake ECMV: Short circuit
circuit 40-498 40-558
Failure code [DWN5KY] Fan pump solenoid 1: Short Failure code [DXHCKA] Left brake ECMV: Disconnection
circuit 40-500 40-560
Failure code [DWNCKA] Fan pump solenoid 2: Failure code [DXHCKB] Left brake ECMV: Short circuit
Disconnection 40-502 40-562
Failure code [DWNCKB] Fan pump solenoid 2: Short Failure code [DXHCKY] Left brake ECMV: Short circuit
circuit 40-504 40-564
Failure code [DWNCKY] Fan pump solenoid 2: Short Failure code [DXJBKA] S/C ECMV: Disconnection
circuit 40-506 40-566
Failure code [DXH1KA] Lock-up ECMV: Disconnection Failure code [DXJBKB] S/C ECMV: Short circuit 40-567
40-508 Failure code [DXJBKY] S/C ECMV: Short circuit 40-568
Failure code [DXH1KB] Lock-up ECMV: Short circuit Failure code [DY2HKA] Pre lub. motor: Disconnection
40-509 40-570
Failure code [DXH1KY] Lock-up ECMV: Short circuit Failure code [F@BBZL] ENG blow-by pressure high level
40-510 40-572
Failure code [DXH4KA] 1st clutch ECMV: Disconnection Failure code [F@BYNR] F exhaust temp high level (2)
40-512 40-573
Failure code [DXH4KB] 1st clutch ECMV: Short circuit Failure code [F@BYNS] F exhaust temp high level (1)
40-514 40-574
Failure code [DXH4KY] 1st clutch ECMV: Short circuit Failure code [F@BZNR] R exhaust temp high level (2)
40-516 40-575
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection Failure code [F@BZNS] R exhaust temp high level (1)
40-518 40-576
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit Failure codes table 40-40
40-520 Final drive 10-105,60-43
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit FRESH/RECIRC air changeover damper 80-15
40-522 Fuse locations table 40-110
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection
40-524
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit H
40-526 H-1 Machine lacks power(or drawbar pull) 40-648
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit H-2 Machine cannot travel (at 2nd or 3rd each speed)
40-528 40-650
Failure code [DXH7KA] R clutch ECMV: Disconnection H-3 Machine cannot travel at any gear speeds 40-651
40-530 H-4 Machine travels only in one direction, forward or
Failure code [DXH7KB] R clutch ECMV: Short circuit reverse 40-653
40-532 H-5 Large time lag at gear shifting or directional change
Failure code [DXH7KY] R clutch ECMV: Short circuit 40-654
40-534 H-6 Machine connot turn 40-655
H-7 Machine turns only to one side 40-656

D375A-6R 5
(01)
Index

H-8 Machine overruns at turnning 40-657 Main relief valve and torque converter relief valve
H-9 Brake does not work 40-658 10-50,60-22
H-10 Torque converter does not lock up 40-659 Measuring compression pressure 30-18
H-11 Power train oil overheats 40-660 Measuring fan speed 30-36
H-12 All work equipment operates too slow or lacks power Method of disassembling and connecting push-pull type
40-661 coupler 00 -32
H-13 All work equipment does not operate 40-662 Method of using troubleshooting chart 40-674
H-14 Blade lift cylinder speed is too slow or lacks power Monitor system 10-210
40-663
H-15 Blade tilt cylinder speed is too slow or lacks power O
40-664 ORBCOMM system 10-247
H-16 Ripper lift cylinder speed is too slow or lacks power Outline of refrigeration cycle 80-7
40-665 Overall disassembly and assembly of track shoe 50-227
H-17 Ripper tilt cylinder speed is too slow or lacks power Overall drawing of power train unit 10-36
40-666
H-18 Excessive hydraulic drift of blade lift cylinder40-667
H-19 Excessive hydraulic drift of blade tilt cylinder40-668 P
H-20 Excessive hydraulic drift of ripper lift cylinder40-669 Palm command control system 10-232
H-21 Ripper pin puller cylinder does not operate (machine Parking brake valve 10-102,60-42
with giant ripper) 40-670 Parts and connectors layout 80-28
H-22 Blade pitch does not work (machine with dual tilt PCCS lever 10-60
specification) 40-671 Pin puller solenoid valve 10-146
H-23 Abnormal noise from around work equipment pump Pin puller switch 10-145
40-672 Piston valve 10-142
H-24 Abnormal fan rotation(noise and/or vibration are Pm Clinic service 30-184
abnormally large or engine overheats) 40-673 Points to remember when troubleshooting 40-10
Handling of compressor oil 80-64 Power train 10-34
Handling of connectors newly used for engines 00 -23 Power train and lubrication pump 60-32
Handling of electric equipment and hydraulic components Power train hydraulic diagrams and drawings 90 -5
00 -14 Power train hydraulic equipment arrangement drawing
Handling of fuel system devices 30-24 10-38
Handling of no injection cranking operation 30-28 Power train unit 60-14
Handling of optional devices 30-158 PPC control piping diagram 10-123
Handling of reduced cylinder mode operation 30-27 PPC lock valve 10-129
Handling of voltage circuit of engine controller 30-148 PPC valve 10-130,60-68
How to read electric wire code 00 -26 Precautions for disconnecting and connecting 80-62
How to read the shop manual 00 -10 Precautions for refrigerant 80-3
How to read this manual 50-4 Precautions for replacing VHMS controller 30-178
Hydraulic circuit diagram 90 -7 Precautions when carrying out work 00 -29
Hydraulic cylinder 60-74 Preparation work for troubleshooting for electrical
Hydraulic tank 10-126 equipment system 30-153
Procedure for testing and troubleshooting 80-22
I
Idler 60-52 Q
Idler cushion 10-112,60-50 Quick drop valve 10-143,60-77
Information contained in troubleshooting table 40-578
Information in troubleshooting table 40-52,40-644,80-40 R
Initialization procedures for VHMS controller 30-161 Receiver drier 80-18
Inspecting wear of sprocket 30-64 Releasing remaining pressure in work equipment
Inspection procedure of diode 30-157 cylinders 30-76
Releasing residual pressure from fuel system 30-25
L Removal and installation of aftercooler 50-63
Lamp system 10-230 Removal and installation of air conditioner unit assembly
Link press press-fitting jig dimensions 50-245 50-314
List of Abbreviation 00 -39 Removal and installation of blade assembly 50-295
List of Failure Modes and Causes 40-646 Removal and installation of bogie assembly 50-211
Lockup clutch ECMV and stator clutch ECMV Removal and installation of carrier roller assembly50-206
10-52,60-23 Removal and installation of control valve assembly
50-272
Removal and installation of cooling assembly (radiator,
M after cooler, and hydraulic oil cooler) 50-55
Machine monitor 10-212 Removal and installation of cylinder head assembly
Main frame 10-114,60-61 50-35

6 D375A-6R
(01)
Index

Removal and installation of damper assembly 50-86 S-8 Oil is consumption is excessive(or exhaust smoke is
Removal and installation of engine assembly 50-64 blue) 40-687
Removal and installation of engine controller assembly S-9 Engine oil becomes contaminated quickly 40-688
50-321 S-10 Fuel consumption is excessive 40-689
Removal and installation of engine front seal 50-74 S-11 Oil mixes into coolant(coolant blows back or is
Removal and installation of engine hood assembly 50-71 reduced) 40-690
Removal and installation of engine rear seal 50-76 S-12 Engine pressure monitor lights up (drop in engine oil
Removal and installation of equalizer bar 50-256 pressure) 40-691
Removal and installation of fan drive assembly 50-80 S-13 Oil level rises (Coolant or fuel mixes into oil) 40-692
Removal and installation of fan motor assembly 50-82 S-14 Coolant temperature rises too high (overheating)
Removal and installation of fan pump assembly 50-270 40-693
Removal and installation of final drive assembly 50-168 S-15 Abnormal noise is heard 40-694
Removal and installation of first bogie assembly 50-218 S-16 Vibration is excessive 40-695
Removal and installation of floor frame assembly 50-309 S-17 Air cannot be bled from fuel circuit (when air
Removal and installation of fuel injector assembly 50-30 bleeding is performed after filter is replaced or fuel is used
Removal and installation of fuel supply pump assembly up and then air is bled, engine does not start or it starts
50-25 but stalls) 40-696
Removal and installation of fuel tank assembly 50-84 Safety notice 00 -5
Removal and installation of hydraulic oil cooler 50-62 Scavenging pump 10-57,60-24
Removal and installation of hydraulic tank assembly Self-pressure reducing valve 10-187,60-94
50-263 Sensor 10-235
Removal and installation of idler assembly 50-188 Separation and connection of track shoe assembly
Removal and installation of machine monitor assembly 50-223
50-324 Sequence of events in troubleshooting 40-11
Removal and installation of operator's cab assembly Simple test procedure for brake performance 30-57
50-305 Sketches of special tools 50-17
Removal and installation of pivot shaft assembly 50-255 Special functions of machine monitor (EMMS) 30-90
Removal and installation of power train pump and Special tool list 50-9
lubrication pump assembly 50-166 Specification drawing 01 -3
Removal and installation of power train unit assembly Specifications 01 -4
50-93 Sprocket 60-46
Removal and installation of radiator 50-60 Standard tightening torque table 00 -35
Removal and installation of radiator guard assembly Standard value table for engine 20-3
50-50 Standard value table for machine 20-4
Removal and installation of recoil spring assembly Steering and brake control 10-84
50-193 Steering clutch ECMV and Steering brake ECMV
Removal and installation of ROPS guard 50-304 10-94,60-41
Removal and installation of scavenging pump assembly Steering control valve 10-92,60-40
50-167 Sudden stop prevention valve 10-103
Removal and installation of segment tooth 50-262 Suspension 10-116,60-63
Removal and installation of track frame assembly 50-183 Symbols use in electric circuit diagrams 90 -11
Removal and installation of track roller assembly 50-200 Symbols used in hydraulic circuit diagrams 90 -3
Removal and installation of transmission controller System diagram 80-26
assembly and steering controller assembly 50-320
Removal and installation of VHMS controller assembly T
50-323 Table of fuel, coolant and lubricants 01 -11
Removal and installation of work equipment pump T-branch box and T-branch adapter table 40-93
assembly 50-266 Testing and adjusting operator's cab 30-84
Replacing and adjusting alternator and air conditioner Testing and adjusting track shoe tension 30-65
compressor belt 30-35 Testing and adjusting work equipment oil pressure 30-66
Request for opening ORBCOMM terminal 30-159 Testing blow-by pressure 30-21
Ripper 60-104 Testing control circuit main pressure 30-69
Testing engine oil pressure 30-23
S Testing engine speed 30-6
S-1 Engine does not start easily 40-678 Testing exhaust gas color 30-14
S-2 Engine does not start 40-679 Testing exhaust temperature 30-11
S-3 Engine does not rev up smoothly (response-up is Testing fan circuit oil pressure 30-37
poor) 40-682 Testing FRESH/RECIC air changeover 80-33
S-4 Engine stops during operation 40-683 Testing fuel circuit for leakage 30-34
S-5 Engine does not rotate smoothly (hunting) 40-684 Testing fuel pressure 30-26
S-6 Engine lacks power (or output shortage) 40-685 Testing intake air pressure (boost pressure) 30-9
S-7 Exhaust smoke is black (Incomplete combustion) Testing leakage from pressure limiter and return rate from
40-686 injector 30-29

D375A-6R 7
(01)
Index

Testing leakage inside work equipment cylinder 30-75


Testing output pressure of ripper pin-puller solenoid valve
30-73
Testing power train oil pressure 30-42
Testing PPC valve output pressure 30-70
Testing relay 80-34
Testing temperature control 80-32
Torque converter and PTO 10-42,60-19
Torque converter control valve 10-48
Track frame 10-110,60-48
Track roller 60-54
Track roller bogie 10-113,60-58
Track shoe 60-58
Transfer unit, bevel gear shaft and steering 10-86
Transfer, bevel gear shaft and steering unit 60-34
Transmission 10-64,60-26
Transmission control 10-58,60-25
Transmission ECMV 10-78
Transmission lubricating oil relief valve 60-31
Transmission lubrication relief valve 10-83
Troubleshooting chart 1 80-36
Troubleshooting chart 2 80-38
Troubleshooting for blower motor system (Air does not
come out or air flow is abnormal) 80-48
Troubleshooting for compressor system (Air is not cooled)
80-44
Troubleshooting for FRESH/RECIRC air changeover
80-56
Troubleshooting for power supply system (Air conditioner
does not operate) 80-42
Troubleshooting for temperature control 80-54
Troubleshooting method for disconnecting wiring harness
of pressure sensor system 40-54
Troubleshooting with gauge pressure 80-58

U
Using method of KOMTRAX functions of ORBCOMM
terminal 30-175

V
Vehicle health monitoring system (VHMS) 10-241

W
Weight table 01 -9
Work equipment control 10-124
Work equipment hydraulic piping diagram 10-119
Work equipment pump 10-150,60-78

8 D375A-6R
(01)
Shop Manual
DRAFT

D375A-6R BULLDOZER

Form Number: SEN05214-01

2010 KOMATSU
All Rights Reserved
Printed in Japan 03-10

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